1. Fama Spa provided gaskets and connection systems for the excavation of the Milan Metro Line M4 Route EXPO project. 2. Measurements of gap and offset were taken at joints between precast concrete tunnel segments to document the in-use performance of these products. 3. The results found average gap and offset values much lower than project specifications allowed, demonstrating the effectiveness of the SmartBlock connection system and UG022A sealing gasket used.

1. CASE HISTORY
MILAN-LINE BLUE
-
VERIFICATION IN EXECUTION OF SYSTEM PERFORMANCE
OF CONNECTION AND GASKET
Issue Date Check Project Rev.
S.LUPI 10/09/2014 G. BOMBEN METRO BLUE 1

2. CASE HISTORY
INTRODUCTION
Fama Spa is an Italian company operating since 1988 in design, certification,
manufacture of products for precast lining of tunnels.
Fama Spa is specialized in the development of sealing systems and a wide
range of accessories for the connection, lifting and anchoring systems for
the construction of tunnels with TBM.
For the excavation of the line M4 - Route EXPO, FAMA SpA provided gaskets
and connection systems.
To complete a strategic path that began with the design and continued with
the certification through laboratory tests, with a campaign of
measurements, it was possible to document the performance of these
products in exercise.

3. CASE HISTORY
METRO MILAN - LINE M4 – Section EXPO
DESIGN OF THE PRECAST RING
- UNIVERSAL RING 5+1
- KEY 1/3 OTHER SEGMENT
- EX. DIAMETER 6.060 mm
- IN. DIAMETER 5.500 mm
- THICKNESS OF SEGMENT 280 mm
- LENGTH OF SEGMENT 1.400 mm
- GASKET 29 x 14 mm
- 16 CONNECTORS FOR RING
(3 FOR EACH SEGMENT, 1 FOR THE KEY)
- GUIDE ROD ON THE RADIAL JOINT

4. CASE HISTORY
METRO MILAN - LINE M4 – Section EXPO
HYDROGEOLOGICAL PROFILE
- FULL TRACK UNDER THE WATER TABLE
- MAXIMAL WATER PRESSURE 2.1 BAR

5. CASE HISTORY
EPDM SEALING GASKET
- UG022A
- 29 x 14 GLUED
- SPECIFICATIONS REQUIRED TO
CONTRACT
 PRESSURE 13 bar
 GAP 4 mm
 OFFSET 12 mm

6. CASE HISTORY
CONNECTION SYSTEM
- SMARTBLOCK 60-180/300-80
- PULL OUT 60 KN
- SHEAR STRENGTH 160 KN
- LENGTH 300 mm
- DIAMETER OF CENTERING 80 mm

7. CASE HISTORY
1. We want to calculate the current state of misalignment and separation of the joints between the
segments in the gallery;
2. The relief is performed with the use of two measurement gauges: one for the depth, with which
recalculate the offsets and one for the width of the slots for the recalculation of the gap;
3. The joints are first classified according to the orientation angle to the progress of the excavation;
4. Usually the relief is performed on a continuous succession of five joints, reached by the operator
that runs through the tunnel by foot. In case of severe anomalies the relief can be conducted on the
entire ring with the aid of suitable lifting equipment. The measuring block 5 of joints may, at the
operator's discretion, be repeated several times;
5. The sequence of measurements, if necessary, can be performed on the right side and on the left side
of the tunnel with reference to the direction of advance of the excavation;
6. May be conducted punctual detections in the presence of water infiltration, in order to evaluate if
this is generated by an excessive misalignment, or spreading of the coupling or, finally, from other
causes;
7. If necessary measurements can be performed on the blocks, facing the opposite of progress to
compare with those initial misalignment stabilized along the tunnel.
PROCEDURE FOR DETECTION GAP AND OFFSET OF THE
JOINTS BETWEEN THE SEGMENTS INTO THE TUNNEL

8. CASE HISTORY
PROCEDURE FOR DETECTION GAP AND OFFSET OF THE
JOINTS BETWEEN THE SEGMENTS INTO THE TUNNEL
The measurements of gap and offset are performed at approximately 20
mm from the T joint, where the deviations from nominal are maximums.
Measurement
scheme of
GAP
Measurement
scheme of
OFFSET

9. CASE HISTORY
PROCEDURE FOR DETECTION GAP AND OFFSET OF THE
JOINTS BETWEEN THE SEGMENTS INTO THE TUNNEL
In the diagrams below are identified types of angles between segments of a
same ring adjacent each other refer to the direction of excavation.

10. CASE HISTORY
PRESENTATION OF RESULTS
MEASURES OF GAP IN THE CIRCUMFERENTIAL JOINTS

11. CASE HISTORY
PRESENTATION OF RESULTS
MEASURES OF GAP IN THE LONGITUDINAL JOINTS

12. CASE HISTORY
PRESENTATION OF RESULTS
MEASURES OF OFFSET IN THE CIRCUMFERENTIAL JOINTS

13. CASE HISTORY
PRESENTATION OF RESULTS
MEASURES OF OFFSET IN THE LONGITUDINAL JOINTS

14. CASE HISTORY
PRESENTATION OF RESULTS
PICTURES OF THE TUNNEL

15. CASE HISTORY
ANALYSIS OF THE RESULTS
ASSESSMENT OF THE EFFICIENCY OF THE CONNECTION SYSTEM
There have been 205 measurements of gap and offset.
The average weigth gain of the gap is 0.5 mm, the offset of 1.4 mm.
The requirements of the specifications of the project M4 Milan provide a
mounting tolerance of 4 mm on the opening of the joint (gap) and 12 mm on the
misalignment of the joint (offset). The connection system SmartBlock allowed a
mounting error is much lower than expected.
The connection system SmartBlock has minimized the effect of the divergence of
the longitudinal and circumferential joints generated by the thrust of the gasket.
The performance of the pull-out and shear of the SmartBlock are suited to the
conditions of employment, ensuring the correct dimensioning of the system.

16. CASE HISTORY
ANALYSIS OF RESULTS
ASSESSMENT OF THE EFFICIENCY OF THE SEALING GASKET
The gallery of the Milan line M4 is dry.
The gasket sealing UG022A has been tested at the University “Tor Vergata” in
Rome – Department of Civil Engineering – Structures and Material Tests
Laboratory - for the hydraulic performance requirements in the specifications
of the project M4 in Milan.
The gasket UG022A requires a load of 42 KN/m for its complete compression
facilitating, in fact, the permanence of the closed joint.
The geometry of UG022A well balanced between width and height and
angles conformed to the geometry of the concrete allow, during assembly of
the ring, to remain in its seat.

17. CASE HISTORY
THANK YOU
www.famaspa.it