Freyssinet Exoleaf - Ultra High Performance Concrete Solutions 2020 PDF

UHPC /UHPFRC
capabilities and
references - Exoleaf™
Table of Contents
1. Freyssinet in the UK
2. Concrete repairs – a brief overview
3. A History of UHPFRC
4. Our experience with UHPFRC in the UK and abroad
• Technical expertise and know how
• Footbridges
• Exoleaf®
• Corbels and blisters
• Sprayed UHPFRC
Freyssinet in the UK
The Freyssinet way
Sustainable technology is not just a tag line
We can do more with less if we plan and consider what we do and take account of how much
carbon we can genuinely save by reusing, reenergising and making what we do more resilient
UHPC footbridge Wind towers built with the Freyssinet Eolift® method Hammersmith flyover strengthening
Mediterranean Civilisation Museum Marseille - France Trairi - Brasil London - UK
Freyssinet in the UK
 Present in the UK since 1950, we have 160 permanent staff
across 6 offices
 £33M revenue in 2019
Scotland
Projects office
 The benchmark in specialist civil and structural
engineering for new structures and the repairs and
maintenance of highways, buildings, railways, water,
commercial and industrial structures A’ One Plus’ Projects
Leeds ‘Northern office
 Strong reputation and relationships with Highways Office’
England, Network rail, Framework Contractors and leading

Telford Head Office
industry Consultants.
 A different approach – With our in-house engineering London Southern
Office & Technical Cell
capabilities and deep knowledge of structural products we Hinkley Nuclear
Projects office
offer innovative and cost effective solutions to our clients
and partners
 Value-added solutions supported by subsidiary companies
Aquaforce Concrete Services, Corrosion Control Services
Limited (CCSL) and Foreva Concrete Repairs
Our Accreditations
Our Teams are Highly Qualified & Highly Skilled Specialists

Concrete repairs – a
brief overview
Typical defects:
Low cover steel reinforcement

where carbonation or
chlorides have reached the
reinforcement altering its
passive nature
brief overview
Two Main Catalysts Cause Corrosion
Chloride ions (Cl-)

Chloride ions from salt (sodium chloride] break down the
protective layer on the steel that was established by the
alkalinity within the concrete.
Carbonation
This is caused through atmospheric carbon dioxide, an acid gas,
that permeates through the pores and reacts with the alkalinity
brief overview
Traditionally we remove
the concrete and repair it
using various methods.
• Flowable repairs
• Sprayed repairs
• Hand applied repairs
All using traditional repair

mortars. Excellent for
many applications
A History of UHPFRC
1990’s - Bouygues + Lafarge in France
Improve the performances of concrete
Focus on porosity
1997 Sherbrooke footbridge, Qc, CAN

30 mm thick deck, 60 m span
2002 Seonyu Footbridge, Korea

120 m span arch footbridge
2002 AFGC-SETRA recommendations

First set of rules of design and construction
(FR+ENG)
2015 NF P18 470 and 710

Standards and NA to Eurocode 2
A History of UHPFRC
The typical constituents of ‘Typical’ UHPFRC can be outlined as
follows:
• Largest particle 1 to 7 mm
• Water to cement ratio < 0.2
• Cement around 1,000 kg/m3
• Super-plasticizer 0.5 to 2% of C
• Silica fumes 20 to 30% of C
• 2 to 3% steel fibres in volume: 150 to 250 kg/m3, sometimes
more
• Characteristic compressive strength: 150 to 250 MPa (cylinder)
Other methods
• UHPC, UHPFRC
• Organic fibers
• Non-structural?
A History of UHPFRC -
Standards
• NF P18-470: self-supporting standard, substitute to EN 206 (similar outline)
• Covers the material: non-fragile!
• UHPFRC type S for structures – metal fibers
• UHPFRC type A or Z for non-structural elements
• Material tests defined in appendices
• Published in French and English in 2016
• NF P18-710: French National Addition to Eurocode 2 – EN 1992:

• Design of structures with UHPFRC type S
• Follows the structure of Eurocode 2
• Sets all rules (structural, durability, etc.)
• Published in French and English in 2016
• Execution of UHPFRC structures will soon be covered by:

NF P18-451: French National Addition to Eurocode 2 – EN 1992:
• Execution of UHPFRC structures
• Expected in 2018
A History of UHPFRC –
Standards, Type - S
• Compression : 150 – 250 MPa
• Non-fragile in bending
• Tension ~6 – 8 MPa, maybe more: T1 softening, T2 low strain hardening, T3 high strain hardening
• Young’s modulus 55 GPa, sometimes more
• Water porosity
• Chloride diffusion
• Permeability to gases
• Consistencies: Ca – self compacting, Cv – viscous, Ct – holds a slope
• Heat treatment
• Improved durability: Dp+ water, Dc+ chloride, Dg+ gases
• Resistance to abrasion: 3 classes
• Design life up to 150 years – possibly 200 years
• Generally no rebars
A History of UHPFRC
We use Ductal in the UK and France.

There are other types of UHPFRC
A History of UHPFRC
Why UHPFRC?
Elegance
Performance
Durability
Safety
Cost
Key attributes
• Fire resistance
• Pre-cast
• In-situ
• Sprayed
• Post-tensioned, what else?
• Freedom !
Elegance
Performance
Durability
Safety
Cost
Museé de Marseille
Elegance
Performance
Durability
Safety
Cost
Pont de la République, Montpellier

A History of UHPFRC
Our experience with UHPC
in the UK and abroad
Hammersmith flyover
More recently we have used the

properties of UHPFRC for other uses –
repair and structural strengthening
This has lead us to develop our

expertise
Our technical expertise and know how
Wide range of knowledge and expertise
• Key promoter and user of UHPFRC in the UK construction market

• Local technical expertise in design and construction
• Central world-class design and construction expertise in Paris
head office hosting key UHPFRC experts
• Support of Vinci Scientific department for R&D if required
• Strong trust link with our supply chain, in the UK and abroad
• UK reference projects demonstrating value for money of the
material
• Freyssinet wide range of techniques can be integrated
Our technical expertise and know how
UHPFRC – A reminder of its impressive material characteristics
• 130-180 MPa compressive
• 6.0 to 9.0 MPa tensile
• 55-58 GPa Young’s modulus
• Best durability ever achieved for concrete
• Excellent resistance to water abrasion
• Fantastic surface finish
• Freedom of shape
• Can meet any texture wish

Footbridges – additional information
The exceptional properties of UHPFRC enable elegant and
economical design
• No passive reinforcement generally required
• Shear resistance relies on the concrete, the steel fibres

and the PT tendons.
• Bursting resistance is provided by the steel fibres.
• The foot bridges are intended to be designed as

segmental elements of ~2.5m, assembled on site and
lifted as one element after PT tendons tensioning.
• Unrivalled durability, no maintenance
• Integral design: no ancillaries elements, no interfaces.
• Simply supported
Work Site Reference
Footbridge Pont du Diable
• The Pont du Diable footbridge was designed for

pedestrians and cyclists and crossed over a gorge
requiring a span of 68 m and height of 10 m – worth
noting that the span on the Museé de Marseille was
over 100m
• The environmentally sensitive site features brought

the idea of a single span bridge with no intermediary
support to the forefront, thus minimizing the impact
on natural surroundings and the local flora & fauna
• This was achieved using high performing concrete

(Ductal®) combined with post-tensioning along two
beams that form handrails which allowed a minimum
visual impact through very small static height
Industry Reference
Footbridge at Cannet des Maures railway station – designers now work for Freyssinet
Footbridge crossing a railway line made of post-tensioned UHPC precast segments. The
UHPC segments were prefabricated in factory and assembled on site and then lifted into
place in 3h.
Deck
Length : 35m
Effective width: 2.5m
UHPC concrete: 35m2
Post-tension: 16 cables T15S, 3 tendons 3T15S and 2 Tendons 12T15S
Supports
Weathering steel: 21T
Foundations: 50m3 C30 and 3T passive reinforcement
Supports and glassed access lifts built whilst railway in operation
25
Exoleaf®
Innovative structural improvement
Thin shells of UHPFRC are used to improve structures:
• Structural capabilities
• Durability
• Water abrasion and impact protection
The form of construction is flexible to adapt to the project

• In-situ
• Precast
• Sprayed
“Make the most of what we have”

Corbels and blisters
Local, critical parts
UHPFRC blister were developed to anchor additional PT:
 Unrivalled durability
 Smaller size made the project possible on HFO2
 Quality of manufacture is superior
(no passive reinforcement)
UHPFRC Corbels on car parks: Hammersmith Flyover blisters

 Faster operations on site
 Economical repairs
 Unrivalled quality and finish
 Improved user’s experience
UHPFRC blister on the left

Equivalent RC blister on the right
 conventional vs. UHPC 

Sprayed UHPFRC
Fast construction
Material sprayed with steel fibres:
• Innovative formulation
• Very fast construction
• Very thin reinforcement
• Flexible and strong
Space gains on corrugated steel culverts repairs

Sam Cleobury
Business Development Engineer
[email protected]
Freyssinet Ltd
www.freyssinet.co.uk
Headquarters
Innovation House
Euston Way
Telford TF3 4LT
South East Region Office

33 Colville Rd
Acton
London W3 8BL
North Region Office

Pure Offices,
Turnberry Park
Morley
Leeds LS27 7LE

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UHPC /UHPFRC

England, Network rail, Framework Contractors and leading

Our Teams are Highly Qualified & Highly Skilled Specialists

Low cover steel reinforcement

Chloride ions (Cl-)

All using traditional repair

1997 Sherbrooke footbridge, Qc, CAN

2002 Seonyu Footbridge, Korea

2002 AFGC-SETRA recommendations

2015 NF P18 470 and 710

• NF P18-710: French National Addition to Eurocode 2 – EN 1992:

• Execution of UHPFRC structures will soon be covered by:

We use Ductal in the UK and France.

Pont de la République, Montpellier

More recently we have used the

This has lead us to develop our

• Key promoter and user of UHPFRC in the UK construction market

• 130-180 MPa compressive

• 6.0 to 9.0 MPa tensile

• 55-58 GPa Young’s modulus

• Best durability ever achieved for concrete

• Excellent resistance to water abrasion

• Fantastic surface finish

• Can meet any texture wish

• No passive reinforcement generally required

• Shear resistance relies on the concrete, the steel fibres

• Bursting resistance is provided by the steel fibres.

• The foot bridges are intended to be designed as

• Unrivalled durability, no maintenance

• Integral design: no ancillaries elements, no interfaces.

• The Pont du Diable footbridge was designed for

• The environmentally sensitive site features brought

• This was achieved using high performing concrete

Supports and glassed access lifts built whilst railway in operation

The form of construction is flexible to adapt to the project

“Make the most of what we have”

UHPFRC Corbels on car parks: Hammersmith Flyover blisters

UHPFRC blister on the left

 conventional vs. UHPC 

Space gains on corrugated steel culverts repairs

South East Region Office

North Region Office

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