PRECAST CONCRETE SEGMENTAL LINERS FOR LARGE DIAMETER ROAD TUNNELS Literature Survey and Synthesis FHWA-HIF-20-035 September 2020 Precast Concrete Segmental Liners Large Diameter Road Tunnels – Literature Survey and Synthesis Technical Report Documentation Page 1. Report No. 2. Government Accession No. 3. Recipient’s Catalog No. FHWA-HIF-20-035 4. Title and Subtitle 5. Report Date September, 2020 Precast Concrete Segmental Liners for Large Diameter 6. Performing Organization Code Road Tunnels – Literature Survey and Synthesis 7. Principal Investigator(s): 8. Performing Organization Report William Bergeson, PE (FHWA), John Wisniewski, PE (WSP), Sotirios Vardakos, PhD, (WSP), Michael Mooney, PhD, PE (Colorado School of Mines), Axel Nitschke, PhD, PE (WSP) 9. Performing Organization Name and Address 10. Work Unit No. (TRAIS) WSP USA, Inc. One East Pratt Street 11. Contract or Grant No. Suite 300 DTFH6114D00048 Baltimore, MD 21202 12. Sponsoring Agency Name and Address 13. Type of Report and Period Covered Final Report Federal Highway Administration 09, 2018 – 09, 2020 U.S. Department of Transportation 14. Sponsoring Agency Code 1200 New Jersey Avenue, SE DOT/FHWA/HIF Washington, DC 20590 15. Supplementary Notes Cover photo: SR 99 Tunnel, Seattle, Washington. Photo: John Wisniewski. 16. Abstract Increased roadway traffic demands have led to a notable increase of large diameter tunnel boring machine-driven tunnels across the world. The technological advancements of tunnel boring machines have made them a viable technical option for tunneling in difficult conditions in urban environments at ever increasing diameters. Such tunnels utilize precast concrete segmental linings. Although precast concrete segments have been widely used and designed in the US since the mid-1970s, the significant increase in diameter demands brings about new challenges in design and construction. Various international publications and practice manuals have been authored about segmental lining design. The present document is the first phase of an FHWA research initiative focused on the design of large diameter precast concrete segmental linings. This document provides an overview of the literature survey and synthesizes the current state of the practice along with raising potential knowledge gaps for future research. 17. Key Words 18. Distribution Statement Tunnel, lining, precast concrete, segmental lining, fiber reinforced concrete, literature, research, knowledge gap, design, codes, standards. No restrictions. 19. Security Classif. (of 20. Security Classif. (of 21. No. of Pages 22. Price this report) this page) UNCLASSIFIED UNCLASSIFIED 154 Form DOT F 1700.7(8-72) Reproduction of completed page authorized i Precast Concrete Segmental Liners Large Diameter Road Tunnels – Literature Survey and Synthesis FOREWORD The Federal Highway Administration (FHWA) sponsors research about the use of large diameter precast concrete segmental tunnel linings in highway tunnels. The basic technology of conventionally reinforced precast concrete segments is relatively matured for smaller diameter tunnels. It has been in use in the United States for nearly 40 years (and even longer in other parts of the world). However, recent advances in the use of steel fibers for concrete reinforcement, joint hardware and details, gasket technology, high-strength concrete mixes, and material durability warrant study to provide uniformity of application, identification of practices and details for use in large-diameter tunnels. The work of this research includes a literature survey to identify gaps in the current body of knowledge (“knowledge gaps”), computer modeling and laboratory research, and engagement of industry stakeholders through a workshop that will be used to solicit input on the research plans. The work herein will also build on prior research work performed on design approaches for Tunnel Boring Machine (TBM) excavated tunnels. The objective of this research is to provide technical expertise to advance the current state of practice for the analysis, design, detailing, fabrication, installation, inspection, and maintenance of precast concrete segmental tunnel linings for large diameter highway TBM-tunnels in the US. The research includes several elements: • conducting a literature survey and development of a literature synthesis of the current state of the practice; • development of computer modeling and laboratory testing workplans; • hosting an industry workshop to solicit input from technical organizations, designers, contractors and researchers regarding the workplans; • executing research workplans and presenting research results in reports that summarize the finding of the research; • development of document presenting suggested practices for design of large diameter precast concrete segmental tunnel linings. This document provides an overview of the conducted literature survey and synthesizes the current state of the practice. Thus, it may potentially lead to additional research. ii Precast Concrete Segmental Liners Large Diameter Road Tunnels – Literature Survey and Synthesis Notice This document is disseminated under the sponsorship of the U.S. Department of Transportation (USDOT) in the interest of information exchange. The U.S. Government assumes no liability for the use of the information contained in this document. The U.S. Government does not endorse products or manufacturers. Trademarks or manufacturers’ names appear in this report only because they are considered essential to the objective of the document. They are included for informational purposes only and are not intended to reflect a preference, approval, or endorsement of any one product or entity. Non-Binding Contents The contents of this document do not have the force and effect of law and are not meant to bind the public in any way. This document is intended only to provide clarity to the public regarding existing requirements under the law or agency policies. However, compliance with applicable statutes or regulations cited in this document is required. Quality Assurance Statement The Federal Highway Administration (FHWA) provides high-quality information to serve Government, industry, and the public in a manner that promotes public understanding. Standards and policies are used to ensure and maximize the quality, objectivity, utility, and integrity of its information. FHWA periodically reviews quality issues and adjusts its programs and processes to ensure continuous quality improvement. iii Precast Concrete Segmental Liners Large Diameter Road Tunnels – Literature Survey and Synthesis ACRONYMS 2D Two Dimensional 3D Three Dimensional AASHTO American Association of State Highway and Transportation Officials ACI American Concrete Institute AFTES French Tunneling and Underground Space Association ASCE American Society of Civil Engineers ASTM ASTM International BAST German Federal Highway Research Institute BSI British Standards Institute BTS British Tunneling Society Caltrans California Department of Transportation CBBT Chesapeake Bay Bridge Tunnel CEB Comité Euro-International du Béton CFD Computational Fluid Dynamics CMOD Crack Mouth Opening Displacement CNR Italian Research Council DAfStb German Committee for Reinforced Concrete DAUB German Tunneling Committee of the International Tunneling Association DB Federal German Railway Authority DBV German Society for Concrete and Construction Technology DOT Department of Transportation ECIS East-Central Interceptor Sewer EN European Commission Joint Research Center EPB Earth Pressure Balanced FDOT Florida Department of Transportation FE Finite Element FEA Finite Element Analysis FEE Functionality Evaluation Earthquake FHWA Federal Highway Administration fib International Federation for Structural Concrete FIP Fédération Internationale de la Précontrainte FRC Fiber Reinforced Concrete FRP Fiberglass Reinforced Plastic GFRP Glass Fiber Reinforced Polymer HFRC Hybrid Fiber Reinforced Concrete HPFRCC High-Performance Fiber Reinforced Cementitious Composite ICE Institute of Civil Engineers ITA-AITES International Tunneling Association JSCE Japan Society of Civil Engineers kN Kilo Newton LRFD Load and Resistance Factor Design MDE Maximum Design Earthquake Mpa Mega Pascal NAT North American Tunneling Conference NCHRP National Cooperative Highway Research Program NEIS Northeast Interceptor Sewer NFPA National Fire Protection Association iv Precast Concrete Segmental Liners Large Diameter Road Tunnels – Literature Survey and Synthesis NTI National Tunnel Inventory NTIS National Tunnel Inspection Standards NYCDOT New York City Department of Transportation NYSDOT New York State Department of Transportation ÖVBB Austrian Society for Concrete and Construction Technology PCTL Precast Concrete Tunnel Lining PFDHA Probabilistic Fault Displacement Hazard Analysis PGA Peak Ground Acceleration PGV Peak Ground Velocity PIRAC World Road Association RC Reinforced Concrete RETC Rapid Excavation and Tunneling Conference RIFD Radio Frequency Identification RILEM International Union of Laboratories and Experts in Construction Materials, Systems and Structures SEE Safety Evaluation Earthquake SFRC Steel Fiber Reinforced Concrete SIA Swiss Society of Engineers and Architects SSR Stress Strain Relationship STUVA Research Association for Tunnel and Transportation Facilities Svensk Swedish Standards Institute TAC Tunneling Association of Canada TBM Tunnel Boring Machine TOMIE Tunnel Operations, Maintenance, Inspection, and Evaluation UK United Kingdom ULS Ultimate Limit State US United