BOORTUNNEL GROENE HART Contract No. DGP2092 Koop Tjuchem bv Koop Ho1ding Europe B.V 00 FA 19/08/02 Status: Datum Auteur Checked Dèscription I Omschrijving Gecontroleerd FI: For Information I Ter informatie FC: For Consultation I Voor Commentaar FA: For Acceptance I Ter Acceptatie IFCTW:.lssued for construction (Temporary Works) 1Uitgegeven Voor Constructie (Tijdelijk Werk) IFC: Issued for construction I Uit even Voor Constructie Status Reil. Hoofdstuk TUNNELINTERNALSTRUCTURES Check by ISOP: Naam ISOP: Gecontroleerd door !SOP : Ja: Nee: r8J Paraaf: Titiel Titel APPROVAL OF MATERlAL PLASTIC SPACERS FOR VERTiCAl REINFORCEMENT OF THE TUNNEllNTERNAL STRUCTURES Archiving Code Format Archief code: Formaat: HSL Code : Number I Nummer: Rev. 13181 CO 24.10 A4 13461 PRoe AOM 88133 00 Issuer I Uitgever Package Document PROD AOM 88129 oe.doc Consortium Bouygues I Koop, Postbus 76, 2350 AB Leiderdorp, Tel. +31 (71) 5817000, Fax +31 (71) 5817070 Page 1 of2
Transcript
BOORTUNNELGROENE HART
Contract No. DGP2092
Koop Tjuchem bvKoop Ho1ding Europe B.V
00 FA19/08/02
Status:
Datum Auteur Checked Dèscription I OmschrijvingGecontroleerd
FI: For Information I Ter informatie FC: For Consultation I Voor CommentaarFA: For Acceptance I Ter Acceptatie IFCTW:.lssued for construction (Temporary Works) 1Uitgegeven Voor Constructie (Tijdelijk Werk)IFC: Issued for construction I Uit even Voor Constructie
StatusReil.
HoofdstukTUNNELINTERNALSTRUCTURES
Check by ISOP: Naam ISOP:Gecontroleerd door !SOP :
Ja: Nee: r8J Paraaf:
Titiel Titel
APPROVAL OF MATERlALPLASTIC SPACERS FOR VERTiCAl REINFORCEMENT
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Bouygues Koop
Approval of Materials
HSL Zuid 8oortunoel Groene Hart
[ ~s: :;=f~r vertical reinforcemenls a plied in !he tunnel intemal structuresDocument number:PROD·AOM·88133
All these spacers have been checked by ConsortiumBouygues I Koop on behalf Certificates andconformity statement provided by the suppllers. Fulldescription of these certificalions are attachee hereinappendix 1.
At the light of these test results and certification itappears that all the related requlrements andspecifications are fulfilled.
ë Durability demonstration compliance to NEN Full description of the requirements, the associated6722. test method and the results obtained are fully
described in. appendix 2.
The selected spacers fulfil with all relatedrequirements and specifications.
SuppliersTechnicalspecifications
Appendix 2:
TNO's report2001-BT-MK-R104401
AU tests made on this concrete during onsäe production throughout the works is controlled in accordance with:
Consortium I Koop HSL Zuid Boortunl1el Groene Hart
Approval of Materals Koop Tjuchem
Plastic specers tor verticel reinforcements applied in Ihe tunnel intemal structures
Document number:
PRO[l·AOM-88133
APPENDIX TABi..E OFCONTENTS
1. Spacers' Technical speelfloatons x
2. Durability assessment -compliance to NEN 6722 x
Farm 20.8,01.01 rellÜ5 Consortium Bouygues I Koop, Postbus 76, 2250 AB Leiderdorp, Tel,: 21 (O) 71 5817000, Fax 31 (O) 71 5817070 Page of
This appendix presente the material speeiûcatons and certfficate provloed by the suppäers of the spaeer. The alm of this analysis is tocheck whetherthe spacers satlsfy all requirements in the relevant specläcaüons and standerds.
At the light of these test results and certfieaton itappears that aHthe related requirements and specifications are fulfilled.
from Phone ne, ++49 (0) 202 9644-140---------Haraid Kotzur
Cemposltien of tbe material for uur plastic spacers "Dux-offen and Dinki"
Dear Mr. Taibi,
for economical as wen as for environment reasons we produce all plastic spacers - which are manufacturedin an injection mcalding process - form recycling material.
The a. m. products are made of recycled PE (Polyethelene), which means that about 95% of the material isrecycled PE-material and about 5% are different plastics. Recycled PE-material means that the material wasalready used for ether products (first products) made ofPE and is now crushed to the basic material for ourspacers. As we as well as our supplier for the basic material for OUT spacers don't know who had producedthe "first product" we are not in a position to give a material composition and to acknowledge the type ofstabilizer which was used. This is a general problem whenever recycled material is used. On the other handimprooved separation of plastic materials which are used for recycling purposes have resulted in a higherquality of regenerated base material.
As a wellknown supplier of plastic spacers in the European market we get our raw material only fromreliable sourees in big quantities, to ensure the quality of our products. We have sold our plastic spacers formore than fourty years now and have never got any problems with them particularly in respect to durabilityeven under problèrnatie requirements.
hope I could give you some informative help and remain
U kan mij T6chtSfeek5 bete/kIM op het nummer: 021683.02.54 of Vfl([email protected]~ f$x nummer: 021258.40,00
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600fG raers HN ni/U} 6S:l/0 NHI 10, l/O/LU
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Ecarteur___._--l:t0urarmature verticaleDINKl et DtlX OFFEN ;.fiche teelmiql.le
L Delgl1onduproduit
Leséc~~p<)~ annature '1ertjcal~(DINKI et OUX OFFEN) en plastique som utihaés pour réaliser I'enrobagedeslU::iers~caux dans les stnrcturea en héton armé.
2. Domair.ted'ap:pU,ca:ûtm
Armatures vtrticales dans Ie béton armé,
CertificatsMatériauCouleurCrnl.1'lÎque
: selon DIN et ISO 900 t: polyéthylène PE; gris; résiste aux plus fréquerns acides et basiques présents dans ie béton
Gräce à leurperlte surface de contact sur Ie coffrage, ces écartems soot très.peu visibles dans Ie béton,DINKI etm1X OFFEN: se clipsent SUT l'lU::ier et sant poUlVUS d'un dispositif sp6cial qui les tmp&he de tombe r,DL"X OF'F'SN est uae cale plus rigide et pr!isente des conta<lts réduits avec te coffra.ge.
Verticale____.~ape~ingsafstandhoudersDiNKl en DUX eFFEN: Technische fiche
1. Pl"Odbetbescluiiviltlg
De verticalewapeningsafsumdhouders (DINK! en DUX OFFEN) in ktl.l1StStOfworden gebruikt als afstandhouderin gewapend betA)llfussen' de verticale wapening en de bekisting.
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2. ToepaMinmebied
Afstandhouder voor de verticale wapening in gewapend beton.
4. EigemcllaAAcn
CertificaatMateriaalKleurChemisch
: volgens DIN en ISO 9001: polyethyleen PE: grijs: bestendig tegen de meest voorkomende zuren en basen, aanwezig in beton.
DlNKI on OUX OFFEN. : worden vastgeklemd op de wapening en zijn voorzlen van een speciaal systeem dat het Iloskomen van de afstandshouder tegengaat.DUX OFFEN : heefr'ee» grotere stijfheid en kleine contactpunten met de bekisting. I
Bereich: Entwic!dung, Prol1ukUon und Vertrieb venSpezialartikeln für die Bauindustrilll
ein Qualitätsmanagementsystem entsprechend der ob engenannten Norm (SI94) eingeführt hat und dleses
wlrksam anwencet. Der Nachweis wurde imRahmen de$ Zertifizierungs-Audits,Sericht-Nr. W-2971633 erbracht,
Datum derErstzertitizierung: 09.03.1995DI4!lsesZertifikat ist güttigbis: ~~~ 3UJ3;:001
/i~'~
Oá\tum der letzaenRe;,:erlifizierullg: 23.03.1998Zertifik:at~Registl'Ïer·Nr.: 4039504711
Akl(r~djtlert (/yreh I'.lie TGA
im Deutschen Akkreditierungs Rat
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Lüü1LOO'o tLllL#
D..• Ariikel. Teehnik im Bau.
Consortium Bouygues I Koop
APPROVAl OF MATERlALS (AOM)
APPENDiX - 02
HSL Zuid Boortunnel Groene Hart
DURABILITYASSE:3Sfl~E~ITOF THE PLft,STIC SPACERS - COMPUANCE TO NEN 6722
Consortium Bouygues I Koop
Content
ARTICLE 1 - SCOPE
ARTICLE 2 - REQUIREMENTS
APPROVAL OF MATERlALS (AOM)
lied in the tunnel intemal structures
ARTICLE 3 - PLASTIC SPACER COMPUANCE
ARTICLE 4 - CONCLUSION
ARTICLE 5 - ANNEXE
Document number:PROD - AOM - 88133
HSL Zuid Boortunnel Groene Hart
3
3
3
3
4
Consortium Bouygues I Koop HSL Zuid Boortunnel Groene Hart
APPROVAL OF MATERiALS (AOM)
ARTlCLE 1 • Scope
In the design and construct contract for the Groene Hart tunnel a requirement of a design life of at least 100 year has been stated, Toprove that this design life is valid, performance and reliability based calculations, according to the design method 'DuraCrete', have beenbe provided.For the spacers, that wil! be used to guarantee the thiekness of the concrete cover, ths question occurred whether these have a sufficientservice life.
ARTiCLE 2 • Reql.l.irements
• NeN 5950:1995 "Voorchriften Beton-Technologie (VeT 1986). Eisen, Vervvaardigind en Keuring" - Regulations for concrete- Technologie - Requirements, production and inspection;
I» NEN 6722:1989 "Voorchriften Beton Uitvoering (VBU 1988)" - Regulations for concrete Construction;
ARTICLE 3 • Plasticspaeer compnance
The durability of the separaten wall between the two tracks in the bore tunnel was analysed on the basis of the service life design. In theservice life design for this project the corrosion of reinforcement through the carbonation and the chloride diffusion were regarded as themost important threatof degradations (refer to documents PROO-AOM-88022 and PROO-AOM-88004)The exposure conditions identified for separaäon waUare considered with regards of the carbonation degradation mechanism to be anoutdoor sheltered type, and with regards to the chloride ingress degradation mechanism to be an atmospheric type. The structure part isonly expoeed to air.
At this moment it is not yet possible to make a proper service life design for spacers. This is primarily due to the fact that we do notunderstand the initiation and propagation mechanisms related to corrosion of the part of the reinforcement bar directly behind the spaeer.An expert opinion byTNO concludes that for the durability of cementitious or plastic spacers we must rely, tor the time being, onexperience, Experience shows that both type of spacers do not cause serious durabiHty problems. Therefore, plastic and cementitiousspaeers have in principle similar effects on service !ife and should be considered equivalent in that respect. There is alittle preference toapply cementitious spacers, as the experience with cementitious spacers is longer than with plastic spacers. (refer 10 TNO report number001-8T -MK-R1 04401).
If we look in NEN 6722 with respect to plastic spacers we found there, that they may be used under lhe conditons.lil For theproper adhesion of plastic cover blocks to the concrete, they must have a surface of recesses of at least 25% of the
gross surfaceco Cover bloeks applied in watertight work must be of a cement-bound materiallil If plastic cover bleeks are applied in situations in which the fresh concrete temperature may exceed 50°C, it must be shown
by means of tests that they do not undergo any unpermissible deformation at the occurring laad.
With respect to the separaten wall, the last two conditions may appiy to the GHT and nood to ba analysed.lil Water tightness is not applicable in the case of the separaüon wall, the durability investigation demonstrared that this
structure. is only exposed to air.GAsSeparation wall is relatively thin (45 cm), a rise of.concrete temperature over 50°C due to hydration process is not
expected. Whatever the weaking point of the PE that is used for the plastic spaeers is aoout 120°C. This means fhat noproblems with respect to the temperature must be expected.
ARTIClE 4 • Concluslon
The plastics spacers comply to the requirements of NEN 6722.TNO analysed that as far ths durability of plastic spacers and also cementitious ones is concerned, we can rely, for the time being, only onexperience. Experience shows that both type of spacers do not cause serleus durabiIity problems. Therefore, plastic and cementitiousspacers have in principle similar effects on service life and shouid be considered equivalent in that respect.
Consortium Bouygues I Koop HSL Zuid Boortunne! Groene Hart
APPROVAl OF MATERIALS (AOM)
Beside the applicatiol'l of the plastic spaoer. wheel shaped, permits to lower tlle risk of bad concrete cover on vertical relnforcement, slncethey can net twist when the formworks are applied.
It can be considered that plastic spacers do not impair the quality and the durability of the concrete structure. Therefore these plasticspacers can be used tor construction .
ARTICLE 5 • Annexe
., TNO 's report 2001-BT-MK-R104401,Service life design segments ofthe bored tunnel expert opinlon on the effect of plasticspacers
( me Building anti CODstruction Research
TNO report
2601·B1 -MK·Rl044l01
Groene Hart TunnelService Life Design Segments of the Bored TunnelExpert Opinion on the Effect of Plastic Spacers
Date 30 November 2001
Amhor(s) Ir. AJ.M. Siernes
Copy noNo. of copiesNumberof pages 20Number of appendicesSponsor Bouygues Travaux Publies
alm. Mr. Y. TaibiProject name OHT SLO plastic spaersProject number
All tights reserved,No part of this publiestien may be reprodeeed and/or publisbed by print. photoprint, microfilmor any ether means without the previous written consent of TNO.
In case thls report was drafted on instructions, the rights aad obligations of coatracting partjesare subject te either the Standard Conditions for Research Instructiens given to TNO. or therelevant agreement concluded between tbe contracting parties. Subrnitting tbc report forinspection to parties who have a direct interest is perrnitted.
@2001 TNO
CivillnfraslrUetureSchoemak:erstraat 97P.O. Box 492600 AA Delft
www.tno.nl
T +311.52763000F +31 152763018
CI.I '''~'KA:Iop__ t ftke./OlI<fl:Ih.Codilt1. C.C. U.Oz.~. : lo5!>b
Jp het ontwerp- en bouwcontract voor de Groene Hart Tunnel in de hoge snelheids1ijniûssen Amsterdam and Brussel is een levensduur van tenminste 100 jaar geëist voorbelangrijkste onderdelen van de tunnel. De tunnel bestaat uit een boortunnel. gemaaktvan geprefabriceerde betonnen segmenten, toeritten en diafragmawanden. Om aan tetonen dat deze ontwerplevensduur daadwerkelijk aanwezig is moeten berekeningenworden gemaakt die zijn gebaseerd op prestaties en betrouwbaarheid, volgens demethode 'DuraCrete' . Dit bewijs moet ook worden gegeven voor de kunststofafstandhouders die zullen worden toegepast in de segmenten van de boortunnel.
In het rapport is een analyse gegeven van de duurzaamheid van kunststofafstandhouders, die geleverd worden door Plakabeton - Coffratec uit Ternat in België.Het daarbij om de typen DINKI, DUX OFFEN en DRANFIX. De analyse was gerichtop het aantonen van de minimum levensduur van 100 jaar. In de analyse is gekeken.naar drie aspecten:- de duurzaamheidseisen uit de VEU (NEN (722) voor wat betreft afstandhouders in
beton- de mogelijke bijdrage van de afstandhouders aan de aantasting van het beton en de
wapening~ de mogelijke aantasting van de afstandhouders zelf.
Uit. de analyse bleek dat de kunststof afstandhouders aan alle gestelde eisen kunnenvoldoen, met uitzondering van de eis uit de VBU dat in waterdicht beton geen kunstsofafstandhouders mogen worden gebruikt. Er is echter aangetoond dat wel kan wordenvoldaan aan de prestatie-eis ten aanzien van de waterdichtheid, die is gegeven in het'Programma van Eisen Groene Hart Tunnel' .
Vanuit een praktisch oogpunt bezien kan ook worden opgemerkt dat in de praktijknauwelijks duuraaarrëietdscbaëe voorkomt bij het gebruik van kunststof afstandhoudersin constructies die geplaatst zijn in een zeewatermilieu.
Er kan dus worden geconcludeerd dat de betreffende kunststof afstandhouderszodanige, met de duurzaamheid samenhangende, eigenschappen hebben dat een ont-werplevensduur van tenminste 100 jaar aanwezig is.
TNO report II {l404 3/1.!l
"Snmmary~,,'
\.;
~. the design and construct contract for tbe Groene Hart Tunnel in the high speedniilway tink between Amsterdam and Brussels a requirement of a design Iife of at least100 year has been stated, The tunnel consists of a bored tunnel. made of prefabricatedconcrete segments. ramps and ëiaphragm wall, To prove that this design life is vaUd.performance and reUabiHty based ealculations, according to the design metsod'OuraCrete', should he provided; The proof of this service life must also he given forthe plastic spacers to he used in the segments of the bored tunnel,
Tbe durability of the plastic (polypropylene) spacecs that are delivered by Piakabeton -Coffratee in Pemat Belgium, the types DlNKI, DUX OFPEN, and DRANFIX wasanalysed witb respect to the minimum service life. The analysis was directed to threedifferent aspeets:- tbe durabHity requirements given in N'EN 6722 (VBU) with respect to spacers in
concrete- the possible contdbution of the spacers to tbe degrndation meehanisms of the
concrete or the reinforcement- the possible degrsëetiona of the spacers,
It was found that the polypropylene spacers can satisfy all rrentioned requirements.exeept the requirements from NEN 6722 that plastic spacers are not allowed inwaternght coaesese.-ït.was-however shownthat-the related performance requirementgiven in the 'Programme of Reqairements.Green Heart Tunnel' will be satisfied,
From a practical point of'.view.i; earl be stared that concrete spacers used in sea watersnucterea show no special durability problerns.
The concrete spacers{havein Principle durabitity characteristics that will guarantee adesign service life of at least lOOyear.
TNO report! l044
Contents
:AppendicesA Appendix: brochures of the spacers'i:
16
1 Introduction 5
:2 Thc twmellining anti lts poosible degradations 72.1 Deseripëon of the Iining and the spacers?2.2 Exposure conditions for the lining 82.3 Exposure eonditions for the plastic spacers 10
:3 Expert opinion on tbc service lire of tbe lining in reiation to tbc spacers usedl13.1 Requirements from N'EN 6722 'Regulations for concrete Construction (VBU 1988)'
113.2 ldentifying the possible degradations ] 13.3 Degradatien of tne polyetbylene123.4 Contribution of the plastic spacers 10 the degradation of the concrete 12
4 Conclusions- 14
TNO report 11044 5 115
1 Introduetion.... ,,
Jhe Green Hemt Tunnel is probably one of the most important structures in thenorthem part of the high-speed railway link between Amsterdam and Brussels. Thetunnel consists of:
One bored tunnel with El separation wall between the two tracks in the tunnel. Thelining of the tunnel wil! Oe made of prefabricated reinforeed concrete. In the liningplastic spacers will Oe used, These wil! he supplied by C.V.A. Plakabeton -Coffratec S.CA in Ternat Belgium, Between me elements rubber gaskets will heprovided,Ramps as entrences for the tunnel from me north and the south side, The ramps(walls and bottom) will be made in situ of reinforeed concrete. The ramp will hesupported by a system of under-water concrete bleeks that are conneered by rensionpiles to the bottom of the ramp.
- Diaphragm walls hetween the ramps and the bored tunnel.
In the design and construct contract for this tunnel lil requirement of a design life of atleast 100year has been stated, To prove that this design life is valid, performance andreliabiHty based caleulations, aceording to the design method 'DuraCrete', should heprovided, Toe proof of this service lire must also De given for the concrete spacers.
The designmethod 'DuraCrete' fellows in principle the same line as the structaraldesign concept. The design is based on:- Perfermances, where me border between wen performing and bad performing is
given by limit states.Limit states should, In principle, model the behaviour of the structure on basis offundamental correct formulas; in case of lack of these formatas empirica! relation-ships are aceeptable if consensus is present to use these roedels. A distinction will hemade between ultimate limit states (ULS) and serviceability limit states (SLS).Reliability, Prove should he given that the relevant performances wil! be reliablethrough tie whole design service life (reference period), The required reliabiJity forthe ULS should he at least i:> :: 3.6 and for the SLS ~ :: 1.8.
Fusther aspeets of the design metbod 'DuraCrete' are:The environmental eoedinons are modelled within the limit states.The degradation proeesses are modelled within tbc limit states,There is in principle a possibility to formalate new, to durability or maintenancerelated, limit states. An example is a limit state to prevent to enter into the peopa-gation phase of eerrosion. Such a limit state redaces the probability that repair has toOe done on the strueture,
The 'DuraCrete' design method is described in a manaal nl. For the calculations of theconcrete structure this method will he followed, in the sense that the calculations will hemade on a probabilistic level.
The manual gives also a possibility for a simplified semi-probabilistic design withsafety margins between tbe losding or environmeatal condiäoas and tae materialresistanee, Thts simphfied approach wilt not be fellewed as it is expected to he toocrude for a design for 100 year in case of the preseace of chloride. To simplify the
TNO report 11044 6/15
calculations this approach may be fellewed for performances that presumably are notçritica1. TOe semi-probabilistic calculation is than used to prove this,
Tbe design metbod DuraCrete is fully foeussed on reinforeed concrete structures, It cannot yet he used for special parts in the tunnel like the plastic spacers, the rubber lining,tbe stainless steel anchors. as no degrsdation rnodels and data for the parameters arespecified,
In this report an expert opinion will be given on the service life of tlle plastic spacers, itstrived to give this opinion on basis of tbe performance and reliabiltty of the spacers fora service Iife of 100 year, In other words the expert opinion win be based on the sameprinciples as in DuraCrete.
TNO report IHl44 7 1tf5
2 The tunnel lining and its possible degradations
2.1 Descripti.on of the lining and the spaeers
The lining of the Green Hart Tunnel consists of prefabricated reinforeed concretesegments, Each tunnel ring with a width of 2 mand an internat diameter of 13.3 mconsists of nine segments and a keystone (Figure 2.1). The lining has a wall thickness of0.6 m. Around each segment and key stone a rubber joint profile is applied to secure thewater tightness of the tunnel lining. The surfaces of the joints between the segments areprovided with the plastic guiding bar to accurately position the segments during theconstruction of the lining, To provide the proper concrete cover plastic spacers of willhe used, that wH1he delivered by C.V.A. Plakabeton - Coffratec S.C.A. in TernatBelgium. The spaeer are produced by Reuf3 Teehuik irn Bau in Wuppertal Germany.
1 I
I !i Ii ,.~I :, I
Figure 2.1 Cross sections of tne tunnel ring in longitudinal and transverse direction
FOT the horizontal reinforcement bars DRANFIX spaeer wiU be used and for the verticalreinforcement bars DINK! anti DUX OFPEN (Figure 2.2).
Figure 2.2 Respectively DINKl. DRANFIX and DUX OFFEN (scale about 1 : 2)
TNO report 11044 8115
The standard DRANFIX sparers are avaUable for concrete covers of 35 mm and 40 mm.. itP combination with reinforcement diameters of 6 to 16 mmo This product is described:~nhe Outen brochure VOS 2102, dated 02108/00, and in the Freeeh brochure W 05 21..~2, dated 06107199.
The standard spacers are of tbe type DINKI are for a cover of 40 mm and reinforcementdiameters of 5 to 14 mrn and DUK OFf'EN for a cover of 35 mm in combination withreinforcemem diameters of 10 to 20 mm and for a cover of 40 mm in combination withreinforcement diameters hetween 14 and 18 mmo These products are described in theDureh brochure V 05 1902, dsted 02108/00, and in the Freneh brochure W 05 1902,dated 06107199.
Plakabeton wiU however prodaee similar spaeers with ecversend reinforcememdiameters tbat are specific for tbo application in the Green Heart Tunnel. No brochuresare avallable for tbis. Scans of the brochures are given in Appendix A.
As far as the exposure environment is concemed, the tunnel lining is generally incontact with tbe salt contaminated groundwater on tbc outside. On tbe inside mere isalso a possibility for salt contaminated ground water, due to leakage though tbe joints.Further the concrete segments are exposed to tbe armesphese on the inner sine and in apart of tbe joints. The tbreat of degradations sucb as trost in combination witb de-icingagents.cbemieal and biologica! attaek are less or not relevant for the tunnel lining. ASRwill he considered by selecting proper cement and by avoiding the appäeetion of tbcpoteatial reaetive aggregates (research coaceraing tbis aspect hasbeen carriedout byBouygues).
Carbon dioxide from the atmospbere can have negative effect on the inner side of thetunnel lining conceming tbe carboeation since the coacentratioa of carbon dioxideinside the tunnel will be raised in cornparison with tbe outdoor environment due to thelow ventdarion in tbc tunnel, In addition, tbere will he no preeipitation.
Therefore blockage of !he pores in the concrete cover due to predpitation wil] not takeplace, altbough condeasaäon may partly compensate tbat. The eerrosion of reinforce-ment tbrough carbooation has to he coasidered in tbe service life design of tbe tunnellining,
On the basis of the Program of Requirements - Green Hart (5.1.4) tbc content ofchloride in tbe groand water must he consiöered as thai. in !he sea water. The salineground water will penetrate in the outside of the tunnel Iining (i.e. concrete outside therubber joints). Due to possible ieakage of the joints (immediately aftel' construction orduring tbe service life), the saline ground water wil! also penetrate in tbe joints at theinner side of !he tunnel lining. Therefore, the corresion of reinforcement throughchloride ingress bas to be considered in tbc service life design of the tunnet tining.
The cntical points eoaeeming the thrests of earbonstien and chloride ingress on mesegment are illustrated in Figure 2.3. These two types of threats eau he identified in thesegment aceording to the exposure conditions:
TNO report 11044
e e e c c ::::.;:..;:.:
l"'~'~r_'·-- L OutskIa(Chl~ pe:::a:) . __ .._....- '.-
Posslble ieakage at (chloride penetration) alffte joint betwe9tl!he rings
Figure 2.3 Critica! points concerning the treats of carbonaston and chloride ingress onthe segment
Outside:
The outside surface of me concrete segment is constantly exposed to thechloridecontaminated ground water. The enviroamental condition is similar to the submergedcondition in the sea water.
Inside:
The inside surface of tbc concrete segment is coastantly expoeed to the air with arelatively high CO2 concentratien due to the low ventäation in the tunnel. The mainlythreat is the carbenation. Due ro the possible leakage the inside of the segment at thebottorn of the tunnel could be also threatened by the chloride penetratien. This part canbe considered as the splash zone as far as the exposure condition is coneerned,
The joint between tbe rings:
The smal! part outside the rubber profile is constantly exposed to tbe chloridecontaminated ground water. This part can be considered as the submerged exposurecondition. The surface behind the rubber joint could be possibly in contact with toesaline water due to the leakage. The exposure condition of this part of the surface can beregarded as the tidal zone (Figlli"'e 2.2a).
TNO report I 1044 lOf 15
The joint between the segments:
The smal! part outside the robber profile is constantly exposed to me chloridecoetaminated ground water. This part can be consinered as the submerged exposureeonditioa. The surface bebind the robber joint and/or bebind the plastic guide bar couldhe possibly in contact with the saline water due to the leakage. The exposure conditionof this part of the surface cao he regarded as the tidal zone (Figure 2.2b).
2.3 Exposure oonditioos for tbc plastic spacers
Spacers:
In all these critica] points tbc plastic spacers, delivored by Plakabeton, for the concretecover will be present. These durability parameters of the spacers differ oom tbeparameters of the concrete of the segments, Therefore it is necessary to look to theservice life of the spacers.
Poly-ethene (LDPE and HOPE) have in principle a goed resistance against:
weak and streng acids
weak and streng alkalies
oils and fats
The westher resistance is moderate, but by adding special additives this cao beimproved, Tbc resistance against oxidizing acids is poor.
TNO report 11044 nn5
3 Expert opnnon on the service life of the lining inrelation to the spacers used
3.1 R.equirements trom NEN 6722 'Regula&ns for concrete Construction (VBU1985)'
In NEN 6722 some requirements related to durability are specified:1 spacers may not contribete to air enclosures2spacers may not induce tbe ingress of moisture af ter hardening of the concrete3 spacers may nor contribate to cracking4 in case of watertigbt concrete the spacers must he made from a cement bound
material , with a water/cement ratio that is at least equal to the water/cement ratio ofthe concrete
5 the area of the recesses in the plastic spaeers should he at least 25 % of tbc grossarea of the spacers
6 in case the spaeers are used in situatioes where the température can rise above 50 oeis should he proved that no unacceptable deformations occur,
With respect to these requirements the following remarks can Oe made:1 tbc open structure of tbc spaeers to be used wil! prevent that air enclosures can oceur2 as no realoonding will occur between the plastic spaeer and the surrounding
concrete, it is unavoidable thet á small opening win he present near the interface; the'crack width' wilt he substantially lower than the allowable crack width in theconcrete
3 giving the low modulus of elasticity of the polyethylene the spaeer will notcontribute to the cracking of the concrete
4 all civil engineering parts of the stracture should he watertight: for tbc bored tunnel,the access ramps, and the shafts this is translated in the 'Programme of RequirementsGreen Heart Tunnel, in a performance requirement that in the operational stage theleak water discharge is less then 0.05 lIm2/day as an average over 50 m length; thelocal maximum is 0.10 lIm2/day; the spaeer reduces the thickness of the concreteparts locally with about 10 %, as the amount of perrneated water is inverselyproporëonal witb the thickness of the concrete element it is deal' that a plastic spaeerwill nor inerease the discharge with a factor 2
5 it is obvious trom Fig. 2.1 that thc DINK! and DUX OFPEN spacers fulfil thisrequirernent; after meesurement of the reeesses in the DRANFIX spaeer it was foundthat these spacers also fulfil the requirement
6 the weakening point of polyethylene is about 110 10 130 Oe, depending on thedensity of the material; the highest temperature due to sun radietion will he about 60oe and due to hydratien of the cement 70 oe.
As given in Chapter 2 the polyethyleae, should he able to resist during the designservice life the following main degradations:- alkali attack- weathering- oxidizing acids.
TNO report I 1044
Parther conditlens for the plastic sparers are, that they may not contribute to the mamdegradation mechanisms for the concrete:
chloride ingress in the splssh zonecarbonation
as both degradations can initiate eerrosion in the concrete.
•1IIII1;I.
lmgres
concrete
spaeer
reinforcement steel
••
a. b.Figure 3. J Concrete without a spaeer (a) and with oplastie spaeer (b)
3.3 Degmdatioo of tbe polyethyiene
As mentioned in Chapter 2 the main.degrading agents for polyethylene are:- weathering~ oxidizing acids.
Apart from calamities it is not expeeted that oxidizing acids wil! he present in the GreenHeart Tunnel. If these types of aeids would be present, the attacking effect on tbeconcrete would deminare the effect on the spacers.
The weathering effect on the polyethylene is mainly due to ultraviolet light, and for asmall part to oxidizing and physiea! aging. As the spacers are emoedded in the concrete(Fig. 3.1) !he effect win be negligible. Further we must realise that most of the plasticspacers are situated in pl aces where no tigbt is present: outside surface, joints, elementsunder the railway body etc.
For srnall products, like these concrete spacers, that are also produeed in a specific way,it is difficult to perferm the usual compliance test with respect to earbonation andchloride ingress. A possibility for testing would he to cast some spacers in standerdconcrete cubes or prisms, made of the same concrete mix as win he used for thesegments. The cubes cao he tested in the ReM-test (Rapid Chloride Migration) and theprisms in a rapid carbonation test. The testing procedure need however to he developedand consensus should he found on the interpretanen of the test results. This goesbeyend the scope of the present service life design of the spacers,
In the situation of Figure 3.1,a the chlorides or the carbon dioxide cao reach thereinforcement steel through the original concrete mix. For this situation a probabilistic
TNO report I 1044 13/15
service life calculation has shown that with the concrete mix M4So-AM, mat Bouygneswill use for the production of the segments, the requirements with respect to the servicelife of tbe segments can he fulfilled,
From practical experience it is known that plastic spacers that are applied in a sea waterelimate (ander water, tidal zone, or splash zone) seldom are involved in damages due tocorrosion, This may he due to me fact that no oorrosion of the reinforcing bar, that is incontact witb the spaeer, wil! occur. It mayalso he do to the fact that eerrosion occurs,but being a local eerrosion spot the amount of corrosion product will he limited, and mespaces available in the concrete matrix (air voids, pores and small cracks) can heenough to prevent cracking of me concrete due swelling of the original iron.
The situation in most concrete structures in a sea water elimate is in tbis last respect ingenera! more favourable than the concrete in the segments, The minimum cover in thesegments will he probably 35 mrn, In prsctice this win he about 50 mmo This meansthat the force, due to theswelling eerrosion products needed to break out (pop-out) aconcrete cone is quadratic with the heighr of the concrete cover (Figure 3.2).
Figure 3.2 Pop-outforce is quadratic with the concrete cover
This possible unfavourable effect is in praenee not to important. The mass of concretethat will pop-out in case of a 35 mm spaeer is limited, and estimated at about 100 gram.The darrage or injuries that a mass of 100 gram can cause is Iimited, Besides it ma)' heexpeeted dun sueh type of pop-outs have a high degree of deteetability duringinspeedons.
TNO repol111044 14 HS
4 Conclusions
jbe durability of the plastic spaeers provided by Plskabeton Coffratee in TernatBelgium, the types DINK!, DUX OFFEN, and DRANFIX has been assessed withrespect 00:- the durability requirements in NEN 6722 VBU- tbe degradation of the spacers- the contribution of the spacers to the degradation of the concrete.
The plastic spacers fulfil tbc durability requirements that are given in NEN 6722. exeeptthat it is notaäowed 10 use plastic spacers in watertight concrete structures, In the'Programme of Requirements Green Hemt Bored Tunnel' the requirement with respectto watertightness is specified as a performance: a limitation to an average of 0.05lIm2/day and a local maximum of 0.10 lIm"Jday. It has been shown that tbc présence ofa plastic spaeer will not double tbe local leak water discharge. This means that theinflueace of tbe plastic spacers on the watertightness is negligible,
From the service life design of tbc segments it followed that the main threats for theconcrete are:
Corrosion of the reinforcement due to carbonation of the concrete, for thc concretethat is expoeed to the atmosphere.
- Cosrosion of tbc reinforcement due to the ingress of chloridesIt was found that these degradations are not negatively influenced by plastic spacers.
Polypropylene is in general good resistant to acids and alkalies. The last property meansthat the spacers will he good resistent to the alkaline environment in concrete. Theresistance of polypropylene against oxidizing acids is low, but these types. of aeids arenot present in the tunnel. Further is cao he stated that the spacers are embedded in theconcrete. The moderate westher resistance is therefore no real problem,
From a practical point of view itcan he stated that plastic spacers, used in sea waterstructures, show no special durability problems.
The plastic spacers have in principle durability characteristies that will guerantee adesign service life of at least 100 year,
Tbe plastic spacers to he used for the Green Hemt Tunnel have dimension that are notavailable within the delivery programme of the producer. Therefore special spaeers willhe produeed re he used for the Green Heart Tunnel. Giving tbc considerations in thisreport. there is no reasen why spacers with other dimensioas win have another service!ife.
