A tunnel can ride out a fire without collapsing (or even critical visible structural damage), but a question whether it is safe for operations, and what is its long-term residual fire resistance remains. With repair bills being in high seven-eight figures, this is more than just a theoretical question... In this episode we dig into the hard middle ground of fire damage post mild/large fires, and cover where modeling and fire science can help reducing the uncertainty and guiding decisions. With Professor Negar Elhami-Khorasani from University at Buffalo, we map how ventilation settings, tunnel slope, and fuel push temperatures into either safe or punishing regimes, and why spalling can turn a survivable event into a structural headache.

We break spalling down to first principles—vapor pressure, thermal gradients, and restraint—then translate that into a practical method: update the section as concrete “disappears” so the thermal boundary moves and heat penetrates realistically. From there, we track damage you can act on: concrete volumes beyond 300°C, steel temperatures that risk incomplete recovery, and bond loss that forces major repairs. Just as important, we model through cooling, when heat keeps migrating and residual capacity sinks. The result isn’t a guess; it’s a bounded map of what to replace and why.

We also take on the tactical questions that matter: How long would an extreme fire need to threaten collapse, given different soils and depths? What’s the real value of polypropylene fibers in high-strength mixes? How should owners structure a fast, post-fire workflow—quick checks for reopening within days, followed by a deeper, simulation-informed durability plan? By pairing observed spalling and known operations with targeted heat transfer and mechanical analysis, you can reconstruct the event, communicate risk clearly, and spend repair budgets where they return the most resilience.

If you care about structural fire engineering, tunnel safety, spalling mitigation, and performance-based design that reduces downtime, this conversation delivers a roadmap you can use.

Further reading - recommended papers by Negar Elhami-Khorasani and her team:

Structural fire behavior of tunnel sections: assessing the effects of full burnout and spalling effects

Numerical modeling of the fire behavior of reinforced concrete tunnel slabs during heating and cooling

Fire Damage Assessment of Reinforced Concrete Tunnel Linings

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