BOORTUNNEL
GROENE HART
Contract No. DGP2092
Koop
Tjuchem
bv
Koop Ho1ding Europe B.V
00
19/08/02
Reil.
Datum
Status:
FA
Auteur
Checked
Dèscription I Omschrijving
Gecontroleerd
Status
FI: For InformationI Ter informatie
FC: For Consultation I Voor Commentaar
FA: For Acceptance I Ter Acceptatie
IFCTW:.lssued for construction (Temporary Works) 1Uitgegeven Voor Constructie (Tijdelijk Werk)
IFC: Issued for construction I Uit even Voor Constructie
Naam ISOP:
Check by ISOP:
Hoofdstuk
TUNNELINTERNALSTRUCTURES
Gecontroleerd
Ja:
door !SOP :
Nee:
r8J
Paraaf:
Titiel Titel
APPROVAL OF MATERlAL
PLASTIC SPACERS FOR VERTiCAl REINFORCEMENT
OF THE TUNNEllNTERNAL
STRUCTURES
Archiving Code
Archief code:
Format
Formaat:
CO 24.10
A4
HSL Code :
Number INummer:
13461
PRoe
Issuer I Uitgever
PROD AOM 88129 oe.doc
Rev.
13181
AOM
Package
88133
00
Document
Consortium Bouygues I Koop, Postbus 76, 2350 AB Leiderdorp, Tel. +31 (71) 5817000, Fax +31 (71) 5817070
Page 1 of2
GROENE HART TllNNEL
Koop
Tjuchem
Koop Holding
TITLEBLOCK
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Eu.ropé
bv
B. V
Bouygues Koop
[ ~s:
:;=
HSL Zuid 8oortunoel Groene Hart
Approval of Materials
f~r vertical reinforcemenls a plied in !he tunnel intemal structures
Document number:
PROD·AOM·88133
All these spacers have been checked by Consortium
Bouygues I Koop on behalf Certificates and
conformity statement provided by the suppllers. Full
description of these certificalions are attachee herein
appendix 1.
Suppliers
Technical
specifications
At the light of these test results and certification it
appears that all the related requlrements and
specifications are fulfilled.
ë
Durability demonstration compliance to NEN
6722.
Full description of the requirements, the associated
test method and the results obtained are fully
described in. appendix 2.
Appendix 2:
TNO's report
2001-BT-MKThe selected spacers fulfil with all related
requirements and specifications.
AU tests made on this concrete during onsäe production throughout the works is controlled in accordance with:
R104401
Consortium
HSL Zuid Boortunl1el Groene Hart
I Koop
Koop Tjuchem
Approval of Materals
Document number:
Plastic specers
tor verticel
reinforcements applied in Ihe tunnel intemal structures
PRO[l·AOM-88133
APPENDIX TABi..E OFCONTENTS
1.
Spacers' Technical speelfloatons
x
2.
Durability assessment
x
Farm 20.8,01.01 rellÜ5
-compliance to NEN 6722
Consortium Bouygues I Koop, Postbus 76, 2250 AB Leiderdorp, Tel,: 21 (O) 71 5817000, Fax 31 (O) 71 5817070
Page
of
Consortium Bouygues I Koop
HSL Zuid Boortunnel Groene Hart
APPROVAL OF MATERlALS (AOM)
APPENDIX - 01
, ~-~,. , SPE'CIF!Ci~nONS
.a t
VI
'-VI<
H 11\1:-',
Consortium Bouygues / Koop
HSL Zuid Boortunnel Groene Hart
APPROVAL OF MATERlALS (AüM)
This appendix presente the material speeiûcatons and certfficate provloed by the suppäers of the spaeer. The alm of this analysis is to
check whetherthe spacers satlsfy all requirements in the relevant specläcaüons and standerds.
At the light of these test results and certfieaton itappears that aHthe related requirements and specifications are fulfilled.
Attention of
Teehuik im Ban
Mr. Yan Taibi
Ree6 GmbH & Co.KG
Breslauer Straäe 59
Fax No.:
from
D 42277 WuppertaJ
Haraid Kotzur
---------
Page(s)
1
Phone ne, ++49 (0) 202 9644-140
Date:
2002-08-16
Ust.Id.Nr.DE 121023244
Tel.: ++49 2029644-0
Fax: ++49 282 9644-187
info@reuss-wuppertal.com
http://www.reuss-wuppertal.com
Cemposltien of tbe material for uur plastic spacers "Dux-offen and Dinki"
Dear Mr. Taibi,
for economical as wen as for environment reasons we produce all plastic spacers - which are manufactured
in an injection mcalding process - form recycling material.
The a. m. products are made of recycled PE (Polyethelene), which means that about 95% of the material is
recycled PE-material and about 5% are different plastics. Recycled PE-material means that the material was
already used for ether products (first products) made ofPE and is now crushed to the basic material for our
spacers. As we as well as our supplier for the basic material for OUT spacers don't know who had produced
the "first product" we are not in a position to give a material composition and to acknowledge the type of
stabilizer which was used. This is a general problem whenever recycled material is used. On the other hand
improoved separation of plastic materials which are used for recycling purposes have resulted in a higher
quality of regenerated base material.
As a wellknown supplier of plastic spacers in the European market we get our raw material only from
reliable sourees in big quantities, to ensure the quality of our products. We have sold our plastic spacers for
more than fourty years now and have never got any problems with them particularly in respect to durability
even under problèrnatie requirements.
hope I could give you some informative help and remain
with best regards
i.V. Dipt-Lig Haraid Kotzur
Technical Manager
I.....-
---l
Spezialartikel für die Banindustrie
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IfrfpLAKAB
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BestemmslinglD8stinataire :
0031 71/581.70.10
F$.\(:
Ter attentie van I A "attention de:
'0031' i1ï581".iö.oo ..
Tel. :
Mr. Van Talbi
,çl!.~~~~~J"jmm~~~f.l~,
PI..AtQBETON • COfFAAïeC
Datum
0710812001
Date
0, ReUN.Réf.:
Betreft:
- 2, lr\~aan
Aant. blz.
Nbrpg :
1740 Tl!RNAT·
FAX: 021582.19.62 rei,
:021582.21).45
7
,VN/2001NCI926
BoortunneA Groen Hart - tieh. teennique DiNKI, DUX OFFEN et DRA.NPoc.
ConOOryll!) :
MOlisle'Jr,
ei-joint nous vous envoyon$ notre fiche tecnnlque des écarteurs DINK', DUX OFFEN et DRANF1X,
SalutatÎons distinguées.
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Véronique Nouis.
lngél"lieur.
U kan mij T6chtSfeek5 bete/kIM op het nummer: 021683.02.54 of Vfl(PQN.flOU!s@pJakabliltDn.oo
Rac~
LOO/'\OO'd
UVL#
f$x nummer: 021258.40,00
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600fG
raers
HN ni/U}
6S:l/0
NHI 10,
l/O/LU
W051902
Ecarteur
___
._--l:t0urarmature verticale
DINKl et
DtlX OFFEN ;.fiche teelmiql.le
L Delgl1onduproduit
annature '1ertjcal~(DINKI et OUX OFFEN) en plastique som utihaés pour réaliser I'enrobage
dans les stnrcturea en héton armé.
Leséc~~p<)~
deslU::iers~caux
2. Domair.ted'ap:pU,ca:ûtm
Armatures vtrticales
Certificats
Matériau
Couleur
Crnl.1'lÎque
dans Ie béton armé,
: selon DIN et ISO 900 t
: polyéthylène PE
; gris
; résiste aux plus fréquerns acides et basiques présents dans ie béton
Gräce à leurperlte surface de contact sur Ie coffrage, ces écartems soot très.peu visibles dans Ie béton,
DINKI etm1X
OFFEN:
se clipsent
SUT l'lU::ier
et sant
d'un dispositif sp6cial qui les tmp&he de tombe r,
poUlVUS
DL"X OF'F'SN est uae cale plus rigide et pr!isente des conta<lts réduits avec te coffra.ge.
E (mm),
(()(mm)
plbox
5 14
500
H)-20
14-18
1000
A
DUXOFFEN
35
40
Coasommaäon : &elanJ'a~
500
1.à6plnr
C.V.A. PLAKABETON • COF'F'lU. TEC S.CA
rp.32 1. 582 2945 Fax 32 2 582 19 Q2
Blz. 111
\
NO.L;'HIVX'i'1d
Indus1ritlaan. 2 - B 1740 TERNAT
E-mail; plakabetoo.bèlgiu.rn@sl-ynet.be
Website: www.plabberon.oom
Verticale
____
.~ape~ingsafstandhouders
DiNKl en DUX eFFEN: Technische fiche
1. Pl"Odbetbescluiiviltlg
De verticalewapeningsafsumdhouders (DINK! en DUX OFFEN) in ktl.l1StStOfworden gebruikt als afstandhouder
in gewapend betA)llfussen' de verticale wapening en de bekisting.
"',;.
2. ToepaMinmebied
Afstandhouder voor de verticale wapening in gewapend beton.
4. EigemcllaAAcn
Certificaat
Materiaal
Kleur
Chemisch
: volgens DIN en ISO 9001
: polyethyleen PE
: grijs
: bestendig tegen de meest voorkomende zuren en basen, aanwezig in beton.
I
DlNKI on OUX OFFEN. : worden vastgeklemd op de wapening en zijn voorzlen van een speciaal systeem dat het
loskomen van de afstandshouder tegengaat.
DUX OFFEN : heefr'ee» grotere stijfheid en kleine contactpunten met de bekisting.
I
E(mm}
o (mm)
Si/box
5 -14
500
st/box
DUXOFFEN
10-20
14-18
35
40
I
LOO ISOO'ö
1000
500
:t
Verbruik:
2à6Stlm~
C.V.A. PLAKABETON - COFFRATEC S.C.A.
9' 32 2 582 29 45 Fax 32 :2 5'821962
Industrielaan)-B
1740 TERNAT
E-mail; plabbeton.belgium@Skynet.be
Website; www.pl.aka.heron.com
tUL;?
Blz. I/I
90{l~
!Z6U
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6S:80
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10.
RO/LO
ZERTIFIKAT
DIN E
IS
DEKRA Certification
90 1
Services
GmbH
besc.l-aeinÎgt hiarmit, da~ die Flrrnengruppe
Technik: irn Bav
Recu~GmbH
Breuer & Dausend
<'I'.Co. KG
et~
$traBe 59, 0«42717 WuppetUu
GWQAmBO/'Ill:Iemm.
0-141i.lti9Tf'(lbbln
GWrJ Stöbnitz. Q.OO249 Müchêln
UnternehmensQruppe
Dausend GmbH
Breslaoor Str3ne 59, D-4:!277 WUP!'é1t!ll
GmOH 8. Co, KG
M~~2S,
D42Z75Wupj:lel\al
Srullauar StraBtl 59, D-4Z277 WuppMal
wo Bautechnlk
GmbH & Co. Ka
WU~l1liIler
$1(.79, 0·45549 Sprockhövel
Bextru GmbH & Co. KG
H/5llw FeJd 30. 0-42279 WUPpêl'tilll
Bereich:
Entwic!dung,
Spezialartikeln
Prol1ukUon und Vertrieb ven
für die Bauindustrilll
ein Qualitätsmanagementsystem
entsprechend
der ob en
genannten Norm (SI94) eingeführt hat und dleses
wlrksam anwencet. Der Nachweis wurde im
Rahmen de$ Zertifizierungs-Audits,
Sericht-Nr. W-2971633 erbracht,
Datum der
Erstzertitizierung:
DI4!lsesZertifikat ist
bis:
~~~
/i~'~
09.03.1995
güttig
3UJ3;:001
Oá\tum der letzaen
Re;,:erlifizierullg:
23.03.1998
Zertifik:at~Registl'Ïer·
Nr.:
4039504711
Akl(r~djtlert
(/yreh I'.lie TGA
im Deutschen Akkreditierungs
LOc/soc"a
1I.fJL#
Rat
LOO~
~.hJ Y8/XJ.J
[Z618
6S:90
NHI Hl,
90lLO
0 .. Artikel im Detail
e ••
III Kurze Ue1ertermine
Die D.Artik@f werd~ ftlcht nor im Zencralia9E!r in Wuppert$lgefunrc.
sondern auch in
KunClennliht in unsaren Nieoerlassl,lOQen
uno fnv/alèf'I
atlf Inren WUl1sd1
DurCt'l den eigenen wet1aeuI;lbau kónrlE!rl wir
èlllCh 50ndértYpen und sonaerkonstruktioneo nach den Ani'orderUnl;ll!f'1 des Kunden
.ehnell verwirkilch@n.
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erwelst Sien auch als oestänaig Qegen
und SUlfate Olë Materialfestlg\:eit
mindestef1, 25
Vereretet1ilgern.
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eherrllscher Elelastuog empfehlen wir die
Drufa·S@rie aus F,aserbeton OÎeslil Serie
Fron
beträSt
l\ilmm1
tavcl1 bei Beton·Abstat"ldhilll;efll),
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halt> var $onlWneillstrahh.Jng b2.W. hl»tem
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e.nstand/genQUalil:äts.
kO(lcrolfen Avcn PrQduktion, lager und Ver.
a Fissaden-Plattel'l
waltunQ sind in eln QuaJiräts.Managemem5vstern elngebtlnoen. Das l'Iîl·!)èf'I wir ur.s
na en OIN EN lSO 900'l .w-rll'izleren IasslIn.
Il uasere Matenan~n
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F3Sèrb$1:On·A\.?$Ul1dbalter
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si.llfatoeständill1t!f1 Faserberon-Mischul'lgen
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Hi!'rrür verw~nclen wir ausschliel5ljch den
r..,~l(biegefàr.i9~nai!rofl;tahl
SSt SOOS (IV Si,
Weit~re ~at~1"Î31k\n
Auf !}~onlfe(eM~teriaUe.n (zB EClelSl:ähJel
v\ie.~n wir in dieser P'eisliste jewei1s neben
dan Produkten hin.
. 11Die Unbeclenklic:hkeit
PriJl'ZelJgflÏsse welsen fûr liine Relhe 'IOn
D... Arcikeln rael1, doe der KorrOsionsscr.l;u
der Bewel'\l'ung bel sachgö!miiaer AI\Wèf'lClunQ
nl~ht beeint:<lcl"ltigt wird. Weit.ere Prüffl;lch-
wêise beStatigen emsprli\Cnenàen Spernaian;iJ<>lln rH:me SelaSCbl'lrkeit. WasserundurCh·
fllss,gk"it u.v.a.rn
Ii pie SesüinCilgkElIt
TtlermisCl1 und(:hemiSCh
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siM
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b:IW best<\'mclig ge9eo am Bau Ob
ynd l.allge~.Bei naher thermlSeer
o er
uren
Ruçk>eIDS 91ldämmce Fassaden-Elemente
erhitzen .icn trn somrner U.u. auf bis zu 800 C.
besonders bei dtlflk~ Ot,:ernêChe. im Bereich
der Abstiln(j·halterIGM es dano ZIJ f=arba~·
plil'Cl:ungen kommen, a~ zwar ClanKorrosions·
scnut2 eltr eeWElhrung nicht 9mhrosn, aber
optiSCh stören
TreHefl Sle daMr die Ausw.ml der Abstand-
naJr~ mit o.sonderer Sorgflilt uM Stellen
Sie VI!lf$J.lChsotactel'l r,er
Um ROSt;1lecken ZIJ lIarmei<;!en,
Zemenc!ilebur.der.e Atl5tMdllaiter nicht wàssem, wfmfl Stahlschalung verwefldet wiro
Vêl'al"beltung;l+limiYl\!ise CI~ Trennmictei·
her>tdenl ll,lm $parsa~n Eins.1lt2
das
Trennmletelsbaaenren.
11 NOrmen und empfe.hlungen
Eletondeckung. und i<CIm:lsion.ssc:hutz
(CIN 1045 Au"gabe 7/1988, AbS. 13,11
.Die 5C3hleil1lagen sifl::! ZIJ eH1&m sceifeo
Gen."pe Zl.i ver~Odef\ Ul'ld dureh Absrana·
halter. del'efi DiCke dim Nentll"rnlS der Betondeckung nacn AbSchniet 13.2.1. (3) 4int\1prlcht.
. 'und, dle den Korr1:lsi(;)n~hutz nient Meir.'
trá:;htigen. In iM~rv0!'geseJ1enen ~age so
fesCWlégen, daB sie sien beim Einbringen uno
VI1!f(licl1ten oes Becons nl::;he verschleberl",
DBV'llllerkblatt Setonded<ungund
Bewehrung
Ausgabe 1/97,AIJS.. 6 (3)
.lIJm Einhalten der erForderlichen VerleQè'
rnase Sind die ÄtlStanClnalter
eOODrechM1d
dó!n ;::orOiOfUngen des DBV-Merkbiau1!i AbstananaiCer2/97 ziJ bero!llen un(l elnzubauen".
lmsert AbsrandhaJter fJJf waaSeteehte und
seni(rE!(l'lte Elewehrung werden bQ~i.iQlich
,,,rel' einorCl:'lun!:l
in die leisrunQSJ(!&ssen
gemiill D8\1"\M!rl<blatt AJ)standhalter 21S'i
geprlif!:. Die Priiful1gen war!'n bei DAAl:·
iéglJng c!ieser PreislÎ$te Men fllCl'lt aoge,
sctllO$Sert Einzelheiten k6nnen .i$doch in
uns.erer Atlteillllig TeChnl1: erf'r.l1Jt wer6ef1.
ÁI1Zihl uno AnordniJllg dér Ab&andl'llli~r
Ist TabelIe 4 DSV·Merk!>Jatt Saforn:lec!O.Jl'l;l
und 8e1Nthrvng 1197 lU entnehmen.
Die OSV-Merkblältterkönnen
belOQOO
werdénbl!im
Del.ltSChE'n Bètol'l-llerl!fl1
aIJen
K •.•OSCieofflîtJscandhalter
eV ..
;:'OStr3ch 2126. 65011 Wiesbi!den
Srandvemalte1'\
(OIN 4102. 'feil 41
Beten. StahlOecon voo SPàflfll)etO.11 werden in
aie Kt;i$$e A 1 (rueht brennbiilP@inglilSCufc.
AlsAbst:3ndhalterrür diE: eewenn ••ng curfen
Oblieh!!
der
9aunoi'fl<lassa 8 lIerwendet
dal! die Klassifjzlerung
werctef'., onne
- Ab$chrJitt Teil 4,
9 $.1,$,4 - verlorengeht
Werlm:offe ISeto:1+lal'lobuCt'l1984, Dav!
.AbstanC!halCer müssen <lVS ~
Werksroi'f
bestenen oer den Beton
oid'lt SChädigr
der SeJbi, wOOer dureh den Beron noen
unc
duren FalJchtll/Kelt uOd WiCtlill'UM a:lge·
griffen wird, ~.B,Beton, ...., Od>it"Kt;nmtof'-,
D.. .Artikel·AbSUlndNilJter
sind uMchädllch
für Bl?[cn uf1Cl a~hrung
.aêllotreChtefi 5tliben siOOam Slcnersten
AtlStaOOhalrtr In Form von "gèfochtan .
SchtlOen, aie é1uf die cetrêff'en~enStàJ:)e
aurgeKremmt bzw. auf~~~lt
Wl!rder/
IzB. Drum und DuxoCffenl.'
' .
Abteennungfl1(VOB,
Teil Cl •..
GerntlB VOB, Tel! C, Ztf'fer $·3.1 1,\'iet'lören (1Ie·
Kosten fûr AbSCanclllairerzur Be\I;êl1rung
unQ werd er: rrit dieser abgereCI'IQee. '.,
GelÎnges Gewicht, leict\re Hanahabung und
stabile Au;1iûhn.ng
halter
llU5
StlafElr"
~,r
0" ,Areike/cAbStilnd.,
KunststoF!' J'lell'en,KoSten
.'
tU'
.
11 Weltere Utlterlagen
Auf Wunsch schicken Ivir ll"rnefi garoe aus·
fuhriicl1e prosr;ekte, taehniSChelnfonm;j,
tionen unê f'riifzeugnisse zû 'einzelnèn .
Artikel
n.
.' ,
Hil'll.lleiSe z\,Ir veraftleituns
4nd Lagliln,mg
entnehmeo
Si.: hitte der VerPillcki,If1Qs,
Aufschrifl: oder .aallage.
MehrwertstelJêr wird extra berecnoet,
Ij Nachd~ucl( C1iaserPreisliste. auch auszui;lsweise, n..,r mit unserll'f SCI'lI'iftliChoo Cenehmigung
ilIi AIIl! Aobifd..lngen in uoseren Werbe· una verkaul'suntel1agen
dienen ledig I/eh der Dernonstration
llnClen.lngen siM iEiderzelt vOrtlehall:en
D..• Ariikel. Teehnik im Bau.
Lüü1LOO'o
tLllL#
AbwelchUl'l>!e1'l und Konstruktions.
HSL Zuid Boortunnel Groene Hart
Consortium Bouygues I Koop
APPROVAl OF MATERlALS (AOM)
APPENDiX - 02
DURABILITYASSE:3Sfl~E~ITOF
THE PLft,STIC SPACERS - COMPUANCE TO NEN 6722
Consortium Bouygues I Koop
HSL Zuid Boortunnel Groene Hart
APPROVAL OF MATERlALS (AOM)
lied in the tunnel intemal structures
Document number:
PROD - AOM - 88133
Content
ARTICLE 1 - SCOPE
3
ARTICLE 2 - REQUIREMENTS
3
ARTICLE 3 - PLASTIC SPACER COMPUANCE
3
ARTICLE 4 - CONCLUSION
3
ARTICLE 5 - ANNEXE
4
HSL Zuid Boortunnel Groene Hart
Consortium Bouygues I Koop
APPROVAL OF MATERiALS (AOM)
ARTlCLE 1 • Scope
In the design and construct contract for the Groene Hart tunnel a requirement of a design life of at least 100 year has been stated, To
prove that this design life is valid, performance and reliability based calculations, according to the design method 'DuraCrete', have been
be provided.
For the spacers, that wil! be used to guarantee the thiekness of the concrete cover, ths question occurred whether these have a sufficient
service life.
ARTiCLE 2 • Reql.l.irements
•
I»
NeN 5950:1995 "Voorchriften Beton-Technologie (VeT 1986). Eisen, Vervvaardigind en Keuring" - Regulations for concrete
- Technologie - Requirements, production and inspection;
NEN 6722:1989 "Voorchriften Beton Uitvoering (VBU 1988)" - Regulations for concrete Construction;
ARTICLE 3 • Plasticspaeer
compnance
The durability of the separaten wall between the two tracks in the bore tunnel was analysed on the basis of the service life design. In the
service life design for this project the corrosion of reinforcement through the carbonation and the chloride diffusion were regarded as the
most important threatof degradations (refer to documents PROO-AOM-88022 and PROO-AOM-88004)
The exposure conditions identified for separaäon waUare considered with regards of the carbonation degradation mechanism to be an
outdoor sheltered type, and with regards to the chloride ingress degradation mechanism to be an atmospheric type. The structure part is
only expoeed to air.
At this moment it is not yet possible to make a proper service life design for spacers. This is primarily due to the fact that we do not
understand the initiation and propagation mechanisms related to corrosion of the part of the reinforcement bar directly behind the spaeer.
An expert opinion byTNO concludes that for the durability of cementitious or plastic spacers we must rely, tor the time being, on
experience, Experience shows that both type of spacers do not cause serious durabiHty problems. Therefore, plastic and cementitious
spaeers have in principle similar effects on service !ife and should be considered equivalent in that respect. There is alittle preference to
apply cementitious spacers, as the experience with cementitious spacers is longer than with plastic spacers. (refer 10 TNO report number
001-8T -MK-R1 04401).
If we look in NEN 6722 with respect to plastic spacers we found there, that they may be used under lhe conditons.
lil
For theproper adhesion of plastic cover blocks to the concrete, they must have a surface of recesses of at least 25% of the
gross surface
co
Cover bloeks applied in watertight work must be of a cement-bound material
lil
If plastic cover bleeks are applied in situations in which the fresh concrete temperature may exceed 50°C, it must be shown
by means of tests that they do not undergo any unpermissible deformation at the occurring laad.
With respect to the separaten wall, the last two conditions may appiy to the GHT and nood to ba analysed.
lil
Water tightness is not applicable in the case of the separaüon wall, the durability investigation demonstrared that this
structure. is only exposed to air.
GAsSeparation
wall is relatively thin (45 cm), a rise of.concrete temperature over 50°C due to hydration process is not
expected. Whatever the weaking point of the PE that is used for the plastic spaeers is aoout 120°C. This means fhat no
problems with respect to the temperature must be expected.
ARTIClE 4 • Concluslon
The plastics spacers comply to the requirements of NEN 6722.
TNO analysed that as far ths durability of plastic spacers and also cementitious ones is concerned, we can rely, for the time being, only on
experience. Experience shows that both type of spacers do not cause serleus durabiIity problems. Therefore, plastic and cementitious
spacers have in principle similar effects on service life and shouid be considered equivalent in that respect.
Consortium Bouygues I Koop
HSL Zuid Boortunne! Groene Hart
APPROVAl OF MATERIALS (AOM)
Beside the applicatiol'l of the plastic spaoer. wheel shaped, permits to lower tlle risk of bad concrete cover on vertical relnforcement, slnce
they can net twist when the formworks are applied.
It can be considered that plastic spacers do not impair the quality and the durability of the concrete structure. Therefore these plastic
spacers can be used tor construction .
ARTICLE 5 • Annexe
.,
TNO 's report 2001-BT-MK-R104401,Service life design segments ofthe bored tunnel expert opinlon on the effect of plastic
spacers
(
me
Building anti CODstruction Research
CivillnfraslrUeture
Schoemak:erstraat 97
P.O. Box 49
2600 AA Delft
TNO report
2601·B1 -MK·Rl044l01
www.tno.nl
Groene Hart Tunnel
T +311.52763000
F +31 152763018
Service Life Design Segments of the Bored Tunnel
Expert Opinion on the Effect of Plastic Spacers
CI.I
__
'''~'KA:Iop
I<fl:Ih.Codilt1.
~.
Date
30 November 2001
Amhor(s)
Ir. AJ.M. Siernes
Copy no
No. of copies
Numberof pages
20
Number of appendices
Sponsor
Bouygues Travaux Publies
alm. Mr. Y. Taibi
Project name
OHT SLO plastic spaers
Project number
All tights reserved,
No part of this publiestien may be reprodeeed and/or publisbed by print. photoprint, microfilm
or any ether means without the previous written consent of TNO.
In case thls report was drafted on instructions, the rights aad obligations of coatracting partjes
are subject te either the Standard Conditions for Research Instructiens given to TNO. or the
relevant agreement concluded between tbe contracting parties. Subrnitting tbc report for
inspection to parties who have a direct interest is perrnitted.
@2001 TNO
$Il'I:i
i.OOI$t1C
t
ftke./Ol
C.C. U.Oz.
: lo5!>b
TNO report 11044
\~~:'
Jp het ontwerp~:~
en bouwcontract voor de Groene Hart Tunnel in de hoge snelheids1ijn
iûssen Amsterdam and Brussel is een levensduur van tenminste 100 jaar geëist voor
belangrijkste onderdelen van de tunnel. De tunnel bestaat uit een boortunnel. gemaakt
van geprefabriceerde betonnen segmenten, toeritten en diafragmawanden. Om aan te
tonen dat deze ontwerplevensduur daadwerkelijk aanwezig is moeten berekeningen
worden gemaakt die zijn gebaseerd op prestaties en betrouwbaarheid,
volgens de
methode 'DuraCrete' . Dit bewijs moet ook worden gegeven voor de kunststof
afstandhouders die zullen worden toegepast in de segmenten van de boortunnel.
In het rapport is een analyse gegeven van de duurzaamheid
van kunststof
afstandhouders, die geleverd worden door Plakabeton - Coffratec uit Ternat in België.
Het daarbij om de typen DINKI, DUX OFFEN en DRANFIX. De analyse was gericht
op het aantonen van de minimum levensduur van 100 jaar. In de analyse is gekeken
.naar drie aspecten:
- de duurzaamheidseisen uit de VEU (NEN (722) voor wat betreft afstandhouders in
beton
- de mogelijke bijdrage van de afstandhouders aan de aantasting van het beton en de
wapening
~ de mogelijke aantasting van de afstandhouders zelf.
Uit. de analyse bleek dat de kunststof afstandhouders aan alle gestelde eisen kunnen
voldoen, met uitzondering van de eis uit de VBU dat in waterdicht beton geen kunstsof
afstandhouders mogen worden gebruikt. Er is echter aangetoond dat wel kan worden
voldaan aan de prestatie-eis ten aanzien van de waterdichtheid, die is gegeven in het
'Programma van Eisen Groene Hart Tunnel' .
Vanuit een praktisch oogpunt bezien kan ook worden opgemerkt dat in de praktijk
nauwelijks duuraaarrëietdscbaëe voorkomt bij het gebruik van kunststof afstandhouders
in constructies die geplaatst zijn in een zeewatermilieu.
Er kan dus worden geconcludeerd dat de betreffende kunststof afstandhouders
zodanige, met de duurzaamheid samenhangende, eigenschappen hebben dat een ontwerplevensduur van tenminste 100 jaar aanwezig is.
3/1.!l
TNO report II {l404
" Snmmary
~,,'
\.;
~. the design and construct contract for tbe Groene Hart Tunnel in the high speed
niilway tink between Amsterdam and Brussels a requirement of a design Iife of at least
100 year has been stated, The tunnel consists of a bored tunnel. made of prefabricated
concrete segments. ramps and ëiaphragm wall, To prove that this design life is vaUd.
performance and reUabiHty based ealculations, according to the design metsod
'OuraCrete',
should he provided; The proof of this service life must also he given for
the plastic spacers to he used in the segments of the bored tunnel,
Tbe durability of the plastic (polypropylene) spacecs that are delivered by Piakabeton Coffratee in Pemat Belgium, the types DlNKI, DUX OFPEN, and DRANFIX was
analysed witb respect to the minimum service life. The analysis was directed to three
different aspeets:
- tbe durabHity requirements
given in N'EN 6722 (VBU) with respect to spacers in
concrete
- the possible contdbution of the spacers to tbe degrndation meehanisms of the
concrete or the reinforcement
- the possible degrsëetiona of the spacers,
It was found that the polypropylene spacers can satisfy all rrentioned requirements.
exeept the requirements
from NEN 6722 that plastic spacers
are not allowed
in
waternght coaesese.-ït.was-however
shownthat-the
related performance requirement
given in the 'Programme of Reqairements.Green Heart Tunnel' will be satisfied,
From a practical point of'.view.i; earl be stared that concrete spacers used in sea water
snucterea show no special durability problerns.
The concrete spacers{havein Principle durabitity characteristics
design service life of at least lOOyear.
that will guarantee a
TNO report! l044
Contents
:Appendices
A Appendix: brochures of the spacers
16
'i:
1
Introduction 5
:2
2.1
2.2
2.3
Thc twmellining anti lts poosible degradations
Deseripëon of the Iining and the spacers?
Exposure conditions for the lining 8
Exposure eonditions for the plastic spacers 10
:3
3.1
Expert opinion on tbc service lire of tbe lining in reiation to tbc spacers usedl1
Requirements from N'EN 6722 'Regulations for concrete Construction (VBU 1988)'
3.2
3.3
3.4
ldentifying the possible degradations ] 1
Degradatien of tne polyetbylene12
Contribution of the plastic spacers 10 the degradation of the concrete 12
4
Conclusions- 14
7
11
TNO report 11044
5 115
1 Introduetion
.... , ,
Jhe Green Hemt Tunnel is probably one of the most important structures in the
northem part of the high-speed railway link between Amsterdam and Brussels. The
tunnel consists of:
One bored tunnel with El separation wall between the two tracks in the tunnel. The
lining of the tunnel wil! Oe made of prefabricated reinforeed concrete. In the lining
plastic spacers will Oe used, These wil! he supplied by C.V.A. Plakabeton -
Coffratec S.CA in Ternat Belgium, Between
me elements
rubber gaskets will he
provided,
Ramps as entrences for the tunnel from me north and the south side, The ramps
(walls and bottom) will be made in situ of reinforeed concrete. The ramp will he
-
supported by a system of under-water concrete bleeks that are conneered by rension
piles to the bottom of the ramp.
Diaphragm walls hetween the ramps and the bored tunnel.
In the design and construct contract for this tunnel
lil
requirement of a design life of at
least 100year has been stated, To prove that this design life is valid, performance and
reliabiHty based caleulations, aceording to the design method 'DuraCrete', should he
provided, Toe proof of this service
lire must
also De given for the concrete spacers.
The designmethod
'DuraCrete' fellows in principle the same line as the structaral
design concept. The design is based on:
-
Perfermances, where me border between wen performing and bad performing is
given by limit states.
Limit states should, In principle, model the behaviour of the structure on basis of
fundamental correct formulas; in case of lack of these formatas empirica! relationships are aceeptable if consensus is present to use these roedels. A distinction will he
made between ultimate limit states (ULS) and serviceability limit states (SLS).
Reliability, Prove should he given that the relevant performances wil! be reliable
through tie whole design service life (reference period), The required reliabiJity for
the ULS should he at least i:> :: 3.6 and for the SLS ~ :: 1.8.
Fusther aspeets of the design metbod 'DuraCrete' are:
The environmental eoedinons are modelled within the limit states.
The degradation proeesses are modelled within tbc limit states,
There is in principle a possibility to formalate new, to durability or maintenance
related, limit states. An example is a limit state to prevent to enter into the peopagation phase of eerrosion. Such a limit state redaces the probability that repair has to
Oe done on the strueture,
The 'DuraCrete' design method is described in a manaal nl. For the calculations of the
concrete structure this method will he followed, in the sense that the calculations will he
made on a probabilistic level.
The manual gives also a possibility for a simplified semi-probabilistic design with
safety margins between tbe losding or environmeatal condiäoas and tae material
resistanee, Thts simphfied approach wilt not be fellewed as it is expected to he too
crude for a design for 100 year in case of the preseace of chloride. To simplify the
TNO report 11044
calculations this approach may be fellewed for performances that presumably
calculation is than used to prove this,
6/15
are not
çritica1. TOe semi-probabilistic
Tbe design metbod DuraCrete is fully foeussed on reinforeed concrete structures, It can
not yet he used for special parts in the tunnel like the plastic spacers, the rubber lining,
tbe stainless steel anchors. as no degrsdation rnodels and data for the parameters are
specified,
In this report an expert opinion will be given on the service life of tlle plastic spacers, it
strived to give this opinion on basis of tbe performance and reliabiltty of the spacers for
a service Iife of 100 year, In other words the expert opinion win be based on the same
principles as in DuraCrete.
7 1tf5
TNO report IHl44
2 The tunnel lining and its possible degradations
2.1
Descripti.on of the lining and the spaeers
The lining of the Green Hart Tunnel consists of prefabricated reinforeed concrete
segments, Each tunnel ring with a width of 2 mand an internat diameter of 13.3 m
consists of nine segments and a keystone (Figure 2.1). The lining has a wall thickness of
0.6 m. Around each segment and key stone a rubber joint profile is applied to secure the
water tightness of the tunnel lining. The surfaces of the joints between the segments are
provided with the plastic guiding bar to accurately position the segments during the
construction of the lining, To provide the proper concrete cover plastic spacers of will
he used, that wH1he delivered by C.V.A. Plakabeton - Coffratec S.C.A. in Ternat
Belgium. The spaeer are produced by Reuf3 Teehuik irn Bau in Wuppertal Germany.
.
1
I
I
!
i I
i ,
~
I :
,I
Figure 2.1 Cross sections of tne tunnel ring in longitudinal and transverse direction
FOT the horizontal reinforcement bars DRANFIX spaeer wiU be used and for the vertical
reinforcement bars DINK! anti DUX OFPEN (Figure 2.2).
Figure 2.2 Respectively DINKl. DRANFIX and DUX OFFEN (scale about 1 : 2)
TNO report 11044
8115
The standard DRANFIX sparers are avaUable for concrete covers of 35 mm and 40 mm
.. itP combination with reinforcement diameters of 6 to 16 mmo This product is described
:~nhe Outen brochure VOS 2102, dated 02108/00, and in the Freeeh brochure W 05 21
..
~2, dated 06107199.
The standard spacers are of tbe type DINKI are for a cover of 40 mm and reinforcement
diameters of 5 to 14 mrn and DUK OFf'EN for a cover of 35 mm in combination with
reinforcemem diameters of 10 to 20 mm and for a cover of 40 mm in combination with
reinforcement diameters hetween 14 and 18 mmo These products are described in the
Dureh brochure V 05 1902, dsted 02108/00, and in the Freneh brochure W 05 1902,
dated 06107199.
Plakabeton wiU however prodaee similar spaeers with ecversend reinforcemem
diameters tbat are specific for tbo application in the Green Heart Tunnel. No brochures
are avallable for tbis. Scans of the brochures are given in Appendix A.
As far as the exposure environment is concemed, the tunnel lining is generally in
contact with tbe salt contaminated groundwater on tbc outside. On tbe inside mere is
also a possibility for salt contaminated ground water, due to leakage though tbe joints.
Further the concrete segments are exposed to tbe armesphese on the inner sine and in a
part of tbe joints. The tbreat of degradations sucb as trost in combination witb de-icing
agents.cbemieal and biologica! attaek are less or not relevant for the tunnel lining. ASR
will he considered by selecting proper cement and by avoiding the appäeetion of tbc
poteatial reaetive aggregates (research coaceraing tbis aspect hasbeen carriedout by
Bouygues).
Carbon dioxide from the atmospbere can have negative effect on the inner side of the
tunnel lining conceming tbe carboeation since the coacentratioa of carbon dioxide
inside the tunnel will be raised in cornparison with tbe outdoor environment due to the
low ventdarion in tbc tunnel, In addition, tbere will he no preeipitation.
Therefore blockage of !he pores in the concrete cover due to predpitation wil] not take
place, altbough condeasaäon may partly compensate tbat. The eerrosion of reinforcement tbrough carbooation has to he coasidered in tbe service life design of tbe tunnel
lining,
On the basis of the Program of Requirements - Green Hart (5.1.4) tbc content of
chloride in tbe groand water must he consiöered as thai. in !he sea water. The saline
ground water will penetrate in the outside of the tunnel Iining (i.e. concrete outside the
rubber joints). Due to possible ieakage of the joints (immediately aftel' construction or
during tbe service life), the saline ground water wil! also penetrate in tbe joints at the
inner side of !he tunnel lining. Therefore, the corresion of reinforcement through
chloride ingress bas to be considered in tbc service life design of the tunnet tining.
The cntical points eoaeeming the thrests of earbonstien and chloride ingress on me
segment are illustrated in Figure 2.3. These two types of threats eau he identified in the
segment aceording to the exposure conditions:
TNO report 11044
l
"'~'~r_'·
--
e e e c c ::::.;:..;:.:
L
OutskIa
(Chl~ pe:::a:)
. __
.._....
- '.-
Posslble ieakage at (chloride penetration) alffte joint betwe9tl!he
~--,,;•.
_._"'---...~
,
t~e
rings
(chIorldepeoelnitiol1)
Figure 2.3 Critica! points concerning the treats of carbonaston and chloride ingress on
the segment
Outside:
The outside surface of me concrete segment is constantly exposed to thechloride
contaminated ground water. The enviroamental condition is similar to the submerged
condition in the sea water.
Inside:
The inside surface of tbc concrete segment is coastantly expoeed to the air with a
relatively high CO2 concentratien due to the low ventäation in the tunnel. The mainly
threat is the carbenation. Due ro the possible leakage the inside of the segment at the
bottorn of the tunnel could be also threatened by the chloride penetratien. This part can
be considered as the splash zone as far as the exposure condition is coneerned,
The joint between tbe rings:
The smal! part outside the rubber profile is constantly exposed to tbe chloride
contaminated ground water. This part can be considered as the submerged exposure
condition. The surface behind the rubber joint could be possibly in contact with toe
saline water due to the leakage. The exposure condition of this part of the surface can be
regarded as the tidal zone (Figlli"'e 2.2a).
TNO report
I 1044
lOf 15
The joint between the segments:
The smal! part outside the robber profile is constantly exposed to me chloride
coetaminated ground water. This part can be consinered as the submerged exposure
eonditioa. The surface bebind the robber joint and/or bebind the plastic guide bar could
he possibly in contact with the saline water due to the leakage. The exposure condition
of this part of the surface cao he regarded as the tidal zone (Figure 2.2b).
2.3
Exposure oonditioos for tbc plastic spacers
Spacers:
In all these critica] points tbc plastic spacers, delivored by Plakabeton, for the concrete
cover will be present. These durability parameters of the spacers differ oom tbe
parameters of the concrete of the segments, Therefore it is necessary to look to the
service life of the spacers.
Poly-ethene (LDPE and HOPE) have in principle a goed resistance against:
weak and streng acids
weak and streng alkalies
oils and fats
The westher resistance is moderate, but by adding special additives this cao be
improved, Tbc resistance against oxidizing acids is poor.
n n5
TNO report 11044
3 Expert opnnon on the service life of the lining in
relation to the spacers used
3.1
R.equirements
trom NEN 6722 'Regula&ns
for concrete
Construction
(VBU
1985)'
In NEN 6722 some requirements related to durability are specified:
1 spacers may not contribete to air enclosures
2spacers may not induce tbe ingress of moisture af ter hardening of the concrete
3 spacers may nor contribate to cracking
4 in case of watertigbt
concrete the spacers must he made from a cement bound
material , with a water/cement ratio that is at least equal to the water/cement ratio of
the concrete
5 the area of the recesses in the plastic spaeers should he at least 25 % of tbc gross
area of the spacers
6 in case the spaeers are used in situatioes where the température can rise above 50
is should he proved that no unacceptable deformations occur,
oe
With respect to these requirements the following remarks can Oe made:
1 tbc open structure of tbc spaeers to be used wil! prevent that air enclosures can oceur
2 as no realoonding
will occur between the plastic spaeer and the surrounding
concrete, it is unavoidable thet á small opening win he present near the interface; the
'crack width' wilt he substantially lower than the allowable crack width in the
concrete
3 giving the low modulus of elasticity of the polyethylene the spaeer will not
contribute to the cracking of the concrete
4 all civil engineering parts of the stracture should he watertight: for tbc bored tunnel,
the access ramps, and the shafts this is translated in the 'Programme of Requirements
Green Heart Tunnel, in a performance requirement that in the operational stage the
leak water discharge is less then 0.05 lIm2/day as an average over 50 m length; the
local maximum is 0.10 lIm2/day; the spaeer reduces the thickness of the concrete
parts locally with about 10 %, as the amount of perrneated water is inversely
proporëonal witb the thickness of the concrete element it is deal' that a plastic spaeer
will nor inerease the discharge with a factor 2
5 it is obvious trom Fig. 2.1 that thc DINK! and DUX OFPEN spacers fulfil this
requirernent; after meesurement of the reeesses in the DRANFIX spaeer it was found
that these spacers also fulfil the requirement
6 the weakening point of polyethylene is about 110 10 130 Oe, depending on the
density of the material; the highest temperature due to sun radietion will he about 60
oe and due to hydratien of the cement 70 oe.
As given in Chapter 2 the polyethyleae,
service life the following main degradations:
- alkali attack
- weathering
- oxidizing acids.
should he able to resist during the design
TNO report I 1044
Parther conditlens for the plastic sparers are, that they may not contribute to the mam
degradation mechanisms for the concrete:
chloride ingress in the splssh zone
carbonation
as both degradations can initiate eerrosion in the concrete.
reinforcement steel
•
••
1
I
I
I
I
1
spaeer
concrete
;
I.
lmgres
a.
b.
Figure 3. J Concrete without a spaeer (a) and with oplastie spaeer (b)
3.3
Degmdatioo of tbe polyethyiene
As mentioned in Chapter 2 the main.degrading agents for polyethylene are:
- weathering
~ oxidizing acids.
Apart from calamities it is not expeeted that oxidizing acids wil! he present in the Green
Heart Tunnel. If these types of aeids would be present, the attacking effect on tbe
concrete would deminare the effect on the spacers.
The weathering effect on the polyethylene is mainly due to ultraviolet light, and for a
small part to oxidizing and physiea! aging. As the spacers are emoedded in the concrete
(Fig. 3.1) !he effect win be negligible. Further we must realise that most of the plastic
spacers are situated in pl aces where no tigbt is present: outside surf ace, joints, elements
under the railway body etc.
For srnall products, like these concrete spacers, that are also produeed in a specific way,
it is difficult to perferm the usual compliance test with respect to earbonation and
chloride ingress. A possibility for testing would he to cast some spacers in standerd
concrete cubes or prisms, made of the same concrete mix as win he used for the
segments. The cubes cao he tested in the ReM-test (Rapid Chloride Migration) and the
prisms in a rapid carbonation test. The testing procedure need however to he developed
and consensus should he found on the interpretanen of the test results. This goes
beyend the scope of the present service life design of the spacers,
In the situation of Figure 3.1,a the chlorides or the carbon dioxide cao reach the
reinforcement steel through the original concrete mix. For this situation a probabilistic
TNO report
I 1044
13/15
service life calculation has shown that with the concrete mix M4So-AM, mat Bouygnes
will use for the production of the segments, the requirements with respect to the service
life of tbe segments can he fulfilled,
From practical experience it is known that plastic spacers that are applied in a sea water
elimate (ander water, tidal zone, or splash zone) seldom are involved in damages due to
corrosion, This may he due to me fact that no oorrosion of the reinforcing bar, that is in
contact witb the spaeer, wil! occur. It mayalso he do to the fact that eerrosion occurs,
but being a local eerrosion spot the amount of corrosion product will he limited, and
me
spaces available in the concrete matrix (air voids, pores and small cracks) can he
enough to prevent cracking of
me concrete
due swelling of the original iron.
The situation in most concrete structures in a sea water elimate is in tbis last respect in
genera! more favourable than the concrete in the segments, The minimum cover in the
segments will he probably 35 mrn, In prsctice this win he about 50 mmo This means
that the force, due to theswelling eerrosion products needed to break out (pop-out) a
concrete cone is quadratic with the heighr of the concrete cover (Figure 3.2).
Figure 3.2 Pop-outforce
is quadratic with the concrete cover
This possible unfavourable effect is in praenee not to important. The mass of concrete
that will pop-out in case of a 35 mm spaeer is limited, and estimated at about 100 gram.
The darrage or injuries that a mass of 100 gram can cause is Iimited, Besides it ma)' he
expeeted dun sueh type of pop-outs have a high degree of deteetability during
inspeedons.
TNO repol111044
14 HS
4 Conclusions
jbe durability of the plastic spaeers provided by Plskabeton Coffratee in Ternat
Belgium, the types DINK!, DUX OFFEN, and DRANFIX has been assessed with
respect 00:
- the durability requirements in NEN 6722 VBU
- tbe degradation of the spacers
- the contribution of the spacers to the degradation of the concrete.
The plastic spacers fulfil tbc durability requirements that are given in NEN 6722. exeept
that it is notaäowed 10 use plastic spacers in watertight concrete structures, In the
'Programme of Requirements Green Hemt Bored Tunnel' the requirement with respect
to watertightness is specified as a performance: a limitation to an average of 0.05
lIm2/day and a local maximum of 0.10 lIm"Jday. It has been shown that tbc présence of
a plastic spaeer will not double tbe local leak water discharge. This means that the
influeace of tbe plastic spacers on
the
watertightness is negligible,
From the service life design of tbc segments it followed that the main threats for the
concrete are:
Corrosion of the reinforcement due to carbonation of the concrete, for thc concrete
that is expoeed to the atmosphere.
- Cosrosion of tbc reinforcement due to the ingress of chlorides
It was found that these degradations are not negatively influenced by plastic spacers.
Polypropylene is in general good resistant to acids and alkalies. The last property means
that the spacers will he good resistent to the alkaline environment in concrete. The
resistance of polypropylene against oxidizing acids is low, but these types. of aeids are
not present in the tunnel. Further is cao he stated that the spacers are embedded in the
concrete. The moderate westher resistance is therefore no real problem,
From a practical point of view itcan he stated that plastic spacers, used in sea water
structures, show no special durability problems.
The plastic spacers have in principle durability characteristies that will guerantee a
design service life of at least 100 year,
Tbe plastic spacers to he used for the Green Hemt Tunnel have dimension that are not
available within the delivery programme of the producer. Therefore special spaeers will
he produeed re he used for the Green Heart Tunnel. Giving tbc considerations in this
report. there is no reasen why spacers with other dimensioas win have another service
!ife.
Ir A.J.M. Siernes
15/15
'::r;.:.;
TNO report 11044
A
16/15
Appendix:brochures of the spacers
Ecarteur
pour armamre horizontale
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TNO report 11044
wa
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181 is
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TNO report 11044
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