Extruded Tunnel Lining Regeneration Project (ETLR): experimental campaign on real scale SFRC tunnel mock-ups

List of Authors

  1. Andrea Marcucci
    ,  
  2. Stefano Guanziroli
    ,  
  3. Marco Borroni
    ,  
  4. Bernardino Chiaia
    ,  
  5. Liberato Ferrara
    ,  
  6. Marco Peroni
    ,  
  7. Marco Lamperti Tornaghi ,  
  8. Francisco Javier Molina ,  
  9. Simone Peloso ,  
  10. Daniel A. Pohoryles ,  
  11. Georgios Tsionis
Article Authors & roles Authors Peer review record Peer review Metrics
Cite

Abstract

Background

Automation in the construction industry is gaining increasing relevance, driven by the need to enhance productivity, foster innovation, and meet evolving societal demands. Slip-forming with extrudable steel fibre-reinforced concrete (SFRC) offers an innovative framework for the maintenance and refurbishment of highway and railway tunnels. However, its structural performance requires full-scale validation before adoption in practice.

Methods

Four full-scale mock-ups replicating a motorway tunnel lining were constructed using slip-forming with extrudable SFRC and tested under load conditions simulating the relevant action combinations for tunnel linings in the intended scenarios. Both symmetric and non-symmetric loading combinations were examined, including a sequential loading case to assess accumulated damage and residual bearing capacity. Digital Image Correlation (DIC) analysis was performed to study cracking in the mock-ups, enabling computation of crack opening, which was related to the load applied by the hydraulic jacks employed in the experiment. Testing was conducted at the ELSA laboratory of the European Commission, Joint Research Centre in Ispra, as part of the OPENLAB ETLR project.

Results

The relationship between crack opening and applied load enabled characterisation of the post-cracking residual capacity of the SFRC tunnel lining structure under the tested loading combinations, including its behaviour under sequential loading and the associated accumulation of damage.

Conclusions

The full-scale tests provide a preliminary validation of the adopted design criteria and an assessment of the effectiveness and structural reliability of the proposed slip-forming SFRC technology for tunnel lining refurbishment.

Corresponding author
Stefano Guanziroli
Grant information

This project has received funding from the Joint Research Centre Physical Research Infrastructures of the European Commission under Research Infrastructure Access Agreement No 36506-1 / 2021-1-RD-ELSA-ReactionWall (ETLR project). This research was generated through access to the ELSA Reaction Wall.

The funders had no role in study design, data collection and analysis, decision to publish, or preparation of the manuscript.

Copyright
© 2026 Andrea Marcucci (Co-Author); Stefano Guanziroli (Corresponding Author, Co-Author); Marco Borroni (Co-Author); Bernardino Chiaia (Co-Author); Liberato Ferrara (Co-Author); Marco Peroni (Co-Author); Marco Lamperti Tornaghi (Co-Author); Francisco Javier Molina (Co-Author); Simone Peloso (Co-Author); Daniel A. Pohoryles (Co-Author); Georgios Tsionis (Co-Author) Creative Commons License

This work is licensed under a Creative Commons Attribution 4.0 International License.

First version published
Latest version published

Comments

Authors & roles

Andrea Marcucci

Department of Civil and Environmental Engineering, Politecnico di Milano, Milan, Lombardy, 20133, Italy

Roles
Co-Author, Formal Analysis, Software, Writing – Original Draft Preparation

Stefano Guanziroli

Hinfra s.r.l., Casale Monferrato, Italy

Roles
Corresponding Author, Co-Author, Conceptualization, Methodology, Project Administration, Supervision, Writing – Original Draft Preparation

Marco Borroni

Hinfra s.r.l., Casale Monferrato, Italy

Roles
Co-Author, Conceptualization, Project Administration, Supervision

Bernardino Chiaia

Politecnico di Torino Department of Structural, Building and Geotechnical Engineering, Torino, Piemonte, Italy

Roles
Co-Author, Conceptualization

Liberato Ferrara

Department of Civil and Environmental Engineering, Politecnico di Milano, Milan, Lombardy, 20133, Italy

Roles
Co-Author, Conceptualization, Supervision, Writing – Review & Editing

Marco Peroni

European Commission Joint Research Centre Ispra, Ispra, Lombardy, Italy

Roles
Co-Author, Conceptualization, Data Curation, Software

Marco Lamperti Tornaghi

European Commission Joint Research Centre Ispra, Ispra, Lombardy, Italy

Roles
Co-Author, Conceptualization, Supervision

Francisco Javier Molina

European Commission Joint Research Centre Ispra, Ispra, Lombardy, Italy

Roles
Co-Author, Conceptualization, Data Curation

Simone Peloso

European Commission Joint Research Centre Ispra, Ispra, Lombardy, Italy

Roles
Co-Author, Data Curation, Writing – Review & Editing
0000-0002-2658-6009

Daniel A. Pohoryles

European Commission Joint Research Centre Ispra, Ispra, Lombardy, Italy

Roles
Co-Author, Data Curation, Writing – Review & Editing
0000-0002-7196-5454

Georgios Tsionis

European Commission Joint Research Centre Ispra, Ispra, Lombardy, Italy

Roles
Co-Author, Data Curation, Writing – Review & Editing

Awaiting peer review

Downloads over the last 12 months:

Cited by

via Crossref

View citing articles