PRODUCTS AND SERVICES FOR A SUSTAINABLE TUNNEL
Sealing
Connection and Accessories
Precast Plant
Technical Co-generation
Reputation | Competitiveness | Skills
[email protected] | www.famaspa.it Index
FAMA Profile p.4 Sustainability p.5 FAMA Time Line p.6 FAMA Products p.6 Best References p.7
SEALING p.8 FAMA Gasket Strength Elements p.8 FAMA Soft Corner Technology p.9 ANCHORED GASKETS p.10 MIXED ANCHORED GASKETS with Hydrophilic Barrier p.10 GLUED-IN GASKETS p.11 MIXED GLUED-IN GASKETS with Hydrophilic Barrier p.11 FAMA Special Gasket p.12 HYDROPHILIC GASKETS p.12 SWELLING GASKET p.12 CHEMICAL PROTECTION SYSTEM p.13 GASKET PROTECTION SHIELD p.13 CONFINEMENT GASKET p.13
CONNECTION SYSTEMS AND ACCESSORIES p.14 FAMA Connection Systems p.14 FAMA Technology for Heeled Tooth p.15 SMARTBLOCK p.16 SCREW SMARTBLOCK p.16 SMARTBLOCK HS – CROSS PASSAGE p.17 SMARTBLOCK FOR LAUNCHING RING p.17 SMARTBLOCK FOR REMOVABLE SEGMENTS p.17 SMARTBLOCK AUTO-PROTECTED AGAINST AGGRESSIVE AGENTS p.17 CENTERING PINS p.18 INJECTION AND LIFTING SYSTEMS p.19 SOCKETS WITH DIN 405 THREAD p.20 SOCKETS WITH ISO 261 METRIC THREAD p.20 RAIL SOCKETS p.20 BOLTS AND WASHERS p.21 GUIDING RODS p.22 PACKERS p.23
PRECASTING PLANTS AND EQUIPMENT p.24 FAMA Sizes and Designs Precast Plants p.24 FAMA Has the Competency to Produce Molds p.25 FAMA Designs Plants for Carousel and Fixed Formwork p.26 PRECASTING PLANT EQUIPMENTS p.28 SPECIAL DEVICES p.29
TECHNICAL COGENERATION p.30 ANTI-SEISMIC DEVICE p.30 Technical Support Documentation p.31 SPECIAL SERVICES p.32
SCIENTIFIC COLLABORATIONS p.34 INDUSTRY ASSOCIATIONS p.34 FAMA Profile FAMA is the only company to provide a single business solution for precast tunnel lining segments. It provides molds, sealing gaskets and accessories manufactured by FAMA according to strict ISO 9001 quality standards. This means a single technical reference for the complete tunnel-lining project.
From 1988 FAMA has been operating in the tunnel sector, initially as a subcontractor for large Italian companies; then, for over ten years, the company has focused on the design, study, development and testing of its own products to be placed directly on the market. FAMA has originally and autonomously contributed to innovation and about ten of its products have already been internationally recognized and have been patented.
FAMA has collaborated with the most important technology transfer centers and universities and it fully complies with STUVA and AFTES recommendations, with the guidelines of ITA and other competence centers of the sector of tunnels
FAMA has a total area of 20.000 m², 10.000 m² is covered area.
• A factory for gasket production • A factory for accessories production • A warehouse for product storage
FROM ITS EXPERIENCE AS A MANUFACTURER FAMA HAS TAKEN ITS STRENGTH AND AWARENESS TO STUDY VERY EFFICIENT SOLUTIONS AT LOW COST
4 Sustainability To preserve the planet, concrete and rapid actions occur, such as those planned in the UN Global Agenda for Sustainable Development. Production and use of renewable energy, energy savings, regeneration of production waste and recovery of products from differentiated waste disposal, fostering diversity in order to promote a culture of inclusion in a world market where variety contributes to the creation of value, these are the concrete actions taken by FAMA which has always pursued a sustainable business model.
FAMA aims to promote the transition from a direct and extractive economy to a regenerative and circular economy.
FAMA attaches to all its offers a document on the environmental impact assessment. It illustrates the savings of carbon dioxide emission and water that result from the meas- ures adopted.
5 FAMA Time Line
1988 2010 2013 2015 2019 COMPANY SUPPLY OF FIRST DIRECT SALES DELIVERY ATTRIBUTION OF ESTABLISHMENT THIRD-GENERATION WORLDWIDE OF FIRST AVIS D’EXPERTS AFTES GASKET CAROUSEL PLANT 2010 SUPPLY OF FIRST HEELED TOOTH CONNECTOR
2008 2012 2014 2016 FIRST PRODUCT SUPPLY OF FIRST DELIVERY OF FIRST DELIVERY OF FIRST ENTRUSTED ANCHORED GASKET STATIONARY PLANT ANTI-SEISMIC DEVICE TO A DEALER
FAMA Products
400+ 68 621 KM OF CONNECTED TUNNELS KM OF TUNNEL TUNNEL 25+ COUNTRIES 450+ KM OF SEALED OVER THE 5 TUNNEL CONTINENTS
6 Best References TUNNEL EXTERNAL YEAR PROJECT TUNNEL TYPE COUNTRY TUNNEL LENGTH - MT DIAMETER 2008 METRO B1 ROMA Subway Italy 6.500 mm 6.000,00 2010 SURUC WATER TUNNEL Hydraulic Turkey 7.600 mm 4.500,00 2010 LOVAT TUNNEL NAPOLI Railway Italy 4.000 mm 2.300,00 2010 QUEJIGARES Railway Spain 8.900 mm 2.900,00 2011 KISHANGANGA HEADRACE TUNNEL Hydroelectric India 5.900 mm 14.631,00 2011 PANAMA PANDO Hydroelectric Panama 3.500 mm 5.160,00 2011 PANAMA MONTELIRIO Hydroelectric Panama 3.700 mm 7.878,00 2011 RAILWAY TO JERUSALEM ISRAEL Railway Israel 9.700 mm 23.200,00 2012 METRO COPENHAGEN Subway Denmark 5.500 mm 28.140,00 2012 SCILLA REGGIO CALABRIA Power cable Italy 3.800 mm 2.760,00 2013 EVERGREEN VANCOUVER Subway Canada 9.540 mm 1.950,00 2013 DIAMOND HILL TO KAI TAK TUNNELS HONG KONG Subway Hong Kong 7.100 mm 1.540,00 2013 MILANO METRO 4 EXPO LINE Subway Italy 6.060 mm 6.450,00 2014 XEPIAN-XENANMOY LAOS Hydroelectric Laos 5.900 mm 12.365,00 2014 RIYADH METRO LINE 3 Subway Qatar 9.800 mm 4.590,00 2014 RED LINE NORTH UNDERGROUND DOHA Subway Qatar 6.770 mm 22.800,00 2014 METRO CALTANISSETTA Road Italy 14.650 mm 7.800,00 2014 WINDOW POLCEVERA "TERZO VALICO DEI GIOVI" Railway Italy 9.450 mm 1.800,00 2014 AL HAER Sewage Saudi Arabia 3.500 mm 11.900,00 2015 METRO SALONICCO Subway Greece 5.900 mm 3.600,00 2015 METRO TORINO Subway Italy 7.480 mm 1.820,00 2015 PALERMO KNOT TUNNEL Subway Italy 9.070 mm 2.100,00 2015 ST. MARTIN DE LA PORTE TORINO-LIONE Railway France 10.800 mm 8.750,00 2015 VISHNUGAD HEADRACE TUNNEL Hydraulic India 9.500 mm 12.300,00 2015 INNSBRUCK Railway Austria 7.900 mm 28.900,00 2016 CATANIA METRO LINEA NESIMA MONTE PO Subway Italy 10.240 mm 1.760,00 2016 “TERZO VALICO DEI GIOVI” HIGH SPEED MILANO-GENOVA LINES RADIMERO E SERRAVALLE Railway Italy 9.400 mm 34.350,00 2016 FORRESTFIELD AIRPORT LINK Subway Australia 6.770 mm 14.400,00 2016 MILANO METRO 4 LINE EST Subway Italy 6.060 mm 3.730,00 2016 MILANO METRO 4 LINE OVEST Subway Italy 6.400 mm 6.150,00 2016 METRO SALONICCO KALAMARIA Subway Greece 5.900 mm 7.200,00 2016 RIACHUELO LOTTO 1 Hydraulic Argentine 3.600 mm 9.600,00 2017 ANGAT WATER TRANSMISSION Hydraulic Philippine 4.700 mm 6.500,00 2017 DUBAI METRO 2020 Subway United Arab Emirates 9.300 mm 2.500,00 2017 MILANO METRO 4 CENTER LINE Subway Italy 8.850 mm 8.485,00 2017 CUENCA-MATANZA RIACHUELO LOTTO 3 Hydraulic Argentine 4.900 mm 12.040,00 2017 SARMIENTO Subway Argentine 11.120 mm 6.660,00 2017 CATANIA METRO LINEA STESICORO AEROPORTO Subway Italy 10,240 mm 1.875,00 2018 DESVIO COLECTOR DE LA BAJA COSTANERA RIACHUELO Fognario Argentine 5,000 mm 5.400,00 2018 DOHA STORM WATER Hydraulic Qatar 4.140 mm 10.130,00 2018 DUBAI STORM WATER Hydraulic United Arab Emirates 10.700 mm 10.300,00 2018 MANILA PROJECT Subway Philippine 3.500 mm 7.220,00 2018 METRO ALGERI Subway Algeria 10.200 mm 8.450,00 2018 NORTHEAST BOUNDARY TUNNEL WASHINGTON DC Hydraulic United States of America 7.721,6 mm 8.140,00 2018 METRO C ROMA Subway Italy 6.400 mm 5.320,00 2019 BRENNERO TUNNEL CONSTRUCTION EXPLORATIVE CUNICLE Railway Italy 6.420 mm 13.900,00 2019 BRENNERO TUNNEL CONSTRUCTION LINE TUNNEL Railway Italy 10.170 mm 31.500,00 2019 GRAND PARIS L14S GCO4 Subway France 8.450 mm 4.060,00 2019 METRO LIONE Subway France 9.350 mm 2.260,00 2019 METRO PUNE Subway India 6.350 mm 8.960,00 2019 METRO VARSAVIA Subway Poland 6.000 mm 9.660,00 2020 CENTRAL INTERCEPTOR TUNNEL AUCKLAND Sewage New Zealand 5.155 mm 14.400,00 2020 CENTRAL KOWLOON Road Hong Kong 6.830 mm 800,00 2020 CITY LINK AUCKLAND Railway New Zealand 6.840 mm 3.260,00 2020 COASTAL ROAD MUMBAI Road India 11.750 mm 4.140,00 2020 TUNNEL LONATO Railway Italy 9.700 mm 9.300,00 2020 GRAND PARIS LIGNE 16 LOT 2 Subway France 9.500 mm 10.760,00 2020 KERENZENBERGTUNNEL Railway Switzerland 6.770 mm 4.735,00 2020 PALERMO-MESSINA RADDOPPIO LINEA FIUMETORTO-CEFALÙ-CASTELBUONO Railway Italy 9.600 mm 13.400,00 2020 LOS ANGELES OUTFALL Hydraulic United States of America 6.096 mm 11.200,00 2020 METRO LIMA Subway Peru 9.900 mm 22.100,00 2020 RTE MESIL PARIS Power cable France 3.600 mm 2.410,00 2020 SHIP CANAL WATER SEATTLE Hydraulic United States of America 6.298,8 mm 4.250,00 2020 SNOWY HYDRO 2.0 Hydraulic Australia 10.660 mm 29.100,00 2020 TUNNEL SWINOUJSCIE Road Poland 13.000 mm 1.490,00 2020 T2 TRUNK ROAD Road Hong Kong 13.500 mm 4.840,00 2020 TUNNEL MULARROYA Hydraulic Spain 3.300 mm 12.630,00 2020 HANOI METRO CP03 Subway Vietnam 6.300 mm 5.230,00
7 SEALING
FAMA Gasket Strength Elements
Integration system Internal design into formwork of third generation that makes quicker, that allows gasket easier and precise compression gasket positioning thanks to the elongation of the meniscus
Anchorage system into concrete which is currently the best available for its tear resistance
COMPARISON OF CONCRETE ANCHORAGE LOADS EXPERIMENTAL VIRTUALIZATION AND GASKET INTEGRATION TO FORMWORK 14
12 Concrete anchorage load 10 +56%
8 Mold integration strength 6 Load ( kN/m) 4
2
0 0 2 4 6 8 10 12 14 16 18 20 Displacement (mm)
FAMA develops the shape of its profiles through a of stability that, according to FAMA experience, is a massive use of virtualization software (Marc) which condition necessary to obtain good hydraulic seal- allows it to design, profile, and define its characteris- ing performances. tics. Commissioning time is thus reduced As you can see, FAMA gaskets shows excellent re- FAMA has supplied anchored gaskets for many action properties to compression and a good level large works of several hundred km of tunnel.
8 FAMA Soft Corner Technology
r e O n r b o t u c s le e g Soft Corner a an n e gl ut e c Ac orner
COMPARISON OF THE COMPRESSIVE FORCE BETWEEN THE CORNERS OF THE ANCHORED GASKETS Dihedral 140 Gasket used in a angle corner great project in France
120
100 Gasket used in a Compressive force great project in Italy
of FAMA Soft Corner 80 compared to other angles Anchored gasket FAMA 33x16 SOFT CORNER on the market 60
40 Anchored gasket FAMA Load ( kN/202mm) 26x17 SOFT CORNER 20
0 Anchored gasket FAMA 29x14 SOFT CORNER 0 2 4 6 8 10 12 14 16 Gap (mm)
FAMA has designed, certified, produced and suc- FAMA corner angles are manufactured with inno- cessfully used the special Soft Corner to minimize vative technologies and automation. loads and preserve the segment corners from Thus, they perfectly match the segments for a breakage. better sealing.
9 ANCHORED GASKETS
UG046 UG066 UG018 26 x 11 26 x 17 29 x 14
UG016 UG020 33 x 16 44 x 20
MIXED ANCHORED GASKETS With Hydrophilic Barrier
UG027 UG037 UG059 26 x 17 29 x 14 33 x 16
UG048 UG054 33 x 17 33 x 20
Each gasket can be customized to suit technical requirements of pressure and compressive force of the load. The type of compound changes according to use requirements and special conditions.
10 products and services for a sustainable tunnel
GLUED-IN GASKETS
UG068 UG025 UG022 20 x 14 26 x 17 29 x 14
UG004 UG026 UG013 33 x 12 33 x 14 33 x 16
UG057 UG021 33 x 24 44 x 20
MIXED GLUED-IN GASKETS With Hydrophilic Barrier
UG038 UG039 UG028 29 x 14 33 x 14 26 x 17
11 FAMA Special Gasket
HYDROPHILIC GASKETS
STRIP STRIP WITH RIBS HYDROPHILIC CORD
SWELLING OF HYDROPHILIC MATERIAL OVER TIME IN DEMINERALIZED WATER 500
450
400 FAMA supplies a wide range 350 of customizable hydrophilic gaskets 300 conceived according to different % 250 functional techniques. 200 The hydrophilic profile is tested 150 with the groundwater 100 from the place where it would be used. 50
0 0 5 10 15 20 25 30 Time (days)
SWELLING GASKET For abnormal GAPS recovery
UG035 26 x 11 • Contact surface swelling can support abnormal GAPS • Contact surface swelling can compress gaskets after segment installation, thus reducing sliding.
12 products and services for a sustainable tunnel
CHEMICAL PROTECTION SYSTEM For the integration of a protective film on tunnel intrados
Joint sealing with HDPE film is usually done overlapping welded HDPE sheets. FAMA’s solution helps to avoid this long and expensive operation with the use of a special gasket of many integrated keys: • Gasket is anchored to the concrete • Gasket integrates PVC film, thus ensuring sealing • High resistance to organic contaminants • Gasket can have a hydrophilic cord, thus creating a second sealing barrier
GASKET PROTECTION SHIELD For Highly Aggressive Environments
UG043 44 x 26 Gasket Protection Shield is made of two couple profiles that can anchor to concrete. • The external profile is manufactured from materials that can resist high aggressivity • The internal profile is manufactured from materials with high elastic energy conservation
CONFINEMENT GASKET With a Double Barrier
For projects that require a double seal, both on the extrados and on the intrados, FAMA uses the anchored confinement seal that prevents the widespread of water in the lining because of the channeling due to the two gaskets.
13 CONNECTION SYSTEMS AND ACCESSORIES
FAMA Connection Systems
Smartblock may have, The female socket in particular conditions, is manufactured a side that can be screwed in a unique shape into the threaded socket with high-performance concrete anchorage geometry
Smartblock connector is highly customizable in size and performance
FAMA offers, besides gaskets, a complete range of Connector functions are: accessories, and in particular connectors that repre- • Speeding up the installation of the tunnel segment sent the second vital step for a good sealing and an Ensuring segment suspension in cantilever excellent installation of tunnel lining rings. • • Securing closed joints FAMA has a wide range of connectors that can be • Ensuring well-aligned joints customized in size, shape and performance. Preserving concrete integrity FAMA provides detailed technical information on re- • quest. • Ensuring a suitable performance in the concrete female interface of the connector
14 CONNECTION SYSTEMS AND ACCESSORIES
FAMA Connection Systems FAMA Technology for Heeled Tooth
HEELED TOOTH
Collected GAP Data Collected OFFSET Data
HIGH SEALING CONDITION OF LOW RISK CONDITION OF HIGH RISK HIGH SEALING CONDITION OF LOW RISK CONDITION OF HIGH RISK CONDITION OF WATER INFILTRATION OF WATER INFILTRATION CONDITION OF WATER INFILTRATION OF WATER INFILTRATION 70 35
60 30
50 25
40 20 % % 30 15
20 10
10 5
0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 Gap (mm) Offset (mm)
FAMA has patented a particular and innovative de- system offers greater solidity. FAMA connector, in sign for its connectors. The heeled tooth was cre- synergy with the third-generation gasket, ensures ated after a close examination of existing products excellent sealing results, significantly reducing water in the market, identifying their weak points and sug- ingress. gesting improvements. FAMA connector has a grip- FAMA connectors have extraordinary shear and pull- ping system that fits in immediately, without leaving out performance and are manufactured to meet cus- any gaps. The female tooth shape, the male tooth tomer technical requirements. shape, and the materials used, all protect the system The range of FAMA connectors is integrated with against the misaligned insertions that often occur special connectors used for specific requirements. during the phase of segment launching. They include Cross Passage, launching rings, test We can therefore safely affirm that this connection rings and much more.
15 SMARTBLOCK
SB 70-150 220-60 SB 90-160 300-60
SB 90-180 300-80 SB 50-100 250-60
SCREW SMARTBLOCK
SB 90-160 350-60 SB 90-180 350-80
The illustrated connectors represent the basic versions of the category from which the required multiple performance variants are obtained.
16 products and services for a sustainable tunnel
SMARTBLOCK HS - CROSS PASSAGE
HS 130-300 300-80 HS 80-500 330-95
SMARTBLOCK FOR LAUNCHING RING
SEMI SMARTBLOCK SEMI SCREW SMARTBLOCK WITH INTERNAL THREAD
SMARTBLOCK SMARTBLOCK AUTO-PROTECTED FOR REMOVABLE SEGMENTS AGAINST AGGRESSIVE AGENTS
17 CENTERING PINS
CENTERING PIN 65-80 CENTERING PIN 50-90
CENTERING PIN 180-60
CENTERING PIN 230-95 CENTERING PIN 250-95
FAMA centering pins are designed to perform different functions which determine their dimensions and charac- teristics. A full range of devices is available and customizable.
18 products and services for a sustainable tunnel
INJECTION AND LIFTING SYSTEMS
INJECTION SOCKET D60 LIFTING AND INJECTION SOCKET D70
INJECTION SOCKET D121 SAFETY PIN
Injection and lifting systems are designed and manufactured for any of segment dimensions and can be custom- ized in accordance with the customers specific technical request.
19 THREADED SOCKETS DIN 405 THREADED SOCKET THREADED SOCKET THREADED SOCKET T25 × 120 T25 × 140 T25 × 170
THREADED SOCKET T28 × 160
SOCKET WITH METRIC THREAD ISO 261 THREADED THREADED THREADED THREADED SOCKET M10 SOCKET M12 SOCKET M16 SOCKET M24
RAIL SOCKETS THREADED SOCKET T20
20 products and services for a sustainable tunnel
BOLTS AND WASHERS
HDPE washer
Metal washer
Grommet washer
Grommet
Fixing systems with bolts, washers and embedded sockets are used on the radial and circumferential joints of the lining segments in the tunnel; they increase shear and pull-out resistance on connecting joints. A full range of bolts and their FAMA threaded sockets can support tensile strengths from 70 to 400 kN. Bolt length is customized to fit design specification. The length of thread on the bolts ranges from 115 to 155 mm, according to the socket type. Bolts are available in different diameters (20/25/28 mm). The threaded pitch ranges from 5 mm to 12.5 mm (rail screws). The bolts are C40/C45 steel grade and, on customer request, stainless steel 316L or of any other grades. FAMA fixing systems are available in different resistance grades (ASTM A325, 10.9, 12.9). When they can be removed, raw or electrolytically galvanized bolts and washers are supplied, while permanent bolts are treated through a hot-dip galvanizing process or made of stainless steel. The range also includes additional accessories such as HDPE washers, grommet washers and simple grommets.
21 GUIDING RODS
GUIDING ROD WITH CLIP -45° BLUNT GUIDING ROD
GUIDING ROD WITH SCREW GUIDING ROD WITH HOLE
FILLED GUIDING ROD
Guiding rods functions are: • Allowing correct positioning and longitudinal alignment of segments • Reducing the risk of segment damage during installation • Increasing shear resistance between segments of the same ring • Reducing offset between segments minimizing leakage risks FAMA guiding rods are available with requested diameter and length dimensions and are produced using recycled materials.
22 products and services for a sustainable tunnel
LOAD-SHARING CUSHIONS
BITUMINOUS STANDARD OR SELF-ADHESIVE PACKER
WOOD PACKER
FAMA packers are used to avoid cracking and breakage of the segments because of load concentrations. Load-sharing cushions are usually installed on the circumferential side of the segment. The shape and dimensions of the load-sharing cushions are designed for each specific tunnel segment. Load-sharing cushions are available in different materials according to customer technical specifications.
23 PRECASTING
FAMA Sizes and Designs Precast Plant
TBM requirement plan, production, carousel and storage
TBM Total cumulative production Carousel cumulative production Total storage FAMA PRECAST PLANT
Fixed Carousel plant installation plant
Precast plant Precast plant with fixed with variable configuration configuration M1 M2 M3 M4 M5 M6 M7 M8 M9 M1 M2 M3 M4 M5 M6 M7 M8 M9 M1 M2 M3 M4 M5 M6 M7 M8 M9 M1 M2 M3 M4 M10 M11 M12 M10 M11 M12 M10 M11 M12 2019 2020 2021 TBM absorption graphic is structured according to advancement rate and it sizes strategic stocks.
• FAMA plant for segments includes molds both in fixed or carousel configuration
• FAMA designs and manufactures formwork that can be installed on any existing carousel plant with full integration of operational functions and dimensional conditions
• FAMA’s renowned formworks are designed and tested to operate with reinforcing fiber ensuring its excellent distribution within the formwork. Fibres are evenly distributed as a result of the formwork’s perfectly designed and dimensioned vibration system.
24 PRECASTING
FAMA has the Competences to Produce Formworks of the Best Quality and Ergonomics
The study aims to plan tunnel lining precasting, determining: • Precast plant productivity • Precast plant layout • Precast plant size • Ensuring continuous supply of segments to TBM, on schedule The study of the plant ensures a technical coordination with the accessories used and the best result to the customer.
CAROUSEL STRUCTURAL DEFINITION
RING CHARACTERISTICS RINGS SETS
No. Average Maximum No. total ø extrados ø intrados Average width segments Ring volume Formworks set segment segment No. total No. No. sets Transfer formworks [m] [m] [m] / ring [m³] weight ̴ [kg] volume [m³] volume [m³] rings formworks formworks formworks in the carousel
9,6 8,5 2 8 31,3 40000 4 - 1000 48 6 0 48
CAROUSEL CHARACTERISTICS No. of position No. No. No. between No. No. Average no. Concrete Concrete Mold No. formworks No. formworks formworks casting total positions formworks rings in aging volume in aging weight in aging weight in aging assembly lines on assembly aging lines on aging line in translation chamber and in the carousel in aging chamber chamber chamber chamber line aging chamber chamber ̴ [m³] ̴ [kg] ̴ [kg] 1 11 3 12 1 3 48 36 4,5 140,7 337765 180000
PRODUCTION MONTHLY PRODUCTION
Cleaning Complete maintenance Daily Aging time Time in curing cycle time No. shift / day No. hours Working hours hours per day segment (From casting chamber RINGS/ DAY M³ concret Working days M³ concrete Total ring on assembly / shift [hours] per day (included in production to demolding) [hours] / day / month / day / month line [min] working hours) [hours] 10,0 2 8 16 2 84,00 6,5 6,0 10,5 328,4 22 7224 231
ESTIMATION OF REQUIRED PERSONNEL ON ASSEMBLY LINE EACH SHIFT INCIDENCE DIRECT LABOR COST
Incidence of Incidence of Total cost of Insertion Pre-storage Estimated direct labor direct labor the direct labor Formwork Formwork Formwork Disarming Gasket cage and Formwork Extrados and storage workers on on each on m³ on the entire opening demolding cleaning distribution mounting accessories casting finishing managing assembly line segment of concrete production each shift [€ / segment] [€ / m³] [K€] 2 2 2 1 1 2 1 2 1 14 67 17 533
ESTIMATED CONSUMPTIONS
Aging chamber Estimated Estimated Estimated Diesel tank size GPL tank size Temperature Maximum heat request per Steam Reinforcement natural gas diesel GPL (for one day (for one day increasing temperature hour [Kcal/hour] generator size Total cage weight Total consumption consumption consumption consumption) consumption) per hour in the in aging (+12% for (kg steam/h concrete each m³ of reinforcement [Nm³/h] [Kg/h] [Kg/h] [m³] [m³] aging chamber chamber [°C] thermal @ 12 bar) volume concrete cage weight [°C/hour] dissipation) 34,3 27,9 26,1 0,5 0,8 15 50 1894983 3158 31.275 90 2.814.710
Considering TBM supplying requirements during advancement, FAMA has designed a parametric system of plant sizing to identify different configurations which had been evaluated during the preliminary study in order to better support and suggest customer.
25 FAMA Designs Plants for Carousel and Fixed Formworks FAMA designs inhouse the plants for fixed and carousel formworks with its own technicians. The first step for mold design is the creation of a 3D model and a specific FEM analysis that allows the evaluation of the loads to which the formwork is subjected.
Particular attention is given to position safety and ergonomics in order to facilitate the activities of the operator and the consequent increase in efficiency and reduction of concrete segment waste and defects.
FAMA manufacturing is carried out by selected Italian manufacturers having thirty years’ experience in the fab- rication of the equipment.
26 products and services for a sustainable tunnel
FORMWORK FORMWORK WITH AUTOMATIC COVERS WITH FOLDABLE COVERS FOR CAROUSEL
STATIONARY FORMWORK PLANT CAROUSEL SYSTEM PLANT
27 PRECAST EQUIPMENT
CAROUSEL EQUIPMENT CAGE TRANSPORT BELT
DEMOLDING AND TILTING DEVICE TRANSFER WAGON
MECHANICAL OR HYDRAULIC CLAMP
28 products and services for a sustainable tunnel
SPECIAL DEVICES
FORMWORK GROOVE HYDROPHILIC CORD LIFTING BALL CLEANER INSERTER DEVICE FOR SEGMENT ERECTOR
PEA GRAVEL RAIL SOCKET SUPPORT SCREW TOOL INJECTION NOZZLE FOR GROUTING SOCKET PLUG D60-D70
SCREW TOOL SCREW TOOL SCREW TOOL FOR GROUTING FOR NO-RETURN FOR SCREW SOCKET PLUG D121 VALVE SMARTBLOCK
SPECIAL HAMMER TBM STARTER GASKET FOR ANCHORED GASKET TBM starter gasket is used MOUNTING to seal the first tunnel ring
29 TECHNICAL COGENERATION
Sharing Skills and a Propensity for Innovation
FAMA has a wealth of competence and excellence and an attitude to innovation recognized and appreciated by the best global players. An example of this approach is the ANTI-SEISMIC DEVICE
ANTI-SEISMIC DEVICE
Fault
Ductile Convex tensioner spherical washer
Compression flange
Springs Operative Design Maximum Credible Earthquake (ODE) Earthquake (MCE)
GAP (horizontal 10,0 [mm/ring] 18,5 [mm/ring] displacement) OFFSET (vertical 15,0 [mm/ring] 30,0 [mm/ring] Anchor plate displacement)
FAMA anti-seismic device was installed for the first time in 2016 in the metro project of Thessaloniki, in Greece. It was officially presented at WTC 2017 in Bergen (Norway). The anti-seismic device ensures the tunnel rings connection and support its displacement in case of a seismic event, within the maximum technical design limits provided by seismological analysis. The special anti-seismic device features are: • A flexible part of metal springs, suited to avoid adjacent rings displacements • A ductile part to increase the system’s overall deformability • An easy-to-install system • The installation of the device in the segment does not modify significantly the normal preparation steps • Devices for the segment predispositions required to receive the system can be installed in pre-existing formworks • The modification of the formwork is reversible.
30 Technical Support Documentation
SUPPLEMENT FOR PRODUCTS
FAMA usually supplies a series of technical documents produced according to the current rules or on specific customer requests:
• PRECISE ANALYSIS OF PRODUCTS TECHNICAL CHARACTERISTICS • QUALITY ASSURANCE PLAN • PRODUCT TECHNICAL DATA SHEETS • TECHNICAL REPORTS OF VALIDATION TESTS • PRODUCT DRAWINGS • GASKET AND ACCESSORIES INSTALLATION MANUAL • CASE HISTORY
SUPPLEMENT FOR PROJECTS
FAMA usually supplies a series of technical documents produced according to the current rules or on specific customer requests:
• TECHNICAL REPORT – STUDY OF FEASIBILITY • GANTT • QUALITY ASSURANCE PLAN • SAFETY AND ENVIRONMENTAL PROCEDURES MANUAL • FORMWORK DIMENSIONAL CONTROL MANUAL (MCE) • VALIDATION MANUAL • INSTALLATION MANUALS • USE AND MAINTENANCE MANUALS
THE DOCUMENTATION COULD BE TRANSLATED INTO THE REQUESTED LANGUAGE.
31 SPECIAL SERVICES
• Professional support to designers in the technical choice of products and their use. (technical calculation reports, plant and layout sizing, new products’ study and related validation tests).
• Fitting tests for each construction site start-up: FAMA uses the augmented reality technology to overcome travel restrictions, mainly because of COVID-19 pandemic.
• Assistance for the construction site start-up: FAMA provides all the necessary technical support to instruct the staff which uses FAMA accessories and the gaskets in order to facilitate their correct use and minimize errors.
• Trial ring, formwork and tunnel segments measurement, on customer request: - FAMA makes use of state-of-the-art tools such as laser tracker and laser scanner for a precise dimensional measurement. - FAMA carries out, on customer request, the trial ring preparation in its workshops or in the construction site.
TECHNICAL REPORT - VALIDATION OF GASKET SUITABILITY TO PROJECT CHARACTERISTICS
RTC Var. Rev. Lang. Author Approved Date Project
185.21 1 0 IT BORTOLUSSI D. G. BOMBEN 12/01/2021
32 products and services for a sustainable tunnel
33 SCIENTIFIC COLLABORATIONS
TRADE ASSOCIATION
REV0.eng March, 2021 Printed by LUCE S.r.l. - Udine - Italy CONCEPT TECHNICAL CO-GENERATION DESIGN AND DEVELOPMENT TEST AND QUALIFICATION PRODUCTION AND DIRECT SALE SUPPORT AND ASSISTANCE
Reputation | Competitiveness | Skills
FAMA S.r.l Via della Fossa, 6 - 33080 Zoppola, Pordenone - Italy www.famaspa.it | [email protected]