The Precast Show 2015
UHPC by
Architectural Precast UHPC Elements Presented by: Kelly Henry, M.Arch, LEED AP Lafarge North America 2
Outline •
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Definition Characteristics • Strength – Liquid Wall Project Example • Ductility – Villa Navarra Project Example • Durability – Rialto Hotel & Chillon Bridge Project Example • Aesthetics
What does a plant set up to work with UHPC look like – – – –
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Defining UHPC “Materials with a cement matrix & characteristic compressive strength in excess of 20,000 psi, possibly attaining 36,000 psi -- containing fibers in order to achieve ductile behavior under tension.” - SETRA (French Society of civil Engineers)
What is UHPC (Ultra High Performance Concrete)
Specific PPE Blender and Hopper Equipment Precision Mold Work, Casting and Curing R&D expectations
Accomplished Projects in UHPC – – – –
Dumbo Lofts – Brooklyn New York • Large Scale Panels with Fins MuCEM – Marseille France • Columns & Perforated Lattice façade Jean Bouin Stadium – Paris France • Perforated Roof and lattice walls Quick review of Other Projects
Concrete
UHPC
Compressive Strength 2,000 to 5,000 psi Flexural Strength ~ 570 psi Direct Tension ~ 450 psi Ductility None Abrasion Resistance Weak Impermeability Steady carbonation and penetration of chlorides.
Compressive Strength 25,000 to 30,000 psi Flexural Strength up to 6,000 psi Direct Tension up to 1,450 psi Ductility Greater capacity to deform and support flexural and tensile loads, even after initial cracking. Abrasion Resistance Similar to natural rock Impermeability Almost no carbonation or penetration of chlorides.
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Ultra-High Strength
UHPC at the micro scale Optimum Mix:
Modified Mix:
Typical Concrete
UHPC
Beams of Equal Load Carrying Capacity Pre-stressed Ductal
Aggrega ¼ to ¾ inch te Sand Cement High Shear
Sand 500 microns Cement Quartz Silica Fume Fibers Compact gradation
kg/lineal meter 140 lbs/lineal ft. 94 5
NPCA
Reinforced Concrete
Steel
Mass (weight) of Beams 112 467 75 313
530 355
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The Precast Show 2015
Ultra-High Strength
Ductility
Equivalent Stress (MPa)
Liquid Wall Project 50
® Ductal Ductal
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HPC 80 HPC
40 35 30 25 20 15
First Crack
10 5 0 0.0
0.5
1.0
1.5
Deflection (mm)
2.0
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2,000 lb car on a 1 ¼ -inch sheet of Ductal® 8
Durability
Ductility
Treat Island, Maine, USA
Villa Navarra Project
U.S Army Corp. of Engineers Long-term Exposure Site several samples of Ductal® installed in 1996
EXPOSURE since: 2013 •1590 freeze/thaw cycles, •11950 wet/dry cycles in saturated sea water •High abrasion from waves and ice •No sign of corrosion on rebar with only 10mm (3/8”) cover 9
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Aesthetics
Durability Rialto Hotel and Chillon Bridge
Replicates texture, form and shape very precisely. Finished products can be created in a range of colors and textures
UHPC Ductal® TX overlay
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NPCA
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The Precast Show 2015
Plant Set up – Getting Started
Plant Set up – Getting Started Personal Protection Equipment
Blenders / Mixers and Hoppers
Respirator (OV P100 rated) Puncture resistant gloves (working with steel fibers) Rubber gloves Protective eye wear Steel toed boots Hard hat
High Sheer Mixer (Vertical Shaft Preferred) Modifications to paddles and gates may be necessary Plan for utilizing only ½ the volume capacity of the mixer Typical concrete Hopper Modifications to the gate will help with dripping waste and better introduction of premix into mold work
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R&D
Casting Techniques Molds, Materials, and Casting
Capturing the understanding of working with UHPC The largest expense to starting up with UHPC is developing an in house understanding of how to work with it.
Mold / Casting Types Open Closed / Rotational Injection Displacement Vaccume Form Mold Materials Rubber / Polyeurathane Wood with Epoxy paint coating polished Steel Potential issues to be aware of Dehydration of premix Shrinkage Cracking Mold surface finish precision Other Casting / Curring Equipment Steam Cure Chamber Presstressing tables
The Key Assign a small group of workers to become experts on the material Work in small batches and ½ or ¼ size molds to understand reactions first QA/QC is a must to gain the same results from batch to batch Always monitor temperatures and or have reference samples ASK! 1 5
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Dumbo Lofts Projects
Brooklyn, New York Designer: Alloy Development Built: December 2014 Dimensions: panels 18’ wide x 11’ tall Fabricator: Gate
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The Precast Show 2015
Dumbo Lofts Dumbo Lofts
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Dumbo Lofts
Dumbo Lofts
Section Details
Plan Sections 2 1
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MuCEM Façade - Columns
MuCEM Marseille, France Designer: Rudy Riciotti Built: 2012 / 2013 Components in UHPC: Columns, Lattice Work, and Pedestrian Bridge Fabricator: Bonna Sabla Discussion: Two Façade Elements – Columns & Lattice Work
• 308 UHPC columns • Each column is 6 m (19.6 ft) to 9 m (29.5 ft) in height varying in diameter from 25cm (9.8 in) to 40 cm (15.7 in) • 20 basic types resulting in 80 different configurations
image by Lisa Riciotti
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NPCA
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The Precast Show 2015
MuCEM Façade - Columns
MuCEM Façade - Columns Floor to Column Transfer
Sequence of Column Installation
|May 2013|
|May 2013| 2 5
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MuCEM Façade - Columns
MuCEM Façade - Columns Floor Bean Configuration and Leave in Place Form
Sections
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MuCEM Façade - Lattice MuCEM Façade - Lattice
• 384 UHPC panels that cover a total area of 15,000m2 (49,213ft2). • Each panel is 18 m2 [194 ft2] or 6m (19.6 ft) x 3m (9.8 ft) • 7cm (2.7 in) thickness for the roof panels and 10 cm (3.9 in) thickness for wall panels
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NPCA
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The Precast Show 2015
Jean Bouin Stadium
Jean Bouin Stadium Paris, France Designer: Rudy Ricciotti Built: 2012 / 2013 Dimensions: Panels 9m x 2.5m x 4.5cm (average) Fabricator: Bonna Sabla Discussion: Perforated Roof & Lattice Work
Perforated Roof
image by Lisa Riciotti
• 1,800 perforated panels with glass inserts • Triangular panels are 8 to 9 m (26 to 29 ft) long, 2 to 2.5 m (6.5 to 8 ft) wide • 3.5 to 4.5 cm (1 to 2 in) thick • 12,000 m² (129,100 ft2) waterproof roof • 20% to 27% Perforated glass space
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Jean Bouin Stadium
Jean Bouin Stadium Perforated Roof
Lattice Facade
Casting Photo Bonna Sabla
image by Lafarge
• 1,800 perforated panels with glass inserts • Triangular panels 9 m (29 ft ) long x 2.5 m (8 ft) wide and 11 cm (4”) thick •11,000 m² (118,400 ft2) façade • 51% open perforation
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Jean Bouin Stadium
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Other Projects
Lattice Facade
image by Lafarge
• 1,800 perforated panels with glass inserts • Triangular panels 9 m (29 ft ) long x 2.5 m (8 ft) wide and 11 cm (4”) thick •11,000 m² (118,400 ft2) façade • 51% open perforation
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NPCA
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The Precast Show 2015
G8WAY Pavilion - Panels
G8WAY Pavilion
Site Plan by Davis Brody Bond
Washington, DC Designer: Davis Brody Bond Built: 2013 Components in UHPC: Façade / Roofing Panels Fabricator: Gate Precast
Drawing by Davis Brody Bond
• 181 UHPC panels that cover a total area of 2,884 m2 (9,462 ft2). • Each panel averages15.9 m2 [52 ft2]. • Range between 2.1 m (7 ft) and 4.3 m (14 ft) in length, with a gradual dimensional change in width from 2.7 m (9 ft) to 61 cm (2 ft) over the entire structure. • 4.4 cm (1.75 in) thickness
image by Davis Brody Bond
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G8WAY Pavilion - Panels
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Rotman School of Management
Open Air Market & Balcony
(expansion)
Toronto, Canada Designer: KPMB Architects Built: 2012 Dimensions: panels 0.5 m to 1.0 m wide x 3.5 m to 5.3 m high x 2.5cm thick Fabricator: Armtech
image by Davis Brody Bond
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Rotman School of Management
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The Atrium Victoria, Canada Designer: Franc D’Ambrosio Built: 2010 Dimensions: panels 1.3m x 1.3m x 1.7cm Fabricator: Lafarge Precast
(expansion)
2011 PCI Design Award
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NPCA
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The Precast Show 2015
Louis Vuitton
The Atrium
Miami, USA Designer: Peter Marino Built: 2012 / 2013 Dimensions: 2m x 1.7m x 25mm (varies) Fabricator: DEX industries
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Crèche Pierre Budin
Louis Vuitton
Paris, France Designer: Emmanuel Combarel & Dominique Marrec Built: 2012 Dimensions: panels 1.6m x 3.8m x 3.5cm (varies) Fabricator: Bonna Sabla
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Crèche Pierre Budin
Architectural Precast UHPC Elements Presented by: Kelly Henry, M.Arch, LEED AP Lafarge North America 4 7
NPCA
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