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Shear Testing of Flange/Web Adhesive Bond Lines in Wood I-Joists

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Shear Testing of Flange/Web Adhesive Bond Lines in Wood I-Joists A method for glue bond quality testing of flange/web adhesive connections of wooden I-beams Nordtest project no. 1583-02 Erik Serrano, Mikael Fonselius, Carl-Johan Johansson and Kjell H. Solli A method for glue bond quality testing of flange/web adhesive connections of wooden I-beams SP Rapport 2004:02 Bygg och Mekanik Borås 2004 2 Abstract A test method for assessing the quality of glue bonds in the web-flange joint of I-beams has been developed. The method is based on a shear test of small pieces cut from the beam. The investigation has included shear tests on different specimen sizes, including the influence of the wood density, the wood moisture content and the influence of different pre-treatments (boiling) in order to detect possible gluing errors. A limited finite element analysis was also performed. The main conclusion is that pre-treatment of the specimen by boiling is necessary in order to detect gluing errors. Another confirmation is that the wood failure percentage can be used as a good indicator of the bond quality. Finally, a draft test method for a possible standard is given. Key words: quality control, test method, I-beam, shear test, engineered wood product SP Sveriges Provnings- och SP Swedish National Testing and Forskningsinstitut Research Institute SP Rapport 2004:02 SP Report 2004:02 ISBN 91-7848- ISSN 0284-5172 Borås 2003 Postal address: Box 857, SE-501 15 BORÅS, Sweden Telephone: +46 33 16 50 00 Telex: 36252 Testing S Telefax: +46 33 13 55 02 E-mail: [email protected] 3 Contents Abstract 2 Contents 3 Summary 5 1 Introduction 7 1.1 Background 7 1.2 Aim 7 1.3 Current method used by a manufacturer 7 1.4 Work content and disposition of the report 8 2 Materials and methods 9 2.1 Beam materials 9 2.2 Test set-ups 9 3 Task 2 – Influence of specimen thickness 11 3.1 General remarks 11 3.2 Test programme 11 3.3 Test results 11 3.4 Finite element study 12 3.4.1 FE-model 12 3.4.2 FE-Results 14 3.5 Conclusions – Task 2 15 4 Task 3 – Influence of moisture content 16 4.1 General remarks 16 4.2 Test programme 16 4.3 Test results 16 5 Task 4 – Influence of pre-treatment 18 5.1 General remarks 18 5.2 Test programme 18 5.3 Test results 19 6 Discussion and conclusions 23 6.1 Gluing errors 23 6.2 Detecting errors 23 6.2.1 General 23 6.2.2 Without pre-treatment 23 6.2.3 With pre-treatment (boiling) 23 6.2.4 Decision based on shear strength or wood failure percentage 24 References 25 Appendix A: Wooden I-beams – Test method for evaluation of flange/web glue bond quality A1 4 Preface This report was prepared as the final project report for the Nordtest project 1583-02 “Träbaserade lättbalkar. Utveckling av metod för bestämning av limfogskvalitet” (Wood I-beams. Development of a method for the determination of adhesive bond line quality”). The project has been performed as a co-operation by SP – Swedish National Testing and Research Institute, VTT –Technical Research Centre of Finland and NTI – Norwegian Institute for Wood Technology. SP has had the responsibility of the final compilation of the results and editing of this report. Borås, October 2003 Erik Serrano 5 Summary An important aspect of the production of wooden I-beams is the control of the quality of the adhesive joint that bonds the web to the flange. A test method needs to be developed, since the existing ones as described, for example in EN 392 (Anon.1995), cannot be used due to the geometry of the joint. The development of such a test method is the aim of the current project. The work reported here has included different investigations in order to establish a reliable test method. The influence of the test piece thickness was studied in order to obtain a test specimen size of appropriate dimensions. The influence of the moisture content and of different pre-conditioning climates was also investigated. Finally, in order to be able to detect less severe gluing errors, the influence of boiling the specimens prior to testing was investigated. In total 800 individual shear tests have been performed, each being evaluated at least in terms of shear strength and wood failure percentage. Based on the findings, it is recommended that a test method based on a compressive shear test of the bond between web and flange (push-through) be used. It is recommended that the test pieces should be 20 mm in thickness, which was found to be a good compromise between the strive for a large enough specimen in order not to cause to much damage when cutting it and the strive for small specimens resulting in lesser load levels and more uniform stress distribution. It is furthermore recommended that the testing be preceded by repeated boiling of the specimens in water. This pre-treatment has shown to be enough to predict the most severe gluing errors. An alternative pre-treatment to use is boiling the specimens only once, but to use a stricter pass/fail criterion. When evaluating the test results, it is recommend that the wood failure percentage be used as a pass/fail criterion in combination with a minimum shear strength criterion. The level for the wood failure percentage is set to 70% for repeated boiling as a pre-treatment. This means that, in order to accept the quality of the bond line, the wood failure percentage should be 70% or more. For the alternative pre-treatment of boiling only once, the level is set to 80% wood failure. The reference shear strength value to be met, should be determined at the products initial type testing. A test method, which can be used as starting point for future standardisation, can be found in Appendix A. 6 7 1 Introduction 1.1 Background Different types of engineered wood products (EWP) have gained importance in recent years. A large part of these EWP are I-beams, where the web is adhesively bonded into grooves machined into the flanges. Other EWP include such products like oriented strand board (OSB) and Laminated Veneer Lumber (LVL). In the US the increased use of I-beams is evident from the increase in number of producers, which is fast growing. During the 1990’s, the number of plants producing I- beams increased in number from 16 to 43 (Zylkowski 2000). The use of I-beams has, to a large extent, replaced the use of solid timber for floor and roof structures. 1.2 Aim A test method for the web/flange connection of I-beams needs to be developed, since the existing test methods for glue bonds, as described for example in EN 392 (Anon.1995), cannot be used due to the geometry of the joint. Typically the web is bonded into a slightly wedge-shaped groove, see Figure 1. The development of such a test method is the aim of the current project. 47 4 47 47 20 8 Figure 1. Example of web-to-flange geometry of a wood I-beam. 1.3 Current method used by a manufacturer At the present, one manufacturer uses an in-house method to determine whether the adhesive bond has an acceptable quality. The method is based on a shear test of a thin slice of the complete I-beam cross-section. A loading device applies a compressive force on the web material, as indicated in Figure 2. This method has served as a starting point for further development within the present project. 8 Figure 2. A steel plate is used to push through the web material in shear. Only part of the cross-section and the loading device is shown. 1.4 Work content and disposition of the report The project has been divided into a number of tasks, of which Tasks 2, 3 and 4 relate to testing and evaluation of tests using a proposed test method. The work contents of these tasks are described below. • Task 2 o The influence of the test piece thickness. Normally, size effects should be investigated for any kind of material or structural test. A finite element study was also conducted in this task. • Task 3 o The influence of the moisture content. Different pre-conditioning climates are used in order to investigate their effect on the glue bond quality. • Task 4 o The influence of pre-treatment (boiling) of the specimens prior to testing in order to detect any problems with glue bond quality. Chapter 2 gives a general description of the materials and methods used for the respective tasks. Chapters 3-5 describe the results from the tests performed in tasks 2-4 and the FE- simulations performed in task 2. Chapter 6 gives a general discussion on the project results and includes some final remarks and recommendations. Appendix A, finally, presents the draft test method as proposed by the project partners. 9 2 Materials and methods 2.1 Beam materials For this project it was decided to use two different beam types, manufactured in Sweden and in Norway. The Swedish beam is manufactured by Masonite Beams AB. The Norwegian beam is manufactured by Forestia AS and is sold under the commercial name “Rantibjelken”. The two beams are based on the same principles of an I-beam, but differing in their material composition and geometrical shape of the web-to-flange joint. In Figure 3 is shown two cross-sectional views of the beam types investigated.
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