RILEM-^ö-AFGC Int. Symposium on Ultra-High Performance Fibre-Reinforced Concrete, TJHPFRC 2013 - October 1-3, 2013, Marseille, France
P A R K B R I D G E : O P T I M I Z A T I O N O F A S L E N D E R B R I D G E I N
UHPFRC
Steffeii Grünewald (1-2), Hans Köhne (3), Maurice Nio (4), Matteo Serafini (4), Anja Verdonk (4), Rogier van Nalta (5), Rob Huijben (6), Viktor Mechtcherine (7), Lukasz Dudziak (7), Leo Gielbert (8)
(1) Faculty of Civil Engineering, Delfl University of Technology, The Netherlands (2) Hurks Prefabbeton, Veldhoven, The Netherlands
(3) Cement&BetonCentmm, 's Hertogenbosch, The Netherlands (4) NIO architecten, Rotterdam, The Netherlands
(5) Pieters Bouwtechniek, Delft, The Netherlands
(6) Hurks Delphi Engineering, Veldhoven, The Netherlands (7) Technische Universitat Dresden, Dresden, Germany (8) Strukton, Maarssen, The Netherlands
Abstract /
Ultra High Performance Fibre Reinforced Concrete (UHPFRC) is a concrete type with superior characteristics concerning strength, ductility and durability compared to conventional concrete. In spite of extensive research efforts the number of applications is still limited. In order to promote UHPFRC in the Netherlands, Cement & Beton Centrum initiated a program that aimed at designing and realizing attractive stractures with UHPFRC; the Parkbridge is one of the cases considered. This paper describes the design and the optimization of the 'Parkbridge', a slender bridge with a span of about 20 meters. This pedestrian bridge was designed to replace the existing wooden bridge of a nature park. The bridge consists of a parabolic-shaped load-bearing stmcture and an ultra-slender balustrade. A tailor-made UHPFRC was applied to produce the largest element of the balustrade. Besides design considerations, production aspects of the slender UHPFRC balustrade-element are discussed.
Résumé
Les bétons fibrés a ultra-hautes performances sont une gamme de béton possédant des caractéristiques exceptiormelles en termes de résistance, ductilité et durabilité par rappoit au béton traditionnel. Malgré d'importantes actions de recherche le nombre d'applications reste limité. Afin de développer les BFUP aux Pays-Bas, le centre technique des bétons (C&BC) a
RILEM-y?è-AFGC Int. Symposium on Ultra-Higli Perfomance Fibre-Reinforced Concrete UHPFRC 2013 - October 1-3, 2013, Marseille, France
lancé un projet visant a concevoir et réaliser des structures en BFUP susceptibles de faire école. Le pont du pare (Parkbridge) en est un exemple. L'article décrit la conception et l'optimisation du "Parkbridge", ouvrage élancé d'environ 20 m de portée. Cette passerelle pietonne a été eon?ue pour remplacer le pont en bois existant d'un pare naturel. L'ouvrage consiste en une stmcture porteuse parabolique assoeiée a un garde-coips ultra-mince Une formule spécifique de BFUP a été utilisée pour réaliser l'élément le plus important du garde-corps. Outre les considérations de calcul, l'article détaille les questions de fabrication de eet élément mince de garde-corps.
1. U H P F R C CASE-STUDY
UHPFRC is more than an improvement of traditional vibrated concrete; eonceming material performance and production technique it can be considered a new technology. Clients want examples of successful applications and require a perspective on profit on investments. The Parkbridge is one of three case-studies in UHPFRC and an initiative of Cement & Beton Centrum to increase the acceptance of UHPFRC in the Netherlands as an excellent building material. A n aim of these studies was to demonstrate the additional value of an integral design approach of cooperating architect, engineer, producer and contractor. The advantages of freedom of shape, a stmcture without maintenance, ease of use and durability have to outweigh the initial constmction costs in order to convince owners.
The design process of the Parkbridge focused on two aspects: harmonious embedment of the bridge m its suiToundings (in a nature park close to Voorstonden, The Netherlands) and making full use of the material characteristics of UHPFRC. Figure 1 shows an impression of the bridge in its final version.
RILEM-y?Z?-AFGC Int, Symposium on Ultra-High Performance Fibre-Reinforced Concrete, UHPFRC 2013 - October 1-3, 2013, Marseille, France
The design should result in a very slender structure with an organic appearance. The new pedestrian bridge had to replace a rotten wooden bridge, which would be a step ahead towards reconstraction of this nature park. The Parkbridge was a realistic project with the possibility to constract the bridge in case the design solution would be convincing both in design and project costs. According to the owner of the park, a solution in concrete had a good chance to be selected because of the high durability of the material. By applying UHPFRC a special bridge solution seemed to be achievable.
2. DESIGN OF T H E B R I D G E D E C K
NIO architects wanted to design an extremely slender bridge, completely made from UHPFRC. Inspiration for the architect was found in the structiire of leave-veins of the countless leaves at the site. The bridge-deck and the balustrade have different functions in the stractural design. The balustrade should be as slender as possible and should demonstrate the freedom of shape of concrete. The balustrade does not increase the stiffness or the load-bearing capacity of the slender bridge-deck. The design of the bridge-deck was an exercise in optimal utilisation of the strength and the stiffness of UHPFRC. The bridge-deck (design load: 500 kg/m^) was designed to be as thin as possible. The optimum stinacture of the deck is the arc. Figure 2 shows a view of the bridge as well as two cross-sections (in the middle of the span and above the abutments).
RILEM,^-AFGC Sy,^^^^^^^^^ Utoa-High Performance Fibre-Reinforced Concrete, UHPFRC 2013 - October 1-3, 2013, Marseille, France
cross-section bridge-deck above the abutments
The compressive strength of UHPFRC is much higher compared to conventional concrete' n an arc situation the bridge-deck is loaded mamly in compression, which is S hisTpe of
significant effect on the stress distribution in the arc. By restraining the bridge-deck at the thetfddl
^Tth ^"-^'^"-^^r
J"^'^^^)^ff-t
IS mimmized and as a sfde-efShe m o m n t tthe middle of the span is decreased. As a result, a robust stmcture with a very slendT b r i d . l deck was obtained With the assumed UHPFRC-charactenstics listed Tn ^ T a ï i was" possible to design the bridge-deck with a varying thickiress of 330 mm t the support I d 120 mm m the middle of the span. The prefabricated abutments were des gi ed n T d Ï o n a l concrete (strength grade C53/65). In order to make the bridge appea ^ o r e sl n d r S r e thickness of both sides of the deck was reduced to 80 mm (pfgure 2). T l " o a Z of tS bridge results m a bending moment at the supports of 410 IcN.m and of 98 kN m in the midd e of the span (m comparison: the moment in the middle of the span would b72S^0 iSl m f o f a beam on two supports). The deformations of the bridge are small due to the stiff stioict L the vertical deformation is less than 40 mm and the horizontal displacement of tl e slp^^^^^^ Its maximum 13 mm. In order to minimize the costs for formwork and tlspo^^^^^^^^^^^^ deck IS prefabricated m two identical parts with a joint at mid-span. Both pai s are p s S e d at the site on temporary supports at mid-span and the joint is coimected afterwards with an in ^tu^comrection. The bridge-deck and the abutments are connected with ™ e n l t S a n ;
Table 1; Material characteristics of two concrete tvnes'
Characteristic Prefab concrete C53/65 [MPa] U H P F R C [MPal f c k AD (0,6- f c k ) E-modulus Shear strength, x 65 3 9 3 8 5 0 0 0,86 150 9 0 5 0 0 0 0 2 , 5 0 3. B A L U S T R A D E : DESIGN CONSIDERATIONS
The leaf-impression of the balustrade was studied on different levpk T t , . f
contiibute to tlie load-bearing of the bridge-deck. Still, they have to be connected to the biidge-deck with a moment-resistant comiection in order to transmit the d e ï g i fo ce Ïn horizontal direction (load acting perpendicular to the span-direction: 1 ^ a e C o n t^^
RILEM-y?ö-AFGC Int. Symposium on Ultra-Higli Performance Fibre-Reinforced Concrete, UHPFRC 2013 - October 1-3, 2013, Marseille, France
hand-rail of the balustrade). Several options were discussed to design this connection (i.e. in-situ cast joint and steel anchors with bolts). Material characteristics, economic considerations and production boundaiy conditions also have to be taken into account to determine the minimum thickness of the leaf-veins. In an iteration process of engineering, material and production optimization a balustrade element was developed and produced. Important considerations were:
- UHPFRC with steel fibres had to be applied in order to meet the high demand on the flexural strength; by applying fibres instead of rebars no concrete cover was required to protect rebars from coiTosion.
- Steel anchors connect the balustrade to the bridge-deck (along the straight side of the element).
- The volume of UHPFRC of a balustrade-element is small; costs for formwork, abutments, transport and erection of the structure mainly determine the price of the bridge. Due to repetition related to the use of formwork the total costs of the Parkbridge can be reduced.
- An optimized UHPFRC had to be developed in order to produce the balustrade-element. De maximum aggregate size was 1 mm; a combination of short and long steel fibres (12 & 20 mm) was applied.
In order to study the applicability, different UHPFRC-mixtures were tested containing either steel or plastic fibres; different materials were used for the formwork (wood and different plastic materials i.e. Expanded Polystyrene (EPS)). Figures 3a and 3b show two test elements that were produced in order to study the filling ability and passing ability of UHPFRC, element dimensions and formwork material.
Figure 3 a/b; UHPFRC-test elements a) left: element cast in a wooden mould b) right: element cast m a wooden mould with dimensions of 12x30x 1000 mm
RILEM-y?è-AFGC Int. Symposium on Ultra-High Performance Fibre-Reinforced Concrete
UHPFRC 2013 ^ October 1-3, 2013, Marseille, France
4. U H P F R C AND AUTOGENOUS SHRINICAGE 4.1 UHPFRC-mixture
The vein-structure o f a balustrade-element is i n contact w i t h a relatively large formwork surface area, w h i c h makes it d i f f i c u l t to f o r m o f f an element. The shrinkage i n an earlv hardenmg phase o f U H P F R C is higher compared to conventional concrete. I n order to decrease the risk o f cracking during hardening and to facilitate demoulding it was decided to cany out tests on the autogenous defonnation i n an early phase after casting. Table 2 shows the composition o f the applied UHPFRC. A combination o f two types o f steel fibres was applied (steel fibre length: 12 and 20 m m ) ; the fibre dosage was 300 k g / m ^
Table 2: Mixture composition o f the applied UHPFRC
Component kg/m^
C E M I 52,5 R white
C E M I 52,5 R grey 500 Metakaolin JQQ Limestone powder 9Q Water (excl. water i n superplasticizer), W/C=0.30 285
Polymers SAP 2 85 Superplasticizer 3Q g
Steel fibres 12 m m jgQ Steel fibres 20 m m 120 Sand 0-1 m m
Water-absorbing polymers were added to provide sufficient water during hardening The addition o f the polymers had a pronounced effect on the workability; in order to obtain a workable concrete the dosage o f water and superplasticizer had to be increased compared to the rel^srence UHPFRC, that did not contain water-absorbing polymers. The compressive strength decreased fi-om 150.1 to 122.5 MPa (after 28 days) due to the adjustment o f the mixftire composition and the addition o f the polymers. Table 3 lists test results o f compression tests (cubes o f 100 m m ) and bending tests (prisms o f 40/40/160 m m ) These tests were can-ied out load-controlled; each test was executed w i t h three specimens.
Table 3: Test resuhs compressive and flexural strengths
Concrete age Compressive strength
[ M P a l Flexural strength [MPa] 7 days 28 days 117.1 (STD: 2.7) 122.5 (STD: 2.1) 35.3 (STD: 4.6) . 36.5 (STD: 2.5)
4.2 Measuring autogenous shrinkage
UHPFRC can significantly shrink i n the first period after casting due to self-desiccation and the resulting stresses can exceed the tensile strength i n the early hardening phase. Autogenous shnnkage tests were executed by the Technical University o f Dresden- the effect o f polymers on shi-mlcage was investigated. The autogenous shi-inkage was measured w i t h the
RILEM-y?è-AFGC Int. Symposium on Ultra-Higii Performance Fibre-Reinforced Concrete,
UHPFRC 2013 - October 1-3, 2013, Marseille, France
con-ugated tube method (Figure 4). This technique was developed b y Jensen and Hansen m 1995 [ 1 ] , one exemplaiy small-scale set-up w h i c h became a ASTM-standard test most recently '[2]. It involves a special measuring device called dilatometer (Figure 4) that is equipped w i t h linear displacement transducers o f high measuring accuracy and waterproof tube-shaped polyethylene moulds (approximately 420 m m long and 29 m m wide).
Figure 4: Dilatometer f o r the measurement o f autogenous shrinkage
The tubes ffossess characteristic corrugations and low longitudinal restraint. Other relevant accessories are a reference bar and, f o r eveiy mould, two T e f l o n end plugs bemg 19 m m high and having a geometry f i t t i n g i n at both ends o f the tube. The autogenous deformation captured by this solution is believed to be the linear strain that results f r o m transfoimation o f volumetric change before cementitious material solidification [3]. Prior to casting, the tubes were encapsulated at one end and subsequently placed i n a supporting tube. Then the freshly produced m i x was poured into the mould under activity o f gentle vibration. The casting process was finalized by closing the other end o f the tube w i t h a second plug. The measurement started after transporting the moulds to the calibrated dilatometer and was can-ied out at a quasi-constant temperaftire o f 2 0 ± r C . Although the method allows continuous monitoring o f concrete defonnation starting immediately after filling aird encapsulating the tubes, deformation before final setting was neglected. I n fact, while deformations i n the fluid state are incapable o f producing stresses, this point and time-zero i n measurements conesponds w e l l w i t h deviation o f chemical and autogenous shrml^age as confu-med by other techniques, c f [ 4 ] .
Figure 5 shows the average results o f the measurements; two tubes were tested f o r each mixture Thi-ee different mixtures were tested: 1) a reference mixture, containing no water-absorbing polymers, 2) the reference mixture w i t h a decreased superplasticizer dosage and 3)
RILEM-^è-AFGC tat Symposium on Ultra-High Performance Fibre-Reinforced Concrete UHPFRC 2013 - October 1-3, 2013, Marseille, France
a mixture containing polymers (the vv/c-ratio was increased by 0,06). Most of the autogenous s b t d age was recorded dunng the first four days after castitrg. The autogenous shrinkageTf nd I T 7 ^ ' ' ^ ^ ^ ^""^P^'-^'l without polymers and wtth less supeiplasttctzer and 62,lo/„ compared with the mixture with 100% superplasticizer and no polymers.
g time [da^s]
10 12 14
-200
1
-400 .2 -600- UHPC with polymers (no fibres, less superplasticizer. 0,22% SAP. extrawater 0,06) • LIHPC reference (no fibres, less superplasticizer)
UHPC reference (no fibres, 100% superplasticizer)
Figure 5: Deformation of UHPFRC after final set within the first 14 days
Lentned ^^^^^V^' ' ' ' ' ' pronounced with preferably oriented fibres. As d flow b^^^^^^ TT' ^ ^ P - P l - t ' - - - had to be increased in order to obtain the t m e n t ^ - 0 3 0 ^ 7 ' ' T water (autogenous shrinlcage testing: :w/c=0.33; balustrade element, w/c-0.30) the autogenous shrinkage might be slightly higher than Figure 5 suggests.
5. PRODUCTION O F A B A L U S T R A D E - E L E M E N T
t h e ^ i m n S r o f " " f ^ " ' ' ' ' ' ' ^"^8^ be constmcted. After tl^e cotnpletion of the design process, it was decided to produce the largest
balustrade-desrand
f" . • ' ^ " ^ ^^''^^^ ° ' ™ ^
'''''' ^^^^^
^
hffmal
T h e ? / 1 '''''' ''^'"^ '^^^ffi'^ients are considered in Ms design strength
abound
t^e ve r T ° ' ' " " ^'"^'^ ''''''''''
cross-sections: a thfcker girder around the veins load-cairymg veins as well as veins that comiect the thicker girder and the load-canymg veins. The thickness of the veins and girder was in the range of I 2 to 24 mm S u ^ a H 7 " r ' ' " ' '° ' ' " ^ ' P'^'"'"^^ f ^ i l - ^ l - g - defomiation. The L C e d " f o X 7 T 1::^ ^T""''" P ^ l y ^ ' - - — w h i c h had to be stripped andvolZi lTi
H f * ^ ^ l ^ " ^ ^ ' ^ *thi'^^
days after casting. Anchors are diScult to C e a s e the si f 7 T""''- ^""^ ^PS-surface was coated m advance in order to c o r e c f ! r . ^ f r " " ^ ï ' ' ' - f ^ " ' ' S'^^^ ^'"P^-^^^i"" °f *e mould; a complex connection of five veins is shown by Figure 6b.RILEM-/;è-AFGC Int. Symposium on Ultra-Higli PerfoiTaance Fibre-Reinforced Concrete, UHPFRC 2013 - October 1-3, 2013, Marseille, France
Figure 6 a/b: Impressions of the milled mould produced in EPS
The casting proceeded according to a prescribed path to avoid weak points in the connections of the veins. The balustrade-element (Figure 7) was demolded three days after casting. Due to the length of the fibres, which were in some cases longer than the width of the veins, the fibres oriented in the direction of the flow. A preferred fibre orientation assures that the flexural strength is at least the strength determined by flexural tests.
RJLEM-y/ö-AFGC Int. Symposium on Ultra-High Perfonnance Fibre-Reinforced Concrete,
UHPFRC 2013 - October 1-3, 2013, Marseille, France
I n spite o f the mould surface being covered by a coating, the adherence o f U H P F R C to the mould vi'as locally strong; demoulding required special attention i n order not to damage the element. N o cracks were observed on the surface o f the balustrade-element.
6. CONCLUSIONS
This paper discusses a case-study w i t h U H P F R C that aimed at convincing the owner o f a nature park i n Voorschoten to construct a slender Parkbridge w i t h UHPFRC. I n an integrated design process between architect, engineer and concrete producer an optimized solution was developed. The proposed technical solution represents the state-of-the-art related to material technology, structural design and production technology.
The budget o f the bridge was not specified i n advance. Finally, the costs o f a single bridge turned out to be too high f o r the owner and an altemative solution was chosen (a wooden bridge); by producing more and preferably identical bridges a significant cost reduction could be achieved making the bridge more competitive. Soft soil (sand is a common ground i n the Netherlands) was assumed for the design; f o r a more stable ground (i.e. rock), the foundation costs o f the chosen solution are relatively lower. The costs o f the balustrade-elements (unique elements w i t h a repetition o f 2) also are relatively high due to the high mould costs; an UHPFRC-bridge w i t h an adopted balustrade design and optimized concrete w o u l d be an option.
R E F E R E N C E S
[1] Jensen, O.M. and Hansen, P.P., ' A dilatometer for measuring autogenous deformation in hardening Portland cement paste', Materials and Sti-iictiires, 28(7) (1995) 406-409.
[2] ASTM C1698-09, 'Standard test method for autogenous strain of cement paste and mortar'. [3] Tian, Q and Jensen, O.M., 'Measuring autogenous strain of concrete with cormgated moulds'. In:
Sun, W.; Van Breugel, K.; Miao, C ; Ye, G.; Chen, H . (Eds.): MicrostracUire Related Durability of Cementitious Composites, R I L E M Proceedings ProOól, RILEM Publications (2008) 1501¬ 1511.
[4] Sant, G., Dehadrai, M . , Lura, P., Bentz, D., Ferraris, C.F., Bullard, J. and Weiss, W.J., 'Detecting the Fluid-to-Solid Transition in Cement Pastes: Part I - Assessment Techniques', Concrete
International, 31 (6) (2009) 53-58.
[5] PaiUere, A . M . ; Bull, M . and Serrano, J. J., 'Effect of fiber addition on the autogenous shrinkage of silica fume concrete', ACIMate?-ial Journal, 86 (2) (1989) 139-144.
UHPFRC 2013
Proceedings of the RILEM-/«^7-AFGC
International Symposium on Ultra-High Performance
Fibre-Reinforced Concrete
Edited by
Frangois TOUTLEMONDE
Jacques RESPLENDINO
UHPFRC 2013
Proceedings of the RILEM-/f&-AFGC International Symposium on
Ultra-High Performance Fibre-Reinforced Concrete,
1-3 October 2013, Marseille, France
Edited by Frangois Toutlemonde and Jacques Resplendino
"UHPFRC" international symposium was first organized in Marseille
(France) in 2009 for synthesizing the know-how and applications related to
Ultra-High Performance Fibre-Reinforced Concrete (UHPFRC). Four years
later, projects and constructions using UHPFRC have definitively gained a
growing importance in Europe and North America, as well as in Australia,
Far East, and especially Japan.
"UHPFRC 2013" has thus aimed at updating and complementing
experience gained in the loiowledge and use of UHPFRC, based on recent
practice of: design of building structures, components, civil works and
bridges; industrial realizations (both on site and in precast factories); and
large-scale applications. More than eighty presentations detailed the
technical and scientific advances, focusing on major recent realizations;
decisive use of UHPFRC in structural retrofitting and combination of
UHPFRC and ordinary RC; durability and resistance of UHPFRC under
severe on-site or laboratory conditions; prospective appHcations of
UHPFRC in current or outstanding works; recent advances in UHPFRC
structures design and ductility assessment; and recent results of
constitutive characterization and mix optimization of UHPFRC.
In 2013, Marseille, recognized as European capital of culture, has renewed
its urban figure and shoreline with iconic architectural achievements.
Among them, the Museum of European and Mediterranean Civilizations
(MUCEM) constitutes an outstanding realization due to the systematic
structural and decorative use of UHPFRC. The MUCEM, in hosting the
venue of UHPFRC 2013 symposium, has appeared as a symbol of
worldwide engineering commxmity, technical breakthrough and creativity.
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Assessment o f coupled themo-mechanical behaviour o f ultra-high performance p. 315 concrete columns i n case o f fire
Verification du comportement thermo-mécanique coiiplé de poleaux en BFUP en cas d'incendie Matthias SIEMON, Dielmar HOSSER
Current and prospective TJHPFRC applications: shells, building elements, p. 325 bridges, civil structures
Applications des BFUP en coins etprospeclives : coques, couiposnnts de batimenis, ponts, génie civil
UHPFRC i n large span shell structures p. 327
Le BFUP dans des structures de voiiles et coques de grande portée
RichardN. TER NJATEN, Steffen GRÜNEWALD, Joost C. WALRAVEN
CFRP tendons i n U H P F R C - B o n d behaviour and applications to folded and p. 335 cui-ved shells
Cables composites a fibres de carbone dans du BFUP - Adhérence et application dans des coques courbes ou repliées
Alexander STARK, Josef HEGGER
Fundamental study on constmction systems for complete reuse using U H P F R C blocks p. 343
Etude d'un nouveau systeme constructif apartir de composants BFUP réutilisables HiroshilTO, Tomoya NISHIWAKI, Suhnin KWON, Takatune KIKUTA
UHPFRC cladding f o r the Qatar National Museum p. 3 51
Bardage en BFUP pour le Musée National du Qatar Philippe MENETREY
UHPC i n the U.S. highway infrastmcture: experience and outiook p. 361
Le BFUP dans les infi'astructures routières aux Etats-Unis : bilan et perspectives Benjamin A. GRAYBEAL
T r i a l constmction o f U H P C highway bridge p. 371
Realisation pilote d'un pont routier en BFUP
Sung Yong PARK, Sung Tae KIM, Jeong Rae CHO, Jeong Woo LEE, Byung, Suk KIM
Parkbridge : optimization o f a slender bridge i n UHPFRC p. 379
Parkbridge : optimisation d'un pont en BFUP ultra-élancé
Steffen GRÜNEWALD, Hans KÖHNE, Maurice NIO, Matteo SERAFINL Anja VERDONK, Rogier VAN NALTA. Rob HUIJBEN, Viktor MECHTCHERINE, Lukasz DUDZIAK, Leo GIELBERT
Express bridge deck and light duty bridge p. 389
Tablier et passerelle Express YvesBRUGEAUD
F D N modular U H P F R C bridges p. 395
Fonts modulaires FDN en BFUP DU TIRIMANNA, Jan FALBR
A n assessment o f the steel fibre distribution to load bearing capacity o f lost p. 405 shuttering slabs made f r o m U H P F R C
Evaluation de ta distribution des fibres en vue de la capacité portante de prédalles en BFUP Milan RYDVAL, Jiri KOLISKO, Miroslm' VOKAC, Petr HUNKA
