Thermal and mechanical modeling of thermal breaks in structural steel point transmittances

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1 Thermal and mechanical modeling of thermal breaks in structural steel point transmittances Presented to the American Society of Mechanical Engineers Presented by: Scott Hamel P.E., Ph.D. Co-Author: Sava White, M.S. 11/08/2016

2 Presentation outline Introduction to Thermal bridges and breaks Industry Survey Calibrated hot box Thermal FEA Structural Testing Structural FEA Conclusions Project Goal: Experimentally and computationally evaluate the thermal and mechanical characteristics of a set of common structural steel thermal break details a2

3 Thermal bridging Excessive heat flow through the building envelope by a highly conductive element Linear Btu Units of: hr ft Point Units of: Btu hr Radiation Convection Conduction Convection Radiation a3

4 Linear thermal bridge a4

5 Point thermal bridge a5

6 Point thermal bridge a6

7 Thermal bridging in structural k steel = 347 k XPS insul. = 0.2 Btu in hr ft 2 F Btu in hr ft 2 F steel a7

8 Issues with thermal bridges Heat loss Cooling loss Condensation Corrosion Façade and interior coverings damage Mold growth Occupancy comfort Indoor humidity problems a8

9 Thermal breaks Bearing pads Neoprene Wood FRP a9

10 Thermal breaks Bearing pads Neoprene Wood FRP a10

11 Proprietary thermal breaks Manufactured thermal break assemblies (MSTBAs) a11

12 AISC/ RCSC Code provisions AISC / RCSC 2014 Section 3.1, p Compressible materials shall not be placed within the grip of the bolt. Commentary Compressible materials preclude the development and/or retention of the installed pretensions in the bolts, when required..greater slopes [than 1:20, of connected elements] are undesirable because the resultant localized bending decreases both the strength and the ductility of the bolt. a12

13 Kemper arena roof collapse June 4, 1979 a13

14 Kemper arena roof collapse June 4, 1979 a14

15 Industry survey & results

16 Local interviews Industry survey AISC members May responses Map of survey respondents a16

17 Survey results Which thermal bridging detailing situations do you find to be more common? Check all that apply. # Answer Response % 1 Cantilever levels/ beams % 2 Facade elements % 3 Roof protrusions 96 63% 4 Foundation penetrations 30 20% 5 External braces 22 14% 6 Other 10 7% a17

18 Survey results How does your company currently address thermal bridging of steel members that protrude through a building s thermal envelope? Check all that apply. # Answer Response % 1 Avoid entirely (e.g., double columns, etc.) 39 27% 2 Use gasket material (e.g., plywood, neoprene, fiberglass, etc.) 67 46% 3 Use a Manufactured Structural Thermal Break Assembly (MSTBA) 34 23% 4 Replace member with less conductive material (such as stainless steel, timber, etc.) 35 24% 5 Surround protruding steel member with insulating material % 6 Do nothing 63 43% 7 Other 17 12% a18

19 Survey results Which of the following materials does your company employ to mitigate thermal bridging effects? Check all that apply. # Answer Response % 1 Neoprene 43 56% 2 Nitrile 1 1% 3 High Density Polyethylene (HDPE) 31 40% 4 Wood/ engineered wood 35 45% 5 Fibre-reinforced polymer (FRP) 26 34% 6 Fibre-reinforced polymer bolts 5 6% 7 Stainless steel 31 40% 8 Stainless steel bolts 29 38% 9 Other (list as many as apply) 9 12% a19

20 Calculating heat loss in a thermal bridge Calculating thermal bridge heat flow: Linear thermal bridge: Ψ = Q Q 0 L = U U 0 A total L Point thermal bridge: χ = Q Q 0 = U U 0 A total Total: Q = T U 0 A total + Ψ i L i + χ i n i a20

21 Condensation Calculating condensation potential: Dew point, indoor temp Temperature index: TI = T s T o T i T o = = 0.58 < 0.7, not good T s = 40.8ºF T o = 0ºF T i = 70ºF a21

22 Calibrated Hot-Box Testing Experimental Thermal Performance

23 Experimentally measuring heat flow Modified ASTM C : Standard Test Method for Thermal Performance of Building Materials and Envelope Assemblies by Means of a Hot Box Apparatus Calibrated hot box: a23

24 Calibrated hot box a24

25 Calibrated hot box 25

26 PID control 1.5in. FRP break, steel bolts a26

27 Temperature a27

28 Calibrated hot box specimens 2in. XPS insulation Thermal bridge Thermal break a28

29 Calibrated hot box specimens Thermal bridge W10x19 beam through 2-in. XPS Thermal break Beam to beam end-plate connection Neoprene pad (0.5, 1.0, & 1.5in. thick) Fabreeka pad (0.5, & 1.0in. thick) Steel & stainless-steel bolts a29

30 Heat flow rate (Btu/hr F) Experimental results Neoprene pad, steel bolts Neoprene, stainless bolts FRP pad, steel bolts FRP, stainless bolts in. thick 1 in. thick 1.6 Continuous beam No pad Neoprene steel Neoprene stainless FRP steel bolts FRP stainless Neoprene steel Neoprene stainless FRP steel FRP stainless

31 Thermal Finite-Element Modeling

32 FEA heat transfer model Idealized beam and break scenario Thermal bridge Parameters: Beam size Thermal break Parameters: Pad material Pad thickness Bolt material a32

33 FEA heat transfer model Idealized beam and break scenario Thermal bridge Parameters: Beam size Thermal break Parameters: Pad material Pad thickness Bolt material a33

34 Heat transfer FEA Abaqus 6.14/ Standard (& Solidworks) Steady-state ASHRAE values for: Material thermal conductivity Steel, k = 347 Btu in/ft 2 hr ºF Stainless steel, k = 118 FRP, k = 2.0 Neoprene, k = 1.32 XPS insulation, k = 0.2 Surface heat transfer coefficient 1.5 Btu/ (hr ft 2 ºF), both sides Sink temperature: Inside: 1ºF Outside: 0ºF No gap resistance a34

35 Continuous beam a35

36 Thermal break results a36

37 Temperature (ºF) Continuous beam thermal bridge acts as a cooling fin Q h k P A c T i T o 2 O Inside air temperature 0.5 T b Outside air temperature Parametric distance (in)

38 Heat flow rate (Btu/hr ºF) Continuous beam heat flow for all W-shapes (P A) Finite element analysis Eq. 3-8 Q h k P A c T i T o 2

39 Thermal break pad thickness (k in units of Btu in/ft 2 hr ºF) a39

40 Heat flow rate (Btu/hr F) Temperature index Bolt material Heat flow rate Steel bolts Better heat flow rate Better temperature index Stainless-steel bolts FRP bolts Temperature index Steel Bolts Stainless-steel bolts FRP bolts Neoprene pad thickness (in.) a40

41 Heat flow rate (Btu/hr F) Heat flow - pad vs. bolts Heat flow through neoprene pad Heat flow through steel bolts Neoprene pad thickness (in.) a41

42 Covering insulation a42

43 Covering insulation results TI = 0.57 Heat flow = 0.98 TI = 0.85 Heat flow = 0.71 a43

44 Structural Testing

45 End-plate thermal break End-plate moment connection W10x19 A992 steel beam A572 Gr. 50 end-plate A325 bolts Neoprene pad, 0.5, 1, 1.5 a45

46 Bending tests a46

47 Bending tests a47

48 Bending tests a48

49 Bending test results 0.5 in. neoprene pad test at failure a49

50 Bending test results 1.5 in. neoprene pad test at failure a50

51 Moment-rotation a51

52 Shear tests a52

53 Shear tests a53

54 Shear test results a54

55 Shear test results a55

56 Structural Finite-element Modeling

57 Finite element model Abaqus 6.14/ Standard 3D deformable elements Mesh C3D8RH elements (8-node, linear, hybrid formulation) Mesh density 5 elements across any thickness in bending Maintain ~ 1:1 aspect ratio a57

58 Steps Study properties Step 1: tighten bolts to 2000lb Step 2: apply deflection at 45.9in Automatic Incrementation Direct solution method Full-Newton solution technique a58

59 Stress (psi) Stress (psi) Steel material definition 160,000 Non-linear elastic Plate and beam 160,000 A325 bolts 120,000 Nominal stress True stress 120,000 80,000 80,000 40,000 40,000 Nominal stress True stress Strain (in/in) Strain (in/in)

60 Neoprene material Ogden 2 nd order model Function that fits complex incompressible material behaviors Expressed in terms of principal stretches W N p 1, 2, p 1 p p p p N=2 1 2 µ i α i D 0 0

61 Nominal stress (psi) Neoprene material Uniaxial stress-strain curve Nominal strain

62 Boundary conditions/ interactions Boundary conditions Rigid plate fixed for all DOF Constraints Nuts tied to bolts Bolt heads tied to -plate Interactions Bolts & neoprene (fric = 0.4) Neoprene and end-plate (fric = 0.4) Neoprene and rigid plate (fric = 0.4) Nuts to rigid plate (fric = 0.2) a62

63 Finite element modeling No neoprene 0.5 neoprene 1.0 neoprene 1.5 neoprene a63

64 Plate No neoprene 0.5 neoprene 1.0 neoprene 1.5 neoprene a64

65 FEA vs. experimental no neoprene

66 FEA vs. experimental FEA limit of convergence

67 FEA vs. experimental

68 Research Conclusions Thermal Thin thermal break pads (<0.5in for neoprene, <1.0in for FRP) increases heat flow greater than continuous beam case Thicker thermal break pads provide reduced heat flow Stainless-steel and FRP bolts reduce heat flow for a 0.5in neoprene pad by 19.4% and 66.3%, respectively, compared to steel bolts Structural Rotational stiffness is reduced approximately linearly for increasing neoprene pad thickness Bolt rupture occurred at a lower applied moment for neoprene pad connections Shear stiffness is reduced exponentially with increased pad stiffness Prying action occurs on bolts in connections with a neoprene pad a68

69 Practical Conclusions Thin neoprene pads Bad for heat flow Good for temperature index Good structural behavior Thick neoprene pads Good for heat flow Good for temperature index Bad for stiffness in bending Thick FRP pads (Northeastern University) Good for heat flow Good for temperature index Good for stiffness in bending? a69

70 Acknowledgements American Institute of Steel Construction Structural Engineers Association of Alaska University of Alaska Anchorage, CoEng Sava White Corbin Rowe Nathaniel Cox Matheus Bastos Silva a70

71 Questions? a71

72 Contact information Scott Hamel, P.E., Ph.D. p: (907) e: a72

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