AW-TUN 10 - US
P R O D U C TS I N APPLICA TIO N: TUNNEL CON STR U CTION
Introduction
Mountings in tunnel construction
Modern industrial societies need efficient and reliable traffic
infrastructure, for both road and rail. High speed modes
of transport require routes with gentle curves and inclined
sections with small gradients. The topographical conditions
in most countries require tunnels and bridges when planning
the route, and these are very expensive engineering structures.
Tunnel construction requires a large amount of geological
investigation and static calculation of the tunnel cross section.
Issues such as safety, fire protection, corrosion protection,
technical equipment and the durability of the construction
require a substantial amount of planning which usually takes
years. Owing to the efficiency of the tools, machines and
high-strength concretes which are available today, tunnels
can now be built in much shorter times than was possible a
few decades ago.
The safety equipment, such as signalling devices, lighting,
ventilation systems, retrieval anchors and emergency exits
contribute substantially to safety in tunnels.
Items from the HALFEN product range are used in different
areas of tunnel construction for adjustable and cost-effective
mountings and reinforcement.
2
The regulations listed below contain definitive references
for the range of mounting designs:
ZTV-ING (Additional technical contract conditions and
guide­lines for civil engineering works. Edition March 2003,
Part 5.1 and 5.2 (Road tunnels by closed or open cut method)
• Mountings for tunnel installations must be made from
stainless steel with material numbers 1.4529 or 1.4547
and Resistance class IV according to German Industrial
Standard DIN EN ISO 3506 and according to DIN EN 10088.
Official approval certificate No. Z-30.3-6 of “Products,
connecting devices and structural components made from
stainless steel”
• Table 1: Classification of grades of steel according to
strength classes and corrosion resistance classes as well as
typical applications for structural components and connecting devices.
Swiss standard SIA 179 (Swiss association of architects and
engineers, Edition 1998, Recommendations for mountings in
concrete and masonry)
• Section 4,14. Mounting elements made from stainless
steel or special materials
• Table 10: Corrosion resistance class IV,
Material No. 1.4529, 1.4547
• Table 11: stainless steel Group IV:
Well suited for use in tunnels.
© 2010 HALFEN · AW-TUN 10 - US · www.halfen.com
P R O D U C TS I N A PPLICA TIO N: TUNNEL CON STR U CTION
Contents
Application
-----------
Page
Mountings in tunnel construction, regulations and recommendations
2
Halfen channels for tunnel construction / HCR steel
4
Road tunnels / mounting the lighting system
5
Road tunnels / reinforcement connections
6
Road tunnels / retrieval anchors
7
Railway tunnels / contact-wire mountings
8
Railway tunnels / earthing of HALFEN channels
9
Road tunnels / ventilation duct supports
10
References11
Addresses12
Cross section of a typical
road tunnel
(Picture: periodical
'Tunnel’,
Bauverlag BV GmbH)
© 2010 HALFEN · AW-TUN 10 - US · www.halfen.com
3
HA L F E N C A S T - IN CHA NNE LS F O R T U NN EL CON STR U CTION
A v a i l a b l e i n l e n g t h s f r o m 6 " t o 19 ' 11 "
Designation
HTA
HM
1.4529
HCR
HL
HZL toothed
2-1/16"
1-5/16"
2"
1-3/16"
1-15/16"
1-3/16"
1-9/16"
Material / finish
1.4571
A4
hot-dipgalvan.
Allowable single point
lbs (kN)
pull, concrete
grade B ≥ 25
available Halfen T-head bolts
M
6
M
8
M
10
M
12
M
16
M
20
(1/4")
(5/16")
(3/8")
(1/2")
(5/8")
(3/4")
gv
fv
gv
fv
gv
fv
gv
fv
A4
A4
A4
gv
fv
gv
fv
gv
fv
A4
A4
A4
gv
fv
gv
fv
gv
fv
HTA 52/34
4950
(22)
HM 52/34
→ see catalogue MT
HTA 50/30
2250
(10)
HM 50/30
→ see catalogue MT
HTA 49/30
2250
(10)
HM 49/30
→ see catalogue MT
HTA 40/22
1350
(6)
gv
gv
fv
gv
fv
HM 40/22
→ see catalogue MT
A4
A4
A4
HTA 40/25
1350
(6)
gv
gv
fv
gv
fv
HM 40/25
A4
A4
A4
→ see catalogue MT
HTA 38/17
1000
(4.5)
gv
fv
gv
fv
gv
fv
HM 38/17
→ see catalogue MT
HTA 28/15
675
(3)
HM 28/15
→ see catalogue MT
HL 28/15
→ see catalogue MT
HM 41/41
→ see catalogue MT
HL 41/41
→ see catalogue MT
HZL 41/41
→ see catalogue MT
HM 36/36
→ see catalogue MT
HL 36/36
→ see catalogue MT
HM 28/28
→ see catalogue MT
HL 28/28
→ see catalogue MT
gv
fv
gv
fv
A4 A4 A4
HCR HCR HCR
7/8"
1-9/16"
1"
1-1/2"
5/8"
1-1/8"
9/16"
1-5/8"
1-5/8"
1-3/8"
1-3/8"
1-1/16"
1-1/8"
4
A4 A4 A4
HCR HCR HCR
gv
gv
gv
fv
gv
A4 A4
HCR HCR
gv
fv
fv
A4
A4
gv
fv
gv
fv
gv
fv
A4
A4
A4
gv
gv
fv
gv
A4
A4
© 2010 HALFEN · AW-TUN 10 - US · www.halfen.com
R oad Tunnels
Mounting lighting systems
Special, glare-free lights are usually mounted on the tunnel
ceiling at relatively short distances to provide the optimum
lighting for road tunnels. Since HALFEN channels embedded
in concrete are particularly suitable for strip mountings, they
are offten used by experienced planners for these applications.
Because the mountings could be exposed to chloride contamination, they are often made from stainless steel CorrosionResistance Class IV in accordance with the German Construction supervision approval No. 30.3-6.
The material numbers of the highly corrosion resistant steels
are specified as 1.4529 and 1.4547. The HALFEN channels
which are made from these materials and can be embedded
in concrete are labelled:
HTA 28/15-HCR,
HTA 38/17-HCR,
HTA 49/30-HCR.
Halfen cast-in channels provide an adjustable mounting method for
lighting systems
© 2010 HALFEN · AW-TUN 10 - US · www.halfen.com
5
R OA D T U N N E LS
Reinforcement connections
A tunnel is a complex structure consisting of numerous
sections with a large number of concrete construction joints.
For example, if the diaphragm walls to which the tunnel sofit
or tunnel vault is attached are pre-concreted, reinforcement
connections are used for the linkage to the structural components.
Later connection of the tunnel vault to the pre-concreted diaphragm walls
Type HBS-05 HALFEN screw connections are used in this
case. Connections from #4 to #10 (12 mm to 32 mm) bar
diameter are available.
Reinforced concrete wall
HBS-05-A
The load-bearing connection for the reinforcement is made using HBS-05
screw connections
HBS-05-SG
Reinforced
concrete ceiling
Reinforcement connections are also used in road tunnels for
later connection to steel reinforced concrete intermediate
ceilings. HBT rebend connections are used for the structural
connection of concrete components without static proof.
These are available in bar diameters #3 and #4 (10 mm and
12 mm).
6
© 2010 HALFEN · AW-TUN 10 - US · www.halfen.com
R OA D TU N N E LS
Retrieval anchors
Retrieval anchors are provided in road tunnels to pull apart
vehicles which are wedged together in road traffic accidents
so that they can be rapidly removed from the traffic.
Retrieval anchors consist of DEHA spherical head anchors
(Load class 20 T, 16 tons) embedded in the concrete. The
free-swivelling shackles normally used for transporting precast
concrete components are attached to the spherical head anchors. The shackles are secured with a chain to prevent them
from being stolen. Retrieval anchors are placed in niches
in the tunnel walls every 300 ft. City and municipal rescue
services are increasingly demanding that retrieval anchors are
provided.
Retrieval anchors are concreted into the tunnel wall at regular intervals.
Further detailed information is included in the technical
brochure for Spherical Head Transport Anchors.
Please download catalogue KKT at www.halfen.com.
The anchors must not project into the tunnel space.
They are stowed in niches.
The chain secures the anchor
from being stolen.
Spherical head anchor
with shackle.
© 2010 HALFEN · AW-TUN 10 - US · www.halfen.com
7
R A I L W A Y T U NNE LS
Mounting contact wires, wheel tensioners, return lines and line feeders
In railway tunnels for electrified stretches of railway lines,
a large amount of equipment has to be installed along the
tunnel cross section. This includes the contact-wire tensioners,
line feeders and signal systems. HALFEN channels embedded
in the concrete (cast-in channels) have proved to be an
effective way of mounting equipment in numerous tunnels
across the world and have become a standard means of
attachment.
Contact wire equipment adjustably mounted on the HTA Halfen channels.
Anchor channel for
supplementary
conduit
Anchor channel Anchor channel for
for back conduit wheel tensioner
Anchor channel
for anchoring a
fixed point
Anchor channel
for support strut
Anchor channel
for weight guide
8
© 2010 HALFEN · AW-TUN 10 - US · www.halfen.com
R A I L WA Y TU N NE LS
Earthing
Type HTA hot-rolled HALFEN channels together with the
relevant Type HS tee bolts are used in tunnels to attach the
structural components for the overhead line (contact lines).
The structures are made to take any stresses, such as those
which can occur on the Cologne Rhine/Main or NurembergIngolstadt high-speed lines.
If desired, the HALFEN channels can be made short-circuit
proof and adapted at site to the intended earthing arrangements. If installed as a channel pair, the short-circuit current is
conducted via two welded spacers. The earth connection to
the respective ring earth electrode can then be made from an
earthing strap welded to the back of the channel.
The channel pair is fixed to the bottom of the formwork
and then the multi-layer reinforcement mesh can be installed.
For this assembly method, the earthing strap (flat steel) is vertically aligned so that in the final assembly condition the strap is
always accessible and can be connected easily to the ring earth
electrode.
Pair of Halfen channels with
distance spacers and earthing
strap, which is bent and welded
to the upper reinforcement after
it has been laid.
© 2010 HALFEN · AW-TUN 10 - US · www.halfen.com
Halfen cast-in channels mounted on segment formwork
9
R OA D TU N N E Ls
Pipe suppor t for ventilation ducts
The connecting passages between two parallel main tunnel
tubes are subject to strong contamination due to the irregular
airpressure and suction waves from the main tunnels. The
technical equipment housed in the tunnels must therefore be
inspected and cleaned at short intervals.
In the Swiss Seelisberg tunnel, this problem was solved by
connecting the crossways, which are spaced approximately
1000ft apart, to the outside air with new ducting and ventilating them under slight positive pressure. The overpressure
prevents contaminated air from entering the crossways.
Since it was necessary for the ventilation ducts to run via the
carriageway of the road tunnel, it was particularly important
for the ducting to be installed quickly. The HALFEN Powerclick framing system was the best solution for providing a
means of support for the ducting which would be fast, safe
and adjustable. By using this system, interruptions to the
traffic could be reduced to a minimum.
Pipe support with HALFEN Powerclick framing system
Photos: Tis-Air (www.tis-air.ch)
Further information on the HALFEN Powerclick framing
system is provided in the technical catalogues and on the
website www.halfen.com.
High rigidity profile with toothed
inner channel
Multi-functional angle
connector
Toothed connection
HALFEN Powerclick framing system
10
© 2010 HALFEN · AW-TUN 10 - US · www.halfen.com
P R O D U C TS I N APPLICA TIO N: TUNNEL CON STR U CTION
Some reference projects worldwide
Germany
XFEL X-Ray Laser Project, Hamburg
Finnetunnel, Highspeed RL
Tunnel river Elbe, 4th tube
S-Railway tunnel Hamburg
Herren tunnel Lübeck
Service tunnel hospital Eppendorf
Road tunnel Hemelingen
Katzenberg tunnel
U 2 city railway
Pragsattel B10 Stuttgart
Hornberg tunnel
Neu-Ulm 21
Stuttgart 21
Schwarzkopf tunnel
Tunnel Hösbach
Audi tunnel, Ingolstadt
Tunnel Geisberg
Tunnel motorway junction Frankfurt
Wandersmann tunnel north & south
Tunnel Breckenheim
Tunnel Idstein
Tunnel Montabaur
S-Railway Ostentor/Dortmund
Bypass Gevelsberg road tunnel
City railway Bochum
City railway Dortmund
Tunnel A2 Gelsenkirchen-Erle
Lange Issel tunnel
Troisdorf tunnel, Highspeed RL
Siegauen tunnel, Highspeed RL
Dickheck tunnel, Highspeed RL
Wahnscheid tunnel, Highspeed RL
Himmelberg tunnel, Highspeed RL
Rottbitze tunnel, Highspeed RL
Aegidienberg tunnel, Highspeed RL
Ittenbach tunnel, Highspeed RL
Günterscheid tunnel
Subway 3 Nuremberg
Subway Fürth
Tunnel Lehrter train station, Berlin
Tramway tunnel station Rostock
Motorway tunnel BAB 113
Ems tunnel / Leer
Subway Düsseldorf
Tunnel Farchant A95
Tunnel Allach
Subway Munich
Subway Hamburg
Bibratunnel, Highspeed RL
Reitersbergtunnel, Highspeed RL
Richard-Strauss Road Tunnel, Munich
Luise-Kiesselbach Road Tunnel, Munich
© 2010 HALFEN · AW-TUN 10 - US · www.halfen.com
Belgium/Luxembourg
Diabolotunnel
Liefkenshoektunnel
Tunnel Antwerpen ASDAM-HAST
Tunnel Zelzate-Knokke
Subway Antwerpen
Tunnel de Cointe Liège
Tunnel E5/E9 Liège
Metro Antwerp
Metro Bruxelles
Cointe tunnel
Tunnel Gestel
Rolo tunnel
CEE tunnel, Bruxelles
Kennedy tunnel, Antwerp
Metro Charleroi
Tunnel de Gousselerbierg/Luxemburg
Tunnel de Markusbierg/Luxemburg
Tunnel Howald
Italy
Variante di valcio autostrada FI-BO
Variante di valcio autostrada FI-BO
Tunnel for Caselle Airport
Tunnel Monte Bianco
Switzerland
Tunnel de Sauges, A5, Neuchatel
Conn. tunnel Bettmerhorn-Fischeralp
Quarten tunnel A3
Eggflue tunnel J18
Utlisberg tunnel A4
Hauenstein tunnel
Metro Alpine tunnel
Rosenbergtunnel, St.Gallen
Islisberg tunnel
Hafnerberg tunnel
Chienberg tunnel
Seelisberg tunnel
Lötschberg tunnel
Gotthard base tunnel
Netherlands
Zeeburg tunnel, Amsterdam
Sophia tunnel
Tunnel Pannerdens Kanaal
Geldersepoort
Schiphol tunnel
Heijnenoord tunnel
Wijker tunnel
Austria
Tunnels Semmering
Tunnels Kalus Phyrna Autobahn
Plabutsch tunnel
Karawanken tunnel, Carinthia
Inntal tunnel
Sausenstein tunnel
Metro Vienna
Czech Republic
Tunnel Praha-Mrazovka
Tunnel Jihlava / bypass road
Motorway tunnel Prague
Sweden
Södra Länken, tunnel near Stockholm
Railway Tunnel , Malmö
Hallands Tunnel (Railway)
Great Britain
Channel Tunnel
Tunnel A1, Hatfield
France
Metro Paris
Metro Lille
Eurotunnel, Calais
Tunnel de Villejust
Tunnel du Puymorens
Tunnel de l’Epine
Tunnel du Landy
Tunnel de Tartaiguille
Tunnel du Prado-Carenge
Singapore
Circle Line MRT
South Korea
Railway tunnel Seoul-Pusan
Malaysia
Kuala Lumpur Storm Water Management
and Road Tunnel (SMART)
Other
Metro Cairo, Egypt
Metro Taipei, Taiwan
Storebelts tunnel, Denmark
Tunnel route 5, Hongkong
Junk Bay tunnel, Hongkong
Wu Guang Highspeed RL, China
11
Contact H alfen Worldwide
Phone:
E-Mail:
Web:
Web:
+1 800.323.6896
halfen@meadowburke.com
www.halfenusa.com
www.halfen.com
Fax:
+1 888.277.1695
Canada
UCC Industries International (Distributor)
Units 12 & 13
895 Sandy Beach Road
Pickering
Ontario
L1W 3N7
Phone:
E-Mail:
Web:
+1 905.831.7724
bhughes@ucci.ca
www.ucci.ca
Fax:
+1 905.831.5872
Provinces of British Columbia and Alberta:
Meadow-Burke Products
8521 F.M. Road 1976
Converse, TX 78109 • USA
Phone:
E-Mail:
Web:
+1 210.658.4671
halfen@meadowburke.com
www.halfenusa.com
Fax:
+1 210.658.8312
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Katzbergstrasse 3
40764 Langenfeld
Austria, Czech Republic, Poland, Switzerland
Phone:
E-Mail:
Web:
+49 2.173.9700
info@halfen.de
www.halfen.de
Fax:
+49 2173 97.0225
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18, rue Goubet
75019 Paris
Belgium, Italy, Netherlands, Portugal, Spain
Phone:
E-Mail:
Web:
+33 14.452.3100
halfen@halfen.fr
www.halfen.fr
Fax:
+33 14.452.3152
HALFEN Ltd.
Humphrys Road
Woodside Estate
Dunstable LU5 4TP
Denmark, Finland, Norway, Sweden
Phone:
E-Mail:
Web:
+44 158.247.0300
info@halfen.co.uk
www.halfen.co.uk
Fax:
+44 158.247.0304
China
HALFEN (Beijing) Construction Accessories
Distribution Company Limited - HQ
Room 601, Tower D, Vantone Centre, No. A6
Chao Yang Men Wai Street, Chaoyang District,
Beijing, P.R. China 100020
Chengdu, Guangzhou, Shanghai
Phone:
E-Mail:
Web:
+86 105.907.3200
info@halfen.cn
www.halfen.cn
Fax:
+86 105.907.3218
Japan
HALFEN GmbH
Japan Representative Office
Ark Mori Building 12 Floor
1-12-32 Akasaka, Minato-Ku
Tokyo 107-6012
Phone:
E-Mail:
Web:
+81 34.360.9269
masaki.okamoto@halfen.com
www.halfen.jp
Fax:
+81 34.360.8201
India
CRH India Management Services Pvt. Ltd.
73-C, 3 North Avenue, Maker Maxity,
Bandra-Kurla Complex, Bandra (East),
Mumbai 400 051
Phone:
E-Mail:
Web:
+91 224.202.4000
bhisham.vaswani@halfen.in
www.halfen.in
Fax:
+91 224.202.4001
Central-East Europe
Germany
West Europe
France
North Europe
UK
Furthermore HALFEN is represented with distributors in Argentina, Australia, Azerbaijan, Belarus, Brazil, Bulgaria, Chile,
Colombia, Croatia/Bosnia-Herzegovina/Macedonia/Montenegro, Cyprus, Denmark, Estonia, Greece, Hong Kong, Hungary,
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Peru, Philippines, Kazakhstan, Romania, Russia, Serbia, Singapore, Slovenia, Taiwan/ROC, Thailand, Turkey, Ukraine, United
Arab Emirates, Uruguay, Vietnam
NOTES REGARDING THIS CATALOGUE
Technical and design changes reserved. The information in this publication is based on state-of-the-art technology at the time of publication. We reserve the right to make technical and design changes at any time. HALFEN GmbH shall not accept liability for the accuracy of
the information in this publication or for any printing errors.
The Quality Management System of Halfen GmbH is certified for the locations in Germany, Austria, Poland, Switzerland and the Czech
Republic according to ISO 9001:2008, Certificate No. QS-281 HH.
x.000 10/10
HALFEN Anchoring Systems
Meadow-Burke Products
8521 F.M. Road 1976
Converse, TX 78109
AW-TUN 10 - US - 10/10
North America
USA
© 2010 Halfen GmbH, Germany
applies also to copying in extracts.
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