Master Builders Solutions

Michal Zamenik, Manager of Central Europe Underground Construction

Jose Mª Vaquero, CSM Europe
Carles Cots, Fiber Business Development
Fiber Reinforced shotcrete in tunneling
GENERALNA DYREKCJA DRÓG KRAJOWYCH I AUTOSTRAD

1. BASF CC Introduction
CONTENTS

2. Solution in tunneling

3. PP fibers vs. Steel mesh in shotcrete

Alternative technology based on MasterFiber reinforced
4.
shotcrete
5. Additional benefits

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Fiber Reinforced shotcrete in tunneling
GENERALNA DYREKCJA DRÓG KRAJOWYCH I AUTOSTRAD
1. BASF CC Introduction
MICHAL

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Fiber Reinforced shotcrete in tunneling
GENERALNA DYREKCJA DRÓG KRAJOWYCH I AUTOSTRAD
2. Solution in tunneling
MICHAL

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Fiber Reinforced shotcrete in tunneling
GENERALNA DYREKCJA DRÓG KRAJOWYCH I AUTOSTRAD
3. PP fibers vs. Steel mesh in shotcrete
Fiber reinforced shotcrete mechanism of action
Fiber reinforced shotcrete improves the structural behavior of this material due to two reasons:
• Redistribution stresses capacity  Network creation.
• Structural response in conditions of high deformation.

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Fiber Reinforced shotcrete in tunneling
GENERALNA DYREKCJA DRÓG KRAJOWYCH I AUTOSTRAD
3. PP fibers vs. Steel mesh in shotcrete
Fiber reinforced shotcrete mechanism of action
The mechanism of action of a fiber in a shotcrete matrix is function of:

Shotcrete Fiber T = τ * perímeter * x = τ * π Ø * x

τ
T (assuming circular section)

Where:
Ø: fiber diameter
x
x: bonding length of the fiber in the
mass of the concrete

Fiber reinforced shotcrete behavior influencing factors:

• Shotcrete matrix
• Number of fiber
• Fiber length

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Fiber Reinforced shotcrete in tunneling
GENERALNA DYREKCJA DRÓG KRAJOWYCH I AUTOSTRAD
3. PP fibers vs. Steel mesh in shotcrete
Mesh
• The positioning of the mesh with the respect to the variable
thickness of the shotcrete does not ensure a good efficiency of the
reinforcement (ie in the wrong place).
• Over breaks and difficult geometry - thicker layer behind the mesh -
creating of the pockets behind the mesh and the deflection of the
mesh – shotcrete is not in direct contact with the rock.
• Additional SFRS consumption due to the requirement of steel cover
(this is often not satisfactorily achieved).
• Creations of shadows behind reinforcing reducing its effectiveness
and durability.
• Increased rebound as stone rebounds of mesh until covered.
Advantages of PP fibers
• Fibers give resistance to tensile stresses at any point in the
shotcrete layer.
• Homogeneously reinforced concrete with excellent density
and less shadows.
• The use of fibers allows the shotcrete to better follow the
contours of the ground and avoid the voids
• Fibers are delivered in the concrete eliminating one whole
operation i.e. mesh installation.

!!!
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Fiber Reinforced shotcrete in tunneling
GENERALNA DYREKCJA DRÓG KRAJOWYCH I AUTOSTRAD
3. PP fibers vs. Steel mesh in shotcrete
why is FRC advantageous for tunnel and mining applications?
1. Higher safety level - precaution when the geological conditions require an immediate support after
excavation. No need for the manual installation of the mesh underneath the unsecured rock,…

2. Increased efficiency and production rates = increased speed of the excavation – less operations
during the in the installation of conventional reinforcement, less logistic operations,…

3. Quality is improved – elimination of the corrosion of the steel mesh during the storage on the job site, no
voids, less shadows….

4. Isotropic structural behavior Fibers provide, while reinforcement provides anisotropic behavior.

Fiber network creation

Shotcrete Fiber

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Fiber Reinforced shotcrete in tunneling
GENERALNA DYREKCJA DRÓG KRAJOWYCH I AUTOSTRAD
4. Alternative technology based on MasterFiber reinforced shotcrete
EN 14488-5 .Determination of energy absorption capacity of fiber reinforced slab specimens

Specimen:
Dimensions: 600x 600 x 100 (mm)
Point load: 50 x 50 mm.

Constant displacement rate: 1 mm/min

Total displacement: 30 mm

Results: Energy (J)

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Fiber Reinforced shotcrete in tunneling
GENERALNA DYREKCJA DRÓG KRAJOWYCH I AUTOSTRAD
4. Alternative technology based on MasterFiber reinforced shotcrete
SECTIONAL ANALISYS
PLAIN CONCRETE

MRd
Fc,t
h
Nsd

fct
b

STEEL REINFORCED CONCRETE FIBERS REINFORCED CONCRETE

MRd
Fc,t
h Nsd

Fs,t
fct
b

STEEL REINFORCED CONCRETE FIBERS REINFORCED CONCRETE

MRd
MRd
h Nsd
h Nsd

Fs,t
10 fct fct
b b
Fiber Reinforced shotcrete in tunneling
GENERALNA DYREKCJA DRÓG KRAJOWYCH I AUTOSTRAD
4. Alternative technology based on MasterFiber reinforced shotcrete
PROJEKT WARSZTATOWY

Project configuration: steel mesh  6 #150 -150

Shotcrete thickness: 25 cm.
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Fiber Reinforced shotcrete in tunneling
GENERALNA DYREKCJA DRÓG KRAJOWYCH I AUTOSTRAD
4. Alternative technology based on MasterFiber reinforced shotcrete
PROJEKT WARSZTATOWY Calculation results - conventional reinforcement
h= 250 mm

b= 1000 mm

d= 90 mm

As’= 0 mm2

As = 188 mm2

Æ 6 #150-150 in the middle

plane of the cross section

Bending moment capacity of the concrete section with

conventional reinforcement  Mu=7,2 kN·m/m.

Project configuration: steel mesh  6 #150 -150

Shotcrete thickness: 25 cm.
Fiber Reinforced shotcrete in tunneling
GENERALNA DYREKCJA DRÓG KRAJOWYCH I AUTOSTRAD
4. Alternative technology based on MasterFiber reinforced shotcrete
PROJEKT WARSZTATOWY - Fiber reinforced shotcrete lining
h= 250 mm
b= 1000 mm
As’= As = 0 mm2

fR1=1,1 N/mm2 mean residual flexural strength CMOD1=0.5 mm

fR4=1,1 N/mm2 mean residual flexural strength CMOD4=3.5 mm

σR1 = 0.45· fR1 = 0,5 N/mm2

σR4 = 0.37· fR4 = 0.4 N/mm2

FRC Bending moment capacity with MasterFiber 151 

Mu=7,5 kN·m/m.
Fiber reinforced shotcrete lining
macro synthetic fiber MasterFiber 151.
Shotcrete thickness: 25 cm.
Fiber Reinforced shotcrete in tunneling
GENERALNA DYREKCJA DRÓG KRAJOWYCH I AUTOSTRAD
5. Additional benefits
Technical benefits
 The fibers reinforce the shotcrete homogeneously and
gives a resistance to tensile stresses at any point in the
shotcrete layer
 Increased load bearing capacity due to the redistribution
of stresses
 The removal of mesh leads to an increased shotcrete
bond to the substrate
 No corrosion. PP fibers eliminates the problem of
spalling due to rebar corrosion
 Excellent control of cracks giving less leakage
 Avoids “shadowing” or voids behind mesh
 Elimination of the risk of the dropping of the shotcrete
applied on the steel ribs
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Production benefits
 Safety - the safety of underground construction
workers is of utmost importance. PP fibers provides
instant support without manual risky installation of
the mesh.
 Time - the use of PP fibers, means no installation of
the mesh, therefore better efficiency and the
tunneling cycle time is dramatically reduced and also
reduces non-productive time with tunneling
equipment. = PP fibers shortens the total
construction time.
 Quality - FRC shotcrete follows the ground contours
to give constant thickness and less rebound and
drops off.