Solutions the Magazine About Uhpcs by Lafarge

octobeR 2013 - No.14

Solutions The magazine about UHPCs by Lafarge

Standardization: UHPCs enter the industrial age

An Architect’s Vision: Bernard Tschumi

Mucem designed by Rudy Ricciotti: Ductal® for performance and creativity contents News - 3 > 6

Standardization > 4 UHPCs enter the industrial age

Insights - 7 > 9

Bernard Tschumi Architecture invents concepts and makes them a reality

Markets - 10 > 17

Façade > 10 Giving the envelope new functions

Wind turbines > 13 Resistance, sealing and flexibility

Bridges & footbridges > 14 Pont de la République (France) Blandan footbridge (France) The evolution of Ductal® Joint Fill (North America)

Project - 18 > 23

Mucem > 18 Ductal® combines technical performance with architectural creativity

Editorial committee: Editor-in Chief: Jean Martin-Saint-Léon - Editors and contacts: Lisa Birnie - [email protected]; Marie Escaich - [email protected] - Photo credits: Lafarge photo library - Charles Plumey-Faye - Philippe Ruault - Max Lerouge - Patrick Kennedy - Luc Boegly - Hervé Abbadie - Ignus Gerber - Brian Moore, Wapello County - Andy Marshall, Ricciotti Architecte - Lisa Ricciotti - Martin Mai - Peter Mauss/Esto - Christian Richters - Iwan Baan - J. M. Monthiers - Base - Explorations architecture - Design/Editorial production: Agence All Write - Translation: TagLine - Printing: TCS/ARCM

Business Contacts - E-mail: [email protected] - Mailing addresses: Europe, Africa, Asia, Middle East: UHPC / Ductal® - Lafarge - 2, avenue du Général de Gaulle - 92148 Clamart Cedex - France North America: UHPC / Ductal® - Lafarge North America Inc. - 6509 Airport Road, Mississauga, Ontario - Canada L4V 1S7

PAGE 2 I News

Jean-Bouin stadium (france)

Inaugurated on 30 August 2013, the new Jean-Bouin Stadium, designed by the architect, is covered by an asymmetric, curving envelope made from 3,600 light grey, self-supporting triangular panels in Ductal®. The roof panels create a 12,000m² waterproof roof; and the horizontal façade panels create a tool surface area of 11,000m². Architect: Rudy Ricciotti.

casablanca: Pérez Art Museum Miami 2.2km The Pérez Art Museum in Miami, Florida (USA), OF SUNSHADES designed by award winning architects Herzog & The new Casa-Port station in Casablanca de Meuron will open to the public in December (Morocco), designed by AREP and Groupe3 2013. The Museum will have 200,000 square Architectes, will open its doors in 2014. On feet of space for works of art, educational its western façade, the station will be clad in activity, relaxation and dining. To meet the a contemporary moucharaby (latticework) cast aesthetic and resilience requirements, Ductal® from 840m² of UHPC, exposing the station UHPC was chosen to produce approximately to the outside while regulating the amount 100 long-span, precast vertical mullions of sunlight that filters through to the inside. to blend with the structure’s cast-in-place Next to the station, an office building will be elements and support the large curtain wall protected by UHPC sunshades with a total glazing which surrounds the building. Architects: Agences AREP et Groupe3 Architectes. length of 2.2km.

I PAGE 3 News

Standardization UHPCs enter the industrial age

Industrial companies’ investments in engineering, sustained by the commitment and innovation of designers and project owners, has enabled ultra-high performance concretes (UHPCs) to demonstrate their superior capabilities. Today, UHPCs require a technical and legal framework tailored to their volume growth and diversity of their applications. The standardization work now in progress should improve projects’ insurability over the short term by providing recognized and shared reference systems.

THREE-FOLD Ultra-high performance concretes are the these new concretes. Drafted in French and STANDARDIZATION WORK result of industrial research carried out in English, it addressed the initial questions and the 1990s and have exceeded previously expectations of an increasingly global market.” In line with existing standards, unexplored frontiers in terms of performance. “Nevertheless, the document is simply a the current approach to Numerous projects, supported by partnerships technical consensus,” explains François standards has three main and public research, have confirmed the many Toutlemonde. “Although risk-taking is reduced focuses in relation to UHPCs, advantages of these materials, validated in as the amount of reference material increases as identified in the AFGC each case by extensive technical research and volumes grow, from the perspective of recommendations from June insurers, as well as international economic 2013: “Until now, reference documents have reflected factors, nothing can match the power of an - a standard for the material, an accepted industry standard rather than an official standard.” including characterization official standard,” says François Toutlemonde. tests, “The revolution made possible by UHPCs, “Not even the ATEX directive, which involves - a standard for calculation their calculation methods – far removed from a relatively complex procedure and, in relation methods, those used for most industrial applications to UHPCs, often focuses more on ancillary - an implementation standard. – led the AFGC (French Civil Engineering questions than specific performances,” adds Although it is too early to Association) to develop the first provisional Jacques Resplendino. announce publication dates, recommendations document for UHPCs in Standardization is now even more urgent, since for the first part concerning January 2002, in partnership with government UHPCs have continued to develop and an materials, a working version ministries, large project owners, industrial increasing number of players are considering (draft) is likely to be produced in companies, supervisory bodies and civil their use in niche applications which were not 2014 and a standard compatible engineering companies. In June 2013, a new necessarily envisioned during the initial R&D. with Eurocode 2 should be ready definitive version of these recommendations “This diversification of the product range in within two years. was published, incorporating more than 15 response to new functional requirements years of feedback. This version was brought (heightened mechanical resistance, fire- into line with European calculation standards retardant properties, performances in (Eurocodes)” says Jacques Resplendino. “This aggressive environments, etc.) reflects the more voluntary pre-standardization work was vital to mature market which now exists,” continues be able to apply the innovation represented by François Toutlemonde. “In this context,

The objective of developing a standard UHPFRC 2013 is to facilitate the specification of UHPCs International symposium and their acceptance by the supervisory In Marseille at the MuCEM authorities. October 1-3, 2013 under the aegis of AFGC, this meeting is François Toutlemonde dedicated to engineers, architects, contractors, Scientific representative at IFSTTAR industries, laboratories, universities, building (the French Institute of Science and Technology for owners... Transport, Development and Networks) The objective is to review the complementary experience and knowledge in the use of UHPC, oriented on research and development.

PAGE 4 I News

This standardization work was vital to be able to apply the innovation represented by these new Standardization concretes. Jacques Resplendino South-East Director of Ingeneering organization with Setec UHPCs enter the industrial age Tpi, coordinator of the AFGC working group on UHPCs

the objective of developing a standard is to perspective,” says Jacques Resplendino. “The both the technical and economic approach. facilitate the specification of UHPCs and their technological and documentary advantage Through this standardization work, France is acceptance by the supervisory authorities. The achieved by France has supported work carried committed to maintaining this advantage and standard, which is far more enforceable than out in many countries (China, Switzerland, spirit of innovation.” existing documents, offers a range of reference Australia, Germany, the USA, etc.) and inspired systems, a guaranty and an insurability which others to produce their own recommendations. serve to reassure project managers regarding It is therefore urgent to give France a reference their choice of construction solution.” system to firmly establish the standards we have become used to working with and which The development of a standard addresses make us a driving force within international technical as well as economic challenges. standardization organizations.” “It is therefore vital for this work to involve all “At the end of the day, the main purpose stakeholders, so that the final text results from a of standardization work is to consolidate a transparent and responsible consensus,” says technology’s quality and safety. The move from François Toutlemonde. “And these aspects are a system of patents to a system of standards is obviously very important to us at IFSTTAR.” a guaranty of higher quality. All experts agree “Another factor adding to the urgency of this that the standard should promote this quality standardization process is the international aspect, which provides a strict framework for

EXPERT NOTES Juan Carlos López Agüí, What challenges are presented by the switch How does the UHPC standardization approach former chairman of the CEN (European from professional rules to a UHPC standard? differ from the standardization of concrete Juan Carlos López Agüí: These standards will under EN 206? Committee for Standardization) from 2007 represent an extension to the use of UHPC. It Michel Delort: The standardization approach to 2012 and an expert in the reliability of is crucial that they maintain the levels of quality dedicated to UHPCs stands out in at least three concrete structures and professionalism established in France, key ways: since these have prevented disputes, something - Standard EN 206 sets out categories of Michel Delort, vital to the development of any innovation. With reinforced or non-reinforced concrete Products and Applications Director at the extension of UHPC and the establishment designed for structures calculated according ATILH (Technical Association for the of these standards, the challenge will also be to to Eurocode 2, while our work focuses on Hydraulic Bonding Agents Industry) move from spectacular reference worksites to concretes reinforced only with fibers, which and coordinator of the AFNOR/P18B standard worksites which are just as convincing. are designed, specified and implemented standardization committee’s UHPC working I am confident that this task has been entrusted according to AFGC recommendations; group to the very best project participants and - With UHPCs, there is a jump in categories technicians. of resistance. While standard EN 206 covers concretes with maximum resistance of What are the main elements of the 2013 100 MPa, for UHPCs we are dealing with recommendations? structural concretes with resistance greater J.C.L.A.: I was struck by the global approach than 130 MPa; and the coordination between all aspects of the - Finally, our standardization work aims to project, from materials to execution. In particular, include a performance-based component, the reliable description of the orientation of which is not yet the case with standard fibers is something new and essential, especially EN 206. for non-reinforced structures. The method may be further improved, with an even stricter and more carefully researched safety margin. But, even applied in their current form, the 2013 recommendations guarantee a high level of reliability.

I PAGE 5 News North America ACI 239: Defining UHPC

To develop and report information on UHPC – that is the mission of the ACI 239 Committee chaired by Tess Alhborn

What is the mission of the ACI 239 committee? construction purposes. We must provide the necessary Tess Alhborn Tess Ahlborn: ACI 239 is a technical committee established technical and construction guidance and evaluate current Associate professor in 2009 and supported by ACI to work towards a common codes and standards in order to make recommendations of civil and definition for UHPC - that is comprehensive and inclusive. on required changes for UHPC in the precast US market. environmental Our mission is: “To develop and report information on engineering UHPC”. Currently, there is no common definition in the US, What are the challenges for the ACI 239 committee? at Michigan nor in the world. All of us on the committee are experts on T.A.: We are faced with many challenges, both short- and Technological UHPC, but of course we have different opinions. long-range. All of us are working on a voluntary basis, so University (USA) The following proposed definition, which is very generic the biggest challenge at the moment is to find sufficient with a research and simple, is currently in the process of ACI review and time to work on these reports. Long-range activities include program in the pending acceptance: identification of gaps in knowledge and research, as well area of innovative as development of guides for mix proportioning, design, concrete “Concrete, ultra-high performance - concrete that has placement, and certification. materials related a minimum specified compressive strength of 150 MPa to prestressed (22,000 psi) with specified durability, tensile ductility and Do you expect Lafarge to play a role in this process? concrete bridges, toughness requirements; fibers are generally included to T.A.: Yes; of course, Lafarge can’t write the standards for including UHPC achieve specified requirements.” the US market, nor should they, but the first UHPC testing applications; methods I used were written by Lafarge. We need codes Director of How will ACI 239 contribute to the development of and standards written and approved by the industry, such the Center for UHPC in the US? as ACI and ASTM, not on a single product but on UHPC Structural Durability T.A.: Our goal is to educate and gain acceptance of UHPC as a whole. with the Michigan and establish guides. This is long overdue as there is a Tech Transportation lack of awareness by owners, designers and precasters of What is the next step? Institute; founding the benefits and potential of UHPC in the US; how and T.A.: Several members of ACI 239 are co-organizing a member of the why to use it, etc. It is a challenge for companies who “Symposium on UHPC” with ASTM (American Society “North American want to generate a market for the material, therefore we for Testing and Materials) International on December UHPC Working are working on two documents: an Emerging Technology 8th, 2013, in Jacksonville, Florida. The purpose of the Group” and; report, a short-term document to introduce UHPC into Symposium is to provide a forum to discuss where founding member of practice by providing basic information for implementation current ASTM material specifications and test methods for one of the American and performance and; a State-of-the-Art report, which will concrete are inadequate for UHPC, propose new tests for Concrete Institute’s be a comprehensive document regarding development, UHPC, and exchange ideas as to where new specifications newest committees, deployment and recommendations for broader use of and methods need to be developed. It will be a very “ACI 239 – UHPC”. UHPC in the concrete industry. important event, as we will discuss the development of new standards, new subcommittees and/or expanded roles for What do you think of the UHPC design guidelines and existing ATSM subcommittees. recommendations published in France, Japan, and Australia? T.A.: It is important to learn from our colleagues worldwide, and similar documents should be generated for US

The Hodder Avenue Underpass in Thunder Bay, Canada has field-cast UHPC connections and precast Canopies, Chester, United Kingdom, Architect: Donald Insall elements including 3 pier columns shells and a large pier cap. Engineer: Hatch Mott MacDonald. Associates Limited.

PAGE 6 I Insights

This French-Swiss architect lives and works both in Paris, France and New York, USA. He studied architecture at ETH Zurich, taught at AA in London and then headed the Faculty of Architecture at Columbia University in New York. His theoretical essays include “The Manhattan Transcripts”, “Architectural and Disjunction”, “Event-Cities”, and more recently; “Architecture Concepts: Red is Not a Color”. He designed and built the Parc de la Villette in Paris, the Acropolis Museum in Athens, the Alésia MuséoParc, Le Fresnoy in Tourcoing, and the Zénith stadiums in Rouen and Limoges. His personal exhibitions include MoMA in New York (1994) and the Venice Biennale (2006). He also won the French Grand Prize for architecture (1996). Bernard Tschumi Architecture invents concepts and makes them a reality

What does Lafarge’s new signature “Building better cities” evoke; how does it fit in with its architecture and urban planning work; and what links can be forged between the architectural concept and materials innovation? These questions are addressed by Bernard Tschumi, recipient of the French Grand Prize for Architecture in 1996.

I PAGE 7 Insights

Blue Tower, New York, United States. Architect: Bernard Tschumi. Entrance lobby, Zénith in Limoges, France. Architect: Bernard Tschumi.

What does Lafarge’s new signature, “Building What are the main innovations in the field of better cities”, evoke for you? building materials which you have noticed recently; and how do you see the relationship Bernard Tschumi: It is strange to observe that with the manufacturers of these materials in for almost half a century, architects and urban relation to your areas of consideration? planners have come up with very few ideas and proposals to invent or transform cities. After B.T.: Architecture invents concepts and makes the CIAMs (International Modern Architecture them a reality. By that I mean that there is no Conferences) in the 1930s and 40s, Team X architecture without an idea or a concept, and in the 1950s, the inventions of the Metabolists that an idea or a concept is more important than and Yona Friedmann in the 1960s, and a form. But architecture differs from philosophy recommendations for a return for the past with or mathematics in that this concept always Aldo Rossi and Colin Rowe in the 1970s, there refers to a potential reality, a real object. So is almost nothing today. With a few very rare there is a close relationship between concept exceptions, there are no more creative projects, and material. For example, a material may despite the fact that we are experiencing the suggest an idea. Bricks for the Romans, iron most intense period of urbanization since the architecture in the 19th century, concrete in the start of humanity. Look at the cities that are early 20th century, and glass from the 1970s springing up in a few years in China and the were all drivers of architectural innovation. Middle East – there is no concept and almost Lafarge knows a thing or two about fibrous no new ideas. concrete. Conversely, an idea may generate That is why the emphasis placed recently research into a new material. These are the by Lafarge on “Building better cities” may two types of relationship which can exist with be important. We remember the arguments industrialists. put forward by Le Corbusier and his “Plan Voisin” (named after a car manufacturer) to revolutionize Paris. When will Lafarge come up with a plan to build a new type of city in several ...a material places in the world? may suggest Alésia MuséoParc, France. Architect: Bernard Tschumi. an idea.

Bernard Tschumi

PAGE 8 I Insights

Follies in the Parc de la Villette, France. Architect: Bernard Tschumi.

The relationship between concept and Interior, Acropolis Museum, Athens, Greece. Architect: Bernard Tschumi. material has

What are the two major production focuses Which of your projects do you think best always been of your current work as an architect or urban illustrates the phrase “Building better cities”? planner? crucial in B.T.: Since 2006 we have been working on a B.T.: The relationship between concept and brand-new city at a previously unused site near my team’s material has always been crucial in my team’s Santo Domingo, to house 40,000 inhabitants. architectural production. That is why, for each We call it “Elliptic City” and the first buildings architectural new building, we have tried to develop a concept are due to be delivered in 2015. The concept is based on the choice of a specific material, radical and seeks to preserve the forest covering production whether traditional or innovative. the site by creating a series of functional and Projects have found their expression in the spatial clearings, each containing homes, Bernard Tschumi red enameled steel follies of the Parc de la offices, schools, stores, etc. The project is Villette, the concrete and steel double envelope innovative in the sense that it is inventing high- of the Zénith in Rouen (followed by the wood- density pockets of development, but in a forest, polycarbonate double envelope of the Zénith in allowing the city to breathe… Limoges), the colored glass of the Blue Tower in Manhattan, and the wooden envelopes in Alésia and for the Vincennes Zoo. Not to mention the concrete at the Acropolis Museum and now our ANIMA Center in Italy made entirely from solid concrete poured in situ, 80cm thick on the southern façade and 24m high. For this last building, on which construction will begin in 2014, we chose not to use the lightness and translucent qualities of a Ductal® for example, focusing instead on solidity and weight, firmly anchoring the building in its site by playing on various types of perforation for each of the five façades.

Entrance lobby, Zénith in Rouen, France. Architect: Bernard Tschumi.

I PAGE 9 Markets

Façade Giving the envelope new functions

To offer façade elements which provide greater functionality – that is the challenge facing new UHPCs. As well as the technological ambition, project economics have changed. Guillaume Aelion, chairman of Betsinor, explains how these new-generation UHPCs offer a wide range of solutions for addressing contemporary construction challenges.

Textured panels, Thiais bus depot, France. Architect: Agence ECDM (Emmanuel Combarel - Dominique Marrec).

What is your analysis of changes in the façade changes – particularly in the façades market. market? As well as being the best representation of a Guillaume Aelion: That question should be building’s image, façades are now fulfilling addressed in the broader context of the current more and more functions. This presents a economic environment. We are currently number of challenges to materials, to ensure seeing a cyclical change whereby the prosperity that façades’ project economics are more in we experienced previously no longer applies. line with the budgetary and environmental Betsinor, We cannot allow ourselves to proceed by trial constraints faced by our society. prefabricator and error and backtrack when necessary. of architectural Remember that construction methods have What are Betsinor’s responses to these changes? components, and a changed little in 30 years. But regulations G.A.: Betsinor specializes in the design, member of Lafarge’s have intensified considerably in the meantime, production and installation of architectural network of UHPC significantly driving up construction costs. elements made from cement-matrix licensees since This means we face a transformation in composites. We offer several types of solutions, 2004. construction methods, involving radical although all are focused on the objective

PAGE 10 I Markets

Perforated panels, in a continuation of the stamped concrete, Musée d’Art Moderne in Lille, France. Architect: Manuelle Gautrand.

of offering lighter, more efficient functional to respond to the problems A UHPC solution façades. of each type of project and for each type For instance, both wall systems we offer (BEPIV therefore promote façades of project and WOODIV) have complex characteristics, which benefit from the including passive sealing which is already in performances of UHPCs line with the likely requirements of the RT 2020 and offer ever greater thermal regulations. functionality, creativity and Their total thickness ranges durability. from 15cm to a maximum As an example of this approach, UHPC was of 35cm, one of the major required to provide air-sealing with self- advantages of UHPCs. This supporting elements in order to hold insulation The virtuous results in considerably lower and door and window frames – which no construction consumption of materials, sprayed product currently allows. therefore lighter buildings, That is the revolution offered by the future, circle less pollution (caused by sprayed applications of UHPC. This technology transportation) and faster makes it possible to break free of backing construction, while at the molds – often required for elements with same time offering greater complex geometry – and, at 20mm thick, will functionality and durability. offer functions equivalent to 20cm of sprayed This means that UHPC façade solutions concrete. can offer a virtuous construction circle that The main focus of our work is always on responds to the transformation mentioned product quality, experience and expertise in earlier. innovation, which has always given Lafarge the technological advantage that Betsinor has So light façades are the future? relied on for many years. G.A.: Studies show that it is hard to estimate the moment when the traditional market reaches its limits. However, in the exterior thermal insulation segment, which has been steadily growing in recent years, the sub-segment that is developing fastest is customized, attached facades.

What is the objective of the partnership you have with Lafarge? Curtain wall, Rotman School G.A.: One of the changes imposed by the of Management in Toronto, current economic climate is to move on from Canada. Architect: KPMB a system which only offered one solution. Our Architects. joint ambition is to offer formulas tailored to manufacturing processes, making it possible

I PAGE 11 Markets

23cm The thickness of a UHPC façade that provides good external thermal insulation

Waterproof insulated render, Budin daycare Full-height latticework at the Rue Blanche hospital in Paris, France. Architect: Philippon- center in Paris, France. Architect: Agence Kalt Architectes. ECDM (Emmanuel Combarel - Dominique Marrec). Façade: Roundup of new UHPC solutions

Elimination of thermal bridges, air- and water-tightness, lightweight, thinness, solidity – Ductal® has demonstrated how UHPCs’ characteristics respond brilliantly to external thermal insulation challenges. Following in the footsteps of this revolutionary product, new formulations are now available which offer easy-to-implement solutions for façades that combine external thermal insulation, aesthetics and durability.

Insulated, impermeable frameworks, façade panels, sun- Drawing on the know-how it has developed over 15 years shades and facings – UHPCs today are offering more with Ductal®, “Lafarge is now expanding its range of applications for innovative, contemporary façades. These dedicated UHPCs, optimizing the parameters according to new solutions, such as external insulation elements, the planned use,” continues Emilie Hergott. “For UHPCs enhance the functions fulfilled by the façade. containing organic fibers, the ambition of our research effort “The mechanical performances of UHPCs enable façade has been to revise the constituents of the cement matrix elements to be much lighter and very to offer alternatives, with almost identical performances, easy to implement,” explains Emilie tailored to each project’s architectural and budgetary Hergott, project management engineer objectives.” with the Lafarge UHPC team and project This applied research, part of the Group’s core identity, is Sprayed manager for light façades. The insulated, also focused on the development of new sprayable formulas. UHPC: impermeable framework solutions we are In partnership with Betsinor (see interview with Guillaume currently developing produce efficient Aelion pages 10-11), this solution will release UHPC from a major external thermal insulation with 23cm the mold/backing mold process for the creation of elements innovation walls, while it is difficult to make the brick/ which are not flat. insulation/cladding solution less than This unique casting process will permit the production of 36cm.” façade panels with complex geometries, a UHPC solution These same mechanical performances that benefits from all the combined expertise of Lafarge and therefore represent a major creative Betsinor.” advantage. “The pouring process and ductility of the material allow it to adapt to all geometries. The thinness of the cement matrix also ensures that all the patterns in the mold are reproduced, enabling significant textural freedom.” All these characteristics are now being used in formulas dedicated to creating open, lattice style facade systems as well as very slender balconies and sun-shades which contribute to the energy efficiency of the building, while

offering designers new creative possibilities. © D eSo A rchitectes ssociés - Hervé bbadie

Perforated panels at the media library in Evry, France. Architect: DeSo Architectes Associés.

PAGE 12 I Markets Wind turbines Resistance, sealing

and flexibility Imagine new solutions with UHPC for wind turbine masts.

Alternative energy sources, The masts of most wind turbines have so several structures in a marine environment, particularly wind farms, are far been constructed from stainless steel. thereby suggesting that these materials could Early models required a significant sacrificial provide an excellent alternative in the future. enjoying a fair wind these increase in the thickness of the steel to ensure “The repair of a beacon off the coast of Lorient days - judging by the rapid a structural lifespan of around 25 years. Many (France), by pouring Ductal® into forms from a increase in calls for tenders. consider this insufficient given the investment helicopter, demonstrated the possibilities and and complex construction involved. performance benefits of using this material, Feedback on the first masts Alternatively, the proven performance even in the open sea,” says Dominique Corvez, built from steel has revealed characteristics of UHPC indicates that for Head of UHPC-Ductal® for North America. the limited life-span of this the same mass as steel (a decisive factor for This experience reinforces the idea that this type of structure), this material could be partnerships between general contractors, choice of technology for off- used to construct masts that last up to 4 times turbine operators, energy companies and shore installations. longer. UHPC manufacturers are capable of paving Could UHPCs provide a the way for a global market, inresponse to The inability to penetrate UHPCs with marine the growing energy challenges faced by all sustainable alternative? salt has been observed during repairs to countries.

Successful application of pouring at sea

Illustrating the possibilities offered by UHPC Ultra-high performance concretes are products for the wind farm market and well-suited for extremely harsh marine offshore structures, the partnership between environments, since they offer excellent Lafarge, the CETMEF (French center for durability (5.10-20 permeability) encouraging maritime and river technical studies) and the resistance to external aggressions (chlorides, EPFL (Lausanne Federal Polytechnic School, freezing/thawing, erosion, etc.). The product’s Switzerland) led to the development of a UHPC implementation was also very specific since specifically formulated for the repair of a badly the mixing was carried out at a concrete deteriorated turret in Lorient harbor (France). batching plant to ensure rapid production of The operation involved complete cladding of large quantities of UHPC, i.e. 5m³ of UHPC in the Cabon turret by pouring UHPCs in situ to a two hours. The formula, with long rheological depth of 6cm. In response to the configuration consistency (three hours) was transported in of the structure, this innovative UHPC formula mixer trucks and then by helicopter to the top offers reduced shrinkage and hardened of the turret. traction resistance due to a high level of metallic The strengths demonstrated on this project fibers, and reduced shrinkage to absorb drag show that, as well as their impressive forces. Its self-placing characteristics (EN 206- mechanical performances, UHPCs also benefit 9 standard, class SF2) are also essential for from durability and flexibility of use. They are pouring in confined spaces. therefore particularly well suited for remote or difficult-to-access locations such as offshore sites. Pouring UHPC by helicopter at the Cabon turret in the bay of Lorient, France.

I PAGE 13 Markets Bridges & footbridges

Fine Y-shaped legs made of UHPC support the bridge deck of Pont de la République. Architect: Rudy Ricciotti.

Pont de la République in Montpellier: immaculate elegance

The Pont de la République, designed by the architect Rudy Ricciotti and the Lamoureux et Ricciotti engineering office – the new bridge to span the Lez river in France, which flows through the newer districts of Montpellier – won over the municipal committee due to “its elegance and the finesse of its architectural approach”. These aesthetic characteristics are attributable to a new Ductal® formulation blended with stainless steel fibers, with no signs of corrosion on the 34 white piers that support the deck.

74m long Connecting the new districts of Montpellier’s One of the reasons this 17m wide Hôtel de Ville and the Odysseum, the Pont structure, designed (by de la République carries a two-lane highway, Rudy Ricciotti) “in the style 2 rows of cycle paths and sidewalks. of a millipede”, appealed to A major 17 Y-shaped piers Above the Lez (a bucolic river with potential the local authorities, is the aesthetic with 9m range and flooding), the bridge needed to be extremely immaculate elegance which challenge 30cm in diameter, resistant to chemical corrosion and humidity. makes it so original. made from stainless The structure, made from UHPC, is 17m steel white Ductal® wide and 74m long. It includes 3 sections of “By coating all the prestressed equal length, each comprising precast beams elements, UHPC not only reinforces durability” Pier compression supported by 17 precast piers and tilting explains Alexandro Guitton, “the new resistance upper piers made from Ductal®, prestressed (post formulation of this White Ductal® incorporates 150 MPa after heat -tensioned) in the plant. The beams were stainless steel fibers – a first – avoiding any treatment assembled crosswise on site by prestressing. possibility of rust development and contributing to achieving the specific aesthetic desired by A new formulation: “One of the challenges of this project, which the designers.” made from White was launched last May, was to respect the Ductal® with stainless periods of high water to avoid postponing steel fibers everything for a year,” says Alexandro Guitton, Lafarge project management engineer. “Prefabrication therefore saved us valuable time on site.”

PAGE 14 I Markets

Blandan footbridge: UHPC enhances heritage

Located on a former military site, the 42-acre Blandan Park will offer a green space bordering three districts in the center of Lyon, France. Including various leisure facilities – landscaped green areas, solarium and play wall – the park will feature a walkway “attacking the old barriers” on a footbridge constructed from UHPC. This reveals what happens when an extraordinary material becomes widespread to offer inhabitants a discreet and durable aesthetic.

Blandan Park, planned as the third green space in the city of Lyon, is situated on the site of a former army barracks with architectural features that the city wanted to preserve as part of its 19th-century military heritage. “To support this major historical project, the BASE landscaping agency – the main contractor through which we became involved – suggested a pathway to represent military The defense systems from the ramparts to the present day,” explains Yves Pagès from thinness Explorations architecture, designer of the of steel footbridge crossing the park. “The site’s topography made it possible and the to symbolize this ‘attack on the walls’ via durability a footbridge connecting to them after a 100m path, while offering an alternative ® of view of the park, particularly for those with The Ductal footbridge provides a 100 meter pedestrian promenade that connects directly to the ancient walls. Architect: Explorations Architecture. concrete reduced mobility.”

“In this very sophisticated landscape, we Composed of a 5cm-thick, dark gray Ductal® deck felt it would be interesting to incorporate and a 40cm-thick side rail supported by steel a mineral structure presenting the thinness and posts, the 100m-long and 2.30m-wide footbridge durability of concrete, while blending with the overlooks the park while gently rising 4m in height. architectural heritage contained in the park. “Our goal is to demonstrate that UHPCs are Additionally, the footbridge would be uniform, not reserved for large symbolic sites. Their discreet and integrated as best as possible within performances and capacities cover an extremely these green spaces.” wide range of applications, enabling them to respond equally well to the most modest specifications, both in terms of scale and budget. The durability and total lack of maintenance helped convince the local authorities of this elegant and discreet project,” says Yves Pagès. “Produced from Ductal®, the structure enjoys a level of durability which was very reassuring for the project owner,” explains Dominique Corvez, Head of UHPC-Ductal® for Lafarge North America. “Combined with the prefabrication by Bonna Sabla of 10 railings using just 2 molds and 2 backing molds, we managed to achieve project economics in line with the city’s budgetary requirements.”

Monolithic and discrete, the footbridge in Ductal® is integrated with green spaces. Architect: Explorations architecture.

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The evolution of Ductal® Joint Fill From humble beginnings to significant growth

It has been almost a decade since Lafarge and the Ministry of Transportation of Ontario (MTO) embarked on a collaboration that led to the development of a revolutionary, ultra-high performance concrete solution called “Ductal® Joint Fill”. Since then, this highly durable UHPC solution (which is field-cast and primarily used for the connection of precast bridge elements) has been used on numerous projects. With these proven successes and significant, validated research studies now behind us, the momentum in North America is growing rapidly.

The world’s first Ductal® Joint Today, Ductal® UHPC Joint Fill is being used Fill project was completed on much larger, high-profile structures. Earlier for the MTO in 2006 on a projects were small, simple span bridges Superior small, single span (24.4m requiring an average of 5m³. More recently, Performance long x 11m wide) highway multiple span, larger projects have been bridge over the Canadian completed and new projects awarded that are National Railway at Rainy designed to incorporate up to 500m³. Lake, Ontario. Successful completion of this project The Mackenzie River Twin Bridge project proved that multiple benefits could be realized in Ontario, Canada is the largest Ductal® for precast bridge systems with Ductal® Joint Joint Fill project to date. Each bridge has 2 Fill connections: superior strength, durability, lanes and 3-spans for a total length of 180m. fluidity and increased bond capacity. The Altogether, 130 precast deck material’s fiber matrix is significantly stronger panels were used; the transverse than conventional concrete and performs joints (between panels) are filled better in terms of fatigue, abrasion and with Ductal® as well as the shear Changing chemical resistance, freeze-thaw, carbonation pockets and haunches (between and chloride ion penetration. Testing has panels and steel girders). The Scope proved that after 10 million equivalent wheel precast approach slabs also have load cycles, there is no leaking through the Ductal® connections. All precast joint and, when used with precast concrete elements for this project were bridge elements, fabrication and installation manufactured by Lafarge Precast in Winnipeg, processes are simplified, full deck continuity is Manitoba. Ultimately, it took just ten days to achieved and the bridge deck joint is no longer cast the 175m³ of material required for this the weakest link. project.

The use of this solution, together with precast concrete bridge elements, has dramatically increased in recent years, with several bridge owners now specifying Ductal® Joint Fill. The MTO and the New York State Department of Transportation (NYSDOT) continue to lead the way with repetitive use of UHPC on their bridge projects; the majority requiring quick rehabilitation or replacement of existing, deficient structures. Previously, the NYSDOT would not consider closing an interstate highway due to high traffic volumes. Now

Little Cedar Creek Bridge, Iowa - The first bridge in North America however; thanks to experiences gained from constructed with a Ductal® UHPC waffle deck, girders and joints. Engineer: Wapello County.

PAGE 16 I Markets

The largest Ductal® Joint Fill project so far - Mackenzie River Twin Bridges near Thunder Bay, Ontario, Canada. Engineer: McCormick Rankin Corp.

previous successes in rural areas, they have the ability to replace bridge decks during weekend closures. Adding

In North America, the Ductal® Value Joint Fill business has become self-perpetuating, indicating an opportunity for enormous growth. In 2010, 5 bridges were completed with Ductal® UHPC Joint Fill. In the summer of 2013, 36 projects were slated for completion by year-end. With projects now completed in Ontario, New York, Iowa, Montana, Massachusetts and Oregon, acceptance is increasing at a rapid pace. By the end of 2014, it is expected that Ductal® Joint Fill projects will also be completed in Ohio, Pennsylvania, Pouring Ductal® UHPC into a joint on a precast deck panel system. Manitoba, Nebraska, New Jersey, Utah and South Carolina.

Precast UHPC and HPC bridge solutions work extremely well when used in combination with field-cast UHPC connections, creating sustainable, durable, more resilient bridge structures that are built to last. In remote areas, this solution is especially valuable where access to ready-mix concrete is not available awards and post-tensioning can be eliminated, thereby The following is a list of awards for Ductal® Joint Fill projects: simplifying the construction process. > Portland Cement Association (PCA) Concrete Bridge Award - Hawk Lake Bridge, Ductal® UHPC Joint Fill is also an excellent Ontario, Canada (2010); solution for Accelerated Bridge Construction > Precast/Prestressed Concrete Institute (PCI) Design Awards, Honorable (ABC). For example, some projects have been Mention/Special Solution - Route 31 Bridge over Canandaiga Outlet, New successfully completed during closures of just York, USA (2010); Little Cedar Creek Bridge, Iowa, USA (2012) and Hodder one month, one week or even one weekend. Avenue Underpass, Ontario, Canada (2013); Ultimately, by utilizing UHPC’s combination > Ontario Concrete Awards - Whitemans Creek Bridge, Ontario, Canada (2012); of superior properties in conjunction with > PCI Harry H. Edwards Industry Advancement Award - Hodder Avenue Underpass, precast bridge elements, bridge performance Ontario, Canada (2013). is advanced, accelerated and improved.

I PAGE 17 Project

Architect: Rudy Ricciotti.

PAGE 18 I Project

MuCEM DUCTAL® COMBINES TECHNICAL PERFORMANCE WITH ARCHITECTURAL CREATIVITY The official opening of the new Museum of European and Mediterranean Civilizations (MuCEM) is a major event in Marseille (France), this year’s European Capital of Culture that showcases the amazing performance delivered by UHPC.

Created by Rudy Ricciotti, MuCEM uses the structural strength and aesthetic properties of Ductal® to create an architectural masterpiece that introduces new construction methods and new opportunities for creativity. From post-tensioned, prestressed anchors to the lattice canopy and footbridge (linking the museum to the stone ramparts of Fort Saint- Jean), Ductal’s ductility, durability and mechanical strength properties are fully exploited in this beautiful, lightweight building that is resistant to the ocean and its salty atmosphere.

Take a guided tour of this new technological and aesthetic benchmark.

I PAGE 19 Project

Suspended between the sea, land and sky, MuCEM occupies Pier J4 of the former city docks, and is almost unobtrusive by comparison to the Fort Saint-Jean and Old Port of Marseille. Nevertheless, with its prestressed vertical structures and lattice envelope, this 15,000 square meter building is immediately striking because of its technological achievement. Architect, Rudy Ricciotti, wanted to create ‘an ethereal project that was very feminine, but also very muscular with clearly defined tendons and nerves’. The result is a building that is uncluttered to the point of being stripped almost bare. The choice of UHPC enabled the dimensions to be reduced “to the point where all that remains are skin and bones.” MuCEM exploits all of the architectural and structural performances of Ductal® to create the signature elements that make it so distinctive including: pedestrian footbridges, arboresque style columns and a lattice roof and facade.

UHPC elements 5

1 Lattice walls 2 Footbridge linking the museum to Fort Saint-Jean (135 meters with return) 3 Arboresque columns 4 Lattice roof 5 Anchor points

TESTED AND PROVEN level of resistance to engineers), made it TECHNICAL PROWESS high temperatures. The possible to overcome Using UHPC for the assembly techniques were all these obstacles. structural elements of a customized and dictated The prefabricated public building meant that by the systematic use of elements for MuCEM the material formulation prefabrication, not only were the subject of 5 ATex had to be adjusted, for the building’s UHPC (Technical Experimentation especially in terms of its elements but also for its Assessments) conducted seismic and fire resistance. floors. Close collaboration by the CSTB (the French For this purpose, adding between Lafarge, Bonna Scientific and Technical the optimum quantity of Sabla, Dumez-Freyssinet Center for Building). polypropylene fibers gave and Lamoureux & Ricciotti the UHPC the required (architect and structural Architect: Rudy Ricciotti.

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The longer of the two footbridges is constructed from 25 prefabricated segments that are assembled with post-tensioned cables and a deck consisting of 4cm slabs laid over the segments. The specification demanded construction tolerances of between 0.3 and 0.4mm between components. Architect: Rudy Ricciotti.

The footbridges

135 From the Panier district of the city, Ricciotti, co-founder of Lamoureux THE LENGTH (in visitors approach Pier J4 over a & Ricciotti. These footbridges are meters) OF THE succession of two footbridges. One of constructed in individual precast FOOTBRIDGE LINKING MUCEM TO FORT the bridges is 69 meters long and links UHPC segments, each 4.60 meters SAINT-JEAN the Esplanade Saint-Laurent to Fort long and cast from a single mold. They Saint-Jean. The other is are assembled by prestressing and even longer, reaching post-tension with no buttressing and out over the sea below no bracing stays. “UHPC was the only 4.6m BUILDING like a stretched thread material that would allow us to use such THE LENGTH OF EACH connecting the Fort with high compression ratios,” says Romain SEGMENT CAST FROM THE SAME MOLD ON PREVIOUS Pier J4, and spanning Ricciotti. What makes the segments of EXPERIENCE 76 meters between these footbridges particularly special abutments (135 meters is that their webs contain no passive with return). “In terms of reinforcement. 0.3Mpa

their design, construction, THE PRESSURE USED method and foundations, TO ASSEMBLE THE these two footbridges are based on SEGMENTS the same concept as the Passerelle des Anges in France’s Hérault valley,” explains Patrick Mazzacane, project leader at Bonna Sabla, and Romain 4cm THE THICKNESS OF THE FOOTBRIDGE DECKS

I PAGE 21 Project

Architect: Rudy Ricciotti. Architect: Rudy Ricciotti.

In order to control deflections, such as buckling under load in The columns the event of fire, and to assist with component assembly, cables were Inside the building, a second, 52-meter square run through vertical space, houses the museum’s exhibit halls. ducts in each column Between this core and the service spaces, and tightened using voids surround the central square to create jacks at either end. communicating walkways. The walls of the These columns are also building created on Pier J4 contain 308 engineered to withstand structural arboresque style seismic risk through the columns. Like individual use of Freyssinet ball- sculptures, 80 different and-socket joints top and configurations are created MILLIMETER bottom. from three types of columns that are Y-, I- and N-shaped. ACCURACY “The prestressed UHPC columns were cast vertically and within a millimeter of accuracy tolerance,” explain Patrick Mazzacane and Romain Ricciotti. A specially developed fiber counting technique was used to check fiber orientation and distribution throughout the full length of each column, and to ensure that there was no fiber segregation present. After the molds were removed, the columns - like the footbridge segments and lattice panels - were sprayed with waterproof sealant and heat treated to achieve their required mechanical performance. Contrary to conventional construction techniques, and for reasons of project phasing, the prestressed concrete floors were installed first on substructures completely independent of the columns.

3 types of columns and 80 different configurations.

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The lattice facade and roof

The second footbridge leads to the roof terrace of the building: a perfect square with sides that are 72 meters long and 18 meters high. A UHPC lattice panel system envelopes two sides of the building and its roof. Its purpose is to protect the interior With nine different types of lattice panels to create, each with perforations accounting for more than 50% of their against very high surface, fabrication required the development of a vertical molding process to guarantee a smooth finish inside levels of sunlight, and outside. Architect: Rudy Ricciotti. while allowing the PROTECTING sea air to penetrate THE the building. Two INTERIOR, different types of lattice systems WHILE OPEN were created for TO THE this project, using EXTERIOR horizontal panels for the roof, and vertical panels for the facade. “We achieved all of that with a thickness of only 7 centimeters for the roof and 10 centimeters for the facade; that’s totally unprecedented for horizontal applications,” continues Patrick Mazzacane. The 384 lattice panels were fabricated using a vertical mold to ensure a smooth finish on both sides. Installation began with the roof panels, which are supported on UHPC T-beams. The self- supporting panels were then stacked to create the full height of each facade, retained in position and secured to the main structure using metal connectors.

From every point of view, the unique construction techniques used to create MuCEM are very different from those used in traditional concrete structures. In the words of Romain Ricciotti: “UHPC buildings are now more like metal structures than concrete structures in terms of their conception and design. The problems lie not in the dimensions of a particular element, but in the way they function interactively.” That is one of the great challenges to which MuCEM responds so successfully.

The façade lattice panels are secured to the main structure using stainless steel stays. Architect: Rudy Ricciotti.

I PAGE 23 Lafarge UHPC / Ductal® 61, rue des Belles Feuilles BP 40 - 75782 Paris Cedex 16 France E-mail: [email protected] www.ductal-lafarge.fr