Civil

Ci il Engineering
E i i
Tunnel Construction

Prepared by

Mr. Roland von Ah

Presented by

Mr. Kirby Lorenzo

Page 1 31.05.2007
Scope

Page 2 31.05.2007
Scope

water reservoir coated with

HD-PE 2.0mm

cleaning pool coated and welded

with ASTRO

Page 3 31.05.2007
 Scope

artificial lake on golf course welded

with COMET 70mm

Page 4 31.05.2007
Scope

Landfill, HDPE liner welded

Landfill
with ASTRO

PVC 2.5mm for groundwater

sealing with TWINNY T

Page 5 31.05.2007
Scope

Drainage channel sealed with HDPE

on a heap leaching copper mine.

Water basin used as shrimp

p farm,,
HDPE liner welded with COMET.

Page 6 31.05.2007
Scope

Secondary containment for ground water protection

Page 7 31.05.2007
Scope

tunnel cover with PVC 3mm, carried

outt with
ith TWINNY S

Tunnel driving in a side-gallery with

bl ti
blasting

Page 8 31.05.2007
Welding Procedure

Page 9 31.05.2007
Welding Procedure

Following welding procedures are possible:

extrusion welding
hot wedge welding (heating element)
hot air welding

All welding procedures require an accordance of the following parameters:

temperature
pressure
speed

Joining areas must be dry and free of impurity. For T-joints and when build-up
welding the front surface of the upper membrane must be held slanted.

Page 10 31.05.2007
Welding Procedure

Hot Wedge Welding

COMET ASTRO COSMO

Page 11 31.05.2007
Welding Procedure

Combi Wedge Welding

TWINNY S TWINNY T TWINMAT

Page 12 31.05.2007
Welding Procedure

Hot Air Welding

TRIAC DRIVE - HAND TOOLS

Page 13 31.05.2007
Welding Procedure

FUSION 3 WELPLAST WELDMAX

Page 14 31.05.2007
Welding Procedure Under Construction Site Conditions

C diti off Surface

Condition S f
solid underground with smooth surface without bumps
Building sites should be free of sharp items, roots and stones.

Environment Conditions / Weather Conditions / Rain

In case of rain it must not be welded without any special safety measures.

Air Temperature
Welding procedures have to be stopped at temperatures under +5C
+5 C in
order to prevent high thermal strains of the membrane.

Page 15 31.05.2007
Welding Procedure Under Construction Site Conditions

Air H
Ai Humidity
idit
High air humidity might cause perspiration water on the welding surface which
is unfavourable for the seam strength (towel or pre-heat).

Wind
Due to strong wind the required welding temperature might not be reached. To
solve this problem, the welding temperature has to be increased up to 2030C.
If the wind is too strong,
strong the welding area should be protected
protected, or the welding
process has to be stopped.

Sunshine
Sunshine causes strong heat, especially of black membranes. This causes an
increased thermal expansion of the membrane and results in wrinkles. The
welding process becomes more difficult, and when cooling down abnormal strain
in the seam area occurs.
occurs

Page 16 31.05.2007
Welding shape according DVS 2225 Teil 1

Page 17 31.05.2007
 Test procedure: Test on construction site
according DVS 2225 Teil 2

Outer appearance of the seam (visual control of notches, grooves and irregularities)

Examination of the dimension (measuring)

Strength test (tensile test)

Leak-tightness test (Testing with compressed air)

Page 18 31.05.2007
Test Procedure: Test on construction site
according DVS 2225 Teil 2

Strength test (tensile test)

Page 19 31.05.2007
Test Procedure: Test on construction site
according DVS 2225 Teil 2

Leak-tightness test
(Testing with compressed air)

Page 20 31.05.2007
A t
Automatic
ti Machines
M hi

Page 21 31.05.2007
Hot Wedge and Combi Wedge
automatic welding machines

Combi Wedge Welding Machines (hot air heated)

TWINNY S
TWINNY T
TWINMAT

Hot Wedge Welding Machines (contact heat)

COMET
ASTRO
COSMO

Page 22 31.05.2007
Wedge Welding Machine

COMET
W d welding
Wedge ldi machine
hi

smallest compact
machine
wide range of
applications
HD-PE, PP and PVC

Page 23 31.05.2007
Wedge Welding Machine

ASTRO
W d welding
Wedge ldi machine
hi
worldwide the fastest
wedge welding machine
very robust
one-handle operation

Page 24 31.05.2007
Wedge Welding Machine

ASTRO BSP (for nap-material)

W d welding
Wedge ldi machine
hi

faster than conventional

welding
ldi procedures
d

up
p to 3.5mm membranes

up to 19mm nap-material

Page 25 31.05.2007
Concrete Guard Plates Nap Membranes

Omega - naps T - naps

V - naps Flat naps

Page 26 31.05.2007
Wedge Welding Machine

COSMO
W d welding
Wedge ldi machine
hi

process control by direct

measuring

welding printouts for quality

assurance

max. pressure of 2500N

Page 27 31.05.2007
Wedge Welding Machine

COSMO
W d welding
Wedge ldi machine
hi Protocol printout of a
weld for quality
assurance

process control by direct measuring of welding seam

reduction
d ti

Page 28 31.05.2007
Hot Air welding machine

TWINNY T
C bi wedge
Combi d welding
ldi machine
hi

small and handy

combi wedges easy to
change
suitable for all materials

Page 29 31.05.2007
Hot Air welding machine

TWINNY S
C bi wedge
Combi d welding
ldi machine
hi

ideal for tunnel construction

low weight
highest speed up to
4m/min

Page 30 31.05.2007
Hot Air welding machine

TWINNY S
C bi wedge
Combi d welding
ldi machine
hi

Page 31 31.05.2007
TWINNY S: Different Gears

G
Gear 144:1
144 1 G
Gear 256:1
256 1

speed of 0.8 4.0 m/min speed of 0.2 2.5 m/min

max. pressure of 500N max. pressure of 1000N
thin materials are suitable thick materials are suitable
current limiter (motor
( switches off)
ff) currentt limiter
li it ((motor
t switches
it h off)
ff)

Page 32 31.05.2007
TWINNY S / T: Application Range Nozzles

Combi Wedge Material Thickness

PE-HD, PE-C, PFA, PP 0.3 - 1.0mm

1 PVC-P, PE-LD, EVA 0.3 - 2.0mm

1 short combi wedge with test channel

2 2 short combi wedge without test channel

Combi Wedge Material Thickness

3
PE-HD,
PE HD PE
PE-C,
C PFA
PFA, PP 0.8
0 8 - 2.0mm
2 0mm
PVC-P, PE-LD, EVA 1.0 - 3.0mm

3 long combi wedge with test channel

4
4 long combi wedge without test channel

Page 33 31.05.2007
Hot Air

TWINMAT
C bi wedge
Combi d welding
ldi machine
hi

Process control by direct

measuring

welding printouts for quality

assurance

max. pressure of 2500N

Page 34 31.05.2007
 Differences of Hot Wedge and Combi Wedge

Hot Wedge Combi Wedge

no change of nozzle (PVC/PE)

Advantages: small heat output
suitable for thin materials
compact design
blows away dirt in the seam
low noise
stress-free welding procedure

Disadvantages:
change of wedge PVC/PE high heat output (wattage)
depending on weather slow speed
cleaning of seam absolutely
necessary when wet

Page 35 31.05.2007
 Application Range According to Material

HD-PE LD-PE PVC

0.3 0.5 1.0 1.5 2.0 2.5 3.0 4.0 5.0 0.3 0.8 1.0 1.5 2.0 0.8 1.0 1.5 2.0 2.5 3.0

g
Wedge
COMET 70mm (copper wedge) (X) X X (X) X X
COMET 50mm (copper wedge) X X (X) X X
COMET 70mm (steel wedge) X X X
COMET 50mm (steel wedge) X X
COMET 20mm ((steel wedge)
g ) X X X X
ASTRO X X X X
COSMO X X X X

Combi wedge
TWINNY S (short wedge) X X X X X X X X X
TWINNY S (long wedge) X X X X X X X
TWINNY T (short wedge) X X X X X X X X X
TWINN T (long wedge) X X X X X X X
TWINMAT X X X X X X

Page 36 31.05.2007
 Useful welding parameter for HDPE Membranes
Please note: the indicated welding parameter may vary depending on the ambient temperature and the material
configuration. Test welds needs to be done and the parameter aligned accordingly !

HDPE
Wedge 0.3 0.5 1 1.5 2 2.5 3 4 5
COMET 70mm (copper) 380 C
380C 420C
420 C 420 C
420C 420 C
420C
2.5 m/min 2.5 m/min 2.2 m/min 2.0 m/min
600 N 800 N 1000 N 1000 N
COMET 50mm (copper) 380C 420C 420C
2.3 m/min 2.2 m/min 2.0 m/min
500 N 600 N 800 N
COMET 70mm (steel)
COMET50mm (steel)
COMET 20mm (steel) 400C 420C
2.0 m/min 1.5 m/min
400 N 500 N
ASTRO 420C 420C 420C 420C
5.0 m/min 4.5 m/min 4.2 m/min 4.0 m/min
1250 N 1500 N 1500 N 1500 N
COSMO 420C
420 C 420C
420 C 420C
420 C 420C
420 C
3.0 m/min 2.5 m/min 2.3 m/min 2.0 m/min
1250 N 1500 N 1500 N 1500 N
Combi wedge
TWINNY S (short) 450C 500C 500C
3.5 m/min 3.0 m/min 2.0 m/min
400 N 600 N 800 N
TWINNY S (long) 550 C
550C 550C
550 C
2.0 m/min 1.8 m/min
800 N 1000 N
TWINNY T (short) 420C 500C 500C
3.2 m/min 3.0 m/min 2.0 m/min
400 N 600 N 800 N
TWINNY T (long) 550C 550C
2 0 m/min
2.0 1 8 m/min
1.8
800 N 1000 N
TWINMAT 530C 550C 550C 550C 550C 550C
2.5 m/min 2.5 m/min 2.3 m/min 2.0 m/min 1.6 m/min 1.2 m/min
1250 N 1250 N 1300 N 1500 N 1750 N 2000 N

Page 37 31.05.2007
Useful welding parameter for LDPE & PVC Membranes
Please note: the indicated welding parameter may vary depending on the ambient temperature and the material
configuration. Test welds needs to be done and the parameter aligned accordingly !

LDPE PVC
Wedge 0.3 0.8 1.0 1.5 2.0 0.8 1.0 1.5 2.0 2.5 3.0
COMET 70mm
70 ((copper)) 400C 400C
2.8 m/min 2.5 m/min
600 N 800 N
COMET 50mm (copper) 380C 420C
2.5 m/min 2.5 m/min
500 N 600 N
COMET 70mm (steel) 400C 420C 420C
2.8 m/min 2.5 m/min 2.4 m/min
700 N 800 N 1000 N
COMET 50mm (steel) 400C 420C
2.8 m/min 2.5 m/min
600 N 600 N
COMET 20mm (steel) 350C 350C
2.0 m/min 2.0 m/min
500 N 400 N
ASTRO
COSMO

Combi wedge
TWINNY S (short) 480C 500C 500C 500C 550C 600C
3 5 m/min 3.0
3.5 3 0 m/min 2.0
2 0 m/min 2 5 m/min 2.5
2.5 2 5 m/min 2.5
2 5 m/min
400 N 500 N 600 N 400 N 500 N 600 N
TWINNY S (long) 500C 550C 550C 580C 600C
2.5 m/min 2.0 m/min 2.5 m/min 2.5 m/min 2.0 m/min
600 N 700 N 600 N 700 N 800 N
TWINNY T (short) 450C 500C 500C 500C 550C 560C
3.2 m/min 3.0 m/min 2.0 m/min 2.5 m/min 2.5 m/min 2.3 m/min
400 N 500 N 600 N 400 N 500 N 600 N
TWINNY T (long) 500C 550C 550C 550C 560C
2.5 m/min 2.0 m/min 2.5 m/min 2.5 m/min 2.0 m/min
600 N 700 N 600 N 800 N 1000 N
TWINMAT

Page 38 31.05.2007
Semii automatic
S t ti and
d hand
h d
welding tools

Page 39 31.05.2007
Hand Tools Semi Automatic Welding Tools

TRIAC PID TRIAC DRIVE

TRIAC S

Page 40 31.05.2007
TRIAC DRIVE Application

horizontal, vertical, diagonal

different welding seam widths
applicable in the most confined spaces

ideal job for diagonal connections in a

t
tunnel l

Page 41 31.05.2007
TRIAC S / PID Application

Overlap welding of connections with Tacking of HDPE membrane prior

TRIAC PID (PVC-P or modified PE) to extrusion welding

Page 42 31.05.2007
T
Tensiometer
i t

Page 43 31.05.2007
Construction Site Tensiometer

EXAMO
Peeling, tensile and shearing tool

portable and designed for

construction
t ti siteit conditions
diti

optional data recording

possible

optional for geote

geotextiles
tiles

Page 44 31.05.2007
E t d
Extruder

Page 45 31.05.2007
Leister Extruder Overview

Page 46 31.05.2007
Digital controlled Extruder

- Air and plast seperate heated and controlled

- Display
Di l ffor air
i and
d plast
l t ttemperature
t
- Weldplast: integrated menue for common materials

Page 47 31.05.2007
Air heated Extruder

-Air heating for preheating and plast

-Simple handling
-Compact and light

Page 48 31.05.2007
Leister Extrusion Welding

Leister Output(PEHD) Lenght, Weight Welding addition

Extruder kg/h

WELDMAX 443 mm, 3.8 kg

0.3 0.7 kg/h Welding rod 4mm

WELDPLAST S4 1.5 3.8 kg/h 560 mm,8.7 kg

Welding rod 3 and 4 mm
WELDPLAST EC4
0.7 3.8 kg/h 560 mm,10.5kg
FUSION 3 Welding rod 3 and 4 mm
1.6 3.5 kg/h
690mm, 7.2 kg

FUSION 3C
1.6 3.5 kg/h 588mm, 6.9 kg Welding rod 3 and 4 mm

1.3 1.8 kg/h 450mm, 5.9kg Welding rod 4 mm

Fusion 2

Page 49 31.05.2007
Extruder Application

Connections and drainages Repair badge

Page 50 31.05.2007
Thank you for
your attention!

Page 51 31.05.2007