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ABSTRACT: The ability of sprayed concrete to hold the rock mass around an opening, avoiding pro-
gressive loosening and destabilization, is widely recognized. On the other hand, design of shotcrete supports
is still more of an art than a science, with the majority of designs based on experience, on empirical recom-
mendations or on monitoring and adapting during construction. In order to improve both the mechanical and
the durability characteristics of sprayed linings. a recent trend is to replace the ordinary mesh reinforcement
with steel fibres. It is well-known, in fact, that the usage of high-strength fibres (e.g. steel fibres) in the con-
crete mixture permits to maintain a high compressive strength while considerably improving the toughness
and thus the structural ductility. In this paper, the evaluation of the strength and ductility characteristics of fi-
bre-reinforced shotcrete linings is performed by adopting suitable theoretical and numerical models. Analyses
show that failure of a shotcrete support is generally a two-step process, initially generated by loss of adhesion
to the rock, followed by flexural failure. Flexural strength and toughness play a critical role in the post-peak
region once adhesion is lost. After analysing the stress state in traditional underground configurations, the
bridged crack model is used in order to define the correct softening curve of the material, based on the fibre
content. By means of a numerical code based on the cohesive crack model, the post-peak behavior of the
structure is investigated. It is shown that the fibre reinlòrcement greatly enhances the flexural and punching
shear strength, as w-el1 as the energy absorption capacity.
1. INTRODUCTION
In the following, attention rn'ill be focused onto fi-
We def-rne as shotcrete, or spritzbeton, a particular bre-reinforced shotcrete, possibly accompanied by a
concrete mixture carried under pressure into a closed radial bolting system, as a composite sustaining
pipe system, projected against the application sur- structure. The strength and ductility aspects of this
fàce where it realizes a supporting shell. material, together with its energy absorption capa-
Fibre reint-orced shotcrete, as a parlicular case, in bilities, will be investigated through analytical and
addition to the classical ingredients - cement, water, numerical methods.
aggregates and additives, contains a reinforcing The theoretical analysis of the shear and flexural
phase made of fibres which provides the material behavior of shotcrete shells will provide closed-form
with enhanced mechanical (e.g. ductility and frac- analytical solutions which are helpful in determining
ture energy) and durability (related to the reduced the safety factor of composite underground linings.
crack-ing extent due to plastic shrinkage) properties. The numerical analysis will permit to translate the
One of the most important field of application for tools of nonlinear fracture mechanics (e.g., of the
the shotcrete is the field of undergroung engineering. cohesive crack model) into design rules, under the
Excavation of tunnels, in fact. causes the change of hypothesis of a monocoque support. The geotechni-
the stress field in the rock mass, with consequent cal aspects related to the excavation of a circular
stress redistribution and strain development. Without tunne[ will be investigated through the FLAC[')
appropriate confinement, large deformation may commercial code, whereas, by means of the
converge towards equilibriun'r or induce unaccetable C.CRA.P. algorithm (developed at Politecnico di
damage which requires a reinforcing structure. Torino), the post-peak response of the reinforcing
shell will be modelled, by considering the entire
stress-strain relation of fibre-reinforced shotcrete.
2 . COLLAPSE MECHANISMS OF SHOT- 2.1 Bendins behavior of a shotcrete shell: limit
CRETE LININGS analvsis"and structural response
loading system:
6. compression collapse (Fig. 1.e);
7. tension collapse (Fig. 1.f .
loaded by the weight of rock wedges. In Fig. 4 the The analysis permits to evaluate the ultimate
moment distribution under such loading is shown: bending moment of fibre-reinforced composites, in
percentages are referred to the moment M0 eqùal to: the framework of limit analysis coupled with cohe-
Mo=l
E
, G-rf . e) sive crack approach.
Marti (1999) provides two different analyse: the
where 4 is the distributed load, s is the spacing of the general one explicitly considers the extent of the
radial bolts and c is the width of the bolt anchorage compressed zone (modelled by a stress-block)
plate. within a plastic hinge in a bent element of height h.
The second one neglects the extent of the com-
pressed area.
Figure 5 represents the scheme referring to the
i.ansverse Moménl complete analysis: the plastic hinge, within the ele-
ment of height h, is characterized by a compressed
FS
/-7 zone of height z and by a finite rotation 0 (l.r :
length of the fibres).
Uf,dcrnelh the SIab
0.r5/;
E-l
Fig. 5 General analysis of a cohesive hinge (Marti,
l ee9)
oo (3-38+E')
f -l
t:20
I ,6-8É+
.r t9
. =(;),, o i
cm
Stille:
rr=0.68-t'.2.10.0.+th-2.t.
' ' "rl = l. rgr elastic
v;1%
L t2-t2(+ a( ) approach
o,=4.22MPa
The value op (Fig. 6) to be used into equation (7) M1: 10.8 KN.m
0<6_< ,,=[9-5*] o, r,. (r2) Comparing the various theories, we observe that
the approaches by Di Tommaso (1990) and Marti
o^-h) (1999) provide similar results. Instead, the ultimate
4r1, t1 =L- (1 3) bending moment obtained according to the theory by
t2. E', Barrett & McCreath (1995) is considerably higher.
In conclusion, if we consider a generic cross sec- This is due to adopting the bidimensional plate the-
tion of the fibre-reinforced shotcrete shell as the ory (instead of beam theory) and to the beneficial
element of height h, we need to decide the best ap- presence of the radial bolts which has not been taken
proach (considering or neglecting the compressive into account by the other Authors.
zone) also with regard to the efficiency of the adhe- Moreover, there is a clear difference between the
sion to the rock. Thereby, on the basis of the value load-carrying capacity calculated according to
of z, the ultimate bending moment can be calculated Stille's theory (1992) and the other theories. The k-'
with the appropriate formula. As a rule, the design parameter, used by Stille to take explicitly into ac-
moments shall be sufflciently smaller than this limit count the bridging action of the fibres, affects di-
state. rectly the value of the elastic bending moment.
Finally, it is important to stress that, since the ef- tensile stresses arise in the upper part of the support,
fèct of fibres is essentially confined to the post-peak although the plastic zone around the hole is always
softening branch (where they provide the shotcrete of limited size.
with an unexpected reserve of ductility), adopting a
linear elastic approach does not permit to consider JOB lilLE . modellÒ rid.no
o 28 1
i
3. NUMERICAL APPROACHES TO EVALU-
i
ATE THE LOAD-CARRYING CAPACITY
OF SHOTCRETE LININGS L
cal aspects related to the excavation operations and Fig. 7 Undeformed mesh for the FLAC simulations of rock-
the soil-structure interaction have been analysed by support interaction
means of the finite-difference code FLACT'. After-
wards, the post-peak behavior of the fibre-reinforced
critical cross sections has been analysed with the fi- 3.2 The finite element code C.CRA.P. (Cohesive
nite-element code C.CRA.P (Cohesive CRAck Pro- CRAck Program)
gram), developed at Politecnico di Torino by one of
tlre Authors (Barpi, 1996). This code is able to fol- The finite element program C.CRA.P. was im-
low the entire load history of a fibre-reinforced shot- plemented to simulate the entire behavior of fibre-
crete section, from the linear elastic ascending reinforced shotcrete linings in the framework of the
branch to the softening stage, since it is based on the cohesive crack model.
fictitious crack model. Since the loading conditions are those typical of
Mode I fracture propagation, the crack path can be
3.1 The FLAC@] numerical code (vers.3.40) determined a priori by symmetry reasoning.
Moreover, in the cohesive crack model, stress
The commercial code FLACI" ldeveloped by the singularities are absent, since the maximum princi-
ITASCA Consulting GrouprM), is commonly used in pal stress at the apex of the fictitious crack is equal
geotechnical engineering, especially in the presence to o, (ultimate tensile strength of concrete), and re-
of excavation operations. It is based on an explicit mains constant during crack propagation.
fìnite-difference algorithm and permits simulation of This permits to define a subset of the finite ele-
two-dimensional plane stress, plane strain or axi- ment mesh, named 'rosette', which is constructed
symmetrical conditions. In our simulation, we upon a moving reference system, with the origin
adopted a plane strain condition, which is close to coincident with the fictitious crack tip, which fol-
the situation of long tunnels excavation (constant lows crack propagation as a gauge area where the
cross section and loads acting in the plane). A deep stresses are highest. The rosette is made by an odd
circular hole was considered, inspired by an existing number of regions in order to have, in any loading
engineering situation encountered in the Frasnadello situation, at least one element symmetrical to the x-
/Antea tunnel in San Pellegrino Terme (BG-Italy). axis of the moving system.
The stress coefflcient k6was put equal to 1, 0.3, 0. The crack propagation condition is that the
The cases when ko:0.3 and k6: 0, which are typical maximum principal stress in the centroid of such
of shallow tunnels or of stratified and fractured rock element attains the ultimate tensile strength of the
masses with considerable stress release around the material.
hole, were chosen in order to analyse the role of ten- Due to the symmetry conditions, numerical
sile stresses (as well as their extent) arising in the analyses have been carried out on an archetype of
shotcrete support. tunnel support, by modelling only one half of the
The Mohr-Coulomb plastic criterion was adopted circular lining. The resulting circular arch was gen-
in the analyses. Due to the symmetry, the simulation erated, by means of GiD 6.1.2, possessing the inter-
was carried out only for a quarter of the domain nal radius Ri,;5.7 m and the external radius R,,f5.9
(Fig. 7). The fibre-reinforced shotcrete support was m, i.e. a 20 cm thick shotcrete support was mod-
simulated by assigning the pertinent mechanical elled. As shown in Fig. 8, the boundaries of the arch
properties to a shell of elements at the boundary of were constrained symmetrically.
the hole. By applying localized rock gravity loads,
Steel fibre
content l%l 0 I 1.5
(Dramix@ ([kg/m3]) (0) (78.5) (l 17.5)
zc 30/.s0)
Elastic
Modulus [MPal 30400 33100 34800
E
Poisson
coefficient t-l 0.25 0.25 0.25
Fig. 8 The rnodel for crack propagation used in C.CRA.P.
under the action of a localized gravity load Extension of
the area
[ml I
i= 60000,,,,,,,"'''
I d
-;:ffir\-*
la-Lr
J 40am
.i:r'
--.L--
ol
o o.o2 o.o4 o 06 o.oe I
Ci\lOD (cm)
Fibre conlenl: 0o,o Fibre content: lqo I
The maximum load that the support is able to Finally, once the maximurn load bearing capacity
sustain is one of the numerical outputs. It is plotted of a fibre-reinforced shotcrete shell has been fixed
in Fig. 12. For instance, considering a volumetric (see, e.g., Fig. l2'), we can calculate the maximum
percentage of fibres equal to l.5oA. the maximum height of a unstable rock wedge pushing against the
punching load that the support can resist results top of the hole (see Fig. 13). Consider the worst
equal to almost l2 tons. situation for the support, i.e., the presence of a py-
The hrst points of the curves shown in Figs. 9 and ramidal block whoJe size is compaìable to the cliar-
10 correspond, instead, to the load of first crack acteristic size of the hole (e.g., diameter of the hole
formation P,,. which is a function of concrete ulti- : 11.8m). For a volumetric percentage of fibres
mate tensile stress (o,,), of the cross-section area of equal to l.5oÀ (117.5 kg/ m'; Pn,^:12 tons), the
the support (b,h). and of the radius of the hole (R) maximum height of the wedge sustainable by the
according to the following formula (which is valid shotcrete support alone is equal to 1.5 m. In the
under the hypothesis of infinite axial stiffness): presence of lòwer fibre contents (e.g., V1:30 kg/m3
o .b.h2.6.0.t82 : 0,38Yo; Pn,or:6 tons), which are more common
,,R
n_l/
(1 4) for undergroung mixtures, the maximum height of
the rock wedge becomes equal to 0.8m.
The shape of the curve beyond the first crack load
Considering a less dramatic situation, e.g. a
depends deeply on the bridging action of the hbres.
punching rock wedge with a smaller size, compara-
Considering, as an example, the situation depicted in
ble for instance to the tunnel radius (equal to 5.9 m),
Fig 10, we can notice that the action of the fibres not
the following values of the maximum height are
only raises the load-carrying capacity of the support,
provided by the analysis:
but, more imporlantly, improves the fracture energy
- Vf :l17.5 kgim' :l ,5%o; P*o,:12 t è hn o,: 3,4 m
of the shotcrete and favours the transition from a - Vf: 30 kg/m3 :0,38Yo; P*o,:6 t h.^: 1,8 m.
brittle behavior towards a ductile behavior of the =
structure. Notice. in fact, that the post-peak response l
This means that, once the maximum load P,,* is at- q 26m
tained. further deformation of the shotcrete support
is possible under constant, or slightly decreasing
load. Of course, this result is possible because nu-
merical analyses are carried out by C.CRA.P. under
crack length control.
I
Nlaxirnum load
120000
1 00000
z 80000
60000
40000 Fig. 13 Qualitative representation of the potentially unstable
20000 - rock wedges
0
100 120
Fibre contents (kg/m3) I
REFERENCES