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Design considerations for precast tunnel

segments according to international


recommendations, guidelines and
standards
Mehdi Bakhshi & Verya Nasri
AECOM, New York, NY, USA

ABSTRACT
Segmental tunnel linings are designed as initial ground support and final lining in TBM-bored tunnels. Procedures to
design concrete lining for ground and groundwater loads, cross sectional changes in joints, and checks against
production and construction loads such as segment demolding, storage, transportation, handling, TBM jack thrust forces
and grouting pressure are presented. Several recommendations, guidelines and standards are available for analyses
and design of precast concrete segmental linings. These guidelines and standards from various countries in Europe,
Asia and America including Austria (ÖVBB), France (AFTES), Germany (DAUB), Japan (JSCE), the Netherlands (NEN),
United States (FHWA) and International Tunneling Association (ITA) are evaluated. Standard code requirements are
presented and their merits are discussed for the case of design of segments. In this paper, special attention is given to
recommendations and guidelines for analyses of segments for determining ground and groundwater loads in one hand,
and tensile stresses in joints due to jack thrust forces and cross section change in the other. Standard design methods
for precast concrete segments are presented. Best method of practice for analysis and design of these elements is
recommended. Latest developments and technologies in segmental tunnel lining systems are presented including
anchored gaskets, Bicones as shear recovery systems for tunnel openings and fiber reinforced concrete (FRC)
segments. Design of FRC lining for aforementioned load cases are discussed with presentation of specified residual
tensile strength and specified compressive strength as two key design parameters.

1 INTRODUCTION (JSCE, 2007). The most significant and widely accepted


methods in the field are presented in the followings
Segmental tunnel linings are designed as initial ground sections.
support and final lining in TBM-bored tunnels. Procedures
to design concrete lining for embedment loads, cross 2.1 Elastic Equations Method
sectional changes in joints, and checks against
construction loads such as segment demolding, stacking, Elastic equations method recommended by JSCE (2007)
handling, TBM jack thrust forces and grouting pressure and ITA (2000) is a simple method for calculating member
have been presented elsewhere (Bakhshi and Nasri, forces of circular tunnels. Load distribution model consist
2013a; 2013b; 2013c). of uniform vertical soil and water pressures, a triangularly
Several recommendations, guidelines and standards distributed horizontal soil reaction between 45° to 135°
are available for analyses and design of precast concrete from the crown on both sides in addition to a linearly
segmental linings. In this paper, special attention is taken varying lateral earth pressure, and dead weight of the
to recommendations and guidelines for analyses of lining. Distribution of loads used in this method is shown
segments for determining embedment loads in one hand, in Figure 1. Member forces are calculated using elastic
and tensile stresses in joints due to jack thrust forces and equations available in the literature (JSCE, 2007 and ITA,
cross section change in the other. Standard design 2000). In this method, a uniform bending rigidity is
methods for precast concrete segments are presented. assumed for the lining which cannot represent the
Best method of practice for analysis and design of these staggered geometry of segmental lining. This method is
elements is recommended. Finally, latest developments mostly used in preliminary design and cost estimation for
and technologies in segmental tunnel lining systems are new tunnel projects.
presented.
2.2 Beam – Spring Method

2 METHODS OF ANALYSIS FOR GROUND AND In the beam – spring method, recommended by JSCE
GROUNDWATER LOADS (2007), ÖVBB (2011) and FHWA (2009), the lining is
modeled in the cross-sectional plane perpendicular to the
Selection of a suitable analysis method to calculate longitudinal direction of tunnel as a series of beam
member forces due to embedment loads depends on elements spanning between longitudinal joints of
many factors such as functions of the tunnel, ground segments. The interaction between the ground and the
conditions, design loads, structures of segments, required lining is modeled by linear translational springs in radial,
accuracy of analyses, and the required check items tangential and longitudinal directions.
Figure 2. Multiple hinged segmented double ring beam –
spring model

A two-dimensional approach is sufficient for a continuous


Figure 1. Distribution of loads used in Elastic Equations linear structure without sudden changes in cross section
method (ITA, 2000) or concentrated load intensities, while three-dimensional
approaches are only recommended for areas of
Since the lining and ground are represented by a series of intersection between crosscuts and the main tunnel
beams and springs, this method is referred to as beam – (ÖVBB, 2011). In FEM, as shown in Figure 3, the
spring method. Method of calculation of the springs’ surrounding ground is modeled as a continuum medium
stiffness can be found elsewhere (Bakhshi and Nasri, discretized into a limited number of smaller elements
2013b). Various 2D approaches have been developed in connected at nodal points. The stress, strain, and
order to evaluate effect of the segment joints, including deformation to be analyzed are caused by changing the
models that assume the segmental ring as a solid ring original subsurface conditions due to tunneling process.
with fully bending rigidity, solid ring with reduced bending Results of analysis including deformations and
rigidity (Muir Wood, 1975), ring with multiple hinged joints subsequently member forces are obtained by solving a
and ring with rotational springs. However, 2D models matrix equation which relates the unknown quantities to
cannot represent circumferential joints and the staggered known quantities using a global stiffness matrix based on
arrangement of segments in adjoining rings. As shown in stress-strain relationships of the materials.
Figure 2, a 3D or a so-called “2½-dimensional” multiple This method of analysis has the advantage of taking
hinged segmented double ring beam – spring model can into account the deformability of the ground and in
be used to evaluate the reduction of bending rigidity and particular, its behavior after failure, the redistribution of
effects of staggered geometry by modeling segments as loads resulting from lining deformation, and excavation
curved beams, longitudinal joints as rotational springs stages (ÖVBB, 2011). This numerical method of analysis
(Janßen joints) and circumferential joints as shear is also valid for non-uniform and anisotropic initial
springs. Equations and estimations regarding rotational stresses, i.e. when a dissymmetrical feature is present in
spring stiffness and shear spring constant of the joints the surrounding ground due to several different formations
have been presented in previous publications (Bakhshi or in the external loads due to nearby existing structures
and Nasri, 2013a, 2013b, 2013c). Two rings are used in (AFTES, 2005). By means of FEM, complex underground
this analysis in order to evaluate the coupling of rings; conditions and tunnel characteristics can be analyzed.
however, only half of the segment width is considered in Furthermore, this method enables the simulation of
this model to include only influence zone of longitudinal complex constitutive laws, non-homogeneities, and the
and circumferential joints of one ring. Considering dead impact of advance and time dependent characteristics of
weight of the lining, and applying ground and water the construction methods.
pressures as distributed member loads projected along
the beam direction, member forces are calculated using a
structural analysis package. 3 METHODS OF ANALYSIS FOR JACK THRUST
FORCES AND CROSS SECTION CHANGE
2.3 Finite Element and Finite Difference Methods
TBM jack thrust force are studied as one of the most
Two-dimensional Finite Element Method (FEM) or the significant construction load cases in design of precast
Finite Difference Method (FDM) is recommended by segmental tunnel lining. After assembly of a complete
ÖVBB (2011) and AFTES (2005) for calculation of tunnel ring, the TBM moves forward by pushing its jacks on the
lining forces in soft ground, loose rock and in solid rock bearing pads placed on the circumferential joints of the
classified as partly homogeneous. newest assembled ring. This action results in developing
high compression stresses under the jack pads, as well as
Figure 4. Bursting tensile forces and associated
parameters recommended by ACI 318 R18.13

Figure 3. FEM model for tunnel excavation in soft ground Fsd = 0.25 ⋅ N Ed ⋅ (1 − d1 / d s ) [2]
bursting tensile stresses deep in the segment and splitting
tensile forces between the pads. In a similar action to the e 1
Fsd , R = N Ed ⋅ ( − ) ; Fsd , 2 = 0.3 Fsd , R [3]
effect of jack thrust forces in circumferential joints, d 6
bursting tensile stresses are present at the longitudinal
joints due to change of cross section because of the where Fsd, Fsd,R and Fsd,2 are bursting, splitting and
gasket and the stress relief grooves . Different standards, secondary tensile stresses developed close to the
guidelines and recommendations to analyze such effects segment face and NEd is the maximum normal force due
are discussed herein. to jack thrust force or embedment loads.
As shown in Figure 5, for the case of cross section
3.1 ACI Simplified Equations Methods change at the longitudinal joints, e is the total eccentricity
consisting of eccentricity of normal force and the hinge
ACI 318 section 18.13 (ACI, 2008) specifies simplified neck (e = el + ek = M/N + ek), dk is the width of the hinge
equations to determine the magnitude of the bursting neck, d1 is the length of load transfer zone on the face of
force, Tburst, and its centroidal distance from the face of segment (d1 = dk – 2e), ds is the distributed width of
the segment, dburst as: tension block inside the segment (ds = 2e’ = d - 2el) and d
is the total width of the segment cross section. Note that
h anc DAUB recommends splitting and secondary tensile
Tburst = 0.25 Ppu (1 − ) ; d burst = 0.5 ( h − 2e anc ) [1] reinforcement for only highly eccentric normal force
h
conditions (e > d/6).
where Ppu is the normal force, hanc is the width of load
transfer area on the face of segment, h is the width of the
load distribution area deep inside the segment, and eanc is
the total eccentricity with respect to the centroid of the
cross section.
As shown in Figure 4, for the case of jack thrust forces
applied on the circumferential joints, Ppu is the maximum
extraordinary jacking force applied on each jack pad, hanc
is the length of contact area between jack pads and
reduced depth of cross section on the segment face, h is
the depth of cross section, and eanc is the maximum
possible eccentricity of jack pads with respect to the
centroid of the cross section. For the case of cross section (a)
change at the longitudinal joints, Ppu is the maximum
normal force due to permanent embedment loads, and
eanc is the maximum total eccentricity consists of normal
force eccentricity (M/N) and eccentricity of load transfer
area.

3.2 DAUB Simplified Equations Methods

Similar to ACI, DAUB (2013) is recommending simplified


equations for bursting and splitting tensile stresses in the (b)
joints based on the assumption of force transfer by means
of a tension block. Figure 5. Force transfer recommended by DAUB in: (a)
longitudinal joints using a tension block concept, (b)
circumferential joints under an eccentric jack thrust force
load case (e = 50 mm)
According to DAUB (see Figure 5), bursting tensile
reinforcement are placed at a distance of 0.4ds from the
face of segments, while splitting and secondary tensile
reinforcement, if necessary, are placed at 0.1ds and 2/3d
from the face of segment, respectively.

3.3 Method of Diagram of Iyengar

The analytical method of Iyengar Diagram (1962) for


calculation of bursting tensile stresses has been used in
design of tunnels in Netherland (Groeneweg, 2007).
Similar to previous methods, the extent of the spreading Figure 7. 3D FEM model for case of jack thrust force
and therefore the magnitude of the tensile stresses, as
shown in Figure 6, depend on the dimensions of the
introduction surfaces (β) and final spreading surfaces (a).
According to this diagram, bursting tensile stresses (σcx),
which varies significantly from the face toward inside the
segment, are determined as a fraction of the fully spread
compressive stress (σcm = F/ab).

(a)

Figure 6. Diagram of Iyengar (1962) for determining


bursting tensile stresses

3.4 Finite Element Methods

Three-dimensional and two-dimensional analyses using


finite element methods are performed to simulate effect of
TBM jack thrust forces on the circumferential joints and
normal force transfer through the longitudinal joints,
respectively. As shown in Figure 7, effect of jack thrust (b)
force is simulated modeling typical segments of two Figure 8. Bursting and spalling tensile stresses developed
adjoining rings. The jack thrust forces are applied on the in segments due to TBM jack thrust forces and gasket
net contact area of the jack pads and segment face on the pressure: a) transversal stresses, b) radial stresses
front circumferential joint. The recess (due to the gasket
and the stress relief grooves) is modeled on the Bursting stresses at the vicinity of the longitudinal
connection between two segments to simulate force joints are analyzed for the case of maximum normal force
transfer through a reduced cross section through the and gasket pressure. Two-dimensional FE model to
middle circumferential joint. Compressive forces of the simulate the longitudinal joint consists of small end parts
gasket in the early hours of installation are simulated by of two adjacent segments in a ring (curvature of elements
applying maximum reaction force of gasket. Solid are neglected) modeled with recess of the gasket and the
elements are used for this analysis. The translational stress relief grooves. The contact zone is modeled as a
degrees of freedom are fixed in all directions at the end of discontinuity between two adjacent segments. Non-linear
the back segment which is assumed to be installed before non-tension springs attach segments faces in the
the front segment. As shown in Figure 8, typical results of longitudinal joint, simulating behavior of the plywood
analysis consists of transversal and radial bursting and material. Translational degrees of freedom along the
spalling tensile stresses developed under the jack pad farthest vertical face of one of segments are fixed in both
and in the areas between the pads. directions, while vertical face of other segment is loaded
with the uniformly distributed pressure of maximum 6720 (1995) specifies 35 mm as the minimum concrete
normal force. Figure 9 shows typical results of analysis cover for precast elements.
including bursting tensile and compressive stresses in the
area around longitudinal joints. 4.2 Reinforcing Spacing

There is no specific recommendation available in ACI 318


(2008) for reinforcement in the precast segmental tunnel
linings. However, general spacing limits for reinforcement
include minimum and maximum clear spacing between
steel bars of 1 in (25 mm) and 18 in (457 mm),
respectively. DAUB (2013), provides a typical reinforcing
spacing range of 100 mm to 150 mm for segmental tunnel
linings. DAUB (2013) specifies a minimum clear spacing
(a) range of 90 mm to 120 mm. In the absence of any
reinforcement spacing requirement by ITA (1988), FHWA
(2009), and ÖVBB (2011), JSCE (2007) specifies a
minimum bar spacing of 1.25 times the width of the
maximum size of aggregates plus the diameter of the
reinforcement. AFTES (2005) referring to Section 4.4.5 of
BAEL 91 (2007) specifies the maximum spacing for
reinforcing bars as the smaller of 20 cm and 1.5 times the
segment thickness. NEN 6720 (1995) on the other hand
specifies minimum bar spacing as the greater of 4/3 of the
maximum size of aggregates, the largest bar diameter,
and 25 mm.

(b) 4.3 Compressive Strength of a Partially Loaded Surface

In the standards, guidelines and recommendations, no


Figure 9. Developed stresses around longitudinal joints specific requirement is found for compressive strength of
due to maximum normal force and gasket pressure: a) precast concrete tunnel segments. However, in the joint
bursting tensile stresses, b) compressive stresses design, due to cross section change or jack thrust force,
end faces of segments are only partially loaded and
therefore developed compressive and tensile stresses
4 DESIGN CONSIDERATIONS FOR PRECAST must be compared with the factored strength of a partially
CONCRETE SEGMENTS pressured surface. Maximum allowed compressive stress
of a partially pressured surface (σRd) according to the ACI
4.1 Concrete Cover 318 (2008), Dutch code NEN 6720 (1995) and DAUB
(2013) is:
DAUB (2013) recommends a minimum concrete cover of
40 mm on the surfaces of the tunnel segments. On the Ac1
end faces of segments and in areas close to bolt pockets, σ Rd = f c′ [4]
the minimum concrete cover recommended by DAUB is Ac 0
20 mm. However, ACI 318 (2008) specifies a minimum
concrete cover of 1-1/2 in (38 mm) for precast concrete
where Ac0 is the load transfer surface area in the face of
elements exposed to earth. ITA (1988) specifies a
segment, Ac1 is the mathematical load distribution area
minimum 50 mm cover only for the cast-in-place concrete
inside the segment, and f’c is the 28-day compressive
lining at its outer surface in contact with ground and
strength of concrete.
ground water. Nonetheless, it is clearly mentioned that
this specification does not apply to segmental lining
especially when a one-pass lining system is adopted.
5 BEST METHODS OF PRACTICE
Among other codes, guidelines and recommendations,
FHWA (2009) does not specify a minimum concrete
Among different methods of analysis for determining
cover. JSCE (2007) specifies a minimum 25 mm concrete
embedment loads, Elastic Equations Method gives largest
cover over reinforcement and a minimum 35 mm in a
member forces since a uniform bending rigidity is
corrosive environment for a one-pass segmental lining
assumed for the lining. Multiple hinged segmented double
system. ÖVBB Guideline (2011) refers to Austrian
ring beam – spring model gives reasonable forces as a
standard ÖNORM EN 1992-1-1 which specifies a
result of analysis especially for the transferred bending
minimum concrete cover of 25-45 mm depending on
moment in the longitudinal joints. Finite Element and
exposure conditions. AFTES (2005) specifies 30 mm as
Finite Difference Methods are superior methods when a
the minimum cover on the intrados and extrados faces,
dissymmetrical feature is present in the structure, in the
and 20 mm concrete cover on other zones, and NEN
surrounding ground, or in the external loads.
D
Simplified equations methods of analysis for determining (σp or f’ 150) and specified compressive strength (f’c).
jack thrust forces and cross section changes in the joints Following the approach of scaling the residual flexural
result in a more conservative and uniformly distributed strength obtained by ASTM C1609 (2012) tests, a factor
reinforcement plan. Analytical and numerical methods of D
of 0.34 is considered to convert f’ 150 to σp. Designed
analysis such as Iyengar Diagram and FEM may results in D
early-age and 28-day f’ 150 strengths are 2.5 and 4 MPa,
a more cost effective and non-uniform reinforcement respectively. Specified compressive strengths are 15 MPa
design. for early-age and 45 MPa for 28-day FRC segment. As
shown in Figure 10, capacity of FRC segments are
calculated based on equilibrium conditions assuming a
6 LATEST TECHNOLOGIES IN SEGMENTAL post-crack plastic behavior in the tension zone. First crack
TUNNEL LINING flexural strength (f1) is assumed as 4 MPa. Design checks
for the production and transitional loads are shown in
6.1 Fiber Reinforced Concrete Segments Table 1. The tunnel is excavated in soft ground. Two-
dimensional FEM packages are used for calculation of
Conventionally, steel bars are used in concrete segments tunnel lining forces in three different geological reaches
to resist tensile stresses developed due to all loading defined along the alignment of this tunnel case. Design
cases from the time of casting through service condition. checks for the load case of the ground and groundwater
However, there are some issues associated with the use pressure is shown in Figure 11.
of steel bars including large crack widths, high labor costs In this project, a TBM machine is used with the
and long time for placement of curved bars in maximum total thrust of 45,000 kN applied on 16 jack
manufacturing plant. As an alternative, Fiber Reinforced pairs. Maximum thrust forces on each pair is therefore 2.8
Concrete (FRC) considerably improves the concrete post- MN. The length and width of the contact area between the
cracking behavior, allows for a better crack control and jack pads and segments, considering a maximum
offers plastic shrinkage resistance to the concrete mix and eccentricity of e = 0.025 m, are al = 0.87 m and hanc = 0.2
improves the concrete durability. Considering all these m, respectively. Dimensions of fully spread stresses are at
benefits, FRC represents a competitive material for tunnel = 3.4/3 = 1.13 m and h = 0.3 m in tangential and radial
segments. The fiber presence close to segment surface is directions, respectively. Conforming to simplified
very advantageous with high tensile stresses developed in equations of ACI 318 (2011), bursting force (Tburst) and its
this zone induced by TBM thrust jack forces during centroidal distance from the face of section (dburst) in
installation. tangential directions are:
FRC has been used since 1982 in numerous projects
around the world, e.g. water/waste water, gas pipeline, d burst = 0.5 (a t − 2e) = 0.5 (1.13 − 2 × 0.025) = 0.54 m
power cable, subway, railway, and road tunnels, as the
preferred material for the construction of tunnel precast
segmental lining. In most of the projects, small to mid-size Ppu  al  2.8 0.87
Tburst = 1 −  = 0.25 × × (1 − ) = 0.68MN / m
tunnels have been reinforced with only steel fibers at a
3
4  at − 2e  0.2 1.08
dosage ranging between 25 to 60 kg/m . Internal
diameters of these tunnels range between 2.2-11.4 m and In the radial direction, Tburst and dburst are calculated as:
their thicknesses are between 0.15 and 0.4 m. The design
has been performed using constitutive laws
recommended by international codes and standards such d burst = 0.5 (h − 2eanc ) = 0.5 (0.3 − 2 × 0.025) = 0.125 m
as DBV (2001), RILEM TC 162-TDF (2003), CNR DT
204/2006 (2007), EHE (2008) and fib Model Code (2010). Ppu  hanc  2.8 0.2
This section presents a design example pertaining to a Tburst = 1 −  = 0.25 × × (1 − ) = 0.16MN / m
4  h − 2eanc  0.87 0.25
case of mid-size tunnel and key material parameters for
design are summarized. Effects of residual strength and
different standard constitutive laws on axial force-bending Using this method of analysis, the maximum bursting
moment interaction diagrams as the key design tools are stress developed in radial and transverse directions are
discussed. determined.

6.1.1 Design example for FRC segments Tangential: σ = Tburst 0.68


p = = 0.9 MPa
φ (2d burst ) 0.7 × 2 × 0.54
An example for design of a mid-size TBM tunnel lining
with precast FRC segments is presented. It is assumed
that internal diameter of the segmental ring is Di = 5.74 m, Radial:
Tburst 0.16
σp = = = 0.9 MPa
and the ring composed of 5 large segments and one key φ (2d burst ) 0.7 × 2 × 0.125
segment (one-third of the size of large segments). Width,
thickness and curved length at centerline of the large These stresses are less than 28-day specified residual
segments are 1.5, 0.3 and 3.4 m, respectively. A stress- D
tensile strength of FRC segment as σp= 0.34 f’ 150 = 1.36
strain diagram according to ACI 544.FR report (2014) is MPa, and the design is valid for load case of TBM thrust
adopted. Key design parameters for aforementioned load jack forces.
cases are the specified residual tensile or flexural strength
Figure 11) results in determining the required residual
parameter and the required fiber content based on fiber
manufacturer product datasheets. Effect of choice of
standard constitutive laws on a similar tunnel segment
with a residual strength of 4 MPa is shown in Figure 12b.
Results show that choice of constitutive laws does not
have a significant effect on the axial force-bending
moment interaction diagram of FRC segments and
subsequently does not affect the design outcome.

Figure 10. Strain and stress distributions through the


section as part of it undergoes tension (a)
Table 1. Design checks (production and transport stages)
Phase Specified Maximum Resistance
Residual Developed Bending
Strength Bending Moment
(MPa) Moment (kNm/m)
(kNm/m)
Demolding 2.5 (early-age) 5.04 26.25
Storage 2.5 (early-age) 18.01 26.25
Transportation 4.0 (28d) 20.80 42.00
Handling 4.0 (28 d) 10.08 42.00

(b)

Figure 11. Design checks for the load case of ground and
groundwater pressure

6.1.2 Parametric studies

Increasing the fiber content in the mix directly results in


D
increase of the residual flexural strengths (f’ 150) of FRC.
D
A parametric study on effects of increasing f’ 150 from 1 to
5 MPa on the axial force-bending moment interaction
diagrams are shown in Figure 12a. Other parameters and
segment geometry for this study are similar to the ones
presented in previous example.
Comparing such diagrams with the results of analyses for Figure 12. Effects of residual strength and constitutive law
aforementioned loading cases (e.g. results shown in on axial force-bending moment interaction diagrams
6.2 Anchored Gasket 8 REFERENCES

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