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Abdichtung Uetliberg Tunnel
Abdichtung Uetliberg Tunnel
Abdichtung Uetliberg Tunnel
fill one of the last gaps in the Swiss motorway network. The Uetliberg tunnel project is part of this bypass and consists of two 4.4 km long two-lane tunnels, a cut-and -cover section comprising the ventilation plant, gallery link and a gallery with a 80 m high shaft for the evacuation of the vitiated air. The waterproofing work is very demanding on all parties involved. The tunnels need in some places (ground water zone) water pressure containing waterproofing and in some places drained, non water pressure containing waterproofing. To prevent water infiltration from the pressure-containing section into the non pressure-containing section, the transition zones between the sections must also be sealed off against the rock. The water pressure-containing waterproofing system consists of a single, monitorable and injectable membrane layer with "Rckfallebene" (second defence line). The pressureless, drained waterproofing system is not designed for systematic injections. In both sections, injectable waterbars welded onto the membrane serve the purpose to enclose possible leakage zones. The invert/vault joints are sealed off with special waterbars and systematically injected. In order to ensure an as par as possible creaseless installation the closest possible to the substrate, the waterproofing membrane is fastened by VELCRO system. The waterproofing system described in this paper has been developed by the project designer, main contractor and waterproofing subcontractor in close teamwork. This way it was possible to make fruitful use of all experience gathered in the course of the last years. Keywords: Project, sealing system, application methods. Outline
Project Overview Characteristics, Milestones Project participants Sealing System waterproofing membranes Requirements Substrate, Drainage system Areas with/without water pressure Compartments, joint details Application methods Costs /Conclusion
A51
Airport Kloten Schaffhausen Germany
A1 A1 A1
Bern France
The Lim
tunnel Gubrist
ma
A4
Zurich
Birmensdorf
N20.1.4
Uetlib
N4.1.4
uric eZ Lak
N4.1.6
N4
Luzern Italy
A3
Swiss city on their 1000 to 2000 km journey to the Italian beach resorts for their annual holidays. This situation will change in 2010 when the western bypass of Zurich will be completed and linked to the already existing northern motorway ring. Several tunnels are being built for that at this time. One of these tunnel projects is the subject of this paper. However, the Uetliberg tunnel project is worth mentioning not only with respect to the excavation which, thanks to a proposal submitted by the contractors, is done using the most advanced method by means of a 14.10 -14.40 meters widening TBM equipped with undercutting technology.
Project Description
The project comprises two parallel tubes, each about 4.4 km long. The tunnel falls with a gradient of about 1.6% from the Zrich South motorway interchange at Brunau to the Zrich West interchange at Filderen. The tunnel tubes are connected every 300 m by a pedestrian gallery and every 900 m by a gallery practicable by vehicles. The SOS niches are spaced 150 m apart. Portal stations are located at both the east and west part with control and machinery rooms. An
underground ventilation facility is being built at Landikon in the Reppisch Valley. Three lane crossover points are built for the diverting traffic in the event of disturbance such as accidents, fire etc. The construction of the Uetliberg Tunnel will generate about 1.7 millions m3 of broken rock and debris. The portion of this muck, not used in the project, has to be removed by rail. Road transportation is not allowed. Consequently a conveyor was installed from the Landikon construction pit to the railway loading station in Filderen. The conveyor belt runs through a 550 m transportation tunnel, diameter 3.70 Meter, especially built for this purpose.
+800
UETLIBERG ETTENBERG
Portalstation Wannenboden Abluftkamin Eichholz
Eichholztunnel Uetlibergtunnel
+700
+600
Portalstation Gnziloo
+400
5
Morne Verschwmmte Morne Sandstein Mergel Lehm
~ ~
~ ~ 2800.00 m Mechanischer Vortrieb (Pilot-TBM+ TBE ) 4 Molassestrecke Uetliberg 5 Lockergesteinstrecke Juchegg ~ 410.00 m Konventionell (Bagger, Stahleinbau etc.) Leitniveaus Grundwasserspiegel
210.00 m Konventionell (Bagger, Stahleinbau etc.) 500.00 m Sprengtechnischer Vortrieb 240.00 m Konventionell (Bagger, Stahleinbau etc.)
Characteristics
Excavated area 143 160 m2 Volume of muck and spoil material 1.7 million solid m3 Shotcrete 137000 m3 Concrete 187000 m3 Waterproofing membrane 360000 m2 Allowed time for shell construction 6 years
Milestones
Approval of the project by the Swiss Federal Roads Authority January 2000 Award of the tunnelling works September 2000 Start of the maintunnel works October 2000 End of shell construction End of 2006 Official opening of tunnel End of 2008
Cut and cover sections Fiez AG, civil engineers, Zrich Henauer + Gugger AG, engineering company, Zrich Hans Eichenberger AG, engineers, Zrich Construction Joint Venture Uetli, led by Zschokke Locher, Zrich
Murer AG Erstfeld Prader AG, Tunneling Zrich CSC Bauunternehmung AG, Construction Zrich Wayss & Freytag, Munich/Frankfurt Alpine Mayreder Bau GmbH, Salzburg_Wals ZblinSchlittlerSpaltenstein Bau AG; Zrich
Waterproofing
In the Ettenberg Tunnel zone, in the loose soil zones Uetliberg and in the zone of the waste air installation, the tunnel waterproofing is executed in different ways i.e. integral membrane system containing water pressure in loose soil and molasse ground water zones and drained integral membrane system containing no water pressure in the "dry" molasse zones. Two and three millimetre thick polymer waterproofing membranes on synthetic fleece and/or drainage mats are used.
Due to the specified almost creaseless and surface close application of 3 mm membranes we recommend: 10 : 1 for PVC membranes and 12-15 : 1 for FPO membranes. The requirements regarding evenness were met with shotcrete with the following mix designs: Wet sprayed concrete: B 25/15 Cement content: 450 kg/m3, grain size: 0-4 mm spraying output: approx. 6-8 m3/h onto a layer of wet sprayed concrete: B 35/25, cement content: 425 kg/m3, grain size: 0-8 mm, spraying output: approx.10-14 m3/h. For purposes of testing the roughness, a sample of shotcrete was applied onto a 40 x 40 cm precast concrete slab and approved by the waterproofing subcontractor. When required, the sample has been compared visually with the applied shotcrete.
Geotextile fleece, 1000 gr / m2 (2 x 500 gr) Waterproofing system non water pressure-containing
Cross section integral waterproofing, non water pressure-containing, in the TBM excavation section
The build-up of the waterproofing system comprises an 8 mm thick Enkamat- drainage layer fixed onto the shotcrete and a 3 mm thick polymer waterproofing membrane Sikaplan 30 PECO, installed all around. The drainage consists of a 250 millimetre drainage pipe embedded in gravel and covered with a knobbed, 1,5 m wide drainage mat. In the invert zone a 3 mm protective membrane is welded onto the waterproofing membrane. The waterproofing of the tunnel vault consists of a single, 3 mm thick membrane. Protective membranes are applied only in zones with steel reinforcements. In Switzerland tunnels are in principle not reinforced. The intermediate tunnel roof slab joint in the Uetliberg tunnel is an exception. This joint zone is reinforced for structural reasons and therefore covered with a 1.5 metre wide protective membrane. For purposes of compartmental sealing off, type Sika AR 40/6 PECO inject waterbars have been welded all around onto the waterproofing membrane., at 75 metres intervals in the middle of a block, in order to limit the field needing injection in case of possible leakage. The waterbars are made from the same material as the waterproofing membranes and are therefore compatible and perfectly weldable. In zones without water pressure no injection tubes were installed. I case of the need for injections, holes will therefore have to be drilled through the inner concrete lining. Remark: We recommend compartmental sealing off by means of waterbars also for waterproofing systems not containing water pressure. Taking this measure prevents uncontrolled spreading of leaking water and makes repair work in possible leakage zones much easier. Injections must however be carried out with due caution in order to avoid clogging of the drainage system.
Resin Injections into waterbar injection-channel Cement Injections through Sika injection inlet-element
Experience shows that surface waterbars in the tunnel vault crest zone, even if installed professionally, are hardly ever properly embedded in the concrete if not additional measures are taken. Injection sleeves are therefore installed in the tunnel vault crest zone, allowing on the one hand the entrapped air to escape, and on the other hand to inject cement suspensions. These injections were carried out systematically, unlike the injection of the waterbars done only if and when required, in addition to the tunnel vault crest injections.
Invert zone waterproofing: 3mm Sikaplan waterproofing membrane with protective membrane
Tunnel vault waterproofing: 3mm Sikaplan waterproofing membrane, protective membrane only in the block joint areas
For the invert, a two-layer injectable waterproofing system designed for a maximum water pressure of 5 bar is used. The build-up comprises 2 x 500 gr. fleece protective layer fastened onto the shotcrete substrate and the membrane, an outer 3 mm Sikaplan-PECO 30 waterproofing membrane and a 3 mm Sikaplan-30 PECO DIA knobbed membrane welded onto it.
Double layer sealing system, Injection connections and pipes in invert area
For the tunnel vault, the thickness of the knobbed membrane is reduced from 3 to 2 mm, except in the zones of the transversal galleries and the reinforced concrete zones, where also 3 mm thick membranes are used.
Saeling detail with injecable waterbar and connection flange and injection hoses
Groundwater relief element and Rckfallebene ("second defence line", injectable and drainable, connected to the drainage system)
Injection sleeves for the grouting of the space between the two waterproofing membranes, are fitted onto the inner membrane and connected to injection tubes running through the tunnel lining concrete. These tubes end up in a control box remaining always accessible. This allows checking of the waterproofing system at any time. Leaking water can this way either be evacuated into the tunnel drainage system (Rckfallebene = second defence line) or the leaking zone can be sealed by means of injections. Water seepage during construction phase calls for additional measures. Ground water relief elements are necessary for evacuation of the water. The tubes of the relief elements must be tightly sealed at the time of completion of the project. These relief elements are situated in the duct channel and therefore always accessible. In our case they will not be covered with concrete but will remain accessible for monitoring purposes. The relief elements have been fitted with pressure gauges for checking the waterpressure.
Groundwater relief element and Rckfallebene Block joint seal The joint between the tunnel invert and vault has been carried out according to the already described sealing off system by means of single-fin waterbars and systematic injections. The block joints have been carried out with Sika AR 60/6 Inject special waterbars. The waterbars have a smooth, 25 cm wide middle section without fins, serving as support for the shuttering and protecting the membrane from being damaged. In the crown of the vault, the waterbar is fitted with injection sleeves for grouting with cement suspension.
Conclusion
Not only the fact that ever more tunnels are built in ground water zones and bad experience of project owners with recently built tunnels, most of them leaking and causing enormous repair and maintenance costs, but also the generally higher quality standards call for innovative solutions for waterproofing work.
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Thank God, the still often heard quality requirement : Raining outside, raining inside makes little by little way for higher quality requirements. For the Uetliberg tunnels, project owner, project designer, main contractor and waterproofing sub-contractor have co-operated in designing a waterproofing concept representing the middle course between the desirable, the technically and economically feasible and the practical. The solution is the result of years of experience, development work and innovative laying technology. The costs for the waterproofing, representing approximately 2.7% of the total project costs, are in spite of that very modest. 1) Author: Roland Frstler, Sika Schweiz AG Tunneling Mining, e-mail: foerstler.roland@ch.sika.com Tel: +41 55 640 41 67/ Fax +41 55 650 26 65/ Bellikonerstrasse 218/ CH-8967 Widen
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