high performance tunnel lining systems as a cost effective ... · high performance tunnel lining...
TRANSCRIPT
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High performance tunnel lining systems as a cost effective part of a fire
protection system
Dr.-Ing. Roland Bornemann
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Contents
• material introduction
• structural safety in tunnels according to ZTV-regulations and xicompensation measures
• user safety – retrofit of smoke extraction
• quick installation methods
• Colouring of lining systems and effect of colour
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Group of companies
Xella International GmbH
Building materials / bricks & elementsDry lining
systems / boardsRaw
materials
Calcium silicateblocks
Aerated concrete
Aerated concrete
Gypsum fibreboards
Fireprotection
boards
Lime &limestone
Mineralinsulation
boards
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What we are taking about: cementitious fire protective boards
consisting mainly out of:
• Hydraulic binder• Perlite
• AR-resistent fibres
• Water
Highly resistant against
• Humidity• frost/thaw
• Deicing agents
Fire protection via:
• Low lambda values
• Water evaporation
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Protection of tunnel structures -Type I: cast on version
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Protection of tunnel structures -Type I: cast on version
Installation of boards and fixation
of backing strips
Placing of steelreinforcement
Placing of concrete
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Protection of tunnel structures -Type I:cast on version
Fire protection boards on framework
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Bolted version –Type II: for new structures and retrofit
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Bolted to concrete of circular tunnels with backing strip es.
Lilla Bommen, GothenburgHerrentunnelLübeck, D
Backing stripes in order to safeguard
protection in joint area
View into a completed structure
Bolted version –Type II: for new structures and retrofit
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Why tunnel lining systems?
Montblanc tunnel 24/03/1999
• Truck with 9 tons of margarine and 12 tons of flour caug ht fire
• Other vehicles caught fire
• fire burnt for over 53 hours
• Peak temperatures higher than 1000°C were reached
• 39 people died
• tunnel was closed for over 3 years
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Objectives of a protection system
• Structural safety
• Protection of users (self rescue, 15 minutes)
• Third party rescue (fire fighters)
Theses targets are similar worldwide
Measures taken differ according to national regulations
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Structural safety
• Keep temperatures at reinforcement steel < e.g. 300°C (ZTV-Ing criteria)
resi
dual
str
engt
h
resi
dual
str
engt
h
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Structural safety
• Avoid spalling of concret
Tensile strength of HPC
Tensile strength of OPC
Vap
our
pres
sure
[N/m
m²]
Temperature [°C]
Vapourpressure
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Destruction of concrete due to:
• Limit concrete deterioration
Structural safety
Bornemann, Roland et al.: fire restistance of UHPC. IN: beton, p.418-422 (9/2002)
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Measures for structural safety – ZTV-ING
• peak temperature at reinforcement shall not exceed 300°C
• concrete cover of 60mm plus N94 mesh keeps concrete cove r in place when spalling starts
• further measures are not taken – is that sufficient?
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With N94 mesh
Check*) of ZTV-criteria
*) Dehn, F.; Nause,P.; Juknat,M.; Orgass, M.; König, A.: Brand- und Abplatzverhalten von Faserbeton in Straßentunneln. IN: Berichte der Bundesanstalt für Straßenwesen Heft 73B
Tubbingconstruction
Open construction
Fly ash
HWRA
water
Aggregates
Fibres
CEM I 32,5R
Fly ash
w/c(eq.)
w/c
Open construction
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ZTV-Ing fire curve and effect on open construct.: steel d12/15mm test with N94 mesh
Thermocouples at 60mm
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Thermocouples at 3 – 60mm
ZTV-Ing fire curve and effect on open construct.: steel d12/15mm test with 2kg/m³ PP-fibre
Thermocouples at 60mm
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Conclusion:
• No spalling possible because of a porous structure >60vol-%
• better insulation properties
• easy to replace
•Concrete is not kept from spalling by using a N94 mesh
• This is an unreliable approach
• PP-fibres enhance performance
• PP is not perfect because the ZTV-Ing- criteria of <300°C at 60mm is notxfulfilled in all parts
• Concrete cover nevertheless is destroyed > repair with sprayed concrete
Improvement
Solution = porous tunnel lining system
• concrete cover can be reduced > savings• Lining boards can be used as formwork > savings
Positive side effects
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Complete heat consumption
At 1.200°C = cp + phase change =
For a 30mm board = 11.700Wh
This equals 19Liter/m² of water
Fundamental idea: consumption of energy from fire
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Porous structure: No spalling possible > room for vapour expansion
Stark et al.:Durability of conrete
Calcium Silicate phases dehydrate
� 3CaO*SiO2 + 3*H2O
� 24wt.% are chemically bound water
Ca(OH)2 about 25% of cement weight
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Example: tunnel ceiling with 20mm board as lost formwork
Boards 20mm
ceiling
Concrete cast on fireprotective board withoutfixations
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Test setup:
• temperature and duration according to ZTV-Ing
• Thermocouples at interface and at 50mm
In order to simulate this setup test according to ZTV-Ing on a furnace
150
20
50
1200
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Thermocouples 7 and 8: 50mm fromconcrete surface
Results
∆ 220°C
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Conclusion 1:
• ZTV-Ing (car) criteria of 300°C over 90 minutes can be m atched with a reduced concrete cover (e.g. cmin 40mm exposition class XD > EC2-1-1/ZTV-5)
• Spalling is avoided by highly porous material
• Fire protective board can easily be replaced (anchored version)
Conclusion 2:
• In order to take advantage of a reduced concrete cover, the material mustsufficiently resistant against frost and thaw
• If not it will deteriorate and no longer offer a sufficient fire protection
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Water spray, splash water and leaks > sources of water
Passive fire protection boards should withstand frost
According to ZTV-Ing Part 3 tunnel members should comply with the exposition classes:
� Ceilings exposed to spray = XF2/XD2 (modestly water saturated + deicing agent/Clorides)
� Ramps and portals (spray and splash water) = XF2/XD2
Cementious boards underneath a leakybutt joint Water sprag at portals
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Test method: EN 12467 „fibre reinforced boards“
�100 Cycles (class X for all usages, exposed to weather) �Frost (-20°C) / deicing in water bath (20°C) � Comparision of bending strength of frosted/unfrosted samples
(ratio of bending strength >0,75)
Problem: X-class can´t be matched with XF2
Deicing in water Frosting
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Surface resistance to thaw and deicing agents
Test method: Slab test (Ö-Norm B3003), 56 cycles
• Guideline „Protective coatings for enhanced fire protection in undergroundtransport systems of the austrian association of concrete and engineering
Number of CyclesScaling
Exposition class Scaling [cm³/m²]
XF4 = for road tunnels without protective coating for portals
XF2 = for road tunnels without protective coating in frosted areas
XF2 = XF 3 = for road tunnels with protective coatings
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Surface resistance to thaw and deicing agents
Uncoated specimen > Test method: Slab test > extrapolation of 25 years of use
Before cycling
After 56 cycles
Exposition classes XF1 / 2 / 3
• Guideline „Protective coatings for enhanced fire protection in undergroundtransport systems of the austrian association of concrete and engineering
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Surface resistance to thaw and deicing agents
After 56 frost and deicing cycles
• Epoxy coated surfaces
Exposition classes XF1 / 2 / 3 / 4
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Other fire curves are more challenging in terms of temperature and duration –what can we do?
Higher requirements than ZTV-Ing:
Femern-belt-Tunnel
RWS 180 minutes
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Comparison of ZTV-Ing.-curve versus RWS-curve with regard to temperatureof steel behind 60mm concrete cover*)
*)Dehn, F.; Hauswaldt, S.; Juknat, M.: Grundsätzliche Überlegungen zur Brandprüfung von Tunnelbauteilen. IN: Beton- und Stahlbetonbau 104 (2009), Heft 12
ZTV-ING curve 140 minutes
Exposure to RWS-curve over120Minutes and defined coolingafterwards
Concrete with 2 kg/m³ PP-fibre addition (mix 1)
Concrete with 2 kg/m³ PP-fibre addition (mix 2)∆ 300°C
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Elevation:
RWS 120 with 40mm and anchored boards
Temperatures on concrete surface
Elapsed time [min.]
tem
pera
ture
[°C]
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Thermal analysis of fire protective board lined walls• finite element analysis
• unidirectional
• parameters: λ(temp), α and enthalpy > dE/dtemp
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Layer temperatures 20mm boards with equilibrium moisture and firecurves according to ZTV-Ing and EBA
�Good match between measurement and calculation
� substitute for real fire test
Inner surface
Outersurface
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Objectives of a protection system
• Structural safety �
• Protection of users (self rescue, 15 minutes)
• Third party rescue (fire fighters)
EC guideline 2004/54/EG to improve safety in tunnels
Emergency exits accord. to RABT every 300m > retrofit sometimes difficult
Alternatively smoke extraction system > installation at night shifts
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Idea: retrofit of existing tunnels with prefabricated smoke extraction ceilings
Example: Elbtunnel Hamburg, tube 4 (Kaefer Construction)
• 3100m long – transverse smoke removal
• smoke extraction every 60m by four extraction flaps
• 1700 prefabricated elements with Aestuver 2x50mm boards
• Installation speed 10 – 12m per night (8h shift, closin g of tunnel)
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� Quick and effective installation overnight� Design according to ZTV-Ing 5
> Stainless steel substructure class II (ZTV-4 betriebstech. Ausstatt.)> matches 300°C criteria for steel substructure> average surface temperatures < ∆140K> leakage <10Vol.-%
� Complies with RABT-requirements> tunnel longer >1200m > smoke extraction via electric driven flaps> adjustable flaps at a distance of 60m> Air extraction approx. 240m³/s
Idea: retrofit of existing tunnels with prefabricated smoke extraction ceilings
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Film
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Other ways to make installation easier
Wesertunnel
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Experience of safety –
or what people prefer
What should be changed?
Which are the prefered colours?
Andreas Mühlberger, university of würzburg:behaviour of humans in tunnel. IN: Solid² conference 2012 in Berlin
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Epoxy coated surfaces
Light blue Patterns Orange
Gloss