AW-TUN 05-E

PRODUCTS IN APPLICATION: TUNNEL CONSTRUCTION

Introduction

Mountings in tunnel construction

Modern industrial societies need efficient and reliable traffic infrastructures. That is true both for road and rail. High speed
modes of transport require routes with the gentlest curves and inclined sections with small upward and downward gradients.
The topographical conditions in most countries require tunnels and bridges when planning the route, and these are very
expensive engineering structures.
Tunnel construction requires a large amount of geological investigation and static calculation of the tunnel cross section. Issues
such as safety, fire protection, corrosion protection, technical equipment and the durability of the constructions require a
substantial amount of planning which usually drags on for years. Owing to the efficiency of the tools, machines and high

strength concretes which are available today, tunnels can now be built in much shorter times than was previously possible a
few decades ago.
The safety equipment, such as signalling devices, lighting, ventilation systems, retrieval anchors and emergency exits contribu

te substantially to safety in tunnels.
Parts from the HALFEN DEHA product range are used in different areas of tunnel construction for adjustable and cost
effective
mountings and reinforcement technology.

The regulations listed below contain definitive references for the range of the mounting designs:

ZTV
ING (Additional technical contract conditions and guidelines for civil engineering works. Edition March 2003, Part 5.1 and
5.2 (Road tunnels by closed or open cut method)
• Mountings for tunnel installations must be made from stainless steel with material numbers 1.4529 or 1.4547 and
Resistance class IV according to German Industrial Standard DIN EN ISO 3506 and according to DIN EN 10088.

Official approval certificate No. Z
30.3
6 of “Products, connecting devices and structural components made from stainless
steel”
• Table 1: Classification of grades of steel according to strength classes and corrosion resistance classes as well as
typical applications for structural components and connecting devices.

Swiss standard SIA 179 (Swiss association of architects and engineers, Edition 1998, Recommendations for mountings in
concrete and masonry)
• Section 4,14. Mounting elements made from stainless steel or special materials

• Table 10: Corrosion resistance class IV, Material No. 1.4529, 1.4547
• Table 11: stainless steel Group IV: Well suited for use in tunnels.

2
PRODUCTS IN APPLICATION: TUNNEL CONSTRUCTION
Contents

Application Page

Mountings in tunnels construction, regulations and recommendations 2

Halfen channels for tunnels construction / HCR steel 4

Road tunnels / mounting the lighting systems 5

Road tunnels / reinforcement connections 6

Road tunnels / retrieval anchors 7

Railway tunnels / contact
wire mountings 8

Railway tunnels / earthing the Halfen channels 9

Road tunnels / retrieval anchors 10

Contact 11

Adress 12

Cross section of a road tunnel Cross section of a railway tunnel

(Picture: periodical 'Tunnel', Bauverlag BV GmbH)

3
HALFEN CAST-IN CHANNELS FOR THE TUNNEL CONSTRUCTION
Available in lengths from 0,15 m to 6,07 m

Designation Material/finish Allowable single load available Halfen T-head bolts

HTA HM HL 1.4529 1.4571 hot-dip- pull, concrete

M M M M M M
HZL toothed HCR A4 galvan. grade B ³ 25 6 8 10 12 16 20
52
HTA 52/34 22 kN (25 kN ³ B 35) gv gv gv gv
fv fv fv fv
34
22 HM 52/34 ® see catalogue MT A4 A4 A4

50 HTA 50/30 10 kN gv gv gv gv
fv fv fv fv
30
® see catalogue MT A4 A4 A4
22 HM 50/30

49 gv gv gv gv
HTA 49/30 10 kN
fv fv fv fv
A4 A4 A4
30

22 HM 49/30 ® see catalogue MT HCR HCR HCR

40 HTA 40/22 6 kN gv gv gv
fv fv
22
18 HM 40/22 ® see catalogue MT A4 A4 A4

40 HTA 40/25 6 kN gv gv gv
fv fv
25
A4 A4 A4
18 HM 40/25 ® see catalogue MT

gv gv gv
38 HTA 38/17 4,5 kN
fv fv fv
17 A4 A4 A4
18 HM 38/17 ® see catalogue MT HCR HCR HCR

HTA 28/15 3 kN gv gv gv gv
28
fv
15 HM 28/15 ® see catalogue MT A4 A4
12 HCR HCR
HL 28/15 ® see catalogue MT
41 HM 41/41 ® see catalogue MT
fv fv
41 H L 41/41 ® see catalogue MT A4 A4
22 HZL 41/41 ® see catalogue MT

36
HM 36/36 ® see catalogue MT gv gv gv
fv fv fv
36
HL 36/36 A4 A4 A4
® see catalogue MT
18

27
HM 28/28 ® see catalogue MT gv gv gv gv
28 fv
A4 A4
12
HL 28/28 ® see catalogue MT

4
ROAD TUNNELS
Mounting lighting systems

Special, glare
free lights are usually mounted on the tunnel

ceiling at relatively short distances to provide the optimum
lighting for road tunnels. Since concrete
embedded Halfen
channels are particularly suitable for strip mountings, they
are tendered out by experienced planners for these applica

tions.
Because the mountings could be exposed to chloride conta

mination, they are made from stainless steel Corrosion

Resistance Class IV in accordance with the German Con

struction supervision approval No. 30.3
6.
The material numbers of the highly corrosion resistant steels
are specified as 1.4529 and 1.4547. The Halfen channels
which are made from these materials and can be embedded
in concrete are labelled:
HTA 28/15
HCR,
HTA 38/17
HCR,
HTA 49/30
HCR.

Halfen Cast
in Channels provide an adjustable mounting

system for lighting systems

5
ROAD TUNNELS
Reinforcement connections

A tunnel is a complex structure consisting of numerous

sections with a large number of concrete construction joints.
For example, if the diaphragm walls to which the tunnel
sofit or tunnel vault is attached are pre
concreted, reinforce

ment connections are used for the linkage to the
structural components. Type HBS
05 Halfen screw connec

tions are used in this case. Connections from 12 to 32 mm
bar diameter are available.
Reinforcement connections are also used in road tunnels for
later connection to steel reinforced concrete intermediate
ceilings. HBT rebending connections are used for the struc

tural connection of concrete components without static
proof. These are available with bar diameters of 8 to 12 mm.

Later connection of the tunnel vault to the pre
concreted

diaphragm walls

Reinforced concrete wall

HBS
05
A

HBS
05
SG Reinforced concrete

ceiling

The load
bearing connection for the reinforcement is made

using HBS
05 screw connections (previously WD 90)

6
ROAD TUNNELS
Retrieval anchors

Retrieval anchors are provided in road tunnels to pull apart

vehicles which are wedged together in road traffic accidents
so that they can be rapidly removed from the traffic.
Retrieval anchors consist of DEHA spherical head anchors
(Load class 200 kN (20 t)) embedded in the concrete. The
free
swivelling shackles normally used for transporting
precast concrete components are attached to the spherical
head anchors. The shackles are secured with a chain to
prevent them from being stolen. Retrieval anchors are placed
in niches in the tunnel walls every 100 m. City and municipal
fire
brigades are increasingly demanding that retrieval
anchors are provided.

Retrieval anchors are concreted into the tunnel wall at regular

intervals.

The anchors must not project into the tunnel space. They are The chain secures the anchor from Spherical head
stowed in niches. being stolen. anchor with
shackle.

Further detailed information is included in the technical information for Spherical Head Transport Anchors.
Please download catalogue KKT at www.halfen
deha.com.

7
RAILWAY TUNNELS
Mounting contact wires, wheel tensioners, return lines and line feeders

In railway tunnels for electrified stretches of railway lines, a

large amount of equipment has to be installed along the
tunnel cross section. This includes the contact
wire tensio

ners, line feeders and signal systems. Halfen channels
embedded in the concrete (cast
in channels) have been
proved to be an effective way of mounting equipment in
numerous tunnels across the world and have become a
standard means of attachment.

Anchor channel for Anchor channel Anchor channel for

supplementary conduit for back conduit wheel tensioner
Anchor channel for
anchoring a
fixed point

Anchor channel for

support strut

Anchor channel for

weight guide

Curved Halfen channels are connected to the reinforcement. The contact wire bracket is bolted to
The jumbo presses itself against the Halfen channels, so that the channels later lie the Halfen channel so that it can be
flush with the surface of the concrete. adjusted.

8
RAILWAY TUNNELS
Mounting contact wires, wheel tensioners, return lines and line feeders

Type HTA hot
rolled Halfen channels together with the

relevant Type HS hook bolts are used in tunnels to attach the
structural components for the overhead line (contact lines).
The structures are made to take any stresses, such as those
which can occur on the Cologne Rhine/Main or Nuremberg

Ingolstadt high
speed lines.

If desired, the Halfen channels can be made short
circuit

proof and adapted at the works to the intended earthing
arrangements. If installed as a channel pair, the short
circuit
current is conducted via two welded spacers. The earth
connection to the respective ring earth electrode can then
be made from an earthing lead welded to the back of the
rail.

The channel pair is fixed to the bottom of the formwork and

then the multi
layer reinforcement mesh can be installed.
For this assembly state, the earthing lead (flat steel strap) is
vertically aligned so that in the final assembly condition the
strap is always accessible and can be connected flexibly to
the ring earth electrode.

Wheel tensioners adjustably mounted on the HTA Halfen

channels.

Pair of Halfen channels with distance straps and earthing

lead, which is bent and welded to the upper reinforcement
after it has been laid.

9
ROAD TUNNEL
PIPE SUPPORT FOR VENTILATION DUCTS

The crossways between two parallel main tunnel tubes are

subject to strong contamination due to the irregular air
pressure and suction waves from the main tunnels. The
technical equipment housed in the tunnels must therefore
be inspected and cleaned at short intervals.
In the Swiss Seelisberg tunnel, this problem was solved by
connecting the crossways, which are distanced approxima

tely 300 m from each other, to the outside air via newly
installed ducting and ventilating them under slight positive
pressure. The overpressure prevents contaminated air from
entering the crossways.
Since it was necessary for the ventilation ducts to run via the
carriageway of the road tunnel, it was particularly important
for the ducting to be installed quickly. The new HALFEN
POWERCLICK FRAMING SYSTEM was the best solution for
providing a means of support for the ducting which would
be fast, safe and adjustable. By using this system, interrup

tions to the traffic could be reduced to a minimum.

Further information on the HALFEN POWERCLICK

FRAMING SYSTEM is provided in the technical catalogues
and on the website www.halfen
powerclick.com.

Pipe support with HALFEN POWERCLICK FRAMING SYSTEM

Photos: Tis
Air (www.tis
air.ch)

High rigidity profile

with toothed inner channel

Multi
functional angle connector

Toothed connection

HALFEN POWERCLICK FRAMING SYSTEM

10
PRODUCTS IN APPLICATION: TUNNEL CONSTRUCTION
Reference projects in Germany and worldwide

Germany Tunnel Zelzate-Knokke Plabutsch tunnel

Tunnel river Elbe, 4th tube Subway Antwerpen Karawanken tunnel, Carinthia
S-Railway tunnel Hamburg Tunnel de Cointe Liège Inntal tunnel
Herren tunnel Lübeck Tunnel E5/E9 Liège Sausenstein tunnel
Service tunnel hospital Eppendorf Metro Antwerp Metro Wien
Road tunnel Hemelingen Metro Bruxelles
Katzenberg tunnel Cointe tunnel Tschech Republic
U 2 city railway Tunnel Gestel Tunnel Praha-Mrazovka
Pragsattel B10 Stuttgart Rolo tunnel Tunnel Jihlava / bypass road
Hornberg tunnel CEE tunnel, Bruxelles Motorway tunnel Prague
Kennedy tunnel, Antwerp
Metro Chaleroi Schweden
Tunnel de Gousselerbierg/Luxemburg Södra Länken, tunnel near Stockholm
Tunnel de Markusbierg/Luxemburg Railway Tunnel , Malmö
Tunnel Howald Hallands Tunnel (Railway)

Italien Great Britain

Variante di valcio autostrada FI-BO Channel Tunnel
Variante di valcio autostrada FI-BO Tunnel A1, Hatfield
Tunnel for Caselle Airport
Tunnel Monte Bianco France
Neu-Ulm 21 Metro Paris
Stuttgart 21 Schweiz Metro Lille
Schwarzkopf tunnel Tunnel de Sauges, A5, Neuchatel
Tunnel Hösbach Conn. tunnel Bettmerhorn-Fischeralp
Audi tunnel, Ingolstadt Quarten tunnel A3
Tunnel Geisberg Eggflue tunnel J18
Tunnel motorway junction Frankfurt Utlisberg tunnel A4
Wandersmann tunnel north & south Hauenstein tunnel
Tunnel Breckenheim Metro Alpine tunnel
Tunnel Idstein Rosenbergtunnel, St.Gallen
Tunnel Montabaur Islisberg tunnel
S-Railway Ostentor/Dortmund Hafnerberg tunnel
Bypass Gevelsberg road tunnel Chienberg tunnel
City railway Bochum Seelisberg tunnel
City railway Dortmund Lötschberg tunnel
Tunnel A2 Gelsenkirchen-Erle Gotthard base tunnel
Eurotunnel, Calais
Lange Issel tunnel
Tunnel de Villejust
Troisdorf tunnel, ICE railway Niederlande
Tunnel du Puymorens
Siegauen tunnel, ICE railway Zeeburg tunnel, Amsterdam
Tunnel de lèpine
Dickheck tunnel, ICE railway Sophia tunnel
Tunnel du Landy
Wahnscheid tunnel, ICE railway Tunnel Pannerdens Kanaal
Tunnel de Tartaiguille
Himmelberg tunnel, ICE railway Geldersepoort
Tunnel du Prado-Carenge
Rottbitze tunnel, ICE railway
Aegidienberg tunnel, ICE railway
Singapore
Ittenbach tunnel, ICE railway
Circle Line MRT
Günterscheid tunnel
Subway 3 Nuremberg
Südkorea
Subway Fürth
Railway tunnel Seoul-Pusan
Tunnel Lehrter train station, Berlin
Tramway tunnel station Rostock
Kuala Lumpur
Motorway tunnel BAB 113
Kuala Lumpur Storm Water Manage-
Ems tunnel / Leer
ment and Road Tunnel
Subway Düsseldorf
Tunnel Farchant A95 Schiphol tunnel
Tunnel Allach Heijnenoord tunnel Sonstige
Subway Munich Wijker tunnel Metro Kairo, Ägypten
Subway Hamburg Metro Taipeh, Taiwan
Austria Storebelts tunnel, Dänemark
Tunnels Semmering Tunnel route 5, Hongkong
Belgium/Luxemburg
Tunnels Kalus Phyrna Autobahn Junk Bay tunnel, Hongkong
Tunnel Antwerpen ASDAM-HAST
11
CONTACT
HALFEN-DEHA Worldwide

HALFEN-DEHA is represented in more than 35 countries worldwide. Please contact us.

Australia HALFEN-DEHA Pty Ltd. Phone: +61 – 2 – 96 42 83 96 Fax: +61 – 2 – 96 42 01 55

70 Cosgrove Road E-Mail: bmetham@halfen-deha.com.au
Enfield NSW 2136

Belgium/Luxembourg HALFEN-FRIMEDA N.V. Phone: +32 – 3 – 6 58 07 20 Fax: +32 – 3 – 6 58 15 33

Borkelstraat 131 E-Mail: info@halfen.be
2900 Schoten Internet: www.halfen.be

Denmark Gottfred Petersen A/S Phone: +45 – 63 41 – 12 66 Fax: +45 – 64 41 – 14 19

Langelandsvej 15 E-Mail: e-post@gottfred.dk
5500 Middelfart

Finland Semtu Oy Phone: +358 – 9 – 27 47 95 0 Fax: +358 – 9 – 2747 9540

Box 124 E-Mail: mailbox@semtu.fi
04201 Kerava Internet: www.semtu.com

Hong Kong HALFEN-DEHA Limited Phone: +852 – 25 63 28 38 Fax: +852 – 25 63 23 39

402A, 4th Floor, Kerry Warehouse Bldg., 2 San Po st. E-Mail: info@halfen-deha.com.hk
Sheung Shui, New Territories

Italy HALFEN - OROBIA s.r.l. Phone: +39 – 035 - 89 38 11 Fax: +39 – 035 - 89 30 71

© 2004 HALFEN-DEHA Vertriebsgesellschaft mbH,

Via Dei Curti N° 33 E-Mail: info@halfen.it
24059 Urgnano (BG) Internet: www.halfen.it

Malaysia HALFEN-DEHA Sdn. Bhd. Phone: +603 – 6250 9630 Fax: +603 – 6250 9650
Lot E/23117, Jalan 5/32A · ff Batu 6 ½, Jalan Kepong E-Mail: info@halfen-deha.com.my

applies also to copying in extracts

52100 Kuala Lumpur Internet: www.halfen-deha.com

Norway HALFEN-FRIMEDA A/S Phone: +47 – 51 – 82 34 00 Fax: +47 – 51 – 82 34 01

Flintegaten 4 E-Mail: post@halfen-frimeda.no
4004 Stavanger Internet: www.halfen-frimeda.no

Singapore HALFEN-DEHA Pte. Ltd. Phone: +65 – 64 55 93 31 Fax: +65 – 64 55 85 35

148 Tagore Lane E-Mail: info@halfen-deha.com.sg
Singapore 787564

Spain HALFEN-DEHA S.L. Phone: +34 – 91 - 632 18 40 Fax: +34 – 91 - 633 42 57

Pol. Ind. Prado del Espino · C/Vidrieros Naves 2 y 3 E-Mail: info@halfen-deha.es
28660 Boadilla Del Monte (Madrid) Internet: www.halfen-deha.es

Sweden HALFEN-DEHA AB Phone: +46 – 31 – 98 58 00 Fax: +46 – 31 – 98 58 01

Box 150 E-Mail: info@halfen-deha.se
435 23 Mölnlycke Internet: www.halfen-deha.se

United Arab Emirates Salam Enterprises L.L.C. Phone: +971 – 4 – 28 96 289 Fax: +971 – 4 – 28 96 089
PO Box 28326 E-Mail: mail@salamenterprisesllc.com
Dubai Internet: www.salamenterprisesllc.com
11/04
0.00011/04

United Kingdom / HALFEN Ltd. Phone: +44 – 8705 – 31 63 00 Fax: +44 – 8705 – 31 63 04
Ireland 31 Humphrys Road · Woodside Estate E-Mail: info@halfen.co.uk
5.000

Dunstable LU5 4TP Internet: www.halfen.co.uk

USA Meadow-Burke Products Phone: +1 – 210 – 65 84 671 Fax: +1 – 210 – 65 88 312

8521 F.M. Road 1976 E-Mail: tbg@texas.net
Converse, TX 78109 Internet: www.halfenusa.com
11/04
012- -11/04

For futher adresses HALFEN-DEHA Vertriebsgesellschaft mbH Phone: +49 - 2173 - 970 840 Fax: +49 - 2173 - 970 425
please contact: Liebigstr. 14 E-Mail: info@halfen-deha.com
NE- -012

40764 Langenfeld, GERMANY Internet: www.halfen-deha.com

N

NOTES REGARDING THIS CATALOGUE:

Technical and design changes reserved
The information in this publication is based on state-of-the-art technology at the time of publication. We reserve the right
to make technical and design changes at any time. HALFEN-DEHA shall not accept liability for the accuracy of the
information in this publication or for any printing errors.

The HALFEN-DEHA Quality Management System is certified for the locations in Germany, Switzerland and
Poznan/Poland according to DIN EN ISO 9001/2000, Certificate No. QS-281 HH.