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To help engineers and designers design with fibers for shotcreting and final linings To help you quantify the value, from an owners point of view, of using fibers instead of traditional reinforcement
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Agenda
Identification of the correct fiber for various applications How to quantify material and labor savings of fibers vs. traditional reinforcement Designing with fibers Fibers in precast, final linings and cast-in-place liners Fibers in conjunction with admixtures Fibers which can reduce spalling in fires Waterproofing membranes combined with fibers vs. waterproofing PVC and rebar
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Steel Fibers by
Macro Fiber for secondary, post first crack reinforcement Macro fiber typical features Length 1.5 to 2 typically Tensile Strength min of 40ksi (275MPa) Modulus of Elasticity min of 4,000ksi (2,750MPa) Average Residual Strength 150psi @ 3 lb/yd (1.8kg/m)
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Shotcrete Savings Safety issues reduce tripping, material handling & falls
The faster you can excavate, faster contractor gets paid and can move on to next job
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Why are steel fibers a better choice than wire mesh or rebar?
They can provide superior residual load carrying capacity at small deformations and equivalent performance at large deformations You can do away with installation costs of WWR and rebar Reduce hazards for employees It can follow the exact contours of the rock face whereas WWR often requires 2 in. (50mm) of cover as well as filling of voids behind the mesh w/ shotcrete You may see a drastic reduction (up to 40%) in shotcrete material with SFRC in blocky or fractured rock surfaces If there are voids behind the WWF, then phenomenon like ice-jacking can occur more easily Production rates/advance rates should be faster with SFRC up to 50% of labor time can be reduced
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When specs are being created, you use the manufacturers information to determine which material to use For example, if a segment needs to achieve 400 psi at 3mm deflection according to ASTM C1609, a fiber is selected which has the necessary properties and dosage rate. There is a mandatory procedure in any precast job that you do a test using the mix design, aggregate and fibers which will be used to make sure that performance requirements are met. A QC person will then perform testing for a pre-determined number of segments or distance to make sure everything is still in spec.
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fct
+
Ec CTODm Pre-peak, -
s1 w1
w
wc
Post-peak, -w
From experimental tests Inverse analyses The numerical inverse analyses were provided by using NLFE software
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Experimental Numerical
CTODm [mm]
-6 -5 -4 -3 -2 -1 0 0.0 0.1 0.2 0.3 0.4 0.5
CTODm [mm]
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Experimental Numerical
Experimental Numerical
CTODm [mm]
CTODm [mm]
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Constitutive Laws -w
MasterFiber FF1
MasterFiber FF3
4 3 2 1 0 0 1 2
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Precast Tunnel
Tunnel Lining Cross-Section
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Tunnel ground condition evaluation of bending moment and axial force diagram
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Wood Blocks
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Reinforcement comparison
Rebar only
SFRC + Rebar
350
350 350
We suggest a combined reinforcement made of 35 kg/m3 of MasterFiber FF3 and steel rebar as shown in the following picture
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Tunnel segments
Displacement under service load
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Tunnel segments
Longitudinal stress under service load
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Optimized reinforcement
Load [kN]
45FF1 RC RCO35FF1
Plain RC35FF1
Displacement [mm]
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Segments in storage
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20-30 (34-50)
250-400 (10-16)
35-50 (60-85)
250-400 (10-16)
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Materials: Fiber reinforced concrete: Compression: 35 MPa Tension resistance at peak load= 4 MPa Tension in 0.6 mm of crack opening =3.5 MPa Tension in 1.5 mm of crack opening= 2 MPa Rock around the tunnel: Elastic Modulus: 2000 MPa Unit Weight= 2.2 Ton/m3 Load Case: Internal radial pressure from inside to the rock: 200 kPa 300 kPa 500 kPa The drawing units are in meters.
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ASTM C 1550-02: Standard Test Method for Flexural Toughness of FRC and Shotcrete (Using Centrally Loaded Round Determinate Panel)
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The required dimensions of the panel are 75 mm (3 in.) in thickness and 800 mm (31.5 in.) in diameter
Loading piston
Specimen
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Load (kN)
LVDT
20 Integrate the area under the curve between the (corrected) origin and the specified total deflection 10
LVDT yoke anchored at transfer plates
0 0 10 20 30 40 50
Displacement (mm)
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Shotcrete Guideline - based on energy absorption test for excavation rock stability
Reference TR-63
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Tunneling Shotcrete Usual dosage and typical lining thickness by Energy Absorption Test
Fiber Type ASTM C1550 = 225 J Dosage kg/m3 (lb/yd3) MasterFiber FS3N MasterFiber FS7 35 (60) 25 (44) ASTM C1550 = 350 J Dosage kg/m3 (lb/yd3) 40 (67) 30 (50) ASTM C1550 = 450 J Dosage kg/m3 (lb/yd3) 35 (75) 35 (60)
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SFRC Final Lining Highway SS203 Agordina Cencenighe BL Italy Dosage rate: 35 kg/m3 (60 lb/yd3) MasterFiber FF1
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Uses and Applications: Synthetic fibers used more in mines than in tunnels Predominately wet shotcrete, very rarely in dry shotcrete Used more in initial support shotcrete Typical Dosages: Mining 8-12 lb/yd3, some as much as 14 lb/yd3 Shotcrete initial support 8-12 lb/yd3 Limits 18 lb/yd3 difficult for matrix to support anymore due to high volume Approximate equivalents 12 lb/yd3 can perform similar to 60 lb/yd3 of steel Tests: 1550 panel test synthetics will typically outperform steel 1609 beam test steel typically outperforms synthetics
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Shotcrete Dry-Mix No changes to mix design, but be aware that if you cut back too much on cementitious content, there may be more total rebound and specifically, fiber rebound. Synthetic fibers in a dry mix are more difficult to deal with due to high level of rebound. It is not recommended to use micro fibers as they can very easily get blown out of the mix Steel fibers provide the most consistent quality in a dry mix Shotcrete Wet-Mix Use water reducers @ ~8oz/cwt (.5l/100kg) and superplasticizers for silica fume concrete @ ~16-24oz/cwt (1-1.5l/100kg) Wet mixes are more conducive to any fibers use Notes Dosages of high/mid range will increase with higher fiber dosages Slump may decrease at higher fiber dosages by 1-2 in. Although slump may decrease workability will not avoid temptation to re-temper mix which can result in segregation and balling of the fibers and a final product which has lost hardness quality. Just put some energy on the mix and it will move.
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Source: Applications of Micro-Synthetic Fibers for Resistance to Explosive Spalling in Fires. Trevor Atkinson & Peter C. Tatnall
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Surface spalling If temperature rise is relatively slow, concrete moisture migrates from the heat exposed side and thus pressure build up is minimal, resulting in less spalling Corner break-off spalling Also called sloughing off Occurs at corners and edges during later stages in the fire when concrete has cracked and weakened Explosive spalling Occurs with rapid heat rise within the first 10-20 minutes (usually hydrocarbon based) and is by far the most dangerous and damaging form of spalling. Moisture in the concrete is heated faster than it can move away from the heat, moisture changes to vapor and the vapor increases pore pressure. Once the pressure exceeds the tensile capacity of the concrete, concrete is violently and explosively dislodged from the concrete exposing more concrete to the fire
Typical specs Fibers with diameters less than 32 Lengths between 6mm 13mm At least 60MM fibers/lb Recommended dosages 1.7 lb/yd (1 kg/m) 3.4 lb/yd (2 kg/m) Some Things To Avoid Shorter (6mm), smaller diameter (18) fibers may tend to ball and may greatly increase air content (6-8%) Macro polypropylene and steel fibers have shown no resistance to spalling (due mostly to their lower fiber count/yd/m vs. the PP fibers)
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Most Severe Hydrocarbon Fuelled Fire RWS (Rijkswaterstaat) Curve furnace temperatures rise rates increase at a rate of 400 F (200 C) per minute to 2000 F (1100 C) in 5 minutes, with final temperature reaching 2460 F (1350 C) and then held there for 2 hours Another Hydrocarbon Fuelled Fire Method Eurocode I Hydrocarbon final temperature ~1100 C and held for 160 minutes Test for Slower Temperature Rise Fires ISO 834 Cellulose final temperature ~1100 C and held for 160 minutes but slope of rise more gradual
BASF Will Design Its M100 UL Test After the RWS Method
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Channel Tunnel Rail Link UK Dublin Port Tunnel Ireland Gotthard Base Tunnel Switzerland T5 Heathrow Express Tunnel UK Weehawken Tunnel USA Paramatta/Chatswood Tunnel Australia Vomp-Terfens Tunnel - Austria
Addition of correct PP fiber is an inexpensive means of protecting lives, reducing catastrophic collapse, repair costs and commercial disruption
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Waterproofing
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Waterproofing membranes combined with fibers vs. waterproofing PVC and rebar
The most common types of membranes are PVC membrane with heat welded seams The most common problems with them are that they are: Difficult to shotcrete unless theres strong reinforcement against the PVC Prone to leaks behind the PVC Vulnerable to chasing leaks It is often not recommended to shotcrete steel fibers onto them because of risk of punctures Solution Masterseal 345 Its a fully bonded system if theres a leak visible, thats where the leak is The main property of the membrane is that it bonds to both the substrate and the concrete which is applied to it creating an impermeable interface this is what keeps the leak from migrating. No special equipment is needed to apply Masterseal 345 just use a standard dry gunnite machine Thickness of membrane should be a minimum of 2mm and optimum of 3mm. Do not exceed 5mm in thickness since this can cause slow curing. Substrate preparation Its essential to have a smooth substrate with limited roughness in order to achieve a continuous membrane. Use a sprayed concrete w/ maximum grain size of 4mm Curing starts immediately after application and once started, its irreversible. Possible Difficulties Seepages penetrating through membrane in areas where continuous membrane was not achieved. If these occur, theyll happen within the first day after application. To remediate, inject locally where water seepage is visible.
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MASTERSEAL 345
Features
Dry-process material, ready-for-use Elasticity 80-140% b/w -4 & 68 F (-20 & 20 C) Fast curing No toxic components Environmentally friendly
Benefits
Easily applied by spraying with uncomplicated equipment Two-sided bond with sprayed-concrete allows for monolithic behavior
How are leaking spots repaired? What can happen if you spray with too much / too little water?
External tests results and certifications EMPA Switzerland: long term pressure test Mott Mc Donald: Technical report with summary of actual test results BMI (Innsbruck): Practical feasibility test
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About the tunnel - The Nordy road tunnel passes below the fiord between the two islands of Eystury and Bordy in the Faroe Islands. The total length of the tunnel is 6,155 m with a cross section of 64 m(two lanes). The maximum depth under the sea is 150 m with a minimum rock cover of approximately 40 m. The rock types in the area are extrusive basalts. Goal - Waterproofing of the tunnel contour to avoid the dripping of water onto the actual road surface. Cost - The total cost of the waterproofing of the tunnel made up approximately 10% of the total project cost. Trend - In the last few years there has been a trend to avoid flammable materials in underground construction. The flammable PE foam sheets were therefore not in accordance with a modern design philosophy with non-flammable materials. The goal was to reduce the amount of the PE foam waterproofing by more than 50%. Solution - A sprayable waterproofing membrane in a composite liner based on sprayed concrete. Steel fiber reinforced concrete applied after membrane had achieved sufficient curing (10-14 days) Advantages - possibility to locally waterproof smaller areas without the need to bring the waterproofing all the way down to the invert, no inflammable materials, reduced total lining thickness and significant financial benefits to owner and contractor over a technical solution with PVC sheet membrane and cast-in-place concrete lining.
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