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Sprayed sUstainable PErmanent Robotized CONcrete tunnel lining

Alternativ tittel: Sprøytebetong for permanent tunnelsikring – bærekraftig og automatisert

Tildelt: kr 14,0 mill.

SUPERCON har nå kommet til veis ende. I løpet av de fire årene prosjektet har vart har vi vært involvert i og kjørt skalerte og fullskala tester på utvalgte sprøytebetongresepter en rekke steder. Det er blitt testet en rekke resepter for en oppdatert sprøytebetong som gir de ønskede effekter; fortsatt beholde en viss tidligfasthet, samme langtidsstyrke og samtidige med redusert rissdannelse ved herding. Prosjektet gjennomførte en slutt-test på Hestnes-tunnelen ved Mjøsa der endelige resepter ble avprøvet. Det kan vise seg at en vanntett sprøytebetong er utenfor rekkevidde, men at man klarer å etablere sprøytebetong med betydelig mindre rissdannelse og nært vanntett, eller som vi har kalt det 'functional dry'. I tunnelsammenheng kan dette være mer riktig mål for arbeidet enn å etablere en vanntett sprøytebetong. Det jobbes nå med en avsluttende rapport fra prosjektet som vil bli lagt ut og gjøres tilgjengelig for tunnelbransjen. Den vil primært bli laget for det norske markedet og derfor utgis i norsk språkdrakt. Det er absolutt et behov for å møte de utfordringer klimapolitikerne fremmer på generell basis, og en sprøytebetong som har et lavere sement-innhold, slik vi har kommet ferm til i vår forskning er ett bidrag til disse bestrebelesene.

The project has increased the understanding and competence on how sprayed concrete structurally behaves, how its water tigthness appears and the potential to become watertight. A lot of testing has been performed for the sake of identifying a mix design that reduces the shrinkage cracking, reduces the sement content, reduces the CO2-emission, reduces the permeability and finally becomes as water tight as practically possible. Still, the mix design must produce a sprayed concrete mix that remains to be pumpable and sprayable. The project has reached a level where it can be concluded that all these goals have been met, except that making a water tight solution may not be achievable. The project has decided that it can be concluded that a sprayed concrete mix design which is producing a solution that is functionally dry has been acj\hieved.

The SUPERCON proposal is a counterweight to a trend in Norwegian tunnelling projects towards adopting the "European way" of tunnelling, with in-situ casting or pre-cast segment lining. The European Way requires high concrete volumes, resulting in increased materials consumption and costs, with negative environmental loads and costs. SUPERCON aims at producing thin sprayed concrete layers with the quality to act as temporary support during construction and permanent lining over the service life of tunnels. The primary objective is to provide the tunnelling industry with the required knowledge to produce Sprayed sUstainable Permanent Robotized CONncrete tunnel linings, which meet modern demands for functionality, sustainability and eco-friendliness in new infrastructure projects, such as Ringeriksbanen and The Ferry-free E39, without compromising the environment. Improvement of robustness and durability shall reduce cost and environmental loads for the public infrastructure owners. This multidisciplinary project will focus on complex challenges involving structural-, civil production- and geological engineering. Theoretical, numerical modelling, laboratory and full-scale investigations are planned to study the decisive parameters and processes that control technical quality, as well as sustainability of the lining. The most critical R&D challenges of the project are to: 1) compose sustainable materials fulfilling also technical requirements, 2) establish measurement methods to quantify key parameters such as spray-ability, 3) model and design crack-free thin shell solutions, 4) measure lining permeability and durability, 5) investigate the environmental performance in varying scenarios by LCA inventory and, 6) bring the knowledge to the industry to make it competitive and profitable. SUPERCON includes; NTNU, SINTEF, NGI, AMV, BASF, Bekaert Maccaferri, Bever Control, Entreprenørservice, Elkem, Norcem, SWECO, Veidekke, Wacker, Bane Nor, Nye Veier, SVV

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