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Concrete technology and durability design

COWI and concrete

COWI – the company COWI participates in R&D net-


COWI is internationally recognised works and projects with universi-
as a major consultant in several ar- ties, government institutions as well
eas from energy and waste to eco- as private partners in several coun-
nomics, but in particular known for tries. COWI’s concrete technologists
its leading position in major bridge, and designers participate in national
road, airport, marine structures and and international standard organisa-
tunnel projects throughout the tions, through CEN-groups, Danish
world. Concrete is a key material and European standardisation work,
for these modern structures and FIB model codes, RILEM, etc. They
COWI has therefore created a strong are often invited speakers or key
concrete design and research envi- note lecturers at international con-
ronment within the company to ferences on concrete technology and
provide specialist services in this this is reflected in the large number
area. of COWI publications and refer-
ences in the concrete field.
Concrete – the material COWI seeks to include innovative
The structural design, suitable speci- ideas as part of large and small
fications for the concrete and the projects in order to create value for
reinforcement, the placing and the their customers through savings to
proper curing are all important pa- provide durable and sustainable
rameters to achieve the desired re- solutions.
sults.
COWI’s concrete technology ex-
Beirut Seafront and Marinas, Lebanon pertise covers standards and specifi-
cations both in Europe and Concrete technology and
internationally. Suitable specifica- durability design
tions can be prepared to ensure that • Durability and service life design
the customer receives the concrete • Specifications and construction
solution that is optimal for the in- monitoring
• Materials technology
tended service life requirements and
• Special design solutions
the exposure conditions.

Seeb International Airport, Oman

Green Heart Tunnel, The Netherlands

Chedi Hotel, Oman


3

Sutong Bridge, China


4 Durability and
Villamar at the Harbour Development Project, Bahrain
service life design

Probabilistic service life design COWI’s leading position within du-


COWI’s durability design services Nowadays, civil engineering struc- rability design is based on more
• Assistance in defining the owner’s
tures, such as bridges, tunnels, ma- than 40 years of worldwide experi-
service life requirement, e.g. end rine structures and other infrastruc- ence in design, operation and main-
of design life, level of reliability and ture projects, are designed for a tenance of reinforced concrete struc-
frequency of maintenance
service life of 100, 120 or even 200 tures.
• Elaboration and evaluation of
different durability design options years. This surpasses the assumed COWI, spearheading the interna-
including appropriate structural design service life of most codes and tional development of rational serv-
detailing
standards substantially. ice life designs, provides a modern
• Assessment of macro and micro
exposure conditions The operational approach to de- fully probabilistic design methodol-
• Modelling of deterioration sign for durability is to define dura- ogy for durable concrete structures,
mechanisms for materials and bility as a service life requirement. i.e. the DuraCrete approach. COWI
environmental actions
In this way, the non-factual and implements this state-of-the-art ap-
• Service life modelling and design
using the DuraCrete approach rather subjective concept of ‘dura- proach in new designs and in the re-
• Development of appropriate bility’ is transformed into a factual evaluation of existing structures. It
specifications for materials through requirement of a number of years has been adopted by national au-
durability modelling
during which the structure performs thorities and individual clients all
• Conversion of specifications
to concrete mix designs and satisfactorily without unforeseen over the world as well as by interna-
compliance testing high costs for maintenance. In this tional associations, e.g. fib.
• Back analysis of service life upon way, the time factor is introduced as The DuraCrete approach can ef-
completion of construction
a design parameter. Service life de- fectively combat chloride and car-
• Quality assurance programmes
• Life cycle costing
sign based on these functional re- bonation induced reinforcement
• The Birth Certificate quirements is carried out in a similar corrosion. All uncertainties regard-
way to the load and resistance fac- ing environmental exposure, mate-
tor design concept used for structur- rial properties and deterioration are
al design. taken into account.

Assumptions

Terms of definitions

Other administrative provisions

Principles of service life

Design criteria
structure becomes either obsolete or subject to a redesign
In case of non-confirmity with the performance criteria, the

Full probabilistic Avoidance of


Partial factor design Deemed to satisfy design
approach deterioration

Probabilistic models: Design values:


- Resistances - Characteristic values
Exposure classes Exposure classes
- Load/exposure - Partial safety factors
- Geometry - Combination factors

Limit states Design equations Design provisions Design provisions

Design/verifications

Project specification for material selection and execution


Maintenance plan
Inspection/monitoring plan

Quality plan for execution


(optional)

Inspection of execution
Service life design flow chart
after fib: “Model Code for
Maintenance Condition control during service life
Service Life Design”
5

Busan-Geoje Fixed Link, South Korea

Life cycle costing The Birth Certificate ��������������


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Life cycle cost optimisation, e.g. A valuable means to increase the ��
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formulated as an optimisation of the knowledge of the expected perform- �� ��������������
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net present value of a structure, has ance and service life is to establish a �� ������������
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become an integral part of COWI’s baseline study of the finally achieved



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service life design philosophy. With- quality of the in-situ structure. This
� � �� �� �� �� ��� �����
out this, a rational evaluation of could conveniently be done and re- �������������������������� �����������
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future costs in a comparable manner ported as part of the handing-over


Influence of concrete cover on service life
to rate alternative solutions, prefer- of the structure from the contractor
ably as a life cycle costing (LCC), to the owner. Therefore, COWI has
the service life design will not be established the concept of the Birth
Guidelines for service life design
possible. This is mainly because any Certificate, which includes a first
serious savings in future mainte- forecast of the service life based on
nance costs will not be adequately factual data, e.g. the actual cover
considered to compensate for any thicknesses and the actual chloride
increased initial construction costs, diffusion coefficients, from the exist-
although such future savings may be ing structure. At later inspections
very substantial. COWI’s LCC serv- this data can be updated and used
ices include: to revise the expected residual serv-
• Recognition of potential savings ice life resulting in an ever-increas-
in whole-life costs through built- ing accuracy of the remaining serv-
in durability, e.g. selective use of ice life forecast. This powerful fib:
stainless steel decision tool provides the owner Model code for
DuraCrete: service life design
• Evaluation of life-cycle costing with valuable information on future General guidelines for
durability design and
and cost options maintenance and repair needs. redesign

Financial Harbour, 53-storey tower, Bahrain Stonecutters Bridge, Hong Kong, China
6 Specifications and construction monitoring

The Pearl Development Project, Qatar

Specifications Quality assurance and


COWI has many years experience in construction monitoring
assisting both clients and contrac- In order for a concrete structure to
tors in the preparation and/or review function as foreseen by the design,
of specifications for major internation- the construction process must be
al projects, including immersed and controlled by a suitably framed
bored tunnels, all types of bridges, quality assurance (QA) scheme.
QA at precasting yard, Busan-Geoje marine structures, airports and in- COWI has the knowledge to es-
Fixed Link, South Korea frastructure schemes all over the tablish suitable QA schemes in line
world. Irrespective of the type of with the preparation of project spec-
contract COWI can provide specialist ifications. In addition, COWI has
assistance to fulfil particular needs. experienced concrete specialists,
COWI’s expertise is based on a who can review/audit construction
thorough understanding of the rel- materials, mix designs, functional
evant international standards comple- requirements, method statements
mented by an extensive knowledge and inspection and test plans, etc.,
of concrete and materials technology against specified requirements and
QA at immersed tunnel site, Busan-
Geoje Fixed Link, South Korea in combination with experience in a project objectives.
multiplicity of construction tech- Consequently, the same personnel
niques. Consequently, COWI has have the ability to assess the accept-
the ability to interpret any special ability of non-conformances if and
demands, be they structural, envi- when they arise and the suitability
ronmental or financial, in order to of associated corrective actions, re-
provide specific requirements for medial works, etc., to ensure that
particular parts of a project. the project objectives are met.

QA at segment factory, Hallandsås


Tunnel, Sweden
7

Customised formwork, Hallandsås Tunnel, Sweden Cooling pipes for control of heat
development during curing

Architectural finishes Curing technology Most of the above curing conditions


Architectural finishes is another area In order to secure the long term du- are interconnected and cannot be
of importance as the achievement of rability of a concrete structure a well considered in isolation.
an acceptable surface finish to the thought-out curing programme COWI has experienced personnel
concrete is often in conflict with the should be specified and the curing and specialist tools, e.g. 2/3-D finite
durability requirements of a struc- properly monitored during construc- element method (FEM) programmes
ture. This is particularly important tion. for temperature and stress simula-
where prestigious and/or innovative COWI’s main areas of curing tion to design appropriate integrated
structures are exposed to harsh en- technology expertise include: curing systems and/or review pro-
vironments, e.g. the Middle East. • Control of early age cracking due posed systems against specified re-
COWI has special experience and to thermal movements, early quirements.
interest in this area and can advice shrinkage, creep and settlements
on appropriate solutions to achieve • Evaporation control to avoid the
the overall architectural objectives damaging effects of drying out
of the project. which can lead to cracking and
reduction in surface quality
• Hot weather concreting, particularly
relevant to the Middle East and
other high temperature environments
• Cold weather concreting to ensure
early protection from damage due
to freezing conditions
• Limitation of maximum temperature 3-D FEM simulations of heat
to avoid the deterioration effect of development during curing. Based
Architect’s model for underground station, on R&D collaboration with IPL,
Copenhagen Metro, Denmark delayed ettringite formation (DEF) DTU, Lyngby, Denmark
8 Materials technology

COWI’s concrete and materials spe- chemical analyses and petrography COWI’s materials and concrete spe-
cialists have broad international to destructive as well as non-de- cialists are recognised in their sepa-
experience from almost every region structive methods. rate fields as independent experts to
around the world and from almost With funding from the World perform investigations and evalua-
every type of civil engineering struc- Bank and DANIDA, COWI has pre- tions of new or deteriorated con-
ture. sented innovative solutions in road crete and whenever a technical dis-
COWI’s concrete and materials construction with the use of alterna- pute may arise. This also includes
group has more than 40 years expe- tive binders and/or marginal aggre- expert witness assistance in cases
rience in materials and concrete in- gates in road stabilisation. Besides which may end up in court. Design
vestigation methods, durability and providing passable roads all year topics and expert knowledge on
technology and contribute regularly round in third world regions, such materials and standards from all
to national and international confer- solutions are also environmentally over the world are also part of
ences, books and magazines on con- friendly with regard to preservation COWI’s knowledge base.
crete and reinforcement, from the of aggregate resources as well as
design stage up to and including the limiting CO2 emissions.
as-built phase.
Activities include all kinds of ma- Concrete microstructure
terial and construction topics, rang- COWI’s specialists have been in-
ing from petrography and scanning volved in many investigations con-
electron microscopy at nanometre cerning concrete durability and de-
level to large scale tunnelling, bridge terioration of various kinds of
and pavement construction. concrete structures worldwide; espe-
COWI has an in-house, ISO 9001 cially with several references from
certified concrete laboratory special- the Middle East known for its harsh
ised in concrete investigations from climate.
Optical microscopy
on thin sections

Concrete block with severe cracking caused by DEF and


testing of cores by thin section microscopy and residual
expansion measurements
9

Innovative, environmentally friendly and


low-cost road construction methods using
blast furnace slag or local pozzolans for
Deterioration mechanisms Such evaluations, alone or combined stabilisation of secondary or marginal
aggregate resources, Tanzania
COWI’s main fields of expertise in with other advanced investigations,
materials technology include evalua- can solve almost any case of prema-
tion of concrete concerning: ture concrete deterioration. Investi-
• Surface attack gations of concrete exposed to chlo-
• Chloride ingress and risk of corro- rides can include determination of
sion chloride profiles and determination
• Surface carbonation of the chloride diffusion coefficient
• Detection of causes of cracking to quantify the future risk of rein-
• Determination of concrete compo- forcement corrosion.
sition including water-cement ra- Modelling of the residual service
tio, type and content of cement as lifetime by the DuraCrete approach
well as aggregate, use of air en- or other models is based on reliable
trainment, addition of fly ash, results obtained from advanced lab-
blast furnace slag, silica fume, etc. oratory investigations.
• Sulphate and seawater attack,
delayed ettringite formation (DEF)
and thaumasite formation
• Soft water leaching, carbonic acid
and aggressive CO2 attack
• Alkali-silica reactions (ASR) and
residual reactivity and expansion
potential. Experience with local
aggregate types and test methods
• Freeze-thaw durability, evaluation
of quality of entrained air void
Thin section microscopy showing alkali-silica Scanning electron microscopy
systems reactive aggregate and gel in air void showing ettringite in paste, cracks
and voids of concrete exposed to
sea water
10 Special design
solutions

COWI’s durability and concrete


specialists have a broad internation-
al experience in tailored, special
concrete and reinforcement design
solutions.
Selected special design solutions
offered by COWI include, but are
not limited to the following:
• High performance concrete
• Self-compacting concrete
• Steel fibre reinforced concrete
SFRC foundations and slab for high-bay warehouse,
• Polypropylene fibre concrete Carlsberg Brewery, Fredericia, Denmark
• Green concrete
• Membranes
• Diaphragm walls and secant piles HPC sets high demands on compe- Compressive
strength test of
• Corrosion resistant reinforcement tence and experience; competence HPC. Courtesy
and experience that COWI can of- of BAM, Berlin,
Germany
High performance concrete fer.
The continuous demand for in-
creased strength and improved du- Self-compacting concrete
rability of concrete structures has A concrete mix, where the placing
led to the development of HPC. This and compaction has minimal de-
development had three main objec- pendence on the available work-
tives: manship on site, improves the true
• Protect the reinforcement against quality of the concrete in the final
corrosion structure. This has been the main
• Resist deterioration of the con- driving force in recent years’ devel-
crete itself opment of self-compacting concrete
• Provide adequate high strength to (SCC). With the aid of a range of
fulfil the structural requirements chemical admixtures and optimal
grading of the aggregates, concrete
HPCs for normal type structures with a low water-cement ratio can
usually have a high cementitious be made to flow through complicat-
binder content, a low water-cement ed form geometry and around com- Constituents of a typical HPC mix,
ratio and higher contents of plasti- plex reinforcement without segrega- “cocktail concrete”
ciser and superplasticiser. Such con- tion. The form can be filled and a
crete can be used for bridges, tun- uniform compaction without honey-
nels, marine works, offshore combs can be achieved, also in the
structures and high rise buildings, cover zone of the concrete. SCC
where the strength requirements exerts an increased pressure (at
usually remain within a range of 50- times close to the hydrostatic pres-
80 MPa. A drawback of HPC is that sure) on the formwork.
the more refined the concrete mixes COWI’s concrete specialists pro-
become, the higher is the sensitivity vide expert knowledge on both mix Slump flow test with 4C-Rheometer to
in relation to the actual handling design and execution including determine the yield stress and plastic
viscosity of SCC. Courtesy of DTI,
during execution. formwork design for SCC. Taastrup, Denmark
11

Steel fibre reinforced concrete With regard to concrete structures


For many applications steel fibre the addition of a relatively small
reinforced concrete (SFRC) is a very amount of polypropylene fibres
suitable solution for structural mem- (PPF) to the concrete during the
bers, which are not highly loaded in mixing process can provide consid-
flexure or tension. Besides advan- erable improvement in the fire re-
tages in terms of construction and sistance of the finished structure. A
cost, SFRC grants structural benefits recent innovation has been to add
and superior durability properties PPF to shotcrete to improve the fire Tunnel fire test. Courtesy of SINTEF,
compared to conventional rein- resistance of existing structures and Trondheim, Norway
forced concrete. The capacity of the unstable rock formations.
fibres to reduce crack width and COWI has considerable experi-
deflection is often more important ence in this area to provide assist-
than the increase in tensile strength ance with the following:
of the concrete. Furthermore, the • Concrete and shotcrete mix designs
addition of fibres enables bearing • Fixing systems for shotcrete
capacities after cracking and allows • Fire testing
stress redistribution, which makes • Acceptance criteria
the otherwise quasi-brittle behav-
iour of the concrete more ductile. Green concrete Concrete slab without PPFs during fire
test, Hallandsås Tunnel, Sweden
COWI has manifold experience Green concrete is a synonym for
and expert knowledge in all phases resource-saving concrete. Use of
of the design and the execution of green concrete reduces the environ-
SFRC structures. mental impact of concrete structures
with regard to energy consumption,
Polypropylene fibre concrete waste water and CO2 emissions.
The provision of an adequate level Green concrete can be less expensive
of fire protection is particularly im- to produce, because waste products
portant for tunnels as has been wit- can be used as a partial substitute
nessed by the Great Belt and Chan- for cement, landfill taxes can be
nel Tunnel experience, but it can avoided and the energy consump-
also be relevant to other structures tion in production can be lowered.
where the evacuation of personnel COWI’s concrete specialists have
and emergency services should be been involved in related R&D
protected. projects and are experienced in speci-
fying green concrete.

FE simulation of principal stress


distribution from concentrated
loading of TBM push rams for
structural design of SFRC lining
segments, District Heating SFRC lining segments, District Heating
Tunnel, Copenhagen, Denmark Tunnel, Copenhagen, Denmark
12 Special design solutions

Membranes ment corrosion. This method does


The application of membranes for not only solve the corrosion prob-
concrete structures can be twofold: lem in an infallible way even in the
either to achieve a watertight con- most corrosive chloride environ-
crete structure or to act as a protec- ments, but it also leaves the site
tive barrier in case of concrete at- activities nearly unchanged. The
tack, e.g. high sulphate concentrations selective use of stainless steel rein-
in soil/groundwater. forcement in zones exposed to high
COWI has specialist experience chloride concentrations is a highly
and can support clients and contrac- reliable solution. This solution en-
tors with selecting the most appro- sures very long problem-free service
priate membrane type depending on life in that part of the structure, pro-
Waterproofing membrane installed in the aggressivity of the environment, vided the concrete itself is made suf-
bored tunnel, Hallandsås Tunnel, Sweden
the geometric conditions of the ficiently resistant to avoid other
structure and the construction pro- types of deterioration. Of particular
cedure. importance is the often overlooked
fact, that SSR can be coupled with
Diaphragm walls and secant carbon steel reinforcement without
piles causing galvanic corrosion. Another
Historically, diaphragm walls and benefit is the added value, which
secant piles have been used with follows from the possibility of ac-
success in relatively benign environ- cepting the use of locally available
ments. However, in more hostile or materials even with chloride con-
aggressive environments, e.g. in the tamination and the possible lack of
Middle East, and with extended special qualifications of the local
service life expectancy, special meas- work force.
Selective use of stainless steel reinforcement,
Stonecutters Bridge, Hong Kong, China
ures are necessary to secure the re- COWI has expert knowledge in
quired durability of the structure. specifying appropriate reinforce-
COWI has specialist experience in ment solutions to attain the required
this area and can support clients service life in all possible environ-
and contractors by providing inno- ments.
vative durability design solutions, as COWI’s durability specialists can
Photomontage: HPR

special reinforcement solutions and/ also offer services concerning the


or concrete mix-design requirements assessment of alternative corrosion
to mitigate the effects of chloride countermeasures for concrete rein-
Selective use of stainless steel reinforce- induced reinforcement corrosion. forcement and for the evaluation of
ment, Sheikh Zayed Bridge, Abu Dhabi
corrosion protection of exposed
Corrosion resistant structural steel. This is supported by
reinforcement a continuous cooperation with uni-
The implementation of corrosion versities and COWI’s involvement in
resistant steel reinforcement is the various related ongoing and future
simplest and most effective method R&D projects.
to eliminate the risk of reinforce-

Testing of reinforcement
corrosion countermeasures
13

Photo: Henrik Pyndt Sørensen

Tunnel shaft with secant piles and


waterproofing membrane, District
Heating Tunnel, Copenhagen, Denmark
14 COWI and European research projects

During recent years the European


Union supported a number of close-
ly related research projects and tech-
DuraNet
“Network for Supporting the Devel-
opment and Application of Perform-
D•A•R•T•S
nical networks of considerable mag- ance-Based Durability Design and DARTS
nitude and with very valuable and Assessment of Concrete Structures”, “Durable and Reliable Tunnel Struc-
directly applicable output in relation 1998-2001, 18 partners. tures”, 2001-2004, 8 partners.
to safety, durability and service life The recognised success of the Du- The objective of DARTS was to
design of concrete structures for raCrete project resulted in the Euro- develop operational methods and
major infrastructure projects. pean Commission granting further supporting practical tools for the
COWI is the only consultant in all support for establishing the special best pro-active decision-making
of the five interrelated projects: Du- international network DuraNet to process for choosing, in each indi-
raCrete, DuraNet, UPTUN, DARTS disseminate the valuable possibilities vidual case, the cost optimal tunnel
and FIT. of applying the DuraCrete service type and construction procedures.
This has placed COWI in the ab- life design methodologies on an in- The dominating innovation of
solute forefront in the rational serv- ternational level. DARTS was the integration of reli-
ice life design and safety assurance ability-based structural design, geo-
of tunnel concrete structures. The technical issues, service life design
results are generally applicable for based on the DuraCrete methodol-
all types of concrete structures ex- ogy, hazard design including risk
posed to an aggressive environment assessment, environmental aspects,
and have been implemented in nu- society’s needs, sustainability and
merous recent and current construc- economic aspects.
tions. COWI was the key proposer and
the project and scientific manager of
UPTUN the DARTS project and acted as
“Cost-effective, Sustainable and appointed coordinator between
Innovative Upgrading Methods for DARTS and FIT.
Fire Safety in Existing Tunnels”,
2002-2006, 42 partners.
The UPTUN project main objects
were the development of innovative
DuraCrete and cost-effective fire-protection
“Probabilistic Performance-Based technologies for tunnel applications
Durability Design of Concrete Struc- and the development, demonstra-
tures”, 1996-1999, 12 partners. tion and promotion of procedures
The objective of DuraCrete was to for rational safety level evaluation. FIT
use available knowledge of concrete The main output of UPTUN was a “Fire in Tunnels”, 2001-2005, 33
deterioration through scientifically set of innovative cost-effective tech- partners.
based modelling of the transport nologies and a risk-based evaluation The European thematic network
and deterioration mechanisms gov- and upgrading model. FIT is a group of stakeholders fo-
erning the service life performance COWI was a member of UPTUN cusing on the exchange of knowl-
of concrete structures. and responsible for one key working edge, integration and creation of
The project resulted in the publi- party. know-how. FIT has strong links
cation of design guides for service life. with actual and future European
COWI was the key proposer and and national research projects.
the scientific manager of the Dura- COWI was a FIT member and
Crete project. leader of two task forces.
Selected references 15

Hellmuth, Obata + Kassabaum (HOK)


Offshore wind turbines, Sweden.
Durability design of foundations for
Villamar at the Harbour Development service life of 25 years, 2005
Project, Bahrain. Durability design for
service life of 50 years, 2007

Lusail Development Project, Qatar.


Durability design for service life of 50
years, 2007

Photo: Henrik Pyndt Sørensen


Photo: Rene Strandbygaard

District Heating Tunnel, Copenhagen,


Denmark. Structural design of SFRC lining
Metro Circle Line, Copenhagen, Denmark. segments and durability design of shafts for
Durability design for service life of 100 service life of 100 years, 2004
years, 2007-2018

National Library, Qatar. Reassessment of


piles and foundation, 2005-2006

Al Reem Island Development Project, Abu Busan-Geoje Fixed Link, South Korea.
Dhabi. Durability design of foundations Durability design of bridge and immersed
for service life of 50 years, 2007 tunnel for service life of 100 years, 2005
Courtesy of ATI Impregilo S.p.A

Financial Harbour Development Project,


Bahrain. Durability assessment including
Birth Certificate, 2006

Messina Strait Bridge, Italy. Tender Sutong Bridge, China. Durability design
durability design for service life of 200 for service life of 100 years, 2003
years, 2005
Photom.: Ove Arup & Partners
Photo: Jan Kofoed Winther

Sitra Bridges, Bahrain. Durability study of


design alternatives for replacement of
bridges, 2004
Great Belt Link, Denmark. Service life Stonecutters Bridge, Hong Kong, China.
update from 100 to 150 years based on Audit of durability design service life of
actual chloride profiles, 2001 100 years, 2005
COWI offices
International Projects
www.cowi.com

COWI is a leading northern Euro-


pean consulting group. We provide Headquarters:
state-of-the-art services within the
COWI A/S
fields of engineering, environmental Parallelvej 2
science and economics with due DK-2800 Kongens Lyngby
Denmark
consideration for the environment Tel.: +45 45 97 22 11
Dr.-Ing.
and society. COWI is a leader with- Fax: +45 45 97 22 12
Carola Edvardsen
E-mail: cowi@cowi.com
Henrik Pyndt Sørensen
Daniel Andersson and

in its fields because COWI’s 3500 Section Manager


Internet: www.cowi.com
Photo front page:

Concrete Technology
employees are leaders within theirs. and Durability Design
+45 4597 2813
cle@cowi.com
Printet in Denmark by Kailow
021-1700-031e-07a

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