Senior Design 2003- -2004 2004 Senior Design 2003 Project # 04024 - - PowerPoint PPT Presentation

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Senior Design 2003- -2004 2004 Senior Design 2003 Project # 04024 - - PowerPoint PPT Presentation

Dec 28, 2023 239 likes •395 views

www.ozsaferooms.com Senior Design 2003- -2004 2004 Senior Design 2003 Project # 04024 Project # 04024 Team: Team: Chris Moore (ME) Chris Moore (ME) Brett Kimball (ME) Brett Kimball (ME) Matt Barton (ME) Matt Barton (ME) Matt Weaver

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SLIDE 1

Senior Design 2003 Senior Design 2003-

  • 2004

2004

Project # 04024 Project # 04024 Team: Team:

Chris Moore (ME) Chris Moore (ME) Brett Kimball (ME) Brett Kimball (ME) Matt Barton (ME) Matt Barton (ME) Matt Weaver (ME) Matt Weaver (ME) Brian Conway (ISE) Brian Conway (ISE) Rugwed Phatak (EE) Rugwed Phatak (EE) Faculty Mentor: Benjamin Varela (ME) Faculty Mentor: Benjamin Varela (ME)

www.ozsaferooms.com

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SLIDE 2

Zagorski Zagorski Forms Specialists, Inc Forms Specialists, Inc

  • Drew

Drew Zagorski Zagorski, Sr. is the , Sr. is the inventor of OZ inventor of OZ Saferooms Saferooms

  • Continuously Poured, Steel

Continuously Poured, Steel-

  • Reinforced, Concrete

Reinforced, Concrete Structures Structures

  • Tornado safe room

Tornado safe room

  • Fabricated on

Fabricated on-

  • site

site

  • Headquartered in Rochester,

Headquartered in Rochester, NY NY

  • Installed 53 safe rooms since

Installed 53 safe rooms since 2000 (New York, Texas, 2000 (New York, Texas, Oklahoma) Oklahoma)

R-I -T OZ Saferooms Project # 04024

Survived the passage of an F5 tornado on May 8, 2003 Moore, Oklahoma

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SLIDE 3

Project Description Project Description

  • Project Objective: Analyze the structure to determine its survi

Project Objective: Analyze the structure to determine its survivability vability

  • Finite Element Analysis (FEA)

Finite Element Analysis (FEA)

  • Experimental impact testing

Experimental impact testing

  • Sensor package design

Sensor package design

  • Scope Limitations

Scope Limitations

  • Budget = $2000

Budget = $2000

  • Time period = 20 weeks

Time period = 20 weeks

  • Did not analyze the structure

Did not analyze the structure’ ’s door s door

  • Stakeholders

Stakeholders

  • Zagorski

Zagorski Forms, Families, Federal Emergency Management Agency (FEMA), Forms, Families, Federal Emergency Management Agency (FEMA), RIT, local authorities and rescue workers RIT, local authorities and rescue workers

  • Key Business Goals of

Key Business Goals of Zagorski Zagorski Forms Forms

  • Testing will quantify stresses on structure

Testing will quantify stresses on structure

  • FEMA support

FEMA support

  • Consumers to buy product

Consumers to buy product

R-I -T OZ Saferooms Project # 04024

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SLIDE 4

Deliverables Deliverables

  • Mechanical Properties

Mechanical Properties

  • Determine mechanical properties of concrete by 3

Determine mechanical properties of concrete by 3-

  • point bending and

point bending and compression testing compression testing

  • Impact Test

Impact Test

  • Impact test on existing OZ

Impact test on existing OZ Saferoom Saferoom

  • Provide data and calculations from impact test

Provide data and calculations from impact test

  • Finite Element Analysis (FEA)

Finite Element Analysis (FEA)

  • FEA on three structures

FEA on three structures

  • FEA on

FEA on Zagorski Zagorski Forms Forms’ ’ preliminary design of a 20 ft. x 30 ft. structure preliminary design of a 20 ft. x 30 ft. structure

  • Compare FEA and impact test results

Compare FEA and impact test results

  • Determine the conditions under which the structure will fail

Determine the conditions under which the structure will fail

R-I -T OZ Saferooms Project # 04024

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SLIDE 5

Mechanical Testing of Concrete Samples Mechanical Testing of Concrete Samples

Experimental Procedure and Data Analysis Experimental Procedure and Data Analysis

  • ASTM C 78

ASTM C 78-

  • 02 three

02 three-

  • point bending

point bending test test

  • Determine flexural strength or

Determine flexural strength or modulus of rupture modulus of rupture

  • 9 samples (14 in. x 4 in. x 4 in.)

9 samples (14 in. x 4 in. x 4 in.)

R-I -T OZ Saferooms Project # 04024

  • ASTM C 39 compression test

ASTM C 39 compression test

  • Determine compression strength of

Determine compression strength of cylindrical concrete specimens cylindrical concrete specimens

  • 9 samples (6 in

9 samples (6 in diam diam., 12 in. length) ., 12 in. length)

141 501 0.121 STDDEV 711 2528 19.075 AVG σbend (psi) Loadmax (lb) W (lb)

σ bend = 3 2

2

FL wh

f F d

c

' = 4

2

π

314 8868 0.137 STDDEV 8034 227157 27.65 AVG f’c (psi) Loadmax (lb) W (lb)

  • Conclusion

Conclusion

  • E = 5.11 x 10

E = 5.11 x 106

6 psi

psi

  • ρ

ρ = 141 lb/ft = 141 lb/ft3

3

E f

c c

= 57 000

, '

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SLIDE 6

Finite Element Analysis Finite Element Analysis

  • I

I-

  • DEAS

DEAS

  • The software assists in calculating

The software assists in calculating stress, shear force, loads, stress, shear force, loads, deflections, frequency response deflections, frequency response and other parameters and other parameters

  • Four different structures (outside

Four different structures (outside dimensions) dimensions)

  • Existing 78 in. x 78 in. x 92 in. safe

Existing 78 in. x 78 in. x 92 in. safe room room

  • 102 in. x 102 in. x 92 in. safe room

102 in. x 102 in. x 92 in. safe room

  • 126 in. x 126 in. x 92 in. safe room

126 in. x 126 in. x 92 in. safe room

  • Preliminary design of 20 ft. x 30 ft.

Preliminary design of 20 ft. x 30 ft. x 92 in. safe room x 92 in. safe room

  • Assumptions

Assumptions

  • Properties of Concrete determined

Properties of Concrete determined from experimental testing from experimental testing

  • Monolithic Pour

Monolithic Pour

  • Rebar not analyzed

Rebar not analyzed

R-I -T OZ Saferooms Project # 04024

f f

r c

= 6

'

Preliminary analysis on four structures 2500 lb. distributed load

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SLIDE 7

Finite Element Analysis Finite Element Analysis

Verify Mesh: H Verify Mesh: H-

  • Convergence

Convergence

R-I -T OZ Saferooms Project # 04024

25.74 5.45 6.26 1.91E-04 10 24.44 3.47 6.37 1.95E-04 7 0.95 1.49 8.35 1.99E-04 5

  • 8.43

2.02E-04 4 % Difference Stress % Difference displacement Stress (psi) Displacement (in) Mesh size (in^2)

Note: 78 in. x 78 in. x 92 in. Structure Mesh Values 2500 lb Distributed Load

Mesh = 4 Mesh = 10 Mesh = 7

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SLIDE 8

Finite Element Analysis Finite Element Analysis

f f psi

r c

= =

6 538 '

  • Failure Analysis

Failure Analysis

  • Concrete is strong in

Concrete is strong in compression and weak in tension compression and weak in tension

  • Cracks develop whenever loads

Cracks develop whenever loads induce tensile stresses in excess induce tensile stresses in excess

  • f the tensile strength
  • f the tensile strength
  • Failure if Max Stress >

Failure if Max Stress > f fr

r

629280 81144 56304 39468 Applied Pressure - Wall (lbs.) 241920 246078 223686 231192 Applied Pressure - Roof (lbs.) 538 19 540 2.8 240 in. x 360

  • in. x 92 in.

542 7 544 15.5 126 in. x 126

  • in. x 92 in.

610 6 545 21.5 102 in. x 102

  • in. x 92 in.

574 5.5 539 38 78 in. x 78 in. x 92 in. Von Mises Stress (psi) Applied Pressure - Wall (psi) Von Mises Stress (psi) Applied Pressure - Roof (psi) Structure

R-I -T OZ Saferooms Project # 04024

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SLIDE 9

Impact Test Impact Test

  • Impact Testing (April 16, 2004)

Impact Testing (April 16, 2004)

  • Existing safe room in Macedon, NY

Existing safe room in Macedon, NY

  • 485 lb. pallet full of sand bags dropped

485 lb. pallet full of sand bags dropped from 20 ft. from 20 ft.

  • Acquire structure

Acquire structure’ ’s deflection and s deflection and frequency response data frequency response data

  • This data was then compared with

This data was then compared with finite element analysis to verify the finite element analysis to verify the models and results were correct models and results were correct

R-I -T OZ Saferooms Project # 04024

Acceleration vs. Time

  • 30
  • 20
  • 10

10 20 30 3.98 4 4.02 4.04 4.06 4.08 4.1 4.12 4.14 4.16 t (sec) acceleration (ft/s^2)

Deflection vs. Time

0.0005 0.001 0.0015 0.002 0.0025 4 4.1 4.2 4.3 4.4 4.5 4.6 t (sec) deflection (in)

Frequency Response

  • 200

200 400 600 200 400 600 freq (Hz) |H(f)|

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SLIDE 10

FEA and Impact Test Comparison FEA and Impact Test Comparison

  • Failure Analysis of roof slab

Failure Analysis of roof slab

  • Johanson

Johanson’ ’s s Yield Line Analysis Yield Line Analysis

  • Theory addresses the Yield Line

Theory addresses the Yield Line Criterion used for the Criterion used for the elasto elasto-

  • plastic

plastic behavior of a reinforced concrete slab behavior of a reinforced concrete slab

  • Max theoretical distributed load = 14.5

Max theoretical distributed load = 14.5 (88,218 lbs.) (88,218 lbs.)

  • FEA of roof slab

FEA of roof slab

  • 88,218 lb. distributed load applied

88,218 lb. distributed load applied

  • Resulting stress = 615

Resulting stress = 615 psi psi

  • 15% higher than theoretical tensile

15% higher than theoretical tensile strength (538 strength (538 psi psi) )

  • Frequency Response

Frequency Response

  • Impact Test

Impact Test

  • 1

1st

st resonant frequency = 15 Hz

resonant frequency = 15 Hz

  • 2

2nd

nd resonant frequency = 260 Hz

resonant frequency = 260 Hz

  • Modal Analysis of structure

Modal Analysis of structure’ ’s roof s roof

  • 1

1st

st natural frequency = 315 Hz

natural frequency = 315 Hz

  • No rebar applied

No rebar applied

R-I -T OZ Saferooms Project # 04024

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SLIDE 11

Structural Integrity Structural Integrity

  • Determine the conditions in which the structure will

Determine the conditions in which the structure will fail fail

  • 485 lb. pallet (3 ft. x 3 ft.) falling from 20 ft.

485 lb. pallet (3 ft. x 3 ft.) falling from 20 ft.

  • Potential energy = 70 KJ

Potential energy = 70 KJ

  • Impact duration = 0.1 seconds

Impact duration = 0.1 seconds

  • 5,600 lb. distributed over 9 ft

5,600 lb. distributed over 9 ft2

2 = 4

= 4 psi psi

  • 1/10 pressure from FEA failure analysis

1/10 pressure from FEA failure analysis

  • Comparison to falling vehicle

Comparison to falling vehicle

  • Mass ten times as great, distributed over area twice as large,

Mass ten times as great, distributed over area twice as large, same impact duration for worst case scenario same impact duration for worst case scenario

  • Energy of 4 cars (4000 KJ) falling at the same time for failure

Energy of 4 cars (4000 KJ) falling at the same time for failure

  • Such debris is not common in most severe tornados

Such debris is not common in most severe tornados

R-I -T OZ Saferooms Project # 04024

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SLIDE 12

Sensor Package Design Sensor Package Design

  • Purpose

Purpose

  • Analyze future OZ

Analyze future OZ Saferooms Saferooms subjected to impact tests subjected to impact tests

  • Useful in measuring actual tornado

Useful in measuring actual tornado impacts impacts

  • Yield Line analysis for sensor

Yield Line analysis for sensor locations locations R-I -T OZ Saferooms Project # 04024

Accelerometer locations - roof Accelerometer locations - wall Mounted Accelerometer

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SLIDE 13

Sensor Package Design Sensor Package Design

  • Items Needed

Items Needed

R-I -T OZ Saferooms Project # 04024

Actual DAQ used for impact test Cross-section of roof, rebar, and anchor bolt

$7,646.30 Total Cost:

  • Wire Tie
  • McMaster
  • Carr

$14.30 $2.86 5 Anchor Bolt 91592A205

  • 1

Computer

  • National

Instrument s $995.00 $995.00 1 Labview Software

  • National

Instrument s $695.00 $695.00 1 SCXI Chassis

  • National

Instrument s $2,295.00 $2,295.00 1 Signal Conditioner SCXI 1531 National Instrument s $1,595.00 $1,595.00 1 PC Interface Card 6052E PCB $769.50 $153.90 5 Cable (100ft) 003EB100AC PCB $1,282.50 $256.50 5 Accelerometer 353B03 Supplier Cost $/per QTY Description P/N

  • Cost

Cost

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SLIDE 14

Budget Budget

$981.70 Total Cost: RIT Machine Shop

  • 1
  • Base Plate for three-point bending fixture
  • RIT Machine Shop
  • 1
  • 3 steel rods for three-point bending fixture
  • Sponsor
  • 9
  • 14"x4"x4" concrete beam samples
  • Sponsor
  • 9
  • 6" diameter x 12" height cylindrical concrete samples
  • RIT Mechanics Lab
  • 1
  • Computer
  • RIT Mechanics Lab
  • 1
  • Tinius Olsen machine
  • Sample Testing

Keystone Builders $19.85 1

  • Misc. Supplies
  • Home Depot

$13.45 1

  • Misc. Supplies

Sponsor

  • 1
  • Impact Load
  • Sponsor
  • 1
  • Crane
  • RIT Machine Shop
  • 1
  • Accelerometer Fixture
  • PCB
  • 1
  • 10-32 Mounting Stud

081B05 National Instruments

  • 1
  • Labview Software
  • National Instruments
  • 1
  • SCXI Chassis
  • National Instruments
  • 1
  • Signal Conditioner

SCXI 1531 National Instruments

  • 1
  • PC Interface Card

6052E PCB $25.00 1 $25.00 Freight Charge

  • PCB

$153.90 1 $153.90 Cable (100ft) 003EB100AC PCB $769.50 3 $256.50 Accelerometer 353B03 Impact Testing Supplier Total Qty $/per Description P/N

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SLIDE 15

Conclusion Conclusion

  • Project objectives completed successfully

Project objectives completed successfully

  • Opportunity for further projects with OZ

Opportunity for further projects with OZ Saferooms Saferooms

  • Testing of wall, door

Testing of wall, door

  • Destructive test

Destructive test

  • Dynamic loading in FEA

Dynamic loading in FEA

  • Complete FE model of reinforced structure

Complete FE model of reinforced structure

R-I -T OZ Saferooms Project # 04024