“30 St Mary Axe” in London with Datwyler sealing profiles
Since 2004 London has had a new landmark, “30 St Mary Axe” by the star architect Sir Norman Foster, which informs the skyline with its distinctive fir cone shape – and is praised by architecture critics as the most beautiful skyscraper in the world.
The technologically challenging metal and glass façade of Swiss Re’s new London building was executed by one of the world’s leading façade builders. For its sealing profiles it put its trust in Datwyler know-how. The 250 kilometres of profile made of EPDM rubber take on an important function in sealing the metal and glass façade against wind and rain. Depending on the season, they minimise the heat or cooling loss from the façade and thus make a contribution to the energy-friendly properties of the 180 metre high building. “30 St Mary Axe”, affectionately known by Londoners as “the gherkin”, is an example of how Datwyler with its long years of competence in engineering and extrusion has developed into an innovative partner of leading façade builders worldwide.
Burj al Arab - The hotel in the sea
In architectural terms this hotel is unique, as it has the form of a sail and is built in the sea. The glass façade of the Burj al Arab has a total area of 14,000 m². Due to the fact that the hotel is in the sea, it is exposed to every form of wind and weather completely unprotected. This makes it especially important that the glass façade be completely sealed. Hence Datwyler was commissioned to deal with the issues. In total 16 different rubber profiles were developed for the special façade of the Burj al Arab, and 80,000 metres of profile were supplied with a total weight of 15 tonnes.
Dätwyler makes a contribution to the football World Cup 2010
Numerous football stadiums were newly erected for the 2010 football World Cup in South Africa, among them the Green Point Stadium in Cape Town. In this stadium a glass construction company developed a glass roofing system for which ca. 37,000 m² of glass were installed. Dätwyler supplied the glazing profiles for this and thus played its part in allowing the spectators to stay dry during the games.
Datwyler provides tight windows in rail vehicles
Datwyler sealing profiles are being successfully used as window seals by a rail vehicle manufacturer. Fire protection, ease of mounting as well as visual effect and surface feel make for high demands on the profiles.
The Datwyler window profile is what is known as a “zipper profile”. This expression describes the installation process of the profile and glass pane: First the basic profile is inserted in the body of the car. In a second step the glass pane is inserted and fixed, or the necessary pressure is produced, by means of a base profile.
Extensive tests on the object as well as on the window test stand were necessary to meet the high demands on the profile. Simulated changes of load with up to 200,000 cycles ensure that the Datwyler seals will withstand the high demands of harsh everyday use. Datwyler develops its sealing profiles in close cooperation with the manufacturer. This demands above all competence in materials and extrusion know-how. Before delivery the Datwyler profiles are assembled into frames as required for installation of the window panes.
Datwyler with its rubber profiles supplies a contribution to more species-appropriate animal husbandry
A manufacturer of slatted concrete floors has developed a pioneering form of tread. The integrated profiles from Datwyler form the cushioning, non-slip and heat-insulating surface of the concrete segments. The result is species-appropriate animal husbandry which leads to higher milk yields and better fertility. Fattening times are shortened by the great reduction of heat loss into the ground, which significantly improves profitability.
A hard and slippery tread surface can lead to painful foot lesions, lameness or disorders in movement behaviour. Added to this is the danger of fall injuries.
Absorber profiles from Datwyler mean football can be played even when frosty
The fact that the Austrian football champions Red Bull Salzburg can play their home games in winter is not least due to a manufacturer of solar installations and ice rinks. The company provides for football turf that can be played on even in winter. It developed a heating system for synthetic turf surfaces which is installed 60 millimetres under the turf to keep it frost-free. The functional scheme resembles nothing so much as an oversized underfloor heating system. The heating mats installed under the synthetic turf are connected to manifolds linked to the heating plant. The heating mat area is filled with an environmentally friendly glycol-water mixture. The precisely calibrated heating plant then supplies the necessary heat energy. The heated mixture is then sent through the heating mats by means of pumps. These give off their heat energy to the synthetic turf field.
Datwyler has for years proved its worth as a supplier of the absorber profiles for this manufacturer. There are Datwyler profiles under the synthetic turf at TSV 1860 München and Red Bull Salzburg among others.
Reliably sealed with profiles from Datwyler
Datwyler is the main supplier of swellable and injection profiles to the world market leader in one-component PUR sealants and biggest supplier of plastic liners in the world. The profiles are used in concrete construction. As the name implies, these must reliably swell on contact with all kinds of materials.
Datwyler has distinguished itself above all by its technical competence and delivery reliability as well as by its flexibility. It is precisely this flexibility that is important in the sector in which this client operates, since in certain projects changes at short notice are an almost daily occurrence in spite of rigorous planning.
Expansion joint profiles
Datwyler supplies expansion joint profiles for various civil engineering clients for driveable traffic areas with movement joints, or building separation joints. These may be used in airports, car parks or even atomic power stations.
Datwyler also produces large-volume mat profiles of up to approximately 20 kg/m for road construction, e.g. as bridge transition profiles (bridge/road transition) for the new construction sector as well as for redevelopment.
Mat profiles are also used in the area of railway bridges. Temperature fluctuations and traffic loads can lead to metre-long changes in length. That is why at each end of a bridge, a so-called “deck transition” is built which can slide back and forth. Various construction types have been developed for this purpose over the course of time.
Olympic honours for Datwyler tunnel seals
Since acquiring Phoenix Dichtungstechnik, Dätwyler has been the unquestioned worldwide number one in the growth market for tunnel seals. Dätwyler sealing gaskets even played a successful part in the Winter Olympics in Sochi.
The Winter Olympic Games in Sochi were held without major problems — and a share of the credit belongs to Dätwyler tunnel gaskets. These seals have a permanent role in one of the most important infrastructure projects carried out in the preparations for the 2014 Winter Olympics, the upgrade of road and rail infrastructure between the city of Sochi on the Black Sea coast and the winter sporting region of Krasnaya Polyana in the Caucasus mountains. The new combined rail line and motorway carried thousands of athletes, officials and spectators swiftly to their destinations during the Games. After the Olympics, they will help support Sochi’s new potential as a summer and winter tourist destination.
Geometric and material challenges
To make all this possible, the Russian government ordered the construction of twelve road, rail and service tunnels with a total length of some 30 km on a previously undeveloped route between Sochi and Krasnaya Polyana from 2009 to 2013. The six longest of these tunnels were carved out using tunnel boring machines and fitted out with single-layer steel and concrete lining segments. The Dätwyler gaskets were used to seal the gaps between these tunnel lining segments. The hydrological and geological conditions prevailing in the different tunnels presented significant geometrical and material challenges for the segment gaskets. A tight tunnel seal is essential for safety and to protect costly electromechanical equipment and systems.
Innovative anchored tunnel seals
Conventional tunnel seals are fixed to a pre-cast groove in the concrete segment using a contact adhesive – a labour-intensive process. Poor process reliability makes this procedure the weakest link in the installation of concrete segments for a tunnel project. Anchored tunnel seals are a Dätwyler innovation that significantly improves process reliability, reduces labour costs and completely eliminates the cost of adhesives. The new process involves encasing the sealing gasket in concrete during the casting of the segments themselves. The idea has been successfully tested in real-world conditions, and acceptance among customers is very high. Since the first anchored tunnel gasket was installed three years ago, the process has so far been used in sealing a further fifteen tunnel projects worldwide, with many more to come.
In the course of expanding the ICE route "NBS Erfurt-Halle-Leipzig” belonging to Deutsche Bahn AG it was necessary to tunnel 7 km through a ridge of hills (the Finne) near Erfurt. The expansion was carried out using twin tubes in the mechanical tunnelling with segmental expansion.
Dätwyler developed a special sealing strip for this, which was tested at 12.2 bars. 46,760 bespoke sealing frames were delivered and installed from this sealing strip.
Since this project was on the border between Thuringen and Saxony, and thus only an hour's drive from our production site in Waltershausen, it was possible to organise an information event with the ARGE Finnetunnel customers whilst also visiting the construction site as well as the DTS production plant in Waltershausen.
L.A. Gold Line
Extension of the Metro network in Los Angeles, completion 2006 to 2008, with double frames that were specially tested for water and methane gas tightness.
Length of the section of tunnel construction: 4.3 km
This was the first of Datwyler's further metro projects to expand the metro network in Los Angeles. The bedrock in the Los Angeles area was particularly tricky as crude oil was extracted and processed here in the past. As a result high concentrations of methane gas can be found in large areas in addition to tar and oil residues in the subsoil. In addition to the required water tightness, these are very critical, additional requirements for the sealing.
For over a year now our seals have been subject to various approval tests in the USA and Germany for a total of a further approx. 33 km of section of tunnel construction.
Following these tests that have been positive up to now, there are good prospects for the follow-up projects MTA LAX Crenshaw, MTA Regional Connector, MTA Westside which are due to begin in 2015/2016.
Lake Arrowhead, USA
Drinking water supply tunnel Lake Arrowhead, USA
Segmental lining and sealing system
According to American Tunnel Consultants, as well as the experts who were involved in the construction at the time, the first attempt of this building project failed in the 90s. This was not just due to tunnelling technology that was in its early stages but also ultimately due to the segment design at the time, and especially because no elastomer segment seal frames were planned for.
It is actually incredible as existing extreme geological conditions and tightness requirements are to be taken into consideration in this project. In line with a strict European model, as well as extensive know how and the transfer of equipment from England, France and Germany, everything should run smoothly for the second attempt. At the same time the contractor, MWD, insisted on very detailed preliminary plans which accompanied very comprehensive test programmes with regards to the segment design and choice of seal.
In addition to the renowned American tunnel consultant, Jacob Associates, the extensive experience of the company, Halcrow, whose head office is in London, Great Britain, was also relied upon. Other planning and consultancy firms, such as Hatch Mott McDonald and the office, Babendererde, based in Lübeck, were on hand to even offer advice and direct support from time to time.
With regards to the segment sealing frames, the company Datwyler from Waltershausen was included in the planning process at an early stage whilst searching for a suitable cross-section and design of the respective sealing groove. This was because Phoenix was already able to put forward their recommendations whilst working with the preliminary study (tightness and concrete spalling attempts) at the MWD La Verne Facility, California back in 2001.
The result of this collaborative and comprehensive planning work was, amongst others, a very demanding and technical product specification, which ultimately consisted of very high, generous and yet low-key guarantees with regards to the tightness of the structure. In light of the previous history and the associated political sensitivity of this project this is perhaps understandable.
The following indicate several technical data regarding reinforced concrete segmental lining and sealing requirements that ultimately came from this new product specification:
External diameter: 5,537.5 mm
Internal diameter: 4,877.2 mm
Segment thickness: approx. 330 mm
Width of coil: 1,524 mm
Segment division and design: 5 plus a small keystone as left taper and right taper Seal groove: Width of groove base 44 mm, as simple circumferential sealing level on the outside of the segment Water Pressure: approx. 22 bar, required test pressure: 43 bar
The contract for the manufacture of reinforced steel segments was saved early on by a group that consisted of Traylor Brothers, Ghazi Contractors and Shea. As a result a joint venture called Traylor-Shea-Ghazi was formed, whereby it was possible to look back at an already successful collaboration prior to the completed NOS-ECIS and NEIS projects - two large sewer tunnels in Los Angeles.
Consequently the core of this young company was established back in 2001 in Littlerock in South California, which is a good hour's drive from Los Angeles. A segment production site with impressive dimensions as well as the most modern carousel systems and understandably with the clear early intention to be able to offer and establish a geographically well located supplier of a range of planned major projects in the Los Angeles area. Consequently Traylor-Shea-Ghazi-Precast will not only have the major order for the Arrowhead Feeder Tunnels, but will also manufacture the segments for the new MTA Eastside line, which is a new metro line of the LRT in Los Angeles.
Traylor-Shea-Ghazi relies on the established formwork technology of the French company, CBE, for the Arrowhead Feeder Tunnels project as it has done in the past for other previous projects. Similarly, the company, SOFRASAR, from France also delivers its dowel connection systems and Datwyler Sealing Technologies Deutschland GmbH, based in Waltershausen delivers a sealing system which consists of segment sealing frames "Wesertunnel type" as well as injectable special assembly adhesive using a pressure gun, whereby Traylor-Ghazi-Shea has incorporated the assembly of the sealing frames into its carousel production.
The segment production for the Arrowhead project has been in operation since early 2003 in Littlerock. Due to the unpredictable events at the tunnel construction site in the mountains of San Bernadino, such as the bush fire and the subsequent landslide following heavy rainfall, production had to be pushed back from autumn until further notice.
The segment extension in the Arrowhead tunnel is initially supposed to be a temporary initial lining and after approx. 5 years into the build is intended for the conveyance of drinking water with a so-called "inner lining".
Installation of Rail Comfort System at a total distance of: 15.938 m
Installation of Rail Comfort System at a total distance of: 29.000 m
Installation of Rail Comfort System at a total distance of: 25.500 m