Barros, Joaquim A. O.

Bonaldo, Everaldo

Lourenço, Paulo B.

Oliveira, Juliana T.

Universidade do Minho: RepositoriUM

       Task T3.2 Contribution for a Full Prefabrication Approach of Masonry Reinforced Shells  Joaquim O. Barros, Paulo B. Lourenço,  Juliana T. Oliveira, Everaldo Bonaldo  Report 03-DEC/E-05    The present research has been carried out under  contract GROW-1999-70420 “ISO-BRICK” from the European Commission        Date:  February 2003 No. of pages: 15   Keywords: Reinforced masonry shells, Prefabrication     Escola de Engenharia   Departamento de  Engenharia Civil   Universidade  do Minho  Azurém, 4800-085 Guimarães - Tel. +351 253 510 200 - Fax +351 253 510 217 - E-mail secG@civil.uminho.pt     Universidade do Minho  Departamento de Engenharia Civil   Contribution for a Full Prefabrication Approach / GROW-1999-70420 “ISO-BRICK”   Azurém, P – 4800-058 Guimarães                                         Tel. +351 253 510200 • Fax +351 253 510217      Table of Contents  1. General Aspects ............................................................................................................... 1  2. Description of the Construction Process ......................................................................... 4  3. Shell Appearance ............................................................................................................. 7  4. Conclusion ....................................................................................................................... 8   Annex .............................................................................................................................. 9     Universidade do Minho  Departamento de Engenharia Civil   Contribution for a Full Prefabrication Approach / GROW-1999-70420 “ISO-BRICK” – 1/15   Azurém, P – 4800-058 Guimarães                                          Tel. +351 253 510200 • Fax +351 253 510217 1 General Aspects  A reinforced masonry shell model was built at the Laboratory of the Structural Division, of the Civil Engineering Department from Minho University, as a result of a research aiming at defining adequate (micro-) concrete compositions to infill both masonry joints and shell topping.  For this purpose, the model geometry and the material characteristics were the following: Mould: The formwork had a catenary geometric configuration with a span of 4m and a rise of 1m, see Figure 1. To assure masonry joints of equal width and to avoid brick slipping, timber strips with a cross section of 3mm height and 25mm width were fixed to the base of the mould. The timber strips in the longitudinal direction had a length of 1.10m, while the timber strips in the transversal direction had length of 1m, see Figure 2.  400cm20cm52.7cm65.6cm76.3cm84.9cm91.5cm96.2cm99cm100cm37.6cm Figure 1 - Shell's mould of catenary geometry.    Universidade do Minho  Departamento de Engenharia Civil   Contribution for a Full Prefabrication Approach / GROW-1999-70420 “ISO-BRICK” – 2/15   Azurém, P – 4800-058 Guimarães                                         Tel. +351 253 510200 • Fax +351 253 510217  Figure 2 – Detail of the timber strips.  Concrete: The adopted concrete was composed by 300Kg/m3 of cement, 279.32Kg/m3 of sand 0.6-5mm, 654.70Kg/m3 of sand 0.3-0.6mm and 805.79Kg/m3 of gravel 5-10mm. The sieve curves of these aggregates are presented in the enclosed Annex. Rebuilt®1000 superplasticizer was used in a content of 2.5% of the cement quantity. Cement 52.5R of high initial strength was selected. The water/cement ratio was 0.55. Due to the facts that (i) masonry joints were narrow (only 25mm width), (ii) joints included conventional reinforcement and (iii) the shell model had a pronounced curvature, the concrete must have adjusted consistence to ensure good filling of the joints, without the presence of segregation of the aggregates and concrete slipping. The designed concrete has a slump of about 210mm, which seems adequate for these purposes.  Ceramic Bricks: In general, the brick dimensions were 215mm length, 100mm width and 65mm height. When the length of the bricks was bigger than 215mm, their faces were regularized to get the aforementioned maximum length. In this way, the bricks could be placed between the timber strips used to guarantee a joint width of 25mm. Polystyrene pieces were introduced in the extremities of the brick holes, to avoid excessive concrete penetration. Main Reinforcement: Longitudinal and transversal reinforcement was made of steel bars of 8mm and 6mm diameter, respectively. The transversal reinforcement was placed each second transversal joints, while longitudinal reinforcement was placed in all longitudinal joints. Details of the cross sections are given in Figures 3 and 4. In the Transversal timber strips Longitudinal timber strips    Universidade do Minho  Departamento de Engenharia Civil   Contribution for a Full Prefabrication Approach / GROW-1999-70420 “ISO-BRICK” – 3/15   Azurém, P – 4800-058 Guimarães                                         Tel. +351 253 510200 • Fax +351 253 510217 concrete topping, immediately above the brick units, a welded wire mesh of bars of 3mm diameter, spaced at 75mm, was placed. 3065338625concretelongitudinalreinforcement reinforcementtranversalbrick welded wire meshtimber stripholejoint251725 2516 1717piece of steel wirepiece of steel wire Figure 3 – Detail of longitudinal section (A-A in Fig 6) of brick masonry shell, (dimensions in mm).    3023251736215 25 215reinforcementtranversalreinforcementlongitudinalholewirepiece of steel concretewelded wire meshbricktimber stripjoint38 Figure 4 – Detail of transversal section (B-B in Fig 6) of brick masonry shell, (dimensions in mm).     Universidade do Minho  Departamento de Engenharia Civil   Contribution for a Full Prefabrication Approach / GROW-1999-70420 “ISO-BRICK” – 4/15   Azurém, P – 4800-058 Guimarães                                         Tel. +351 253 510200 • Fax +351 253 510217 2 Description of the Construction Process   Initially, a demoulding product was applied on the formwork top surface to facilitate the process of removing the shell from the formwork. Then, the bricks were placed between the strips and shown previously in Figure 2. After this procedure, some pieces of steel wire (“spacers”) were placed between the holes of adjacent bricks (see Fig. 4). The spacers provide support, maintain the longitudinal and the transversal reinforcement in place, and ensure a 20mm cover of concrete, see Figure 5(a). Finally, the joints were filled with concrete, see Figure 5(b). To guarantee adequate filling of the joints, manual compaction (no vibration) of the joints was made.       (a)     (b) Figure 5 – Construction process: (a) Placing the longitudinal and transversal reinforcement; (b) Joints infilled by concrete.  After filling the joints, the welded wire mesh was placed on the top surface of the brick units, see Figure 6.     Universidade do Minho  Departamento de Engenharia Civil   Contribution for a Full Prefabrication Approach / GROW-1999-70420 “ISO-BRICK” – 5/15   Azurém, P – 4800-058 Guimarães                                         Tel. +351 253 510200 • Fax +351 253 510217  Figure 6 – Welded wire mesh positioned on the top surface of the brick unities (AA and BB indicate the cross section details on Figure 3 and 4).  In a second phase, a concrete layer of 30mm thickness was poured and compacted using vibration equipment, see Figure 7. After casting, the top surface of this layer was regularized with a ruler, in order to remove any concrete excess and to obtain a smooth surface, see Figure 8(a,b).   Figure 7 – Casting the top concrete layer.    A A B B    Universidade do Minho  Departamento de Engenharia Civil   Contribution for a Full Prefabrication Approach / GROW-1999-70420 “ISO-BRICK” – 6/15   Azurém, P – 4800-058 Guimarães                                         Tel. +351 253 510200 • Fax +351 253 510217     (a)     (b) Figure 8 – Shell finishing: (a) Removing excessive concrete; (b) Surface regularization.      Universidade do Minho  Departamento de Engenharia Civil   Contribution for a Full Prefabrication Approach / GROW-1999-70420 “ISO-BRICK” – 7/15   Azurém, P – 4800-058 Guimarães                                         Tel. +351 253 510200 • Fax +351 253 510217 3 Shell Appearance  Figure 9 shows the shell after construction. It is noted that during the curing process the humidity of shell surface was controlled and the formwork was removed twenty-four hours after the construction.    Figure 9 – View of the shell in the mould.   Figure 10(a) shows the shell after removing it from the mould. According to aesthetic requirements, concrete should not stain the bricks and concrete voids in the joints could not be accepted. Figure 10(b) reveals that this objective was perfectly accomplished. Moreover, the timber strips produce a 3 mm recess in the joint, which makes the finished product very appealing. It can be concluded the concrete consistence was adequate for this application, both for the topping and for the joints.       (a)     (b) Figure 10 – (a) General view of the shell; (b) Appearance of the shell bottom surface.    Universidade do Minho  Departamento de Engenharia Civil   Contribution for a Full Prefabrication Approach / GROW-1999-70420 “ISO-BRICK” – 8/15   Azurém, P – 4800-058 Guimarães                                         Tel. +351 253 510200 • Fax +351 253 510217 4 Conclusion A concrete composition of adequate slump was designed for reinforced masonry shells, applicable to reinforced joints of 25mm thickness and to a top layer of 30mm thick. To ensure that the joints are properly filled, manual compaction or a vibrator must be used, locally in joints, if possible.  With the proposed materials and techniques, no evidence of concrete slurry was observed in the brick faces and no evidence of joint concrete voids was found. The recesses in the transversal and in the longitudinal joints seem to result in an appealing shell finishing.    Universidade do Minho  Departamento de Engenharia Civil   Contribution for a Full Prefabrication Approach / GROW-1999-70420 “ISO-BRICK” – 9/15   Azurém, P – 4800-058 Guimarães                                         Tel. +351 253 510200 • Fax +351 253 510217     ANNEX     Universidade do Minho  Departamento de Engenharia Civil   Contribution for a Full Prefabrication Approach / GROW-1999-70420 “ISO-BRICK” – 10/15   Azurém, P – 4800-058 Guimarães                                         Tel. +351 253 510200 • Fax +351 253 510217 UNIVERSIDADE DO MINHO ANÁLISE GRANULOMÉTRICA DE MATERIAIS INERTESDEPARTAMENTO DE ENGENHARIA CIVIL AMOSTRA Nº: 1  Requerente: JULIANA TORRESLABORATÓRIO DE ENGENHARIA CIVIL   Obra: MEIA AREIA  Lugar \ Rua:Azurém - 4800 Guimarães   Freguesia:Telef. 510211/4   Fax 510217   Concelho:  Processo nº:PENEIRAÇÃO MATERIAL MEIA AREIADESCRIÇÃO DO MATERIAL MEIA AREIAPESO TOTAL DA AMOSTRA (P1) 1000,5 gPENEIROS PESO RETIDO % RETIDA % RET.ACUMULADA % PASSADA3" 76,2 100,002" 50,8 100,0011/2" 38,1 100,001" 25,4 100,003/4" 19,1 100,001/2" 12,7 100,003/8" 9,52 100,004 4,76 18,80 1,88 1,88 98,128 2,38 130,70 13,06 14,94 85,0616 1,19 259,50 25,94 40,88 59,1230 0,595 279,70 27,96 68,84 31,1650 0,297 205,90 20,58 89,42 10,58100 0,149 100,20 10,01 99,43 0,57200 0,074 5,30 0,53 99,96 0,04RESTO 0,40 0,04 100,00 0,00TOTAL 1000,50 100,00ENSAIOU  OBSERVAÇÕES:VERIFICOUDATA Sieve report for sand 0.6-5mm        Universidade do Minho  Departamento de Engenharia Civil   Contribution for a Full Prefabrication Approach / GROW-1999-70420 “ISO-BRICK” – 11/15   Azurém, P – 4800-058 Guimarães                                         Tel. +351 253 510200 • Fax +351 253 510217 UNIVERSIDADE DO MINHO  ANÁLISE GRANULOMÉTRICA DE MATERIAIS INERTES AMOSTRA Nº:1DEPARTAMENTO DE ENGENHARIA CIVIL  Requerente: JULIANA TORRES  Obra: MEIA AREIALABORATÓRIO DE ENGENHARIA CIVIL  Lugar \ Rua:Azurém - 4800 Guimarães  Freguesia:Telef. 510211/4   Fax 510217   Concelho:  Processo nº:CURVA GRANULOMÉTRICA0102030405060708090100d 1/5% PASSADA (Total)01020304050607080901000.1 0.5 2 5 10 15 20 25 30 35 40 50 60 70 80 90 100% RETIDA (Acumulada)0.3 0.40.2 1 3 4mm20010050 30 16 8 4 3/8" 1/2" 3/4"1" 11/2"2" 3"150 Sieve curve for sand 0.6-5mm                              Universidade do Minho  Departamento de Engenharia Civil   Contribution for a Full Prefabrication Approach / GROW-1999-70420 “ISO-BRICK” – 12/15   Azurém, P – 4800-058 Guimarães                                         Tel. +351 253 510200 • Fax +351 253 510217 UNIVERSIDADE DO MINHO ANÁLISE GRANULOMÉTRICA DE MATERIAIS INERTESDEPARTAMENTO DE ENGENHARIA CIVIL AMOSTRA Nº:  Requerente: JULIANA TORRESLABORATÓRIO DE ENGENHARIA CIVIL   Obra: AREIA FINA  Lugar \ Rua:Azurém - 4800 Guimarães  Freguesia:Telef. 510211/4   Fax 510217  Concelho:  Processo nº:PENEIRAÇÃO MATERIAL AREIA FINADESCRIÇÃO DO MATERIAL AREIA FINAPESO TOTAL DA AMOSTRA (P1) 1000 gPENEIROS PESO RETIDO % RETIDA % RET.ACUMULADA % PASSADA3" 76,2 100,002" 50,8 100,0011/2" 38,1 100,001" 25,4 100,003/4" 19,1 100,001/2" 12,7 100,003/8" 9,52 100,004 4,76 100,008 2,38 100,0016 1,19 100,0030 0,595 36,50 3,65 3,65 96,3550 0,297 816,40 81,64 85,29 14,71100 0,149 140,60 14,06 99,35 0,65200 0,074 2,80 0,28 99,63 0,37RESTO 3,70 0,37 100,00 -0,00TOTAL 1000,00 100,00ENSAIOU  OBSERVAÇÕES:VERIFICOUDATA Sieve report for sand 0.3-0.6mm         Universidade do Minho  Departamento de Engenharia Civil   Contribution for a Full Prefabrication Approach / GROW-1999-70420 “ISO-BRICK” – 13/15   Azurém, P – 4800-058 Guimarães                                         Tel. +351 253 510200 • Fax +351 253 510217 UNIVERSIDADE DO MINHO  ANÁLISE GRANULOMÉTRICA DE MATERIAIS INERTES AMOSTRA Nº:DEPARTAMENTO DE ENGENHARIA CIVIL   Requerente: JULIANA TORRES  Obra: AREIA FINALABORATÓRIO DE ENGENHARIA CIVIL   Lugar \ Rua:Azurém - 4800 Guimarães  Freguesia:Telef. 510211/4   Fax 510217  Concelho:  Processo nº:CURVA GRANULOMÉTRICA0102030405060708090100d 1/5% PASSADA (Total)01020304050607080901000.1 0.5 2 5 10 15 20 25 30 35 40 50 60 70 80 90 100% RETIDA (Acumulada)0.3 0.40.2 1 3 4mm20010050 30 16 8 4 3/8" 1/2" 3/4"1" 11/2"2" 3"150 Sieve curve for sand 0.3-0.6mm                        Universidade do Minho  Departamento de Engenharia Civil   Contribution for a Full Prefabrication Approach / GROW-1999-70420 “ISO-BRICK” – 14/15   Azurém, P – 4800-058 Guimarães                                         Tel. +351 253 510200 • Fax +351 253 510217 UNIVERSIDADE DO MINHO ANÁLISE GRANULOMÉTRICA DE MATERIAIS INERTESDEPARTAMENTO DE ENGENHARIA CIVIL AMOSTRA Nº: 1  Requerente: JULIANA TORRESLABORATÓRIO DE ENGENHARIA CIVIL   Obra: GRAVILHA 5/10  Lugar \ Rua:Azurém - 4800 Guimarães  Freguesia:Telef. 510211/4   Fax 510217   Concelho:  Processo nº:PENEIRAÇÃO MATERIAL GRAVILHA 5/10DESCRIÇÃO DO MATERIAL GRAVILHA 5/10PESO TOTAL DA AMOSTRA (P1) 2999 gPENEIROS PESO RETIDO % RETIDA % RET.ACUMULADA % PASSADA3" 76,2 100,002" 50,8 100,0011/2" 38,1 100,001" 25,4 100,003/4" 19,1 100,001/2" 12,7 100,003/8" 9,52 64,30 2,14 2,14 97,864 4,76 1977,00 65,92 68,07 31,938 2,38 802,80 26,77 94,83 5,1716 1,19 61,40 2,05 96,88 3,1230 0,595 22,10 0,74 97,62 2,3850 0,297 15,50 0,52 98,14 1,86100 0,149 17,20 0,57 98,71 1,29200 0,074 30,40 1,01 99,72 0,28RESTO 8,30 0,28 100,00 -0,00TOTAL 2999,00 100,00ENSAIOU  OBSERVAÇÕES:VERIFICOUDATA Sieve report for gravel 5-10mm     Universidade do Minho  Departamento de Engenharia Civil   Contribution for a Full Prefabrication Approach / GROW-1999-70420 “ISO-BRICK” – 15/15   Azurém, P – 4800-058 Guimarães                                         Tel. +351 253 510200 • Fax +351 253 510217  UNIVERSIDADE DO MINHO  ANÁLISE GRANULOMÉTRICA DE MATERIAIS INERTES AMOSTRA Nº:1DEPARTAMENTO DE ENGENHARIA CIVIL   Requerente: JULIANA TORRES  Obra: GRAVILHA 5/10LABORATÓRIO DE ENGENHARIA CIVIL   Lugar \ Rua:Azurém - 4800 Guimarães  Freguesia:Telef. 510211/4   Fax 510217   Concelho:  Processo nº:CURVA GRANULOMÉTRICA0102030405060708090100d 1/5% PASSADA (Total)01020304050607080901000.1 0.5 2 5 10 15 20 25 30 35 40 50 60 70 80 90 100% RETIDA (Acumulada)0.3 0.40.2 1 3 4mm20010050 30 16 8 4 3/8" 1/2" 3/4"1" 11/2"2" 3"150 Sieve curve for gravel 5-10mm 

Contribution for a full prefabrication approach of masonry reinforced shells

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Universidade do Minho: RepositoriUM