Study on the Flexural Performance of Composite Wall Panels with Ceramsite Foam Concrete and Normal Concrete

Traditional exterior walls are heavy, offer insufficient insulation, and have poor durability, making it challenging to meet the combined requirements of energy efficiency and structural enclosure performance. To address the issues of excessive weight and inadequate insulation in conventional concrete exterior wall panels, alternative materials and designs are being adopted. A novel double-layer composite wall panel structure is proposed, arranging normal concrete (NC) on the exterior side to ensure the panel’s durability and ceramsite foam concrete (CFC) on the interior side to enhance thermal insulation and reduce thermal bridging effects. To address the scenario where the wall panel is subjected to out-of-plane loads during service, causing stress in the CFC layer, bending performance tests were conducted on CFC-NC double-layer composite panels under load applied on the CFC side. Research shows that CFC-NC double-layer composite wall panels exhibit bending performance under four-point bending conditions that is basically consistent with that of monolithic wall panels. As the thickness of the CFC layer increases, cracks may appear near the interface in the CFC layer that do not extend from NC cracking, and may even occur earlier than NC cracking. As the density grade of CFC decreases, the compressive deformation of CFC becomes more pronounced; however, no crushing of the CFC occurs at the ultimate bearing capacity stage. Under four-point bending conditions, the strain at the mid-span section of the composite wall panel along the thickness direction is basically linearly distributed. Under the same conditions of wall panel thickness, reinforcement ratio, and shear span ratio, the flexural bearing capacity of CFC-NC double-layer composite wall panels with CFC density grades A8, A6, and A4 is approximately 12.5%, 25.03%, and 18.29% lower, respectively, compared to C30 cast-in-place wall panels. The flexural bearing capacity of the composite panels increases correspondingly with the increase in CFC layer thickness and reinforcement ratio. Specimens with smaller shear span ratios exhibit more pronounced shear effects. Based on the stress–strain relationship of CFC, a modified calculation method for the flexural capacity of ordinary concrete sections is presented. Referring to the ACI 318-14 code, a calculation method for the bending deformation of composite wall panels is provided. The research results can offer a theoretical basis for the design and application of CFC-NC double-layer composite wall panels.