Application of High-Strength and 1

High-Performance Fiber Reinforced

Concrete to Precast Elements
International Seminar on Design and Construction
of Precast Structures in Seismic Regions
October 2015, Chile

Hideki Kimura
Senior Chief Researcher, Dr.Eng
R & D Institute
Takenaka Corporation
Contents of todays speech
2

1. Introduction
2. Classification of FRCC
3. Application of Fiber Reinforced HSC
3.1 High Rise Building Columns
3.2 Slender Columns
3.3 B/C Joint in Precast Systems
4. Application of UFC
4.1 Bridge Precast Elements
4.2 Offshore Structures
4.3 Precast Plates or Forms
5. Application of HPFRCC (ECC)
5.1 Precast Coupling Beams in Buildings
5.2 Retrofit Projects
 Tokyo Scene
3

1. Introduction

Tukuda island, Tokyo water front

 4

Evolution of
High Strength Concrete
is
Evolution of
High Rise RC buildings
Evolution of high-rise RC buildings
5

RCResponse controled structures 68 buildings

RCSeismic isolation structures 75 buildings
50 RC Seismic structures 369 buildings
40
Number
Number

30
of
20
Building
10
0
1970 1975 1980 1985 1990 1995 2000 2005
/ BCJ data
/ Over 60m high
Year end
Designed of structural
Year (at the enddesign evaluation)
of appraisal) / Total number exceeded 500

Transition of Number of High-Rise RC Buildings

Energy Energy
Large Small
absorption drift absorption
drift

Displacement
as solid body

Large
displacement

Isolation
bearing
Seismic Resistant Seismic Control Seismic Isolation
 6
Evolution of high-strength materials
Research
on FRCC

160
Fc (MPa)Fc[N/mm2]

140 Maximum
past record New RC
Annual
maximum value
Specified design strength

120 Annual
average value Project
100 Annual
minimum value

80
60
40
20
0
1970 1975 1980 1985 1990 1995 2000 2005
Year (end of structural
design evaluation)

Transition of concrete strength

 7
History of High-Rise RC Buildings of Takenaka
Year Keywords Structural Planning 1986 Hikarigaoka D5 (30F)
Early Dev elopment of High-ris e
1970 Early Dev elopment
RC Buildings as Takenaka Corporation
1975 Of High-rise RC

27,300
Buildings Concrete strength Fc42 , Height 88m

20,600
1980
Realiz ation of High
strength concrete 31,800

1985 Fc42
D5
45,000 1996 Bellemarge Sakai (43F)
Frame Structure 3
Double Tube Structure
1990 High strength
Double Tube Concrete strength Fc70 , Height 136m
Structure
concrete Fc70
1997 Park City Suginami(28F)
20,600
High-rise RC Structure using Seismic Isolation
1995 High-rise RC
System Concrete strength Fc48 , Height 87m
1996 Structure using
Kuzuha Tower City

22,930
Seis mic Is olation 29,000 2001
System
1997
T Building (42F)
1998 Using of Structural Wall 40,200

High-rise RC Structure using Seismic Isolation

High strength T
1999 Seismic Isolation Concrete strength Fc80 , Height 133m
concrete Fc100
2000 System Renaissance Tower
32,500

2002
(Free Plan)
2001
Takenaka Hybrid Ueno Ikenohata (38F)
Flat Slub System 32,500
Super Flex Tube Structure using a damper
2002
Concrete strength Fc60 , Height 130m
Super Flex Seismic Isolation 2003 DGrafort Kobe Sannomiya (43F)
System(Free Plan) Takenaka Hybrid Flat Slub System
2003 Tube
Structure High-rise RC Structure using Seismic Isolation
2004 of World ex treme height
Concrete strength Fc60 , Height 145m
To the height
2005 SUPER
SUPER FLEX STRUCTURES 2005 Musashi Kosugi plan
200m
(59F47F) Height 201m
Advanced High Performance Concrete
 8
High-rise building with Complex Floor Plan
Outline
/ Use: Condimunium
/ Location: Osaka
/ No. of Story: 42F (B1F)
/ Maximum Height: 136.8 m
/ Total Floor Area: 32,720 m2
/ Construction Period : 2001.32003.12
/ Structure: Reinforced Concrete
with Base Isolation System
/ Max. Concrete Strength
: Fc 80 Mpa
Base Isolated Super High-rise RC Building Composed 9
of Three Connected Towers with Vibration Control Systems
Island Tower Sky Club (Winner of fib 2010 Awards for
Outstanding Structures )
 Outline of Structure
10

42-story residential Vibr ation control

Vibration
Controldevice
Device
(zinc aluminum
damper)
building(2008) (Zinc-Aluminium Alloy Damper)
Seamless
steel

Extremely slender steel columns
columns(~250 dia.)
200250
200250

< Techniques Used > High Flatslab

Flat slab

Story
Fc30
High-rise (No
() Beams)
(void slab)

Zone
zone
1)Three Tower Box shape RC walls Frame
Super-Flex-Wall

(core area)
Connecting System ()
(Core Wall)

27FL
2) Precast Concrete Sky-Garden
Sky Garden

System with 70 Mpa 145.3m
m Fc39
(Steeltruss
(steel
() structure)
Truss Structure)
Vibration
control device
Concrete Medium 21FL
Vibration
Control Device
(viscoelastic damper)
Story


Medium-rise (Broad-Band

(oil damper) Damper)

Zone (Oil Damper)
3) Core Wall System zone Fc48

16FL
Bending Restoration Beam
4) Base Isolation Bending restoration beam
(SRC:15th,26th ,
Fc54 (SRC:15th,26th,37th37th
floor) Floor)
System Low
11FL


Low-rise
Story Precast Concrete
Fc60 Precast concrete
zone 6FL
5) Dampers of the Sky
Zone (Column,Beam,Slab)
(colum,beam,slab)
Garden truss Fc70
1FL

6) Dampers of the Fc48

Foundation Base Isolation
Base-isolated
System
foundations
upper stories Piles
Fc32 Steel tube in-situ driven
Cast-in-place
concrete pile
concrete enlarged base
(Zinc-Alminum alloy

with outer
piles
Steel Tube
dampers)
Ordinary High Strength Concrete
11

Less Fire Resistance Premature Cover Spalling

Separation and
fall down of
cover due to
lateral
displacement
 12

2. Classification of Fiber
Reinforced Cementitious
Composites
 Classification of Fiber Reinforced 13

Cementitious Composites

(SHCC in
HPFRCC : High Performance Fiber RILEM)
(High)

Pseudo strain Reinforced Cement Composites with

hardening
characteristics multiple fine cracks
under uni-axial
tensile stress (RPC in
ECC: Engineered France)
Cementitious Composites
Ductility

Deflection UFC:Ultra High

hardening
characteristics Strength Fiber
under bending Reinforced Concrete
stress
DFRCC:Ductile Fiber Reinforced Cementitious Composite
(Low)

Strain softening FRC:Fiber Reinforced Concrete

characteristics
under tensile
stress FRCC : Fiber Reinforced Cementitious Composites

(Low) Strength (High)

Behavior of Different Classes of FRC
14

Tensile Stress-Crack
Opening Behavior of
Different Classes of
Fiber Reinforced
Concrete
 15
JSCE Recommendations for UFC and HPFRCC
UFC HPFRCC
(Ultra High-Strength Fiber (High Performance Fiber
Reinforced Concrete) Reinforced Cement Composite)

Recommendations for Design and Construction of Ultra Recommendations for Design and Construction of High
High-Strength Fiber Reinforced Concrtee Structures Performance Fiber Reinforced Cement Composite with
(Draft), 2006 Multiple Fine Cracks (HPFRCC), 2007
 16

3. Application of Fiber
Reinforced HSC

3.1 High-rise Building Columns

First Practical Application of

150MPa SFRC to Building
Park City Musashi Kosugi Building17
(Winner of fib 2014 Awards for Outstanding Structures )

Building Use: Condominium

D Location: Kanagawa Pref.
Building
E No. of Story: 59F (B1, PF2F)
Height of Building: 197.6 m
Maximum Height: 203.5 m
Total Floor Area: 103,670 m2

Structure: RC Moment Frames

with Vibration Control Devices
Concrete Strength: Fc150 MPa
Main Bar: SD678 (y: 685MPa)

Design: Takenaka Corporation

Construction:
Takenaka Corporation
Construction Period:
2005.10 2009.4
Park City Musashi Kosugi Building
 Outline of Structure 18

Steel structure Spancrete Column, beam:

composite slab precast
Non-column space Balcony: precast
9.6mx31.6m
Spancrete
composite slab Staircase:
Column, beam, precast precast
joint: precast Balcony:
Floor: deck plate
Balcony: precast Damper column
3F 10F
Mega-frame
Visco-elastic
damper wall
Large span
super frame

Column SRC,
olumn
Beam S

Concrete: 150MPa
Steel bar: 685MPa
Mega-frame
Composite wall
Visco-elastic
Wall pier damper wall
Typical Floor Plan 3F 38F
Section Piled raft

Park City Musashi Kosugi Building

 19
Application of 150MPa Concrete
Casting
Column
Concrete

Column
Section

as of May 28 2007
 20
Strongest practiced concrete in the world
Height (mm)

Specified strength
Fc150N/mm2

Core from solid (91d)

Insulated curing (91d)

Standard curing (56d)

Curtain on the building wall Core (91days)

says
Core (28days)
Strongest Concrete in the
World (150N/mm2)
One coin area of concrete Compressive strength (N/mm2)
can support the weight of an
elephant
Strength of Concrete Core
Application of 150MPa Concrete
21

High-range water reducer

Break up
Repulsion

Cement Cement

Silica fume

Silica fume cement High-range water reducer

Conventional technique New technique

Fire Resistant Concrete
22

Ordinary Advanced
high-strength fire-resistant
concrete concrete

Park City Musashi Kosugi Building

Prevention of Cover spalling
23

Ordinary High-strength Concrete Advanced Performance Composite

Separation and
fall down of
concrete due to
Prevention of
lateral
separation and
displacement
fall down of
concrete
Steel
fiber

Steel Fiber Reinforced Concrete

Park City Musashi Kosugi Building
 Precast Concrete Elements
24

Balcony
PC

Beam with Beam-column Joint

PC2

Beam with Beam-column Joint

PC Corner Beam with Tile-coating
PC

LEGEND
PC
Column
Beam
PC
Balcony
PC
Column with Tile-coating
PC
Column
PC
PC
 25

Column Test

using 150 Mpa SFRC

 26
Structural Test for High-Rise R/C Buildings

Laboratory test of structural elements used in RC high-rise buildings

 Test Results for 150MPa SFRC columns 27

(without SF)
Shear Force : Q [kN]

(without SF)

Lateral Drift Angle : R10-3[rad.]

(with SF1)
Shear Force : Q [kN]

(with SF1%)

Lateral Drift Angle : R10-3[rad.]

Lateral Drift Angle = (1/200) (1/100) (1/50) (End of test)
 28

Subassemblies Test

using 150 Mpa SFRC

Beam-Column Joint Test
29

Axial force Reversed cyclic loads were applied

Nc=0.2fC BD at the both tips of the beam while
axial load was kept constant.

 Test Results for 150MPa Beam-column Joint30

J150-0
[kN] : Q [kN]

800

600
fc:150MPa



400 without
SF

Force

200

0
Story Shear

-200

-400

-600
at maximun Final
-800
-40 -30 -20 -10 0 10 20 30 40 strength appearance
Story Drift Angle
-3
: R 10 [rad.]
[1/1000rad.]
J150-1.0
800
[kN] : Q [kN]

600
fc:150MPa



400 with 1% SF


Force

200

0
Story Shear

-200

-400

-600
at maximun Final
-800
-40 -30 -20 -10 0 10 20 30 40 strength appearance
Story [1/1000rad.] -3
Drift Angle : R 10 [rad.]
 31

3.2 Slender Columns

Practical Application of 150MPa

SFRC to Precast Slender Columns
Base Isolated Hospital 32

Outline
/ Use: Hospital
/ Location: Kanagawa
/ No. of Story: 14F (B1F)
/ Maximum Height: 74 m
/ Total Floor Area: 95,748 m2

/ Structure: Reinforced Concrete

with Base Isolation System
/ Max. Concrete Strength
: Fc150 Mpa
 33
Outline of 150 MPa PCa Columns

Outline of Columns

/ Precast Concrete Columns

440 Pieces were used.
/ Diameter of 350 mm
/ Length of 4200 mm

/ Specified Concrete Strength

fc= 150 Mpa
/ Measured Concrete Strength
(28 days)
fc28= 170 MPa
 34
Erection of 150 MPa PCa Columns
 35
Overview of construction site

440Pieces
were used
 36

PCa Slender Column Test

using 150 Mpa SFRC

 37
Structural Test for Slender PCa columns

400ton
 38
Structural Test for Slender PCa columns

Verification of structural Drift Angle(R)=0.5%

performance
No creck was
Design Criteria R=2.0 %.
observed
Design Criteria R= 0.5 %.
300 Sufficient
Unit901 structural

200
performance
Force : Q [kN]
Q [kN]

100
Drift Angle(R)=2.0%
0
Story Shear

-100
Axial force of


4000 kN was
-200 sustained
ACI318

-300
-20 -15 -10 -5 0 5 10 15 20
Story Drift R
Angle[10 10-3[rad.]
: R-3rad.]
 39
Practical Application of 200MPa SFRC

(Football Stadium)
 40
Practical Application of 200MPa SFRC

200 MPa PCa

Concrete Columns

(Football Stadium)
 41

3.3 B/C Joint in Precast System

Practical Application of SFRC

to B/C Joint of Precast Systems
 42
Application of SFRC to B/C Joint
Beam longi. bars
Plain concrete with headed bars
Shear reinf. in joint
Steel fibre concrete

No shear Reinf.
in joint

(Ordinary Interior B/C joint) (Newly Developed interior B/C joint )

 43
Application of SFRC to B/C Joint
 44
Application of SFRC to B/C Joint

1) Setting of PCa Columns

2) Setting of PCa Beams

with Headed Bars

FL
 45
Application of SFRC to B/C Joint
3) Casting Concrete 4) Setting of Upper
with Fibers in B/C Joint Floor PCa Columns

FL
 46

Beam/Column Joint Test

using 60 Mpa SFRC

 47
Test Specimen using 60 Mpa SFRC
450
200 200
Beam-column joint

87.5
Concrete fc75.3
Steel fiber 1.0% Vol.
87.5
450
Axial force Nc 46 119 120 119 46

46 105 98 105 46
Axial force ratio c=Nc/(BDFc)=0.15

400
Grout-filled steel sleeve joint
800

Column : BD400450
800

Headed bar 225

34 60 262 60 34
450

Specimen NJID
450 Beam : BD225450
1512 1512
 48
Test Results of Newly Developed B/C Joint

Beam flexural yielding was confirmed using FRC in the B/C joint
 49

Photo Animation during test

Comparison of Ordinary and 50
Newly Developed B/C Joint
400
Shear Force : Q [kN]

300

200
Q[kN]

100

-100

Flexural Strength
Story

-200
PJI0()
Ordinary B/C J.
-300
FJI1()
New B/C J.
-400
Eq. Damp. Factor : heq [%]

30
25
20
15
10 FJI0
5 FJI1
0
-60 -50 -40 -30 -20 -10 0 10 20 30 40 50 60
Story Drift Angle : -3R[rad]
R10 10-3[rad.]
6 story Base Isolated Hospital
51

Outline
/ Use: Hospital
/ Location: Nagoya City
/ No. of Story: 6F (B1F)
/ Maximum Height: 24 m
/ Total Floor Area: 10,076 m2
/ Structure:
RC and Steel
with Base Isolation System
/ Max. Concrete Strength
: Fc60 Mpa
6 story Base Isolated Hospital
52

Less congested than ordinary B/C joint

6 story Base Isolated Hospital
53

Casting condition of SFRC

FL
 54

4. Application of UFC

4.1 Bridge Precast Elements

Practical Application of UFC

to Prdestrian Bridge
 What is UFC ?
55

Composition of UFC

Stress- Strain Relationship

Ultra-High-Strength Fiber-Reinforced Concrete

UFC is an epoch-making high-ductility/high-durability concrete
having a compressive strength exceeding 150 N/mm2 as well as a
high tensile strength exceeding 10 N/mm2.
 Application of UFC to Bridge
56

Sakata-Mirai Bridge Using 200MPa UFC

(Reference)
Nikkei construction:
September 13, 2002
 Comparison of Girder Section
57

Sakata-Mirai Bridge Using 200MPa UFC

Effective
Effective width
width 1.6 m
1.6 m

Effective

3.0
width
1.6 m
1.56

2.1
Main cable
19S15.28x4
Main cable
25S15.28x2
Ordinary Concrete
UFC 200N/mm2 40N/mm2 Steel Girder

Outer cable PS structure

Span50m
Floor thickness5cm
(Reference)
Web thickness8cm Nikkei construction:
Completed in 2002 September 13, 2002
 Application of UFC to Bridge
58

Akakura Onsen-Yukemuri Bridge

Section

(Reference)
Nikkei construction:
September 13, 2002
Span : 35.3m
Depth : 950mm
Outer cable PS structure
Slab thickness : 70mm
Web thickness : 70mm
Completed in 2004
 Application of UFC to Bridge
59

Mikaneike Bridge Using

Length : 81.2m
Span : 39.9m
Width : 3.6m
PC outer cable structure
U shaped girder
Completed in 2007

Y. Uchida et al : Review of Japanese

Recommendations on Design and
Construction of Different Classes of Fiber
Reinforced Concrete and Application
Examples, Keynote Paper, 8HSC/HPC
Symposium, 2008.10
 Application of UFC to Bridge
60

Riverside Senshu Renraku Bridge

Length : 30.5m
Span : 2+26+2m
Width : 4.1m
PC outer cable structure
Slab thickness : 70mm
Web thickness : 100-200mm
Completed in 2007

Y. Uchida et al : Review of Japanese

Recommendations on Design and
Construction of Different Classes of Fiber
Reinforced Concrete and Application
Examples, Keynote Paper, 8HSC/HPC
Symposium, 2008.10
 61
Application of UFC to Monorail Girder

Tokyo Monorail 800

130 540 130

70
50

1850
2000
PC
12S15.2B
=3

150
Y. Uchida et al : Review of Japanese
Recommendations on Design and 940
Construction of Different Classes of Fiber
Reinforced Concrete and Application
Examples, Keynote Paper, 8HSC/HPC
Symposium, 2008.10
 Application of UFC to Girders
62

Ramp way of East

Kyushu Expressway
using 200MPa UFC

Y. Uchida et al : Review of Japanese

Recommendations on Design and
Construction of Different Classes of Fiber
Reinforced Concrete and Application
Examples, Keynote Paper, 8HSC/HPC
Symposium, 2008.10
 63

4.2 Offshore Structures

Haneda Airport Runway

 64
Application of UFC to Airport Slabs

UFC precast slabs (7,000 pieces,

standard dimension 7.8 m x3.6 m )
World largest volume of 24000 m3
Y. Uchida et al : Review of Japanese Recommendations
on Design and Construction of Different Classes of Fiber
Reinforced Concrete and Application Examples, Keynote
Paper, 8HSC/HPC Symposium, 2008.10
 65

4.3 Precast Plates or Forms

Retrofit Projects
Application of UFC to Repair Project
66

Y. Uchida et al : Review of Japanese Recommendations

on Design and Construction of Different Classes of Fiber
Reinforced Concrete and Application Examples, Keynote
Paper, 8HSC/HPC Symposium, 2008.10
 67

5. Application of HPFRCC

5.1 Precast Coupling Beams in

Buildings
 68
Application of HPFRCC to Building
27-story residential building(2006)
Core wall

HPFRCC coupling beam

Support column

Flat slab

Kajima Corporation
(http://www.kajima.co.jp/news/press/200509/29a1fo-j.htm)
 69
HPFRCC Short Beam Test
160 160
BB0 BB2
120 120
cQfu cQfu
80
(kN)
80
Force Q (kN)

Q (kN)
Shear Force Q (kN)
40 40
ShearQ

0 0
-40 -40
-80 -80
-120 -120
-160 -160
-30 -20 -10 0 10 20 30 -30 -20 -10 0 10 20 30
-3
R
Disp. (10-3rad.)
Angle R(X10 rad.) R
-3
(10-3rad.)
Disp. Angle R(X10 rad.)

(Normal Concrete Beam) (HPFRCC Beam)

Kajima Corporation
(http://www.kajima.co.jp/news/press/200509/29a1fo-j.htm)
 70
Application of HPFRCC to Building
41-story residential 54-story residential
building (2007) building (2009)
 71

5.2 Retrofit Project

 72
Application of HPFRCC to Public Works

Y. Uchida et al : Review of Japanese Recommendations on Design and Construction of Different Classes of

Fiber Reinforced Concrete and Application Examples, Keynote Paper, 8HSC/HPC Symposium, 2008.10
 73
Application of HPFRCC to Public Works

Y. Uchida et al : Review of Japanese Recommendations on Design and Construction of Different Classes of

Fiber Reinforced Concrete and Application Examples, Keynote Paper, 8HSC/HPC Symposium, 2008.10
 74

6. Concluding Remarks
 Concluding Remarks (1) 75

Fiber Reinforced HSC

1) In building structures, evolution of high-rise RC buildings

has been related to the evolution of HSC.

2) Because high strength concrete is less performance in

terms of fire-resistance and has a brittle behavior, organic
and steel fibers are added in order to improve its
characteristics.

3) Some recent research advances and applications

associated with fiber reinforced HSC were presented
focusing on applications to precast concrete elements in
Japan.
 Concluding Remarks (2)
76

UFC (Ultra High-Strength Fiber Reinforced

Concrete)

1)UFC is high-ductility/high-durability concrete of a

compressive and a high tensile strengths exceeding 150
MPa and 5 MPa, respectively.

2)UFC has been applied to bridge girders where 1) small

member thickness, 2) light weight and 3) small beam section
height , are required.

3)UFC precast slabs of the world largest volume are used

for the deck slabs at the off shore airport runway. The
reasons of the application are weight reduction and the
durability against the salt attack.

4)UFC precast forms are used in the retrofit projects due to

the improvement of the durability including the wearing or
abrasion resistance.
 Concluding Remarks (3) 77

HPFRCC (High Performance Fiber Reinforced

Cement Composite)

1) HPFRCC has been applied to many civil engineering

structures (tunnels, bridges, gravity dams, etc.) where cracks
must be kept fine or large ductility is required.

2) HPFRCC was applied to connecting beams between

shear walls in a high-rise RC building because of its
excellent energy absorbing performance and less damages.
Tokyo Scene
78

Shinjuku Business
center west of Tokyo
Contents of todays speech
79

1. Introduction 7min.
2. Classification of FRCC 3.7min
3. Application of Fiber Reinforced HSC
3.1 High Rise Building Columns 8min.
3.2 Slender Columns 4min.
3.3 B/C Joint in Precast Systems 4.4+ min.
4. Application of UFC
4.1 Bridge Precast Elements 4min.
4.2 Offshore Structures 1.2min.
4.3 Precast Plates or Forms 1.0min.
5. Application of HPFRCC (ECC)
5.1 Precast Coupling Beams in Buildings 1.7min.
5.2 Retrofit Projects 2.1min.
6. Concluding Remarks 2.1min.
Total 39.2min.