Getting you there. - Hilti€¦ · and fastening technology to tunnel projects around the world. In fact, there are probably very few tunnels where Hilti has not done so. Hilti’s

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Getting you there.

Hilti. Outperform. Outlast.

Competence in Tunneling

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Hilti – decades of competence in tunnels.

Since its early beginnings in the 1940s, Hilti has supplied toolsand fastening technology to tunnel projects around the world. In fact, there are probably very few tunnels where Hilti has notdone so.Hilti’s expertise is utilised in all phases of tunnel construction,from tunnel driving all the way through to the installation ofequipment. More recently, the field of tunnel rehabilitation andretrofit has gained in importance. In many cases, the key benefitfor designers and contractors is Hilti’s technical support, combined with dependable products. The specific experiencegained through Hilti’s involvement in many tunnel projects worldwide results in a competitive advantage for our customers.

Temporary applications

During the tunnel drive a great numberof items must be fixed and kept out of harms way. Electricity, compressedair, water and ventilation air must all betransported through cables and pipesfastened along the tunnel.

Pages 4– 9

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Structural and civil works

Where formwork must be fastened,membranes fixed or rebar installed afterthe concrete is poured, Hilti’s productscome into their own. No surprises can betolerated when a problem in one area ofthe tunnel may bring the whole construction process to a halt.

Pages 10–16

Mechanical and electrical

Equipment and installations make up20% of the total investment for a modern tunnel. Whether the corrosive attack of exhaust fumes or design fora catastrophic fire is of relevance,Hilti’s competence can be dependedupon.

Pages 17–22

Retrofit and rehabilitation

Existing tunnels have to be widened and heightened, repairs undertaken after fires and ventilation conceptschanged. All these lead to adaptations in the tunnel structure requiring fasteningand demolition technology provided byHilti.

Pages 23–27

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Temporary Fastening

DX 460 powder-actuatedfastening tool • Robust and reliable• The world’s most widely used

cartridge tool

R 36 washer • For attaching to nails and studs• Additional accessories available

to accommodate special needs

Washer holder • Key when handling extra washers

X-ZF general purpose nail • Easy to load, all in one

HSA-W angled anchor • An efficient alternative where

powder-actuated fasteners arenot the optimum solution

Challenge of the application Especially when using drill and blast tunneling (e.g. NATM), shotcrete is used to provide the initial lining. Often this will be reinforced with wire mesh. While this issometimes held in place by the main rock anchors, additional layers of mesh haveto be fastened to the first shotcrete coating.

Hilti solution & competence For decades, the Hilti X-ZF nail with large steel washers has been the solution ofchoice. Speed, reliability and economy considerations are the key decision factors. Alternatively, the Hilti HSA-W angled anchor will provide a hold in substrates thatmay not be suitable for nail penetration.The relevant accessories, such as a washer holder, make the application professional and suitable for underground work.

Reference projects • Serebryanoborsky Tunnel, Moscow (2006)• Arlberg Tunnel, Austria (2005)• Val de Rennes, France (2004)• Gotschna Tunnel, Switzerland (2003)• Flims, Switzerland (2002)• Bergbock Tunnel, Germany (2003)• Rennsteig Tunnel, Germany (2002)

Fastening reinforcing mesh for shotcrete

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DX 460 powder-actuated fastening tool • Rugged, robust, simple to service• Easy-to-load cartridge strips

Yellow cartridges • Optimal for medium-duty applications

X-SW nail • Flexible, to protect membrane from

tearing• Available for use with magazined

nails

HPS-1 impact anchor • Economical• Ideal where DX cannot be used

Temporary Fastening

X-ZF general purpose nail • Perfect in shotcrete• Reliable hold – every time

Challenge of the application Water is perhaps the most natural companion of any tunnel builder. Where drainage is required locally or across large surfaces, eggbox-pattern drainage membranes ordrainage half-pipes are used.

The installation must be fast and subsequent work (membrane fastening, concretepouring) must not jeopardize the location of the drainage membrane or half-pipes.

Hilti solution & competence Hilti’s DX powder-actuated fastening system is recommended by several of theleading drainage membrane manufacturers.

The Hilti DX 460 fastenig tool has been used successfully in this application under-ground as well as above ground. The X-ZF 32 S23 nail has proven to be a universalsolution many million times over, but the Hilti fastener range offers many alternatives to accomodate changing requirements.

Reference projects • Gotthard Tunnel NEAT, Switzerland (2005)• Brixlegg Tunnel, Austria (2005)• Botniabanan, Sweden (2005)• Socatop Tunnel, France (2005)• Tunnel de Monts, France (2005)• Metro Madrid, Spain (2005)• Madrid-Valencia high-speed train, Spain (2005)• Metro de Mallorca, Spain (2005)• Bergbock Tunnel, Germany (2003)• Hochwald Tunnel, Germany (2001)

Fastening drainage membranes and half-pipes

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X-ZF 37 S23 nail with washer • Large steel washer to distribute

clamping force • Economical for mass application

DX 351 powder-actuated fastening tool • Fully automatic• Well balanced and light

DX 35 powder-actuated fastening tool • Robust and strong• Well suited to stretch geo-textile

with protruding nail

PVC / polyolefine washer • Material compatibility to membrane

safeguarded• Defined rupture point in washer socket

to account for rock movementsChallenge of the application Speed is almost everything when the highly specialised crews of membrane fixerstake over a tunnel section. Almost - because the near-religious attention to notdamaging the membrane in any way is yet more paramount.

1– 3 mm thick membranes from PVC or polyolefines are attached in 1 or 2, sometimes 3 layers. A geotextile between the shotcrete and the membrane provides drainage paths and cushioning.

Hilti solution & competence For several decades Hilti has dominated the use of DX nails (e.g. X-ZF 32 S23) incombination with specific synthetic washers designed to be hot-welded to themembrane.

The nail and plastic washer is fastened through the geotexile and thus holds thesame.

Where 1000 shots per day are almost commonplace, reliability of the tools (e.g. DX 35, DX 351) is paramount.

Reference projects • Brixlegg Tunnel, Austria (2005)• Tunnel de Monts, France (2005)• Gotthard Tunnel, Switzerland (2005)• Lötschberg Tunnel, Switzerland (2004)• Sidney PRL, Australia (2005)• Strengen Tunnel, Austria (2004)• Semmering, Austria (2003)

Fastening impermeable membranes

Temporary Fastening

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HUS-H screw anchor • Fully removable• High loads at small edge distances

HLC-EO hook sleeve anchor • Removable• Economic solution

X-FB fastener • Quick to install• Compatible with dozens of other

temporary applications

TE 16-M rotary hammer• Compact dimensions and good bal-

ance for high working comfort

PD 30 laser range meter• One-person distance measuring• Pocket size• Rugged and dust protected (IP54)

Challenge of the application Fresh air, water, electricity, compressed air – all these need to be carried along any tunnel during the construction phase. In addition, temporary lights must be fastened, telecom units installed, transformer stations held in place.

The requirements to be met by the relevant fastenings are as numerous as the tunnels: When pre-cast concrete segments are used for lining, drilling is often restricted to certain areas of the element. Anchors that allow small edge distancesare then useful. Often, removability is a key asset as well. And in all cases nobodywants to spend much time fastening the ventilation ducts.

Hilti solution & competence Hilti’s added value really is the breadth of its product range: DX cartridge technology for quick light-duty fastening is part of our offering, as areheavy duty anchors to hold up large-diameter water evacuation pipes.

Thus, Hilti can offer what you need, not what just happens to be in the catalogue.

Reference projects • Collector Blagis, France (2004)• Val de Rennes, France (2004)• Metro Cairo, Egypt (2003)• Metro de Mallorca, Spain (2004)• Amsteg Power Station, Switzerland (2002) • Dresden Coschütz /Dölzschen Tunnel, Germany (2004)• Bergbock Tunnel, Germany (2003)• Hochwand Tunnel, Germany (2001)

HKD flush anchor • Internally threaded• Flush with the surface

DX 460 powder-actuated fastening tool • Rugged, robust and simple to service• Easy-to-load cartridge strips

Fastening temporary ducts, cables, illumination, pipes

Temporary Fastening

HVU adhesive anchor system • Suitable for dynamic loading• Easy to install, no waste of resin• Economical heavy duty anchor for

serial applications

PR 25 rotating laser • Leveling and aligning up to 200 m• Rugged design and dust protected

TE 16-M rotary hammer • Compact dimensions and good bal-

ance for high working comfort

Challenge of the application Temporary rails are commonly used in underground construction. The two mainapplications are • Fastening of rails for the complete supply of tunnels by train, especially if driven by

TBMs• Fastening of rails for the tunnel formwork carriage of the inner lining and

≠subsequent work stations

Depending on the application and required life span, the requirements vary fromminimal to significant in terms of load level, dynamic resistance, removability andcost.

Hilti solution & competence While many products of the Hilti range can be fit for the purpose, the typical anchorused is HVU in the case of more severe loading and life span requirements, such asfor tunnel rails. Where only little load and a few load cycles are expected, HUS-Hand HSA have been utilised successfully.

By using Hilti drills such as the TE 16 in combination with a PR 25 rotating laser thetrue line for the rails can be found with precision.

Reference projects • Tunnel de Monts, France (2005)• Metro Madrid (Metronorte), Spain (2005)• Gotschna Tunnel, Switzerland (2004)• Flims Tunnel, Switzerland (2005)• Vereina Tunnel, Switzerland (2000)

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Fastening rails for TBM trailers or formwork carriages

HUS-H 16.5 screw anchor • Perfect for temporary fastenings• Fully removable • Standard product comes in corrosion

protection class “hot-dip galvanized”

HSA stud anchor • Easy to install• Economical for volume temporary

applications

DD EC-1 diamond coring system • Hand-held tool for anchor and through

holes of 8–35 mm diameter

Temporary Fastening

HVU adhesive anchor system • Suitable for cyclic loading• Easy to install, no waste of resin• Economical heavy-duty anchor for

serial applications

PR 25 rotating laser • Save on the most time consuming

operation of fastening: Alignment andpositioning

• Leveling and aligning up to 200 m• Rugged design and dust protection

TE-C3X hammer drill bits • Up to 30% longer life than regular drill

bits• Innovative helix design for rapid drilling

progress and excellent dust removal

Challenge of the application Especially in TBM-driven tunnels, mucking out is frequently done with conveyor beltsystems. Their high capacity and continuous operation help reduce traffic in thealready congested tunnel cross section.

Conveying systems are installed temporarily but often remain in place for severalyears in long tunnels.

Fastenings must be economical, yet securely withstand any dynamic loading and oscillation from the belt operation.

Hilti solution & competence Given the loads, dynamic effects and economic considerations, the solution ofchoice is often an adhesive anchor.

The HVU adhesive capsule system or the HIT injection mortar have both been usedsuccessfully.

Reference projects • Collecteur Blagis, France (2004)• Gotthard Tunnel, Switzerland (2004)• Guadarrana Tunnel, Spain (2004)• Metro Barcelona, Spain (2006)

HIT-RE 500 adhesive anchorsystem and HAS-E rods • Comparably insensitive to installation

variations • Highest load values combined with low

sensitivity to installation anomalities• Easy adaptability with respect to

anchor length

TE 16-M rotary hammer • Robust and versatile:

Ideal for most on-site installation jobs

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Fastening conveyor belts

Temporary Fastening

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Challenge of the application Post-installed rebars using adhesive resins are a common sight in constructiontoday. They are indispensable, however, in tunnel retrofit. Where cross sectionsneed to be altered when their use changes or suspended ceilings are renewed asthe ventilation concept becomes obsolete, rebars are generally used to connect oldand new concrete.

As part of the primary tunnel structure the connections must have a life expectancy in line with the main parts of the structure.

Hilti solution & competence With more than 20 years in the market, the Hilti HIT family can offer by far thelongest experience in injection technology for anchors and rebars. With a load performance fully equivalent to cast-in bars and corrosion resistance even better(e.g. HIT-RE 500), the solution of the market leader is capable of fulfilling the mostadvanced requirements.

The resin itself is complemented by a powerful range of accessories like dispensersand hole cleaning equipment, even for jobs of industrial proportions.

In addition, the Hilti drilling technology (hammer or diamond) as well as the PS 200Ferroscan helps you identify and combat any problems, even before you hit them.

Reference projects • Metro Madrid, Spain (2005) • Dresden Coschütz/Dölzschen Tunnel,• Metro Barcellona, Spain (2005) Germany (2004)• Tunnel de Monts, France (2005) • Weser Tunnel Bremen,• Socatop, France (2005) Germany (2005)• Bruxelles Airport, Belgium (2000) • Herren Tunnel Lübeck, • Tunnels in Velasquez Highway, Germany (2005)

Chile (2005) • High Speed Train Madrid-Valencia,Spain (2005)

TE-YX drill bit • Full carbide head for high durability• Anti block tip for rebar impacts

TE 76P ATC combi hammer • High performance and safety with

Active Torque Control ATC• Theft Protection System TPS

PS 200 Ferroscan • Rebar detection, cover measurement

and rebar diameter estimation• Immediate high-res image• Wireless, dust-protected, rugged

HIT P-8000 D pneumatic dispenser for jumbo foil pack (1400 ml) • Speedy injection• Pre-selection of resin volume

Rebar installation

HIT-RE 500 adhesive anchorsystem • Highest load values combined with low

sensitivity to installation anomalities• Foil pack minimizes waste• Better corrosion protection than cast-in

bars

Structural and Civil

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HVZ adhesive anchor system • Available in many steel qualities,

including HCR 1.4529• Tolerates concrete cracks (shrinkage)• Suitable for fatigue loads• Good electric isolation• Tested for fire resistance

X-BT stainless steel threadedstud for coated steel• Corrosion resistant equal to or better

than standard A4 (A316) steel.• Blunt tip: no through penetration• High load values with high consistency• Speed of fastening

Challenge of the application While aesthetic considerations are often the principal objective, tunnels are in factclad for a number of reasons. Cladding panels can provide improved reflectivity,easy tunnel cleaning, sound absorption especially in portal areas, as well as fireprotection for the tunnel structure.

Shock-like suction and compression loads from passing trains and trucks requiresubstantial fatigue resistance of fasteners. Today’s high-speed trains can causepressure changes of more than 6kN/m2. With humidity and corrosive agents alwayspresent in tunnels, corrosion is also a key consideration. Not to mention fire resistance where panels must not become detached in a catastrophic event.

Hilti solution & competence For decades, Hilti has provided fastening solutions to contractors concerned withcladding systems. Due to difficult accessibility for inspection, stainless steel in highgrades is more often the rule than the exception.

If serious dynamic loads must be considered, adhesive anchors such as the HVZ adhesive capsule system are most suitable. In less demanding cases, mechanicalanchors such as the Hilti HSA stud anchor or the Hilti HKD impact anchor can beused.

Where cladding sub-structures have to be fastened to steel members, the X-BT cartridge driven fastener delivers obvious speed advantages and high load valuesat the same time.

Reference projects • Tokyo Metropolitan, Japan (2006)• Metro Prag, Czech Republic (2002)• Metro München, Germany (2005)• Bramsch-Tunnel Dresden, Germany (2002)

HKD flush anchor • Internally threaded• Flush with the surface• Economical for mass applications• Tested for fire resistance

DX 351 BT powder-actuatedfastening tool • For efficient and convenient setting

of the X-BT M10 threaded studs

PD 32 laser range meter • High accuracy (±1.5 mm)• Set offset of panels• Measure clearances and check traffic

gauge

Cladding panels


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HK6 board fastener • Available in all relevant steel qualities• Various head configurations available

for optimal installation

TE 2 rotary hammer • Powerful, light-duty rotary hammer drill

for a variety of applications

TE-C3X hammer drill bits • Up to 30% longer life than regular drill

bits• Innovative helix design for rapid drilling

progress and excellent dust removal• Gradient technology for superior

ruggedness

PD 32 laser range meter • Measures distances & calculates areas

on the spot• Easy one-person verification of

«as-built» measurements

HSA stud anchor • Easy to install• Economical for volume applications

Challenge of the application Tunnel fires produce extremely high temperatures within very short time spans.Amongst other damage, this is known to cause “explosive spalling”. For years, fire protection board has been used to shield structural components from the heat.

Depending on the system, four to ten fasteners are used per square metre. Theanchors are exposed to the corrosive tunnel atmosphere and/or cyclic wind suctionloads during their complete life time. Of course, an adequate fire resistance of thefasteners is paramount.

Hilti solution & competence Since 1981, Hilti has continuously gathered data on corrosion of materials in tunnelatmospheres (see page 29). Material samples have been monitored for decades inreal- life weathering tests.The resulting knowledge is coupled with a comprehensive understanding of fireresistance in fasteners gained through hundreds of in-house and independent firetests.Drilling and measuring technology complements this competence on fasteners.

Reference projects • M30 Madrid, Spain (2006)• Metropolitan Highway, Japan (2006)• Tokyo Chinmai Tunnel, Japan (2001)• Frejus Tunnel, France (2003)• Metro Prague, Czech Republic (2002)

Fastening fire protection board


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X-CR 48 S15 stainless steel nail • Very fast installation• Stainless steel material similar to

grade 1.4546

DX 460 powder-actuated fastening tool • Robust and reliable• The world’s most widely used

powder-actuated fastening tool

HK6 anchor with wire-mesh-clip • Available in all usual steel grades• Suitable for cracked concrete

HSA stud anchor • Easy to install• Economical for volume applications

Challenge of the application Temperatures of up to 1300°C within a few minutes of a fire starting can cause significant damage to concrete structures. Fire protection mortars are used moreand more frequently in tunnel construction and rehabilitation. Due to their relativelylow cost they often compete well with more traditional board systems. These mortars are usually applied in thicknesses of 30 –50 mm. In order to secureand reinforce any sections with disturbed bond to the substrate, a wire mesh isusually fastened to the base material.

An economical fastening solution that nevertheless withstands the fire and possible corrosion attack must be used.

Hilti solution & competence The fasteners supplied by Hilti are only a part of the complete solution. Designersand applicators are usually looking for a harmonized system of mortar, wire meshand the fastening solution that is – ideally – tested together.

Hilti therefore works with several suppliers in the relevant fields to develop and test adequate solutions.

Depending on the requirements, DX powder-actuated fasteners and HK6 or HSAanchors can be utilised optimally. In most cases, stainless steel fasteners and wiremesh are selected.

Reference projects • Serebryanoborsky Tunnel, Russia (2007)• Tunnel Brünnen, Switzerland (2006)• Tunnel de Foix, France (2005)

TE 2 rotary hammer • Powerful, light-duty rotary hammer drill

for a variety of applications

Fastening wire mesh for sprayed fire protection


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Challenge of the application The majority of transportation tunnels are rail or metro tunnels. These require fastening of the track, often on a solid concrete slab. These fixings are subjected tovery high alternating loads making fatigue the governing design factor. In addition,stray currents and related corrosion effects are a major issue to be dealt with. Andgiven the industrial operation, a professional setting process is essential.

An early decision on the fastening system can – in many cases – save millions by reducing the required tunnel cross section.

Hilti solution & competence Hilti offers three major rail anchor lines (HRA, HRT, HRC), designed to safely transfer the oscillating axle loads from the rail into the concrete structure. As no two tunnels are the same, and as the requirements vary from country to country, these are available in many variants. Where called for, simpler solutions have been engineeredas well.

In addition, Hilti provides a comprehensive range of drilling, setting and aligningequipment – satisfying the industrial approach of today’s rail installation professional.

Reference projects • Perth Light Rail, Australia (2006)• London Underground, UK (2005)• Metro Madrid, Spain (2005)• Metro Milan, Italy (2005)• New York City Metro, USA (2005)• Tram Way Milano-Ginisello, Milan (2005)

HRA, HRT, HRC rail anchors • Fully tested for fatigue loads• Plastic sleeve or injection mortar pro-

tect effectively against stray currents

DD 130 diamond coring system • Hand-held or rig mounted operation

for flexibility in use

PD 32 laser range meter • Set-out and adjust with laser

accuracy

HIT-RE 500 adhesive anchorsystem • Highest load values combined with low

sensitivity to installation abnormalities• Foil pack minizes waste• Better corrosion protection than

cast-in bars

Fastening rail track

HIT P-8000 D pneumatic dispenser forjumbo foil pack (1400 ml) • Speedy injection• Pre-selection of resin volume


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Challenge of the application Inner city tunnels and other shallow underground works are often constructed usingthe cost effective “cut & cover” method. This usually requires the roof slab to befastened into diaphragm walls. Such ceilings are typically constructed of cast-in-place concrete or steel girders with pre-cast concrete slabs. Depending on thedesign, the requirements range from shear and / or moment transfer via grouteddowels and rebars to water tightness, corrosion resistance and fire safety considerations.

Hilti solution & competence Whether a professional rebar-connection is needed or steel bearings must be fastened with anchors, Hilti as global leader in fastening technology can provideboth, in addition to professional design support, on-site installation training andHilti’s compatible drilling technology.

Reference projects • Metro Madrid, Spain (2005)• Metro Singapore, Singapore (2000)• Metro Sydney, Australia (2001)

Cut & cover: Fastening of roof slab

TE 76P ATC combi hammer • High performance and safety with

Active Torque Control ATC• Theft Protection System TPS

HDA heavy duty anchor • Undercut security and highest loads• Performance reserves when ground

movements cause load peaks

HVU + HAS • Any diameter, any size M8 – M39• Flexibility and high loads• Minimised sensitivity to site irregu-

larities



HIT-HY 150 dual foil packresin • For concrete• 10 years experience for zero surprises• Added cement for corrosion protection


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Challenge of the application Where thousands of people pass through a metro station on a daily basis, underground structures require attractive, safe and bright finishes on walls and ceilings. In addition, safety equipment such as screen doors on the platforms arebecoming the rule in many municipal networks.

Hilti solution & competence Strut support systems with all their components, enabling quick installation, areavailable in many versions and materials. In this way one system can be used toadvantage in various situations – always supplemented by Hilti’s broad anchor systems range.

Where fire compartmentalisation is required, Hilti’s fire stop engineers can help withthe market leader’s products and expert advice.

Reference projects • Metro Paris, France (2005)• Metro Shanghai, China (2005)• Metro Guang-Zhou, China (2005)• Metro Vienna, Austria (2005)• Metro Munich, Germany (2005)• Metro Hong Kong, Hong Kong (2003)• Metro Prague, Czech Republic (2002)• Airport Tunnel Kloten, Switzerland (2002)• Metro Singapore, Singapore (2001)• Metro Berlin, Germany (2004)

MQ channel system • Flexible and versatile• Quick-lock system for speedy

installation

HIT-RE 500 adhesive anchorand HAS-E rods with centering rings • Guaranteed electrical insulation • No loosening of the anchor even after

millions of load cycles

PML 32 line laser • Self-leveling for horizontal and vertical

alignment• High dust and moisture protection

HST stud anchor • Available in HCR stainless steel for road

tunnels• Tested for tunnel fires

Finishing of metro stations (cladding, screen doors, ceilings)

HVU adhesive anchor system• Suitable for dynamic loading• Easy to install, no waste of resin• Economical heavy duty anchor for serial

applications


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HVZ adhesive anchor system • Highest safety level• Tolerates concrete cracks (shrinkage!)• Suitable for dynamic loads• Good electric insulation



Challenge of the application Jet ventilators are some of the heaviest pieces of equipment placed directly above traffic in a tunnel. In addition to the weight, their fasteners can be subject to dynamic loading from unbalanced propellers or wind pressure induced by traffic.

The high requirements on security are also manifested by the use of various safetycables or chains designed to hold a falling ventilator if the anchors should fail.

High standards regarding anchor corrosion resistance, dynamic loading or concretecracks are therefore the rule.

Hilti solution & competence These requirements are reflected in many different national codes and regulationswhich govern this application. Hilti offers a comprehensive range of fasteners:• Adhesive anchors such as HVZ, HVU in stainless steel

(including HCR material 1.4529)• Mechanical anchors such as HDA, HSC, HSL-3 and HST, in various stainless

steel grades.

Hilti hammer and diamond drilling technology complements the offering.

Reference projects • Péripherique Paris, France (2006)• Socatop, France (2006)• Nad Al Hamar Tunnel, Dubai (2004)• North Passage Basel, Switzerland (1998–2005)• Metro Singapore, SGP (2000)• Tunnel Les Vignes, Switzerland (1997)• Dresden Coschütz /Dölzschen Tunnel, Germany (2004)• Tunnel Wiener Platz Dresden, Germany (2002)

HDA-R heavy duty anchor • Self-undercutting anchor for through

fastening applications• Stainless steel 1.4401

HSC-AR safety anchor • Self-undercutting anchor• Small drilling depth

Jet ventilator fastening

TE 16-M rotary hammer • Versatile tool for most drilling jobs

on site

Mechanical & Electrical

ML channel system • Optimal for electrical supports• Light weight for easy handling• Quick-install features

MI channel system • Heavy-duty system that will take the place

of most welded structures in tunnels• Fully compatible with MQ

HST stud anchor • Economical anchor for safety relevant

fastenings• Suitable for cracked concrete

(shrinkage)

MQ channel system • Versatile, with numerous specialised

components• Eight different channel profiles for

optimised use of material

Challenge of the application 15–25% of the total investment for modern tunnels relates to mechanical and electrical equipment and the corresponding supply services. While the design life ofthese M&E installations is often significantly below the expectation for the tunnel structure itself, most projects nevertheless require great attention to the durability offastenings and supports of pipe and cable lines.

In addition, the linearity of the structure requires industrial installation processes thatleave little room for improvisation and on-the-spot decisions.

Hilti solution & competence With the support systems MI, MQ and ML, Hilti offers a comprehensive range of compatible systems designed to take either loads of just a few cables or the weight of a 1000 mm water pipe. The system solution also comprises perhaps the most comprehensive range of fastenings and drilling technology, covering many materialsand corrosion protection classes. To increase productivity, laser positioning tools help to save on the most expensive part of the works, namely labour.

A key part of the Hilti offering is the calculation service and software, together with true on-site support available in 120 countries.

Reference projects • Serebryanoborsky Tunnel, Russia (2006) • Rennstein Tunnel, Germany (2002)• Metro Prague, Czech Republic (2006+2003) • Madrid Airport Tunnel, Spain (2005)• Uetlibergtunnel, Switzerland (2005)• Tunnel de Monts, France (2005)• Metro Singapore, SGP (2000)• Utility Tunnel Vienna Airport, Austria (2005)• Dresden Coschütz/Dölzschen Tunnel, Germany (2005)

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Cable tray and pipe support

PML 32 line laser • Self-leveling, for horizontal and vertical

alignment• High dust and moisture protection

PD 32 laser range meter • Mark support spacing in one-person

operation• Verify pipe offset & lengths to ± 1.5 mm


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HVZ adhesive anchor system • Highest safety level• Tolerates concrete cracks (shrinkage)• Suitable for dynamic loads• Good electrical insulation

HIT-RE 500 adhesive anchorsystem and HAS-E rods withcentering rings • Guaranteed electrical insulation • Highest load values combined with low

sensitivity to installation anomalities• Easy adaptability with respect to

anchor length

TE 56-ATC combi hammer • Rugged tool for use in tunnels• Low vibration for repetitive anchor

setting

Challenge of the application Overhead catenaries are loaded by the dynamic forces of passing trains (friction,pressure of pantograph). In addition, any metal part is potentially subject to significant stray currents which can cause corrosion. Despite this, the design life oftunnel structures is usually more than 50–100 years, making it essential to pay special attention to detail.

In tunnels, such catenaries are fastened to the tunnel soffit, which may be heavily reinforced or entirely un-reinforced concrete. High requirements on geodetical posi-tion and small tolerances on the steel brackets usually make drilling a challenge.

Hilti solution & competence Hilti provides a whole portfolio of anchor products suitable for the application inorder to fit with local requirements, design codes and customs. Preferred adhesive anchor systems: • HVZ and HVU capsule systems• HIT-RE500 resin injection system. With a specific centering ring to hold the rod in

place overhead and to guarantee perfect electrical insulation on all sides.Preferred mechanical anchor systems: • HDA and HSC undercut anchors, both with easy to install self-cutting

technology. A range of materials and coatings is available to suit the specific requirements.

Hilti can provide suitable drilling technology as well as robotic drilling tools, drilling templates and lasers to align the installation.

Reference projects • Channel Tunnel Rail Link, Great Britain (2005)• Lötschbergtunnel, Switzerland (2005)• Tabladillo Tunnel, Spain (2005)• High Speed Line Rome-Naples, Italy (2002)• Arlberg Tunnel, Austria (2002)• Vereina Tunnel, Switzerland (2001)• Metro Berlin, Germany (2005)• Metro Naples, Italy (2005)

HDA-R heavy-duty anchor • Undercut anchor for highest safety

level• Easy installation - even overhead

DD130 diamond coring system• Hand-held or rig mounted operation for

case-by-case flexibility• 3 different diamond matrix specifications

to optimise drilling performance and corebit life

Fastening catenaries


HSA stud anchor • Easy to install• Economical for volume fastening

applications• Available from stock in more than 100

variations

CP firestop systems • Complete range• Effective sealing of fire compartments

PR 25 rotating laser • Easy alignment and positioning up

to 200 m• Rugged design and dust protected• Projects horizontal or vertical plane

MQ channel system • Comprehensive system to accommo-

date most designs• Eight different channel profiles for

optimised use of material

Challenge of the application Lighting and the relevant feeding cables have to be fastened in virtually every tun-nel. Depending on the type of tunnel (e.g. road or rail), corrosion aspects will usuallybe an important consideration in order to avoid any failure during the lifetime of thetunnel.In addition, the illumination system forms a key component of the escape system in the case of a smoke-emitting fire. Furthermore, in both new build and rehabilitation projects, emergency lighting systems are installed in addition to the regular illumination. Fastenings must therefore demonstrably be able to withstand the temperatures of tunnel fires.

Hilti Solution & competence There are numerous systems of illumination utilised in tunnels. Some are fixeddirectly into the ceiling, others fasten onto the cable trays that carry the feedercables. Yet others are situated on sophisticated metal structures made of channeland strut.

Hilti offers an extensive range of anchors, DX powder-actuated fasteners and channel systems that will accommodate most designs. Using this comprehensivesystem allows the use of Hilti’s design software and reduces the number of interfaces between components.

Where required, Hilti can provide customized fire testing and related expert advice, both in-house and from independent organisations.

Reference projects • Zürich Airport Tunnel, Switzerland (2002)• San Bernardino Tunnel, Switzerland (2003)• Socatop, France (2005)• Péripherique Paris, France (2006)• 30 Tunnels, Germany (2002)• NBS Köln-Rhein/Main, Germany (2002)• Rennsteig-Tunnel, Germany (2002)• Eichenberg-Tunnel, Germany (2004)• Helleberg-Tunnel, Germany (2004)• Escherberg-Tunnel, Germany (2004)• Landrücken-Tunnel, Germany (2004)

HST stud anchor • Available in HCR stainless steel for

road tunnels• Tested to withstand tunnel fires

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Fastening lighting systems

X-FB fastener • Speedy installation• All-metal solution for adequate fire

performance


21

HST stud anchor • Available in HCR stainless steel for

road tunnels• The standard for fast, economical

installations

MQ channel system • Almost unlimited possibilities to build

any frame• Available in hot-dip galvanized and

stainless steel qualities

PR 25 rotating laser • Save on the most time-consuming

operation: Easy alignment and positioning

• Self-leveling in horizontal and verticalposition

Challenge of the application Modern tunnels are equipped with dozens of communication, information and safety systems: Traffic signalisation, radio and mobile communication cables orcameras all require fastening and support systems capable of withstanding thesevere corrosion conditions in tunnels.

Given the multitude of applications, the range of requirements applied to the fastening systems in terms of load level and direction, anchor type, corrosion protection, cost implications, etc. is also almost unlimited.

Hilti solution & competence Mirroring the numerous applications and requirements, Hilti offers what is one of theworld’s largest ranges of fastening and support products. Thousands of differentanchor types and variants, sizes, lengths and diameters in many different materialsare available from stock. And if something is not on hand as a standard item, Hiltihas decades of experience in custom-manufacturing solutions.As usual, these fastening products are always supported by state-of-the-art drillingand measuring technology, all from one hand.

Reference projects

• Wilsecker-Tunnel, Germany (2006)• Péripherique Paris, France (2006)• Königstuhl-Tunnel, Germany (2005)• Götatunnel, Sweden (2005)• Socatop, France (2005)• Metro Berlin, Germany (2005)• Walensee Tunnels, Switzerland (2004)• Dresden Coschütz/Dölzschen Tunnel, Germany (2004)• Metro Prague, Czech Republic (2002)

HVZ adhesive anchor system • High loads, even where alternating

wind loads cause fatigue• Available in High Corrosion Resistant

steel (HCR)

Fastening signalisation, radio and safety equipment

TE 16-M rotary hammer • Versatile tool for most drilling jobs

on site


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HSC-R safety anchor • Approved for shock loads• Short drilling depth at high loads

PR 25 rotating laser • Rugged design and dust protection• Easy alignment and positioning up to

200 m

TE 16-M rotary hammer • Optimal performance for holes up

to 20 mm• Full versatility: 2 gears, hammer

or rotary

Challenge of the application More and more tunnels are protected by way of sprinkler or – more recently – highlyadvanced water mist systems.

When sprinklers are switched on, a water hammer effect in the piping systemexerts very significant shock-type forces on the fastenings. These are difficult tocalculate. At the same time, the resistance of the fastenings is critical to the functioning of the sprinkler system and, thus, the survival of tunnel users. Moreoften than not, fire mains are fastened along the tunnel.

The usual requirements with regards to corrosion and design life of tunnels producean additional consideration in the design.

Hilti solution & competence The design of anchors for dynamic loads is one of Hilti’s key competencies.Hundreds of tests and various approvals allow to-the-point designs and significantoptimisation as a result of extensive knowledge of the behaviour of Hilti’s anchors.

Undercut anchors for serial applications such as the HSC have been used withgreat advantage to transfer the impact of sprinkler systems to the tunnel lining.

In addition, Hilti drilling technology (hammer drilling and diamond), as well as laser technology to align the anchors can be obtained from one expert supplier.

Reference projects • Betuwe Tunnel, Netherlands (2005)• SOCATOP, France (2006)• Tunnel Stammham, Germany (2004)• Königstuhl-Tunnel, Germany (2005)• Wilsecker-Tunnel, Germany (2006)• 30 Tunnels on NBS: Köln-Rhein/Main, Germany (2002)

HST stud anchor • The standard for fast, economical

installations• Available in High Corrosion Resistant

steel (HCR)

Fire mains and sprinkler system

PD 32 laser range meter • Mark support spacing in one-person

operation• Verify pipe offsets & lengths to ± 1.5 mm


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Hilti HY150 injectable adhesive • Fire resistant due to water-cement

matrix• Excellent long-term behaviour

HDA undercut anchor • Highest safety through undercut• Highest performance

HCC concrete connector • For bonding new concrete to old

concrete

Challenge of the application Perhaps the most significant type of rehabilitation work going on in dozens of tunnels around the world is the change of the ventilation system. The toxic exhaustgasses of cars some 20 years ago made complicated ventilation systems with multiple air ducts necessary. With today’s cleaner cars these can often be retrofittedto help contain smoke in the case of a tunnel fire.

This may require the change of existing (or introduction of new) suspended ceilings.Also, in some cases the course of time, corrosion or fires have taken their toll on existing suspended ceilings in tunnels.

Hilti solution & competence Here more than anywhere the understanding that every project is different has itsmerits: Depending on the tunnel lining encountered, the fire and corrosion conditions as well as the actual alteration required, Hilti has developed various solutions in close cooperation with the responsible engineers. These includedchemical anchors, e.g. Hilti HIT-HY 150, HIT-RE 500, as well as mechanical anchorssuch as the self-undercutting anchor HDA-R. These are always supported by theavailability of a complete system of drilling equipment, laser tools as well as firestopping products to seal any remaining gaps in the new fire compartments.

Reference projects • Pozzano Tunnel, Italy (2007)• Serebryanoborsky Tunnel, Moscow (2006)• Lecco-Ballabio Tunnel, Italy (2005)• Felbertauerntunnel, Austria (2005)• Plabutschtunnel, Austria (2004)• Sesera Tunnel, Italy (2004)• Sonnenberg Tunnel, Switzerland (1999)• Gotthard Tunnel, Switzerland (1999)• PfänderTunnel, Austria (1995)

RE500 injectable adhesive• Reduced hole depth due to high bond

strength• Low sensitivity to many application

irregularities

CP 606 fire stop sealant• Optimised viscosity for easy installation• 30-year age tested

Suspended ceiling slab

PD 32 laser range meter • One-person verification of “as built”

measurements• Setting and adjustment of formwork

Retrofit & Rehabilitation

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HIT-HY 150 adhesive in dualfoil pack • For concrete• 10 years experience for zero surprises• Added cement for corrosion protection

HIT-RE 500 adhesive anchorsystem (1400 ml jumbo foilpack) • Speedy injection• Pre-selection of adhesive volume• Highest load values combined with low

sensitivity to installation anomalities

HVU adhesive anchor system • Suitable for dynamic loading• Easy to install, no waste of adhesive• Economical heavy duty anchor for

serial applications

Challenge of the application Wherever the typical cross section of a tunnel is altered, it is likely that the normal formwork system cannot be used or additional shuttering is needed. Alternatively, sections of secondary concrete may have to be poured, calling for post-fix rebar connections. This will regularly require fastening technology capable of sustaining substantial hydrostatic concrete pressure.

In TBM-type tunnels, it is sometimes necessary to cut out already placed pre-cast concrete liners with diamond coring and sawing technology. Furthermore, ventilation and other services are required.

Hilti solution & competence Where rebar connections are concerned, Hilti is clearly the world leader in adhesiveanchor technology. With a range of products and technologies available, most requirements can be fulfilled, even the most demanding. Please refer to page 10 forfurther details.

The formwork systems used in tunnels differ widely as far as the specific fasteningdetails are concerned. Heavy-duty mechanical and adhesive anchor systems havebeen used successfully in the past.

Reference projects • Guadarrama Tunnel, Spain (2005)• Socatop, France (2005)• Arlberg Tunnel, Austria (2005)• Lötschberg Tunnel, Switzerland (2004)• Tunnel de Pertus, Spain (2006)

SFV anchor and HIT-RE 500adhesive anchor system • Connects Dywidag rods• Rod retractable when formwork is

removed

DD 300 diamond coring system • Simple handling, no specialised

workforce needed• Water-cooled and water-protected for

wet tunnels• Brushless high-frequency motor with

10 speed settings

Additional SOS niches and escape routes


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DS-WS 15 wire saw

Challenge of the application While tunnels are virtually “cast in stone”, increase in traffic and innovations intransport systems may lead to new demands on the available traffic gauge.

In such cases, every centimetre counts: Tunnel bottom levels are lowered, liningsreduced in critical curves, ballast replaced by rigid slabs in rail tunnels.

Hilti solution & competence In many cases, Hilti’s demolition and fastening technology can help reduce tinkeringon site and to conceive a professional methodology for complex rehabilitation projects.

Hilti’s HIT injection systems are frequently used to connect existing and new concrete structures with rebars or to fasten formwork and scaffolding. For example, the SVH formwork anchor can tie back one-sided shuttering usingregular Dywidag rods.

Diamond saws as well as electric demolition breakers are used where machine-mounted or pneumatic hammers are too clumsy or heavy.

Where rail tracks need to be lowered, it can be beneficial to use Hilti HRA railanchors which save the height of the ballast and, thus, increase traffic gauge.

Reference projects • Arlberg Tunnel, Austria (2006)• Schöni Tunnel, Switzerland (2006)• Güetli Gallery, Switzerland (2006)• Naxberg Tunnel, Switzerland (2006)• Glion Tunnel, Switzerland (2006)

D-LP 32 /DS-TS 32 wall saw

Increase of traffic gauge

HIT-HY 150 adhesive in dualfoil pack • For concrete• 10 years experience for zero surprises• Added cement for corrosion protection

SFV anchor and HIT-RE 500adhesive anchor system • Connects Dywidag rods• Rod retractable when formwork is

removed

TE 706 breaker• Less tiring to use, higher daily

productivity• Excellent balance and significantly

lower dynamic vibration• Constant, high performance even when

the voltage drops


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HCC-B conrecte connector • Built-in quality assurance through

internal adhesive injection• Accurate positioning and fastening

of rebars

Challenge of the application As a consequence of the corrosive atmosphere and salt often found in tunnels, ordue to fire damage, the concrete lining of many tunnels requires attention:Excessive cracking, spalling or insufficient cover to protect rebar from corrosion callfor removal and replacement of concrete layers.

These new concrete overlays must be tied in with the existing concrete to form a load-transferring unit.

Hilti solution & competence While for large surfaces the removal is usually carried out using high pressure waterjets or mechanical means, on smaller areas Hilti’s demolition breakers such as theTE 706 have been used to advantage. Where concrete grinding is needed, the HiltiDG 150 diamond grinder has been used to good effect.

Concrete cover and rebar position can be determined, analysed and visualised withthe PS 200 ferroscan.

Hilti’s HCC concrete connector is a specialised fastening system designed to trans-fer shear and tension loads between concrete overlay and the substrate.

Reference projects • A2 Wassen, Switzerland (2000)• Pfändertunnel, Austria (2002)• Wallenseestrasse, Switzerland (2005)• Roffla Tunnel, Switzerland (2004)• SKN Bernadino Tunnel, Switzerland (2005)

Concrete repair & concrete overlays

Hilti HIT-RE 500 adhesiveanchor system and SFV anchor• Connects Dywidag rods for formwork

anchors• Rod retractable when formwork

removed

TE 706 breaker• Less tiring to use, higher daily

productivity• Excellent balance and significantly

lower dynamic vibration• Constant, high performance even when

the voltage drops

PS 200 Ferroscan• Measures and checks concrete cover

on large surfaces• Allows statistical analysis


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HIT P-8000 D pneumatic dispenser for jumbo pack(1400 ml) • Handy, yet powerful enough to inject

adhesive into small deep holes• Uses regular pressurised air available

on any construction site

TE 56-ATC combi hammer • Rugged tool for use in tunnels• Low vibration for repetitive anchor

setting

Challenge of the application Rock movements and water pressure can cause problems with the tunnel lining.These problems and their solutions are highly individual, of course, so the examplesgiven here are not a representative cross section. What they often have in common,though, is that Hilti’s fastening experts are frequently called on site to help.

Hilti solution & competence Many of Hilti’s products can be used in situations that are far beyond their regular applications. Hilti’s engineers accompany you with judgement, analysis, testing,approval support and – finally – with hands-on installation, training and support.

In the first example (large picture above), the steel lining of a race pipe in a hydropower station had become deformed due to external water pressure. In collaboration with the specifying engineer, Hilti devised a special fastening system to secure the lining, featuring minimal protrusion, based on the HIT-RE 500injection mortar.

The smaller pictures show an example where ground movements caused excessive relative displacement of pre-cast concrete segments. In order to stabilise these, asteel tube was inserted into a pre-drilled opening, with the annular gap later injectedwith HIT-RE 500. A specialised injection technology was devised and tested for thistask before using it on site.

Reference projects • Seelisbergtunnel, Switzerland (2006)• KWO Gallery, Switzerland (2005)

DD 300 diamond coring system• Simple handling, no specialised

workforce needed• Water-cooled and water-protected for

wet tunnels• Brushless high-frequency motor with

10 speed settings

Damage repair – specialised solutions

HIT-RE 500 adhesive anchorsystem • Epoxy injection mortar with high

adhesive strength• Optimised viscosity for injection into

small voids


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Corrosion, fire, dynamics.

While there are many areas in which Hilti’sexpertise can help during the design process,corrosion, fire resistance and dynamic loadingusually feature high on any tunnel designer’slist of priorities.

For Hilti, the key has always been to trulyunderstand the customer’s needs within a veryspecific application. We then make it ourresponsibility to translate that into – simply – agood solution.

Hilti’s competence goes far beyond the mereknowledge of codes and regulations. Ourresearch more often than not provides thebasis for standards as it drives innovation.

Fields of special competence.

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Competence in corrosion and materials.

The atmosphere in tunnels is known to be highly corrosive due to exhaust gases,dust, humidity and frequently salt and other influences. This leads to highly accelerated corrosion in mild steel and may cause hydrogen embrittlement in high-strength grades. In stainless steel these agents can cause pitting and crevicecorrosion, which can lead to stress corrosion cracking, perhaps the most treacherous form of corrosion.

Hilti started live tunnel exposure studies in 1981 since short-term laboratory testsare insufficient as a sole source of information. For decades, Hilti has tested• numerous types of carbon and stainless steel,

incl. highly corrosion-resistant grades• alloys of titanium, aluminium and nickel• samples from various manufacturers• products of various geometriesThese samples have been exposed to the atmosphere of eight road and rail tunnels. In order to simulate service loads part of the bolts were pre-stressed.

The subsequent analysis includes microscopic investigation and load tests incompari-son to unexposed reference samples of the same material.

These in-situ experiments are supported by Hilti’s corrosion laboratories whichfocus on • simulating real application conditions (pollutants, temperature, humidity, etc.)• accelerated corrosion testing.

To complement in-house competence, Hilti also cooperates with academic institu-tions including ETH Zurich, Switzerland; Montan-University Leoben, Austria andUniversity Stuttgart, Germany. The results of Hilti’s testing have significantly influenced codes and regulations, as well as the related academic debate.

These activities have yielded what is probably the world’s most extensive corrosion database for tunnels. This is used to optimise the specific corrosion protection in a given tunnel for a given application.

In fact, it is this capability to economically optimise structures in a safe way thatmany customers view as Hilti’s key strength in tunneling applications.

Life-long safety.

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More than one iron in the fire.

Competence in fire safety.

Hilti has been active for decades in the field of passive fire protection, which essentially consists of the application fields• fire protection of structural components• fire resistance of fastening systems• fire stopping of penetrations and construction joints

Steel and concrete are impacted by high temperatures. Fires in tunnels produce temperatures up to 1300°C in very short periods of time due to the spatial confinement.Tunnel structures are typically protected by fire protection boards or proprietarysprayed mortars. In both cases fasteners are needed, either to hold up the board, or – in the case ofsprayed mortars – to attach wire mesh reinforcement.

Hilti works closely with manufacturers of fire protection systems to provide tailoredsystem solutions with real expertise built in.

As world leader in fastening technology, Hilti has long focussed on qualifying its products regarding fire resistance. This includes mechanical and chemical anchors, DX powder-actuated fasteners as well as channel support systems. In fact, Hilti usesits own test furnaces to help build the necessary knowledge base. Hilti also works together with external bodies for independent fire assessments.

This long-term commitment to in-depth fire testing has led to perhaps one of theworld’s broadest portfolio of fire-rated fastening products.

Hilti is the world’s leading supplier of fire stopping products designed to close gaps infire-rated structures, such as service penetrations or building joints.

But Hilti’s expertise does not only cover the actual product. The true value for our customer is generated when a reliable product is combined with on-site applicationknowledge provided by our fire stop engineers. It is this competence that drives realistic test settings and therefore real-life results.

Foto: Arno Balzarini

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Shock. Fatigue. Vibration.

Competence in dynamic loading.

As the world leader in fastening technology, Hilti has developed an in-depth under-standing of dynamic loading situations over the decades and investigated their impacton fastening solutions.• fatigue loading (e.g. anchors for jet ventilators, rail fastenings)• repetitive shock loading (e.g. cladding panels, fire protection board)

Hilti’s main laboratory for dynamic anchor testing at corporate headquarters in Liechtenstein is used for internal tests. In addition, many international experts and academic institutions use our facilities in various forms of cooperation.For our partners, Hilti’s competency is a key benefit – the detailed knowledge of anchor behaviour under dynamic loading. This is complemented by what many experts consider the world’s most sophisticated set of anchor testing laboratories.Hilti’s testing equipment is capable of applying enormous loads in high frequencies and loading velocities.

In order to analyse anchor loads in sufficient precision, Hilti has developed individual measuring technology.

Hilti has used this technology in many projects where dimensioning anchors is difficultdue to uncertainties with regards to the expected load levels.

Especially in fatigue and shock design, the loading history of structures and fastenersis of vital interest. Often, critical loads only occur infrequently and unpredictably. Hiltiuses a combination of measuring equipment and the relevant recording equipment oncustomers’ real life structures to help understand what the true loads are over a periodof time.


Hilti in tunneling. More information by fax or e-mail.

Fax to: Hilti Corporation or e-mail to: [email protected]: +423 234 30 96

Company:

Contact:

Street:

Town, post code:

Phone:

E-mail:

Area of activity:

Application topics

Corrosion

Dynamic loading

Fire safety

Technical data for products

Approvals for product

Rail fastening

Rebar analysis /coverage

Software

PROFIS anchor calculation software

Exbar (rebar fastening) calculation software

Exbar overlay (concrete overlays)

Channel & pipe support design software

PS 200 Ferroscan

Please arrange an appointment with me.

I am particularly interested in:

Product lines

Measuring

Anchors

Installation

DX powder-actuated fastening

Firestop

Drilling and demolition

Diamond drilling and sawing

Screw fastening

Cutting and sanding

Others

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Hilti Corporation | 9494 Schaan | Liechtenstein | P +423-234 2111 | F +423-234 2965 | www.hilti.com

Hilti. Outperform. Outlast.

Documents

Getting you there. - Hilti€¦ · and fastening technology to tunnel projects around the world. In fact, there are probably very few tunnels where Hilti has not done so. Hilti’s