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Flat Plate Voided Slabs: a Lightweight Concrete Floor System Alternative

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Flat Plate Voided Slabs: a Lightweight Concrete Floor System Alternative Flat Plate Voided Slabs: A Lightweight Concrete Floor System Alternative by Hunter Wheeler B.S., Kansas State University, 2018 A REPORT submitted in partial fulfillment of the requirements for the degree MASTER OF SCIENCE Department of Architectural Engineering College of Engineering KANSAS STATE UNIVERSITY Manhattan, Kansas 2018 Approved by: Major Professor Bill Zhang, Ph.D., P.E., S.E., LEED AP Copyright © Hunter Wheeler 2018. Abstract In structural engineering, it can be challenging to incorporate a sustainable design without sacrificing structural integrity. However, flat plate voided slabs are an interesting alternative to standard flat plate concrete slab systems due to the reduction in concrete and the recycled plastic void formers that are located inside the slab. This research is necessary because an increased use of voided slabs in concrete structures would help fight climate change by reducing the CO 2 emissions caused from cement production. This report will discuss the advantages and disadvantages of implementing plastic void formers into solid flat plate slabs and examine a parametric study comparing voided flat plate slabs to solid flat plate slabs. The design of the voided slabs follows the CRSI Design Guide for Voided Concrete Slabs while also referencing the ACI 318-14 Building Code Requirements for Structural Concrete . Three different slabs for typical square bay sizes of 25 feet, 30 feet, and 35 feet are designed to compare the effectiveness of voided slabs to traditional solid slabs. Table of Contents List of Figures ................................................................................................................................ vi List of Tables ................................................................................................................................ vii Acknowledgements ...................................................................................................................... viii Chapter 1 - Introduction .................................................................................................................. 1 Chapter 2 – The History and Evolution of Voided Slabs ............................................................... 3 The Pantheon ...................................................................................................................... 3 Contemporary Voided Slabs ............................................................................................... 3 Modern Voided Slabs ......................................................................................................... 6 Chapter 3 – Advantages and Disadvatages ..................................................................................... 7 Advantages .......................................................................................................................... 7 Disadvantages ................................................................................................................... 10 Chapter 4 – Variations in Flat Plate Voided Slabs ....................................................................... 12 Manufacturers ................................................................................................................... 12 Construction Methods ....................................................................................................... 13 Void Formers .................................................................................................................... 16 Chapter 5 – Past Projects in North America ................................................................................. 17 Perez Art Museum ............................................................................................................ 17 Columbia University Medical Center Graduate Education Building ............................... 18 Labahn Hockey Arena ...................................................................................................... 20 Harvey Mudd College Teaching & Learning Building .................................................... 21 Chapter 6 – Design Process .......................................................................................................... 22 Voided Slabs ..................................................................................................................... 22 Slab Thickness ...................................................................................................... 22 Void Former Selection .......................................................................................... 22 Self-Weight ........................................................................................................... 23 Moments at Critical Sections ................................................................................ 23 Flexural Design ..................................................................................................... 24 Two-Way Shear .................................................................................................... 26 Deflection .............................................................................................................. 28 iv Solid Slabs ........................................................................................................................ 29 Chapter 7 – Parametric Study ....................................................................................................... 30 Chapter 8 – Sustainability ............................................................................................................. 34 Chapter 9 – Conclusion ................................................................................................................. 37 Material and Labor Cost ................................................................................................... 37 Future Research ................................................................................................................ 39 References ..................................................................................................................................... 40 Appendix A – Voided Slab Design Examples .............................................................................. 42 Appendix B – Solid Slab Design Examples ................................................................................. 51 v List of Figures Figure 2-1 Pan-Joist System. .......................................................................................................... 4 Figure 2-2 Waffle Slab in Washington DC Metro Station. ............................................................ 5 Figure 3-1 Floor-to-Floor Height Reduction of Flat Plate Voided Slabs. ...................................... 8 Figure 4-1 Cobiax Semi Pre-Cast Voided Slab Section. .............................................................. 14 Figure 4-2 Cobiax Cast-in-Place Voided Slab Section. ................................................................ 14 Figure 5-1 Perez Art Museum Voided Slab. ................................................................................. 18 Figure 5-2 CUMCGEB Cantilevered Flat Plate Voided Slab ...................................................... 19 Figure 5-3 Bubbledeck Voided Slab at Labahn Hockey Arena. ................................................... 20 Figure 5-4 Semi Pre-Cast Voided Slab Construction at Harvey Mudd College ........................... 21 Figure 7-1 Parametric Study Framing Plan .................................................................................. 30 Figure 8-1 Global CO 2 Emissions from Cement Production Since 1920 ..................................... 35 vi List of Tables Table 6-1 Summary of Distribution Factors at Critical Moment Sections ................................... 24 Table 7-1 Summary of Parametric Study Results ......................................................................... 31 Table 7-2 Concrete Reduction in Slabs from Voids. .................................................................... 32 Table 9-1 Final Cost Analyis. ....................................................................................................... 39 vii Acknowledgements I am very thankful for the encouragement and support I have received throughout my college career from my family, friends, classmates, and professors. I would especially like to thank my major professor, Dr. Bill Zhang, and committee members, Professor Kimberly Kramer and Associate Professor Fred Hasler, for all of the knowledge they have shared with me throughout this process. A lot of the information I found about voided slabs came from Michael Rusillo, President of Cobiax USA, which was very helpful in writing this report. viii Chapter 1 - Introduction Reinforced concrete is the most commonly used building material in the world. Over 2 billion tons of concrete is produced annually and that quantity will continue to increase in years to come. Its use can range from a common sidewalk to the Burj Khalifa, the tallest manmade structure in the world (Crow, 2008). Reinforced concrete has a wide variety of uses and is a common material for structural floor systems. Common reinforced concrete floor systems include post-tensioned slabs, one-way pan-joists, hollow core planks, one-way flat plate slabs, and two-way flat plate slabs. Each of these floor systems have advantages and disadvantages and are efficient systems for certain scenarios. This report will primarily focus on two-way flat
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