Anchored rubber gasket UG027A presentation

ANCHORED RUBBER GASKET UG027A
WITH HYDROPHILIC STRIP
ANCHORED RUBBER GASKET
UG027A WITH HYDROPHILIC STRIP
Redaction Date Approval Rév.
S.LUPI 07/04/2015 G. BOMBEN 1

-> The best embedment to the concrete in
the market
-> Improved compression stability
-> Fully integrated with the segment moulds
-> Optimal interpenetration of the gasket
on itself
-> 200 years design life

First
Generation
Second
Generation
Third
Generation
Forth
Generation
Fifth
Generation
GLUED GASKETS ANCHORED GASKETS

WITH HYDROPHILIC STRIIP
CHARACTERISTICS OF RUBBER
The rubber is a flexible material and non-compressible.
Max compres. Relax Max flex.
h 6 mm h 10 mm h 40 mm
For this reason, in the course of time, the form of hydraulic gaskets
gradually has undergone conceptual changes to its shape. It has gone from
forms that included a deformation in compression alone to forms that use in
form also increasing elongation.

RUBBER GASKETS FIRST GENERATION
COMPRESSIVE DEFORMATION
• Slight changes in shape and hardness of gasket,
cause high variations of compression.
• Rapid drop of tightness performances
• High stress conditions in the connection system
• High reaction forces for closed gaps
CONS

DEVELOPMENT THE SECOND GENERATION
STEP COMPLICATED
1. Forms apparently similar during compression behave a
completely different way
2. The evolution of the gasket from the first to the second
generation is particularly complex

RUBBER GASKETS SECOND GENERATION
SEPTA DEFLECTION GASKET
SEPTA DEFLECTION GASKET
CONSPROS
• Improves the compression
behaviour
• Lower forces for the closed
gap.
• Better hydraulic performance
• Remains a certain instability
• Need for a taller gasket profile
to mantain good watertightness
performances.

SECOND GENERATION GOOD SOLUTION
•Good contact between the groove flanks
•Contact surfaces between the rubber gaskets even.
•Instability of the upper part

• Bad contact between the groove flanks
• Contact surfaces between the rubber gaskets neither even or flat
• General instability
SECOND GENERATION BAD SOLUTION

• Better behaviour in compression and in
relaxation
• Higher stability to the tightness
performances
• No stress in the connection systems
• Higher stability to compression
• Lower forces for the closed gap
RUBBER GASKETS THIRD GENERATION
«FOLDING» GASKET BY COMPRESSION
PROS

• Good contact with groove flanks
• Contact surfaces between the rubber gaskets even.
• Perfect gasket foldability and no instability.
RUBBER GASKETS THIRD GENERATION
«FOLDING» GASKET BY COMPRESSION

ANALYSIS OF GLUED GASKETS
APPLICATION ON CONCRETE
SEGMENTS

• Repair from the concrete groove if damaged
• Repair and fill cavities higher than 1 mm
• Treat the concrete groove with brushes to remove all the roughness
A. CONCRETE GROOVE PREPARATION
• Dust must be removed from concrete groove
• Concrete grooves surface must be dry
• Concrete grooves should be oil/grease free
B. BONDING
• Strictly observe the glue preparation’s procedure
• Glue should be applied with paintbrush or spry gun
• Glue shall be applied with a constant thickness film
• Glue shall be applied particularly on the groove’s flanks
• Strictly comply with the solvent evaporation time before the installation of the
rubber gasket
C. GLUE APPLICATION

• The application should be made only at glue’s right
ripeness (the glue should be neither too wet nor too dry)
• Rubber gasket must be coupled with concrete segment
by a rubber hammer without getting damaged
• Operation to be carried out in a specific finishing line
using a specific press rig to improving the coupling
between gasket and concrete segment
D. Rubber gasket application
• The pre casting plant must be equipped with a finishing
line
• It’s necessary to have an additional handling of the
segments before their storage. This cause higher damage
risks;
• It’s necessary to have a special press tool to obtain a
perfect coupling between rubber gasket and concrete
segment.
E. Glued rubber gaskets critical issues

Note: the white cross hatch was made on the profiles prior to the simulation test in order to show more clearly
the effects
DISPLACEMENT BEHAVIOUR OF THE FRAME CORNER
1
2
3
1. Expulsion of the corner gasket from its groove due to the compression
exerted by the erected segment.
2. Unbonding of the rubber gasket due to the reaction forces by the
concrete segment during its erection.
3. Higher deformation of the gasket frame corner.
MAIN CONS

• Corner geometry perfectly fits to the concrete segment
MEASURES TO IMPROVE THE HYDRAULIC WATER TIGHTNESS OF GLUED
GASKETS
Acute and oblique corner Obtuse and oblique corner

• Corner geometry perfectly fits to the concrete segment
Good fitting Bad fitting

ANALYSIS OF ANCHORED
RUBBER GASKET UG027A

ANCHORING OF RUBBER GASKET TO CONCRETE.
RUBBER GASKETS FORTH GENERATION
This technological innovation allows to increase in a relevant way the quality of
the produced parts but also to significantly reduce the manufacturing costs.
Installed in the 4.1m diameter TBM tunnel that brings two sets of cables from
Sicily to the mainland under the sea (Scilla Tunnel)

+ =
Scilla Tunnel
Vancouver Evergreen Line

ANCHORING OF RUBBER GASKET WITH HYDROFILIC STRIP
TO CONCRETE. RUBBER GASKETS FIFTH GENERATION
This technological innovation allows to increase in a relevant way the quality of
the produced parts but also to significantly reduce the manufacturing costs.

ANCHORING OF GASKET WITH HYDROPHILIC STRIP TO CONCRETE
RUBBER GASKETS FIFTH GENERATION
• Good contact with groove flanks
• Contact surfaces between the rubber gaskets fully even.
• Perfect gasket foldability and no instability.

The gasket maintains a good contact between the surfaces and a proper
crushing also to offset 10

The gasket maintains a good contact between the surfaces and a proper
crushing even if accidentally missing the hydrophilic cord

• The labyrinth shape of the anchoring part assure an high resistance to the
water infiltrations
• The concrete makes an imprint that perfectly replicate the gasket anchoring
feet’s geometry without gap or air inclusions

ADVANTAGES OF THE RUBBER GASKET UG027A
PROS
• Guaranteed and remarkably higher adhesion between gasket and the
concrete
• Ensure that during concrete segments assembly, rubber gasket isn’t being
expelled from its groove particularly in the corner zone
• Higher hydraulic tightness due of the increasing distance for the water
between gasket and concrete.
QUALITY

PROS
• Shortened process in the precast factory due to time savings for correction
of imperfections and cleaning of the groove area
• Reduced assembly time of the gasket
• Saving costs for glue and glueing equipment
TIME SAVING

PROS
• No environmental pollution associated with the use of solvent in the glue.
ENVIRONMENTAL

ANCHORED RUBBER GASKET WITH HYDROFILIC STRIP: SELF REPAIR
During concrete segment assembly there could be the following actions:
• Anomalous deformations of the gasket
• Gap and offsets higher than required in the technical specification and
for which the gasket is being designed
Therefore rubber gasket should work in unplanned conditions causing
water infiltrations.
To overcome this situation, is being added to the rubber gasket a
hydrophilic part which swell when in contact with the water.
The swelling action allows the recovery of the abnormal gaps and the
reinstatement of the sealing.

ANALYSIS OF ANCHORED RUBBER GASKET
UG027A
WITH HYDROFILIC STRIP: TECHNICAL
FEATURES (STUVA Method)

Cross section
a=274 mm² (including
swelling strip Ø 5)
b=57,5 mm²
Compound EPDM 70 Shore A
Groove width at
bottom
26 mm
Groove depth 10 mm
Groove angle 15°
Groove dimension 286,8 mm²
At full compression the groove is used at 95%

RUBBER COMPOUND TECHNICAL DATA SHEET
DESCRIPTION
Compound code PGSA70 or similar
Compound type EPDM BLACK
TEST
TEST
METHOD
U.M. VALUE STUVA
Hardness DIN53505 Shore A 70 N.V. ±5
Tensile strenght DIN53504(S2) Mpa 9,7 ≥ 9
Elongation DIN53504(S2) % 350 ≥ 200
Residual pressure deformation DVR22h at 70°C ISO 815A % 19 ≤ 25
Ozone resistance ISO1431-1 - No cracks not required
UV resistance - - - not required
Thermal ageing 168h a 70°C
Change in hardness DIN53505 % +3% da -5% a +8%
Change of crack resistance DIN53504(S2) % +3 da -20 a +10
Change of elongation DIN53504(S2) % -15 da -30 a +10
Stress relaxation 3 months at 70°C ISO3384 % 42 ≤ 45
Restorative capacity at 20°C STUVA % 91 ≥ 80
Fire resistance DIN4102-1 Class B2 not required
Operating temperature - °C -40/+100 not required
PHYSICAL FEATURES

WATERTIGHTNESS TEST RIG

WATERTIGHTNESS DIAGRAM FOR UG027A
0
5
10
15
20
25
30
35
40
0 1 2 3 4 5 6 7 8 9 10 11 12
Gap ( mm )
Waterpressure(Bar)
Offset 0
Offset 5
Offset 10
Offset 15

LOAD DEFLECTION DIAGRAM FOR UG027A
0
5
10
15
20
25
30
35
40
45
50
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Gap (mm)
Load(kN/m)
Offset 0
UG027A
UG027A

STRESS RELAXATION TEST ACCORDING TO STUVA RECOMMENDATIONS
for ANCHORED EPDM GASKET UG027A
UG027A

4mm
PRESENTATION OF THE CORD HYDROPHILIC ACTION

HYDROPHILIC SWELLING STRIP: MAXIMUM SWELLING

HYDROPHILIC SWELLING STRIP: EXPANSION
PRESSURE/TIME IN CONCRETE WATER

TECHNICAL IMPLICATIONS OF EPDM GASKET
AND HYDROPHILIC SWELLING STRIP AT THE
DOHA’S SPECIFIC WATER CONDITIONS

The concentrations of chlorydes and sulphates in the Doha’s water do not
influence the performance of EPDM.
Doha’s water
Basicity 7,47 Ph
Chloride 0,7%
Sulphate 0,2%
EPDM Gasket
Excellent resistance of EPDM
to water (pH 7 normal)
to chloric acid
to sulfuric acid (20%)

Doha’s Water
Basicity 7,47 Ph
Chloride 0,7%
Sulphate 0,2%
Hydrophilic swelling strip
Successfully tested within a range from 5
until 12 pH . No negative effect observed in
terms of chemical stability.
Successfully tested until 0,5% and no
negative influence on the chemical stability
of hydrophilic observed.
Not tested with sulphates but with
Diammonium phosphate (DAP) and with
positive behaviour.

FULFILLMENT OF THE SPECIFICATION’S REQUIREMENTS
Hydrophilic anchored rubber gasket UG027A has the features that
fulfill specification’s requirements.
 Water resistance up to 4 bar external water pressure (considering
the maximum of 38 m waterhed to the tunnel crown );
 26 mm gasket groove width at bottom and 17 mm gasket height;
 Max gasket compression force: 45 kN/m at 0 mm gap;
 Safety factor of 2,5 for the long-term loads.
 Gasket made with EPDM compound;
 Gasket tollerances according to UNI EN 3302-1 Class E2;
 120 years long term life estimation gasket according to standards
ISO 11346 ( Stuva recommendations ) and ISO 3384;
 Resistance to Doha’s water conditions.

CONCLUSIONS
• EPDM rubber gasket is suitable for Doha’s Red Line North
Underground.
• Hydrophilic swelling strip is suitable for Doha’s Red Line
North Underground.

THANK YOU FOR YOUR ATTENTION
www.famaspa.it

Anchored rubber gasket UG027A presentation

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