Final Lining FRC Applications Some Examplesfib CEB-FIP Model Code 2010 (fib Bulletins 65-66). Two...

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 [email protected]

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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


Client: Dai-Ni-Tomei

Contractor: Taisei

Country: Japan


Fiber type: 3D 65/60BG



Case Study: Shimizu n°3 – Twin Tunnel

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Date: 2006

Project name: Craviale & Turina

Craviale (1,055 m)

Turina (664 m)


Client: Agenzia Torino

Country: Italy





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)


Dosage rate: 30 – 35 kg/mc


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

0

1

2

3

4

5

0,0 0,5 1,0 1,5 2,0 2,5 3,0CTODm [mm]

Nom

inal

Str

ess

sN [M

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)


Client: ANAS

Country: Italy

Contractor: SIS Scarl


Dosage rate: 40 kg/mc

SFRC for crown only


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


SFRC for crown only



Design support: Maccaferri Tech. Office

Dominus 1.0 (UNIBS)

Case Study: Variante di Moline S.R. 50

Dominus 1.0 – University ofBrescia

-300

-200

-100

0

100

200

300

-500 0 500 1000 1500 2000

Normal Force [kN]

Be

nd

ing

Mo

me

nt

[kN

m]

Concrete + fibres computed forces - Piedritto Dx

-300

-200

-100

0

100

200

300

-500 0 500 1000 1500 2000

Normal Force [kN]

Be

nd

ing

Mo

me

nt

[kN

m]

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




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




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




Res. Flex. Strengths: fR1m & fR3m > 5 MPa

Max diameter: 11 meters (internal)

Thicknesses (*): convergence ≥ 250 mm

(400 crown, 600 walls))

Designer: TTS Engineering



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




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)


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



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


Thickness: 5200 mm

Depth: 106 meters

Client: Borealis Polymers OY

Country: Finland

Contractor: Lemminkäinen OY




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


Dosage rate: 37 kg/mc (final solution)


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 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

[email protected]

Final Lining FRC Applications Some Examplesfib CEB-FIP Model Code 2010 (fib Bulletins 65-66). Two...

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Transcript of Final Lining FRC Applications Some Examplesfib CEB-FIP Model Code 2010 (fib Bulletins 65-66). Two...