2.1 Geometry and materials
The mock-up is composed of 3D printed plastic blocks with dry joints made at 1:5 scale. Figure 2 presents the geometry of the mock-up.
The shape and the geometry were defined by considering standard rules of thumb (Heyman 1995; Cangi 2009; Gaetani et al. 2015; Croci 2000; Huerta 2004) and a generic cross-section of a central bay located in a lateral nave of a three-nave church, derived from the intersection of two semi-circular barrel vaults. This example could be representative of a generic monumental church in Central Italy and other locations, generated by a squared base groin vault with a net span of 3.125 m span and 1.125 m rise at full scale (scaled 1:5).
In historical applications, it is common to find filling material placed above the shell of the vaults, which helps to reduce the thrust forces applied in the lateral piers. In this case, due to the setup, the application of filling material above the corners of the vault was not considered. The reason for this was the small size of the mock-up and, also the fact that, the filling material requires more complex boundary conditions, which could compromise the interpretation of the results.
The mock-up is composed of 1132 blocks (Figure 3), being 232 made fully of plastic and 880 made of plastic with a steel core (Figure 4). They have been 3D printed with the SLS (Selective Laser Sintering) technology, which allows to generate small-scale models by a numerically controlled machine starting from a 3D digital model, with high geometrical accuracy (±0.1 mm) and a reasonably short time of production. Indeed, the time of production was estimated between 4-5 hours for the blocks of the shell, and 2 hours for the supports, counting a total duration of about 6-7 hours.
The adopted plastic material is a composite of zp150 powder and zb61 clear binder, printed with a ZPrinter 650. After production, the blocks have been impregnated with Z-bond 101 for improving the strength and durability. This technique was previously adopted by Rossi et al. (2017a) and ensures good stiffness and friction to take into account rigid block assumption, to allow the repeatability of the tests by minimizing the damage and to inhibit sliding between blocks. Indeed, the choice of adopting this particular material and technology was led by the need of performing several tests with different configurations without causing damage in the units.
The standard blocks (red blocks in Figure 3a) were designed considering the typical dimensions of clay bricks, namely 0.06 × 0.12 × 0.24 m3, in order to keep the classic bond stereotomy of medieval groin vaults. Blocks with different dimensions are placed along the outer edges of the webs to guarantee the offset of the joints. The blocks’ shape is slightly trapezoidal to compensate for the absence of mortar between them. Special care was taken to design the stereotomy of the elements located along the diagonals (Figure 3b) to guarantee the correct interlocking between adjacent webs. Each block was identified by a numeric code, in order to easily rebuild the mock-up after each test.
Due to the accumulation of error in the 3D printing of the blocks, very thin steel plates have been properly designed and placed at the key of the vault to perfectly close its shell (Figure 2b). The selected arrangement of the blocks corresponds to the easiest one to be assembled (Rossi 2015) and it is called “orthogonal weaving”. It allows to directly transfer the thrusts to the supports, being commonly found in medium and large vaults.
This masonry bond needs a temporary structure for the construction of the shells. Therefore, a scaffolding made of plywood has been designed, which is composed of four pieces corresponding to the vault webs. Once the mock-up is built, the scaffolding is removed by letting the pieces slide on proper inclined rails. Care and attention are required to remove the scaffolding, in order not to incur into undesirable configurations and defects. This aspect is important to ensure the repeatability of the tests, since defects in the construction process could compromise the analysis of the results and their comparisons.
The material density (ρ) of the diagonals (Figure 2) was determined to be equal to 0.55±0.02 g/cm3. It corresponds to a low-density value that could compromise the model stability under accidental actions. Therefore, as previously stated, the weight of the standard blocks was increased by inserting a steel core inside each block (Figure 4). In this way, the density of the standard blocks was set at the value of 2.70±0.05 g/cm3. The final weight of the mock-up is about 35.6 kg, while the whole structure is about 43 kg, considering the steel base at the bottom of the mock-up. The friction angle (μ) of the blocks is equal to 29.6°±2.46°, which was determined by testing 12 samples of standard blocks. Table 2 summarises the properties of the materials of the reduced scale mock-up.
Table 2. Material properties of the mock-up.
Parameter
|
Standard blocks
|
Diagonals and abutments
|
Steel plates/corner
|
Young’s modulus [MPa]
|
123.0
|
2.50
|
210000
|
Poisson’s ratio [-]
|
0.2
|
0.2
|
0.3
|
Density [g/cm3]
|
2.7
|
0.55
|
7.8
|
Although the mock-up presents different types of materials and the scale reduction factor equal to 5 is considerable, the mock-up is still able to represent the main features of masonry cross vaults. As stressed by ancient treatises (Heyman 1995), masonry cross vault’s behaviour is mainly linked to the geometry of the system, namely size and shape, less depending on mechanical properties. The scale is less important for static tests (unless of important nonlinear geometric effects, such as in shallow arches or vaults) but it is much relevant for dynamic tests. Nevertheless, it is possible to scale up models numerically after validation in smaller scales.
The choice of using a dry joint mock-up is also an important aspect. In real structures, units are far from being rigid and with infinite strength but, in comparison, joints have rather low tensile strength and cohesion. In literature, several treatises refer that the elastic deformability of the joints does not significantly affect the response at the collapse, which is again correct for static loading. Still, neglecting the strength of the joints may slightly influence the static capacity, providing a conservative response. A dry joint mock-up allows to easily rebuild the mock-up after a test and to perform more tests. Therefore, it is very useful for research purposes and it can also represent ancient constructions that were built with dry joints or during times have experienced a significant loss of mortar due to the environmental conditions, becoming similar to dry joint structure (Lourenço and Ramos 2004; Pulatsu et al. 2019).
2.2 Test setup
The dynamic tests were performed in the National Laboratory of Civil Engineering, Lisbon, Portugal (LNEC), namely in the three axial shake table (Figure 5). The setup was carefully designed, aiming at obtaining the relevant outputs associated to the shear failure of the mock-up, with similar conditions to real prototypes and necessary for the performance assessment (Figure 5b).
In order to simulate the particular boundary conditions that cause an in-plane shear response of the vault, the special testing device adopted by Rossi et al. (2016) was used. It consists of a frame composed of four steel squared plates, linked to each other by the use of aluminium bar couples hinged at both ends with uniball joints. In this way, the distance between the abutments does not vary and their rotation along the vertical axis was prevented. Moreover, the abutments of the vault were rigidly fixed on the top of plates, which could freely move on a flat aluminium surface thanks to four spherical wheels.
As shown in Figure 5c, the abutments p1 and p2 were anchored to the ground with bolts, while p3 and p4 were let free to move on the flat surface. In Rossi, Calderini, and Lagomarsino (2016), the displacements were assigned along the Y (longitudinal) direction (see Figure 5b and c), through an external actuator, for the quasi-static tests.
The instrumentation and boundary conditions used during the shake table tests were similar to those used for the quasi-static tests. At the same time, due to the small geometrical dimensions of the mock-up, specific instrumentation was also implemented. One linear variable displacement transducer (LDVT1) was located at the N-W corner, measuring the relative longitudinal displacement of the movable piers. Six piezoelectric accelerometers (Acc1x, Acc1y, Acc1z, Acc2x, Acc2y, Acc2z in Figure 5b) were placed at the bottom of the vault to measure the response of the fixed plated, while five variable capacitance unidirectional accelerometers (Acc3y, Acc4x, Acc5z, Acc6x, Acc7y) were placed on the vault, since they are compatible with the dimension of the blocks in terms of dimensions and weight. Moreover, two optical cameras were used to record the response of the key of the western arch and the movable piers using automatic tracking, respectively, along the plane xy (OP1xy) and yz (OP2yz).
Two video cameras were used to record the tests: one exactly at the top of the mock-up, using scaffolding, and another located in front of the East façade on a tripod outside of the shake table. From those cameras, the collapse mechanism was evaluated (Section §4).