Competence in Tunneling Eng Final

8/3/2019 Competence in Tunneling Eng Final

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Getting you there.

Hilti. Outperform. Outlast.

Competence in Tunneling


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Hilti decades of competence in tunnels.

Since its early beginnings in the 1940s, Hilti has supplied tools

and fastening technology to tunnel projects around the world.

In fact, there are probably very few tunnels where Hilti has not

done so.Hiltis expertise is utilised in all phases of tunnel construction,

from tunnel driving all the way through to the installation of

equipment. More recently, the field of tunnel rehabilitation and

retrofit has gained in importance. In many cases, the key benefit

for designers and contractors is Hiltis technical support,

combined with dependable products. The specific experience

gained through Hiltis involvement in many tunnel projects world

wide results in a competitive advantage for our customers.

Temporary applications

During the tunnel drive a great number

of items must be fixed and kept out

of harms way. Electricity, compressed

air, water and ventilation air must all be

transported through cables and pipes

fastened along the tunnel.

Pages 4 9


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Structural and civil works

Where formwork must be fastened,

membranes fixed or rebar installed after

the concrete is poured, Hiltis products

come into their own. No surprises can be

tolerated when a problem in one area of

the tunnel may bring the whole

construction process to a halt.

Pages 1016

Mechanical and electrical

Equipment and installations make up

20% of the total investment for a

modern tunnel. Whether the corrosive

attack of exhaust fumes or design for

a catastrophic fire is of relevance,

Hiltiscompetence can be depended

upon.

Pages 1722

Retrofit and rehabilitation

Existing tunnels have to be widened

and heightened, repairs undertaken

after fires and ventilation concepts

changed. All these lead to adaptations

in the tunnel structure requiring fastening

and demolition technology provided by

Hilti.

Pages 2327


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Temporary Fastening

DX 460 powder-actuated

fastening tool

Robust and reliable

The worlds most widely used

cartridge tool

R 36 washer

For attaching to nails and studs

Additional accessories available

to accommodate special needs

Washer holder

Key when handling extra washers

X-ZF general purpose nail

Easy to load, all in one

HSA-W angled anchor An efficient alternative where

powder-actuated fasteners are

not the optimum solution

Challenge of the application

Especially when using drill and blast tunneling (e.g. NATM), shotcrete is used to

provide the initial lining. Often this will be reinforced with wire mesh. While this is

sometimes held in place by the main rock anchors, additional layers of mesh have

to be fastened to the first shotcrete coating.

Hilti solution & competence

For decades, the Hilti X-ZF nail with large steel washers has been the solution of

choice. Speed, reliability and economy considerations are the key decision factors.

Alternatively, the Hilti HSA-W angled anchor will provide a hold in substrates thatmay not be suitable for nail penetration.

The relevant accessories, such as a washer holder, make the application

professional and suitable for underground work.

Reference projects

Arlberg Tunnel, Austria (2005)

Val de Rennes, France (2004)

Gotschna Tunnel, Switzerland (2003)

Flims, Switzerland (2002)

Bergbock Tunnel, Germany (2003)

Rennsteig Tunnel, Germany (2002)

Fastening reinforcing mesh for shotcrete


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fastening tool

Rugged, robust, simple to service

Easy-to-load cartridge strips

Yellow cartridges

Optimal for medium-duty applications

X-SW nail

Flexible, to protect membrane fromtearing

Available for use with magazined

nails

HPS-1 impact anchor

Economical

Ideal where DX cannot be used

Temporary Fastening

X-ZF general purpose nail

Perfect in shotcrete

Reliable hold every time

Challenge of the applicationWater is perhaps the most natural companion of any tunnel builder. Where drainage

is required locally or across large surfaces, eggbox-pattern drainage membranes or

drainage half-pipes are used.

The installation must be fast and subsequent work (membrane fastening, concrete

pouring) must not jeopardize the location of the drainage membrane or half-pipes.


Hiltis DX powder-actuated fastening system is recommended by several of the

leading drainage membrane manufacturers.

The Hilti DX 460 fastenig tool has been used successfully in this application under-ground as well as above ground. The X-ZF 32 S23 nail has proven to be a universal

solution many million times over, but the Hilti fastener range offers many

alternatives to accomodate changing requirements.

Reference projects

Gotthard Tunnel NEAT, Switzerland (2005)

Brixlegg Tunnel, Austria (2005)

Botniabanan, Sweden (2005)

Socatop Tunnel, France (2005)

Tunnel de Monts, France (2005)

Metro Madrid, Spain (2005)

Madrid-Valencia high-speed train, Spain (2005) Metro de Mallorca, Spain (2005)


Hochwald Tunnel, Germany (2001)

Fastening drainage membranes and half-pipes


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X-ZF 37 S23 nail with washer Large steel washer to distribute

clamping force

Economical for mass application


fastening tool

Fully automatic

Well balanced and light


fastening tool

Robust and strong

Well suited to stretch geo-textile

with protruding nail

PVC/ polyolefine washer

Material compatibility to membrane

safeguarded

Defined rupture point in washer socketto account for rock movements

Challenge of the applicationSpeed is almost everything when the highly specialised crews of membrane fixers

take over a tunnel section. Almost - because the near-religious attention to not

damaging the membrane in any way is yet more paramount.

1 3 mm thick membranes from PVC or polyolefines are attached in 1 or 2,

sometimes 3 layers. A geotextile between the shotcrete and the membrane

provides drainage paths and cushioning.


For several decades Hilti has dominated the use of DX nails (e.g. X-ZF 32 S23) in

combination with specific synthetic washers designed to be hot-welded to the

membrane.

The nail and plastic washer is fastened through the geotexile and thus holds the

same.

Where 1000 shots per day are almost commonplace, reliability of the tools

(e.g. DX 35, DX 351) is paramount.

Reference projects

Brixlegg Tunnel, Austria (2005)


Gotthard Tunnel, Switzerland (2005)

Ltschberg Tunnel, Switzerland (2004)

Sidney PRL, Australia (2005)

Strengen Tunnel, Austria (2004)

Semmering, Austria (2003)

Fastening impermeable membranes

Temporary Fastening


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HUS-H screw anchor

Fully removable

High loads at small edge distances

HLC-EO hook sleeve anchor

Removable

Economic solution

X-FB fastener

Quick to install

Compatible with dozens of other

temporary applications

TE 16-M rotary hammer

Compact dimensions and good bal-

ance for high working comfort

PD 30 laser range meter

One-person distance measuring

Pocket size

Rugged and dust protected (IP54)


Fresh air, water, electricity, compressed air all these need to be carried along any

tunnel during the construction phase. In addition, temporary lights must be

fastened, telecom units installed, transformer stations held in place.

The requirements to be met by the relevant fastenings are as numerous as the

tunnels: When pre-cast concrete segments are used for lining, drilling is often

restricted to certain areas of the element. Anchors that allow small edge distances

are then useful. Often, removability is a key asset as well. And in all cases nobody

wants to spend much time fastening the ventilation ducts.


Hiltis added value really is the breadth of its product range:

DX cartridge technology for quick light-duty fastening is part of our offering, as are

heavy duty anchors to hold up large-diameter water evacuation pipes.

Thus, Hilti can offer what you need, not what just happens to be in the catalogue.

Reference projects

Collector Blagis, France (2004)

Val de Rennes, France (2004)

Metro Cairo, Egypt (2003)

Metro de Mallorca, Spain (2004)

Amsteg Power Station, Switzerland (2002)

Dresden Coschtz /Dlzschen Tunnel, Germany (2004)


Hochwand Tunnel, Germany (2001)

HKD flush anchor

Internally threaded

Flush with the surface


fastening tool

Rugged, robust and simple to service

Easy-to-load cartridge strips

Fastening temporary ducts, cables, illumination, pipes

Temporary Fastening


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HVU adhesive anchor system Suitable for dynamic loading

Easy to install, no waste of resin

Economical heavy duty anchor for

serial applications

PR 25 rotating laser

Leveling and aligning up to 200 m

Rugged design and dust protected


Compact dimensions and good bal-

ance for high working comfort


Temporary rails are commonly used in underground construction. The two main

applications are

Fastening of rails for the complete supply of tunnels by train, especially if driven by

TBMs

Fastening of rails for the tunnel formwork carriage of the inner lining and

subsequent work stations

Depending on the application and required life span, the requirements vary from

minimal to significant in terms of load level, dynamic resistance, removability and

cost.


While many products of the Hilti range can be fit for the purpose, the typical anchor

used is HVU in the case of more severe loading and life span requirements, such asfor tunnel rails. Where only little load and a few load cycles are expected, HUS-H

and HSA have been utilised successfully.

By using Hilti drills such as the TE16 in combination with a PR 25 rotating laser the

true line for the rails can be found with precision.

Reference projects


Metro Madrid (Metronorte), Spain (2005)

Gotschna Tunnel, Switzerland (2004)

Flims Tunnel, Switzerland (2005)

Vereina Tunnel, Switzerland (2000)

8

Fastening rails for TBM trailers or formwork carriages

HUS-H 16.5 screw anchor

Perfect for temporary fastenings

Fully removable

Standard product comes in corrosion

protection class hot-dip galvanized

HSA stud anchor

Easy to install

Economical for volume temporary

applications

DD EC-1 diamond coring

system

Hand-held tool for anchor and through

holes of 835 mm diameter

Temporary Fastening


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HVU adhesive anchor system Suitable for cyclic loading


Economical heavy-duty anchor for

serial applications


Save on the most time consuming

operation of fastening: Alignment and

positioning

Leveling and aligning up to 200 m

Rugged design and dust protection

TE-C3X hammer drill bits

Up to 30% longer life than regular drill

bits Innovative helix design for rapid drilling

progress and excellent dust removal


Especially in TBM-driven tunnels, mucking out is frequently done with conveyor belt

systems. Their high capacity and continuous operation help reduce traffic in the

already congested tunnel cross section.

Conveying systems are installed temporarily but often remain in place for several

years in long tunnels.

Fastenings must be economical, yet securely withstand any dynamic loading and

oscillation from the belt operation.


Given the loads, dynamic effects and economic considerations, the solution of

choice is often an adhesive anchor.

The HVU adhesive capsule system or the HIT injection mortar have both been used

successfully.

Reference projects

Collecteur Blagis, France (2004)


Guadarrana Tunnel, Spain (2004)

Metro Barcelona, Spain (2006)

HIT-RE 500 adhesive anchor

system and HAS-E rods

Comparably insensitive to installationvariations

Highest load values combined with low

sensitivity to installation anomalities

Easy adaptability with respect to

anchor length


Robust and versatile:

Ideal for most on-site installation jobs

9

Fastening conveyor belts

Temporary Fastening


10/3210


Post-installed rebars using adhesive resins are a common sight in construction

today. They are indispensable, however, in tunnel retrofit. Where cross sections

need to be altered when their use changes or suspended ceilings are renewed as

the ventilation concept becomes obsolete, rebars are generally used to connect old

and new concrete.

As part of the primary tunnel structure the connections must have a life expectancy

in line with the main parts of the structure.


With more than 20 years in the market, the Hilti HIT family can offer by far the

longest experience in injection technology for anchors and rebars. With a load

performance fully equivalent to cast-in bars and corrosion resistance even better

(e.g. HIT-RE 500), the solution of the market leader is capable of fulfilling the most

advanced requirements.

The resin itself is complemented by a powerful range of accessories like dispensers

and hole cleaning equipment, even for jobs of industrial proportions.

In addition, the Hilti drilling technology (hammer or diamond) as well as the PS 200

Ferroscan helps you identify and combat any problems, even before you hit them.

Reference projects

Metro Madrid, Spain (2005) Dresden Coschtz/Dlzschen Tunnel,

Metro Barcellona, Spain (2005) Germany (2004)

Tunnel de Monts, France (2005) Weser Tunnel Bremen,

Socatop, France (2005) Germany (2005)

Bruxelles Airport, Belgium (2000) Herren Tunnel Lbeck,

Tunnels in Velasquez Highway, Germany (2005)

Chile (2005) High Speed Train Madrid-Valencia,

Spain (2005)

TE-YX drill bit

Full carbide head for high durability

Anti block tip for rebar impacts

TE 76P ATC combi hammer

High performance and safety with

Active Torque Control ATC

Theft Protection System TPS

PS 200 Ferroscan

Rebar detection, cover measurement

and rebar diameter estimation

Immediate high-res image

Wireless, dust-protected, rugged

HIT P-8000 D

pneumatic dispenser

for jumbo foil pack

(1400 ml)

Speedy injection

Pre-selection of resin volume

Rebar installation


system



Foil pack minimizes waste

Better corrosion protection than cast-in

bars

Structural and Civil


11/3211

HVZ adhesive anchor system

Available in many steel qualities,

including HCR 1.4529

Tolerates concrete cracks (shrinkage)

Suitable for fatigue loads

Good electric isolation

Tested for fire resistance

X-BT stainless steel threaded

stud for coated steel

Corrosion resistant equal to or better

than standard A4 (A316) steel.

Blunt tip: no through penetration

High load values with high consistency

Speed of fastening


While aesthetic considerations are often the principal objective, tunnels are in factclad for a number of reasons. Cladding panels can provide improved reflectivity,

easy tunnel cleaning, sound absorption especially in portal areas, as well as fire

protection for the tunnel structure.

Shock-like suction and compression loads from passing trains and trucks require

substantial fatigue resistance of fasteners. Todays high-speed trains can cause

pressure changes of more than 6kN/m2. With humidity and corrosive agents always

present in tunnels, corrosion is also a key consideration.

Not to mention fire resistance where panels must not become detached in a

catastrophic event.


For decades, Hilti has provided fastening solutions to contractors concerned with

cladding systems. Due to difficult accessibility for inspection, stainless steel in high

grades is more often the rule than the exception.

If serious dynamic loads must be considered, adhesive anchors such as the HVZ

adhesive capsule system are most suitable. In less demanding cases, mechanical

anchors such as the Hilti HSA stud anchor or the Hilti HKD impact anchor can be

used.

Where cladding sub-structures have to be fastened to steel members, the X-BT

cartridge driven fastener delivers obvious speed advantages and high load values

at the same time.

Reference projects

Tokyo Metropolitan, Japan (2006)

Metro Prag, Czech Republic (2002)

Metro Mnchen, Germany (2005)

Bramsch-Tunnel Dresden, Germany (2002)

HKD flush anchor

Internally threaded

Flush with the surface

Economical for mass applications

Tested for fire resistance

DX 351 BT powder-actuated

fastening tool

For efficient and convenient setting

of the X-BT M10 threaded studs


High accuracy (1.5 mm)

Set offset of panels

Measure clearances and check traffic

gauge

Cladding panels



12/3212

HK6 board fastener

Available in all relevant steel qualities

Various head configurations available

for optimal installation

TE 2 rotary hammer

Powerful, light-duty rotary hammer drill

for a variety of applications

TE-C3X hammer drill bits

Up to 30% longer life than regular drillbits

Innovative helix design for rapid drilling

progress and excellent dust removal

Gradient technology for superior

ruggedness


Measures distances & calculates areas

on the spot

Easy one-person verification of

as-built measurements

HSA stud anchor

Easy to install

Economical for volume applications


Tunnel fires produce extremely high temperatures within very short time spans.

Amongst other damage, this is known to cause explosive spalling. For years, fire

protection board has been used to shield structural components from the heat.

Depending on the system, four to ten fasteners are used per square metre. The

anchors are exposed to the corrosive tunnel atmosphere and/or cyclic wind suction

loads during their complete life time. Of course, an adequate fire resistance of the

fasteners is paramount.


Since 1981, Hilti has continuously gathered data on corrosion of materials in tunnel

atmospheres (see page 29). Material samples have been monitored for decades in

real- life weathering tests.

The resulting knowledge is coupled with a comprehensive understanding of fire

resistance in fasteners gained through hundreds of in-house and independent fire

tests.

Drilling and measuring technology complements this competence on fasteners.

Reference projects

M30 Madrid, Spain (2006)

Tokyo Chinmai Tunnel, Japan (2001)

Frejus Tunnel, France (2003)

Fastening fire protection board



13/3213

X-CR 48 S15 stainless

steel nail

Very fast installation

Stainless steel material similar to

grade 1.4546


fastening tool

Robust and reliable

The worlds most widely used

powder-actuated fastening tool

HK6 anchor with wire-

mesh-clip

Available in all usual steel grades

Suitable for cracked concrete

HSA stud anchor

Easy to install

Economical for volume applications


Temperatures of up to 1300C within a few minutes of a fire starting can cause

significant damage to concrete structures. Fire protection mortars are used more

and more frequently in tunnel construction and rehabilitation. Due to their relatively

low cost they often compete well with more traditional board systems.

These mortars are usually applied in thicknesses of 30 50 mm. In order to secure

and reinforce any sections with disturbed bond to the substrate, a wire mesh is

usually fastened to the base material.

An economical fastening solution that nevertheless withstands the fire and possible

corrosion attack must be used.


The fasteners supplied by Hilti are only a part of the complete solution. Designers

and applicators are usually looking for a harmonized system of mortar, wire mesh

and the fastening solution that is ideally tested together.

Hilti therefore works with several suppliers in the relevant fields to develop and test

adequate solutions.

Depending on the requirements, DX powder-actuated fasteners and HK6 or HSAanchors can be utilised optimally. In most cases, stainless steel fasteners and wire

mesh are selected.

Reference projects

Tunnel Brnnen, Switzerland (2006)

Tunnel de Foix, France (2005)

TE 2 rotary hammer

Powerful, light-duty rotary hammer drill

for a variety of applications

Fastening wire mesh for sprayed fire protection



14/3214


The majority of transportation tunnels are rail or metro tunnels. These require

fastening of the track, often on a solid concrete slab. These fixings are subjected to

very high alternating loads making fatigue the governing design factor. In addition,

stray currents and related corrosion effects are a major issue to be dealt with. And

given the industrial operation, a professional setting process is essential.

An early decision on the fastening system can in many cases save millions by

reducing the required tunnel cross section.


Hilti offers three major rail anchor lines (HRA, HRT, HRC), designed to safely transfer

the oscillating axle loads from the rail into the concrete structure. As no two tunnels

are the same, and as the requirements vary from country to country, these are

available in many variants. Where called for, simpler solutions have been engineered

as well.

In addition, Hilti provides a comprehensive range of drilling, setting and aligning

equipment satisfying the industrial approach of todays rail installation

professional.

Reference projects

Perth Light Rail, Australia (2006)

London Underground, UK (2005)


Metro Milan, Italy (2005)

New York City Metro, USA (2005)

Tram Way Milano-Ginisello, Milan (2005)

HRA, HRT, HRC rail anchors

Fully tested for fatigue loads

Plastic sleeve or injection mortar pro-

tect effectively against stray currents

DD 130 diamond coring

system

Hand-held or rig mounted operation

for flexibility in use

PD 32 laser range meter Set-out and adjust with laser

accuracy


system Highest load values combined with low

sensitivity to installation abnormalities

Foil pack minizes waste

Better corrosion protection than

cast-in bars

Fastening rail track

HIT P-8000 D

pneumatic dispenser for

jumbo foil pack (1400 ml)

Speedy injection

Pre-selection of resin volume



15/3215


Inner city tunnels and other shallow underground works are often constructed using

the cost effective cut & cover method. This usually requires the roof slab to be

fastened into diaphragm walls. Such ceilings are typically constructed of cast-in-

place concrete or steel girders with pre-cast concrete slabs. Depending on the

design, the requirements range from shear and / or moment transfer via grouted

dowels and rebars to water tightness, corrosion resistance and fire safety

considerations.


Whether a professional rebar-connection is needed or steel bearings must be

fastened with anchors, Hilti as global leader in fastening technology can provide

both, in addition to professional design support, on-site installation training and

Hiltis compatible drilling technology.

Reference projects


Metro Singapore, Singapore (2000)

Metro Sydney, Australia (2001)

Cut & cover: Fastening of roof slab

TE 76P ATC combi hammer

High performance and safety with

Active Torque Control ATC

Theft Protection System TPS

HDA heavy duty anchor

Undercut security and highest loads

Performance reserves when ground

movements cause load peaks

HVU + HAS

Any diameter, any size M8 M39

Flexibility and high loads

Minimised sensitivity to site irregu-

larities

DD EC-1 diamond coring

system



HIT-HY 150 dual foil pack

resin

For concrete

10 years experience for zero surprises

Added cement for corrosion protection



16/3216


Where thousands of people pass through a metro station on a daily basis,

underground structures require attractive, safe and bright finishes on walls and

ceilings. In addition, safety equipment such as screen doors on the platforms are

becoming the rule in many municipal networks.


Strut support systems with all their components, enabling quick installation, are

available in many versions and materials. In this way one system can be used to

advantage in various situations always supplemented by Hiltis broad anchor

systems range.

Where fire compartmentalisation is required, Hiltis fire stop engineers can help with

the market leaders products and expert advice.

Reference projects

Metro Paris, France (2005)

Metro Shanghai, China (2005)

Metro Guang-Zhou, China (2005)

Metro Vienna, Austria (2005)

Metro Munich, Germany (2005)

Metro Hong Kong, Hong Kong (2003)

Metro Prague, Czech Republic (2002)

Airport Tunnel Kloten, Switzerland (2002)

Metro Singapore, Singapore (2001)

Metro Berlin, Germany (2004)

MQ channel system

Flexible and versatile

Quick-lock system for speedy

installation


and HAS-E rods with

centering rings

Guaranteed electrical insulation

No loosening of the anchor even after

millions of load cycles

PML 32 line laser

Self-leveling for horizontal and vertical

alignment

High dust and moisture protection

HST stud anchor

Available in HCR stainless steel for road

tunnels

Tested for tunnel fires

Finishing of metro stations (cladding, screen doors, ceilings)

HVU adhesive anchor system

Suitable for dynamic loading


Economical heavy duty anchor for serial

applications



17/3217

HVZ adhesive anchor system Highest safety level

Tolerates concrete cracks (shrinkage!)

Suitable for dynamic loads

Good electric insulation

DD EC-1 diamond coringsystem




Jet ventilators are some of the heaviest pieces of equipment placed directly above

traffic in a tunnel. In addition to the weight, their fasteners can be subject todynamic loading from unbalanced propellers or wind pressure induced by traffic.

The high requirements on security are also manifested by the use of various safety

cables or chains designed to hold a falling ventilator if the anchors should fail.

High standards regarding anchor corrosion resistance, dynamic loading or concrete

cracks are therefore the rule.


These requirements are reflected in many different national codes and regulations

which govern this application. Hilti offers a comprehensive range of fasteners:

Adhesive anchors such as HVZ, HVU in stainless steel(including HCR material 1.4529)

Mechanical anchors such as HDA, HSC, HSL-3 and HST, in various stainless

steel grades.

Hilti hammer and diamond drilling technology complements the offering.

Reference projects

Pripherique Paris, France (2006)

Socatop, France (2006)

Nad Al Hamar Tunnel, Dubai (2004)

North Passage Basel, Switzerland (19982005)

Metro Singapore, SGP (2000) Tunnel Les Vignes, Switzerland (1997)

Dresden Coschtz /Dlzschen Tunnel, Germany (2004)

Tunnel Wiener Platz Dresden, Germany (2002)

HDA-R heavy duty anchor

Self-undercutting anchor for through

fastening applications

Stainless steel 1.4401

HSC-AR safety anchor

Self-undercutting anchor

Small drilling depth

Jet ventilator fastening

TE 16-M rotary hammer Versatile tool for most drilling jobs

on site

Mechanical & Electrical


18/32

ML channel system

Optimal for electrical supports

Light weight for easy handling

Quick-install features

MI channel system

Heavy-duty system that will take the place

of most welded structures in tunnels Fully compatible with MQ

HST stud anchor

Economical anchor for safety relevant

fastenings

Suitable for cracked concrete

(shrinkage)

MQ channel system

Versatile, with numerous specialised

components

Eight different channel profiles for

optimised use of material


1525% of the total investment for modern tunnels relates to mechanical and

electrical equipment and the corresponding supply services. While the design l ife of

these M&E installations is often significantly below the expectation for the tunnel

structure itself, most projects nevertheless require great attention to the durability of

fastenings and supports of pipe and cable lines.

In addition, the linearity of the structure requires industrial installation processes

that leave little room for improvisation and on-the-spot decisions.


With the support systems MI, MQ and ML, Hilti offers a comprehensive range ofcompatible systems designed to take either loads of just a few cables or the weight

of a 1000 mm water pipe. The system solution also comprises perhaps the most

comprehensive range of fastenings and drilling technology, covering many materials

and corrosion protection classes. To increase productivity, laser positioning tools

help to save on the most expensive part of the works, namely labour.

A key part of the Hilti offering is the calculation service and software, together with

true on-site support available in 120 countries.

Reference projects

Uetlibergtunnel, Switzerland (2005) Rennstein Tunnel, Germany (2002)

Tunnel de Monts, France (2005) Madrid Airport Tunnel, Spain(2005)


Metro Singapore, SGP (2000)

Utility Tunnel Vienna Airport, Austria (2005)

Dresden Coschtz/Dlzschen Tunnel, Germany (2005)

18

Cable tray and pipe support

PML 32 line laser

Self-leveling, for horizontal and vertical

alignment

High dust and moisture protection


Mark support spacing in one-person

operation

Verify pipe offset & lengths to 1.5 mm



19/3219


Highest safety level

Tolerates concrete cracks (shrinkage)

Suitable for dynamic loads

Good electrical insulation


system and HAS-E rods with

centering rings

Guaranteed electrical insulation



Easy adaptability with respect to

anchor length

TE 56-ATC combi hammer

Rugged tool for use in tunnels

Low vibration for repetitive anchorsetting


Overhead catenaries are loaded by the dynamic forces of passing trains (friction,

pressure of pantograph). In addition, any metal part is potentially subject to

significant stray currents which can cause corrosion. Despite this, the design life of

tunnel structures is usually more than 50100 years, making it essential to pay

special attention to detail.

In tunnels, such catenaries are fastened to the tunnel soffit, which may be heavily

reinforced or entirely un-reinforced concrete. High requirements on geodetical posi-

tion and small tolerances on the steel brackets usually make drilling a challenge.


Hilti provides a whole portfolio of anchor products suitable for the application in

order to fit with local requirements, design codes and customs.

Preferred adhesive anchor systems:

HVZ and HVU capsule systems

HIT-RE500 resin injection system. With a specific centering ring to hold the rod in

place overhead and to guarantee perfect electrical insulation on all sides.Preferred mechanical anchor systems:

HDA and HSC undercut anchors, both with easy to install self-cutting

technology.

A range of materials and coatings is available to suit the specific requirements.

Hilti can provide suitable drilling technology as well as robotic drilling tools, drilling

templates and lasers to align the installation.

Reference projects

Channel Tunnel Rail Link, Great Britain (2005)

Ltschbergtunnel, Switzerland (2005)

Tabladillo Tunnel, Spain (2005)

High Speed Line Rome-Naples, Italy (2002)


Vereina Tunnel, Switzerland (2001)


Metro Naples, Italy (2005)

HDA-R heavy-duty anchor

Undercut anchor for highest safety

level

Easy installation - even overhead

DD130 diamond coring system

Hand-held or rig mounted operation for

case-by-case flexibility

3 different diamond matrix specificationsto optimise drilling performance and core

bit life

Fastening catenaries



20/32

HSA stud anchor

Easy to install

Economical for volume fasteningapplications

Available from stock in more than 100

variations

CP firestop systems

Complete range

Effective sealing of fire compartments


Easy alignment and positioning up

to 200 m

Rugged design and dust protected

Projects horizontal or vertical plane

MQ channel system

Comprehensive system to accommo-

date most designs

Eight different channel profiles for

optimised use of material


Lighting and the relevant feeding cables have to be fastened in virtually every tun-

nel. Depending on the type of tunnel (e.g. road or rail), corrosion aspects will usually

be an important consideration in order to avoid any failure during the lifetime of the

tunnel.

In addition, the illumination system forms a key component of the escape system in

the case of a smoke-emitting fire.

Furthermore, in both new build and rehabilitation projects, emergency lighting

systems are installed in addition to the regular illumination. Fastenings must

therefore demonstrably be able to withstand the temperatures of tunnel fires.

Hilti Solution & competence

There are numerous systems of illumination utilised in tunnels. Some are fixed

directly into the ceiling, others fasten onto the cable trays that carry the feeder

cables. Yet others are situated on sophisticated metal structures made of channel

and strut.

Hilti offers an extensive range of anchors, DX powder-actuated fasteners and

channel systems that will accommodate most designs. Using this comprehensive

system allows the use of Hiltis design software and reduces the number of

interfaces between components.

Where required, Hilti can provide customized fire testing and related expert advice,

both in-house and from independent organisations.

Reference projects

Zrich Airport Tunnel, Switzerland (2002)

San Bernardino Tunnel, Switzerland (2003)



30 Tunnels, Germany (2002)

NBS Kln-Rhein/Main, Germany (2002)

Rennsteig-Tunnel, Germany (2002)

Eichenberg-Tunnel, Germany (2004)

Helleberg-Tunnel, Germany (2004)

Escherberg-Tunnel, Germany (2004)

Landrcken-Tunnel, Germany (2004)

HST stud anchor

Available in HCR stainless steel for

road tunnels

Tested to withstand tunnel fires

20

Fastening lighting systems

X-FB fastener

Speedy installation

All-metal solution for adequate fire

performance



21/3221

HST stud anchor

Available in HCR stainless steel for

road tunnels The standard for fast, economical

installations

MQ channel system

Almost unlimited possibilities to build

any frame

Available in hot-dip galvanized and

stainless steel qualities


Save on the most time-consuming

operation: Easy alignment and

positioning Self-leveling in horizontal and vertical

position


Modern tunnels are equipped with dozens of communication, information and

safety systems: Traffic signalisation, radio and mobile communication cables orcameras all require fastening and support systems capable of withstanding the

severe corrosion conditions in tunnels.

Given the multitude of applications, the range of requirements applied to the

fastening systems in terms of load level and direction, anchor type, corrosion

protection, cost implications, etc. is also almost unlimited.


Mirroring the numerous applications and requirements, Hilti offers what is one of the

worlds largest ranges of fastening and support products. Thousands of different

anchor types and variants, sizes, lengths and diameters in many different materials

are available from stock. And if something is not on hand as a standard item, Hiltihas decades of experience in custom-manufacturing solutions.

As usual, these fastening products are always supported by state-of-the-art drilling

and measuring technology, all from one hand.

Reference projects


Gtatunnel, Sweden (2005)

Walensee Tunnels, Switzerland (2004)




Dresden Coschtz/Dlzschen Tunnel, Germany (2004) Wilsecker-Tunnel, Germany (2006)

Knigstuhl-Tunnel, Germany (2005)


High loads, even where alternating

wind loads cause fatigue

Available in High Corrosion Resistant

steel (HCR)

Fastening signalisation, radio and safety equipment


Versatile tool for most drilling jobs

on site



22/3222

HSC-R safety anchor

Approved for shock loads

Short drilling depth at high loads


Rugged design and dust protection

Easy alignment and positioning up to

200 m


Optimal performance for holes up

to 20 mm

Full versatility: 2 gears, hammer

or rotary


More and more tunnels are protected by way of sprinkler or more recently highly

advanced water mist systems.

When sprinklers are switched on, a water hammer effect in the piping system

exerts very significant shock-type forces on the fastenings. These are difficult to

calculate. At the same time, the resistance of the fastenings is critical to the

functioning of the sprinkler system and, thus, the survival of tunnel users. More

often than not, fire mains are fastened along the tunnel.

The usual requirements with regards to corrosion and design life of tunnels produce

an additional consideration in the design.


The design of anchors for dynamic loads is one of Hiltis key competencies.

Hundreds of tests and various approvals allow to-the-point designs and significant

optimisation as a result of extensive knowledge of the behaviour of Hiltis anchors.

Undercut anchors for serial applications such as the HSC have been used with

great advantage to transfer the impact of sprinkler systems to the tunnel lining.

In addition, Hilti drilling technology (hammer drilling and diamond), as well as laser

technology to align the anchors can be obtained from one expert supplier.

Reference projects

Betuwe Tunnel, Netherlands (2005)

SOCATOP, France (2006)

Tunnel Stammham, Germany (2004)

Knigstuhl-Tunnel, Germany (2005)

Wilsecker-Tunnel, Germany (2006)

30 Tunnels on NBS: Kln-Rhein/Main, Germany (2002)

HST stud anchor

The standard for fast, economical

installations

Available in High Corrosion Resistant

steel (HCR)

Fire mains and sprinkler system


Mark support spacing in one-person

operation

Verify pipe offsets & lengths to 1.5 mm



23/3223

Hilti HY150 injectable adhesive

Fire resistant due to water-cement

matrix

Excellent long-term behaviour

HDA undercut anchor

Highest safety through undercut

Highest performance

HCC concrete connector

For bonding new concrete to oldconcrete


Perhaps the most significant type of rehabilitation work going on in dozens of

tunnels around the world is the change of the ventilation system. The toxic exhaust

gasses of cars some 20 years ago made complicated ventilation systems with

multiple air ducts necessary. With todays cleaner cars these can often be retrofitted

to help contain smoke in the case of a tunnel fire.

This may require the change of existing (or introduction of new) suspended ceilings.

Also, in some cases the course of time, corrosion or fires have taken their toll on

existing suspended ceilings in tunnels.


Here more than anywhere the understanding that every project is different has its

merits: Depending on the tunnel lining encountered, the fire and corrosion

conditions as well as the actual alteration required, Hilti has developed various

solutions in close cooperation with the responsible engineers. These included

chemical anchors, e.g. Hilti HIT-HY 150, HIT-RE 500, as well as mechanical anchors

such as the self-undercutting anchor HDA-R. These are always supported by the

availability of a complete system of drilling equipment, laser tools as well as fire

stopping products to seal any remaining gaps in the new fire compartments.

Reference projects

Plabutschtunnel, Austria (2004)

Felbertauerntunnel, Austria (2005)

Sonnenberg Tunnel, Switzerland (1999)


PfnderTunnel, Austria (1995)

RE500 injectable adhesive

Reduced hole depth due to high bond

strength

Low sensitivity to many applicationirregularities

CP 606 fire stop sealant

Optimised viscosity for easy installation

30-year age tested

Suspended ceiling slab


One-person verification of as built

measurements

Setting and adjustment of formwork

Retrofit & Rehabilitation


24/3224

HIT-HY 150 adhesive in dual

foil pack

For concrete




system (1400 ml jumbo foil

pack)

Speedy injection

Pre-selection of adhesive volume



HVU adhesive anchor system

Suitable for dynamic loading

Easy to install, no waste of adhesive

Economical heavy duty anchor for

serial applications


Wherever the typical cross section of a tunnel is altered, it is likely that the normal

formwork system cannot be used or additional shuttering is needed. Alternatively,

sections of secondary concrete may have to be poured, calling for post-fix rebar

connections. This will regularly require fastening technology capable of sustaining

substantial hydrostatic concrete pressure.

In TBM-type tunnels, it is sometimes necessary to cut out already placed pre-cast

concrete liners with diamond coring and sawing technology.Furthermore, ventilation and other services are required.


Where rebar connections are concerned, Hilti is clearly the world leader in adhesive

anchor technology. With a range of products and technologies available, most

requirements can be fulfilled, even the most demanding. Please refer to page 10 for

further details.

The formwork systems used in tunnels differ widely as far as the specific fastening

details are concerned. Heavy-duty mechanical and adhesive anchor systems have

been used successfully in the past.

Reference projects

Guadarrama Tunnel, Spain (2005)



Ltschberg Tunnel, Switzerland (2004)

Tunnel de Pertus, Spain (2006)

SFV anchor and HIT-RE 500

adhesive anchor system

Connects Dywidag rods

Rod retractable when formwork is

removed


system

Simple handling, no specialised

workforce needed

Water-cooled and water-protected for

wet tunnels Brushless high-frequency motor with

10 speed settings

Additional SOS niches and escape routes



25/3225

alt

neu

DS-WS 15 wire saw


While tunnels are virtually cast in stone, increase in traffic and innovations in

transport systems may lead to new demands on the available traffic gauge.

In such cases, every centimetre counts: Tunnel bottom levels are lowered, linings

reduced in critical curves, ballast replaced by rigid slabs in rail tunnels.


In many cases, Hiltis demolition and fastening technology can help reduce tinkeringon site and to conceive a professional methodology for complex rehabilitation

projects.

Hiltis HIT injection systems are frequently used to connect existing and new

concrete structures with rebars or to fasten formwork and scaffolding.

For example, the SVH formwork anchor can tie back one-sided shuttering using

regular Dywidag rods.

Diamond saws as well as electric demolition breakers are used where machine-

mounted or pneumatic hammers are too clumsy or heavy.

Where rail tracks need to be lowered, it can be beneficial to use Hilti HRA rail

anchors which save the height of the ballast and, thus, increase traffic gauge.

Reference projects


Schni Tunnel, Switzerland (2006)

Getli Gallery, Switzerland (2006)

Naxberg Tunnel, Switzerland (2006)

Glion Tunnel, Switzerland (2006)

DS-TS32C wall saw

Increase of traffic gauge

HIT-HY 150 adhesive in dual

foil pack

For concrete



SFV anchor and HIT-RE 500

adhesive anchor system

Connects Dywidag rods

Rod retractable when formwork is

removed

TE 706 breaker

Less tiring to use, higher daily

productivity

Excellent balance and significantly

lower dynamic vibration

Constant, high performance even when

the voltage drops



26/3226

HCC-B conrecte connector

Built-in quality assurance throughinternal adhesive injection

Accurate positioning and fastening

of rebars


As a consequence of the corrosive atmosphere and salt often found in tunnels, or

due to fire damage, the concrete lining of many tunnels requires attention:Excessive cracking, spalling or insufficient cover to protect rebar from corrosion call

for removal and replacement of concrete layers.

These new concrete overlays must be tied in with the existing concrete to form a

load-transferring unit.


While for large surfaces the removal is usually carried out using high pressure water

jets or mechanical means, on smaller areas Hiltis demolition breakers such as the

TE 706 have been used to advantage. Where concrete grinding is needed, the Hilti

DG 150 diamond grinder has been used to good effect.

Concrete cover and rebar position can be determined, analysed and visualised with

the PS 200 ferroscan.

Hiltis HCC concrete connector is a specialised fastening system designed to trans-

fer shear and tension loads between concrete overlay and the substrate.

Reference projects

A2 Wassen, Switzerland (2000)

Pfndertunnel, Austria (2002)

Wallenseestrasse, Switzerland (2005)

Roffla Tunnel, Switzerland (2004)

SKN Bernadino Tunnel, Switzerland (2005)

Concrete repair & concrete overlays

Hilti HIT-RE 500 adhesive

anchor system and SFV anchor Connects Dywidag rods for formwork

anchors

Rod retractable when formwork

removed

TE 706 breaker

Less tiring to use, higher dailyproductivity

Excellent balance and significantly

lower dynamic vibration

Constant, high performance even when

the voltage drops

PS 200 Ferroscan

Measures and checks concrete cover

on large surfaces

Allows statistical analysis



27/3227

HIT P-8000 D pneumatic

dispenser for jumbo pack

(1400 ml)

Handy, yet powerful enough to inject

adhesive into small deep holes

Uses regular pressurised air available

on any construction site

TE 56-ATC combi hammer

Rugged tool for use in tunnels

Low vibration for repetitive anchor

setting


Rock movements and water pressure can cause problems with the tunnel lining.

These problems and their solutions are highly individual, of course, so the examples

given here are not a representative cross section. What they often have in common,

though, is that Hiltis fastening experts are frequently called on site to help.


Many of Hiltis products can be used in situations that are far beyond their regular

applications. Hiltis engineers accompany you with judgement, analysis, testing,

approval support and finally with hands-on installation, training and support.

In the first example (large picture above), the steel lining of a race pipe in a hydro

power station had become deformed due to external water pressure.

In collaboration with the specifying engineer, Hilti devised a special fastening

system to secure the lining, featuring minimal protrusion, based on the HIT-RE 500

injection mortar.

The smaller pictures show an example where ground movements caused excessive

relative displacement of pre-cast concrete segments. In order to stabilise these, a

steel tube was inserted into a pre-drilled opening, with the annular gap later injected

with HIT-RE 500. A specialised injection technology was devised and tested for this

task before using it on site.

Reference projects

Seelisbergtunnel, Switzerland (2006)

KWO Gallery, Switzerland (2005)


system

Simple handling, no specialised

workforce needed

Water-cooled and water-protected for

wet tunnels

Brushless high-frequency motor with

10 speed settings

Damage repair specialised solutions


system

Epoxy injection mortar with high

adhesive strength

Optimised viscosity for injection into

small voids



28/3228

Corrosion, fire, dynamics.

While there are many areas in which Hiltis

expertise can help during the design process,

corrosion, fire resistance and dynamic loadingusually feature high on any tunnel designers

list of priorities.

For Hilti, the key has always been to truly

understand the customers needs within a very

specific application. We then make it our

responsibility to translate that into simply a

good solution.

Hiltis competence goes far beyond the mere

knowledge of codes and regulations. Our

research more often than not provides the

basis for standards as it drives innovation.

Fields of special competence.


29/3229

Competence in corrosion and materials.

The atmosphere in tunnels is known to be highly corrosive due to exhaust gases,

dust, humidity and frequently salt and other influences. This leads to highly

accelerated corrosion in mild steel and may cause hydrogen embrittlement inhigh-strength grades. In stainless steel these agents can cause pitting and crevice

corrosion, which can lead to stress corrosion cracking, perhaps the most

treacherous form of corrosion.

Hilti started live tunnel exposure studies in 1981 since short-term laboratory tests

are insufficient as a sole source of information. For decades, Hilti has tested

numerous types of carbon and stainless steel,

incl. highly corrosion-resistant grades

alloys of titanium, aluminium and nickel

samples from various manufacturers

products of various geometries

These samples have been exposed to the atmosphere of eight road and rail

tunnels. In order to simulate service loads part of the bolts were pre-stressed.

The subsequent analysis includes microscopic investigation and load tests in

compari-son to unexposed reference samples of the same material.

These in-situ experiments are supported by Hiltis corrosion laboratories which

focus on

simulating real application conditions (pollutants, temperature, humidity, etc.)

accelerated corrosion testing.

To complement in-house competence, Hilti also cooperates with academic institu-

tions including ETH Zurich, Switzerland; Montan-University Leoben, Austria and

University Stuttgart, Germany. The results of Hiltis testing have significantly

influenced codes and regulations, as well as the related academic debate.

These activities have yielded what is probably the worlds most extensive corrosion

database for tunnels. This is used to optimise the specific corrosion protection in a

given tunnel for a given application.

In fact, it is this capability to economically optimise structures in a safe way that

many customers view as Hiltis key strength in tunneling applications.

Life-long safety.


30/3230

More than one iron in the fire.

Competence in fire safety.

Hilti has been active for decades in the field of passive fire protection, which essentially

consists of the application fields

fire protection of structural components fire resistance of fastening systems

fire stopping of penetrations and construction joints

Steel and concrete are impacted by high temperatures. Fires in tunnels produce

temperatures up to 1300C in very short periods of time due to the spatial confinement.

Tunnel structures are typically protected by fire protection boards or proprietary

sprayed mortars.

In both cases fasteners are needed, either to hold up the board, or in the case of

sprayed mortars to attach wire mesh reinforcement.

Hilti works closely with manufacturers of fire protection systems to provide tailored

system solutions with real expertise built in.

As world leader in fastening technology, Hilti has long focussed on qualifying its

products regarding fire resistance. This includes mechanical and chemical anchors,

DX powder-actuated fasteners as well as channel support systems. In fact, Hilti uses

its own test furnaces to help build the necessary knowledge base. Hilti also works

together with external bodies for independent fire assessments.

This long-term commitment to in-depth fire testing has led to perhaps one of the

worlds broadest portfolio of fire-rated fastening products.

Hilti is the worlds leading supplier of fire stopping products designed to close gaps in

fire-rated structures, such as service penetrations or building joints.

But Hiltis expertise does not only cover the actual product. The true value for ourcustomer is generated when a reliable product is combined with on-site application

knowledge provided by our fire stop engineers. It is this competence that drives

realistic test settings and therefore real-life results.

Foto: Arno Balzar ini


31/3231

Shock. Fatigue. Vibration.

Competence in dynamic loading.

As the world leader in fastening technology, Hilti has developed an in-depth under-

standing of dynamic loading situations over the decades and investigated their impact

on fastening solutions. fatigue loading (e.g. anchors for jet ventilators, rail fastenings)

repetitive shock loading (e.g. cladding panels, fire protection board)

Hiltis main laboratory for dynamic anchor testing at corporate headquarters in

Liechtenstein is used for internal tests. In addition, many international experts and

academic institutions use our facilities in various forms of cooperation.

For our partners, Hiltis competency is a key benefit the detailed knowledge of anchor

behaviour under dynamic loading. This is complemented by what many experts

consider the worlds most sophisticated set of anchor testing laboratories.

Hiltis testing equipment is capable of applying enormous loads in high frequencies and

loading velocities.

In order to analyse anchor loads in sufficient precision, Hilti has developed individual

measuring technology.

Hilti has used this technology in many projects where dimensioning anchors is difficult

due to uncertainties with regards to the expected load levels.

Especially in fatigue and shock design, the loading history of structures and fasteners

is of vital interest. Often, critical loads only occur infrequently and unpredictably. Hilti

uses a combination of measuring equipment and the relevant recording equipment on

customers real life structures to help understand what the true loads are over a period

of time.


32/32


Hilti in tunneling. More information by fax.

Fax to: Hilti Corporation

Number: +423 234 30 96

Company:

Contact:

Street:

Town, post code:

Phone:

E-mail:

Area of activity:

Application topics

Corrosion

Dynamic loading

Fire safety

Technical data for products

Approvals for product

Rail fastening

Rebar analysis /coverage

Software

PROFIS anchor calculation software

Exbar (rebar fastening) calculation software

Exbar overlay (concrete overlays)

Channel & pipe support design software

PS 200 Ferroscan

Please arrange an appointment with me.

I am particularly interested in:

Product lines

Measuring

Anchors

Installation

DX powder-actuated fastening

Firestop

Drilling and demolition

Diamond drilling and sawing

Screw fastening

Cutting and sanding

Others

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Documents

Competence in Tunneling Eng Final