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Chapter 13
Safety assessment during construction
of shotcrete tunnel shells using
micromechanical material models
Stefan Scheiner, Bernhard
Pichler, Christian Hellmich &
Josef Eberhardsteiner
Institute for Mechantes of
Materials .id Structures,
Vienna University of
Technology, Vienna, Austria
ABSTRACT
Knowledge of the stresses in shotcrete tunnel shells
is of great importance for assessing their safety
against severe cracking or failure. Estimation of
these stresses from optical measurements of 3D
shell displacements requires shotcrete material
models capable to deal with variations of the watercement and the aggregate-cement ratio. This is the
motivation for employing two representative
volume elements within a continuum micromechanics framework: One of them relates to cement
paste (with a spherical material phase representing
clinker, needle-shaped hydrate phases with
isotropically distributed spatial orientations, a
spherical water phase, and a spherical air phase,
with all phases being in direct mutual interaction),
whereas the second one relates to shotcrete (with a
spherical aggregate phase, embedded into a matrx
phase made up by cement paste). Elasticity
homogenization follows self-consistent schemes (at
the cement paste level) and Mori-Tanaka estimates
(at the shotcrete level). Stress peaks in the
hydrates related to quasi-brittle material failure are
13.1 INTRODUCTION
If a high degree of flexibility is required
during the tunnel excavation process (e.g. in
difficult ground conditions or in urban reas),
the New Austrian Tunneling Method (NATM),
pioneered by (Rabcewicz 1948), is well suited.
When driving tunnels according to the NATM,
after excavation of a cross-section of a
tunnel, shotcrete is sprayed onto the tunnel
walls, constituting a thin and flexible shell.
Accordingly, the excavation mode (type of
cross section, sequence of excavation steps,
time
span
between
excavation
and
shotcreting) and the shotcrete mixture
characteristics (such as water<.-nt ratio
wlc and aggregate-cement ratio ale) are key
0.001
0.002 compressive axial0.003
strairt [-]
0.0G0
5
7
8
with the mass densities of clinker, water,
and hydrates, pdh, ph0, a.n:phyd, following from
(Acker 2001), see also (Pichler et al. 2009): pdin =
3.15 kg/dm3, pHJ= 1 kg/dm3, and phyd = 2.073
kg/dm3. The creation of air voids filling far stems
16 (b)
17 (d)
uniaxial compressive strength of drained18
shotcrete [MPa]
wlc = 0.60
wlc = 0.35
wlc = 0.50
model predictions: seaied conditions drained conditions
2.5
7.5
18
10
15
20 25 dynamic Young's modulus [GPa]
0 2.5 5 7.5 10 2.5 15 17.5 dynamic Young's modulus [GPa]
18 fi gure 13.4 Comparison of model
predictions
with
experimental
data characterized by diff erent wlc
ratios (wlc = 0.35, 0.50, 0.60): (a)(c) dynamic shear modulus versus
dynamic Young's modulus, and (d)
uniaxial compressive strength of
drained cement paste.
19
20
By
comparing
modelpredicted
to
experimentally
obtained
vales
for
the
uniaxial strength of cement
pastes with different WLC ratios,
a
prediction
accuracy,
quantified
by
a
squared
correlation
coefficient
r2
=
97%,
is
obtained,
see
Fig.
13.4(d). This cor-roborates the
assumption
of
the
single
strength-type
valu
for
hydrates, C& = 26 MPa (Pichler
et al. 2009).
21
22 13.3.3 Experimental validation on
shotcrete level
23
A second homogenization
step, resulting in a two-step
homogenization scheme, is
necessary to predict
stiffnesses and strengths of
shotcrete, see Fig. 13.1(b).
24 For the sake of experimental model
validation, the model-predicted Young's
odulus of shotcrete is compared to
corresponding experimental vales of
(Lafarge 002) who subjected a shotcrete
characterized by wlc = 0.48 and ale =
5.3, to reso-ant frequeney tests, see Fig.
13.5(a). The agreement between-model
predictions and xperiments is excellent
for sealed conditions (underlined by a
mean relative error f 1.0% and a
corresponding standard deviation of
6.5%), confirming findings in Hellmich
and Mang 2005) that the tests of (Lafarge
2002) are rather characterized y sealed
than by drained conditions. Model
predictions related to sealed conditions
orrelate to experimental results by r 1 =
98.8%, see Fig. 13.5(a),
25 Experimental validation of the
micromechanics-based homogenization of
shot-rete strength is carried out
according to the experiments of (Lafarge
1997) and (Pillar 002): The applied
mefhodology of experimental strength
determination (Hilti gun nd penetrometer
tests) suggests that model predictions
referring to drained condi-ions are cioser
to the experimental findings than the
ones referring to sealed con-itions
(Pichler et al. 2008). The agreement
between model predictions (related to
rained conditions) and experimental data,
characterized by wlc = 0.5, ale = 3.8
Pillar 2002), and by wlc = 0.4, ale =
3.94 (Lafarge 1997), is quantified by a
mean elative prediccin error of -5.0%
and by a related standard deviation o
19.4%. The elatve errors constitute
upper bounds (Pichler et al. 2008),
suggesting that the corre-rtion between
26
27
13.4 MICROMECHANICS-BASED
CHARACTERIZATION OF SHOTCRETE:
INFLUENCE OF WATER-CEMENT AND
AGGREGATE-CEMENT RATIOS ON
ELASTICITY AND STRENGTH EVOLUTIONS
28 the
experimentally
validated
micromechanics model (see Section 13.2)
allows for pre-sicting hydration degreedependent
evolutions
of
Young's
modulus, Poisson's ratio, and he uniaxial
gure 13.5 Comparison of model predictions with experimental data characterized by wlc = 0.48
compressive
strength
of
different
shotcrete mixtures as functions of their
wlc and ale ratios, see Figs. 13.6 and 13.7.
We observe that Poisson's ratio increases or
decreases with increasing water-cement
ratio, for drained or sealed conditions,
respec-tively, see Figs. 13.6(b) and 13.7(c,d).
Sealed conditions, as a rule, lead to higher
stiff-ness
and
strength
vales
when
compared to drained conditions, but this
difference becomes very small for complete
hydration ( t ) > 1), see Figs. 13.6 and 13.7.
We also observe that both Young's modulus
and the uniaxial compressive strength
decrease with increasing water-cement ratio,
whereby the percental decrease of Young's
modulus is smaller than that of the
compressive sttength, see Figs. 13.6(a) and
(c). The loss in final strength (at completed
hydration) with increasing water-cement
ratio almost perfectly follows Feret's famous
empirical relationship (Feret 1892), stating
that the final strength [L"lt ( t = )] is
proportional to the square of a ratio between
the volumes of cement, water, and air
contained in a material volume of concrete,
30
29
31
37
13.5.1 Water-cement
ratio-dependence of structural
safety
38 Three shotcrete mixtures are
investigated: wlc = 0.40 (mix I), wlc
= 0.50 (mix II), and wlc = 0.60 (mix
III), each with ale = 5, see Fig.
13.6. The simulation results show
that throughout the observed
loading phase the resulting level
of loading of the tunnel shell is
decisively infl uenced by the wlc
ratio, see Fig. 13.10. On the other
hand, the devia-tions between the
levis of loading predicted for
sealed conditions in the shotcrete,
see Fig. 13.10(a), only negligibly
diff er from those predicted for
drained conditions in the
shotcrete, see Fig. 13-10(b). Still,
we note that, in principal, sealed
conditions result in slightly lower
levis of loading as compared to
drained conditions.
39
40
13 3.5.2 Aggregatecement ratio-dependence of
structural safety
41 During shotcreting, shotcrete
constituents may detach from the
sprayed material,
is composed of
46
Safety assessment during construction of
0.4
o 0.3
58
I
0.2
0.4
0.6 0.8 degree of hydration
0.2[-] 0.4 0.6 degree o hydration [-]
drained, a/c == 3.5 drained, a/c - 5.0 sealed,
a/c
= 4.5
---------drained, a/c - 4.5
drained, a/c 4.0
59
63 Hg
urc
13.
8
Co
mp
aris
on
of
mic
ro
me
cha
nic
sbas
ed
mo
del
pre
dict
ion
s
wit
h
pre
dict
ion
s of
Fer
et's
for
mul
a
(6)
spe
cifi
cd
for
P=
010?030 40
Feret predictions
64
65 Figur
e
13.9
H/brid
metho
d for
determ
ination
of the
level of
loading
69 Figure
13.11
Evolution
of
the
level
of
loading Cmlx as
70
71 wie = 0.40
73 w/c = 0.S0
74
76 R =
0.0% R
7.8% R = 15.6%
= 23.4%
77 R = 0.0% R
7.7% R = 15.4%
= 23.l%
=
R
=
R
78
79 in the tunnel shell. Henee, the level of
loading shows no significan! dependence on
the (actual) a/c ratio for the investigated
shotcrete mixtures. This structural behavior
can be considered as beneficial: Our
calculations suggest that such changes of the
(actual) a/c ratio because of shotcrete
rebound do not compromise the structural
safety of the tunnel shell. Since the
investigated shotcrete mixes exhibit a
mximum rebound of 23,4% (see Table 13.2),
thus comprising common rebounds in wet
shotcreting, the insenstity of the loading
level of the tunnel shell with respect to
aggregate rebound is a robust featuxe of the
NATM. It suggests that careful in sit.it
monitoring of the w/c ratio, as compared to
the ale ratio, is much more critical.
80
81 13.6 CONCLUSION
82
Many tunnels are constructed with the New
Austrian Tunneling Method (NATM). Combining tnsitu data stemming from 3D optieal displacement
monitoring of NATM tunnel shells with realistic
material models for shotcrete "Hellmich 1999;
Hellmich et al. 1999; Hellmich and Mang 2005;
Hellmich et al. 2001; Hellmich et al. 199.9b;
Lechner et al. 2001; Brandtner et al. 2007) allows
engineers to look incide the tunnel shell.
Comparing interna! forces with the currenr
strength of the (hydrating; shotcrete results in
quantitative safety assessments. This hybrid
method reduces risks and ensures not only
structural integrity of the ning and safety of the
tunneling crew, but also economic construction. In
NATM tunneling. shotcrete composition is adapted
to changing needs. When employing macroscopic
material models, every change of shotcrete mix
requires an additional, expensive, and timeconsuming series of mechanical tests. We have
developed new micromechanics models which
economically account for the impact of the
shotcrete composition on the elasticity and
strength properties of the material. On this basis,
we have shown the pdtentially major influence of
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
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