octobeR 2013 - No.14

Standardization: UHPCs enter tHe indUStrial age

an arCHiteCt’S ViSion: Bernard tSCHUmi

muCem deSigned By rUdy riCCiotti: dUCtal® for PerformanCe and CreatiVity

SolUtionSthe magaziNe about uhPcs by LafaRge

News - 3 > 6

standardization > 4UHPCs enter the industrial age

iNsights - 7 > 9

bernard tschumiArchitecture invents concepts and makes them a reality

maRkets - 10 > 17

façade > 10Giving the envelope new functions

wind turbines > 13Resistance, sealingand flexibility

bridges & footbridges > 14Pont de la République (France)Blandan footbridge (France)The evolution of Ductal® Joint Fill (North America)

PRoject - 18 > 23

mucem > 18Ductal® combines technical performance with architectural creativity

ContentS

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editorial Committee:

Editor-in Chief: Jean Martin-Saint-Léon - Editors and contacts: Lisa Birnie - lisa.birnie@lafarge.com; Marie Escaich - marie.escaich@lafarge.com - Photo credits: Lafarge photo

library - Charles Plumey-Faye - Philippe Ruault - Max Lerouge - Patrick Kennedy - Luc Boegly - Hervé Abbadie - Ignus Gerber - Brian Moore, Wapello County - Andy Marshall,

Ricciotti Architecte - Lisa Ricciotti - Martin Mai - Peter Mauss/Esto - Christian Richters - Iwan Baan - J. M. Monthiers - Base - Explorations architecture - Design/Editorial

production: Agence All Write - Translation: TagLine - Printing: TCS/ARCM

BUSineSS ContaCtS

- E-mail: ductal@lafarge.com

- Mailing addresses:

EURoPE, AFRICA, ASIA, MIDDLE EAST: UHPC / Ductal® - Lafarge - 2, avenue du Général de Gaulle - 92148 Clamart Cedex - France

NoRTH AMERICA: UHPC / Ductal® - Lafarge North America inc. - 6509 Airport Road, Mississauga, Ontario - Canada L4V 1S7

Jean-BoUin StadiUm (franCe)

The Pérez Art Museum in Miami, Florida (USA), designed by award winning architects Herzog & de Meuron will open to the public in December 2013. The Museum will have 200,000 square feet of space for works of art, educational activity, relaxation and dining. To meet the aesthetic and resilience requirements, Ductal®

UHPC was chosen to produce approximately 100 long-span, precast vertical mullions to blend with the structure’s cast-in-place elements and support the large curtain wall glazing which surrounds the building.

Pérez art mUSeUm miami 2.2km

The new Casa-Port station in Casablanca (Morocco), designed by AREP and Groupe3 Architectes, will open its doors in 2014. On its western façade, the station will be clad in a contemporary moucharaby (latticework) cast from 840m² of UHPC, exposing the station to the outside while regulating the amount of sunlight that filters through to the inside. Next to the station, an office building will be protected by UHPC sunshades with a total length of 2.2km.architects: agences areP et groupe3 architectes.

CaSaBlanCa:

of SUnSHadeS

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inaugurated on 30 August 2013, the new Jean-Bouin Stadium, designed by the architect, is covered by an asymmetric, curving envelope made from 3,600 light grey, self-supporting triangular panels in Ductal®. The roof panels create a 12,000m² waterproof roof; and the horizontal façade panels create a tool surface area of 11,000m². Architect: Rudy Ricciotti.

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Ultra-high performance concretes are the result of industrial research carried out in the 1990s and have exceeded previously unexplored frontiers in terms of performance. Numerous projects, supported by partnerships and public research, have confirmed the many advantages of these materials, validated in each case by extensive technical research

“Until now, reference documents have reflected an accepted industry standard rather than an official standard,” says François Toutlemonde. “The revolution made possible by UHPCs, their calculation methods – far removed from those used for most industrial applications – led the AFGC (French Civil Engineering Association) to develop the first provisional recommendations document for UHPCs in January 2002, in partnership with government ministries, large project owners, industrial companies, supervisory bodies and civil engineering companies. in June 2013, a new definitive version of these recommendations was published, incorporating more than 15 years of feedback. This version was brought into line with European calculation standards (Eurocodes)” says Jacques Resplendino. “This voluntary pre-standardization work was vital to be able to apply the innovation represented by

these new concretes. Drafted in French and English, it addressed the initial questions and expectations of an increasingly global market.”“Nevertheless, the document is simply a technical consensus,” explains François Toutlemonde. “Although risk-taking is reduced as the amount of reference material increases and volumes grow, from the perspective of insurers, as well as international economic factors, nothing can match the power of an official standard.”

“Not even the ATEX directive, which involves a relatively complex procedure and, in relation to UHPCs, often focuses more on ancillary questions than specific performances,” adds Jacques Resplendino. Standardization is now even more urgent, since UHPCs have continued to develop and an increasing number of players are considering their use in niche applications which were not necessarily envisioned during the initial R&D. “This diversification of the product range in response to new functional requirements (heightened mechanical resistance, fire-retardant properties, performances in aggressive environments, etc.) reflects the more mature market which now exists,” continues François Toutlemonde. “in this context,

Industrial companies’ investments in engineering, sustained by the commitment and innovation of designers and project owners, has enabled ultra-high performance concretes (UHPCs) to demonstrate their superior capabilities. Today, UHPCs require a technical and legal framework tailored to their volume growth and diversity of their applications. The standardization work now in progress should improve projects’ insurability over the short term by providing recognized and shared reference systems.

standardizationuhPcs enter the industrial age

The objective of developing a standard is to facilitate the specification of UHPCs and their acceptance by the supervisory authorities.

François ToutlemondeScientific representative at iFSTTAR (the French institute of Science and Technology for Transport, Development and Networks)

tHree-fold Standardization worK

In line with existing standards, the current approach to standards has three main focuses in relation to UHPCs, as identified in the AFGC recommendations from June 2013: - a standard for the material,

including characterization tests,

- a standard for calculation methods,

- an implementation standard. Although it is too early to announce publication dates, for the first part concerning materials, a working version (draft) is likely to be produced in 2014 and a standard compatible with Eurocode 2 should be ready within two years.

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UHPFRC 2013 International symposium In Marseille at the MuCEM October 1-3, 2013Under tHe aegiS of afgC, tHiS meeting iS dediCated to engineerS, arCHiteCtS, ContraCtorS, indUStrieS, laBoratorieS, UniVerSitieS, BUilding ownerS...tHe oBJeCtiVe iS to reView tHe ComPlementary exPerienCe and Knowledge in tHe USe of UHPC, oriented on reSearCH and deVeloPment.

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standardizationuhPcs enter the industrial age

the objective of developing a standard is to facilitate the specification of UHPCs and their acceptance by the supervisory authorities. The standard, which is far more enforceable than existing documents, offers a range of reference systems, a guaranty and an insurability which serve to reassure project managers regarding their choice of construction solution.”

The development of a standard addresses technical as well as economic challenges. “it is therefore vital for this work to involve all stakeholders, so that the final text results from a transparent and responsible consensus,” says François Toutlemonde. “And these aspects are obviously very important to us at iFSTTAR.” “Another factor adding to the urgency of this standardization process is the international

perspective,” says Jacques Resplendino. “The technological and documentary advantage achieved by France has supported work carried out in many countries (China, Switzerland, Australia, Germany, the USA, etc.) and inspired others to produce their own recommendations. it is therefore urgent to give France a reference system to firmly establish the standards we have become used to working with and which make us a driving force within international standardization organizations.”“At the end of the day, the main purpose of standardization work is to consolidate a technology’s quality and safety. The move from a system of patents to a system of standards is a guaranty of higher quality. All experts agree that the standard should promote this quality aspect, which provides a strict framework for

both the technical and economic approach. Through this standardization work, France is committed to maintaining this advantage and spirit of innovation.”

what challenges are presented by the switch from professional rules to a UHPC standard?Juan Carlos lópez agüí: These standards will represent an extension to the use of UHPC. it is crucial that they maintain the levels of quality and professionalism established in France, since these have prevented disputes, something vital to the development of any innovation. With the extension of UHPC and the establishment of these standards, the challenge will also be to move from spectacular reference worksites to standard worksites which are just as convincing. i am confident that this task has been entrusted to the very best project participants and technicians.

what are the main elements of the 2013 recommendations?J.C.l.a.: i was struck by the global approach and the coordination between all aspects of the project, from materials to execution. in particular, the reliable description of the orientation of fibers is something new and essential, especially for non-reinforced structures. The method may be further improved, with an even stricter and more carefully researched safety margin. But, even applied in their current form, the 2013 recommendations guarantee a high level of reliability.

How does the UHPC standardization approach differ from the standardization of concrete under en 206?michel delort: The standardization approach dedicated to UHPCs stands out in at least three key ways: - Standard EN 206 sets out categories of

reinforced or non-reinforced concrete designed for structures calculated according to Eurocode 2, while our work focuses on concretes reinforced only with fibers, which are designed, specified and implemented according to AFGC recommendations;

- With UHPCs, there is a jump in categories of resistance. While standard EN 206 covers concretes with maximum resistance of 100 MPa, for UHPCs we are dealing with structural concretes with resistance greater than 130 MPa;

- Finally, our standardization work aims to include a performance-based component, which is not yet the case with standard EN 206.

Juan Carlos lópez agüí, former chairman of the CEN (European Committee for Standardization) from 2007 to 2012 and an expert in the reliability of concrete structures

michel delort, Products and Applications Director at ATiLH (Technical Association for the Hydraulic Bonding Agents industry) and coordinator of the AFNOR/P18B standardization committee’s UHPC working group

exPert noteS

This standardization work was vital to be able to apply the innovation represented by these new concretes.

Jacques ResplendinoSouth-East Director of ingeneering organization with Setec Tpi, coordinator of the AFGC working group on UHPCs

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To develop and report information on UHPC – that is the mission of the ACI 239 Committee chaired by Tess Alhborn

what is the mission of the aCi 239 committee?tess ahlborn: ACi 239 is a technical committee established in 2009 and supported by ACi to work towards a common definition for UHPC - that is comprehensive and inclusive. Our mission is: “To develop and report information on UHPC”. Currently, there is no common definition in the US, nor in the world. All of us on the committee are experts on UHPC, but of course we have different opinions. The following proposed definition, which is very generic and simple, is currently in the process of ACi review and pending acceptance:

“Concrete, ultra-high performance - concrete that has a minimum specified compressive strength of 150 MPa (22,000 psi) with specified durability, tensile ductility and toughness requirements; fibers are generally included to achieve specified requirements.”

How will aCi 239 contribute to the development of UHPC in the US?t.a.: Our goal is to educate and gain acceptance of UHPC and establish guides. This is long overdue as there is a lack of awareness by owners, designers and precasters of the benefits and potential of UHPC in the US; how and why to use it, etc. it is a challenge for companies who want to generate a market for the material, therefore we are working on two documents: an Emerging Technology report, a short-term document to introduce UHPC into practice by providing basic information for implementation and performance and; a State-of-the-Art report, which will be a comprehensive document regarding development, deployment and recommendations for broader use of UHPC in the concrete industry.

what do you think of the UHPC design guidelines and recommendations published in france, Japan, and australia?t.a.: it is important to learn from our colleagues worldwide, and similar documents should be generated for US

construction purposes. We must provide the necessary technical and construction guidance and evaluate current codes and standards in order to make recommendations on required changes for UHPC in the precast US market.

what are the challenges for the aCi 239 committee?t.a.: We are faced with many challenges, both short- and long-range. All of us are working on a voluntary basis, so the biggest challenge at the moment is to find sufficient time to work on these reports. Long-range activities include identification of gaps in knowledge and research, as well as development of guides for mix proportioning, design, placement, and certification.

do you expect lafarge to play a role in this process?t.a.: Yes; of course, Lafarge can’t write the standards for the US market, nor should they, but the first UHPC testing methods i used were written by Lafarge. We need codes and standards written and approved by the industry, such as ACi and ASTM, not on a single product but on UHPC as a whole.

what is the next step?t.a.: Several members of ACi 239 are co-organizing a “Symposium on UHPC” with ASTM (American Society for Testing and Materials) international on December 8th, 2013, in Jacksonville, Florida. The purpose of the Symposium is to provide a forum to discuss where current ASTM material specifications and test methods for concrete are inadequate for UHPC, propose new tests for UHPC, and exchange ideas as to where new specifications and methods need to be developed. it will be a very important event, as we will discuss the development of new standards, new subcommittees and/or expanded roles for existing ATSM subcommittees.

North America aci 239: Defining uhPc

the Hodder avenue Underpass in thunder Bay, Canada has field-cast UHPC connections and precast elements including 3 pier columns shells and a large pier cap. engineer: Hatch mott macdonald.

Canopies, Chester, United Kingdom, architect: donald insall associates limited.

teSS alHBornAssociate professor of civil and environmental engineering at Michigan Technological University (USA) with a research program in the area of innovative concrete materials related to prestressed concrete bridges, including UHPC applications; Director of the Center for Structural Durability with the Michigan Tech Transportation Institute; founding member of the “North American UHPC Working Group” and; founding member of one of the American Concrete Institute’s newest committees, “ACI 239 – UHPC”.

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inSigHtS

Bernard tschumi Architecture invents concepts and makes them a reality

What does Lafarge’s new signature “Building better cities” evoke; how does it fit in with its architecture and urban planning work; and what links can be forged between the architectural concept and materials innovation? These questions are addressed by Bernard Tschumi, recipient of the French Grand Prize for Architecture in 1996.

This French-Swiss architect lives and works both in Paris, France and New York, USA. He studied architecture at ETH Zurich, taught at AA in London and then headed the Faculty of Architecture at Columbia University in New York. His theoretical essays include “The Manhattan Transcripts”, “Architectural and Disjunction”, “Event-Cities”, and more recently; “Architecture Concepts: Red is Not a Color”. He designed and built the Parc de la Villette in Paris, the Acropolis Museum in Athens, the Alésia MuséoParc, Le Fresnoy in Tourcoing, and the Zénith stadiums in Rouen and Limoges. His personal exhibitions include MoMA in New York (1994) and the Venice Biennale (2006). He also won the French Grand Prize for architecture (1996).

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what does lafarge’s new signature, “Building better cities”, evoke for you?

Bernard tschumi: it is strange to observe that for almost half a century, architects and urban planners have come up with very few ideas and proposals to invent or transform cities. After the CiAMs (international Modern Architecture Conferences) in the 1930s and 40s, Team X in the 1950s, the inventions of the Metabolists and Yona Friedmann in the 1960s, and recommendations for a return for the past with Aldo Rossi and Colin Rowe in the 1970s, there is almost nothing today. With a few very rare exceptions, there are no more creative projects, despite the fact that we are experiencing the most intense period of urbanization since the start of humanity. Look at the cities that are springing up in a few years in China and the Middle East – there is no concept and almost no new ideas.That is why the emphasis placed recently by Lafarge on “Building better cities” may be important. We remember the arguments put forward by Le Corbusier and his “Plan Voisin” (named after a car manufacturer) to revolutionize Paris. When will Lafarge come up with a plan to build a new type of city in several places in the world?

what are the main innovations in the field of building materials which you have noticed recently; and how do you see the relationship with the manufacturers of these materials in relation to your areas of consideration?

B.t.: Architecture invents concepts and makes them a reality. By that i mean that there is no architecture without an idea or a concept, and that an idea or a concept is more important than a form. But architecture differs from philosophy or mathematics in that this concept always refers to a potential reality, a real object. So there is a close relationship between concept and material. For example, a material may suggest an idea. Bricks for the Romans, iron architecture in the 19th century, concrete in the early 20th century, and glass from the 1970s were all drivers of architectural innovation. Lafarge knows a thing or two about fibrous concrete. Conversely, an idea may generate research into a new material. These are the two types of relationship which can exist with industrialists.

inSigHtS

alésia muséoParc, france. architect: Bernard tschumi.

entrance lobby, zénith in limoges, france. architect: Bernard tschumi.

Blue tower, new york, United States. architect: Bernard tschumi.

...a material may suggest an idea.Bernard Tschumi

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what are the two major production focuses of your current work as an architect or urban planner?

B.t.: The relationship between concept and material has always been crucial in my team’s architectural production. That is why, for each new building, we have tried to develop a concept based on the choice of a specific material, whether traditional or innovative.Projects have found their expression in the red enameled steel follies of the Parc de la Villette, the concrete and steel double envelope of the Zénith in Rouen (followed by the wood-polycarbonate double envelope of the Zénith in Limoges), the colored glass of the Blue Tower in Manhattan, and the wooden envelopes in Alésia and for the Vincennes Zoo. Not to mention the concrete at the Acropolis Museum and now our ANiMA Center in italy made entirely from solid concrete poured in situ, 80cm thick on the southern façade and 24m high. For this last building, on which construction will begin in 2014, we chose not to use the lightness and translucent qualities of a Ductal® for example, focusing instead on solidity and weight, firmly anchoring the building in its site by playing on various types of perforation for each of the five façades.

which of your projects do you think best illustrates the phrase “Building better cities”?

B.t.: Since 2006 we have been working on a brand-new city at a previously unused site near Santo Domingo, to house 40,000 inhabitants. We call it “Elliptic City” and the first buildings are due to be delivered in 2015. The concept is radical and seeks to preserve the forest covering the site by creating a series of functional and spatial clearings, each containing homes, offices, schools, stores, etc. The project is innovative in the sense that it is inventing high-density pockets of development, but in a forest, allowing the city to breathe…

The relationship between concept and material has always been crucial in my team’s architectural productionBernard Tschumi

follies in the Parc de la Villette, france.architect: Bernard tschumi.

inSigHtS

entrance lobby, zénith in rouen, france. architect: Bernard tschumi.

interior, acropolis museum, athens, greece. architect: Bernard tschumi.

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what is your analysis of changes in the façade market?guillaume aelion: That question should be addressed in the broader context of the current economic environment. We are currently seeing a cyclical change whereby the prosperity we experienced previously no longer applies. We cannot allow ourselves to proceed by trial and error and backtrack when necessary. Remember that construction methods have changed little in 30 years. But regulations have intensified considerably in the meantime, significantly driving up construction costs. This means we face a transformation in construction methods, involving radical

changes – particularly in the façades market. As well as being the best representation of a building’s image, façades are now fulfilling more and more functions. This presents a number of challenges to materials, to ensure that façades’ project economics are more in line with the budgetary and environmental constraints faced by our society.

what are betsinor’s responses to these changes? g.a.: Betsinor specializes in the design, production and installation of architectural elements made from cement-matrix composites. We offer several types of solutions, although all are focused on the objective

To offer façade elements which provide greater functionality – that is the challenge facing new UHPCs. As well as the technological ambition, project economics have changed. Guillaume Aelion, chairman of Betsinor, explains how these new-generation UHPCs offer a wide range of solutions for addressing contemporary construction challenges.

façade giving the envelope new functions

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textured panels, thiais bus depot, france. architect: agence eCdm (emmanuel Combarel - dominique marrec).

BetSinor, prefabricator of architectural components, and a member of Lafarge’s network of UHPC licensees since 2004.

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of offering lighter, more efficient functional façades. For instance, both wall systems we offer (BEPiV and WOODiV) have complex characteristics, including passive sealing which is already in line with the likely requirements of the RT 2020 thermal regulations.

Their total thickness ranges from 15cm to a maximum of 35cm, one of the major advantages of UHPCs. This results in considerably lower consumption of materials, therefore lighter buildings, less pollution (caused by transportation) and faster construction, while at the same time offering greater functionality and durability.

This means that UHPC façade solutions can offer a virtuous construction circle that responds to the transformation mentioned earlier.

so light façades are the future? g.a.: Studies show that it is hard to estimate the moment when the traditional market reaches its limits. However, in the exterior thermal insulation segment, which has been steadily growing in recent years, the sub-segment that is developing fastest is customized, attached facades.

what is the objective of the partnership you have with Lafarge? g.a.: One of the changes imposed by the current economic climate is to move on from a system which only offered one solution. Our joint ambition is to offer formulas tailored to manufacturing processes, making it possible

to respond to the problems of each type of project and therefore promote façades which benefit from the performances of UHPCs and offer ever greater functionality, creativity and durability. As an example of this approach, UHPC was required to provide air-sealing with self-supporting elements in order to hold insulation and door and window frames – which no sprayed product currently allows. That is the revolution offered by the future, sprayed applications of UHPC. This technology makes it possible to break free of backing molds – often required for elements with complex geometry – and, at 20mm thick, will offer functions equivalent to 20cm of sprayed concrete. The main focus of our work is always on product quality, experience and expertise in innovation, which has always given Lafarge the technological advantage that Betsinor has relied on for many years.

tHe VirtUoUS ConStrUCtion CirCle

a UHPC SolUtion for eaCH tyPe of ProJeCt

marKetS

Perforated panels, in a continuation of the stamped concrete, musée d’art moderne in lille, france. architect: manuelle gautrand.

Curtain wall, rotman School of management in toronto, Canada. architect: KPmB architects.

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Elimination of thermal bridges, air- and water-tightness, lightweight, thinness, solidity – Ductal® has demonstrated how UHPCs’ characteristics respond brilliantly to external thermal insulation challenges. Following in the footsteps of this revolutionary product, new formulations are now available which offer easy-to-implement solutions for façades that combine external thermal insulation, aesthetics and durability.

Façade: Roundup of new uhPc solutions

23cmtHe tHiCKneSS of a UHPC façade tHat ProVideS good external tHermal inSUlation

SPrayed UHPC: a maJor innoVation

full-height latticework at the rue Blanche hospital in Paris, france. architect: Philippon-Kalt architectes.

insulated, impermeable frameworks, façade panels, sun-shades and facings – UHPCs today are offering more applications for innovative, contemporary façades. These new solutions, such as external insulation elements, enhance the functions fulfilled by the façade. “The mechanical performances of UHPCs enable façade

elements to be much lighter and very easy to implement,” explains Emilie Hergott, project management engineer with the Lafarge UHPC team and project manager for light façades. The insulated, impermeable framework solutions we are currently developing produce efficient external thermal insulation with 23cm walls, while it is difficult to make the brick/insulation/cladding solution less than 36cm.”These same mechanical performances therefore represent a major creative

advantage. “The pouring process and ductility of the material allow it to adapt to all geometries. The thinness of the cement matrix also ensures that all the patterns in the mold are reproduced, enabling significant textural freedom.”All these characteristics are now being used in formulas dedicated to creating open, lattice style facade systems as well as very slender balconies and sun-shades which contribute to the energy efficiency of the building, while offering designers new creative possibilities.

Drawing on the know-how it has developed over 15 years with Ductal®, “Lafarge is now expanding its range of dedicated UHPCs, optimizing the parameters according to the planned use,” continues Emilie Hergott. “For UHPCs containing organic fibers, the ambition of our research effort has been to revise the constituents of the cement matrix to offer alternatives, with almost identical performances, tailored to each project’s architectural and budgetary objectives.” This applied research, part of the Group’s core identity, is also focused on the development of new sprayable formulas. in partnership with Betsinor (see interview with Guillaume Aelion pages 10-11), this solution will release UHPC from the mold/backing mold process for the creation of elements which are not flat.This unique casting process will permit the production of façade panels with complex geometries, a UHPC solution that benefits from all the combined expertise of Lafarge and Betsinor.”

waterproof insulated render, Budin daycare center in Paris, france. architect: agence eCdm (emmanuel Combarel - dominique marrec).

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Perforated panels at the media library in evry, france.architect: deSo architectes associés.

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Alternative energy sources, particularly wind farms, are enjoying a fair wind these days - judging by the rapid increase in calls for tenders.Feedback on the first masts built from steel has revealed the limited life-span of this choice of technology for off-shore installations.Could UHPCs provide a sustainable alternative?

The masts of most wind turbines have so far been constructed from stainless steel. Early models required a significant sacrificial increase in the thickness of the steel to ensure a structural lifespan of around 25 years. Many consider this insufficient given the investment and complex construction involved.Alternatively, the proven performance characteristics of UHPC indicates that for the same mass as steel (a decisive factor for this type of structure), this material could be used to construct masts that last up to 4 times longer.

The inability to penetrate UHPCs with marine salt has been observed during repairs to

several structures in a marine environment, thereby suggesting that these materials could provide an excellent alternative in the future. “The repair of a beacon off the coast of Lorient (France), by pouring Ductal® into forms from a helicopter, demonstrated the possibilities and performance benefits of using this material, even in the open sea,” says Dominique Corvez, Head of UHPC-Ductal® for North America. This experience reinforces the idea that partnerships between general contractors, turbine operators, energy companies and UHPC manufacturers are capable of paving the way for a global market, inresponse to the growing energy challenges faced by all countries.

wind turbines

Resistance, sealingand flexibility

marKetS

Successful application of pouring at sea illustrating the possibilities offered by UHPC products for the wind farm market and offshore structures, the partnership between Lafarge, the CETMEF (French center for maritime and river technical studies) and the EPFL (Lausanne Federal Polytechnic School, Switzerland) led to the development of a UHPC specifically formulated for the repair of a badly deteriorated turret in Lorient harbor (France).The operation involved complete cladding of the Cabon turret by pouring UHPCs in situ to a depth of 6cm. in response to the configuration of the structure, this innovative UHPC formula offers reduced shrinkage and hardened traction resistance due to a high level of metallic fibers, and reduced shrinkage to absorb drag forces. its self-placing characteristics (EN 206-9 standard, class SF2) are also essential for pouring in confined spaces.

Ultra-high performance concretes are well-suited for extremely harsh marine environments, since they offer excellent durability (5.10-20 permeability) encouraging resistance to external aggressions (chlorides, freezing/thawing, erosion, etc.). The product’s implementation was also very specific since the mixing was carried out at a concrete batching plant to ensure rapid production of large quantities of UHPC, i.e. 5m³ of UHPC in two hours. The formula, with long rheological consistency (three hours) was transported in mixer trucks and then by helicopter to the top of the turret.The strengths demonstrated on this project show that, as well as their impressive mechanical performances, UHPCs also benefit from durability and flexibility of use. They are therefore particularly well suited for remote or difficult-to-access locations such as offshore sites.

Pouring UHPC by helicopter at the Cabon turret in the bay of lorient, france.

imagine new solutions with UHPC for wind turbine masts.

fine y-shaped legs made of UHPC support the bridge deck of Pont de la république. architect: rudy ricciotti.

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The Pont de la République, designed by the architect Rudy Ricciotti and the Lamoureux et Ricciotti engineering office – the new bridge to span the Lez river in France, which flows through the newer districts of Montpellier – won over the municipal committee due to “its elegance and the finesse of its architectural approach”.These aesthetic characteristics are attributable to a new Ductal® formulation blended with stainless steel fibers, with no signs of corrosion on the 34 white piers that support the deck.

bridges & footbridges

Connecting the new districts of Montpellier’s Hôtel de Ville and the Odysseum, the Pont de la République carries a two-lane highway, cycle paths and sidewalks. Above the Lez (a bucolic river with potential flooding), the bridge needed to be extremely resistant to chemical corrosion and humidity. The structure, made from UHPC, is 17m wide and 74m long. it includes 3 sections of equal length, each comprising precast beams supported by 17 precast piers and tilting piers made from Ductal®, prestressed (post -tensioned) in the plant. The beams were assembled crosswise on site by prestressing.

“One of the challenges of this project, which was launched last May, was to respect the periods of high water to avoid postponing everything for a year,” says Alexandro Guitton, Lafarge project management engineer. “Prefabrication therefore saved us valuable time on site.”

One of the reasons this structure, designed (by Rudy Ricciotti) “in the style of a millipede”, appealed to the local authorities, is the immaculate elegance which makes it so original.

“By coating all the prestressed elements, UHPC not only reinforces durability” explains Alexandro Guitton, “the new formulation of this White Ductal® incorporates stainless steel fibers – a first – avoiding any possibility of rust development and contributing to achieving the specific aesthetic desired by the designers.”

Pont de la République in Montpellier: immaculate elegance

a maJor aeStHetiC CHallenge

74m long 17m wide

2 rows of 17 y-shaped piers with 9m range and 30cm in diameter, made from stainless steel white Ductal®

Pier compression resistance upper 150 mPa after heat treatment

A new formulation: made from white ductal® with stainless steel fibers

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Blandan Park, planned as the third green space in the city of Lyon, is situated on the site of a former army barracks with architectural features that the city wanted to preserve as part of its 19th-century military heritage.“To support this major historical project, the BASE

landscaping agency – the main contractor through which we became involved – suggested a pathway to represent military defense systems from the ramparts to the present day,” explains Yves Pagès from Explorations architecture, designer of the footbridge crossing the park. “The site’s topography made it possible to symbolize this ‘attack on the walls’ via a footbridge connecting to them after a 100m path, while offering an alternative view of the park, particularly for those with reduced mobility.”

“in this very sophisticated landscape, we felt it would be interesting to incorporate

a mineral structure presenting the thinness and durability of concrete, while blending with the architectural heritage contained in the park. Additionally, the footbridge would be uniform, discreet and integrated as best as possible within these green spaces.”

Composed of a 5cm-thick, dark gray Ductal® deck and a 40cm-thick side rail supported by steel posts, the 100m-long and 2.30m-wide footbridge overlooks the park while gently rising 4m in height. “Our goal is to demonstrate that UHPCs are not reserved for large symbolic sites. Their performances and capacities cover an extremely wide range of applications, enabling them to respond equally well to the most modest specifications, both in terms of scale and budget. The durability and total lack of maintenance helped convince the local authorities of this elegant and discreet project,” says Yves Pagès. “Produced from Ductal®, the structure enjoys a level of durability which was very reassuring for the project owner,” explains Dominique Corvez, Head of UHPC-Ductal® for Lafarge North America. “Combined with the prefabrication by Bonna Sabla of 10 railings using just 2 molds and 2 backing molds, we managed to achieve project economics in line with the city’s budgetary requirements.”

Blandan footbridge: uhPc enhances heritage

Located on a former military site, the 42-acre Blandan Park will offer a green space bordering three districts in the center of Lyon, France. Including various leisure facilities – landscaped green areas, solarium and play wall – the park will feature a walkway “attacking the old barriers” on a footbridge constructed from UHPC. This reveals what happens when an extraordinary material becomes widespread to offer inhabitants a discreet and durable aesthetic.

tHe tHinneSS of Steel and tHe dUraBility of ConCrete

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monolithic and discrete, the footbridge in ductal® is integrated with green spaces.architect: explorations architecture.

the ductal® footbridge provides a 100 meter pedestrian promenade that connects directly to the ancient walls. architect: explorations architecture.

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It has been almost a decade since Lafarge and the Ministry of Transportation of ontario (MTo) embarked on a collaboration that led to the development of a revolutionary, ultra-high performance concrete solution called “Ductal®

Joint Fill”. Since then, this highly durable UHPC solution (which is field-cast and primarily used for the connection of precast bridge elements) has been used on numerous projects. With these proven successes and significant, validated research studies now behind us, the momentum in North America is growing rapidly.

The world’s first Ductal® Joint Fill project was completed for the MTO in 2006 on a small, single span (24.4m long x 11m wide) highway bridge over the Canadian National Railway at Rainy Lake, Ontario. Successful

completion of this project proved that multiple benefits could be realized for precast bridge systems with Ductal® Joint Fill connections: superior strength, durability, fluidity and increased bond capacity. The material’s fiber matrix is significantly stronger than conventional concrete and performs better in terms of fatigue, abrasion and chemical resistance, freeze-thaw, carbonation and chloride ion penetration. Testing has proved that after 10 million equivalent wheel load cycles, there is no leaking through the joint and, when used with precast concrete bridge elements, fabrication and installation processes are simplified, full deck continuity is achieved and the bridge deck joint is no longer the weakest link.

Today, Ductal® UHPC Joint Fill is being used on much larger, high-profile structures. Earlier projects were small, simple span bridges requiring an average of 5m³. More recently, multiple span, larger projects have been completed and new projects awarded that are designed to incorporate up to 500m³.

The Mackenzie River Twin Bridge project in Ontario, Canada is the largest ductal® Joint fill project to date. Each bridge has 2 lanes and 3-spans for a total length of 180m. Altogether, 130 precast deck panels were used; the transverse joints (between panels) are filled with Ductal® as well as the shear pockets and haunches (between panels and steel girders). The precast approach slabs also have Ductal® connections. All precast elements for this project were manufactured by Lafarge Precast in Winnipeg, Manitoba. Ultimately, it took just ten days to cast the 175m³ of material required for this project.

The use of this solution, together with precast concrete bridge elements, has dramatically increased in recent years, with several bridge owners now specifying Ductal® Joint Fill. The MTO and the New York State Department of Transportation (NYSDOT) continue to lead the way with repetitive use of UHPC on their bridge projects; the majority requiring quick rehabilitation or replacement of existing, deficient structures. Previously, the NYSDOT would not consider closing an interstate highway due to high traffic volumes. Now however; thanks to experiences gained from

CHanging SCoPe

SUPerior PerformanCe

the evolution of Ductal® joint fill From humble beginnings to significant growth

little Cedar Creek Bridge, iowa - the first bridge in north america constructed with a ductal® UHPC waffle deck, girders and joints. engineer: wapello County.

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I PAGE 17

the largest ductal® Joint fill project so far - mackenzie river twin Bridges near thunder Bay, ontario, Canada. engineer: mcCormick rankin Corp.

previous successes in rural areas, they have the ability to replace bridge decks during weekend closures.

in North America, the Ductal®

Joint Fill business has become self-perpetuating, indicating an opportunity for enormous growth. in 2010, 5 bridges were completed with Ductal® UHPC Joint Fill. in the summer of 2013, 36 projects were slated for completion by year-end. With projects now completed in Ontario, New York, iowa, Montana, Massachusetts and Oregon, acceptance is increasing at a rapid pace. By the end of 2014, it is expected that Ductal® Joint Fill projects will also be completed in Ohio, Pennsylvania, Manitoba, Nebraska, New Jersey, Utah and South Carolina.

Precast UHPC and HPC bridge solutions work extremely well when used in combination with field-cast UHPC connections, creating sustainable, durable, more resilient bridge structures that are built to last. in remote areas, this solution is especially valuable where access to ready-mix concrete is not available and post-tensioning can be eliminated, thereby simplifying the construction process.

Ductal® UHPC Joint Fill is also an excellent solution for Accelerated Bridge Construction (ABC). For example, some projects have been successfully completed during closures of just one month, one week or even one weekend. Ultimately, by utilizing UHPC’s combination of superior properties in conjunction with precast bridge elements, bridge performance is advanced, accelerated and improved.

adding ValUe

awardSThe following is a list of awards for Ductal® Joint Fill projects:

> Portland cement association (Pca) concrete bridge award - Hawk Lake Bridge, ontario, Canada (2010);

> Precast/Prestressed concrete institute (Pci) Design awards, Honorable Mention/Special Solution - Route 31 Bridge over Canandaiga outlet, New York, USA (2010); Little Cedar Creek Bridge, Iowa, USA (2012) and Hodder Avenue Underpass, ontario, Canada (2013);

> ontario concrete awards - Whitemans Creek Bridge, ontario, Canada (2012);> Pci harry h. edwards industry advancement award - Hodder Avenue Underpass,

ontario, Canada (2013).

Pouring ductal® UHPC into a joint on a precast deck panel system.

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ProJeCt

architect: rudy ricciotti.

I PAGE 19

mucem DuctaL® combiNes techNicaL PeRfoRmaNce with aRchitectuRaL cReatiVity

ProJeCt

The official opening of the new Museum of European and Mediterranean Civilizations (MuCEM) is a major event in Marseille (France), this year’s European Capital of Culture that showcases the amazing performance delivered by UHPC.

Created by Rudy Ricciotti, MuCEM uses the structural strength and aesthetic properties of Ductal® to create an architectural masterpiece that introduces new construction methods and new opportunities for creativity. From post-tensioned, prestressed anchors to the lattice canopy and footbridge (linking the museum to the stone ramparts of Fort Saint-Jean), Ductal’s ductility, durability and mechanical strength properties are fully exploited in this beautiful, lightweight building that is resistant to the ocean and its salty atmosphere.

Take a guided tour of this new technological and aesthetic benchmark.

PAGE 20 I

teSted and ProVen teCHniCal ProweSSUsing UHPC for the structural elements of a public building meant that the material formulation had to be adjusted, especially in terms of its seismic and fire resistance. For this purpose, adding the optimum quantity of polypropylene fibers gave the UHPC the required

level of resistance to high temperatures. The assembly techniques were customized and dictated by the systematic use of prefabrication, not only for the building’s UHPC elements but also for its floors. Close collaboration between Lafarge, Bonna Sabla, Dumez-Freyssinet and Lamoureux & Ricciotti (architect and structural

engineers), made it possible to overcome all these obstacles. The prefabricated elements for MuCEM were the subject of 5 ATex (Technical Experimentation Assessments) conducted by the CSTB (the French Scientific and Technical Center for Building).

Suspended between the sea, land and sky, MuCEM occupies Pier J4 of the former city docks, and is almost unobtrusive by comparison to the Fort Saint-Jean and Old Port of Marseille. Nevertheless, with its prestressed vertical structures and lattice envelope, this 15,000 square meter building is immediately striking because of its technological achievement. Architect, Rudy Ricciotti, wanted to create ‘an ethereal project that was very feminine, but also very muscular with clearly defined tendons and nerves’. The result is a building that is uncluttered to the point of being stripped almost bare. The choice of UHPC enabled the dimensions to be reduced “to the point where all that remains are skin and bones.” MuCEM exploits all of the architectural and structural performances of Ductal® to create the signature elements that make it so distinctive including: pedestrian footbridges, arboresque style columns and a lattice roof and facade.

ProJeCt

UHPC elements

1 Lattice walls 2 Footbridge linking

the museum to Fort Saint-Jean (135 meters with return)

3 Arboresque columns 4 Lattice roof 5 Anchor points

1

2

3

4

5

architect: rudy ricciotti.

I PAGE 21

BUilding on PreVioUS exPerienCe

The footbridges

the longer of the two footbridges is constructed from 25 prefabricated segments that are assembled with post-tensioned cables and a deck consisting of 4cm slabs laid over the segments. the specification demanded construction tolerances of between 0.3 and 0.4mm between components. architect: rudy ricciotti.

From the Panier district of the city, visitors approach Pier J4 over a succession of two footbridges. One of the bridges is 69 meters long and links the Esplanade Saint-Laurent to Fort

Saint-Jean. The other is even longer, reaching out over the sea below like a stretched thread connecting the Fort with Pier J4, and spanning 76 meters between abutments (135 meters with return). “in terms of their design, construction, method and foundations,

these two footbridges are based on the same concept as the Passerelle des Anges in France’s Hérault valley,” explains Patrick Mazzacane, project leader at Bonna Sabla, and Romain

Ricciotti, co-founder of Lamoureux & Ricciotti. These footbridges are constructed in individual precast UHPC segments, each 4.60 meters long and cast from a single mold. They are assembled by prestressing and post-tension with no buttressing and no bracing stays. “UHPC was the only material that would allow us to use such high compression ratios,” says Romain Ricciotti. What makes the segments of these footbridges particularly special is that their webs contain no passive reinforcement.

135tHe lengtH (in meterS) of tHe footBridge linKing mUCem to fort Saint-Jean

4.6mtHe lengtH of eaCH Segment CaSt from tHe Same mold

0.3MPatHe PreSSUre USed to aSSemBle tHe SegmentS

4cmtHe tHiCKneSS of tHe footBridge deCKS

ProJeCt

PAGE 22 I

inside the building, a second, 52-meter square space, houses the museum’s exhibit halls. Between this core and the service spaces, voids surround the central square to create communicating walkways. The walls of the building created on Pier J4 contain 308 structural arboresque style columns. Like individual sculptures, 80 different configurations are created from three types of columns that are Y-, i- and N-shaped. “The prestressed UHPC columns were cast vertically and within a millimeter of accuracy tolerance,” explain Patrick Mazzacane and Romain Ricciotti. A specially developed fiber counting technique was used to check fiber orientation and distribution throughout the full length of each column, and to ensure that there was no fiber segregation present. After the molds were removed, the columns - like the footbridge segments and lattice panels - were sprayed with waterproof sealant and heat treated to achieve their required mechanical performance. Contrary to conventional construction techniques, and for reasons of project phasing, the prestressed concrete floors were installed first on substructures completely independent of the columns.

millimeter aCCUraCy

The columnsin order to control

deflections, such as

buckling under load in

the event of fire, and to

assist with component

assembly, cables were

run through vertical

ducts in each column

and tightened using

jacks at either end.

these columns are also

engineered to withstand

seismic risk through the

use of freyssinet ball-

and-socket joints top and

bottom.

ProJeCt

3 types of columns and 80 different configurations.

architect: rudy ricciotti. architect: rudy ricciotti.

I PAGE 23

The second footbridge leads to the roof terrace of the building: a perfect square with sides that are 72 meters long and 18 meters high. A UHPC lattice panel system envelopes two sides of the building and its roof. its purpose is to

protect the interior against very high levels of sunlight, while allowing the sea air to penetrate the building. Two different types of lattice systems were created for this project, using

horizontal panels for the roof, and vertical panels for

the facade. “We achieved all of that with a thickness of only 7 centimeters for the roof and 10 centimeters for the facade; that’s totally unprecedented for horizontal applications,” continues Patrick Mazzacane. The 384 lattice panels were fabricated using a vertical mold to ensure a smooth finish on both sides. installation began with the roof panels, which are supported on UHPC T-beams. The self-supporting panels were then stacked to create the full height of each facade, retained in position and secured to the main structure using metal connectors.

From every point of view, the unique construction techniques used to create MuCEM are very different from those used in traditional concrete structures. in the words of Romain Ricciotti: “UHPC buildings are now more like metal structures than concrete structures in terms of their conception and design. The problems lie not in the dimensions of a particular element, but in the way they function interactively.” That is one of the great challenges to which MuCEM responds so successfully.

ProteCting tHe interior, wHile oPen to tHe exterior

The lattice facade and roof

with nine different types of lattice panels to create, each with perforations accounting for more than 50% of their surface, fabrication required the development of a vertical molding process to guarantee a smooth finish inside and outside. architect: rudy ricciotti.

the façade lattice panels are secured to the main structure using stainless steel stays. architect: rudy ricciotti.

ProJeCt

www.ductal-lafarge.fr

lafargeUHPC / ductal®

61, rue des Belles feuillesBP 40 - 75782 Paris Cedex 16

france e-mail: ductal@lafarge.com