Development of sustainable, innovative and energy-efficient concrete, based on the integration of all-waste materials: SUS-CON panels for building applications

The building sector requires the worldwide production of 4 billion tonnes of cement annually, consuming more than 40% of global energy and accounting for about 8% of the total CO2 emissions. The SUS-CON project aimed at integrating waste materials in the production cycle of concrete, for both ready-mixed and pre-cast applications, resulting in an innovative light-weight, ecocompatible and cost-effective construction material, made by all-waste materials and characterized by enhanced thermal insulation performance and low embodied energy and CO2. Alkali activated “cementless” binders, which have recently emerged as eco-friendly construction materials, were used in conjunction with lightweight recycled aggregates to produce sustainable concrete for a range of applications. This paper presents some results from the development of a concrete made with a geopolymeric binder (alkali activated fly ash) and aggregate from recycled mixed plastic. Mix optimisation was achieved through an extensive investigation on production parameters for binder and aggregate. The mix recipe was developed for achieving the required fresh and hardened properties. The optimised mix gave compressive strength of about 7 MPa, flexural strength of about 1.3 MPa and a thermal conductivity of 0.34 W/mK. Fresh and hardened properties were deemed suitable for the industrial production of precast products. Precast panels were designed and produced for the construction of demonstration buildings. Mock-ups of about 2.5 x 2.5 x 2.5 m were built at a demo park in Spain both with SUS-CON and Portland cement concrete, monitoring internal and external temperatures. Field results indicate that the SUS-CON mock-ups have better insulation. During the warmest period of the day, the measured temperature in the SUS-CON mock-ups was lower.

Rapid construction of arch bridges using the innovative FlexiArch

Masonry arches are strong, durable, aesthetically pleasing and largely maintenance free, yet since 1900 there has been a dramatic decline in their use. However, designers, contractors and clients now have access to a new method of constructing arches incorporating precast concrete voussoirs interconnected via polymeric reinforcement and a concrete screed. No centring is necessary, as the FlexiArch, when it is lifted, transforms under the forces of gravity into the desired arch shape. After discussing general aspects of innovation, the basic concept of the arch bridge system is presented along with technological advances since it was patented. Experiences gained from building over 40 FlexiArch bridges in the UK and Ireland and from model and full-scale tests carried out to validate the system during installation and in service are described. Thus under load the system behaves like a traditional masonry arch and existing analysis methods can be used for design and assessment.

Investigation of thermal resistance and bridging in examples of contemporary and vernacular solid wall architecture

Contemporary architecture has tended to increase envelope insulation levels in an unceasing effort to reduce U-values. Traditional masonry architecture in contrast was devoid of insulation, except for the inherent insulative nature of vernacular materials. Also the consistency of the outer membrane of the building skin diminished any impact due to bridging. In contemporary highly insulated walls bridges are numerous due to the necessity to bind inner and outer structural skins through insulation layers. This paper examines thermal bridging in an example of contemporary façade design and compares it with an example of traditional vernacular architecture currently being researched which is characterized by a lack of bridging elements. Focus is given to heavy weight materials of high thermal mass, which appropriately for passive architecture help moderate fluctuations in internal temperature. In an extensive experimental study samples of highly insulated precast concrete sandwich panels and lime rendered masonry walls are tested in a guarded hot-box. The building construction methods are compared for static and dynamic thermal transmittance, via heat flux and surface temperature differential measurements. Focus is given to the differential heat loss due to the thermal bridging in the sandwich panels and its associated impact on overall heat loss relative to traditional masonry construction.

Arch bridges – unlocking their potential

Arch bridges are strong, durable, aesthetically pleasing and require little maintenance but very few have been built since the early 1900s. However, this trend has changed as more than 60 FlexiArch bridges have been installed since the system was launched in 2007. The FlexiArch uses precast concrete voussoirs, requires neither corrodible reinforcement, nor centring, can be installed in hours and is contractor friendly. Details of this innovative method of construction and installation of arch bridges are given and the enormous potential of the system for multi-span
viaducts is also highlighted.

Influence of aggregate and curing regime on the mechanical properties of ultra-high performance fibre reinforced concrete (UHPFRC)

A new generation of concrete, Ultra-high performance fibre reinforced concrete (UHPFRC) has been developed for its outstanding mechanical performance and shows a very promising future in construction applications. In this paper, several possibilities are examined for reducing the price of producing UHPFRC and for bringing UHPFRC away from solely precast applications and onto the construction site as an in situ material. Recycled glass cullet and two types of local natural sand were examined as replacement materials for the more expensive silica sand normally used to produce UHPFRC. In addition, curing of UHPFRC cubes and prisms at 20 degrees C and 90 degrees C has been investigated to determine differences in both mechanical and ductility.

Load Testing of Floor Slabs in a Full-Scale Reinforced Concrete Building

A series of short and long term service load tests were undertaken on the sixth floor of the full-scale, seven storey, reinforced concrete building at the Large Building Test Facility of the Building Research Establishment at Cardington. By using internally strain gauged reinforcing bars cast into an internal and external floor bay during the construction process it was possible to gain a detailed record of slab strains resulting from the application of several arrangements of test loads. Short term tests were conducted in December 1998 and long term monitoring then ensued until April 2001. This paper describes the test programmes and presents results to indicate slab behaviour for the various loading regimes.