Early Works Package - Specification B (Section 317210) - Tunnel Primary Support - Ground Reinforcement

B. All lattice girders shall normally consist of not less than three primary reinforcing bars,
dimensioned and arranged as shown on the Drawings and connected by stiffening
elements of the manufacturer’s design or as shown on the drawings. They shall be
designed to:

1. Facilitate prompt assembly and placement

2. Facilitate shotcrete penetration into and behind the girder, thereby minimising the
creation of shadows.

3. Provide good quality bonding between the steel and shotcrete, to form a
composite structure

4. Ensure stability against buckling, the maximum spacing between stiffening

elements shall be less than three times the cross-sectional height of the girder

5. Be fabricated to meet minimum clearances shown on the drawings under

consideration of construction tolerances, material tolerances, and of lining
deflection following installation

6. Each of the primary retaining bars of a lattice girder segment shall be composed
of only one piece of high strength steel with no splices having a minimum yield
strength of 500MPa, or as shown on the Drawings.

7. Connection elements at the end of lattice girder segments shall be constructed of

angled structural steel having a yield strength of 235MPa or stronger, or of welded
flat steel ensuring similar strength characteristics.

8. The Contractor shall ensure that any lattice girders that are damaged or bent are
not used, and are immediately removed from the site. Steel that is visibly pitted by
rust shall be treated as non-conforming and removed from site.

9. Lattice girder inspection and weld quality inspection checks shall follow the BTS
Specification for Tunnelling 3rd edition.

2.9 STEEL SETS

A. Steel sets shall comprise structural sections fabricated to the dimensions, shapes and
minimum structural sectional properties shown on the Drawings. Rolled structural
sections shall conform with ASTM A572 Grade 50: Minimum yield stress of 345 N/mm2
or equal typically used unless otherwise noted.

B. Sets shall be provided with footing plates and tie rods and collar braces as shown on
the Drawings or as required to properly brace sets.

C. Connection details, including welds, bolts, nuts and washers shall comply with the
standards and categories detailed on the Drawings.

D. Grout socks for blocking of the sets shall be as shown on the Drawings. They shall be
dimensioned to suit the sets and installed in accordance with the manufacturer’s
recommendations.
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1. Design precast structural concrete framing system and connections to maintain clearances
at openings, to allow for fabrication and construction tolerances, to accommodate live-
load deflection, shrinkage and creep of primary structure, and other movements. Maintain
precast structural concrete deflections within limits of SBC codes and ACI 318.

a) Thermal Movements: Allow for in-plane thermal movements resulting from annual
ambient temperature changes.

2. Fire-Resistance Rating: Select material and minimum thicknesses to provide 2 hours

minimum fire rating, unless otherwise indicated.

2.3 MOLD MATERIALS

A. Molds: Rigid, dimensionally stable, non-absorptive material, warp and buckle free, that will
provide continuous and true precast concrete surfaces within fabrication tolerances indicated;
nonreactive with concrete and suitable for producing required finishes.

1. Mold-Release Agent: Commercially produced liquid-release agent that will not bond with,
stain or adversely affect precast concrete surfaces and will not impair subsequent surface
or joint treatments of precast concrete.

B. Form Liners: Units of face design, texture, arrangement, and configuration as required. Furnish
with manufacturer's recommended liquid-release agent that will not bond with, stain, or
adversely affect precast concrete surfaces and will not impair subsequent surface or joint
treatments of precast concrete.

C. Surface Retarder: Chemical set retarder, capable of temporarily delaying final hardening of
newly placed concrete mixture to depth of reveal specified.

2.4 REINFORCING MATERIALS

A. Refer to Section 033000 “Cast-in-Place-Concrete”.

B. Supports: Suspend reinforcement from back of mold or use bolsters, chairs, spacers, and
other devices for spacing, supporting, and fastening reinforcing bars and welded wire
reinforcement in place according to PCI MNL 116.

2.5 PRESTRESSING TENDONS

A. Pretensioning Strand: ASTM A416/ A416M, Grade 270, uncoated, 7-wire, low-relaxation
strand.

B. Unbonded Post-Tensioning Strand: ASTM A416/ A416M, Grade 270, uncoated, 7-wire, low-
relaxation strand.

1. Coat unbonded post-tensioning strand with post-tensioning coating complying with ACI
423.7 and sheath with polypropylene tendon sheathing complying with ACI 423.7 Include
anchorage devices and coupler assemblies.

C. Post-Tensioning Bars: ASTM A722/ A722M, uncoated high-strength steel bar.

2.6 CONCRETE MATERIALS

A. Refer to Section 033000 “Cast-in-Place-Concrete”.

2.7 STEEL CONNECTION MATERIALS

A. Carbon-Steel Shapes and Plates: ASTM A36/ A36M.

B. Carbon-Steel Headed Studs: ASTM A108, Grade 101 through 1020, cold finished; AWS D1.1/
D1.1M, Type A or B, with arc shields and with minimum mechanical properties of PCI MNL 116.

C. Carbon-Steel Plate: ASTM A 283/A 283M, Grade C.

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D. Malleable-Iron Castings: ASTM A47/A47M, Grade 32510 or Grade 35028.

E. Carbon-Steel Castings: ASTM A27/ A27M, Grade 60-30 (Grade 415-205).

F. High-Strength, Low-Alloy Structural Steel: ASTM A 572/A 572M.

G. Carbon-Steel Structural Tubing: ASTM A500/ A500M, Grade B or Grade C.

H. Wrought Carbon-Steel Bars: ASTM A675/ A675M, Grade 65 (Grade 450).

I. Deformed-Steel Wire or Bar Anchors: ASTM A1064/ A1064M or ASTM A706/ A706M.

J. Carbon-Steel Bolts and Studs: ASTM A307, Grade A (ASTM A563M, Property Class 4.6);
carbon-steel, hex-head bolts and studs; carbon-steel nuts, ASTM A563/ A563M; and flat,
unhardened steel washers, ASTM F844.

K. High-Strength Bolts, Nuts, and Washers: ASTM F3125/F3125M, Grade A325 (Grade A325M),
Type 1, heavy-hex steel structural bolts; ASTM A563, Grade DH, (ASTM A563M, Class 10S)
heavy-hex carbon-steel nuts; and ASTM F436/F436M, Type 1, hardened carbon-steel
washers.

1. Finish: Hot-dip zinc coating.

2. Do not zinc coat ASTM F3125/ F3125M bolts.

L. High-Strength Bolts, Nuts, and Washers: ASTM F3125/F3125M, Grade A490 (Grade A490M),
Type 1, heavy-hex steel structural bolts; ASTM A563, Grade DH, (ASTM A563M, Class 10S)
heavy-hex carbon-steel nuts; and ASTM F436/F436M, Type 1, hardened carbon-steel
washers; all with plain finish.

M. Zinc-coated Finish: For exterior steel items, steel in exterior walls, and items indicated for
galvanizing, apply zinc coating by hot-dip process according to ASTM A123/ A 123M, after
fabrication, and ASTM A153/ A 153M, as applicable or electrodeposition according to ASTM
B 633, SC 3, types 1 and 2.

1. For steel shapes, plates, and tubing to be galvanized, limit silicon content of steel to less
than 0.03 percent or to between 0.15 and 0.25 percent or limit sum of silicon and 2.5 times
phosphorous content to 0.09 percent.

2. Galvanizing Repair Paint: High-zinc-dust-content paint with dry film containing not less
than 94 percent zinc dust by weight, and complying with SSPC- Paint 20.

N. Shop-Primed Finish: Prepare surfaces of nongalvanized steel items, except those surfaces to
be embedded in concrete, according to requirements in SSPC-SP 3 and shop-apply lead- and
chromate-free, rust-inhibitive primer, complying with performance requirements in FS TT-P-664
according to SSPC-PA 1.

O. Welding Electrodes: Comply with AWS standards.

P. Precast Accessories: Provide clips, hangers, plastic shims, and other accessories required to
install precast structural concrete units.

2.8 STAINLESS-STEEL CONNECTION MATERIALS

A. Stainless-Steel Plate: ASTM A240/A240M or ASTM A 666, Type 304, of grade suitable for
application.

B. Stainless-Steel Bolts and Studs: ASTM F593, Alloy Group 1 or 2, hex-head bolts and studs;
ASTM F594, Alloy Group 1 or 2 (ASTM F836M, Grade A1 or A4) stainless-steel nuts; and flat,
stainless-steel washers.

1. Lubricate threaded parts of stainless-steel bolts with an antiseize thread lubricant during
assembly.

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