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Post-tensioned ceramic structures: design, analysis and prototy**

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Abstract

This research reports on numerical and experimental methods for the use of post-tensioning with brittle ceramic extrusions. It proposes a novel construction approach, including new joint typologies, and demonstrates the viability of ceramic as a primary structural material in a bending-active context through two pavilion-scale prototypes. The research proceeded in three distinct phases. First, relevant material properties —compressive strength, bending strength, modulus—were determined experimentally. Next, several post-tensioned beam prototypes were tested to examine the interaction between post-tensioning steel and ceramic, understand failure modes, and refine construction details. Finally, two post-tensioned prototypes were designed based on these findings, the Vierendeel Arch and the Hypar Tower. The design process for each prototype involved a novel digital workflow that utilized multiple parametric models to generate and analyze global design geometry, link to structural analysis software, discretize the forms into components based on available stock sizes, accommodate for assembly tolerances, and generate component cut lists. The prototypes behaved as predicted, demonstrating that post-tensioning can successfully control bending stresses in ceramic extrusions, and introducing entirely new applications for the material.

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Notes

  1. We will use the term post-tensioning for the work presented here, since the forces in the tendon are induced after the assembly of the member, much as in concrete systems with unbonded tendons. Mechanically speaking prestressing and post-tensioning can have very similar effects.

  2. Unpublished data provided by Cerámica Mayor S.A. via email 5/25/2018

  3. Bending stresses were calculated as follows: M = [(w L2) / 8] + [(P L) / 4] with w = 0.832 N/mm; L = 2140 mm for beams A and C, L = 1365 mm for beam B; the largest positive moment in the beams A and C at maximum point load was 0.166 kNm. Maximum tensile bending stresses can be found with: f = [M / S] – [F / A] with M the maximum moment, F the post-tensioning force, S the section modulus, and A the cross-sectional area of the profile. A positive number indicates the amount of residual tensile stresses, a negative number indicates that the tensile zone is subject to compressive stress due to post-tensioning stress overriding the tensile bending stresses.

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Acknowledgements

The authors thank ASCER Tile of Spain for their continuing support. Cevisama 2019 and 2020 provided additional support for the exhibition of the design prototypes. Javier Mira from the Instituto de Tecnología Cerámica as well as Groupo on Market helped realize the design. Windmill Structural Consultants S.L.P. provided the structural peer review. Simpson Gumpertz & Heger assisted with compression testing. TriPyramid Structures Inc. designed and fabricated hardware for the construction-scale prototype beams. We would also like to thank Natalia Bechthold and Olga Mesa for their contributions during the prototype design process.

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  1. Martin Bechthold and Zach Seibold contributed equally to the work presented in this manuscript.

Authors and Affiliations

  1. Material Processes and Systems (MaP+S) Group, Harvard University Graduate School of Design, 48 Quincy Street, Cambridge, MA, 02138, USA

    Martin Bechthold, Zach Seibold & Saurabh Mhatre

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Bechthold, M., Seibold, Z. & Mhatre, S. Post-tensioned ceramic structures: design, analysis and prototy**. Archit. Struct. Constr. 2, 165–182 (2022). https://doi.org/10.1007/s44150-022-00025-0

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