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Fiber-Reinforced Concrete Segmental Lining Design - Mexico - Fibrocemento
Fiber-Reinforced Concrete Segmental Lining Design - Mexico - Fibrocemento
Fiber-Reinforced Concrete Segmental Lining Design - Mexico - Fibrocemento
reinforcement
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Fourth International Symposium on Tunnels and Shafts in Soils and in Rocks
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Colegio de Ingenieros Civiles de Mexico (CICM)
Mexico, CDMX
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May, 26-27, 2016
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Bruno Rossi
FRC Specialist - Design & Technical Support
bruno.rossi@bm-underground.com
Summary
Fibers for concrete – Basic knowledge
Main application fields for FRC
Material properties – Standards and guidelines
Design guidelines for FRC
Design guidelines for segmental linings
EN 14651 bending test (material ductility)
From the mechanical properties to the design values
4D 80/60BG fibers
Segment full scale test (structural ductility)
Segmental Lining Design
Segmental Lining Case Studies
2
Fibers for concrete – Basic knowledge
• The Fibre-Reinforced Concrete (FRC) is a composite material made of basic concrete in
which a fibre reinforcement is incorporated and homogeneously distributed
• Fibres can be made of steel, polymers, glass or natural materials
• Fibre’s addition in concrete controls plastic and hydraulic shrinkage cracking, reducing crack
spacing and crack width, thereby improving durability (even in aggressive chlorinated
environment as Abu Hamour Surface & Ground water drainage tunnel – Doha –
Qatar)
• Fibres with an High Young’s Modulus considerably improves the concrete post-cracking
behaviour
• Fibre materials with a Young’s-Modulus which is significantly affected by time and/or
thermo-hygrometrical phenomenon, are not covered by the Model Code 2010 and, in
general, should not be considered as structural materials
• Structural design of FRC elements is based on the post-cracking residual strength
provided by fibre reinforcement
• For structural use, a minimum mechanical performance of FRC must be guaranteed
3
Concrete: strong material but weak
4
Main application fields for FRC
Paving Tunneling
Industrial & commercial floor slabs
Jointless floors Temporary lining (Sprayed concrete)
Container port pavements Segmental lining
Concrete roads Cast-in-place final lining
Parking areas for aircrafts
Foundations
Precast elements
Concrete pipes
Shotcrete Prestressed (roof) elements
Linings & galleries Water collectors
Pit shafts, ore passes Septic tanks
Slope protection Garage cells
5
FRC for tunneling
key stone
standard
element
driving joints
direction
hydraulic jacks
Segmental lining
Temporary lining
CARGAS SOBRE EL REVESTIMIENTO DEFENITIVO
(Sprayed Concrete)
Cobert uras Alt as
6
Material properties - Standards and Guidelines
Fiber’s geometrical and mechanical characteristics are defined by the following
standards (some international codes):
• EN 14889-2006: Fibres for concrete; this standard specifies the requirements of fibres
for structural or non-structural use in concrete, mortar and grout;
• ASTM A820 / A820M-11: Standard Specification for Steel Fibers for Fiber-Reinforced
Concrete;
• ISO 13270-2013: Steel fibres for concrete;
The flexural behaviour of Fiber-Reinforced Concrete 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
7
Design guidelines for FRC
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 Controllo di
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.
8
Design guidelines for segmental linings
For the fiber-reinforced concrete segmental lining design, some guidelines have been
published in France and Germany and, recently, USA and ITA-AITES:
• AFTES Recommendations GT38R1F1 (2013) – La conception, le dimensionnement et
la realisation de voussoirs préfabriqués en béton de fibres métalliques;
• DAUB (German Tunnelling Committee) (2013) – Recommendations for the design,
production and installation of segmental rings;
• ACI 544.7R-16 (2016) – Report on Design and Construction of Fiber-Reinforced Precast
Concrete Tunnel Segments;
• ITAtech (2016) – Design Guidance for Precast Fibre Reinforced Concrete Precast
Segments – Draft Report;
• ITA Working Group 2 (2016) – Twenty years of FRC tunnel segments practice: lessons
learnt and proposed design principles;
• PAS 8810, Design of concrete segmental tunnel linings – Code of practice
The upcoming guideline /code is:
• fib TG 1.4.1 – Tunnels in fiber reinforced concrete
9
EN 14651 bending test (material ductility)
10
EN 14651 bending test (material ductility)
11
EN 14651 bending test (material ductility)
From these results the limit of proporzionality (LOP) fL and the post-cracking residual flexural tensile strengths fR,j have been
calculated.
The limit of proportionality LOP is the stress at the tip of the notch which is assumed to act in an uncracked mid-span
section, with linear stress distribution, of a prism subjected to the centre-point load FL:
The residual flexural tensile strengths are the fictitious stresses at the tip of the notch which are assumed to act in an
uncracked mid-span section, with linear stress distribution, of a prism subjected to the centre-point load Fj corresponding to
CMODj where CMODj > CMODFL:
12
EN 14651 bending test (material ductility)
Characteristic test results: fRjk = fRim – kx x sp
fR1k = residual flex strengths (CMOD1 = 0,5 mm) (Serviceability Limit State)
fR3k = residual flex strength (CMOD3 = 2,5 mm) (Ultimate Limit State)
Residual loads FR,i, referring to a defined CMODj
13
EN 14651 bending test – 4D 80/60 fibers
• University of Rome “Tor Vergata”, February 2015
• 9 FRC beams (EN 14651), dosage rate 40 kg/m3, steel wire fibres L = 60mm, L/D = 80,
Rm,nom = 1800 N/mm2; improved hooked end (Dramix 4D 80/60BG)
• Average compressive strength at 28 days 61,20 MPa (8 cubic specimens tested),
max. aggregate diameter 25 mm, W/C < 0.40, CEM 42.5 N;
• Flexural tensile strengths: fLk = 4,30 MPa; fR,1k = 5,58 MPa; fR,3k = 7,65 MPa;
• Classification (Model Code 2010): fR,1k is the strength interval (1.0, 1.5, 2.0, 2.5, 3.0, 4.0,
5.0, 6.0, 7.0, 8.0, … [MPa]) and a letter a, b, c, d or e is the ratio fR,3k / fR,1k ratio:
a if 0,5 ≤ fR,3k / fR,1k < 0,7
b if 0,7 ≤ fR,3k / fR,1k < 0,9
c if 0,9 ≤ fR,3k / fR,1k < 1,1
d if 1,1 ≤ fR,3k / fR,1k < 1,3
e if 1,3 ≤ fR,3k / fR,1k
The tested material can be classified as 5e (5 < fR,1k = 5,58 Mpa < 6; 1,3 ≤ fR,3k / fR,1k)
This material has shown a bending hardening behaviour, which is typical of SFRC and
suitable for the crack control.
14
EN 14651 bending test – 4D 80/60 fibers
15
From the mechanical properties to the design values
Here below the steps to derivate the design values from a bending test:
16
Design indications for Segmental Linings – 4D fibers
17
Segment full scale test (structural ductility)
Possibility of totally removing the traditional reinforcement according to the MC10, 5.6.1
Introduction, fig. 5.6.1:
In all FRC structures without the minimum
conventional reinforcement, one of the following
conditions shall be satisfied:
dU ≥ 20 dSLS ; dPeak ≥ 5 dSLS
where du is the ultimate displacement, dPeak is
the displacement at the maximum load and dSLS
is the displacement at maximum service load
computed by performing a linear elastic analysis with the assumptions of uncracked concrete and
initial elastic Young’s modulus.
Usually, du is related to the maximum deformation requirement of the structure.
The ultimate load Pu should always be higher than the load at crack initiation Pcr and higher than the
maximum service load PSLS.
18
Segment full scale test (structural ductility)
19
Segment full scale test (structural ductility)
BENDING TEST – Load vs Displacement and crack pattern
300
250 W2
W1
W3
200
Load (kN)
150
100
50
0
0 2 4 6 8 10 12 14
Displacement (mm)
The first crack appears for a load value of about 170 kN, at the intrados surface close to the midspan of the
segment and propagates on the lateral surfaces.
It can be noted that multi-cracking phenomenon takes place.
In particular, a series of cracks forms close to the segment midspan both at the intrados and lateral surfaces.
20
Segment full scale test (structural ductility)
POINT LOAD TEST
During the test, the following
measures were continuously
registered:
21
Material properties – cut off beams from segment
22
Material properties – Fiber’s distribution and segment
finishing – Melbourne and Singapore
23
Segmental lining design – Input Data
For a preliminary segmental lining design, the following information are required:
• Geometry of the Tunnel Segments: thickness, radius, width, segment angle, number
of the segments per ring, RAM shoes dimensions;
• Material properties: compressive and residual flexural strengths, at early and long-term
age;
• Material safety factors: concrete, FRC and steel rebars depending on the loading
conditions (EC2);
• Loading safety factors: for demoulding, the dynamic factor is gD = 3,00; for stacking gF
= 1,35 (static load factor) and gD = 1,50 (dynamic load factor) for TBM thrust loads, gj =
1,05 (for maximum load);
• Demoulding and handling: type of lifting device (mechanical or vacuum), lifting points
spacing or vacuum width;
• Segment’s storage: n°of segments stacked, stacking spacing, misalignment of the
supports;
• TBM thrust loads: max. TBM load, n°of rams, ram shoe dimensions, eccentricity;
• Axial forces N, bending moments M, shear forces V (ground loading)
24
Geometry of the tunnel segments
Thickness t (mm) t
Segment Information
Thickness t 400 mm
Inner radius ri 4250 mm
Width w 1600 mm
Segment developed length ld 3728,0 mm
Number per ring n 7 7,5
Key 1/2 0,5
Segment slenderness l d/t 9,32
25
Material properties
Concrete compressive strength Cxx/yy (EN 206)
• Early age (demoulding & stacking) (Mpa)
• Long term (TBM thrust & ground loads) (Mpa)
SFRC residual flexural strengths fRjk (EN 14651)
• Early age (demoulding & stacking) (Mpa)
• Long term (TBM thrust & ground loads) (Mpa)
Steel bars
• Yield strength fyk (Mpa)
• Bar diameter (mm), spacing (mm), concrete cover (mm)
Material characteristics
TBM RAM loads
2
Characteristic compressive strength (cylinder) fck 45 N/mm
Characteristic compressive strength (cube) f cu 55 N/mm2
Fiber's type 4D 80/60BG
3
Dosage rate 40 kg/m
Characteristic limit of proportionality (CMOD = 0,05 mm) f LOP 4,41 N/mm2
Characteristic residual flexural strength (CMOD = 0,50 mm) f R1k 4,18 N/mm2
Characteristic residual flexural strength (CMOD = 2,50 mm) f R3k 5,16 N/mm2
Long term effects on the compressive strength coefficient a cc 1,00 #REF!
Characteristic residual tensile strength f Ftuk 1,72 N/mm2
Partial safety factor for concrete and FRC in compression gc 1,50 #REF!
Partial safety factor for FRC in tension gf 1,20
2
Design compressive strength f cd 30 N/mm
26
Segmental lining design – Loading conditions (please note
that in the new ACI 544.7-16 design code are listed 11 different loading
conditions)
27
Segmental lining design
Stacking
Number of stacked segments n
Supports spacing x (3/5 segment cord length
is suggested)
Δx
Eccentricity Dx (to limit at 100 mm possibly)
Static load safety factor gf (= 1,35) x
Dynamic load safety factor gDyn (= 1,50)
Stacking
Failure mechanism: Flexural Segment weight per width meter W1 37280,2 N/m
Number of stacked segments N 7 7,5
Testing required to confirm Misalignment of stacking points y 150 mm
Segment angle a 48,0000 °
the design: Radius at mid thickness R 4450,0 mm
Stacking supports spacing (by default x = 3/5 * C) x 2100,0 mm
• Flexural strength (TR 63, Half segment angle ab 24,0000 °
table 9, pag. 63) Stacking supports half angle aa 13,6479 °
Segment arc length ld 3728,0 mm
• Residual flexural strength
Segment cord length C 3620,0 mm
(MC10 & ACI design approach) Segment unit linear weight qw 10000 N/m2
Permanent loads factor gF 1,35
Dynamic load factor gDyn 1,5
Self weight bottom segment bending moment Mb 2,45 kNm/m
N-1 upper segments weight bending moment MN-1 18,17 kNm/m
Design bending moment at the mid-span of the bottom segment M = (Mb + MN-1) g F g Dyn 41,77 kNm/m
28
Segmental lining design
TBM thrust forces
Maximum push of TBM Ft
Number of rams shoes n°
Width of ram shoe a
Length of ram shoe b
Jack force safety factor gf
Max load eccentricity e Maximum load per each RAM jack
Installation stresses caused by the TBM applied load
F 1850 kN
Number of jacks per RAM shoe n° 2
Failure mechanism: Tensile Number of RAM shoes n° 15
Width of RAM shoes (by default 75% of the thickness) ws 250 mm
bursting (TBM rams) Length of RAM shoes l RAM 1000 mm
29
Segmental lining design
Section forces (M-N)
generated by ground loads
and related safety factors
Failure mechanism: compressive
and tensile bursting (joints)
Testing required to confirm the
design:
Indirect tensile strength and
compressive strength (TR 63)
Residual flexural strength and
compressive strength (MC10 &
ACI design approach)
30
Verification of safety and serviceability for transient
and permanent loading conditions
The Model Code 2010 proposes two different constitutive laws for the SFRC in
tension:
a rigid-plastic behavior (left)
a linear post crack softening or hardening behavior (right)
f R 3k
f Ftuk
3
Where:
fFtuk is the ultimate residual
strength
fR3k is the residual flexural tensile strength at crack opening = 2,5mm
32
Segmental lining design
Which constitutive law?
Is the choice making a difference?
33
Verification of safety and serviceability for transient
and permanent loading conditions
The design values for ULS check of the combined bending and compressive
stress section is obtained by dividing the characteristic value of residual tensile
strength fFtuk for the material safety factor of FRC.
For production under improved control procedures, as it is the case of
segments, a reduced safety factor gF ≥ 1.30 may be adopted (MC 10):
fFtud = fFtuk / gF
34
Verification of safety (ULS) – Bending and/or axial
compression in linear members (7.7.3.1, MC 10)
The bending failure stage is supposed to be reached when one of the following
conditions applies (figure below):
attainment of the ultimate compressive strain in the FRC, ecu;
attainment of the ultimate tensile strain in the steel (if present), esu;
attainment of the ultimate tensile strain in the FRC, eFu;
35
Verification of safety (ULS) – Bending and/or axial
compression in linear members (7.7.3.1, MC 10)
36
Verification of safety (ULS) – Bending and/or axial
compression in linear members (7.7.3.1, MC 10)
Project name: Segmental Lining Design - West Segment Red Line
Project nr:
Location: Tel Aviv - Israel
Contractor:
Author: Bruno Rossi Concrete class: C45/55
Client: Fiber type: 4D 80/60BG
Standard: Model Code 2010 Fiber dosage: 40 kg/mc
600
allowable
compression:
0.8Nmin 400
200
M [kNm]
0
-12000 -10000 -8000 -6000 -4000 -2000 0 2000
-200
M-N domain
-400
0.8Nmin
NSd, MRd
-600
N [kN]
Date: 17 May 2016
Plotted domain: FRC (no reinforcement) Dominus v2.0
37
Verification of safety (ULS) – Shear in beams (7.7.3.2,
Model Code 2010)
38
Verification of serviceability (SLS) – (Model Code 2010)
39
FRC segmental lining reference projects
From the early 90’s, over 80 projects have been realized with steel fibers, by
Bekaert and Maccaferri worldwide:
– 25 hydraulic projects
– 20 metro lines
– 21 utilities
– 9 railways
– 6 roads
– 3 others
• Over 50 of them are steel fiber’s only reinforced
• 33 are reinforced combining steel fibers and rebars
Max Fext for steel fiber’s only solution (Dramix): 12,4 m (North-South Bypass
Tunnel (Clem 7), Brisbane & Airport Link / Northern Busway, Brisbane)
40
Combined reinforcement for segmental lining:
Some (empirical) design indications from the Bekaert-Maccaferri
joint experience
41
Segmental linings: some case studies
42
Segmental linings
Case study: Channel Tunnel Rail Link, UK
Date: 2003-2004
Project name: Channel Tunnel Rail Link (CTRL)
Tunnel type: Railway
Tunnel length: 20 km
Max int. diam.: 7,15 meters
Thickness: 350 mm
Fiber type: 3D 80/60BG
Dosage rate: 30 kg/m3 Table 1: Overall damage rate to segments CTRL project published in TT magazine
43
Segmental linings
Case study: Big Walnut sewage tunnel, Columbus Ohio
Date: 2005
Project name: Big Walnut sewage tunnel
Tunnel type: Sewage
Country: USA
Tunnel length: 4,8 km
Max int. diam.: 3,65 meters
Thickness: 230 mm
Fiber type: 3D 80/60BG
Dosage rate: 30 kg/m3
Concrete class: C40/50
44
Segmental linings
Case study: Brisbane Airport Link, Australia
Date: 2010
Project name: Brisbane Airport Link and Northern Busway
Tunnel type: Road
Country: Australia
Tunnel length: 6,7 km
Max ext. diam.: 12,4 meters
Thickness: 400 mm
Segmentation: 10 segments
Fiber type: 3D 80/60BG
Dosage rate: 40 kg/m3
Concrete class: C50/60
45
Segmental linings
Case study: Sao Paulo Metro Line 5
Date: 2012
Project name: Sao Paulo, Metro Line 5
lots 3 and 7
Tunnel type: Metro
Country: Brazil
Tunnel length: 11,5 km
Max ext. diam.: 8,43 meters
Thickness: 400 mm
Fiber type: 3D 80/60BG
Dosage rate: 35 kg/m3
Concrete class: C40/50
46
Concluding remarks
47