Escolar Documentos
Profissional Documentos
Cultura Documentos
ET DE LESPACE SOUTERRAIN
Organization member of the AFTES
www.aftes.asso.fr
AFTES
Recommendations
Geometry, concrete mixes,
formwork and concrete
pouring practice
for tunnel linings
GT36R1A1
CONTENTS
Pages
Pages
1 - PRESENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 - Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 - Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 - General background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 - Administrative framework . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
3
3
3
4
5
5
5
6
6
6
6
2.2.1 - Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.2 - Examples of Profile Optimisation . . . . . . . . . . . . . . . . . . . . . . . .
2.2.3 - Consequences on operating formwork systems . . . . . . . . . . . . . .
6
7
8
2.3 - Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
8
8
9
9
10
10
10
10
10
11
11
11
11
11
12
12
12
12
12
3.2.1 - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2 - Aggregate quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.3 - Cementitious materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.4 - Mixing water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.5 - Admixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.6 - Additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
12
12
12
13
13
Pages
Pages
13
3.3.1 - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.2 - Specification of basic properties . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.3 - Specification of supplementary properties . . . . . . . . . . . . . . . . . .
3.3.4 - Concrete classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
13
13
13
14
14
14
14
14
15
15
15
15
16
16
16
16
4 - FORMWORK SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . .
4.1 - Description of formwork systems and Minimum fabrication rules
16
16
4.1.1 - Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.2 - Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.3 - Different types of formwork system . . . . . . . . . . . . . . . . . . . . . . .
4.1.4 - Details of formwork system components . . . . . . . . . . . . . . . . . . .
16
17
17
23
29
29
30
31
31
31
32
34
34
34
34
35
35
38
40
41
42
42
5.5.1 - Portals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5.2 - Niches and intersections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
44
44
44
44
45
46
46
46
46
46
47
47
47
47
47
47
49
50
50
50
50
7 - SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 - Safety and formwork system design . . . . . . . . . . . . . . . . . . . . .
51
51
35
36
36
36
51
51
51
51
51
51
51
52
52
52
52
53
36
36
52
52
36
37
37
38
7.4 - Trainning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
52
REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53
1 - PRESENTATION
1.1 - Objective
1.2 - Content
POURING LINING
FORMS: FAULTY
WORKMANSHIP
AND DISTRESS
ENGINEERS
Preliminary
design
ENGINEERS
CETU Pilot Dossier
SNCF RATP
Eurocodes
Final design
DESIGN
OFFICES
CETU Fire
Guidelines 2006
CCTG
Fascicule 69:
Article TOS No. 121
Pressure during
Underground works
concreting
WORKMANS,HIP INSPECTION
DESIGN AND OPERATIONAL SAFETY
JOBSITE ACCIDENT PREVENTION
OWNERS
CCTG Fascicule 65
Exposed surfaces
IMPORTANT
PROJECT
DOCUMENTS FROM DESIGN STAGE CONTRIBUTORS
OTHER SOURCES*
Tender
Documents
CONSTRUCTION
CONTRACTORS
SUPPLIERS
Construction
Contract
IN-HOUSE AND
INDEPENDENT
SUPERVISION
OPPBTP - CRAM
SNCF Classification
of structures.
Catalogue of visible flaws in tunnels, supplemented with
Catalogue of
glossary of tunnel parts names 1980
Damage Livret K
Catalogue of structural damage in underground structures Tunnels 1996
CETMEF Notes on
GT14 HS 3 Chambry
monitoring and
Diagnostic Method for Lined Tunnels
maintenance of canal
tunnels with
catalogue 2000
Guidelines for
Inspection of Road
Tunnels, with
catalogue 2004
OPERATION
INSPECTION
CONCRETING
FORMWORK INTERFACES
CONCRETE
DESIGN ANALYSES
PROJECT
PLANNING
STAGE
These Guidelines are written in sections which fill the gaps between other relatively exhaustive and very recent documents, and
are presented in a descriptive manner in the form of recommendations or advice, so that interested parties may find the information needed for their design and construction operations.
CETU GTFE
(French Operators
Group)
Progress reports
and inspection
reports
Inspection and
maintenance
reports
INDEPENDENT
SUPERVISION
EXPERTS
SPECIALISTS
OPERATORS
*Standards relevant to tunnel linings cited in the Guidelines are listed in the Reference section at the end of the document
does not normally allow sufficient time for letting the ground to
decompress sufficiently to arrive at an equilibrium state and the
lining must be designed accordingly. This quite frequently results
in the need for a high-stress lining with inverted vault invert.
Dead weight loads may be factored to include for stresses due to
temperature changes and concrete drying shrinkage. These are
usually not considered to be critical items in lined tunnel design.
The lining may be poured, according to circumstances:
either after excavation and installation of temporary support
when there has been time for a new equilibrium to be reached
between the surrounding ground and the support; in this case,
the permanent lining is necessary and useful for providing long
term stability and the loads from the surrounding ground are
applied to it very gradually,
or keeping pace with excavation, by heading and benching if
necessary, when the previously described approach is not possible when, for example the tunnel is passing through poor
ground or there are severe settlement criteria. The design must
accordingly include for a very complex construction sequence
and finely-tuned organisation (different items of plant all
concentrated in a small space for driving / temporary support /
waterproofing / shuttering, and all well ventilated); the loads
acting on the lining will generally be higher than in the previous example.
2.1.1.2 - Mobilisation of Ground / Support /
Structure Interaction
It is common knowledge that, if it is to contribute to the permanent support, the lining must be conceived in such a way as to
efficiently make use of its interaction with the surrounding
ground. This implies appropriate decisions as to the cross sectional shape and stiffness of the lining as compared with that of the
host ground, and careful choice of construction method to ensure
tight contact with the ground everywhere.
A tight interface does not in itself guarantee sufficient mobilisation of the ground / support / lining interaction to control bending stresses in the lining to the preferred degree. The other requirements are:
The mean axis of the roof arch must be appropriately shaped,
which may require an iterative analytical method. A very flat
top arc will keep down excavation volumes but in return, will
very frequently allow high bending stresses to develop. Sudden
changes of curvature commonly cause locally high stresses, and
smooth transitions are eminently to be desired.
The host ground must possess significant stiffness. In ground
exhibiting plastic behaviour or poor stiffness, the soil/structure
interaction may be too weak not to have to resort to systematic
reinforcement of the lining.
*Guidelines in TOS 165. Owing to structural considerations, the minimum permissible design thickness of an in situ concrete lining is dictated by tunnel size
(generally 200 mm for small tunnels and 300 mm for tunnels with a diameter of approximately 10 m).
2.3 - Conventions
In general, once the design analyses have been completed, linear
underground structures are usually drawn up on a set of what are
known as Typical Cross Sections, which show temporary support,
waterproofing and lining details and the conventional payment
lines.
Linings and their minimum, nominal and mean thicknesses may
raise questions for the designer and the next part of this section
presents some simple minimum rules and the most widely used
conventions adopted by design offices, consulting engineers and
construction contractors (they will be a compromise between all
the conventions studied and accepted), always keeping in mind
the requirements in CCTG Fascicule 69 (Underground Works)
specifications, with additional material when the issue of extrados
waterproofing systems arises.
2.3.1 - Typical cross section
Sidewalls
Springing
Shoulder
Crown
Key
Circular arch
Invert
Arched
invert
A Line
B Line
E Line
10
gly stringent appearance requirements. The contract must stipulate what finishes are required where.
2.6.2.1 - Plain finish
Plain or ordinary surfaces (category 3) are surfaces left as-cast for
which the only requirement is for a regular shape. This usually
applies to ancillary cross galleries to the tunnel and its foundations.
2.6.2.2 - Fine finish
Fine surfaces (category 2) are surfaces left as-cast covered by special requirements as regards shape, and concrete texture and
colour. This finish is mostly used on sidewalls to the tunnel or bypasses and shelters.
Where light-coloured or special concretes are specified, specific
documents can be incorporated into the contract and samples
must be produced, as follows:
Specimens must be made at the same time as for the suitability
tests using reinforcement equivalent to that used in the tunnel
(if necessary) and the same concrete as is to be incorporated
into the works,
Specimens must be truly representative of the structure to be
concreted under actual field conditions in order to ascertain
that the resources (identical forms, vibration, etc.) assigned by
the Contractor are adequate to meet the contract requirements,
They must be acceptable to the Engineer.
2.6.2.3 - Featurework
Featurework surfaces are very special surfaces which must meet
decorative and architectural requirements (category 1); they are
often stipulated for the first rings of urban road tunnels.
The contract must specify precisely all the characteristics of these
surfaces and some characteristics of the forms.
This category also includes surfaces left as-cast exhibiting some
degree of relief or special shapes, and worked surfaces.
2.6.2.4 - Unspecified finish
Except as otherwise stipulated, surfaces exposed to view have a
fine finish and concealed surfaces have a plain finish.
2.6.3 - Lift Joints and Construction Joints
Exposed surfaces may have joints highlighted, i.e. horizontal lift
joints at the foundation ledge, if exposed to view, horizontal lift
joints between sidewalls and roof arch, and vertical construction
joints between lining rings. Trapezoidal joint formers are preferred
for reasons of ease of form removal, using stiff rubber or metal
shapes fixed to the forms.
11
4.0 to 2.4
(coarse sand)
MF
2.8 to 1.5
(medium sand)
FF
2.1 to 0.6
(fine sand)
12
Corrector sand
A corrector sand is by definition a sand added in a proportion of
up to 30% of the total sand mass. When used, the tests are made
on the mixture of corrector sand and natural sand in proportions
set by the producer.
3.2.2.2 - Gravel
The gravel routinely used is graded 5/20 with two gaps.
Gravel with a D (diameter) ranging from 16 mm to 31.5 mm can
be considered.
Particular specifications are required for items subject to severe
abrasion (e.g. some drainage works).
3.2.3 - Cementitious materials
3.2.3.1 - Cements
Cements must comply with NF EN 197-1 or approved equivalent.
3.2.3.2 - Additions
Permissible additional ingredients are:
silica fume complying with Standard NF P 18-502 and NF
EN 13263-1,
ground vitrified blast furnace slag complying with Standard
NF P 18-506,
coal fly ash complying with Standard NF P 450,
calcareous admixtures complying wth Standard NF P 18-508,
siliceous admixtures complying with Standard NF P 18-509.
These additions are tested with a procedure recognised as being
equivalent to the procedure employed for preparing concretes
bearing the NF mark or equivalent.
3.2.3.3 - Special Features for Tunnel Linings
The cementitious material selected must achieve the best compromise between the rate of strength development and sensitivity to
cracking (heat of hydration, shrinkage). The usual cements are
CEM I plus admixtures or CEM II blended cements having a
total cementitious content of the order of 350 kg per cubic metre
of concrete. Recourse to CME III or CEM IV cements is possible
but not really compatible with the 24 hour working cycle (set
formwork pour concrete concrete hardens strike forms
move shuttering on to next station).
3.2.4 - Mixing Water
Water used for mixing the concrete must comply with Standard
NF EN 1008; seawater must not be used and recycled water from
exposure class,
chloride content class,
concrete consistency.
3.2.5 - Admixtures
The CE certification mark allows products to circulate freely
throughout the European Union, regardless of their country of
origin. It is proof of EC compliance. It is complusory but does not
replace the NF mark.
Standard NF EN 934-2 redefines the eleven types of concrete
admixtures (Tables 2 to 12), this is the quality mark attesting to
the quality aptitudes of the product (tested by an independent
outside body).
Having both accreditations is the new quality baseline for concrete admixtures.
All admixtures must bear the NF quality mark or approved equivalent.
3.2.6 - Additives
Additives, not covered by Standards, may be incorporated into
the concrete to modify some of its properties or confer special
properties to it.
Coming under the heading of additives are natural or synthetic
non-organic dyes, fibres, pozzolana fines,, cohesion agents, etc.
Metal fibres can be mixed into the freshly-mixed concrete to
improve its properties, especially its ductility, durability and crack
resistance. Metal fibres must comply with Standard EN 14889-1
Fibres for Concrete Part 1 Steel Fibres Definitions, Specifications and Conformity.
The unique properties of fibre-reinforced concrete may be
particularly attractive if lining thickness has to be reduced or a
self-compacting concrete has to be used. Pumping fibre-reinforced
concrete might raise a few problems.
The minimum proportion of fibres depends on fibre properties
(tensile strength, anchoring system, length/diameter ratio). It
must be determined by testing (e.g. by measuring strain energy).
The recommendations from the Brite-Euram* european project
set out the criteria for selecting steel fibre properties and use.
Steel fibres can replace all or part of the traditional concrete reinforcement in specific structures provided that bending tensile
strength values are cross checked with appropriate tests.
* Project BRPR-CT98-0813 Recommendations on Quality Assurance
of SFRC.
EXPOSURE CLASSES
XC3-XF1
XF2
Maximum water/equivalent binder ratio
Minimum equivalent binder content (kg/m3)
Minimum air content in concrete
Characteristic 28-day strength
0.60
280
N/A
C25/30
0.55
300
4%
C25/30
13
14
At the very least, this means hot water (up to 60C) must be
available for mixing concrete in winter.
It is also important when lining rings consume large amounts of
concrete, to provide a back-up batching plant capable of being
brought on line promptly if the primary plant breaks down.
3.4.3 - Concrete Transport
3.4.3.1 - Mixer Truck Transport
A delivery note must be filled in for every batch delivered by
mixer truck, stating, in addition to the requirements of Standard
NF EN 206-1, complete identification of the materials used and
the detailed composition of the batch.
No water may be added on delivery or in the drum.
In the case of self-compacting concrete, every precaution must be
taken to avoid concrete losses or incomplete filling of the drum
(use of a plug, etc.).
Not more than two hours may elapse between the time a batch
leaves the concrete mixing plant and the time it begins to enter
the shuttering (transport time + waiting time), and must be stipulated in the contract specification and assumed in the concrete
mix design.
3.4.3.2 - Pumped Concrete, Long Lines and
Booster Pump
The Contractor must propose the means of transport and pumping parameters from which he shall deduce any special mix
design requirements (conservation of rheology, workability, risk of
setting, etc.).
When a priming slurry is used to start the pumps, it must not be
incorporated in the works but discharged to waste.
must be realised that they are closely interrelated (strength development over time).
The parameters in question are (the list is not exhaustive):
type and proportion of cement in the concrete,
water/cement ratio,
air temperature at time of form removal,
whether or not a curing agent is used (see next section),
air velocity through tunnel at time of form removal,
concrete mass (thickness), since concrete setting is an exothermal reaction,
tunnel geometry: diameter (in small tunnels, tensile stresses in
the young concrete will be low) and shape (forms for a circular
roof arch can be struck earlier than for a flatter roof shape).
In all cases to guarantee early-age structural performance, regularity in concrete production and control of concrete temperature
during placing are the overriding factors.
3.5.2 - Minimum Requirement
The minimum concrete strength required before forms can be
removed must be justified by the Contractor and the concrete mix
must be optimised to obtain the necessary strength within the
time allowed. However, as a general rule, forms should not be
removed before the concrete has had ten hours to harden.
3.5.3 - Recommended Values
Recommended values for a circular arch roof 8-10 metres wide are
as follows:
compressive strength 8 to 10 MPa,
minimum time before stripping forms: 10 hours (knowing
that the required compressive strength is usually reached
within this time) under normal tunnel conditions (air velocity
< 5 m/s, temperature > 15C).
These two values should be measured on the last concrete batch
delivered (filling the crown) except if there is very extensive overbreak or other special considerations.
If the minimum compressive strength on removal of the forms is
stipulated in the contract, the Contractor does not have to justify
it with his own calculations. But if no value is imposed or the
Contractor wishes to change it, he must justify the proposed value
with a suitable analysis.
The minimum form removal time may be adjustable in the light
of precautions adopted after stripping (whether or not a curing
agent or plastic sheets are provided, etc.). A formal procedure
approved by the Engineer is necessary for this.
The specified concrete strength value is the internal in situ
strength, not the strength measured on an isolated laboratory specimen.
There are several ways of making this measurement:
on specimens heated to the same temperature as the concrete
in the works (hot cap method),
by measuring the internal concrete temperature, correlated
with strength after calibration at the commencement of the
works (maturity-meter).
The recommended method is the maturity-meter. If test specimens are still used, the Contractor must prove that the age of
the specimens is the same as the age of the last concrete poured
in the ring.
It is stressed that arriving at a concrete mix design with which
the targets can be attained is very important. An excessively
prompt concrete or one containing too much cement might
develop the required strength quickly but only at the cost of
excessive heat generation liable to cause cracking and demanding extensive precautions after removing the forms. Similarly,
special precautions would have to be taken with self-compacting concrete (types of additions and admixtures, etc.).
3.5.4 - Curing
The exposed concrete surface must be protected against drying
out (water evaporation) and sudden temperature changes
which might lead to significant shrinkage. Cracking can be
controlled by applying special measures, consisting of not restraining deformations, adapting concrete composition, and
providing appropriate curing. The appropriate curing method
for lining concrete must be described in the Contractor's
Quality Assurance Plan, which must comply with the stipulations in Standard EN 13670.
Since most in situ tunnel linings are plain concrete, shrinkage
cracking will inevitably occur sooner or later. It is acceptable
in the majority of cases providing cracks are not more than
0.5 mm wide.
If controlled curing is planned, it must be covered by a detailed
procedure described in the Contractor's Quality Assurance
Plan; trials must be made if a chemical curing agent is to be
used.
Specific rates must be included in the contract and applied to
remunerate curing.
Controlled curing is strongly recommended. It must be designed with reference to the intrinsic properties of the concrete
(heat of hydration, etc.) and external influences (air temperature, percent relative humidity, air velocity, etc.), as well as the
consequences of the curing on the following aspects:
possible changes in concrete surface conditions which might
have to be cleaned off before painting,
congestion caused by portal frame, although not so severe as
for the formwork system,
possible influence on concreting cycles and therefore on the
main lining works schedule,
possible negative environmental effects (water-sensitive environment in swelling ground for example if curing involves
spraying water).
As a general rule, water curing must be continued until such
time as concrete strength has reached at least 35% of the
specified 28-day characteristic strength (criterion adopted in
Fascicule 65A).
15
4 - FORMWORK SYSTEMS
This Chapter of the Guidelines is in two parts:
The first focuses on the precise description of the formwork system and dimensioning principles, at the same time, giving an overview
of the plan of the tender documents. It is addressed chiefly to the Contractor and formwork system manufacturer/supplier.
The second part sets out the different steps in producing the formwork system, beginning with the formal order and ending with
acceptance on site. The various steps describe the principles of interest to the Contractor, Supplier and Engineer.
In addition, this Chapter applies more particularly to the roof and sidewalls of linings to road and rail tunnels, and purposely ignores
full-circle linings poured in a single shot (as frequently found in drainage tunnels and sewers) and telescoping forms, because the manner
in which these systems operate and construction methods in this kind of work are entirely different.
16
Form end stop: radial stop at the forward end of each lining
ring;
Windows: openings in the form liner to pump in concrete
(must measure at least 500 mm x 500 mm);
Shutters: panels closing off windows;
Distributor: mechanical device facilitating distribution of the
concrete to all parts of the formwork system (windows and
stub pipes);
Stub pipe: orifice and tube welded onto the form liner through
which the concrete is pumped into the form (generally in the
key of the crown, 100 to 150 mm diameter with a sliding
closure panel);
Skirt: lower, hinged part of formwork system.
4.1.3 - Different Types of Formwork System
Modern formwork systems are all free-standing and break down
into three main categories:
Type 1: Free standing system without portal frame, with means
of translation mounted on the form liner backing, and without
a skirt locking system built in. The Type 1 system is commonly
called a free standing system without portal frame.
Type 2: Free standing system with portal frame independent of
the form liner and backing, but without an incorporated skirt
locking system. The Type 2 system is commonly known as a free
standing system with independent portal frame.
Type 3: Free standing system with built-in portal frame for
translation and skirt locking incorporated in the system. The
Type 3 system is commonly known as a self-locking system
with integrated portal frame.
Free standing systems with portal frames are more complex than
systems without this frame but they do shorten the cycle time,
making them especially attractive on moderate to large tunnels,
despite the higher cost involved.
Figure 7 - Leg (wheel and winch) and sidewall (collapsers, hydraulic cylinders, short struts) on the formwork system
17
TYPE 1
HINGES
TRANSLATION
SYSTEM
SKIRT
MOVEMENT
POSITIONING
DEVICES
LOCKING
FORMWORK
IN PLACE
BEARING POINTS FOR
CONCRETING
(Forms & Concrete)
The lower parts of the shuttering at the bottom of the skirts are fixed
to the foundations by anchor bolts in the ledges or held in place by
short and long horizontal struts spanning from sidewall to sidewall.
When pouring concrete, the weight of the formwork and concrete
is transmitted through the collapsers. The hinges at shoulders or
crown are locked by means of linkages (generally hand-operated)
and the adjustment devices on the legs are raised off the floor.
Free standing formwork systems without portal frame are generally used in short tunnels and for small transverse structures with
a flat or arched invert (lay-bys, niches, galleries, etc.).
Form liners and backings must be designed to have sufficient stiffness
during translation and remain undeformed when pouring the concrete.
The various functions and variants of Type 1 shuttering systems
appear in the following table.
b) Type 1 Plan
1
2
3
4
5
6
7
8
9
- Lining extrados
- Lining intrados
- Form liner backing
- Crown hinge
- Form release motion / Concrete stub pipe
- Collapser
- Concreting window
- Leg-to-leg strut
- Translation wheel
18
c) Advantages
simple design, easy to build,
attractive for re-use, especially for ancillary works,
very quick field assembly and dismantling time,
maximum clearance for traffic under formwork (when struts
are not in place),
simplified forward translation system,
unequalled quality for price (cheaper than portal frame types).
d) Drawbacks
limited transverse movement and back-off due to short strokes
of hydraulics or screw jacks,
need for additional means of translation (site plant for example),
no platforms or walkways on formwork,
interference with site traffic.
4.1.3.2 - Type 2: Free standing system with portal
frame independent of the form liner and backing
assembly, but without an incorporated skirt locking
system
TYPE 2
HINGES
TRANSLATION
SYSTEM
SKIRT
MOVEMENT
POSITIONING
DEVICES
LOCKING
FORMWORK IN
PLACE
BEARING POINTS FOR
CONCRETING
(Forms & Concrete)
a) Definition
Independent portal frame formwork systems are only hinged at
the shoulders, not at the crown. Due to the portal frame with its
various functions, the formwork has full degrees of freedom in
translation and transverse, horizontal and inclined adjustments,
but the system remains conventional because the bottoms of the
skirts (hinged at the shoulders) are held in position by anchors in
the ledges or by horizontal spreader struts.
The working platform is built into the formwork, forming part of
the form liner backing assembly (transverse beams and bracing);
the portal frame is supported under the platform.
The most widely used independent portal frames come in two
categories: fixed and adjustable. There is a third hybrid category
because the functions of the two types are often "mixed."
Formwork system with independent fixed-dimensions
portal frame
The portal frame legs and transverse beams are fixed and vertical
and transverse (horizontal and inclined) movements of the formwork system are obtained by telescoping components, hinges,
pivots and screw jacks on the upper beams of the portal frame.
19
b) Type 2 Plan
1
2
3
4
5
6
7
8
9
10
11
- Lining extrados
- Lining intrados
- Form
- Shuttering hinge (shoulders)
- Upper formwork positioning system
(V = vertical, H =horizontal)
- Hinge locking linkage
- Portal frame
- Skirt struts
- Bottom shuttering prepositioning system
- Transverse screw strut
- Collapser / support device
20
Figure 14
Type 2 formwork system
Lotschberg Tunnel
Switzerland
Short struts from foundation
to edge of excavation
d) Drawbacks
needs a concrete base,
demands an extra set of shuttering, relatively expensive but
very useful,
less need for telescoping legs on gradients (risk of sliding members jamming),
may block passage through shuttering if left in place.
4.1.3.3 - Type 3: Self-locking shuttering with integral
portal frame and skirt locking
a) Definition
With this type of shuttering (form liners + backing + portal
frame), the stiff portal frame is intimately merged with the shuttering and the devices for holding and locking the skirt bottoms are
also integral with the shuttering. The Type 3 formwork system is
also known as the free-standing formwork system with integral
portal frame.
Devices for moving and positioning the shuttering are mounted
on the portal frame and provide for all longitudinal, transverse,
height and banking adjustments.
The formwork system must be powered and advance at very slow
speed. The telescoping stanchions forming the legs of the portal
frame (beams with powerful vertical hydraulic cylinders) provide
for rough height adjustment of the shuttering; the devices (hin-
21
When striking the forms, the portal frame must take the load and
the hinge linkages must be removed. This will cause the collapsers
to unstick the formwork from the concrete, the sidewall skirts are
lifted off from the lining by the oblique hydraulic cylinders and
the portal frame lowers the complete form.
This highly mechanised self-locking formwork system requires less
labour but operations require some skill, especially when unsticking the forms, in order not to lift off the adhering green concrete.
TYPE 3
HINGES
TRANSLATION
SYSTEM
SKIRT
MOVEMENT
POSITIONING
DEVICES
LOCKING
FORMWORK
IN PLACE
very wide back-off gap between liner and freshly exposed concrete face,
dispenses with the need for fixings in the foundation,
strokes of hydraulic cylinders on legs and skirts such as to leave
a clear passage underneath the formwork,
less labour needed,
possibility of semi-automated concrete distribution,
increased safety,
b) Type 3 Plan
1
2
3
4
5
6
7
8
9
10
11
- Lining extrados
- Lining intrados
- Form liner backing
- Formwork hinge (shoulders)
- Upper formwork positioning system
(H = horizontal)
- Concreting windows
- Integral portal frame with positioning device
(V = vertical)
- Oblique skirt movement braces
- Formwork pre-positioning system
(formwork legs)
- Motorised translation bogey
- Collapser / Support device
22
Plywood sheets
Plywood sheets must be mounted on a rigid backing. In so far as
these liners are used several times, they may have to be protected
against damage to edges and leakage of laitance.
Plywood liners are often used for the headwalls of lay-bys, niches,
or boxes.
With both timber and plywood liners, the final colour of the concrete may be affected by certain varieties of wood and the number
of times the liner is used (tannin seeping out).
Sheet metal
Sheet metal liner panels usually come in standard sizes. They are
assembled by welding onto frames, not to each other. Thickness is
generally 8 mm 10 mm and must be compatible with pressure
from the fresh concrete and the number of times they are to be
used; they must be free from deformations unacceptable for the
type of concrete finish required. These liners are used for the tunnel intrados (sidewalls, roof arches) and transverse works repeated
many times on the same project. Various styles of sheet steel are
available: black steel, zinc electroplated, hot dip galvanised, stainless. Black steel is recommended.
Panels faced with synthetic materials
No recommendations can be made on this type of formwork
material because there are too few reported instances of its use.
Whatever materials are chosen, the required finish for the concrete
surface will only be achieved if the following minimum rules are
observed:
- Cutting, positioning and orientation of the joints must be decided on the basis of the results specified for architectural appearance, if applicable.
- Materials for form liners must be selected on the basis of the
results specified for concrete surface quality.
- The feasibility of re-using form liners must be examined with
reference to the required regularity of colouring, texture and geometrical shape specified for the concrete surface.
23
24
d) Adjustments
The legs (vertical stanchions) of the portal frame are generally fitted with main primary hydraulics for raising, lowering, striking
forms and the lowering of the whole system. Secondary and fine
(vertical, horizontal and inclined) adjustments can be effected by
systems mounted on the upper horizontal members of the portal
frame. These jacks, hinges and pivots must enable the structure to
move at very slow speed (inching) and to position the system
accurately to within one millimetre, without jerks. These devices
are essential for staying within the construction tolerances and
also for avoiding the risk of cracking the previous lining ring.
e) Access and walkways
Roles
- Access ways and walkways must provide for safe access to all
workstations for the following operations:
- Longitudinal travel (translation),
- Placing and striking forms,
- Placing and striking end stops,
- Concrete pouring and vibration,
- Cleaning and oiling the forms,
- Fixing through bars when the forms are used for casting twosided walls at portals.
Design
The formwork must have at least the following items:
- A platform level with the top strut of the form providing access
to all workstations on the upper part of the roof,
- Side walkways on brackets on the side skirts providing access to
the concrete pouring windows,
- Main access giving onto the top platform consisting of a stair
or ladder which must move with the form,
- Secondary access for the side walkways consisting of ladders or
steps from floor level or from the upper platform,
*For a 3 km long tunnel with the lining being carried out while boring is ongoing at the face, two ventilation ducts measuring 2 and 1.5 m are required
for supplying fresh air to the face and must pass through the formwork system(s).
** Burbach rails are used on overhead travelling cranes
25
- Access to the perimeter of the form stop for fitting and removing the end stop.
In addition, the general design of the formwork must consider all
phases of the shuttering process (folding skirts, lowering the form,
longitudinal travel, etc.) in order to avoid having to remove parts
of the access ways or walkways.
Configuration
Access ways and walkways must provide for the following essential configurations:
- Forward and backward longitudinal travel with the form in the
lowered position,
- Lowering the formwork system to pass beneath utilities
suspended from the roof if necessary,
- Maintaining nominal clearances for traffic,
- Passage of supply lines and ventilation ducting if necessary,
- Folding side skirts without encroaching on the traffic clearances and allowing collateral activities to proceed,
- Assembly and disassembly.
Ergonomics
The ergonomics of the formwork system at each workstation
must be designed with reference to the needs of each workstation,
to be specified at the time of inviting tenders.
The design of access ways must meet very stringent criteria. For
example, the portal frame must be designed around the forms and
the following points must be considered:
- keep some minimum distance between any two stairs (perpendicular to the slope of the stair) and walkways,
- provide for ease of workforce movement inside the structure,
- provide a fast emergency exit route free from obstacles in the
event of an accident,
- use solid steel chequerplate with expanded metal surface pattern,
- provide for independent lighting for all walkways,
- provide flights of stairs to the top landing instead of the usual
ladders,
- fix the end stop stairs and access landings to the frame rather
than the form, etc.
26
Crown Concreting
Pipe with Sliding
Closure Panel
Figure 27
b) Concreting Equipment
Concrete is placed with a concrete pump. Depending on the size
of the tunnel cross section and length, formwork system type,
working conditions and concrete mix, the concrete may be placed
directly through the pump delivery line or via a semi-automatic
distributor.
Direct Pumping
For the lower part of the formwork (roughly up to the height of
the shoulders), the concrete is placed by inserting the concrete
delivery line into a window or connecting this line to a stub pipe
on the window closure panel. For the upper part of the roof, the
concrete is introduced through the grouting pipes on the form
liners with sliding closure panels as close as possible to the form
liner.
Manoeuvring the heavy, stiff pump delivery lines is extremely
tiring for the workmen.
Placing via Distributor
The chief incentive for using a distributor is that it does away with
nearly all the manhandling of the concrete delivery line. It also has
a very beneficial impact in reducing concrete spillage on the wor-
27
c) End Stops
End stops placed at the ends of the forms must be designed with
the following points in mind:
- The materials used for the panels must be strong enough with
respect to concrete slump (especially with self-compacting concrete mixes) and the rate of rise of the concrete,
- The forms must not leak especially where they are in contact
with a waterproofing system (where present or the primary support system), in order to prevent loss of laitance,
- They must not damage the waterproofing system.
End stops may be made of:
- the usual materials (mainly boards) fixed to the formwork,
- metal, bolted and/or hinged on the backing structure,
- or metal bolted or welded to the form with a Satujo type inflatable seal at the extrados intrados??; only suitable where there are no
excessive variations in concrete thickness (e.g. in tunnel renovations where a second internal lining is being added).
d) Vibration
Formwork design must consider the effects of vibrating the forms
unless self-compacting concrete is used.
When using conventional mixes, the fresh concrete is vibrated to
ensure it completely fills the forms (primarily that it flows around
reinforcement and box-outs), consolidates to obtain a dense,
compact concrete, and produces the required surface finish.
Two alternatives are available:
- internal vibration (poker vibrators inserted through the concrete
pouring openings in the forms),
- external vibration (used with metal form liners).
In large tunnels, both methods are used simultaneously. However, there are no scientific rules for the number of vibrators needed and the length of time vibration is applied. One must rely on
the practical experience of equipment suppliers working closely
with formwork manufacturers. They usually determine the num-
28
Figure 35 - Electrical box-outs and conduits - Formwork for niche with release keys
29
30
Special points, if any (intersections with other galleries, unbalanced pouring, etc.).
4.2.1.6 - Formwork Characteristics to be Provided by
Supplier
In his design report, the Supplier must state:
Formwork type (type 1, 2 or 3),
Formwork system dimensions and weights,
Form liner type (minimum metal gauge for crown 8 mm),
Effective length of lining ring,
Method of fixing on foundation (skirt reaction),
Kinematics of lining formwork system (this section must describe in detail the motions necessary for operating the formwork),
Size of transverse adjustments (vertical, horizontal, inclined)
and translation adjustments,
Floor bearing points (pressure and material),
Required construction sequence.
4.2.1.7 - Formwork System Equipment Required
The items listed below (especially for the primary formwork but
also for the forms for ancillary works) must be described in detail
by the Supplier and comply with safety rules:
walkways,
access stairs or ladders,
windows (numbers and dimensions),
stub pipes and sliding closure panels (number and details),
items for fixing reinforcement and/or box-outs,
embedded items and grout lines for subsequent contact grouting,
miscellaneous items (lighting, telephone, plastic sheeting),
end stops (metal, timber, Satujo seals, etc.)
vibration equipment (vibrator types and numbers if separate
order from formwork system),
concrete placement technique (distributor, concrete pump
lines, etc.).
4.2.2 - Contractor's Tendering Procedure for
Suppliers
4.2.2.1 - Invitation to Tender for Suppliers
The Contractor invites tenders from tunnel formwork manufacturers/suppliers on the basis of the specification as described
above.
Tender documents must present the general background to the
Construction Contract (i.e. define the Works, Owner, Engineer,
Main Contractor, project completion time, interim deadlines and
required date of delivery of the machinery and equipment to be
supplied) and clearly state the anticipated supply order.
4.2.2.2 - Suppliers' Tenders
Manufacture and supply tenders must contain
Company description (fields of competence, personnel,
factory, offices, contact details, etc.),
Details of recent similar projects,
Brief technical report,
A costed tender,
Deadlines for manufacture and delivery.
31
In addition to the self-weight of the structures and internal prestress of the backing (if any), the concrete pressure to be considered
is the hydrostatic pressure over the whole height of the concrete
lift except if limited to a lesser value determined and justified by
the manufacturer and user, plus a maximum pumping pressure of
3 bars at each stub pipe and contact grouting pipe and at overbreaks at the crown, if any.
Form liners must be analysed without any pressure reduction.
After the first rough models, the real structure with a variety of
loads and load combinations can be addressed; these analyses provide information on stresses and strains, from which the structures can be modified or strengthened:
during translation,
when setting up formwork on station with prestress,
during concrete pouring, including for unbalanced concrete
load and when filling voids at the crown.
All internal mechanical parts of the formwork system must be
checked, plus all linkages with external items (shafts, fastenings,
collapsers, hydraulic cylinders, etc.).
Simple tests can be run for special parts not amenable to analysis.
b) Structural analysis of portal frame
For Type 2 and 3 formwork systems as described in these Guidelines, two analyses might be needed.
The first concerns the "normal" situation: type 2 and 3 portal frames are analysed on the basis of the weight of the formwork and
accessories during "slow" translation and when setting up the
formwork on station. The portal frame must have ample strength
and not allow the forms to deform out of true.
The second concerns the concrete pouring situation (exceptional
case). The Type 2 portal frame never carries the weight of the
concrete, whereas the Type 3 portal frame may under exceptional
circumstances have to carry the weight of the concrete, accidental
pressures and loads. The formwork is considered as fixed on the
portal frame and it must be analysed as simply supported on the
four portal frame legs and on the "n" number of collapsers.
Allowable deformation limits are set in the specification and the
structures must be verified.
4.2.4.4 - Tolerances on formwork construction and use
There are various types of tolerances associated with the functions
of the different parts of the formwork system and they are not
cumulative. Tolerances on manufacture, installation and operation presented hereunder are examples only.
a) Manufacture
Tolerance on cutting parts of formwork system: <1 mm
Tolerance on construction of parts of formwork systems:
<3 mm
General tolerance on geometry of assembled formwork system:
<10 mm
b) Installation
Tolerance on installation and setting-up: <5 mm
Tolerance on bending of the formwork during concrete
pouring: acceptable deflection 1 mm
Geometrical tolerance with reference to the design curve and
formwork length: <10 mm.
32
33
34
5.1.3.3 - Sidewalls
If the sidewalls are lined first, as is frequently the case on renovation jobs or when the sidewalls are heavily reinforced, it is preferable to optimise the cycle by incorporating the majority of boxouts and inserts in the sidewalls.
5.1.3.4 - Crown(semi-circular arch)
Crown forms must not bear on sidewalls that have been built previously. The best way of ensuring this is to use a free-standing
formwork system with incorporated portal frame or the alternative prestressed model (as for the Monts tunnel rehabilitation project). In this set-up, the forms are supported by false sidewalls
(sidewall forms without form liners or collapsers), forced against
the top of the sidewalls by means of struts placed obliquely between the cross members and the bottom of the formwork system.
This type of system is easier to position in the transverse direction
than a complete formwork system but the overall positioning task is
much more complex. Planning the job must make allowance (as for
the foundations) for concrete hardening and obtaining the required
strength to withstand loads applied by the formwork system.
5.1.3.5 - Sidewalls and Crown
The sidewalls and crown are built with one formwork and in a
single operation, as in most conventional new-build tunnels.
5.1.3.6 - Slabs and Partition Walls
The presence of slabs and partition walls in most cases has an
impact on the construction approach for the crown (because brackets, hangers, etc. needed). The time taken to set-up the formwork
system on station is longer than in the standard arrangement.
5.2 - Q / S / E
(Quality/Safety/Environment) aspects
The Q/S/E section of this chapter is very important and these
aspects are dealt with in greater detail than the other parts. The
Contractor can therefore use the following points directly in his draft.
5.2.1 - Content of Quality Assurance Plan
The object of the Contractor's Quality Assurance Plan in so far as
it concerns the tunnel lining is to describe:
the organisation to be set up in order to obtain the required
level of quality and safety,
the means and resources needed to achieve this objective (manpower, plant and equipment, planning, etc.)
the supervisory resources needed.
Quality Assurance Plans for tunnel linings are based on two types
of document:
General and specific organisation memorandums which define:
- the general organisation and sharing of responsibility,
- the quality assurance system,
- document management system used,
- procurement processes (tendering, selection, ordering),
- resources management (staff training and qualifications,
provision and upkeep of plant and equipment),
- control of measurement systems (field survey and laboratory),
- organisation for dealing with non-conformities.
35
36
The procedure for setting up the formwork system(s) must describe the tasks to be performed, in chronological order.
Details of the phases mentioned below, accompanied if need be
by data on constraints or design assumptions, must be given in
the method statements:
Removal of forms from the last ring poured, along with precautions specific to this phase,
Translation of formwork system to next ring site to be concreted,
Curing of struck ring,
Preparation of form liners,
Setting up and final adjustment of formwork system ready for
concreting,
Setting up and checking formwork locking points,
Steel fixing if applicable,
Fitting end stop(s) and seals,
Concrete pouring,
Concrete hardening.
The following should also be mentioned:
Project-specific features and constraints,
Unit times for each operation, the sum of these times being the
cycle time,
The level of automation of the formwork system, which is
dependent on the number of times it is re-used and the cycle
time (some highly automated systems drastically reduce the
heavier tasks to be performed by the workmen and the dangers
to which they are exposed).
5.4.1 - Form Striking and Precautions Specific to
this Phase
When pouring the crown, the formwork system rests (and must
factors (high ambient temperatures, strong draughts, etc.) generally justify it. With some types of concrete (high heat of hydration cements, self-compacting concrete), a curing agent must be
applied immediately after form striking.
Curing may be effected by:
Spraying a curing agent directly onto the concrete surface to
prevent the escape of water vapour. These products must have
the Engineer's approval and be compatible with the required
quality and colour of the exposed surface and with subsequent
paints, if any. They may be cleaned off after the concrete has
hardened if the surface is to be painted.
Leaving the formwork in place for longer than the time needed
for a daily concreting cycle.
By building a curing chamber with controlled temperature and
humidity. It usually takes the form of a portal frame the same
length as the lining ring installed immediately after removal of
the formwork (wheeled steel frame and plastic or non-woven
sheeting) to create an annular space of controlled humidity in
contact with the concrete surface (with or without water
spraying). The sheeting also insulates the concrete from the air
currents in the tunnel.
5.4.3.1 - Curing with commercial curing agent
Curing agents must be submitted to the Engineer for approval,
who may require a trial application.
The curing agent is applied by spraying immediately after form
removal, keeping pace with the advance of the formwork system.
Wheeled scaffolding or hydraulic elevated platforms are the safest
way to perform this job.
If the curing agent is found to be incompatible with a painted
finish, it may be removed by light sandblasting or rubbing down,
although this may alter the appearance of the concrete surface, as
it becomes less smooth.
Similarly, stains left by the curing agent are not always compatible
with the required architectural finish.
5.4.3.2 - Leaving forms in place
Leaving the forms in place prevents the too rapid loss of water
from the concrete and so helps in controlling shrinkage cracking.
The length of time the formwork is left in place may vary from
one lining ring to another according to the cycle time, ambient
temperature, etc., but as a general rule, the extra time as compared
with the normal cycle can be limited to 24 hours.
Using this method generally doubles the cycle time (48 instead of
24 hours) and only applies to short-repetition cycles. To achieve
the daily cycle time, there would have to be twice as many formwork systems on the job.
Furthermore, curing with the forms in place may cause mottling
or stains on the surface.
Experimental French standard AFNOR (XP 18-325) "Placing
Concrete" cites curing times of one to ten days.
5.4.3.3 - Curing Frame
If it is to be truly effective, the use of a water-spraying portal
frame should be done as close as possible behind the formwork
37
(less than one-half metre behind), with the frame preferably being
towed by the formwork system.
If the rate of advance of the formwork system is fast, the curing
frame should cover two rings.
The two must be designed to move simultaneously in order to
avoid untreated strips being left between the two units. This
requirement must be allowed for in cycle scheduling and definition.
Curing with a semi-heavy or lightweight portal frame with continuous siding may take the following forms:
Spraying cold or warm water (or mist) but this is not advisable
in some cases, when there is a likelihood of freezing weather,
pollution of the platform (invert or roadway), presence of lighting systems,
The newly-exposed lining ring can be confined with a damp
membrane hanging from the siding a few centimetres from the
concrete surface, closed off at both ends.
The curing frame approach may be cumbersome but may be
made necessary in some particular cases when shrinkage cracking
is a major risk for the durability of the tunnel or when the required level of quality is particularly high. If this approach is calles
for, it must be clearly stated in the Specification (choice of technique) and a special rate provided therefor in the Schedule of
Rates and Prices.
38
5.4.5.2 - Positioning
Before final positioning, it is advisable to check that the geometry
of the trailing edge transverse profile of the formwork system matches the mating leading edge profile so that the formwork system
can achieve a tight fit without excessive voids or hard points.
When setting up the formwork, the end zones of the preceding
ring with its foundation must therefore be treated with care.
At this stage, the trailing edge of the formwork mates with the
previously poured ring with a few centimetres' overlap; for the
final settings, it is preferable to provide a device for making small
movements of the formwork system while the portal frame
remains stationary (horizontal transverse hydraulic cylinders and
vertical altitude-adjustment hydraulic cylinders with a type 3 system).
If the formwork system has long-stroke hydraulic cylinders or
prestressed struts, it is most strongly recommended not to use the
previously poured crown as the reaction for positioning the system, for fear of cracking or breaking the fresh concrete; this is a
frequent error and can be recognised by the crescent-shaped cracking.
Once the formwork system is in its final position, its position
must be checked in the manner described in the chapter of these
Guidelines on testing and inspection.
5.4.5.3 - Contact with previous ring and foundations
The seals necessary for preventing leakage of laitance must never
be obtained by forcing the forms hard against the concrete to get
rid of all voids. This might rupture the previously-poured concrete. Tunnel inspection frequently comes across lining rings with
cracks caused by this poor work practice.
A good seal can be obtained by fixing compressible rubber joint
seals to the forms. As described above, excessive pressure must not
be used for fear of cracking the concrete. Seals must be submitted
to the Engineer for approval.
The match between capacity of the seal to deform and the tolerance on misalignment at the joint must be checked.
The quality of the seals must be regularly checked and the seals
changed if necessary.
39
With integrated portal frame type formwork systems (but not systems with independent portal frame), vertical loads are either all
transferred through the formwork system (in the same way as for
types 1 and 2 systems, transferred through collapsers) or partially
transferred through the portal frame which provides a partial
stress path to the track (rails). In general, this latter arrangement is
only used for small sections where the loads transferred through
the legs are small.
In the same way as for type 1 and 2 systems, the support to the
track and collapsers must be checked and strengthened if necessary. An incorrectly stabilised system will inevitably adversely
affect the concreting through unstoppable leaks of concrete, especially when pouring high slump or self-compacting mixes.
c) Horizontal loads
Horizontal loads due to the pressure of the wet concrete on the
side skirts are not carried by the portal frames but:
at the top, by struts between the skirts (top members of the
formwork system at the shoulder hinges),
at the bottom, by one of the following arrangements:
- high capacity anchors in the ledge. Horizontal loads may be
accompanied by heave due to the shape of the sidewalls. In
this case, a means of distributing the load at the bottom of
the skirt must be provided and the positioning of the
anchors must be carefully checked.
- horizontal struts at the bottom of the skirts. This approach
is only possible on jobs where there is no need to provide for
traffic passing under the formwork system, except if a
bridge is provided over the struts, and the heave is countered by the weight of the formwork alone.
- prestressed inclined struts. These struts, fitted with high
capacity hydraulic cylinders, provide a horizontal component at the bottom of the skirts which balances out the pressure from the wet concrete, and a symmetrical horizontal
component at the top which balances out in the horizontal
member of the formwork system. The vertical components
in the struts act at the bottom on the collapsers and at the
top are countered by the weight of the formwork system.
Prestressing the struts must not be allowed to cause distress
at the top of the ledges and must be increased steadily to
keep pace with the rising concrete.
5.4.5.7 - Reinforcement, fastenings and
other embedded items
Devices used for fastening or positioning items to be embedded in
the concrete, including steel reinforcement, must not be allowed
to adversely affect the strength or durability of the works.
Metal fastenings must not be nearer the outside face than the
minimum depth of concrete cover prescribed for reinforcing steel.
In particular, rods or ties cut off just below the surface are not
allowed.
Starter bars must be treated to prevent rust stains on the exposed
concrete. Holes left by the construction process must not be filled
in, except as otherwise provided for in the contract. Details of the
positions, shapes and dimensions of these holes must be submitted to the Engineer for approval after examining their appearance.
Where a fine or featurework finish is required, plastic blocks must
not be used in in situ concrete.
40
41
b) Form monitoring
While pouring concrete, the following points in particular must
be constantly monitored:
The formwork must remain in intimate contact with the previously poured lining ring, it must not be displaced causing
uncontrolled leakage,
Side skirt fastening (anchors or struts),
Concrete workability time limit (usually 2 hours),
Correct placing of concrete, without segregation, without
displacing reinforcement or box-outs, and without the forms
deforming,
Pumping must proceed without excessive pressure rise,
Concrete falling from windows must not segregate.
Note. Concrete placement can commence before the fitting of the
end stop has been completed provided it has a sufficient lead not
to interfere with the concrete pour.
5.4.7.4 - Vibration
All concrete (except self-compacting concrete) must be vibrated
so that it completely fills the forms with dense concrete.
Self-compacting concretes must not be vibrated, they compact
under their own weight.
The stipulations in the CCTG General Specifications (Fascicule
65A) apply along with the following recommendations.
a) Internal vibration
When internal vibration is achieved with electric, compressed air
or other type of poker vibrator (poker diameter 25 mm to 86
mm), the following rules apply:
Choose the right poker size to suit the amount of concrete to
be consolidated, on the basis of the radius of action of the
poker being ten times its diameter,
Do not let the poker touch the side of the form or reinforcing
bars,
The vibrator should be lowered into the concrete quickly and
withdrawn slowly,
Do not use the vibrator to shift concrete laterally (it should
remain upright as it is lowered and withdrawn),
When pouring concrete in layers, the vibrator should penetrate
100 mm into the previous layer,
Layers should not be more than 450 mm thick,
When metal forms are used, external vibration should be used
as well as poker vibrators where sidewalls are more than 400 mm
thick,
Where the lining rings are reinforced, provide "vibration wells"
with guidance devices if necessary (this arrangement is recommended when concreting the first few metres from the portals
with their reinforcement, box-outs and special lining ring shapes).
b) External vibration
External vibrators are usually employed on metal forms, plus
internal vibration as necessary.
Concrete should not be poured in layers more than 400 mm deep.
While external vibrators can be moved to keep pace with the
rising concrete, it is advisable to fit the forms with a sufficient
number of units so that they do not need to be moved during the
pour; only those vibrators on the part of the formwork being
filled are switched on.
42
Geometry, concrete mixes, formwork and concrete pouring practice for tunnel linings
Ring length 10m, Concrete Volume 60 m3 approx. 1 no. 30 m3/hr pump, 24 hours full cycle
43
Figure 50 - ??????????
Figure 49
Installing wood form for niche
44
45
46
47
48
49
Fine finish
Fine finish surfaces must be free from the following defects:
- Exposed reinforcement, segregation or honeycombing,
- Deformation such that f > 3 mm or F > 4 mm,
- Misalignment between adjacent panels greater than 1 mm,
- Wood fibre or other foreign matter trapped in concrete,
- Patches where concrete skin has been torn off,
- Spalls,
- Rust stains,
- Runs of laitance,
- Layering and mottling showing the different batches poured,
- Obvious cold joint between concrete lifts,
- Severe colour discrepancies between form panels,
- Extensive air pitting (blowholes),
- Bleed line.
Featurework
In addition to the above defects, wrought surfaces must also be
free from the following:
- Cracks,
- Small scale mottling,
- Circular stains due to laitance leaks.
Tasks involved in building the
tunnel lining
Excavation
- Check clearances
- Acceptance of excavation
- Trim profile if necessary
Waterproofing system behind
permanent lining
- Inspect before concreting
- Waterproofing system
protection present
Formwork, embedded pipe
and ducting, etc.
- Geometry of formwork system
- Cleanliness
- Positioning
- Box-outs, inserts
- Ducting
Critical points
(internal and
external supervision)
Stop points
cleared
by Engineer
x
x
x
x
x
x
x
x
x
x
x
x
x
Reinforcement
Concrete
- Approved mix
- Suitability (fit for purpose)
- Supervision of mixing
- Supervision of pouring
- Striking forms
x
x
x
x
x
x
x
50
x
x
x
x
x
7 - SAFETY
7.1 - Safety and formwork system
design
The structures used for building tunnel linings are classed as
machines and as such they must be designed in keeping with the
regulations, which impose two types of duty:
The design must comply with the technical requirements for
new machines, according to the design rules in Annex 1 of Article R233-84,
Design must follow procedures for conformity certification as
relating to EC self-certification as described in Article R233-53.
General requirements are set forth in the IMRS document entitled Design of Working Equipment and Means of Protection.
The designer must analyse identified risks to eliminate them,
inform users of any residual risks, state what special training is
needed and whether or not individual or collective protective
equipment is necessary.
The designer's attention must focus on the undermentioned
items, among others.
7.1.1 - Moving Parts
Moving parts must be designed, made and positioned in such a
way as to avoid any risks and, if risks subsist, the parts must be
provided with protective devices.
Parts of the machine on which people are liable to have to walk or
stand must be designed in such a way that they cannot slip, trip or fall.
Furthermore, the machine must be designed in such a way that
there can be no possibility of contact with the wheels or tracks
when the driver or other on-board operatives are in the operating
position.
7.1.2 - Access and Working Items
All stairs, ladders, landings and walkways must allow the workforce
to reach their workstations and perform their jobs in safety anywhere on or in the machine, allowing for the lack of space in some
parts the machine. Where there is danger of falling objects, the
machine must be equipped with the necessary protective devices.
The design and fabrication of formwork systems must take
account of the following requirements:
Minimum width of working platforms: 1.00 m
Minimum width of access walkways and stairs: 0.60 m
Headroom: 1.90 m
Minimum height of safety barriers: 1.10 m
Minimum height of toeboard: 0.15 m
Avoid salient corners in the load-bearing structure and supporting components to the form liners, provide protective devices
if necessary,
Landings and floors must be solid non-slip chequer plate (try
to avoid the use of wooden boards),
There must be elevated landings at the front and rear of the
formwork system providing convenient access to the front end
form stop and the construction joint at the rear,
Access ladders must have safety hoops and landings for heights
greater than 4 m.
7.1.3 - Concreting Tools and Accessories
The tools and accessories needed for concrete pouring must be
selected such as to limit manual work and its strenuous nature.
This applies to:
Routing the concrete pour by manhandling large heavy hoses;
a monorail with hoists should be provided, or better still, a
concrete distributor,
Use electric poker vibrators and form vibrators to keep down
noise,
Use water to clean concrete delivery lines rather than a foam
pig pushed through by compressed air,
Keep the use of compressed air to a minimum, because it raises
dust and is noisy.
7.1.4 - Ancillary Components for Translation,
Positioning and Form Stripping
These are complex and delicate operations; even if the formwork
system operator is fully conversant with the controls, he must
know and fully control the range of operations he must perform,
especially:
Coordination of vertical, horizontal, transverse and longitudinal motions which may be manual or electric/hydraulic powered motions,
Sound alarm to warn workforce before starting a manoeuvre,
Check the track has been laid correctly, and is firmly fixed and
stable,
Check safety pins which must be provided on certain moving
parts such as the skirt props, adjustable feet, etc.; they must be
easy to pull,
Inspect braking and blocking systems, make sure they are
capable of holding the machine stationary, whatever the gradient.
7.1.5 - Fluids Pressure
Pipes and hoses carrying fluids under pressure must be able to
withstand external loads without damage and must be firmly attached and protected. Emergency stop controls must always be provided. They must be highly visible and all workmen must know
where to find them.
7.1.6 - Lighting
Lighting suitable for all manoeuvres of the formwork system and
associated tasks must be provided. The lighting installation must
be inspected at the time of acceptance of the formwork system.
7.1.7 - Handling and Controls
The various handling operations needed for the correct working
of the formwork system must be incorporated at the design stage
(remember to provide lifting handles).
Controls must be designed so that no dangerous situation can
51
7.1.8 - Starting
The machine must only start as the result of a voluntary action on
a control specially provided for this purpose.
7.1.9 - Emergency Stop
An emergency stop control must be provided except if the control
being used returns automatically to its neutral position when
released by the operator.
7.1.10 - Instruction Manual
The geometry of the formwork system must consider safety issues
from the earliest design stages, and lighten the men's workload.
All machines must be accompanied by a highly detailed and very
easy to understand instruction manual, drafted jointly by the
formwork system supplier / manufacturer and Contractor. The
manual is issued to the works director and formwork system
manager.
52
7.4. Training
There is no nationwide training scheme; the only effective training is dispensed within the company by site foremen, experienced workers and senior staff.
Before shuttering and pouring concrete for the lining crown but
after the Manufacturer has issued the formwork system operating
manual and the Contractor has issued a job-specific health and
safety plan, the Manufacturer must organise a demonstration of
the motions of the formwork system and safety conditions to be
observed.
The senior staff in charge of the tunnel lining work must train the
workforce in the proper use of the formwork system and safety
rules before commencement of the lining works.
Training, awareness enhancement and repeated safety announcements must be continually provided with back-up, if necessary, by
contributions from the CRAM (regional sickness insurance
fund), OPPBTP (construction industry professional prevention
organisation), occupational doctor, Engineer, Safety Coordinator,
etc.
s REFERENCES
Fascicules
Fascicule 65 du CCTG : Btons
Fascicule 67 du CCTG : Etanchit
Fascicule 69 du CCTG : Travaux en souterrains
Dossiers, catalogues, notices, proceedings and guidelines
Annales de lInstitut du btiment et des travaux publics N526 - Septembre 1994 - Etude de la fissuration du bton
dans le cas des revtement de tunnels
CETMEF - Notice sur la surveillance et lentretien des tunnels canaux avec catalogue - 2000
Dossier Pilote du CETU Gomtrie 1990
GTFE (Groupe [permanent] de Travail Francophone des Exploitants) Ministre des Transports - CETU
Guide technique " Rsistance du bton dans louvrage, la maturomtrie " - Ministre des Transports - LCPC - 2003
Guide du bton coffr en tunnel CETU Centre dEtudes es Tunnels - Direction des routes - 1983
Guide de linspection du gnie civil des tunnels routiers - Ministre des Transports - CETU - 2004
Guide technique du LCPC - Dfauts daspect des parements en bton - Ministre des Transports - 1991
Catalogue des avaries Tunnels ferroviaires (Livret K) - Cotation des OA - SNCF - 1996
AFTES Guidelines
GT7 : Rflexions sur les mthodes usuelles de calcul des revtements - TOS N14 / 1976
GT7 : Lutilisation du bton non arm - TOS N 149 / 1998
GT9 : Etanchit - TOS N 159 / ????
GT14 : Catalogue des dfauts apparents des tunnels complt par une nomenclature des parties douvrages en tunnels - 1980
GT14 : Mthode de diagnostic pour les tunnels revtus - HS 3 Chambry
GT29 : Utilisation des rgles et normes gnrales de conception et de dimensionnement pour les revtements en bton arms et non arms
TOS N165 / 2001
GT31 : Peinture des parements en bton - TOS N178 / 200.
GT35 : Gestion et valorisation des matriaux - TOS N199 / 2007
GT37 : Comportement au feu des structures de gnie civil (Recommandation en cours)
Article "Vers les moyens de prvenir lcaillage du bton en tunnel" - TOS N196 / 2006
Article "Pression au btonnage" - TOS N 121/ 1994
Article "Utilisation du bton non arm en tunnel" - TOS N149 / 1998
Standards
NF EN 197- 1 : Composition, spcifications et critres de conformit des ciments courants - Fvrier 2001
NF EN 206-1/A1 : Bton - Partie 1 : Spcifications, performances, production et conformit (amendement la norme NF EN 206 -1 avril 2004
et IDC P18-325 -1/A1 - avril 2005
NF EN 206-1/A2 (IDC P 18-325-1/A2 - Amendement 2) - Bton - Partie 1 : Spcification, performances, production et conformit - Oct. 2005
.../...
53
NF EN 450 : Cendres volantes pour bton / Partie 1 : Dfinition, spcifications et critres de conformit (IC : P18-050-1) - Octobre 2005
NF EN 934 - 2 - Adjuvants pour bton, mortier et coulis - Partie 2 : adjuvants pour btons. Dfinitions et exigences - Avril 1998
NF EN 1008 - Eau de gchage pour btons - Spcifications d'chantillonnage, d'essais et d'valuation de l'aptitude l'emploi, y compris les
eaux des processus de l'industrie du bton, telle que l'eau de gchage pour bton (P18-211) - Juillet 2003
NF EN 12390 - 2 : Essai pour bton durci Partie 2 : confection et conservation des prouvettes pour essais de rsistance - Octobre 2001
NF EN 13263 - 1 : Fumes de silice pour bton / Partie 1 : Dfinitions, exigences et critres de conformit (IC : P18-502-1) - Septembre 2005
NF EN 13670 - 1 : .Excution des ouvrages en bton - Juin 2003
NF EN 14889 - 1 : Fibres pour bton. - Partie 1 : Fibres d'acier - Dfinitions, spcifications et conformit (indice de classement : P18-328-1). Octobre 2006
NF- LH ou quivalent : Ciments conformes aux normes EN 197-1, NF P 15-317 (Prise Mer) et NF P 15-319 (Eaux sulfates)
NF P 18 - 502 : Additions pour bton hydraulique - Fumes de silice - Mai 1992
NF P 18 - 503 : Surfaces et parements de bton - Elments d'identification - Novembre 1989
NF P 18 - 506 : Bton - Ractivit d'une formule de bton vis--vis de l'alcali-raction - Critres d'interprtation des rsultats de l'essai de performance - Novembre 2004
NF P 18 - 508 : Additions pour bton hydraulique - Additions calcaires - Spcifications et critres de conformit - Juillet 1995
NF P 18 - 509 : Additions pour bton hydraulique - Additions siliceuses - Spcifications et critres de conformit - Dcembre 1998
FD P 18 - 457 (Fascicule de documentation) : Bton - Guide d'application des mthodes d'essais - Juin 2005
Projet BRPR-CT98 - 0813 : Test and design methods for steel fibre reinforced concrete
Circulaire interministrielle n 2000- 63 (du 25 aot 2000) relative la scurit dans les tunnels du rseau routier national
ISO 15189 COFRAC : Organisme mis en place par les pouvoirs publics pour permettre aux laboratoires qu'il accrdite d'apporter la preuve
de leur comptence et de leur impartialit
ISO 1518 : Test de rsistance la rayure
R233 84 du Code du travail. Dcret no 92-767 du 29 juillet 1992 relatif aux rgles techniques et aux procdures de certification de conformit applicables aux quipements de travail et modifiant le code du travail (deuxime partie: Dcrets en Conseil d'Etat)
CM 66 additif 80 : Rgles de calcul des constructions en acier
Eurocode 2 : Annexe Nationale franaise
Eurocode 3 : Construction mtallique - Calcul des structures en acier et Document d'Application Nationale dont :
NF EN 1993 - 1 - 1 : Eurocode 3 - Calcul des structures en acier - Partie 1 - 1 : rgles gnrales et rgles pour les btiments (P22-311-1) Octobre 2005
NF EN 1993 - 1 - 2 : Eurocode 3 - Calcul des structures en acier - Partie 1 - 2 : rgles gnrales - Calcul du comportement au feu
(P22-312-1) - Novembre 2005
NF EN 1993 - 1 - 8 : Eurocode 3 - Calcul des structures en acier - Partie 1 - 8 : calcul des assemblages (P22-318-1) - Dcembre 2005
NF EN 1993 - 1 - 9 : Eurocode 3 - Calcul des structures en acier - Partie 1 - 9 : fatigue (P22-319-1) - Dcembre 2005
XP ENV 1993 - 6 : Eurocode 3 - Calcul des structures en acier - Partie 6 : chemins de roulement. (P22-360) - Avril 2002
P22380 - 1 : Euro code 3 - Calcul des structures en acier - Partie 1 -10 : choix des qualits d'acier - Dcembre 2005
54
www.aftes.asso.fr
All rights for reproduction or adaptation in whatever format are expressly reserved