nstallation of waterproofing systems in tunnels requires precise coordination of surface preparation, membrane installation, and protection layers. Production rates vary based on tunnel geometry, ground conditions, and installation method. Modern spray-applied and sheet membrane systems have improved efficiency, with installation rates of up to 400-500m²/day under optimal conditions.
Key Statistics:
- Average production: 300-400m²/day
- Sheet membrane: 250-350m²/day
- Spray applied: 400-500m²/day
- Overlap joints: 100mm minimum
- Testing coverage: 100%
- Membrane thickness: 2-3mm
- Water pressure: Up to 10 bar
- Service life: 100+ years
INTERNATIONAL EXAMPLES
| Country | Project | Area (m²) | Type | Rate (m²/day) | Cost ($/m²) | Contractor | Duration (weeks) | Source |
|---|---|---|---|---|---|---|---|---|
| Australia | Sydney Metro | 45,000 | Sheet/PVC | 300-350 | 85 | CPB-Ghella | 24 | TfNSW |
| UK | Crossrail | 68,000 | Spray/Sheet | 350-400 | 95 | BAM-Ferrovial | 32 | Crossrail |
| Hong Kong | MTR Shatin | 52,000 | Sheet/TPO | 280-320 | 90 | Gammon | 28 | MTR |
| Switzerland | Gotthard Base | 120,000 | Sheet/PVC | 400-450 | 110 | AlpTransit | 48 | SBB |
| Singapore | Thomson Line | 38,000 | Spray Applied | 450-500 | 75 | Samsung C&T | 20 | LTA |
Installation Phase Analysis:
SURFACE PREPARATION:
- Requirements:
- Smoothness: ±10mm
- Moisture content: <4%
- Temperature: 5-35°C
- Cleanliness: No debris
- Production Rates:
- Cleaning: 600-800m²/day
- Repairs: 100-150m²/day
- Priming: 500-600m²/day
- Testing: 800-1000m²/day
MEMBRANE INSTALLATION:
Sheet Systems:
- Production Rates:
- Main areas: 300-350m²/day
- Details: 50-80m²/day
- Joints: 150-200m/day
- Testing: 400-500m²/day
Spray Applied:
- Production Rates:
- Main areas: 400-500m²/day
- Details: 80-100m²/day
- Thickness build: 2-3 coats
- Testing: 600-700m²/day
REGIONAL VARIATIONS:
European Standards:
- Membrane thickness: 2.5-3.0mm
- Joint overlap: 120mm
- Testing frequency: 100%
- Documentation: Comprehensive
Asian Requirements:
- Membrane thickness: 2.0-2.5mm
- Joint overlap: 100mm
- Testing frequency: 100%
- Documentation: Digital systems
Note 1: Production rates are indicative only.
Note 2: Rates vary based on:
- Tunnel geometry
- Access conditions
- Ground water
- Surface preparation
- Weather conditions
- Ventilation
Note 3: Area calculation formula:
A = (P × L × CF × DF) + DA, where:
- A = Total area
- P = Perimeter
- L = Length
- CF = Complexity factor (1.1-1.4)
- DF = Detail factor (1.1-1.3)
- DA = Detail area
Quality Control:
Testing Methods:
- Visual Inspection:
- Coverage: 100%
- Joints: 100%
- Details: 100%
- Documentation: Daily
- Physical Testing:
- Spark testing: 100%
- Thickness: 1 per 100m²
- Adhesion: 1 per 200m²
- Seam testing: 100%
Cost Breakdown:
Materials:
- Membrane: 45-50%
- Protection layer: 15-20%
- Accessories: 10-15%
- Testing: 5-10%
Installation:
- Labor: 35-40%
- Equipment: 20-25%
- Testing: 10-15%
- Documentation: 5-10%
Additional Considerations:
- Ventilation requirements
- Lighting conditions
- Access scaffolding
- Material storage
- Emergency procedures
- Quality documentation
- Environmental controls
- Safety protocols
Note: All data subject to:
- Local standards
- Ground conditions
- Water pressure
- Temperature
- Humidity
- Access restrictions
- Testing requirements
- Safety protocols
Other production rates – Indicative only
- RAIL INDUSTRY PRODUCTION RATES COMPREHENSIVE TABLE
-
- Ballast Cleaning Operations Analysis
- Canopy Installation Analysis for Aerial Concourses
- Cut and Fill Production Rates in Railway Station Construction
- CSR (Cable Service Routes) Installation Analysis
- Demolition Works Analysis for Railway Infrastructure
- Electrical Overlaps (OHW) 33kV Installation Analysis
- Elevated Service Access Platforms (ESAPs) for Stabling Yards Analysis
- Escalator Installation Analysis for Rail Stations
- Fence Installation Between Tracks Analysis (Live Corridor vs Possession Works)
- HDD Under Rail Tracks – 48-Hour Possession Analysis
- High-Speed Rail Construction Analysis
- Horizontal Directional Drilling (HDD)
- Lght Rail Construction Production Rates: Global Analysis
- Lift Replacement Projects Analysis
- Mechanical Gap Fillers Installation Analysis
- New Aerial Concourse Installation Analysis for Train Stations
- New Intercity Fleet (NIF) Platform Extension Projects Analysis
- Overhead Wire (OHW) Structure Installation Analysis
- Platform Extension Projects: Global Analysis
- Platform Marker Repainting Analysis
- Railway Sleeper Replacement Analysis
- Roadheader Production Rates in Underground Station Construction: Global Performance Analysis
- Screen Indicator Installation Analysis for Rail Stations
- Segregation Fence Installation Analysis Between Tracks
- Slab Track Construction in Railway Stations: Global Production Analysis
- Sound Barrier Installation Analysis Along Rail Corridors
- Stabling Yard Construction and Production Analysis
- Track Replacement in Railway Stations: Production Analysis
- Transport Access Program (TAP) Production Rates and Delivery Analysis
- Tunnel Boring Machine (TBM) Production Analysis and Performance Metrics
- Tunnel Membrane/Waterproofing Installation Analysis
- Under Line Crossing (ULX) Installation Analysis
- Underpass Access Construction Analysis for Train Stations
- Utilities Relocation in Railway Environments Analysis
- Water-Filled Traffic Barriers Installation Analysis
Our Partners
- FR2 Infrastructure – Constructability advise and project and planning controls
- Staging Diagrams – Staging diagrams for possession planning
Possession Planning – Current Possession Calendars
✨ Support Our Mission ✨
Help us continue building tools that simplify complexity!
Every contribution fuels new features and improvements
Thank you for being part of our journey! 🚀
