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है”ह”ह

IS 5878-5 (1976): Code of practice for construction oftunnels conveying water, Part 5: Concrete lining [WRD 14:Water Conductor Systems]

Indian StandardCODE OF PRAcrICE FOR CONSTRUcrION OF

TUNNELS CONVEYING WATER

PART V CONCRETE LINING

(First Revision)

Third Reprint SEPTEMBER 1994

UDe 624.191.2:69.034.92

@ COPJ,igM 1976

8 U REA U or I N D I A N S TAN DAR D SMANAK BI-IAVAN,9 BAIIADUR SI{AH lAFAR MARG

NEW DELIII 110002

Gr3 NOVllllb" 1976

IS I 5878 ( Part V ) • 1976

Indian StandardCODE OF PRACTICE FOR CONSTRUCTION OF

TUNNELS CONVEYING WATER

PART V CONCRETE LINING

(First Revision)

Water Conductor Systems Sectional Committee, BDC 58

M1m6"JSUBIS.P.BHA'r

ChairmanSARI P. M. MANX

Ramalayam, Peddar Road, Bombay 40002G

Re/Jresenti"1Public Works and Electricity Department,

Government of Karnataka, BangaJoreSUBI K. R. NARAYANA RAO (Alternate)

CUIEF ENGIlCBBR ( CIVIL) Andh 'l, Pradesh State Electricity Board,Hyderabad

SUPBRINTENDING ENOINBBR(DESIGN AllD PLANNING)( Alt"fUlt, )

CUIEI' ENGINBBB ( CIVIL) Kcrala State Electricity Board, TrivandrumSURI K. RAMABBADRAN NAIR ( Alternate)

CUIlUI' ENGINBBB (IBRIGATION ) Public Works Department, Government ef TamilNadu, Madras

Hindustan Construction Co Ltd, BombaySHBI H. L. SHARMA i Alumat« )

SR.I R. G. GANDHISaBI R. K. JOBBI ( Aller1l4t, )

SUPBRINTBNDING ENOINBEB( DBSIG!(8) (Alllrnale )

CHIEF ENGINBBB (PROJBOT AND Tamil Naclu Electricity Board, MadrasCONSTBUOTION)

SUPBRlNTBNDING ENGINEER( TEOHNIOAL/CIVIL ) (Alternate)

SUBI O. P. DATTA Beas Designs Organization, Nanga) TownshipDIREOTOR ( HCD-I ) Central Water Commission, New Delhi

DJCPUTY DIBBOTOR ( PH-!) (Alternate)DIBECTOR,IPRI Irrigation Department, Government of Punjab,

Chandigarh

( Continu,d onpage 2 )

@ Copyright 1976BURFAU OF INDIAN STANDARDS

This publication i. protected under the Indian Copyright Act (XIV of 1957) andreproduction in whole or in part by any means except with wriuen.permission of thepubliaber aball be deemed to be an infringement of copyright under the said Act.

18 I S87S ( Part V ) • 1916

of Uttar

Allam State Electricity Board, ShiUoag

Director General, lSI ( &-ojfieio M,m6" )

R.J. Shah &. Co Ltd, BombayMYlOre Power Corporation Ltd, GovernmeDt of

Karnataka, BangaloreIrrigation Department, Government of Uttar

Pradesh, LucknowConcrete Association of India, Bombay

( Conli1lwd from pa" I )

MnnIJ"1DB S. P. GARQ

Irrigation Department, Government of Maha­ralhtra, Bombay

SaBI S. M. BUALBRAO ( All,naGI,)SUBI D. N. KOOBBAR National Project. Oonstruction Corporation Ltd,

New DellliSSBI G. PltBTBA8AllTHY (AII,rnal,)

SSBI Y. G. PATBL Patel Engineering Co Ltd, BombaySURI C. K. CRoKeDI ( Alt"nal, )

S8BIS.N. PSUKANSaal S. C. SEN (Altmuu,)

SSBt A. R. RAICBUBSSBI S. R. S. SASTRY

SBBI B. T. UNWALLASURI E. T. ANTIA ( AII,rnat, )

SHBI D. AIITBA SIMBA,Director ( Civ Engg )

R,pr,untmgIrrigation Department, Government

Pradesh, LuckDOWSSBI M. S. JAnf Geological Survey of India, Calcutta

SlIIn N. K. MAlfDW AL ( AI'''flat, )JOINT DIREOTOR STANDARDS (8M) Miniltry of Railways, New Delhi

DZPUTY Dr.soToK STAKDABD8( BBtS)-1 (Allmaal,)

S8BZ B. S. KAPBB

SaB. G. N. TAXDON

S,crltarySH.I K. K. SHARKA

As,iltaat Director ( Civ Engg ), lSI

Panel For Construction of Tunnels, BDC 58 : P2

Coravnu,SSBI B. S. KAPBB Irrigation Department, Govel1UDeDt of Maha-

rubtn, Bombay t .

M""b"sSURI C. K. CBOK8Hl Patel Engineering Co Ltd, Bombay_nJ:PUTY DIR.OTOB ( HCD·I ) Central Water Commission, New DelhiD B PUT Y DIBBOTOR R._.aoR Miniatry of RailwaY', New Delhi

(8M )-1DBPUTY DIBBCTOB STANDARD­

( B&S )-1 (AllmuJ")Ssal R. K. J08S1 HiDdUJtaD CoDltructioD Co Ltd, Bomba,-

SRBI R.. M. VIDWAX8 (~ImuJ,,)'"SIIBI K. RAIlABBADBAlf NAIll Kerall State Electricity Board, TrivaDdrwD

SRBI JOHN M~ JOBl'f ( AI"".." )SaRI A. R. RAICBt7B R.J. Shah a. Co Ltd, Bomba,SURI G. L. RAIIA••AIltAB Indian Hume Pipe Co Ltd, Bomba,

SIIBI S. A. VIJAYAKURTY (All",..")S.81 G. N. TARPoN l,rigati~D Department, GOYerDlDeat or Uttar

Pradeall,Lucbow

2

IS I 5878 (Part V ) • 1976

Indian Standard

CODE OF PRACTICE FOR CONSTRUCTION OFTUNNELS CONVEYING WATER

PART V CONCRETE LINING

( First Revision)

o. FOREWORD

0.1 This Indian Standard (Part V ) was adopted by the Indian StandardsInstitution on 31 August 1976, after the draft finalized by the WaterConductor Systems Sectional Committee had been approved by the CivilEngineering Division Council.

0.1 This Indian Standard was first published in 1971 and is being revisedwith a view to keeping abreast with the technological developments thathave taken place in the field of tunnel design and construction.

0.3 The construction of tunnels involves a large number of problems.Because of the great extent of variations in the nature of the work manydifferent kinds of conditions are encountered which for maximum economyJ

consistent with technical requirements should be treated differently. Thisstandard coven recommendations which would be generally applicable toconstruction of zunnels for the assistance of. engineers engaged on suchprojects. This standard should, however, be used with caution since dueto the very nature of the subject it is not possible to lay down detailedspecifications to cover each and every possible case and the discretion of theeng~in-ehargewould be required in some cases.

0.4 LiniDg in tunnels is technically an important component and generallyconstitutes SO to 40 percent of the total cost of the tunnel. Thereforelinin, operati(tn requires considerable study and careful planning. TunnelsfOnDIng part of water conductor system have to be invariably lined withcement concrete from structural and hydraulic considerations with someexceptioDi when the rock is extremely hard, sound and massive like graniteand/or where the tunnel may be in operation for short periods in a year,

IS 15878 (Part V)-1976

0.5 This standard has been published in parts. Other parts of this standardare as follows:

Part I Precision survey and setting outPart II Underground excavation in rock

'Section 1 Drilling and blastingSection 2 Ventilation, lighting, mucking and dewateringSection 3 Tunnelling method for steeply inclined tunnels, shafts

and underground power housesPart III Underground excavation in soft strataPart IV Tunnel supportsPart VI Steel liningsPart VII Grouting

1. SCOPE1.1 This standard (Part V) lays down specifications and procedures forplacing concrete lining for tunnels conveying water.

2. _REQ,UIREMENTS2.1 The requirements for concrete lining of tunnels shall be carefully draftedas the conditions for lining tunnels are quite different from those of othercement concrete works. Requirements of lining of tunnels are special onaccount of curvature, thin sections and difficulties in placement andcompaction in restricted spaces.

2.1.1 All the requirements for coarse and fine aggregates, cement, water,and concrete grading and corresponding strength in accordance withIS : 456·1964* shall apply. On account of curvature, irregularities in rockprofile. thin sections and placing of concrete generally required to be doneeither through a concrete pump or pneumatic placer, the concrete neces­sarily requires to be flowy to avoid seggregation and to ensure proper fiUingin. The slump of concrete should not be less than 10 em and the sandcontent shall be more than that specified in IS T456·1964·. The cementcontent shall also be more than what is indicated by laboratory tests alone(se, Note below). Where concrete is placed directlyJ as in inverts andkerbs, the slump should be reduced to 5 em, Use of natural aggregates,especially sand, either wholly or partly, improves the pumpability of concreteand is recommended commensurate with practicability and economy. Themaximum size of aggregate shall not exceed 40 mm, This should, however,be reduced suitably for specific locations and conditions.

NOTB - The cement content in concrete may vary from 350 to 400 klima.However, in particular locations where experience jndicata, tbe minimum cemeDtconteat may be reduced to 325 kg/ml where natural alll'eptel are used aDd there

-Code or practice for plaiq and reinforced concrete (",,"d "Dido,.).

4

IS t 5878 ( Part V ). 1976

Is no hindrance of supports or reinforcement. Where crushed aggregates are usedand where supports or reinforcement come in the way, the minimum cement contentmay be suitably increased to ensure adequate workability. All the above mentionedcement contents are applicable to concrete placed through a concrete pump or bypneumatic placer.

2.1.2 It is advisable to use air entraining agent, to entrain up to 4percent of air for improving workability of concrete.

3. CONTROL OF SEEPAGE WATER

3.1 Seepage water shall be suitably controlled and prevented from gettingmixed with green concrete in the lining.

4. APPROPRIATE TIME FOR PLACING CONCRETE LINING

4.1 The appropriate time for placing concrete lining will be governed bythe conditions of rock tunnelled through. In cases where due to tectonicforces rock dilates, it is advisable to allow sufficient time for such dilationsto reduce to reasonable limits to ensure that concrete lining will not fail bycracking due to heavy and unequal external forces. In cases where rockmay not dilate much but may deteriorate in structure causing spalling,placing of a thin layer of concrete between steel ribs to support full surfaceof the rock and transfer the forces to the steel supports would be desirable(in certain conditions, shot-crete may be resorted to in place of such block­ing concrete, taking care to ensure that the gap between external flange ofthe support and rock is fully filled up). Blocking concrete or shot-cretehas to be placed with minimum possible time lag after excavation. Shot­crete can be applied more quickly than blocking concrete. In cases whererock is of better type than referred to above, concrete lining may comeat any time convenient to suit the construction programme and practicalconsiderations.

s, SEQ,UEN~CES OF LINING

5.1 The sequence of concrete placement for tunnel lining depends on theshape of the tunnel, its size, the nature of the rock strata and the type ofform work and other plant and equipment used and has to be selectedtaking Into account the construction schedule and progress scheduled to beachieved for the particular work. The sequences generally adopted forlining in tunnels are:

a) placing concrete to form the kerbs first, followed by side walls andarch and finally the invert;

b) placing concrete to form the invert first followed by sides and arch;and

c) placing concrete for the invert, side walls and arch all at one time.

IS I 5878 ( Part V ) • 1916

5.1.1 The sequence given at 5.1 (a) is suited for horse-shoe, D-shapedand other flat bottomed and wide tunnels. The kerb shall be built up toa section of sufficient width to serve as a base for the errection of forms forsides and shall be properly anchored and made stable to withstand theloads of concrete lining and form work. After the kerb is constructed, thelining of the sides and arch follows. The sides of the kerb against whichthe sides and the invert concrete will be laid later should preferably beradial to their respective curvatures. This sequence has the advantage thatall operations of concreting kerb, placing of shutters and forms and liningof sides and arches can be done with minimum disturbance to the tracklines on the floor and for movement of other traffic. Then the track linesand other service lines are removed and invert concreting is done last. Bythis method the bottom concrete surface does not get damaged. Anadditional advantage in this is that it permits of concreting the sides andarch simultaneously with excavation with a suitable gap.

5.1.2 The sequence described at S.1 (b) is suitable when the bottom ofthe tunnel is narrow or when the section is circular. The invert concretingis done first and a regular base for the erection of the form workfor sides and. arches is obtained making further work easier. But thisprocedure entails the removal of trolley tracks and other service lines laidon the floor and again laying them over the concreted invert for lining ofsides and arch. It has also the disadvantage that the concrete surface of theinvert is likely to get damaged during the operations for laying the overt.These practical difficulties increase if transport is by trucks.

5.1.%.1 In tunnels through weak strata, where the tunnel floor tends towear out fast or heave up, the above sequence is required to be adopted.In cases where large horizontal thrusts are encountered, the placing ofinvert concrete in advance of lining of sides, serves as strutting between thesides. The concrete surface can be protected suitably.

5.1.3 The sequence described at 5.1 (c) is possible only in small andcircular tunnels. It is difficult to be adopted in ordinary course .and maybe resorted to only where concrete pumping facilities are available andconstruction programme demands it. It has some advantages in steeplyinclined tunnels. These present problems in proper alignment along thetunnel axes.

5.1.4 In case of tunnels through loft rock, when it is found that the rockstrata is likely to collapse, it may become necessary to. provide a primarylining over and between the steel supports. ( if provided) at the time ofdriving the tunnel, or by shot-creting immediately, ( se« 4 ).

NOTII- Different types and methods or primary and main liniDS are deacribedin IS : 5878 ( Part III )-1972-.

-Code of practice for construction of tUDDell conveying wat,r; Part III UOderp'OUDdexeavatiOD in loft Itrata.

6

IS. Sa78(Pa~V )-197'

6. PORMWORK

6.1 Geaeral- Generally for tunnel lining steel forms are used in theinterest of speed and economy due to their multiple use. There are varioustypes of form work used for tunnel lining, such as rib and plates, rib andlaggings, travelling shutters with or without telescoping. Timber formworkhas to be resorted to in sharp bends, transitions and junctions. The use ofa particular type for a job depends on the size, shape and the lengthof tunnel.

6.1.1 In a rock tunnel where the concrete is placed mechanically, formsmay be removed after 16 to 24 hours from the placing of last batch ofconcrete. The form surface shall be oiled before concreting to avoidconcrete sticking to it.

6.1 Rib and Plate or Rib aDd Lagging - This type of form work maybe used for tunnels of medium size, that is, up to 5 m diameter. Whenconcrete is to be hand placed on short tunnels, this type of form workis convenient.

6.2.1 Ribs made of either channels or Tvsections placed at intervals ofabout 1 m according to the thickness of the concrete lining shall be erectedfirmly over the invert and either adequately stiffened steel plates or timberlagging shall be fixed from the bottom upwards as the concrete rises.

6.3 Travelling Non-telescoping Form Work - In this "case the wholeform work is prcasscmbled and mounted on a travelling frame fixed withwheels running on a track and screw jacks are provided for colJapsing .theform work, when required. In aU types or travelling forrns the sections arehinged to permit collapsing. Jacks are required for bracing and aligningthe forms.

6.3.1 Thi~ type is easy and economical to move. For this type of formsconcrete for the sides and arch may be placed in one continuous operation.The traveller which carries the form structurally forms a part of the formwork. The forms arc made in units 6 to 12 m long and can be struck andreassembled quickly depending on the requirements of construction trafficand matching concreting equipment.

6.4 Travelling Telescoping Form Work~ This is so designed that theback unit can be collapsed and moved forward through the front unitwithout disturbing it. The side plates are hinged to the arch plate so thatit is possible to collapse them. The traveller is equipped with jacks andother accessories for this purpose. The form work shalf be self-supportingwhile travelling in the collapsed condition also.

7

6.5 MoaoUthlc Form Work - This is practically a slip form work forcontinuous use. This type of form work is only suitable for a circular ornear circular tunnel when the lining of full section is done in one operation.This type of form work may be suitable in steeply inclined tunnels/shafts.

6.6 GeIleral Requ1rem~t of Forms - All form work should haveinspection windows about 50 X 30 em in size and not more than 3 m apart.Horizontal and vertical intervals of spacings will 'depend on the size andshape of tunnel, thickness of lining, method of placement and workabilityof concrete. The aim shall be to eusure dense compact concrete. Thesewindows are used to place and vibrate the concrete. The shutters to theseshould be strong and easily operable and fitting well as not to permit cementslurry to flow out or to leave projections in the finished concrete surface.Flexible shaft internal type vibrators may be used through these windows.

6.6.1 All forms, except where continuous non-stop concreting is adopted,require provision of a bulk head shuttering at the other end where use oftimber is generally convenient. The bulk head is necessary to make a neatconstruction joint.

7. BATCHING AND MIXING PLANT

7.1 In large tunnel lining jobs, it is necessary to use batching and mixingplants to manufacture concrete for lining. Depending on the size of tunneland equipment available, the concrete may be mixed in a standard batchingand mixing plant outside the tunnel and the mixed concrete taken to site ofplacement or the aggregates batched and mixed dry outside and taken tosite of placement inside the tunnel and nlixed with water inside the tunnel.It is advisible to add cement also inside to avoid its setting as the aggregatesare aften wet or moist. Except in small or very short tunnels, the concreteplacer or concrete pump shall be inside the tunnel, near the site of lining.In large tunnels especially long ones, wherever it is possible and convenient,taking the mixing and hatching plants also inside the tunnel is advisable.

8. TRANSPORTING CONCRETE OR DRY MIXED AGGREGATES

8.1 For tunnels of short length and where comparatively large volumes ofconcrete are required, concrete is generally mixed in a hatching plant locatedat a suitable site outside the tunnel, and the mixed concrete conveyed asquickly as possible to the site of placement by means of short belt conveyors,agitator cars, truck mounted mixers, etc, and poured into the hopper of theconcrete pump or placer kept close to the location of concreting. This. hasa disadvantage that as the .time of transportation increases, the quality ofconcrete tends to get affected through over-mixing in the case of agitatorcars and truck mounted mixers and a certain amount of initial set may takeplace before actual placement.

8

IS 15878 (Put V)-U7'

1.2 For tunnels of comp~tively longer leniths, it is advantageous to batchand mix the concrete in dry eondition outside the tunnel and then conveythe same inside the tunnels to locations of placement by means of tippingwagons or dumpers. The dry mixed aggregates are then remixed at site addingthe required quantity of cement and water to obtain the specified slump andwater cement ratio. The aggregates should be as dry as possible when mixedoutside. The mixer for mixing at site of placement has to be so located thatthe dry mixed aggregates can be easily dumped into the hopper of themixer and the mixed concrete pouring out of it can fall into the hopper ofthe placer or pump. Suitable retarders may be used where ready mixedconcrete is transported in transit cars. In case of vertical shafts used asconstruction adit, mixed concrete can be conveyed through ' elephanttrunks '. These' trunks' should be made up of short tapered pieces linkedto each other. The drop from the bottom -of the C trunk' to the concreteheap below shall not be more than 1 m,

: 9. PLACING CONCRETE

9.1 If the invert concreting or kerb concreting is done first, the surface ofold concrete shall be covered by 25 mm thick layer of mortar (of the samemix as the concrete, without COarse aggregate) to get a proper bond withthe new concrete. During concreting by a pump or a placer behind formwork for sides and arch, if the placing is interrupted for a period' of morethan one hour, a batch ( sufficient to cover the area by a 15 mm layer) ofmortar as above shall be pumped to cover the cold joints.

9.1.1 Care shall be taken while pouring through side doors in forms sothat no hollow pockets remain. In the case of monolithic forms, as theconcrete will fill the invert first, there may be a tendency for the form tofloat, and therefore the form shall be strutted down rigidly from the sidesand the roof of the tunnel as well.

9.1.2 The concrete may be placed either by a con-crete pump orpneumatic placer. Concrete in the invert may be placed direct. Thedischarge end of the concrete delivery pipe may be ke ouried a fewcentimetres inside the freshly placed concrete, as far as practicable, to avoidsegregation. Pumps and especially placers are sensitive to the pressure ofthe compressed air supply. In case of long compressed air supply lines, airchambers of adequate capacity shall be provided on the pipe line near thedischarge end to reduce pressure drop.

10. REINfORCEMENT

10.1 It is generally not necessary to provide any reinforcement in the liningin good rock [se, IS : 4880 (Part IV). 1971• ]. Whenever it becomes

·Code of practice for design of tunnels conveying water: Part IV Structural design ofconcrete liom. in rock. -

9

IIIS811 ( Part V ) •-1976

necessary to provide reinforcement, sufficient cover shall be prQlVided. Thespacing of reinforcement shall be adequate to pt-rrilit flow of concrete aroundit without any hollows anywhere.11. CONSTRUCTION JOINT11.1 Two types of construction joints generally become necessary namely,(a) bulk head and (b) longitudinal.

11.1.1 Bulk head joints are required to be provided at the end of eachabutter.

11.1.2 Longitudinal joints become necessary at the junction of the sidesand the invert where the kerb becomes an integral part of either the invertor the sides. Where the kerbs are laid separately, there will be two such~oints at each kerb. When the sides and arch are laid separately similarJoints become necessary at sides and arch. No special treatment i~

necessary for such construction joints except general cleaning and, whereapplicable, a layer of cement sand mortar as specified in 9.1 may be laid onthe joint.

12. CONSOLIDATION12.1 As far as possible, flexible shaft immersion type vibrators having avibrating needle of 50 mm dia and 8 000 vibrations/min frequency shouldbe used for vibration of concrete (.fee IS: 2505-1968*). In addition theconcrete shall be vibrated by external form vibrators of minimum 0·5 kWcapacity. The spacing of form vibrators depends on the size of vibrator,mass of form work, tnickness ofconcrete, etc. The spacing shall be adequateto ensure satisfactory compaction. The vibrator spacing shall be closer atthe crown portion.13. CURING13.1 Curing may be generally done by spraying water at short intervals tomaintain a wet surface. Strong draft of wind shall be avoided through thetunnel to reduce chances of sudden drying and 'consequent cracking.14. GROUTING14.1 Concrete lining of underground works shall be grouted to pack thehollow space (gaps) between rock and concrete lining. Grouting shall bedone under flow pressure not exceeding 5 kg/em' or as required dependingon the circumstances. The pattern and spacing of the holes shall be decidedin accordance with IS: 5878 (Part VII )-1972t. - Where grout intakeindicates gap of more than 10 DUD, very fine sand or rock dust should beadded to the grout to fill the gap. In certain locations addition of bentonitemay be helpful to hold cement in suspension for satisfactory grouting. Thegrout pressure should be reduced adequately when contact grouting incrown portion is done before invert is laid.

~~~cificatiODfor concrete vibrators) immersion type (first rm.liotl).toode uf practice for construction of tunnels conveying water: Part VII GroutiDlo

10

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