ASSOCIATION FRANAISE DES TUNNELS

ET DE LESPACE SOUTERRAIN
Organization member of the AFTES
www.aftes.asso.fr

AFTES
Recommendations
Watertightness of precast
concrete lining segments
GT9R6A1

AFTES WORKING GROUP 9

GUIDELINES ON

WATERTIGHTNESS OF PRECAST CONCRETE LINING

SEGMENTS
AFTES welcomes comments on this article before final approval

ES

Version 1 1998 - Approved by Technical Committee 7 April 1998

Drafted by

LONGCHAMP (Bouygues),
MERCIER (SOFRETU), and MEYNIEL (RATP)

PREAMBLE

AFTES Working Group 9 on tunnel watertightness has previously drafted and published
Guidelines on the watertightness of precast
segmental concrete tunnel linings.

(excluding gaskets)
- Mass porosity

- Cracking due to temporary or permanent

loads

FT

They dealt with gaskets and other points

directly concerned with them.

TYPES OF DISTRESS LIABLE

TO AFFECT WATERTIGHTNESS

Since tunnel watertightness does not depend

solely on the gaskets used in this type of
construction, it was found necessary to commit to writing fur ther ideas on the other
causes potentially affecting water tightness
performance and propose recommended
leakage preventive methods.

2. Segment
casting

- Flaws or distress affecting the gasket groove

or gasket contact surface.
ANALYSIS OF CAUSES OF DISTRESS LIABLE TO AFFECT WATERTIGHTNESS OF SEGMENTAL
LININGS

This list clearly illustrates that, at each stage of

the life of the lining, events may adversely
affect tunnel watertightness.
For clarity, details of the analysis of the causes
and possible remedies are presented in tabular form.

Excessive porosity

Insufficient concrete density

Gap graded aggregate

Special laboratory tests on concrete formulation

with porosity checks

Concrete deterioration

Cement and admixture proportions

Identification and analysis of natural and artificial

(contamination) factors in surrounding ground
liable to detract from concrete durability
Second lining and watertight system
Protection applied to lining extrados (coal tar)

1. Materials

- Concrete shrinkage cracking (insignificant in

precast lining segments)

The causes addressed arise from:

1. Constituent material of segments
2. Segment casting
3.Transport and storage of segments
4. Segment installation
5. Loads due to shield thrust
6. Grouting of annular space between lining
and tunnel bore
7. Llining ring and segment performance
during tunnel operation.

Physical/chemical reaction with

environment inside or outside tunnel

Non-homogeneous mix
(honeycombs, segregation)

Hydraulic binder quality

Test cement and concrete for compatibility with

environment

Compatibility between binder

and aggregate

Cement selection

All causes connected with concrete

casting, especially insufficient
VIBRATION

Compatibility of reinforcement design with

concrete composition (bar spacing ver sus
aggregate size)
Check vibration intensity
Experiments on effects of vibration and influence
zone and efficiency

TUNNELS ET OUVRAGES SOUTERRAINS HORS-SERIE N 1 2005

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Watertightness of precast concrete lining segments

For large items, resilient mould mounting that
does not dampen vibration
Avoid leaky moulds
Rough machined mould surfaces
Form release agents

Specify mould roughness

Poor segment geometry

Mould manufacturing tolerances

Specify finished mould manufacturing tolerances

as segment design volume, not just as tolerances
on lengths and flatness
See Fascicule 56A
Special attention to tolerances on angles of bearing surfaces between segments and between
rings

ES

Bubbles (at gasket

position)

Spalls, chipped arrises,

cracking

Mould not rigid enough, deforms

Include effects of vibration in mould design

Inadequate kinematics of moving

demoulding parts

Demoulding kinematics to be addressed in

segment mould design to specify draft angles

'Thermal shock' especially when

demoulding (Dt between concrete
and outside temperature)

Analyse segment stresses with reference to

handling equipment effectively used
Consider suction stresses due to demoulding.
Protect segments by inser ting compressible
material under gripper jaws

Concrete sticking to mould

Specify mould roughness

Choice of release agent and/or mould lining
Avoid sharp edges

Inadequate concrete early strength

Test effective strength on demoulding

Flaws in reinforcement; tolerance on

cage assembly

Specify tolerances on concrete cover on

drawings
Position reinforcement cages with accurate templates specially designed for each segment type
Specific testing and inspection

Positioning of cages in mould

Support reinforcement cages

FT

Spalls, chipped arrises,

cracking

Effects of segment handling systems

(gripping and turning)

Poor gasket bonding

3. Segment transport and storage

Inadequate concrete/adhesive/gasket
complex
Poor workmanship

Write detailed procedure for adhesive preparation and application and gasket fitting

Adhesive out of date

Use-by date to be shown on packaging

Use within stated time
Storage conditions to be stated and met

Inadequate protection to
hydrophilic gaskets

Gaskets expanded before fitting

Proper protection from the weather

Spalls, chipped arrises,

cracking

Impact damage (accidental or when

positioning)

Write detailed procedure for each handling and

storage operation
Use compressible supports on storage, transport
and handling equipment

TUNNELS ET OUVRAGES SOUTERRAINS HORS-SERIE N 1 2005

247

Watertightness of precast concrete lining segments

Spalls, chipped arrises,

cracking

Provide suitable supports during storage

Handling machines to have inching mechanism or
proportional speed control
Attention to storage support material, positioning and levelling, and base
Stock management to avoid excessive handling

Stacks too high

Provide enough storage yard area

See sections 2 & 3

Segment installation kinematics

Plan movements of segment in its immediate

environment when homing into place
Detailed study of key, counterkey and machine
interfaces when designing lining ring

ES

4. Segment installation

Supports poorly positioned or adjusted (especially with newly-cast segments)

Insufficient reinforcement

Allow for stray stresses often associated with

introduction of key between counterkeys

Excessively tight ring

Check free space between counterkeys before

inserting key
Accurate control of segment installation from
first to last

Gasket damaged by rubbing or snagging

Excessive friction
Poor bond

Grease longitudinal gaskets before installing segment

Check gasket bond

Key dislodges when

nearly home

Key self-guiding system not working

Provide for guidance between key and counterkeys in segment design

FT

Broken arrises on key and

counterkey

5. Loads applied by
shield

Chipped arrises, cracking,

broken edges, misalignment

5.1.Thrust

5.2. Shield rubbing

against lining rings

Chipped arrises, cracking

Thrust cylinder pads poorly seated

Use resilient thrust pads

Check kinematics of cylinder movement in tightest curves

Poor transmission of thrust loads between lining segments

Analyse stress paths in successive rings

Keep segment casting tolerances as tight as possible
Arrange for loads to be 'filtered' between rings

Rear effects of thrust cylinders in tight

curves

Mount cylinders on resilient ring or similar device

to allow enough angular movement between
cylinders and shield

Excessive thrust load from cylinders

Control pressure to groups of cylinders rather

than on/off control

Excessive pressure from thrust cylinder pads

Check bearing area

Check pad stiffness
Check segment tightness near pad positions and
contacts between rings

Clearance between lining and tailskin

too tight

Specify clearance with sketch

Use tailskin with free articulation

Lining ring off-centre

Procedure for setting out rotational position of

ring
High performance guidance/navigation system

Shield guidance

In the event of errors, specify correction curve

compatible with design,TBM and pinching of ring

TUNNELS ET OUVRAGES SOUTERRAINS HORS-SERIE N 1 2005

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Watertightness of precast concrete lining segments

6. Grouting stresses

Excessive grouting pressure

Provide active and passive overpressure devices

on grout pumps

Out-of-round
Dislodged key segment

Imbalance between grouting holes

Provide balanced grouting device

Grout mix suitability study

Upward movement of
lining due to buoyancy

Incomplete grouting
Grout formulation unsuitable

Control grouting pressure

Malfunctioning grouting plant and equipment

Other forms of distress

(unusual)

Effects of combined stress due to

groundwater, soil, and internal and
external loads

Review design assumptions

ES

7. Segmental lining
during operation of
tunnel

Distress at contact surfaces between segments

Electrical continuity between segments (bonding)

Cathodic protection
Materials quality
Reinforcement completely surrounded by
concrete

Various

Dowels between rings

FT

Displacements between
segments or between
rings

Ageing

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