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Composite Structures
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Article history:
Available online 26 June 2013
Keywords:
Insulated panels
Load-bearing panels
Sandwich panels
Steel bre reinforced self-compacting
concrete (SFRSCC)
Glass bre reinforced polymer (GFRP)
Pull-out test
a b s t r a c t
In this paper, an innovative and thermally efcient sandwich panel is proposed for the structural walls of
a pre-fabricated modular housing system. Traditionally, sandwich concrete panels consist of reinforced
concrete wythes as outer layers, polystyrene foam as core material and steel connectors. However, steel
connectors are known to cause thermal bridges on the building envelope, with possible consequent
occurrence of condensation and mould problems. Furthermore, the reduction/optimization of the thickness of conventionally reinforced concrete layers is frequently limited by minimum concrete cover
requirements for the protection of the reinforcement from corrosion. To overcome these issues, the proposed sandwich panel comprises Glass Fibre Reinforced Polymer (GFRP) connectors and two thin layers
of Steel Fibre Reinforced Self-Compacting Concrete (SFRSCC). This paper presents the material and structural concept of the proposed building system. Moreover, the feasibility of using the proposed connectors
and SFRSCC on the outer wythes is experimentally investigated through a series of pull-out tests where
failure modes and load capacity of the connections are analysed.
2013 Elsevier Ltd. All rights reserved.
1. Introduction
The main advantage of using sandwich panels in building construction is related to the structural and thermal efciency that
can be achieved with this technology. By putting together thin, stiff
and ductile concrete wythes, with a thermally-efcient core material, it is possible to obtain lightweight panels that are energy efcient, and can be easily handled and erected. This kind of structural
solution has been extensively applied in precast structural panels,
which are known to provide adequate weather sheltering, protection against mechanical damage, vapour barrier, efcient acoustic
performance and thermal insulation [1].
Traditionally, these sandwich panels adopt conventionally reinforced concrete layers and steel devices to establish the connection
between them. Commonly used shear transfer devices include wire
truss connectors, bent wire connectors, and solid zones of concrete
penetrating the foam [25].
Due to their high thermal conductivity, the steel connectors
cause thermal bridging effects on the building envelope that result
in additional transmission losses, decreasing the thermal efciency
of the sandwich panel, and promoting the occurrence of
Corresponding author. Tel.: +351 253 510 200; fax: +351 253 510 217.
E-mail address: rmlameiras@civil.uminho.pt (R. Lameiras).
0263-8223/$ - see front matter 2013 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.compstruct.2013.06.022
condensation and mould problems [6]. The existence of these thermal bridges increases the building energy demand for heating and
cooling, and thus their avoidance is an essential challenge to
achieve more thermally/energetically efcient and sustainable
buildings. According to previous research [7], the use of steel pin
connectors that represent 0.08% of the sandwich panel area, can reduce the insulation performance (R-value) of a wall up to 38%. The
same research also reports that a thermal performance reduction
of 77% is expected when the connection between outer layers is
made through 0.08% of steel pin connectors and 21.25% of solid
concrete zones. With the steadily increasing cost of energy, the
interest in having energetically efcient buildings is no longer limited to environmental sustainability aspects, broadening its justication to actual economic reasons.
The use of Glass Fibre-Reinforced Polymer (GFRP) bent bars as
connectors in replacement of the traditional metal wire trusses
was introduced by Salmon et al. [4]. Test results showed that the
use of GFRP provided a high level of composite action and ensured
thermal benets similar to non-composite insulated sandwich wall
panels. Following the same concept, the use of Carbon Fibre-Reinforced Polymer (CFRP) shear connection grids was introduced in
the construction of sandwich wall panels in 2003 [8,9]. Nevertheless, both these alternative solutions have higher initial costs than
those of traditional sandwich panels. In fact, the pultrusion
447
a structural exterior wall system that incorporates all the installations (water, electrical, network and telephone connections), thermal insulation and nishes. The entire system is prefabricated at a
plant and transported to the construction site, where the remaining tasks to be performed are placement of the panels and application of connections to foundations and adjacent elements. Even
though this construction system can be deployed for multi-storey
buildings, the research efforts are currently being centred in single-storey buildings.
The prefabricated structural sandwich panel comprising thinwalled SFRSCC is schematically shown in Fig. 1a, where the various
components involved are identied, and a possible arrangement of
connectors is indicated. This wall system acts as the primary load
carrying component of the structure transferring the loads to the
foundation of the structure. The single storey wall panels span vertically between foundations and oor/roof panels without the need
for additional intermediate supports. Horizontal oor and roof
panels shall behave as one-way slabs, continuously supported on
the inner concrete layer of wall panels, as shown in Fig. 1b. This
eliminates the need for beams and columns along exterior walls.
The horizontal panels shall also act as diaphragms that transfer
the lateral loads to the walls.
The horizontal joints connect oor and wall units. In the case of
dwellings, the principal forces to be transferred are vertical loads
from the roof. The connection methods to be employed in these
joints can be grouting, bolting, welding or a combination of these
techniques [19,20]. The authors suggest the use of bearing pads
combined to grouting dowels projected from the wall panel and
from the roof/slab members. If the slab is used with a composite
concrete topping, the connection can also be achieved using dowels from the wall to the cast-in-place topping.
Continuous footings are used to support the lower surface of the
wall. The connection between the panel and the corresponding
footing can be made through cast-in-place grout, as suggested in
Fig. 1b.
2.1. Geometry of panels
The maximum possible length and weight of a panel is determined based on handling, transportation and installation requirements. Its dimensions should be as large as possible to reduce
costs by diminishing the number of panels needed and, consequently, the number of joints and connections required. The thicknesses of the SFRSCC layers are as thin as possible to withstand the
imposed loads over its service life, while being thick enough to
make viable connections between both concrete layers and between the panel itself and adjacent horizontal/vertical panels.
The thickness of the insulation material is primarily tailored to
meet the desirable thermal performance for the building envelope.
However, this thickness can be also specied based on structural or
even on constructive requirements, since it inuences the exural
stiffness and capacity of the panel, and the core can be also used to
accommodate other installations.
2.2. Connections between the concrete layers
The connection between the two SFRSCC layers of a sandwich
panel is assured by discrete or continuous one-way GFRP connectors. While the continuous connectors extend along the full height
or length of the panel, the discrete connectors have much lower
length than the in-plane dimensions of the panels, and are strategically positioned to ensure optimised strength/stiffness benets.
Since these connectors are the main load transfer mechanism
between both SFRSCC layers, they must resist to the forces resulting from loadings to which the panel may be subjected. It should
be noticed that, if the panels are stripped from the horizontal posi-
448
Fig. 1. Proposed building system: (a) components of the devised load-bearing sandwich wall panel and (b) system cross section.
Fig. 2. Cross-sectional scheme of investigated connections for sandwich panels: (a) embedded simply perforated plate; (b) embedded proled and (c) adhesively bonded.
449
Fig. 3. Phases of manufacture of a sandwich panel with pre-positioned embedded one-way discrete connectors: (a) connectors positioned before casting; (b) pouring the rst
SFRSCC layer; (c) positioning the insulating material plates; (d) pouring the second SFRSCC layer.
450
Table 1
Mix proportion for 1 m3 of SFRSCC.
Material
Quantity
Cement (kg)
Limestone ller (kg)
Superplasticizer (dm3)
Water (kg)
Fine river sand (kg)
Coarse river sand (kg)
Crushed granite 512 mm (kg)
Hooked ends steel bres (kg)
412.2
353.4
7.8
124.5
179.4
654.6
588.0
60.0
Fig. 4. Load-CMOD curves obtained in the three point notched SFRSCC beam
bending tests.
are positioned and held rmly in position with the aid of temporary supports (see Fig. 3a). Then, the rst layer of SFRSCC mix is
poured into the panel form (see Fig. 3b). At this stage, the bottom
perforated part of the connectors becomes submerged to the
SFRSCC layer. Afterwards, while the rst concrete layer hardens,
insulating material plates are placed on top of the rst concrete
layer. In order to make the inner SFRSCC layer have a shorter height
than the outer layer (see Fig. 1b), placeholders are used according
to the scheme of Fig. 3c. These placeholders can also be used to
materialise openings, such as windows and doors. After putting
all of the insulating blocks on the top of the rst SFRSCC layer, handling inserts and/or plate inserts are installed above the insulating
blocks for the connection of these panels to the roof/oor elements.
Later, the SFRSCC mix is poured, thus materialising the second
SFRSCC layer (Fig. 3d). After initial curing, the panel is removed
from the mould and stocked.
Table 2
Results of the three point notched SFRSCC beam bending tests.
Specimen
1
2
3
4
5
6
7
Average
L. bound*
U. bound*
*
ffct,L (N/mm2)
6.77
6.47
6.16
6.10
5.73
6.05
6.84
6.30
6.00
6.61
4.74
4.53
4.31
4.27
4.01
4.24
4.79
4.41
4.20
4.62
feq,2 (N/mm2)
feq,3 (N/mm2)
fR,1 (N/mm2)
fR,2 (N/mm2)
fR,3 (N/mm2)
fR,4 (N/mm2)
9.19
10.42
9.48
9.52
9.86
9.00
10.89
9.77
9.26
10.27
4.29
6.12
8.37
8.69
7.67
8.76
10.86
7.62
6.26
9.38
9.64
10.43
9.46
9.44
9.90
8.84
10.93
9.81
9.29
10.32
3.54
6.05
8.72
8.95
8.37
8.61
12.71
8.13
6.05
10.22
1.97
3.56
7.37
7.69
5.47
5.23
9.24
5.79
3.93
7.65
1.40
2.25
6.30
6.52
3.80
4.12
6.87
4.46
2.86
6.07
fR;i
3F i L
2
2bhsp
where fR,i (N/mm2) and Fi (N) are, respectively, the residual exural
tensile strength and the force corresponding to CMOD = CMODi
(mm), b (=150 mm) and L (=500 mm) are the width and the span
of the specimen, and hsp (=125 mm) is the distance between the
tip of the notch and the top of the cross section. The concept of
equivalent exural tensile strength parameters (feq,2, feq,3) proposed
by RILEM TC 162-TDF [31] is similar to fRi, but instead of a force for a
certain CMOD, it considers the energy consumed (area under the
F-CMOD curve) up to the aforementioned CMOD values or
451
Fig. 5. Direct tensile tests on GFRP laminates: (a) test setup; (b) C2 tested specimens; (c) detail of the C4 specimens; and (d) ruptured specimens (units in millimetres).
452
Table 3
Mechanical properties of different GFRPs under direct tensile tests.
GFRP type
Number of specimens
Quasi laminate 0
Quasi laminate 90
CSM laminate
Quasi sandwich
CSM sandwich
5
6
8
4
4
Average
St. dev.
Average
St. dev.
Average
St. Dev.
363.4
350.1
202.0
194.7
100.8
17.2
12.8
8.8
5.4
2.9
26185.1
25912.3
17881.4
21910.9
16462.4
1982.1
1501.2
969.0
2732.1
1912.5
14.30
13.52
12.65
9.51
6.89
0.32
0.27
0.47
0.24
0.41
In the case of the sandwich composites, the computed tensile modulus of elasticity corresponds to a stressstrain proportionality constant, since two different materials are
involved.
Fig. 6. Representative tensile stressstrain curves from direct tensile tests with
GFRP specimens.
an increase of the exural stiffness of the sandwich composite without substantial increment in weight and cost of the nal product.
All these GFRPs were manufactured by Vacuum Assisted Resin
Transfer Moulding (VARTM) process [33]. The option for the
VARTM process is justied by its relatively low cost, which allows
obtaining parts with reduced dimensional variations through a
highly automated process. All the GFRPs have a polyester resin matrix, due to its low cost and because it is one of the most common
thermosetting resins used in the reinforced plastics.
For the determination of the mechanical properties of the composites, direct tensile tests under constant head-speed rate of
2 mm/min were executed. In the case of the laminate C1, in which
the content of bre is slightly different in the different directions,
tests were carried out loading the laminate in tension along the
0 and 90 bre directions (hereafter called C1-0 and C1-90,
respectively). On the other hand, the laminate C3 was tested only
along the 90 direction.
Plates were manufactured using the same process that was chosen for the connectors production, and test specimens were cut
from the at plate using a diamond saw wheel. The specimens were
25 mm wide, and with the exception of the quasi laminates, the
specimens were 250 mm long. In the case of the quasi laminates,
the specimens were 280 mm long for the 0 direction and
205 mm long for the 90 direction. The test procedures described
in ASTM D3039 [34] were followed, and tensile strength, stiffness
and stressstrain relationship up to failure were determined. A
clip-gauge with reference length of 50 mm, xed in the middle of
each specimen, was used to measure the strain in the longitudinal
direction (see Fig. 5a). To provide appropriate anchorage during
testing and to diffuse the clamping stresses, rectangular aluminium
tabs (50 mm 25 mm 1 mm) were bonded at the extremities of
the laminate specimens, as shown in the Fig. 5b. In the case of the
sandwich composites the thickness of each laminate skin was increased to 3 mm in the extremities of the specimens to avoid gripping damage. In the extremities of these specimens the
polyurethane foam was replaced by a wood plate to prevent premature failure, as result of crushing the foam in the region where the
specimen is gripped by the clamps (Fig. 5c). All the tested specimens presented failures in the measuring gage region. During the
tests with sandwich composites, a premature delamination of the
specimens between the foam and the laminate skin was veried
prior to the failure of the skin laminates. Representative failure
modes for each type of composite can be observed in Fig. 5d. The
tensile stresses of the laminate specimens were calculated for each
data point simply dividing the registered force by the average crosssectional area of specimen. For the sandwich composites the tensile
stresses were computed only considering the contribution of the
laminate skins, disregarding the sectional area of the foam. The direct tensile test results are presented in Table 3 and representative
results of the tensile stress strain curves obtained for the several
types of GFRP are shown in Fig. 6. It is further remarked that each
representative curve fairly matches the average behaviour, and that
453
Fig. 7. Manufacturing of GFRP connectors by VARTM process: (a) cutting the CSM layers; (b) positioning the CSM layers in the mould; (c) resin injection for the proled
connectors; (d) resin injection for the production of a at plate and (e) drilling process in the perforated connectors.
454
and adhesively bonded (TAB) had the same geometry, both having
a ange width of 100 mm (see Fig. 8d and f).
In the case of the embedded connectors (L4C, L3E and TEM),
they were previously positioned in the steel formwork in order
to guarantee their alignment with the SFRSCC block and the
prescribed concrete cover (Fig. 9a). Then, the SFRSCC blocks were
rst poured from the end of the mould, allowing the concrete to
ow through the holes of the perforated connectors, as shown in
Fig. 9b, or behind the connector in the case of TEM. All the specimens were cast in the horizontal position to simulate the casting
Fig. 8. Pull-out test specimens: (a) perforated plates front view; lateral view of (b) L4C, (c) L3E; (d) TEM front view; (e) TEM lateral view; (f) TAB front view; and (g)
TAB lateral view (units in millimetres).
455
Fig. 9. Manufacturing of specimens for pull-out test program: (a) embedded connectors pre-positioned for pouring the SFRSCC; (b) detail of pouring of perforated connectors;
and (c) treated surface for the adhesively bonded connections.
conditions of the panels production. SFRSCC blocks without connectors were also produced for the adhesively bonded connectors.
The specimens were cured in ambient conditions for 4660 days
until the testing dates.
In the case of adhesively bonded connection (TAB), the GFRP
proles were bonded to the SFRSCC blocks using a two-component
epoxy adhesive [35]. According to the data provided by the manufacturer, the adhesive strength of this resin applied on concrete
after 3 days of curing at 20 C is, at least, 3.0 MPa. To improve
the bonding conditions, the concrete surface was treated by
removing the supercial cement paste layer with a needle gun scaler before applying the resin (Fig. 9c). The GFRP proles were glued
to the SFRSCC blocks at 54 days of age. Immediately after bonding,
the specimens were kept in a room with temperature of 20 C and
humidity of 60% for 7 days up to the test.
Three specimens per type of connector were produced using the
L4C and TEM connectors, whereas two specimens per type of connector were produced using the L3E and TAB connectors.
Fig. 11. Details of the instrumentation: (a) front view and (b) side view (units in
mm).
456
Fig. 12. (a) Rupture of L4C 01 GFRP connector; (b) rupture of L3E 02 GFRP connector; (c) fracture of SFRSCC in the test of L4C 01; (d) typical failure mode of TEM connectors;
(e) debonding of TAB connector during test; and (f) typical appearance of the failure surfaces of TAB connectors.
457
Fig. 13. Strains in the GFRP until the peak load for the specimens: (a) L4C 01; (b) L3E 01; (c) TEM 01; and (d) TAB 02.
458
Fig. 14. Representative load-slip responses for the connectors: (a) L4C; (b) L3E; (c) TEM and (d) TAB.
Table 4
Individual values of failure loads per length of connector (qu), average slip (du) and maximum strain in the GFRP (eGFRP,max).
eGFRP,max (le)
qu (kN/m)
du (mm)
L4C 01
L4C 02
L4C 03
L3E 01
L3E 02
TEM 01
TEM 02
TEM 03
2525
2515
2781
2729
2063
3247
3480
4610
107.32
98.58
113.92
114.80
95.84
116.72
112.58
106.05
1.719
1.441
0.940
1.144
1.226
1.288
4.340
2.650
TAB 01
TAB 02
1455
1556
70.25
69.44
0.013
0.062
Specimen
Embedded connections
Perforated plates
Proled connector
459
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