OPPORTUNITIES OF MANUFACTURING ENGINEERING RUBBER PRODUCTS FROM NATURAL RUBBER:

Kamarudin Ab Malek & Shamsul Kamaruddin Malaysian Rubber Board

CONTENTS
Introduction of Seismic Bearing -Bridge Bearing -Parand Project Manufacturing of Shock Cell Manufacturing of Lateral Suspension Conclusions

30 September 2009 Padang earthquake

About 300,000 buildings destroyed or damaged

Conventional Structure
Amplification of forces Large interstory drift Contents destroyed Buildings response Requires costly repair

Base-Isolated Structure
No amplification of forces Contents are protected No interstory drift No costly repair

ground motion

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

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

INSTALLED BEARINGS UNDERNEATH THE BUILDING

A SEISMIC BEARING BEING SHEARED AND COMPRESSED TO SIMULATE EARTHQUAKE

WEST JAPAN POSTAL SERVICE COMPUTER CENTRE IN KOBE 6 Storey, 500,000 sq ft space, supported on 120 bearings

Response during Kobes 1995

Ground 6th Floor Isolated 0.30g 0.10g 67 % reduction Conventional 0.27g 0.97g 260 % amplification

Damage to Bridges

Totsukawa bridge built in 2002

3 span box girder, 175 m Isolator: 1.7 x 1.6 x 0.3 m Max movement: 0.40 m Supporting load: 18.8 MN

Amami Island bridge

Max movement: 0.61m Supporting load: 17.5 MN/pc Built in 2001

Malaysian first base-isolated building completed in July 2001

INSTALLED SEISMIC RUBBER BEARINGS

Mould top plate being fixed before curing

A 9-storey base-isolated building in Shantou, China: UNIDO/MRB PROJECT (1994)

The first building in China to be installed with rubber bearings

Today more than 800 structures all over China have used the technology

MRB/UNIDO POJECT IN INDONESIA 4-storey building in Pelabuhan Ratu, Java (1993)

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 to build 150 blocks of 8 and 12 storey high a total of 17,000 apartments. All have been fully booked. Total land area - 160 hectares

The foundation and pedestals of the first five 12storey blocks were being constructed (23 Aug 2007)

About 9,000 bearings will be used for the Parand project

600mm diameter

Anchorage sockets

32 rubber layers 31 reinforcements

Prototype bearings being tested under simultaneous compression (3850kN) and shear up to 337mm

damping

Iran HDRB Type 'A-600' - Prototype Test (Bearing No. 3 & 4) - 1925kN/311.0mm
400

300

200

100

Shear force kN

Shear stiffness

-100

-200

-300

-400 -350

-300

-250

-200

-150

-100

-50

50

100

150

200

250

300

35

Displacement mm

Final inspection of the bearings before shipment

Parand project: the construction of the first floor

Rubber bearings wrapped in plastic

Rubber shock cells ensure safety and effective mating of offshore platform and legs
Production of gas and oil focus on deeper and distant fields

It is more economical to construct offshore platform onshore and transport it to the required location

Crucial stage of platform installation is to ensure a safe and damage-free mating

THE FUNCTION OF RUBBER SHOCK CELL

Platform

Barge
Rubber shock cells

SEA

Leg

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

THE FOUR FULLY ASSEMBLED SHOCK CELL UNITS

Installation of Leg Mating Unit (LMU) to the legs

THE SHOCK CELLS WERE INSTALLED IN THE LEGS IN NOVEMBER 2007

RAILING THE RM1.25 BILLION PLATFORM TO THE SHIP

PARTIAL DEFLECTION OF THE SHOCK CELL

THE SHOCK CELL AT THE MAXIMUM DEFLECTION

Platform successfully installed 31st

December 08

KL Monorail straddles on a single rail using lateral suspension

Malaysian Hevea Academy

A KL MONORAIL TRAIN CONSISTS OF 2 COACHES. A COACH HAS TWO BOGIES Uses rubber tires -quiet ride.

A BOGIE

Load wheel tyre

Guide wheel tyre

Rubber buffer
Concrete beam guideway
Malaysian Hevea Academy

EXAMPLES OF SHARP TURNS

Malaysian Hevea Academy

UNDERNEATH A COACH VIEW OF ONE SIDE OF A BOGIE

Rubber buffer

Malaysian Hevea Academy

Original rubber buffer not effectively designed

Original rubber buffer

Malaysian Hevea Academy

COMPARISON OF ORIGINAL AND DESIRED RUBBER BUFFER

10 9 8 Load 7 tonnes 6 5 4 3 2 1 0 0

Required buffer Original buffer

10

20
Displacement, mm
Malaysian Hevea Academy

30

40

MODELING USING FINITE ELEMENT ANALYSIS (FEA) COMPUTER-AIDED DESIGN TOOL

FEA enables

optimum configuration to be evaluated quickly

15 kN LOAD

Malaysian Hevea Academy

A completed rubber buffer after curing process

Malaysian Hevea Academy

Testing of the rubber buffer

Malaysian Hevea Academy

1 MILLION CYCLE FATIGUE TEST

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
5000 4500 4000 3500

Load N

3000 2500 2000 1500 1000 500 0 200,000 CYCLES 400,000 CYCLES 600,000 CYCLES 800,000 CYCLES 1,000,000 CYCLES

5Deflection, mm 10 Malaysian Hevea Academy

15

GOOD PERFORMANCE OF MRB SUSPENSION IN THE TRIAL

RMS Vs Frequency
1.40E-06

1.20E-06

1.00E-06
OEM SUSPENSION MRB SUSPENSION

RMS, ms /ms

-2 -2

8.00E-07

6.00E-07

4.00E-07

2.00E-07

0.00E+00 0.00E+00

2.00E+01

4.00E+01

6.00E+01

8.00E+01

1.00E+02 Frequency, Hz

1.20E+02

1.40E+02

1.60E+02

1.80E+02

2.00E+02

Malaysian Hevea Academy

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.

kshamsul@lgm.gov.my