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No. 35.

12 September 2012 Wet Mix Precast

Sika at Work

Tunnel Segment Production


with SikaRapid
Life Cycle Impact Assessment
Tunnel Segment Production with SikaRapid
Projects Special requirements
Modern tunneling methods in weak rock conditions demand concrete The newly demolded segments must be cured by covering or spray-
segments which are immediately load bearing as linings to the fully ex- ing with a curing agent such as Sika Antisol. However, to obtain a
cavated tunnel section. Precast concrete units called tunnel segments combination of maximum durability in variable ground conditions and
or Tbbings perform this function. optimum curing, the segment surfaces are treated more often with a
special SikaGard protective coating immediately after striking. With
this additional protection against chemical attack, extremely durable
concrete surfaces are achieved.
Requirements
Due to the large numbers required and heavyweight (up to several met-
ric tons each), tunnel segments are almost always produced close to
the tunnel portal in specially installed precasting facilities. They have to
meet high accuracy specifications. Heavy steel formwork is therefore
the norm. Because striking takes place after only 5 6 hours and the
concrete must already have a compressive strength of >15 N/mm, ac-
celerated strength development is essential. There are several methods
for this. In the autoclave (heat backflow) process, the concrete is heat-
ed to 28 30 C during mixing (with hot water or steam), placed in the
form and finished. It is then heated for about 5 hours in an autoclave
at 50 60 C to obtain the necessary strength for formwork removal.
Sika Solutions
Improved concrete hardening in tunnel segment production Exemplary heating cycles with and without application of SikaRapid
and the resulting concrete temperature with the corresponding early
Tunnel segment production combines the challenge of realization of strength can be seen in the graphics below. With the application of
a specified high early strength and fulfilment of highest requirements SikaRapid the hardening process of the concrete was optimized,
regarding durability. Strength development is usually secured by utiliza- with the result that approximately 150 minutes of heating could be
tion of heat or steam curing which can be contradictory to durability if eliminated. At the same time the early and final strength requirements
the concrete core temperature is too high. The concrete performance were attained. Moreover the durability of the tunnel segments was
regarding early strength and durability can be enhanced with the improved as the concrete peak temperature was limited to less than
SikaRapid technology. 60 C.

150 min. less heating

25 C lower concrete temperature


100 Specimens produced without SikaRapid-1
Specimens produced with SikaRapid-1(150 min. less heating)
Concrete temperature development [C]

80 80

Concrete compressive strength [MPa]


62 62,6
60 60

40 40

Heating without SikaRapid-1 25,8 25,4


20 Concrete temperature without SikaRapid-1 20
Heating with SikaRapid-1
Concrete temperature with SikaRapid-1

0 60 120 180 240 300 360 0


6 hours 28 days 6 hours 28 days
Time [min]

Heating development and development of concrete temperature Comparison of compressive strength

Life Cycle Impact Assessment


Life Cycle Impact Assessment of two concrete systems to compare the impact in steam reduction with SikaRapid-1

Concrete Systems Components

Cement Additive Sand / Gravel Water Concrete Admixture


Steam curing time: 150 min.
High early strength concrete CEM I 52,5 900 kg/m w/c-ratio = 0.42 Sika ViscoCrete 20 HE
with SikaRapid 350 kg/m 1030 kg/m 142 liter SikaRapid-1
Steam curing time: 300 min.
High early strength concrete CEM I 52,5 900 kg/m w/c-ratio = 0.42 Sika ViscoCrete 20 HE
350 kg/m 1030 kg/m 142 liter

Definition Life Cycle Impact Assessment


Cradle-to-Gate, including packaging of the Concrete Admixtures
(IBC container) and production of steam
Functional Unit: 1 m concrete
Modeled in the software GaBi, from PE-International accorfing to the
ISO 14040 series

Saving potential Tunnel Segment project


Length: 5 km / Diameter: 14 m / Thickness elements: 30 cm

Energy savings equivalent to


687000 liter oil

Carbon savings equivalent to


1.50 Mio km (truck 15 to)
Life Cycle Impact Assessment
Invironmantal impacts and resource inputs

Cumulative Energy Demand



Cement
Water/Gravel/Sand
Concrete Admixture
Steam Production
[MJ]
Total amount of primary energy from High early strength Concrete
renewable and non-renewable resources

High early strength Concrete


(with SikaRapid)

0 500 1000 1500 2000 2500 3000 3500

Cumulative Energy Demand [MJ] for 1m concrete

Global Warming Potential



Cement
Water/Gravel/Sand
Concrete Admixture
Steam Production
[kg CO2-eq.], CML 2001
Potential contribution to climate change High early strength Concrete
due to greenhouse gases emission
High early strength Concrete
(with SikaRapid)

0 50 100 150 200 250 300 350 400

Global Warming Potential (GWP 100 years) [kg CO2-eq.] for 1m concrete

Input Water [m3]


Concrete Mix
Consumption of water Steam
(for the concrete production)
High early strength Concrete

High early strength Concrete


(with SikaRapid)

0 0.05 0.1 0.15 0.2 0.25 0.3


Input Water [m ] for 1m concrete

Eco Indicator 99 [points]



Cement
Water/Gravel/Sand
Concrete Admixture
Steam Production
Impact score which takes into account sev-
eral damage categories (to mineral and fossil High early strength Concrete
resources, to ecosystem quality and to human
health), which are then normalized and added
High early strength Concrete
to give a dimensionless result (with SikaRapid)

0 1 2 3 4 5 6 7
Eco Indicator 99 [points] for 1m concrete
Sika Services AG / BU Concrete / SAW / 09.2012 / CMS / ID: 00000

Sika Services AG Our most current General Sales Conditions shall apply.
Corporate Business Unit Concrete Please consult the Product Data Sheet prior to any use and
Tffenwies 16 processing.
CH-8048 Zurich
Switzerland
Phone +41 58 436 40 40
Fax +41 58 436 41 50
www.sika.com

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