halfen tunnel catalog

AW-TUN 10 - US

2 © 2010 HALFEN · AW-TUN 10 - US · www.halfen.com

In t roduct ion

PRODUCTS IN APPLICATION: TUNNEL CONSTRUCTION

Mountings in tunnel construction

Modern industrial societies need efficient and reliable traffic infrastructure, for both road and rail. High speed modes of transport require routes with gentle curves and inclined sections with small gradients. The topographical conditions in most countries require tunnels and bridges when planning the route, and these are very expensive engineering structures. Tunnel construction requires a large amount of geological investigation and static calculation of the tunnel cross section. Issues such as safety, fire protection, corrosion protection, technical equipment and the durability of the construction require a substantial amount of planning which usually takes years. Owing to the efficiency of the tools, machines and high-strength concretes which are available today, tunnels can now be built in much shorter times than was possible a few decades ago. The safety equipment, such as signalling devices, lighting, ventilation systems, retrieval anchors and emergency exits contribute substantially to safety in tunnels. Items from the HALFEN product range are used in different areas of tunnel construction for adjustable and cost-effective mountings and reinforcement.

The regulations listed below contain definitive references for the range of mounting designs:

ZTV-ING (Additional technical contract conditions and guide lines for civil engineering works. Edition March 2003, Part 5.1 and 5.2 (Road tunnels by closed or open cut method)•Mountingsfortunnelinstallationsmustbemadefrom stainless steel with material numbers 1.4529 or 1.4547 and Resistance class IV according to German Industrial Standard DIN EN ISO 3506 and according to DIN EN 10088.

Official approval certificate No. Z-30.3-6 of “Products, connecting devices and structural components made from stainless steel”•Table1:Classificationofgradesofsteelaccordingto strength classes and corrosion resistance classes as well as typical applications for structural components and connecting devices.

Swiss standard SIA 179 (Swiss association of architects and engineers, Edition 1998, Recommendations for mountings in concrete and masonry)•Section4,14.Mountingelementsmadefromstainless

steel or special materials•Table10:CorrosionresistanceclassIV,

Material No. 1.4529, 1.4547•Table11:stainlesssteelGroupIV:

Well suited for use in tunnels.

3© 2010 HALFEN · AW-TUN 10 - US · www.halfen.com

Contents


Crosssectionofatypicalroad tunnel(Picture:periodical'Tunnel’, Bauverlag BV GmbH)

Application Page

- Mountings in tunnel construction, regulations and recommendations 2 - Halfenchannelsfortunnelconstruction/HCRsteel 4 - Road tunnels / mounting the lighting system 5 - Road tunnels / reinforcement connections 6 - Road tunnels / retrieval anchors 7 - Railway tunnels / contact-wire mountings 8 - Railway tunnels / earthing of HALFEN channels 9 - Road tunnels / ventilation duct supports 10 - References 11 - Addresses 12


Avai lab le in lengths f rom 6" to 19 '11"

HALFEN CAST- IN CHANNELS FOR TUNNEL CONSTRUCTION

HTA HM HL HZL toothed

Designation Material / finish Allowable single point available Halfen T-head bolts

1.4529 HCR

1.4571 A4

hot-dip- galvan.

lbs (kN)

pull, concretegrade B ≥ 25

M 6

(1/4")

M 8

(5/16")

M 10

(3/8")

M 12

(1/2")

M 16 (5/8")

M 20 (3/4")

HTA 52/34 4950 (22)

gv fv

gv fvA4

gv fvA4

gv fvA4HM 52/34 → see catalogue MT

HTA 50/30 2250 (10)

gv fv

gv fv A4

gv fv A4

gv fv A4HM 50/30 → see catalogue MT

HTA 49/30 2250 (10)

gv fv

gv fv A4

HCR

gv fv A4

HCR

gv fv A4

HCRHM 49/30 → see catalogue MT

HTA 40/22 1350 (6)

gv

A4

gv fv A4

gv fv A4HM 40/22 → see catalogue MT

HTA 40/25 1350 (6)

gv

A4

gv fv A4

gv fv A4

HM 40/25 → see catalogue MT

HTA 38/17 1000 (4.5)

gv fv A4

HCR

gv fv A4

HCR

gv fv A4

HCRHM 38/17 → see catalogue MT

HTA 28/15 675 (3)

gv gv

A4

HCR

gv fv A4

HCR

gv

HM 28/15 → see catalogue MT

HL 28/15 → see catalogue MT

HM 41/41 → see catalogue MT fv A4

fv A4 HL 41/41 → see catalogue MT

HZL 41/41 → see catalogue MT

HM 36/36 → see catalogue MT gv fv A4

gv fv A4

gv fv A4HL 36/36 → see catalogue MT

HM 28/28 → see catalogue MTgv gv

A4

gv fv A4

gv

HL 28/28 → see catalogue MT

1-1/16"

1-1/8"

1-1/8"

9/16"

1-1/2"

5/8"

1-9/16"

1"

1-15/16"

1-3/16"

1-3/8"

1-3/8"

1-5/8"

1-5/8"

2-1/16"

1-5/16"

1-9/16"

7/8"

2"

1-3/16"


Mount ing l ight ing sys tems

ROAD TUNNELS

Special, glare-free lights are usually mounted on the tunnel ceiling at relatively short distances to provide the optimum lighting for road tunnels. Since HALFEN channels embedded in concrete are particularly suitable for strip mountings, they are offten used by experienced planners for these applications. Because the mountings could be exposed to chloride conta-mination,theyareoftenmadefromstainlesssteelCorrosion-ResistanceClassIVinaccordancewiththeGermanConstruc-tion supervision approval No. 30.3-6.

The material numbers of the highly corrosion resistant steels are specified as 1.4529 and 1.4547. The HALFEN channels which are made from these materials and can be embedded inconcretearelabelled:HTA28/15-HCR,HTA38/17-HCR,HTA49/30-HCR.

HALFEN cast-in channels provide an adjustable mounting method for lighting systems


Reinforcement connect ions

ROAD TUNNELS

A tunnel is a complex structure consisting of numerous sections with a large number of concrete construction joints. For example, if the diaphragm walls to which the tunnel sofit or tunnel vault is attached are pre-concreted, reinforcement connections are used for the linkage to the structural com-ponents.

Type HBS-05 HALFEN screw connections are used in this case.Connectionsfrom#4 to #10 (12 mm to 32 mm) bar diameter are available.

Reinforcement connections are also used in road tunnels for later connection to steel reinforced concrete intermediate ceilings. HBT rebend connections are used for the structural connection of concrete components without static proof. These are available in bar diameters #3 and #4 (10 mm and 12 mm).

Later connection of the tunnel vault to the pre-concreted diaphragm walls

The load-bearing connection for the reinforcement is made using HBS-05 screw connections

HBS-05-A

Reinforced concrete wall

Reinforced concrete ceiling

HBS-05-SG


Retr ieva l anchors

ROAD TUNNELS

Retrieval anchors are provided in road tunnels to pull apart vehicles which are wedged together in road traffic accidents so that they can be rapidly removed from the traffic. Retrieval anchors consist of DEHA spherical head anchors (Load class 20 T, 16 tons) embedded in the concrete. The free-swivelling shackles normally used for transporting precast concrete components are attached to the spherical head an-chors. The shackles are secured with a chain to prevent them from being stolen. Retrieval anchors are placed in niches inthetunnelwallsevery300ft.Cityandmunicipalrescueservices are increasingly demanding that retrieval anchors are provided.

Retrieval anchors are concreted into the tunnel wall at regular intervals.

The anchors must not project into the tunnel space. They are stowed in niches.

The chain secures the anchor from being stolen.

Spherical head anchor with shackle.

Further detailed information is included in the technical brochure for Spherical Head Transport Anchors.Please download catalogue KKT at www.halfen.com.

8 © 2010 HALFEN · AW-TUN 10 - US · www.halfen.com8

Mount ing contact wi res , wheel tens ioners , re turn l ines and l ine feeders

RAILWAY TUNNELS

ContactwireequipmentadjustablymountedontheHTAHALFEN channels.

Anchor channel for supplementary conduit

Anchor channelfor back conduit

Anchor channel forwheel tensioner

Anchor channel for anchoring a fixed point

Anchor channel for weight guide

Anchor channel for support strut

In railway tunnels for electrified stretches of railway lines, a large amount of equipment has to be installed along the tunnel cross section. This includes the contact-wire tensioners, line feeders and signal systems. HALFEN channels embedded in the concrete (cast-in channels) have proved to be an effective way of mounting equipment in numerous tunnels across the world and have become a standard means of attachment.


Ear th ing

RAILWAY TUNNELS

Type HTA hot-rolled HALFEN channels together with the relevant Type HS tee bolts are used in tunnels to attach the structural components for the overhead line (contact lines). The structures are made to take any stresses, such as those whichcanoccurontheCologneRhine/MainorNuremberg-Ingolstadt high-speed lines.

If desired, the HALFEN channels can be made short-circuit proof and adapted at site to the intended earthing arrange-ments. If installed as a channel pair, the short-circuit current is conducted via two welded spacers. The earth connection to the respective ring earth electrode can then be made from an earthing strap welded to the back of the channel.

The channel pair is fixed to the bottom of the formwork and then the multi-layer reinforcement mesh can be installed. For this assembly method, the earthing strap (flat steel) is verti-cally aligned so that in the final assembly condition the strap is always accessible and can be connected easily to the ring earth electrode.

HALFEN cast-in channels mounted on segment formwork

Pair of Halfen channels with distance spacers and earthing strap, which is bent and welded to the upper reinforcement after it has been laid.


Pipe suppor t for vent i la t ion ducts

ROAD TUNNELS

The connecting passages between two parallel main tunnel tubes are subject to strong contamination due to the irregular airpressure and suction waves from the main tunnels. The technical equipment housed in the tunnels must therefore be inspected and cleaned at short intervals.

In the Swiss Seelisberg tunnel, this problem was solved by connecting the crossways, which are spaced approximately 1000ft apart, to the outside air with new ducting and ventila-ting them under slight positive pressure. The overpressure prevents contaminated air from entering the crossways.

Since it was necessary for the ventilation ducts to run via the carriageway of the road tunnel, it was particularly important for the ducting to be installed quickly. The HALFEN Power-click framing system was the best solution for providing a means of support for the ducting which would be fast, safe and adjustable. By using this system, interruptions to the traffic could be reduced to a minimum.

Further information on the HALFEN Powerclick framing system is provided in the technical catalogues and on the website www.halfen.com.

Pipe support with HALFEN Powerclick framing systemPhotos:Tis-Air(www.tis-air.ch)

High rigidity profile with toothed inner channel

Multi-functional angle connector

Toothed connection

HALFEN Powerclick framing system

11© 2010 HALFEN · AW-TUN 10 - US · www.halfen.com 11

Some reference pro jects wor ldwide


AustriaTunnels SemmeringTunnels Kalus Phyrna AutobahnPlabutsch tunnelKarawankentunnel,CarinthiaInntal tunnelSausenstein tunnelMetro Vienna Czech RepublicTunnel Praha-MrazovkaTunnel Jihlava / bypass roadMotorway tunnel Prague SwedenSödra Länken, tunnel near StockholmRailway Tunnel , MalmöHallands Tunnel (Railway) Great BritainChannelTunnelTunnel A1, Hatfield FranceMetro ParisMetro LilleEurotunnel,CalaisTunnel de VillejustTunnel du PuymorensTunnel de l’EpineTunnel du LandyTunnel de TartaiguilleTunnelduPrado-Carenge

SingaporeCircleLineMRT

South KoreaRailway tunnel Seoul-Pusan

MalaysiaKuala Lumpur Storm Water Managementand Road Tunnel (SMART)

OtherMetroCairo,EgyptMetro Taipei, TaiwanStorebelts tunnel, DenmarkTunnel route 5, HongkongJunk Bay tunnel, HongkongWuGuangHighspeedRL,China

GermanyXFEL X-Ray Laser Project, HamburgFinnetunnel, Highspeed RLTunnel river Elbe, 4th tubeS-Railway tunnel HamburgHerren tunnel LübeckService tunnel hospital EppendorfRoad tunnel HemelingenKatzenberg tunnelU 2 city railwayPragsattel B10 StuttgartHornberg tunnelNeu-Ulm 21Stuttgart 21Schwarzkopf tunnelTunnel HösbachAudi tunnel, IngolstadtTunnel GeisbergTunnel motorway junction FrankfurtWandersmann tunnel north & southTunnel BreckenheimTunnel IdsteinTunnel MontabaurS-Railway Ostentor/DortmundBypass Gevelsberg road tunnelCityrailwayBochumCityrailwayDortmundTunnel A2 Gelsenkirchen-ErleLange Issel tunnelTroisdorf tunnel, Highspeed RLSiegauen tunnel, Highspeed RLDickheck tunnel, Highspeed RLWahnscheid tunnel, Highspeed RLHimmelberg tunnel, Highspeed RLRottbitze tunnel, Highspeed RLAegidienberg tunnel, Highspeed RLIttenbach tunnel, Highspeed RLGünterscheid tunnelSubway 3 NurembergSubway FürthTunnel Lehrter train station, BerlinTramway tunnel station RostockMotorway tunnel BAB 113Ems tunnel / LeerSubway DüsseldorfTunnel Farchant A95Tunnel AllachSubway MunichSubway HamburgBibratunnel, Highspeed RLReitersbergtunnel, Highspeed RLRichard-Strauss Road Tunnel, MunichLuise-Kiesselbach Road Tunnel, Munich

Belgium/LuxembourgDiabolotunnelLiefkenshoektunnelTunnel Antwerpen ASDAM-HASTTunnel Zelzate-KnokkeSubway AntwerpenTunneldeCointeLiègeTunnelE5/E9LiègeMetro AntwerpMetro BruxellesCointetunnelTunnel GestelRolo tunnelCEEtunnel,BruxellesKennedy tunnel, AntwerpMetroCharleroiTunnel de Gousselerbierg/LuxemburgTunnel de Markusbierg/LuxemburgTunnel Howald ItalyVariante di valcio autostrada FI-BOVariante di valcio autostrada FI-BOTunnelforCaselleAirportTunnel Monte Bianco SwitzerlandTunnel de Sauges, A5, NeuchatelConn.tunnelBettmerhorn-FischeralpQuarten tunnel A3Eggflue tunnel J18Utlisberg tunnel A4Hauenstein tunnelMetro Alpine tunnelRosenbergtunnel, St.GallenIslisberg tunnelHafnerberg tunnelChienbergtunnelSeelisberg tunnelLötschberg tunnelGotthard base tunnel NetherlandsZeeburg tunnel, AmsterdamSophia tunnelTunnel Pannerdens KanaalGeldersepoortSchiphol tunnelHeijnenoord tunnelWijker tunnel

HALFEN is represented by subs id iar ies in the fo l lowing countr ies , p lease contact us :

CONTACT HALFEN WORLDWIDE

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NOTES REGARDING THIS CATALOGUETechnical and design changes reserved. The information in this publication is based on state-of-the-art technology at the time of publica-tion. We reserve the right to make technical and design changes at any time. HALFEN GmbH shall not accept liability for the accuracy of the information in this publication or for any printing errors.TheQualityManagementSystemofHalfenGmbHiscertifiedforthelocationsinGermany,Austria,Poland,SwitzerlandandtheCzechRepublic according to ISO 9001:2008,CertificateNo.QS-281HH.

Furthermore HALFEN is represented with distributors in Argentina, Australia, Azerbaijan, Belarus, Brazil, Bulgaria, Chile, Colombia, Croatia/Bosnia-Herzegovina/Macedonia/Montenegro, Cyprus, Denmark, Estonia, Greece, Hong Kong, Hungary, Indonesia, Ireland, Israel, Jordan, South Korea, Latvia, Lebanon, Lithuania, Luxemburg, Malaysia, Malta, Mexico, New Zealand, Peru, Philippines, Kazakhstan, Romania, Russia, Serbia, Singapore, Slovenia, Taiwan/ROC, Thailand, Turkey, Ukraine, United Arab Emirates, Uruguay, Vietnam

North AmericaUSA

HALFEN Anchoring Systems Meadow-Burke Products 8521 F.M. Road 1976Converse,TX78109

Phone: +1800.323.6896 E-Mail: [email protected]: www.halfenusa.com Web: www.halfen.com

Central-East EuropeGermany

West EuropeFrance

Canada

HALFEN Vertriebsgesellschaft mbH Katzbergstrasse 340764 Langenfeld

HALFEN S.A.S18, rue Goubet75019 Paris

Austria,CzechRepublic,Poland,Switzerland

Belgium, Italy, Netherlands, Portugal, Spain

Denmark, Finland, Norway, Sweden

UCCIndustriesInternational(Distributor) Units 12 & 13895 Sandy Beach RoadPickeringOntarioL1W 3N7

ProvincesofBritishColumbiaandAlberta:Meadow-Burke Products 8521 F.M. Road 1976Converse,TX78109•USA

Phone: +492.173.9700 E-Mail: [email protected]: www.halfen.de

Phone: +1905.831.7724 E-Mail: [email protected]: www.ucci.ca

Phone: +1210.658.4671 E-Mail: [email protected]: www.halfenusa.com

North EuropeUK

China

JapanJapan

India

HALFEN Ltd. Humphrys RoadWoodside EstateDunstable LU5 4TP

Chengdu,Guangzhou,Shanghai

HALFEN(Beijing)ConstructionAccessoriesDistributionCompanyLimited-HQ Room601,TowerD,VantoneCentre,No.A6 ChaoYangMenWaiStreet,ChaoyangDistrict,Beijing,P.R.China100020

CRHIndiaManagementServicesPvt.Ltd.73-C,3NorthAvenue,MakerMaxity, Bandra-KurlaComplex,Bandra(East), Mumbai 400 051

HALFEN GmbH Japan Representative OfficeArk Mori Building 12 Floor1-12-32 Akasaka, Minato-KuTokyo 107-6012

Phone: +44158.247.0300 E-Mail: [email protected]: www.halfen.co.uk

Phone: +3314.452.3100 E-Mail: [email protected]: www.halfen.fr

Phone: +86105.907.3200 E-Mail: [email protected] Web: www.halfen.cn

Phone: +91224.202.4000 E-Mail: [email protected] Web: www.halfen.in

Phone: +8134.360.9269 E-Mail: [email protected] Web: www.halfen.jp

Fax: +1888.277.1695

Fax: +1210.658.8312

Fax: +49217397.0225

Fax: +1905.831.5872

Fax: +44158.247.0304

Fax: +3314.452.3152

Fax: +86105.907.3218

Fax: +8134.360.8201

Fax: +91224.202.4001

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