Precast Elements Made of UHPC From Research to Application

Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue

Graz University of Technology Institute for Structural Concrete

Development ofConcrete Compressive Strength

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

UltraHighPerformanceConcrete (UHPC)
AHighTechConcrete

Very densed Microstructure

High workability High compressive strength (150-230MPa) High durability ..

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

Composition ofUHPC
Silica fume PCE superplasticizer Quartz powder

water

UHPC

Micro steel fibre

cement Basalt gravel Quartz sand

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

Properties ofFresh UHPC

Flow ability of UHPC Composition of raw materials Mixing procedure Content and type of superplasticizer
Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue

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Graz University of Technology Institute for Structural Concrete

Properties ofUHPCinUniaxial Compression

UHPC 172 N/mm

Stress [N/mm]

UHPC HSC NSC

HSC 96 N/mm

Lateral strain Querrichtung

Longitudal strain Lngsrichtung

NSC 36 N/mm

Strain [0/00] High compressive strength (fc > 150 N/mm) High E-Modulus (Ec > 45000 N/mm) Linear relationship up to 70 - 80% of the peak
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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

Hardened UHPCinUniaxial Compression

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

Properties ofUHPCsubjected toTension

RILEM TC 162-TDF 3-point-bending-test
Load application

Support

Notch

Support

Fairy ductile behavior in post-peak range High flexural tensile strength Possible strain hardening due to multiple cracking The properties can be optimized though varying fibre geometry & contents!
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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

AComparison ofthe MaterialCosts

15 x

Material cost [EUR/m]

x5

NSC

HSC

UHPC With coarse Without coarse aggregates aggregates

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Graz University of Technology Institute for Structural Concrete

Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue

Comparison ofBendingCapacity ofNSCandHSC

Rel. bending capacity related to concrete C50/60 NSC HSC Truss UHPC

beam (rectangulare section) Concrete strength [N/mm] In conventional concrete structures, the advantages of UHPC can not be fully used!!!
Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue

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Graz University of Technology Institute for Structural Concrete

Properties ofFresh UHPC

Elephant skin on the casting surface (about 15 minutes after mixing)

The using UHPC in precast elements is recommended!

Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue

Graz University of Technology Institute for Structural Concrete

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Modular Truss System made of UHPC

Side View UHPC-joint Advantages
No monolithic joint Dependence of the truss only on the joint element Serges fabrication of the truss member Assembling in precast plant and on site possible Non-destructive disassembling and reutilization of the construction
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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

Elements

Modular Truss System made of UHPC

Elements
2
Upper chord

1
Tension element UHPC-joint Post

1
Brace

UHPC-joint

Lower chord

1 3
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Graz University of Technology Institute for Structural Concrete

Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue

Modulares Fachwerk aus UHFB Modular Truss System

made of UHPC

Assembling of the joints / posts

Assemling of the braces

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

Modulares Fachwerk aus UHFB Modular Truss System

made of UHPC

Montage of the joints / posts

Prestressing of the chords

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

Modulares Fachwerk aus UHFB Modular Truss System

made of UHPC

UHPC-Joint

Chord

Post Brace Chord

Tension element

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

Modulares Fachwerk aus UHFB Modular Truss System

made of UHPC
UHPC-Joint Chord Brace

Post

UHPC-Joint

Chord

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

Modular Truss System Knotenelement im Bauteilversuch

made of UHPC

Test Set-up for UHPC-joint

prestressing force (post)

tensile force (brace)

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

Modular Truss System made of UHPC

Influence of the Casting Technology
Technology 4

Tensile force [kN]

Technology 2 Technology 3 Technology 1

Casting Vibration point

Deformation in tensile force direction [mm]

Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue

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Graz University of Technology Institute for Structural Concrete

Modular Truss System made of UHPC

Numerical Simulations
Tensile force [kN]
Joint movement (test) Gap opening (test) Joint movement (simulation) Gap opening (simulation)

Displacement [mm]

Crack
ATENA software package Fracture-plastic model for concrete Interface element
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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

Modular Truss System made of UHPC

Numerical Simulations
Tensile stress in MN/m Tensile force in kN

Crack opening in mm

Displacement in mm

Tensile force in kN

Displacement in mm
Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue

Tensile force in kN

Displacement in mm

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Graz University of Technology Institute for Structural Concrete

Modular Truss System made of UHPC

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

Modular Truss System made of UHPC

UHPC-joint with Brace Inclination of 45

Prestressing force Tensile force [kN]

Friction failure

a) without reinforcement: Brittle failure of the UHPC-joint Load capacity is influenced by the fibre orientation and fibre distribution b) With reinforcement: Ductile failure of the friction between UHPC-joint and chord ( 0.65)

Failure of the UHPC-joint

(favorable fibre orientation and distribution)

Failure of the UHPC-joint

(unfavorable fibre orientation and distribution)

Deflection in tensile force direction [mm]

Friction can be increased up to 0.80

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue

Graz University of Technology Institute for Structural Concrete

Modular Truss System made of UHPC

Influence of the Production Tolerance

2,50 m

24 / 2 = 12 m

Chord b/h = 30/30 cm

Brace/ post b/h = 30/30 cm

Prestressing force:

P = 950 kN (upper chord) P = 950 kN (lower chord)

P = 100 kN (brace) P = 660 kN (post)

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue

Graz University of Technology Institute for Structural Concrete

Modular Truss System made of UHPC

Influence of the Production Tolerance

Upper chord Lower chord Post

Geometry axis Geometry axis Geometry axis Geometry axis

Short element Long element

Brace

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Graz University of Technology Institute for Structural Concrete

Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue

Modular Truss System made of UHPC

Influence of the Production Tolerance
Production tolerance L = 0,50 mm
-12.8

-6.56

Tensile stress due to production tolerance Upper chord + 3,16 MN/m Lower chord + 3,20 MN/m Brace + 2,19 MN/m Post + 2,10 MN/m

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

Geometry axis

ModularTruss Systemmade ofUHPC

Test Set-up for full scale test

F F 2,50 24,0
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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

Modular Truss System made of UHPC

Chord joint

F 2,20 24,0
Unbounded prestessing Chord joint
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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

F
Chord joint

ModularTruss Systemmade ofUHPC

F F Joint movement

Deflection

Opening chord joint

Force F [kN]

Force F [kN]

Chord joint opens

Joint movement deflection opening chord joint

Time t [min]
Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue

Deflection [mm]

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Graz University of Technology Institute for Structural Concrete

Modular Truss System made of UHPC

Failure of Truss System

lower chord F F

Upper chord

Tendon

Gap opening

2,20

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

Modular Truss System made of UHPC

space System
Connecting element

Joint Connecting element

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

TheGrtnerplatz Bridge,Germany
AHybridUHPCSteelBridge

Ekkehard FEHLING, Professor; University of Kassel,Germany Kai BUNJE, Civil Engineer, IBB Fehling+Jungmann, Kassel, Germany Michael SCHMIDT, Walter SCHREIBER 32
Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

TheGrtnerplatz Bridge

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

TheGrtnerplatz Bridge
Bending Test
Crack spacing << Crack width <<
STATIC EQUILIBRIUM

60

mm

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

TheGrtnerplatz Bridge
Shear / Tension Test

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

TheGrtnerplatz Bridge
Structural Analysis

SOFiSTiK software package Detailed considerations of construction sequence Effects of force redistributions due to creep (and shrinkage)
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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

TheGrtnerplatz Bridge
Precast UHPC elements for Bridge Decks

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

TheGrtnerplatz Bridge
Precast UHPC Element for upper chords

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

TheGrtnerplatz Bridge
Connecting Steel Truss and upper chord

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

TheGrtnerplatz Bridge
Transpotation to site

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

TheGrtnerplatz Bridge
Connecting of superstructur to continous beam

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

The Grtnerplatz Bridge

Assembling of bridge decks

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

The Grtnerplatz Bridge

Assembling of bridge decks

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

The Grtnerplatz Bridge

Assembling of handrails

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

TheWILDBridge,Austria UHPCforPrecastSegmentalArchStructure
Swivel with Method of Arch Erection

Road Bridge WILD - UHPFRC for a precast segmental arch structure 45

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

Erection and Elements

TheWILDBridge

bolt 80mm
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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

TheWILDBridge
Modelling, Analysis and Design
SLS/ULS Stress-strain relations for the design of cross-sections taken from German Sachstandsbericht SLS: Decompression in the arch and the segmental joints under characteristic loads in longitudinal direction adequate durability!!!! In transverse direction and in the knee-elements the tension stresses should be lower then the matrix strength under the characteristic loads ULS: Segments; stress-strain relation for tension and compression, segmental joints; only compression Gaping of the segmental joints is limited by one third of the height of the section Low shear force easily transferred in the remaining compression zone through friction Shear carrying capacity calculated according to German guideline Stahlfaserbeton 47
Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

1 : 1 Full Scale Test

Adapter

TheWILDBridge
Knee-segment Anchorage Element

Thin-walled Box Girder

Testing-jack Testing-wall

V+M

Steel Threadbars N+M N

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

TheWILDBridge

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

TheWILDBridge

-16 N [MN] -14 -12 -10 -8 -6 -4 -2 0 2 4 6 -1 0 1 2 3

1,33; -4,592 0,41; -3,662

N-M Interaction

ULS* M 6.255; -7.9674

Decompression
ULS 4.17; -5.312

internal forces springing resistance section (mean) internal forces knee element resistance section (design) load path failure prediction FEM

9 M [MNm] 11 10

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

TheWILDBridge

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

TheWILDBridge

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue Graz University of Technology Institute for Structural Concrete

UHPC Stair without Conventional Reinforcement

Comparison

Thickness h = 5,0 cm

Conventional stair Concrete volume Mass 0,850 m3 2.125 kg

UHPCstair 0,205 m3 515 kg

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Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue

Graz University of Technology Institute for Structural Concrete

Thanks for your kind attention!

Leipzig University Institute for Structural Concrete and Building Materials Prof. Dr.-Ing. habil. Nguyen Viet Tue

Graz University of Technology Institute for Structural Concrete