waterproofing system - fatrafol

Waterproofing system

FATRAFOL-T

CONSTRUCTION AND TECHNOLOGICAL INSTRUCTION

for application of the waterproofing system

in tunnels and underground structures related to tunnels

Waterproofing system FATRAFOL-T page 2

01/2017

PN 5421/2016 FATRAFOL-T

Title: Construction and technological instructions for the waterproofing system of tunnels and underground structures related to tunnels

Author: Studio of waterproofing services

Publisher: Fatra, a.s., třída Tomáše Bati 1541, 763 61 Napajedla, Czech Republic

Version: 01/2017

Effective from: 01-01-2017

TABLE OF CONTENTS


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1. GENERAL TERMINOLOGY AND TUNNEL CLASSIFICATION ................................................................. 6

1.1 GENERAL TERMINOLOGY AND TUNNEL CLASSIFICATION .............................................................................. 6 1.2 GENERAL CLASSIFICATION OF TUNNELS ..................................................................................................... 6

2. APPLICATION AND CHARACTERISTICS OF FATRAFOL-T SYSTEM.................................................... 9

2.1 SCOPE OF FATRAFOL-T SYSTEM APPLICATION ........................................................................................ 9 2.2 CHARACTERISTIC END-USE PROPERTIES OF FATRAFOL-T SYSTEM ........................................................... 9

3. FATRAFOL-T WATERPROOFING SYSTEM MATERIALS ...................................................................... 10

3.1 WATERPROOFING MEMBRANES ............................................................................................................... 10 3.1.1 Waterproofing membrane FATRAFOL 803/VST .......................................................................... 10

3.2 SUPPLEMENTARY WATERPROOFING AND AUXILIARY MATERIALS ................................................................ 12 3.2.1 Drainage mat PETEXDREN 900 .................................................................................................. 12 3.2.2 PVC outer waterstop bar .............................................................................................................. 12 3.2.3 Mechanical fasteners .................................................................................................................... 12

3.2.3.1 Fixing disk ................................................................................................................................................ 12 3.2.3.2 HP-PVC fixing point ................................................................................................................................. 13 3.2.3.3 HP fixing plate (type 44) .......................................................................................................................... 13

3.2.4 Injection system ............................................................................................................................ 13 3.2.4.1 Injection port with a push-on case-straight ............................................................................................... 13 3.2.4.2 15BPERT Injection pipe ........................................................................................................................... 13 3.2.4.3 Fittings for pipe connection and ending ................................................................................................... 14

3.2.5 Other supplementary and auxiliary components .......................................................................... 14

4. MAIN DESIGN PRINCIPLES...................................................................................................................... 16

4.1 UNDERLAY ............................................................................................................................................. 16 4.2 TYPICAL STRUCTURE OF WATERPROOFING SANDWICH .............................................................................. 16 4.3 REINFORCEMENT OF CORNERS AND EDGES, ETC. ..................................................................................... 17 4.4 FASTENING SEPARATION, WATERPROOFING, DRAINAGE AND PROTECTIVE LAYERS...................................... 17 4.5 DIVIDING INTO SECTORS ......................................................................................................................... 18 4.6 PHASE CONNECTION OF WATERPROOFING ............................................................................................... 18 4.7 INJECTION SYSTEM ................................................................................................................................. 18

5. PROCEDURES OF TECHNICAL PREPARATION OF WATERPROOFING WORKS ............................. 19

5.1 PREPARATION DETAILS ........................................................................................................................... 19 5.2 PREPARATION WORKS ............................................................................................................................ 19

6. TECHNOLOGICAL PROCEDURES .......................................................................................................... 20

6.1 SITE PREPARATION AND WORKING CONDITIONS ........................................................................................ 20 6.2 WORKING PROCEDURES ......................................................................................................................... 20

6.2.1 Modification of underlay structures ............................................................................................... 20 6.2.2 Installation and jointing the underlay separation textile ................................................................ 20 6.2.3 Fastening waterproofing membrane to the underlay .................................................................... 20 6.2.4 Setting and jointing waterproofing membranes, test weld ............................................................ 20 6.2.5 Reinforcement of corners and edges ........................................................................................... 21 6.2.6 Assembly of HP-PVC fixing point ................................................................................................. 21 6.2.7 Setting protective and drainage layers ......................................................................................... 21 6.2.8 Dividing into sectors...................................................................................................................... 21 6.2.9 Injection system ............................................................................................................................ 21

6.2.9.1 Injection port - straight ............................................................................................................................. 21 6.2.9.2 Laying injection pipes ............................................................................................................................... 21

7. REPAIR OF LEAKING SECTOR ............................................................................................................... 22

8. HEALTH AND SAFETY AT WORK, FIRE PROTECTION ........................................................................ 22

9. INSPECTION AND ACCEPTANCE OF WORKS IN FATRAFOL-T SYSTEM .......................................... 22

9.1 GENERAL PRINCIPLES ............................................................................................................................. 22 9.2 SITE WATERPROOFING TESTS ................................................................................................................. 22

10. QUALIFICATION AND EQUIPMENT THE WORK CREW OF INSULATION TECHNICIANS ............. 23


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11. LIST OF CITED STANDARDS ............................................................................................................... 24

12. PRINCIPLES FOR STRUCTURAL DESIGN OF CHARACTERISTIC DETAILS .................................. 26

12.1 DETAILS REVIEW ................................................................................................................................. 26 12.2 TYPE STRUCTURES ............................................................................................................................. 26

12.2.1 Membrane joints, reinforcement in sectors ............................... Chyba! Záložka není definována. 12.2.2 Injection system ............................................................................................................................ 26 12.2.3 Connection in phases ................................................................................................................... 26 12.2.4 3D diagram of FATRAFOL-T system installation ......................................................................... 26

12.3 SCHEMATIC DRAWINGS OF DETAILS ...................................................................................................... 26


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INTRODUCTION

Waterproofing system FATRAFOL-T is defined by using waterproofing membranes, supplementary and auxiliary materials, and by design principles and technological procedures. The Construction and technological instructions (hereinafter referred to as CTI) determines principles for designing and execution of waterproofing in tunnels and underground structures related to tunnels.

This Instructions manual is part of the FATRAFOL-T system and represents the summary of theoretical and practical experience and knowledge from previous verification, designing, execution and use of waterproofing systems made with waterproofing membranes manufactured by Fatra, a.s., Napajedla. All requirements stated herein are fully justified; all suggested design solutions and work procedures are prepared fully in compliance with respective current technical standards. CTI FATRAFOL-T is based, follows conceptually, and where purposeful refers to CTI FATRAFOL-H in effect, and at some points also to details and CTI of the system FATRAFOL-HP.

Any changes motivated by economic, performance or operations interests may be effected exclusively after previous verification and approval by author of this CTI. The author assumes no responsibility for the design and execution of the waterproofing structure which is in conflict with this CTI.

Information stated in this CTI is subject to special training of technicians and applicators, project designer, etc., provided by Fatra, a.s., Napajedla.

Please address your prospective inquires to:

Fatra, a.s. třída Tomáše Bati 1541 763 61 Napajedla

tel.: +420 577 503 323 +420 272 657 572 e-mail: [email protected] internet: http://www.fatrafol.cz

mailto:[email protected]


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1. GENERAL TERMINOLOGY AND TUNNEL CLASSIFICATION

1.1 General terminology and tunnel classification

Tunnelling – development of mined underground structures, which includes all works connected with the development of designed underground premises and provision of their stability during execution, in operation, and for the service life period of the work.

Disintegration, mining – by this activity creates free space or stope. Disintegration is carried out in the tunnel head by blasting operations or using heading machines. Disintegrated rock is called muck.

Lagging, shield – a structure providing stope stability.

Boring (excavation, driving)– operation connected with disintegration, loading, removal of the mock and provisory reinforcement

Tunnel head – tunnel cross-section. In the top section, it is called calotte. The area that connects both side (supporting) parts of the tunnel is called Bench or also supporting part of lining in the Bench. The lower section of the stope is called bottom or invert.

Primary lining – most frequently from sprayed concrete (shotcreed) or prefabricated panels, it supports walls of the stope immediately after excavation and creates an underlay for waterproofing measures

Secondary (definite) lining – most frequently from reinforced concrete or plain concrete. It is a multipurpose permanent functional part of the structure, which is statically effective for all real load combinations.

1.2 General classification of tunnels

Tunnels and underground structures related to tunnel development can be classified according to several criteria as follows.

According to their interior layout:

Linear structures, characterised by stope length prevailing over the height and width. According to the size of the cross stope area, these structures are divided into:

adits – cross section is less than 16 m2, longitudinal slope is max. 10°

tunnels - cross section is more than 16 m2, longitudinal slope is max. 10°

sloping adits and tunnels – longitudinal slopes are 10° to 60°

shafts – cross-section size is unlimited, work axis is vertical

structures – with two approximately identical horizontal dimensions prevailing significantly over the height, e.g. under-crossings, etc.

Large-span structures, so-called caverns, which have large ground-plan area and height and all their three dimensions are almost identical, e.g. underground hydroelectric power stations, power reservoirs, etc.

According to their use:

Underground structures for transportation – railway, road, canal, subway tunnels, pedestrian under-crossings

Water-management underground structures – water supply conduits, sewer collectors and channels, supply, by-pass, and drainage tunnels at dams and hydroelectric power stations, pressure-balance and other shafts

Municipal underground structures – cable ducts (light and heavy current), steam lines, hot-water lines, caliducts, collectors for common utility networks

Fig.1: General terminology


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Halls and underground structures – hydroelectric power stations, balancing chambers, valve chambers, transformer stations, power reservoirs, etc.

According to their execution:

Bored tunnel, the whole development of which is carried out underground without interventions to the overlay, excavation uses either the conventional method, e.g. NRTM (New Austrian tunnelling method), or tunnel boring machines (TBM), using the shields with cutting wheel.

Fig.2: Typical cross-sections of driven tunnels

Underground works executed from the surface, so-called cut and covered tunnels – developed from the surface in an open ditch or trench, and backfilled after completion

Fig.3: Typical cross-sections of the cut and covered tunnel

Overfilled structures, false tunnels developed from the surface and then backfilled, also indicated as buried bridges

Fig.4: Typical cross-sections of the buried tunnel

According to their length we can classify tunnels for communications over land as:

short with the length of 100 to 500 m

medium with the length of 500 to 1000 m

long with the length more than 1000 m


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According to the waterproofing system:

tunnels, protected against adverse water effects by tightness of the definite lining

tunnels with open (so-called umbrella type) waterproofing system, which is used most frequently in undemanding hydro-geological conditions. Underground water soaks through the primary lining to the waterproofing membrane, and is diverted to the longitudinal back drainage located at the level of lining base and tunnel bottom. The lower part of the cross-section is not insulated. Single-ply waterproofing membrane from PVC material is used most frequently.

tunnels with closed waterproofing system, which is used, if the underground water level is not to be influenced significantly by tunnel development permanently. Waterproofing layer is built all around the tunnel. According to exigency of hydro-geological conditions, a single-ply PVC waterproofing membrane or a PVC waterproofing membranes sandwich divided into sectors and enabling repair is used.

Fig.5: Left- closed waterproofing system, Right - open (umbrella type) waterproofing system


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2. APPLICATION AND CHARACTERISTICS OF FATRAFOL-T SYSTEM

2.1 Scope of FATRAFOL-T system application

Waterproofing system FATRAFOL-T is designed for both-side integrated membrane covers of tunnels and underground sections of structures related to tunnel development protecting against adverse effects of water and certain liquids. FATRAFOL-T is suitable for both open and closed waterproofing systems and it is applied in mined, cut and cover tunnels. Its high variability enables to form a basic single-layer open system without the possibility of repairs and without dividing into sectors, but also a more complex closed waterproofing system, divided into sectors and enabling targeted repairs.

The system is suitable for almost all types of the environment, with various types of corrosion stress and temperatures within 20 °C to +40 °C.

2.2 Characteristic end-use properties of FATRAFOL-T system

waterproofing layer is formed by single layer of PVC-P membrane FATRAFOL, min. thickness 1.50 mm

yellow signal waterproofing layer enables easy identification of mechanical damage

high variability of the system

all joints of the waterproofing membrane are formed by high-strength, water-tight, and gas-tight welds

recommended double-track hot air welds allow to perform the vacuum test of joint

ability to transfer stress from mechanical load of building structures without losing the functionality

resistance against negative effects of underground water and macerates from building materials

possibility to install waterproofing all year long, except for rainy and snowy days, the membrane can be laid even on wet underlay

high elongation and functional reliability


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3. FATRAFOL-T waterproofing system materials

Classification of materials of the FATRAFOL-T waterproofing system is identical as for the system FATRAFOL-H. According to the function in the waterproofing structure, materials are classified as follows:

Waterproofing membranes

Supplementary waterproofing materials

Auxiliary materials

Particular materials stated hereafter are manufactured for specific purposes directly by Fatra, a.s., or selected and verified from the production of other manufacturers. When applying the FATRAFOL-T system, it is necessary to consider specified waterproofing membranes and stated particular materials non-interchangeable, eventual substitution of materials is however possible after previous assessment and written approval by author of this CTI.

3.1 Waterproofing membranes

Waterproofing membranes are the basic material to develop a single ply waterproofing cover. In the FATRAFOL-T system, in particular the PVC-P membrane FATRAFOL 803/VST is used to form a waterproofing layer.

3.1.1 Waterproofing membrane FATRAFOL 803/VST

PRODUCT DESCRIPTION

FATRAFOL 803/VST is an non-reinforced membrane based on plasticized polyvinylchloride (PVCP), produced by multiple extrusion. FATRAFOL 803/VST meets requirements for polymer geo-synthetic insulations under ČSN EN 13491.

FATRAFOL-T SYSTEM USE

For closed insulations of tunnels and underground sections of structures related to tunnel development

Against aggressive, pressure and soaking water

To form a protective layer at the work joint of the secondary (definite) lining and/or to create a protective layer between sectors

APPLICATION

Membranes can only be applied in sites by companies trained for that purpose.

The membrane is applied in compliance with principles set and described herein and in other CTI s in effect.

Membranes can be jointed together by hot-air or hot-wedge welding. Applying and jointing can be carried out at temperatures above 5 °C.


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PRODUCT DATA

Table 1: Dimensions and basic data for packaging of FATRAFOL 803/VST membranes

Width Surface

density *) Winding on roll

Roll weight *)

[mm] [mm] [kg/m2] [m] [m

2] [kg]

1.50 2000 1.97 20 40 79

2.00 2000 2.62 20 40 104.80

2.10 2000 2.75 20 40 110

*) informative values only

Appearance and colour design

Smooth membrane with mat surface

FATRAFOL 803/VST top side – yellow (signal layer) underside – black 100 mm from the edge, print with identification data

Note: Information on other thicknesses of FATRAFOL 803/VST membrane on request.

Table 2: Technical parameters of FATRAFOL 803/VST membranes – guaranteed values

Property Test standard

Guaranteed value for individual product thicknesses

1.50 mm 2.00 mm 2.10 mm

Water-tightness EN 1928/B 5 bar / 72 hr, 10 bar /10 hr

Resistance to static load EN 12730/B ≥ 2kN

Tensile strength ČSN EN ISO 12311-2 method B

17 N/mm2 +- 2 N/mm

2

Elongation ≥ 270 %

Chemical resistance ČSN EN 14414 ≤ 10%

Roots penetration ČSN CEN/TS 14416 no perforation

Response to fire EN 13501-1 class E

Joint strength EN 12317-2 ≥ 840 N/50 mm ≥ 1120 N/50 mm ≥ 1120 N/50 mm

Straightness EN 1848-2 satisfactory

RELATED TECHNICAL DOCUMENTATION

Data sheet TL 5-1033-16 of waterproofing membrane FATRAFOL 803/VST, issued by Fatra, a. s., Napajedla

Data sheet TL 5-1035-16 of waterproofing membrane FATRAFOL 803/VST, issued by Fatra, a. s., Napajedla

Documentation validity: To apply the membrane in particular project, it is necessary to use current product documentation in effect (Data sheet, Declaration of properties, Attest, Certificate, etc.), which is available on the Internet address www.fatrafol.cz.

http://www.fatrafol.cz/


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3.2 Supplementary waterproofing and auxiliary materials

Some supplementary waterproofing and auxiliary materials, common for systems FATRAFOL-H and FATRAFOL-T, are specified in details in CTI FATRAFOL-H instructins in effect.

In addition to regular materials stated in CTI FATRAFOL-H, following supplementary and auxiliary components may form the FATRAFOL-T system:

Drainage mat PETEXDREN 900

PVC outer waterstop bar

Specific fastening elements

Injection system

3.2.1 Drainage mat PETEXDREN 900

A mat with 3D structure from polyethylene fibres, extruded by set of jets.

Colour: black Dimensions / Weight: width: 1500 mm thickness, compressed by 0,2 MPa: 3 mm surface density: 900 g.m

-2

Packaging: mat is winded on rolls, diameter ca 500 mm, 35 m per roll

Application: to create drainage layer between PVC-P FATRAFOL membrane and secondary or primary lining

SAP order no.: 32100508

3.2.2 PVC outer waterstop bar

PVC waterstop bar with 4 ribs or 6 ribs.

Colour: transparent Dimensions / Weight: width and number of ribs: 250 mm, 4 ribs 320 mm, 4 ribs 600 mm, 6 ribs

Packaging: strip winded on roll, 25 m per roll

Application: to form horizontal and vertical sector SAP order no.: 32102643 – width 250 mm, 4 ribs SAP order no.: 32102644 – width 320 mm, 4 ribs SAP order no.: 32102645 – width 600 mm, 6 ribs

3.2.3 Mechanical fasteners

3.2.3.1 Fixing disk

Round fixing disk from plasticized PVC, enabling hot-air welding of PVC-P membrane FATRAFOL. Colour: black Dimensions / Weight: diameter: 80 mm total thickness: 10 mm

Application: to fix FATRAFOL waterproofing membrane in required position



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3.2.3.2 HP-PVC fixing point

Special fixing point, made from round timber from PVC-P membrane FATRAFOL 803/VS or 803/V, and pair of steel induction plates Isoweld riveted to each other. Colour: PVC-P point of yellow-black (yellow top, black bottom) or brown colour. Dimensions / Weight: diameter: 200 mm total thickness: 12 mm

Packaging: 120 pcs of points/cardboard box

Application: for mechanical fixation of protective layer of the waterproofing membrane


3.2.3.3 HP fixing plate (type 44)

Plate made from HDPE membrane EKOTEN 915, thickness 1 mm.

Colour: black Dimensions / Weight: diameter: 140 mm thickness: 1 mm

Packaging: 50 pcs / bag, 12 bags / cardboard box

Application: to fix the drainage layer PETEXDREN 900 or protective layer from FATRAFOL 803/V (803). The plate shape allows its insertion into the fixing point HP-PVC.


3.2.4 Injection system

Injection system consists of:

direct (side) injection port

injection pipes

fittings to connect and close pipes

3.2.4.1 Injection port with a push-on case-straight

Direct injection port id designed for connection of the injection tube with the sector.

Colour: cream Dimensions / Weight: diameter: 178 mm height: 38 mm

Packaging: 50 pcs / cardboard box

Application: to connect the sector with injection tube


3.2.4.2 15BPERT Injection pipe

Injection pipe connects direct injection port with interior of the tunnel or underground structure.

Colour: white Dimensions / Weight: diameter: 15 mm

Packaging: in rolls 200 or 600 m

Application: to connect the injection port with interior of the tunnel

SAP order no.: 32101181 – pipe length 200 m SAP order no.: 32101174 – pipe length 600 m


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3.2.4.3 Fittings for pipe connection and ending

Fittings are installed on injection pipes based on the need to change the pipe direction, end the pipe, or reduce its diameter.

Colour: white

Packaging: PE bag / cardboard box

Application: for connection, reduction or ending the injection pipe

PEM221515W stem elbow: 10 pcs/bag, 80 pcs/box

SAP order no.:32101170

PEM0315W equal elbow: 10 pcs/bag, 50 pcs/box


PEM 0415W direct connector: 10 pcs/bag, 60 pcs/box


15ESOT Shut-off valve: 5 pcs/bag, 40 pcs/box


PSM4615W pipe ending: 10 pcs/bag, 200 pcs/box


3.2.5 Other supplementary and auxiliary components

In the FATRAFOL-T system, other supplementary and auxiliary components are applied, specified in details in respective CTI s of FATRAFOL-H and FATRAFOL-S. These are in particular the following components:

Separation textile, weight 500 g/m2, 100% PP

SAP order no.: 32100357 or 32100444

Separation textile, weight 500 g/m2, combination PP+PES


PU sealant FATRAPUR 25 FC grey, cartouche 310 ml


Internal corner, type 10, made of FATRAFOL 803 membrane


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External corner, type 11, made of FATRAFOL 803 membrane


Wall strip 70 mm from plastic-coated sheet metal FATRANYL PVC



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4. Main design principles

Design principles of the waterproofing system FATRAFOL-T are in main aspects not different from the design of single-layer waterproofing of structures described in details in the CTI -FATRAFOL-H in effect.

4.1 Underlay

Immediate underlay of waterproofing cover is formed by primary lining in case of mined tunnels, or reinforced concrete structure in case of cut and covered tunnels.

The underlay must be load-bearing, strong and straight, without cavities, sharp fractures, lugs, stubs, and sharp-edge objects that might damage the waterproofing. It is not recommended to round off underlay structures in external and internal corners.

Waterproofing system can be applied even on immature concrete, however the load capacity of mechanical fasteners in concrete must be ensured. The underlay need not to be absolutely dry, but must be free of water pools, snow, ice and frost deposits.

4.2 Typical structure of waterproofing sandwich

Tunnel protection against underground and surface water is suggested taking into account hydrological and hydro-geological conditions, aggressiveness of underground water, development method chosen, and the type of tunnel structure. In the area of cut and covered tunnels, the structure and principles described in CTI FATRAFOL-H and FATRAFOL-HP can be used.

FATRAFOL-T system may in principle be designed as:

single-ply waterproofing cover without protective layer

single-ply waterproofing cover, fully protected by separation textile or layer from PETEXDREN 900

single-ply system, fully protected by PVC-P membrane

single-ply system, fully protected by PVC-P membrane, divided into sectors using waterstop bars, and provided with injection system

Basic and the simplest structure – TYPE STRUCTURE A – single-ply waterproofing cover without protective layer is in the FATRAFOL-T system (Detail 201T) as follows:

rock massive / natural soil

primary lining (shotcrete, prefab lining)

unwoven separation textile from 100% synthetic material of min. 500 g.m-2

. In case of rougher or uneven underlay, we suggest to use the textile of 800 g.m

-2. Separation textile may be substituted

with a drainage mat PETEXDREN 900.

waterproofing layer from PVC-P membrane FATRAFOL 803/VST, min. thickness 1.50 mm. The membrane must be applied with the signal layer towards the structure, and fastened by fixing disks .

secondary lining

Single-ply waterproofing cover structure – TYPE STRUCTURE B – with protective layer from separation textile or PETEXDREN 900 layer is in the FATRAFOL-T system (Detail 202T) as follows:








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waterproofing layer from PVC-P membrane FATRAFOL 803/VST, min. thickness 1.50 mm. The membrane must be applied with the signal layer towards the structure, and fastened by fixing disks.

unwoven separation textile from 100% inorganic material of min. 500 g.m-2

or PETEXDREN 900 layer, fastened by HP-PVC fixing points and HP fixing point

secondary lining The structure of the single-ply waterproofing cover – TYPE STRUCTURE C - with protective layer from PVC-P membrane (Detail 203T) is as follows. This structure also enables installation of the injection pipes and eventual repair of leakage.







waterproofing layer from PVC-P membrane FATRAFOL 803/VST, min. thickness 1.50 mm. The membrane must be applied with the signal layer towards the structure, and fastened by fixing disks .

PVC-P membrane FATRAFOL 803/VST, min. thickness 1.50 mm, forming protective layer

secondary lining

4.3 Reinforcement of corners and edges, etc.

In the tunnel waterproofing system FATRAFOL-T, the waterproofing layer is usually reinforced for cut and cover tunnels only, which in its development method do not differ significantly from underground sections of conventional ground structures. Edges in all horizontal and vertical corners are reinforced with a linear strip of FATRAFOL 803/VST membrane. Applying the reinforcing strip black side up is beneficial due to clear identification of the reinforcement placement. The strip is welded by hot air on the edges and corners with the weld width of min. 30 mm.

At the intersection of three planes (if any in the structure), the waterproofing membrane is reinforced and additionally sealed by full-size welding on Internal corner, type 10, or External corner, type 11. If the detail cannot be provided with system fittings, a patch from PVC-P membrane FATRAFOL 803/VST of required shape and size is used, with identical thickness as the main waterproofing layer.

For mined tunnels, reinforcement is usually made at points of working joints, incurred in concreting of secondary lining, or in concreting the bottom/roadway. Reinforcement is made by welding on a strip of FATRAFOL 803/VST membrane of ca 300-500 mm width to the surface of FATRAFOL 803/VST membrane (Detail 302T). Welding on the reinforcing strip black side up is beneficial due to clear identification of the reinforcement placement.

For closed waterproofing systems divided into sectors, a waterstop bars used at the points of working joints of secondary lining instead of the reinforcing strip of PVC-P membrane.

4.4 Fastening separation, waterproofing, drainage and protective layers

In cut and covered tunnels, it is possible to use line components from plastic-coated sheet FATRANYL PVC for fastening. If FATRANYL PVC profiles are used to fasten the waterproofing membrane in cut and covered tunnels and if double-track welds are required, the membrane must not be welded to profile on edges. Leave free edge of membrane of the width of ca 150-200 mm. Welding on the membrane to the FATRANYL PVC profile in full width of the membrane makes double-track welds impossible.

In mined tunnels, the waterproofing membrane is fastened by using fixing disks . Disks are shot on to primary lining at regular vertical and horizontal distances over the separation textile, which is this way fixed in its position. Horizontal distance (pitch) is chosen so that it allows trouble-free welding of sheets of FATRAFOL 803/VST membrane of 2000 mm width, i.e. ca 630-640 mm (Detail 201T-203T)


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For mechanical fastening of the protective separation textile, HP-PVC fixing points and HP fixing plate are used. If the protective layer is formed by PVC-P membrane only, HP-PVC fixing points and HP plates are not used. In such case, the protective PVC-P membrane is welded on by hot air to the surface of the waterproofing membrane FATRAFOL 803/VST and/or to waterstop bars.

4.5 Dividing into sectors

Dividing the whole waterproofing cover into smaller mutually separated and independent sectors is possible in the FATRAFOL-T system by using waterstop bars. Sectors are made mainly in closed waterproofing systems. Optimum size of a sector is ca 250 m

2.

In mined tunnels, waterstop bars are usually installed all around the tunnel at regular distances corresponding with the point of the secondary lining working joint (Detail 303T). Also horizontal dividing into smaller separated sectors is possible. Sizes of sectors are in practice independent of the membrane width.

4.6 Phase connection of waterproofing

In mined tunnels, it is possible in waterproofing assembly to distinguish work stages along both, the tunnel cross-section and axis.

Along the tunnel cross-section in closed systems, insulation of the bottom with overlap to the bench section (Detail 501T) is made first. In open systems, insulation of parts of the bench from the drainage system above the level of e.g. road is usually made first, and the remaining waterproofing is connected in the bench and calotte in the second phase (Detail 502T).

In the tunnel axis, staging is made as required by the construction or its development process. In both cases, waterproofing is usually terminated with free edge. In the bench, it is most frequently welded on plastic disks, protected efficiently at the tunnel bottom for example by separation textile, so that it is possible to join it reliably in the next stage.

In cut and covered tunnels, built in the area of a shored trench of so-called “Hamburg type”, staging is possible using e.g. a reverse joint described in details by in the CTI FATRAFOL-HP in effect.

4.7 Injection system

Injection system is installed usually for closed sector waterproofing systems, and it makes a connection between the sector and tunnel interior. The system has two basic functions.

It indicates failure of sector tightness by water running from the pipe

After completion of the work, it enables targeted injection– repair – of the leaking sector only, which reduces dramatically the cost of repairs of the whole waterproofing system

Injection system consists of the straight injection ports and Injection pipes with fittings for connections, direction changes, reduction and termination.

At least six straight injection ports should always be fitted on a regular sector in the FATRAFOL-T system. Injection ports are installed at the distance of ca 500 mm from the sector edge; in case of narrow sectors, in the middle of their width. Unlike the system FATRAFOL-HP, injection ports are welded by hot air on the main waterproofing membrane FATRAFOL 803/VST. Welding must be made in the collar section only, so that the port enables discharge of the injected substance. Protective PVC-P membrane is welded from the top to the port collar (Detail 401T).

Injection pipe is connected by push-on direct or angular fittings. Injection pipes are led into a single, in practice however into several collection points, where pipes are terminated in collection boxes; see the detail (Detail 706HP). In these boxes, pipes are closed by shut-off valves and provided with an indication label, colour indication, or other permanent indication.


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5. PROCEDURES OF TECHNICAL PREPARATION OF WATERPROOFING WORKS

5.1 Preparation details

For preparation of the project documentation of waterproofing measures on tunnels, it is necessary to proceed particularly from the following details:

Hydro-geological research results

Type and intensity of hydro-physical stress

Tunnel development method

Requirements for influencing the underground water level in tunnel vicinity (surroundings)

Drainage options

Specifications of corrosive environment

Requirements for waterproofing reliability

The basic detail for realization of the waterproofing system is the project documentation. In cases where the project documentation is not prepared, the company providing the realisation bears the responsibility for the design.

5.2 Preparation works

Prior to initiation of waterproofing works, material consumption must be determined for:

Waterproofing area

Creating sectors

Reinforcement of corners and edges

Fastening

Injection system

Termination of waterproofing on vertical structures

Processing details

Underlay, protective and separation layers

In addition, it is necessary to define the method of laying subsequent layers, requirements for insulation stages, technological breaks, method to protect waterproofing system, etc.

The outcome of preparation works are the following written documents:

Technological process of works

Unique specification of materials

Sample sandwich of waterproofing layers

Solutions of construction details

Proposal on how to divide waterproofing layer into sectors, and their indication, positions of injection ports, or collection points, if applied

Price budget (cost calculation)


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6. TECHNOLOGICAL PROCEDURES

6.1 Site preparation and working conditions

Requirements for site preparation and working conditions of the ambient environment are specified in detail in the CTI FATRAFOL-H in effect.

6.2 Working procedures

6.2.1 Modification of underlay structures

For general requirements for final quality of the underlay and its eventual modification see par. 4.1.

6.2.2 Installation and jointing the underlay separation textile

Setting and jointing the underlay separation textile is described in details in par. 5.2.2. of the CTI FATRAFOL-H in effect.

6.2.3 Fastening waterproofing membrane to the underlay

Vertical waterproofing membrane is fasten by fixing disks. After removed from the package, disks are pressed along with the separation textile at application points to primary lining at regular horizontal and vertical distances and fixed by nail gun to the underlay.

6.2.4 Setting and jointing waterproofing membranes, test weld

Setting and jointing principles of waterproofing membranes are described in details respective CTI FATRAFOL-H in effect, par. 5.2.3. and 5.2.3.2. In addition to FATRAFOL-H principles, following specifics apply to the FATRAFOL-T system.

All joints of waterproofing membranes can be made either by hot air or hot wedge. Other welding method, e.g. cold welding using L-494 thinner is not permitted in the FATRAFOL-T system. Waterproofing membrane joints with shaped pieces are made by hot air only.

Following types of joints and welding methods are suggested for the waterproofing system FATRAFOL-T:

Double-track weld by hot wedge using an automatic welding machine, see par. 5.2.3.2.2 fig. 9, CTI FATRAFOL-H

Double-track weld by hot air using an automatic welding machine, see par. 5.2.3.2.1 fig. 7, CTI FATRAFOL-H

Where the welding machine and double-track welds cannot be used, single-track welding by hot air is carried out. Details are made exclusively using a handheld hot-air welding gun. Following types of welds are allowed in the FATRAFOL-T system:

Single-track hot-air weld using an automatic welding machine, see par. 5.2.3.2.1 fig. 6, CTI FATRAFOL-H

Single-track hot-air weld using a handheld hot air gun, see par. 5.2.3.2.1 fig. 5, CTI FATRAFOL-H

Prior to welding, a test weld is made in the length of ca one meter to set up correct welding parameters depending on climatic conditions. The parameters set will vary according to the membrane thickness, air temperature, humidity, wind speed and direction, membrane exposure to sunlight, etc. Two welded strips of membranes must be left to cool down, and subsequently ca 20-40 mm wide strips are cut out perpendicular to the weld, and a peel test is performed at jobsite. Testing is made with various settings, until the correct setting is reached and the membrane is ruptured outside the weld. Selected welding parameters are written on the tested samples and in the Building Log. The samples should be saved and stored. Temperature resistance and range of welding temperatures are dealt with in details in CTI FATRAFOL-S, pa. 2.1.2.


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6.2.5 Reinforcement of corners and edges

Along a corners and edges (if any for given tunnel type), the waterproofing layer is reinforced by adding strip of FATRAFOL 803/VST membrane, min. width 300 mm. The membrane is first heated up by hot air, evened up along edges and corners, and then welded at the periphery by hot air – weld width min. 30 mm. Application of the membrane with black side up enables easy identification of the reinforcement made.

Pre-shaped internal and external corners (Type 10, 11), or patches made at site from FATRAFOL 803/VST membrane are briefly heated up by hot air, pressed by their centres to the contact point of three insulated planes, and welded by hot air to the membrane while simultaneously pressed by roller. This way the fitting is spatially shaped according to the underlay.

6.2.6 Assembly of HP-PVC fixing point

For mechanical fixing of protective layers like a separation textile or drainage membrane PETEXDREN 900, the fixing point HP-PVC can be used. The fixing points are removed from the package and welded by hot air on the installed, tested and accepted waterproofing membrane at regular horizontal and vertical distances (Detail 202T).

6.2.7 Setting protective and drainage layers

If PETEXDREN 900 membrane sheets are used for protective or drainage layers, they are unrolled after removed from the package, laid as required and straightened beside each other. Sheets are applied with the min. 50 mm overlap over each other. At the points of previously welded on HP-PVC fixing points, an opening is cut corresponding with the size of the PH-PVC fixing point using a hook knife. The layer of PETEXDREN 900 is fixed by inserting the HP fixing plate to HP-PVC fixing points; see e.g. (Detail 202T). Overlaps of PETEXDREN 900 are welded by hot air.

The same procedure is applied also for separation textiles; however their overlaps are min. 100 mm and welded by hot air.

6.2.8 Dividing into sectors

PVC waterstop bars can be installed after successful testing and handover of the finished waterproofing membrane or its part. The waterstop bar is unrolled alongside the future sector border, straightened and let “rest” for about 30 minutes. It is then welded on both sides by hot air to the waterproofing membrane. The strip end must not be welded to enable connection of another strip or pre-shaped fitting (crossing and ect..). Both connecting ends of strips need to be cut exactly and perpendicular to the strip axis and welded by hot wedge. After that, the connected strips or pre-shaped fittings can be welded to the waterproofing membrane.


6.2.9.1 Injection port - straight

Injection port is installed after completing the prescribed tightness testing and official handover and acceptance of finished waterproofing layer. Injection port is after removal from the package placed freely to the required point and welded on to the waterproofing membrane FATRAFOL 803/VST. Protective PVC-P membrane FATRAFOL 803/VST is welded to the collar of port (Detail 401T).

6.2.9.2 Laying injection pipes

Injection pipe is installed after applying the protective PVC-P membrane. Injection pipe is unrolled at the point of application and cut to the required length using PVC pipe cutters.

When diverting injection pipes to one or more collection points, stem elbow is fitted first to the push-on opening in the injection port, and then the pipe of required length is inserted into this elbow (Detail 401T). If the pipe needs to be extended, a direct connector is used. If the direction needs to be changed from horizontal to vertical positon, an equal elbow is used. Pipe is led to the collection point in the shortest way possible.

The pipe ends inside the collection point, which is usually a steel or plastic box concreted in the secondary lining. The pipe is in the box fitted with a shut-off valve. Each pipe is indicated with an identification label, with colour analogous to each sector, or using other suitable permanent method.


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7. REPAIR OF LEAKING SECTOR

The installed and fully functional injection system enables targeted transport of injection substance to the area between the face of the support structure and the membrane surface without the need of difficult drilling of the support structure.

In case of moisture symptoms in the tunnel, caused by leakage in waterproofing system FATRAFOL-T at the stage when the waterproofing layer has been already covered and there is thus no other way to fix is, a chemical injection is applied. The injection works may be executed by specialized company only, with demonstrable experience in such type of works. Before starting, it is always necessary to carry out an expert inspection on site and assess the scope of defects. Before starting remedial works, the implementing company must present the specific technological work flow. The suggested injection material must be compatible with the waterproofing membrane. Previous consulting and a written manufacturer’s approval for the use of specific injection material are suggested.

8. HEALTH AND SAFETY AT WORK, FIRE PROTECTION

Health and safety at work and fire protection issues are described with in details in par. 6 of respective CTI FATRAFOL-H in effect.

9. INSPECTION AND ACCEPTANCE OF WORKS IN FATRAFOL-T SYSTEM

9.1 General principles

General principles for inspections of the waterproofing system FATRAFOL-T are described in details in par. 7.1 of the CTI FATRAFOL-H in effect.

9.2 Site waterproofing tests

Regulations for site quality tests of the waterproofing assembly and principles for joints testing of the waterproofing system FATRAFOL-T are defined in details by par. 7.2 of CTI -FATRAFOL-H in effect. For the system FATRAFOL-T just as for the system FATRAFOL-HP, it is characteristic to make double-track welds creating a chamber enabling a control of weld by overpressure. The overpressure test principle is described in CTI FATRAFOL-H, par. 7.2.2.3.


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10. QUALIFICATION AND EQUIPMENT THE WORK CREW OF INSULATION TECHNICIANS

Qualification and equipment of the crew of insulation technicians is identical as in case of FATRAFOL-H system and specified in details in CTI FATRAFOL-H, par. 8.

In addition to the regular instrument equipment, it is necessary to have available the following in the FATRAFOL-T system:

Welding machine with hot wedge enabling double-track welds – suggested types Herz Mion, Leister Twinny etc.


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11. LIST OF CITED STANDARDS

Standard code Title (Czech) Title (English)

ČSN 73 0250 Geometrická přesnost ve výstavbě. Navrhování geometrické přesnosti.

Geometric accuracy in building. Design geometrical accuracy.

ČSN P 73 0600 Hydroizolace staveb – Základní ustanovení Waterproofing of buildings – Basic provisions

ČSN P 73 0606 Hydroizolace staveb – Povlakové hydroizolace – Základní ustanovení

Waterproofing of buildings – Continuous sheet water proofing – Basic provisions

ČSN 73 7501 Navrhování konstrukcí ražených podzemních objektů

Design of structures for driven tunnels. Common provisions

ČSN 73 7507 Projektování tunelů pozemních komunikací Design of road tunnels

ČSN EN 1990 Eurokód: Zásady navrhování konstrukcí Eurocode: Basis of structural design

ČSN EN 13491 Geosyntetické izolace – Vlastnosti požadované pro použití jako hydroizolace při stavbě tunelů a podzemních staveb

Geosynthetic barriers - Characteristics required for use as a fluid barrier in the construction of tunnels and associated underground structures

EN 13967

Waterproofing pásy a fólie – Plastové a pryžové pásy a fólie do izolace proti vlhkosti a plastové a pryžové pásy a fólie do izolace proti tlakové vodě – Definice a charakteristiky

Flexible sheets for waterproofing - Plastic and rubber damp proof sheets including plastic and rubber basement tanking sheet - Definitions and characteristics

EN ISO 1043-1 Plasty – Značky a zkratky – Část 1: Základní polymery a jejich zvláštní charakteristiky

Plastics – Symbols and abbreviated terms – Part 1: Basic polymers and their special characteristics

EN ISO 9001 Systémy managementu kvality – Požadavky Quality management systems – Requirements

EN ISO 9712 Nedestruktivní zkoušení – Kvalifikace a certifikace pracovníků NDT.

Non-destructive testing – Qualification and certification of NDT personnel

EN ISO 14001 Systémy environmentálního managementu - Požadavky s návodem pro použití

Environmental management systems - Requirements with guidance for use


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Comments:


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12. PRINCIPLES FOR STRUCTURAL DESIGN OF CHARACTERISTIC DETAILS

12.1 Details review

Detail 101T Typical tunnel section by technology of construction Detail 102T Bored tunnels terminology Detail 103T Closed an open waterproofing system

12.2 Type structures

Detail 201T Waterproofing layer without protection layer - TYPE COMPOSITION A Detail 202T Waterproofing layer with protection layer from separation textile or PETEXDREN 900 - TYPE COMPOSITION B Detail 203T Waterproofing layer with protection layer from PVC-P membrane - TYPE COMPOSITION C

12.2.1 Membrane joints, reinforcement in sectors

Detail 301T Double-track weld Detail 302T Waterproofing layer-reinforcement installed on secondary lining construction joint Detail 303T Waterstop bar installed on secondary lining construction joint


Detail 401T Injection pipe and injection port joint in type composition C

12.2.3 Connection in phases

Detail 501T Membrane joint - Phase 1 Detail 502T Membrane joint - Phase 2 Detail 503T Open waterproofing system ending by welding membrane on water stop bar next to drainage

pipe Detail 504T Waterproofing system ending with water stop bar by entry of tunnel

12.2.4 Diagram of FATRAFOL-T system installation

This applies to the basic open waterproofing system, i.e. type structure A. Detail 601T Open waterproofing system - 1. stage - excavation Detail 602T Open waterproofing system - 2. stage - primary lining (shotcrete) Detail 603T Open waterproofing system - 3. stage - separation textile installation Detail 604T Open waterproofing system - 4. stage - separation textile fastening by fixing disk Detail 605T Open waterproofing system - 5. stage - installation of waterproofing membrane in lower

section of the Bench Detail 606T Open waterproofing system - 6. stage - installation of PVC membrane reinforcement in place

of future construction joint of secondary lining Detail 607T Open waterproofing system - 7. stage - Bottom and part of Secondary lining concreting Detail 608T Open waterproofing system - 8. stage - waterproofing membrane installation in the rest of

Bench and Top heading Detail 609T Open waterproofing system - 9. stage - installation of reinforcing PVC-P membrane on the rest

of Bench and Top heading perimeter Detail 610T Open waterproofing system - 10. stage - concreting Secondary lining in stages Detail 611T Open waterproofing system - 11. stage - concreting Secondary lining in stages, next segment Detail 612T Open waterproofing system - 12. stage - after tunnel inspection

12.3 Schematic drawings details

Schematic drawings of details

Following figures show the scheme of standard type details.


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waterproofing system - fatrafol

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