Structural Response and In-Service Deflection of Hollow Beams Constructed with Recycled TetraPak (Thermo-Stiffened Polymeric Aluminum Composite)

This study evaluates the use of recycled materials in producing hollow section structural beams (HSSBs) from agglomerated sheets of thermo-stiffened polymeric aluminum (TSPA) derived from post-consumer Tetra Pak® containers. A novel geometric configuration for the TSPA beam assembly is proposed to reduce the deflections observed in the original Casa Eco Sísmica (CES) project. A combined numerical and statistical approach, incorporating Monte Carlo simulations and finite element method (FEM) models, was employed to assess different assembly alternatives and identify the configuration with the lowest deflection, while maintaining values below the L/78 limit. Experimental tests, were performed to compare the proposed configuration with the existing CES beams. Results show that the
new configuration reduces deflections by 61% and increases vertical load capacity by 287% compared to the original beams. These findings highlight the critical influence of assembly methods on the structural performance of TSPA beams. The original configuration exhibited deficiencies in deflection and load-bearing capacity due to its construction method, whereas the new assembly efficiently exploits the mechanical properties of the TSPA material.