Competence in Tunneling

Getting you there.

Hilti. Outperform. Outlast.
1

Hilti decades of competence in tunnels. Since its early beginnings in the 1940s, Hilti has supplied tools and fastening technology to tunnel projects around the world. In fact, there are probably very few tunnels where Hilti has not done so. Hiltis expertise is utilised in all phases of tunnel construction, from tunnel driving all the way through to the installation of equipment. More recently, the field of tunnel rehabilitation and retrofit has gained in importance. In many cases, the key benefit for designers and contractors is Hiltis technical support, combined with dependable products. The specific experience gained through Hiltis involvement in many tunnel projects world wide results in a competitive advantage for our customers.

Temporary applications During the tunnel drive a great number of items must be fixed and kept out of harms way. Electricity, compressed air, water and ventilation air must all be transported through cables and pipes fastened along the tunnel.

Pages 4 9

Competence in Tunneling

Structural and civil works Where formwork must be fastened, membranes fixed or rebar installed after the concrete is poured, Hiltis products come into their own. No surprises can be tolerated when a problem in one area of the tunnel may bring the whole construction process to a halt. Pages 10 16

Mechanical and electrical Equipment and installations make up 20% of the total investment for a modern tunnel. Whether the corrosive attack of exhaust fumes or design for a catastrophic fire is of relevance, Hiltis competence can be depended upon. Pages 17 22

Retrofit and rehabilitation Existing tunnels have to be widened and heightened, repairs undertaken after fires and ventilation concepts changed. All these lead to adaptations in the tunnel structure requiring fastening and demolition technology provided by Hilti. Pages 23 27

Temporary Fastening

Fastening reinforcing mesh for shotcrete

DX 460 powder-actuated fastening tool Robust and reliable The worlds most widely used cartridge tool

X-ZF general purpose nail Easy to load, all in one

R 36 washer For attaching to nails and studs Additional accessories available to accommodate special needs

Washer holder Key when handling extra washers

Challenge of the application Especially when using drill and blast tunneling (e.g. NATM), shotcrete is used to provide the initial lining. Often this will be reinforced with wire mesh. While this is sometimes held in place by the main rock anchors, additional layers of mesh have to be fastened to the first shotcrete coating. Hilti solution & competence For decades, the Hilti X-ZF nail with large steel washers has been the solution of choice. Speed, reliability and economy considerations are the key decision factors. Alternatively, the Hilti HSA-W angled anchor will provide a hold in substrates that may not be suitable for nail penetration. The relevant accessories, such as a washer holder, make the application professional and suitable for underground work. Reference projects Arlberg Tunnel, Austria (2005) Val de Rennes, France (2004) Gotschna Tunnel, Switzerland (2003) Flims, Switzerland (2002) Bergbock Tunnel, Germany (2003) Rennsteig Tunnel, Germany (2002)

HSA-W angled anchor An efficient alternative where powder-actuated fasteners are not the optimum solution

Temporary Fastening

Fastening drainage membranes and half-pipes

DX 460 powder-actuated fastening tool Rugged, robust, simple to service Easy-to-load cartridge strips

Yellow cartridges Optimal for medium-duty applications

X-ZF general purpose nail Perfect in shotcrete Reliable hold every time

Challenge of the application Water is perhaps the most natural companion of any tunnel builder. Where drainage is required locally or across large surfaces, eggbox-pattern drainage membranes or drainage half-pipes are used. The installation must be fast and subsequent work (membrane fastening, concrete pouring) must not jeopardize the location of the drainage membrane or half-pipes. Hilti solution & competence Hiltis DX powder-actuated fastening system is recommended by several of the leading drainage membrane manufacturers. The Hilti DX 460 fastenig tool has been used successfully in this application underground as well as above ground. The X-ZF 32 S23 nail has proven to be a universal solution many million times over, but the Hilti fastener range offers many alternatives to accomodate changing requirements. Reference projects Gotthard Tunnel NEAT, Switzerland (2005) Brixlegg Tunnel, Austria (2005) Botniabanan, Sweden (2005) Socatop Tunnel, France (2005) Tunnel de Monts, France (2005) Metro Madrid, Spain (2005) Madrid-Valencia high-speed train, Spain (2005) Metro de Mallorca, Spain (2005) Bergbock Tunnel, Germany (2003) Hochwald Tunnel, Germany (2001)

X-SW nail Flexible, to protect membrane from tearing Available for use with magazined nails

HPS-1 impact anchor Economical Ideal where DX cannot be used

Temporary Fastening

Fastening impermeable membranes

X-ZF 37 S23 nail with washer Large steel washer to distribute clamping force Economical for mass application

PVC / polyolefine washer Material compatibility to membrane safeguarded Defined rupture point in washer socket to account for rock movements

Challenge of the application Speed is almost everything when the highly specialised crews of membrane fixers take over a tunnel section. Almost - because the near-religious attention to not damaging the membrane in any way is yet more paramount. 1 3 mm thick membranes from PVC or polyolefines are attached in 1 or 2, sometimes 3 layers. A geotextile between the shotcrete and the membrane provides drainage paths and cushioning.

DX 351 powder-actuated fastening tool Fully automatic Well balanced and light

Hilti solution & competence For several decades Hilti has dominated the use of DX nails (e.g. X-ZF 32 S23) in combination with specific synthetic washers designed to be hot-welded to the membrane. The nail and plastic washer is fastened through the geotexile and thus holds the same. Where 1000 shots per day are almost commonplace, reliability of the tools (e.g. DX 35, DX 351) is paramount. Reference projects Brixlegg Tunnel, Austria (2005) Tunnel de Monts, France (2005) Gotthard Tunnel, Switzerland (2005) Ltschberg Tunnel, Switzerland (2004) Sidney PRL, Australia (2005) Strengen Tunnel, Austria (2004) Semmering, Austria (2003)

DX 35 powder-actuated fastening tool Robust and strong Well suited to stretch geo-textile with protruding nail

Temporary Fastening

Fastening temporary ducts, cables, illumination, pipes

HUS-H screw anchor Fully removable High loads at small edge distances

HLC-EO hook sleeve anchor Removable Economic solution

Challenge of the application Fresh air, water, electricity, compressed air all these need to be carried along any tunnel during the construction phase. In addition, temporary lights must be fastened, telecom units installed, transformer stations held in place. The requirements to be met by the relevant fastenings are as numerous as the tunnels: When pre-cast concrete segments are used for lining, drilling is often restricted to certain areas of the element. Anchors that allow small edge distances are then useful. Often, removability is a key asset as well. And in all cases nobody wants to spend much time fastening the ventilation ducts. Hilti solution & competence Hiltis added value really is the breadth of its product range: DX cartridge technology for quick light-duty fastening is part of our offering, as are heavy duty anchors to hold up large-diameter water evacuation pipes. Thus, Hilti can offer what you need, not what just happens to be in the catalogue. Reference projects Collector Blagis, France (2004) Val de Rennes, France (2004) Metro Cairo, Egypt (2003) Metro de Mallorca, Spain (2004) Amsteg Power Station, Switzerland (2002) Dresden Coschtz / Dlzschen Tunnel, Germany (2004) Bergbock Tunnel, Germany (2003) Hochwand Tunnel, Germany (2001)

HKD flush anchor Internally threaded Flush with the surface

X-FB fastener Quick to install Compatible with dozens of other temporary applications

DX 460 powder-actuated fastening tool Rugged, robust and simple to service Easy-to-load cartridge strips

TE 16-M rotary hammer Compact dimensions and good balance for high working comfort

PD 30 laser range meter One-person distance measuring Pocket size Rugged and dust protected (IP 54)

Temporary Fastening

Fastening rails for TBM trailers or formwork carriages

HVU adhesive anchor system Suitable for dynamic loading Easy to install, no waste of resin Economical heavy duty anchor for serial applications

HUS-H 16.5 screw anchor Perfect for temporary fastenings Fully removable Standard product comes in corrosion protection class hot-dip galvanized

HSA stud anchor Easy to install Economical for volume temporary applications

Challenge of the application Temporary rails are commonly used in underground construction. The two main applications are Fastening of rails for the complete supply of tunnels by train, especially if driven by TBMs Fastening of rails for the tunnel formwork carriage of the inner lining and subsequent work stations Depending on the application and required life span, the requirements vary from minimal to significant in terms of load level, dynamic resistance, removability and cost. Hilti solution & competence While many products of the Hilti range can be fit for the purpose, the typical anchor used is HVU in the case of more severe loading and life span requirements, such as for tunnel rails. Where only little load and a few load cycles are expected, HUS-H and HSA have been utilised successfully.

PR 25 rotating laser Leveling and aligning up to 200 m Rugged design and dust protected

By using Hilti drills such as the TE 16 in combination with a PR 25 rotating laser the true line for the rails can be found with precision. Reference projects Tunnel de Monts, France (2005) Metro Madrid (Metronorte), Spain (2005) Gotschna Tunnel, Switzerland (2004) Flims Tunnel, Switzerland (2005) Vereina Tunnel, Switzerland (2000)

TE 16-M rotary hammer Compact dimensions and good balance for high working comfort

DD EC-1 diamond coring system Hand-held tool for anchor and through holes of 8 35 mm diameter
8

Temporary Fastening

Fastening conveyor belts

HVU adhesive anchor system Suitable for cyclic loading Easy to install, no waste of resin Economical heavy-duty anchor for serial applications

Challenge of the application Especially in TBM-driven tunnels, mucking out is frequently done with conveyor belt systems. Their high capacity and continuous operation help reduce traffic in the already congested tunnel cross section. Conveying systems are installed temporarily but often remain in place for several years in long tunnels. Fastenings must be economical, yet securely withstand any dynamic loading and oscillation from the belt operation. Hilti solution & competence Given the loads, dynamic effects and economic considerations, the solution of choice is often an adhesive anchor. The HVU adhesive capsule system or the HIT injection mortar have both been used successfully. Reference projects Collecteur Blagis, France (2004) Gotthard Tunnel, Switzerland (2004) Guadarrana Tunnel, Spain (2004) Metro Barcelona, Spain (2006)

HIT-RE 500 adhesive anchor system and HAS-E rods Comparably insensitive to installation variations Highest load values combined with low sensitivity to installation anomalities Easy adaptability with respect to anchor length

PR 25 rotating laser Save on the most time consuming operation of fastening: Alignment and positioning Leveling and aligning up to 200 m Rugged design and dust protection

TE 16-M rotary hammer Robust and versatile: Ideal for most on-site installation jobs

TE-C3X hammer drill bits Up to 30% longer life than regular drill bits Innovative helix design for rapid drilling progress and excellent dust removal

Structural and Civil

Rebar installation

HIT-RE 500 adhesive anchor system Highest load values combined with low sensitivity to installation anomalities Foil pack minimizes waste Better corrosion protection than cast-in bars

HIT P-8000 D pneumatic dispenser for jumbo foil pack (1400 ml) Speedy injection Pre-selection of resin volume

TE-YX drill bit Full carbide head for high durability Anti block tip for rebar impacts

Challenge of the application Post-installed rebars using adhesive resins are a common sight in construction today. They are indispensable, however, in tunnel retrofit. Where cross sections need to be altered when their use changes or suspended ceilings are renewed as the ventilation concept becomes obsolete, rebars are generally used to connect old and new concrete. As part of the primary tunnel structure the connections must have a life expectancy in line with the main parts of the structure.

PS 200 Ferroscan Rebar detection, cover measurement and rebar diameter estimation Immediate high-res image Wireless, dust-protected, rugged

Hilti solution & competence With more than 20 years in the market, the Hilti HIT family can offer by far the longest experience in injection technology for anchors and rebars. With a load performance fully equivalent to cast-in bars and corrosion resistance even better (e.g. HIT-RE 500), the solution of the market leader is capable of fulfilling the most advanced requirements. The resin itself is complemented by a powerful range of accessories like dispensers and hole cleaning equipment, even for jobs of industrial proportions. In addition, the Hilti drilling technology (hammer or diamond) as well as the PS 200 Ferroscan helps you identify and combat any problems, even before you hit them. Reference projects Metro Madrid, Spain (2005) Metro Barcellona, Spain (2005) Tunnel de Monts, France (2005) Socatop, France (2005) Bruxelles Airport, Belgium (2000) Tunnels in Velasquez Highway, Chile (2005)

TE 76P ATC combi hammer High performance and safety with Active Torque Control ATC Theft Protection System TPS

Dresden Coschtz/Dlzschen Tunnel, Germany (2004) Weser Tunnel Bremen, Germany (2005) Herren Tunnel Lbeck, Germany (2005) High Speed Train Madrid-Valencia, Spain (2005)

10

Structural and Civil

Cladding panels

HVZ adhesive anchor system Available in many steel qualities, including HCR 1.4529 Tolerates concrete cracks (shrinkage) Suitable for fatigue loads Good electric isolation Tested for fire resistance

HKD flush anchor Internally threaded Flush with the surface Economical for mass applications Tested for fire resistance

Challenge of the application While aesthetic considerations are often the principal objective, tunnels are in fact clad for a number of reasons. Cladding panels can provide improved reflectivity, easy tunnel cleaning, sound absorption especially in portal areas, as well as fire protection for the tunnel structure. Shock-like suction and compression loads from passing trains and trucks require substantial fatigue resistance of fasteners. Todays high-speed trains can cause pressure changes of more than 6kN / m 2. With humidity and corrosive agents always present in tunnels, corrosion is also a key consideration. Not to mention fire resistance where panels must not become detached in a catastrophic event. Hilti solution & competence For decades, Hilti has provided fastening solutions to contractors concerned with cladding systems. Due to difficult accessibility for inspection, stainless steel in high grades is more often the rule than the exception. If serious dynamic loads must be considered, adhesive anchors such as the HVZ adhesive capsule system are most suitable. In less demanding cases, mechanical anchors such as the Hilti HSA stud anchor or the Hilti HKD impact anchor can be used. Where cladding sub-structures have to be fastened to steel members, the X-BT cartridge driven fastener delivers obvious speed advantages and high load values at the same time. Reference projects Tokyo Metropolitan, Japan (2006) Metro Prag, Czech Republic (2002) Metro Mnchen, Germany (2005) Bramsch-Tunnel Dresden, Germany (2002)

X-BT stainless steel threaded stud for coated steel Corrosion resistant equal to or better than standard A4 (A316) steel. Blunt tip: no through penetration High load values with high consistency Speed of fastening

DX 351 BT powder-actuated fastening tool For efficient and convenient setting of the X-BT M10 threaded studs

PD 32 laser range meter High accuracy (1.5 mm) Set offset of panels Measure clearances and check traffic gauge

11

Structural and Civil

Fastening fire protection board

HK6 board fastener Available in all relevant steel qualities Various head configurations available for optimal installation

HSA stud anchor Easy to install Economical for volume applications

TE 2 rotary hammer Powerful, light-duty rotary hammer drill for a variety of applications

TE-C3X hammer drill bits Up to 30% longer life than regular drill bits Innovative helix design for rapid drilling progress and excellent dust removal Gradient technology for superior ruggedness

Challenge of the application Tunnel fires produce extremely high temperatures within very short time spans. Amongst other damage, this is known to cause explosive spalling. For years, fire protection board has been used to shield structural components from the heat. Depending on the system, four to ten fasteners are used per square metre. The anchors are exposed to the corrosive tunnel atmosphere and/or cyclic wind suction loads during their complete life time. Of course, an adequate fire resistance of the fasteners is paramount. Hilti solution & competence Since 1981, Hilti has continuously gathered data on corrosion of materials in tunnel atmospheres (see page 29). Material samples have been monitored for decades in real- life weathering tests. The resulting knowledge is coupled with a comprehensive understanding of fire resistance in fasteners gained through hundreds of in-house and independent fire tests. Drilling and measuring technology complements this competence on fasteners. Reference projects M30 Madrid, Spain (2006) Tokyo Chinmai Tunnel, Japan (2001) Frejus Tunnel, France (2003)

PD 32 laser range meter Measures distances & calculates areas on the spot Easy one-person verification of as-built measurements

12

Structural and Civil

Fastening wire mesh for sprayed fire protection

X-CR 48 S15 stainless steel nail Very fast installation Stainless steel material similar to grade 1.4546

DX 460 powder-actuated fastening tool Robust and reliable The worlds most widely used powder-actuated fastening tool Challenge of the application Temperatures of up to 1300 C within a few minutes of a fire starting can cause significant damage to concrete structures. Fire protection mortars are used more and more frequently in tunnel construction and rehabilitation. Due to their relatively low cost they often compete well with more traditional board systems. These mortars are usually applied in thicknesses of 30 50 mm. In order to secure and reinforce any sections with disturbed bond to the substrate, a wire mesh is usually fastened to the base material. An economical fastening solution that nevertheless withstands the fire and possible corrosion attack must be used. Hilti solution & competence The fasteners supplied by Hilti are only a part of the complete solution. Designers and applicators are usually looking for a harmonized system of mortar, wire mesh and the fastening solution that is ideally tested together. Hilti therefore works with several suppliers in the relevant fields to develop and test adequate solutions. Depending on the requirements, DX powder-actuated fasteners and HK6 or HSA anchors can be utilised optimally. In most cases, stainless steel fasteners and wire mesh are selected. Reference projects Tunnel Brnnen, Switzerland (2006) Tunnel de Foix, France (2005)

HK6 anchor with wiremesh-clip Available in all usual steel grades Suitable for cracked concrete

HSA stud anchor Easy to install Economical for volume applications

TE 2 rotary hammer Powerful, light-duty rotary hammer drill for a variety of applications

13

Structural and Civil

Fastening rail track

HRA, HRT, HRC rail anchors Fully tested for fatigue loads Plastic sleeve or injection mortar protect effectively against stray currents

HIT-RE 500 adhesive anchor system Highest load values combined with low sensitivity to installation abnormalities Foil pack minizes waste Better corrosion protection than cast-in bars

Challenge of the application The majority of transportation tunnels are rail or metro tunnels. These require fastening of the track, often on a solid concrete slab. These fixings are subjected to very high alternating loads making fatigue the governing design factor. In addition, stray currents and related corrosion effects are a major issue to be dealt with. And given the industrial operation, a professional setting process is essential. An early decision on the fastening system can in many cases save millions by reducing the required tunnel cross section. Hilti solution & competence Hilti offers three major rail anchor lines (HRA, HRT, HRC), designed to safely transfer the oscillating axle loads from the rail into the concrete structure. As no two tunnels are the same, and as the requirements vary from country to country, these are available in many variants. Where called for, simpler solutions have been engineered as well. In addition, Hilti provides a comprehensive range of drilling, setting and aligning equipment satisfying the industrial approach of todays rail installation professional. Reference projects Perth Light Rail, Australia (2006) London Underground, UK (2005) Metro Madrid, Spain (2005) Metro Milan, Italy (2005) New York City Metro, USA (2005) Tram Way Milano-Ginisello, Milan (2005)

HIT P-8000 D pneumatic dispenser for jumbo foil pack (1400 ml) Speedy injection Pre-selection of resin volume

DD 130 diamond coring system Hand-held or rig mounted operation for flexibility in use

PD 32 laser range meter Set-out and adjust with laser accuracy

14

Structural and Civil

Cut & cover: Fastening of roof slab

HIT-HY 150 dual foil pack resin For concrete 10 years experience for zero surprises Added cement for corrosion protection

TE 76P ATC combi hammer High performance and safety with Active Torque Control ATC Theft Protection System TPS

DD EC-1 diamond coring system Hand-held tool for anchor and through holes of 8 35 mm diameter Challenge of the application Inner city tunnels and other shallow underground works are often constructed using the cost effective cut & cover method. This usually requires the roof slab to be fastened into diaphragm walls. Such ceilings are typically constructed of cast-inplace concrete or steel girders with pre-cast concrete slabs. Depending on the design, the requirements range from shear and / or moment transfer via grouted dowels and rebars to water tightness, corrosion resistance and fire safety considerations. Hilti solution & competence Whether a professional rebar-connection is needed or steel bearings must be fastened with anchors, Hilti as global leader in fastening technology can provide both, in addition to professional design support, on-site installation training and Hiltis compatible drilling technology. Reference projects Metro Madrid, Spain (2005) Metro Singapore, Singapore (2000) Metro Sydney, Australia (2001)

HDA heavy duty anchor Undercut security and highest loads Performance reserves when ground movements cause load peaks

HVU + HAS Any diameter, any size M8 M39 Flexibility and high loads Minimised sensitivity to site irregularities

15

Structural and Civil

Finishing of metro stations (cladding, screen doors, ceilings)

MQ channel system Flexible and versatile Quick-lock system for speedy installation

HST stud anchor Available in HCR stainless steel for road tunnels Tested for tunnel fires

HVU adhesive anchor system Suitable for dynamic loading Easy to install, no waste of resin Economical heavy duty anchor for serial applications

Challenge of the application Where thousands of people pass through a metro station on a daily basis, underground structures require attractive, safe and bright finishes on walls and ceilings. In addition, safety equipment such as screen doors on the platforms are becoming the rule in many municipal networks. Hilti solution & competence Strut support systems with all their components, enabling quick installation, are available in many versions and materials. In this way one system can be used to advantage in various situations always supplemented by Hiltis broad anchor systems range. Where fire compartmentalisation is required, Hiltis fire stop engineers can help with the market leaders products and expert advice. Reference projects Metro Paris, France (2005) Metro Shanghai, China (2005) Metro Guang-Zhou, China (2005) Metro Vienna, Austria (2005) Metro Munich, Germany (2005) Metro Hong Kong, Hong Kong (2003) Metro Prague, Czech Republic (2002) Airport Tunnel Kloten, Switzerland (2002) Metro Singapore, Singapore (2001) Metro Berlin, Germany (2004)

HIT-RE 500 adhesive anchor and HAS-E rods with centering rings Guaranteed electrical insulation No loosening of the anchor even after millions of load cycles

PML 32 line laser Self-leveling for horizontal and vertical alignment High dust and moisture protection

16

Mechanical & Electrical

Jet ventilator fastening

HVZ adhesive anchor system Highest safety level Tolerates concrete cracks (shrinkage!) Suitable for dynamic loads Good electric insulation

HDA-R heavy duty anchor Self-undercutting anchor for through fastening applications Stainless steel 1.4401

HSC-AR safety anchor Self-undercutting anchor Small drilling depth

Challenge of the application Jet ventilators are some of the heaviest pieces of equipment placed directly above traffic in a tunnel. In addition to the weight, their fasteners can be subject to dynamic loading from unbalanced propellers or wind pressure induced by traffic. The high requirements on security are also manifested by the use of various safety cables or chains designed to hold a falling ventilator if the anchors should fail. High standards regarding anchor corrosion resistance, dynamic loading or concrete cracks are therefore the rule. Hilti solution & competence These requirements are reflected in many different national codes and regulations which govern this application. Hilti offers a comprehensive range of fasteners: Adhesive anchors such as HVZ, HVU in stainless steel (including HCR material 1.4529) Mechanical anchors such as HDA, HSC, HSL-3 and HST, in various stainless steel grades. Hilti hammer and diamond drilling technology complements the offering. Reference projects Pripherique Paris, France (2006) Socatop, France (2006) Nad Al Hamar Tunnel, Dubai (2004) North Passage Basel, Switzerland (19982005) Metro Singapore, SGP (2000) Tunnel Les Vignes, Switzerland (1997) Dresden Coschtz / Dlzschen Tunnel, Germany (2004) Tunnel Wiener Platz Dresden, Germany (2002)

TE 16-M rotary hammer Versatile tool for most drilling jobs on site

DD EC-1 diamond coring system Hand-held tool for anchor and through holes of 8 35 mm diameter

17

Mechanical & Electrical

Cable tray and pipe support

ML channel system Optimal for electrical supports Light weight for easy handling Quick-install features

MQ channel system Versatile, with numerous specialised components Eight different channel profiles for optimised use of material

MI channel system Heavy-duty system that will take the place of most welded structures in tunnels Fully compatible with MQ Challenge of the application 1525% of the total investment for modern tunnels relates to mechanical and electrical equipment and the corresponding supply services. While the design life of these M&E installations is often significantly below the expectation for the tunnel HST stud anchor structure itself, most projects nevertheless require great attention to the durability of Economical anchor for safety relevant fastenings and supports of pipe and cable lines. fastenings Suitable for cracked concrete In addition, the linearity of the structure requires industrial installation processes (shrinkage) that leave little room for improvisation and on-the-spot decisions. Hilti solution & competence With the support systems MI, MQ and ML, Hilti offers a comprehensive range of compatible systems designed to take either loads of just a few cables or the weight of a 1000 mm water pipe. The system solution also comprises perhaps the most comprehensive range of fastenings and drilling technology, covering many materials and corrosion protection classes. To increase productivity, laser positioning tools help to save on the most expensive part of the works, namely labour. A key part of the Hilti offering is the calculation service and software, together with true on-site support available in 120 countries. Reference projects Rennstein Tunnel, Germany (2002) Uetlibergtunnel, Switzerland (2005) Tunnel de Monts, France (2005) Madrid Airport Tunnel, Spain (2005) PD 32 laser range meter Metro Prague, Czech Republic (2003) Mark support spacing in one-person Metro Singapore, SGP (2000) operation Utility Tunnel Vienna Airport, Austria (2005) Verify pipe offset & lengths to 1.5 mm Dresden Coschtz /Dlzschen Tunnel, Germany (2005)
18

PML 32 line laser Self-leveling, for horizontal and vertical alignment High dust and moisture protection

Mechanical & Electrical

Fastening catenaries

HVZ adhesive anchor system Highest safety level Tolerates concrete cracks (shrinkage) Suitable for dynamic loads Good electrical insulation

HDA-R heavy-duty anchor Undercut anchor for highest safety level Easy installation - even overhead

Challenge of the application Overhead catenaries are loaded by the dynamic forces of passing trains (friction, pressure of pantograph). In addition, any metal part is potentially subject to significant stray currents which can cause corrosion. Despite this, the design life of tunnel structures is usually more than 50 100 years, making it essential to pay special attention to detail. In tunnels, such catenaries are fastened to the tunnel soffit, which may be heavily reinforced or entirely un-reinforced concrete. High requirements on geodetical position and small tolerances on the steel brackets usually make drilling a challenge. Hilti solution & competence Hilti provides a whole portfolio of anchor products suitable for the application in order to fit with local requirements, design codes and customs. Preferred adhesive anchor systems: HVZ and HVU capsule systems HIT-RE500 resin injection system. With a specific centering ring to hold the rod in place overhead and to guarantee perfect electrical insulation on all sides. Preferred mechanical anchor systems: HDA and HSC undercut anchors, both with easy to install self-cutting technology. A range of materials and coatings is available to suit the specific requirements. Hilti can provide suitable drilling technology as well as robotic drilling tools, drilling templates and lasers to align the installation. Reference projects Channel Tunnel Rail Link, Great Britain (2005) Ltschbergtunnel, Switzerland (2005) Tabladillo Tunnel, Spain (2005) High Speed Line Rome-Naples, Italy (2002) Arlberg Tunnel, Austria (2002) Vereina Tunnel, Switzerland (2001) Metro Berlin, Germany (2005) Metro Naples, Italy (2005)

HIT-RE 500 adhesive anchor system and HAS-E rods with centering rings Guaranteed electrical insulation Highest load values combined with low sensitivity to installation anomalities Easy adaptability with respect to anchor length

TE 56-ATC combi hammer Rugged tool for use in tunnels Low vibration for repetitive anchor setting

DD 130 diamond coring system Hand-held or rig mounted operation for case-by-case flexibility 3 different diamond matrix specifications to optimise drilling performance and core bit life

19

Mechanical & Electrical

Fastening lighting systems

HSA stud anchor Easy to install Economical for volume fastening applications Available from stock in more than 100 variations

HST stud anchor Available in HCR stainless steel for road tunnels Tested to withstand tunnel fires

X-FB fastener Speedy installation All-metal solution for adequate fire performance

Challenge of the application Lighting and the relevant feeding cables have to be fastened in virtually every tunnel. Depending on the type of tunnel (e.g. road or rail), corrosion aspects will usually be an important consideration in order to avoid any failure during the lifetime of the tunnel. In addition, the illumination system forms a key component of the escape system in the case of a smoke-emitting fire. Furthermore, in both new build and rehabilitation projects, emergency lighting systems are installed in addition to the regular illumination. Fastenings must therefore demonstrably be able to withstand the temperatures of tunnel fires. Hilti Solution & competence There are numerous systems of illumination utilised in tunnels. Some are fixed directly into the ceiling, others fasten onto the cable trays that carry the feeder cables. Yet others are situated on sophisticated metal structures made of channel and strut. Hilti offers an extensive range of anchors, DX powder-actuated fasteners and channel systems that will accommodate most designs. Using this comprehensive system allows the use of Hiltis design software and reduces the number of interfaces between components. Where required, Hilti can provide customized fire testing and related expert advice, both in-house and from independent organisations.

MQ channel system Comprehensive system to accommodate most designs Eight different channel profiles for optimised use of material

PR 25 rotating laser Easy alignment and positioning up to 200 m Rugged design and dust protected Projects horizontal or vertical plane

CP firestop systems Complete range Effective sealing of fire compartments

20

Reference projects Zrich Airport Tunnel, Switzerland (2002) San Bernardino Tunnel, Switzerland (2003) Socatop, France (2005) Pripherique Paris, France (2006) 30 Tunnels, Germany (2002) NBS Kln-Rhein / Main, Germany (2002) Rennsteig-Tunnel, Germany (2002) Eichenberg-Tunnel, Germany (2004) Helleberg-Tunnel, Germany (2004) Escherberg-Tunnel, Germany (2004) Landrcken-Tunnel, Germany (2004)

Mechanical & Electrical

Fastening signalisation, radio and safety equipment

HST stud anchor Available in HCR stainless steel for road tunnels The standard for fast, economical installations

HVZ adhesive anchor system High loads, even where alternating wind loads cause fatigue Available in High Corrosion Resistant steel (HCR)

Challenge of the application Modern tunnels are equipped with dozens of communication, information and safety systems: Traffic signalisation, radio and mobile communication cables or cameras all require fastening and support systems capable of withstanding the severe corrosion conditions in tunnels. Given the multitude of applications, the range of requirements applied to the fastening systems in terms of load level and direction, anchor type, corrosion protection, cost implications, etc. is also almost unlimited. Hilti solution & competence Mirroring the numerous applications and requirements, Hilti offers what is one of the worlds largest ranges of fastening and support products. Thousands of different anchor types and variants, sizes, lengths and diameters in many different materials are available from stock. And if something is not on hand as a standard item, Hilti has decades of experience in custom-manufacturing solutions. As usual, these fastening products are always supported by state-of-the-art drilling and measuring technology, all from one hand. Reference projects Metro Prague, Czech Republic (2002) Gtatunnel, Sweden (2005) Walensee Tunnels, Switzerland (2004) Socatop, France (2005) Pripherique Paris, France (2006) Metro Berlin, Germany (2005) Dresden Coschtz/Dlzschen Tunnel, Germany (2004) Wilsecker-Tunnel, Germany (2006) Knigstuhl-Tunnel, Germany (2005)

MQ channel system Almost unlimited possibilities to build any frame Available in hot-dip galvanized and stainless steel qualities

PR 25 rotating laser Save on the most time-consuming operation: Easy alignment and positioning Self-leveling in horizontal and vertical position

TE 16-M rotary hammer Versatile tool for most drilling jobs on site

21

Mechanical & Electrical

Fire mains and sprinkler system

HSC-R safety anchor Approved for shock loads Short drilling depth at high loads

HST stud anchor The standard for fast, economical installations Available in High Corrosion Resistant steel (HCR)

TE 16-M rotary hammer Optimal performance for holes up to 20 mm Full versatility: 2 gears, hammer or rotary

Challenge of the application More and more tunnels are protected by way of sprinkler or more recently highly advanced water mist systems. When sprinklers are switched on, a water hammer effect in the piping system exerts very significant shock-type forces on the fastenings. These are difficult to calculate. At the same time, the resistance of the fastenings is critical to the functioning of the sprinkler system and, thus, the survival of tunnel users. More often than not, fire mains are fastened along the tunnel. The usual requirements with regards to corrosion and design life of tunnels produce an additional consideration in the design. Hilti solution & competence The design of anchors for dynamic loads is one of Hiltis key competencies. Hundreds of tests and various approvals allow to-the-point designs and significant optimisation as a result of extensive knowledge of the behaviour of Hiltis anchors. Undercut anchors for serial applications such as the HSC have been used with great advantage to transfer the impact of sprinkler systems to the tunnel lining. In addition, Hilti drilling technology (hammer drilling and diamond), as well as laser technology to align the anchors can be obtained from one expert supplier.

PR 25 rotating laser Rugged design and dust protection Easy alignment and positioning up to 200 m

PD 32 laser range meter Mark support spacing in one-person Reference projects operation Verify pipe offsets & lengths to 1.5 mm Betuwe Tunnel, Netherlands (2005) SOCATOP, France (2006) Tunnel Stammham, Germany (2004) Knigstuhl-Tunnel, Germany (2005) Wilsecker-Tunnel, Germany (2006) 30 Tunnels on NBS: Kln-Rhein / Main, Germany (2002)

22

Retrofit & Rehabilitation

Suspended ceiling slab

Hilti HY150 injectable adhesive Fire resistant due to water-cement matrix Excellent long-term behaviour

RE500 injectable adhesive Reduced hole depth due to high bond strength Low sensitivity to many application irregularities

Challenge of the application Perhaps the most significant type of rehabilitation work going on in dozens of tunnels around the world is the change of the ventilation system. The toxic exhaust gasses of cars some 20 years ago made complicated ventilation systems with multiple air ducts necessary. With todays cleaner cars these can often be retrofitted to help contain smoke in the case of a tunnel fire. This may require the change of existing (or introduction of new) suspended ceilings. Also, in some cases the course of time, corrosion or fires have taken their toll on existing suspended ceilings in tunnels. Hilti solution & competence Here more than anywhere the understanding that every project is different has its merits: Depending on the tunnel lining encountered, the fire and corrosion conditions as well as the actual alteration required, Hilti has developed various solutions in close cooperation with the responsible engineers. These included chemical anchors, e.g. Hilti HIT-HY 150, HIT-RE 500, as well as mechanical anchors such as the self-undercutting anchor HDA-R. These are always supported by the availability of a complete system of drilling equipment, laser tools as well as fire stopping products to seal any remaining gaps in the new fire compartments. Reference projects Plabutschtunnel, Austria (2004) Felbertauerntunnel, Austria (2005) Sonnenberg Tunnel, Switzerland (1999) Gotthard Tunnel, Switzerland (1999) PfnderTunnel, Austria (1995)

HDA undercut anchor Highest safety through undercut Highest performance

HCC concrete connector For bonding new concrete to old concrete

CP 606 fire stop sealant Optimised viscosity for easy installation 30-year age tested

PD 32 laser range meter One-person verification of as built measurements Setting and adjustment of formwork

23

Retrofit & Rehabilitation

Additional SOS niches and escape routes

HIT-HY 150 adhesive in dual foil pack For concrete 10 years experience for zero surprises Added cement for corrosion protection

HIT-RE 500 adhesive anchor system (1400 ml jumbo foil pack) Speedy injection Pre-selection of adhesive volume Highest load values combined with low sensitivity to installation anomalities

SFV anchor and HIT-RE 500 adhesive anchor system Connects Dywidag rods Rod retractable when formwork is removed

HVU adhesive anchor system Suitable for dynamic loading Easy to install, no waste of adhesive Economical heavy duty anchor for serial applications

Challenge of the application Wherever the typical cross section of a tunnel is altered, it is likely that the normal formwork system cannot be used or additional shuttering is needed. Alternatively, sections of secondary concrete may have to be poured, calling for post-fix rebar connections. This will regularly require fastening technology capable of sustaining substantial hydrostatic concrete pressure. In TBM-type tunnels, it is sometimes necessary to cut out already placed pre-cast concrete liners with diamond coring and sawing technology. Furthermore, ventilation and other services are required. Hilti solution & competence Where rebar connections are concerned, Hilti is clearly the world leader in adhesive anchor technology. With a range of products and technologies available, most requirements can be fulfilled, even the most demanding. Please refer to page 10 for further details. The formwork systems used in tunnels differ widely as far as the specific fastening details are concerned. Heavy-duty mechanical and adhesive anchor systems have been used successfully in the past. Reference projects Guadarrama Tunnel, Spain (2005) Socatop, France (2005) Arlberg Tunnel, Austria (2005) Ltschberg Tunnel, Switzerland (2004) Tunnel de Pertus, Spain (2006)

DD 300 diamond coring system Simple handling, no specialised workforce needed Water-cooled and water-protected for wet tunnels Brushless high-frequency motor with 10 speed settings

24

Retrofit & Rehabilitation

Increase of traffic gauge

HIT-HY 150 adhesive in dual foil pack For concrete 10 years experience for zero surprises Added cement for corrosion protection

alt neu

SFV anchor and HIT-RE 500 adhesive anchor system Connects Dywidag rods Rod retractable when formwork is removed

Challenge of the application While tunnels are virtually cast in stone, increase in traffic and innovations in transport systems may lead to new demands on the available traffic gauge. In such cases, every centimetre counts: Tunnel bottom levels are lowered, linings reduced in critical curves, ballast replaced by rigid slabs in rail tunnels. Hilti solution & competence In many cases, Hiltis demolition and fastening technology can help reduce tinkering on site and to conceive a professional methodology for complex rehabilitation projects. Hiltis HIT injection systems are frequently used to connect existing and new concrete structures with rebars or to fasten formwork and scaffolding. For example, the SVH formwork anchor can tie back one-sided shuttering using regular Dywidag rods. Diamond saws as well as electric demolition breakers are used where machinemounted or pneumatic hammers are too clumsy or heavy. Where rail tracks need to be lowered, it can be beneficial to use Hilti HRA rail anchors which save the height of the ballast and, thus, increase traffic gauge. Reference projects Arlberg Tunnel, Austria (2006) Schni Tunnel, Switzerland (2006) Getli Gallery, Switzerland (2006) Naxberg Tunnel, Switzerland (2006) Glion Tunnel, Switzerland (2006) DS-WS 15 wire saw

DS-TS32C wall saw

TE 706 breaker Less tiring to use, higher daily productivity Excellent balance and significantly lower dynamic vibration Constant, high performance even when the voltage drops

25

Retrofit & Rehabilitation

Concrete repair & concrete overlays

HCC-B conrecte connector Built-in quality assurance through internal adhesive injection Accurate positioning and fastening of rebars

Hilti HIT-RE 500 adhesive anchor system and SFV anchor Connects Dywidag rods for formwork anchors Rod retractable when formwork removed

TE 706 breaker Less tiring to use, higher daily productivity Excellent balance and significantly lower dynamic vibration Constant, high performance even when the voltage drops

Challenge of the application As a consequence of the corrosive atmosphere and salt often found in tunnels, or due to fire damage, the concrete lining of many tunnels requires attention: Excessive cracking, spalling or insufficient cover to protect rebar from corrosion call for removal and replacement of concrete layers. These new concrete overlays must be tied in with the existing concrete to form a load-transferring unit. Hilti solution & competence While for large surfaces the removal is usually carried out using high pressure water jets or mechanical means, on smaller areas Hiltis demolition breakers such as the TE 706 have been used to advantage. Where concrete grinding is needed, the Hilti DG 150 diamond grinder has been used to good effect.

PS 200 Ferroscan Measures and checks concrete cover on large surfaces Allows statistical analysis

Concrete cover and rebar position can be determined, analysed and visualised with the PS 200 ferroscan. Hiltis HCC concrete connector is a specialised fastening system designed to transfer shear and tension loads between concrete overlay and the substrate. Reference projects A2 Wassen, Switzerland (2000) Pfndertunnel, Austria (2002) Wallenseestrasse, Switzerland (2005) Roffla Tunnel, Switzerland (2004) SKN Bernadino Tunnel, Switzerland (2005)

26

Retrofit & Rehabilitation

Damage repair specialised solutions

HIT-RE 500 adhesive anchor system Epoxy injection mortar with high adhesive strength Optimised viscosity for injection into small voids

HIT P-8000 D pneumatic dispenser for jumbo pack (1400 ml) Handy, yet powerful enough to inject adhesive into small deep holes Uses regular pressurised air available on any construction site

Challenge of the application Rock movements and water pressure can cause problems with the tunnel lining. These problems and their solutions are highly individual, of course, so the examples given here are not a representative cross section. What they often have in common, though, is that Hiltis fastening experts are frequently called on site to help. Hilti solution & competence Many of Hiltis products can be used in situations that are far beyond their regular applications. Hiltis engineers accompany you with judgement, analysis, testing, approval support and finally with hands-on installation, training and support. In the first example (large picture above), the steel lining of a race pipe in a hydro power station had become deformed due to external water pressure. In collaboration with the specifying engineer, Hilti devised a special fastening system to secure the lining, featuring minimal protrusion, based on the HIT-RE 500 injection mortar. The smaller pictures show an example where ground movements caused excessive relative displacement of pre-cast concrete segments. In order to stabilise these, a steel tube was inserted into a pre-drilled opening, with the annular gap later injected with HIT-RE 500. A specialised injection technology was devised and tested for this task before using it on site. Reference projects Seelisbergtunnel, Switzerland (2006) KWO Gallery, Switzerland (2005)

TE 56-ATC combi hammer Rugged tool for use in tunnels Low vibration for repetitive anchor setting

DD 300 diamond coring system Simple handling, no specialised workforce needed Water-cooled and water-protected for wet tunnels Brushless high-frequency motor with 10 speed settings

27

Fields of special competence.

Corrosion, fire, dynamics. While there are many areas in which Hiltis expertise can help during the design process, corrosion, fire resistance and dynamic loading usually feature high on any tunnel designers list of priorities. For Hilti, the key has always been to truly understand the customers needs within a very specific application. We then make it our responsibility to translate that into simply a good solution. Hiltis competence goes far beyond the mere knowledge of codes and regulations. Our research more often than not provides the basis for standards as it drives innovation.

28

Life-long safety.

Competence in corrosion and materials. The atmosphere in tunnels is known to be highly corrosive due to exhaust gases, dust, humidity and frequently salt and other influences. This leads to highly accelerated corrosion in mild steel and may cause hydrogen embrittlement in high-strength grades. In stainless steel these agents can cause pitting and crevice corrosion, which can lead to stress corrosion cracking, perhaps the most treacherous form of corrosion. Hilti started live tunnel exposure studies in 1981 since short-term laboratory tests are insufficient as a sole source of information. For decades, Hilti has tested numerous types of carbon and stainless steel, incl. highly corrosion-resistant grades alloys of titanium, aluminium and nickel samples from various manufacturers products of various geometries These samples have been exposed to the atmosphere of eight road and rail tunnels. In order to simulate service loads part of the bolts were pre-stressed. The subsequent analysis includes microscopic investigation and load tests in compari-son to unexposed reference samples of the same material. These in-situ experiments are supported by Hiltis corrosion laboratories which focus on simulating real application conditions (pollutants, temperature, humidity, etc.) accelerated corrosion testing. To complement in-house competence, Hilti also cooperates with academic institutions including ETH Zurich, Switzerland; Montan-University Leoben, Austria and University Stuttgart, Germany. The results of Hiltis testing have significantly influenced codes and regulations, as well as the related academic debate. These activities have yielded what is probably the worlds most extensive corrosion database for tunnels. This is used to optimise the specific corrosion protection in a given tunnel for a given application. In fact, it is this capability to economically optimise structures in a safe way that many customers view as Hiltis key strength in tunneling applications.

29

More than one iron in the fire.

Foto: Ar n o B a l z a r i n i

Competence in fire safety. Hilti has been active for decades in the field of passive fire protection, which essentially consists of the application fields fire protection of structural components fire resistance of fastening systems fire stopping of penetrations and construction joints Steel and concrete are impacted by high temperatures. Fires in tunnels produce temperatures up to 1300C in very short periods of time due to the spatial confinement. Tunnel structures are typically protected by fire protection boards or proprietary sprayed mortars. In both cases fasteners are needed, either to hold up the board, or in the case of sprayed mortars to attach wire mesh reinforcement. Hilti works closely with manufacturers of fire protection systems to provide tailored system solutions with real expertise built in. As world leader in fastening technology, Hilti has long focussed on qualifying its products regarding fire resistance. This includes mechanical and chemical anchors, DX powder-actuated fasteners as well as channel support systems. In fact, Hilti uses its own test furnaces to help build the necessary knowledge base. Hilti also works together with external bodies for independent fire assessments. This long-term commitment to in-depth fire testing has led to perhaps one of the worlds broadest portfolio of fire-rated fastening products. Hilti is the worlds leading supplier of fire stopping products designed to close gaps in fire-rated structures, such as service penetrations or building joints. But Hiltis expertise does not only cover the actual product. The true value for our customer is generated when a reliable product is combined with on-site application knowledge provided by our fire stop engineers. It is this competence that drives realistic test settings and therefore real-life results.

30

Shock. Fatigue. Vibration.

Competence in dynamic loading. As the world leader in fastening technology, Hilti has developed an in-depth understanding of dynamic loading situations over the decades and investigated their impact on fastening solutions. fatigue loading (e.g. anchors for jet ventilators, rail fastenings) repetitive shock loading (e.g. cladding panels, fire protection board) Hiltis main laboratory for dynamic anchor testing at corporate headquarters in Liechtenstein is used for internal tests. In addition, many international experts and academic institutions use our facilities in various forms of cooperation. For our partners, Hiltis competency is a key benefit the detailed knowledge of anchor behaviour under dynamic loading. This is complemented by what many experts consider the worlds most sophisticated set of anchor testing laboratories. Hiltis testing equipment is capable of applying enormous loads in high frequencies and loading velocities. In order to analyse anchor loads in sufficient precision, Hilti has developed individual measuring technology. Hilti has used this technology in many projects where dimensioning anchors is difficult due to uncertainties with regards to the expected load levels. Especially in fatigue and shock design, the loading history of structures and fasteners is of vital interest. Often, critical loads only occur infrequently and unpredictably. Hilti uses a combination of measuring equipment and the relevant recording equipment on customers real life structures to help understand what the true loads are over a period of time.

31

Competence in Tunneling

Hilti in tunneling. More information by fax.

Fax to: Number: Company: Hilti Corporation +423 234 30 96

Contact:

Street:
Hilti = registered trademark of Hilti Corp., Schaan | W 3227 0806 3-en | 1 Printed in Liechtenstein | 2006 | Right of technical and programme changes reserved S. E. & O.

Town, post code:

Phone:

E-mail:

Area of activity: Please arrange an appointment with me. I am particularly interested in:

Product lines Measuring Anchors Installation DX powder-actuated fastening Firestop Drilling and demolition Diamond drilling and sawing Screw fastening Cutting and sanding Others

Application topics Corrosion Dynamic loading Fire safety Technical data for products Approvals for product Rail fastening Rebar analysis / coverage Software PROFIS anchor calculation software Exbar (rebar fastening) calculation software Exbar overlay (concrete overlays) Channel & pipe support design software PS 200 Ferroscan

Hilti. Outperform. Outlast.

Hilti Corporation | 9494 Schaan | Liechtenstein | P +423-234 2111 | F +423-234 2965 | www.hilti.com