Isolatori Foto Interessanti
46
OPPORTUNITIES OF MANUFACTURING ENGINEERING RUBBER PRODUCTS FROM NATURAL RUBBER: Kamarudin Ab Malek & Shamsul Kamaruddin Malaysian Rubber Board
Transcript of Isolatori Foto Interessanti
OPPORTUNITIES OF MANUFACTURING
ENGINEERING RUBBER PRODUCTS FROM NATURAL RUBBER:
Kamarudin Ab Malek & Shamsul KamaruddinMalaysian Rubber Board
CONTENTS
Introduction of Seismic Bearing-Bridge Bearing-Parand Project
Manufacturing of Shock CellManufacturing of Lateral SuspensionConclusions
30 September 2009 Padang earthquake
About 300,000 buildings destroyed or damaged
Presenter
Presentation Notes
Padang Earthquake occurred on 30th Sept 2009. At that time, most of the building collapsed. About 300,000 buildings destroyed or damaged. Just imagine, if some of the buildings use seismic bearing, may be the number less than 300,000.
•Amplification of forces• Large interstory drift• Contents destroyed• Requires costly repair
• No amplification of forces• Contents are protected• No interstory drift• No costly repair
Base-Isolated StructureConventional Structure
groundmotion
Building’sresponse
Presenter
Presentation Notes
I would like to explain the different between conventional structure and base isolated structure. These are seismic bearings for base isolated structure and this building without using seismic bearing. So, when earthquake occurred the building’s response show a high amplitude for the conventional building whereas the amplitude of base isolated building is mostly uniform. The content of the building is protected and no interstory drift. In addition, no need repairing cost.
FOOTHILL COMMUNITIES LAW & SERVICE CENTRE, SAN BERNADINO, CALIFORNIA USA
First building (4-storey) in the world to use natural rubber bearings to withstand up to 8.3 Richter
Completed in 1985 at a cost of US$38 Million Total number of bearings are 98
Presenter
Presentation Notes
As shown here, this is the 1st building (4 story) in the world to use natural rubber bearing to sustain up to 8.3 Richter. The construction of the building completed in year 1985 at a cost of USD38million. The total number of seismic bearing is 98.
Evans & Sutherland manufacturing facility, Salt Lake City
•Manufactures the most advanced flight simulators•4-storey building costing US$8 mil, completed 1988•Installed with 98 bearings •At any time contents exceed US$100 mil•No conventional system can protect contents
Presenter
Presentation Notes
Again, Evans & Sutherland manufacturing facility at Salt Lake City. They manufacture the most advanced flight simulators. The building also used 98 bearings. Just imagine at any time , the contents exceed USD100million
INSTALLED BEARINGS UNDERNEATHTHE BUILDING
Presenter
Presentation Notes
As shown here, the bearings are installed underneath the building. The bearings are placed on the concrete columns.
A SEISMIC BEARING BEING SHEARED AND COMPRESSED TO SIMULATE EARTHQUAKE
Presenter
Presentation Notes
Bearings have to be designed and fabricated properly so that the bearing can simultaneously support the weight of the building and undergo shear deformation.
WEST JAPAN POSTAL SERVICE COMPUTER CENTRE IN KOBE
6 Storey, 500,000 sq ft space, supported on 120 bearings
Response during Kobe’s 1995
Isolated ConventionalGround 0.30g 0.27g
6th Floor 0.10g 0.97g
67 % reduction
260 %amplification
Presenter
Presentation Notes
This is the building of the West Japan Postal Service Computer Centre in Kobe. It has 6 storey building which supported on 120 bearings. The sixth floor of a base isolated building showed a reduction in the acceleration by factor of 10 compared to conventional building.
Damage to Bridges
Presenter
Presentation Notes
After the Kobe earthquake, the demand for base isolation increased in Japan especially the bridges where 99% of new built bridges are now using base isolation compared to 5% before Kobe Earthquake. This photo shows the bridge using natural rubber bearing and this photo without rubber bearing.
Totsukawa bridge built in 2002
3 span box girder, 175 mIsolator: 1.7 x 1.6 x 0.3 mMax movement: ± 0.40 mSupporting load: 18.8 MN
Presenter
Presentation Notes
As shown here, this is the Totsukawa bridge which was built in year 2002. This bridge was constructed using bridge bearing.
Amami Island bridge
Max movement: 0.61mSupporting load: 17.5 MN/pcBuilt in 2001
Presenter
Presentation Notes
Again, this is Amani Island bridge which was built in year 2001 using bridge bearing.
Malaysian first base-isolated building completed in July 2001
Presenter
Presentation Notes
We also have constructed the first base isolated building in Malaysia which completed in July 2001.
INSTALLED SEISMIC RUBBER BEARINGS
Presenter
Presentation Notes
These are the seismic bearings where we placed it on the column underneath the building.
Mould top plate being fixed before curing
Presenter
Presentation Notes
We also have designed and fabricated the mould of seismic bearing. This is the mould top plate being fixed before curing.
A 9-storey base-isolated building in Shantou, China: UNIDO/MRB PROJECT (1994)
The first buildingin China to be installed with
rubber bearings
Today more than800 structures allover China have
used the technology
Presenter
Presentation Notes
We also have made collaboration project between UNIDO and MRB in 1994 to construct the base isolated building in Shantou, China. Today more than 800 structures all over China have used the technology.
MRB/UNIDO POJECT IN INDONESIA4-storey building in Pelabuhan Ratu, Java (1993)
Presenter
Presentation Notes
Again, this is also MRB/UNIDO project in Indonesia. The 4storey building in Pelabuhan Ratu, Jawa that was built in year 1993. For your information, in Indonesia they have 3 base isolated buildings. In Malaysia, we have one base isolated building. But, in Japan about 2000 base isolated structures. How about Vietnam??? May be we can discuss in other conference.
ARTIST IMPRESSION OF THE IRANIAN PARAND NEW TOWNSHIP
On 26 September 2006 the Iranian government awarded a Malaysian developer two housing projects in new town ship of Parand and Hertsgard.
The Parand project is currently underway tobuild 150 blocks of 8 and 12 storey high – a total of 17,000 apartments. All have been fully booked. Total land area - 160 hectares
Presenter
Presentation Notes
Since 2004, MRB has been actively promoting seismic rubber bearing technology in Iran. Last year the Iranian government agreed to use this technology for the first time in Iran for a housing project awarded to a Malaysia developer. The project involves the construction of apartment buildings in parand, a new township about 30km from south of Tehran.
The foundation and pedestals of the first five 12-storey blocks were being constructed (23 Aug 2007)
Presenter
Presentation Notes
As shown here, these are the reinforcements and concrete work for the foundation and pedestals of the first 5 blocks of the building are being carried out.
About 9,000 bearings will be used for the Parand project
32 rubber layers31 reinforcementsAnchorage sockets
600mm diameter
Presenter
Presentation Notes
It is expected that more 9000 pieces of seismic bearing will be used for Parand project. This is the seismic bearing and inside it has 32 rubber layers and 31 reinforcement plates.
Prototype bearings being tested under simultaneous compression (3850kN) and shear up to 337mm
Iran HDRB Type 'A-600' - Prototype Test (Bearing No. 3 & 4) - 1925kN/311.0mm
-400
-300
-200
-100
0
100
200
300
400
-350 -300 -250 -200 -150 -100 -50 0 50 100 150 200 250 300 35
Displacement mm
Shea
r for
ce k
N
damping
Shear stiffness
Presenter
Presentation Notes
We tested all the seismic bearings and checked all the properties of stiffness and damping.
Final inspection of the bearings before shipment
Presenter
Presentation Notes
Again, we did a final inspection of the bearing before shipment
Parand project: the construction of the first floor
Rubber bearings wrapped in plastic
Presenter
Presentation Notes
This is the construction of the first floor. We wrapped the rubber bearings in plastic to protect from any defect.
Rubber shock cells ensure safety and effective matingof offshore platform and legs
It is more economicalto construct offshore platform onshore andtransport it to the required location
Production of gas and oil focuson deeper and distant fields
Presenter
Presentation Notes
Next I would like to move on to the rubber shock cell. Nowadays most oil and gas fields are no longer in shallow water. They are in deeper and distant fields. Therefore it’s more economical to fabricate the oil platform onshore and transport it on ship to the required offshore location.
THE FUNCTION OF RUBBER SHOCK CELL
Crucial stage ofplatform installationis to ensure a safe and damage-freemating
SEARubbershock cells
Platform
Barge
Leg
Presenter
Presentation Notes
Typically a shock cell consist of a series of thick rubber layers connected in series. The final size depends on the space available inside the leg here. In theory we can design the shock cell to support any loads but the space restriction here makes the design challenging.
Testing of shock cells using 500kN capacity machine
One layer being tested
A shock cell consists of a series of bonded rubber layers and stabilizing plates
Presenter
Presentation Notes
These are photos of our design work based on scaled-down model with a scaling factor of about 9.8. This on the right here shows testing of a single layer shock cell. And this on the left is the testing of a complete unit of the shock cell.
THE FOUR FULLY ASSEMBLED SHOCK CELL UNITS
Presenter
Presentation Notes
Based on the results of downed scaled model we designed and fabricated the actual size. These are the four fully assembled shock cell unit.
Installation of Leg Mating Unit (LMU) to the legs
Presenter
Presentation Notes
Next, as you can see here. The shock cell was installed to the legs.
THE SHOCK CELLS WERE INSTALLED IN THE LEGS IN NOVEMBER 2007
Presenter
Presentation Notes
The installation of the shock cells were installed on the 17th Nov 2007.
RAILING THE RM1.25 BILLION PLATFORM TO THE SHIP
Presenter
Presentation Notes
The platform would be placed on barges and pulled by boats to deep water locations where the platform is to be constructed.
PARTIAL DEFLECTION OF THE SHOCK CELL
Presenter
Presentation Notes
It is crucial that the platform is gradually and safely lowered to the legs, otherwise the expensive platform would be damaged and the whole construction would be in jeopardy.
THE SHOCK CELL AT THE MAXIMUM DEFLECTION
Platform successfully installed 31st
December 08
Presenter
Presentation Notes
The platform of this project – a joint venture between Petro Vietnam, Petronas carigali and Talisman – was successfully installed on the 31st December 2008.
Malaysian Hevea
Academy
KL Monorail straddles on a single rail using lateral suspension
Presenter
Presentation Notes
Next I would like to move on to the use of lateral suspension. KL monorail is a light railway system. It began operation in the Kuala Lumpur City in year 2003. The monorail lateral suspension that control the lateral displacement and vibration did not perform effectively.
Malaysian Hevea
Academy
A KL MONORAIL TRAIN CONSISTS OF 2 COACHES. A COACH HAS TWO BOGIES
Rubber buffer
A BOGIE
Concrete beam guideway
Guide wheel tyre
Load wheel tyre
Uses rubber tires -quiet ride.
Presenter
Presentation Notes
This slide shows a schematic diagram of a bogie underneath the coach. Each bogie has 6 guide wheels to ensure that the coach moves along the guide way safely. Each bogie also has 6 rubber buffers to control the lateral vibration and displacement.
Malaysian Hevea
Academy
EXAMPLES OF SHARP TURNS
Presenter
Presentation Notes
These are the examples of sharp turns. The passenger can feel vibration and irritating noise.
Malaysian Hevea
Academy
UNDERNEATH A COACHVIEW OF ONE SIDE OF A BOGIE
Rubber buffer
Presenter
Presentation Notes
This is the view of one side of bogie. There are 3 rubber buffers were used at one side of bogie.
Malaysian Hevea Academy
Original rubber buffer – not effectively designed
Original rubberbuffer
Presenter
Presentation Notes
This slide shows the original rubber buffer which was not properly designed resulting in uncomfortable ride.
Malaysian Hevea Academy
Loadtonnes
Displacement, mm
Original bufferRequired buffer
COMPARISON OF ORIGINAL AND DESIREDRUBBER BUFFER
0123456789
10
0 10 20 30 40
Presenter
Presentation Notes
This slide shows the original buffer is too stiff. The required stiffness for a comfortable ride is much lower. MRB started to design the new rubber buffer so that it has this characteristic which will give a more comfortable ride.
Malaysian Hevea Academy
MODELING USING FINITE ELEMENT ANALYSIS (FEA)COMPUTER-AIDED DESIGN TOOL
• FEA enables optimum configuration to be evaluatedquickly
15 kN LOAD
Presenter
Presentation Notes
Fortunately, we were able to use the FEA which enabled us to obtain an optimum configuration within a very short time – one month. The shape is a cone with hollow space in the middle. Using conventional design technique, we would not be able to arrive at this configuration within such a short period of time because this is a complicated configuration.
Malaysian Hevea Academy
A completed rubber buffer after curing process
Presenter
Presentation Notes
We designed and fabricated the mould. This is the new rubber buffer after we cured it.
Malaysian Hevea Academy
Testing of the rubber buffer
Presenter
Presentation Notes
MTS831 servo hydraulic machine was used to carry out static and fatigue tests.
Malaysian Hevea Academy
1 MILLION CYCLE FATIGUE TEST
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
0 5 10 15
200,000 CYCLES400,000 CYCLES600,000 CYCLES 800,000 CYCLES1,000,000 CYCLES
Deflection, mm
LoadN
•The rubber buffer showed no sign of damage•No significant change in stiffness•In real application the buffer is expected to undergo only 500,000 cycles
Presenter
Presentation Notes
Again, graph shows the results of stiffness. There is no significant different of stiffness between 200,000 cycles and 1 million cycles.
Malaysian Hevea Academy
GOOD PERFORMANCE OF MRB SUSPENSION IN THE TRIAL
RMS Vs Frequency
0.00E+00
2.00E-07
4.00E-07
6.00E-07
8.00E-07
1.00E-06
1.20E-06
1.40E-06
0.00E+00 2.00E+01 4.00E+01 6.00E+01 8.00E+01 1.00E+02 1.20E+02 1.40E+02 1.60E+02 1.80E+02 2.00E+02
Frequency, Hz
RM
S, m
s-2/m
s-2
OEM SUSPENSIONMRB SUSPENSION
Presenter
Presentation Notes
We also have carried out the vibration test. Based on the results, the performance of MRB rubber buffer is better than original component.
CONCLUSIONS Natural rubber is a very versatile green engineering
material for many demanding engineering applications, Base isolation is a simple and effective method which can
save lives, protect buildings and contents from earthquakes,
1995 Kobe earthquakes have proven the effectiveness of base isolation,
Rubber shock cells are successfully used for offshore applications,
Rubber lateral suspensions were successfully designed for KL Monorail.
