Steel Fibre Reinforced Concrete for Tunnel Lining – Verification by Extensive Laboratory Testing and Numerical Modelling
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Acta Polytechnica –(–):1–9, 2013 © Czech Technical University in Prague, 2013 available online at http://ctn.cvut.cz/ap/ STEEL FIBRE REINFORCED CONCRETE FOR TUNNEL LINING – VERIFICATION BY EXTENSIVE LABORATORY TESTING AND NUMERICAL MODELLING Jaroslav Beňoa,b,∗, Matouš Hilara,c a Faculty of Civil Engineering, Czech Technical University in Prague, Thákurova 7, 166 29 Prague, Czech Republic b Metrostav a.s., Koželužská 2246, 180 00 Prague, Czech Republic c 3G Consulting Engineers s.r.o., Na Usedlosti 16, 147 00 Prague, Czech Republic ∗ corresponding author: [email protected] Abstract. The use of precast steel fibre reinforced concrete (SFRC) for tunnel segments is a relatively new application of this material. It was first applied in Italy in the 1980s. However, it did not begin to be widely applied until after 2000. The Czech Technical University in Prague (CTU), together with Metrostav, carried out a study to evaluate the use of this new technology for tunnels in the Czech Republic. The first tests were carried out on small samples (beams and cubes) produced from SFRC to find an appropriate type and an appropriate dosage of fibres. The tests were also used to verify other factors affecting the final product (e.g. production technology). Afterwards, SFRC segments were produced and then tested at the Klokner Institute of CTU. Successful test results confirmed that it was possible to use SFRC segments for Czech transport tunnels. Consequently a 15 m-long section of segmental lining generated from SFRC without steel rebars was constructed as part of line A of the Prague metro. Keywords: Steel fibre reinforced concrete, segmental tunnel lining, mechanical excavation, laboratory testing. 1. Introduction are influenced by several factors: the material of the Steel fibre reinforced concrete (SFRC) is a relatively fibres, the shape of the fibres (especially adjustment new structural material. In the past, it was used of the ends), the amount of added fibres, and the mainly for construction of industrial floors. Nowadays, composition of the concrete mixture. It is necessary SFRC often replaces steel bar reinforced concrete; the to ensure uniform distribution of fibres in the con- tunnel lining from precast segments is one of many crete, and to ensure that they are well coated with examples. In tunnelling SFRC is used in three basic cement mortar. SFRC cannot be generated just by modifications – sprayed concrete for primary outer adding fibres to a standard concrete mix. The com- lining, in situ cast concrete for the secondary inner position of the SFRC mix has to be designed taking lining, and precast segments for tunnels constructed into account the increased volume of the aggregate with tunnelling shields. The main advantages of SFRC caused by fibres. The dosage of fibres is determined over widely-used steel bar reinforced concrete (RC) by McKee’s theory. The minimum amount of fibres segments are as follows: simple production, higher depends on their length and thickness. Some types of durability, lower consumption of steel, lower number of fibres can generate conglomerates during the mixing defects, etc. A major disadvantage of SFRC segments process; they should therefore be added to the mix without steel rebars is their lower bending capacity. using dosing and dispersing equipment before mixing. Uniformly distributed and randomly oriented fibres The length of the fibres length should be approxi- transform brittle plain concrete into ductile SFRC. mately three times the maximum aggregate size. This SFRC can be used to replace plain concrete or re- will bridge cracks located on the border of the grains, inforced concrete. The steel fibres improve the me- and avoiding pulling out of fibres during the develop- chanical properties of the concrete. The fibres carry ment of these cracks. The strength of SFRC parame- local tensions caused by three-dimensional stress be- ters depend mainly on the aspect ratio of the fibres tween aggregate particles. Fibres in concrete enhance (length to diameter) and on the dosage of fibres (when its compressive strength, but especially SFRC tensile there is the same concrete matrix). A higher aspect strength is higher. SFRC has high resistance against ratio (or a higher fibre content) generally means better the development of microcracks. This feature is re- performance of the SFRC. lated to SFRC’s high resistance against dynamic load SFRC is especially suitable for structures loaded and resistance against sudden temperature changes. in more than one direction, where traditional bar re- The physical and mechanical properties of SFRC inforcement is problematic. This means that SFRC 1 J. Beňo, M. Hilar Acta Polytechnica Figure 1. Spalling of unreinforced edges of traditionally reinforced segments [1] is not appropriate for unidirectionally loaded struc- tor (a hydraulic arm at the rear part of the shield). tures, because the randomly oriented fibres would One ring usually has dimensionally identical segments; be largely unloaded. SFRC is therefore suitable for the final segment (the key segment) has a different tunnel segments loaded in various directions during shape and is smaller in size. Individual segments are their production, installation and permanent func- connected by bolts. The space between the lining and tion. Polypropylene (PP) fibres cannot be used as a the ground is grouted. reinforcement for concrete structures, because they Segments are loaded by a wide range of loading have a low modulus of elasticity (lower than concrete), conditions during their lifetime. Similarly to other which means big deformations. Moreover, PP fibres precast structures, the segments have to endure de- lose their mechanical properties at 50°C and melt at moulding, manipulation, storage and transportation 165°C. PP fibres can be used in SFRC structures or to the construction site. They also have to carry loads in reinforced concrete structures to increase their fire during their installation, namely they should be able resistance. to carry the axial forces generated by the hydraulic rams that push the shield into the ground. The load 2. Segmental tunnel lining generated by shield rams is often decisive for the de- sign of the segments. All load cases mentioned here Tunnel linings constructed from precast reinforced are only temporary. The segments are loaded only concrete segments started to be used in the 1950s, by ground pressure and hydrostatic pressure during when they gradually replaced steel and cast-iron seg- tunnel operation. This load case should correspond ments. Reinforced concrete linings from precast seg- with the reinforcement of the segments. ments were widely used in the construction of the metro in Prague, where the lining was not waterproof due to the manufacturing tolerances. Water-tightness 3. A comparison of traditionally of the lining was reached by additional grouting of reinforced segments and SFRC the joints between segments, but the risk of leakage was relatively high. Modern segmental linings have segments manufacturing tolerances of ±0.5 mm, and water tight- SFRC segments are suitable for structures without ness is guaranteed by impermeable concrete together high bending moments. A tunnel lining constructed with EPMD (ethylene propylene diene monomer) gas- by tunnelling shields is circular in shape, which is kets between the segments. SFRC segments can have advantageous due to the low bending moments. In complicated details, as every part of the segment is standard geotechnical conditions, the segments are uniformly reinforced by fibres (Fig. 1). There is there- loaded mainly by compression with relatively small fore less damage of segments during transportation eccentricity (i.e. without bending and without tensile and installation, which means that there is a lower stress). risk of leakage and fewer repairs are required. After reaching tensile strength, the deformation of Nowadays segmental lining is used only in mechani- SFRC does not increase abruptly, but thanks to the cal tunnelling with tunnelling shields (Tunnel Boring uniformly distributed fibre deformations it increases Machine technology – TBM). A permanent lining is gradually and causes a greater number of small cracks. installed directly behind the tunnel face under the This is because the fibres are activated and are contin- shield protection. The lining has a circular shape uously pulled out from the concrete. The cracks are composed of several precast concrete segments. Each relatively small, and the crack openings remain small. segment is placed in the required position by the erec- The total value of the tensile strength of the segments 2 vol. -- no. --/2013 Steel Fibre Reinforced Concrete for Tunnel Lining is significantly lower than in the case of bar-reinforced uniformity in the design methods and required tests. concrete segments. A European standard for the design of SFRC struc- The behaviour of reinforced concrete is different. tures is currently being prepared. The standard will After reaching tensile strength, the increment of the be based on EC 2 for concrete structures; parts fo- deformation develops until full activation of the bar cused on SFRC will be amended. reinforcement. This results in wider cracks than in the case of SFRC, and one main crack usually appears. 4. Tests on SFRC samples Afterwards, however, the deformation stabilizes and Laboratory tests on SFRC are similar to plain con- grows approximately linearly, until it reaches the yield crete tests. In contrast to plain concrete, the tensile strength of steel bars. This is significantly higher strength or the equivalent tensile strength after crack- than the strength of steel fibre reinforced concrete ing of SFRC structures can be taken into consideration. in tension. Destruction of the structure occurs after The effect of added fibres on increasing of the cube reaching the ultimate strength of steel in tension or compressive strength, the tensile splitting strength crushing of concrete in compression. and the equivalent flexural strength is not identical. SFCR structures are better protected against cor- Due to the added steel fibres, the tensile strength rosion. This is mainly because there are lower crack usually increases more than the compressive strength.