Beruflich Dokumente
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Chapter 4
by
Tunnelling and UndergroundSpace Technology, Vol, 12, No.2, pp. 111 - I 24, 1997
© 1997 Elsevier Science Ltd. All fights reserved
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Pergamon
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Chapter 4: Waterproofing and Maintenance
. INTRODUCTION AND BACKGROUND
, STEEL TUNNELS
2.1 Recent Joint Evolution
2.2 Waterproof Joints for Immersed Tunnel Elements
2.3 Closure Joints
2.4 Terminal Joints
2.5 Underwater Connections to Terminal Elements Constructed in Rock
2.6 Seismic Joints
2.7 Concrete Requirements
2.8 Cathodic Protection of Steel Elements
3, CONCRETE TUNNELS
3.1 Water Leakage through the Concrete Structure
3.2 Joints
o MAINTENANCE
4.1 Experience with Leakage in Steel Shell Tunnels
4.2 Leakage in Concrete Tunnels
5. REFERENCES
Volume 12, Number 12, 1997 TUNNELLING AND UNDERGROUNDSPACE TECHNOLOGY 115
Bulkhead P/ate ,~ , Omega Gasket Assemblr
(Removed/ r- Drain
• for Omega Gasket
u=-7 ~ -- --:-,
£'-- ExPan Si on Met=.m
I
•i ' - M a i n Gasket System
t. ;°
Figure 4-3. Typical joint detail for Boston's Ted Williams Tunnel.
2.6 Seismic Joints control in the steel elements; and this can have the undesir-
The only seismic joint design used to date in the United able effect of introducing excessive reflected cracking in
States was developed for the BART Transbay Tunnel in San finished tile surfaces.
Francisco. The seismic joint was designed to permit triaxial
displacements of +8 cm in the longitudinal direction and +15 2.8 Cathodic Protection of Steel Elements
cm in any direction in a vertical plane, while maintaining Except for concrete protection, it has not been the prac-
watertight integrity. tice in the United States to provide special protection to the
The vertical and transverse horizontal motions are per- steel shell of immersed tunnels, unless stray direct currents
mitted by precompressed rubber gaskets sliding on radial are determined to be present. Where stray currents do exist
Teflon bearing surfaces. The longitudinal motion is taken or are expected, such as in an electrified rapid transit
by similar gaskets sliding on a circumferential Teflon bear- tunnel, provisions may be made for coating the steel shell
ing surface. Both sets of bearings are compressed by tensioned with materials such as coal tar epoxy and/or the provision
cables that allow the motions by rotating on Teflon-coated of impressed current cathodic protection systems.
spherical bearings. Alternatively, stray current test stations may be speci-
The assembly is protected from mud and the marine fied to permit periodic measurements at several locations
environment by exterior rubber boot enclosures. These along the steel shell of the immersed tunnel. This arrange-
assemblies were prefabricated, assembled and tested as ment permits flexibility in adjusting the extent of the
units before being attached to the elements. Four of these cathodic protection to the actual conditions encountered i n
seismic joints were required for the Transbay Tunnel. The the completed project. In this regard, the internal reinforc-
joints performed well during the 1989 earthquake in San ing steel and the steel shell must be carefully bonded
Francisco. Figure 4-4 shows the ar-
rangement of this seismic joint.
better elastic properties than the former, a factor that is 3.1.1.3 Polymeric sheet membranes
important, for example, in clamping strips at the edges.
For tunnel waterproofing, the polymer-modified bitumi- Polymeric sheet membranes may be thermoplastic ma-
nous membrane is preferable to the normal bituminous terials such as polyvinyl chloride (PVC), polyethylene (PE),
membrane because it reduces plastic deformations and loss chlorinated polyethylene (PEC), and polyisobuthylene (PIB),
of pressure under the clamping plates. The membranes or elastomeric materials as chlorosulphanated polyethyl-
must fully adhere to the primed concrete surfaces in order ene (CSM), polychloroprene (Neoprene) (CR) and isoprene-
to prevent water ingress through leaks in the membrane to isobuthylene (butyl rubber) (IIR).
flow in the space between the membrane and the concrete Thermoplastic materials may be joined by hot air or plate
structure. welding, which are rather simple operations. Elastomeric
A bituminous membrane is normally composed of two materials are joined by adhesion, while the rubber types
layers of bitumen-impregnated mats. The mats are placed (neoprene, butyl, etc.) may be vulcanized. Although fairly
with at least 100 mm overlap, and the joints in the two expensive, vulcanization provides a strong connection.
layers are staggered. These types of membranes are very thin and therefore
In order to avoid water seeping from behind the mem- are very vulnerable to mechanical damage during construc-
brane, all free edges of the membrane must be clamped, e.g., tion.
by clamping strips of steel (see Fig. 4-5). A concrete slab 100 The butyl rubber membrane used on Denmark's Limfjord
mm to 150 mm thick initially protects the bituminous Tunnel was glued on by a polymer-modified cement slurry.
membrane when it is placed on the tunnel roof. Because the The advantages of polymeric sheet membranes are:
bituminous membrane cannot transmit shear forces of long • They are low-cost, in comparison to membranes.
duration, it is necessary to anchor the protection slab (see • Fewer discontinuities in details, thereby reducing the
Fig. 4-6). chance of errors.
If the membrane is used on the tunnel sides, a sliding • They are less subject to damage during and after
layer of soft bitumen is applied to reduce shear transfer construction.
from the backfill (as was done at the Rupel Tunnel in
Belgium), or protected by 100-mm-thick concrete plates
bolted to the walls (as at the Drecht Tunnel in The Nether-
lands). At the tunnel bottom, where it is difficult and
complicated to secure the membrane to the concrete, steel
plate is still used.
Bituminous membranes at the tunnel roof have often ONCRETE
been combined with steel membranes at the sides (and
TE
bottom) of the tunnels. This method has been applied to the
DOFING FELT
Elbe Tunnel in Germany, the Conwy Tunnel in Wales, and
the Guldborgsund Tunnel in Denmark.
Bituminous membranes have the following advantages: 'MBRANE
• They are cheaper than steel.
• Their performance has been demonstrated to be suc-
cessful.
• The membranes are relatively robust, if placed in two
layers.
• The membranes can bridge normal fissures.
• The membranes can be applied on roofs, where steel
membranes are difficult to place.
The following disadvantages are associated with bitumi- Figure 4-6. Connection between structural and protective
concrete.
nous membranes:
•NESS ,
BEARIN6 BLOCK *
HEARDOWEL --OMEGA SEAL
Figure 4-7. Intermediate joint. Figure 4-8. Shear key of steel at intermediate joint.
previous tunnel element, which has been provided with a 3.2.3 Terminal joints
matching steel frame. This type of joint is often identical to the immersion joints
In some early immersed tunnels (e.g., the Limfjord when the portal has been built before the element is placed.
Tunnel), the frames were made of U-profiles. Although cast- In this case,, the sea or river end of the portal building is
in separately, the frames could not be adjusted, after the provided with a bulkhead and a cast-in steel frame, like the
concrete had been cast, to ensure sufficiently accurate secondary ends of the tunnel elements.
alignment. The Dutch tunnels and other recent tunnels If the elements are built in the entrance, as was done for
(e.g., the Elbe, Conwy and Guldborgsund Tunnels), have the Guldborgsund Tunnel and the Prinses Margriet Tun-
used an H profile, and the end plates of the frames were nel, the joints will be sealed temporarily between the tunnel
welded after the concrete had been cast. The space behind element and the entrance structure. The permanent water-
the plates was injected with grout. This method permits tightening Omega seal could be constructed as shown in
very small tolerances to be met. F!gure 4-10.
After the Omega seal has been installed, the two tunnel The possibility of differential settlements between t h e
elements can be connected by casting reinforced concrete in in-situ constructed part and the immersed tunnel part must
the remaining space between them. This procedure was always be considered. With a sandjetted or sand-flow foun-
used on the Limfjord and the Guldborgsund Tunnels. dation, settlement will occur when the load on the tempo-
Alternatively, a permanent expansion joint with shear rary foundations is transferred to the sand foundation.
keys can be made. The shear keys may be constructed of In Dutch tunnels, the shear keys in the floor are placed
reinforced concrete or of steel. This method was used on the as late as possible in the construction process in order to let
Conwy Tunnel, the Singapore Cable Tunnel, and the new the sand settle. The shear keys prevent unequal settle-
Bilbao (Spain) Metro Tunnel (see Fig. 4-8). ment between the immersed element and portal while
If the shear keys are of reinforced concrete, which has
been common practice until recently, access to the Omega
seal is hindered, whereas access is retained if shear keys of
steel are used. The shear keys of Dutch tunnels are installed
only in the floor and are made of steel tubes filled with
concrete (see Fig. 4-9).
Even when the joint is used as a permanent expansion
joint, the movements are usually not large and the Gina
gasket stays watertight. This means that the Gina and the
Omega constitute a watertight barrier in the joint. No
serious leakages of this type of joint have been reported.
OVER PLATES
IMMERSED
TUNNEL STRUCTURE
;EAL
-°,.'-- /
INJ(CT|CI II'~W [~l~y I q E | I N " ~
l#JECTtO 11111,1~ I ~ I ' ~YAII-,,,-- h I
~SHEET PILE CUT - OFF
Figure 4-9. Shear key in floor. Figure 4-10. Terminal joint at the Guldborgsund Tunnel.
FDYWIDAGROD,WRAPPEDWITH
BONDBREAKINGTAPE
I--BLOCK-OUTFORCUTTING
SHEARKEY
WATERSTOP
STEELOHE6A
I i
L STEE(MEMBRANE
Figure 4-14. Temporar 3, reinforcement at expansion joint. Figure 4-15. Expansion joint with steel Omega profile.
precast segments of prestressed tunnels. An example from 4.2 Leakage in Concrete Tunnels
a cable tunnel in Singapore is shown in Figure 4-20. 4.2.1 Leakage through the tunnel structure
Reports of leakages in some Dutch concrete tunnels, both
4. Maintenance with and without membranes, have mainly concerned mi-
4.1 Experience with Leakage in Steel Tunnels nor leakages through the floor, walls and roof.
Leakage in the immersed portion of steel tunnels gener- In tunnels with membranes, leakage through cracks in
ally is minimal. Watertightness depends to the greatest the walls or floor is difficult to repair because it is almost
extent on the care with which the integrity of the steel shell impossible to find where the corresponding leak in the
is maintained through design and execution. Tunnel speci- membrane is located. In such cases, the leakage is stopped
fications must therefore require suitable welder qualifica- by injecting all cracks. When leakage through one crack is
tion, as well as radiographic, ultrasonic and dye-penetra- stopped, water will appear through another crack. It is
tion methods of weld inspection and tests for watertightness easier to stop leakage in tunnels without membranes,
during fabrication. because the leakage point can be detected. In both cases, the
Permanent penetrations of the shell are to be avoided injection has to be done in the absence of a water flow.
whenever possible in the design. Where openings are pro- There have been some leakage problems at the Limfjord
vided for access or concrete placement, great care must be Tunnel in Denmark. The leaks have mainly occurred through
taken to inspect and test welds of the closure plates for transverse construction joints, which were provided with
watertightness. waterstops. The total amount of water leakage in the tunnel
The soap bubble and vacuum box test are good water- is rather small--on the order of 50-100 l/hour (based upon
tightness tests for smaller openings in the shell, after the measurements of a minor area). However, even small
concrete has been placed. Temporary piping used in placing amounts of leakage through the concrete structure are
operations must be cut off and sealed with a cover plate seal- unacceptable, as the water in the fjord is saline and there-
welded over the opening. Special details such as cross- fore has caused corrosion of the reinforcement in the tunnel
passages between tubes must permit good welding accessi- structure.
bility to assure quality welding. The tunnel was provided with a membrane of butyl
Although the experience with watertightness of steel rubber. Obviously, this membrane is not watertight; and,
tunnels has been very good, given proper design and fabri- because the adhesion to the concrete is probably insuffi-
cation procedures, if a leakage problem arises, it most often cient, the water may have spread between the membrane
occurs at the terminal joints with the land section. The and the structure. The leakages had already begun during
problem usually occurs at the transition from a totally the construction stage. Since then, further attempts have
enclosing steel shell to a conventional externally applied been made to stop the water seepage. Trial injections have
structural waterproofing system. Furthermore, there may 6een made with epoxy, polyurethane and acrylic gel. The
be problems in keeping the excavation area dry where the latter has produced the best results, but in all cases the
waterproofing is being installed. Hence, proper detailing at leaks started again after some time had elapsed since
this interface is critical. injection. It is assumed that the reason for this lies in
I ! , , / t /
~CWE-PROF]LE
T~PE ~ E 2DA
"
I
I_ fin I 25 I
I; ,5, :1
Figure 4-16. Injectable rubber-metal waterstop. Figure 4-17. Expansion joint in walls.
4.2.3 Summary
/ .N Inherently, immersed tunnels offer great opportunities
for engineers and contractors to build bone-dry tunnels.
For this reason, the watertightness that can be achieved
within an immersed tunnel is a major advantage in favour
of selecting this form of tunnel, particularly for deep sea
crossings.
mANCHOR For both concrete and steel tunnels, the watertightness
250x30x6
and the continuity of the joints between the tunnel ele-
ments are critical. The joints should allow some movement
I.'oo I '" I without leakage or any other detrimental effect on the
functioning of the tunnel. In the Ted Williams Tunnel in
Boston, a flexible joint has been used for the first time in a
Figure 4-18. Expansion joint in floor. steel tunnel in the United States.
As the awareness of seismic exposure increases, so the
joints in a tunnel must increasingly be designed to carry
high seismic shears and must be restrained positively
against excessive opening. Axial motions can be restrained
by using stressed or unstressed post-tensioning across the
joints, while vertical shears must often be carried by steel
shear keys stressed onto the concrete and fitted with
bearings.
For watertightness, joints within and at the ends of
tunnel elements are some of the most vulnerable zones in
an immersed tunnel crossing. The goal is to achieve water-
tight intermediate and immersion joints that can be suc-
cessful for all time and are maintenance free. Improve-
ments to these design details continue to be made, both for
temporary and permanent seals. For joints within ele-
ments, considerable advances have been made in this
respect with the use of hydrophillic sealants and groutable
waterstops.
As stated above for concrete tunnels, care taken in
concrete mix design, cooling, and reductions in the heat of
Figure 4-19. Construction joint. hydration can help considerably in reducing or preventing
the formation of cracks. Recent tunnels have also used
pulverized fuel ash (p.f.a.) to replace some cement content,
seasonal temperature variations, since the long monolithic further reducing the heat generated. Maintaining a low
tunnel is alternately exposed to tension and compression, water/cement ratio through additives also aids in creating
which cause movements of the cracks. a high quality concrete.
Other measures, such as internal membranes (polyure- For membrane application, the ability to bridge fissures
thane and fiber texture-reinforced cement-paste membrane) that develop after application of the membrane has been a
have been tested. The adhesion of the polyurethane mem- drawback to earlier membranes that were comparatively
brane to the concrete was not sufficient, and the cement brittle, but the most recent membranes have improved this
paste membrane was very expensive. Therefore, attempts significantly. With complete adhesion, the source of a leak
to find a suitable repair method are continuing. can be traced. Repairs to a spray-on membrane are diffi-
cult, though improvements in this field are expected. As
4.2.2 Leakage through joints the quality of these membranes improves, so the emphasis
Leakages through expansion joints are usually caused on preventing leaks must switch to the joints used in both
by gravel pockets that formed under the rubber-metal steel and concrete tunnels. To improve the puncture
waterstop during concrete placement. Leakage problems resistance of areas between immersion joints, advances
are usually handled by injection; however, if injection is are being made in spray-on membranes.
not successful the water must be directed to the drains
within the tunnel.
In Dutch tunnels, a control system is available to detect
leakage through the Gina gasket. During construction, a 1/
2-in. pipe is embedded in the concrete, connecting the
space between the Gina and Omega to the central gallery.
A leak through the Gina was detected at the Zeeburger
Tunnel. However, the water did not enter the tunnel,
JOINT
which means that the Omega seal is watertight.
This type of leakage occurs because of the high position- TUBE
ing of the terminal joint, which lies just below the surface
of the water. During winter, when the river freezes, the
Gila loses its elasticity and the tunnel shrinks, causing the
(T
joints to open. The stiff Gina cannot swell to keep the gap
closed. :OR
A survey of leakage in existing tunnels was performed PIPE
within the Working Group. The responses indicated no
serious leakages, and only some small drippings, for both Figure 4-20. Joint between precast segments.
Volume 12, Number :2, 1997 TUNNELLING AND UNDERGROUNDSPACE TECHNOLOGY 123
For concrete tunnels, a cost comparison must be made 5. References
between producing a dense, crack-free concrete and pro- Reina, Peter and Naoaki, Usui. 1989. Sunken tube tunnels
viding external barriers to l e a k a g e - - i . e . , barriers compat- proliferate. Engineering News Record, July 13, 1989, 30-37.
ible with existing site conditions.
124 TUNNELLING AND UNDERGROUND SPACE TECHNOLOGY Volume 12, Number 2, 1997