REFORTEC REPAIR AND STRENGTHENING OF STRUCTURES WITH HIGH PERFORMANCE CONCRETE Lisbon, 25th of october 2013 TECNOCHEM Italiana SpA Dr. D. Rosignoli (CEO) Ing. Roland Vaes Ing. Herman Van Damme
INTRODUCTION TECNORIV AC100 COMPLEMENTARY CASE STUDIES TECHNOLOGIES Marketing office construction division in Belgium 2
INTRODUCTION TECNORIV AC100 COMPLEMENTARY CASE STUDIES TECHNOLOGIES
REPAIR AND STRENGTHENING OF STRUCTURES WITH HIGH PERFORMANCE CONCRETE WHAT is REFOR-tec The ultra high performance concretes/mortars range REFOR-tec was initially developed to make existing concrete structures fit to resist to earthquakes. REFOR-tec mortars are mostly used by applying a thin layer of REFOR-tec around existing columns or beams, or on top of a concrete floor. In this way, the construction is strongly reinforced and becomes more stiff and ductile.
REPAIR AND STRENGTHENING OF STRUCTURES WITH HIGH PERFORMANCE CONCRETE Possible applications: Structural reinforcement of pillars, beams, nodes,... Structural reinforcement at low thickness of concrete/brick, concrete/steel and wood floors Structural repair when casting or in confined spaces Seismic adjustment with absorbance and transfer of the lateral and direct tensions with high dynamics. Repair of floors where there is a need for high static and dynamic resistance and exceptional resilience values. Production of light structural elements at thin dimensions.
REPAIR AND STRENGTHENING OF STRUCTURES WITH HIGH PERFORMANCE CONCRETE Possible applications: Structural reinforcement of pillars, beams, nodes,... Structural reinforcement at low thickness of concrete/brick, concrete/steel and wood floors Structural repair when casting or in confined spaces Seismic adjustment with absorbance and transfer of the lateral and direct tensions with high dynamics. Repair of floors where there is a need for high static and dynamic resistance and exceptional resilience values. Production of light structural elements at thin dimensions.
REPAIR AND STRENGTHENING OF STRUCTURES WITH HIGH PERFORMANCE CONCRETE 4.0 4.0
REPAIR AND STRENGTHENING OF STRUCTURES WITH HIGH PERFORMANCE CONCRETE -UHPC Ultra - High Performance Concrete -HPFRCC High Performance Fiber Reinforced Cementitious Composites -ECC Engineered Cementitious Composites -HPECCMF High Performance Engineered Cementitious Composites Multiple Fine Cracks
REPAIR AND STRENGTHENING OF STRUCTURES WITH HIGH PERFORMANCE CONCRETE
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Case History: reinforcement of floor slabs for seismic rehabilitation Object: Hospital Cotugno Place: Bari Repair: Seismic rehabilitation Reinforcement of brick-concrete floor-slabs with a cooperating cover layer Quantity: 22 000 m 2 (15 mm) Material: Micro-concrete fiber-reinforced HPFRCC
Case History: reinforcement of floor slabs for seismic rehabilitation General restoration works were going on the buildings of Domenico Cotugno Hospital, erected in the year 1930, destined to be the new headquarters of IRCCS Istituto Tumori Giovanni Paolo II in Bari. After having achieved the level of knowledge of the structures of the entire LC1 Hospital Complex, first the need for seismic retrofitting of these structures was verified and, therefore, the plan of seismic strengthening.
Case History: reinforcement of floor slabs for seismic rehabilitation Insertion of new reinforced concrete partitions inside the buildings, to limit the movements and absorb the horizontal forces in case of earthquake. Membrane reinforcement of the floors using REFOR-tec GF5/ST-HS fibrereinforced micro-concrete anchored to the existing concrete floors in order to obtain ridged floor behaviour. Such behaviour is necessary in order to guarantee that the horizontal forces are transferred to the new partitions/walls. Intervention on the joints: dimensions of the existing structural joints, 60 mm on all levels, is insufficient to avoid the pounding effect in case of high intensive seismic activity therefore the insertion of metal plates with neoprene was specified.
Case History: reinforcement of floor slabs for seismic rehabilitation ground plan septum 15mm 40mm HPFRCC 1 x Ø 6mm 200mm bricks 2 x Ø 16mm Traverse in concrete 360mm
Case History: reinforcement of floor slabs for seismic rehabilitation Preparation of substrate Hydro-jet cleaning Application (consumption: 450m 2 /d)
Case History: reinforcement of floor slabs for seismic rehabilitation Hydro-jet cleaning
Case History: reinforcement of floor slabs for seismic rehabilitation Hydro-jet cleaning
Case History: reinforcement of floor slabs for seismic rehabilitation
Case History: reinforcement of floor slabs for seismic rehabilitation
Case History: reinforcement of floor slabs for seismic rehabilitation Characteristics of the micro-concrete (Refortec GF5 - Tecnochem spa) rheology: self-compacting matrix: hydraulic binder steel fibre: 0.18x15mm workability time: 1.5 h accepting foot traffic: after 10h modulus of elasticity: 40 GPa tensile strength: 8.5 MPa flexural strength (3 point test / 4x4x16): 32 MPa compressive strength : 130 MPa Fracture energy: ~ 32.500 N/m density: 2450 g/l hygrometric shrinkage 90d < 0.7 adhesion to the substrate: 1.0 MPa (failure in the substrate) surface is smooth, free from hairline cracks or detachments
Case History: reinforcement of floor slabs for seismic rehabilitation REFOR-tec GF5/ST-HS ADVANTAGES IN RESPECT WITH A TRADITIONAL CONCRETE COOPERATIVE DECK Low application thickness (15-20 mm) and then, limited increase of load Adhesion to the substrate without necessity for connectors or resins No reinforcement nets Very high ductility and resistance to cyclic loads Increase of bearing capacity in terms of bending moment and stiffness and reduction of the deflection of the floor Speed of application thank to self-levelling material properties 22000 sq.m. : free of construction and shrinkage joints
Case History: reinforcement of floor slabs for seismic rehabilitation
Rotterdam The Netherlands Parking Erasmus hospital 500 m² repair and reinforcement of concrete floor with REFORTEC GF5 ST-HS October 2012 Applicator: BALM with the assistance of SRS Headcontractor: BAM
Erasmus Hospital case History: reinforcement of floor slabs The Netherlands This 500m² situated at level +1 of this parking building at the ERASMUS city hospital of Rotterdam was seriously degraded, including seriously damaged rebars due to chloride induced corrosion. Not knowing or able to calculate the loss of performance of the steel, BAM, headcontractor of this project, appointed BALM to restore the strength of this surface by applying a layer of REFORTEC GF5 ST-HS. Substrate was prepared by mechanical removal of deteriorated concrete, followed by grinding, and next waterjetting to remove all the dust. The rebars exposed were treated by steel primer. Prior to the application, the surface was saturated with water. Average thickness of the application was 2 cm, with areas where the rebars were exposed, with 5 cm thickness. The application was assisted by SRS Benelux, as to ensure professional application, as this was the first REFORTEC application by BALM. The application was done in two days, appying around 30tons of REFORTEC GF5 ST-HS.
REFOR-tec - reinforcing constructions concrete floor reinforcement REFORTEC Erasmus Hospital case History: reinforcement of floor slabs The Netherlands
REFOR-tec - reinforcing constructions concrete floor reinforcement REFORTEC Erasmus Hospital case History: reinforcement of floor slabs The Netherlands
REFOR-tec - reinforcing constructions concrete floor reinforcement REFORTEC Erasmus Hospital case History: reinforcement of floor slabs The Netherlands
REFOR-tec - reinforcing constructions concrete floor reinforcement REFORTEC Erasmus Hospital case History: reinforcement of floor slabs The Netherlands
REFOR-tec - reinforcing constructions concrete floor reinforcement REFORTEC Erasmus Hospital case History: reinforcement of floor slabs The Netherlands
REFOR-tec - reinforcing constructions concrete floor reinforcement REFORTEC Erasmus Hospital case History: reinforcement of floor slabs The Netherlands
REFOR-tec - reinforcing constructions concrete floor reinforcement REFORTEC Erasmus Hospital case History: reinforcement of floor slabs The Netherlands
REFOR-tec - reinforcing constructions concrete floor reinforcement REFORTEC Erasmus Hospital case History: reinforcement of floor slabs The Netherlands
Liege, Belgija; 2012 Headcontractorr: Duchêne Application REFOR-tec : SRS Benelux
MNEMA case History: reinforcement of beams, columns BELGIUM Liège is a city of more than 1000 years old, with different arms of the Legia river running trough this city, to end in the large Meuse River. In 1938 the construction of the city swimming pool began based on the design of the architect Dedoyard. The building is about 85 m long and had two very different functions: a bus terminal and a swimming pool combined with boxing gym and saunas. The pool which is situated above ground level, is surrounded by a tribune for the spectators of swimming and diving competitions. The heating systems and heavy fuel driven boilers were installed in the caves; also bomb shelters have been built in the caves, as protection of the local Belgian people during the second world war against the German bombing. The swimming pool stops its activity due to financial problems in the late 90 s. Mnema means "memory" in ancient Greek. The association was created on initiative of the Province of Liège, the University of Liège as well as other organizations. The goal was to create a research center, a documentation center, an exhibition center, a forum for meetings and seminars.
MNEMA case History: reinforcement of beams, columns BELGIUM
MNEMA case History: reinforcement of beams, columns BELGIUM
MNEMA case History: reinforcement of beams, columns BELGIUM The transformation of the building respecting the current EUROCODE standards implied extra loads on the current structure : - transformation of the swimming pool to a public function theatre - installation of a monumental entrance as well as elevators - destruction of the base of the swimming pool and lowering of the level of the load bearing beams - leveling the height of the bus decks for the museum area - certain local weaknesses in the structure ( Shear cracks ) The quality of the concrete was acceptable; the chlorine of the swimming pool and the CO2 emissions of the buses have had few effect on the concrete. The steel reinforcements, on the contrary, were very different to the steel bars which are used today: smooth steel bars with a measured resistance of 250 MPa compared to steel bars at these days with a resistance of 500 MPa (and not smooth).
MNEMA case History: reinforcement of beams, columns BELGIUM ANALYSES AND SIMULATION The engineering office submitted the new loads to the reinforced structure (reinforced with steel and carbon fibre), to evaluate the tensions in the different elements, and in particular in the old soft steel reinforcements. The calculation showed that the original steel bars were submitted to loads (stress) from 150 MPa to 180 MPa, but the original hypothesis and the current norms obliged a maximum of 120 MPa. Carbon fibre reinforcement didn t allow to limit the stresses in these steel bars. SOLUTIONS - U.H.P.F.R.C.C. REFOR-TEC - for the structural calculations, University Professor and Project Engineers established a calculation method meeting the current norms, and based on testing results of REFOR-TEC in the universities of Liège, Rome, Bergamo and Zurich. - the fire resistance testing, based on the official norms (EN 1363-1 and EN 1363-3) was realized in the university of Liège (Belgium). The test results (made on 300 KN loaded 4,2 meter beams reinforced with 4 cm REFOR-TEC jacket) showed that REFOR-TEC is exceptionally stable in these extreme circumstances.
MNEMA case History: reinforcement of beams, columns BELGIUM
MNEMA case History: reinforcement of beams, columns BELGIUM
MNEMA case History: reinforcement of beams, columns BELGIUM
MNEMA case History: reinforcement of beams, columns BELGIUM
MNEMA case History: reinforcement of beams, columns BELGIUM
MNEMA case History: reinforcement of beams, columns BELGIUM
MNEMA case History: reinforcement of beams, columns BELGIUM
MNEMA case History: reinforcement of beams, columns BELGIUM ADVANTAGES - Excellent strain-hardening performances and fracture energy - The Axial Load and the Resistant Moment of r.c. COLUMNS increases up to 300% with 4 cm REFOR-TEC jacket. - Possible doubling of the resistant moment of BEAMS under bending by applying 40 mm REFOR-TEC jacket. Increased stiffness with reduction of the displacement times (comparable to a pre-compression) and with considerable reduction of the stress on the existing bars. The flexural strengthening induces important shear strength increase on the beams. - Considering a tensile strength equal to ft = 5 MPa, the increase of the resistance for the FLOOR, obtainable in the hypothesis of using a collaborating layer made with REFORTEC fibre reinforced micro-concrete at various thicknesses, results in:
Structural reinforcement and seismic retrofitting Milano (Italy) 1600Tons of REFOR-tec
REFOR-tec - reinforcing constructions beam and column reinforcement REFORTEC Case History : reinforcement of beams, columns ITALY
Case History : reinforcement of beams, columns ITALY
Case History : reinforcement of beams, columns ITALY
Case History : reinforcement of beams, columns ITALY VIDEO
REFORTEC wooden floor reinforcement
Case History : reinforcement of wooden floor ITALY
REFOR-tec - reinforcing constructions wooden floor reinforcement REFORTEC Case History : reinforcement of wooden floor ITALY
REFOR-tec - reinforcing constructions wooden floor reinforcement REFORTEC Case History : reinforcement of wooden floor ITALY
REFOR-tec - reinforcing constructions wooden floor reinforcement REFORTEC Case History : reinforcement of wooden floor ITALY
REFOR-tec - reinforcing constructions wooden floor reinforcement REFORTEC Case History : reinforcement of wooden floor ITALY
REFOR-tec - reinforcing constructions wooden floor reinforcement REFORTEC Case History : reinforcement of wooden floor ITALY Cantiere
REFOR-tec - reinforcing constructions wooden floor reinforcement REFORTEC Case History : reinforcement of wooden floor ITALY Cantiere
REFOR-tec - reinforcing constructions wooden floor reinforcement REFORTEC Case History : reinforcement of wooden floor ITALY
REFOR-tec - reinforcing constructions wooden floor reinforcement REFORTEC Case History : reinforcement of wooden floor ITALY Cantiere
REFOR-tec - reinforcing constructions wooden floor reinforcement REFORTEC Case History : reinforcement of wooden floor ITALY Cantiere
REFORTEC references REPAIR AND STRENGTHENING OF STRUCTURES WITH HIGH PERFORMANCE CONCRETE More than 100 references troughout europe Structural reinforcements Seismic reinforcements and retrofitting Precast and on site applications
REFORTEC test reports REPAIR AND STRENGTHENING OF STRUCTURES WITH HIGH PERFORMANCE CONCRETE Universities Milano / Bergamo (Italy) Rome (Italy) Zurich (Suisse) Liège (Belgium) Ghent (Belgium) Vilnius
REFORTEC - test Test reports University of Liège (Belgium) compression/flexion
Test reports University of Bergamo (Italy) shear bond strength
Fire test report University of Liège (Belgium) Fire test report Beam 4,2 meter 120 minutes >1000 C load: 2 x 150kN
Fire test report
Fire test report
Fire test report
Compared to carbon fibre reinforcement PILAR 30 x 30cm Concrete C20/25 CLS 3+3 dia16 FeB44k Reinforced with carbon textile Elastic Modulus: 240 Gpa Weight 300/400 g/m² Or reinforced with REFORTEC GF5 ST-HS 4 cm thickess around pilar