ultra high performance fibre reinforced concrete (uhpfrc...
TRANSCRIPT
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Ultra High Performance Fibre Reinforced Concrete (UHPFRC) for durable rehabilitation of bridges
Dr. Aljoša Šajna
Slovenian National Building and Civil Engineering Institute
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0. OUTLINE
1. Motivation2. UHPFRC materials3. What is proposed ?4. Existing knowledge/experiences5. Recent advances in Slovenia6. Conclusions7. Links and documents
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1. Motivation ARCHES
• The goal of ARCHES (Assessment and Rehabilitation of Central European Highway Structures): reduce the gap in the standard of highway infrastructure between Central and Eastern European Countries (CEEC) and the rest of the EU.
• To develop more appropriate tools and procedures;• To avoid unnecessary interventions (repairs/replacements) in
structures;• To prevent the development of corrosion by simpler, and less
expensive techniques;• To implement faster, more cost-effective, and longer lasting
rehabilitation techniques (repair or strengthening) of sub-standard and unsafe bridges;
• To disseminate results and general best practice to the key stakeholders.
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Limited resources for management of road structures (time and money, including user’s costs)!
Limit duration of construction sites Increase durability and efficiency
for rehabilitations for new constructions
Promote Strategy A Make best use of most
advanced materials Combine materials in
efficient composite structures !
1. Motivation WP5
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1. Why UHFPRC
Durable Outstanding protective properties Outstanding mechanical properties Tensile strain hardening Applicable on site Adoptable to site conditions Sustainable repair solution
Fractured surface of UHPFRC
10 mm
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2. UHPFRC composition
• Water/Binder = 0.125 to 0.140• Cement: 1051 to 1434 kg/m3
• Silica fume: SF/C = 0.05 to 0.26 (mass)• Superplasticizer: SP/C = 1 % (mass, dry extract)
MicrosilicaCement
CEM I 52.5Fine sand
Dmax=0.5 mm
Ultra compact cementitious matrix
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2. UHPFRC composition
• Steel wool + steel fibres • Total dosage 468 - 706 kg/m3 (6 to 9 % Vol.)
Fibrous reinforcement
MicrofibresSteel wool
MacrofibresL=10 mm, D=0.2 mm
CEMTECmultiscale® developed by Rossi et al. (2002)
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2. UHPFRC characteristics
• Selfleveling• Outstanding protective properties
“Selfleveling”
“Low air permeability (Torrent)”
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2. Tensile response
Deformation capability > restrained shrinkage E modulus: 30 % higher than usual concretes Tensile strength: 3 to 4 times higher than usual concretes !
UHPFRC results on 5 specimens, at 28 days, Mix CM23, cast on site
fct = 13.5 MPa (mean)εhardening = 1.5 ‰ (mean)
“Ductile as steel”
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3. What is proposed ?
UHPFRC
Brühwiler, 1999
Liquid water + Cl- = XD2, XD3 Most aggressive for structures !
Apply protective watertight UHPFRC overlay Improve durability without waterproofing
membrane Increase load bearing capacity, if needed
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3.2 Background
Successful structural rehabilitation is a major challenge for engineers
Cracking has both material and structural origins
Major issues:
Processing on site
Monolithic behaviour
Protective function
Mechanical performance
Durability
T, RH external
T, RH interactions overlay - substrate
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• Numerous laboratory tests on UHPFRC materials and composite members, since 1999 at MCS/EPFL – EU Project SAMARIS.
• 6 successful full-scale applications realised in Switzerland (2004, 2006, 2007, 2008) on road bridges and industrial buildings.
3.3 UHPFRC validation /application
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Case 1: Bridge rehabilitation
Rehabilitation and widening of the Bridge over river La Morge – Wallis, CHExecution: October – November 2004
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Case 1: Bridge rehabilitation
Span 10 m
• No waterproofing membrane
• Protective function provided by UHPFRC
• Widening of the bridge
• Prefabricated UHPFRC kerb downstream
• Thin UHPFRC overlay (3 cm) applied on deck
• UHPFRC rehab. kerb upstream
Span 10 m
Denarié et al. (2004)Bridge over river « La Morge » - Wallis - CH
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Challenge: Pouring of the UHPFRC in the limited space + high degree of restraint of the UHPFRC layer + batches of 1 m3
UHPFRC (3 cm)
Case 2: Protection of a crash barrier
A1 Furtbachbrücke, Würenlos
Owner : Canton Argovie, CH
Realisation : 2006
CEMTECmultiscale®Oesterlee et al. (2006)
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Heavily trafficked highway 4 cm thick prefabricated UHPFRC shell elements Joints glued on site with epoxy resin
Case 3: Protection of a bridge pier
Owner : Canton Argovie, CH
Realisation : spring 2007
UHPFRC precast shell (4 cm)
Self-compacting mortar Cast-on site
Oesterlee et al. (2007)
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Case 4: Strengthening of a slab
• Increased traffic load• Increase load-bearing capacity
and improve protective functions • Replacement of mortar overlay by
4 cm UHPFRC with rebars• 720 m2 (i.e. 36 m3) of UHPFRC
Autumn 2007Geneva, CH
HIFCOMEPFL13s
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5. Recent advances in Slovenia
Challenges of ARCHES project Develop UHPFRC mixes from local components (overcome
cement-superplasticiser compatibility issues) Make the mixes tolerant to slopes of 5 % Improve surfacing technique («barefoot walk») Repair a bridge!
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5.1 ARCHES WP 5 team
Dr. E. Denarié, MCS-EPFL (CH) – WP Leader
- MCS-EPFL (CH): Prof. E. Brühwiler, Dr. H. Sadouki, Mrs. A. Switek, Mr. H. Kamyab, Mrs. T. Noshiravani, Mr. C. Oesterlee, Dr. J. Wuest
- ZAG (Slovenia): Dr A. Šajna, Mrs J. Šuput, Mr V. Bras- Salonit (Slovenia): Mrs L. Resčič- IBDIM (Poland): Prof. M. Lagoda, Mr. A. Sakowski- LCPC/FEHRL (France): Dr. P. Rossi
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5.2 New UHPFRC matrices
A: pure CEM I 52.5 cement (Salonit)
B: CEM I 52.5 cement (Salonit) blended with mineral addition
Similar recipes with Water/(Cement+Addition) ratio = 0.155 Case A: impossible to achieve sufficient workability when fibres are added Case B: excellent workability, comparable to reference UHPFRC mixes with
reference cement –adapted for addition of fibres at high dosages
Denarié - 2007
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5.3 Improved slope tolerance
Slovene based similar recipes with W/C = 0.170New unconfined slope test from EPFL/MCS Case A: no slope tolerance to 3 % Case B: tolerance to slope of 3 %ZAG confirmed results and extended to 5 % slope
B: UHPFRC with thyxotropizerA: UHPFRC without thyxotropizerMCStests
ZAG tests
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5.4 Validation – protective function
Recipes with Slovenian components exhibit excellent protective properties comparable to reference mix (project SAMARIS).
Air permeability testing
UH
PFRC
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5.4 Validation - mechanical performance
Recipes with Slovenian components exhibit excellent mechanical performance comparable to the reference mixes (SAMARIS).
• Flexural response under 4PB• Plates 50 x 20 x 3 cm• Span 42 cm• Average curves on 5 to 10 specimens
MA= Mineral addition
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5.4 Validation - durability
Recipes with Slovenian components exhibit excellent free-thaw-salt durability.
500 cycles passed >> 50 cycles required
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5.5 Field trial tests – Salonit, SLO
300 litres batchesTotal 900 litresLoss = 50 litres
Slopes of 5+ % can be cast without difficultiesApplication time: 10 m2 = 10 minutes
CEMTECmultiscale®
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5.6 Full scale application – SLOVENIAOwner: Municipality of Bovec
65 m
Log Čezsoški bridge – Soča river, NW SloveniaAssignment: rehabilitation of the sidewalk and deck, replacement of dilation
4.50 m
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5.6 12,7 km detour
Challenge Limit site duration Increase durability and
efficiency of rehabilitation
The bridge
Vilage of Log Čezsoški
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2.5 cm UHPFRC
4.50 m
Application of a continuous watertight UHPFRC on the deck and footpaths
5.6 No-joint “coat”
3 cm UHPFRC
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Surfacing technique of UHPFRCusing DuPont Zemdrain® formwork liner (ZAG-2009)
5.6 Improved UHPFRC surface
Horizontal surface Vertical surface
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5.6 Preparation works
Low roughness requirements
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5.6 Preparation works
Minimum preparation works needed
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5.6 Execution
• Batches of 320 litres in 500 l concrete plant• Mixing time = 12 minutes• Only 2 or 3 batches per truck
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5.6 Execution
12 m3 UHPFRC applied in 2.5 to 3 cm layers.
Execution in 2 days with a transversal joint at mid-deck surface
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5.6 The bridge after rehabilitation
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5.6 Owner, user, contractor
Tradition repair vs. UHFPRC
repair
Site duration 3 moths > 1 month
Costs 12 MM > 12 m3 UHPFRC
Durability and efficiency of rehabilitation ? < Minimum the
double
CO2 balance / rehabilitation* 21 tons ≅ 23 tons
CO2 balance / repair service life* ? > Maximum the
half
CO2 balance due to difference in site duration* 18 tons > 6 tons
*) G. Habert, LCPC, France: ARCHES final seminar
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6. Conclusions
Focus on the conceptual approach – why and where are UHPFRC really needed
Provide concepts for "portable mixes" with universally applicable components
Develop cast-in situ applications in different countries
Take advantage of combination with rebars
Dare try and be creative UHPFRC concept = durable/sustainable repair of
bridges
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7. Links and documents
EU 5th FP SAMARIS/WP 14, deliverables D22 and D25 onhttp://samaris.zag.si
EU 6th FP ARCHES/WP 5, deliverables D06 and D14 onhttp://arches.fehrl.org
[email protected]@epfl.ch
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AcknowledgementsLocal partners of the application
Municipality of Bovec (Slovenia):Mr. D. Krivec (Mayor)
TKK Srpenica: Mrs. L. Černilogar (Admixtures)
Primorje: Mr. B. Ipavec (Designer)
CPG: Mr. M. Popović, Mr. Z. Jerkič, Mr. J. Brecelj(Contractor)
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Thank you for your attention !