INDIVIDUAL ASSIGNMENT C CONCRETE PROCESSES

Image (Thoms & Gertsmann, 2008)

Production of Precast Concrete Tunnel Lining

KN Volmink
Word Count Main text Tables (3 x 150) Figures (3 x 150) Total 2787 450 450 3687

INDIVIDUAL ASSIGNMENT C CONCRETE PROCESSES Production of Precast Concrete Tunnel Lining

Individual Assignment C
An undersea vehicle tunnel 7 km long, with a circular cross-section of finished internal diameter 5.8m, is to be machine-bored and lined with pre-cast reinforced concrete segments. The segments are 300mm thick, each of the ring segments is 1.5m wide (measured along the longitudinal axis of the tunnel) and there are six segments per ring of approximately equal size. These will be produced by the tunnelling contractor over a period of 18 months. The concrete strength is specified as C60/75 with an intended working life of 100 years. a. Compare and contrast the use of self-compacting concrete with concrete of slump class S2 for the production of segments, and state your preference. b. For your preferred concrete, produce method statements for: i. the production, handling, placing and compaction of the concrete ii. demoulding, inspection, curing, handling and storage of the segments.

INDIVIDUAL ASSIGNMENT C CONCRETE PROCESSES Production of Precast Concrete Tunnel Lining

TABLE OF CONTENTS
Page 1.
1.1 1.2

INTRODUCTION ........................................................................................... 1
Tunnel Lining Production ......................................................................................... 1 Installation ............................................................................................................... 1

2.
2.1 2.2

CONCRETE FOR PRECAST TUNNEL LINING SEGMENTS ...................... 2

Introduction ............................................................................................................. 2 Project Requirements .............................................................................................. 2 2.2.1 Concrete Specification ............................................................................... 2 2.2.2 Production Quantities ................................................................................ 2 Productivity.............................................................................................................. 2 2.3.1 Concrete Production and Transportation ................................................... 2 2.3.2 Concrete Placement .................................................................................. 3 Manufacturing Cost ................................................................................................. 3 2.4.1 Material Cost ............................................................................................. 3 2.4.2 Labour Cost ............................................................................................... 3 Quality ..................................................................................................................... 4 2.5.1 Quality Control ........................................................................................... 4 2.5.2 Concrete Quality ........................................................................................ 4 Working Environment .............................................................................................. 4 Conclusion .............................................................................................................. 5

2.3

2.4

2.5

2.6 2.7

3.
3.1 3.2 3.3 3.4

METHOD STATEMENT: PRODUCTION, HANDLING, PLACING AND COMPACTION OF SCC................................................................................ 6

Production ............................................................................................................... 6 Handling .................................................................................................................. 6 Placing .................................................................................................................... 6 Compaction ............................................................................................................. 7

4.
4.1 4.2 4.3 4.4 4.5

METHOD STATEMENT: DEMOULDING, INSPECTION, CURING, HANDLING AND STORAGE OF SEGMENTS ............................................. 8
Demoulding ............................................................................................................. 8 Inspection ................................................................................................................ 8 Curing ..................................................................................................................... 8 Handling .................................................................................................................. 8 Storage ................................................................................................................... 9

5.

REFERENCES ............................................................................................ 10

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INDIVIDUAL ASSIGNMENT C CONCRETE PROCESSES Production of Precast Concrete Tunnel Lining

LIST OF FIGURES Figure 1-1 Mechanised installation of precast concrete tunnel lining segments (Thoms & Gertsmann, 2008)........................................................................................................... 1 Figure 2-1 Mechanised placing of SCC (EFNARC, 2005) ..................................................... 3 Figure 4-1 Trial ring assembly ............................................................................................... 9 LIST OF TABLES Table 2-1 Quality control test methods for SCC (EFNARC, 2005) ......................................... 4 Table 2-2 Working environment benefits of SCC (Walraven, 2002)....................................... 5 Table 3-1 Relative comparison of placement techniques and energy delivered (Daczko & Vachon, 2006) ................................................................................................................ 7

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INDIVIDUAL ASSIGNMENT C CONCRETE PROCESSES Production of Precast Concrete Tunnel Lining

1.
1.1

INTRODUCTION
Tunnel Lining Production
Tunnel lining systems prior to the 1940s were characterised by bolting steel plates through flanges and it was only in the 1970s that precast concrete tunnel lining systems emerged. (McBean, 1988) Today the use of precast concrete segments is one the most preferred tunnelling lining methods employed. Precast concrete tunnel lining owes, to a large extent, its popularity as a construction method to the high production rates that can be achieved. During the construction of the Channel Tunnel rail link between Britain and France a total of about 740,000 precast segments were produced to line more than 53km of the tunnel. Two precast factories were setup each producing up to 1000 precast concrete segments per day to keep up with the 11 tunnel boring machines (Wallis, 1989)

1.2

Installation
Besides the production benefits of precast concrete tunnel lining the installation and relative ease of installation also plays a major role in it being one of the most preferred systems of tunnel lining. Figure 1-1 details the mechanised installation process of a precast concrete tunnel lining system highlighting the relative ease of installation (Thoms & Gertsmann, 2008).

Figure 1-1 Mechanised installation of precast concrete tunnel lining segments (Thoms & Gertsmann, 2008)

INDIVIDUAL ASSIGNMENT C CONCRETE PROCESSES Production of Precast Concrete Tunnel Lining

2.
2.1

CONCRETE FOR PRECAST TUNNEL LINING SEGMENTS

Introduction
To achieve the production rate that makes precast concrete tunnel lining such an efficient method of construction all the components to the manufacturing and installation process must be optimised. One critical component of the manufacturing process is the type of concrete used. The productivity, manufacturing costs, quality, and working environment are all affected by the type of concrete used. Successful precast tunnel lining manufacturing is therefore dependant on the type of concrete used. Self-compacting concrete (SCC) and conventional concrete (CV) are two different families of concrete presenting different advantages and disadvantages to the manufacturing process. These concretes are critically compared to determine which is best suited for the demands of precast tunnel lining manufacturing.

2.2
2.2.1

Project Requirements
Concrete Specification A C60/75 strength and S2 consistence concrete with a 100 year service life is required for the precast concrete tunnel lining of 7km undersea road tunnel. This specification, according to BS EN 206-1:2000, translates to a concrete with characteristic cube strength of 40 MPa and slump of 50mm to 90mm. The specified consistence is for concrete compacted by conventional means and is measured with the slump test. This therefore precludes the use of SCC unless presented as an alternative to the specification. This alternative would have to specify a slump flow class according to BS EN 206-9:2010 for the SCC. Walraven (2003) recomends a slump flow class of SF2 for floor and slabs which most closely resembles a tunnel lining segment in geometry.This consistence class is therefore be recommended for the SCC.

2.2.2

Production Quantities Based on the 7km tunnel length and the 1.5m ring width (along the longitudinal axis of the tunnel) approximately 28 000 precast concrete segments will be required. These segments are to be produced over a period of 18 months which results in a production rate of approximately 76 segments per working day (based on a 5 day week and including construction holidays). To achieve this production rate the production time of each segment has to be minimized.

2.3
2.3.1

Productivity
Concrete Production and Transportation The mixing time for SCC is longer than that of CV as more time is required for the efficient dispersion of the finer constituent materials to ensure mix homogeneity and stability. (Gaimster & Dixon, 2003) This would increase production time should there not be sufficient concrete production capacity.

INDIVIDUAL ASSIGNMENT C CONCRETE PROCESSES Production of Precast Concrete Tunnel Lining

2.3.2

Concrete Placement Agitation during the placement of the concrete to achieve compaction is not necessary with self-compacting concrete. Therefore the placement process is often mechanised as shown in Figure 2-1. This is a major advantage SCC has over CV with regards to productivity as SCC can be placed faster and with fewer workmen than conventional concrete.

Figure 2-1 Mechanised placing of SCC (EFNARC, 2005)

2.4
2.4.1

Manufacturing Cost
Material Cost The only evident difference in material costs between SCC and CV is due to cementitious binder and admixture content. The higher paste content and the fresh concrete requirements for cohesion and segregation resistance, typically results in SCC having a higher cementitious binder content than CV. Also admixtures (superplasticizers) are essential in SCC to reduce water content and maintain fluidity (Beushausen, 2009) As a result the material costs of SCC is greater than that of CV.

2.4.2

Labour Cost Despite the higher material costs of SCC the labour costs of manufacturing with SCC is lower than that of CV. In addition to the greater productivity the selfcompacting property of SCC means fewer workmen are required to place the concrete. Therefore the labour cost for placing SCC is lower than CV.

INDIVIDUAL ASSIGNMENT C CONCRETE PROCESSES Production of Precast Concrete Tunnel Lining

2.5
2.5.1

Quality
Quality Control More rigorous quality control of materials used in SCC is required than for CV due to the fact that minor changes in material properties may have a significant influence on workability. (Beushausen, 2009) EFNARC (2005) outlines the various test methods, given in Table 2-1, for the filling ability and stability of SCC defined by four key characteristics i.e. flowability, viscosity, passing ability and segregation. The process from production to placement may be more time-consuming for SCC than for CV. This is as a result of the the testing reuired to ensure the compliance of the SCC, by the manufacturer, before the concrete is dispatched and in the field where the concrete is used. Table 2-1 Quality control test methods for SCC (EFNARC, 2005) CHARACTERISTIC Flowability Viscosity (assessed by rate of flow) Passing Ability Segregation TEST METHOD(S) Slump-flow Test T500 Slump-flow test or V-funnel test L-box test Segregation resistance (sieve) test

2.5.2

Concrete Quality Despite the more arduous testing, improved homogeneity is achieved with SCC. With CV proper compaction of the concrete is dependant on skilled workmanship, of which there is a great shortage, (the original reason for developing SCC, Okamura & Ouchi, 1999). The full compaction of SCC is however not workmanship dependant and therefore lends itself to improved homogeneity. This Improved homogeneity in turn enhances concrete quality with regards to durability and surface finish.

2.6

Working Environment
A marked difference in the working environment where SCC is used as compared to CV is the reduction in noise levels due to the elimination of hand held poker vibrators to compact the concrete. (Skarendahl & Billberg, 2006) Table 2-2 (Walraven, 2002) illustrates that with the high production demands of precast concrete tunnel lining construction and due consideration of occupational health and safety using SCC is more beneficial.

INDIVIDUAL ASSIGNMENT C CONCRETE PROCESSES Production of Precast Concrete Tunnel Lining

Table 2-2 Working environment benefits of SCC (Walraven, 2002) Conventional Concrete Self-compacting Concrete Recommended Limits
Protective measure required if > 80 dB Protective measure required if > 0.25 2 m/s
3

Noise Protection

93 dB

< 80 dB

Vibrations

0.75 to 4 m/s

0 m/s

Quartzite dust Dust

Not measured 34 mg/m

3

0.01 mg/m 0.2 mg/m

Max 0.075 mg/m

Industry goal is 1 3 mg/m

Savings due to elimination of vibration

Energy Consumption: - 10 % Forms cost: - 20 % Maintenance Cost: 10 % Illness time: - 10 %

2.7

Conclusion
In comparing the various aspects of the manufacturing of precast concrete tunnel lining using self-compacting concrete (SCC) and conventional concrete (CV), SCC is clearly the better alternative. The main advantages of using SCC as opposed to CV are summarised as follows: Greater productivity Lower construction costs Higher quality Better working environment

INDIVIDUAL ASSIGNMENT C CONCRETE PROCESSES Production of Precast Concrete Tunnel Lining

3.
3.1

METHOD STATEMENT: PRODUCTION, HANDLING, PLACING AND COMPACTION OF SCC

Production
The same batching and mixing equipment for the production of conventional concrete may be used. On site concrete trials are to be done on an approved mix design to determine the best batching sequence and the optimum mixing time. Routine quality control testing is to be conducted to ensure that the required concrete properties are achieved before dispatching to the site. Table 2-1, in the previous section, details the test to be done and the concrete property that is measured. Due to the sensitivity of SCC to moisture variation (Daczko & Vachon, 2006) the aggregate moisture content shall be carefully controlled and accurately monitored. Any variation in the moisture content of the aggregate must be compensated for in the mix proportions.

3.2

Handling
SCC can be transported in the same concrete mixing trucks as conventional concrete however due to the higher fluidity attention must be given to possible leakage. If the transportation route is causes shaking of the mixer further consideration to the possible segregation of the mix is to be given. The concrete must therefore be further mixed after transportation and before placing. The distance over which the concrete is transported is to be evaluated to ensure that the workability of the concrete is retained. The concrete is to be further tested in the field before placing to ensure the specified flowability of SF2. The slump flow test must therefore be done on every batch before placing.

3.3

Placing
Concrete shall be placed in such a manner that the discharge direction corresponds to the direction of flow unless placed vertically. The rate of placing shall be slow enough to ensure sufficient time for the escape of air bubbles but fast enough to maintain flowability. The energy imparted to the concrete shall therefore be considered in choosing the placing equipment/technique (Daczko & Vachon, 2006). Table 3-1 compares the different placement techniques and the energy delivered to the concrete. Placement shall be continuous to prevent the formation of any joints. In the case of a discontinuity the concrete already in place may require agitation (not through vibration) to ensure placing against a live concrete surface. Concrete may be allowed to flow uninterrupted through forms however the flow length is to be limited to 10m to prevent dynamic segregation or void formation. (EFNARC, 2005) Time to finishing shall be carefully monitored as thixotropic thickening can resulting difficulty on finishing.

INDIVIDUAL ASSIGNMENT C CONCRETE PROCESSES Production of Precast Concrete Tunnel Lining

Table 3-1 Relative comparison of placement techniques and energy delivered (Daczko & Vachon, 2006)
Placement Technique Truck Discharge Pump Conveyor Buggy Crane and Bucket Auger Discharge Tremie Discharge Rate High Medium/High Medium Medium High Medium High Discharge Type Continuous Continuous Continuous Discontinuous Discontinuous Continuous Discontinuous Single Discharge Volume High Medium High Low Low Medium High Relative Energy Delivered High Medium/High High Low Low/Medium Medium High

3.4

Compaction
Vibrating equipment shall not be used to achieve compaction as this may cause segregation and unwanted movement in the concrete once in place. Compaction should be achieved through correct placement practices detailed above.

INDIVIDUAL ASSIGNMENT C CONCRETE PROCESSES Production of Precast Concrete Tunnel Lining

4.
4.1

METHOD STATEMENT: DEMOULDING, INSPECTION, CURING, HANDLING AND STORAGE OF SEGMENTS

Demoulding
Demoulding of the concrete segments can take place once the concrete has achieved a recommended strength of 15MPa. (Dwi Hariyanto, et al., 2005) The time to achieve this strength can be reduced by accelerated curing, detailed below. The segments shall be lifted using vacuum suction equipment once the side formwork has been removed.

4.2

Inspection
Inspection of the segments shall take place after demoulding prior to application of any coatings. Any signs of defects shall be identified for and repaired (if repairable) immediately as per agreed methodology. The segment shall be thoroughly inspected for the following defects (all of which are avoidable): Cavities Honeycombing Blow holes Fines loss Plastic settlement cracking

4.3

Curing
Steam curing will be used to accelerate the strength achievement of the segments and enable demoulding to take place sooner. The heating rate, curing time and cooling rate shall be determined through trials and shall be carefully controlled during construction. The heat shall be evenly applied to achieve the required temperature and the essential moisture maintained. Values for steam curing can range between 6 and 8 hours (Wallis, 1989). After accelerated curing to achieve the striking strength is complete the segments shall be lifted and further cured by applying an approved curing compound.

4.4

Handling
The segments shall be lifted using suction lifting equipment after striking of the formwork. Care shall be taken to ensure that segments are lifted at the specified lifting positions and the regulated lifting equipment and procedures are employed. Segments shall be clearly marked with the relevant segment information such as casting date, segment no etc.

INDIVIDUAL ASSIGNMENT C CONCRETE PROCESSES Production of Precast Concrete Tunnel Lining

Trial/mock ring assembly shall be done periodically, as shown in Figure 4-1, to ensure that segments are constructed within dimensional tolerance and bolting arrangement is correct.

Figure 4-1 Trial ring assembly

4.5

Storage
Segments shall be stacked in the approved ring arrangement with the inside face facing upward. The segments shall be supported by timber spacers and tightly secured together to prevent falling during transporting. Segment shall be stored in the prepared and allocated storage area.

INDIVIDUAL ASSIGNMENT C CONCRETE PROCESSES Production of Precast Concrete Tunnel Lining

5.

REFERENCES
1. Beushausen, H., 2009. Chapter 20: Self-compacting Concrete. In: G. Owens, ed. Fulton's Concrete Technology. Midrand: Cement & Concrete Institute, pp. 317-327. 2. Daczko, J. A. & Vachon, M., 2006. Self-Consolidating Concrete (SCC). In: J. F. Lamond & J. H. Pielert, eds. Significance of Tests and Properties of Concrete and Concrete-Making Materials - STP 169D. West Conshohocken: ASTM International, pp. 637-645. 3. Domone, P., 2010. Part 3: Concrete. In: Construction Materials their Nature and Behaviour 4th edition. London: Spon Press, pp. 83-208. 4. Dwi Hariyanto, A., Cheong, Y. W. & Kwan, H. P., 2005. Quality Control in Precast Production - A Case Study on Tunnel Segment Manufacture. Dimensi Teknik Arsitektur, 33(1), pp. 153-164. 5. EFNARC, 2005. The European Guidelines for Self Compacting Concrete. [Online] Available at: http://www.efnarc.org/publications.html [Accessed 11 02 2013]. 6. Gaimster, R. & Dixon, N., 2003. Self-compacting Concrete. In: J. Newman & B. S. Choo, eds. Advanced Concrete Technology: Processes. London: Butterworth Heinemann, pp. 9/1-9/23. 7. McBean, R., 1988. Developing a Tunnel-lining System. Concrete, 22(5), pp. 15-17. 8. Okamura, H. & Ouchi, M., 1999. Self-compacting Concrete: Development, Present Use and Future. Stockholm, RILEM Symposium on Self-compacting Concrete. 9. Skarendahl, A. & Billberg, P., 2006. Casting of self-compacting concrete, Paris: RILEM Technical Committee 188-CSC. 10. Thoms, I. & Gertsmann, O., 2008. World-class Tunnel Lining. Civil Enigneering, 1 August, pp. 46-48. 11. Wallis, S., 1989. Precast concrete forms the backbone of the Channel Tunnel, London: The Arberdeen Group. 12. Walraven, J., 2002. Self-compacting Concrete in the Netherlands. Evanston, Proceedings of the First North American Conference on the Design and Use of Selfcompacting Concrete. 13. Walraven, J., 2003. Structural applications of self compacting concrete. Reykjavik, Iceland, Proceedings of the 3rd International RILEM symposium on self compacting.

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