8

Part 11

Lining Railway Tunnels1

— 2012 –

TABLE OF CONTENTS

Section/Article Description Page

11.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11-2

11.1.1 Scope (2004) R(2012) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11-2

11.2 Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11-2

11.2.1 Interior Dimensions (2004) R(2012) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11-2 1
11.2.2 Preliminary Data (2004) R(2012) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11-2
11.2.3 Floors (2004) R(2012) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11-2
11.2.4 Sidewalls and Arch (2004) R(2012) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11-3
11.2.5 Construction and Expansion Joints (2004) R(2012) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11-3
11.2.6 Drains (2004) R(2012) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11-7
11.2.7 Refuge Niches (Bays) (2004) R(2012) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11-7 3
11.2.8 Conduit and Inserts (2004) R(2012) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11-7

11.3 Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11-7

11.3.1 General (2004) R(2012) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11-7
11.3.2 Filling of Forms (2004) R(2012) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11-7
11.3.3 Removal of Forms (2004) R(2012) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11-7
11.3.4 Inspection Doors (2004) R(2012) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11-8

11.4 Concrete. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11-8

11.4.1 General (2012) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11-8
11.4.2 Order of Placing (2004) R(2012) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11-8
11.4.3 Consolidation (2004) R(2012) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11-8
11.4.4 Laitance and Bonding (2004) R(2012) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11-8
11.4.5 Drainage During Placing (2004) R(2012) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11-8
11.4.6 Shotcrete (2004) R(2012). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11-8

1
References Vol. 37, 1936, pp. 645, 1042; Vol. 42, 1941, pp. 309, 878; Vol. 54, 1953, pp. 814, 1343; Vol. 62, 1961, pp. 445, 861; Vol. 63, 1962, pp. 277, 687;
Vol. 74, 1973, p. 140; Vol. 89, 1988, p. 108. Rewritten 1988.

© 2017, American Railway Engineering and Maintenance-of-Way Association

8-11-1
Concrete Structures and Foundations

LIST OF FIGURES

Figure Description Page

8-11-1 Plain Concrete Tunnel Lining – Rock Section Single Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11-4
8-11-2 Plain Concrete Tunnel Lining – Single Track Temporary Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11-5
8-11-3 Plain Concrete Tunnel Lining – Double Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11-6

SECTION 11.1 GENERAL

11.1.1 SCOPE (2004) R(2012)

This recommended practice covers the lining of new tunnels in rock and those portions of old tunnels in rock which involve no
extraordinary side pressure or special features. The recommended practice covers linings of cast-in-place concrete and
shotcrete with steel sets.

SECTION 11.2 DESIGN

11.2.1 INTERIOR DIMENSIONS (2004) R(2012)

a. The interior dimensions of the clear space provided for single and double-track tunnels should not at any point be less
than tunnel clearances recommended by the AREMA Manual. Where legal requirements provide clearances greater
than AREMA, such legal requirements shall govern.

b. On curved track, the lateral clearance should be increased in conformance with Chapter 28, Clearances, Part 1,
Clearance Diagrams – Fixed Obstructions. The superelevation of the outer rail should be in accordance with the
recommended practice of Chapter 5, Track.

c. To provide for drainage, minimum side clearance of 10 feet (3 m) from centerline of track should be used in tunnels
likely to be wet. Where ventilation is required, the height of single-track tunnel should be increased 1 foot (300 mm)
minimum.

11.2.2 PRELIMINARY DATA (2004) R(2012)

Information shall be obtained for design of new tunnels, consisting of field surveys showing geological formations,
groundwater conditions, environmental conditions, adjacent structures, locations of faults, core borings, hardness and
condition of rock to be encountered, together with any special features and data on existing tunnels through similar formations.
Where a new tunnel is driven adjacent to an existing tunnel, records shall be searched for data as to groundwater conditions,
fault zones, and other special features. Consideration should be given to taking core borings from existing adjacent tunnels.

11.2.3 FLOORS (2004) R(2012)

Floors should, if practical, be paved and may have a ballasted track section, direct fixation to the concrete floor, or other
suitable track design. Paved floors shall be designed for the track section to be used.

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 Lining Railway Tunnels

11.2.4 SIDEWALLS AND ARCH (2004) R(2012)

a. The depth of sidewalls in sound rock shall be at least 6 inches (150 mm) below the bottom of the gutter and at least 6
inches (150 mm) below the intersection of the floor surface with the sidewalls. In unsound rock, the sidewalls shall be
carried down to provide a stable foundation. At portals and vicinity, sidewalls shall extend at least 6 inches (150 mm)
below the frost line.

b. The minimum thickness of the cast-in-place sidewalls and arch shall be:

(1) Where temporary supports for excavation are not required:

• Single track – See Figure 8-11-1.

• Double track – See Figure 8-11-3.

(2) Where temporary supports are required for face of excavation see Figure 8-11-2 or Figure 8-11-3.

c. Encased timber sets are subject to decay and are not recommended. Exposed timber sets create a fire hazard and also
are not recommended.

d. Steel sets are spaced at least 8 inches (200 mm) apart, and in general not greater than 4 feet (1.2 m) apart. Solid liners
may also be considered.

e. Lagging may be wood, steel lags, steel liner plates, or steel water-diverting lagging. Where the nature of the rock and
water conditions permit, lagging shall be spaced to allow a clearance of 4 inches (100 mm) or more between lags to 1
permit free access of concrete to the face of the tunnel excavation. Prior to concreting, remove as many lags as is
possible. Where it is necessary to solid-lag for protection during excavation and where it is impractical to open up the
lagging just prior to concreting, the space between the lagging and face of excavation shall be packed with lean
concrete, crushed stone, coarse gravel, or pea gravel placed pneumatically. Consolidation grouting shall be used to fill
any voids behind lining. Where timber lagging is used, or where existing packing consists of timber, special care must
be exercised in torch cutting or welding of steel ribs or other components to eliminate the risk of fire.
3
f. Rock bolts may be considered as part of a support system.

11.2.5 CONSTRUCTION AND EXPANSION JOINTS (2004) R(2012)

a. Properly placed and consolidated construction joints do not require keyways. Waterstops shall be provided as
necessary. Monoliths shall be as long as practical to minimize the number of construction joints. 4
b. Construction joints shall not be formed at such locations where they might reduce the effectiveness of the lining to
resist pressure from surrounding earth or rock.

c. Where construction joints are provided, expansion joints are not required.

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Concrete Structures and Foundations

Figure 8-11-1. Plain Concrete Tunnel Lining – Rock Section Single Track

© 2017, American Railway Engineering and Maintenance-of-Way Association

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 Lining Railway Tunnels

4
Figure 8-11-2. Plain Concrete Tunnel Lining – Single Track Temporary Supports

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Concrete Structures and Foundations

Figure 8-11-3. Plain Concrete Tunnel Lining – Double Track

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 Lining Railway Tunnels

11.2.6 DRAINS (2004) R(2012)

a. Wherever groundwater is encountered or anticipated, vertical and diagonal openings, trench drains, PVC or iron pipe
drains shall be installed between the concrete lining and rock. Adequate outlets shall be provided through sidewalls
with the outer end of the outlets not less than 12 inches (300 mm) above the bottom of the gutter. Subdrains shall be
provided under the concrete floor wherever groundwater is found. Drains shall be provided through curb to drain
ballast section.

b. Where hydrostatic pressure below the floor may be present, consideration should be given to designing the floor to
withstand the pressure.

c. Wherever groundwater drains are installed, they shall be attached to the rock so as to prevent being clogged when
concrete is poured.

d. Drain type selection should take into consideration an analysis of groundwater constituents and effects of water
aeration to discourage formation of precipitates or adverse chemical reaction which may plug or damage the drainage
system.

11.2.7 REFUGE NICHES (BAYS) (2004) R(2012)

Refuge niches shall be provided as shown on the example figures at approximate intervals of 200 feet (60 m) and staggered
with opposite sides so that spacing of niches shall be approximately 100 feet (30 m). Width of niches should accommodate the
number of people and the equipment to be protected. Bottom of niches shall be at elevation of bottom of track ties for
ballasted track sections and at elevation of intersection of invert and walls for solid track sections. For long tunnels, larger
refuge niches should be considered at appropriate intervals to accommodate equipment. 1
11.2.8 CONDUIT AND INSERTS (2004) R(2012)
Where required, provisions shall be made in the lining for conduit or hangers for cables, wires, and lights.

3
SECTION 11.3 FORMS

11.3.1 GENERAL (2004) R(2012)

a. Forms shall conform to requirements as outlined in Part 1, Materials, Tests and Construction Requirements, together
with additional provisions given herewith.
4
b. The length of forms between construction joints shall be as long as possible to limit number of joints. Waterproofing at
joints should be considered where appropriate.

11.3.2 FILLING OF FORMS (2004) R(2012)

The space between the face of the form and face of excavation or tight lagging shall be entirely filled with concrete, except for
drainage openings, and except that large cavities back of the normal face of excavation may be packed as outlined in
Paragraph 11.2.4(e).

11.3.3 REMOVAL OF FORMS (2004) R(2012)

Forms shall not be removed until concrete has reached strength sufficient to prevent distortion and sustain the applied load.

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Concrete Structures and Foundations

11.3.4 INSPECTION DOORS (2004) R(2012)

Forms shall be provided with inspection doors in the arch and walls so that the concrete can be thoroughly vibrated and
inspected during the placing.

SECTION 11.4 CONCRETE

11.4.1 GENERAL (2012)

Concrete for lining shall be proportioned and placed in accordance with Part 1, Materials, Tests and Construction
Requirements, together with the additional provisions given herewith. Placement of reinforcement shall be in accordance with
Part 2, Reinforced Concrete Design.

11.4.2 ORDER OF PLACING (2004) R(2012)

A section of the wall and footing may be placed separately from the rest of the wall, but a construction joint shall not be more
than 2 feet (600 mm) above the top of ballast curb elevation. The remainder of the wall and arch shall be placed
monolithically. The floor ballast retainers shall preferably be placed in one operation.

11.4.3 CONSOLIDATION (2004) R(2012)

All concrete shall be consolidated during and immediately after placing by means of internal vibration applied in the mass of
concrete and external vibration applied to the forms.

11.4.4 LAITANCE AND BONDING (2004) R(2012)

a. Concrete surfaces receiving new concrete shall be roughened and cleaned of all laitance, dirt, and water before fresh
concrete is placed. The consistency of the concrete and method of placement shall be such that laitance seams are not
formed. If such seams are formed, they shall be completely removed before additional concrete is placed.

b. All loose or unsound rock shall be removed behind walls and below floors before concrete is placed. Where the type of
rock makes this impractical, the floor and foundations for the walls shall be reinforced.

11.4.5 DRAINAGE DURING PLACING (2004) R(2012)

Concrete shall not be placed in moving water. Separate and distinct provisions shall be provided to drain any area receiving
fresh concrete. Effective weeps and drains shall be provided to prevent any hydrostatic pressure against the lining. Temporary
drains shall be grouted after concrete liner has attained design strength.

11.4.6 SHOTCRETE (2004) R(2012)

Shotcrete and reinforcement for shotcrete for lining shall be proportioned in accordance with Part 14, Repair and
Rehabilitation of Concrete Structures.

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8-11-8 AREMA Manual for Railway Engineering