Document type: Techical Paper ‘Author: dian Douolas Eur og. MEog CEno MICE. M Sth BScittons).. Hunt BEng(ons) CEng MICE. OF Publishing Publication Date: 31/0872016 (Be the first to rate this document) ABSTRACT ‘The Moorgate shaft at CrossralLverpocl Sret station Is one ofthe deepest in London. Construction ofthe base slab tothe shaft required close collaboration between the cent. designer, contractor and supplies to give assurance thatthe slab was wateight. Dense reinforcement was detailed to ‘ensure ease of ing within he tight canines of the shaft and allow forthe talarance on he dlapnragm walls. The concrete design was developed to ‘ensure that it mat he requirement for placing and structural strength whilst achieving good cotrl on the temperature developed. The conerete mx ‘was tale for temperature development and nial set to allw relaxation ofthe original specication, The pour plan was developed wih the cooperation of al he ste teams to ensure appropriate contingency measures were in place. Temperature mantoring was cai out o ensure hat ‘mignon measures could be applied io contol placed concrete temperature aganst pre-determined tigger level. READ THE FULL DOCUMENT KEY WORDS Concrete structures, Tharmal effects, Stength and toting of matrials INTRODUCTION Figure 1 shows how the new Crossrail station at Liverpool Stree extonés between te London Underground stations at Liverpool Steel and Moorgate, ‘The Moorgate shat isa the west end and contains part ofthe main escalator bank fom the tiket hall, emergency ogress from the station platforms, a ‘eo ightng it, a passenger i, station ventilation tunnel ventlaton and past ofthe connection othe Londen Underground Norther Line. The new “Stations plattorms are the deopest below ground level on CrossralFigure 1 ~ Liverpacl Strast Crossrail tation -Mocrgate shaft is onthe left “The shafts an ireguar shape, approximately 24 m square in plan and i 42 m deep to bottom of excavation, The plan at base slab lvelis shown in Figure 2and atypical secon in Fgure 3. A goneral view looking down the shall is shown in Fgure 4 9 9 Figure 3 - Vertical section through shaft grid 8 Figure 2—Plan of dase slab looking west (m LUD, metres above London Undarground ‘alum whichis 100m below Ordnance datum) ‘This paper describes the design requirements fort base slab atthe boom ofthe shat, te dealing ofthe reinforcement, the planning forthe concrete pour, the execution ofthe pour and the temperature monitoring ater the pour. The principal pour parameters are given i Tale 1 Concrete C3515, DC-4, 5 s750m2 Reinforcement tonnage sso‘Number of relnfrcement etal ravings s18Ne “Teme te deta cranings 110 days Tame to fe relforcoment St cays “Time for pour for base slab Tours oak moasured concrato lomporature ssc Maximum measured diferental temperatire aoe ‘Table 1 ~ Principal pour parameters The shaft was designed by Matt MacDonald (MML) as pat ofthe Crossrail (CRL) design convact C138. The conractoc forthe shat was @ joint venture ‘of Bam Nltall and Kier (BNK) under the CRL enabling works contact CSO, BNK wee responsible for dealing the reinforcement fom design nent {RIBAE:) rawings prepared by MML.Figure 4 View o shaft and construction access jetty during conerete pour DESIGN ‘The shat was excavated through London Clay into the top ofthe Lambeth Group. A300 mm thick Blnaing slab was east ono the ground atthe bottom ‘ofthe excavation to stut he diaphragm walls whist he base slab was constructed. The ground beneath the base slab is expected to heave by up to +140 mm, The ground water is underdrainedto te uncerying chalk so anough he water table is near ground level he base slab is only subject o &haractristic water pressure of270 kPa (27 m head) (Used for design approach * combination 2 in aecordance wih BS EN 1887-1 (BSI, 2004). ‘Acontola collapsible void former was spaced under he slab to ithe lad cua to ground heave to 75 KPa, The 2m thick base slab is connected to the perimeter ciaphragm wall ana central tension barrett as shown n Figure S. The slab was designed lobe watertight to cass 1 to BS EN 1992-3 (Bs, 2006) ‘This requces a minimum of 50/mm thickness of eonerole in compression, or where racks may passthrough the whole hikness of he section, crack es ited to 0.15 mm a the hycraule gradient of 18.5 across te sab is greater than , The jin wh the diaphragm wall wil be incorporated into ‘ho base ofthe lining walls whore the watertight joint tothe base slab is achieved with hydrophili stp. Very dense reinforcement was cents in each direction in he etical areas on top and bottom faces, and was crtale to one layr of BAD reinforcement inte compression zones, However, the anchorage length ofthe reinforcements so long that there were few areas wihout multiple layers of B40 reinforcement. Shear Inks were required across the whole area ofthe base, wih a higher density around the perimeter and adjacent the tension bates. quired to meet the crack width imitations The reinforcement generally comprisd tree layer of B40 at 150 mm ‘An earthing mat was required under the sla with watertight connections tough to earth pits east into the slab. A drainage network fr fe water and ‘seepage water was also cast nto the slab, Ths dened toa sump onthe east de ofthe sab ‘Tho concrote was specified as @dosignod mixin accordance with BS 8500 (BSI, 2006) stable or sxposurs lass XOS and DC-4 duo to aggressive ground conditions exacerbated by hycraulc gradient greats than 5, Strength grade C36!45 was adopted for stuctural design, and a minimum ‘cementitaus content of 260 kgm3 and maximum water cement rato of 045 were specified The specication for conerote or the shaft works lined the poak conerote temperate to 7OYC and the diferent temperature between coce and surface to 25°C. The reinforcement design for early thermal effects assumed a concrete mix wih 380 kg/m? cementiious content with 8% ground Say deoulee Figure 18 - Routes int the holding areaPersonnel (each shit) Equipment Mater NK nominated concrete co-ordinator | 200, 62 reach concrete pumps | Frost Blanket 3 shit onginaers ‘ino. 38 mreach concrete pump | screed rails + elactican ‘ino. 58 mreach concrete pump | Stainless steel ying wre 2 singers (ack) Spray applied curing membrane 15 concrete operatives ‘ower eae Ful diesel bowser Crawl crane + concrete wagon Booking operate operatives at tne concrete pump | Vratra pokes Hand tools 6 secury guards 2 concrete skip Cantoen stat ‘3 conerata skip Sate men 6 concrete testing technicians Roller seeds ‘3 batching plants Trae management eub-conracior ae ‘wan 25 concrete wagons 3 main concrete pump divers ‘Thermocouples and data loggers + back up pump devor S propane hosters + Camfoud itor Table 4 — Resources planned for pour “The roa closure forthe pour was booked rom 20:00 on Friday through o 06:00 on Menday o allow for setting up, c delays. ing avay and significant ‘Within the shaft an access bridge was constructed from the main acess jetty over to the previously east sump to arable xt rm the shat boom after Fishing to one ofthe sino (Figure 24). The site cantoen was planned lo be pen thoughout the pau’ and ree of charg Inthe days leading Up to the pour te folowing were put into place + Al qualty contol documentation for construction drawings, material conformance cords et. agreed and signed of + Testing of dowel bars and embedded drainage completed rapares and sufcent printed of + Concrete placement lines assembled on reinforcement + Seroed rails sett lavel and secured + Thermocouples installa + Record sh + Embedded drainage pipes fled wih water to prevent flotation: + Proposed traffic routes inspected for diversions or road works CONCRETE POUR “The road closure for to pour was putin place at 20:00 on Friday. The two 63 m reach Camfaus concrete pumps wore Set up on Moorgate lo the east tho shaft aligned so thal one recaves conerote wagons from the north andthe other From the south, The 36 m reach pump was st up othe noth of tho sha and connected o@ static line installed for tho eat constuction as shown in Fie 4 “The fist conerate was delivered at 2810. was fund thatthe reach ofthe 83 m reach pumps was suficient to cover the whole area a he pour so the ‘moveable concrete lines on he reinforcement cage were deamed unnecessary and removed. When planing the pump layout it was assumed thatthe ‘arms were vertical or horizontal In practce twas possible to angle some ofthe arm segements down the shaft with some increase in reach. The 38m reach pump was stood dawn frm 10:30 on Saturday. Only one of the 63 m reach pumps was used from 16:00 on the Saturday, te reduced pour rats allowing forthe effort require fr fshing. Coneeting was complete by 16:15. The number of wagons departing each hours shown in Figure *9.£ = 20 = 215 & 10 63m Pumps 2 36m Pump 5° = 63m Pump N o g8esse3288888888888 BsSsesssssegssagnsa sagas SSSSSSSSSSSssseagsg Date (day hr:min) Figure 19 ~ Number of coneote wagons departing each hour during the pour “Thore wore no delays othe concrete supply o incidents during the pou. Review oft dolvay ticks indicated tata maximum pour rat of 150 m3 ‘was sustained for one hour. The pour rate was reduce to 100 m® er hou during he et change around 06:00 on Saturday morning. The ene 1750, 1m had boon placed in 5 minutes over 17 hours. ‘The delivery temperature ofthe concrete (shown in Figure 20) varied from 14°C to 18°C wih an average af 158°C wih no clear corslation fo ambient temperate. The low had a linting range of S20 mm to G60 mm, Measured flw shown in Figure 21 had an average of 618 rem. Only two ofthe 60 tat rule were greatrthan the upper ii of 660 mm. 5° 5 om “15 16 Delivery temperature (°C) a = v8 Figure 21 - Variation of measured conerete ow at ‘delvery Figure 20 Variation of concrte delivery temperature ‘Tho only causes fr cancom were ths unseasonably hightemperature of 21°C onthe Saturday afternoon and the heavy rain onthe Sunday attemncon. Inspection of the conerate surface, when accessible onthe Menday showed tat the rain had not had any datimental fects The equipment and pragcess ofthe pours ustrated in Figure 22 to Figure 26,Figure 23 Vagons marshalled on Moorgate Figure 24 - Nearing completionFigure 25 Finishing works Figure 26 - Last man off TEMPERATURE IN SLAB ‘Temperatures were mantored after the concrete pout. The concrete temperature when poured varied betwoen 15°C and 23°C. As the predicted ‘maximum temperature was based on a maximum delvery temperature of 25°C, wih the low ambient temperatures in he fst week there was no cause for any contingency measures. The predicted temperature shown in Figure 27 is based on the average as placed concrete temperature of 158°C. 70.0 600 50.0 40.0 300 200 10.0 0.0 30 00:01 000093 00:05 00:007 00-0009 000411 00:0013 00:04 00:00 Date (day hrmin) Temperature (°C) bottom =——middle top = middle predicted Figure 27 — Actus an predite temperate i slab ated accurat fallin temperature But afer about Fe days there is a sign-icant divergence between measured and predicted. The 3 temperature, shown in Figure 28, was underestimated, but the time ofthe maximum dfrential temperature was accurately predicted.300 250 200 150 100 50 o 90 ~ >> = 50 a : ae "=o es e 828 8 # 8 «8 = 8 8 8 8 8 8 8 8 8 a 8 8 8 8 8 8 8 8 8 E R 3S 3S 3 8 8 = a a 5 £ average middle-bottoR it? (2 hemin) average middle-top = = = maxmidale-top = = = min middie-bottom ~ middle predicted Figure 28 ~ Actual and predicted ferential temperature in slab “The development over time of temperature pofe through te slab is shown in Figure 29. 2.00 1.80 1.60 1.40 #120 = 1.00 8 0.80 0.60 0.40 0.20 0.00 200 20.0 400 50.0 60.0 Tempearture (°C) —— 03 09:00 —— 03 12:00 ——05 04:30 06 17:00 —— 1016:00 12.17:00 -------02 14:04 - 03 09:12 04 10:18 ------- 10 15:44 Figure 29 Actual and predicted temperature prolein slab Intal the measured and prdicod profiles are similar, but after 4 days they have diverged withthe botlom tomperature remaining much higher than predicted. At 10 days, although the surface temperature is similar othe preccted, the peak and bottom temperatures ae significantly higher than predicted. CUBE TESTS‘Cubes were taken for conerete strength compliance from each 100 m8 of concrete delivered, These wore tested at 7 days and 28 days under standaré test condtions a the ial mc had inccaled that testing at 58 days was nol required, ‘The follow on works inthe shaft could nt stat unt the slab concrete has reached 20 MPa design strength. This was expected to be achieved wth the ‘seven day cubes. The rebut ofthe seven day cubes are shown in Figur 20. ‘The avorag ofthe fst six cubes was oss than required, However, two ofthe lowes strngth cubes were sampled late an Fay and tora testo al slg less than seven days. These were inte oltom fer ofthe pour and remote trom where the flow on contactor wished to start work. In practic the folbw on works dd not start unt at on Sataray ar tho work ct no significantly bad the slab unt early the following Wook so tore ‘wore no cancoms over the strangth, The results war sgh owor than te Ul mix whic is posily due to adjustment inthe dose of otardor. ‘The 28 day cube toot results are summarised in Figure 31. These ehow thatthe design strength of 45 MPa is exceeded, Que toa singlo low test result ‘he characteristic strength ofthe resus is 53 MPa, thats 4 MPa mare than the lowest rest in accordance wih BS EN 208 6 © s 5 i i 4 i i p : #2 52 : 2 1 1 I ° I oll, e's 38s oy P2233 i i 2 9 of rs Td ube strength (Pa) Cube strength (Ma) Figure 30— Concrete cube strength tests a7 days Figure 31 - Concrete cube svongh toss at 28 days CONCLUSION ‘The temperature monitoring of the sla gave te project team confidence tha 8 watertght concrete sla has been achieved within the specied parameters. Temperature prediction gave mxed results. When signleant hea is being generated by the setting concrate the CIRIA Guide C60 spreadsheet maiches the measured temperature accurately, but dig te cooling phase this sno the case, and sabuted to the slab being cast ‘onto well insulated base. The peak concrete temperature is accurately predicted andthe maximum dferental temperature reasonably prod ‘Separating dosign ntnt forte reinforcement ram the dealing by the contractor, alfrough normal practice for buléings, was difcll fo manage or his hheany cil engineering work Colour coding ofthe reinorcament cravings was a ‘and avoid gaps inthe reinforcement ve and the 3d modeling essential in places to avo lashes, define the construction sequence ‘Outine design of temporary works supporting the heavy woightof lop reeforcomont and appropriate assassment ofthe constuction loads was roqu {0 spect the required working strength ofthe vos fermer and therfore the cals oad Used nthe dasign ofthe hab. ‘Carel planning ofthe conerete pou rm reinforcement detiing through to road closures to give access to contrsined sien the heart af the Gy of London, the contingency measures for dstupted concrete supply an the conta f concrete temperature led to the successful executon of wnat was a ‘hat tme Crossral's largest concrets pour. REFERENCES Bamfoch,P.B., 2007. Eanj-age thermal erack contol in concrete (C860), London: CIRIA BSI, 2004, Eurocode 7: Geotechnical design — Pant 1: General rule (BS EN 1997-1) London: 8S! |, 2006. Eurecode 1 - Actions on sructures, Pat 1-6: General actions — Actions during execution (2S EN 1991-1). London: BSL BSI, 2006, Concrote— Complementary Brilsh Standard o BS EN 206-1 - Part 1: Method of speclyng and guidance forte speci (BS 8500). London: BSI BSI, 2006. Eurecode 2 Design of concrate structures ~ Part 3: Liquid retaining and containment structures (BS EN 1992-3) London: BSI 81,2009. Executaon of conerote situs (BS EN 13670). London: BS ‘Tho Concrete Centre, 2011. Specifying Sustainable Concrete, Understanding the role of canstuent materials. Camberly: mpa,AUTHORS Adrian Douelas Eur Ine, MEne CEng MICE - Mott MacDonald Principal Enger ‘M Smith BSc(Hons) - BAM Nuttall Kier Construction Manager J.Hunter BEng(Hons) CEng MICE - Crossrail Ltd ‘Site Manager ice emcee es publishing ACE Publishing Froe accoss sponsored by ICE Publishing ntodewweevitualbrary.comMOVING LONDON FORWARD ‘TRANSPORT FOR LONDON ae Department for Transport MAYOR OF LONDON Privacy and Cookies Accessibilty Statement Terms and Condions © Crossrall Li 2021