BULLFLEX® Structural Sealings

2

Introduction

BULLFLEX® Structural Sealings have been developed as a special solution for underground excavation. The main application of this system are O-ring Sealing Systems used in combination with tunnel boring machines (TBMs).

BULLFLEX® Structural Sealings consist of patented textile groutable hoses made of high-strength fabric, which are subsequently filled with concrete, featuring an excellent sealing and load-bearing capacity. The hoses are available in different dimensions, allowing an optimum alignment to the excavation dimensions or support perimeter. All system components are light-weight as well as easy to transport and install.

DSI has long-time experience in the application of BULLFLEX® Structural Sealings. With the engineering and on-site support of DSI, this system solution has been successfully used for various global infrastructure projects.

Contents

Introduction ...................................................................................................................3

Fields of Application ......................................................................................................4

Main Advantages ...........................................................................................................4

System Description .......................................................................................................4

System Components .....................................................................................................5

Specifications ................................................................................................................5

Characteristics ..............................................................................................................6

Installation Procedure O-ring Sealing for Microtunneling ..............................................7

TBM O-ring Sealing Installation Procedure (Hose-in-Hose System) .............................8

General Health and Safety Regulations .........................................................................9

Accessories .................................................................................................................10

Further References ......................................................................................................10

3

System Description

The BULLFLEX® system provides an immediate load transfer and form fit between the passive support lining and the ground or rock mass. Thanks to the special filter effect of the BULLFLEX® fabric, the surplus water in the grout fill is immediately drained out, providing an accelerated curing procedure. Hence, the pressure inside the BULLFLEX® system is maintained, inducing an active pre-load into the excavation perimeter which leads to an immediate sealing action. The BULLFLEX® system can easily be adapted to on-site conditions using different diameters or filling media.

Due to the product characteristics of the BULLFLEX® textile, this system can be used for various different sealing applications. The endless, patented BULLFLEX® hose enhances the application as reliable and easy-to-use O-ring

sealings for tunnel boring machines, featuring a special hose-in-hose system.The first BULLFLEX® hose seals the start and launching platforms of shield TBMs (sealing of the annular gap between sealholder and the TBM shield skin). Subsequently, the second BULLFLEX® hose secures the sealing between the excavation line and segment ring. Further applications are so-called bedding hoses for flotation control of process tubes, or O-ring sealings for pipe jacking and structural repair works.

The use of BULLFLEX® structural sealing ensures the protection of machinery and civil structures against flushing media, compressed air, water, and building materials. Each BULLFLEX® structural sealing is customized for its application, backed up with extensive global experience and engineering solutions.

Fields of Application

■ O-ring sealing membrane, installed in the annulus between lining segment rings and outer shell or ground

■ Sealing against water (liquids) and compressed air ■ Launch and receptions of TBMs ■ Sealing or re-lining of existing tunnels ■ Sealing of annular gaps in civil structures ■ Protection and stabilization of the cutterhead during a TBM repair process

Main Advantages

■ Quick and easy to install ■ Pressure rating up to 4 [bar] (58 [psi]) ■ Easy compensation of eccentric and uneven excavation surfaces

■ Application possible even in confined spaces ■ Proven safety against failure of the sealing function in all working phases during passing-by of the TBM

■ Special hose-in-hose system for TBM launching applications ■ Easy handling on-site due to light-weight components ■ Shrink free, UV resistant material ■ High resistance against tearing; no longitudinal seams ■ Inflation can be achieved using various filling media

4

System Components

■ BULLFLEX® hoses ■ Patented endless round woven fabric ■ Default outer diameter range: 230 [mm] (9.1 [in]) to 800 [mm] (31.5 [in])

■ Off-size diameters and special designs are available on request

■ Permeable to air and water ■ Fabric made of Polyamide 6.6 ■ Anti-static, flame resistant, and self-extinguishing

■ Fabric treated with inverse salt-pairs which cool down the flames thanks to an endo-thermal reaction under the flame-point of the fabric

■ Working pressure up to 4 [bar] (58 [psi]) ■ Retention of the grout mineral content while draining due to the special filter effect of the BULLFLEX® system

■ BULLFLEX® filling ports ■ With check valve ■ Inner diameter 32 [mm] (1¼ [in]) or 50 [mm] (2 [in])

■ Fixing devices ■ Webbings ■ Hook-and-loop tapes ■ Clip systems

■ Cement grout ■ Portland cement ■ High early strength

Specifications

Characteristics 1) Unit Value Notes

Material [–] Polyamide 6.6 NylonWeight [g/m2] / [oz/yd2] Approx. 660 / 19.44

Fabric thickness [mm] / [in] Approx. 1 / 0.04

Minimum tensile strengthL 2)

T 3) [N] / [lbf]12,000 / 2,69824,000 / 5,395

100 [mm] / 3.94 [in] widthAccording to EN ISO 10319

Corresponding maximum elongationL 2)

T 3) [%]2020

According to EN ISO 10319

Elastic elongationL 2)

T 3) [%]1515

According to EN ISO 10319

Minimum seam strength [kN/m] / [lbf/ft] 155 / 113

Airflow through fabric at pressure [mbar] ([psi])

10 (0.15)20 (0.30)30 (0.45)

[l/min] / [gal/min]6.5 / 1.713 / 3.419 / 5.0

At 100 [cm2] / 15.5 [in2]

Residual tensile strength [%] 20 - 30After 1 year and under light

exposure in Florida

1) The indicated values are laboratory values and may deviate on-site2) Longitudinal3) Transversal

BULLFLEX® O-ring seal Outer shell Backfill materialGround

Inner shell Filling valve with check function

Principle BULLFLEX® O-ring Sealing

5

Characteristics

Theoretical max. Pressure Resistance depending on the Lining Gap and the BULLFLEX® Diameter

Van Zanten, R. V.: Geotextiles and Geomembranes in Civil Engineering. A.A. Balkema. Rotterdam/Boston, 1986.

Ø = 230 [mm] Ø = 320 [mm] Ø = 400 [mm] Ø = 500 [mm] Ø = 630 [mm] Ø = 800 [mm]

Theo

retic

al m

ax. p

ress

ure

resi

stan

ce [b

ar]

Lining gap [mm]

40

20

35

15

30

10

25

5

00 600100 700200 800300 900400 1000500

6

Note: during inflation (cement injection), all default and recommended personal protective equipment must be used. BULLFLEX® Structural Sealings are resistant against mine water inflow; the fabric itself is only soluble in concentrated inorganic acids and phenol.

Installation Procedure O-ring Sealing for Microtunneling

Mounting of the BULLFLEX® O-ring Sealing for marking the welding spots

Fixation of filling pipes into the BULLFLEX® filling valves Note: to be able to ensure a proper grouting sequence, the filling pipes must be marked with different colors

Welding of screws to the sealing holder Note: BULLFLEX® hoses must be protected against sparks & melted steel

Stepwise grouting process of the three sections

Fixation of the BULLFLEX® O-Rring Sealing in the lower area Increase of the filling pressure up to 4 [bar] (58 [psi]) to achieve active pre-loading

7

TBM O-ring Sealing Installation Procedure (Hose-in-Hose System)

■ Mounting of two hose-in-hose BULLFLEX® O-ring Sealings for marking of the welding spots

■ Welding of screws to the sealing holder Note: BULLFLEX® hoses must be protected against sparks & melted steel

■ Fixation of the BULLFLEX® O-ring Sealing in the lower area ■ Fixation of filling pipes into the BULLFLEX® filling valves Note: it is required to mark the filling pipes with different colors (see above)

■ Phase 1: stepwise grouting of the inner sections of the first and the second hose-in-hose BULLFLEX® O-ring Sealings - sealing of the annular gap between the excavation line (sealholder) and the TBM shield skin

■ TBM advance until the tail has reached the second BULLFLEX® O-ring Sealing (view against driving direction)

■ Phase 2: grouting of the outer hose section of the first BULLFLEX® O-ring Sealing – sealing of the annulus between the TBM shield skin and segment ring.

■ TBM advance until the tail has passed the first BULLFLEX®-O-ring Sealing

■ Phase 3: grouting of the outer hose section of the first BULLFLEX®-O-ring Sealing – now both BULLFLEX® O-rings proof the annulus between excavation line and segment ring

Note: in principle, the sealing will work with one single BULLFLEX® O-ring hose-in-hose assembly as well. However, based on previous experience, a redundant sealing system is recommended.

8

BULLFLEX® O-ring-Seals (hose-in-hose) BULLFLEX® O-ring-Seals (hose-in-hose)

TBM shield skin TBM shield skinSegment ring Segment ring

Excavation direction Excavation direction

TBM tail seal TBM tail seal

General Health and Safety Regulations

■ Ensure that injection hoses are laid out without kinks ■ Avoid contact with any sharp edges in order to prevent the fabric from being damaged

■ Wherever there is a change of direction, the bending radius must not be less than six times the outside hose diameter

■ Screw pumps are high-pressure pumps, therefore only steel-reinforced hoses may be used for grout transport

■ Before starting the machine, ensure that easily workable grout is being used

■ The intake hose must not leak anywhere (especially not at connections), and the inner side of the hoses must be sufficiently lubricated

■ Before undoing the unions and the pump outlet flange, ensure that these components are de-pressurized by starting the main motor of the injection pump in REVERSE direction

■ In order to prevent eye injuries, protective goggles must be worn, also when removing obstructions from the pump

■ The person carrying out the task of pump operation must be at a safe distance from any material that may be discharged

■ Accordingly, other people must be kept out of the immediate vicinity

■ During inflation (cement injection), all default and recommended personal protective equipment must be used

■ BULLFLEX® hoses are resistant against tunnel water inflow; the fabric itself is only soluble in concentrated inorganic acids and phenol

■ Further information is included in the BULLFLEX® material data sheet

TBM O-ring Sealing Installation Procedure (Hose-in-Hose System)

Principle of the hose-in-hose system

■ Phase 1: 2 seals close the annulus between TBM skin and the excavation line

■ Phase 2: The TBM’s tail is located under the second seal. The outer hose of the first seal has been filled and seals the annulus between inner lining and excavation line

9

Accessories

■ BULLFLEX® filling nozzle ■ Attachments for BULLFLEX® filling nozzles ■ Flexible functional sealing inserts and protective inserts for the improvement of sealing capabilities

■ Watertight inlets for up to 8 [bar] (116 [psi]) for emergency sealings and adjustment of existing sealings

■ Steel-reinforced grout pumping hoses or grout pipes, minimum diameter: 2 [in]

■ Gunite pipes ■ Valve extensions ■ Repair kit ■ Electric mortar-mixing pump type MP06 ■ Other injection pump types are available on request

Further References

■ United States Patent No. 5,971,401 ■ Dürrfeld, W.: The Method Of Bullflex® – An Entire New Approach In Making Steel-Rib Supports For Roadways Far More Effective. Rapid Excavation And Tunneling Conference Proceedings. 1981

■ Van Zanten, R. V.: Geotextiles and Geomembranes in Civil Engineering. A.A. Balkema. Rotterdam/Boston, 1986

■ Beyer, M.: Handling of Heavily Alternating Water Inflow in the Shield Driven “Mangfallstollen”. Rapid Excavation and Tunneling Conference Proceedings. 1995

■ Bigby, D.: Application Of RMT’s Remote Reading Telltale System To Monitor Roof Movement During Face Retreat At West Colliery, Germany. 22nd International Conference on Ground Control in Mining (ICGCM). Morgantown, 2003

■ Brown, R., Court, D.: Tunnelling for the Channel Tunnel Rail Link. Rapid Excavation and Tunneling Conference Proceedings. 2003

■ Traylor, M. et al.: Construction of the Detroit River Outfall No. 2. Rapid Excavation and Tunneling Conference Proceedings. 2003

■ Zernich, B.: Northeast Interceptor Sew er Case History. Rapid Excavation and Tunneling Conference Proceedings. 2005

■ Schwarz, J. et al.: Wirksamkeit von Brillendichtungs-systemen bei Ein- und Ausfahrvorgängen unter hohem Wasserdruck – Stand der Technik und neue Entwicklungen. In: Forschung und Praxis 42. Bau Verlag. Köln, 2007

Characteristics 1) Unit Value Notes

Nominal power [kW] 5.5 - 7.5Power supply [V/Hz] 400/60

Pump capacity [m³/hr] / [gph] ≥ 3.5 / 925At 100 [bar] (1450 [psi]);

spiral pump type required

Max. delivery pressure at the hose

[bar] / [psi] 4 / 58Water transport pump

or pressure control pump required

Required inlet pressure [bar] / [psi] 2 - 5 / 29 - 72.5 Mixing liquid: water

W/C ratio [1] 0.4530% cement and 70% fly ash

or equivalent filler material

Max. grain size filling material [mm] / [in] 4 / 0.161) In combination with the BULLFLEX® system

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Please Note: This brochure serves basic information purposes only. Technical data and information provided herein shall be considered non-binding and may be subject to change without notice. We do not assume any liability for losses or damages attributed to the use of this technical data and any improper use of our products. Should you require further information on particular products, please do not hesitate to contact us. 04

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