555Tunnel Liner

555.1 General Description

This work includes: • Driving a tunnel • Furnishing and installing steel plates for tunnel liner • Furnishing and erecting brick portals to close each end of the tunnel, when required • Pressure grouting Construct to Plan line, grade, and dimensions, according to the applicable specifications.

555.1.01 Definitions

General Provisions 101 through 150.

555.1.02 Related References

A. Standard Specifications Section 608—Brick Masonry Section 615—Jacking or Boring Pipe Section 645—Repair of Galvanized Coatings Section 834—Masonry Materials Section 844—Steel Pipe B. Referenced Documents AASHTO LRFD Road Tunnel Design and Construction Guide Specification AASHTO LRFD Bridge Construction Specifications AASHTO LRFD Bridge Construction Specifications Manual on Uniform Traffic Control Devices ASTM A 569/A 569M

555.1.03 Submittals

A. Special Permit Application Before working with explosives, apply to the Department for a special permit. This permit will be in addition to a tunneling permit not involving explosives. Special permits will be issued when the proposed operational procedures outlined in the permit form are submitted and approved. B. Design Data For Projects not under Contract to the Department but are being performed under permit, the owner shall submit complete design data including working or Shop Drawings for approval before receiving the permit. Include the following applicable design data: • Design data as required by AASHTO LRFD Road Tunnel Design and Construction Guide Specification • Subsoil surveys, including the elevation of the water table and the classification and relative density of the soils from the ground line to 3 ft. (1 m) below the tunnel liner • Rock coring data, including rock type and core recovery, where required • Water control plans, where required C. Repair Plan If tunneling damages the roadway, submit a roadway repair plan for approval.

555.2 Materials

Ensure that materials meet the following requirements: Material Specification Section Liner Plates ASTM: A 569/A 569M Galvanizing Bituminous Coating and Bolts 844 Brick for Portal 608

834.2 01

A. Liner Plates Construct the completed liner with a series of steel liner plates assembled with staggered longitudinal joints and fabricated to fit the tunnel cross section. 1. Characteristics Use hot-dipped galvanized, bituminous-coated steel of the size, thickness, and sectional modulus specified. Use plates made of hot-rolled, cold-formed steel that conform to ASTM A 569/A 569 M. Use plates with the following mechanical properties before cold forming: • Tensile strength = 42,000 psi (290 MPa) • Yield strength = 28,000 psi (190 MPa) • Elongation, 2 in. (50 mm ) = 30 percent 2. Grout Intrusion Nipples Provide grout intrusion nipples 2 in. (50 mm) or larger in diameter in the top plates at intervals 10 ft (3 m) or less. This will permit grouting while the tunnel liner is erected. For larger tunnels, or where conditions make more grout openings advisable, install additional plates with nipples at the top quarter points and/or on each side between the top openings. Stagger these additional openings but keep the distance between them 10 ft. (3 m) or less in any one line. 3. Flanged Joints Form plates to provide circumferential flanged joints. Use longitudinal joints that are flanged or offset lap seam type. Punch plates for bolting on both longitudinal and circumferential seams or joints. Space bolts in circumferential flanges according to the manufacturer’s standard spacing. Space bolts a multiple of the plate length so that plates with the same curvature are interchangeable and will permit staggering of longitudinal seams. 4. Longitudinal Seams For lapped longitudinal seams, ensure that bolt size and spacing is according to the manufacturer’s standard, but meets the longitudinal seam strength requirements of Section 12 of the AASHTO LRFD Bridge Design Specifications. Galvanizing Bituminous Coating and Bolts shall be in compliance with applicable information in Section 844. B. Grout Use grout that consists of: • One-part Portland cement • Two parts masonry lime • Four parts mortar sand • Two percent of an approved admixture, (i.e., Bentonite, Septamine Stearex, or Hydrocide Liquid) • A retardant, where required Use enough mixing water to produce a workable mixture of grout capable of being pumped into the voids created by tunneling. C. Brick Brick for portal shall conform to Section 608 and Subsection 834.2.03.

555.2.01 Delivery, Storage, and Handling

General Provisions 101 through 150.

555.3 Construction Requirements

555.3.01 Personnel

General Provisions 101 through 150.

555.3.02 Equipment

A. Pumping Equipment Provide pumping equipment for grouting operations. Use equipment with enough pump horsepower and grouting line pressure to completely fill voids without buckling or shifting the liner plates or damaging the roadway. B. Water Control When water control is required, operate well points or other drainage systems in the vicinity of the tunnel construction limits.

555.3.03 Preparation

General Provisions 101 through 150.

555.3.04 Fabrication

General Provisions 101 through 150.

555.3.05 Construction

Excavate the tunnel using any of the following procedures: • Full face • Heading and bench • Multiple drift Do not use a full or partial shield, a tunneling machine, or other equipment that exerts a force on the liner plates to propel, steer, or stabilize the equipment. Prevent the overpassing roadway or railway section from settling when constructing tunnels by using: • Poling plates • Brest boards • Shields • Soil solidification • A combination of these methods A. Installation of Liner Plates Use the same type of liner plates for the full length of the tunnel. Flanged and lapped seam methods of construction are acceptable. 1. General Install self-supporting steel liner plates according to the manufacturer’s recommendations. Do not leave more than 5 ft. (1.5 m) of tunnel unlined while tunneling. Do not leave more than 1 ft. (300 mm) of tunnel unlined at the end of the day’s operation. 2. Sealing Before grouting tunnel liner segments, seal that segment sufficiently between the liner plates and the surrounding soil to retain the grouting pressure. Place the seals in these locations: • At the tunnel entrance • Between grout intrusion nipples • Within 1 ft. (300 mm) of the end of the tunnel 3. Pressure Grouting Pressure grout voids in the area outside the plates every 10 ft. (3 m) at the end of the work shift. Grout more frequently if soil conditions dictate. 4. Repair Repair damaged spelter coating according to Section 645. Replace plates with damaged spelter or bituminous coatings at no additional cost to the Department if the Engineer determines they cannot be repaired. B. Safety Schedule the Work to avoid interfering with or endangering traffic flow on the highway or railway. Follow required safety measures specified in the Manual on Uniform Traffic Control Devices. 1. Begin tunneling at one end of a pit that has been sheeted and shored as necessary. Comply with Section 615. Perform work below the level of the roadbed. 2. Complete tunneling at one location before beginning work at another. 3. If the Engineer determines that tunneling is endangering overpassing roadway or the traveling public, stop tunneling until making the necessary corrections. 4. Provide a well-braced, temporary bulkhead against the face of the excavation when work stops while the heading is within 20 ft. (6 m) of railroad tracks or highway pavement. 5. If distress occurs to roadway due to tunneling, the Contractor shall submit for approval a plan to repair the roadway. C. Portals Close tunnel portals at each end using a three-course mortared brick wall according to Plan details. Erect one of the three courses inside the liner.

555.3.06 Quality Acceptance

Ensure that the tunnel has a diameter essentially the same as the outside diameter of the liner plates.

555.3.07 Contractor Warranty and Maintenance

General Provisions 101 through 150.

555.4 Measurement

Tunnel liner installed according to the approved design and these Specifications is measured by the linear foot (meter) complete in place. The liner is measured between the ends of the liner along the invert.

555.4.01 Limits

Portals are not measured for separate payment.

555.5 Payment

This Work, measured as specified above, will be paid for at the Contract Unit Price bid per linear foot (meter) of liner for each diameter and plate thickness. The specified thickness is used for either a two-flange plate or a four-flange plate. This payment will be full compensation for: • Furnishing materials, labor, tools, and equipment • Removing and satisfactorily disposing of all excavated materials • Force grouting • Providing tunnel portals, where required • Restoring and cleaning, including regrassing, as required • Installing liner Payment will be made under: Item No. 555 Tunnel liner ___ diameter, ___ plate thickness (2 flange), or ___ plate thickness (4 flange) Per linear foot (meter)

555.5.01 Adjustments

General Provisions 101 through 150.