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Fire performance of HPLWC hollow core slabs

Conference Paper · May 2006

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 FIRE PERFORMANCE OF HPLWC HOLLOW CORE SLABS

MARCO BRECCOLOTTI1, ANNIBALE LUIGI MATERAZZI2, ILARIA VENANZI3

ABSTRACT

In this paper are presented experimental and numerical investigation carried out to
evaluate the fire behaviour of high performance lightweight concrete (HPLWC) hollow core
slabs.
In particular, a series of full-scale furnace tests was performed to assess the slabs’ load
bearing capacity under fire conditions along with the characteristics of the thermal field.
Numerical simulations of the heat diffusion process were also carried out using a finite
element model of the panel cross section. The ultimate strength was evaluated according to
the advanced calculation methods suggested by the Eurocodes, using decay laws of the
mechanical properties found in literature.
The comparison between the experimental and numerical investigation gave insight
into the fire performance of HPLWC hollow core slabs and enlightened on the phenomena
governing their fire resistance.

1. INTRODUCTION

Pre-stressed concrete hollow core slabs have been manufactured for several years
using normal weight-normal strength concrete (NSC).
The flexural behaviour of pre-stressed NSC hollow core slabs under fire conditions
has been deeply investigated in the last few years and can be considered satisfactory if the
onset of torsion moments is prevented through suitable design provisions.
Some doubts still stand about the shear strength, as remarked by Van Hacker [1] and
Fellinger [2] who developed extensive surveys on this topic. Both Authors highlighted the
role of the connections details on the full-scale fire behaviour and recommended to pay
1
Research Fellow, University of Perugia, Department of Civil and Environmental Engineering, 06125 Perugia,
Italy, email: breccolotti@strutture.unipg.it
2
Professor, University of Perugia, Department of Civil and Environmental Engineering, 06125 Perugia, Italy,
email: materazzi@unipg.it
3
Research Fellow, University of Perugia, Department of Civil and Environmental Engineering, 06125 Perugia,
Italy, email: ilaria.venanzi@strutture.unipg.it
special attention, during the organization of furnace tests, on the boundary restraints, in order
to simulate accurately the conditions usually met in the real structures.
During the last years the use of high performance lightweight concrete (HPLWC) has
been considered to manufacture these structural components. In fact the characteristics of
lightness, relatively high strength and superior durability make this material suitable for many
structural applications.
The low thermal diffusivity of this material, due to the low density of the aggregates
and to the latent heat of the free water, as highlighted in [3,4], may be considered, in
principle, a favorable property in case of exposure to fire. In the specific case of hollow core
slabs, which have no transverse reinforcement, these characteristics may lead in some cases to
the onset of cover spalling, due to the high thermal gradients and the internal pore pressures.
However the information on the mechanical and thermal properties of the HPLWC
and, in particular, on the fire resistance of HPLWC structural components is still incomplete.
The research mainly dealt with the fire behaviour of light weigh concrete, considering small
size samples, paying special attention to the study and the prevention of the phenomenon of
the spalling through the addition of various types of fibres (Sullivan & Sharshar in 1992 [5],
Hertz in 1984 [6] and 1991 [7], Hammer in 1995 [8], Felicetti et al. in 2002 [3] and Felicetti
and Gambarova in 2003 [4]), even though some interesting studies on beams are available
(Hansen & Jensen in 1995 [9] and Sullivan in 2000 [10]).
The present paper is aimed at giving a contribution to the understanding of the fire
behaviour of HPLWC hollow core slabs, presenting and critically discussing the results of full
scale furnace tests. The experimental results are analysed with the support of a numerical
simulation of the thermal field, carried out applying the finite element method and using data
on the thermal properties of the high performance light weight concrete taken from the
available literature.

2. FURNACE TESTS

Two full-scale furnace tests were carried out on a total of four HPLWC hollow core
slabs.
To highlight the effect of concrete maturity on the possible onset of spalling, the
second test was carried out almost one year after the first one.
During each test, two panels, simply supported on the furnace walls, were
simultaneously heated following the ISO 834 thermal program. One of them was loaded
following a four point bending scheme, while the other one was left unloaded during the
heating and was used to assess the residual strength after cooling.
Fig. 1 shows a picture representing the experimental set up
The slabs were 4.3 m long with a cross section of 1.2 x 0.2 m, made from C48/58
N/mm2 concrete and had a unit weight of 1.9 kN/m3. The pre-stressing reinforcement was
made up of seven 3/8” strands per slab. The mix design of the concrete used for the slabs is
listed in Table 1.
Additional shear reinforcement was placed at both ends of each slab by cutting the
concrete over two cores, setting in place steel stirrups and casting concrete to fill the holes.
The thermal boundary conditions at the slabs ends varied between the two tests. In
fact, while during the first test the holes were left open, during the second test they were
closed, using mineral wool to prevent air circulation. The holes insulations are visible in the
picture of Fig. 1.
The specimens were built on the 29th of June 2002 and were stored in the factory
under the same curing conditions used for the everyday production until September 23rd,
2004, when the first furnace test was carried out. The second furnace test was performed the
12th of October 2005. During the period between the first and the second test the panels were
stored near the furnace, in extremely dry conditions, further contributing to the maturity of
concrete and to the reduction of free water content.

Table 1. Mix design of the HPLWC.

Material Quantity
Cement 380 kg/m3
Water 100 kg/m3
T8 expanded clay 578 kg/m3
Fine sand 526 kg/m3
Sand 279 kg/m3
Slurry 41 kg/m3

Fig. 1. Experimental set up of the 2nd test.

2.1 Experimental set-up

During each furnace test, two slabs were used: one was loaded during the furnace tests
following a four point bending scheme, while the other was only heated and submitted to an
analogous four point bending test after cooling, to estimate the residual strength after
exposure to fire. The value of the vertical load was selected to cause a bending moment at the
mid-span section equal to 60% of the corresponding value in service conditions. In particular,
the total load of 40 kN (20 kN at each point), corresponding to a bending moment of 33.7
kNm, was applied.
 The vertical deflections of the loaded slabs were monitored for the whole duration of
the tests.
Both slabs have been fitted with thermocouples placed at different locations and depth
(Fig. 2).
The thermocouples have been installed inside the hardened concrete by drilling holes
and using insulating material to close them. It was decided to use insulating material instead
of cement mortar to avoid possible measurement inaccuracy due the evaporation of the
residual moisture of the sealing material.

Fig. 2. Temperature sensors location.

2.2 Experimental results

The experimental results are presented in Figures 3 to Fig. 5. In particular, Figures 3

and 4 represent the deflection and the deflection speed of the loaded slabs during the two
furnace tests.
During the 1st test a brittle collapse in shear of the loaded slab occurred after 76
minutes and is clearly visible in Fig. 3. It was anticipated at the 40th minute by the formation
of a pass-through vertical hole, which allowed the hot gases to escape and by several concrete
cover spalling that seriously damaged the loaded slab. The pass-through hole was closed on
the spot with insulating material to continue the test until failure.
During the 2nd test no cover spalling and no brittle failure occurred. The loaded slab
was assumed to collapse, according to the UNI-EN 1363-1 [11], when the deflection speed
reached the limiting value expressed by:

dz L2
v= = (mm / min) (1)
dt 9000×d
 where L is the net length of the test specimen and d is the specimen design height. In our case
the limiting deflection speed was equal to:

40002
v= = 8.89 mm/min (2)
9000 ⋅ 200

As depicted in Fig. 4 the overcoming of this threshold value occurred at 90 min, time
at which the collapse was considered to have occurred.
30 30
Deflection Deflection
Deflection speed Deflection speed
Max deflection speed Max deflection speed
25 25

Deflection speed (m m /m in)

D eflection speed (m m /m in)

Deflection (m m *10 -1 )
D eflection (m m *10 -1 )

20 20

15 15

10 10

5 5

0 0
0

10

20

30

40

50

60

70

80

90

100

110
0

10

20

30

40

50

60

70

80

Time (min) Time (min)

Fig. 3. Deflection D and deflection speed Fig. 4. Deflection D and deflection speed
dD/dt of the loaded slab during the 1st dD/dt of the loaded slab during the 2nd
furnace test. furnace test.

In Fig. 5 are represented the temperature histories in the loaded slabs measured during
the 1st and the 2nd furnace tests. Their values represent the increments with respect to the
ambient temperature. In the 1st picture relating to the thermocouples no. 15 are also shown
the furnace temperature histories, together with the target heating programme ISO 834. In
each case the actual furnace temperature was matched quite precisely by the target furnace
temperature.
A good agreement between data for the 1st and the 2nd tests was generally exhibited.
Some irregularities in the temperature time histories of the 1st test can be seen at the
sensors no. 18, 21, 23 and 26, most likely due to the effect of the spalling, which occurred
during the test. Visual checks during the execution of the test confirmed that the areas where
the thermocouples 18, 21, 23 and 26 had been installed were subjected to explosive spalling.
Almost the totality of the thermocouples installed in the unloaded slabs exhibited a
good agreement between the results of the experimental tests.
The presence of insulating material at the ends of the holes did not affect the
temperature inside the slabs. This behaviour can be ascribed to the low amount of heat that
the slabs exchange with the external atmosphere by convection, as the hole axes are
horizontal.
 1200 1200
Thermocouples 15 ISO 834 temperature Thermocouples 16
ISO 834 temperature
1st test temperature 1st test temperature
2nd test temperature 2nd test temperature
1000 1st test temperature 1000
2ndtest temperature

800

Temperature (°C)
800
Temperature (°C)

600 600

400 400

200 200

0 0
0 15 30 45 60 75 90 105 0 15 30 45 60 75 90 105
Time (min) Time (min)

1200 1200
ISO 834 temperature Thermocouples 17 ISO 834 temperature Thermocouples 18
1st test temperature 1st test temperature
2nd test temperature 2nd test temperature
1000 1000

800 800
Temperature (°C)

Temperature (°C)
600 600

400 400

200 200

0 0
0 15 30 45 60 75 90 105 0 15 30 45 60 75 90 105
Time (min) Time (min)

1200 1200
ISO 834 temperature Thermocouples 19 ISO 834 temperature Thermocouples 21
1st test temperature 1st test temperature
2nd test temperature 2nd test temperature
1000 1000

800 800
Temperature (°C)

Temperature (°C)

600 600

400 400

200 200

0 0
0 15 30 45 60 75 90 105 0 15 30 45 60 75 90 105
Time (min) Time (min)

1200 1200
ISO 834 temperature Thermocouples 23 ISO 834 temperature Thermocouples 25
1st test temperature 1st test temperature
2nd test temperature 2nd test temperature
1000 1000

800
Temperature (°C)

800
Temperature (°C)

600 600

400 400

200 200

0 0
0 15 30 45 60 75 90 105 0 15 30 45 60 75 90 105
Time (min) Time (min)

1200 1200
ISO 834 temperature Thermocouples 26 ISO 834 temperature Thermocouples 27
1st test temperature 1st test temperature
2nd test temperature 2nd test temperature
1000 1000

800 800
Temperature (°C)

Temperature (°C)

600 600

400 400

200 200

0 0
0 15 30 45 60 75 90 105 0 15 30 45 60 75 90 105
Time (min) Time (min)

Fig. 5. Temperatures recorded by the thermocouples during the 1st and the 2nd tests.
2.3 Residual strength

The load bearing capacity after cooling of the slabs that were not loaded during the
furnace tests was evaluated by means of additional 4 points bending tests. In the evaluation of
the results, one must keep in mind that the duration of the second test was longer than that of
the first one: the first fire test lasted 75 minutes, while the second one was interrupted after
105 minutes.
The moments that caused the collapse of the slabs were 51.17 kNm and 54.08 kNm
including a bending moment of 5.75 kNm due to the self-weight, respectively for the slab of
the 1st and the 2nd test.
The small difference (roughly a 5%) between the ultimate moments measured during
the tests is evidently due to experimental fluctuations.
Two aspects of these results can be highlighted.
First of all the residual strength of the heated slabs is quite small in comparison with
the ultimate bending moment of the undamaged slabs, which is equal to 101.5 kNm. The
reduction of the load bearing capacity after cooling the slabs due to fire exposure is
approximately equal to 50%, for both 75 and 105 minutes ISO 834 fire exposure.
Furthermore, the data demonstrated that the residual mechanical properties of the slabs
heated during the first and the second test are almost the same, apart from their age and water
content of concrete, and that the different duration of the fire exposures has a negligible
effect.

3. NUMERICAL ANALYSIS OF THE FIRE RESISTANCE

The analytical evaluation of the load bearing capacity under fire of the slabs was
carried out assuming the commonly adopted hypothesis that the thermal and the mechanical
problems can be studied as uncoupled.

3.1 Analysis of the thermal field

The analysis of the time variant temperature field inside the slabs cross sections was
carried out using the finite element code FIRES T3 [12].
As thermal properties of HPLWC, the experimental data provided by Felicetti and
Gambarova [3,4] in 2002 were used in the analysis of the thermal field. Fig. 7 is shown the
thermal diffusivity Dc defined as:

λ
Dc = (3)
ρc

with ρ = density, c = specific heat and λ = thermal conductivity of the material.

Such data regards a concrete almost identical to that used for the production of the
hollow core slabs of the present study. It was assumed a constant density value of 1900
Kg/m3 and a constant specific heat value of 840 J/Kg°K as suggested by the Eurocode 4 [13]
for the lightweight concrete. The thermal conductivity was computed in order to give,
together with the previous properties, the thermal diffusivity taken from the literature.
The lower surface of each slab was considered exposed to the ISO 834 standard fire
and a two dimensional analysis was performed, assuming the temperature field as constant
along the slab’s longitudinal axis. Taking advantage of the slab symmetry with respect to a
vertical plane, only half of the section was modelled.
 In a previous investigation by the Authors [14] it was observed that the temperature of
the air in contact with the upper surface of the cross section only slightly affects the ultimate
strength of the slab, while the actual temperature of the air inside the holes has a great
influence on the fire resistance of the slab and therefore must be accurately modelled. Since
the time histories of the air temperature inside the holes can not be determined, a priori, the
simplified hypothesis of constant temperature inside the holes has been adopted and a
parametric analysis, considering four different constant values of this temperature (100, 200,
300 and 400 °C), was performed.
In Fig. 6 the temperature recorded by particular thermocouples during the two
experimental tests compared with the corresponding temperature foresaw by the numerical
simulation are depicted. The 1st picture relates to thermocouples no. 7, placed close to one of
the strands; the 2nd one is related to the thermocouples no. 9, placed in the lower point of the
inner surface of a hole; the 3rd regards to a point at the extrados of the unloaded slab and the
last one a point placed at mid height of the loaded slab.

3.2 Evaluation of the load bearing capacity under fire

The bending load bearing capacity has been calculated taking into account the pre-
stressing of the hollow core slabs and the degradation of the constitutive materials’ properties
due to exposure to fire.
Knowing the cross-section geometry, the initial pre-stress (74.1 kN per strand), the
area of the 3/8” strands (52 mm2), and the actual stress – strain relationship of the pre-
stressing steel, the initial value of steel’s stress and strain before the cut of the strands has
been evaluated.
600 600
1st test temperature Thermocouples 7 1st test temperature Thermocouples 9
2nd test temperature 2nd test temperature
Hole temp. 100 °C Hole temp. 100 °C
500 500
Hole temp. 200 °C Hole temp. 200 °C
Hole temp. 300 °C Hole temp. 300 °C
Hole temp. 400 °C Hole temp. 400 °C
400 400
Temperature (°C)

Temperature (°C)

300 300

200 200

100 100

0 0
0 15 30 45 60 75 90 105 0 15 30 45 60 75 90 105
Time (min) Time (min)

120 450
1st test temperature Thermocouples 13 1st test temperature Thermocouples 16
2nd test temperature 2nd test temperature
400
Hole temp. 100 °C Hole temp. 100 °C
100
Hole temp. 200 °C Hole temp. 200 °C
Hole temp. 300 °C
350 Hole temp. 300 °C
Hole temp. 400 °C Hole temp. 400 °C
80 300
Temperature (°C)

Temperature (°C)

250
60
200

40 150

100
20
50

0 0
0 15 30 45 60 75 90 105 0 15 30 45 60 75 90 105
Time (min) Time (min)

Fig. 6. Comparison of the experimental and numerical temperatures of the thermocouples

no. 7, 9, 13 and 16.
 2.0 1.0

0.8
1.5
D c (103 mm 2/h)

0.6

σc / fc
1.0

0.4

0.5
0.2

0.0 0.0
0 100 200 300 400 500 600 700 800 900 1000 1100 0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0

Temperature (°C) εc/ε1

Fig. 7. Concrete diffusivity [3,4]. Fig. 8. Concrete stress-strain curve at 20°C

[3,4].
14 1.0

12
0.8
10
0.6
ε c1 (10 -3)

8 20
fc /fc
T

6 0.4
4
0.2
2
0 0.0
0 100 200 300 400 500 600 700 800 900 1000 1100 0 100 200 300 400 500 600 700 800 900 1000 1100

Temperature (°C) Temperature (°C)

Fig. 9. Variation of εc1 for HPLWC with Fig. 10. Variation of fc for HPLWC with
temperature [3,4]. temperature [3,4].
2000 2000
σ (N/mm )

20°C
2

100°C
Ultimate stress and 200°C
strain
1500 1500
Initial stress and 300°C
strain
S tress (M P a)

Infinite time stress

1000 1000
and strain
400°C

500
500 500°C

600°C

0
0 0.00 0.05 0.10 ε 0.15
0 0,005 0,01 0,015 0,02 0,025
Strain

Fig. 11. Effective stress – strain curve for Fig. 12. Stress-strain curves for pre-stressing
pre-stressing steel. steel [2].

Later on, assuming a pre-stress loss at infinite time equal to 24%, the corresponding
values of stress (σop) and strain (εop) have been calculated. Stating that the cross section
remains in a plain, a first tentative strain diagram across the section, defined by the position of
the neutral axis and by the value of the curvature 1/R, was assumed.
The corresponding compressive force C1 acting on the concrete was determined from
the stress-strain law taken from the results of the experimental tests reported in [3,4], using
the proper values of the temperature-dependent parameters εc1 and fc and setting the partial
safety factors to 1. In Fig. 8 the stress-strain law for the HPLWC at the ambient temperature is
depicted. Figs. 9 and 10 show the variation of εc1 and fc with temperature.
For determination of tensile force T1 in pre-stressing strands the value of the total
strain:

εtot =εop +ε1 (4)

was first determined, where εop is strain of the strands for time equal to infinite and ε1 the
increase of the strain corresponding to the application of the external moment (Fig. 11). The
stress corresponding to this strain value has been taken from the Eurocode 2 [15] (Fig. 12).
The condition C1 = T1 indicates that the tentative strain diagram is correct and that the
internal moment can be calculated as

M = C1 × z = T1 × z (5)

with z equal to the lever arm of the internal forces. If C1 ≠ T1 the computation has to be
repeated assuming different values for the position of the neutral axis until the equilibrium is
reached. Repeating this procedure for different values of the curvature 1/R allows the
construction of a Moment – Curvature diagram, whose maximum value can be assumed as the
ultimate bending moment for the corresponding fire exposure duration (Fig. 13). The
procedure was repeated again for different fire exposure durations and for the 4 different
thermal boundary conditions considered in the parametric analysis. The results of such
investigation are summed up in Fig. 14, along with the value of the external applied moment.
The time of collapse for the 1st and the 2nd test are also highlighted.

4. COMMENTS ON THE EXPERIMENTAL AND NUMERICAL RESULTS

Observing the results of the experimental tests, a general good agreement can be found
between the results of the numerical modelling of the thermal field and the values of the
temperature recorded by the thermocouples.
The comparison of the experimental and the numerical results of the temperature
values in the concrete generally shows a better agreement in the cases where the temperature
inside the holes has been assumed equal to 100 and 200 °C (see Fig. 6).
40 120
Inner temp. 100°C
Inner temp. 200°C
Mult Inner temp. 300°C
100 Inner temp. 400°C
Applied moment
30 1st test collapse
2nd test collapse
80
Mult (kNm)
M (kNm)

20 60

40

10
20

0 0
0,00 0,05 0,10 0,15 0,20 0,25 0 30 60 90 120 150

Curvature (rad/m) Time (min)

Fig. 13. Example of the Fig. 14. Ultimate moment for different
Moment – Curvature relationship. boundary condition.
 From this point of view the influence of the water contained in the concrete in
modifying the temperature time histories has to be highlighted. For instance, thermocouples
no.5, 7, 19 and 21 for several minutes during the 1st or the 2nd test recorded a constant
temperature equal to about 100°C, which is the water’s ebullition temperature, event
unpredictable by the model adopted for the numerical analysis of the thermal field. Aside, this
fact testifies the presence of water, which is responsible for the onset of the spalling
phenomena.
The comparison between the experimental and numerical data for the load bearing
capacity presents more difficulties. During the 1st test, the fact that the occurrence of spalling
greatly reduced the load bearing capacity of the slab, aspect this latter that can not be easily
taken into account in the numerical evaluations.
However in the 2nd test, since the collapse of the slab occurred for the overcoming of the
threshold deflection speed value, no clear comparison between numerical and experimental
data can be done, even if it is evident from Fig. 14 that the decay of the load bearing capacity
of the slab for the case of temperature inside the holes equal to 200 °C reaches the external
applied moment at 90 minutes, duration at which the experimental test was considered to be
completed.

5. CONCLUSIONS

In the present study the fire behaviour and residual strength after a fire of pre-cast
hollow core slabs made of high performance light weight concrete have been investigated, by
means of experimental tests and numerical simulations.
The tests were carried out in a furnace on full-scale specimens using the ISO 834
standard fire.
The tests showed that the exposition of the concrete elements to a dry environment,
after a preliminary and adequately long hardening phase, heavily reduces the amount of water
entrapped in the concrete pores, thus decreasing the risk of spalling. In this case a good
structural performance of the elements exposed to fire has been revealed, comparable with
those currently manufactured using normal-weight normal-strength concrete. On the contrary,
when the spalling occurs, the degradation of the load bearing capacity can be so relevant to
cause the collapse for values of the external loads well below the expected theoretical ones.
The tests performed on the slabs left unloaded during the heating showed a
considerable reduction (around 50%) of the load bearing capacity after cooling if compared
with the theoretical values.
The comparison between the numerical and the experimental tests showed that the
numerical model used in the present study can be reliably applied to evaluate the temperature
fields and the load bearing capacity of the hollow core slabs, if realistic mechanical and
thermal materials properties are used in the analysis and if no concrete spalling occurs during
the fire tests.

ACKNOWLEDGEMENTS

The Authors gratefully acknowledge the logistic support of the firm Generale
Prefabbricati S.p.A. of Perugia (Italy) for having kindly manufactured and supplied the test
slabs and the financial support from the Association of the Italian Producers of Concrete,
which was granted through the “Ulisse” Project, Subproject “High-Performance Light-Weight
Concrete”.
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Delft University Press, 2004.
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