August 2006

Tunnel Fire Protection

A lost formwork system, using PROMATECT®-H

The Palm Jumeirah Development, Dubai, United Arab Emirates

www.promat-tunnel.com
LOST FORMWORK SYSTEM, PROMATECT®-H
Contents

1. Project Background 3

2. Companies Involved 4

3. Technical Specification and Requirements for Fire Protection of Structural Concrete 5/7

4. Promat Technical Offer 8/17

5. Installation Guide and Experiences 18/20

6. Project References in Lost Formwork Application 21

7. Acknowledgement and Reference List 22

8. PROMATECT -H Technical Data Sheet for The Palm Jumeirah Tunnel, Dubai
® .
23

This brochure describes the use of Promat fire protection lining boards installed
on the tunnel project on The Palm Jumeirah.

The photographs on the cover page and pages 2 and 3 of this brochure are reproduced courtesy
of the Taisei Corporation.

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LOST FORMWORK SYSTEM, PROMATECT®-H
1. Project Background

The Palm Jumeirah development on the coast of Dubai is a man-made island in

the shape of a palm tree extending into the Arabian Gulf.

The project was launched in 2001 with reclamation starting the same year.
Approximately 100 million cubic meters of sand were placed to form the The Palm Jumeirah,
which consists of a main trunk with a total of 17 fronds extending each side, all being encircled
by a Crescent, which forms a breakwater. The island extends 5 kilometres into the Arabian Gulf
area and is 5 kilometres wide.

The Crescent is connected to the trunk by a 1.4 kilometre long cut and cover, sea-crossing
tunnel. In addition to vehicular traffic, a mono rail system is being constructed from the
Gateway station for the entire length of the island’s trunk to the Atlantis station with two
intermediate stations. On completion, The Palm Jumeirah which is envisaged to be one of the
world’s premier living and tourism destinations, will contain a total of approximately 1540 villas in
a number of distinctive styles. There will also be 20 shoreline apartment buildings of 13/14 levels
containing a mixture of 1, 2 and 3 bedroom units, totalling approximately 2500 apartments.
In addition to this there will be 4 large marinas and over 30 of the world’s top hotels.

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 LOST FORMWORK SYSTEM, PROMATECT®-H
2. Companies Involved

NAKHEEL – PROPERTY DEVELOPER

Comments by Mr Akihiko Mochizuki,
Project Manager for Taisei Corporation. The project developer for The Palm Jumeirah is Nakheel, the Middle East’s leading property
Main Contractor, The Palm Jumeirah tunnel development company.
project.
As the developer of more than $30 billion of real estate in Dubai, Nakheel has been instrumental

“ We ordered PROMATECT -H boards in

®

October 2005, with a schedule of required

in turning Dubai into one of the fastest growing cities in the world, and a world class destination
for business and tourism. In addition to The Palm Jumeirah, Nakheel is developing two other
deliveries to meet our construction palm shaped islands, The World – 300 islands in the shape of the world – and Dubai Waterfront,
programme through to mid-2006. the world’s largest waterfront development and a number of large scale inland developments.
The boards were received on, or before,
our required dates.
PARSONS BRINCKERHOFF - PROJECT MANAGEMENT CONSULTANTS
The boards were well packed and protected One of the leading transportation engineering companies in the world providing design,

and no transit damage was experienced. construction and programme management world-wide and specialising in transit systems,
tunnels, bridges and airports.
We decided to set up a dedicated
storage/workshop area on site, where
PARSONS DE LEUW CATHER - SUPERVISING CONSULTANTS
we could prepare the boards prior to
Internationally renowned consultants on roads and highways, transportation systems,
installation. This area was manned by a
bridges and tunnels.
team of men who prepared and cut the
boards. The same team was also responsible
for installation. TAISEI CORPORATION - DESIGN AND BUILD MAIN CONTRACTOR
One of the largest Japanese construction and engineering companies working on
Promat sent two engineers to site during
major projects world-wide. Taisei appointed Halcrow International Partnership as their
our first few days of the project to give
design partners.
advice to our installation team. Promat
continued with periodic on-site advice during
the project.

The PROMATECT®-H boards were supplied

accurately cut and finished within the
required dimensional tolerances.

Our installation team found the boards

easy to handle and place, as proved by the
improved production and installation rate.

The key point of the installation was the

curved section, where each row of boards
was placed on plywood in the workshop
area and cut in one go. This resulted in
minimising the gap between the boards
as a result of Promat’s and Taisei’s idea.

The finished lining to the tunnel provided

a pleasant appearance with minimised gaps
between boards.
”

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LOST FORMWORK SYSTEM, PROMATECT®-H
3. Technical Specification and Requirements for Fire Protection of Structural Concrete

3.1. REASONS TO PROJECT A CONCRETE TUNNEL AGAINST FIRE

Concrete tunnels are vulnerable to elevated temperatures caused by fire. Tests have shown that
when the temperature of the reinforcement reaches 300˚C, the bond between the rebar and
concrete will be significantly reduced, leading to irreparable sagging and possible collapse of
the total structure. Moreover, when concrete is exposed to fire temperatures as experienced
in tunnels, concrete spalling often occurs.

Spalling is an umbrella term, covering different damage phenomena that may occur to a
concrete structure during fire. These phenomena are caused by different mechanisms:
pore pressure, thermal gradient, internal thermal micro-cracking, cracking around reinforcement
bars and strength loss due to chemical transitions. In different combinations of these
mechanisms, possible spalling phenomena include violent spalling, progressive gradual
spalling, explosive spalling, corner spalling and post-cooling spalling [1]*.

The Palm Jumeirah tunnel is constructed using a C40 concrete grade, which was cast in place.
If left unprotected, such concrete would typically suffer from violent spalling if it was exposed
to a typical tunnel fire, which creates temperatures up to 1200˚C within only 5 minutes.
Violent spalling is the separation of small or larger pieces of concrete from the cross section,
during which energy is released in the form of popping off of the pieces and small slices with
a certain speed, and also a popping or cracking sound. This type of spalling is caused by pore
pressure and thermal gradients [1]*.

* Refer to ‘References List’ on page 22.

Severe concrete spalling after

fire exposure in tunnel

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 LOST FORMWORK SYSTEM, PROMATECT®-H
3. Technical Specification and Requirements for Fire Protection of Structural Concrete

3.2. DEFINITION OF DESIGN FIRE CURVE

In the late 1970’s the Dutch Ministry of Transport, Rijkswaterstaat (RWS), contemplated
the structural safety of their immersed tunnels in case a large fire would occur.
In co-operation with TNO Centre for Fire Safety in the Netherlands, a series of small-scale tests
were carried out, which resulted in the time-temperature curve as we now know as the RWS
fire curve.
RWS fire curve, RijksWaterStaat, NL

1400 1350
1300 1300

1200 1200
1200
1140

1000
Temperature [°C]

890

800

600

400

200

20
0
0 30 60 90 120
Time [min]

RWS fire curve, 120 minutes as applied in The Palm Jumeirah tunnel

The worst case scenario was defined as a 50m3

Test nr. Description of the fire load in Runehamar tests Total
weight (kg) petrol tanker that would catch fire in the tunnel,
creating a pool-fire size of some 150m2 and lasting
1 360 wood pallets measuring 1200 x 800 x 150mm 10911
20 wood pallets measuring 1200 x 1000 x 150mm 120 minutes. Such a fire would create a heat release
74 PE plastic pallets measuring 1200 x 800 x 150mm
rate of 300MW. Years later, the accuracy of this fire

2 216 wood pallets 6853 curve was confirmed by the Eureka tests, BRE and
240 PUR mattresses measuring 1200 x 800 x 150mm the Memorial Tunnel tests in the USA. In the frame of
a Swedish national and a European research program
3 Furniture and fixtures (tightly packed plastic and wood cabinet doors 8500
upholstered PUR arm rest, upholstered sofas, stuffed animals, on tunnel safety (UPTUN), comprehensive large scale
potted plant (plastic), toy house of wood, plastic toys). fire tests have been carried out in the abandoned
10 large rubber tyres (800kg)
Runehamar road tunnel in the western part of Norway
4 600 corrugated paper carton with interiors (600 x 400 x 500mm) 3120 in September 2003.
and 15% of total mass of unexpanded polystyrene (PS) cups
(18000 cups) and 40 wood pallets (1200 x 1000 x 150mm) In the 4 tests that were conducted during this project,
the RWS curve was confirmed to be the right choice
as a design fire curve for tunnels. Even with very limited fire loads temperatures reached up to
1250-1350˚C.

It should be noted that all combustible materials, which were used in these tests, are not listed
as hazardous/dangerous. Products like petrol, paints, resins etc were not used as combustibles.
A fire in a truckload of pallets (test 1) made the gas-temperatures rise up to 1365˚C. A small
truckload of plastic cups in cardboard boxes (test 4) created gas-temperatures of over 1200˚C.

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LOST FORMWORK SYSTEM, PROMATECT®-H
3. Technical Specification and Requirements for Fire Protection of Structural Concrete ASSOCIATION
INTERNATIONALE DES TRAVAUX
EN SOUTERRAIN ITA
AITES
INTERNATIONAL
TUNNELING
ASSOCIATION
Towards an In Consultative Status, Category II with the
improved use United Nations Economic and Social Council
of underground http : //www.ita-aites.org
space

Working Group 6 of the ITA (International Tunnelling Association), focussing on Maintenance International Tunneling Association
Association Internationale De Travaux En Souterrain
and Repair of tunnels, has adopted the complete Runehamar report as mentioned under [2]*.
They included the Runehamar report in their final document [3]*, thus acknowledging the GUIDELINES FOR STRUCTURAL
FIRE RESISTANCE
conclusion that the RWS curve is the right choice as a design fire curve for tunnels. FOR
ROAD TUNNELS

Based on the information opposite and conducted research from all over the world, the
DIRECTIVES POUR LA RESISTANCE AU
developer decided to apply the highest and safest available standards for fire protection FEU DES STRUCTURES DE TUNNELS
ROUTIERS
of tunnels to the The Palm Jumeirah tunnel: the RWS requirements.

BY
Working Group No.6 Maintenance and Repair
o
Groupe de Travail N 6 Entretien et Repaire

May, 2004

International Tunneling Association, WG-6 document

3.3. THERMAL PERFORMANCE CRITERIA

The Dutch Ministry of Transport, Rijkswaterstaat (RWS), in close co-operation with TNO,
Centre for Fire Research in The Netherlands has issued a test procedure for fire protection
of tunnels [4]*.

As described in section 6.1 of this procedure, the thermal performance should comply with
RijksWaterStaat (RWS) fire, 120 minutes
the following criteria:
Protected concrete specimen
When spalling is not decisive during the 2 hours heating period the following temperature values and RWS temperature criteria

shall not be exceeded:

a) 380°C for each measuring point in the interface concrete/protective material;

b) 250°C for each measuring point at 25mm above the bottom of the concrete slab
(thermocouples fixed to the under side of the reinforcement).

During the 2 hours heating period, the material must not fall down as a result of failure of
the offered fixing system.

* Refer to ‘References List’ on page 22.

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 LOST FORMWORK SYSTEM, PROMATECT®-H
4. Promat Technical Offer

4.1. THERMAL PERFORMANCE OF PROMATECT®-H BOARDS

Promat conducted several fire tests at TNO Centre for Fire Research which proved
that the system meets the specifications as defined in the RWS test procedure.
The conclusion of these tests is that 27,5 mm PROMATECT®-H boards will provide sufficient
insulation to the concrete structure to meet the RWS requirements as listed in paragraph 3.3.

The graphs below indicate the thermal performance of 27,5 mm PROMATECT®-H boards when
applied for concrete protection [5]*. As can be seen, the recorded temperatures on the interface
(approximately 320ºC) and the reinforcement (165ºC) are well below the RWS criteria of 380ºC
and 250ºC respectively.

350.0

300.0

TNO Efectis Netherlands: largest RWS-fire

capable furnace in Europe
250.0
ºC

200.0
Temperature

150.0
p

100.0

50.0

0.0
0 20 40 60 80 100 120 140
Time (min) T rebar average
T interface average

Thermocouple recordings during the fire

* Refer to ‘References List’ on page 22.

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LOST FORMWORK SYSTEM, PROMATECT®-H
4. Promat Technical Offer

4.1.1. PROMATECT®-H CEILING SYSTEM, LOST

FORMWORK METHOD
In this project the PROMATECT®-H boards in the ceiling were applied
using the lost formwork method. Basically this system consists of the
following installation steps:

1. The boards are laid on the load-bearing formwork

The PROMATECT®-H boards will be laid with the smooth face down
A - Principle of lost formwork
(see drawing A), as this will provide the fair faced finish after
completion of the tunnel.

It is very important to align the first row of boards preferably alongside

a ruler or a strip of plywood, which is screwed to the formwork.
The rest of the boards are laid next to each other, with butted joints,
utilising the previous row as the next ruler. No special treatment on
the joints is required (see photographs B, C and D).

Where the tunnel is designed with sloped sections, so called haunches, B - Fixed strip of plywood serves as a ruler for the first row of boards
the edges of the boards are simply cut under an angle and installed
butt-jointed (see photograph E).

In order to minimise tolerances by cutting on the job site, there are

two options. One is to lay the boards on the formwork, draw the
cutting line (for example at the end of a section) and cut all boards
in one go alongside a ruler on the formwork. The second option is to
pre-cut the boards in a dedicated workshop on site. This second
method was used by Taisei and has proven its accuracy, based on C - The boards are laid with the smooth face down

the minimised gaps between the boards.

The boards can either be installed using staggered joints or straight joints. Experience from
contractors has learned that the staggered joint method results is less gaps in between the
boards, as this method allows to compensate for certain tolerances, whereas the straight joint
method does not allow for much compensation. For The Palm Jumeirah tunnel, Taisei chose
to lay the boards with straight joints.

D - The joints are just butted, no special E - The boards are cut under an angle at the haunches
treatment of the joints are required

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 LOST FORMWORK SYSTEM, PROMATECT®-H
4. Promat Technical Offer

The locations of the screws are marked on the boards, using a template and
a spray-can with red paint (see par. 5.1.), (photograph F).

2. The first layer of reinforcement is installed

Prior to the installation of the stainless steel screws, the first layer of
reinforcement is installed on the stools (spacer blocks creating concrete
cover). In this way the screws are always protected from people stepping on
F - The screw locations are pre-marked on the boards them (see photograph G).

3. Stainless steel screws are partly inserted in the PROMATECT®-H

boards
The 50mm long screws (as detailed on page 13) are inserted to a depth of
20mm, through the openings in the reinforcement; the remaining 30mm sticks
out of the board creating the anchorage to the concrete after it has been
poured (see drawing H).

Several methods are available on the market for ease of installation of the
stainless steel screws (see photographs I and J):

G - First layer on reinforcement installed, prior to inserting the screws
Battery-driven drilling machines can be equipped with depth

guiding devices to ensure the correct drilling depth of 20mm.

Screws can be supplied on a plastic strip, which is fed into the

drilling machine, increasing the installation speed.

Battery-driven drilling machines can be equipped with a tube

through which the screw can be dropped down onto the

surface of the board. The installer can remain standing upright
H - Principle of screw insertion while installing the screws.

I - Insertion of the screws

J – Screw installed and protected by reinforcement

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LOST FORMWORK SYSTEM, PROMATECT®-H
4. Promat Technical Offer

4. The concrete is poured

Before the concrete is poured, the PROMATECT®-H boards can be hosed down to remove the
accumulated site debris and to humidify the boards to prevent that water is extracted from the
concrete mixture. Excessive water should be removed from the surface of the boards prior to
the pouring of the concrete (see photograph K). During vibration of the concrete, the machinery
being used should be kept away from the surface of the PROMATECT®-H boards.
K - The pouring of the concrete

5. After the concrete is sufficiently cured the formwork will be extracted

As there is no adhesion between the concrete and the formwork, it will be easy to extract the
formwork and it remains clean (see photograph L).

The following advantages of the PROMATECT® H lost formwork system have been reported by
contractors over the years:

Formwork savings:

The shuttering material only has to have load-bearing properties. There is no need to apply
phenol coated plywood boards as the PROMATECT®-H boards will be laid on top of the L - Extracted formwork. Flush finish of the ceiling
formwork. The formwork elements just have to be installed properly (flush).

As the concrete will not be in direct contact with the formwork, there is no need for
de-moulding oil (no slippery surfaces). The plywood sheets will remain clean and can
be re-used.

Formwork can be installed at a distance of up to 90mm from the side walls.
The PROMATECT®-H boards can span that distance, depending on the expected load.
At this location, care should be taken with the vibrating action during pouring of the concrete.
Extraction of the formwork is much easier as it will not get stuck between the walls.

As there is no adhesion between the concrete and the formwork, it is easy to extract
the formwork

Regular load bearing plywood can be applied,

instead of phenol coated plywood

Cutting the boards on the formwork eliminates the tolerences Wall panels can also be installed using the lost formwork method Distance between formwork and wall, easing
the extraction of the formwork

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 LOST FORMWORK SYSTEM, PROMATECT®-H
4. Promat Technical Offer

Ease of installation:

Joints in between boards only have to be butt-jointed. No special treatment such as filler or
mastic is necessary from a fire performance point of view. The cement water will not run
through the joints. Where gaps of more than 1mm occur, mastic can be used to seal
the gap in order to prevent that cement water would leak through the gap, causing an
unsightly stain.

The vertical wall panels can also be installed using the lost formwork system

Curves in the tunnel can easily be dealt with by cutting the boards on the formwork

Openings in the PROMATECT®-H lining (for manholes and end-walls) can easily be made
by installing a phenol coated formwork panel instead. Afterwards standard size
PROMATECT®-H boards will close the opening by post-fixing the board into the opening.

PROMATECT®-H boards provide a heavy-duty floor surface. The abrasion resistance is such
that the surface can withstand the exposure to people walking and working on top of it,
even in wet conditions. Also, the weight of bundles of reinforcement steel and pallets in
excess of one tonne will not cause any damage to the boards.
Openings for manholes can easily be made
Rapid installation method. Installation rates for the PROMATECT® -H boards of 150m2 per
by using phenol coated plywood panels
man per day have been reported on European tunnel projects.

The installation of the system does not interfere with other construction activities.

Extensive experience is available with this system in immersed and cut and cover tunnels

Tunnel services and special shapes:

Anchor systems (i.e. jet-fans) can be fixed on the boards, prior to casting the concrete

Services, pipes, tubes etc. can be included

After the formwork is extracted, services can be installed on the PROMATECT®-H lining
from below. Anchors can be installed through the boards into the concrete, thus providing
a continuous fire protective layer.

Special shapes in the concrete structure can easily be made (i.e. beams)

Other:

As the PROMATECT®-H boards are installed in the very early stages of the construction
of the tunnel, it provides fire protection during the construction phase.

The PROMATECT®-H lost formwork system provides a flush finish of the ceiling.
Inclusion of services and pipes in formwork
No obstacles like anchor-heads.

Anchors for services are installed through

boards into the concrete, thus creating
a continuous fire protective layer Special shapes in the concrete can easily be made

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LOST FORMWORK SYSTEM, PROMATECT®-H
4. Promat Technical Offer

4.1.1.a. SCREW MODEL DESCRIPTION

The applied screws for the lost formwork system are 5.0 x 50 mm chipboard screws,
with a countersunk (CSK) head type and a pozidrive-2 connection. These screws were applied
in a stainless steel grade A2 (1.4567). See par. 4.1.3 for more details on this.

Dimensional details of this particular screw can be found in the below table and drawing.

Code Description Dimension (mm) Tolerance

L Length 50 -

Lv Length of winding 44 +/- 1,5 mm

Lt Length of serrated winding 29 +/- 1,5 mm

d1 Threat diameter 5,0 +0,2 -0,35 mm

d2 Shaft diameter 3,05 - 3,45 -

dk Head diameter 9,7 +0 -0,5 mm

P Winding distance 2,5 +/- 10%

k Connection depth, Pozidrive-2 2,6 - 3,0 -

m Connection width 5,3 -

,V¼
K
² ¼²
D

D

(
²
²

²
DK
²

²

0 M
,T¼

, Source: Heco

The design of a screw has major influence on the mechanical performance and fire performance,
in combination with PROMATECT®-H boards. Among others, properties like shaft-diameter
versus thread-diameter, sharpness of the tip and distance of the winding (thread) will influence
the stickability of the screws and the performance of the final system.

The above mentioned screw type has been tested to its pullout resistance when partially
(20 mm) inserted into dry as well as water saturated (worst case) 27,5mm PROMATECT®-H
boards [6]*. Even when tested in water saturated conditions the minimum-recorded screw
pullout strength was in excess of 500N, which was satisfactory for the client. In dry conditions
the maximum-recorded screw pullout strength exceeded 725N.

Similar screws as described above have also been used in a lost formwork system in a fire
test at TNO where PROMATECT®-H boards have been exposed to the RWS fire curve for
120 minutes, without any mechanical or thermal failure [7]*..

13 * Refer to ‘References List’ on page 22.

 LOST FORMWORK SYSTEM, PROMATECT®-H
4. Promat Technical Offer

4.1.1.b. TUNNEL EXPANSION JOINTS

The expansion joints are kept watertight by means of a rubber profile which is embedded in
the concrete. During the lifetime of the tunnel an expansion joint can create a gap of up to a
maximum of 35mm as a result of thermal movement of the tunnel. This could potentially cause
a thermal leak in case of fire as the PROMATECT®-H boards will follow the movement of the
structural concrete it is mounted on. In order to address this, cover strips of the same
PROMATECT®-H 27,5 mm material are installed behind the joints and are fixed with stainless
steel screws to one side. In this way a potential gap in between the boards, at the location
of the expansion joint, is always closed and the fire performance is secured.

Detail of an expansion joint and cover

strip allowing movement 4.1.2. PROMATECT®-H WALL SYSTEM, POST-FIXED METHOD
Just like the ceiling system, the wall panels can also be installed as a lost formwork system.
The boards are temporarily connected to the vertical formwork by means of 4 screws per panel.
The anchorage of the PROMATECT®-H board to the concrete is again done by means of partially
inserted screws.

For the Palm Jumeirah tunnel it was decided to install the wall panels after the walls had been
constructed. The boards were installed by means of stainless steel anchors, creating fire
protection over a height of 1200mm on the wall. The boards were anchored to the concrete,
butt jointing one board next to the other. The reason for protecting the top section of the wall
is that the bending moment in the roof introduces compression stresses into the upper part of
the wall. Research has proven that concrete that is exposed to compression stress is more
vulnerable to fire exposure (spalling), as opposed to neutral (non-loaded) or tensioned concrete.

4.1.2.a. ANCHOR MODEL DESCRIPTION

The selected anchor type is the Fischer FNA 6x30/30 A4. These anchors were applied in
a stainless steel grade A4 (1.4401). See par. 4.1.3 for more details on this.

The FNA anchors are installed in combination with a circular washer, diameter 30mm, thickness
1,2mm stainless steel grade A4
Code Description Dimension (mm)
and a hole diameter of 7,5mm.
do Anchor diameter 6
This FNA anchor, including
l Length 68
the washer, was tested at TNO,
h ef Effective anchorage depth 30 Centre for Fire Research in RWS
fire conditions for 120 minutes
t fix Effective length 30
in combination with the 27,5mm
d Diameter of nailhead 13 PROMATECT®-H boards and
Fischer FNA anchor and washer
passed the test, without any
mechanical or thermal failure [5]*.
do d

h ef t fix
l * Refer to ‘References List’
on page 22.
Source: Fischer

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LOST FORMWORK SYSTEM, PROMATECT®-H
4. Promat Technical Offer

The aforementioned anchor type, including the washer, has also been tested for its pull-through
resistance when installed in dry and water saturated (worst case) 27,5mm PROMATECT®-H
boards [8]*.

Even when tested in water saturated conditions the recorded anchor pull-through strength was
in excess of 2400N, which was satisfactory for the client. In dry conditions the recorded anchor
pull-through strength exceeded 3300N.

In general, when selecting anchors for the installation of fire protective boards in tunnels,
following items should be considered:

Preferably M6 in diameter, to avoid heat sink into the concrete in case of fire

Made of stainless steel. Grade in function of local tunnel environment (see par. 4.1.3.)

Of appropriate length to secure the panel, depending on the panel thickness

Expansion action of the anchorage shall be within the concrete and not in the
PROMATECT® panel.

Can be supplied with a nut and washer head to facilitate removal of the PROMATECT®
panels where required.

Suitable for use in the tension zone of concrete (cracked concrete).

Suitable for use where the bolts will be subject to positive and negative pressure fluctuation.

4.1.3. CORROSION RESISTANCE OF FIXATION MATERIALS,

STAINLESS STEEL GRADES
As described in par. 4.1.1.a. and 4.1.2.a. the fixation materials for the installation of the
PROMATECT®-H boards are made out of stainless steel.

Item Group Material DIN AISI Chemical Composition

C Si Mn S Cr Mo Ni Cu

Post fixed wall: A4 1.4401 X4CrNiMo17-12-2 316 0,04 0,50 1,00 0,015 17,50 2,25 12,00 -
Fischer anchor
FNA 6x30/30

Lost formwork A2 1.4567 X3CrNiCu18-9-4 304 Cu 0,03 0,50 1,00 0,015 18,00 - 9,00 3,50
ceiling:
Screw 5 x 50mm

The above mentioned stainless steel grades were also used for the fire tests and mechanical
tests. In general, the corrosion resistance of fixing materials for fire protective boards in a tunnel
should be checked with the fixing supplier as to the suitability of application in the specific
environmental conditions of the tunnel project it is meant for.

* Refer to ‘References List’ on page 22.

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LOST FORMWORK SYSTEM, PROMATECT®-H
4. Promat Technical Offer

4.2. DYNAMIC LOAD EXPOSURE ON THE FIRE PROTECTIVE LINING

When the tunnel is in operation and traffic passes through the tunnel, the tunnel lining gets
exposed to air pressure/de-pressure fluctuations (dynamic loads) especially from trucks.
The de-pressure loads in particular can cause integrity problems to fire protective linings.
Several tests were conducted at the Technical University of Braunschweig, Germany in order
to judge the behaviour of both the lost formwork system (ceiling) as well as the post-fixed
system (wall) [9]*.

4.2.1 DYNAMIC LOAD ON LOST FORMWORK SYSTEM (CEILING)

When concrete is poured on the surface of PROMATECT®-H boards, the boards will absorb
some cement water creating additional adhesion of the boards to the concrete surface.
This effect results in an increased stickability of the boards, as these are not relying on the
screws only. However, during the lifetime of the tunnel the adhesion effect of the cement
water could decrease, as a result of movement of the tunnel tube and temperature differences.
In that case the boards are again relying on the pullout strength of the screws, when the
lining gets exposed to dynamic loads.

In order to simulate this worst case scenario, dynamic load tests were conducted using a
polyethylene foil at the interface, in between the PROMATECT®-H boards and the concrete,
to avoid the adhesion effect [9]*. The whole system was exposed to dynamic loads of up to +/-
3 KPa, which is approximately 3 times the load expected in practice. No mechanical failures or
any damage to the boards were recorded. The deflection between the screws was less than
1/15.000 of the span.

4.2.2. DYNAMIC LOAD ON POST-FIXED SYSTEM (WALL)

27,5 mm thick PROMATECT®-H boards were also tested to dynamic loads when post-fixed
to a concrete slab, using 3,8 anchors per m2, in combination with a 30mm circular washer [9]*.
This average of 3,8 anchors per m2 is even less than the 4,5 to 5 anchors per m2 which
are applied in practice. The system was exposed to respectively 3, 4 and 5 KPa.
The maximum deflection at 5 KPa was recorded at 1/1.500 of the span between
the anchors. No mechanical failures or any damage to the boards were recorded.

4.3. SURFACE QUALITY AND CLEAN-ABILITY

The standard appearance of PROMATECT®-H is a white to off-white colour, having diffuse
light reflectance properties, suitable for tunnel linings. When properly maintained the surface
can be cleaned by means of professional washing equipment. The abrasion resistance of the
surface is such that it will withstand the cleaning action of the brushes.

* Refer to ‘References List’ on page 22.

16
LOST FORMWORK SYSTEM, PROMATECT®-H
4. Promat Technical Offer

4.4. DIMENSIONAL TOLERANCES OF PROMATECT®-H BOARDS

The dimensions of each tunnel section in the ceiling area are approximately 16 x 25 meters.
If the dimensional and squareness tolerances on the PROMATECT®-H boards were too large,
gaps would occur while laying the boards on the formwork as the tolerances will add up.
In order to avoid this effect, PROMATECT®-H boards are cut to tight tolerances in the factory,
such that gaps between the boards will be minimised. 1250 mm

Item Specification Tolerance

Thickness Nominal 27,5 mm Minimum 27,0 mm

Maximum 30,0 mm
A B

Length and width L x W = 2500 x 1250 mm +/- 1,0 mm on L and W

Squareness Difference in diagonal lengths A – B < 1,5 mm

2500 mm
Straightness of edges Maximum theoretical gap in between two boards < 1,5 mm

4.5. REPAIR OF MINOR DAMAGES

PROMATECT®-H boards, when installed in a lost formwork system, provide a heavy-duty floor
surface. The abrasion resistance is such that the surface can withstand the exposure to people
walking and working on top of it, in all weather conditions. However, in practice, minor damage

can occur on the jobsite. In case minor surface damages or gaps in between the boards in Definition of
diagonal lengths
excess of 2 mm would occur, these would be filled with PROMATECT®-T compound, prior to
casting the concrete. This material comes as a dry, white to off white powder made from
calcium-aluminium silicates and additives. It will just be mixed with water and is then applied
with a spatula.

The PROMATECT®-T compound was tested to RWS conditions for a duration of 120 minutes
[10]*. A gap of 10mm width was left open in between two PROMATECT®-H panels of 27,5mm
thick. Also two holes of 10mm diameter were drilled into the panels. Both the gap and the holes
were filled with the PROMATECT®-T compound, which did not show any integrity failures during
and after the fire test. The average interface temperature at the joint (behind the PROMATECT®-T
compound) after 120 minutes of RWS fire exposure was 335ºC, which is well below the interface
criteria of 380ºC according to RWS requirements.

See the technical data sheet for more details and installation and application instructions [11]*.

* Refer to ‘References List’ on page 22.

17
 LOST FORMWORK SYSTEM, PROMATECT®-H
5. Installation Guide and Experiences

5.1. CEILING APPLICATION

12 screws per m2 were applied during the fire test at TNO, The Netherlands [7]*.
In order to ensure the same fire performance in practice, the exact same set-up as during
the fire test should always be followed, including fixing materials.

The screw pattern of a full size board of 2500 x 1250 mm looks as detailed below, providing an
average of 12,8 screws per m2:

In The Palm Jumeirah tunnel the PROMATECT®-H boards were supplied in dimensions of
2500 x 1250 mm. The locations of the
screws were marked on the boards, using
Template for screw location a template and a spray-can with red paint.

The majority of the boards are laid on the

formwork in its standard full size dimension.
Some panels had to be cut to size in order
to cover the whole surface of the formwork
and to connect to the walls and construction
joints. Where cut to size panels are used,
the following criteria should be followed:

The minimum amount of screws

should be 12 screws per m2.
Spray can to mark screw location using template

The edge distance should be 50mm

The screws for cut pieces should
be evenly distributed over the surface
of the panel. That means that the
spacing distances in X and Y direction
should be optimised and be as close
as possible.

* Refer to ‘References List’ on page 22.

18
LOST FORMWORK SYSTEM, PROMATECT®-H
5. Installation Guide and Experiences

The drawing opposite is an example

of a screw pattern on a cut to size
panel of 1675 x 1090mm, in which
all criteria are followed. The surface
area of the panel is 1,83m2 which
means that the minimum amount
of screws should be 22. In this case
the total amount is 24 screws and
the edge distance of 50mm is
followed. The spacing distances are
optimised and are almost equal
(315 and 330 mm).

5.2. WALL APPLICATION

Post-fixed installation of PROMATECT®-H
boards require 4,5 to 5 anchors per m2.
The anchors will be installed using a
circular washer of 30mm diameter, as
described in par. 4.1.2.a.

The anchor pattern of a full size board of

2500 x 1250mm looks as follows, having
an average of 4,8 anchors per m2:

The majority of the boards are installed

against the wall in standard (full size)
dimensions. Some panels have to be cut
to size in order to connect to the ends of
the tunnel element.

19
LOST FORMWORK SYSTEM, PROMATECT®-H
5. Installation Guide and Experiences

In case of cut to size panels, the

following criteria should be
followed:

The minimum amount of anchors

should be 4,5 anchors per m2.

The edge distance should be

100mm.

The anchors for cut pieces

should be evenly distributed

over the surface of the panel.
That means that the spacing
distances in X and Y direction
should be optimised and be
as close as possible.

The drawing opposite is an example

of an anchor pattern on a cut to
size panel of 1820 x 1250mm,
in which all criteria are followed.

The surface area of the panel is 2,28m2 which means that there should be a minimum of
11 anchors. In this case, the total amount is 12 anchors and the edge distance is 100mm.
The spacing distances are optimised and are almost equal (525 and 540 mm).

20
LOST FORMWORK SYSTEM, PROMATECT®-H
6. Project References in Lost Formwork Application

Throughout the world, Promat boards have been applied to protect over 120 tunnels against
the most severe tunnel fires. Amongst others, the PROMATECT®-H lost formwork system as
used in The Palm Jumeirah tunnel was also installed in following reference projects:

Project name Year of Country City Tunnel

Installation Use Aquaduct Abcoude, Netherlands

Aquaduct Abcoude 2005 The Netherlands Abcoude Train

Roer Tunnel 2005 The Netherlands Roermond Road

Gotha Tunnel 2003 Sweden Gothenburg Road

Viaduct Schiphol Airport 2002 The Netherlands Amsterdam Road

Caland Tunnel 2002 The Netherlands Rotterdam Road

High Speed Line 2002 The Netherlands Rotterdam High speed

train

Seitwende Tunnel 2002 The Netherlands The Hague Road

Elbe Tunnel 4th Tube (ramps) 2001 Germany Hamburg Road

2nd Benelux Tunnel 2001 The Netherlands Rotterdam Road

City Northern Bypass Tunnel 1998 Australia Perth Road

Tunnel under North River 1989 The Netherlands Hendrik Ido Road
Roer Tunnel, Netherlands
Ambacht

Harbour Tunnel CANA 1989 USA Boston Road

City Northern Bypass Tunnel - Perth, Australia

Harbour Tunnel CANA, USA Gotha Tunnel, Sweden Seitwende Tunnel, Netherlands
21
The authors are grateful to the owner of LOST FORMWORK SYSTEM, PROMATECT®-H
The Palm Jumeirah tunnel, NAKHEEL, for
7. Acknowledgement and Reference List
allowing Promat to issue this document.

REFERENCE LIST
[1] SPALLING OF CONCRETE AND FIRE PROTECTION OF CONCRETE STRUCTURES
A. J. Breunese and J. H. H. Fellinger
TNO Building and Construction Research, Centre for Fire Research, Delft/Rijswijk,
The Netherlands
[2] SUMMARY OF LARGE SCALE FIRE TESTS IN THE RUNEHAMAR TUNNEL IN
NORWAY, CONDUCTED IN ASSOCIATION WITH THE UPTUN RESEARCH PROGRAM
Jan Brekelmans, TNO Building and Construction Research, Centre for Fire Research,
René van den Bosch, Promat Tunnel Fire Protection
[3] GUIDELINES FOR STRUCTURAL FIRE RESISTANCE FOR ROAD TUNNELS
ITA, International Tunnelling Association, Working Group No.6 Maintenance and
Repair, May, 2004
[4] FIRE PROTECTION FOR TUNNELS, Part 1: Fire Test Procedure,
1998-CVB-R1161 (rev. 1)
TNO Building and Construction Research, Centre for Fire Research, Delft/Rijswijk,
The Netherlands
[5] DETERMINATION OF THE BEHAVIOUR OF A CONCRETE SLAB PROTECTED WITH
CALCIUM SILICATE BOARD TYPE PROMATECT®-H UNDER RWS FIRE
CONDITIONS, 2004-CVB-R0115[Rev.1].
TNO Building and Construction Research, Centre for Fire Research, Delft/Rijswijk,
The Netherlands
[6] SCREW PULLOUT OF PROMATECT®-H IN DRY AND WATER SATURATED
CONDITION
PRTC, Promat Research and Technology Centre, 30 November 2005
[7] DETERMINATION OF THE BEHAVIOUR OF A CONCRETE SLAB PROTECTED WITH
CALCIUM SILICATE BOARD TYPE PROMATECT®-H UNDER RWS FIRE
CONDITIONS, B-85-191(E)
TNO Building and Construction Research, Centre for Fire Research, Delft/Rijswijk,
The Netherlands
[8] PULL THROUGH TEST ON PROMATECT®-H 27,5 MM OF FISCHER FIXATIONS
AT060131
PRTC, Promat Research and Technology Centre, 2 February 2006
[9] TESTING OF DYNAMIC LOAD CYCLES IN 27,5 MM PROMATECT®-H BOARDS
(German)
6432/328-Pm/br Technical University Braunschweig, 25 July 1989
[10] DETERMINATION OF THE BEHAVIOUR OF A CONCRETE SLAB PROTECTED WITH
CALCIUM SILICATE BOARD TYPE PROMATECT®-H UNDER RWS FIRE
CONDITIONS, 2004-CVB-R0114[Rev.1].
TNO Building and Construction Research, Centre for Fire Research, Delft/Rijswijk,
The Netherlands
[11] TECHNICAL DATASHEET PROMATECT®-T COMPOUND
October 2003

22
LOST FORMWORK SYSTEM, PROMATECT®-H GENERAL DESCRIPTION
PROMATECT®-H is a non-combustible,
PROMATECT®-H Technical Data sheet for The Palm Jumeirah Tunnel, Dubai fire protective calcium silicate board.

GENERAL TECHNICAL DATA

Designation Calcium Silicate Fire Protective Board

Reaction to fire Non-combustible

DIN 4102, Part 1; BS 476, part 4
EN 13501-1: A1 (Classification report WFRGent 11527C)
Board format length x width mm 2500 x 1250

Tolerances on length mm +/- 1

and width
Board thickness mm 27,5

Tolerances on thickness mm Minimum 27,0

Maximum 30,0
Tolerances on squareness mm Difference in diagonal length: A – B < 1,5
Straightness of edges mm Maximum gap in between two boards < 1,5

Density (nominal, oven dry) kg/m3 870 ± 15%

Density (nominal, 23°C, kg/m3 940 ± 15%

50%RH)
Alkalinity, pH - Ca. 12

Thermal conductivity, λ W/m°K Ca. 0,175

Water damp diffusion µ – Ca. 20

resistance

Water absorption g/cm3 Ca 0,57

Typical moisture content % 5 – 10

Surface conditions Front face: smooth, un-sanded

Back face: embossed or sanded
Colour: off-white

ADDITIONAL INFORMATION
MECHANICAL PROPERTIES Waste Disposal
All physical and mechanical property values are averages based on standard production. - Refer to local legislation
The figures can change dependent on the test methods used. If a particular value is of prime - If not available: The board is not classified
as a dangerous substance and so no special
importance for a specification, please contact the Promat Technical Services department.
provisions are required regarding the carriage
and disposal of the product to landfill.
Bending strength N/mm2 Average of production: 7.0 They can be placed in an on-site skip with
(average of both directions) Minimum 95% confidence limit: 4.5 other general building waste

Compressive strength N/mm2 Perpendicular to surface: 9.3 Storage

(typical value) Store on flat surface, in a dry area.
Screw pull out resistance: N HECO-FIX PLUS 5,0 X 50 mm: Processing and Machining
screwed in the surface Dry drilled – dry tested: When machining the product with power tools,
– 20 mm deep (typical values) Maximum value 727 N do not breathe dust and follow the regulatory
Minimum value 630 N occupational exposure limits for total inhalable
Dry drilled – wet tested: and respirable dust. Wear safety goggles.
Maximum value 559 N Avoid contact with skin and eyes. Use dust
Minimum value 509 N extraction. In case of insufficient ventilation,
wear suitable respiratory equipment to avoid
Anchor pull through resistance: N Fischer FNA 6x30/30 A4, with 30mm health effects. For more information, request
(typical average values) circular washer A4: a Safety Data Sheet.
Dry: 3368 N
Wet: 2456 N Board Weight Information
Thickness (mm) 27,5
Dry weight (kg/m2) ca. 23,9
Weight 23ºC, 50%RH (kg/m2) ca. 25,9
23
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