Highway & Rail Transit Tunnel Maintenance & Rehabilitation Manual

2005 Edition

PDF Version (8.1 mb)

Table Of Contents

• Table of Contents
• List of Tables
• List of Figures
• Executive Summary

• Chapter 1: Introduction
• Chapter 2: Tunnel Construction And Systems
  1. Tunnel Types
     1. Shapes
     2. Liner Types
     3. Invert Types
     4. Construction Methods
     5. Tunnel Finishes
  2. Ventilation Systems
     1. Types
     2. Equipment
  3. Lighting Systems
     1. Types
  4. Other Systems/Appurtenances
     1. Track
     2. Power (Third Rail/Catenary)
     3. Signal/Communication Systems
• Chapter 3: Preventive Maintenance
  1. Preventive Maintenance of the Tunnel Structure
     1. Tunnel Washing
     2. Drain Flushing
     3. Ice/Snow Removal
     4. Tile Removal
  2. Preventive Maintenance of Mechanical Systems
  3. Preventive Maintenance of Electrical Elements
  4. Preventive Maintenance of Track Systems
     1. Track and Supporting Structure
     2. Power (Third Rail/Catenary)
     3. Signal/Communication Systems
  5. Preventive Maintenance of Miscellaneous Appurtenances
     1. Corrosion Protection Systems
     2. Safety Walks, Rails, and Exit Stair/Ladder Structures
     3. Ventilation Structures and Emergency Egress Shafts
• Chapter 4: Rehabilitation Of Structural Elements
  1. Water Infiltration
     1. Problem
     2. Consequences of Water Infiltration
     3. Remediation Methods
  2. Concrete Repairs
     1. Crack
     2. Spall
  3. Liner Repairs
     1. Cast-in-Place (CIP) Concrete
     2. Pre-cast Concrete
     3. Steel
     4. Cast Iron
     5. Shotcrete
     6. Masonry
     7. Exposed Rock
• Appendix A: Life-Cycle Cost Methodology
• Glossary
• References

List Of Tables

• Table 2.01 - Construction Methods
• Table 3.01 - Preventive Maintenance of Mechanical Systems
• Table 3.02 - Preventive Maintenance of Electrical Systems
• Table 4.01 - Weldability of Steel
• Table 5.01 - Direct Fixation Slab Track
• Table 5.02 - Ballasted Track
• Table 5.03 - Factors from Standard Economic Table

List Of Figures

• Figure 2.01 - Circular Highway Tunnel Shape
• Figure 2.02 - Double Box Highway Tunnel Shape
• Figure 2.03 - Horseshoe Highway Tunnel Shape
• Figure 2.04 - Oval/Egg Highway Tunnel Shape
• Figure 2.05 - Circular Rail Transit Tunnel Shape
• Figure 2.06 - Double Box Rail Transit Tunnel Shape
• Figure 2.07 - Single Box Rail Transit Tunnel Shape
• Figure 2.08 - Horseshoe Rail Transit Tunnel Shape
• Figure 2.09 - Oval Rail Transit Tunnel Shape
• Figure 2.10 - Circular Tunnel Invert Type
• Figure 2.11 - Single Box Tunnel Invert Type
• Figure 2.12 - Horseshoe Tunnel Invert Type
• Figure 2.13 - Natural Ventilation
• Figure 2.14 - Longitudinal Ventilation
• Figure 2.15 - Semi-Transverse Ventilation
• Figure 2.16 - Full-Transverse Ventilation
• Figure 2.17 - Axial Fans
• Figure 2.18 - Centrifugal Fan
• Figure 2.19 - Typical Third Rail Power System
• Figure 2.20 - Typical Third Rail Insulated Anchor Arm
• Figure 4.01 - Ice formation at location of water infiltration in plenum area above the roadway slab
• Figure 4.02a - Temporary drainage systems comprised of neoprene rubber troughs and 25 mm (1 in) aluminum channels
• Figure 4.02b - Temporary drainage systems comprised of neoprene rubber troughs and 25 mm (1 in) aluminum channels
• Figure 4.03 - Temporary drainage system comprised of 50 mm (2 in) plastic pipe
• Figure 4.04 - Insulated panels used as a waterproofing lining to keep infiltrated water from freezing
• Figure 4.05 - Section of membrane waterproofing system
• Figure 4.06 - Leaking crack repair detail
• Figure 4.07 - Repair of a concrete joint or crack by inclusion of a neoprene strip
• Figure 4.08 - Treatment of cracks by membrane covering
• Figure 4.09 - Method of repairing a leaking joint
• Figure 4.10 - Laser controlled cutter for removing portions of existing tunnel liner
• Figure 4.11 - Horizontal surface crack repair detail
• Figure 4.12 - Vertical/over head crack repair detail
• Figure 4.13 - Shallow spall repair detail (shallow spall with no reinforcement steel exposed)
• Figure 4.14 - Shallow spall repair detail (shallow spall with reinforcement steel exposed)
• Figure 4.15 - Deep spall with exposed adequate reinforcement steel
• Figure 4.16 - Deep spall with exposed inadequate reinforcement steel
• Figure 4.17 - Metal Stitching Detail
• Figure 4.18 - Metal Stitching Procedure
• Figure 4.19 - Metal Stitching Completed
• Figure 4.20 - Rock bolt types
• Figure 4.21 - Direct Fixation Slab Track
• Figure 4.22 - Ballasted Track

Executive Summary

In March of 2001, the Federal Transit Administration (FTA) engaged Gannett Fleming, Inc., to develop the first ever Tunnel Management System to benefit both highway and rail transit tunnel owners throughout the United States and Puerto Rico. Specifically, these federal agencies, acting as ONE DOT, set a common goal to provide uniformity and consistency in assessing the physical condition of the various tunnel components. It is commonly understood that numerous tunnels in the United States are more than 50 years old and are beginning to show signs of considerable deterioration, especially due to water infiltration. In addition, it is desired that good maintenance and rehabilitation practices be presented that would aid tunnel owners in the repair of identified deficiencies. To accomplish these ONE DOT goals, Gannett Fleming, Inc., was tasked to produce an Inspection Manual, a Maintenance and Rehabilitation Manual, and a computerized database wherein all inventory, inspection, and repair data could be collected and stored for historical purposes.

This manual provides specific information for the maintenance and rehabilitation of both highway and rail transit tunnels. Although several components are similar in both types of tunnels, a few elements are specific to either highway or rail transits tunnels, and are defined accordingly. The following paragraphs explain the specific subjects covered along with procedural recommendations that are contained in this manual.

Introduction

This chapter presents a brief history of the project development and outlines the scope and contents of the Maintenance and Rehabilitation Manual.

Tunnel Construction and Systems

To develop uniformity concerning certain tunnel components and systems, this chapter was developed to define those major systems and describe how they relate to both highway and rail transit tunnels. This chapter is broken down into four sub-chapters that include: tunnel types, ventilation systems, lighting systems, and other systems/appurtenances.

The tunnel types section covers the different tunnel shapes in existence, liner types that have been used, the two main invert types, the various construction methods utilized to construct a tunnel, and the multiple different finishes that can be applied, mainly in highway tunnels. The ventilation and lighting system sections are self explanatory in that they cover the basic system types and configurations. The other systems/appurtenances section is used to explain tunnel systems that are present in rail transit tunnels, such as: track systems, power systems (third rail/catenary), and signal/communications systems.

Preventive Maintenance

This chapter provides specific recommendations for performing preventive maintenance to the tunnel structure, mechanical systems, electrical elements, track systems, and miscellaneous appurtenances. The tunnel structure recommendations deal with tunnel washing, drain flushing, ice/snow removal and tile removal. The procedures for the mechanical and electrical systems/elements are given in tabular format and include a suggested frequency for each of the tasks listed. Track systems are divided into track and supporting structure, power (third rail/catenary), and signal/communication systems. The last section for miscellaneous appurtenances covers the following three categories: 1) corrosion protection systems, 2) safety walks, rails, and exit stair/ladder structures, and 3) vent structures and emergency egress shafts.

Rehabilitation of Structural Elements

The last chapter of this manual offers general procedural recommendations for making structural repairs to various types of tunnel liner materials. A large section is devoted to covering repairs necessary to slow, stop, or adequately divert water infiltration. Following that section is a detailed section that addresses the various structural repairs that can be made to concrete, such as repairing cracks and spalls. The last section deals with each of the following liner types: cast-in-place concrete, pre-cast concrete, steel, cast iron, shotcrete, masonry, and exposed rock.

Life-Cycle Cost Methodology

Appendix A of this manual includes a general discussion of life-cycle cost methodology. This process could be used when determining which method of repair is most cost effective over the long term. Also, it could be used to determine if it is more beneficial to purchase a new piece of equipment or to continue maintaining the existing piece.