Construction Industry adaptive to Global Warming

Transcription

1 Construction Industry adaptive to Global Warming Materials & Procedures contributing to Carbon Emission Reduction IFAWPCA SEMINAR at Tokyo Makoto Kanai Dr. of Eng., M.Eng., M.Sci.,Registered P.E. Principal Advisor to Obayashi Corporation

2 Today s Topics 1 Carbon Mitigation in Construction Materials Seawater and Sea-sand Mixed Concrete Clean Concrete Slim Concrete 2 Carbon Mitigation in Construction Procedures Strut-less Tilt Retaining Wall URUP Shield Tunneling 2

3 Carbon Mitigation in Construction Materials 1. Sea-water and Sea-sand Mixed Concrete - Man-made Rock Salt - 2. Clean Concrete - 80% Reduction of Carbon Emission - 3. Slim Concrete - Structural Reinforcement & Seismic Retrofit as well as CO2 Reduction -

4 Sea Water & Sea Sand Mixed Concrete - Man-made Rock Salt Prime Minister s Award Art of Manufacturing 2015 M.L.I.T. s Grand Prize R&D in Construction Carbon Emission Reduction approx.50%

5 1. Unconfined & Early Strength Fresh water+ + Furnace C 35.7 Special Features 30%UP 60%UP Permeated Zone Fresh water Sea water Sea water + Furnace C 47.4 Sea water + Furnace C + P-additives + Pozzolana 2. Permeability Compressive strength 28days (Mpa) 1/ (m/sec) (m/sec) 3. Corrosion of Reinforcement Accelerated corrosion test after 100years Epoxy-coated rebar Carbon fiber rod Combination Diffusion (cm 2 /sec) Pearmeability (m/sec) Fresh water + Furnace C Sea water + Furnace C + P- Additives Sea water + Furnace C + P- Additives + Pozzolana Permeability : 1/70 of Furness Slug Cement & Fresh Water Not corroded Not corroded

6 Tsunami Debris of 3 11 Earthquake Reused as Aggregates Production Time 25% Less Production Cost 35% Less

7 Expected Application -Structures under Saline Environment- Harbour Structure Coastal Windfarm Marine Structure Remote Island Preservation

8 Expected Application -Soils Stabilization Grout- Permeability (m/s) Uni-axial strength (Mpa) - Bearing Strength Enhancement - Permeability Control - Liquefaction Prevention Enhanced Compressive Strength 200% Sea Water + P-add. Flesh water Special additive 特 殊 混 和 剤 Dispersion additive 分 散 剤 高 炉 スラグ 系 Slug 超 微 cement 粒 子 セメント 海 水 Sea water Mixer Ajiteter ミキサー アジテータ 海 水 ポンプ グラウトポンプ Grout pump Pump Distance from injection pipe (cm) Improved Permeability 1/14 Contaminated 有 害 物 質 aquifer を 含 む 地 下 水 流 透 Impermeable 水 ゾーン layer Permeable 透 水 層 layer Pump ポンプ 海 Sea Sea Water + P-add. Impermeable 不 透 水 層 layer Flesh water Distance from injection pipe (cm) Injection test Improved strength(200%) & impermeability(1/14)

9 Low Carbon Emission Concrete Clean Concrete - Carbon Emission(kg-CO2/m3) Increasing blast furnace slug and fly ash in cement enables carbon emission reduction as high as 80% compared to conventional concrete % Reduction 最 大 80% 低 減 Conventional Concrete Low Carbon Emission Concrete

10 Low Carbon Emission Concrete Clean Concrete - R&D Inst. Wall -80%(2010/8) R&D Inst. Seismic Wall -80%(2010/12) Pedestrian Pavement -80%(2011/2) Foundation Slab -65% (2010/8) Retaining Wall Slab -75%(2010/8) Road-tunnel Slab -65%(2010/8)

11 Low Carbon Emission Concrete Clean Concrete - Facility Foundation -60%(2012/2) Underground Structure -80%(2012/1) Solar Panel Foundation -60%(2013/6)

12 Super Strong Concrete Slim Concrete - High-strength & -durability in-situ concrete for low LCC RC structure Compression Strength 180 N/mm2 7.5 times higher Tensile Strength 8.8 N/mm2 7 times higher Durability 100 yrs. or over 4 times longer Carbon Emission 100 yrs. 50 % off High-strength Plastic Mortar High-strength Steel Fiber High-strength Organic Fiber High plasticity and conventional curing enables; In-situ concrete In-situ precast concrete Factory precast concrete

13 Super Strong Concrete Slim Concrete - Marine Structure Retrofit by High-strength & -durability Slim Concrete Before After Abrasion Protection by High-strength & -durability Bridge Substructure Foundation Windbreaker by High-strength & -durability Dam Apron H-steel & panel Slim Concrete

14 Super Strong Concrete Slim Concrete Design-ability & Streamline by High-strength & -durability Long Span Sky Corridor - Slim & Slender - Wider and Thinner Cantilever Roof

15 Carbon Mitigation in Construction Procedures 1. Strut-less Tilt Retaining Wall 2. Shaft-less Shield Tunneling - URUP Shield Tunneling -

16 Strut-less Tilt Retaining Wall Carbon Emission 25% Less Construction Period 35% Less Construction Cost 20% Less

17 Strut-less Tilt Retaining Wall Depth 2.5m:Steel Plate Depth 5m:Cement Stabilized Soils Depth 10m:Sheet Pile/Soldier Pile Depth 15m:Sheet Pile w/ Buttress

18 Strut-less Tilt Retaining Wall: ~G.L. -2.5m Conventional Excavation w/ Shoring Recommended Excavation No Shoring Steel Plate W1.5m H3m

19 1.5m 4.45m Strut-less Tilt Retaining Wall: ~G.L. -5m Prototype Construction Access Road(2014/08) 改 良 体 土 留 め 掘 削 深 さ 4.0m 根 入 れ 長 4.0m 床 付 け 面 以 深 0.7m 10 粘 性 土 ( 盛 土 ) N=3 γ=16.0kn/m 3 Φ=0 C=20kN/m 2 Excavation Finished 4.0m 1.0m 水 抜 き 鋼 管 * Stabilized Soils Wall 水 平 10変 8位 6 量 4 (mm) 最 大 変 位 9mm Actual Construction Channel at Power Plant(2015/10~) 護 岸 *: 水 抜 き 鋼 管 は 前 面 の 本 設 ブロック 積 み 擁 壁 用 B 層 γ=17.7kn/m 3 N=8 φ=33 Ap 層 γ=14.2kn/m 3 N=2 C=30kN/m 2 Aco 層 γ=16.2kn/m 3 N=1 C=40kN/m m 放 水 路 底 版 改 良 改 良 体 土 留 め 施 工 ライン 10 GL-1.2m 改 良 体 土 留 め Wall Construction On-going 施 工 延 長 500m 以 上

20 Strut-less Tilt Retaining Wall: ~G.L. -5m Soldier Piles Driving Excavation Leveling Concrete Placement Preparation for RC Structuring

21 Strut-less Tilt Retaining Wall: ~G.L. -10m Conventional Design Type Ⅲ Steel Sheet Pile, L=15m 1 st strut & wales H nd strut & wales H-350 New Design, Tilt angle of 10 degrees Type Ⅳ Steel Sheet pile, L=12m Soils: Dredged Sand Soil Stabilized by Dewatering

22 Strut-less Tilt Retaining Wall: ~G.L. -10m Construction boundary (W=30m) 5.27m 9.6m 1.6m Wide Working Space w/o Obstructions Increase Pipe Installation Productivity Enhance Welded Quality at Pipe Joint Inclined sheet pile type 4 L=12m

23 Depth in m 深 度 (m) Strut-less Tilt Retaining Wall: ~G.L. -10m Observed Pile Tip Deformation δ=45mm Estimated Pile Tip Deformation δ=300mm Displacement in mm 変 位 量 (mm) 土 質 : 成 田 砂 計 測 値 ( 床 付 け 完 了 3 日 後 ) 設 計 値 (φ=35,ただしc=5kn/m²を 考 慮 ) 再 計 算 値 (φ=35,ただし 見 かけのC=23kN/m 2 考 慮 )

24 1150 Strut-less Tilt Retaining Wall: ~G.L. -10m 腹 起 し [ 国 道 357 号 線 火 打 ち 1~3 段 目 H-300 斜 め 土 留 め 鋼 矢 板 ⅤL 型 ( 残 置 ) L=18.5m 既 設 鋼 矢 板 16m 既 設 カルバート 腹 起 し [ 京 葉 線 橋 脚 鋼 矢 板 Ⅳ 型 L=15.5m 既 設 埋 設 管 φ300 Viaduct of Japan Railways タイロッド 異 形 棒 鋼 D38(SD390) 腹 起 し [ 砂 質 土 粘 性 土 砂 質 土 鋼 矢 板 Ⅳ 型 L=15.5m 粘 性 土 Calculated max. displacement 179mm Observed max. displacement 39mm 鋼 矢 板 ⅤL 型 L=18.5m Excav. Depth of 10m m 鋼 矢 板 ⅤL 型 L=18.5m タイロッド 異 形 棒 鋼 D38(SD390) 地 下 水 位 GL-1.60m 鋼 矢 板 Ⅳ 型 L=15.5m 実 測 値 設 計 値 Wall displacement 12~32% of calculated

25 Strut-less Tilt Retaining Wall: ~G.L. -10m

26 Ultra Rapid Underpass(URUP) Shield Tunneling URUP tunneling is a climate-smart technology w/o access shafts resulting in the least carbon emissions.

27 What s URUP? TBM direct launch/arrival from surface Access Shafts for launch/arrival unnecessary Tunneling under small tunnel cover w/o ground disruption Time/Cost Saving Surface Launching Small Cover Advancement Surface Arrival Rapid Tunneling No Launch Shaft No Arrival Shaft Construction Period 30%, Construction Cost 25%, CO2 Emission 60%

28 Job 1 : Metropolitan Express-way Road Tunnel 2. TBM U-turn Excavation Dia. 13.6m Tunnel Cover 0-25m Max. Settlements 5mm 3. Arrival at surface 1.Launching af surface

29 TBM Launching & Penetration TBM Arrival & Breakthrough

30 Inbound Bore Outbound Bore

31 Job 2 : Metropolitan Ring Road Tunnel 3. Arrival at surface 1. Launch at surface 2. TBM U-turn Excav. Section W=11.96m H=8.24m Tunnel Cover m Max. Settlements 10mm

32 12cm Allowing traffic above tunnel w/ cover of 1.2m at arrival

33 Job 3 : Slip Road Tunnel for New Interchange URUP Tunneling 谷 津 干 潟 Daily Traffic of 120,000 vehicles

34 URUP Tunnelling Plan Single used-shield bored 4 times to create spaces for lining structure Keiyo Rd. East Kanto Rd. Site Viaduct L-Wall U-Wall L-Wall L=151m L=129m L=266.5m L=30m Excav. Section W=4.8m H=2.15m Tunnel Cover m Construction Sequence Max. Settlements 3mm STEP STEP 2 Under Pass L=70m (radius = 50m) STEP 3 3 Temporary steel lining 4 Grouting 1 2 Cast in situ concrete Primary tunnel by shield tunnelling Main structure construction in segment Internal Excavation Internal excavation

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36 Job 4 : Cross Harbour Gas Pipe Line Tunnel Arrival to Ground Sea Launching from Ground Excavation Dia. φ2.13m Tunnel Cover m Max. Settlements 5mm Arrival Advancement TBM Assembly And Launching

37 Trenchless Solution for Underpass road tunnel - URUP System - OBAYASHI Ultra Rapid Construction Method of Underpass road tunnel in Developed Urban Area

38 Case Study Tunnel Design Criteria Soil Unit 1 N=15 γ=19.0kn/m 3 c=0kn/m 2 φ=30.0 Soil Unit 2 N=30 γ=19.0kn/m 3 c=0kn/m 2 φ=35.0 Maximum cover : 3.0m Underground water level : GL-5.0m Traffic lanes : 3.65m x 3lanes (each direction) Shoulder : 1.20m (both sides) Slope : 5% Side walk : 0.75m (both sides) Horizontal clearance : min m Vertical clearance : min. 6.00m (above traffic lanes)

39 Non Circular TBM Benefit Obayashi s Non-circular tunnel Tilt Retaining Wall URUP System 505m 416m 3m Reduce tunnel length by 15%, and excavation volume by 28% Achieve shallower road level Conventional circular tunnel 70m 5% 3m 599m 458m 5%

40 Trenchless Solution for Station & Subway Tunnel Surface Launching/Arrival (URUP) No Disruption of Ground Surface 3. Platform Tunnel Non-circular URUP 1. Platform Tunnel Non-circular URUP 2. Main Track Tunnel Non-circular Sustainable & Resilient Construction Method of Underground Metro System in Developed Urban Area

41 Trenchless Solution for Station & Subway Tunnel Concourse & M.E. Track Platform Track Concourse

42 Application to Underground Tunnel Reservoir Floodwater Pump-up Floodwater Inflow Floodwater Inflow Stored Floodwater

43 Advantages of URUP for Tunnel Reservoir Non-circular tunnel configuration gives larger reserve capacity in spite of Conventional Tunneling Deep requiring smaller tunnel cover and pump-up facilities. Tunnel Cover min. 1.0~1.5D Shallow Relieved Loads and Water Head Tunnel Cover 0.7m Irrespective to Geology & Tunnel Configuration URUP Tunneling Storage Capacity Hydrostatic Pressure Earth Pressure Relieved Loads & Smaller Pump-up Facilities Cost Reduction Non-circular Combined Arch Tunnel

44 URUP Conventional Advantages of URUP for Tunnel Reservoir Easier Disposal of Sediment after Floodwater Discharge Vessel Lifting Up Shaft Accumulation Tunnel Sedimentation of Muck Vertical Muck Disposal Direct Access to Surface Safety Improvement Time/Cost Reduction Horizontal & Direct Muck Loading

45 The public has become increasingly aware that development shouldn t result in a compromised and depleted environment. Enlightened citizens see sustainability, not as an unattainable ideal, but as a practical goal. Thank you for your attention. We are always at your disposal!