Glass Fibers Reinforced Composits (GFRP) for TUNNELLING Introduction The main utilization of GFRP Composites is extended to the entire field of temporary consolidation. The success of this application, in spite of the higher initial cost, is justified by the cost-effectiveness of the application: the reinforcements,grfp profiles, are more expensive than the corresponding metal elements, but the installation and the demolition is much faster, resulting in a drastic time (and money) saving for the over-all application. Production Technology ( for GFRP profiles) The shapes are manufactured by an innovative, highly technological, continuous process called PULTRUSION. The process consists in pulling a bundle of long, continuous, glass fibres through a thermoset (usually an unsaturated poly-ester) resin bath and subsequently through a heated, high precision, steel die with the section of the profile to produce. The resulting profiles are typically anisotropic, since all fibres are oriented in the axis direction, generating mechanical properties mostly oriented in the same direction. Applications Consolidation of the nucleus and the perimeter of the advancing bore PRODUCTS a) Tubes The tubular profiles act as duct for injection of mortar ( or similar), and as strength anchoring elements; b) SICS Integrated Systems Structural GRP anchoring bars, with rectangular section, are arranged and fixed around plastic tubes ; the latter ones will carry the injection of the filler ( mortar,.). Tel. +39 (81) 947777 Fax +39 (81) 947740 email : a.giamundo@atp.sa.it Via Casa Pagano, 31 84012 ANGRI (SA) - ITALY
Consolidation of the nucleus of the advancing bore and pre-consolidation of the perimeter PRODUCTS a) Tubes - the tubular profiles act as ducts for injection of mortar or similar, and as strength anchoring elements; b) SICS Integrated Systems Structural GRP anchoring bars, with rectangular section, are arranged and locked around plastic tubes; the latter ones will carry the injection of the filler (mortar,.). c) Auto-Perforating FIT SYSTEM - GRP tubes equipped with metal perforating systems (shafts and partially disposable steel heads).. Radial Advancing Anchoring (for which it is not possible to utilize jet grouting) PRODUCTS a) Tubes b) Rods Radial anchoring of pilot hole PRODUCTS a) Tubes b) Rods Tel. +39 (81) 947777 Fax +39 (81) 947740 email : a.giamundo@atp.sa.it Via Casa Pagano, 31 84012 ANGRI (SA) - ITALY
S-1 S-3 S-2 S-2 Z-1 Z-1 Z-1 S-1 S-2 S-3 Z-1 Z-1 V-1 S-1 S-2 Z-2 S-3 P-1 P-1 Z-2 V-1 Z-1 Application of anchoring elements are utilised in all areas of non permanent consolidation. In detail BERLINESI (at the front of excavation) PRODUCTS a) Active anchoring (pre-tensioned) GRP bolting systems made of rods, heads and load distribution plates. b) Micropoles (200 mm. O/D GRP tubes with different thickness according to strength requirements) micropali in vetroresina Ø 120 mm - Qamm. = 108 t L = 1200 cm posti ad interasse pari a 33 cm tirante in vetroresina Ø 120 mm - Qamm. = 108 t L = 2400 cm n. 5 ogni 1200 cm LARGE DIAMETER POLES AND REINFORCEMENTS FOR PROVISIONAL WALLS (SOFT-EYE). PRODUCTS a) Rebar (rod) with improved surface. b) Custom designed stirrups, usually closet loop type. DISTRIBUTED REINFORCEMENTS FOR CONCRETE OR SPRITZ-BETON APPLICATION PRODUCTS Chapped AR (Alcali Resistant) fiber glass strands Tel. +39 (81) 947777 Fax +39 (81) 947740 email : a.giamundo@atp.sa.it Via Casa Pagano, 31 84012 ANGRI (SA) - ITALY
Tube OD diameter 60 mm and thickness 10 mm SCHEDA N 1 Indice dei prodotti in VTR Tube OD diameter 60 mm and thickness 10 mm - burst resistance up to 4 MPa SCHEDA N 2 Tube OD diameter 60 mm and thickness 10 mm - burst resistance up to 8 MPa SCHEDA N 3 Tube OD diameter 76 mm and thickness 8 mm., for self drilling (Fit-System) SCHEDA N 4 SICS systems = rectangular section rods (plates) for reinforcing systems with separate injection SCHEDA N 5 Active anchoring SCHEDA N 6 Tube for micropoles SCHEDA N 7 Rebar with improved adhesion surface SCHEDA N 8 Custom designed stirrups SCHEDA N 9 Polymeric fiber for concrete reinforcement SCHEDA N 10 Tel. +39 (81) 947777 Fax +39 (81) 947740 email : a.giamundo@atp.sa.it Via Casa Pagano, 31 84012 ANGRI (SA) - ITALY
Tube OD diameter 60 mm - thickness 10 mm. Pag1/1 SCHEDA N 1 GRP tubes made of thermoset polyester resin reinforced with continuous glass fibers; the external surface is roughened for improved pull resistance (roughness is obtained either by machining a 0,5 mm. groove with 60 mm. pitch, or by bonding of spheroid quartz and resin on the surface). Geometrical Characteristic Unit Value Resistant section mm^2 1500 External diameter mm 60 Internal diameter mm 40 Dimensional tolerance according to ASTM D3917 Mechanical Characteristic Unit Minimum value Reference specification Volumetric mass g/cc 1.9 UNI 7092 Tensile resistance MPa 600 UNI EN61 ** Bending resistance MPa 600 ASTM D790 ** Elastic modulus MPa 30000 UNI EN61(ASTM D790 A FLEX)** Shear resistance MPa 100 ASTM D732 ** ** Look at the section on testing The following deals exclusively with variations and interpretation of the existing specifications due to the nature and the geometry of the product. 1) Test samples The test samples must be obtained from the tube as indicated in the picture at right. The parallelepiped test samples, with section a x b x l (l=length) indicated in the cited specifications, must be obtained by mechanical reduction of the dashed section, taking care that the sample must be finally rectified under refrigeration to 0,5 mm. precision for the size a x l. 2) Bending test The bending tests must be performed on samples so that the ratio between span and thickness will be at least 40, in order to minimize the effects from cutting. The value obtained from the testing can be utilised, with excellent approximation, to determine tensile values. 3) Shear test The test for shear resistance according to ASTM D732 should be performed on a disk sample with diameter = 50 mm. (or on a plate 50x50 mm.) which must be totally locked in the punching mould. The punch has round 1 diameter section. From the tube, test samples not larger than 20-25 mm. can be obtained, therefore it is not possible to reproduce the conditions from the cited specification. The punching test then is performed clamping the test sample at the ends, as shown in the drawing at right, and a square section punch or a circular punch with diameter > 50 mm. must be utilised on the 20x3 mm. section test samples. Tel. +39 (81) 947777 Fax +39 (81) 947740 email : a.giamundo@atp.sa.it Via Casa Pagano, 31 84012 ANGRI (SA) - ITALY
Tube OD diameter 60 mm - thickness 10 mm burst resistance up to 4 MPa Pag1/2 SCHEDA N 2 GRP tubes made of thermoset polyester resin reinforced with continuous glass fibers; the external surface is roughened for improved pull resistance (roughness is obtained either by machining a 0,5 mm. groove with 60 mm. pitch, or by bonding spheroid quartz and resin), able to resist to internal pressure up to 4 MPa. Geometrical Characteristic Unit Value Resistant section mm^2 1500 External diameter mm 60 Internal diameter mm 40 Dimensional tolerance according to ASTM D3917 Mechanical Characteristic Unit Minimum value Reference specification Volumetric mass g/cc 1.9 UNI 7092 Tensile resistance MPa 600 UNI EN61 ** Bending resistance MPa 600 ASTM D790 ** Elastic modulus MPa 30000 UNI EN61(ASTM D790 A FLEX)** Shear resistance MPa 100 ASTM D732 ** Burst resistance MPa 4 ** ** Look at the section on testing The following deals exclusively with variations and interpretation of the existing specifications due to the nature and the geometry of the product. 1) Test samples The test samples must be obtained from the tube as indicated in the picture at right. The parallelepiped test samples, with section a x b x l (l=length) indicated in the cited specifications, must be obtained by mechanical reduction of the dashed section, taking care that the sample must be finally rectified under refrigeration to 0,5 mm. precision for the size a x l. 2) Bending test The bending tests must be performed on samples so that the ratio between span and thickness will be at least 40, in order to minimize the effects from cutting. The value obtained from the testing can be utilised, with excellent approximation, to determine tensile values. 3) Shear test The test for shear resistance according to ASTM D732 should be performed on a disk sample with diameter = 50 mm. (or on a plate 50x50 mm.) which must be totally locked in the punching mould. The punch has round 1 diameter section. From the tube, test samples not larger than 20-25 mm. can be obtained, therefore it is not possible to reproduce the conditions from the cited specification. The punching test then is performed clamping the test sample at the ends, as shown in the drawing at right, and a square section punch or a circular punch with diameter > 50 mm. must be utilised on the 20x3 mm. section test samples. Tel. +39 (81) 947777 Fax +39 (81) 947740 email : a.giamundo@atp.sa.it Via Casa Pagano, 31 84012 ANGRI (SA) - ITALY
Tube OD diameter 60 mm - thickness 10 mm burst resistance up to 4 MPa Pag2/2 SCHEDA N 2 Burst resistance test TESTING SCHEME 1 Testing tube 60/40 4 Head plug 2 Metal tension tube with holes for oil injection 5 Sealing cap 3 Flat gaskets Test procedure 1. The test sample (tube) is clamped tightly by screwing the head plug on the metal tensile tube in order to inject oil; 2. Oil is introduced, loading and unloading several times in order to expel any air. When all the trapped air is eliminated, the pressure from the pump will rapidly increase at each manual pressing. 3. The internal pressure is increased at the speed of 20 bar / minute up to the breaking of the test tube. 4. The maximum pressure is recorded as the burst resistance value. Tel. +39 (81) 947777 Fax +39 (81) 947740 email : a.giamundo@atp.sa.it Via Casa Pagano, 31 84012 ANGRI (SA) - ITALY
Tube OD diameter 60 mm - thickness 10 mm burst resistance up to 8 MPa Pag1/2 SCHEDA N 2 GRP tubes made of thermoset polyester resin reinforced with continuous glass fibers; the external surface is roughened for improved pull resistance (roughness is obtained either by machining a 0,5 mm. groove with 60 mm. pitch, or by bonding spheroid quartz and resin), able to resist to internal pressure up to 4 MPa. Geometrical Characteristic Unit Value Resistant section mm^2 1500 External diameter mm 60 Internal diameter mm 40 Dimensional tolerance according to ASTM D3917 Mechanical Characteristic Unit Minimum value Reference specification Volumetric mass g/cc 1.9 UNI 7092 Tensile resistance MPa 600 UNI EN61 ** Bending resistance MPa 600 ASTM D790 ** Elastic modulus MPa 30000 UNI EN61(ASTM D790 A FLEX)** Shear resistance MPa 100 ASTM D732 ** Burst resistance MPa 8 ** ** Look at the section on testing The following deals exclusively with variations and interpretation of the existing specifications due to the nature and the geometry of the product. 1) Test samples The test samples must be obtained from the tube as indicated in the picture at right. The parallelepiped test samples, with section a x b x l (l=length) indicated in the cited specifications, must be obtained by mechanical reduction of the dashed section, taking care that the sample must be finally rectified under refrigeration to 0,5 mm. precision for the size a x l. 2) Bending test The bending tests must be performed on samples so that the ratio between span and thickness will be at least 40, in order to minimize the effects from cutting. The value obtained from the testing can be utilised, with excellent approximation, to determine tensile values. 3) Shear test The test for shear resistance according to ASTM D732 should be performed on a disk sample with diameter = 50 mm. (or on a plate 50x50 mm.) which must be totally locked in the punching mould. The punch has round 1 diameter section. From the tube, test samples not larger than 20-25 mm. can be obtained, therefore it is not possible to reproduce the conditions from the cited specification. The punching test then is performed clamping the test sample at the ends, as shown in the drawing at right, and a square section punch or a circular punch with diameter > 50 mm. must be utilised on the 20x3 mm. section test samples. Tel. +39 (81) 947777 Fax +39 (81) 947740 email : a.giamundo@atp.sa.it Via Casa Pagano, 31 84012 ANGRI (SA) - ITALY
Tube OD diameter 60 mm - thickness 10 mm burst resistance up to 8 MPa Pag2/2 SCHEDA N 2 Burst resistance test TESTING SCHEME 1 Testing tube 60/40 4 Head plug 2 Metal tension tube with holes for oil injection 5 Sealing cap 3 Flat gaskets Test procedure 5. The test sample (tube) is clamped tightly by screwing the head plug on the metal tensile tube in order to inject oil; 6. Oil is introduced, loading and unloading several times in order to expel any air. When all the trapped air is eliminated, the pressure from the pump will rapidly increase at each manual pressing. 7. The internal pressure is increased at the speed of 20 bar / minute up to the breaking of the test tube. 8. The maximum pressure is recorded as the burst resistance value. Tel. +39 (81) 947777 Fax +39 (81) 947740 email : a.giamundo@atp.sa.it Via Casa Pagano, 31 84012 ANGRI (SA) - ITALY
Tube OD diameter 76 mm - thickness 8 mm Pag1/1 SCHEDA N 4 GRP tubes made of thermoset polyester resin reinforced with continuous glass fibers; the external surface is roughened for improved pull resistance (roughness is obtained either by machining a 0,5 mm. groove with 60 mm. pitch, or by bonding spheroid quartz and resin to the external surface), these tubes are utilised with self drilling system (FIT System). Geometrical Characteristic Characteristic Unit Value Resistant section mm^2 1700 External diameter mm 76 Internal diameter mm 60 Dimensional tolerance according to ASTM D3917 Mechanical Characteristic Unit Minimum value Reference specification Volumetric mass g/cc 1.9 UNI 7092 Tensile resistance MPa 600 UNI EN61 ** Bending resistance MPa 600 ASTM D790 ** Elastic modulus MPa 30000 UNI EN61(ASTM D790 A FLEX)** Shear resistance MPa 100 ASTM D732 ** ** Look at the section on testing The following deals exclusively with variations and interpretation of the existing specifications due to the nature and the geometry of the product. 1) Test samples The test samples must be obtained from the tube as indicated in the picture at right. The parallelepiped test samples, with section a x b x l (l=length) indicated in the cited specifications, must be obtained by mechanical reduction of the dashed section, taking care that the sample must be finally rectified under refrigeration to 0,5 mm. precision for the size a x l. 2) Bending test The bending tests must be performed on samples so that the ratio between span and thickness will be at least 40, in order to minimize the effects from cutting. The value obtained from the testing can be utilised, with excellent approximation, to determine tensile values. 3) Shear test The test for shear resistance according to ASTM D732 should be performed on a disk sample with diameter = 50 mm. (or on a plate 50x50 mm.) which must be totally locked in the punching mould. The punch has round 1 diameter section. From the tube, test samples not larger than 20-25 mm. can be obtained, therefore it is not possible to reproduce the conditions from the cited specification. The punching test then is performed clamping the test sample at the ends, as shown in the drawing at right, and a square section punch or a circular punch with diameter > 50 mm. must be utilised on the 20x3 mm. section test samples. Tel. +39 (81) 947777 Fax +39 (81) 947740 email : a.giamundo@atp.sa.it Via Casa Pagano, 31 84012 ANGRI (SA) - ITALY
Rectangular section plates for SICS Pag1/1 SCHEDA N 5 Rectangular section GRP plates made with thermoset polyester resin reinforced with glass fibers. These plates are utilised for structural integrated systems with separate injection ducts. The plates are usually fixed, by means of special plastics supports, around injection tubes. On the external surfaces of the plates facing the hole, there is spheroid quartz sand bonded to improve adhesion, or alternatively there is reproduced a roughness obtained by application of peel-ply during production. Geometrical Characteristic Section dimension (mm*mm) Resistant section for one plate (mm 2 ) Resistant section for a typical 3 plate system (mm 2 ) 40*6 240 720 40*7 280 840 40*9 360 1080 40*12 480 1440 Dimensional tolerance according to ASTM D3917 Mechanical Characteristic Unit Minimum value Reference specification Volumetric mass g/cc 1.9 UNI 7092 Tensile resistance MPa 1000 UNI EN61 ** Bending resistance MPa 1000 ASTM D790 ** Elastic modulus MPa 40000 UNI EN61(ASTM D790 A FLEX)** Shear resistance MPa 140 ASTM D732 ** ** Look at the section on testing The following deals exclusively with variations to the interpretation of the existing specifications due to the nature and to the geometry of the product. 1) Test samples The test samples must be prepared by refrigerated machining in order to reduce the testing sample thickness to a nominal value of 3 mm; the machining must produce a uniform symmetric sample. 2) Bending test The bending tests must be performed on samples such that the ratio between span and thickness will be at least 40, in order to minimize the effects from the cutting. The value obtained from the testing can be utilised, with excellent approximation, to determine tensile values. 3) Shear testing The test for shear resistance according to ASTM D732 should be performed on a disk sample with diameter = 50 mm. (or on a plate 50x50 mm.) which must be totally locked in the punching mould. The punch has round 1 diameter section. From the tube test samples not larger than 20-25 mm. can be obtain, therefore it is not possible to reproduce the conditions from the cited specification. The punching test is then performed clamping the test sample at the ends, as shown in the drawing at right, and a square section punch or a circular punch with diameter > 50 mm. must be utilised on 20x3 mm. section test samples. Tel. +39 (81) 947777 Fax +39 (81) 947740 email : a.giamundo@atp.sa.it Via Casa Pagano, 31 84012 ANGRI (SA) - ITALY
Active anhoring Pag1/1 Round rod or a 3-plates equivalent system (for example 40x6 or 40x7 plates), made of thermoset polyester resin reinforced with glass fibers, with one terminal head which will allow to apply and then to keep a 20 ton load by means of a dedicated tensioning system. Actually, any GRP rod usually utilised for nailing or passive anchoring can be transformed into an active system providing a suitable head and some tensioning equipment (it is well know that anchoring systems based on thread and nut can not be efficiently utilised with GRP systems). The terminal (head), as indicated at right, consists of a steel head with a conical hole which will house blocking cones to create the necessary compression on the rods, and so doing, the axial loads will be transferred to the head by friction. The tensioning equipment is made of a pair of hydraulic cylinders equipped with proportional valves to guarantee a parallel action, connected to the head by means of a threaded ring. The action of the cylinders causes a translation of the head. Between the head and distribution plate there will be positioned a counter plate with contrast bolts which, once screwed, will take up the space created by the translation; this will allow to keep the tensioning of the bar, and to take off the tensioning equipment. of the bars Type of bar Total resistant section (mm 2 ) Data sheet reference Solid round section, D = 32 mm. 804 N 8 System of n. 3 rectangular plates, with section 40x7 mm. 840 N 5 The tests are performed on the head/bar system to check the capacity of the system to transfer the required pull loads and will be run as follows: 1) The anchoring bar is placed in a steel cylinder of the type ENERPACH RCH606 (or similar). 2) Two heads are fixed on both ends of he cylinder in such away that by pressurising the cylinder with introduction oil the, the bar is tensioned. 3) Next, the pressure in the cylinder is increased at the speed of about 20 bar / min. until the pressure corresponding to 20 tons of tension on the bar is reached (this is the pre-tensioning value): this tension is maintained for 1 hour. 4) Next, the pressure is increased, always at the speed of 20 bars / minute until a value corresponding to 30 tons tensile load on the bar is reached, checking that there is no rupture. 5) Last, the pressure is increased up to breaking of the test sample and the limit value is recorded. Tel. +39 (81) 947777 Fax +39 (81) 947740 email : a.giamundo@atp.sa.it Via Casa Pagano, 31 84012 ANGRI (SA) - ITALY
Tube for MICROPILES Pag1/1 SCHEDA N 7 GRP tubes made with thermoset reinforced polyester reinforced with glass fibers, OD = 200 mm., to be utilised for micropiles reinforcement est Geomtrical Thickness A tube W e J e mm mm cm 2 cm 3 cm 4 200 8 48 223 2227 200 10 59 270 2700 200 12 71 314 3144 Mechanical Characteristic Unit Minimum value Reference specification Volumetric mass g/cc 1.9 UNI 7092 Tensile resistance MPa 600 UNI EN61 ** Bending resistance MPa 600 ASTM D790 ** Elastic modulus MPa 35000 UNI EN61(ASTM D790 A FLEX)** Shear resistance MPa 30 ASTM D4475 (Short beam test) ** Look at the section on testing The following deals exclusively with variations to interpretation of the existing specifications due the nature and to the geometry of the products. 1) Test samples The test samples must be taken from the tube as indicated in the picture at right. The parallelepiped test samples, with section a x b x l (L=length) indicated in the cited specifications, must be obtained by mechanical reduction of the dashed section, taking care that the sample must be finally rectified under refrigeration to 0,5 mm. precision for the size a x l Tel. +39 (81) 947777 Fax +39 (81) 947740 email : a.giamundo@atp.sa.it Via Casa Pagano, 31 84012 ANGRI (SA) - ITALY
Rebar with improved adherence Rockworm type Pag1/1 SCHEDA N 8 GRP round rods made with thermoset polyester resin reinforced with glass fibers, with improved adhesion surface obtained by an helicoidal groove produced without cutting any surface: or fibers, and therefore without reducing the mechanical characteristics in the axial direction (reduction of such characteristics is typical for most similar products and it is a consequence of cutting the reinforcing glass fibers). These rods are utilised mainly for the fabrication of cages or as nails or anchoring systems (active and passive). Geometrical and Mechanical Rod diameter (mm) Area section (mm 2 ) Average tensile resistance (MPa) Typical tensile resistance (MPa) Pull resistance (ton) Elastic modulus (GPa) 10 78 1000 900 7 41 12 113 900 900 10 41 16 201 900 800 16 41 22 380 900 780 29 41 25 490 900 730 35 41 26 530 900 730 38 41 30 706 900 690 48 41 32 804 900 670 53 41 The test must be performed according to CNR DT203/2006 Procedure for designing, executing and controlling structures in concrete reinforced with glass reinforced composite rods. Tel. +39 (81) 947777 Fax +39 (81) 947740 email : a.giamundo@atp.sa.it Via Casa Pagano, 31 84012 ANGRI (SA) - ITALY
Stirrups Pag1/1 SCHEDA N 9 Stirrups are circular, rectangular, or other different shapes; they are made from GRP (glass reinforced polyester) rods with different resistant sections and custom shaped, (usually) closed loops, without over lapping; these stirrups are utilised to fabricated GRP cages for reinforcement of concrete. Geometrical and Mechanical Rod equivalent diameter (mm)* Area section (mm 2 ) Average tensile resistance (MPa) Typical tensile resistance (MPa) Pull resistance (ton) Elastic modulus (GPa) 10 78 1000 900 7 41 12 113 900 900 10 41 16 201 900 800 16 41 22 380 900 780 29 41 * Usually we refer to equivalent diameter, because in the case of looped stirrups, the section is irregular. The test must be performed according to CNR DT203/2006 Procedure for designing, executing and controlling structures in concrete reinforced with glass reinforced composite rods. Tel. +39 (81) 947777 Fax +39 (81) 947740 email : a.giamundo@atp.sa.it Via Casa Pagano, 31 84012 ANGRI (SA) - ITALY
Polymeric fiber for concrete reinforcement - SPRITZFIL-CEM -40 - Pag1/1 SCHEDA N 10 Physical/Mechanical properties Material: Thermo-set polyester resin reinforced with glass fibers Color: natural Tensile strenght : >700 Mpa Tensile elastic modulus: >35 Gpa Elongation at break: 2 % Density: 1,8 g/cc. Geometrical characteristics Length of cut fibers: 40 mm. Nominal diameter of each fiber: 1,6 mm. Volumetric glass content: 40% Proportioning Depending on the type of application, it is suggested to mix from 3 to 15 kg/mc of mortar. In accordance with specification EN 14889-2 Tel. +39 (81) 947777 Fax +39 (81) 947740 email : a.giamundo@atp.sa.it Via Casa Pagano, 31 84012 ANGRI (SA) - ITALY