wl WHOL DOCUMENT ava’ rasan . COLLECTION IN echuleal @ room (OG titl , CONCRETE SANDWICH CONSTRUCTION te: FOR ENERGY CONSERVATION author: John R. Keeton date: march 1980 Sponsor: Naval Material Command program MOS: 2F57.571.001.01.001 CIVIL ENGINEERING LABORATORY NAVAL CONSTRUCTION BATTALION CENTER Port Hueneme, California 93043 Approved for public release; distribution unlimited. UE IAS ALIS LO Unclassified SECURITY CLASSIFICATION OF THIS PAGE (When Data Entered) REPORT DOCUMENTATION PAGE 1. REPORT NUMBER 2. GOVT ACCESSION NO, 3. RECIPIENT'S CATALOG NUMBER TN-1574 DN687061 4. TITLE (and Subtitle) 5. TYPE OF REPORT & PERIOD COVERED CONCRETE SANDWICH CONSTRUCTION FOR Final; Oct 1975 — Sep 1978 ENERGY CONSERVATION 6. PERFORMING ORG. REPORT NUMBER 7. AUTHOR(s) 8. CONTRACT OR GRANT NUMBER(s) J. R. Keeton 9. PERFORMING ORGANIZATION NAME AND ADORESS 10. SEO eee ME Nar rire rican TASK CIVIL ENGINEERING LABORATORY 3 F 62765N; Naval Construction Battalion Center 7 Port Hueneme, California 93043 F57.571.001.01.001 11. CONTROLLING OFFICE NAME AND ADDRESS 12. REPORT DATE Naval Material Command Mone eo. 13. NUMBER OF PAGES Washington, DC 20360 15 14. MONITORING AGENCY NAME & ADDRESS(if different from Controlling Office) 15. SECURITY CLASS. (of this report) Unclassified 1Sa, DECLASSIFICATION’ DOWNGRADING SCHEDULE 16. DISTRIBUTION STATEMENT (of this Report) Approved for public release; distribution unlimited. 17. DISTRIBUTION STATEMENT (of the abstract entered in Block 20, if different from Report) 18. SUPPLEMENTARY NOTES 19. KEY WORDS (Continue on reverse side if necessary and identify by block number) Concrete walls, concrete roofs, insulated walls, shrinkage-compensating concrete, shrinkage, expansive concrete 20. ABSTRACT (Continue on reverse side if necessary and identify by block number) An abbreviated research study on use of shrinkage-compensating expansive concrete in sandwich-type wall and roof panels containing insulation at mid-thickness is described. The use of expansive concrete is shown to be a technically viable concept for eliminating shrinkage cracking, thus preventing moisture penetration which can reduce insulation effectiveness, cause deterioration of the insulating material, and accelerate steel corrosion. Embeddable (continued) DD Hlgelalaht 1473 EDITION OF 1! NOV 65 IS OBSOLETE Unclassified SECURITY CLASSIFICATION OF THIS PAGE (When Data Entered) Unclassified SECURITY CLASSIFICATION OF THIS PAGE(When Data Entered) 20. Continued resistance strain gages proved to be reliable for measuring expansion and subsequent shrinkage of the experimental panels. As a result of this study, a comprehensive research program is proposed for experimental verification of design and field control measures that will permit the use of shrinkage-compensating cement mortars in sandwich panel construction. Library Card Civil Engineering Laboratory CONCRETE SANDWICH CONSTRUCTION FOR ENERGY CONSERVATION (Final), by J. R. Keeton TN-1574 15pp illus March 1980 Unclassified 1. Shrinkage-compensating concrete 2. Expansive concrete I. ZF57.571.001.01.001 An abbreviated research study on use of shrinkage-compensating expansive concrete in sandwich-type wall and roof panels containing insulation at mid-thickness is described. The use of expansive concrete is shown to be a technically viable concept for eliminating shrinkage cracking, thus preventing moisture penetration which can reduce insulation effectiveness, cause deterioration of the insulating material, and accelerate steel corrosion. Embeddable resistance strain gages proved to be reliable for measuring expansion and subsequent shrinkage of the experimental panels. As a result of this study, a comprehensive research program is proposed for experimental verification of design and field control measures that will permit the use of shrinkage-compensating cement mortars in sandwich panel construction. Unclassified SECURITY CLASSIFICATION OF THIS PAGEfWhen Data Entered) CONTENTS Page NFER OD U GLMONG eit hati iy ns ba eee tan Mestal< alata fs Parsel Ses leat aca= | ayly oes MeN Ne Myst aerstan sir eae e ee 1 EXPERUTMEN TAG HPROGRAMY ja a Mtn ati silat ledomea al alleu gush iiisy | toumuee Mean tout draatalainay sisiiunsyst elds 2; ENS ERUMEN PATTON Mor ave ieNitce sul anusetnesiuiste sr Uh pean el Garam icecu nv ancaanh cei CNll MEUM Mibse corsiauitsaat ts 2 DES EBRES UT Sienna ie coset cas vorolgs iran eanitleyl bet Hate, satire il siege ie Warayasen nu ulag Mire ea Mew My Sve Gis 3 DIES CUS SHON sey e pees kena: lume alse ist) ior Grune tetcuN etre oh Cues pasa aod eteat Ua wr ciysiall ere 4 CON GEU STON Me ictigt a ucsite ct cua console eters Biers nic rit coe case Cina leais Si Na oc oe Oa eo 4 RE COMMEND AEONS sipngiver sein silage toh wiser d sells uli (a taoel Ain one orn cdl seul ace crams my ont ereemues (is 4 REBEREN GE Sites moni mean crn: ioe acolo eed cae irs sti aa BOTT cA ENTE Sila case oss ae 4 INTRODUCTION Penetration of water into reinforced portland cement concrete structures through shrinkage cracks necessitates expensive installation of membranes and maintenance coatings. In addition, air infiltration through these cracks increases the heating/cooling energy load. In exterior walls and roofs, especially in areas where wind-driven rain is a problem, attempts to bridge working cracks with flexible and expandable coatings have met with only qualified success. Expansive cements were developed to (1) overcome the effects of shrinkage and (2) provide significant compressive prestressing for strength improvement (Ref ll): Detailed recommendations for use of shrinkage-compensating expansive cements were published in 1977 (Ref 2). Commensurate with the demands for energy conservation, sandwich- type expansive concrete wall and roof panels containing insulation at mid-thickness should reduce life-cycle and energy costs of new structures by up to 30%, based on contractors' cost estimates. This saving results from use of concrete wall panels combining insulation and reinforcement. Two of the sandwich walls include "W" Panels made by CS&M Inc., Chino, Calif., and "Impac Panel" made by Covington Brothers Building Systems, Riverside, Calif. The objective of this study is to determine (1) the practicability of using expansive cement mortars to prevent shrinkage cracking and (2) the effective aged thermal resistance of the sandwiched urethane foam, originally in contact with wet mortar (plaster) on both sides. Research directed toward development of sandwich-type walls and roofs began in FY 1976 at the Civil Engineering Laboratory, Port Hueneme, Calif., but demands for research funds for other studies resulted in drastically reduced support for the work in FY-TQ, -77, and -78. The study was terminated in FY-78. In the first year of research (FY-76), the only expansive cement commercially available was Type K shrinkage-compensating cement. The one chosen for experimentation that year was Type K, ChemComp patented by Chemically Prestressed Concrete Corporation, Hacienda Heights, Calif. Wall and roof panels of the type desired for the experiments were obtained from CS&M Incorporated, Chino, Calif., which makes and markets the panels under the trade name "W-Panel."' These panels have been used in construction of houses, barns, and other structures for several years; their greatest use has been outside the continental United States. CS&M states that W-Panels have been used extensively on the island of Guam in U.S. Government housing and that houses made with these panels have successfully withstood severe typhoons. Authorities at Naval Station, Guam have verified use of these panels in housing but were unable to pinpoint locations. Use of W-Panels within the continental U.S. has been impeded by inertia in changing current building codes. The International Conference of Building Officials (ICBO) Uniform Code has approved the use of the panel under their research committee recom- mendation, Report No. 2440 (Ref 3). Small sections of typical panels can be seen in Figure 1. The panel section on the left is set in a simulated footing. The sections shown contain 1 inch of polyurethane foam at mid-thickness; 2 by 2-inch no. 14 galvanized mesh forms the reinforcing on both sides of the foam. The two mats of fabric, one on each side of the foam, are tied together by single no. 14 wires welded to each mat and placed at 45 degrees from the plane of the mat to provide shear strength. About 1 inch of portland cement plaster or mortar is then applied to both sides of the panel to complete the construction. After the concrete has hardened, a finish coat of stucco (including color) may be applied. Plastered or mortared panels will shrink when drying (i.e., when used in a typical wall or roof). If the shrinkage, which is a shortening in length due to loss of water, is restrained or resisted by reinforcement, tensile stresses develop in the material which can exceed its tensile strength, resulting in a crack. Steel reinforcing tends to hold cracks "closed," but moisture can penetrate as a vapor; heat and cold also find their way through. In an insulated wall or roof panel, water vapor can, and often does, condense in the insulation, thus reducing its insulation efficiency by increasing its thermal conductivity. The purpose of using shrinkage-compensating cement in the plaster (or mortar) is to provide enough induced compressive stresses in the hardened plaster to prevent shrinkage cracking, thus making the resultant construction more energy efficient. EXPERIMENTAL PROGRAM Descriptions of the test panels and conditions in the research program undertaken to provide crack-free, sandwich-type insulated, expansive concrete walls and roofs follow. Cement: Type K, Shrinkage-Compensating Cement content: 5.5 bags/cu yd Sand/cement ratio: 3.5/1; 3.0/1 Panel size: (1) 2 by 4 feet; (2) 1 by 2 feet Panel thickness: approximately 3 inches Insulation thickness: 1 inch Strain measurement: (1) mechanical strain gage (2) embedded resistance strain gage Number of panels: Twenty-one INSTRUMENTATION At the outset of the experimental program, it was planned to measure expansion strain and subsequent shrinkage with a mechanical strain gage on reference points cast into the wet concrete after construction of the panels. In addition, reference points were soldered to the mesh rein- forcing at selected locations to measure steel movement. Later in the program, embeddable resistance strain gages were also used. TEST RESULTS The first experimental panels were 2 by 4 feet and were constructed out-of-doors (Figure 2). They were cast into simulated footings to enable them to stand upright without bracing. In Figure 2 the final layer of mortar had been applied to the panel on the left, while only the first lift of mortar had been applied to the one on the right. These panels were cured under wet burlap for 2 days and were then allowed to dry under ambient climatic conditions. At first mechanical strain gage data seemed to be of reasonable magnitude, but after a few weeks very peculiar readings began to appear; in addition, some of the reference points loosened. The earlier readings had shown rather high shrinkage strains immediately following the curing period; at first, they seemed to be reasonable considering the rather thin concrete sections involved (approximately 1 inch). It is highly probable that screws used as the reference points were not securely bonded to the concrete (probably because they had to be pushed into the wet concrete after it had been brought to the proper level). The screws could not be pre-attached without tying them to the mesh, which would have defeated the purpose. It was eventually concluded that the mechanical strain gage data on these two panels were incorrect, and the information was discarded. Strains in the steel mesh, measured on reference points soldered to the steel, were also erratic. Immediately following construction of the 2 by 4-foot panels, a series of 1 by 2-foot panels were constructed and instrumented for measurement with a mechanical strain gage. One of these panels can be seen in Figure 3. These panels were cured in fog for either 9 or 16 days prior to being placed in controlled temperature and humidity rooms (50% or 75% RH) for shrinkage determination. As with the larger panels, mechanical strain gage data seemed to be realistic for a while and then began to vary beyond reasonable limits. By the time 20 panels had been constructed and it had been concluded that mechanical strain gage measurements were unreliable, financial support for the work was severely reduced. For FY-TQ, FY-77, and FY-78 measurements were continued on existing panels, but no additional exper- imental panels were constructed except for one additional 1 by 2-foot panel instrumented with embeddable resistance strain gages. The panel was cured for 16 days in fog and then placed in 50% RH. The embedded strain gages performed very well. Figure 4 shows shrinkage strains in 50% RH for this panel as well as average shrinkage strains for several of the panels in which the strain was measured with a mechanical strain gage. In terms of desired results (i.e., adequate expansion during the curing period to overcome subsequent shrinkage), the upper curve is much better than the lower curve. When the shrinkage curve drops below the horizontal zero strain line, it is in the tension or potential cracking zone. Neither of the curves in Figure 4 shows sufficient expansion. In the case of the upper curve (measured with embedded resistance gages), the expansion should be about 200 microstrain (29%) higher to overcome the drying shrinkage expected in a dry climate (20% RH). DISCUSSION Optimum (and practical) curing procedures as well as optimum cement content are vital to achievement of adequate expansion. Adequate expan- sion to overcome (compensate for) shrinkage will also "prestress" the panel; the magnitude and benefits of this concrete precompression must be determined on a life-cycle basis before the procedure can be economi- cally justified. The life-cycle effects of the wet mortar on the thermal conductivity of the "sandwiched" polyurethane foam must also be determined. Since structural strength of the W-Panels has been established by ICBO, only a few tests of expansive concrete panels will be needed to verify their strength. CONCLUSION Based on results shown in Figure 4, use of expansive cement mortar to prevent shrinkage cracking in the W-Panel is a technically viable concept. Embeddable resistance strain gages are more reliable for measuring strain in the W-Panels than a mechanical strain gage used on embedded screw-type reference points. RECOMMENDATIONS To reduce life-cycle and energy costs of new concrete structures by up to 30% by using expansive concrete panels with insulation at mid- thickness to produce crack-free sandwich-type walls and roofs, the research program outlined below is recommended. ys Experimental sandwich wall and roof panels, containing insulation at mid-thickness, should be made with shrinkage-compensating expansive cement concretes to eliminate shrinkage cracking. Optimum amount of expansive cement, optimum curing method, and optimum panel thickness should be determined. Volume changes (potential to crack from shrinkage), strength, thermal conductivity, and density should be determined on experimental wall and roof panels. In addition, the optimum method of placing the mortar (plaster) should be developed (shotcrete, pumping, etc) Die Design procedures, including tables and charts, should be developed for energy-efficient expansive concrete wall and roof panels. REFERENCES 1. “Expansive cement concretes--Present state of knowledge," Journai 3: the American Concrete Institute, Aug 1970, pp 583-610. 2. "Recommended practice for the use of shrinkage-compensating concrete," Manual of Concrete Practice, Part 1. American Concrete Institute, 1977. (ACI 223-77) Sie International Conference of Building Officials, Research Committee Recommendation Report No. 2440, Jul 1978. ih Sections of W-panels. Figure l. é a at dad Experimental panels constructed outside. Figure 2. Figure 3. Completed 1 by 2-foot panel, showing screw-type reference points for mechanical strain gage ; _ attachment. (sdep) ou y, [210], OOF OSE OOE OST O00Z OST OOT 06 08 OL O09 OS —p-——___, ases ures yeoturyoour a8e8 UIeI]S DDURISISII a [ed11999]9 pappaquia Ov SE O€ “HY ZOS Ut sToued [TPM YyOTMpues o}Je1]DU0D oATSUedKXS Jo sBeyUTIYS ‘h eINnsTy Sc 0c ST or 6 <———— Buiino jo skep 6 uorsuedxa wmnuIxeUur 009 OOS OOF 00¢ OOE oor oos 009 OOL 008 (UIPIISOIOTUL) uUIPIVTS 9191DU0D co DISTRIBUTION LIST AAP NAVORDSTA IND HD DET PW ENGRNG DIV, McAlester. OK AFB (AFIT/LD), Wright-Patterson OH; ABG/DEE (F. Nethers), Goodfellow AFB TX; AF Tech Office (Mgt & Ops), Tyndall, FL; AFCEC/XR,Tyndall FL; AUL/LSE 63-465, Maxwell AL; CESCH, Wright-Patterson; HO Tactical Air Cmd (R. E. Fisher), Langley AFB VA; HQAFESC/DEMM., Tyndall AFB, FL; MAC/DET (Col. P. Thompson) Scoti, IL; SAMSO/MNND, Norton AFB CA; Samso, Vandenburg, AFB, CA; Stinfo Library, Offutt NE ARMY ARRADCOM, Dover, NJ; BMDSC-RE (H. 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