REPORT OF FULL SCALE TEST ON PROTOYPE COMPOSITE SLAB OF PRECAST PRESTRESSED T-BEAMS AND HOLLOW CONCRETE BLOCKS

CLIENT :

M/SITAL PRESTRESS AND CONSTRUCTION COMPANY

INVESTIGATOR:

PROF. C.K. KANKAM CIVIL ENGINEERING DEPARTMENT KNUST

October 2001

EXECUTIVE SUMMARY At the request of M/S ITAL PRESTRESS CONSTRUCTION COMPANY of Accra, Professor C.K. Kankam of the Civil Engineering Department of the Kwame Nkrumah University of Science and Technology, Kumasi assessed the service behaviour of a model composite floor slab on site. The composite structure consisted of prestressed concrete joist, hollow concrete blocks and mass concrete topping. The investigation took the form of uniform loads of bagged sand arranged in layers on the structure and measurement of central span deflection by means of a mechanical dial gauge. Theoretical analysis indicates that, the composite slab flexural capacity if allowed to develop cracks (ie. Class three type of prestressed member) at service conditions is 106.85k Nm. For it to behave as a class two member where tension in the slab is limited to the allowable stress, but no cracking takes place the service moment capacity is 46.73k Nm. The experimental loading was stopped and sustained at 192 tons or 192Kn. This is equivalent to a moment of 546.8kNm. Ther deflection corresponding to this load after nine days of sustained loading when creep had taken place was 14.81mm. Ten fine cracks of average width 0.05mm developed.

REPORT OF FULL SCALE TEST ON PROTOTYPE COMPOSITE SLAB OF PRECAST PRESTRESSED T- BEAMS AND HOLLOW CONCRETE BLOCKS CLIENT : M/S ITAL PRESTRESS AND CONSTRUCTION COMPANY.

INVESTIGATION: PROF. C.K. KAMKAM CIVIL ENGINERING DEPARTMENT K.N.U.S.T. ERECTION OF TEST SPECIMEN The test specimen consisted of a concrete slab. Which was a composite construction of five inverted precast prestressed T- beams (joists) that were laid at 500mm centers (see fig 1) )Each joist was prestressed with 6 stands to a stress of 1500 N/mm2). The space between the beams were filled with the precast hollow cement blocks manufactured from cement and quarry dust. The composite beams- hollow blocks assembly was the topped with 50mm mass concrete. The slab spanned one 0way on simple support of beams with nominal point reinforcement between the end beams and the slab. TEST PROCEDURE The composite floor slab spanned one way was simply supported at its ends on a reinforced concrete portal frame. The span was 6.47m. The composite slab was loaded 2.16. The test loads consisted of 100kg bags of sand. The composite slab was loaded symmetrically from the ends towards the centre until the entire top surface was covered with a total of 48 bags. This set of lads was considered as one complete layer. The layer comprised four bags along the shorter dimension and twelve bags along the span. The central deflection of the slab was recorded by means of a mechanical dial gauge after the full layer of loads was put on.

This procedure of loading was repeated and again the deflection was recorded. (no cracks developed at this stage of the test). The test slab was left for six days under the action of two layers (i.e 96 bags of 100kg) each of loads to assess the effect of creep on the floor, particularly on the main structural members, namely prestressed joists. Loading of the slab resumed the 7th day with an initial deflection recording and followed by 2 layers. (i.e 96 bags of 100kg) of loads. Again the central deflection was recorded after each layer. The results in terms of loads and deflection were presented in Table 1. At the service state, ten structural cracks developed within the central span of 109. 1cm. The maximum average crack width was 0.1mm, which is within allowable limits for partially prestressed beams Appendix 2 presents a calculation of the ser vice moment of the composite floor structure. Computation of the moment due to applied external loads and self-weight dead loads is summarized in appendix 1. The loaded structure was kept for 41 days and exposed to the vagaries of weather sicne1/9/2001. Rain water absorbed by the loading sand bags increased external loads on the structure. This state of affairs leading to wetting and drying of the sand constituted some form of cyclic loading, and combined with the effect of creep, widened extended cracks. The maximum and average crack sizes were 0.4 and 0.2mm, respectively. The deflection of the floor slab was 29.8mm.

Imposed Load Total Load on structure = 19200 kg = 19200 x 10 = 192 KN Over an area of slab of 6.47m span (support to support) width 2.16m (intensity of load = 13.7 KN m2 imposed; compare this to code load) Assuming whole slab is of the same stiffness, this is equivalent to 192 = 88.9 KN 2.16 OOOOOOOOOOOOOOOOOO 6.47(imposed) OOOOOOOOOOOOOOOO 6.47m(dead) 4 x 48 x 100 kg

Dead Load Again assuming the stiffness of the slab i.e. composite structure of precastprestressed beams, hollow concrete blocks and concrete overlay as a single unit. (a) depth of slab = 0.3m dead load = 2.16 x 0.3 x 24 = 15.6 KN/m

Total load = imposed + dead = 88.9 + 15.6Kn/M Maximum moment at midspan = 12 = 104.5 x 6.472 = 546.8 KN 8 8 For a simply supported one-way slab, M = 546.8 KN

Appendix 2 Service Moment Capacity of Transformed Section Equivalent area, Aeq = 64.3 x 103 mm2 Second moment of area, Ieq =348.75 x106 mm4 Distance of bottom fiber from centroid = 157.4 mm Distance of top joist fiber from centroid = 157.4 55 35 = 67.4 mm For elastic behavior, the general engineers equation M = f. I y Two cases to consider Case 1: Based on allowable service tensile stress at base of joist: Initial allowable stress due to Prestress at base of joist is compressive and equal to 15.54 N/mm2 At service load of the joist, as a component of the floor slab this compressive stress should be overcome first before the joist is transformed into tension. For class 2 members in which tension is allowed but no cracking occurs, let allowable tension be 3.35 N/mm2, the total stress is f = 15.54 + 3.5 = 18.89 N/mm2 From the general engineers equation M = f I 18.89 = 348.75 y 157.4 = 41.85 KNm

For class 2 members, where cracking takes place, Let limiting tensile stress = 1/10 x fcu = 55.N/mm Then total Stress f = 15.54 + 5.5 = 21.09 N/mm M = 21.09 x 348.75 157.4 = 46.73 KNm Case 2: Based on allowable concrete compressive stress of top of joist when Cracks have develop and stabilize, corresponding to Class 3 type of prestressing. Initial stress at top of joist is tensile = 2.5 N/mm Allowable concrete stress fe = 0.33fcu = 18.15N/mm Total stress = 20.65 N/mm2 Y top M = 67.4mm =f. I y = 20.65 x 348.75 67.4 = 106.85 KNm

APPENDIX 2: ELASTIC ANALYSIS OF FLOOR SLAB In-situ concrete fcu = 25N/mm Joist concrete fcu = 55N/mm

In-situ concrete Ecu = 25N/mm Esteel = 200kN/mm2 Diameter = 3.9mm Conversion of steel into equivalent concrete section using depth of 3.9mm (corresponding to its diameter) Base Steel Es x 5 x 11. 93 = 200 x 5 x 11.93 = 477. 2mm2

For rectangular equivalent section of depth 3.9mm 477.2 = 122.4 3.9 Top Steel 122.4 3.9

Es x 11.93 = 200 x 11.93 = 95.44mm2 Ec 25

95.44 = 24.5mm 3.9

92.6mm C 157.4 D 18

A B

72mm 160mm 39mm 39.mm 39mm 180mm 55mm 250mm

Portion A B C D

Centroid from base Ay y 500 x 70 = 35 x 103 215 752.5 x 104 160 x 180 = 28.8 x103 90 259.2 x 104 0.507 x 104 2 x 12.25 x 3.9 = 0.955 53.05 x 103 2 x 61.2x 3.9 = 447.36 16.05 0.722 x 104 = 0.45 x 103 Area (mm2) 64.35 x 103
=

1012.93 x 104

y = 1012.93 x 10 = 157.4mm 64.35 x 103 Part Distance of CG from centroid (mm) 57.6 67.4 102.4 139.4 1mm Ay mm IG = mm4 + Ay2

A B C D

14.3 x 10 77.76 x 10 121.1 604.05

11.12 x 10 130.83 x 10 1.00 x 10 8.74 x 10

130.42 x 106 208.59x 106 1 x 106 8.74 x 106 =

348.75x106

I of equivalent section = 348.75 x 106

Table 1: Results of Load Test

LOAD KN 4800 8000 8000 9600 14400 19200 19200 19200 19200 48 80 80 96 144 192 192 192 192 DEFLECTION(mm) 0 1.65 3.68 4.10 4.50 6.97 10.70 11.28 No Cracking 14.81 Effect of creep after 1 hour 40min 29.81 Effect of creep after 3 days. Appearance of 10 fine cracks Sand bags exposed to changing Weather for a period of 41 days. Rainwater absorbed by sand Increased external loads on structure. Cracks extended in length and widened. Maximum crack Width = 0.4mm Average crack = 0.2mm Loading left for 6 days. Increase in deflection due to creep Instantaneous cracking loading, no REMARKS

Instantaneous loading - do Loading left for 2 hours, Increase in deflection due to creep

Section through composite slab

topping 30,40 or 50

joist centers=500mm

block wall thickness=20mm

fig 1

Section of prestressed concrete joist

35mm

15mm

18mm

120m m

fig 2

35mm

40mm