Design and application of fibre reinforced concrete floor ...tutg.or.th/wp-content/uploads/2014/06/Design-of-fibre-reinforced... · Design and application of fibre reinforced concrete

By Gan Cheng Chian,

Bekaert Singapore Pte Ltd

Design and application of fibre reinforced concrete floor and tunnel

linings with 3D, 4D & 5D steel fibres

Steel fibre reinforced concrete for segmental lining 1

Steel Fibre Reinforced Concrete (SFRC)


Precast Segmental Lining


Typical cage reinforcement for precast segmental lining


STEEL FIBRES REINFORCED CONCRETE (SFRC) for precast segmental

lining

Steel fibre reinforced concrete for segmental lining

Technical Advantages

• High impact resistance.

• Multidirectional reinforcement

• No damages at Edges and corner due to the spalling forces

•Post fire durability superior to rebar

• Fire protection in combination with micro –polypropilene fibre

•DURABILITY IMPROVEMENT

Economical Advantages

• Increase of productivity, time saving

• Reduction of repair cost of damage segments

• Elimination of storage and positioning of reinforcement cages.

• Use of automatic dosing and dispensing equipment linked to the control

panel of the batching plant.

Advantages of Dramix Steel Fibre in Segmental Lining


Dramix® fibres are made from prime quality hard

drawn steel wire to ensure high tensile strength and

close tolerances. CE LABEL system 1

A hooked end which slowly deforms during

pull-out is generally considered as the best

form of anchorage.

The glueing of the fibres into bundles

guarantees quick and easy mixing for a

homogeneous distribution

Dramix RC-80/60-BM especially designed for

precast Segment

Length = 60 mm

Diameter = 0.75 mm

L/d = 80

TS = min. 1550 Mpa

RC-80/60-BM

BEKAERT PROPOSAL


Segmental lining design procedure

Demolding

Stacking

Transport

& Placing

Service

Bending

Tension

Compression

Impact

Shrinkage &

Temperature

Effects

Acting forces


Voice of Designer

Load Case Rebar Steel FibreGround loading O.K O.K

Handling and stacking O.K O.K

Bolting O.K O.K

Erection O.K O.K

Grout Pressure O.K O.K

Ram Loading ? O.K

Application of SFRC is possible by selecting a static system for the tunnel ring

in such a way that there is minimal stress from bending moments.


SFRC ONLY : Hi-Perform

Combined solution: low amount of rebars for critical

bending moment + SF : High Perform

Combined solution : low amount of rebars for bursting+SF

Extreme Network

PRECAST SEGMENT : DURABILITY FIRST REQUIREMENT IN EACH CASE

Rebars(No amount decrease) +

Steel Fibre (min fibre dosage):

Extreme Network

RC80/60BM REMAINS THE REFERENCE PRODUCT


QA/QC Testing – EN14651 Beam Testing – Design values

Dramix®

Segmental Linings Coming Soon

1.Klang Valley MRT Line 1 Malaysia – 3600tons RC-80/60-BM based on 9.3km of twin tunnels

– Supplying 50% - on-going.

2.Klang Valley MRT Circle Line Malaysia – 30km of twin tunnels – Approx. 12000tons RC-

80/60-BM based on Line 1 – 1st Qtr 2014 start bidding

3.Klang Valley MRT Green Line Malaysia – 7km of twin tunnels – Approx. 2500tons RC-80/60-

BM based on Line 1 – 3rd Qtr 2014 start bidding

4.Thomson Line MRT Singapore – 3km of twin tunnels – Approx. 1200tons RC-80/60-BM –

Waiting for award

5.Shatin to Central Link C1107 Hong Kong – 400tons RC-80/60-BN – Waiting for award

6.Tuen Mun to Chek Lap Kok Link Hong Kong – 6000tons RC-80/60-BN – Bidding now

7.Tokyo Outer Ring Road Concrete Segments – 42000tons ZP306 – Start end-2013

8.Linear Tokyo to Nagoya Maglev Concrete Segments – 52500tons RC-65/40-CN – Start 2015

9.Jakarta Metro – Planning Stage

10.Bangkok Metro – Planning Stage


Deflection (mm) =0.46 =1.31 =3.00 =2.15

QA/QC Testing – BS14651 Beam Testing – Design Values


STEEL FIBRE REINFORCED SHOTCRETE (SFRS)

Inner tunnel lining:

Crack control

Durability

Slope stabilisation Retaining wall

Steel Fibre Reinforced Shotcrete

Tunnel repair

Caverns


Mesh Reinforced Shotcrete

Shotcrete consumption is high due to:

•irregular rock surface

•filling up voids

•high rebound on the mesh wires


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Mesh Reinforced Sprayed Concrete

Design Information Required

•Thickness of concrete

•Concrete quality

•Size of mesh

•Spacing of rock bolts

Steel Fibre Reinforced Shotcrete - SFRS Design Consideration

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Fiber Reinforced Sprayed Concrete

Design Proposal

•Proposed concrete thickness

•Proposed steel fibre type & dosage

•Proposed concrete quality

•Proposed performance criteria

SFRS Design Consideration

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1 mesh reinforced layer versus fibre reinforced sprayed concrete layer

Design of 1 mesh reinforced layer


20


Design of steel fibre reinforced

sprayed concrete layer

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Double mesh reinforced layer versus fibre reinforced sprayed concrete layer

Design of 2 mesh reinforced layer


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Double mesh reinforced layer versus fibre reinforced sprayed concrete layer

Design of steel fibre reinforced sprayed concrete layer


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Efnarc toughness classification:

500 J: min. requirement; rock; small diameter tunnel

700 J: standard; less good rock

1000 J: high ductility for bad soil condition

500mm

600mm

500mm600mm

100x100mm

F

deflection

25mm

loa

d

QA/QC Testing – EN14488-5 Panel Testing – Design Values

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SFRS Design Consideration – Design Values – EN14488-5 Panel Testing

Some Shotcrete case references in SEA

1. San Roque tunnel – Shotcrete (Philippines)

2. Bakun HPPE – Shotcrete (Philippines)

3. Bakun Hydro Power Project – Shotcrete (Malaysia)

4. Pergau Hydropower – Shotcrete/Cast Lining (Malaysia)

5. Mandai Cavern – Shotcrete (Singapore)

6. Marina MRT line – C825 – Shotcrete/Precast Segments (Singapore)

7. MRT Circle Line – C852 – Shotcrete (Singapore)

8. Deep Tunnel Sewerage System – T02, T04 & T06 – Shotcrete (Singapore)

9. Tanggari Hydropower and Sinkarak Hydropower - shotcrete (Indonesia)

10. Theun Hinboun Hydropower – Shotcrete (Laos)

11. Miri water transfer tunnel – Inner concrete lining (Malaysia)

12. Hai Van Pass Road Tunnels – Shotcrete (Vietnam)

13. Hai Van Pass Railway Rehabilitation Tunnels – Shotcrete (Vietnam)

14. MRT Circle Line – C856 – Shotcrete/Precast Segments (Singapore)

15. Nam Ngum 2 Hydropower Project – Shotcrete (Laos)

16. Jurong Rock Caverns – Shotcrete/Cast Lining (Singapore)

17. Ambuklao & Binga Rehabilitation – Shotcrete (Philippines)

18. Pahang Selangor Raw Water Transfer Tunnel – Shotcrete (Malaysia)

19. Peusanggan Hydropower Project – Shotcrete (Indonesia)

SFRC Floor Design Considerations

- Slab-on-grade • WHEEL LOADS – VEHICLE MODELS

• RACK LOADS – RACKING LAYOUTS & HEIGHTS

• LINE LOADS – BRICK WALL THICKNESS & HEIGHTS

• UNIFORMLY DISTRIBUTED LOADS – GIVING FALSE RESULTS

• SUBBASE INFORMATION

• JOINT INFORMATION – DISTANCE, SAWCUTS & DOWELS

• CONCRETE QUALITY

• SOG 10000sqm x 0.16m x 15 = 24tons

- Slab-on-piles • WHEEL LOADS – VEHICLE MODELS

• RACK LOADS – RACKING LAYOUTS & HEIGHTS

• UNIFORMLY DISTRIBUTED LOADS

• PILE SIZE & SPACINGS

• CONCRETE QUALITY

• SOP 10000sqm x 0.2m x 30 = 60tons

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SFRC Floor Design Considerations – Racking Systems

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SFRC Floor Design Consideration – Dump Trucks

28

SFRC Floor Design Consideration – Container Trucks/Container

Stackers

29

SFRC Floor Design Consideration – Forklifts & VNA Vehicles

30

5D, 4D & 3D Fibre types

31

Perfect anchorage

+ Ultra high tensile

+ Ductile wire

3DDra

mix

®D

ram

ix®

4DDra

mix

®

5DDra

mix

®

Perfect anchorage

Ductile wire

Ultra high

tensile


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Pull out

Max. force at high elongation of the wire

Similar slip pattern but for the at a substantially

higher level

*Comparison between a 3D – 4D – 5D with the same length and diameter

Max. force is utilized, no slip


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Beam test

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Bending hardening

Biggest gain in fR3

Biggest gain in fR1

fR1 => SLS design fR3 => ULS design

CMOD

Jointed Floor

Hard Standings

Jointless Floor

Lightly loaded foundations

Shotcrete

Combislab ; Concrete base for a coated overlay (Epoxy,P.E.,...)

Combislab ; Barriers – Fluid Tight

Combislab ; Jointless overlays

Harbout Pavements

Underwater concrete

Segmental lining

Combislab

- Project info • Date of execution : 2013

• Location : Belgium, Brussels

• Contractor : CFE

• Owner : ELIA

• Outdoor restraint ground slab (Pond)

Project Reference

ELIA at Brussels (Belgium) - Pond

- Technical solution • Fibre type : Dramix® 4D 65/60BG

• Dosage : 35 kg/m³

• Additional reinforcement : Ø10mm / 150 mm (top)

• Slab thickness : 300 mm

• Concrete quality : C30/37

• Design based on a restraint shrinkage

- Benefits • Cost saving : ≈ 0,00 EUR (time saving not included)

• Time saving : because the shape is complicated

• Water-tight (wk = 0,30 mm)

Combislab

- Project info • 06/02/2014

• Sydney Australia

• ADCO Construction

• Australia Post

Project Reference

Australia Post

- Technical solution • Dramix® 4D 65/60BG

• 25 & 30 kg/m3

• SL81 (7.6ɸ @ 100) & SL91 (8.6ɸ @ 100)

• 150mm & 230mm

• C32/40

• 15,000m2

• 25 tonne post load. Client required NO opening

joints – all fully tied.

- Benefits • 15,000m2 completed in 8 pours over 9 days

• Alternative Post Tensioned option would not

have been completed in time for handover

CombiSlab

- Include picture here - Project info

• Nov 2013

• NZ

• Fonterra

Project Reference

Fonterra, joint free truck wash roadway

- Technical solution • Dramix 4D 65/60BG

• 25kg/m3

• Top steel; 10mm bars, 120mm c/c

• 180mm

• C40/50

• Joint free, watertight roadway

- Benefits • This solution reduced the conventional

reinforcing by about 50pc; from two layers of

bar to one layer

CombiSlab

- Project info • January 2014

• NZ

• Conslab

Project Reference

Panalpina saw cut free yard slab


• 20kg/m3

• Top mesh; 6.3mm wires at 150mm c/c

• 150mm

• C40/50

• External saw cut free panels, 30 x 30m

- Benefits • This solution was used to remove the cost

and risk associated with maintaining and

repairing saw cut joints

CombiSlab

- Project info • February 2014

• Australia, Sydney

• Australia Post

Project Reference

Loading dock, joint free


• 25kg/m3

• Top mesh; 7.6mm wire at 100mm c/c

• 150mm

• C32/40

• Joint free restrained loading dock

- Benefits • This solution was used to remove the cost

and risk associated with maintaining and

repairing saw cut and movement joints

CladRack foundation

- Project info • Date: September 2013

• Location: Kingdom Saudi Arabia, Jeddah

• Contractor: RCR Flooring

• Owner: SIBCO

• Hyder Consultant approved Bekaert design

Project Reference

SIBCO Pepsi Mega Plant

- Technical solution • Dramix® 4D 65/60BG )

• 30 kg/m3

• Top mesh (5,24cm²/m), bottom only along

the perimeter (d=12mm/150mm)

• 700mm

• C30/37

• Bigger panels sizes due to thinner slab

- Benefits • Cost saving : 22% =185.000 €

• Time saving : 370 hours

• Fast anchorage (as all columns with

chemical anchors

CladRack foundation

Project Reference

Clarebout Warneton (Freezer floor)

CladRack foundation

Project Reference

Schenker logistics

- Project info • Date: 2013

• Location: Zwevegem - Belgium

- Benefits • Seamless strip at loading docks

• Increased productivity in handling

• Reduced maintenance costs

CladRack foundation

Project Reference

Schenker logistics

Strip without joints and reinforced with

Clad Racks

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Floor on piles

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Structural Rafts

Final lining : Lee tunnel UK

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Foundation rafts

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60

Foundation rafts

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Contact

Bekaert Singapore Pte Ltd

3 Church Street

Level 8 Samsung Hub

Singapore 049483

T +65 97859171

[email protected]

www.bekaert.com/building

Bekaert is always near you

http://www.bekaert.com/building

http://www.bekaert.com/building

63

better together

www.bekaert.com

Documents

Design and application of fibre reinforced concrete floor ...tutg.or.th/wp-content/uploads/2014/06/Design-of-fibre-reinforced... · Design and application of fibre reinforced concrete