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1. ------IND- 2017 0207 D-- EN- ------ 20170608 --- --- PROJET Federal Highway Research Institute (Bundesanstalt für Straßenwesen) Additional Technical Contract Conditions and Guidelines for Civil Engineering Works ZTV-ING Part 5 Tunnel construction Section 5 Waterproofing Version: 2017/05 Additional technical contract conditions and guidelines for civil engineering works – Part 5 Tunnel construction – Section 5 Waterproofing Notified in accordance with Directive (EU) 2015/1535 of the European Parliament and of the Council of 9 September 2015 laying down a procedure for the provision of information in the field of technical regulations and of rules on Information Society services (OJ 241 of 17.9.2015, p. 1). 2 Version: 2017/05 Contents Page 5.1.2 Protective layers and protective measures .............................................. 16 5.2 Bored tunnel construction method........ 17 5.2.1 General ................................................. 17 5.2.2 Installation of protective layer ............... 17 5.2.3 Installation of plastic geomembranes ... 17 Application criteria ...............................8 5.2.4 Joint design .......................................... 17 2.1 General ...................................................8 5.2.5 Joining technique ................................. 17 2.2 Sealing classes .......................................8 5.2.6 Re-injection in the block joint ................ 18 3 System fundamentals ...........................8 5.2.7 Re-sealing work .................................... 18 3.1 General ...................................................8 5.2.8 Installing the protective layer in the base ...................................................... 18 3.2 Cut and cover construction method ........8 5.2.9 Laying aids ........................................... 18 3.3 Bored tunnel construction method ..........9 3.4 Pressure relief systems ..........................9 6 Quality assurance .............................. 18 3.5 Transitions/connections to waterproofing systems ............................9 6.1 Evidence required before starting waterproofing work ............................... 18 6.2 4 Waterproofing elements and installation components ....................10 Internal quality control of construction work by the contractor .......................... 19 6.2.1 General ................................................. 19 4.1 General .................................................10 6.2.2 Inspections of incoming goods ............. 19 4.1.1 Cut and cover construction method ......10 6.3 4.1.2 Bored tunnel construction method ........10 4.2 Plastic geomembranes (KDB) ..............10 Client monitoring of the construction of the plastic geomembrane waterproofing system .................................................. 19 4.2.1 General .................................................10 6.4 Execution documentation ..................... 19 4.2.2 Cut and cover construction method ......11 7 Invoicing and compensation ............. 20 4.2.3 Bored tunnel construction method ........11 4.3 Protective and drainage layer ...............11 4.3.1 General .................................................11 4.3.2 Cut and cover construction method ......11 4.3.3 Bored tunnel construction method ........11 4.4 Installation components ........................11 4.4.1 Fastening components .........................11 4.4.2 Profile strips ..........................................11 4.4.3 Venting and re-injection devices in the block joint ..............................................11 4.4.4 Testing and injection system for resealing...................................................12 5 Execution requirements .....................16 5.1 Cut and cover construction method ......16 5.1.1 Laying plastic geomembranes ..............16 1 General...................................................4 1.1 Fundamentals .........................................4 1.2 Definitions ...............................................4 1.3 Scope ......................................................4 1.4 Requirements for participants .................4 2 Version: 2017/05 3 Additional technical contract conditions and guidelines for civil engineering works – Part 5 Tunnel construction – Section 5 Waterproofing 1 General 1.1 Fundamentals (1) Part 5 Section 5 only applies in combination with Part 1 General. (2) The recommendations on waterproofing systems in tunnel construction (EAG-EDT) issued by the German Geotechnical Society (Deutschen Gesellschaft für Geotechnik e.V. – DGGT] contain additional explanations. geomembranes (KDB) for cut and cover and bored road tunnels. The regulations on cut and cover construction apply accordingly to the necessary waterproofing of trough constructions with plastic geomembranes, e.g. where groundwater is subject to corrosive chemical attack. (2) Sections 1 and 2 apply to concrete structures used with plastic geomembranes and waterproof concrete structures (WUB-KO), unless otherwise provided in these regulations. 1.4 1.2 Definitions (1) Waterproofing system consists of sealing and protective elements. (see Figure 5.5.1 and 5.5.2). (2) Waterproofing is a construction measure to protect the structure against the penetration of mountain water (general term). In this Section, a bound waterproof layer made of plastic geomembranes (KDB) is also referred to as waterproofing. (3) The definitions in Figures 5.5.1 and 5.5.2 also apply. 1.3 Scope (1) This Section applies to the technical construction and maintenance of new road tunnels. It deals with waterproofing systems with plastic Tunnelquerschnitt Einzelheit "A" 4 Requirements for participants (1) Only persons with proven in-depth expertise and practical experience in waterproofing work in tunnel construction can be entrusted with executing waterproofing measures in tunnel construction. Site managers must have at least five years’ and foremen at least three years’ practical experience with waterproofing work in tunnel construction. (2) Jointing work can only be carried out by welders with valid test certificates issued by the German Association for Welding and Related Processes [Deutscher Verband für Schweißen und verwandte Verfahren e.V. – DVS], Guideline DVS 2212-3. (3) Site managers and supervisors must have practical experience of relevant waterproofing work and have sufficient knowledge of how to carry out such work properly. Tunnel cross section Item A Version: 2017/05 Additional technical contract conditions and guidelines for civil engineering works – Part 5 Tunnel construction – Section 5 Waterproofing bodenseitige Schutzschicht z.B. Schutzbeton (bewehrt) Kunststoffdichtungsbahn (KDB) bauwerksseitige Schutzschicht (Geotextil) Konstruktionsbeton (WUB-KO) Abdichtungssystem Einzelheit "B" Konstruktionsbeton (WUB-KO) luftseitige Schutzschicht Sohle (z.B. Kunststoffschutzbahn) Kunststoffdichtungsbahn Schutzschicht (Geotextil) Unterbeton Ground-side protective layer e.g. protective concrete (reinforced) Plastic geomembrane (KDB) Structure-side protective layer (geotextile) Structural concrete (WUB-KO) Waterproofing system Item B Structural concrete (WUB-KO) Airside protective layer base (e.g. plastic protective layer) Plastic geomembrane Protective layer (geotextile) Concrete sublayer Fig. 5.5.1: Definitions (example: Cut and cover tunnel with plastic geomembrane waterproofing) Version: 2017/05 5 Additional technical contract conditions and guidelines for civil engineering works – Part 5 Tunnel construction – Section 5 Waterproofing Querschnitt mit geschlossener Sohle Spritzbetonauβenschale Abdichtungssystem Betoninnenschale Luftseite Einzelheit "A" Luftseite 6 Cross section with enclosed base Outer shotcrete shell Waterproofing system Inner concrete shell Airside Item "A" Airside Version: 2017/05 Additional technical contract conditions and guidelines for civil engineering works – Part 5 Tunnel construction – Section 5 Waterproofing Wasserseite/Bergseite Betoninnenschale Kunststoffdichtungsbahn (KDB) bergseitige Schutzschicht (Geotextil) ggf. Dränelemente Abdichtungsträger Spritzbetonauβenschale Abdichtungssystem Einzelheit "B" Luftseite Betoninnenschale luftseitige Schutzschicht Sohle Kunststoffschutzbahn) KDB bergseitige Schutzschicht (Geotextil) ggf. Dränelemente Abdichtungsträger Spritzbetonauβenschale Wasserseite/Bergseite Abdichtungssystem (z.B. Waterside/mountainside Inner concrete shell Plastic geomembrane (KDB) Mountainside protective layer (geotextile) Drainage elements where applicable Waterproofing supports Outer shotcrete shell Waterproofing system Item B Airside Inner concrete shell Airside protective layer base (e.g. plastic protective layer) Plastic geomembrane Mountainside protective layer (geotextile) Drainage elements where applicable Waterproofing supports Outer shotcrete shell Waterside/mountainside Waterproofing system Fig. 5.5.2: Definitions (example: bored tunnel) Version: 2017/05 7 Additional technical contract conditions and guidelines for civil engineering works – Part 5 Tunnel construction – Section 5 Waterproofing 2 2.1 Application criteria (3) It must be able to withstand potential movements, e.g. temperature deformations, from the surrounding structural elements without damage. General The main criteria for selecting the waterproofing system are water pressure, the sealing class required and the chemical composition of water and in-situ soil. 2.2 Sealing classes (1) The sealing classes as per Table 5.5.1 must be observed in respect of sealing requirements. (2) When waterproofing with plastic geomembranes, sealing class 1 must be met. The requisite waterproofing systems must be taken from Tables 5.5.2 and 5.5.3. (3) No water must escape via the testing and injection system, the injection hoses or the block joints. In the case of demonstrably damaged plastic geomembranes, e.g. water entering via the testing and injection system or via the block joints, sealing class 1 is not achieved. 3 System fundamentals 3.1 General (1) In bored tunnel construction, waterproofing is executed using plastic geomembranes joined together as a flexible and stretchable layer within narrow confines between the outer and inner shell. The plastic geomembrane must be secured against the outer shell with a protective layer. In cut and cover tunnels, the plastic geomembrane is on the outside of the bearing construction and must be secured on the structure side and on the ground side with a protective layer. (4) The waterproofing must be secured against damage e.g. from rough contact areas, punctual load or being driven over during the installation phase. (5) The waterproofing must be continuously dense regardless of adjoining structural elements. Installation material such as fastening components or injection nozzles must not reduce the effectiveness of the waterproofing. 3.2 Cut and method cover construction (1) The waterproofing systems are regulated in Table 5.5.2. (2) Cut and cover tunnels (rectangular or vault cross section) are generally executed as waterproof concrete structures as per Section 2 without external waterproofing. (3) When waterproofing plastic geomembranes against non-pressurised water the plastic geomembrane must not end in horizontal or slightly inclined roof surfaces (danger of water seeping underneath). The plastic geomembrane should be attached with a connecting strap or terminal strip at least 30cm below the transition edge from the horizontal to the vertical plane. If the tunnel ceiling is attached to the wall with a construction joint, the plastic geomembrane must extend from below at least 20cm beyond the construction joint. (4) If traffic routes are covered with a covering less than 1.00m, waterproofing as per Part 7 Sections 1 to 3 must be provided for the tunnel ceiling. (2) The waterproofing must not be used to reduce shearing forces. Table 5.5.1: Sealing classes Sealing class 1 2 3 8 Moisture characteristics Sealing requirements completely dry The structure must be sealed so that no damp patches can be detected on the insides. largely dry The construction must be sealed so that only isolated and slight damp can be detected on the insides (e.g. due to discolouration). No traces of water must be apparent on the hand after touching slightly damp patches with a dry hand. Blotting paper or absorbent newspaper placed on the patches should not discolour due to moisture absorption. capillary moisture The structure must be sealed so that only isolated and locally limited moist patches occur on the insides. Moist patches are those where moisture is clearly visible in the structure and blotting paper or absorbent newspaper placed on these patches discolours due to moisture absorption but there is no dripping water. Version: 2017/05 Additional technical contract conditions and guidelines for civil engineering works – Part 5 Tunnel construction – Section 5 Waterproofing 3.3 Bored method tunnel construction (1) The waterproofing systems are regulated in Table 5.5.3. (2) Shotcrete tunnels are generally waterproofed using a plastic geomembrane layer (see Figure 5.5.2). (3) When waterproofing against non-pressurised water, it must be permanently ensured that no water pressure load can occur due to the tunnel’s position over the mountain water table and/or due to the installation of more reliably effective pressure reduction devices such as drainage works. (4) With the standard drained construction method, waterproofing against non-pressurised water remains restricted to the tunnel vault (umbrella waterproofing). In this case, the plastic geomembrane ends at the vault base/base edge at the height of the drainage works. In a chemically corrosive environment, the plastic geomembrane must also pass through the base. (5) If in-situ mountain water can be conducted away unpressurised in the long term, umbrella waterproofing with 2mm-thick plastic geomembrane is sufficient. (6) If the surrounding water/soil mixture is chemically corrosive, all-round waterproofing with 2mm-thick plastic geomembrane is necessary even with non-pressurised water. (7) If a constant flow of water is to be expected when water pressure builds up and mountain water cannot be drained off without pressure, all-round pressure-retaining waterproofing with 3mm-thick plastic geomembrane must be provided. (8) With single-layer all-round waterproofing against pressurised water, external joint tape (partitioning joint tape) must be applied all the way around each block joint. (9) With all-round pressure-retaining waterproofing, a testing and injection system must be provided to allow for the resealing of grouting between the plastic geomembrane and the inner shell. (10) If water column pressure is greater than 30m above the tunnel floor, the need for special measures must be investigated. The DGGT Recommendations on waterproofing systems in tunnel construction – EAG-EDT contain instructions and examples. 3.4 Pressure relief systems (1) With extremely high water pressure, pressure relief systems such as relief openings may be used in the tunnel lining. They must be connected to a closed pipe system with water pressure limitation. (2) For longer tunnel structures, if the geological conditions are suitable, a partition can be inserted in sections with varying water pressure by installing embankment rings and injection foam. 3.5 Transitions/connections to waterproofing systems The transition from cut and cover to bored tunnel construction and/or the connections and penetrations to other waterproofing systems must be executed with profile strips or loose and fixed flange constructions or bonded connectors. Table 5.5.2: Waterproofing systems in cut and cover tunnel structures Waterproofi ng geometry Hydrostatic pressure above tunnel floor [mWC] Chemical attack on concrete as per DIN 4030 none slightly to moderately chemically corrosive Umbrella all-round up to ca. 25 (0.25 MPa) Version: 2017/05 Sealing elements in the waterproofing system Floor (where Ceiling/vault/wall Block joint necessary) 3mm plastic geomembrane - Construction joint (if available) - Waterproof concrete structures1) inner joint tape highly chemically corrosive 3mm plastic geomembrane - slightly to moderately chemically corrosive Waterproof concrete structures1) inner joint tape with steel tabs - Sheet metal joint 9 Additional technical contract conditions and guidelines for civil engineering works – Part 5 Tunnel construction – Section 5 Waterproofing highly chemically corrosive 1) Waterproof concrete structure + 3mm plastic geomembrane inner joint tape with steel tabs Sheet metal joint Standard construction (See Section 2) Table 5.5.3: Waterproofing systems in bored tunnel structures (shotcrete construction) Waterproofi ng geometry Hydrostatic pressure above tunnel floor [mWC] Chemical attack on concrete as per DIN 4030 none slightly to moderately chemically corrosive Umbrella highly chemically corrosive all-round up to ca. 30 3),4) (0.3 MPa) slightly to moderately chemically corrosive highly chemically corrosive Sealing elements in the waterproofing system Vault Floor (where necessary) Block joint Construction joint (if available) Other - - - inner joint tape with steel tabs Sheet metal joint - 2mm plastic geomembrane - - - 3mm plastic geomembrane1) outer partitioning joint tape injection hose Testing and injection system2) Waterproof concrete structures4) inner joint tape with steel tabs Sheet metal joint - 3mm plastic geomembrane outer partitioning joint tape injection hose Testing and injection system2) 2mm plastic geomembr 1) ane Waterproof concrete structures4) 1) Standard construction can only be used in consultation with the client. 3) with water pressure > 30 mWC (0.3 MPa) special measures must be taken, determined in each individual case 4) See Section 1 2) 4 Waterproofing elements and installation components (2) Profile strips and other waterproofing support measures must be used as additional installation components. 4.1 General 4.1.2 (1) The materials in the waterproofing systems and installation components must be compatible with each other and with the adjoining building materials and components and should also be weldable where applicable. The installation components must not reduce waterproofing function either in installed condition or in service condition. (2) In special cases, if the waterproofing elements and installation components are subject to longterm stress due to high temperatures, pressure or chemical attack for example, specific requirements must be determined in individual cases for the waterproofing elements and installation components. 4.1.1 (1) The waterproofing consists of the plastic geomembrane and a protective layer on the mountain side (see Figure 5.5.2). An additional internal protective layer must be provided in the base area. In the event of water penetration through the outer shell in drained tunnels a drainage layer must also be laid between the shotcrete outer shell and the mountainside protective layer. (2) Fastening components, profile strips and testing, injection systems where applicable and other waterproofing support measures must be used as additional installation components. 4.2 Plastic geomembranes (KDB) 4.2.1 General Cut and cover construction method (1) The waterproofing consists of the plastic geomembrane and a protective layer on the ground side and on the structure side. 10 Bored tunnel construction method The plastic geomembranes must meet the requirements of the technical delivery conditions Version: 2017/05 Additional technical contract conditions and guidelines for civil engineering works – Part 5 Tunnel construction – Section 5 Waterproofing and technical test specifications for plastic geomembranes and associated profile strips (TL/TP KDB). 4.2.2 Cut and cover construction method The plastic geomembranes must have signal coating on the ground side around the wall and ceiling area to indicate damage during laying or subsequent work. 4.2.3 4.3.1 Protective and drainage layer General Protective layers with or without drainage function and drainage layers of geosynthetic materials must meet the requirements of the technical delivery conditions and technical test specifications for protective and drainage layers of geosynthetic materials (TL/TP SD). 4.3.2 (5) The plastic protective strips must be at least 3mm thick and be compatible with the plastic geomembranes. (6) If the base waterproofing is driven over and/or if concentrated load of more than 400 kN/m2 are introduced, e.g. by the formwork carriage, the protective layer must be made of reinforced protective concrete. Bored tunnel construction method The plastic geomembranes must have signal coating on the inside of the tunnel to indicate damage during laying or subsequent work. 4.3 (4) The protective concrete must be at least 7cm thick and reinforced with a Q 131 A mat. Cut and cover construction method (1) Geotextiles must be used as a protective layer on the structure side between the concrete structure and the plastic geomembrane around the wall and ceiling area. A plastic protective layer or protective concrete must be laid in the base area on the structure side. (2) Depending on the framework conditions, protective layers with or without a drainage function on the ground side must be provided. (3) Table 5.5.4 details the types of protective layer on the ground side required for the various components. (4) Combinations of the protective layer types mentioned are possible. 4.4 Installation components 4.4.1 Fastening components (1) The plastic geomembrane may not penetrated by the fasting systems. (2) If rondelles are used, the nail must not punch through when the fastening element is inserted. To avoid damaging the plastic geomembrane, the elements must be designed so that the nail head is placed deep and the spacer does not tilt. (3) The fastening element must be designed to avoid overstressing the plastic geomembrane. If the connections between the plastic geomembrane and the fastening element is overstressed, the break must be made in the fastening element (predetermined breaking point). 4.4.2 Bored tunnel construction method (1) Geotextiles must be installed as a mountainside protective layer without drainage function. (2) Depending on the framework conditions, drainage layers of geosynthetic materials must be laid on the mountainside. (3) Reinforced protective concrete or protective layers of plastic protective strips must be used to protect the base waterproofing. Version: 2017/05 Profile strips (1) With pressure-retaining waterproofing, an outer profile strip (partitioning joint tape) with dimensions as per Figure 5.5.3 must be installed in the block joints. (2) The profile strips must meet the requirements of the technical delivery conditions and technical test specifications for plastic geomembranes and associated profile strips. (3) Working joints are not generally sealed with profile strips (see Table 5.5.3), but are given an injection hose for grouting as required. 4.4.3 4.3.3 be Venting and re-injection devices in the block joint When there is pressure-retaining waterproofing on both sides of the block joint, at least six radially integrated hoses or pipes with an internal diameter of ca. 20mm must be inserted in the stop anchor interspace for venting and scheduled re-injection in the area around the block joints (see 5.2.4). The layout of the re-injection or vent hose is set out in Figure 5.5.4, Figure 5.5.5 and Figure 5.5.6 (element 1 in each case). 11 Additional technical contract conditions and guidelines for civil engineering works – Part 5 Tunnel construction – Section 5 Waterproofing 4.4.4 Testing and injection system for resealing (1) A testing and injection system must be provided for pressure-retaining waterproofing. The elements of the testing and injection system are shown in Figure 5.5.4 (see elements 3 and 4) and described in more detail in paragraphs (2) and (3). The elements of the testing and injection system must also be provided with openings for scheduled top joint injection as per Section 1. (2) One radially integrated grouting hose must be inserted in the ridge area and two radially integrated grouting hoses must be inserted in the side walls on each side of the block joint to re-seal the partitioning joint tape as required with stop anchor interspace distant from the joint. The layout of the grouting hose around the block joints is set out in Figure 5.5.4, Figure 5.5.5 and Figure 5.5.6 (element 3 in each case). (3) The areas adjacent to the partitioning joint tapes must be fitted with radially integrated grouting hose for re-sealing as required. The grouting hoses must be protected against closure during concreting and protected during top joint injection (see Section 1). The distance between grouting hoses must be no more than 3m in longitudinal and circular direction. The layout of the injection devices in the field area is set out in Figure 5.5.4 (see element 4). (4) The contractor is free to lay additional grouting hoses in the side walls at its own expense. The number of additional openings for formwork carriages is limited to four. (5) To avoid damaging the plastic geomembrane, all vent and (re-)grouting hoses in the testing and injection system must be designed so that they do not change position when the concrete is laid. (6) If there is a leak in the waterproofing, the testing and injection system must allow water to exit as well as allow for grouting or injection. (7) Fillers for re-injection or injection and their use are regulated in Part 3 Section 5. Table 5.5.4: Protective layer types depending on installation site of protective layer for cut and cover tunnels Type of protective layer Installation site of protective layer Base 12 Tunnel ceiling Rectangular cross section Vault Vault cross section X X 1) X Protective concrete X Plastic protective strips X X X Geotextiles/drainage mats X X X Protective walls 1) Wall Rectangular cross section X X X 1) only in exceptional cases Version: 2017/05 Additional technical contract conditions and guidelines for civil engineering works – Part 5 Tunnel construction – Section 5 Waterproofing a e b r f1 d g Breiten 600 f c p a [mm] h i b [mm] Profilierung Dicken p [mm] c [mm] d [mm] n [-] e [mm] f [mm] f1 [mm] g [mm] h [mm] i [mm] r [mm] 4-5 3-4 6 70 30-35 26 5 4 12-14 3 200-220 50-60 a Gesamtbreite des Fugenbandes g b Breite des Dehnteils c Dicke der Grundplatte d Dicke der Anschweißenden e Achsabstand der Sperranker f Gesamthöhe des Fugenbandes f1 Höhe der Sperranker über der Grundplatte n Anzahl der Sperranker (ohne Rippen) p Breite der Anschweißenden r Radius der Ausrundung für den Anschluss Breite der Sperranker am Fuß oberhalb der Ausrundung h Breite der Sperranker an der schmalsten Stelle (ohne Rippen) i Breite der Kopfverstärkung an den Sperrankern an die Grundplatte Breiten Dicken Profilierung Gesamtbreite des Fugenbandes Breite des Dehnteils Dicke der Grundplatte Dicke der Anschweißenden Achsabstand der Sperranker Gesamthöhe des Fugenbandes Höhe der Sperranker über der Grundplatte (ohne Rippen) Breite der Sperranker am Fuß oberhalb der Ausrundung Breite der Sperranker an der schmalsten Stelle (ohne Rippen) Breite der Kopfverstärkung an den Sperrankern Anzahl der Sperranker Breite der Anschweißenden Radius der Ausrundung für den Anschluss an die Grundplatte Widths Thicknesses Profiling Overall width of joint tape Width of elongation part Thickness of base plate Thickness of welding ends Centre distance of stop anchors Overall height of joint tape Height of stop anchor above base plate (without ridges) Width of stop anchor at the foot above smoothing Width of stop anchor at the narrowest point (without ridges) Width of head reinforcement on stop anchors Number of stop anchors Width of welding ends Radius of smoothing for connection to the base plate Fig. 5.5.3: Basic dimensions of partitioning joint tape, bored tunnel construction method Version: 2017/05 13 Additional technical contract conditions and guidelines for civil engineering works – Part 5 Tunnel construction – Section 5 Waterproofing Schnitt Firstlinie 14 Section at ridge line Version: 2017/05 Additional technical contract conditions and guidelines for civil engineering works – Part 5 Tunnel construction – Section 5 Waterproofing luftseitige Schutzschicht Sohle (Kunststoffdichtungsbahn) Kunststoffdichtungsbahn (KDB) Bergseitige Schutzschicht (Geotextil) Spritzbetonauβenschale mit Abdichtungsträger Schottfugenband Entlüftungs-/ Nachverpressschläuche bzw. rohre Entlüftungsventil Schottfugenband Verpressschläuche für Nachdichtungsarbeiten Verpressschläuche für Nachdichtungsarbeiten; Abstand ≤ 3m in Längs- und Ringrichtung Hinweis: Nachbetonier- bzw. Nachverpressseinrichtungen des Schalwagens gemäβ Abschnitt 1 Nr. 7.3.1 (2) und (3) sowie Einfüllstutzen für die planmäβige First- spaltverpressung gemäβ Abschnitt 1 Nr. 7.3.5 sind nicht dargestellt. Detail "Schottfugenband First" "Schottfugenband Sohle" air-side protective layer base (e.g. plastic geomembrane) Plastic geomembrane (KDB) mountainside protective layer (geotextile) outer shotcrete shell with waterproofing supports Partitioning joint tape Vent/re-injection hoses or pipes Partitioning joint tape vent valve Injection hoses for re-sealing Injection hoses for re-sealing; distance ≤ 3m in longitudinal and circular direction NB: Re-concreting or re-injection devices on the formwork carriage as per Section 1 point 7.3.1 (2) and (3) filler tubes for scheduled top joint injection as per Section 1 point 7.3.5 are not illustrated. Detail "Partitioning joint tape on ridge" "Partitioning joint tape at base" Fig. 5.5.4: Venting and re-injection devices as well as testing and injection system for pressure-retaining waterproofing, bored tunnel construction method Version: 2017/05 15 Additional technical contract conditions and guidelines for civil engineering works – Part 5 Tunnel construction – Section 5 Waterproofing Entlüftungsund Nachverpressschläuche bzw. –rohre im äuβeren und inneren Sperrankerzwichenraum Entlüftungsventil für den Raum zwichen KDB und Schottfugenband Verpressschläuche für eine eventuell erforderliche Nachdichtung des Schottfugenbandes, alle im fugenfernen Sperrankerzwichenraum Vent and re-injection hoses or pipes in outer and inner stop anchor interspace Vent valve for the space between the plastic geomembrane and the partitioning joint tape Injection hoses to re-seal the partitioning joint tape as required, all with the stop anchor interspace distant from the joint. Firstlinie Ulme Schottfugenband Blockfuge Entlüftungs/Nachverpressschläuche bzw. -rohre Entlüftungsventil Schottfugenband Verpressschläuche für Nachdichtungargeiten Rand des Fugenbandes Ridge line Side walls Partitioning joint tape Block joint Vent/re-injection hoses pipes or Partitioning joint tape vent valve Injection hoses for re-sealing Edge of joint tape Fig. 5.5.6 Venting and re-injection devices around the block joints, execution 5 Execution requirements 5.1 Cut and method 5.1.1 Laying plastic geomembranes Fig. 5.5.5: Vent and re-injection devices around the block joints, bored tunnel construction method cover construction (1) The plastic geomembranes must be laid loose and welded to an entire area. (2) The plastic geomembrane must be welded to the connecting strap or held with a terminal strip at all ends of the waterproofing. 5.1.2 Protective layers and protective measures (1) Areas that are sealed and released for further work must be protected against expected effects and stress such as weather conditions immediately after laying. (2) When filling the excavation pit the waterproofing must not be damaged. The maximum grain size of 16 Version: 2017/05 Additional technical contract conditions and guidelines for civil engineering works – Part 5 Tunnel construction – Section 5 Waterproofing the fill material must not exceed 8mm up to 20cm above the protective layers. The area must be filled in accordance with the additional technical contract conditions and guidelines for earthworks in road construction [Zusätzliche Technische Vertragsbedingungen und Richtlinien für Erdarbeiten im Straßenbau – ZTV E-StB]. (3) Geotextile protective layer membranes must overlap by at least 10cm and must be secured in position. 5.2 Bored method 5.2.1 General tunnel construction (1) A sealing support must be provided as a separate layer (see Section 1). (2) The plastic geomembranes must be laid loose and welded to an entire area. (3) With all-round waterproofing against pressurised water a bulkhead must be provided on each block joint. To do this, joint tapes running all the way around the plastic geomembrane (partitioning joint tape) must be welded and set in concrete in the inner shell. 5.2.2 Installation of protective layer (1) The geotextile must be fastened with suitable fastening elements or aids. 5.2.4 Joint design (1) When waterproofing against unpressurised water, an additional reinforcing plastic geomembrane strip at least 0.50m wide or a plastic protective layer with the same thickness as the plastic geomembrane must be laid centrally above the block joint on the airside of the plastic geomembrane and welded on both sides. Provision must be made for venting. (2) With pressure-retaining waterproofing, the partitioning joint tape (Figure 5.5.3) must be welded onto the plastic geomembrane on both edges and must be water-pressure tight (see 5.2.5). The connection must be so firm that it is impossible to subsequently remove the partitioning joint tape from the plastic geomembrane. (3) If large-scale movements are expected around the block joint when waterproofing against unpressurised water, the use of a partitioning joint tape as per Figure 5.5.3 must be reviewed. (4) In the ridge area, all interspaces between studs must be vented (Figure 5.5.4, Figure 5.5.5 and Figure 5.5.6, element 1 in each case). (5) To prevent an airlock when concreting between the plastic geomembrane and the partitioning joint tape, an opening must be made in the partitioning joint tape (Figure 5.5.4, Figure 5.5.5 and Figure 5.5.6, element 2 in each case). (6) If movements in excess of 5mm are expected between the blocks, special measures must be taken around the block joint (e.g. padding). (2) The membranes must overlap by at least 10cm. 5.2.5 5.2.3 Installation of plastic geomembranes (1) The plastic geomembranes must be fastened using fastening elements so that they are subject to as little load as possible when the inner shell is being concreted and so that wrinkling is avoided. (2) Insufficiently attached fastening elements must be removed and replaced before welding the plastic geomembrane. (3) The following minimum requirements must be met for the number of fastening points: – Base: 1 pcs/m2, – Side walls: 2 pcs/m2 and – Ridges: 3 pcs/m2. (4) The plastic geomembrane must not be driven over before a protective layer is installed in the base (see 5.2.8). Joining technique (1) The seams between plastic geomembranes and the seams between the plastic geomembrane and the profile strip must meet the requirements of DVS 2225-5. The joint seams between the plastic geomembranes must be executed with welding machines (heat-welding). The seams between the plastic geomembrane and the profile strip must be executed either with hand-held welders or with welding machines. (2) The individual plastic geomembranes must overlap by at least 8cm. Connections to the loosely laid plastic geomembrane must be executed as an overlap seam with test channel. (3) With T-joints, the last welded seam must be continuously testable. (4) Cross joints are not permitted. (5) The width of individual seams on an overlap seam with test channel must be at least 15mm. (6) The test channel on the welding seam for connecting two plastic geomembranes must be Version: 2017/05 17 Additional technical contract conditions and guidelines for civil engineering works – Part 5 Tunnel construction – Section 5 Waterproofing between 10 and 20mm wide, depending on the material. (7) The sealing of overlap seams with test channel must be tested with pressurised air as per DVS 2225-5. (8) If at individual points such as recesses or cuts the welding seam between the plastic geomembranes cannot be formed as an overlap seam with test channel, an overlap seam without test channel at least 30mm wide (full seam) created with a hand-held welder is permissible. Sealing must be demonstrated by vacuum testing as per DVS 2225-5. (9) Adhesive joints and swell welding are not permissible. (10) Welding seam connections of loosely laid plastic geomembranes are not permitted without special measures at ambient temperatures below 5°C and relative humidity over 80%. (11) Butt joints of profile strips must be executed with a heater bar with guide mechanism. After jointing the butt seam, the weld bead that forms must be carefully removed. The maximum permissible offset between stop anchor axes is 2mm. 5.2.9 Laying aids (scaffolding, laying carriages, etc.) must be designed so that they do not damage the plastic geomembranes. 6 Quality assurance 6.1 Evidence required before starting waterproofing work (1) The contractor must submit the following product certifications to the client in good time (no later than 4 months) before starting waterproofing work: a) For standardised European products, i.e. plastic geomembranes and geotextile or geotextilerelated protective and drainage layers: CE documents Test reports with the results of initial inspection of incoming goods as per the technical delivery conditions and technical test specifications for plastic geomembranes and associated profile strips and the technical delivery conditions and technical test specifications for protective and drainage layers of geosynthetic materials or test reports for valid suitability testing and valid external production control (FÜ-P) and a valid certificate of conformity as per the technical delivery conditions and technical test specifications for plastic geomembranes and associated profile strips and the technical delivery conditions and technical test specifications for protective and drainage layers of geosynthetic materials. (12) The ambient and welding conditions must be documented during execution. 5.2.6 Re-injection in the block joint Scheduled re-injection when executing the inner shell must be carried out as per Section 1. 5.2.7 Re-sealing work (1) During re-sealing work to remove leaks in pressure-retaining waterproofing, a testing and injection system must be provided around the block joints (see 4.4.4). The testing and injection system may only be used after approval by the client. (2) Any necessary re-sealing grouting or injection work must be executed as per Part 3 Section 5. 5.2.8 Installing the protective layer in the base (1) A protective layer must be installed and subsequent work conducted to avoid the penetration of foreign matter and concrete in the protective layer and the plastic geomembrane. (2) The protective layer must be secured against displacement during the construction stage. Laying aids b) For products not standardised in Europe, i.e. profile strips, plastic protective strips and drainage layers not classified under geotextiles.: Test reports for valid suitability testing and, for profile strips, valid external production control as per the technical delivery conditions and technical test specifications for plastic geomembranes and associated profile strips and the technical delivery conditions and technical test specifications for protective and drainage layers of geosynthetic materials (2) The contractor must also submit the execution schedule and the QS plan. (3) The contractor may not start waterproofing work until after the client has given its approval. 18 Version: 2017/05 Additional technical contract conditions and guidelines for civil engineering works – Part 5 Tunnel construction – Section 5 Waterproofing 6.2 Internal quality control of construction work by the contractor 6.2.1 General defined in the Construction Tendering and Contract Regulations. 6.2.2 (1) Work must be subject to ongoing internal quality control. (2) On delivery, the contractor must identify products in respect of the product characteristics and documentation set out in the technical delivery conditions and technical test specifications for plastic geomembranes and associated profile strips and the technical delivery conditions and technical test specifications for protective and drainage layers of geosynthetic materials and check that they are in order. (3) Certificates of conformity must be checked as appropriate during waterproofing work using the reports on the valid external production control or during inspections of incoming goods for each delivery. (4) All documents required under 6.4 as well as the technical delivery conditions and technical test specifications for plastic geomembranes and associated profile strips and the technical delivery conditions and technical test specifications for protective and drainage layers of geosynthetic materials must be submitted to the client. (5) The waterproofing laid must be examined to rule out the occurrence of any wrinkles when concreting the inner shell or overfilling using the cut and cover construction method. The contractor must conduct the tests, log the results and forward these to the client. The client must be informed in advance of the date when the testing is to be carried out. (6) Testing the joint seams between plastic geomembranes and between plastic geomembranes and profile strips must be jointly conducted and logged by both contractor and client. DVS 2225-5 applies. The reports shall be forwarded to the client. (7) Before and after installing the inner shell reinforcement, the waterproofing must be checked for damage. The contractor must provide the client with report. (8) Injection procedures carried out as scheduled and/or as necessary must be logged and the reports forwarded to the client. (9) The contractor must ensure that individual components are accessible for checking finished partial deliveries. (10) If finished partial deliveries are released to allow subsequent partial deliveries such as the inner shell, this does not qualify as acceptance as Version: 2017/05 Inspections of incoming goods (1) The contractor must have the necessary inspections of incoming goods carried out by an accredited independent conformity assessment body. The competence of the conformity assessment body shall be determined in accordance with the Additional Technical Contract Conditions and Guidelines for Civil Engineering Works, Part 1, Section 1, Table A 1.1.1, line 1. (2) Samples for inspections of incoming goods shall be taken on the contractor’s initiative by the person responsible for supervising the construction of the plastic geomembrane waterproofing system (see 6.3) or by the local construction supervision body. Sampling is done upon delivery at the building site or alternatively at the manufacturing plant from the batch ready for delivery. (3) The contractor must submit the test reports on the inspection of incoming goods to the client and release the client’s products for installation. 6.3 Client monitoring of the construction of the plastic geomembrane waterproofing system In the case of tunnels with highly challenging waterproofing characteristics, e.g. tunnels with allround pressure-retaining waterproofing subject to water pressure of over 10 mWC, special supervision of the waterproofing work must be carried out by a suitably qualified body. The qualification requirements for this body and the tasks are set out in the recommendations on waterproofing systems in tunnel construction (EAGEDT) issued by DGGT working group 5.1 on plastics in geotechnology and hydraulic engineering. If it has the relevant qualifications, the local construction supervision body may also undertake the independent supervision of waterproofing work. 6.4 Execution documentation Project-related documentation must be forwarded by the contractor to the client on an ongoing basis as well as in a final document. The documentation must cover at least the following points: a) Description and explanation of the construction method and schedule for the waterproofing work, b) Description of materials, products, installation components and building aids used, 19 Additional technical contract conditions and guidelines for civil engineering works – Part 5 Tunnel construction – Section 5 Waterproofing c) Data sheets for the waterproofing elements and description of installation components, d) Evidence of construction: internal quality control of – CE documents, – Results of suitability testing and external production control and/or inspections of incoming goods as per the technical delivery conditions and technical test specifications for plastic geomembranes and associated profile strips and the technical delivery conditions and technical test specifications for protective and drainage layers of geosynthetic materials including test reports and certificate of conformity, – As-built laying plan (joint seam plan), – Results of joint seam testing – Installation dates or periods and – Records of grouting procedures, as scheduled and as necessary, including subsequent grouting procedures. e) Results of cross-checks and f) Photographs of key structural stages. 7 Invoicing and compensation (1) Sealing supports, plastic geomembranes, drainage layers and protective layers shall be invoiced individually according to surface area. Profile strips shall be invoiced according to length. (2) The surface area shall be determined by multiplying the theoretical outer periphery of the inner shell by the length in the tunnel axis. Openings, recesses and niches with a surface area of up to 2.50m² shall be discounted. (3) Measures and applications used to make the waterproofing ready to use and functional, e.g. laying carriages, anchoring tracks, welding tracks together and/or with the profile strips, and tightness testing shall not be remunerated separately. (4) Profile strips and reinforcing strips must be provided as separate positions in the specifications. (5) The contractor shall bear inspections of incoming goods. 20 the costs of Version: 2017/05