Tunnelling and Ground Conditions, Abdel Salam (ed.

) 1994 Balkema, Rotterdam, ISBN 90 5410 363 9

Steel fibre reinforced concrete (SFRC) for tunnel linings: A technical
approach
D.Moyson
N. V. Beknert, Belgium
ABSTRACT: Tunnel linings are loaded under the combined action of normal forces and bending moments. In this
paper it is shown that the bearing capacity of plain concrete can substantially be enhanced by the addition of steel
fibres. The steel fibres provide the concrete an improved bending behaviour resulting in a better bearing capacity,
especially for large eccentricities. This improved behaviour together with the practical advantages of the use of steel
fibre reinforced concrete (SFRC) makes this composite material particularly interesting for tunnel linings.
1 INTRODUCTION
SFRC is not a new material in the tunnelling world.
For several years, steel fibres are commonly used for
shotcrete, having several advantages (ref. 1):
I. Technical: the addition of steel fibres provides the
shotcrete an important degree of ductility. This
ductility results in an improved loading capacity of
steel fibre reinforced shotcreted (SFRS) shells
compared to plain shotcreted ones. The technical
performances of SFRS shells are comparable to
conventional reinforced shotcreted shells.
2. Practical: the steel fibres are easy to add to the
concrete aggregates. In ,comparison to conventional
mesh a lot oftime and labour can be saved.
3. Cost: the shorter execution time and savings in
labour costs makes SFRS a competitive alternative.
Since shortly, an increasing growth of SFRC has also
been established in the domain of prefabricated tunnel
segments and tunnel linings casted in situ. The same
practical and technical advantages as for shotcrete are
here obtained.
In what follows the bearing capacity of steel fibre
reinforced tunnel linings is discussed. In paragraph 2,
the toughness ratio of SFRC will be defined. This
toughness ratio is the essential property of SFRC and
represents the effect of the fibre reinforcement. Based
upon the toughness ratio and the stress-strain beha-
viour of plain concrete, the stress-strain behaviour of
SFRC is determined in paragraph 3. By integration of
the different stress distribution lines, corresponding to
the different considered deformation lines, the bearing
capacity in terms of bending moments and normal for-
ces are calculated for a specific cross section. This is
done in paragraph 4. In paragraph 5, the design of a
SFRC tunnel lining is established for a specific load
case according to the method of Bugieva.
2 THE TOUGHNESS OF SFRC
The basic properties of the composite material steel
fibre reinforced concrete (SFRC) are described in an
increasing number of normative publications. In
general they all characterise SFRC by two groups of
parameters : flexural strength and flexural toughness.
Flexural strength is expressed at first crack f., this
is when the pure elastic limit of the material is
reached. From this point on, the stress-strain
relationship is not linear. A second strength parameter
is the modulus of rupture or the ultimate flexural
strength f.. Ultimate flexural strength and flexural
strength at first crack are not different for plain
concrete nor for SFRC with fibre contents up to 40
kg/m3.
Flexural strength at first crack depends on concrete
characteristics and is not influenced by fibre content.
Ultimate flexural strength may increase compared to
plain concrete at fibre contents ;;:: 40 kg/m3,
depending mainly on the length/diameter ratio or
aspect ratio of the fibre. An increase of ca. 15 % is
achieved using 40 kg/m3 of r a m i x ~ ZC 50./50 fibre.
The r a m i x ~ ZC 50/.50 fibre is a steel wire drawn
fibre with a length of 50 mm and a diameter of .50
mm and is hooked at both ends, see figure I.
673
50 nun
figure 1: Dramix< ZC 50/.50
"C
Cll
.Q


d=0.5mm
deflection
figure 2: Typical load-deflection curve for SFRC
The characteristics of SFRC are measured by means
of third-point loading tests, where the beam
parameters are fixed in each standard or
recommendation. Figure 2 shows a typical load-
deflection curve for a SFRC beam reinforced with
steel wire drawn fibres with hooked ends.
Flexural toughness is expressed in very different-
ways. We find definitions of parameters that express
absolute toughness, as equivalent flexural strength f .
This absolute toughness is the average post-crack
strength measured on a test beam under bending up to
a defined deflection.
Relative toughness R. can be expressed by relating
the average post-crack strength to the flexural strength
at first crack, thus creating a toughness rating
expressing against what percentage of loading still can
be resisted after concrete failure.
In this article we will use the flexural strength and
the toughness rating according to the Japanese
standards (ref. 2). The average post crack strength or
equivalent flexural strength f. is calculated elastically
by dividing the total absorbed energy D during the
test (till a deflection of 1/150 of the span length) by
the deflection o, taking into account the dimensions of
the beam (1).
f. D.l (Nfmm
2
) (1)
= a.b.h
2
where
D = total absorbed energy during the test (Nmm)
I = span length (mm)
o = maximal deflection (mm)
b = width of the beam (mm)
h = height of the beam (mm)
The equivalent strength f. is the essential value
which characterises the effect of the steel fibre
reinforcement. Research has shown that the equi-
valent flexural strength, measured on beams according
to the Japanese standards, varies as a function of the
concrete flexural strength. On the other hand, it has
been shown that the relative toughness R.. for
concrete qualities up to 50 N/mm2, remains constant
and is only dependent on the fibre type and dosage.
The relative toughness R. can be expressed as a
percentage of the first crack flexural strength f. of the
plain concrete (2).
R = 100 f, (%) (2)
fo
R. is defined as the ratio between the ultimate
flexural strength of SFRC and the first crack strength
of the plain concrete (3).
R,. = f. (3)
fo
In the figure 3, the toughness ratio R. as well as the
modulus of rupture ratio R. are expressed as a
function of the dosage for the Dramix< ZC 50/.50.
The relation is based upon a large amount of tests _
performed by Bekaert and extern laboratories (ref. 3).
140
120
;- 100
Ru
80
0
or4 80
.,
------ Re
.--
..

40
20
0
0 10 20 30 40 50 80
dosaqe Dramix zc 50/.50 (kqfm3)
674
figure 3: R. and R. as a function of the dosage of
Dramix< ZC 50/.50
From the figure one can see that for a dosage of
50 kg/m3 of Dramix ZC 50/.50 fibres, the ultimate
strength of the concrete is increased by 20 %, while
the equivalent strength is 94 % of the first crack
strength of the concrete.
Based on these R. values, the equivalent flexural
strength values for all concretes up to 50 N/mm2, and
all fibres types and dosages can easily be calculated.
Example : Is the concrete giving a 5,0 MPa flexural
strength, than the design value of this concrete with
steel fibres giving a rating of 90 % will be 4,5 MPa.
These 90 % is achieved (according to the diagram)
using 45 kg/m3 of ZC 50/.50.
3 STRESS-STRAIN RELATIONSHIP FOR SFRC
The equivalent flexural strength f., which is the
average post crack flexural strength of the SFRC, is
deduced from the total absorbed energy (I) assuming
a linear variation of the stresses over the height of the
element as shown in figure 4a.
f.
figure 4a: elastic stress distribution
figure 4b: plastic stress distribution
However, in reality the SFRC does not behave in the
elastic uncracked state, but the concrete is cracked and
the stresses are no more linearly distributed across the
cross-section. The plastic stress distribution along the
cross-section, corresponding to the average post crack
resistance of the test specimen, can simplified be
drawn as in figure 4b.
The compression zone can clearly be distinguished
from the tensile zone. The width of the compression
zone is approximately 0.1 times the width of the
tensile zone. The compressive stresses vary linearly,
while the tensile stresses are constant. The tensile
stress should be considered as a post crack tensile
strength or equivalent tensile strength f .. provided by
the effect of the fibre reinforcement.
Using figures 4a and 4b as a basis, the value of the
post-crack tensile strength f .. can be determined under
the condition that the flexural moment capacity is the
same for the plastic as for the elastic stress
distribution (4).
b. h
2
/.,. b 0 h . 0,9 . 0,5 . h = ' -6-
!., = 0,37 . f. (4)
According to (2) the equivalent tensile strength can
also be written as a function of the ultimate flexural
strength of the plain concrete and the toughness ratio
R,. (5)
R.
!., = 0.37 . - . /
0
(5)
100
This equivalent tensile strength characterises the effect
of the fibre reinforcement. This value is essential,
since it represents the tensile strength that can be
taken up by the concrete thanks to the addition of steel
fibres. Research (ref. 4) has shown that this average
strength can effectively be provided by the steel fibres
for deformations up to 10 %o.
The addition of steel fibres does not only improve
the tensile behaviour of the concrete, the behaviour
under compression is also positively modified
compared to plain concrete. Although the steel fibres
does not enhance the compressive strength of the plain
concrete, they do improve the maximal strain under
compression. Thanks to the addition of steel fibres,
the behaviour of the concrete under compression is
modified from a brittle behaviour into a ductile
behaviour, providing a larger strain capacity. In (ref.
4) a maximum strain of 5 %o in compression is
considered for SFRC, instead of 3.5 %o for plain
concrete.
Based upon the above mentioned characteristics for
SFRC, the stress-strain behaviour of plain concrete
can now be modified. In figure 5, the characteristic
stress-strain behaviour for the plain concrete is drawn.
675
The characteristic stress-strain behaviour is conform
to the actual standards.
10
strain (%o)
---- char. stress-strain
relation plain
concrete
8 6 4 2
figure 5: Characteristic stress-strain behaviour for
plain concrete
The characteristic stress-strain behaviour for SFRC
is drawn in figure 6.
---- Design stress-
strain relation
SFRC
::50 -------
l-40./
i ,'
I I
t ~
- - - - - char. stress-strain f /.
relation SFRC [
'-:-----::------:::--------::----' H10
10 8 6 z j
9
2
strain (%o)
i
" 10
figure 6: Characteristic and design stress-strain
behaviour for SFRC
The maximum tensile strength is equal to the
equivalent tensile strength f., as defined above and is
maintained till a deformation of 10 %o. The stress-
strain relation in the elastic range is the same as in
compression, apart of the sign. The stress-strain
behaviour in compression is equal to the one for plain
concrete, except for the maximum strain which is 5
%o instead of 3.5 %o.
In figure 6 the design stress-strain behaviour for
SFRC is also drawn. The design stress-strain
behaviour can be deduced from the characteristic
stress-strain curves by taking into account a safety
factor in tension and in compression. In compression
a safety factor 'Y. of 1.4 is taken. In tension a safety
factor 'Y is taken which is a function of the toughness
ratio. For a 100 % are more tough material a safety
factor of 1.15 is considered, this is the same value as
for steel. For a 0 % tough material a safety factor of
1.4 is considered as for plain concrete (6).
R
y, = min ( 1 ; 1,4 ~ ( 1,15 - 1,4 ) . 1 ~ ) (6)
4 THE BEARING CAPACITY OF SFRC
In figure 7 the different deformation conditions for
SFRC, which should be considered according to the
plastic theory, are drawn.
lc2 O"t.. _,cl
~ ~ .. :
figure 7: Deformation lines for SFRC
To each deformation line corresponds a specitic
stress distribution. For each deformation line, the
corresponding bearing moment M and normal force N
can easily be determined by integration of the stresses
over the cross-section.
In figure 8, the bearing normal forces and moments
of a section with a thickness of 300 mm is represented
for plain concrete and SFRC. Hereby e/d represents
the ratio between the eccentricity e and the thickness
d of the element. The eccentricity is the ratio between
M and N and is expressed in mm. The characteristics
for both concretes are exposed in table I.
table I: Characteristics of plain concrete and SFRC
plain concrete
char. compressive strength 50 Nlmm
2
safety factor 1.4
maximum strain -3.5 %o
SFRC
char. compressive strength 50 N/mm
2
safety factor 1.4
maximum strain -5 %o
char. flexural strength 5 N/111In'
50 kg/m3 Dramix ZC 50/.50
toughness ratio R. 94%
equiv. tensile strength 1.7 N/mm
2
safety factor 1.17
maximum strain 10 %o
676
12000
10000
E
.....
z
8000

.,

6000
...
ii
4000
E
0
z
2000
0
0
zone 1
50 kglrn3 zc
50/.50
-----no fibers
zone 2
zone 3
200 400 600
Moment (kNmfm)
figure 8: Bearing capacity of a plain and SFRC
section
From the figure one can distinguish three zones :
zone 1, 2 and 3 which corresponds respectively to
small, middle and large eccentricities.
For zone 1 the bearing capacity for SFRC is the
same as for plain concrete. The whole section is
loaded under compression and the maximum com-
pression stress is not influenced by the addition of
steel fibres.
In zone 2 an increasement in load bearing capacity can
be seen by the addition of steelfibres. The increa-
sement varies from a value of 0 % for the smallest
eccentricity till a value of oo for the largest
eccentricity, since for this eccentricity the plain
concrete shows no bearing capacity. In zone 3 the
bearing capacity of plain concrete remains 0, while
for SFRC important forces can be taken up.
The increasement of loadbearing capacity by the
additional steelfibres varies thus as a function of the
eccentricity. For large eccentricities the largest en-
hancements are obtained.
5 DESIGN OF TUNNEL LININGS
The method which will be discussed here to calculate
the forces acting on the segmental linings is the
method of Bugieva (ref. 5). This method takes into
consideration the interaction of the tunnel lining and
the surrounding rock. The method developed by
Bugieva is based on the analysis of the distribution of
bending moments and normal forces in the lining
which is supporting a uniform vertical load and is
transferring the load onto the surrounding rock in an
elastic manner. Figure 9 shows the assumed dis-
tribution of elastic reactions around the rock.
figure 9: Elastic reaction around the rock according to
Bugieva
The calculation of the elastic reaction forces in the
rock, which are due to the deformation of the lining,
makes use of the coefficient of ground reaction. The
bending moments and normal forces in a circular
lining are the functions of the coefficient of ground
reaction and the rigidity of the tunnel lining. An
increase in the coefficient of ground reaction or in the
flexibility of the tunnel lining will result in a decrease
in the acting forces in the cross section of the tunnel.
677
The bending moments M and normal forces N acting
on the cross section of a tunnel lining can be
calculated by the following formulas of Bugieva (1 a
& b).
M = p . R
2
.(A + B + 2 . C . n) (N.mm) (la)
N = p . R .( D + F + 2 . G . n ) (N) (7b)
where
p
=
R
=
I
=
E
=
k
=
uniform vertical load (N/mrn2)
radius (mrn)
moment of inertia (mm4)
elasticity modulus (N/mm2)
coefficient of ground reaction of surrounding
rock (N/mm3)
and (8 a & b)
1
n = -----
m
m + 0,06416
E. I
R
4
.k
(Sa)
(8b)
The values for A,B,C,D and Fare exposed in table 2.
table 2: Values for A,B,C,D and F
A B c D F G
a=O 0.01628 o.o8n -0.0070 0.2122 -0.2122 0.02100
W4 -0.0250 0.0250 -0.00084 0.1500 0.3500 0.1485
W2 -0.1250 -0.1250 0.00825 0.0000 1.0000 0.0057
3n/4 0.0250 -0.0250 0.00022 -0.1500 0.9000 0.01380
n o.osn 0.1628 -0.00837 -0.2122 0.7122 0.02240
Figure lO shows a typical distribution of the
moments along the circumference.
figure 10: Distribution of the moments along the
circumference
Example
The maximal uniform vertical load p acting on the
crown of the tunnel section for a very blocky and
seamy rock is given by Terzaghi (ref. 6) (9) :
p = 2 - 1,1 _ R _ y, (N/m2) (9)
where
R = radius of the tunnel (m)
"f, = unit weight of the rock (N/m3)
For R = 3 m, and for "f, = 25 000 N/m3:
p = 165 000 N/m2.
The coefficient of ground reaction of the
surrounding rock can be written as (10) :
E,
k = ---'---
R(1+v,)
(10)
where
v, = Poisson's ratio for rock
E, = Modulus of elasticity (N/mm2)
For v,=0.25, E,= lOE3 N/mm2 and R=3000 mm:
k = 0.27 N/mm3
The bending moments and normal forces can be
calculated according to (7 a & b) where:
R=3m
I = 2.25 10E9 mrn4 (thickness d=300 mrn)
E = 20 000 N/mm2
k = 0.27 N/mrn3
m = 0.002058
n = 15.11
The values for M, N and e/d are represented in table
3.
table 3: Acting moments and normal forces according
to Bugieva
Cl M N e/d
(kNrnlm) (kN)
a=O 57.2 314 0.61
II/4 37.7 470 0.27
II/4 1.2 581 0.01
31I/4 9.8 578 0.06
II 4.1 582 0.02
The different values of M and N are also represented
in figure 11.
In figure 11, the bearing moments and normal forces
for SFRC as well as for plain concrete are also
represented.
From the figure one can see that the loads, acting on
a section at the crown, exceeds the bearing capacity of
the plain elements. The plain elements are thus not
appropriate. The steel fibre reinforced elements on the
other hand have a bearing capacity which is several
times higher than the acting loads. In table 4 the ratio
between the bearing capacity and the acting forces are
exposed for the plain as well as for the SFRC
678
,....
3000 1
---50 kg/m3 ZC
50/.50
5 -----no fibers
2500 t
8 2000 t
r:::I_ nun .,;, ..
z o: r
0 so 100 1SO
Moment (kNmlm)
figure 11: Acting anO bearing moments and normal
forces
200
elements. From the table one can see that the bearing
capacity of the SFRC elements amounts to 3.6 times
the acting loads, for plain concrete that value is only
0.7. In other words by addition of 50 kg/m3 of
ZC 50/.50 steel fibres, the bearing capacity
in the most critical section is improved by a factor of
5 (=3.6/0.7).
table 4: The ratio between the bearing capacity and
the acting forces
a plain concrete SFRC
0 0.7 3.6
"'4
10.5 11.0
"'2
18.3 18.3
3"/4
17.4 17.4
"
14.1 14.1
6 CONCLUSIONS
The bearing capacity of plain concrete can impor-
tantly be enhanced by the addition of steel fibres. The
steel fibres provide the concrete an improved bending
behaviour resulting in a better bearing capacity
especially for large eccentricities.
For a specific case it has been shown that the
bearing capacity by addition of 50 kg/m3 of Dramix!JI
ZC 50/.50 steel fibres, in the most critical section of
the tunnel lining, is enhanced by a factor of 5.
This improved behaviour together with the practical
advantages of the use of steel fibre reinforced concrete
makes this composite material particularly interesting
for tunnel linings.
REFERENCES
1. "Tunnelling the world",
M. Vandewalle, 1990.
2. JSLE-SF 1 to 7 : "Method of tests
for steel fibre reinforced concrete", Concrete
Library of the Japanese Society of Civil
Engineers, June 1984.
3. "Steel fibre concrete under flexural load",
D. Nemegeer, 1993.
4. "Zur Qualitatspriifung von Stahlfaserbeton fiir
Tunnelschalen mit Biegezugbeanspruchung",
J. Dietrich, Bochum, 1992.
5. "Traite de construction des tunnels", K. Szechy,
1970
6. "Handbuch des Tunnel und Stallenbaus", B.
Maid!, 1988
679