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1ProjectEngineer,ThorntonTomasetti,51MadisonAve.,Floor17,NewYork,NY10010.
2Professor,Dept.ofArchitecturalEngineering,PennsylvaniaStateUniv.,104EngineeringUnitA,UniversityPark,PA16802.
(Accepted17June2010;
publishedonline15February2011)
Introductiontop
Theuseofsteelstudbackupwallforbrickveneersystemshasbeenontheriseduringthepreviousthreedecades.Thereasonsfortheincreasedpopularityofsteelstudbackupwallsystemsincludereducedweight,costsavings,andshorterconstructiontime.However,therearesomeproblemswiththebrickveneeroversteelstud(BV/SS)backupwallsystem.Unlikeconcretemasonryunit(CMU)backupwalls,light-gaugesteelstudsusedinbackupsystemsareveryflexible.Therefore,theycanhavealargedeflectionunderastrongwindloadleadingtothecrackingofthebrickveneer(BV).Wind-drivenraincanpotentiallypenetratethecrackedBVandcorrodethemetaltiesandsteelstuds(SS).Because,inmostsystems,tiesaretheonlyconnectionsbetweentheBVandthesteelstudbackup(SSB),corrodedtiescanleadtoahazardousfailureoftheBVunderhighwindloadorotherout-of-planeloadingsituations.
ConventionalBVoverbothCMUbackupwallsandSSBsystemsmayalsohavepotentialproblemsduringearthquakes.Inbothsystems,gapsundertheshelfanglesserveashorizontalmovementjointsandaresupposedtopreventtheBVfromparticipatinginthein-planeseismicloadresistance.However,duringrecentearthquakes,somewallsfailedorcrackedasaresultofin-planeseismicforces.OnemajorreasonforthispoorperformanceisattributabletotheclosureofthegapsasaresultofthedifferentialmovementoftheBVandthebackup.Thismovementjoint,actingasanisolationmechanism,canmalfunction,andasaresult,BVwallsmaycrackorfailbecauseofthein-planeseismicforces.
Thesefailures,togetherwithaslowrateofconstructioncausedbytheextratimeneededtolaybricksanderectscaffoldingatthejobsite,areconsideredtheshortcomingsofaconventionalBV/SSsystem.Toimprovetheseissues,theconceptofaprefabricatedandpanelizedBVwithasteelframeworkbackupwallsystemwasdevelopedatthePennsylvaniaStateUniversity.Forbrevity,thesystemwillbereferredtoasapanelizedbrickveneeroversteelstud(PBVSS)backupwallsysteminthispaper.Thepilotresearchprogramconsistedofthedesignanddevelopmentofthesystemthatincludedtheconsiderationofthebuildingscience-relatedissues,athree-dimensional(3D)finite-elementmodelingandanalysis,afull-scalesimulatedwind-loadingtest,andafull-scaleseismicrackingtesttoevaluatetheperformanceoftheproposedPBVSSdesign.DetailsoftheentireresearchprogramweredescribedinLiang(200632);
thispaperdiscussesthebuildingscience-relatedresearchresultsafterintroducingthedesignfeaturesoftheproposedPBVSSsystem.
LiteratureReviewofMajorIssueswithConventionalSystemandOverviewofPanelizedSystemstop
AnchoredBVoverbackupwallsystemscanbedesignedmoreefficientlythansingle-wythemasonrybarrierwallstokeepwind-drivenrainwateroutofthebuildingandtoallowtheplacementofinsulationboardsinsidethewallcavity(DrysdaleandSuter199115).TheBVwithbackupwallsystemsmainlyservethreefunctionsinbuildings:
structuralfunctions,screenfunctions,andcomfortfunctions(DrysdaleandSuter199115;
Kroger200529;
StraubeandBurnett200546).Toprovidethesefunctions,thefollowingcomponentsareincludedinmostdesignsofBVwithbackupwallsystems[BrickIndustryAssociation(BIA)19998;
Devalapuraetal.199613;
DrysdaleandHamid200814;
DrysdaleandSutter199115;
Grimm199322;
Hatzinikolasetal.198525;
KPFFConsultingEngineers199828;
TheMasonryStandardsJointCommittee(MSJC)200235]:
veneer,backupwallandframe,sheathing,ties,aircavity,shelfangle,movementjoints,thermalinsulation,vaporretarder,airbarrier,flashing,andweepholes.
Thefailureofunreinforcedmasonry(URM)buildingsandofsomeBVwallsinearthquakesandtornadoswithlife-safetyhazards;
aswellasproblemsrelatedtorainwaterpenetration,corrosionofmasonrytiesandanchorbolts,visiblecrackingofthebrickveneer,andbowingofthewall;
havebeenreported[Brock19969;
Cowie199012;
EarthquakeEngineeringResearchInstitute(EERI)199016,199517,200118;
Hageletal.200723;
Hamidetal.198524;
Jaliletal.199326;
LaBelle200430;
McGinleyandErnest200438;
PetersonandShelton200942;
Schulatzetal.199945].OneoftheprimaryreasonsforthepoorperformanceofBVwallsystemsisthattheyaregenerallyconsideredas“nonstructural”wallsthatarenotdesignedtoparticipateinresistinggravityandlateralloads,whereasinreality,theyparticipatetosomedegreeunlesspropertyisolated.Amisunderstandingofthestructuralfunctionandtheimportanceoftheload-bearingroleofBVwallshasledtothefailureofthesesystems.AccordingtoSchindler(200444),inadequateattentiontothenonstructuralintentoftheconstructiondetailsforisolationpurposeshasbeenacommonsourceofproblems.Moreover,asimpleserviceabilityproblemsuchaswaterleakagethroughaBVwallcanleadtothecorrosionoftiesandanchorboltsandresultinalife-safetyhazardduringhighwindorevenduringamoderateearthquakesituation.
CurrentearthquakedesigndetailsforanchoredBVwallscallforhorizontalmovementjointsundershelfanglestoaccommodateinterstorylateraldrifts.Thesmallgapundertheshelfangleisprovidedtoaccommodatethedifferentialverticaldeformationattributabletotemperature,creep,andmoisturebetweentheclayBVandthestructuralframe.Ifconstructedproperly,thisgapcanalsofunctionasahorizontalisolationjointallowingstorydriftswithoutrestrainingtheBVwalls.However,insomeexistingbuildings,thismovementjointwaspoorlyconstructed,andarecentstudy(Memarietal.2002a39,b40)hasdescribedthepotentialdamageduringearthquakesbecauseoftheabsenceofthegaporbecauseoftheclosureofthegapbymortar.
Adesignassumptionforout-of-planewind-loadingonBV/SSisthattheBVwillcrackbecausetheSSBwallismoreflexiblethantheBV(ChenandTrestain200410).Whentiesarecorroded,theout-of-planeresistanceoftheBVunderhighwindloadsorearthquakeeventswilllikelybejeopardizedwithpotentialfalloutconsequences.OnthebasisofGrimm’sliteraturereview(199221),therecommendationbysomedesignersistouseaheavyconcretemasonrybackupwalltoavoidtheproblemsassociatedwithaconventionalBV/SSsystem.However,suchadesignwilllosetheadvantagesthatlightweightSSBwallscanoffer.Therefore,totakeadvantageoftheweightsavingsofBV/SSwallsystemsinseismicregions,aninnovativedesignofBVwallsystemsshouldaddressthepotentialproblemsunderbothhighwindandseismicloadingconditions.
BVproblemsarenotlimitedtoperformance-relatedissuesunderenvironmentalandotherloadingconditions.Onecanstillseemasonsonscaffoldingseveralstorieshighlayingbricksone-by-one.Reportsofscaffoldingfailuresattributabletovariouscausesincludingexcessivebrickweightandscaffoldingconnectionfailuresthatresultincasualtiesarenotscarce(Gonchar200120).TheconstructionmethodforBValsohasroomforimprovement.
Thebuilt-on-sitecharacterofbrickworkmakesitsconstructionhighlydependentontheweatheranditsqualitycontrolrelativelydifficult.Onesolutiontosuchproblemsistopanelizeandprefabricatethebrickwallconstruction(Tawresey200448).Concretewallpanelswithembeddedthinbricksandprecastconcretecladdingwithafacethatlookslikeabrickwallhavebeencommerciallyprefabricated(Anderson19966).Althoughsomewallmanufacturerscancastconcretepanelswithavarietyoffaceshelltexturesincludingbricklikepatterns,manyownersandarchitectswouldstillliketouserealexteriorclayBVwallsbecauseoftheiraestheticallypleasingappearance.LindowandJasinski(200333)describedapanelizedBVwallsystemforwhichthebackupwall,insulation,andshelfanglewereassembledasapanelatthefactory,andtheBVwythewasconstructedatthejobsite.Moreover,itispossibletodevelopaprefabricatedclayBVwithoutabackupwallsystembyusingverticalsteelreinforcement(Palmer199941)orbyemployingposttensioning(LaursenandIngham200031).Louis(199934)describedmanyoftheissuesthatshouldbeconsideredinthedevelopmentofprefabricatedbrickwallpanelsincludingveneerwallpanels.AlthoughinpanelizedBVwallsthebrickstillhastobelaidone-by-one,theprocesscanalwaysbedoneonthegroundinthecontrolledenvironmentofafabricationplant.Workerswillnothavetolaybricksatahighelevation.Themanufacturingprocessisnotinfluencedbyharshweatherlikerain,snow,orextremelylowtemperature.Continuousproductionisguaranteed,andthetotalerectiontimecanbedecreasedbyupto75%(LindowandJasinski200333).
Thepanelizationofwallsalsomakesitpossibletoadoptbetterseismicisolationconnections.ConventionalBVaresupposedtobeisolatedfromtheseismicmovementsofthemainframethroughhorizontalmovementjointsundertheshelfangles.However,themovementjointsmaybeclosedbydifferentialmovementsorconstructionerrorcausingtheBVtobeinvolvedduringin-planeseismicforceresistance.Toreducethepotentialforsuchproblemsinconventionalsystems,perhapsthedesignprofessionalshouldrequireacloseinspectionofallhorizontalmovementjointsaspartoftheapproval