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11/10/2010 1
Steel and Synthetic Fibers in Tunnels and
Mines
Presented by Jeannine Jones, BASFNovember 5, 2009
Steel Fibers by
11/10/2010 2
Purpose of today’s meeting
To help engineers and designers design with fibers for shotcretingand final linings
To help you quantify the value, from an owners point of view, ofusing fibers instead of traditional reinforcement
11/10/2010 3
Agenda
Identification of the correct fiber for various applications
How to quantify material and labor savings of fibers vs. traditional reinforcement
Designing with fibers
Fibers in precast, final linings and cast-in-place liners
Fibers in conjunction with admixtures
Fibers which can reduce spalling in fires
Waterproofing membranes combined with fibers vs. waterproofing PVC and rebar
11/10/2010 44
Why Use Fibers?Generally…
In Short, Fibers Work!
Fibers Reduce Plastic Shrinkage Cracking
Fibers Reduce Plastic Settlement Cracking
Fibers Add Impact and Abrasion Resistance
Fibers Reduce Permeability
Fibers Provide Shatter Resistance
Fibers Impart Toughness & Residual Strength
Fibers are “Built in” Reinforcement!
11/10/2010 5
Which Fiber to Use?
11/10/2010 6
Identification of the correct fiber for various applications
Explosive spallingMicro Fibers – these fibers provide voids for steam to move into after they melt @ 320°F (160°C)
Spillways, temporary tunnel linings, anything non-structuralMacro fibers – macros can replace WWF and light gauge rebar, provide durability, are pumpable and perform post first crack reinforcement– Economical way of providing some reinforcement for the temporary tunnel linings where tunnels are designed as
only temporary structures
Shotcrete, final tunnel linings Steel fibers – provide primary, structural reinforcement, and some flexural, shear and tensile stress reinforcement, improve durability, toughness, ductility & are pumpable
Where not to useTunnel Linings– Macro fibers – may have creep issuesPVC Sheet Membranes– Steel Fibers – puncture membrane
Not Every Fiber is the Same
Steel Fibers by
11/10/2010 7
Identification of the correct polymericfiber for various applications
Micro Fiber – for explosive spallingMonofilament micro fiber typical features:
– High fiber count/yd³/m³ - at least 60MM/lb
– Length between 6 – 13mm
– Diameter < 32µ
Macro Fiber – for secondary, post first crack reinforcementMacro fiber typical features
– Length 1.5” to 2” typically
– Tensile Strength – min of 40ksi (275MPa)
– Modulus of Elasticity – min of 4,000ksi (2,750MPa)
– Average Residual Strength – 150psi @ 3 lb/yd³ (1.8kg/m³)
11/10/2010 8
Identification of the correct steel fiber for various applications
Aspect ratioAspect Ratio is the length over the diameter of the fiberAspect Ratio gives you an indication of the performance of the fiber. The higher the aspect ratio, the higher the performance with respect to impact resistance, abrasion resistance, toughness, ductility, crack resistance.Typically between 40 – 60
Volume concentrationThe higher the volume, the better the performance, although the shotcrete will become more difficult to mix, convey and shoot atthese higher dosages.
Steel fiber typical features:Length – 1.25 in. (30mm) to 2 in. (50mm)Deformed endsType I meeting ASTM A820 (NB – Type II fibers do not have the same performance qualities as type IDosages between 50 lb/y³ (30 kg/m³) and 135 lb/yd³ (80kg/m³) with most common dosage at 100dlb/ yd³ (60kg/m³)
11/10/2010 9
How Much Can Be Saved Using Fibers?
11/10/2010 10
Quantifying material and labor savings of fibers vs. traditional reinforcement
The steel typically pulled out of the tunnels and mines is #5 & #6 rebar, double layeredHard and Soft Dollar Savings
50% of a shift can be spent hanging mesh – this is time lost on excavationFinal Lining Savings – Can save 20-25% of steel cost– Can increase productivity by 30-50%Cast in Place Savings– Can increase productivity by 50% if you pull out all of the
rebar. If you leave some, then it’s ~ 30%Shotcrete Savings– Can increase productivity by 50%Safety issues – reduce tripping, material handling & falls
#5 Rebar
#6 Rebar
The faster you can excavate, faster contractor gets paid and can move on to next job
11/10/2010 11
Designing with Fibers
11/10/2010 12
Some background on steel fibers
Why use Steel Fiber Reinforced Concrete (SFRC)?Steel fibers will add crack resistance, ductility, energy absorption and impact resistance
Why are steel fibers a better choice than wire mesh or rebar?They can provide superior residual load carrying capacity at small deformations and equivalent performance at large deformationsYou can do away with installation costs of WWR and rebarReduce hazards for employeesIt can follow the exact contours of the rock face whereas WWR often requires 2 in. (50mm) of cover as well as filling of voids behind the mesh w/ shotcreteYou may see a drastic reduction (up to 40%) in shotcrete material with SFRC in blocky or fractured rock surfacesIf there are voids behind the WWF, then phenomenon like “ice-jacking” can occur more easilyProduction rates/advance rates should be faster with SFRC – up to 50% of labor time can be reduced
What may be the negatives to using SFRC?Slightly higher wear on concrete pumping equipment– More wear on equipment with rubber wearing pads – use tougher wearing pads and carefully control tolerance of
setting of wearing pads– May be greater rate of wear in hoses and nozzles– Avoid sharp bends in hoses
11/10/2010 13
Beginning the process
When specs are being created, you use the manufacturers information to determine which material to use
For example, if a segment needs to achieve 400 psi at 3mm deflection according to ASTM C1609, a fiber is selected which has the necessary properties and dosage rate.
There is a mandatory procedure in any precast job that you do a test using the mix design, aggregate and fibers which will be used to make sure that performance requirements are met.
A QC person will then perform testing for a pre-determined number of segments or distance to make sure everything is still in spec.
11/10/2010 14
Mechanical properties and test methodsSelect the appropriate test below to help you decide which design code to use
American Codes:ASTM C1609-07 Standard Test Method for Flexural Toughness and First-Crack Strength of Fiber-Reinforced Concrete (Using Beam With Third-Point Loading)
ASTM C1399-07 Test Method for Obtaining Average Residual-Strength of Fiber-Reinforced Concrete
European Codes:UNI 11039 Steel Fiber Reinforced ConcreteEFNARCEN-14488 Testing Sprayed Concrete: Flexural StrengthsRILEM
Japanese Code:JCI-SF-4 Method of Test for Flexural Strength and Flexural Toughness offiber reinforced concrete
11/10/2010 15
Relevant design codes, guidelines and reports in FRC worldwide:
Rilem TC162 “Test and design methods for steel fiber reinforced concrete” (England)
TR 63 Steel fiber reinforced concrete (England)
“DESIGN , PRODUCTION AND CONTROL OF STEEL FIBER REINFORCED STRUCTURAL ELEMENTS” Standard UNI U73041440 (Italy)
CNR_DT204_2006 – Guidelines for design and construction of Fiber reinforced concrete structures (Italy)
ACI 318-08, Chapter 11. Shear Reinforcement (USA)
ACI 544-3R-08 Guide for Specifying, Proportioning and Production of Fiber-Reinforced Concrete
FRC design guidelines worldwideWhich design code should be used?
11/10/2010 16
•Material testing definition for FRC (compression stress, first crack moment, tensile strength, toughness index , residual strength)
•Constitutive bilinear law definition through flexural residual strength testing. NLFM (non linear fracture mechanics)
Basic guidelines to develop a design with 100% SFRC or a hybrid solution(SFRC + rebar reinforcement)
11/10/2010 17
SFRC Material Constitutive Laws σ-w
From the experimental flexural test ASTM C1609/UNI 11039
σ n
CTODm
Ec
σ
ε
fct
Pre-peak, σ-ε Post-peak, σ-w
σ
w1 wc
w
fct
s1
+
The numerical inverse analyses were provided by using NLFE software
From experimental tests
Inverse analyses
11/10/2010 18
Numerical and experimental
R60 - FF1 - 35 kg/m3 - Vf=0,45%
0
1
2
3
4
5
6
0.0 0.1 0.2 0.3 0.4 0.5CTODm [mm]
Nom
inal
Str
ess
sN [M
Pa]
Experimental
Numerical
R60 - FF1 - 45 kg/m3 - Vf=0,57%
0
1
2
3
4
5
6
7
8
9
0.0 0.1 0.2 0.3 0.4 0.5
CTODm [mm]
Nom
inal
Str
ess
sN [M
Pa]
Experimental
Numerical
R60 - FF3 - 25 kg/m3- Vf=0,32%-6
-5
-4
-3
-2
-1
00.0 0.1 0.2 0.3 0.4 0.5
CTODm [mm]
Nom
inal
Str
ess
sN [M
Pa]
ExperimentalNumerical
R60 - FF3 - 35 kg/m3- Vf=0,45%
0
1
2
3
4
5
6
0.0 0.1 0.2 0.3 0.4 0.5
CTODm [mm]
Nom
inal
Str
ess
sN [M
Pa]
Experimental
Numerical
11/10/2010 19
0
1
2
3
4
5
0 1 2 3 4 5 6
Crack opening [mm]
Nom
inal
str
ess
[MPa
]
Vf = 0,00%Vf = 0,45%Vf = 0,57%
0
1
2
3
4
5
0 1 2 3 4 5
Crack opening [mm]
Nom
inal
str
ess
[MPa
]
Vf = 0,00%Vf = 0,32%Vf = 0,45%
MasterFiber™ FF1 MasterFiber™ FF3
Constitutive Laws σ-w
11/10/2010 20
Flexural test performace
FF1
FF3
FS1
FS3N
FS4N
FS7
11/10/2010 21
Precast Segment Lining Design Examples
11/10/2010 22
Precast TunnelTunnel Lining Cross-Section
11/10/2010 23
Tunnel ground condition evaluation ofbending moment and axial force diagram
11/10/2010 24
Precast tunnel segment geometries
11/10/2010 25
One Ring:7 + 1 segments
Wood Blocks
Storage load condition
11/10/2010 26
Load condition – TBM load action
Escavationdirection
Hydraulicjacks
Shield
Boring head
Segment’s ring
11/10/2010 27
Rebar only
Reinforcement comparison
SFRC + Rebar
We suggest a combined reinforcement made of 35 kg/m3 of MasterFiber FF3 and steel rebar as shown in the following picture
350 350
350
11/10/2010 28
Tunnel segmentsDisplacement under service load
11/10/2010 29
Tunnel segmentsLongitudinal stress under service load
11/10/2010 30
Tunnel Segments: Non Linear Analyses, Comparison
0
5000
10000
15000
20000
25000
30000
0 1 2 3 4 5 6Displacement [mm]
Load
[kN
]
45FF1 Plain
RC RC35FF1
RCO35FF1
Quite the same loadcapacity
Optimized reinforcement
11/10/2010 31
Segment coming out of mold with suction process
11/10/2010 32
11/10/2010 33
Segment being placed on a carousel system
11/10/2010 34
Crane picking up three segments
11/10/2010 35
Segments in storage
11/10/2010 36
Line 9 Subway Barcelona, Spain
•Tunnel diameter: 12 m•6 segments + 1 key•Concrete 50 MPa•Hybrid design :
•Rebar 30 kg/m3 + SFRC 30 kg/m3
•MasterFiber FF3 Steel Fiber
Steel Fibers by
Case history- precast segments
11/10/2010 37
Madrid Subway, Spain
•Tunnel diameter: 10 m•6 segments + 1 key•Concrete 50 MPa•Hybrid design :
•Rebar 60 kg/m3 + SFRC 25 kg/m3
•MasterFiber FF3 Steel Fiber
Steel Fibers by
Case history- precast segments
11/10/2010 38
Genoa Subway, Italy
•Tunnel diameter: 6.2 m•6 segments + 1 key•Concrete 40 MPa•Hybrid design :•Rebar 60 kg/m3 + SFRC 25 kg/m3
•MasterFiber FF3 Steel Fiber
Steel Fibers by
Case history- precast segments
11/10/2010 39
Orakei Main Sewer HobsonDivision in New Zealand
•Tunnel diameter: 3.7 m•6 segments + 1 key•Concrete 50 MPa•100% SFRC Design :•40 kg/m3
•MasterFiber FF3 Steel Fiber
Steel Fibers by
Case history- precast segments
11/10/2010 40
Bright Water Sewer System Seattle Tacoma, WA USA
•Tunnel diameter: 3.7 m to 5 m•5 segments + 1 key•Concrete 50 MPa•100% SFRC Design :•40 kg/m3
•MasterFiber FF3 Steel Fiber
Steel Fibers by
Case history- precast segments
11/10/2010 41
SFRC precast segment lining Design Guideline
250-400 (10-16)35-50 (60-85)250-400 (10-16)20-30 (34-50)MasterFiber FF3
250-400 (10-16)40-60 (67-100)250-400 (10-16)25-35 (44-60)MasterFiber FF1
Thickness mm (in.)
Dosage kg/m3
(lb/yd3)Thickness mm (in.)
Dosage kg/m3
(lb/yd3)
SFRCMix RR + SFRC
Fiber Type
Usual dosage and thickness by application
Tunnel Final Lining
11/10/2010 42
Shotcrete Lining Design Examples
11/10/2010 43
Materials:Fiber reinforced concrete:•Compression: 35 MPa•Tension resistance at peak load= 4 MPa•Tension in 0.6 mm of crack opening =3.5 MPa•Tension in 1.5 mm of crack opening= 2 MPa
Rock around the tunnel:Elastic Modulus: 2000 MPaUnit Weight= 2.2 Ton/m3
Load Case:Internal radial pressure from inside to the rock:200 kPa300 kPa500 kPaThe drawing units are in meters.
Shotcrete lining tunnel example
11/10/2010 44
Cracking shotcrete tunnel lining
The load is increased from 100 – 500 kPa
11/10/2010 45
The load is increased from 100 – 500 kPa
Cracking process in detail
Cracking shotcrete tunnel lining
11/10/2010 46
Shotcrete Round Panel test ASTM C1550
Loading piston Specimen
LVDT yoke anchored at transfer plates
LVDT
The required dimensions of the panel are 75 mm (3 in.) inthickness and 800 mm (31.5 in.) in diameter
ASTM C 1550-02:Standard Test Method forFlexural Toughness of FRC andShotcrete (Using Centrally LoadedRound Determinate Panel)
0 10 20 30 40 50
Displacement (mm)
0
10
20
30
40
Load
(kN
)
Integrate the area under the curvebetween the (corrected) origin andthe specified total deflection
11/10/2010 47
Shotcrete Guideline - based on energy absorption test for excavation rock stability
ReferenceTR-63
11/10/2010 48
•Shotcrete Final Lining PINALITO (Dominican Republic)
•Hydroelectric System
•Dosage rate: 40 kg/m3 (67 lb/yd3) MasterFiber FS3N
Steel Fibers by
Case history- shotcrete final lining
11/10/2010 49
SFRC shotcrete lining Energy absorption guideline
35 (60)30 (50)25 (44)MasterFiber FS7
35 (75)40 (67)35 (60)MasterFiber FS3N
Dosage kg/m3
(lb/yd3)Dosage kg/m3
(lb/yd3)Dosage kg/m3
(lb/yd3)
ASTM C1550 = 450 J
ASTM C1550 = 350 J
ASTM C1550 = 225 J
Fiber Type
Usual dosage and typical lining thickness by Energy Absorption Test
Tunneling Shotcrete
11/10/2010 50
Final Lining Designs Examples
11/10/2010 51
SFRC cast in place final lining Design guideline
Replacing double layer rebar #5
ARC 100% SFRC
67 lb/yd3 SFRC
11/10/2010 52
SFRC cast in place final lining Design guideline
Reducing rebar size from #8 to #7
ARC 100% SFRC
50 lb/yd3 SFRC
11/10/2010 53
SFRC cast in place final lining Design guideline
Tunnel Final Lining
250-400
(10-16)
35-50
(60-85)
250-400
(10-16)
20-30
(34-50)
MasterFiber FF3
250-400
(10-16)
40-60
(67-100)
250-400
(10-16)
25-35
(44-60)
MasterFiber FF1
Thickness mm (in.)
Dosage kg/m3
(lb/yd3)Thickness mm (in.)
Dosage kg/m3
(lb/yd3)
SFRCMix RR + SFRCFiber Type
Usual dosage and thickness by application
11/10/2010 54
•SFRC Final Lining. Highway A3 Salerno –RegioCalabria Italy
•Dosage rate:35 kg/m3 (60 lb/yd3)
•MasterFiber FF1
Steel Fibers by
Case history- final lining
11/10/2010 55
•SFRC Final Lining
•Highway SS203 AgordinaCencenighe BL Italy
•Dosage rate: 35 kg/m3 (60 lb/yd3)
•MasterFiber FF1
Steel Fibers by
Case history- final lining
11/10/2010 56
•SFRC Final Lining
•Highway SS203 AgordinaCencenighe BL Italy
•Dosage rate:30 kg/m3 (50 lb/yd3)
•MasterFiber FF1
Steel Fibers by
Case history- final lining
11/10/2010 57
Using Macro Polymeric Fibers
11/10/2010 58
Macro polymeric fibers
Uses and Applications:
Synthetic fibers used more in mines than in tunnels
Predominately wet shotcrete, very rarely in dry shotcrete
Used more in initial support shotcrete
Typical Dosages:
Mining – 8-12 lb/yd3, some as much as 14 lb/yd3
Shotcrete initial support – 8-12 lb/yd3
Limits – 18 lb/yd3 difficult for matrix to support anymore due to high volume
Approximate equivalents – 12 lb/yd3 can perform similar to 60 lb/yd3 of steel
Tests:
1550 panel test – synthetics will typically outperform steel
1609 beam test – steel typically outperforms synthetics
11/10/2010 59
Examples of polymeric fibers in temporary tunnels
Devil’s Slide - Highway Tunnel
Engineers Est.: $240,000,000
Shotcrete for Initial Support
48mm Macro Polymeric Fiber
11/10/2010 60
Fibers and Admixtures
11/10/2010 61
Fibers in conjunction with admixtures
Shotcrete – Dry-MixNo changes to mix design, but be aware that if you cut back too much on cementitious content, there may be more total rebound and specifically, fiber rebound.Synthetic fibers in a dry mix are more difficult to deal with due to high level of rebound. It is not recommended to use micro fibers as they can very easily get blown out of the mixSteel fibers provide the most consistent quality in a dry mix
Shotcrete – Wet-MixUse water reducers @ ~8oz/cwt (.5l/100kg) and superplasticizers for silica fume concrete @ ~16-24oz/cwt (1-1.5l/100kg)Wet mixes are more conducive to any fiber’s use
NotesDosages of high/mid range will increase with higher fiber dosages Slump may decrease at higher fiber dosages by 1-2 in.Although slump may decrease workability will not – avoid temptation to re-temper mix which can result in segregation and balling of the fibers and a final product which has lost hardness quality. Just put some energy on the mix and it will move.
11/10/2010 62
Concrete Fire Spalling
Source: Applications of Micro-Synthetic Fibers for Resistance to Explosive Spalling in Fires. Trevor Atkinson & Peter C. Tatnall
11/10/2010 63
Types of concrete fire spalling
Surface spalling
If temperature rise is relatively slow, concrete moisture migrates from the heat exposed side and thus pressure build up is minimal, resulting in less spalling
Corner break-off spalling
Also called “sloughing off”
Occurs at corners and edges during later stages in the fire whenconcrete has cracked and weakened
Explosive Spalling is our Focus for Today’s Presentation
Explosive spalling
Occurs with rapid heat rise within the first 10-20 minutes (usually hydrocarbon based) and is by far the most dangerous and damaging form of spalling.
Moisture in the concrete is heated faster than it can move away from the heat, moisture changes to vapor and the vapor increases pore pressure.
Once the pressure exceeds the tensile capacity of the concrete, concrete is violently and explosively dislodged from the concrete exposing more concrete to the fire
11/10/2010 64
How do polypropylene fibers help reduce spalling?
The most common theory is that because the high fiber count fibers melt at 320 °F (160 °C) this allows the steam from the moisture in the concrete an escape void rather than allowing pressure to build causing explosions.
In addition to this, another more comprehensive theory is that because the polypropylene, when heated, expands 8.5x more than the concrete, they turn crystalline and cause micro cracking in the matrix. The micro cracks join and provide channels for the release of steam.
Typical specs
Fibers with diameters less than 32µ
Lengths between 6mm – 13mm
11/10/2010 65
Selecting the right polypropylene fiber
Typical specsFibers with diameters less than 32µ
Lengths between 6mm – 13mm
At least 60MM fibers/lb
Recommended dosages 1.7 lb/yd³ (1 kg/m³) – 3.4 lb/yd³ (2 kg/m³)
Some Things To AvoidShorter (6mm), smaller diameter (18µ) fibers may tend to ball and may greatly increase air content (6-8%)
Macro polypropylene and steel fibers have shown no resistance tospalling (due mostly to their lower fiber count/yd³/m³ vs. the PP fibers)
11/10/2010 66
Time-temperature curve test methods
Most Severe – Hydrocarbon Fuelled FireRWS (Rijkswaterstaat) Curve – furnace temperatures rise rates increase at a rate of 400 °F (200 °C) per minute to 2000 °F (1100 °C) in 5 minutes, with final temperature reaching 2460 °F (1350 °C) and then held there for 2 hours
Another Hydrocarbon Fuelled Fire MethodEurocode I Hydrocarbon – final temperature ~1100 °C and held for 160 minutes
Test for Slower Temperature Rise FiresISO 834 Cellulose – final temperature ~1100 °C and held for 160 minutes but slope of rise more gradual
BASF Will Design It’s M100 UL Test After the RWS Method
11/10/2010 67
Tunnels using polypropylene fibers to mitigate explosive spalling
Channel Tunnel Rail Link – UK
Dublin Port Tunnel – Ireland
Gotthard Base Tunnel – Switzerland
T5 Heathrow Express Tunnel – UK
Weehawken Tunnel – USA
Paramatta/Chatswood Tunnel – Australia
Vomp-Terfens Tunnel - Austria
Polypropylene Fibers Cost ~1% of Constructed Concrete Lining
11/10/2010 68
An example of cost from tunnel fire
Mont Blanc Tunnel Fire in 199939 people died
7.4 miles of tunnel between France and Italy were closed for 3 years
Repair costs totaled $273MM (USD)
Italian government lost >$2B in trade
Addition of correct PP fiber is an inexpensive means of protecting lives, reducing catastrophic collapse, repair costs
and commercial disruption
11/10/2010 69
Waterproofing
11/10/2010 70
Waterproofing membranes combined with fibers vs. waterproofing PVC and rebar
The most common types of membranes are PVC membrane with heat welded seamsThe most common problems with them are that they are:
Difficult to shotcrete unless there’s strong reinforcement against the PVCProne to leaks behind the PVCVulnerable to “chasing leaks”It is often not recommended to shotcrete steel fibers onto them because of risk of punctures
Solution – Masterseal® 345It’s a fully bonded system – if there’s a leak visible, that’s where the leak isThe main property of the membrane is that it bonds to both the substrate and the concrete which is applied to it creating an impermeable interface – this is what keeps the leak from migrating.No special equipment is needed to apply Masterseal 345 – just use a standard dry gunnite machineThickness of membrane should be a minimum of 2mm and optimum of 3mm. Do not exceed 5mm in thickness since this can cause slow curing.Substrate preparation – It’s essential to have a smooth substrate with limited roughness in order to achieve a continuous membrane. Use a sprayed concrete w/ maximum grain size of 4mmCuring starts immediately after application and once started, it’s irreversible.
Possible Difficulties – Seepages penetrating through membrane in areas where continuous membrane was not achieved. If these occur, they’ll happen within the first day after application. To remediate, inject locally where water seepage is visible.
11/10/2010 71
MASTERSEAL® 345
FeaturesDry-process material, ready-for-useElasticity 80-140% b/w -4 & 68 ºF (-20 & 20 ºC)Fast curingNo toxic componentsEnvironmentally friendly
BenefitsEasily applied by spraying with uncomplicated equipmentTwo-sided bond with sprayed-concrete allows for monolithic behavior
Chemistry - Vinylacetate-ethylene copolymer and Cement
FAQsWhat thickness is required for the overspraying of concrete?– Minimum 50 mm concrete thickness with fibers. Smaller thicknesses require special efforts to avoid shrinkage
cracks.How are leaking spots repaired? – Puncture repair injection (acrylic) and application with trowelWhat can happen if you spray with too much / too little water?– Too much water (>50 % water): sagging of the freshly sprayed membrane on the wall, longer curing time, risk of
cracking of membrane by very high ventilation with dry air.– Too little water (<25 %): brittle and discontinous (no membrane!). Excessive dust during application.What capacity during application is realistic to calculate?– 70 – 120 m m2/ hour, depending on experience of crew and layout of working sequence.
11/10/2010 72
MASTERSEAL 345 – BMI test resultsPRACTICAL EFFECTIVENESS OF CEMENT-BONDED SEALING LAYERS FOR SINGLE-SHELL TUNNEL CONSTRUCTION PROJECTS
External tests results and certifications
•EMPA Switzerland: long term pressure test•Mott Mc Donald: Technical report with summary of actual test results•BMI (Innsbruck): Practical feasibility test
11/10/2010 73
Example of Masterseal 345 with fibersWATERPROOFING OF A SUBSEA TUNNEL WITH A UNIQUE SPRAYABLE MEMBRANE - THE NORDÖY ROAD TUNNEL, FAROE ISLANDS
About the tunnel - The Nordöy road tunnel passes below the fiord between the two islands of Eysturöy and Bordöy in the Faroe Islands. The total length of the tunnel is 6,155 m with a cross section of 64 m²(two lanes). The maximum depth under the sea is 150 m with a minimum rock cover of approximately 40 m. The rock types in the area are extrusive basalts.Goal - Waterproofing of the tunnel contour to avoid the dripping of water onto the actual road surface.Cost - The total cost of the waterproofing of the tunnel made up approximately 10% of the total project cost.Trend - In the last few years there has been a trend to avoid flammablematerials in underground construction. The flammable PE foam sheets were therefore not in accordance with a modern design philosophy with non-flammable materials. The goal was to reduce the amount of the PEfoam waterproofing by more than 50%.Solution - A sprayable waterproofing membrane in a composite liner based on sprayed concrete. Steel fiber reinforced concrete applied after membrane had achieved sufficient curing (10-14 days)Advantages - possibility to locally waterproof smaller areas without the need to bring the waterproofing all the way down to the invert, no inflammable materials, reduced total lining thickness and significant financial benefits to owner and contractor over a technical solution with PVC sheet membrane and cast-in-place concrete lining.
11/10/2010 74
Thank you for your time!For follow up questions, please call Jeannine Jones at 216-839-7227 or Ashish Goel at 216-839-7055 or find your BASF Sales Representative by Area below:
Haydn Whittam - coal mining only (US and Canada), 606-331-1212
Wes Morrison - Eastern/Central Division, 571-344-3286
Lauro Lacerda - Western Division, 801-726-6488
Mark Mudlin - Mountain Area (primarily Nevada), 775-397-0188
Keith McDonald - Western Canada, 306-222-2270
Floyd Wudrick - Western Canada, 306-221-7919
Brad Knight - Eastern Canada, 705-499-8448
Bill Brosko - Eastern Canada, 705-507-1130
Visit us on the web at www.masterbuilders.com