Post on 21-Feb-2021
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Final Lining FRC ApplicationsSome Examples
-SHARING EXPERIENCE
Structural Use of Fiber Reinforced Concrete in Unde rground Projects-
Scientific Committee Società Italiana Gallerie – Italian Tunnelling Society
-Underground Solutions Seminar
Auditorium AntonianumRome - 19.05.17
-Bruno ROSSI
EMEA Regional Technical Manager & Global Design Supportbruno.rossi@bm-underground.com
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Summary
• Fibers for concrete
• Tunnelling final lining applications
• Standards and guidelines
• Specifications and practical recommendations for CIP final linings
• Information needed for the design
• From the test results to the design values
• CIP final lining: some Case Studies
• Segmental Linings reference list Bekaert & Maccaferri
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Fibers for concrete
• The Fiber-Reinforced Concrete (FRC) is a composite material made of basic concrete inwhich a fiber reinforcement is incorporated and homogeneously distributed
• Fibers can be made of steel, polymers, glass or natural materials
• Fiber’s addition in concrete controls plastic and hydraulic shrinkage cracking, reducing crackspacing and crack width, thereby improving durability (even in aggressive chlorinatedenvironment as Abu Hamour Surface & Ground water drainage tunnel or Metro Green Line– Doha – Qatar)
• Fibers with an High Young’s Modulus considerably improves the concrete post-crackingbehaviour
• Fiber materials with a Young’s-Modulus which is significantly affected by time and/orthermo-hygrometrical phenomenon , are not covered by the Model Code 2010 and, ingeneral, should not be considered as structural materials
• Structural design of FRC elements is based on the post-cracking residual strengthprovided by fiber reinforcement
• For structural use, a minimum mechanical performance of FRC must be guaranteed
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Tunnelling final lining applications
drivingdirection
hydraulic jacks
key stone
standardelement
jointsdrivingdirection
hydraulic jacks
key stone
standardelement
joints
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Standards and guidelines – Fiber’s and FRC properties
Fiber’s geometrical and mechanical characteristics are defined by the following standards:
• EN 14889-2006: Fibers for concrete; this standard specifies the requirements of fibers for structural or non-structural use in concrete, mortar and grout;
• ASTM A820 / A820M-11 : Standard Specification for Steel Fibers for Fiber-ReinforcedConcrete;
• ISO 13270-2013: Steel fibers for concrete;
Fiber-Reinforced Concrete flexural behaviour has been regulated as follows:
• EN 14651-2005: Test method for metallic fibre concrete. Measuring the flexural tensile strength (limit of prop. (LOP), residual);
• ASTM C1609 / C1609M-2012: Standard Test Method for Flexural Performance of Fibre-Reinforced Concrete (Using Beam with Third-Point Loading);
• JSCE-SF4: Method of tests for flexural strength and flexural toughness of steel fibre reinforced concrete
• UNI 11039-2003: Calcestruzzo rinforzato con fibre di acciaio. Parte 1: Definizioni, classificazione e designazione. Parte 2: Metodo di prova per la determinazione della resistenza di prima fessurazione e degli indici di duttilità
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Several guidelines are available for the design of FRC elements.
In the 2012, the International Federation for Structural Concrete, has published the fib CEB-FIP Model Code 2010 (fib Bulletins 65-66).
Two chapters are dedicated to the Fiber-Reinforced Concrete:
• Chap. 5.6 Fibres/Fibre Reinforced Concrete;
• Chap. 7.7 Verification of safety and serviceability of FRC structures
Other available guidelines are:
• RILEM TC 162-TDF: Test and design methods for SFRC. Materials and Structures, Vol. 36, 2003;
• CNR DT-204/2006: Istruzioni per la Progettazione, l’Esecuzione ed il Controllodi Strutture di Calcestruzzo Fibrorinforzato;
• EHE-2008 ANEJO 14 : Recomendaciones para la utilización de hormigón con fibras;
• DAfStb : Technical Rule on Steel Fibre Reinforced Concrete, 2012.
FRC design guidelines
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• Steel fibres, high strength drawn wire (2300 MPa), L/D ≥ 65, should comply with EN 14889-1, system 1;
• Steel fibres to be added by an automatic dosing system;
• The LOP and the residual flexural strengths are measured with the standard EN 14651; a minimum number of 6 beams must be carried out for pre-construction tests and a min number of 4 beams for continuous quality control (1/2000 m3);
• Fiber content in the fresh concrete to be checked daily, EN 14721;
• A daily visual check of the concrete mix is recommended;
• A casting and compacting check must be done for each application;
Specifications and practical recommendations
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• Working points have to be planned and detailed; the effect of the fibers must not be taken into account in working points; thus additional rebar has to be placed there;
• Slump S3 or higher;
• Maximum aggregate diameter: 25 mm ;
• Min concrete class strength: fck = 30 Mpa
• Fiber type: Dramix ® 5D 65/60BG (structural applications) & Duomix ® M6 Fire(cracking control and fire resistance)
• Dosage rates: 5D 65/60BG 20 – 40 kg/m 3, Duomix M6 1,5 – 2,0 kg/m3
Specifications and practical recommendations
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The Dramix® 5D series provides you with the ultimate in performance, thanks to a unique combination of a perfect shaped hook, a high ductility wire, and extreme tensile strength:
• Ultimate anchorage
• High L/D ratio,
• Glued fibre
• Ultra high tensile strength
• High ductility wire
Dramix® 5D 65/60BG
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Dramix® 5D 65/60BG – Flexural beam tests
� The whole geometry of a single cross-section of the final liningincluding the amount and the position of the steel reinforcementcomputed in the original design
� The bending moments, axial forces and shear forces in different pointsof the selected cross-section of the final lining; this should be repeatedfor all the loading conditions taken into account (e.g., duringearthquake, in absence of water inside the tunnel, …)
� Mechanical properties of concrete (strength class) and steel reinforcingbars (type of steel).
� Partial safety factors for the materials and loading conditions
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Information needed for the design
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Information needed for the design – D.I.S.
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� Applied Loads Fj vs Crack openings CMODj (EN 14651 bending test)
� Flexural tensile strengths: fL, fR,j (EN 14651 / Model Code 2010)
� Characteristic values: fRjk = fR,jm - kx sp (RILEM TC162-TDF)
� MC10 Class.: strength intervals fR,1k and residual strength ratios fR,3k / fR,1k
� Min. requirements to be fulfilled: fR,1k / fLk > 0,4 and fR,3k / fR,1k > 0,5 (MC10)
� Constitutive laws (Model Code 2010)
� Material and loading safety factors: (Eurocode 2 / Model Code 2010)
� Design values for the different loading conditions at SLS and ULS
� Interaction diagram M-N: (Model Code 2010 / Eurocode 2)
From test results to design values
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Case Studies and BMUS Design Support
CIP Final Linings and Segmental Linings Reference List
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Date: 2000 - 2001
Project name: Kakegawa No 1 – Twin tunel
Tunnel type: Highway
Cliente: Dai-Ni-Tomei
Contractor: Maeda
Country: Japan
Max diameter: 15 meters
Fiber type: FL 45/50BN
Dosage rate: 40 kg/m3
Concrete class: C30/37
Case Study: Kakegawa n°1
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Date: 2006
Project name: Shimizu No 3 – Twin tunel
Tunnel type: Highway
Client: Dai-Ni-Tomei
Contractor: Taisei
Country: Japan
Max diameter: 15 meters
Fiber type: 3D 65/60BG
Dosage rate: 40 kg/m3
Concrete class: C30/37
Case Study: Shimizu n°3 – Twin Tunnel
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Date: 2006
Project name: Craviale & Turina
Craviale (1,055 m)
Turina (664 m)
Tunnel type: Highway
Client: Agenzia Torino
Country: Italy
Max diameter: 15 meters
Fiber type: 3D 65/60BG
Dosage rate: 30 kg/m3
Concrete class: C25/30
Design check: Proff. Chiaia & Fantilli
Case Study: Craviale and Turina
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Date: 2006-2007
Project name: SS 203 “Agordina”
Tunnel type: State road (Belluno – Listolade)
Client: Veneto Strade SpA
Country: Italy
Contractor: Adanti SpA
Fiber type: Wirand FF3 (0,75 x 50)
Max diameter: 12 meters
Dosage rate: 30 – 35 kg/mc
Concrete class: C30/37
Design check: Prof. Mammino
Design support: Maccaferri Tech Office
Case Study: S.S. 203 «Agordina»
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The tunnel is located along the Listolade S.S. 203 Agordina, in the section between the progressive Km 31+800 and Km 33 +250, between the towns of Taibon Agordino Cencenighe Agordino in the Province ofBelluno. Among the progressive m 149 m 1375, measured from the entrance NORD, the rock mass iscomposed of carbonate rocks, namely limestones and dolomites as well. In this section there are threeclasses of rock mass: Class III, Class II and faults.
SFRC mix design
� R’ck min (design) 30 Mpa
� Consistence class S4
� Exposition class XF2
� Max aggr. diam 30 mm
� CEM II/A–L 42,5R ≥ 320 kg/m 3
� Water 63 litres
� Gravel 20–30 276 kg/m 3
� Gravel 8-15 488 kg/m 3
� Sand 0-2 1234 kg/m 3
� Plast. Dyn SX14 2.34 litres
� Wirand FF1 30 kg/m 3
Case Study: S.S. 203 «Agordina»
Wirand FF1 - C30/37 - 30 kg/m 3
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0,0 0,5 1,0 1,5 2,0 2,5 3,0CTODm [mm]
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Pa]
Flexural beam test results (UNI 11039) – 30 kg/m³
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Date: 2008-2009
Project name: Galleria Scargicelle
Macrolotto n. 2 in loc. Lagonegro (PZ)
Tunnel type: Highway
Client: ANAS
Country: Italy
Contractor: SIS Scarl
Fiber type: Wirand FF1 (1,00 x 50)
Dosage rate: 40 kg/mc
SFRC for crown only
Concrete class: C30/37
Case Study: Autostrada A3 SA - RC
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Date: 2009-2010
Project name: SR 50 Variante Moline
Tunnel type: State road (Grappa -Passo Rolle)
Client: Veneto Strade SpA
Country: Italy
Contractor: ATI Intercantieri
Vittadello Carron Spa
Fiber type: Wirand FF1 (1,00 x 50)
SFRC for crown only
Dosage rate: 30 kg/mc
Concrete class: C25/30
Design support: Maccaferri Tech. Office
Dominus 1.0 (UNIBS)
Case Study: Variante di Moline S.R. 50
Dominus 1.0 – University ofBrescia
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Concrete + fibres computed forces - Piedritto Dx
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Concrete + fibres computed forces - Calotta
Date: August 2015
Project name: Lee Tunnel
Tunnel type: Sewer
Client: Thames Water
Country: UK
Contractor: MVB JV &
CH2M Hill
Internal diam.: 7.20 m
Fiber type: 5D 65/60BG
Dosage rate: 40 kg/m3
Concrete class: C50/60
Design Support: Bekaert Concrete Laboratory
Acknowledgments for the pictures:
• Thames Water; MVB JV; CH2M Hill
Case Study: Lee Tunnel
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Date: 2013 - 2015
Project name: Riva Tuneli
Northern Marmara Highway - 3rd Bridge
Tunnel type: Highway - Four lane road tunnel
Length: North Tube 626 meters, South Tube 561 meters
Client: General Directorate of Highways
Designer: EMAY Int. Engineering and Consultancy Inc.
Country: Turkey
Contractor: IC Ictas – Astaldi Consortium
Fiber type: 5D 65/60BG
Dosage rate: 20 kg/mc
Concrete class: C30/37
Res. Flex. Strengths: fR1m & fR3m > 5 Mpa (local beam tests)
Max diameter: 22 meters (18 meters free span)
Thicknesses: 600 mm (crown) 1100 (walls)
Design support: BMUS Tech. Office
Dominus 2.0 (Ing. Bettini)
Design Approval: Istanbul Tech. Univ.
Case Study:Riva Tunnel - 3rd Bridge
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Date: 2016 – under construction
Project name: Sabuncubeli Road Tunnels – Two tubes
Connecting Izmir and Manisa
Tunnel type: Two lane road tunnel
Length: 4070 meters
Country: Turkey
Contractor: Kalyon-Makyon Partnership
Reinforcement: Combined solution
Fiber type: 5D 65/60BG
Dosage rate: 25 kg/mc
Concrete class: C30/37
Res. Flex. Strengths: fR1m & fR3m > 5 MPa
Max diameter: 11 meters (internal)
Thicknesses (*): convergence ≥ 250 mm
(400 crown, 600 walls))
Designer: TTS Engineering
Design support: BMUS Tech. Office
Dominus 2.0 (Ing. Bettini)
Design Approval: Istanbul Tech. Univ.
Case Study: Sabuncubeli Road Tunnels
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Date: 2015 - ongoing
Project name: Jansen Mine Shafts - Saskatchewan
Work type: Shaft walls (slip formed, 3 metersper day production rate)
Interior Diameter: 8500 mm
Thickness: from 800 mm up to 1100 mm
Depth. 800 meters
Client: BHP Billiton
Country: Canada
Contractor: Mc Nally Contractors LTD
Fiber type: 5D 65/60BG
Dosage rate: 40 kg/mc
Concrete class: C60/75
Design support: BMUS Technical Office
Case Study: Jansen Mine Shafts
Case Study: Blacklick Creek Sanitary Interceptor SewerDate: 2016 - ongoing
Project name: Blacklick Creek Sanitary Interceptor Sewer
Tunnel type: Segmental Lining (length 6895 meters)
Interior Diameter: 3048 mm
Thickness: 229 mm
Ring width: 1220 mm
N°of segments: 4+2 (4x67,5°+ 2x45°)
Client: City of Columbus – Dept of PublicUtilities
Country: Ohio - USA
Fiber type: 5D 65/60BG
Dosage rate: 35 kg/mc
Concrete class: C45/55 (f’c > 6000 psi)
Equivalent strength: > 7,60 Mpa (1100 psi)
Design support: BMUS Technical Office
Verifications: Demoulding, Stacking, TBM thrust jack loads, ground pressure
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Case Study: LPG Cavern Storage ShaftDate: 2017 - ongoing
Project name: LPG Cavern Storage Shaft
Work type: Shaft holes to be completely filled
Interior Diameter: 5200 mm
Thickness: 5200 mm
Depth: 106 meters
Client: Borealis Polymers OY
Country: Finland
Contractor: Lemminkäinen OY
Fiber type: 5D 65/60BG
Dosage rate: 35 kg/mc
Concrete class: C30/37
Extra information: Raise boring method excavation
Design support: Bekaert Concrete Laboratory andBMUS Technical Office
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Date: 2017 – under construction
Project name: Honaz - Denizli Road Tunnels – Two tubes
Connecting Honaz and Denizli
Tunnel type: Two lane road tunnels
Length: 2 x 2500 meters
Country: Turkey
Contractor: OZCE - INSAAT
Reinforcement: Combined solution
Fiber type: 5D 65/60BG
Dosage rate: 37 kg/mc (final solution)
Concrete class: C25/30
Res. Flex. Strengths: fR1k = 2,54 Mpa; fR3k > 3,53 Mpa (BKT Dbase)
Max diameter: 11,50 meters (internal)
Thicknesses: 400 mm crown, 550 walls
Designer: TTS Engineering
Design support: BMUS Tech. Office
Dominus 2.0 (Ing. Bettini)
Design Approval: Istanbul Technical University
Case Study: Honaz - Denizli Road Tunnels
From the early 90’s, over 131 projects have been realized with steelfibers, by Bekaert and Maccaferri worldwide:
– 49 hydraulic projects (39 only fibers + 10 combined)
– 40 metro lines (23 only fibers + 15 combined + 2 others)
– 18 utilities (17 only fibers + 1 combined)
– 12 railways (4 only fibers + 8 combined)
– 9 roads (3 only fibers + 6 combined)
– 3 others (2 only + 1 combined)
• 88 of them are steel fiber’s only reinforced
• 43 are reinforced combining steel fibers and rebars
Max Φext for steel fiber’s only solution (Dramix): 12,4 m (North-South Bypass Tunnel (Clem 7), Brisbane & Airport Link / Northern Busway, Brisbane)
FRC segmental lining reference projects
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Tramway Nice T2 line West-East – 2015-2016� Tunnel type: Segmental Lining
� Country: France
� Client: Nice Municipality
� Contractor: Bouygues Construction
� Tunnel length: 2930 m
� Max. ext. diameter: 8500 mm
� Thickness: 400 mm
� Segmentation: 7 + 1
� Fibre type & dosage rate: 4D 80/60BG, 40 kg/mc
� Concrete class: C40/50 (design)
� Design support: BMUS Technical Office
� Verifications: Demoulding, Stacking, Segment erectio n duringinstallation, Tunnel-boring machine (TBM) thrust ja ckforces, Localized back-grouting pressure
� Residual flexural str.: Casted fR1k = 6,50 MPa, fR3k = 7,35 MPa
Sawn fR1k = 5,35 MPa, fR3k = 6,44 Mpa
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Concrete mix design and compressive strength
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Beam specimens casted and flexural strength
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Beam specimens cut out from a segment
Thanks for your attention-
Bruno RossiEMEA Regional Technical Manager & Global Design Support
bruno.rossi@bm-underground.com