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Tunnel Segment Gaskets

Global supplier of tunnel segment gaskets worldwide since the 1980’s

TSG Tunnel Segment Gasket Ejpovic 1
TSG Tunnel Segment Gasket Ejpovic
Glue in Tunnel Segment Gasket 2
Glue in Tunnel Segment Gasket 1
Close us Tunnel Segment Gasket
Tunnel Segment Gasket TSG
Corner Cast In Tunnel Segment Gasket TSG
Installation Cast In Tunnel Segment Gasket TSG
VIP-0068 TSG Tunnel Segment Gasket Check

Elastomeric (rubber) gaskets are one of the most effective waterproofing systems for segmentally lined tunnels and shafts where protection is required against water ingress or for retention in tunnels used for fluid transport or storage.

Each profile manufactured by VIP has been specifically designed so that the volume of rubber does not exceed that of its corresponding groove and the compression performance of the gasket is equal along the entire face of the gasket.

VIP’s tunnel segment gaskets are manufactured from high-grade rubber compounds, which meet many internationally recognised standards including EN681-1 (the material requirements standard for pipe and joint seals used in water and drainage applications).

BS EN681-1
GLUED IN TSG
CAST-IN TSG
HYDROPHILIC BANNER

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DESIGN & DEVELOPMENT BANNER
TSG TESTING BANNER
ACCESSORIES BANNER

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Case Studies

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TSG Tunnel Segment Gasket Ejpovic

Innovative gaskets contribute to Shieldhall Tunnel success

TSG Tunnel Segment Gasket Ejpovic 1

Farnworth Tunnel Project

Glued-In Tunnel Segment Gaskets

Traditionally the industry has used elastomeric gaskets that are glued into pre-formed grooves in the concrete segments.

VIP manufactures a range of profiles which are compatible with many pre-existing segment mould groove designs.

The following profiles comprise VIP’s glued-in core range. Further profiles are available or can be developed on request to meet specific design requirements.

Glue in Tunnel Segment Gasket 2
Glue in Tunnel Segment Gasket 1

Corner Angles That Perfectly Match The Segment

VIP’s glued-in profiles have corner joints that can be manufactured to match the angles of the segment design including 90°, acute and obtuse angles.

The corners are formed using an injection process in moulds that match the profile of the extruded gasket.

This ensures that when the segments are joined together, the gasket can collapse into the groove and the load on the corners is equal to the rest of the gasket.

VIP’s Glued-In Core Range Of Profiles

VIP028

VIP044

Further profiles are available or can be developed on request to meet specific design requirements.

Pipe Seals

Benefits of products:

  • VIP’s profiles fit many pre-existing mould groove designs
  • Corner angles that perfectly match the segment
  • Can be manufactured from EPDM and NBR

Downloads

Cast-In Tunnel Segment Gaskets

Cast-in gaskets (also known as anchored gaskets or cast in situ gaskets) are integrated with the segment during the casting process.

This is opposed to being glued into a pre-made groove once the concrete segments have been cast.

Cast-in seals ‘anchor’ themselves to the segment as the concrete surrounds the legs at the base of the seal.

This process ensures a consistent positioning of the gasket around the segment.

The design of the legs ensures that the seal is secure in the segment and will not move during or after the segment is cast.

This is especially important during installation of the tunnel segments.

Benefits of Cast-in Gaskets

  • No need to apply adhesive
  • Cleaner to work with
  • Provide cost savings due to the removal of adhesive and the gluing process.
  • A more secure fit in the segment leading to reduced movement of the seal during installation and increased performance

Unique Corner Jointing System

 

No Solid Corners

No Solid Corners

Cracked or damaged segments caused by corner point loading has traditionally been a problem faced by tunnelling engineers and designers.

VIP’s Cast-in gaskets are designed specifically to eliminate this due to the unique patented (GB2541978 – international patent pending) corner jointing system.

This has allowed us to dramatically reduce the volume of rubber at the corners, thus ensuring the gasket can collapse into the groove.

Minimising Rubber Volumer At The Corner Joint

 

VIP’s unique jointing process results in the profile of the gasket being maintained up to the corner edge.

This differs to a traditional shot-joint corner which can result in excess rubber travelling along the gasket voids during the moulding process.

This results in making the gasket unable to compress at the corners due to the voids being full of rubber, creating a ‘solid’ corner.

Minimising Rubber Volume

The energy exerted at these points during closure of the segments can lead to cracks and spalling as it dissipates through the segment, finding the path of least resistance.

Corner Angles That Perfectly Match The Segment

 

VIP can manufacture corners for cast-in gaskets to obtuse, acute and 90° angles, therefore matching the profile of the segment design perfectly.

90° Angles

Acute Angles

Obtuse Angles

Z Axis Angles

90° Angle
Acute Angles
Obtuse Angles
Z Axis Angles

Segment design can differ with each project. Recognising this and the importance of the gasket matching the exact shape of the segment, VIP can also vary the profile orientation along the Z axis.

VIP’s Cast-In Core Range Of Profiles

 

VIP028CI

VIP035CI

Further profiles are available or can be developed on request to meet specific design requirements.

Pipe Seals

Benefits of products:

  • No solid corners – designed specifically to eliminate corner point loading
  • Corner angles that perfectly match the segment
  • No need to apply adhesive
  • Cleaner to work with
  • Provide cost savings due to the removal of adhesive and the gluing process.
  • A more secure fit in the segment leading to reduced movement of the seal during installation and increased performance
  • Can be manufactured from EPDM and NBR

Downloads

Hydrophilic Tunnel Segment Gaskets

VIP also manufacture hydrophilic gaskets for both our Cast-In and Glued-In profiles.

Hydrophilic compounds are designed to swell when they come into contact with water which can close the gap between the gasket faces.

VIP Hydrophilic Gasket Types

VIP supply hydrophilic gaskets in 2 main formats:

Hydrophilic cord inserted into a slot in a TSG prior to installation

Hydrophilic strip co-extruded onto an elastomeric TSG

Further profiles are available or can be developed on request to meet specific design requirements.

Hydrophilic Chord
Co-extruded Hydrophilic Strip
Pipe Seals

Benefits of products:

  • Available as a chord or co-extruded
  • Available for both Glued-in and Cast-in profiles

Downloads

Design & Development

VIP-Polymers provides engineering, design and development services employing CAD and analytical modelling and finite element analysis techniques. Engineering programs can then be transferred directly into tooling machine programs for fast and accurate mould making.

Product Design and Development:

In addition to our many years of practical engineering experience, VIP-Polymers utilise state-of-the-art CAD technology for product design including Autocad, Pro-Engineer and Advanced Simulation programs to analyse all aspects of dynamic performance under pressure, deformation, fatigue, stress levels and other criteria.

All tool design takes place in-house, utilising tool modelling programs, stereo lithography and computer simulation to determine analysis of flow and cure in injection moulding.

Material & Formulation Development:

VIP-Polymers designs seals for a wide range of applications including:

  • Microbiological resistance
  • Flame retardancy
  • Impact attenuation
  • Electrical resistivity

VIP-Polymers formulates and mixes its own compounds in-house.

Laboratory support facilities, including laboratory mixer, mill, rheometers and other equipment, assist the development of new compounds and control processing.

Compounds produced cover a wide range of polymers including:

Natural Rubber, Neoprene, EPDM, SBR, EVA, Polyethylene, Nitrile, Fluoroelastomer, Polychloroprene, Polyacrylic, Silicone and Epichlorohydrin, and meet a series of complex specifications. Although VIP-Polymers usually has compounds suitable for customers’ specific needs, experience in polymer engineering enables the development of new compounds to meet unusual requirements.

VIP-Polymers is also active in formulating industry standards through membership of several British and European standards committees.

Pipe Seals

Benefits of products:

  • Engineers with experience of end user applications
  • Industry leading compound development personnel
  • Award winning design team

In-House Laboratory & Tunnel Segment Gasket Testing

VIP’s laboratory and quality team undertake various tests and inspections throughout the manufacturing process of our TSGs.

These tests provide assurance that our products are produced to the highest standard and perform as expected.

Tests are undertaken on both the uncured rubber compound prior to manufacture with further tests on the final extruded product which check for:

  • Rheometry
  • Hardness
  • Tensile strength
  • Elongation
  • Compression set
  • Dimensional checks
  • Stress relaxation

Completed gaskets are finally checked on specially designed jigs to ensure they are the correct dimensions for the corresponding segment shape.

Tests Designed To Replicate Real World Applications

Gaskets are also tested at our UK headquarters in specially designed test rigs, which replicate the build of a segment ring in order to measure their performance.

Unique Corner Jointing System

 

VIP undertake a range of tests using T & X rig testing in order to replicate closure forces and pressures experienced both during the tunnel build and throughout the service life of a tunnel.

Pressure testing is undertaken at maximum and minimum gaps, and zero-to-maximum offset / deflection.

Pressure Test With No Offset

This replicates the gaps and displacements that occur between segments either as a result of building tolerances, changes in direction of the tunnel or due to the effects of ground movement.

Pressure Test With Offset
STUVA 54 Water Tightness Curve
STUVA Linear Test
STUVA Corner Test
Pipe Seals

Benefits of products:

  • Our in-house laboratory undertake tests both to the rubber compound prior to manufacture and also the final product
  • Pressure and load deflection tests are designed replicate real world applications

Downloads

Accessories And Service

VIP Polymers can supply a full range of accessories to aid the installations of our seals.

All of our accessories have been tried and tested with our products a meet or exceed industry standards.

tunnel segment gasket adhesive

Adhesive

VIP can recommend a number of approved adhesive suppliers for the application of glued-in gaskets onto the segment. If required, we can also arrange the supply of the adhesive.

tunnel segment gasket lubricant

Lubricants

VIP recommends applying lubricant to the surface of the gasket during segment installation to assist the segments in sliding into place.

This process reduces the friction between gaskets, ensuring corner positioning and reducing the risk of gaskets moving or pinching during installation which can potentially affect their performance. We can recommend and supply an appropriate WRC-approved lubricant.

tunnel segment gasket storage

Storage

TSGs should be stored in the same conditions as for most elastomeric products and ideally in accordance with ISO 2230:2002 (rubber products guidelines for storage). VIP can supply details upon request.

tunnel segment gasket quality

Quality

VIP operates a quality system, which is approved to ISO 9001 standard and certified by BSi. We are renowned in the seal and gasket industry for the high quality of all of our products, and our approach to quality extends to TSGs.

Pipe Seals

Overview:

  • VIP operates to ISO 9001 standard, certified by BSi.
  • Applying lubricant reduces friction between the gaskets during installation.
  • VIP can recommend approved adhesive suppliers.

Downloads