Ci il E i i Civil Engineering â Tunnel Construction - KIV Marketing ...
Ci il E i i Civil Engineering â Tunnel Construction - KIV Marketing ...
Ci il E i i Civil Engineering â Tunnel Construction - KIV Marketing ...
Create successful ePaper yourself
Turn your PDF publications into a flip-book with our unique Google optimized e-Paper software.
<strong>Ci</strong>v<strong>il</strong> <strong>il</strong> <strong>Engineering</strong> i –<br />
<strong>Tunnel</strong> <strong>Construction</strong><br />
Prepared by<br />
Mr. Roland von Ah<br />
Presented by<br />
Mr. Kirby Lorenzo<br />
Page 1<br />
31.05.2007
Scope<br />
Page 2<br />
31.05.2007
Scope<br />
water reservoir coated with<br />
HD-PE 2.0mm<br />
cleaning pool coated and welded<br />
with ASTRO<br />
Page 3<br />
31.05.2007
Scope<br />
artificial lake on golf course welded<br />
with COMET 70mm<br />
Page 4<br />
31.05.2007
Scope<br />
Landf<strong>il</strong>l, HDPE liner welded<br />
with ASTRO<br />
PVC 2.5mm for groundwater<br />
sealing with TWINNY T<br />
Page 5<br />
31.05.2007
Scope<br />
Drainage channel sealed with HDPE<br />
on a heap leaching copper mine.<br />
Water basin used as shrimp farm,<br />
HDPE liner welded with COMET.<br />
Page 6<br />
31.05.2007
Scope<br />
Secondary containment for ground water protection<br />
Page 7<br />
31.05.2007
Scope<br />
tunnel cover with PVC 3mm, carried<br />
out with TWINNY S<br />
<strong>Tunnel</strong> driving in a side-gallery with<br />
blasting<br />
Page 8<br />
31.05.2007
Welding Procedure<br />
Page 9<br />
31.05.2007
Welding Procedure<br />
Following welding procedures are possible:<br />
extrusion welding<br />
hot wedge welding (heating element)<br />
hot air welding<br />
All welding procedures require an accordance of the following parameters:<br />
temperature<br />
pressure<br />
speed<br />
Joining areas must be dry and free of impurity. For T-joints and when bu<strong>il</strong>d-up<br />
welding the front surface of the upper membrane must be held slanted.<br />
Page 10<br />
31.05.2007
Welding Procedure<br />
Hot Wedge Welding<br />
COMET ASTRO COSMO<br />
Page 11<br />
31.05.2007
Welding Procedure<br />
Combi Wedge Welding<br />
TWINNY S TWINNY T TWINMAT<br />
Page 12<br />
31.05.2007
Welding Procedure<br />
Hot Air Welding<br />
TRIAC DRIVE -<br />
HAND TOOLS<br />
Page 13<br />
31.05.2007
Welding Procedure<br />
FUSION 3 WELPLAST WELDMAX<br />
Page 14<br />
31.05.2007
Welding Procedure Under <strong>Construction</strong> Site Conditions<br />
Condition of Surface<br />
solid underground with smooth surface without bumps<br />
Bu<strong>il</strong>ding sites should be free of sharp items, roots and stones.<br />
Environment Conditions / Weather Conditions / Rain<br />
In case of rain it must not be welded without any special safety measures.<br />
Air Temperature<br />
Welding procedures have to be stopped at temperatures under +5°C in<br />
order to prevent high thermal strains of the membrane.<br />
Page 15<br />
31.05.2007
Welding Procedure Under <strong>Construction</strong> Site Conditions<br />
Air Humidity<br />
High air humidity might cause perspiration water on the welding surface which<br />
is unfavourable for the seam strength (towel or pre-heat).<br />
Wind<br />
Due to strong wind the required welding temperature might not be reached. To<br />
solve this problem, the welding temperature has to be increased up to 20–30°C.<br />
If the wind is too strong, the welding area should be protected, or the welding<br />
process has to be stopped.<br />
Sunshine<br />
Sunshine causes strong heat, especially of black membranes. This causes an<br />
increased thermal expansion of the membrane and results in wrinkles. The<br />
welding process becomes more difficult, and when cooling down abnormal strain<br />
in the seam area occurs.<br />
Page 16<br />
31.05.2007
Welding shape according DVS 2225 Te<strong>il</strong> 1<br />
Page 17<br />
31.05.2007
Test procedure: Test on construction site<br />
according DVS 2225 Te<strong>il</strong> 2<br />
• Outer appearance of the seam (visual control of notches, grooves and irregularities)<br />
• Examination of the dimension (measuring)<br />
• Strength test (tens<strong>il</strong>e test)<br />
• Leak-tightness test (Testing with compressed air)<br />
Page 18<br />
31.05.2007
Test Procedure: Test on construction site<br />
according DVS 2225 Te<strong>il</strong> 2<br />
Strength test (tens<strong>il</strong>e test)<br />
Page 19<br />
31.05.2007
Test Procedure: Test on construction site<br />
according DVS 2225 Te<strong>il</strong> 2<br />
Leak-tightness test<br />
(Testing with compressed air)<br />
Page 20<br />
31.05.2007
Automatic ti Machines<br />
Page 21<br />
31.05.2007
Hot Wedge and Combi Wedge<br />
automatic welding machines<br />
Combi Wedge Welding Machines (hot air heated)<br />
• TWINNY S<br />
• TWINNY T<br />
• TWINMAT<br />
Hot Wedge Welding Machines (contact heat)<br />
• COMET<br />
• ASTRO<br />
• COSMO<br />
Page 22<br />
31.05.2007
Wedge Welding Machine<br />
COMET<br />
Wedge welding machine<br />
• smallest compact<br />
machine<br />
• wide range of<br />
applications<br />
• HD-PE, PP and PVC<br />
Page 23<br />
31.05.2007
Wedge Welding Machine<br />
ASTRO<br />
Wedge welding machine<br />
• worldwide the fastest<br />
wedge welding machine<br />
• very robust<br />
• one-handle operation<br />
Page 24<br />
31.05.2007
Wedge Welding Machine<br />
ASTRO BSP (for nap-material)<br />
Wedge welding machine<br />
• faster than conventional<br />
welding procedures<br />
•up to 3.5mm membranes<br />
• up to 19mm nap-material<br />
Page 25<br />
31.05.2007
Concrete Guard Plates – Nap Membranes<br />
Omega - naps<br />
T - naps<br />
V - naps<br />
Flat naps<br />
Page 26<br />
31.05.2007
Wedge Welding Machine<br />
COSMO<br />
Wedge welding machine<br />
• process control by direct<br />
measuring<br />
• welding printouts for quality<br />
assurance<br />
• max. pressure of 2500N<br />
Page 27<br />
31.05.2007
Wedge Welding Machine<br />
COSMO<br />
Wedge welding machine<br />
Protocol printout of a<br />
weld for quality<br />
assurance<br />
process control by direct measuring of welding seam<br />
reduction<br />
Page 28<br />
31.05.2007
Hot Air welding machine<br />
TWINNY T<br />
Combi wedge welding machine<br />
• small and handy<br />
• combi wedges easy to<br />
change<br />
suitable for all materials<br />
Page 29<br />
31.05.2007
Hot Air welding machine<br />
TWINNY S<br />
Combi wedge welding machine<br />
• ideal for tunnel construction<br />
• low weight<br />
• highest speed up to<br />
4m/min<br />
Page 30<br />
31.05.2007
Hot Air welding machine<br />
TWINNY S<br />
Combi wedge welding machine<br />
Page 31<br />
31.05.2007
TWINNY S: Different Gears<br />
Gear 144:1 1 Gear 256:1<br />
• speed of 0.8 – 4.0 m/min<br />
• max. pressure of 500N<br />
• thin materials are suitable<br />
• current limiter (motor switches off)<br />
• speed of 0.2 – 2.5 m/min<br />
• max. pressure of 1000N<br />
• thick materials are suitable<br />
• current tlimiter it (motor switches off)<br />
Page 32<br />
31.05.2007
TWINNY S / T: Application Range Nozzles<br />
Combi Wedge Material Thickness<br />
1<br />
PE-HD, PE-C, PFA, PP<br />
PVC-P, PE-LD, EVA<br />
0.3 - 1.0mm<br />
0.3 - 2.0mm<br />
1 short combi wedge with test channel<br />
2 2 short combi wedge without test channel<br />
Combi Wedge Material Thickness<br />
3<br />
PE-HD, PE-C, PFA, PP 08 0.8 - 20mm 2.0mm<br />
PVC-P, PE-LD, EVA<br />
1.0 - 3.0mm<br />
4<br />
3 long combi wedge with test channel<br />
4 long combi wedge without test channel<br />
Page 33<br />
31.05.2007
Hot Air<br />
TWINMAT<br />
Combi wedge welding machine<br />
• Process control by direct<br />
measuring<br />
• welding printouts for quality<br />
assurance<br />
• max. pressure of 2500N<br />
Page 34<br />
31.05.2007
Differences of Hot Wedge and Combi Wedge<br />
Hot Wedge<br />
Combi Wedge<br />
Advantages:<br />
Disadvantages:<br />
• small heat output<br />
• compact design<br />
• low noise<br />
• change of wedge PVC/PE<br />
• depending on weather<br />
• cleaning of seam absolutely<br />
necessary when wet<br />
• no change of nozzle (PVC/PE)<br />
• suitable for thin materials<br />
• blows away dirt in the seam<br />
• stress-free welding procedure<br />
• high heat output (wattage)<br />
• slow speed<br />
Page 35<br />
31.05.2007
Application Range According to Material<br />
HD-PE LD-PE PVC<br />
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<br />
Wedge<br />
COMET 70mm (copper wedge) (X) X X (X) X X<br />
COMET 50mm (copper wedge) X X (X) X X<br />
COMET 70mm (steel wedge) X X X<br />
COMET 50mm (steel wedge) X X<br />
COMET 20mm (steel wedge) X X X X<br />
ASTRO X X X X<br />
COSMO X X X X<br />
Combi wedge<br />
TWINNY S (short wedge) X X X X X X X X X<br />
TWINNY S (long wedge) X X X X X X X<br />
TWINNY T (short wedge) X X X X X X X X X<br />
TWINN T (long wedge) X X X X X X X<br />
TWINMAT X X X X X X<br />
Page 36<br />
31.05.2007
Useful welding parameter for HDPE Membranes<br />
Please note: the indicated welding parameter may vary depending on the ambient temperature and the material<br />
configuration. Test welds needs to be done and the parameter aligned accordingly !<br />
HDPE<br />
Wedge 0.3 0.5 1 1.5 2 2.5 3 4 5<br />
COMET 70mm (copper)<br />
380°C 420°C 420°C 420°C<br />
2.5 m/min 2.5 m/min 2.2 m/min 2.0 m/min<br />
600 N 800 N 1000 N 1000 N<br />
COMET 50mm (copper)<br />
380°C 420°C 420°C<br />
2.3 m/min 2.2 m/min 2.0 m/min<br />
500 N 600 N 800 N<br />
COMET 70mm (steel)<br />
COMET50mm (steel)<br />
COMET 20mm (steel) 400°C 420°C<br />
2.0 m/min 1.5 m/min<br />
400 N 500 N<br />
ASTRO<br />
420°C 420°C 420°C 420°C<br />
5.0 m/min 4.5 m/min 4.2 m/min 4.0 m/min<br />
1250 N 1500 N 1500 N 1500 N<br />
COSMO<br />
420°C 420°C 420°C 420°C<br />
3.0 m/min 2.5 m/min 2.3 m/min 2.0 m/min<br />
1250 N 1500 N 1500 N 1500 N<br />
Combi wedge<br />
TWINNY S (short) 450°C 500°C 500°C<br />
3.5 m/min 3.0 m/min 2.0 m/min<br />
400 N 600 N 800 N<br />
TWINNY S (long)<br />
550°C 550°C<br />
2.0 m/min 1.8 m/min<br />
800 N 1000 N<br />
TWINNY T (short) 420°C 500°C 500°C<br />
3.2 m/min 3.0 m/min 2.0 m/min<br />
400 N 600 N 800 N<br />
TWINNY T (long)<br />
550°C 550°C<br />
20m/min 2.0 1.8 m/min<br />
800 N 1000 N<br />
TWINMAT<br />
530°C 550°C 550°C 550°C 550°C 550°C<br />
2.5 m/min 2.5 m/min 2.3 m/min 2.0 m/min 1.6 m/min 1.2 m/min<br />
1250 N 1250 N 1300 N 1500 N 1750 N 2000 N<br />
Page 37<br />
31.05.2007
Useful welding parameter for LDPE & PVC Membranes<br />
Please note: the indicated welding parameter may vary depending on the ambient temperature and the material<br />
configuration. Test welds needs to be done and the parameter aligned accordingly !<br />
LDPE<br />
Wedge 0.3 0.8 1.0 1.5 2.0 0.8 1.0 1.5 2.0 2.5 3.0<br />
COMET 70mm (copper)<br />
400°C 400°C<br />
2.8 m/min 2.5 m/min<br />
600 N 800 N<br />
COMET 50mm (copper)<br />
380°C 420°C<br />
2.5 m/min 2.5 m/min<br />
500 N 600 N<br />
COMET 70mm (steel)<br />
400°C 420°C 420°C<br />
2.8 m/min 2.5 m/min 2.4 m/min<br />
700 N 800 N 1000 N<br />
COMET 50mm (steel)<br />
400°C 420°C<br />
2.8 m/min 2.5 m/min<br />
600 N 600 N<br />
COMET 20mm (steel) 350°C 350°C<br />
2.0 m/min 2.0 m/min<br />
500 N 400 N<br />
ASTRO<br />
COSMO<br />
PVC<br />
Combi wedge<br />
TWINNY S (short)<br />
TWINNY S (long)<br />
TWINNY T (short)<br />
TWINNY T (long)<br />
TWINMAT<br />
480°C 500°C 500°C 500°C 550°C 600°C<br />
35m/min 3.5 30m/min 3.0 20m/min 2.0 2.5 m/min 2.5 m/min 25m/min 2.5 400 N 500 N 600 N 400 N 500 N 600 N<br />
500°C 550°C 550°C 580°C 600°C<br />
2.5 m/min 2.0 m/min 2.5 m/min 2.5 m/min 2.0 m/min<br />
600 N 700 N 600 N 700 N 800 N<br />
450°C 500°C 500°C 500°C 550°C 560°C<br />
3.2 m/min 3.0 m/min 2.0 m/min 2.5 m/min 2.5 m/min 2.3 m/min<br />
400 N 500 N 600 N 400 N 500 N 600 N<br />
500°C 550°C 550°C 550°C 560°C<br />
2.5 m/min 2.0 m/min 2.5 m/min 2.5 m/min 2.0 m/min<br />
600 N 700 N 600 N 800 N 1000 N<br />
Page 38<br />
31.05.2007
Semi automatic ti and hand<br />
welding tools<br />
Page 39<br />
31.05.2007
Hand Tools – Semi Automatic Welding Tools<br />
TRIAC PID<br />
TRIAC DRIVE<br />
TRIAC S<br />
Page 40<br />
31.05.2007
TRIAC DRIVE – Application<br />
• horizontal, vertical, diagonal<br />
• different welding seam widths<br />
• applicable in the most confined spaces<br />
ideal job for diagonal connections in a<br />
tunnel<br />
Page 41<br />
31.05.2007
TRIAC S / PID – Application<br />
Overlap welding of connections with<br />
TRIAC PID (PVC-P or modified PE)<br />
Tacking of HDPE membrane prior<br />
to extrusion welding<br />
Page 42<br />
31.05.2007
Tensiometer<br />
Page 43<br />
31.05.2007
<strong>Construction</strong> Site Tensiometer<br />
EXAMO<br />
Peeling, tens<strong>il</strong>e and shearing tool<br />
• portable and designed for<br />
construction ti site conditions<br />
• optional data recording<br />
possible<br />
• optional for geotext<strong>il</strong>est<strong>il</strong>es<br />
Page 44<br />
31.05.2007
Extruder<br />
Page 45<br />
31.05.2007
Leister Extruder Overview<br />
Page 46<br />
31.05.2007
Digital controlled Extruder<br />
- Air and plast seperate heated and controlled<br />
- Display for air and plast temperaturet<br />
- Weldplast: integrated menue for common materials<br />
Page 47<br />
31.05.2007
Air heated Extruder<br />
-Air heating for preheating and plast<br />
-Simple handling<br />
-Compact and light<br />
Page 48<br />
31.05.2007
Leister Extrusion Welding<br />
Leister<br />
Extruder<br />
Output(PEHD)<br />
kg/h<br />
Lenght, Weight<br />
Welding addition<br />
WELDMAX<br />
0.3 – 0.7 kg/h<br />
443 mm, 3.8 kg<br />
Welding rod 4mm<br />
WELDPLAST S4<br />
WELDPLAST EC4<br />
1.5 – 3.8 kg/h<br />
0.7 – 3.8 kg/h<br />
560 mm,8.7 kg<br />
560 mm,10.5kg<br />
Welding rod 3 and 4 mm<br />
FUSION 3<br />
1.6 – 3.5 kg/h<br />
690mm, 7.2 kg<br />
Welding rod 3 and 4 mm<br />
FUSION 3C<br />
1.6 – 3.5 kg/h 588mm, 6.9 kg Welding rod 3 and 4 mm<br />
Fusion 2<br />
1.3 – 1.8 kg/h 450mm, 5.9kg Welding rod 4 mm<br />
Page 49<br />
31.05.2007
Extruder – Application<br />
Connections and drainages<br />
Repair badge<br />
Page 50<br />
31.05.2007
Thank you for<br />
your attention!<br />
Page 51<br />
31.05.2007
Change language