Civil Engineering Training 2005 ENG

Welcome
Civil Engineering –
Tunnel Construction
Product Manager
Daniel Gisler
Page 1 24.03.2005
Page 2 24.03.2005
Summary Theory
• Scope
• Welding Procedure
• Welding Process Under Construction Site Conditions
• Differences of Hot Wedge and Combi Wedge
• Diverse Gears
• Application Range and Parameters
• Tunnel Construction
• Automatic Machines – Tensiometers – Hand Tools –
Extruders
Page 3 24.03.2005
Scope
Page 4 24.03.2005
Scope
artificial rivers with HD-PE

1.5mm
tank coating with TWINNY S

(combi wedge short) for LD-PE
1mm
Page 5 24.03.2005
Scope
water reservoir coated with

HD-PE 2.0mm
cleaning pool coated and welded

with ASTRO
Page 6 24.03.2005
Scope
welding work with COMET 70mm for

artificial lake on golf course
PVC 2.5mm for groundwater

sealing with TWINNY T
Page 7 24.03.2005
Scope
welding connections on pool for

chemistry with ASTRO and FUSION 3
future fish pool welded with COMET
Page 8 24.03.2005
Scope
greenhouse covering assembled with

TWINNY S (combi wedge short)
container coverings made of PVC
Page 9 24.03.2005
Scope
driving in a side-gallery with

blasting
tunnel cover with PVC 3mm, carried

out with TWINNY S
Page 10 24.03.2005
Welding Procedure
Page 11 24.03.2005
Welding Procedure
Hot Wedge Welding
COMET ASTRO COSMO

Page 12 24.03.2005
Welding Procedure
Combi Wedge Welding
TWINNY S TWINNY T TWINMAT
Page 13 24.03.2005
Welding Procedure
Hot Air Welding
TRIAC DRIVE - HAND TOOLS
Page 14 24.03.2005
Welding Procedure
FUSION 3 WELPLAST WELDMAX
Page 15 24.03.2005
Welding Procedure
Following welding procedures are possible:

ª extrusion welding
ª hot wedge welding (heating element)
ª hot air welding
All welding procedures require an accordance of the following parameters:

ª temperature
ª pressure
ª speed
Joining areas must be dry and free of impurity. For T-joints and when build-up
welding the front surface of the upper membrane must be held slanted.
Page 16 24.03.2005
Welding Procedure Under Construction Site Conditions
Condition of Surface
ª solid underground with smooth surface without bumps
ª Building sites should be free of sharp items, roots and stones.
Environment Conditions / Weather Conditions / Rain

ª In case of rain it must not be welded without any special safety measures.
Air Temperature
ªWelding procedures have to be stopped at temperatures under +5°C in
order to prevent high thermal strains of the membrane.
Page 17 24.03.2005
Welding Procedure Under Construction Site Conditions
Air Humidity
ª High air humidity might cause perspiration water on the welding surface which
is unfavourable for the seam strength (towel or pre-heat).
Wind
ª Due to strong wind the required welding temperature might not be reached. To
solve this problem, the welding temperature has to be increased up to 20–30°C.
If the wind is too strong, the welding area should be protected, or the welding
process has to be stopped.
Sunshine
ª Sunshine causes strong heat, especially of black membranes. This causes an
increased thermal expansion of the membrane and results in wrinkles. The
welding process becomes more difficult, and when cooling down abnormal strain
in the seam area occurs.
Page 18 24.03.2005
Differences of Hot Wedge and Combi Wedge
ª Combi Wedge Welding Machines

• TWINNY S
• TWINNY T
• TWINMAT
ª Hot Wedge Welding Machines

• COMET
• ASTRO
• COSMO
Page 19 24.03.2005
Differences of Hot Wedge and Combi Wedge
Hot Wedge Combi Wedge
Advantages: • small heat output • no change of nozzle (PVC/PE)
• compact design • suitable for thin materials
• low noise • blows away dirt in the seam

• stress-free welding procedure
Disadvantages: • change of wedge PVC/PE • high heat output (wattage)

• depending on weather • slow speed
• cleaning of seam absolutely
necessary when wet
Page 20 24.03.2005
TWINNY S / T: Application Range Nozzles
Combi Wedge Material Thickness
PE-HD, PE-C, PFA, PP 0.3 - 1.0mm

1 PVC-P, PE-LD, EVA 0.3 - 2.0mm
1 short combi wedge with test channel
2 2 short combi wedge without test channel
Combi Wedge Material Thickness
3
PE-HD, PE-C, PFA, PP 0.8 - 2.0mm
PVC-P, PE-LD, EVA 1.0 - 3.0mm
3 long combi wedge with test channel

4
4 long combi wedge without test channel
Page 21 24.03.2005
TWINNY S: Diverse Gears
Gear 144:1 Gear 256:1
• speed of 0.8 – 4.0 m/min • speed of 0.2 – 2.5 m/min

• max. pressure of 500N • max. pressure of 1000N
• thin materials are suitable • thick materials are suitable
• current limiter (motor switches off) • current limiter (motor switches off)
Page 22 24.03.2005
COMET / TWINNY: Parameters
Machine Tempeartur (°C) Speed (m/min) Pressure (N)
Comet 50mm 420 3 600

Twinny S (short wedge, 144:1) 550 3.2 500
Material: HD-PE smooth 1.0mm Ambient Temperatur: 20°C
Machine Tempeartur (°C) Speed (m/min) Pressure (N)
Comet 70mm 420 1.5 1000

Astro 420 2.8 1250
Twinny T (long wedge) 550 1.3 1000
Material: HD-PE smooth 2.0mm Ambient Temperatur: 20°C
ATTENTION ATTENTION: According to the configuration of the membranes and

depending on the weather conditions the parameters may change!
Page 23 24.03.2005
Application Range According to Material
HD-PE LD-PE PVC

0.3 0.5 1.0 1.5 2.0 2.5 3.0 4.0 5.0 0.3 0.8 1.0 1.5 2.0 0.8 1.0 1.5 2.0 2.5 3.0
Wedge Welder
Comet 70mm (copper wedge) X X (X) X X
Comet 50mm (copper wedge) X X X X X X
Comet 30mm (copper wedge) X X X
Comet 70mm (steel wedge) X X X
Comet 50mm (steel wedge) X X X X
Comet 30mm (steel wedge) X X
Astro X X X X
Cosmo X X X X
Combi wedge
Twinny S (short wedge) X X X X X X X X X X
Twinny S (long wedge) X X X X X X X X X
Twinny T (short wedge) X X X X X X X X X
Twinny T (long wedge) X X X X X X X X X
Twinmat X X X X X X X X
Page 24 24.03.2005
Welding Tests
Strength Test
• peeling tests (seam strength)
Density Test
• compressed air – vacuum – high-voltage
Measurement Test
• entire overlapping – front overlapping
Page 25 24.03.2005
Tunnel Construction
Page 26 24.03.2005
Tunnel Construction
1. inserted drainage tube

2. lean concrete
3. shotcrete gunite
4. concrete guard plate
5. PVC membrane 2/3mm
6. cleaning channel
Page 27 24.03.2005
Tunnel Construction
1 middle drainage tube
2 concrete
3 foundation
4 mountain water drainage
5 lead concrete
6 rock support
7 PVC waterproofing membrane
8 inner concrete
9 road topping
10 inspection chamber
Page 28 24.03.2005
Automatic Machines
Page 29 24.03.2005
Wedge Welding Machine
COMET
Wedge welding machine
• smallest compact
machine
• wide range of
applications
• HD-PE, PP and PVC
Page 30 24.03.2005
ASTRO
• worldwide the fastest

wedge welding machine
• very robust
• one-handle operation
Page 31 24.03.2005
ASTRO BSP (for nap-material)

• faster than conventional

welding procedures
• up to 3.5mm membranes
• up to 19mm nap-material
Page 32 24.03.2005
Concrete Guard Plates – Nap Membranes
Omega - naps T - naps
V - naps Flat naps
Page 33 24.03.2005
COSMO
• process control by direct

measuring
• welding printouts for quality

assurance
• max. pressure of 2500N
Page 34 24.03.2005
Hot Air
TWINNY T
Combi wedge welding machine
• small and handy
• combi wedges easy to

change
• suitable for all materials
Page 35 24.03.2005
Hot Air
TWINNY S
• ideal for tunnel construction
• low weight
• highest speed up to 4m/min
Page 36 24.03.2005
Hot Air
TWINMAT
• Process control by direct

measuring
• welding printouts for quality

assurance
• max. pressure of 2500N
Page 37 24.03.2005
Semi Automatic
Welding Tools
and Hand Tools
Page 38 24.03.2005
Hand Tools – Semi Automatic Welding Tools
TRIAC PID TRIAC DRIVE
Page 39 24.03.2005
TRIAC DRIVE – Application
• horizontal, vertical, diagonal

• different welding seam widths
• applicable in the most confined spaces
ideal job for diagonal connections in a

tunnel
Page 40 24.03.2005
Tensiometer
Page 41 24.03.2005
Construction Site Tensiometer
EXAMO
Peeling, tensile and shearing tool
• portable and designed for

construction site conditions
• optional data recording

possible
• optional for geotextiles
Page 42 24.03.2005
Extruder
Page 43 24.03.2005
EXTRUDER Generation in Civil Construction
WELDMAX FUSION 3
WELDPLAST G6
WELDPLAST S6
Page 44 24.03.2005
Thank you for
your attention!
Page 45 24.03.2005

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Welcome

artificial rivers with HD-PE

tank coating with TWINNY S

water reservoir coated with

cleaning pool coated and welded

welding work with COMET 70mm for

PVC 2.5mm for groundwater

welding connections on pool for

future fish pool welded with COMET

greenhouse covering assembled with

container coverings made of PVC

driving in a side-gallery with

tunnel cover with PVC 3mm, carried

Hot Wedge Welding

COMET ASTRO COSMO

Combi Wedge Welding

TWINNY S TWINNY T TWINMAT

Hot Air Welding

TRIAC DRIVE - HAND TOOLS

FUSION 3 WELPLAST WELDMAX

Following welding procedures are possible:

All welding procedures require an accordance of the following parameters:

Environment Conditions / Weather Conditions / Rain

ª Combi Wedge Welding Machines

ª Hot Wedge Welding Machines

Hot Wedge Combi Wedge

Advantages: • small heat output • no change of nozzle (PVC/PE)

• compact design • suitable for thin materials

• low noise • blows away dirt in the seam

Disadvantages: • change of wedge PVC/PE • high heat output (wattage)

Combi Wedge Material Thickness

PE-HD, PE-C, PFA, PP 0.3 - 1.0mm

1 short combi wedge with test channel

2 2 short combi wedge without test channel

Combi Wedge Material Thickness

3 long combi wedge with test channel

Gear 144:1 Gear 256:1

• speed of 0.8 – 4.0 m/min • speed of 0.2 – 2.5 m/min

Machine Tempeartur (°C) Speed (m/min) Pressure (N)

Comet 50mm 420 3 600

Material: HD-PE smooth 1.0mm Ambient Temperatur: 20°C

Machine Tempeartur (°C) Speed (m/min) Pressure (N)

Comet 70mm 420 1.5 1000

Material: HD-PE smooth 2.0mm Ambient Temperatur: 20°C

ATTENTION ATTENTION: According to the configuration of the membranes and

HD-PE LD-PE PVC

1. inserted drainage tube

1 middle drainage tube

4 mountain water drainage

7 PVC waterproofing membrane

• HD-PE, PP and PVC

• worldwide the fastest

ASTRO BSP (for nap-material)

• faster than conventional

Omega - naps T - naps

V - naps Flat naps

• process control by direct

• welding printouts for quality

• max. pressure of 2500N

• small and handy

• combi wedges easy to

• suitable for all materials

• ideal for tunnel construction