iii

THE MECHANISM OF FAILURE OF STRUCTURAL LIGHTWEIGHT

CONCRETE INFILL OF IBS BLOCKS SUBJECTED TO FLEXURAL

MUGAHED YAHYA HUSSEIN AMRAN

A project report submitted in partial fulfillment of the

requirements for the award of the degree of

Master of Engineering (Civil & Structure)

Faculty of Civil Engineering

Universiti Teknologi Malayisia

JANUARY 2013

v

أهــــــــــــــــــــــــداء:

في عليين بجوار النبيين والمرسلين من شجعني في صغــرى الي من رحمه هللا تغشــــــــاه واسكنه

(أبي)

عث فيني الهمهظني ومن صوتها وحنانها يبجي ربي ان يحفآفع يداها تنترعد أن ب الي من لم تنام عيناها اال

(أمي)

في سبيل تحقيق أهدافي المرسومه دا لي سن واالي من ساعدوني ووقفوا بجانبي ورفعوا معنوياتي وكان

(واتيخأخواني وأ)

وكانوا نوأبا عن أخواني لي بالغربه –أنسجمت بمصادقتهم و غربتيأحلي لحظات الي من من عشت معهم

(أصدقائيو ي ئزمال)

To my parents and all my beloved family members

vi

ACKNOWLEGEDMENT

In the beginning, I would love to express my greatest and sincere appreciation

to my final master project supervisor and con-supervisor; Ir. Azhar Bin Ahmad and

PM. Dr. Abdul Kadir Marsono respectively, for their guidance, critics,

encouragement, and advises throughout the process of this research. I am indebted to

them for their valuable instructions and guidance along the time of the research. I am

truly grateful to them also in the confidence and trust on me from the beginning of

the project until the stage of research accomplishment.

I am very grateful to have my friends with me during the period of research

preparation whenever I face any obstacles and problems; they always give their

moral support and encouragement to me throughout the process of research and

greatly indebted to all my beloved family members for their consistent

encouragement me and support every moment.

Last but not least, I also would like to thank to my friends who always

accompany me and give their moral support when in need especially those involved

directly or indirectly in my preparation of research. Their opinions and views are

useful indeed. May our friendship last forever and I will keep always praying that

may ALLAH guide them and me to the right path and help us to serve and develop

our nations.

vii

ABSTRACT

Currently there is a strong inclination of the Malaysian construction industry

to utilize industrialized building system (IBS) of lightweight concrete material. The

use of lightweight material has the potential to offset the high cost of production and

transportation of IBS components of normal dense concrete material. This research

presents an experimental contacted testing on the mechanism of failure of structural

lightweight concrete infill of IBS block-works subjected to flexural. Full-scale

experimental push-out test frames were erected to investigate the ultimate behavior

of lightweight concrete beams and blocks. The setup frame consists of lightweight

beams supported at both ends with IBS lightweight infill blocks. Numerous

dimensions and shapes of the lightweight IBS blocks were tested. Each lightweight

IBS blocks were designed based on readily available steel formwork and proper

means of fixing and assembling each IBS blocks to form a complete a full height

lightweight panel. Push-out load (flexural load) is then applied up to failure to

determine the behavior of the IBS panel due to incremental loading. The deflection,

crack pattern, splitting strength, tensile strength and ultimate compressive strengths

of the IBS blocks are recorded and compared with the results obtained with a similar

panel of normal concrete in-fill.

viii

ABSTRAK

Sekarang ini, terdapat kecenderongan dikalangan industri pembinaan di

Malaysia untuk menggunakan Sistem Binaan Berindustri (IBS) yang menggunakan

bahan konkrit ringan. Tidak seperti konkrit biasa, penggunaan konkrit ringan

mempunyai potensi untuk menjimat kos yang tinggi bagi pengeluaran dan

pengangkutan komponen IBS ini. Kajian ini membentangkan ujian eksperimen

dihubungi mengenai mekanisme kegagalan struktur konkrit ringan blok IBS tertakluk

kepada lenturan. Suatu kerangka tolak-keluar yang berskala penuh telah didirikan

untuk meninjau tingkah laku muktamad rasuk dan blok konkrit ringan. Kerangka

yang dibina ini terdiri daripada rasuk ringan yang disokong pada kedua-dua

hujungnya dengan infill blok konkrit ringan IBS. Pelbagai dimensi dan bentuk blok

IBS ringan telah diuji. Setiap blok ringan IBS telah direka bentuk berdasarkan acuan

keluli yang sedia ada dan menggunakan kaedah pemasangan yang betul bagi setiap

blok IBS untuk membentuk panel ringan yang lengkap dengan ketinggian penuh.

Suatu beban sisi kemudian dikenakan sehingga tahap kegagalan untuk menentukan

tingkah laku panel IBS semasa penambahan bebanan. Bacaan pesongan, corak retak,

kekuatan pemisahan, kekuatan tegangan dan kekuatan mampatan muktamad blok

IBS direkod dan perbandingan dibuat dengan keputusan yang diperolehi daripada

panel infill konkrit biasa yang serupa.

ix

TABLE OF CONTENTS

CHAPTER TITLE PAGES

TITLE i

DECLARATION iv

ACKNOWLEDGEMENT vi

ABSTRACT vii

ABSTRAK viii

TABLE OF CONTENT ix

LIST OF TABLES xiv

LIST OF FIGURES xv

LIST OF ABBREVIATION xvii

LIST OF APPENDIX xix

1 INTRODUCTION ....................................................................................... 1

1.1 Background ................................................................................................... 1

1.2 Problem statements ....................................................................................... 4

1.3 Objectives of research ................................................................................... 5

1.4 Significance of study ..................................................................................... 5

1.5 Scope of study ............................................................................................... 6

x

2 LITERATURE REVIEW .......................................................................... 7

2.1 Introduction ................................................................................................... 7

2.2 Background of aerated aggregates (Pumice aggregate) ................................ 9

2.3 Classification of lightweight concrete materials ......................................... 10

2.3.1 Low density concrete ........................................................................... 10

2.3.2 Moderate strength concrete .................................................................. 10

2.3.3 Structural concrete ............................................................................... 11

2.4 Comparison between the three types of lightweight aggregate ................... 13

2.5 Application of lightweight concrete ............................................................ 14

2.6 Advantages and disadvantages of lightweight Concrete ............................. 15

2.7 IBS concrete block production methods ..................................................... 16

2.7.1 Fully Prefabricated Construction Method ............................................ 17

2.8 Characteristics of Precast Concrete beams and blocks ............................... 18

2.8.1 Aerated Concrete Blocks ..................................................................... 19

2.8.2 Stability of IBS pre-cast beams ............................................................ 20

2.9 Basic Beam behavior ................................................................................... 20

2.9.1 Beam tension behavior ......................................................................... 21

2.9.2 Beam compression behavior ................................................................ 22

2.9.3 Beam behavior with two different forces direction. ............................ 23

2.10 Micro-structural behavior for aerated concrete aggregate beam and block 24

2.10.1 Compressive strength ........................................................................... 24

2.10.2 Modulus of elasticity (E) ..................................................................... 25

2.10.3 Splitting tensile strength ...................................................................... 26

2.10.4 Tensile and Flexural tensile strength ................................................... 27

2.10.5 Deflections ........................................................................................... 27

2.10.6 Density ................................................................................................. 28

2.11 Structural Lightweight concrete mix design mechanisms ........................... 29

xi

2.11.1 Ordinary Portland cement content ....................................................... 29

2.11.2 Water content ....................................................................................... 30

2.11.3 Sand ...................................................................................................... 30

2.11.4 Admixture ............................................................................................ 31

2.11.5 Super-plasticizers ................................................................................. 31

2.12 Aerated structural lightweight aggregate concrete related tests .................. 32

2.12.1 At fresh state ........................................................................................ 32

2.12.2 At hardened state .................................................................................. 33

2.13 Behavior of reinforced concrete blocks and beams with lightweight infill 34

2.14 Role of infill walls in response of moment-frame buildings ....................... 35

2.15 Structural lightweight concrete behavior .................................................... 36

2.15.1 Fire Resistance and spall Defect to L.W.C .......................................... 36

2.15.2 Freezing and thawing ........................................................................... 36

2.15.3 Abrasion resistance .............................................................................. 37

2.15.4 Chemical attack .................................................................................... 37

2.15.5 Acid resistance ..................................................................................... 38

2.15.6 Alkali aggregate resistance .................................................................. 38

2.15.7 Carbonation and corrosion ................................................................... 39

3 RESEARCH METHODOLOGY AND PROCEDURE ........................ 40

3.1 Introduction ................................................................................................. 40

3.2 Experimental procedures (Program) ........................................................... 42

3.3 Experimental materials used ....................................................................... 44

3.3.1 OPC Cement ........................................................................................ 44

3.3.2 Sand ...................................................................................................... 45

3.3.3 Aerated aggregates ............................................................................... 45

3.3.4 Water .................................................................................................... 47

xii

3.3.5 Plasticizers ........................................................................................... 48

3.4 Experimental specimens preparation........................................................... 49

3.4.1 Mix composition (concrete mix) .......................................................... 49

3.4.2 Mould & ready formwork .................................................................... 49

3.4.3 Lightweight concrete mix design mixer............................................... 51

3.4.4 Concrete transportation and placing processes .................................... 51

3.4.5 Concrete vibrating ................................................................................ 52

3.4.6 Curing samples ..................................................................................... 55

3.4.7 Test methods ........................................................................................ 56

4 RESULTS, DISCUSSION AND ANALYSIS ......................................... 65

4.1 Introduction ................................................................................................. 65

4.2 Compression test ......................................................................................... 66

4.3 Experimental tests analysis ......................................................................... 67

4.3.1 Splitting test ......................................................................................... 67

4.3.2 E-value test ........................................................................................... 69

4.4 Frame analysis ............................................................................................. 73

4.4.1 Load versus Deflection Relationship ................................................... 73

4.4.2 Load and deflection relationship at cycle 1 ......................................... 74

4.4.3 The maximum load verse deflection at first cycle 1 ............................ 75

4.4.4 Load and deflection relationship at cycle 2 ......................................... 75

4.4.5 The maximum load verse deflection at second cycle 2 ....................... 76

4.4.6 Load and deflection relationship at cycle 3 ......................................... 77

4.4.7 The maximum load verse deflection at the three cycles ...................... 78

4.4.8 The maximum load verse deflection at the cycle 3 .............................. 79

4.4.9 Load verse deflection at point load 1 ................................................... 80

4.4.10 Load verse deflection at point load 2 ................................................... 81

xiii

4.5 Comparison between lightweight concrete and a normal concrete in-fills

results .................................................................................................................... 82

4.6 Mode of failure and cracking outline .......................................................... 85

4.6.1 Cracking outline ................................................................................... 86

4.6.2 Mode of failure .................................................................................... 90

4.7 Manufacturing Problems ............................................................................. 94

4.8 Assembly and erection problems ................................................................ 95

5 CONCLUSION AND RECOMMENDATIONS .................................... 97

5.1 Conclusion ................................................................................................... 97

5.2 Recommendations ....................................................................................... 99

REFERENCES ....................................................................................................... 100

APPENDIXS A - D 102 - 111

xiv

LIST OF TABLES

CHAPTER TITLE PAGE

2.1 Pumice aggregate properties ............................................................. 9

2.2 Chemical analysis of pumice aggregates ........................................ 10

‎2.3 Comparisons between the three types of lightweight aggregate ..... 13

2.4 Advantages and disadvantages of lightweight Concrete ................ 15

‎4.1 Load verse deflection at point load 1 .............................................. 81

4.2 Load verse deflection at point load 2 .............................................. 82

4.3 Frame Load verse deflection measure at point load 1 .................... 83

4.4 Frame Load verse deflection measure at point load2 ..................... 84

‎4.5 Frame Load verse deflection measure at point load 3 .................... 84

xv

LIST OF FIGURES

CHAPTER TITLE PAGE

1.1 IBS lightweight concrete block .................................................... 6

2.1 Aerated aggregate ....................................................................... 12

2.2 Connection of beam and block-work .......................................... 12

2.3 Compressive Strength ................................................................ 15

‎2.4 IBS block production methods ................................................... 17

2.5 Fully prefabricated construction method ................................... 18

‎2.6 General beam action behavior.................................................... 21

‎2.7 Beam tension behavior ............................................................... 22

‎2.8 Beam compression behavior ...................................................... 22

2.9 The forces behavior on beam ..................................................... 23

2.10 Beam shear force and bending moment ..................................... 24

2.11 Splitting tensile strength vs tested compressive strength ........... 26

2.12 Deflection graph for frame load ................................................. 28

‎2.13 Lightweight concrete infill wall ................................................. 35

2.14 Schematic representation of carbonation process ...................... 39

3.1 Laboratory work flow ................................................................ 42

3.2 OPC cement ................................................................................ 44

‎3.3 Sand ............................................................................................. 45

3.4 Aerated aggregates ...................................................................... 46

3.5 Water ........................................................................................... 48

3.6 Plasticizers .................................................................................. 48

xvi

3.7 Cylinder cube mould ..................................................................... 50

3.8 Beam ready formwork .................................................................. 50

3.9 Electric motor powered reverse concrete mixer ........................... 51

3.10 concrete transportation and placing process ................................. 52

3.11 concrete vibration process ............................................................. 53

3.12 Fresh Concrete after Casting ......................................................... 54

3.13 fresh cylinder cube samples .......................................................... 54

‎3.14 curing process of IBS blocks & beam ........................................... 55

‎3.15 curing process of cylinder cubes ................................................... 56

3.16 The compression test machine ...................................................... 57

‎3.17 splitting test ................................................................................... 58

3.18 E-value test .................................................................................... 59

3.19 The flexural test (push-off test) setup ........................................... 60

3.20 The test specified point loads ........................................................ 61

‎3.21 Test hydraulic jack and portable data logger ................................ 62

3.22 The deflection gauges ................................................................... 63

3.23 Frame failure and deflection base ................................................. 63

3.24 5-Gauges of Deflection reading .................................................... 64

3.25 Crack marking, reading and recording .......................................... 64

‎4.1 Cylinder cube extension fracture in the loaded diametral plane ... 68

4.2 30% of expected load ..................................................................... 69

4.3 100% of expected load (Failure mode) .......................................... 70

‎4.4 100% Load verse time (failure) .................................................... 72

4.5 load verse deflection with 5-gauges at cycle 1 ............................. 74

4.6 Maximum deflection at Cycle 1 .................................................... 75

4.7 Load verse deflection with 5-gauges at cycle 2 ............................ 75

‎4.8 Maximum deflection at Cycle 2 .................................................... 76

4.9 Load verse deflection with 5-gauges at cycle 3 ............................ 77

4.10 Maximum deflection at the three cycles ....................................... 78

4.11 Maximum deflection at cycle 3 ..................................................... 79

4.12 Load verse deflection at point load 1 ............................................ 80

4.13 Load verse deflection at point load 2 ............................................ 81

‎4.14 Frame Load verse deflection measure at point load 1 .................. 82

‎4.15 Frame Load verse deflection measure at point load2 ................... 83

xvii

‎4.16 Frame Load verse deflection measure at point load 3 .................. 84

4.17 First crack pattern appearance....................................................... 86

4.18 The cracks pattern appearance on connection B ........................... 87

4.19 The cracks pattern appearance on connection A ........................... 87

4.20 The cracks pattern appearance mid-span ...................................... 88

‎4.21 Crack reading and marking ........................................................... 88

‎4.22 Frame after mode of failure from other side ................................. 89

4.23 Crushing mode .............................................................................. 89

‎4.24 Spalling mode ............................................................................... 90

‎4.25 Mode of the beam failure .............................................................. 91

‎4.26 Failure of a right-side the beam anchorage connection ................ 92

‎4.27 Overall failure of the system ......................................................... 92

4.28 View of point failure ..................................................................... 93

‎4.29 Cut-off links and resist of anchorage re-bars ................................ 93

4.30 Aerated lightweight concrete blocks production defect ................ 94

4.31 compaction difficulties and errors ................................................ 95

‎4.32 Erected testing frame .................................................................... 96

xviii

LIST OF ABBREVIATIONS

IBS - Industrial Building System

AAC - Autoclaved Aerated Concrete

OPC - Ordinary Portland Cement

ALC - Autoclaved Lightweight Concrete

MOR - Modulus Of Rupture

PA - Pumice Aggregate

CA - Crush Aggregate

SCC - Self-Consolidating Concrete

LWRC - Lightweight Reinforced Concrete

RC - Reinforced Concrete

L.W.C - Lightweight Concrete

RTD - Regional Transportation District

xix

APPENDIX

CHAPTER TITLE PAGE

A British mix design form calculation 102

B Experimental test procedures captured photos 107

C Experimental results of the three cycles 109

D Experimental results of point 1 and point 2 111

1

CHAPTER 1

INTRODUCTION

1.1 Background

Lightweight concrete (LWC) has been successfully used since the ancient

Roman times and it has gained its popularity due to its lower density and superior

thermal insulation properties [1]

. Compared with normal weight concrete (NWC),

LWC can significantly reduce the dead load of structural elements, which makes it

especially attractive in multi-storey buildings. Yet, most studies on LWC concern

“semi-lightweight” concretes, i.e. concrete made with lightweight coarse aggregate

and natural sand. Although commercially available lightweight fine aggregate has

been used in investigations in place of natural sand to manufacture the “total-

lightweight” concrete (Chandra, S. and Berntsson L. 2002, Berra, M. And Ferrara, G

1990), more environmental and economic benefits can be achieved if waste materials

can be used to replace the fine lightweight aggregate.

2

The use of lightweight concrete in reinforced concrete structures has several

advantages when compared with ordinary concrete or normal concrete such as

crossing of larger spans, high earthquake resistance, , heat conductivity property,

and fire strength etc. (Hüsem, 1995; Neville, 1975; Durmuş, 1988; Karaca, 1996)

[6,7]. Because of the advantages cited above lightweight concrete is being used in

many industrial countries. Although lightweight concrete has so many advantages

and superiorities over ordinary concrete, thus, the usage of this type of concrete is

not as common as ordinary concrete. The reasons for low usage of lightweight

concrete are the high prices of aggregates in countries whose lightweight aggregate

resources are poor, lack of experience, and knowledge of workers about lightweight

concrete (Karaca, 1996).

Lightweight concrete may also contain normal or lightweight, fine and/or

coarse aggregates. The rigid foam air cell system differs from conventional aggregate

concrete in the methods of production and in the more extensive range of end uses.

Lightweight concrete may be either cast-in-place or pre-cast. Lightweight concrete

mix designs in general are designed to create a product with a low density and

resultant relatively lower compressive strength (when compared to plain concrete)

(J.L.Clarke, 1993). When higher compressive strengths are required, the addition of

fine and/or course aggregate will result in a stronger lightweight concrete with

resultant higher densities. We should note that most lightweight concrete applications

call for a lightweight material. When considering the addition of course aggregate,

one must consider how appropriate this heavy aggregate will be to a project, which

typically calls for lightweight material. The inclusion of aerated aggregate,

particularly course aggregate may be counter-productive to the materials intended

performance (J.L.Clarke, 1993).

3

Structural lightweight concrete has an in-place density (unit weight) on the

order of 90 to 115 lb/ ft3

(1440 to 1840 kg/m3) compared to normal-weight concrete

with a density in the range of 140 to 150 lb/ ft (2240 to 2400 kg/m3). For structural

applications the concrete strength should be greater than 2500 psi (17.0 MPa). The

concrete mixture is made with a lightweight coarse aggregate or in some cases the

engineers can use a portion or the entire may be a lightweight product. Lightweight

aggregates used in structural lightweight concrete are naturally expanded shale, clay

or slate materials that have been fired in a rotary kiln to develop a porous structure.

Other products such as air-cooled blast furnace slag are also used. There are other

classes of non-structural lightweight concretes with lower density made with other

aggregate materials and higher air voids in the cement paste matrix, such as in

cellular concrete (AC1213R).

In this study, the aerated rock (Pumice) is the type of aggregate used, in order

to produce industrial building block with structural lightweight concrete forms.

Pumice (aerated aggregate) aggregate is a low density highly vesicular, volcanic

glass consisting mainly of silica SiO2. The high silica content (70% per g/100g)

positively affects the quality of pumice increasing the hardness of the material and its

resistance to chemical attack. Pumice Aggregate (aerated aggregate) is highly

recommended in lightweight concrete blocks either blended or as an all in pumice

mix. In cast stone as a lightweight backing mix and chimney flue liners. Lightweight

precast structures including IBS concrete block. In continuation, this project presents

the performance of aerated concrete aggregate which is used to produce structural

lightweight concrete block, in function to inspire the construction industries to use it

and design such structural IBS elements, for instance, the industry building system

(IBS) platform can use this type of light aggregate to make the IBS system with

satisfy and high structural compressive strength and low density which is less 20%-

25% than the use of conventional crashed aggregate.

4

1.2 Problem statements

There are many beneficial use of a structural lightweight concrete such as to

reduce the dead load of a concrete block, which then allows the structural designer to

produce a such size of IBS concrete block (with high strength and low density), to

reduce the size of block and other load bearing elements in case to let them to stand

up to carry the structure loads imposed upon them from various partitions of

structural load. However, structural lightweight concrete provides a more efficient

strength-to-weight ratio in structural elements. In most cases, the marginally higher

cost of the lightweight concrete is offset by size reduction of structural elements, less

reinforcing steel and reduced volume of concrete, resulting in lower overall cost, For

instance, in this study it has been planning to produce such samples of IBS block

with structural lightweight concrete mix design with Ordinary Portland cement

(OPC), a full replacement of conventional crashed aggregate by lightweight

aggregate (aerated aggregate) and to check the failure of the samples under flexural.

In continuation, some of the reasons of using aerated aggregate are to produce

lightweight concrete IBS interlocking wall block of size of 900mm in length, 700mm

in height and 200mm in width and wall rectangular beam with size is 2100mm in

length, 500mm in height and 200mm in width. These sizes are considered too

suitable to comply with RTD rule and placement on transport cargo. Due to this

successful function, it will lead to customer convincing attitude as they need to

provide not more transportation for assembly of the components due to the reduction

in weight is followed by savings in transport and greater ease of operation on the site;

there is less human fatigue and lead to faster speed of erection and hence to a

reduction of funding costs, also a powerful way to put new buildings to useful and

profitable employment as early as possible. In this study, the component is

divided into smaller transportable ‘lego’ sizes shaped block. The component

will be made into two or four cuts of component and analysis for best design

for assembly and disassembly with similar predecessor.

5

1.3 Objectives of research

The objectives of this research are:

1- To study the properties and behavior of aerated aggregate and use it as

structural lightweight concrete block-works aggregate on accordance to

BS1881: part 125-102 and BS 5328.

2- To investigate the flexural capacity of structural lightweight concrete of IBS

block-works and beam with a full replacement of conventional crashed

aggregate by aerated aggregate with Ordinary Portland cement (OPC).

3- To check the deflection, cracks, splitting strength, tensile strength and

ultimate compressive strengths of the IBS blocks and beam samples under

ultimate loads @ 28 days on accordance to BS1881: part 120 and compare

the results with a normal concrete in-fill.

1.4 Significance of study

The significance of this research and its findings will inspire the develop a

suitable mix design of lightweight concrete with aerated aggregate, in order to

produce a new approach of structural lightweight concrete block.

1- To develop a new potential technique to produce structural lightweight

concrete block, with an above average of structural compressive strength and

a lower density.

2- To produce a sample of structural lightweight concrete block with different

shape of IBS, in function to encourage the construction industry to made it as

a new approach for future use in IBS building and construction sectors.

3- To encourage of solving the problem of low and middle income earners to

purchase it.

6

1.5 Scope of study

The study was almost experimental in natural and it consists of three-phase

study scheme. First phase was focusing on the research of development based on the

existed studies and preparing the calculation of the structural lightweight mix design.

The second phase is preparing the reinforcements, the casting moulds and testing the

casted blocks @ 28days for the IBS blocks which are showing below in figure 1.1.

The third phase was concerning about the analysis and discussion of the results of

the IBS blocks samples.

The attempt of this study is to check the ultimate strength behavior of

IBS interlocking block system. The performance of this specimen will be estimated

through the capacity test. The crack at frame faces and its deflection will be

monitored during the test in order to get the expected results and fulfill the aims,

significant, objectives and scope of this study. The component consists of lightweight

infill’s that have been use for wall, and a frame which including beams and blocks.

The size of the IBS block is 800 mm × 700mm × 200mm and the size of the

IBS rectangular beam is 2100mm × 450mm × 200mm with length, height and width

respectively.

Figure 1.1: IBS lightweight concrete block

100

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