Ple-02 VSL Brian Lim

ASEP SUMMIT 2012
June 08-09, 2012 Regalia Tower Hotel Suites, Cubao, Quezon City
OBJECTIVES
PRESTRESSEDCONCRETEDESIGNAND CONSTRUCTION:ASTATEOFTHEART REPORT
ASEPSUMMIT2012
JUNE0809,2012
Recentdevelopmentsinnationalcodes,constructionmaterial andemphasisonsustainableconstruction,haveledtoa significantdepartureinthewaywedesignandconstruct prestressedconcretestructures. Inthispaper,astateoftheartprestressedconcretedesign andconstructionofbuildings,bridgesandspecialstructures willbeexamined.
BRIANLIM
SENIORBUSINESSDEVELOPMENTMANAGER VSLHONGKONGLIMITED
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Structuralconcretehasseenanextraordinarydevelopmentand hasbecomethematerialofchoiceforstructures. Significantprogressthroughcontinuousinnovation
Successfactorsforconcrete: Localavailabilityofconcretematerials Developmentofspecificconstructionmethods& specialisedequipment Improvedknowledgeindesignofstructuralconcrete Availabilityofmodernposttensioningtechnology
GatewayBridge,Australia
GBSPlatform,NorthSea
LNGTank,Spain
PTfloors,Chile
ASEP SUMMIT 2012
ASEP SUMMIT 2012
PRESTRESSEDCONCRETE
1. 2. 3. 4. 5. Systems Buildings Bridges OtherApplications NewDevelopmentsandApplications
PRESTRESSEDCONCRETE
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Systems:
StrandType:
Systems:
TendonArrangement:
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Systems:
StressingAnchorages:
TypeCS TypeSC
Systems:
TypeGC ETAG013Compliantfor StaticLoadTest,Load TransferTestandFatigue Test. WillbeapprovedbyHK Highwaysthisyear. ReplacesTypeSc,which compliestothe supersededBS4447
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Systems:
CouplingAnchorages:
TypeKC
Systems:
NonStressingAnchorages:
TypeP TypeAF
TypeH
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Systems:
Sheathing:
Systems:
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Systems:
TypeS TypeVSLAB SSeries S61 S62 S63 S64 S65
Systems:
TypeBondtechTypeS52S51,S61
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Systems:
OtherAnchorages:
TypeSK TypeH
Systems:
IndividualStrandStressing
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Systems:
MultiStrandStressing
Systems:
CableStaySystem&Dampers
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Systems:
CableStaysSSI2000:
Systems:
CableStaysSSI2000:
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Systems:
CableStayAnchorages:
Systems:
CableStayDamperAssembly
Cableflange Deckconnector AntiVandalismPipe (AVP) GensuiPad GuidePipe (GP)
DamperSupport (DS) GPbracket
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Buildings:
PRESTRESSEDCONCRETE
1. 2. 3. 4. 5.
Systems Buildings Bridges OtherStructures NewDevelopments andApplications
25
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Buildings:
Buildings:
Examplesof: LongSpanStructures GradeAOffices CommercialBuildings TransferBeams&Plates
HangSengBank:PTBeams&RCSlab
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Buildings:
Buildings:
900mmdeepPTbeamsspanning29.0m
Duringconstruction
Completed
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Buildings:
Buildings:
GatewayII:Artistsimpression
10~12mspan,260mmflatslabw/drops
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Buildings:
Buildings:
Typicalfloortendonlayout
Large cantilever span 4.5m
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Buildings:
Buildings:
Threetowersconstructedatthesametime
GatewayIICompleted
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Buildings:
Buildings:
OneIslandEast
Variable Floor Outline
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Buildings:
Buildings:
TypicalFloorPTLayout
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Buildings:
Buildings:
OneIslandEast: 70storeybuilding(60PT) 2,000m2perfloor 4/5daycycle Useof VSLClimbform Minitablesand Safetyscreens
Concretinginprogress
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Buildings:
Buildings:
MacaoYaohan:PTbandbeamswith230mmslab
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Buildings:
Buildings:
Artists Impression
DuringConstructionCompleted
VenetianCotai,Macau,Parcel1
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Buildings:
Buildings:
ArtistsImpression
PrecastConstruction:20x20mbay
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Buildings:
Buildings:
Example:Level3(20x20mGrid)
DuringConstruction
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Buildings:
Buildings:
TransferBeams
Completed(Right)
FestivalWalk,KowloonTong
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Buildings:
Buildings:
TransferPlates Transferofhigh concentratedforces Thickplatesorbeams withhighrebarcontent ShearControlled
PTTransferBeams:4.5mdeepx46mspan
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Buildings:
Buildings:
Stage 1: Casting 1st layer (~ 1/3 d) Stressing bottom tendons
Stage 2: Casting remaining plate (supported by 1st layer) Stage 3: Stressing middle and top tendons Stage 4: Construction of floors above can proceed
ArrangementofLoadBearingWall&Columns
LayeredConstruction
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Buildings:
MATERIAL&COSTCOMPARISON PTVSRCTRANSFERPLATE
Buildings:
Design Completed
Transfer Plates in Hong Kong
45
120 100 80 60 40 20 0 Concrete Rebars Fmwk Cost RC PT

Number of Plates
40 35 30 25 20 15 10 5 0 88-89 90-91 92-93 94-95 96-97 98-99 00-01 02-03 04-05 06-07 08-09 10-11 Year
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Buildings:
Concrete
120% 120%
Buildings:
Reinforcement
CO2 emissionforbuildingfloor:
Materialsandquantities Concrete(300kgcement/m3) /m2 PC=0.28m3/m2
RC=0.35m3
100%
100%
80%
80%
RC (kgCO2 /m2) 105.1
PC (kgCO2 /m2)
60%
60%
40%
40%
20%
20%
0%
0%
84.0 24.8 8.3 0 3.0 129.9 95.3
RC
PC
RC
PC
Note:Reductions Concrete:20% Reinforcement: 65% Labour: 60% Sustainability PTfloorshelptoreducematerialhandlingandlabour
Reinforcingsteel RC=42kg/m2 PC=14kg/m2 PTsteel RC=0 PC=5kg/m2 TotalCO2 emission
PToffers27%reductioninCO2 emissioninfloors!
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Bridges
Insituposttensionedconstruction
PRESTRESSEDCONCRETE
Colorado, USA
61
StandardBridges:Castinplaceposttensionedboxgirders
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Bridges
Insituconstruction(formtravellermethod)
Bridges
Insituconstruction(formtravellermethod)
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Bridges
PrecastBeamconstruction(withO/HGantry)
Bridges
PrecastBeamconstruction(withO/HGantry)
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Bridges
Precastsegmentalbridges
Savingsinformworkandscaffoldingandimproved aestheticsfavourprecastsegmentalconstruction
Bridges
Balancedcantileverconstruction(withO/HGantry)
Spanbyspanconstruction(withO/HGantry)
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Bridges
Balancedcantileverconstruction(withLiftingframes)
Bridges
Spanbyspanconstruction(withcrawlercranes)
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Bridges
Largescaleprojectsbecamefeasiblethrough introductionofprecastsegmentalconstruction
Bridges
From highway applications to light rail applications
DallasHighFiveInterchange,USA
WestRailproject,HongKong 13.5kmofviaduct 658spansof35to44m 9400segments 3500tinternalpt
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Bridges
. to high-speed rail bridge applications
Bridges
Cablestaybridges
Avignonviaducts,France 1.5kmoftwinviaduct Spansof100mand50m Precastsegmentaldeck Internalandexternalpt
CableStaysforallClimaticConditions
ASEP SUMMIT 2012
ASEP SUMMIT 2012
OtherApplications:
PRESTRESSEDCONCRETE
1. 2. 3. 4. 5. Systems Buildings Bridges OtherStructures NewDevelopmentsandApplications
UnionSquare,HongKong PTTransferPlates PTOutRigger VSLAF631
75
ASEP SUMMIT 2012
ASEP SUMMIT 2012
OtherApplications:
Prestressed Out-Riggers
OtherApplications:
VerticalPrestressing
PLAN ELEVATION InternationalCommerceCenter(ICC),HongKong
IRSands,Singapore
ASEP SUMMIT 2012
ASEP SUMMIT 2012
OtherApplications:
34storeyleaningtower(18degrees). Verticaltendonsinbuildingcoretocontrol leaningoftower(>towerofPisa).
OtherApplications:
ABUDHABI,CapitalGateTower
HarbourSide,UnionSquare
K11,HanoiRoad,TST
ASEP SUMMIT 2012
ASEP SUMMIT 2012
OtherApplications: CableStayedRoof
OtherApplications: SilosandTanks
Borlmage,Sweden
AlamoDomeStadium Texas,USA
ThermalStorageReservoir(14mhighx33mdia) Texas,USA
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Monostrandposttensioningforroof(33mdiameter)
Horizontal&verticalprestressinginwalls(355mmthick)
ASEP SUMMIT 2012
ASEP SUMMIT 2012
EggShapedDigestors,Singapore
CircumferentialPrestressing
ASEP SUMMIT 2012
ASEP SUMMIT 2012
OtherApplications: NuclearContainmentVessel(PCCV)
OtherApplications: OffShoreStructures
Olje
Hedrun
GBS
OmeshiNuclearPlant,KansaiElectricPower,Japan
ASEP SUMMIT 2012
ASEP SUMMIT 2012
TrollGravityBase OffshorePlatform
Skirtsandlowerdomes underconstructionindrydock.
Platformlegscompletedandready tobeingsunkandtowedout
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Dimensions:220mx46mx16m Displacement:107,000tons
NKOSSACONGOBarge
NKOSSACONGOBarge
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Quantities: 26,400m3HPC, 4,700tonsReinf 2,700tonsPT
NKOSSACONGOBarge
NKOSSACONGOBarge towedout
ASEP SUMMIT 2012
ASEP SUMMIT 2012
NewDevelopmentsandApplications
PRESTRESSEDCONCRETE
1. 2. 3. 4. 5. Systems Buildings Bridges OtherStructures NewDevelopmentsandApplications
CONTENTS: (1)MATERIALS Concrete (2)TECHNOLOGIES PTSYSTEMS DAMPINGDEVICES

95
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Strengthofconstructionmaterialshasevolvedoverlast 2030years,mainlyforconcrete N.B.:Prestressingsteelmayseeincreaseto2160MPa soon
Evolution of material strengths
2000 Strengths (MPa) 1500 1000 500 0 Structural steel Reinforcing steel Prestressing steel Concrete
Developmentof: HighStrength,HighPerformanceConcrete UltraHighStrengthFibreReinforcedConcrete(UHPC) verylowwatercontent,smallaggregateswithhigh packingdensity,largeamountsofrelativelyshortfibres ( 2%ofvolume,1020mmlong)
200 30
1980 2000
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Compressive strength
Ductal-FM
220 200
Maximum 300 MPa
Charact Value 150 - 180 MPa
Porosity
Cumulated porosity of the matrix (in %) 50 40 30 20 10 0 Ductal
Micro-pores C30 C60 C100FS
Capillary
Compressive stress in MPa
180 160 140 120 100 80 60 40 20 0 0
Ductal
Compression test
Ordinary concrete
10
20
50
100
200
1m
0,2
0,4
0,6
0,8
1,2
1,4
1,6
1,8
Strain in %
Low total porosity in range of nano-meters (10-9 m)
Diameter of pores (nm)
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Sherbrooke,Canada Auckland,NewZealand
Applications Highway bridges Severalhighwaybridges werebuiltinAustralia,Japan, France,USA
GSEBridge,Haneda AirportTokyo(2008)
Seonyu/Seoul,Korea
SakataMirai,Japan ShepherdsCreekbridge,Australia(2004)
Applications Pedestrianbridges
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Haneda InternationalAirportextension,TokyoJapan Onethirdofrunwayisbuiltonsteeljacketswithcomposite steelconcretedeckmadeofHPCandUHPCprecastpanels
Durability&55%weightsavingthewinningUHPCarguments
Fabrication7000pretensioned slabs;size3.8x7.8m,total 22000m3 55%weightsavingsduetouse ofDuctal
Applications Haneda InternationalAirport,Tokyo
104
Applications Haneda InternationalAirport,Tokyo
ASEP SUMMIT 2012
ASEP SUMMIT 2012
UHPCpanelsasliningsto protectpilecaps,exposed areasofpiers,andtunnels (examplesfromJapan)
CONTENTS: (1)MATERIALS Concrete (2)TECHNOLOGIES PTSYSTEMS DAMPINGDEVICES
Applications Protection
ASEP SUMMIT 2012
ASEP SUMMIT 2012
ApprovalofPTsystems(ETA)
EuropeanApprovalandCertificationschemeensurethatall systemsofferedonmarketsatisfyessentialcriteriaspecifiedin ETAG013andhavecontinuoussurveillance(FPCand independentaudits)
Initialassessment andapproval ofPTsystem byAB Attestation of Conformity byCB Continuous Surveillance (FPCand controlbyCB) Renewalof Certificateof Conformity after5years
Thisconceptisconsideredpreferrableoverprojectspecificassessmentbyengineer Ref:GuidelineforEuropeanTechnicalApprovalofPTKits(ETAG013)
ASEP SUMMIT 2012
ASEP SUMMIT 2012
QualificationofPTcompanyandpersonnel
PTworksshallbecarriedoutbyPTspecialist companieswhohavequalifiedandtrained personnelandsupervisors/managers Ref:CWA14646,FIPRecommendations(1996)
Corrosionprotection
Corrosionprotectionoftendonsmustbeakeyconsideration indesignofanyPTstructure fib/IABSEworkshopsinGhentandZurich fibBulletin33providesrecommendationsforcorrosion protectionoftendons
YnysYGwas
YnysYGwas
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Corrosionprotection
Mainproblemisaccessofwaterwithchloridesfromthe outsideintothetendon(orwateronlyifnotfullygrouted) Hence,provideleaktightencapsulation toavoidingressof waterandchlorideswhereapplicable
Corrosionprotection
ProposalofthreeprotectionlevelsforPTtendonsadapted toenvironment/exposureandstructuralprotection:PL1, PL2orPL3

Structural Protection Action High
Structural protection layers

Medium Low
Aggressivity / Exposure
High
PL3
Problem:Accessof watertotendon
Medium
PL2
Low
PL1
Groutvoidswithwater:Corrosion
Groutvoidswithoutwater:Nocorrosion
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Corrosionprotection

Corrosionprotection
PL1:Aductandafillingmaterialprovidingdurable corrosionprotection(metalduct,cementgrout) PL2:PL1plusanenvelopeoverfulltendonlength, leaktight barrier(plasticductandcap)
PL3:PL2plusintegrityoftendonorencapsulationtobe monitorableorinspectableatanytime(e.g.EITinacc.with SwissGuidelines)

Rebar
PL 3 PL 1 PL 2
ASTRA Guideline: Measures to ensure the durability of post-tensioning tendons in structures (2001, 2007)
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Corrosionprotection
EITmeasuring:Alternatingcurrent resistancemeasurement Highresistance=intactencapsulation
Corrosionprotection
EITTendon:Locatingofdefectwith measurementofmagneticfield
Sector A Pavement
DEFECT
i
Sector B
Alternating current
16
14
12
10
8 Le ngth [m]
ASEP SUMMIT 2012
ASEP SUMMIT 2012
NewDevelopmentsandApplications Grout:
Corrosionprotectionof strands. Transferofforcesfrom strandstoconcrete.
NewDevelopmentsandApplications GroutSpecifications
Property Flowability /Fluidity VolumeChange Bleed Strengthat7days Strengthat28days FIPGuide EN447 25sec. 2%to+5% 1%to+5% 2% 20MPa 30MPa 2% 27MPa 30MPa TestMethod Flowcone (Dia10or12.7mm) PlasticCylinder (100200mmhigh) PlasticCylinder (100200mmhigh) Cubeorcylinder (50100mm)
ASEP SUMMIT 2012
ASEP SUMMIT 2012
StandardGroutTests:
NewDevelopmentsandApplications Grout: RecommendedTypesofTesting

TESTS Initial testing of grout Approval testing of grout Suitability testing of grout Quality control test Full scale site testing REASONS PROCEDURE confirm Common: tests on site new grout special: optimisation approve confirm grout complies new grout with requirements compare tests flow time, bleed, shrinkage, on site expansion, strength and laboratory control grout local standard tests on site project specifications no void, no bleed, if required no corrosion at high points
OptimisedGrout
CommonGrout
Standardbleedtestisabletoidentifywhichgrout unstable.
ASEP SUMMIT 2012
ASEP SUMMIT 2012
InclinedTubeTest:
NewGroutTests:
WickInducedTest InclinedTubeTest
CommonGrout
Common Grout
Optimised Grout
OptimizedGrout
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Issueofprotectionofinternaltendonsinsegmentjoints Sealingplasticductsacross segmentjoints withleaktightcouplingdevice
Extradosed bridges
Innovativebridge deckstructure forspanrange 100200m
Sealingofsegmentjointswith epoxyresinandfoamseal PakseBridge,Laos(2000): Extradosedtendonsexposedsimilarlytostaycables
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Extradosed bridges
Span range: 100 - 200 m Girder depth at mid span: Span/55 Girder depth at pier: Span/35 Height of pylon above deck: span/12 ED tendon stress range: 20 50 MPa Note: Continuous transition from segmental span into extradosed span
Extradosed bridges
Extradosed compositebridgeswith275mmainspans
Ibigawa/Kisogawa BridgesinJapan Completion2001 Designer:JBSInst. Contractors:4JVs
PakseBridge,Laos(143mextradosedspan)
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Extradosed bridges
Saddleoffersimplifieddetailingofpylon,reductionofpylon dimensions,andsavingsinoverallcostofpylon Extradosed tendonspecification: Maxtendonstress60%GUTS Maxstressrange140MPa
Cable Saddles
Cablesaddleswithimprovedstatic, fatigueandfrictionperformancewith individualholesforeachstrandtocomply withtendonperformance
128
ASEP SUMMIT 2012
ASEP SUMMIT 2012
Conclusions
Throughcontinuousinnovationsin structuralconcrete:materials, technologiesandapplications Structuralprestressedconcretewill remainamaterialofchoicefor structures
Creating Solutions Together

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Ple-02 VSL Brian Lim

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ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

Structuralconcretehasseenanextraordinarydevelopmentand hasbecomethematerialofchoiceforstructures. Significantprogressthroughcontinuousinnovation

Successfactorsforconcrete: Localavailabilityofconcretematerials Developmentofspecificconstructionmethods& specialisedequipment Improvedknowledgeindesignofstructuralconcrete Availabilityofmodernposttensioningtechnology

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

DamperSupport (DS) GPbracket

ASEP SUMMIT 2012

ASEP SUMMIT 2012

Systems Buildings Bridges OtherStructures NewDevelopments andApplications

ASEP SUMMIT 2012

ASEP SUMMIT 2012

Examplesof: LongSpanStructures GradeAOffices CommercialBuildings TransferBeams&Plates

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

Large cantilever span 4.5m

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

Variable Floor Outline

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012

ASEP SUMMIT 2012