BID DOCUMENT PK-4

SUB CHAPTER-5

5. PRE-CAST LINING SEGMENTS

5.1. General
This section includes
1) Requirements for furnishing all labor, materials, tools and equipment, and services for
performing all operations necessary for manufacturing, testing, loading, transporting,
delivering, storing on the Work Site, repair or replacement of damaged segments,
handling, and installing precast concrete tunnel linings in bored tunnel in accordance with
the requirements set forth in the Contract Drawings and as specified herein.
2) Requirements for ensuring compatibility of lining design with selected construction
methods and for performing any design modifications.
3) Definitions:
a) Circumferential Joint: Joint between adjacent precast rings.
b) Gasket: A continuous, deformable, elastomeric joint material installed in a segment joint
groove surrounding each segment to provide permanent watertight seal for the erected
tunnel lining.
c) Packing: Load-distributing pads of constant thickness attached to the circumferential
segment joints to distribute compressive stresses across the joints.
d) Precast Concrete Segment: A precast structural element cast in an arc shape, which
when installed in the tunnel with other segments, forms a continuous ring. A series of
rings forms the tunnel lining that supports the surrounding ground.
e) Precast Concrete Segmental Tunnel Lining: A one-pass structural lining consisting of
bolted, gasketed precast reinforced concrete segments erected and grouted in place.
This concrete segmental lining is called the “lining” or “liner”.
f) Radial Joint: Joint between two precast segments in one ring.
g) Tapered Ring: A ring of precast concrete segments in which the plane of the leading
circular face is not parallel with the plane of the trailing circular face. The distance, or
width, between the leading and trailing faces varies continuously around the ring.
The “taper” is the difference in centimeters between the maximum and minimum
width.

5.2. Cited Standards

1) American Concrete Institute (ACI):
a) 224.1 - Causes, Evaluation and Repair of Cracks in Concrete Structures
b) 301 - Structural Concrete
c) 309 - Consolidation of Concrete
d) 517 - Accelerated Curing of Concrete at Atmospheric Pressure
2) ASTM International (ASTM):
a) A36 - Carbon Structural Steel
b) A153 - Zinc Coating (Hot-Dip) on Iron and Steel Hardware
c) A325 - Structural Bolts, Steel, Heat Treated, 827/724 MPA Minimum Tensile
Strength
d) A563 - Carbon and Alloy Steel Nuts
e) A706 - Low-Alloy Steel Deformed and Plain Bars for Concrete Reinforcement
f) C33 - Concrete Aggregates
g) C39 - Compressive Strength of Cylindrical Concrete Specimens
h) C150 - Portland Cement
i) C156 - Water Retention by Concrete Curing Materials
j) C171 - Sheet Materials for Curing Concrete
k) C403 - Standard Test Method for Time of Setting of Concrete Mixtures by
Penetration Resistance
l) C618 - Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete
m) C666 - Resistance of Concrete to Rapid Freezing and Thawing
n) C1202 - Electrical Indication of Concretes Ability to Resist Chloride Ion Penetration
o) D395 - Rubber Property - Compression Set
p) D412 - Vulcanized Rubber and Thermoplastic Elastomers Tension
q) D471 –-Rubber Property - Effect of Liquids
r) D518 - Rubber Deterioration – Surface Cracking

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s) D573 - Rubber – Deterioration in an Air Oven

t) D1149 - Rubber Deterioration – Surface Ozone Cracking in a Chamber
u) D2240 - Rubber Property – Durometer Hardness
v) D6132 - Standard Test Method for Nondestructive Measurement of Dry Film
Thickness of Applied Organic Coatings Using an Ultrasonic Gage
w) F436 - Hardened Steel Washers
3) American Welding Society (AWS):
a) D1.4 - Structural Welding code - Reinforcing Steel
4) Military Specifications (QPL):
a) 23236 - Paint Coating Systems, Fuel and Salt Water Ballast Tanks
5) National Institute of Standards and Technology (NIST):
a) PS-1 - Construction and Industrial Plywood
6) Precast/Prestressed Concrete Institute (PCI):
a) MNL-116 - Quality Control for Plants and Production of Structural Concrete
Products.

5.3. Noted Restrictions

1) Do not begin segment mold or precast concrete segment production until the required
submittals have been made and the Construction Manager has reviewed submittals.
2) Do not begin segment repairs until the required submittals for segment repairs have
been made and the Construction Manager has reviewed submittals.

5.4. Quality Control

1) General
a) Segment production shall meet the requirements of submitted and reviewed
quality control and quality assurance plans, and of PCI MNL-116 or similar.
2) Qualifications of Manufacturers
a) Employ qualified firms (including mold manufacturer; precast concrete
manufacturer; gasket manufacturer; dowel, dowel insert, and bolt insert
manufacturer; waterproof coating manufacturer) regularly engaged in
manufacture and fabrication of precast concrete tunnel lining segments or
accessories (as applicable) of similar dimensions and tolerances to those
specified, and who has provided precision precast concrete tunnel linings or
accessories (as applicable) for at least two projects comparable to the precast
concrete tunnel linings of this Contract in size and type, in the last five years.
Comparable work shall include bolted, gasketed precast tunnel lining segments
installed as permanent lining below the groundwater table in similar subsurface
conditions.
a) Employ personnel experienced in the manufacturing and installation of gasketed
and mechanically connected precast concrete segmental tunnel linings.
3) Inspection and Testing:
a) Employ an independent testing laboratory to prepare the design of mixes for the
requirements of concrete as indicated on the Contract Drawings and as specified
herein. Perform tests and trial mixes in accordance with related national
specifications.
b) Casting:
i. Provide the Construction Manager with sufficient office space,
communications, labor, assistance, and equipment for performing inspections
and reports at the segment casting yard/factory throughout the duration of the
segment production. The Construction Manager may reject finished
segments not found to be in accordance with these Specifications.
ii. Check the first segment cast in any mold for compliance with the tolerances
specified herein and indicated in the Contract Drawings; thereafter as a
minimum, check every twentieth segment from each mold. When any
variation in segment quality is found, increase the number of segments
checked to that required to re-establish the accuracy and consistency of
production. Check all segments cast from that mold was last checked.
Remove and do not use any segments that fail to comply with requirements
of the Contract Drawings and Specifications.

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iii. Maintain full time inspection personnel at the casting yard/plant who shall be
responsible for ensuring that the specified quality is being achieved and
reviewed procedures are being implemented at all stages of the segment
production process.
iv. Provide adequate equipment including substantial steel templates (master
and working), gauges, and calipers and cover meters to determine
accuracies for the control of the segment production.
v. Provide three certified test results each, by a qualified independent
laboratory, demonstrating, in embedded condition the following: Minimum
pullout (yield) capacity of circumferential joint connector assemblies and the
minimum pullout (yield) capacity of radial bolt assemblies meet the calculated
requirements. Include actual joint connector assemblies. Tested segments
shall not be incorporated in the Work.
4) Molds: The molds shall be fully checked and certified by a licensed surveyor for
compliance with the requirements for dimensional tolerance and the results reviewed by
the Construction Manager before the molds are shipped to the precast concrete plant.
5) Casting Tolerances
a) Fabricate segments to dimensions and tolerances indicated in the Contract
Drawings and cited standards. Use tighter tolerances if necessary for erection
purposes or water-tightness.
b) Contractor may propose more stringent tolerances as may be required to suit his
chosen construction means and methods.
c) Provide written notice at least 30 days before starting manufacture of segments,
to allow the Construction Manager to inspect and accept plant and means and
methods of fabrication.
d) The segment manufacturer shall design and implement a tolerance measurement
system to account and adjust for thermal, moisture, and ambient temperature
effects.
e) Ensure segments of common design and cast in different molds and at different
times are interchangeable.
f) Bearing faces and gasket grooves shall be free from high spots and voids.
g) Non-bearing surfaces shall contain no voids larger than 1cm in diameter or 0.5cm
deep.
h) Tunnel Lining Ring Installation Construction Tolerances:
i) After grouting, the ring of the tunnel lining shall conform to the following
tolerances:
i. As shown on Contract Drawings.
ii. The center of the ring of segments shall not deviate from its design position
by more than 5cm.
iii. The leading edge of the lining shall not be out-of-plane by more than 0.5cm.
iv. The roll of each ring in relation to the previous ring shall be no greater than
can be accommodated within the limitations of bolt hole and dowel
clearances.
v. Offsets (lips and steps) between segments at radial and circumferential joints
shall not exceed 0.8cm.
vi. Width of caulking groove shall not exceed designed width by more than
0.5cm. This represents the gap between bearing surfaces.
j) Submit a non-conformance report immediately for any ring that is found to be out-
of-tolerance.

6) Out-of-Tolerance Lining
a) Propose immediate remedial actions to bring the tunnel drive into tolerance. The
Construction Manager will exercise a Stop Work Order in the event the tunnel
drive is out-of-tolerance and no satisfactory remedial action is proposed or the
remedial action is not implemented in a timely manner or is not effective.
b) Demonstrate that the design track alignment can be accommodated in the out-of-
tolerance sections. If not acceptable, propose a revised alignment of the future
operational tracks to correct minor out-of-tolerance tunnel drive from the
theoretical alignment. It is the responsibility of Contractor to demonstrate that:

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i. Clearances indicated on the Contract Drawings are maintained between the

dynamic envelope and tunnel lining, bench, systems and furniture. Minimum
clearances for the rectangular personnel walkway envelope and for the track
support slab must also be achieved.
ii. The re-alignment does not in any way change the intended operational
characteristics of the Railroad line.
iii. Systems can be accommodated using the designs and layouts indicated in
the Contract Drawings, or to be constructed by future contracts (details
available on request through the Construction Manager), including track,
trackbed, third rail, drainage pipes, conduits, rail lubricators and signals.
c) If track realignment does not meet specified requirements, propose alternative
measures to remedy out-of-tolerance sections.
d) Segment grinding is not permitted.

7) Trial Liner Assembly

a) In order to check on the matching and spacing of bolt holes, dowels and
interchangeability of bolted segments before bulk manufacture is commenced,
assemble and bolt/dowel together on a flat level base, segments to form three
rings from any mold set in the presence of the Construction Manager. The
Construction Manager will select the segments to be used for the trial liner
assembly.
i. Furnish a 15-day written advance notice to the Construction Manager before
the start of the trial liner assembly.
ii. Assemble the entire trial liner rings at the Work Site or another accepted
location above ground. Build the rings one above the other aligned in an
upward position, and the radial joints staggered by one third of a segment.
No packing or gaskets are to be used in the joints between segments in
these trial rings.
iii. Maintain trial liners intact until tolerances of completed rings are verified and
removal of liners is authorized by the Construction Manager. Retain the
lowest ring as a master ring for the duration of the Contract. Use dismantled
segments for lining tunnel, if undamaged and accepted by the Construction
Manager.
iv. If trial liners are not accepted, dismantle liners, adjust forms, cast new
segments, and erect new trial liners for acceptance. Continue this procedure
until trial liners are in accordance with the contract documents.
v. Unacceptable trial liner segments, and other segments cast from the same
molds, will be rejected.
vi. At a minimum frequency of 1 per every 100 segments manufactured from
each mold will be picked at random by the Construction Manager and
assembled by Contractor on the master ring to ensure that tolerances and
interchangeability of segments are being maintained. Unacceptable
segments, and other segments cast from the same molds, will be rejected.
8) Production Units: Do not commence bulk production manufacturing before obtaining
Construction Manager’s written acceptance of the trial liners.
9) Chloride Ion Penetrability: As determined by ASTM C1202. Test the concrete trial mix
designs and test field cured specimens representing each 1,000 segments fabricated.
10) Acceptance
i. Segments with the following defects or damage prior to erection in the tunnel
lining will be rejected:
 A crack extending through a complete cross section of the segment.
 Two or more cracks combined such that a wedge is formed that may
separate from the segment.
 Honeycombing.
 Other damage or defects that could significantly impact the structural
capacity of the segment.
ii. Repair segments containing cracks or other minor damage in accordance
with the reviewed Contractor’s Work Plan. Should the Construction Manager
deem that a segment can not be repaired in accordance with accepted
Contractor’s repair procedures, it will be rejected.

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iii.Segments with visible damage during erection or during the first 30cm of
shove will be rejected. At any time after 30cm of shove, a non-conformance
report shall immediately be raised by Contractor for any segment or ring
which is found to be damaged. Should the Construction Manager deem that
an installed segment can not be repaired in accordance with accepted
Contractor’s repair procedures, or that the damage is sufficient to
compromise the integrity of the lining or its long term function or durability,
the segment will be rejected. Propose remedial works to the Construction
Manager for acceptance.
iv. Segments not meeting tolerance requirements, minimum strength
requirements or other requirements of this specification and contract
drawings will be rejected.
v. Rejected segments shall be indelibly marked on the inner (concave) face,
permanently removed from the Work Site, and not used in the Project.
11) Segment Repair
a) Repair segments to which damage has occurred in accordance with the accepted
Contractor’s repair procedures.

5.5. Submittals
Within 30 days of Date of commencement, submit the following:
1) Name and location of the mould, dowel, and gasket manufacturers
2) Location of segment precasting facility
3) Names and experience of personnel directly managing the production, and list of
comparable tunnel projects and names and telephone numbers of client contacts where
the manufacturer’s products have been used.
4) Shop Drawings for each type of segment showing complete details of molds,
reinforcement, mechanical joint connection assemblies, joint reliefs, gasket grooves,
gaskets, inserts and accessories necessary for manufacture, transportation and erection.
No segments shall be cast until Shop Drawings are reviewed by the Construction
Manager.
5) Segment design modifications listed below may be proposed. Submit calculations and
Shop Drawings of the proposed to the Construction Manager for review, demonstrating
that the proposed design meets or exceeds all structural requirements including grouting
pressure; gasket loads; handling, transportation, stacking, erector arm and segment
erector jack loads; TBM thrust ram loads; and loads from ground, water, railroads and
other sources. Calculations and Shop Drawings shall be prepared and certified by a
Professional Engineer with prior experience in design of precast concrete segmental
tunnel linings for at least two tunnel projects in the last five years of a similar type and
size to be used in the Work.
a) Internal Diameter: Increase in design internal diameter.
b) Segment Geometry: Change in ring width (length along tunnel), segment shape
and segment arcs. If rectangular segments (90 degree corners except adjacent
to key, and key) are proposed, bolts must be used instead of dowels between
rings.
c) Segment Thickness: Increase in segment thickness.
d) Lifting Eye/Grout Hole: Contractor may propose alternative segment lifting
arrangement and alternative details for segment grout holes. If vacuum lifting
proposed, use shoe-locating recesses.
e) Dowels: Change in geometry of dowels and dowel holes. Contractor may
propose to replace dowels with bolts and sockets.
f) Bolts: Change in geometry of bolts and sockets.
g) Reinforcement: Additional reinforcement to meet or exceed requirements for
temporary loading.
h) Modifications for concrete mix, packers, segment coating, polypropylene fiber
ratio, and gasket width will not be acceptable.
i) All costs related to such modifications shall be included in the bid price.
6) Written certification from the precast concrete segment manufacturer indicating full and
complete design coordination between the TBM manufacturer and the precast concrete
segment manufacturer. Include a written certificate by both manufacturers affirming the

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compatibility of the TBM and the liner systems, with particular reference to geometry and
TBM applied thrust.
7) The taper of each type of precast concrete ring, with calculations demonstrating
adequacy for fitting the alignment shown on the Contract Drawings. Submit Shop
Drawing indicating locations of maximum and minimum ring width in relation to key
segment.
8) Provide details of the computer program, methods and parameters, to be used for
selecting the type and orientation of each ring to be delivered to the TBM and
assembled.
9) Material specifications for components of joint connection systems and specification
describing pullout capacity and material properties of the assemblies.
10) Name, certificates, qualifications, and record of experience:
a) Mold Manufacturer
b) Gasket Manufacturer
c) Precast Concrete Manufacturer
d) Independent Testing Laboratory(s)
e) Joint Connection System Manufacturer
11) Work Plans and Procedures:
a) Detailed description of quality control and quality assurance procedures for
manufacturing, casting, curing, identification, handling, transporting, delivering,
storing, stacking, erecting, and repairing segments. Include procedures to control
shrinkage and temperature cracking of segments.
b) Calculations demonstrating capability of mold to provide rigidity and strength
required to maintain manufactured and construction dimensions and tolerances
specified.
c) Gasket manufacturer’s quality control plan ensuring consistency of gasket
material, dimensions, and installation.
d) Detailed design for segment lifting and handling devices. Allow for complete
removal of lifting and handling devices intruding into tunnel space. Lifting and
handling devices includes all devices used for handling segments in tunnel, in
shaft and at shaft top.
e) Layout of facilities for casting, curing and storing segments. Provide calculations
demonstrating required strength and time at which segments can be safely
demolded without causing damage.
f) Details of joint connections for pullout capacity testing.
g) Details of tolerance measurement system, including equipment details, master
and working template configurations and layout, types and numbers of gauges,
calipers, theodolites, and other equipment used to determine accuracies.
h) Detailed description for application and repair method of the segment waterproof
coating and the trial application to verify its compliance with the Specification.
12) Samples of Contractor proposed items:
a) Gasket: 1.5 meter and three corner assemblies.
b) Adhesive: 500 ml of each type proposed.
c) Lifting/grouting insert assembly: Two each.
d) Compression packing: 1 meter
e) Radial and circumferential joint connector assemblies: Two each
f) Reinforcement spacers and chairs: Three each.
g) Waterproof coating: 1-pint of each type proposed.
h) Gasket lubricant: 1-pint of each type proposed.
i) Crack sealing resin: 1-pint of each type proposed.
13) Manufacturer’s product data and material safety data sheets.
14) Gasket Performance: Submit a report demonstrating that the proposed gasket, gasket
groove, and surrounding concrete meet the specified criteria for the design life of the
structure. The report shall additionally include a list of substances known to be
deleterious to the gasket, together with an analysis of the risk of contact with such
substances.
15) Segment repair procedures, which shall include descriptions of the type, location, and
extent of the damage, and their associated repair procedure, or basis for rejection of
segments.
16) Concrete mix design and test data, shall be approved by the Construction Manager.

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Also submit the following:

1) Notice that segment production plant is ready for Construction Manager inspection, prior
to segment production.
2) Notice of start of trial liner assembly prior to that assembly.
3) Documented substantiation of competence in the application of epoxy coating material,
prior to production application.

5.6. Deliverables
1) Prepare, maintain, and provide the following records after each shift during segment
production and TBM bored tunnel excavation. All records shall be in a format acceptable
to the Construction Manager and shall include identification of each segment, and ring, if
applicable:
a) Quality records of manufactured segments.
b) Quality records of segments delivered to the Work Site consisting of bills of lading
(shipping statements).
c) Quality records of all damaged and repaired segments, including rejected
segments.
d) Quality records of each lining ring built:
i. Location of eight points around circumference presented as coordinates
(station, offset and elevations) relative to the design track alignment, and
diametric dimension between opposing points. The points surveyed shall be
one in the crown, one in the invert, one at each horizontal axis, and one at
each end of the diagonals at 45 degrees to the vertical axis. All
measurements shall be taken on the leading edge of the ring and at the
inside face of the linings. Calculate the tunnel centerline from the surveyed
points and presented as coordinates (station, offset, Eastings, Northings, and
elevation).
ii. Maximum size of steps at each radial joint.
iii. Maximum size of steps at each circumferential joint with arc length for any
step exceeding 0.5 cm.
iv. Position of key.
v. Deviation of the crown dowel hole from the tunnel centerline, to nearest 0.25
cm.
vi. Position, dimension and description of any crack and repairs.
vii. Position and description of any other damage.
viii. Date and shift built.
2) Non-conformance reports including:
a) Out-of-tolerance tunnel lining ring installation.
b) Segments or rings that are found to be damaged after erection.

5.7. Delivery Storage and Handling

1) Transport, store, and handle units to avoid damage and prevent development of
excessive stresses within segments. Use spacers between stacked segments, located
within 15 cm of the quarter points.
2) Store segments on a prepared level surface.
3) Prevent damage to all segment surfaces during handling and storage. Keep wire ropes,
chains and hooks from direct contact with all segment surfaces, joint assemblies, mating
surfaces, gaskets, and joint packings.
4) If rings with more than one taper are used, select and deliver combinations of left, right,
or non-tapered rings to provide specified tunnel geometry, and for making alignment
corrections as necessary during construction.
5) Replace gaskets and joint packings that have deteriorated through exposure.
6) During cold weather, prevent ice and water from filling the pockets and recesses of the
segments.
7) Prior to shipping, verify that the segments have attained the specified 28-day design
strength through a combination of in-place strength testing and comparison with strength
gain-maturity curves. Verify results with cylinder tests from concrete cured with
segments.

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8) Inspect completed segments before loading. Discard defective and damaged segments.
Repair minor damage in accordance with procedures reviewed by the Construction
Manager.
9) Group shipped segments in units of complete rings, all properly identified.

5.8. Products
5.8.1. General
1) The segments and components shall resist decomposition from sulfates, chlorides and
contaminated materials described in the Environmental Finding Report Summary
(Reference Document).
2) Materials and products shall be fire retardant and shall not give off toxic fumes in the
event of fire.
3) Use tapered rings to negotiate horizontal and vertical curves and to correct for line and
level. Ring taper shall be between 5-cm and 7.5-cm divided equally between leading
and trailing circumferential joints. Non-tapered segments may be used in conjunction
with tapered rings.

5.8.2. Concrete
1) Cement shall be OPC-53/53S for early strength gain and fast demoulding. Minimum
cement content shall not be less than 425 Kg/cum.
2) Concrete compressive strength (Cube) shall be 50MPa / 55MPa minimum at 28 days as
determined by IS 456.
3) Maximum Water-Cement (Plus Ash) Ratio: 0.38. Superplasticizer shall be incorporated
into the mix to ensure that the minimum possible water/cement ratio consistent with
Contractor’s workability requirements is achieved.
4) Silica Fume: 5- to 7-percent of total cementitious material content shall confirm to IS
15388
5) Water Permeability (40 Days): 3.0x10-15-meter/second maximum as per IS 3085
6) Chloride Ion Penetrability: Average 700-coulombs charge or less and in no case shall
exceed 1,000-coulombs, as determined by ASTM C1202.

5.8.3. Aggregates
1) 1.25- to 1.9-cm, conforming to IS2386 and shall consist of natural sand, gravel, crushed
gravel or crushed rock. Aggregates shall not contain a total mass of reactive alkali
greater than 3-kilograms per cubic meter or any other matter likely to affect the long-term
durability of the concrete.
2) Water absorption shall not exceed 2-percent.
3) Admixtures containing chlorides, nitrates or other corrosive agents shall not be used.
4) Use 100-percent virgin monofilament polypropylene fiber containing no reprocessed
materials. Fibers shall conform as shown on the drawings.
5) Water used for mixing concrete shall be potable fresh water.
In addition, specifications as per Chapter 15 of Technical specifications shall also be read in
conjunction.

5.8.4. Reinforcing Steel

Shall follow specifications as per Chapter 12 of Technical specifications.

5.8.5. Bolts, Dowels, Inserts, Grout Holes and Segment Identification

1) Bolts and Bolt Inserts:
a) Bolts shall be ASTM A325, hot-dip galvanized.
b) Nuts shall be ASTM A563, hot-dip galvanized.
c) Washers shall be ASTM F436, hot-dip galvanized
d) Grommets will not be permitted.
e) Bolt inserts shall be either ASTM A36 steel, zinc coated (hot-dip galvanized) in
accordance with ASTM A153, or non-ferrous. Required anchor pullout capacity
shall be as determined by calculation to maintain required gasket closure, ignoring
confining pressure around lining.
f) Required pullout capacity shall be determined by calculation, sufficient to resist
gasket forces in a fully closed radial joint with fully tightened bolts after erector arm

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