1

Research project:

Waterproof permanent tunnel lining based on

sprayed concrete and bonded membrane
PhD candidate Karl Gunnar Holter
Department for Geology and Mineral resources Engineering, NTNU

11. October 2012

2 Waterproof tunnel lining with sprayed concrete and bonded membrane

Todays presentation
Main scope of work and target
Main objectives
Main plan, research methodology
Expected results

Current status hydrogeological investigations

Ulvin access tunnel
T-connection subsea tunnel
Plan for further in-situ investigations

In-situ freezing testing at the Ulvin access and Gevings rail tunnels
Layout of freezing exposure
Sampling and testing matrix

Laboratory freezing testing at SINTEF

Layout of freezing model
Planned testing

Time schedule
3 Waterproof tunnel lining with sprayed concrete and bonded membrane

CONTRIBUTING ORGANISATIONS
MAIN SPONSORS: SPONSORING ORGANISATIONS
FROM THE SUPPLIER INDUSTRY
Norwegian National Rail
Administration (Jernbaneverket) BASF Construction Chemicals
Europe AG
Norwegian Public Roads
Administration (Statens Minova International GmbH
Vegvesen)

EDUCATION AND RESEARCH

Co-sponsor: ORGANISATIONS:
Norwegian Tunnelling
Association (Norsk Forening for NTNU, Department of Geology and
Fjellsprengningsteknikk Mineral Engineering

SINTEF Byggforsk Rock Engineering

4 Waterproof tunnel lining with sprayed concrete and bonded membrane

MAIN GOAL
Through site and laboratory investigations determine if the sprayed
concrete bonded membrane method is suitable for permanent
waterproof tunnel linings in Norwegian rail and road tunnels

JOINTED ROCK MASS MODERN FUNCTIONAL

HARD ROCK REQUIREMENTS FOR RAIL
GROUNDWATER AND ROAD TUNNELS:
COLD CLIMATE
LONGTERM DURABLE
CONTINUOUS STRUCTURE WATERPROOF
ROCKLINING AIR = STRUCTURAL PERFORMANCE
SIGNIFICANT HEAT FLUX

Supervisor: Professor Bjrn Nilsen

Co-supervisor: Adjunct professor Eivind Grv
5 Waterproof tunnel lining with sprayed concrete and bonded membrane

MAIN GOAL
Through site and laboratory investigations determine if the sprayed
concrete bonded membrane method is suitable for permanent
waterproof tunnel linings in Norwegian rail and road tunnels

Hydrogeological Thermodynamics, Testing of tunnel

TASKS
MAIN

analyses determination of lining structure

freezing loads deterioration
In - situ
RESEARCH
METHODS

Laboratory

Physics Material technology sprayed concrete and

FIELD OF
SCIENCE

membrane

Engineering geology
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EXPECTED RESULTS

Main expected result:

Provide sufficient decision basis for NNRA (Jernbaneverket) and NPRA (Statens
Vegvesen) to recommend the sprayed concrete and bonded membrane method for
permanent tunnel lining within certain areas of use

Expected detailed results:

- Verify groundwater pressure and groundwater flow situation in the rockmass around a
tunnel lined with this method
- Determine which damage mechanisms occur in the tunnel lining when exposed to
severe freezing loads
- Establish the characteristics of freezing events which lead to damage of the tunnel lining
- Suggest testing methods and acceptance criteria the materials for this tunnel lining
system (membrane and sprayed concrete parametres)
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TWO MAIN ISSUES TO BE INVESTIGATED IN THIS RESEARCH

PROJECT

1. Hydrogeological situation: Waterpressure and waterflow situation

around a partially drained tunnel structure

- Is there a build-up of water pressure which would imply a different design of the
tunnel lining?
- Montoring of waterpressure
- Detailed investigation of hydraulic conductivity of rock mass

2. Freezing durability of a sprayed concrete tunnel lining waterproofed

with bonded membrane

- Which range of in-situ conditions of the tunnel lining is relevant ?

- Which freezing loads are relevant ?
- Can any deteriorating processes to the tunnel lining be determined ?
- Full scale in-situ freezing tests, Ulvin access tunnel and Gevings rail tunnel
- Full scale laboratory freezing tests, SINTEF Coastal and Harbor Technology
11 Waterproof tunnel lining with sprayed concrete and bonded membrane

HYPOTHESIS FOR GLOBALLY DRAINED TUNNEL WITH BONDED MEMBRANE

Water drains through joints in the rock mass through invert area
Water pressure negligible

Rock mechanical design basis for tunnel lining:

Point loads caused by jointed rock. Blocks between rock bolts are
only source of instability. Water pressure negligible

Gevings tunnel (N)

Hard rock: jointed greenschist
Light rock reinfocement structure Globally stable rockmass.

Sprayed concrete thicknesses 8 - 20 cm Structural support = rock reinforcement

Globally drained tunnel structure

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HYDROGEOLOGICAL ANALYSES RESEARCH METHODOLOGY
Main goal: Determine if an undrained bonded waterproofing membrane applied in the
walls and crown of a tunnel leads to global water pressure increase

CONSTITUTIVE MODEL EXPERIMENTAL INVESTIGATIONS

Jointed rock mass Goals:
- Determine hydraulic conductivities
Hard rock - Determine water pressure on rock joints in
- UCS t surrounding rock mass around tunnels
- If possible determine water flow in rock mass
Intact rock material impermeable around tunnels

Groundwater flow on joints only In-situ investigations

- Water pressure testing in short sections to
determine hydraulic conductivities
- Long term water pressure testing
- Water flow measurements in short hole sections

Two in-situ test sections:

- Haugesund: T-connection subsea tunnel,
ventilation cavern
- Minnesund: E6-Dovrebanen, Ulvin access
tunnel
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HYDROGEOLOGICAL INVESTIGATION, MAIN ISSUE:

Drained tunnel lining with sprayed concrete and rock bolts Locally undrained tunnel lining with bonded membrane

Is a global drainage of the tunnel taking place when

waterproofing with bonded membrane in walls and crown?
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TEST SITES

Laboratory large scale

freezing testing, SINTEF
- Freezing exposure
- Sprayed concrete and
membrane durability
under freezing

In-situ full scale freezing exposure and sampling of tunnel lining

- Gevings rail tunnel
- Ulvin South access tunnel S, E6-Dovrebanen joint project

In-situ hydrogeological testing, monitoring of groundwater pressure

- Ulvin South access tunnel
- T-connection ventilation cavern, subsea highway tunnel
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TEST SITE T-CONNECTION

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TEST SITE T-CONNECTION

TEST SECTION
VENTILATION
CAVERN
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Test site T-connection. Hydrogeological investigation, monitoring in place
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Haugesund, T-connection
In-situ water pressure monitoring
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Sectioning of holes with
multiple packers for pressure
monitoring at different depths
from the tunnel surface

Each hole has 4 packers. Detailed placement

based on transmissivity measurements
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T-CONNECTION, VENTILATION CAVERN
HYDROGEOLOGY

Measured absolute water pressures 17. April 2012

p0 = 98.4 kPa -57 m

15 m
9m
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T-CONNECTION, VENTILATION CAVERN
HYDROGEOLOGY
Measured absolute water pressures 17. April 2012 and hydraulic
transmissivities after construction of waterproof lining

p0 = 98,4 kPa

9m 15m
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TEST SITE ULVIN ACCESS TUNNEL

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TEST SITE ULVIN SOUTH ACCESS TUNNEL

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TEST SITE ULVIN SOUTH ACCESS TUNNEL
Planar view

ULVIN S
ACCESS
TUNNEL

ULVIN RAIL
TUNNEL

SPRAYED MEMBRANE TEST

SECTIONS
BASF MASTERSEAL 345
MINOVA TEKFLEX DS-M
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TEST SITE ULVIN SOUTH ACCESS TUNNEL

Vertical section
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Ulvin South, access tunnel

Test section at chainage 230-290 m from portal

Core drilling for the water pressure investigation holes

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Ulvin south
Typical seepage situation, ch 260-290
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ULVIN SOUTH ACCESS TUNNEL HYDROGEOLOGY

Joint set #2 Joint set #3

Mean spacing: Mean spacing:
0.66m 0.34m
St.dev: 0.34m St.dev: 0.32m

N
80
230

240

290
250

260

270

280
 50 kPa
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ULVIN SOUTH ACCESS TUNNEL

100
HYDROGEOLOGY

110

50 0
a
10
kP
108
97

106 101

97 106

96
Measured water pressures 26. May
2012, after extensive period of rain

115 115 kPa

102 104
100
50

P0 = 100.3 kPa
 s
m 2/
33
ULVIN SOUTH ACCESS TUNNEL

10 -6
10 -7

50 kPa
10 -8
10 -9
100 0
HYDROGEOLOGY

10 -1
110

50 0
a
10
kP

0
-1
10
-9
10
-8
10
-7
10
-6
108

10
-5
97

m 2 10
/s
106 101

97 106

96
Measured water pressures 26. May
2012 and hydraulic transmissivities
before construction of waterproof tunnel
lining

115 115 kPa

102 104
100
50
10-10
10 -9
10 -8
10 -7
10 -6
m2 /s
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FREEZING DURABILITY ANALYSES (1)
Main goal: Determine if cyclic freezing-thawing loads lead to a deterioration of the waterproofing and
the structural performance of the tunnel lining

Freezing durability issue 1: Heat flux analyses between tunnel space and rock mass in order to
determine freezing exposure of the tunnel lining at different and relevant freezing scenarios

Freezing durability issue 2: Determine deterioration, if any, at relevant freezing loads

CONSTITUTIVE MODEL EXPERIMENTAL INVESTIGATIONS

The rock mass and tunnel lining constitute a Goal:

mechanically continuous structure - Determine relationship between temperature in
tunnel space and penetration depth of relevant
The rock mass is considered an infinitely large isotherms for freezing damage
heat storage with a constant temperature - Determine damage at these freezing loads

The rock mass is water saturated and imposes In-situ investigations:

water a certain degree of water saturation to the - monitoring of temperatures in rock mass and
tunnel lining unilaterally from the rock side tunnel lining
- Sampling of tunnel linings
Freezing of the tunnel lining occurs unilaterally
from the the tunnel space Laboratory investigations

Thawing of the frozen tunnel lining occurs

bilaterally from both the air side and the rock
mass side
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EXPOSURE TO LONGTERM CYCLIC FREEZING
AND THAWING, ANY DETERIORATION ?
Main strategy for testing:
- Verify condition before freezing exposure
- Verify condition after several known number of
freezing cycles with known characteristics

Testing of tunnel lining

structure:

Sprayed concrete part

- Structural performance

Bonded membrane part

- Structural peformance
- Waterproofing
36 Waterproof tunnel lining with sprayed concrete and bonded membrane

FREEZING DURABILITY ANALYSES (2)

WATER AND FREEZING EXPOSURE MATRIX, IN-SITU AND LAB

ULVIN GEVINGS LAB SINTEF

Natural through rockmass Natural through rockmass Artificial water exposure, not
11/2011 07/2014 03/2011- 07/2014 ideal
Water exposure

Natural, measurable, Natural, measureable, not Artificial but realistic, fully

significant and to some extent controllable, not significant controllable and measurable
controllable freezing loads
Freezing exposure

Unlimited no of samples Unlimited no of samples Limited no of samples

Sample collection available, 2012-2014 available, 2012-2014 available, 2013. Careful
planning of selected tests
for lab testing
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FREEZING DURABILITY ANALYSES (3)

SAMPLE AGE AND LAB INVESTIGATION MATRIX
2012 2013 2014
DEGREE OF CAPILLARY
SATURATION
GEVINGS, ULVIN, SINTEF LAB
H2O VAPOUR DIFFUSION

DYNAMIC YOUNGS
MODULUS
STATIC YOUNGS MODULUS &
UCS
SEISMIC VELOCITY AND GEVINGS, ULVIN, SINTEF LAB GEVINGS, ULVIN, SINTEF LAB GEVINGS, ULVIN
ULTRASOUND
SHEAR AND TENSILE BOND
STRENGTH
WATERTIGHTNESS
ELONGATION

AGE OF TUNNEL LINING SAMPLES

LOCATION TIME CONSTRUCTED

ULVIN DEC 2011

GEVINGS MARCH 2011
LAB SINTEF JUN-AUG 2012
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ULVIN SOUTH ACCESS TUNNEL, IN-SITU FREEZING TESTING
OF TUNNEL LININGS

Freezing mode: cold air from outside

230-290 m

Thawing mode: warm return air from the tunnel

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FREEZING DURABILITY TESTING:
GEVINGS RAIL TUNNEL

Construction of tunnel lining finished April 2011

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GEVINGS RAIL TUNNEL
MONITORING AND SAMPLING LOCATIONS

4 km

Hommelvi
k

Location for water Locations for thermal monitoring

pressure monitoring and tunnel lining sampling
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IN-SITU FREEZING TESTING ULVIN AND GEVINGS TUNNELS

Monitoring of temperature in
tunnel lining and rock mass

Ch 5, L=400mm
Extraction of tunnel Ch 6, L=200mm
Ch 7, L=100mm

lining core samples

Ch 4, L=100mm
Ch 3, L=200mm
Ch 2, L=400mm
Ch 1, L=1000mm
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SAMPLING OF TUNNEL LINING, ULVIN AND GEVINGS TUNNELS

Core drilling of reference samples of the tunnel lining in

the Gevings tunnel
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LAB TESTING OF EXPOSED SAMPLES FROM
FREEZING LAB, ULVIN TUNNEL AND GEVINGS
TUNNEL

Lab testing of samples, shear bonding strength

Direct shear testing of membrane interfaces to determine if

freezing causes deterioration
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ROCK
AIR,
TUNNEL
Rock support sprayed Covering S C SPACE
concrete

LOCATION
% OF
CAPILLARY
MEMBRAN
22 POROSITIES Ulvin (BASF
E
20 MS345)
Geving (BASF
18 MS345)
16 Ulvin, 6 month
MACRO POROSITIES (MinovaTekflex
5 DS-M)
2
-300 -200 -100 40 Distance from
membrane (mm)

GEVINGS RAIL TUNNEL, MEMBRANE A, 13

MONTHS
ULVIN TUNNEL TEST SITE, MEMBRANE A, 6
MONTHS
ULVIN TUNNEL TEST SITE, MEMBRANE B, 6
MONTHS
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ROCK
AIR,
TUNNEL
Rock support sprayed Covering S C SPACE
concrete

LOCATION
% OF
CAPILLARY
MEMBRAN
22 POROSITIES Ulvin (BASF
E
20 MS345)
Geving (BASF
18 MS345)
16 Ulvin, 6 month
MACRO POROSITIES (MinovaTekflex
5 DS-M)
2
-300 -200 -100 40 Distance from
membrane (mm)

% DEGREES OF CAPILLARY
SATURATION (DCS) Geving, 13
95
months (BASF
90 MS345)
Ulvin, 6 months
85 (MinovaTekflex
80 DS-M)
Ulvin, 6 month
(BASF MS345)
-300 -200 -100 40 Distance from
membrane (mm)

GEVINGS RAIL TUNNEL, MEMBRANE A, 13

MONTHS
ULVIN TUNNEL TEST SITE, MEMBRANE A, 6
MONTHS
ULVIN TUNNEL TEST SITE, MEMBRANE B, 6
MONTHS
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CRITICAL DEGREE OF CAPILLARY SATURATION FOR FREEZING DAMAGE

Freezing damage:

The ratio :Youngs Modulus after

freezing exposure / Youngs
Modulus before freezing exposure
drops significantly

Problem:

Static Youngs modulus exhibits

relatively large scatter for
sprayed concrete

Dynamic Youngs modulus is

suggested since it gives less
scatter

(Fagerlund, 1977)
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RECONFIGURATION OF FREEZING TEST LAYOUT, SINTEF

New tunne lining structure with water exposure, testing all together 4 products

Tunnel lining with sprayed concrete

and bonded membrane

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50 Waterproof tunnel lining with sprayed concrete and bonded membrane

FULL SCALE FREEZING TESTING, SINTEF FREEZING LAB TRONDHEIM

Section of tunnel lining which will be conditioned with water saturation and freezing
Testing of 4 membrane products from 2 suppliers

12cm 8cm

Air side (tunnel room), Freezing

Rock mass exposure down to -20 oC
T = 8 oC Sprayed concrete, steel fibre
reinforcement, E=1000J

Bonded waterproofing membrane, 3 mm

Sensors for temperature, humidity

in concrete and water pressure

Holes for water saturation of

sprayed concrete (36 holes totally)

Exposure of membrane to water to

achieve capillary saturation

Collection of core
samples
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2.40 m

3.20 m

Rock wall, freezing lab SINTEF, after

demolishing of old tunnel lining
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A1 A2 B1 B2

Level 3

Level 2

Level 1

MEYCO TSL865 MASTERSEAL 345 TEKFLEX DS-M TEKFLEX DS-T

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Measurements of temperature and humidity in the

rock reinforcement sprayed concrete lining
- Electric resistance element sensors for
temperature [T]

- Electrical resistivity measurements between

electrodes for verification of change in humidity [H]

Location of rock wall surface

Location of spryed concrete surface, membrane
56 Installed monitoring for temperature and humidity (electrical resistivity) on the rock wall before shotcreting
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Finished application of 1 (out of 4) membrane products on

the sprayed concrete wall
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Freezing lab: All 4 membrane products applied on the sprayed concrete wall

MEYCO TSL865 MASTERSEAL 345 TEKFLEX DS-M TEKFLEX DS-T

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FREEZING LAB
SAMPLE PREPARATIONS, PANELS FOR VERIFICATION OF REFERENCE
(UNFROZEN) CONDITION

Panels, first layer sprayed concrete shown, with four floated

surfaces and one rough (sprayed)
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Preparation of panels with complete tunnel lining sandwich with four different
membrane products
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Preparation of panels with complete tunnel lining sandwich with four different
membrane products. Freshly applied membrane.
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Scanning of all surfaces for precise verification of thicknesses.

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WHAT HAVE I DONE SO FAR ?
SEPTEMBER 2011 AUGUST 2012
09/2011 01/2012 05/2012 08/2012
COURSE WORK AT NTNU
- Numerical modelling for rock engineering
- Fracture mechanics for rock engineering
- Tunnel lining technology
- Research ethics

FIELD WORK T-CONNECTION

- Construction of test section, one membrane
- Hydrogeol. site testing and installation
FIELD WORK ULVIN ACCESS TUNNEL
- Construction of test section two membranes
- Hydrogeol. site testing and installation
- Tunnel lining sampling and testing
- Planning of in-situ freezing testing

FIELD WORK GEVINGS RAIL TUNNEL

- Tunnel lining sampling and testing
- Planning thermal monitoring, in-situ freezing

LAB WORK NTNU, SINTEF

- Reconstruction, instrumentation freezing lab
- Water saturation testing sprayed concrete
- Pilot tests shear box
- Planning of freezing durability testing
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PLANNED LAB AND FIELD WORK
SEPTEMBER 2012 JULY 2013
09/2012 12/2012 03/2013 07/2013
COURSE WORK
- Hydrogeology for rock engineers (Chalmers)
- Rock stress induced stability problems
FIELD WORK T-CONNECTION
- Hydrogeological testing, existing installation
FIELD WORK ULVIN ACCESS TUNNEL
- Construction freezing section
- Thermal monitoring installation
- In-situ freezing testing and sampling
FIELD WORK GEVINGS RAIL TUNNEL
- In-situ freezing
- Tunnel lining sampling and testing

FREEZING LAB, TEST SERIES #1

- Freezing test, dry condition
- Water saturation of concrete lining
- Freezing test series, wet
- Sampling of tunnel lining structure

FREEZING LAB, TEST SERIES #2

- 3rd membrane supplier showing interest
- Possible reconstruction of tunnel lining
66 Vanntett permanent sprytebetongkledning med sprytbar membran

MAIN TIME SCHEDULE

2011 2012 2013 2014

Hydrogeological testing, ULVIN

and T-CONNECTION

In-situ freezing, sampling and

testing, ULVIN and GEVINGS

Lab testing, full scale freezing

SINTEF

Delivery final thesis

Planned defense: April/May 2015

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Questions ?
Points of view ?