Download 5.2 Bored tunnel construction method

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
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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
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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)
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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
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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)
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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.
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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)
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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
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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
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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.
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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).
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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
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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
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Schnitt Firstlinie
14
Section at ridge line
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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
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Additional technical contract conditions and guidelines for civil engineering works – Part 5 Tunnel
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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
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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
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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.
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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
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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,
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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
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