Structural design of precast segmental lining reinforced by steel fibres

Abstract

Dubai Municipality awarded to Porr Besix JV the Project for the Main Tunnel component of the Deep Storm Water System. The tunnel will collect both rainwater and groundwater from approximately 500 sq. km and transfer the captured flow to the sea. The Design Builder JV selected COWI as Designer of the entire Project and IC Consultant as Design Checker for the Tunnels. The Project includes approximately 10.3 km of 10‐meter‐inside diameter tunnel in rock, three construction shafts and one drop shaft. The main tunnel will convey stormwater and groundwater flows from the EXPO 2020 area near the intersection of Sheikh Mohammed Bin Zayed Road and Jebal Ali Lehbab Road to the sea close to the EGA facility. The tunnel will follow beneath the road easement along Jebal Ali Lehbab Road and along Sheikh Zayed Road and continue to the pumping station. The tunnel traversed through the Barzaman and Fars formation with an overburden of 33 m with maximum water pressure of 4.4 bar and was excavated by EPB TBMs. This project is characterized by its dimensions with an internal diameter of 10 m and 350 mm of segment thickness, and by the use of steel fibre reinforced concrete in the precast segmental lining. The use of fibres aims to reduce the CO2 footprint obtaining an optimized design from the environmental point of view. These facts are associated to a complex design of precast segments, in order to ensure their structural competence and their integrity according to the durability requirements, under large thrust forces (temporary loads) and permanent load. Hence, considering such complexities, the structural design has been carried out producing a 3D structural model by means of a sophisticated FEM structural software. Results of the model allow to identify areas of the segment where spalling and bursting stresses are generated along circumferential joints and maximum value of those stresses in the temporary load cases. Moreover, a structural design verification of the segment has been undertaken considering the contribution of steel fibres class 4c, as it is set up in the FIB model code, aiming to ensure that the precast segments are structurally competent and fulfil the durability requirements of the Project. The article details the design approach and the independent checker design verification approach. The experience gained during construction is also reported, describing challenging aspects of the Tunnel execution and an analysis of the lining damages.