Effect of uniaxial loading on the spalling of concrete panels for Melbourne's Metro Tunnel Project

Abstract

The Metro Tunnel is a Victorian Government funded infrastructure project which will create a new end‐to‐end rail line from Sunbury in the west to Cranbourne/Pakenham in the south east, with bigger and better trains, next generation signaling technology and five new underground stations. This article provides a detailed summary of the structural fire testing requirements for the platform tunnel side wall and arch lining in the Metro Tunnel's State Library and Town Hall stations. Contrasted to building fires, tunnel fires are more significant within a few minutes due to the confined space which can cause concrete spalling and jeopardize the bearing capacity of the tunnel, which is a significant concern to designers. The catastrophic European tunnel fire events in 1999 and 2001 led to the development of innovative regulations and recommendations, including guidelines endorsed by the European Federation of National (EFNARC 132F r3:2006) and Efectis R0695:2020. This paper explains the methodology taken to design the fire rated concrete test for the platform tunnel side wall and arch lining in the State Library and Town Hall stations of Melbourne's Metro Tunnel Project for structural stability for the period of a serious fire event. For the first time, uniaxial loading (500T) was applied to five large‐scale flat concrete panels (1800 × 1800 × 400 mm) which are normally unloaded during fire exposure and exposed to the RABT ZTV (rail) fire curve. The first testing program investigated the influence of polypropylene dosage in the concrete mix design and its effect on the magnitude and severity of concrete spalling. The results indicated that the recommended 2.0 kg/m3 polypropylene dosage requirement as specified by Eurocode is conservative. Concrete mix designs with a stable aggregate and the correct curing regime can mitigate spalling at significantly lower polypropylene dosage rates. The water pooling effect was evident during the fire testing and the surface cracking that developed was vertical to the surface, allowing for the release of the pore water pressure build‐up.