Tender Documents Section 9 TUNNELLING WORKS Welding. Holes for ties, struts and any bolted connections shall be drilled. No burning will be allowed whether for temporary Works items or permanent elements. ‘Threaded tie rods and struts shall be of adequate length to suit arch center and allow 25 ‘mm projection each end beyond the nut. Bolts for bolted connections shall be black bolts to BS 4190 ISO metric black hexagon bolts, screws and nuts - Specification, Where arches are to be provided as part of the Contractor's obligation for support the Contractor shall provide dimensional details of the arches, calculations regarding imposed loads and design and such other inforration that the Engineer may reasonably request. Lattice Girders Lattice girders shall consist of three or four primary bars, connected by stiffening elements to the manufacturer's design. They shall be designed so as to: (facilitate shotcrete penetration into and behind the girder, thereby mi the creation of projection shadows and/or voids; (i) provide good-quality bonding between the steel and shotcrete, to form a composite structure acting as a continuous reinforced concrete lining; and (ii) make allowance for the specified tolerances including convergence. 1) Stiffening elements ‘A minimum 59% of the total moment of inertia shall be provided by the stifening elements. This percentage is calculated as an average along the repeatable lengths of the lattice sider. To ensure stability against buckling, the raximum spacing between the stiffening elements shall be less than three times the cross- sectional height of the girder. Loading and bending test shal be conducted on the giider to analyse its mechanical behaviour. Lattice gider to be used as steel support shall have equivalent capacity as traditional steel support, steel arches. 2) Dimensions and tolerances ‘The lattice girders shall be fabricated to meet minimum clearances and tolerances shown under consideration of accuracy of placement during construction, manufacturing tolerances, andl of lining deftection following installation, Prior to installation, each girder shall be inspected as specified below and allTender Documents Section 9: TUNNELLING WORKS. Each girder inspection shall check the following criteria: (the gicder is fully identified with the girder type and the unique traceability reference, (ithe girder chord length (225 mm) and height (215 mm) is in accordance with the appropriate drawing detail subject to the specified tolerances. (i) the girder inks and sinusoidal are in the comect positions and are adequately welded. (iv) the reinforcement and plate types and sizes areas specified on the Drawings. When inspecting weld quality, the following criteria shall be used! (the reinforcement shall be free from undercut in excess of 1 mm, the weld metal deposition shall be even and blend smoothly with the bars. (ii) the weld metal shall be free from cracks and porosity The chord length shall be checked by measuring the distance from the outer edge of the connection plate to the corresponding point on the connection plate at the other end of the girder. The measurement shall be taken to the nearest millimetre ‘The chord height shall be checked by placing a tight cord across the centerline of the girder between the outer edges of the end plates then measuring the height from the chord to the inside edge of the lower main bar. The measurement shall be taken to the nearest millimetre. Where the girder consists of a double radius the chord lines, the measurement shall be taken along the outer edge of the connection plates to the point at which the radius changes. 3) Fabrication Each of the primary bars of the lattice girder segment shall be composed of only ‘one piece of high-yield steel to BS 4449 Steel for the reinforcement of concrete ~ Weldable reinforcing steel, bar, coll and decolted product (minimum grade 500) or ‘equivalent, Secondary bars are either plain round profite or deformed of high yield to BS 4449 (minimum grade 500) or equivalent. Stiffening bars shall conform to BS 4449 (minimum grade {der segments shall be constructed J products of structural steelTender Documents “Section 9: TUNNELLING WORKS 9834 Contrect f: en Chol -gao Section Technical delivery conditions (grade $275JA) or equivalent, Connections between lattice girder segments shall be bolted; welded connections between segments shall not be permitted, Nuts and bolts supplied are to be grade 8.8 or higher. All welding shall be carried out in accordance with BS EN 1011-1:2009, with ‘welding personnel and fabrication facility approved. Procedures ‘The Contractor shall provide method staternents for the erection of arches to the Engineer for agreement, Arch materials shall be as specified herein. Steet arch ribs and full cicle lattice giders shall be Firnly fixed in ther final positions against the excavation as shown. Arch bases shall be provided with integral base plates of size to suit the bearing capacity of the ground and shall bear on rock or concrete of adequate strength. Arches and ribs shall be sufficiently clear of the excavation and the final intemal profile of the structure to accommodate any required concrete cover. ‘The number of joins in the arch shall be varied to suit the Contractor's method of working subject to the Engineer's agreement. Steel tie bars and struts between arches shall be installed where shawn on the Drawings. ‘A minimum 50 mm thick shotcrete layer must be in place before the installation of the lattice girders, Under no circumstance shal lattice giders be installed under unsupported ground. Lattice gicler segments shall be secured by use of temporary wood blocking, steel wedges, concrete spacers, mortar sacks and/or other appropriate means to maintain position during application of shotcrete. The means of support shall be subject to the approval of the Engineer. All wood blocking shall be removed during the next phase of excavation and any void in filled with shotcrete to ensure continuity of the primary lining Lattice girder segments shall have butt plates or lap joints and the method of installation. shall ensure tight connection of all elements. Immediately prior to concreting, casting or spraying, the arches, tles and struts shall be rendered clean and free from deleterious matter. Lattice girders shall be firmly fixed in thelr final position against the excavation prior to application of shotcrete. Lattice girders shall be sufficiently clear of the excavation and final intemal profile of the structur odate the required shotcrete cover. eee