47 PPT Fibres Boost Performance HKG May 2013 (1)

Fibres boost performance and productivity in segmental linings

Innovative Engineered Solutions for Safe and Cost-efficient Underground Excavation

Hong Kong, 23rd May 2013

Dr.-Ing. Ralf WinterbergTechnical Director – Fibre Division

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1. Introduction to FRC

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Innovative Engineered Solutions, Hong Kong, 23 May 2013

Concrete – strong but weak

Plastic shrinkage

Bending Shear / splitting

Explosive spalling

Performance improvements

by fibres

• Micro-synthetic fibres:Material

enhancement

• Steel fibres:Structural

enhancement

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Steel fibre reinforced concrete (SFRC)

• Toughness and post-cracking behaviour.– After first cracking of concrete, steel fibres sew the cracks and give an

extra strength. This deformation capacity provides ductility (toughness).– The addition of fibres substantially improves the concrete characteristics

transforming its behaviour from elastic-fragile to elastic-plastic (ductile), making it suitable for structural applications.

[Guàrdia, J., 2008]Copyright (c

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Wirand® steel fibre range

Wirand® steel fibre FF1 FF2HS FF3 FF3 HS

50 50

0.75

1500

67

5700

0.90

1450

56

4000

Length [mm] 50 50

Diameter [mm] 1.00 0.75

Tensile strength [MPa] 1130 1230

Aspect ratio L/D 50 67

Units/kg (approx.) 3200 5700

Flooring & precast fibres

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Wirand® steel fibre range

Wirand® steel fibre FS9 FS3N FS4N FS7

Length [mm] 37 33 33 33

Diameter [mm] 0.75 0.75 0.60 0.55

Tensile strength [MPa] 1230 1230 1250 1300

Aspect ratio L/D 49 44 55 60

Units/kg (approx.) 7700 8700 13,600 16,200

Shotcrete fibres

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CE mark for Wirand steel fibres

EC declaration of conformity for Wirand products, first issued 28th of May, 2008

TYPE09

EN 14889-1 BOXFIBRE WIRAND FF3

750NET weight kg:Steel fibres for structural use in concrete, mortar and grout Production Date:

1372 PLANT OM200901WIRANDOfficine Maccaferri SpA

Length: 50

1372-CPD-1050 FIBRE WIRAND FF3

Via Kennedy, 10 STEEL FIBRES40069 Zola Predosa (BO) ITA

1100 N/mm2

Group I Reel:

kg/m3

O.F.:

mmDiameter: 0,75 mmShape: Hook EndedTensile strength:

to obtain 1,5 N/mm2 at CMOD=0,50 mm www.maccaferri.com

Consistence with: 20 kg/m3 fibres:Vebe time: 7 sEffect on strength of concrete: 20 OFFICINE MACCAFERRI GROUP

and 1 N/mm2 at CMOD=3,50 mm

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Toughness – ductile performance

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Problems of conventionally reinforced segments

Spalling or bursting of concrete cover at vulnerable edges and corners

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Comparison of SFRC to conventionally reinforced concrete

Concrete Property Performance of SFRC vs. conventional concrete

Compressive Strength No Change

No Change

Increased

No Change

Reduced

Reduced

Reduced

Increased

Slightly Increased

Slightly Reduced

Increased

Greatly Increased

Strength to First Crack

Tensile Splitting Strength

Plastic Shrinkage Cracking

Early Age Thermal Cracking

Long Term Shrinkage Cracking

Stray Current Corrosion

Durability in Chloride Exposure

Fire Spalling Resistance

Concrete Permeability

Abrasion Resistance

Impact Strength

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3) High resistance against impacts during handling and placing of the segments

2) Reduction of crack widths

4) Reduced risk of unexpected collapse or failure of the lining

1) SFRC is a ductile and robust material

5) Improved precast production efficiency by partial or total elimination of ordinary steel reinforcement

Advantages of SFRC in precast tunnel segments

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2. Passive fire resistance

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Melting reinforcement

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Micro-polypropylene fibres

• Material : Virgin polypropylene• Geometry : Circular, monofilament• Manufacture : Spun and drawn

•• DiameterDiameter :: 18 18 µµmm• Length : 6 mm•• Units/kgUnits/kg :: 720720MM•• Specific surfaceSpecific surface :: 245 m245 m²²/kg/kg

• Tensile strength : 400 MPa• E-Modulus : 3700 MPa

Fibromac FRFR

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CE mark for Fibromac PP fibres

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PP fibre specifications

Fibre type Fibres/kg

Specialized monofilament fibre (18 micron) 720 Million

Other monofilament fibre (≥ 32 micron) 110 Million

Fibrillated fibre 18 Million

Macro synthetic fibre 32 Thousand

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PP fibre degradation

• 160 °C melting temperature• 360 °C conversion back to constituent

material creation of voids

• Remains of the fibre is soot, occupying ca. 5% of the void• Gases given off are burnt away by the fire or will dissipate into

the atmosphere• Toxic gas given off by the fibre is so small that it meets UK

Health and Safety Regulations

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Creating permeability

Microscopic view of a void, created by a degraded fibre, channelling a poreCopyright (c

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Choice of PP fibres

Primary requirement to reduce explosive spalling:

Fineness of the fibreshigh number of individual fibres per unit weightlarge specific surface area per unit weightdiameter of PP fibre ≤ 18micron

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Test results

Plain concrete 2 kg/m³ PP fibre RC

Surfaces immediately after firing

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Test results


Surfaces after cooling

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Test results


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3. Design of SFRC

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SFRC standards and codes

• Structural design standards and guidelines:

– RILEM TC 162-TDF Test and design methods for SFRC, 2003

– Italian code “Guidelines for the design, construction and production control of FRC structures”, CNR DT-204/2006

– Spanish code (EHE), annex 14

– German Guideline “Stahlfaserbeton”, March 2010

– fib Model Code 2010, March 2012

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Testing of SFRC

25mm depth of notch

125 ± 1mm

250250

3

width: 150 mm

F

40

δ

CMOD gage (optional)

both sides

• increase of mid-span deflection 0.05 / 0.2mm/min• deflection in minimum up to 3.0 mm

Bending test according to EN 14651:20053-point loading test with notch (crack inducer)

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Residual flexural strengthEN 14651:2005 - „Test method for metallic fibered concrete“

Residual loads Fi, referring to a defineddeformation/crack width

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Idealized stress–strain diagram (RILEM 2003)

Compression(Eurocode 2)

Tension

σ2d = 0.45 · fR1 · κh · αfc/ γct

σ3d = 0.37 · fR4 · κh · αfc/ γct

κh = size factor

αfc = 0.85 (long term load factor)γct = partial safety factor

25

0.1σ2σ3

σ1 (tensile strength)

εfc [‰] − εfc [‰]

2.0 3.5

− σfc [N/mm²]

σfc [N/mm²]Copyright (c

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Model Code 2010: Constitutive laws

Rigid-plastic model Linear model

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σ

ε

Tension

Compression

• Ultimate Limit States(Bending and normal forces)– Plane strain distribution– Elastic-plastic tensile behaviour– Parabolic branch in compression

Structural design

Bending - Axial Force Diagram

-1000

-750

-500

-250

0

250

500

750

1000

-12000 -10000 -8000 -6000 -4000 -2000 0 2000

Nu (kN)

Mu (

kNm

)

Plain concrete SFRC Reinforced concreteCopyright (c

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Design study: load-bearing capacity (ULS)ULS

Bending - Axial Force Diagram

-600

-400

-200

0

200

400

600

-16000 -14000 -12000 -10000 -8000 -6000 -4000 -2000 0 2000 4000

Nu (kN)

Mu

(kNm

)

Plain concrete SFRC Rebar + SFRC 001002 002a 003 004005 006 007N 007S008N 008S 009N 009S010N 010S

Check of the factored design section forces with hoop thrust-bending moment envelopes

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4. Durability of SFRC

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Steel fiber related crack formations

• Splittings of cracks

• Crack offsets

• Radiating or branching of cracks, or fine side cracks resp.

[Winterberg, 1998, 2003]Splitting Offset Radiating

Concrete surface

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Internal bending crack configuration of RC beams

Ordinary RC Hybrid

wcr = 0.11 mm

5 no. of cracks

wcr = 0.20 mm

3 no. of cracks

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5. Fibre batching systems and quality control

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Circular dosing machine with weighing vibrating channel (Metro Line 9 Barcelona)

DOSO customized installation

Fully integrated and automated dosing systemsCopyrig

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Adding and intermixing the steel fibres with the aggregates

Transcity project, Northern Link, Brisbane – Tunnel segmentsCopyright (c

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Fibre dispersion in the precast segments

Sophisticated fibre dosing system

+ fine tuning of mix design

+ adjustment of slump

(all in balance with vibrating energy and duration)

Perfect fibre dispersion and alignment…

ADDITIVESADMIXTURES

FIBERS

SAND

GRAVEL

WATER

CEMENT

CONCRETE

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Fibre distribution in tunnel segments

Victorian desalination plant project - segments for outfall tunnel

No steel fibresvisible on the mould face (intrados of tunnel)

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Fibre distribution and orientation in the tunnel segments

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6. Case histories with SFRC

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Hobson Bay Sewer and Stormwater TunnelAuckland, New Zealand

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Former sewer viaduct crossing the Hobson Bay

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Hobson Bay tunnel liningFirst EPB TBM excavated tunnel in New Zealand

Geometry of the tunnel and the segments• Tunnel length: 3.0km• Internal diameter: 3.70m• Wall thickness: 250mm • Ring setup: 4 + 2• Segment slenderness: 8.3• Ring width: 1.20m• Erector points: 1 (central, also serves for grouting)

• Conventional reinforcement: 184kg/m3 (tender design)• Alternatively chosen SFRC solution: 40kg/m³ Wirand FF3Copyrig

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Production highlights

Quality assessment:• 15,000 segments

produced

• 7 segments rejected as defective (< 0.05%)

• 6 damaged during installation (0.04%)

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Production highlights

Cost assessment:• 50% time saving

on segment production

• 10% cost saving on total project cost (NZ$118.6 million)

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Why using fibre reinforcement for linings?

• Less steel lower carbon footprint• Less production time higher productivity• Lower production costs, less labour (and human errors)• Ease of accuracy of reinforcement placement• Higher robustness due to fibre reinforced cover concrete• Higher crack resistance, better crack control• Better durability

Modern FRC technology for permanent linings has now been adopted for the first time in a metro tunnel in Asia:Singapore Downtown Line 3, Package A, Contract C933Singapore Downtown Line 3, Package A, Contract C933

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Downtown Line 3, Contract C933Singapore MRT

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Singapore Downtown Line – current and planned system

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Downtown Line 3 – planned system

CB

A

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PACKAGE A

Package A InformationTotal Length - 5 kmStations - 5 CD Station - 1 (Kallang Bahru)Copyrig

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Downtown Line 3 – Project C933

Construction and Completion of Jalan Besar Station and Associated Tunnels for Downtown Line Stage 3 (2.35km TBM driven twin tunnels)

• Client: Land Transport Authority

• Designer: ARUP

• Checker: Meinhardt / Mott McDonald

• Contractor: Penta Ocean Construction Co Ltd

• Precaster: Contech Precast Pte Ltd

• Moulds & carrousel line: CBE

• Fibres & dosing equipment: Maccaferri

Segments made in Singapore!

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Ground conditions

• The tunnels are located predominately in Old Alluvium, some stretches are in Kallang formation.

• The alignment is under roads; except for short stretches under buildings

• The 2.35km long twin bore tunnels will be driven by earth pressure balance TBMs through mostly stacked and some parallel formation near the stations

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Singapore DTL3 project - Ring configuration• 5.80m I.D., 275mm thickness• 1.40m long, +/-20mm taper• Key stagger by 72°• C50/60 concrete• 40kg/m3 Wirand FF3

1kg/m3 Fibromac FR• Ring setup: 7 + 1

(5 ordinary segments, 2 counterkeys and 1 keystone)

• Increased no. of segments to minimize potential damage during handling and installation

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DTL3 C933 – Trial rings at Jurong precast plant

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Working of the installed equipment

Singapore DTL-3 C933 project - segments for MRT tunnel

Intermix aggregates and fibres

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Steel fibre distribution and orientation

Cut 150mm off segment joint face3D distribution of fibres

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Fibre distribution and orientation in the tunnel segments

Singapore DTL-3 C933 project - segments for MRT tunnel

Cut 200mm off segment centrefibres are aligned

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C933 – Transportation to the site

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C933 – Project site at Kallang Bahru

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C933 – TBM launch shaft

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C933 – TBM awaiting deployment

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C933 – View into tunnel

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C933 – Segment installation

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C933 – View toward launch shaft

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Klang Valley MRT, Kuala Lumpur

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Klang Valley MRT, Kuala Lumpur• Kuala Lumpur MRT will comprise three new lines with some 54km of TBM

tunnelling worth some US$4.5bn.• The MMC-Gamuda JV has won the 9.5km long tunnelling contract for the

My Rapid Transit (MRT) line between Sungai Buloh and Kajang in Kuala Lumpur with its bid of US$2.6bn. MMC-Gamuda is also the project delivery partner (PDP) to run the construction of the 54km line, which is the country’s largest infrastructure project.

• KVMRT’s first line, the Sungai Buloh – Kajang Line (SBK Line), comprising 31 stations (24 elevated and seven underground), has just started to produce the precast tunnel segments.

• The first line from Sungai Buloh to Kajang, passing through the centre of Kuala Lumpur, has a total length of 17.4km of tunnels, 7 underground stations, 40km of elevated line, and 28 elevated stations.

• The second line will have 17km of tunnels, 7 underground stations, 37km elevated and 23 elevated stations.

• The third line will have 18.4km of tunnels, 4 underground stations, 23.8km elevated and 15 elevated stations. There will also be 4 new depots.Copyrig

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KVMRT project – Geological map

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KVMRT project – Ring configuration

• 5.80m I.D.• 275mm thickness• 1.40m ring length• C50/60 concrete• 40kg/m3 Wirand FF3 HS

1.8kg/m3 Fibromac FR• Ring setup: 7 + 1

(5 ordinary segments, 2 counterkeys and 1 keystone)

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Conclusions

• Steel fibres improve the main engineering properties of concrete (flexural, shear, fatigue and impact strength)

• Steel fibres substantially improve the cracking behaviour and the durability of concrete

• Steel fibres significantly improve the overall resistance and performance of concrete

• Specialized dosage systems enable problem-free addition and dispersion of fibres

• Steel fibres can replace ordinary reinforcement, leading to significant cost savings on materials and the production time

SFRC is an ideal construction material for tunnel liningsCopyright (c

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References up to date – SFRC segmental lining

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Power Grid Cable TunnelSingapore

Temporary shotcrete works:TBM launch shaft and launch chamber

Product: Wirand FS4N

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Site overview with spraying trial scaffolding

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Spraying trials at different angles

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Spraying punching test panels (EN 14488)

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We strive to be your partner in developingWe strive to be your partner in developinga sound FRC solution for your project.a sound FRC solution for your project.

Barcelona Metro Line 9

ThankThank youyou forforyouryour kindkind attentionattention!!

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Documents

47 PPT Fibres Boost Performance HKG May 2013 (1)