TUNNELLING PRODUCTS

DESIGNED AND MADE IN BRITAINTO BE THE STRONGEST IN THE WORLD

We manufacture standard products and products specifi cally for customers own requirements. The close relationships that we form with all our customers allows us to improve our products and service.

In June 2009, Bosworth Plastics and Tunnelling Accessories formed Technical Tunnelling Components. Both companies had worked very closely together for over 10 years independently and a simpler solution which could only benefi t our customers was to work together under the umbrella of TTC. Together this gives TTC and its customers access to all the expertise and knowledge ‘under one roof’, bringing together the individual talents and expertise from the precast industry, fi rst hand tunnelling practices, plastics manufacture and design.

We have in house design ability as well as computer modeling and 3D modeling which can produce actual prototype models - a technology used by many motor racing teams. This allows TTC and its clients to quickly develop ideas and concepts in a very cost effective way.

Technical Tunnelling Components (TTC) is a company whose activity is focused on the tunnelling industry and more specifi cally on the production of plastic components for use in precast concrete segments.

Dowelock

The Dowelock range of locking dowels is specifi cally designed to meet the performance demanded from the tunnelling industry and to meet the requirements laid down in the British Tunnelling Society’s Specifi cation for Tunnelling.

The Dowelock system is a boltless connection device for joining two segmental rings together on the circumferential joint. Dowelock is designed to operate with compressible gaskets (Hydrophilic or Elastomeric with or without molded corners). The performance of the dowel is compatible with the compression characteristics of these types of gasket and copes with varying joint gaps whilst minimising gasket offset.

Dowelock consists of a connecting dowel moulded from a high strength, high durability plastic, together with two locking assemblies; one cast into each of the adjacent tunnel lining segments. These locking assemblies incorporate patented locking collets that allow the dowel to enter with a minimal insertion force and then lock, thus preventing the dowel from withdrawing. These collets are retained in such a way as to allow the dowel to be entered off line as they have the capability to rotate whilst the dowel is inserted and therefore aligning and securing the precast concrete units. The full locking capacity of the Dowelock is maintained with up to a 15mm gap between adjacent units.

Whilst there are other dowel connection systems on the market there was a need for a product that addressed certain major issues with these systems. The fundamental problem was that these systems relied upon friction between the dowel and a hole in the concrete or a series or threads on a pin that was then inserted into a threaded socket to resist the forces exerted by the Elastomeric gaskets and by the nature of the design this has to be a very tight fi t. These same threads resisted the insertion of these dowels and as well as requiring massive insertion forces (large hammers are the recommended method in some cases) the threads were being damaged/compromised therefore reducing the effectiveness of the system.

Whilst test results show reasonable pull out results for these dowel systems the insertion of the dowel into the socket for these tests is carried out in free air which allow the receiving socket to fl ex (this is not a true test as once inserted in the concrete segment the socket can no longer fl ex and hence damage to the threads can occur.

The other problem addressed by the Dowelock System is the extension of the pin or dowel under load.

Dowelock has the lowest extension fi gures for any dowel used for this application. We believe that the tests we carry out on an ongoing basis are the most accurate and give a fi gure for extension over the whole joint.

Recent product developments have resulted in a further reduction of our extension under load which on Dowelock 30 has been reduced to 2mm at 55 kN .This extension is critical to the performance of the Elastomeric gaskets and therefore the completed tunnel.

The success of this innovative design resulted in winning the Material/ Machinery section of the BTS Tunnelling Industry Awards 2005.

Dowelock 30 (30mm dia. dowel pin) has been used successfully on tunnelling contracts throughout the World, and this has now lead to the development of two further sizes to cater for all tunnel ring requirements.

Tensile Load 60 kN, Shear Resistance 78 kN Minimum.

Dowelock 38 was developed to fi ll the gap between the Dowelock 30 and 45, it has a good tensile resistance at 97 kN with a Shear Resistance of 125 kN. This impressive tensile load makes it very usable on thin walled segments with a high EPDM gasket line load.

Dowelock 45 has very high tensile 120 kN resistance and a Shear Resistance of 185 kN to deal with the requirements of elastomeric gaskets with very high compression, and thick walled concrete segments.

Dowelock assemblies are manufactured from materials that are specifi cally designed for use in precast concrete. The high strength plastic used is one of the most durable groups of the synthetic materials; they are particularly resistant to organic compounds including alcohols, hydrocarbons, agricultural chemicals and weak acids.

Technical Tunnelling Components are designed, tested and manufactured to be the strongest in the world.

Dowelock/Gasket interaction

The graphs on the right for Dowelock 30, 38 and 45 show the joint compression curves for typical EPDM compression gasket requiring compression force to closure of approximately 35 kN/m. This is superimposed on the typical extension curves achieved by the Dowelock giving the equilibrium extensions.

Dowelock 30 Gasket Comparison

Dowelock 38 Gasket Comparison

Dowelock 45 Gasket Comparison

Dowelock/Gasket interaction

The graphs on the right for Dowelock 30, 38 and 45 show the joint compression curves for typical EPDM compression gasket requiring compression force to closure of approximately 35 kN/m. This is superimposed on the typical extension curves achieved by the Dowelock giving the equilibrium extensions.

Grout/ Lifting Socket Assembly

1 Grout/Lifting SocketFor segment erection and/or grouting TTC have various different sockets.

With pull out loads ranging from 100 kN to in excess of 300 kN we have a range of sockets to cover all requirements. Available in standard lengths of 80, 130,168 and 217mm that can be extended to any length with the use of extension tubes.

Our sockets can be supplied with end caps and non return valves that can be inserted from the intrados to allow proof grouting. (See Non –Return Valves and Plugs).

2 Plugs with Sealing WasherTo suit our grout/lifting sockets are available with different seals depending on the sealing pressure required and have been tested to pressures in excess of 15 Bar.

3 Hydrophilic Seal (External Water Bar)We can supply a ‘Hydrophilic Bands’ to prevent the passage of water

around the outside of the socket.

4 Non-Return ValvesManufactured to suit our own sockets with a ‘triple start’ thread that allows the valve to be fi tted from the intrados of the tunnel and with standard threads for use with Bentonite Injection systems in Microtunnels and shafts. Our non-return valves have been water pressure tested to 15 bar without failure.

5 End CapsFor situations where the socket is either used for segment erection only or for proof/back grouting.

6 Extension TubeCan be made to any length to increase the length of any of our sockets to customer’s requirements, these can be fi tted with an end cap if required.

7 Disposable CapTo prevent any material /debris getting into the grout lifting socket prior to its use for grouting or lifting

Bolting Systems

8 Fast Thread Sockets And BoltsTTC’s spear bolt sockets are available in different lengths and diameters depending on segment size, weight and type of sealing system proposed, they are designed so that cross threading is impossible due to it’s ‘reeled’ thread design which is also self cleaning and faster to install. Dowels that align the segments are available in a range of sizes to make construction easier, quicker and safer.

Now familiar to many customers as a fast and effi cient method of fi xing tunnel segments. The large thread design on the plastic socket allows the bolt to be inserted 4 -5 times faster than metric threaded sockets. The design of the threads, utilizes the strength of the concrete instead of relying on the Physical properties of the polymer in the socket.

Available in a range of lengths and diameters to suit different applications and the line loads exerted by gasket sealing systems.

TTC also designs and manufactures a wide range of grout/lifting socket assemblies, bolting systems, alignment dowels and miscellaneous products to work alongside the Dowelock system.

TTC also designs and manufactures a wide range of grout/lifting socket assemblies, bolting systems, alignment dowels and miscellaneous TTC also designs and manufactures a wide range of grout/lifting socket TTC also designs and manufactures a wide range of grout/lifting socket TTC also designs and manufactures a wide range of grout/lifting socket assemblies, bolting systems, alignment dowels and miscellaneous TTC also designs and manufactures a wide range of grout/lifting socket

Grout/ Lifting Socket Assembly

1 Grout/Lifting SocketFor segment erection and/or grouting TTC have various different sockets.

With pull out loads ranging from 100 kN to in excess of 300 kN we have a range of sockets to cover all requirements. Available in standard lengths of 80, 130,168 and 217mm

around the outside of the socket.

4 Non-Return ValvesManufactured to suit our own sockets with a ‘triple start’ thread that allows the valve to be fi tted from the intrados of the tunnel and with standard threads for use with Bentonite Injection systems in Microtunnels and shafts. Our non-return valves have been

TTC also designs and manufactures a wide range of grout/lifting socket assemblies, bolting systems, alignment dowels and miscellaneous products to work alongside the Dowelock system.

TTC also designs and manufactures a wide range of grout/lifting socket assemblies, bolting systems, alignment dowels and miscellaneous

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Bolts can be manufactured to any standard (BS or ASTM), grade, length, diameter and surface fi nish as required by the specifi cation.

Range of Bolt SocketsM20 x 100mm, M20 x 120mm, M20 x 130mm, M20 x 135mm,M24 x 100mm, M24 x 110mm, M24 x 120mm, M24 x 135mm,M24 x 140mm, M24 x 150mm, M24 x 160mm.

9 Alignment Dowels

TTC manufacture a range of alignment dowels for use on the circumferential joints. These dowels can also be used to increase the shear resistance and can be manufactured from plastic or metals in different grades.

TTC also offer their Dowelock Dowel Pins in metals of different grades if a particularly high resistance to shear is required. This allows our customers to utilise the standard Dowelock housings and collets and negates the need for different ring fi ttings or additional segment moulds.

TTC designed a system which combined with their Fast Thread Sockets and was used to great effect in the construction of the running tunnels for the CTRL (Channel Tunnel Rail Link – UK).

Miscellaneous Products

10 M & E FixingA small socket used for fi xing bracketry and other items to the tunnel walls both during and after construction. This fi tting is a inexpensive method for producing multiple fi xing points on the intrados of a tunnel and negates the need to drill holes into the segments. They are easily fi tted into the segment moulds.

11 Non-Return ValvesAs well as the Non-Return Valves we make to suit our Grout/Lifting Sockets we manufacture a wide range of valves in different diameters to suit various applications including Bentonite Injection Systems for Microtunnelling and Caisson shafts.

12 Segment Handling/LiftingFor handling segments at the segment plant , during transportation and on the construction site TTC manufacture a ‘Lifting Socket’ that utilizes a ‘T’ shaped lifting fi nger to handle the segments easily and effi ciently.

This method is very cost effective compared to other systems available for this process.

TTC designed a system which 12 Segment Handling/Lifting

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Bolts can be manufactured to any TTC designed a system which

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DESIGNED AND MADE IN BRITAINTO BE THE STRONGEST IN THE WORLD

Big Walnut Outfall Augmentation Sewer (BWOAS) Columbus, Ohio Bathurst collector and Langstaff Trunk SewerVaughan (Toronto) Ontario YDSS Interceptor Sewer – 19th Ave TunnelsRichmond Hill, Region of York, Ontario

91st and 30 Ave TunnelEdmonton, Canada

Croydon Cable TunnelLondon, United Kingdom

Belfast Sewers Belfast, Northern Ireland

London Water Ring Main Extension London, United Kingdom

City West Cable Tunnel Sydney, Australia

East Ham SewersLondon, United Kingdom

Tsuen Wan Drainage TunnelHong Kong

Lai Chi Kok TransferHong Kong

Lea Vallley ProjectLondon, United Kingdom

Brighton Tunnels Brighton, United Kingdom

Over the last few years we have jointly supplied major projects which include:

Channel Tunnel Rail Link Tunnels – 58km

Heathrow Terminal 5 Tunnels which included extensions to the London Underground, Heathrow Express and an 11 meter diameter Airside Road Tunnel

DTSS Singapore

Singapore Metro

San Paolo Metro

Project Reference List

Contact

Unit K Radius CourtTungsten ParkCoventry RoadHinckleyLeicestershireLE10 3BE

Phone +(0)1455 234401Fax +(0)1455 250578Web www.ttcltd.orgEmail info@ttcltd.org

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