Effective Concrete Failure Area for SC Structures Using Stud and Tie Bar Under Performance Tests


1. Introduction

Steel-plate concrete (SC) structures are currently constructed using steel plates, stud anchors (headed stud anchors), and filled concrete. This construction method is commonly applied to composite bridges that combine both steel and concrete elements as an economical option. To achieve the expected performance of a composite structure, it is necessary to confirm the bonding capability between the concrete and stud materials, which have heterogeneous properties. In SC structures, studs (also known as shear connectors, stud connectors, or headed stud connectors) are welded to steel plates to combine the concrete and surface steel plates [1].

SC structures are formed as sandwich panels that are subjected to bending stresses in many cases. If the bonding strength of each panel is insufficient, separation between the concrete and surface steel plates can easily occur under large shear, tension, moment, or a combination of these forces. Therefore, the concrete breakout strength, shear failure strength of stud connectors, and the maximum strength at the interface between the concrete and surface steel plates are the major forces leading to failure in SC structures. The concrete breakout strength of a single anchor is a failure mode governed by tension, and this strength is also affected by group interference effects in anchors placed close together.

El-Lobody et al. [2] investigated composite girders using a finite element model with 8-node three-dimensional solid elements. Their models predicted deflection behavior and stress distribution along the length of the beam for both solid slabs and precast hollow core elements. Lam et al. [3] examined the shear and load-slip behavior of shear connectors under shear forces. Lin et al. [4] studied the effects of transverse bending moments on stud connections in steel-concrete composite beams, identifying both concrete cone pull-out failure and stud fractures. These failure modes were influenced by stud length under transverse bending moments. Xiang et al. [5] investigated the spacing of studs between concrete slabs and steel girders under transverse bending moments. This study is only tangentially related to the present research, as it focuses on wide shape beams rather than surface steel plates, but it provides insights into the behavior of stud connections under transverse loads.
Badie et al. [6] studied the limits of stud spacing for clusters of studs used in precast concrete panels with wide-shape beams. They performed push-off tests using full-scale composite beams and found that doubling the number of studs per cluster did not significantly affect fatigue. They concluded that full composite action occurred when the spacing between stud clusters was extended to 1220 mm.
J. Qureshi et al. [7] investigated the effects of sheeting thickness and shear connector position on the strength and ductility of shear connectors in long-span composite bridge girders. The authors studied the influence of sheeting thickness and shear stud position on the strength, ductility, and failure modes of the headed shear connector in steel-concrete composite beams. One of the interested variables was the transverse spacing of the shear connectors. Xu et al. [8] also studied the influence of sheeting thickness and shear connector position in composite bridges. Their research focused on the behavior of group studs under biaxial loading in compression. The authors found group studs may lead to comparatively more severe concrete damage at the ultimate stage.
Wang et al. examined the push-out behavior of large stud connectors in steel composite beams. In their study, an empirical shear load-slip equation was proposed, incorporating the maximum stud diameter (25 mm) [9]. Delhomme et al. [10] conducted pullout tests on long anchor bolts, identifying major failure modes such as rod fracture, rod sliding, and cone-shaped concrete breakout. Ballarini et al. [11] studied tension failure mechanisms in rods, including fracture, sliding, and breakout strengths, using 28 specimens to investigate ultimate loads and the relationship between tensile capacity and compressive strength. The variables of the tests were the embedment depth h, the support reaction distance d, and the age of specimens.
Chen et al. [12] examined anchor bolt failure due to the combined effects of tension and shear. DeVries et al. [13] investigated the anchorage capacity of shallow embedment in concrete. Sartipi et al. [14] studied the tensile response of post-installed anchor connections in both reinforced and plain concrete beams, focusing on key parameters such as embedment depth, section width, and reinforcement effects in post-installed chemical anchors.
Eligehausen et al. [15] researched the behavior and design of adhesive-bonded anchors, identifying potential failure modes such as concrete breakout, mortar-concrete interface failure, and steel-mortar interface failure. Fuchs et al. [16] proposed a behavioral model for concrete breakout failure, which is now incorporated into ACI 318-19 [17]. While concrete breakout failure has been extensively studied, no equations were available to predict the ultimate tensile strength of torque-controlled expansion anchors until Chen et al. [18] proposed a design strength for these anchors.
An experimental investigation on normal concrete to examine the pullout capacity of cast-in-place anchors with embedded circular surrounding studs around rebar under monotonic loading conducted by Turker et al. [19] conducted an experimental investigation into the pullout capacity of cast-in-place anchors with embedded circular studs around rebar under monotonic loading. They carefully studied rebar geometry, steel type, bar spacing, concrete cover, concrete strength, and confinement. Mahrenholtz et al. [20] examined the design standards of post-installed and cast-in-place anchors using both EN 1992-4 and ACI 318. The authors discussed the basic anchor design and underlying production qualification.
Delhomme et al. [21] presented results from pullout tests on large-embedment anchors cast in reinforcement blocks. They studied edge effects and identified failure modes, including concrete cone failure, pullout failure, and combined pullout and concrete cone failure, in both cracked and uncracked sections using headed anchors and ribbed bars.

As described above, most experiments in the literature focus on investigating shear failure of anchors in wide shape beams in bridges. Key factors affecting anchor capacity include anchor length, stud spacing limits in clusters, load application methods, top flange thickness, and group stud effects in wide-shape composite beams. When the large depth in steel plate-concrete structures is needed in critical facilities such as nuclear power plants tie bars that connect top and bottom surface plates are always necessary under the bending, compression, and combination loads. However, few studies have explored the combination of surface steel plates, studs, tie bars, and their combinations.

The paper adopts the concrete cone method in accordance with KCI [22], KDS [23], and ACI 349 [24]. The strength and stress behaviors of adhesive-bonded anchors are discussed, focusing on group and edge effects when studs and tie bars are combined.

The goal of this paper is to identify the maximum tensile loads and group interference effects, with modification factors for steel plate-concrete structures that use both studs and tie bars. As a first step, we focus on the tensile capacity of single and group tie bars in steel plate-concrete structures. We then conduct experiments to evaluate the maximum strength of models using single and group tie bars, simulating the real lateral tensile performance of SC structures using full-scale specimens. This paper primarily focuses on the maximum tensile strength of anchors with the effect of anchor spacing and the combination use of both anchor and tie bars in SC structures. Notably, the maximum tensile strength of the group stud and the combination specimens are experimentally investigated to study the non-overlapped spacing and overlapped spacing effects.

4. Suggestion for Estimating the Tensile Ability of SC Structures Having Studs and Tie Bars

Based on the performance tests of the GTST specimens, the tensile failure of SC structures with studs and tie bars can be divided into two stages. The first stage involves concrete cone failure around the studs due to the loss of concrete friction, while the second stage involves the yielding of the tie bars welded to the cover steel plates. The first stage occurs when the concrete around the studs deforms beyond its elastic limit due to the elongation of the studs, leading to cracking. However, in specimens with closely spaced studs, such as GST-2, concrete cone failure was observed earlier, likely influenced by adjacent studs, before the studs themselves lost elasticity. Similar phenomena were observed in SC specimens where the studs were spaced sufficiently apart, but the tie bars were positioned within the concrete failure zone of the studs. Therefore, it can be assumed that the tensile strength of SC structures is influenced by both the tie bars and the studs.

According to Table 9 and Table 12, it is observed that only the edges of the tie bar yield from top view, while the elasticity at the middle of the tie bar remains under tension. From these results, this paper presents the failure mechanism as shown in Figure 14.
Figure 14 illustrates that the elastic behavior of the concrete around the studs is lost under maximum tensile loads, leading to the formation of shear lines [16]. Simultaneously, the tie bars placed between the studs elongate beyond their yield limit, causing concrete cone failure within the interference area of the tie bars—similar to what occurs around the studs. Considering this, the concrete failure area of SC structures with studs and tie bars can be calculated using the same method as SC structures with only studs. It is thus assumed that the maximum tensile load is lower than the expected load if the concrete around the tie bars retains its elasticity. The proposed method for estimating the tensile capacity of SC structures with both studs and tie bars is based on the ACI 318 [17] and KEA [25] guidelines for determining anchorage concrete breakout strength under tension. This report defines the effective plastic length of tie bars under tension as the length of the tie bar in a plastic state. In previous research on anchors in general structures, shallow embedment is typically defined as 3–5 times the bar diameter. The main categories of this model are concrete cone failure and the concrete capacity model. The embedment length (effective plastic length) is directly related to anchor failure. In this paper, the effective plastic length of tie bars is calculated by applying the following assumptions:
(a)

The elastic strain ratio of each tie bar is equal to the strain ratio in the middle of the tie bar.

(b)

The second stiffness (plastic stiffness) of the tie bars at the edges is equal.

The mechanism and method for calculating the effective plastic length, δ i , are presented in Figure 15 and Equation (6).

δ i = ε e , i × l i + ∫ 0 l 1 ε x , 1 − ε m i d d x + ∫ 0 l 2 ε x , 2 − ε m i d d x = ε e , i × l i + ∫ 0 l 1 + l 2 ε x , 1 + ε x , 2 − 2 ε m i d d x = ε e , i × l i + 1 2 ε 1 , i + ε 2 , i − 2 ε m i d , i l 1 + l 2

The effective plastic length, δ i , over the variable length x x, can be summarized through algebraic integration by hand. In Equation (6), it is assumed that the ratio of length is proportional to the ratio of strain, which leads to Equation (7). The strain ratios used in Equation (6) are derived from experimental results. The theoretical lengths, l 1 l 1 and l 2 l 2, vary and change based on the different strain values observed in the tests.

l 1 : l 2 = ε 1 : ε 2 , l 1 l 2 = ε 1 ε 2

The effective plastic lengths of the tie bars, calculated using Equations (6) and (7), are presented in Table 13 and Table 14. Table 14 provides the effective plastic lengths based on the diameter of the tie bar. In these cases, it is assumed that the tension applied to the tie bar is proportional to the strain ratio of each tie bar. Additionally, the average displacement of the tie bars is considered equal to the displacement of the specimen in which the tie bars are embedded.
From Table 14, the effective plastic lengths of the tie bars in GTST-1s, in which the studs are placed so that the concrete failure areas between the studs do not overlap, are 4.56 times the diameter of the tie bars on average. In GTST-2s, in which the studs are placed so that the concrete failure area overlaps that of other studs, the effective plastic lengths are about 1.94 times the diameter of the tie bars on average. Therefore, it is necessary to think of the ranges between 2D through 5D (conservatively) for practical design purposes.
Figure 16 presents the suggested effective concrete failure areas, indicated with hatching, for the GTST-1 and GTST-2 specimens, accounting for the influence of tie bars. These effective areas exclude the regions affected by the tie bars’ interference. The proposed concrete failure areas for the stud group, along with the effective number of studs based on the effective plastic length of tie bars at 2D, 3D, and 5D, are outlined in Table 15. For calculating the tensile strength of the anchors while considering the effect of tie bars, the projected concrete failure area is denoted as A N c . t as shown in Equation (8), where the 9( l 1 o r 2 2 ) was used instead of 9 h e f 2 , and the number of effective studs considering the tie bars’ effect is defined as n e f f , s as shown in Equation (9).

A N c . t = A N c − n t i e × 9 l 1 o r 2 2

n e f f , s = A N c , t n s × A N c 0

Equation (10) presents the suggested method for calculating the tensile load of SC structures with studs and tie bars, while Equation (11) compares this method to the results from performance tests. The performance tests revealed that numerous tie bars were in a plastic state at the maximum tensile load. However, for safety in design, Equations (10) and (11) conservatively apply the average yield load of UTIs (240 kN). The maximum tensile load of a single stud in SC structures N b , t e s t , used in Equation (10), corresponds to the average yield load of USTs (161 kN). The area N b , t e s t , in Equation (11) is the area calculated by accounting for the influence of tie bars, as shown in Table 16.

N b = N b , t e s t × n e f f , s + N y , t i e × n t i e

N b = maximum   tensile   load   of   GSTs × A N c , t A N c + average   of   yield   load   of   UTIs

Table 16 provides a comparison between the suggested method and the test results by dividing the test values by those derived from the assumptions, similar to Table 10. In Table 15, if one can get modified N b using Equations (10) and (11), the one can evaluate various failure cases once more by the normalization using 1.0. From the comparison, the case using an effective plastic length of 2D for the tie bars most closely aligns with the performance test results. Meanwhile, using a plastic length of 3D proves to be the most effective for safety considerations in design. The three calculations (2D, 3D, and 5D) based on test data simplify the maximum load-bearing strength for the GTST specimens, allowing for comparison under assumptions such as (a) tensile load of studs and tie bars using nominal tensile stress, (b) average maximum tensile load of UST and yield load of UTI, and (c) maximum tensile load of GST-2 and yield load of UTI, as seen in Table 10, where effective length is represented by diameter instead of h e f .

The results indicate that both Equations (10) and (11), along with the assumptions, are reasonable. The comparison ratios for the 2D effective length show a range from 0.99 to 1.17, making it a good estimate for practical application. Based on the comparison of the ratio between test results and Equations (10) and (11), the suggested method using effective plastic length can cautiously be applied to non-overlapping anchors, with ratios ranging from 1.01 to 1.03. For overlapping anchors, however, the ratio is higher, between 1.29 and 1.46, indicating that the test values are too high to adopt the maximum strength ratio using 2D and 3D effective lengths.

From these findings, this paper suggests that if the tensile capacity of a stud in SC structures is assured, it is possible to estimate the tensile load of SC structures accurately using the proposed method in Equation (10).



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