Full-scale testing of precast tunnel lining segments under thrust jack loading: Design limits and ultimate response

Abstract

In modern practice, precast segmental tunnel linings are typically installed via a tunnel boring machine (TBM), which advances by thrusting against the previously installed segmental ring. The forces applied through the thrust jack pads can induce significant bursting and spalling tensile stresses and strains in the segment, and improperly designed segments can suffer from cracking as a result. An experimental study has been conducted to evaluate the progression of damage from initial cracking to ultimate capacity for full-scale precast tunnel liner segments under thrust jack loading. The baseline segment design is composed of steel fiber reinforced concrete (SFRC), and the impact of supplemental conventional steel bar reinforcement and load application eccentricity were also investigated. Six full-scale tests were performed with a thrust jack load per pad up to 22.2 MN (which is ∼ 3.8 times the maximum expected installation thrust force). At the maximum expected thrust jack load during installation (5.78 MN per pad), the segments were virtually undamaged, and hairline cracking initiated between the load pads on only one test. At the TBM’s ultimate jacking capacity (9.55 MN per pad) surface cracking was observed between and under the load pads; however, the crack width remained below 0.2 mm for all specimens. The formation of cracking limit states was accurately predicted by pre-test linear and nonlinear finite element (FE) models. At overload conditions, the baseline SFRC-only segment exhibited a radial bursting failure. The inclusion of supplemental conventional reinforcement does not reduce the level of cracking damage or strain development below the TBM’s ultimate jacking capacity; however, at overload conditions, the supplemental reinforcement mitigates cracking and prevents a radial bursting failure at 20.3 MN per pad. A load eccentricity of 38 mm towards the extrados surface increased the transverse strain and the formation of transverse cracking at a lower load level.