122103-TBM5-RT-SL-0001 - (FDS) DSGN RPT Segment - 1637 - Extracts

DESIGN AND CONSTRUCTION OF SEWER TUNNELS FOR THE DEEP TUNNEL SEWERAGE SYSTEM PHASE 2 PROJECT - CONTRACT T -09
Appendix I Gasket Design
Page 1619 of 1971

\\Cowi.net\subs\DAL\Hong Kong\Projects\03 JOBS\JH0044-DTSS2-T09 Detailed Design\Reports\20a. Std Seg (N3-N)\Rev. 1.4 (rev.1)\122103-TBM5-RT-SL-
0001Rev.1_20180914_(clean).docx
Appendix I March 2018
Gasket
As LCAL is current developing the type of gasket to be used, a 33 mm gasket with 66.5 kN/m peak
force has been assumed in the calculations. To ensure the adequacy of gasket and gasket groove
performance, the following checks have been carried out considering a long-term condition, with
𝛼cc,pl .= 0.6 and 𝛾c = 1.5.
 Shear failure of gasket groove

 Gasket groove edge spalling failure
Also, gasket performance has also been checked considering joint rotation and gasket gap
determined based on:
 0.20% (6.0 mm on radius) calculated maximum long-term deflection as given in Section

7.3.3 of the report;
 0.25% additional distortion induced by future development as per Section 2-3-3 of the
specification.
The joint rotation of 0.61° has been determined, which gives a gasket opening gap of
approximately 2.5 mm. As the 66.5 kN/m gasket is the ultimate force the gasket could apply, a
partial load factor of 1.1 has been considered in the calculations.
Gasket force typically relaxes by approximately more than 20% after segment installation. An
example of gasket short term relaxation is presented below. For circumferential joint shear dowels,
a 15% short term relaxation of gasket has been adopted while no further information is available
at the moment of designing this.
Page 1620 of 1971

C:\Users\RYWO\OneDrive - COWI\JH044_DTSS2\10. Bored Tunnel\04. DDA\04. Cals\7.
Gasket\T09_Joint_Rotation_Check_for_Gasket_EC2_(flat)_20180723.xlsx
Contract Deep Tunnel Sewerage System Phase II Job ref
JH044
Contract T09
Part of structure Gasket Rotation Check Calc. sheet No.
(0.35% + 0.25%)
Calculations by Checked by Approved by Date
7/23/2018
COWI Hong Kong Ltd. RYWO
CALCULATIONS NOTES
Joint Opening and Bursting of Segmental Lining Flat Joint

Calculation according to EN 1992-1-1:2008/EN 1992-1-1:2004 and BS8110-1-1997.
wi w wo
h
1. Calculation input
1.1. Internal forces and ovalization
Maximum thrust (SLS) Q max = 0.0 kN/m
Minimum thrust (SLS) Q min = 0.0 kN/m
Maximum thrust (ULS) U max = 0.0 kN/m
Ovalization ratio Ω = 0.450%
1.2. Tunnel geometry and section properity

Outer diameter Do = 7.150 m
Inner diameter Di = 6.550 m
Segment width bs = 1.000 m
Centroid radius Rc = 3.425 m
Lining width h = 0.300 m
Second moment I = h3/12 = 0.002 m4/m
1.3. Segment joint geometry

Outer groove wo = 0.063 m
Inner groove wi = 0.025 m
Tolerance w tol = 0.005 m
Joint thickness w = h - w o - w i - w tol = 0.207 m
Longitudinal groove wL = 0.000 m
Joint contact width bc = bs - 2 wL = 1.000 m
1.4. Typical segment geometry

Typical segment angle m = 67.500 deg
Segment chord length Lc = 2R csin(m /2) = 3.806 m
1.5. Material properties

Concrete grade Grade C50
Concrete strength f ck = 50,000 kPa
Concrete strength γc = 1.50
Longterm effect coefficient α cc = 0.85
Concrete strength f cm = f ck + 8000 = 58,000 kPa
Concrete strength f cd = α cc f ck / γ c = 28,333 kPa
0.3
Concrete elastic modulus E cm = 22[(f ck + 8)/10] = 3.70E+07 kPa Table 3.1 EN 1992-1-1
Allowable stress in steel fs = 200,000 kPa
Page 1621 of 1971

Printed on 7/23/2018 6:24 PM Page 1 of 2
C:\Users\RYWO\OneDrive - COWI\JH044_DTSS2\10. Bored Tunnel\04. DDA\04. Cals\7.
Gasket\T09_Joint_Rotation_Check_for_Gasket_EC2_(flat)_20180723.xlsx
Contract Deep Tunnel Sewerage System Phase II Job ref
JH044
Contract T09
Part of structure Gasket Rotation Check Calc. sheet No.
(0.35% + 0.25%)
Calculations by Checked by Approved by Date
7/23/2018
CALCULATIONS NOTES
Joint Opening and Bursting of Segmental Lining Flat Joint

Calculation according to EN 1992-1-1:2008/EN 1992-1-1:2004 and BS8110-1-1997.
2. Ring ovalization
y
A
P L
m α 𝛽
O N C B M x
2.1. Dimensions
Ovalization deflection BM = Rc Ω = 0.015 m
Deflected radius (long) OM = R c + BM = 3.440 m
Deflected radius (short) OP = R c - BM = 3.410 m
AB = Lc = 3.806 m
α = (180 - m )/2 = 56.250 deg
2.2. Equations of deformed lining shape (ellipse)

LN 2 ON 2 ON 2
2 + = 1 → LN 2 = 1 - OP 2 Eq. 2A
OP OM 2 OM 2
(OM - ON )2 + LN 2 = LM 2 Eq. 2B
AB = LM Eq. 2C
Using equations 2A, 2B and 2C:

OP 2
1 - ON 2 - 2OM ON + OM 2 + OP 2 - AB 2 = 0
OM 2
0.018 ON 2 - 6.9 ON + 9.0 = 0
ON = 1.309 m
β = cos-1[(OM - ON )/LM ] = 55.946 deg

=
Birdsmouthing angle θ = 2 (α - β ) = 0.6084 deg
= 0.0106 rad
Page 1622 of 1971

Printed on 7/23/2018 6:24 PM Page 2 of 2
Project Deep Tunnel Sewerage System Phase II By Ryan Wong
Structure Gasket Quick Check (33 mm) Date 7/23/2018
Radial joint and gasket material information

Max. ovalization 0.45% (from double ring model)
Joint rotation angle, θ 0.0106 rad
wg
w
Lining thickness 300.00 mm
Caulking groove 25.00 mm
Outer groove 63.00 mm θ δ
Joint face, w 212.00 mm
Gasket groove, w g 38.00 mm w'
Distance to gasket CL, w ' = w + w g/2 231.00 mm

Rotation opening, δ = 2 w ' sin (θ/2) 2.45 mm
Joint Rotation
Testing hydrostatic pressures (2 times) 13.00 bars
Max. gasket force 66.50 kN/m
100 year residual stress 65%
Gasket Force Fg
f ck 50 MPa
f ctk,0.05 2.9 MPa (Table 3.1 EN 1992)
f ctd,pl = 0.6 f ctk,0.05 / 1.5 1.16 MPa (Table 3.1 EN 1992)
45°
Gasket force Check

Shear failure
Failure surface to extrados (see figure) 44.0 mm Shear Failure
Shear surface distance (45 deg) 62.2 mm
Share shrength along slip surface, S shear 72.2 kN/m
Gasket Force Fg
Spalling failure
Failure surface to extrados (see figure) 25.0 mm
Shear surface distance (45 deg) 35.4 mm
Max. possible spalling force Fg/2
Share shrength along slip surface, S spall 41.0 kN/m
Allowable gasket force

45°
Partial load factor adopted, γ g 1.1
Shear failure model: F g,allow = S shear/(γ g sin 45o) 92.8 kN/m
Shear failure model: F g,allow = 2 S spall/(γ g cos 45o) 105.5 kN/m
Maximum allowable gasket force 92.8 kN/m > 66.5 kN/m Edge Saplling Failure
Page 1623 of 1971

RADIAL JOINT ARRANGEMENT
Page 1624 of 1971

DESIGN AND CONSTRUCTION OF SEWER TUNNELS FOR THE DEEP TUNNEL SEWERAGE SYSTEM PHASE 2 PROJECT - CONTRACT T -09
Appendix J Joint Fixings Design

› J1. Radial joint bolts design
› J2. Circumferential joint shear dowels design
Page 1625 of 1971

\\Cowi.net\subs\DAL\Hong Kong\Projects\03 JOBS\JH0044-DTSS2-T09 Detailed Design\Reports\20a. Std Seg (N3-N)\Rev. 1.4 (rev.1)\122103-TBM5-RT-SL-
0001Rev.1_20180914_(clean).docx
J1. Radial joint bolts design
Page 1626 of 1971

C:\Users\niwa\COWI\Ryan Wong - 10. Bored Tunnel\04. DDA\04. Cals\8a. Bolt Design\DTSS2_T09_Bolt design_Daeyrong-gasket_20180411.xlsx
Contract Job ref.

Deep Tunnel Sewerage System Phase II JH044
Part of structure Calc. sheet No.

Design of bolt in radial joint
Originator Checked by Approved by Date

16/04/2018
COWI Hong Kong Ltd. NIWA RYWO CHHY
CALCULATIONS NOTES

ETAG 001, Annex C - Design methods for anchorages
BS 4190 - ISO metric black hexagon bolts, screws and nuts - Specification
Gasket force N Gasket
Bolt tensile
θb
NEL load Tb
Y-direction
dw Lag Lab
dnom
Pocket side Insert side

X-direction
Caulking groove
1. Segmental lining geometry
Lining thickness h = 0.300 m
2. Bolting data
Nos. of bolts Nb = 2 bolts
Bolt angle to horizontal θb = 28.0 ˚ 0.02316
Outter dia. of anchor bolt d nom = 0.02316 m (BS 4190 - Table 10)
Bolt washer diameter dw = 0.050 m 0.03
Distance to caulking groove L ab = 0.125 m
Bolt strength grade Gb = 8.8 (BS 4190 - Table 7)

Bolt char. tensile strength f uk,b = 800,000 kPa
Bolt char. yield strength f yk,b = 640,000 kPa fuk,b/1.25
2
Threaded area of bolt Ab = ϖ (d nom/2) = 0.0004 m²
Bolt washer area Aw = ϖ (d w/2)2 = 0.0020 m²
3. Bolt embedment length

Pocket side embed. length h ef,p = 0.200 m 0.274
Insert side embed. length h ef,i = 0.150 m 0.16
4. Gasket geometry and compression load in radial joint 2.0

Nominal segment width L gh = 1.600 m cos = 2/2.04-> =
Radial joint taper angle θt = 9.46 ˚ 11.36
Ring taper thickness Tr = 0.060 m 0.04
Max. gasket force Ng = 66.5 kN/m (short term force)
100kN/m
Distance to caulking groove L ag = 0.231 m 0.33
Gasket total length Lg = L gh / cosθ t + T r / 2 = 1.65 m
Total gasket compr. load N = Ng Lg = 109.9 kN
Page 1627 of 1971

Printed on 16/04/2018 at 11:19 Page 1 of 5
Contract Job ref.



16/04/2018
CALCULATIONS NOTES
Moment ab 'O'=
Design of bolt in radial joint N*Lag = NEL * Lab
5. Design load of bolt

Partial load factor γL = 1.10
Bolt load X-component N EL = N L ag / L ab = 203.0 kN (moment equilibrium)
Total bolt tensile load Tb = N EL / (N b cos θ b) = 115.0 kN/bolt
Design bolt tensile load T bd = γ LT b = 126.5 kN/bolt
6. Concrete material properties

Char. cylinder strength f ck = 50,000 kPa
Char. cube strength f ck,cube = 60,000 kPa
Concrete material factor γc = 1.5
Long term effects coefficient α cc = 1.0 (Gasket force is temporary
construction load, i.e.
Design concrete strength f cd = α cc f ck / γ c = 33,333 kPa shorterm)
7. Reinforcing steel material properties

Char. yield strength of steel f yk,RF = 500,000 kPa
Partial material factor γ RF = 1.15
Shear reinforcement
8. Shear reinforcement
Nos. of reinforcement N RF = 4 bars
Reinforcement dia. d RF = 13 mm
9. Partial FOS for concrete cone failure

Partial facor for installation γ2 = 1.0 (as lining segments anchor
are cast in precisely, γ2 =
Partial factor for concrete cone resistance 1.0 is adopted)
γ Mc = γ cγ 2 = 1.5
Page 1628 of 1971

Contract Job ref.



16/04/2018
CALCULATIONS NOTES

10. Check against steel failure
Steel failure
Bolt tensile load Tb
Pocket side
(ETAG 001 Annex C

10.1. Partial material factor for tensile failure
Y Ms>=1.4)
Partial material factor γ Ms = Max (1.2/(f yk,b/f uk,b),1.4) = 1.5
10.2. Bolt tensile capacity

Bolt char. tensile resistance N Rk,s = A b f uk,b = 337.02 kN
Bolt design tensile resistanceN Rd,s = N Rk,s / γ Ms = 224.68 kN
Okay, bolt tensile capacity sufficient.
11. Concrete bearing capacity
Washer
dnom
Bolt tensile
load, Tb
dw
Bolt
11.1. Partially loaded area (EN 1992 Section 6.7)

Concrete bearing area A cs0 = Aw- Ab = 0.0015 m² Acs0
Distribution area A cs1 = 32(A w - A b) = 0.0139 m²
Design bearing stress f cd,b = f cd min[(A cs1 / A cs0)0.5, 3] = 100,000 kPa
11.2. Bearing capacity check

Design bear capacity N Rd,cs = f cd,b A cs = 154.22 kN
Okay, concrete bearing capacity sufficient.
Acs1
Page 1629 of 1971

Contract Job ref.



16/04/2018
CALCULATIONS NOTES

12. Non-cracked concrete cone failure check

12.1. Concrete cone failure checking (pocket side)
Cone failure
hef,p Bolt tensile load Tb

Cmax
Pocket side
Cmin θc
Min. edge distance C min = 0.098 m

Max. edge distance C max = 0.204 m
Critical edge distance C cr,N = 3 h ef,p / 2 = 0.300 m

Angle of concrete cone θc = arc tan (h ef,p /C cr,N) = 33.7 ˚
Critical spacing S cr,N = 2 C cr,N = 0.600 m
Cone area (no edge) A cN,0 = S cr,N S cr,N = 0.360 m²

Actual cone area A cN = [(C min+min(C max,C cr,N)]S cr,N = 0.181 m²
Crack condition coefficient k1 = 10.1 (non-cracked concrete)

Initial char. tensile resist. N Rk,c0 = k 1 √(f ck,cube) h ef,p1.5 = 221.28 kN
Edge effect factor ψ s,N = 0.7+0.3C min/C cr,N = 0.80

Shear spalling factor ψ re,N = 1.00
Group effect factor ψ ec,N = 1.00 (no anchor group)
Char. tensile resistance N Rk,c = N Rk,C0(A cN/A cN,0)ψ s,Nψ re,Nψ ec,N Cone failure
= 89.04 kN
Design tensile resistance N Rd,c = N Rk,c/γ Mc = 59.36 kN

Insufficient concrete capacity. Reinforcement required.
12.2. Reinforcement requirement (pocket side)

Required rebar area A RF,req = √3 (T bd γ RF / f yk,RF) = 504 mm² Shear rebars
Provided rebar area A RF,pro = 531 mm² (shear cone failure is either
fully taken by concrete or
Okay rebars)
Page 1630 of 1971

Contract Job ref.



16/04/2018
CALCULATIONS NOTES

12.3. Concrete cone failure checking (insert side)
Cone failure
θc Cmin
Bolt tensile load Tb

hef,i Cmax
Insert side
Min. edge distance C min = 0.125 m

Max. edge distance C max = 0.184 m
Critical edge distance C cr,N = 3 h ef,i / 2 = 0.225 m

Angle of concrete cone θc = arc tan (h ef,i /C cr,N) = 33.7 ˚
Critical spacing S cr,N = 2 C cr,N = 0.450 m
Cone area (no edge) A cN,0 = S cr,N S cr,N = 0.203 m²

Actual cone area A cN = [(C min+min(C max,C cr,N)]S cr,N = 0.139 m²
Crack condition coefficient k1 = 10.1 (non-cracked concrete)

Initial char. tensile resist. N Rk,c0 = k 1 √(f ck,cube) h ef,i1.5 = 143.73 kN
Edge effect factor ψ s,N = 0.7+0.3C min/C cr,N = 0.87

Group effect factor ψ ec,N = 1.00 (no anchor group)
Char. tensile resistance N Rk,c = N Rk,C0(A cN/A cN,0)ψ s,Nψ re,Nψ ec,N Cone failure
= 85.69 kN
Design tensile resistance N Rd,c = N Rk,c/γ Mc = 57.12 kN

Insufficient concrete capacity. Reinforcement required.
12.4. Reinforcement requirement (insert side)

Required rebar area A RF,req = √3 (T bd γ RF / f yk,RF) = 504 mm² Shear rebars
Provided rebar area A RF,pro = 531 mm² (shear cone failure is either
Okay rebars)
Page 1631 of 1971

J2. Circumferential joint shear dowels design
 Shear dowel design
 Shear dowel socket design
 Product references
Page 1632 of 1971

C:\Users\RYWO\OneDrive - COWI\JH044_DTSS2\10. Bored Tunnel\04. DDA\04. Cals\8b. Shear Dowels Design\02 Shear Dowel Design\TBM_shear_dowels_20180419a_RW.xlsx
Contract Deep Tunnel Sewerage Tunnel Phase II Job ref.

Contract T-09
Circumferential Shear Dowels Design
Orginator Checked by Approved by Date

4/19/2018
CALCULATIONS NOTES
Circumferential Joint Shear Dowels

Reference OPTIMAS ANIXER data sheets of shear dowel ANIX 60 and 80
The circumferential joint shear dowels design considers the following criteria:
▪ Keeping gasket in full compression
▪ Overturning stability of segments during ring erection (to hold segment in place)
▪ Rotational stability of lining ring under TBM torque
1. Material properties
1.1. Shear dowel
No. of dowels provided Nd = 11
Ultimate tensile capacity R dt,u = see sections below
Ultimate shear capacity R dv,u = see sections below
Parital material factor γd = 1.25
Design tensile capacity R dt,d = R dt,u / γ d = see sections below
Design shear capacity R dv,d = R dv,u / γ d = see sections below
Load-displacement curve -- = (see Sec. 3.2)
1.2. Concrete
Unit weight γc = 25.0 kN/m³ (self-weight partial load
factor of 1.5 installation
Partial load factor γ L,w = 1.50 uncertainties during
consturction)
1.3. Gasket
Max. compression force F g,k = 66.5 kN/m
Short-term relaxation φg = 75% (relaxation after 5 min.
typically, provided by
Partial load factor γ L,g = 1.10 gasket manufacturer by
Ultimate gasket force F g,d = γ L φ g F g,k = 54.9 kN/m testing)
Load-gap curve -- = (see Sec. 3.1)
2. Bored tunnel geometries

2.1. General arrangements
Inner diameter Di = 6.550 m
Outer diameter Do = 7.150 m
Centroid diameter Dc = (D o + D i) / 2 = 6.850 m
Lining thickness h = (D o - D i) / 2 = 0.300 m
Segment width b = 1.600 m
Typical segment angle θ = 67.500 deg
Segment arc length L arc = ϖ D c θ / 360 = 4.035 m
2.2. Circumferential joint arrangements

Packing thickness tp = 2.0 mm
Extrados to gasket CL dist. dg = 44.0 mm
Total gasket length Lg = ϖ (D o - 2 d g) = 22.186 m
2.3. TBM geometry

Cutter head diameter D TBM = 7.560 m
Shield length L TBM = 11.000 m
Page 1633 of 1971

Printed on 4/19/2018 at 4:41 PM Page 1 of 9

Contract T-09

4/19/2018
CALCULATIONS NOTES

3. Criterion 1: Keeping gasket in full compression

3.1. Gasket load-displacement relationship
This section presents gasket load-displacement relationship provided by the gasket
manufacturer. The short-term relaxation has been incorporated in evaluating the
gasket forces.
SLS dowel force -- = φ g F g,k L g / N d

ULS dowel force -- = γ L,g φ g F g,k L g / N d
Table 3.1 From gasket data sheet:

Gap (mm) F g,k (kN/m) φ g F g,k (kN/m) SLS (kN/dowel) ULS (kN/dowel)
0 66.5 49.9 100.6 110.7
1 49.9 37.4 75.4 83.0
3 34.9 26.2 52.8 58.1
5 27.4 20.6 41.5 45.6
7 22.4 16.8 34.0 37.3
9 19.1 14.3 28.9 31.8
11 15.0 11.2 22.6 24.9
13 11.6 8.7 17.6 19.4
15 5.0 3.7 7.5 8.3
17 0.0 0.0 0.0 0.0
70
Fg,k (kN/m)
60
φg Fg,k (kN/m)
50
Gasket Force (kN/m)
40
30
20
10
0
0 2 4 6 8 10 12 14 16 18
Displacement (mm)
Figure 3.1 Gasket gap-force relationship
Page 1634 of 1971


Contract T-09

4/19/2018
CALCULATIONS NOTES

3. Criterion 1: Keeping gasket in full compression (cont.)

3.2. Shear dowel load displacement relationship
This section presents shear dowel load-displacement relationship provided by the
shear dowel manufacturer. The curves are used to evaluate an equilibrium tensile
force for shear dowels design.
Table 3.2. ANIX 60 dowels.

Displacement (mm) Disp. + t p (mm) Capacity (kN) Design Cap. (kN)
0 2 0 0.0
1 3 12 9.6
2 4 40 32.0
3 5 60 48.0
4 6 72 57.6
5 7 80 64.0
6 8 88 70.4
7 9 96 76.8
8 10 100 80.0
9 11 100 80.0
Table 3.3. ANIX 80 dowels.

Displacement (mm) Disp. + t p (mm) Capacity (kN) Design Cap. (kN)
0 2 0 0.0
1 3 12 9.6
2 4 36 28.8
3 5 60 48.0
4 6 82 65.6
5 7 96 76.8
6 8 106 84.8
7 9 114 91.2
8 10 124 99.2
9 11 135 108.0
160
Dowel Force (kN/dowel)
140
120
100
80
60
40
ANIX 60
20
ANIX 80
0
0 2 4 6 8 10 12
Dowel Displacement (mm)
Figure 3.2. Dowel displacement-force diagram.

Page 1635 of 1971

Contract T-09

4/19/2018
CALCULATIONS NOTES


3.3. Force equilibrium
This section presents the ULS and SLS equilibrium states between the gasket forces
and mobilized tensile resistances in shear dowels.
▪ ULS forces equilibrium: to examine whether dowel tensile capacity is sufficient.
(7 mm gap consists of 2
▪ SLS forces equilibrium: to examine if gasket gap < 7 mm as per M&W spec.
mm packing and 5 mm
requirement as per M&W
2 mm joint packing has been considered in the dowel displacement as the shear spec Section 2-4-2)
dowel will not be under tension when the displacement is under 2 mm.
120
ANIX 60
100 ANIX 80
ULS gasket force

80
60
40
20
0
0 5 10 15 20
Figure. 3.3. ULS forces equilibrium.
ULS equilibrium force -- = from Figure 3.3 = 50.0 kN/dowel
Both ANIX 60 and ANIX 80 have sufficient capacities to hold the gasket in compression.
Page 1636 of 1971


Contract T-09

4/19/2018
CALCULATIONS NOTES


3.3. Force equilibrium (cont.)
160
140 ANIX 60
ANIX 80
120
SLS gasket force
100
80
60
40
20
0
0 5 10 15 20
Figure. 3.4. SLS forces equilibrium.
SLS equilibrium force -- = from Figure 3.4 = 45.0 kN/dowel

SLS equilibrium displacement -- = from Figure 3.4 = 4.5 mm
Both ANIX 60 and ANIX 80 have sufficient stiffness to maintain the gasket gap below
7 mm, which is the limiting value that the gasket cannot hold the required hydrostatic
pressures after exceeding this limit.
Page 1637 of 1971


Contract T-09

4/19/2018
CALCULATIONS NOTES

4. Criterion 2: Maintaining segment overturning stability

4.1. Segment self-weight
Point of rotation
Self-weight Ws = γ c L arc h b = 48.4 kN

Design self-weight load W s,d = γ L,w W s = 72.6 kN
Design overturning moment M o1,d = W s,d b / 2 = 58.1 kNm
4.2. Gasket force at failure
Max. gasket gap δ2

(assume gasket on top is
Min. gasket gap not in contact due to
δ3
h6 displacement > 17 mm)
hg h1 + h4
Max. dowel disp. & packing δ1
Packing thickness δ0
Point of
Gasket Gasket rotation
displacemen force
Lg,comp Lg,comp
h6 h2
h3 h1 h5
h4
Gasket under
Dowel installed compression
Packing thickness δ0 = tp = 2.0 mm

Max. dowel + packing disp. δ1 = (from Table 3.2 & 3.3) = 11.0 mm
Max. gasket gap δ2 = (from Table 3.1) = 17.0 mm (gasket force = 0 kN/m
beyond this gap)
Dowel height from CL h1 = = 316.5 mm

o
CL peak and base distance h2 = D c [1 - sin(90 - θ /2)]/2 = 577.2 mm (distance between the peak
and bottom of CL is similar
Gasket height from CL h3 = (h /2 - d g) cos(θ /2) = 88.1 mm to that of gasket, thus h 2
CL height from bottom h4 = h /2 cos(θ /2) = 124.7 mm applies in calculating h 5)
Total height from bottom h5 = h2 + h3 + h4 = 790.1 mm
Height to max. gap h6 = (h 1+h 4)(δ 2-δ 0)/(δ 1-δ 0) = 735.4 mm

< h 5 ,partially closed.
Page 1638 of 1971


Contract T-09

4/19/2018
CALCULATIONS NOTES

4.2. Gasket force at failure (cont.)
Min. gasket gap δ3 = (δ 2-δ 0)(h 3+h 4)/h 6 + δ 0 = 6.3 mm
Length of gasket in segment L g,1 = L g θ / 360o = 4.2 m

Length of gasket in comp. L g,comp = L g,1 (h 6 - h 3 - h 4)/ h 2 = 3.8 m
Average gasket deflection -- = (δ 2 + δ 3) / 2 = 11.7 mm

Average gasket stress (SLS)φ gF g,k = from Table 3.1 = 11.2 kN/m
Design gasket force (ULS) F g,d = γ L,g φ g F g,k = 12.3 kN/m
Moment arm of gasket force h g = (h 6 -h 3 -h 4)/3 + h 3 + h 4 = 387.0 mm
Design overturning moment M o2,d = F g,d L g,comp h g = 18.0 kNm
4.4. Resultant overturning moment

Design overturning moment M o,d = M o1,d + M o2,d = 76.1 kNm
4.5. Shear dowel provided restoring moment
h1 + h4
Point of
rotation
ANIX 60 shear dowels (2 out of 3 dowels provided per big segment)

Design capacity (ULS) R dt,d = from Table 3.2 = 80.0 kN/dowel
Design restoring moment M r,d = 2 R dt,d (h 1 + h 4) = 70.6 kNm

Design capacity (ULS) R dt,d = from Table 3.3 = 108.0 kN/dowel
Design restoring moment M r,d = 2 R dt,d (h 1 + h 4) = 95.3 kNm
Dowel M o,d (kNm) M r,d (kNm) Utilization Remark

ANIX 60 76.1 70.6 107.8% Insufficient capacity
ANIX 80 76.1 95.3 79.8% OKAY
The most critical case would be installing a large segment at the the tunnel crown
while no segment else has been installed yet. The calculations above show that
2 out of 3 ANIX 80 (or equivalent) dowels would provide sufficient tensile capacity to
keep any large segment self standing, which would ensure the stability of all
segments during ring building even when the key stone is installed in the invert.
Page 1639 of 1971

Contract T-09

4/19/2018
CALCULATIONS NOTES

4.6. Shear dowel shear capacity

Ult. shear capacity R dv,k = from data sheet = 145.0 kN/dowel (γ d = 1.25 applied)
Design shear capacity R v,d = 2 R dv,d / γ d = 232.0 kN

Ult. shear capacity R dv,k = from data sheet = 145.0 kN/dowel (γ d = 1.25 applied)
Design shear capacity R v,d = 2 R dv,d / γ d = 232.0 kN
Dowel W s,d (kN) R v,d (kN) Utilization Remark

ANIX 60 72.6 232.0 31.3% OKAY
ANIX 80 72.6 232.0 31.3% OKAY
Page 1640 of 1971


Contract T-09

4/19/2018
CALCULATIONS NOTES

5. Criterion 3: Maintaining rotational stability of lining rings under TBM torque

This section evaluates the shear force on the shear dowel due to TBM
torque. The shear dowels have been designed to maintain the rotational
stability of lining rings.
Skin friction in
Dowel tangential tangential direction
shear force
TBM shield skin
Shear dowels
TBM torque
5.1. TBM skin friction

(friction provided
TBM shield skin friction -- = 1200.0 kN
construction team)
Resistance to torque T s,k = 1200 D TBM / 2 = 4536.0 kNm
5.2. TBM exceptional torque (provided by Herrenknecht)

Exceptional torque (max.) T 1,k = 6658.0 kNm
Partial load factor γ1 = 1.20
Design exceptional torque T 1,d = γ 1 (T 1,k - T s,k) = 2546.4 kNm
5.3. TBM breakout torque (provided by Herrenknecht)

Breakout torque (max.) T 2,k = 7254.0 kNm
Partial load factor γ2 = 1.05
Design breakout torque T 2,d = γ 2 (T 2,k - T s,k) = 2853.9 kNm
5.4. Dowel shear force

Design tangential shear F dtv,d = 2 max(T 1,d ,T 2,d)/(D c N d) = 75.8 kN
6. Required dowel ultimate capacities

This section summarizes the required ultimate tensile and shear capacities of dowels.
Req. ult. tensile capacity -- = γ d M o,d / h 1 = 107.8 kN/dowel

Req. ult. shear capacity -- = γ d max(W s,d/2, F dtv,d) = 94.7 kN/dowel
Dowel Shear capacity utilizationTensile capacity utilization Remark

ANIX 60 65.3% 107.8% Insufficient capacity
ANIX 80 65.3% 79.8% OKAY
Page 1641 of 1971

C:\Users\RYWO\OneDrive - COWI\JH044_DTSS2\10. Bored Tunnel\04. DDA\04. Cals\8b. Shear Dowels Design\02 Shear Dowel Design\DTSS2_T09_Shear
dowel_socket_design_20180419.xlsx
Contract Job ref.

Design of dowel in circumferential joint

4/19/2018
COWI Hong Kong Ltd. NIWA RYWO
CALCULATIONS NOTES
Design of shear dowels socket in circumferential joint

Gasket
he
Dowel tensile load, T
Y-direction
do
Tangential shear Radial shear load, Vy

load, Vz
X-direction
Caulking groove
1. Segmental lining geometry

Lining thickness h = 0.300 m
2. Shear dowel properties

Outer dia. of dowel do = 0.057 m
Dowel embedment length h ef = 0.124 m
Dowel circum. spacing s cir = 1.345 m
Ultimate pull-out resistance N Rk,p = 86.2 kN/dowel
3. Concrete material properties

Char. cylinder strength f ck = 50,000 kPa
Char. cube strength f ck,cube = 60,000 kPa
Concrete material factor γc = 1.5
Long term effects coefficient α cc = 1.0 (Gasket force is temporary
construction load, i.e.
Design concrete strength f cd = α cc f ck / γ c = 33,333 kPa shorterm)
4. Reinforcing steel material properties

Char. yield strength of steel f yk = 500,000 kPa
Partial material factor γs = 1.15
5. Shear reinforcement
Nos. of reinforcement N RF = 3 bars
Reinforcement dia. d RF = 13 mm
6. Design load of shear dowel

Ult. radial shear load V y,u = 32.7 kN/dowel
Ult. tangential shear load V z,u = 75.8 kN/dowel
Ult. dowel tensile load Tu = N Rk,p = 86.2 kN/dowel (circumferential joint is
designed to resist the
Ult. resultant shear load Vu = √(V y,u2+V z,u2) = 82.6 kN/dowel ultimate dowel force)
7. Partial FOS for concrete cone failure / edge failure checking

Partial factor for installation γ 2 = = 1.0 (as lining segments anchor
are cast in precisely, γ 2 =
Partial factor for concrete cone resistance 1.0 is adopted)
γ Mc = γ cγ 2 = 1.5
Page 1642 of 1971

Contract Job ref.


4/19/2018
CALCULATIONS NOTES

8. Non-cracked concrete cone failure check
Cone failure
Dowel tensile load, Tu
c θc
8.1. Concrete cone failure check

Actual edge distance c = h /2 = 0.150 m
Critical edge distance c cr,N = 3 h ef / 2 = 0.186 m
Angle of concrete cone θc = tan-1 (h ef /c cr,N) = 33.7 ˚
Critical spacing s cr,N = 2 c cr,N = 0.371 m
Cone area (no edge) A cN,0 = s cr,N2 = 0.14 m²
Actual cone area A cN = min(c , c cr,N) s cr,N = 0.056 m²
Crack condition coefficient k1 = 10.1

1.5 (for non-cracked concrete,
Characteristic resistance N Rk,c0 = k 1 √(f ck,cube) h ef = 107.70 kN
5.2.2.4a of ETAG001)
Edge effect factor ψ s,N = 0.7 + 0.3 c / c cr,N = 0.94 (reinforcement provided
around anchor)
Group effect factor ψ ec,N = 1.00 (no group)
Characteristic resistance N Rk,c = N Rk,c0 (A cN/A cN,0) ψ s,N = 41.01 kN

Design resistance N Rd,c = N Rk,c/γ Mc = 27.34 kN Cone failure
Insufficient concrete capacity, reinforcement required.
8.2. Reinforcement requirement

Required rebar area A RF,req = √3 (T u γ RF / f yk,RF) = 343 mm² Helix
Provided steel area A RF,pro = N RF (ϖ (d RF / 2)2) = 398 mm²

Okay (shear cone failure is either
rebars)
Page 1643 of 1971

Contract Job ref.


4/19/2018
CALCULATIONS NOTES

9. Concrete pry-out failure

Concrete cone
NRk,c
VRk,cp
9.1. Concrete pry-out failure checking

Pry-out factor k = 1 if h ef < 60 mm, 2 if not = 2.0 (As per Sec 5.2.3.3 of
ETAG 001 - Annex C)
Pry-out resistance V Rk,cp = k N Rk,c = 82.02 kN
Design pry-out resistance V Rd,cp = V Rk,cp / γ Mc = 54.68 kN
Concrete cone
Insufficient concrete capacity, reinforcement required.
9.2. Reinforcement requirement

Required rebar area A RF,req = √3 (V u γ RF / f yk,RF) = 329 mm²
Helix
2
Provided steel area A RF,pro = N RF (ϖ (d RF / 2) ) = 398 mm²
Okay (pry-out failure is either
rebars)
Page 1644 of 1971

Contract Job ref.


4/19/2018
CALCULATIONS NOTES

10. Non-cracked concrete edge failure check
Dowel shear load, V
h
c1
X-direction
Y
1.5c1 1.5c1 1.5c1
W Edge failure V
αV
Z-direction A0c,V c2
10.1. Concrete edge failure checking Z
Shear load direction angle αV = tan-1 (V z,u /V y,u) = 66.7 ˚ free edge
Edge distance c1 = h / (2 cos α v) = 0.379 m

Edge distance c2 = min(1.5 c 1, s cir /2) = 0.568 m
2
Cone area (no edge) A cV,0 = 4.5 c 1 = 0.645 m²
Actual cone area A cV = (1.5 c 1)(2 c 2) = 0.645 m²
Crack condition coefficient k1 = 2.4 (for non-cracked concrete)
Effective length of dowel lf = h ef = 0.124 m

0.5
Factor α α = 0.1 (l f / c 1) = 0.057
Factor β β = 0.1 (d o / c 1)0.2 = 0.069
Edge resistance V Rk,c0 = k 1 d oα h efβ √(f ck,cube) c 11.5
= 100.81 kN
Edge effect factor ψ s,V = min[0.7 + 0.2 c 2/c 1, 1] = 1.00

0.5
Member thickness factor ψ h,V = max[(1.5 c 1 / W ) , 1] = 1.00 (1.5 c 1 << W )
Shear force angle α V factor ψ α,V = max([(cos α V)2 + (sin α V / 2.5)2]-0.5,1)

= 1.85
Group effect factor ψ ec,V = 1.00 (no group)
Cracked concrete factor ψ re,V = 1.00 (non-cracked concrete w/o

edge reinforcement or
stirrups)
Characteristic resistance V Rk,c = V Rk,c0 (A cV / A cV,0) ψ s,V ψ h,V ψ α,V ψ ec,V ψ re,V
= 186.62 kN
Design resistance V Rd,c = V Rk,c/γ Mc = 124.41 kN

Okay, concrete edge capacity sufficient, reinforcement not requried.
10.2. Reinforcement requirement (NOT REQUIRED) Helix

Required rebar area A RF,req = √3 (V u γ RF / f yk,RF) = 329 mm²
Edge failure
2 (edge failure is either fully
Provided steel area A RF,pro = N RF (ϖ (d RF / 2) ) = 398 mm²
taken by concrete or
Okay rebars)
Page 1645 of 1971

Helix rebar arrangement
for concrete cone failure
Helix reinforcement
350
B10 bars at 50 mm
Ladder reinforcement 3B13 bars 57 DIA. c/c spacing
300
34o 250
50 TYP.
MIN. 130
200
From Appendix J2, 343 mm2
Depth (mm)
reinforcing steel required.

Ladder provides 398 mm2, and
B10 helix provides
150 confinements to the dowel
under tension.
100150 DIA.
Lining
Dowel
50
Cone failure
Helix
Ladder bar
0
-200 -150 -100 -50 0 50 100 150 200
Width (mm)
Page 1646 of 1971

Helix rebar arrangement
for concrete cone failure
Helix reinforcement
350
B10 bars at 50 mm
Ladder reinforcement 3B13 bars 57 DIA. c/c spacing
300
34o 250
50 TYP.
From Appendix J2, 329 mm2
MIN. 130
reinforcing steel required.
200
Depth (mm)
Ladder provides 265 mm2, and

B10 helix provides >78 mm2.
Total provided steel area
150 343 mm2 > 329 mm2.
100150 DIA.
Lining
Dowel
50
Pry-out failure
Helix
Ladder bar
0
-200 -150 -100 -50 0 50 100 150 200
Width (mm)
Page 1647 of 1971

Product Sheet - SOF FIX ANIX 60 HSR
Page 1648 of 1971

1
Page 1649 of 1971

2
Page 1650 of 1971

3
Page 1651 of 1971

4
Page 1652 of 1971

Product Sheet - SOF FIX ANIX 80
Page 1653 of 1971

SOFRASAR TUNNEL PRODUCTS
SOF FIX ANIX 80

DOWEL SYSTEM
ANIXTER FRANCE - 9, rue Gutenberg - Z.I. - BP 50535 F-57205 SARREGUEMINES CEDEX - Tél. +33 (0)3 87 98 07 50 - Fax. +33 (0)3 87 98 90 45
Siège social : ANIXTER FRANCE SARL au capital de 25.510.000 € - Paris Nord 2 - 22 Avenue des Nations - 93420 VILLEPINTE - France - SIREN 349 968 388
RCS BOBIGNY - Code APE 4669B
Site internet : www.anixterfasteners.com Page 1654 of 1971
SOF FIX ANIX 80
LAST UPDATE : 13/02/2014
TECHNICAL FEATURES
Dowel: SOF FIX ANIX 80

(1 dowel + 2 sockets)
- Length: 247,5 mm
- Diameter : 68 mm
- Material : Polyamide 6.6 +

Core insert steel M16
- Pull-out Resistance : Yield 80 kN
Ultimate 140kN
- Shear Resistance: Ultimate 160kN
Socket
- Length : 112,2 mm
- External diameter : 57,3 mm
- Material : Polyamide
OUR REFERENCES
Reference Country Outer Ø Year

SAN FRANCISCO USA 2012
MOSCOW METRO LINE RUSSIA 2012
HONG KONG C823A HONG-KONG 2011
Siège social : ANIXTER FRANCE SARL au capital de 25.510.000 € - Paris Nord 2 - 22 Avenue des Nations - 93420 VILLEPINTE - France - SIREN 349 968 388 1
SOF FIX ANIX 80
PULL-OUT TEST
PULL-OUT DIAGRAM of SOF FIX ANIX 80

160
140
120
100
Load (kN)
80
60
40
20
0
0 2 4 6 8 10 12
Displacement (mm)
SHEAR RESISTANCE TEST
SHEAR DIAGRAM of SOF FIX ANIX 80

180
160
140
120
Load (kN)
100
80
60
40
20
0
0 2 4 6 8 10 12 14 16
Displacement (mm)
SOF FIX ANIX 80
MATERIEL DATA SHEET
Socket - Polyamide 6.6
Features Test specification Method Values

Tensile modulus MPa 1mm/min ISO 527-2 3000
Elongation at break % 50mm/min ISO 527-2 30
Flexural modulus MPa 2mm/min ISO 178 2850
Charpy impact strength kJ/m² 23°C ISO 178/1eU n.b.
Melting Point °C DSC, 10K/min DIN EN 11357-1 263
Density g/cm3 23°C ISO 1183 1.1
Water absorption % 23°C, 50% r.h. ISO 62 2.1
Dowel - Polyamide 6
Features Test specification Method Values

Tensile modulus MPa 1mm/min 527-1+2 3000
Elongation at break % 50mm/min 178 >30
Flexural modulus MPa 2mm/min 178 2600
Charpy impact strength kJ/m² 23°C 179/1eU n.b.
Melting Point °C DSC, 10K/min 11357 222
Density g/cm3 23°C 1183 1.06
Water absorption % 23°C, 100% r.h. 1110 2.6
SOF FIX ANIX 80
OUR OTHER RANGE OF PRODUCTS
SOF FIX ANIX 60

Ø 68 Ø 59 Ø 88
Shear
Ultimate 160kN Ultimate 145kN Ultimate 200kN
Resistance
Pull-out Yield 60kN Yield 60kN Yield 60kN
resistance (Ultimate 110kN) (Ultimate 110kN) (Ultimate 110kN)
SOF FIX ANIX 80

Ø 68 Ø 68 TP Ø 68 HSR Ø 59 Ø 88 Ø 88 HSR
Ultimate
Shear Ultimate Ultimate Ultimate Ultimate Ultimate
145kN
Resistance 160kN 160kN 300kN 200kN 300kN
Yield 80kN Yield 50kN Yield 80kN Yield 80kN Yield 80kN Yield 80kN
Pull-out
(Ultimate (Ultimate (Ultimate (Ultimate (Ultimate (Ultimate
resistance 140kN) 80kN) 140kN) 140kN) 140kN) 140kN)
SOF FIX ANIX 110

Ø 76 Ø 100
Shear
Ultimate 200kN Ultimate 250kN
Resistance
Pull-out Yield 110kN Yield 110kN
resistance (Ultimate 170kN) (Ultimate 170kN)

122103-TBM5-RT-SL-0001 - (FDS) DSGN RPT Segment - 1637 - Extracts

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DESIGN AND CONSTRUCTION OF SEWER TUNNELS FOR THE DEEP TUNNEL SEWERAGE SYSTEM PHASE 2 PROJECT - CONTRACT T -09

Appendix I Gasket Design

Page 1619 of 1971

 Shear failure of gasket groove

 0.20% (6.0 mm on radius) calculated maximum long-term deflection as given in Section

Page 1620 of 1971

Joint Opening and Bursting of Segmental Lining Flat Joint

1.2. Tunnel geometry and section properity

1.3. Segment joint geometry

1.4. Typical segment geometry

1.5. Material properties

Allowable stress in steel fs = 200,000 kPa

Page 1621 of 1971

Joint Opening and Bursting of Segmental Lining Flat Joint

2.2. Equations of deformed lining shape (ellipse)

Using equations 2A, 2B and 2C:

β = cos-1[(OM - ON )/LM ] = 55.946 deg

Page 1622 of 1971

Radial joint and gasket material information

Distance to gasket CL, w ' = w + w g/2 231.00 mm

Gasket force Check

Allowable gasket force

Page 1623 of 1971

Page 1624 of 1971

Appendix J Joint Fixings Design

› J2. Circumferential joint shear dowels design

Page 1625 of 1971

Page 1626 of 1971

Contract Job ref.

Part of structure Calc. sheet No.

Originator Checked by Approved by Date

Design of bolt in radial joint

Gasket force N Gasket

Pocket side Insert side

Bolt strength grade Gb = 8.8 (BS 4190 - Table 7)

3. Bolt embedment length

4. Gasket geometry and compression load in radial joint 2.0

Page 1627 of 1971

Contract Job ref.

Part of structure Calc. sheet No.

Originator Checked by Approved by Date

5. Design load of bolt

6. Concrete material properties

7. Reinforcing steel material properties

9. Partial FOS for concrete cone failure

Page 1628 of 1971

Contract Job ref.

Part of structure Calc. sheet No.

Originator Checked by Approved by Date

Design of bolt in radial joint

10. Check against steel failure

Bolt tensile load Tb

(ETAG 001 Annex C

10.2. Bolt tensile capacity

11. Concrete bearing capacity

11.1. Partially loaded area (EN 1992 Section 6.7)

11.2. Bearing capacity check

Page 1629 of 1971

Contract Job ref.

Part of structure Calc. sheet No.

Originator Checked by Approved by Date

Design of bolt in radial joint