Behavior of Composite Beams with Cold Formed Steel Joists and Concrete Slab

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Professor Cheng-Tzu Thomas Hsu, Ph.D., P.E. Pedro R. Muoz, Ph.D., P.E Sun Punurai, Ph.D. Wonsiri Punurai, Ph.D. Yazdan Majdi, Ph.D. Candidate _______________________________
St. Louis, MO - October 24, 2012
___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

Composite Cold Formed Floor System - CCFFS

LIGHTWEIGHT CONCRETE SLAB

STEEL REBAR WIRE MESH SCREWS COLD FORMED JOISTS

___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

CONTINUOUS CFS SHEAR CONNECTOR METAL DECK

Composite Cross Section Components

U.S Patent #: 7,779,590 Granted: August 24, 2010
Composite Floor System Having Shear Force Transfer Member

CONCRETE SLAB

STEEL REBAR CONTINUOUS STEEL SHEAR CONNECTOR METAL DECK COLD FORMED JOISTS
___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

SCREWS

Highlights of CCFFS System and Applications

LIGHTWEIGHT COMPOSITE SYSTEM NO SHORING REQUIRED USES INNOVATIVE AND UNIQUE SHEAR TRANSFER MEMBER COLD FORMED JOISTS WITH HOLES ALLOW FOR DUCTWORK EASY TO INSTALL, ECONOMICAL, DUCTILE, RESILIENT, GREEN SELF-TAPPING SCREWS USED FOR CONNECTORS - NO WELDING

CCFFS LOW-RISE BUILDING APPLICATIONS

HOSPITALITY INDUSTRY HOTELS, TIME-SHARING UNITS, RENTALS SENIOR CARE LIVING FACILITIES HOSPITALS NURSING HOMES CONDOMINIUMS, APARTMENTS, OFFICES, AND STORAGE ROOMS STUDENTS AND MILITARY HOUSING FACILITIES LIGHT INDUSTRIAL STORAGE FACILITIES - MEZZANINES

___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

CCFFS System Components and Experimental Tests

New composite floor system using cold formed steel and concrete to achieve a stronger strength and ductility, consists of three major components: reinforced concrete slab on cold-formed metal deck back to back cold-formed steel joists screwed together cold-formed hat channel shear connector. Six large-scale bending tests conducted to obtain the positive moment capacity, vertical deflection, and end slip of proposed composite beam system. Experimental test results compared with new proposed analysis and design method which is not currently available in either the AISC or AISI specifications.

___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

Four Point Bending Test Setup

Span = 12 feet Concrete Slab = 3 ft.

12 ft.
___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

Experimental Program at NJIT 2003 by S. Punurai and Dr. C.T. Thomas Hsu Materials
Span = 12 feet Simply Supported beam 3 and 3.5 Concrete, total slab depth - 3,000 psi (21 MPa) Cold-formed steel joists (back to back) 600S200-68 (12 ft ), Fy = 45 ksi Cold-formed steel hat channel (shear connector), Fy = 33 ksi Self-Drilling Fastening Hex Screws #10 (0.19) & #12 (0.21) Gage 20 Cold-formed steel deck (0.036 in.- thickness (0.914 mm)). Steel wire mesh concrete slab reinforcement

Specimens
CB1 Non-composite Beam CB2 Composite Beam CB3 Non-composite Beam CB4 Composite Beam CB5 Composite Beam CB6 Built-up CF Steel Beam
___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

Summary of Tested Beam Specimens

CF Joists Size Span Length (ft) (m) 12 3.6 12 3.6 12 3.6 12 3.6 12 3.6 12 3.6 #10/#12 #10/#12 #10 #10/#12 Type of Fastener Concrete Thickness (in x in) (mm x mm) 3 x 36 76 x 915 3 x 36 76 x 915 3.5 x 36 76 x 915 3.5 x 36 76 x 915 3.5 x 36 76 x 915 Concrete Strength fc (psi) (MPa) 2,700 18.62 2,700 18.62 3,200 22.06 3,200 22.06 3,200 22.06 No concrete slab Normal Weight Concrete (145 pcf or 23.87 KN/m3) Specimen Remark

CB1 CB2 CB3 CB4 CB5 CB6

600S200-68 Noncomposite 600S200-68 Composite 600S200-68 Noncomposite 600S200-68 Composite 600S200-68 Composite 600S200-68 Composite

#10

___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

Noncomposite Specimens CB1and CB3

___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

Composite Specimens CB2, CB4, and CB5

___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

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Cold-Formed Steel Specimen CB6

NO CONCRETE SLAB

Selftapping screws
Material: Carbon Steel, Alloy Steel, Stainless steel 304, 316 Grade: 4.8,8.8,10.9 ; Size: various sizes are available Head: flange head, pan head,round head,countersunk head Finish: zinc plated, black, plain, Ni-plated, phosphate, HDP

Double Cold-Formed Joists back to back

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___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

Shear Force Transfer Member Types - Connectors

COLD-FORMED HAT CHANNEL
screws

Simple Continuous shear connector 2 Continuous Shear connector with cutouts at bottom

SHEAR CONNECTOR CROSS SECTION

3 Continuous Shear connector with strip of metal deck

___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

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Flexural Test Results for Specimens CB1 and CB2

Mid-Span Concrete Deflection Maximum strength at Load fc maximum (lbs) (psi) load (kN) (MPa) (in) (mm) 2,300 15.86 CB2 Composite 15.86 50.26 76.73 2,300 9,950 44.26 11,300 1.042 26.47 3.021 Longitudinal shear crack in concrete slab and flexural failure Composite section Flexural and brittle failure Noncomposite section

Remark

Specimen

Mode of Failure

Note

CB1 Noncomposite Point Loads Without transverse bars in concrete slab

___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

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Load-Deflection Curve Specimens CB1 and CB2

- Composite

CB2

Noncomposite

CB1

___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

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Noncomposite Specimens CB1 and CB3

Tilting and shearing of fasteners that connected together the metal deck and the top flanges of coldformed steel joists. The amount of fasteners were not properly designed to carry the flexural loads until flexural failure of these specimens. The neutral axis of the build-up section was moving downwards which was attributed to tilting and failure of the fasteners. The top flanges of the cold-form steel joists had become undergoing compression from under tension stress. The compression buckling on top flanges and local buckling of the web that caused the beams to collapse suddenly.
___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

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Flexural Test Results for Specimens CB3, CB4, & CB5

Concrete strength fc (psi) (MPa) Maximum Load (lbs) (kN) Mid-Span Deflection at Mode of Failure maximum load (in) (mm) 3.05 77.47 4.75 120.65 5.22 132.59 1.48 37.59 Note

Remark

Specimen

CB3 Line loads with transverse bars in concrete slab Noncomposite CB4 Composite CB5 Composite CB6 Steel Only

3,200 22.06 3,200 22.06 3,200 22.06 NA -

14,200 63.16 18,100 80.51 18,348 81.61 5,752 25.58

Flexural failure less Ductile Flexural and Ductile failure Flexural and Ductile failure Lateral and torsional buckling

Noncomposite section Composite section Composite section (bents in rib) No concrete

Point load

___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

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Load-Deflection Curve Specimens CB3 and CB4

Composite

Noncomposite

___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

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Load-Deflection Curve Specimens CB4 and CB5

CB-4 Composite CB-5 Composite with rib bents

___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

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Composite Specimens CB2, CB4

Specimen with hat furring channel shear connector. Shear connector fastened to top flanges of coldformed joists to make a composite section. More fasteners were used in specimen CB2 and CB4 than those of specimen CB1 and CB3. Tilting and shearing of the fasteners The failures were delayed with larger deformations as presented in their load-deflection curves. Eventually, the compression buckling of the top flanges combined with local buckling of the web rendered the beam to fail with some ductile manner. The primary cause of failure is still attributed to shearing failure of the fasteners in theses composite sections.
___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

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Composite Specimen CB5

Shape of continuous shear connector modified to increase bond resisting area by the lips of the shear connector cut and bend up every 2 in. to add the bearing contact area to the concrete. Specimen CB5 failed under flexural loads as soon as concrete crack appeared in the slab, reached the flexural capacity and achieved large ductility.

___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

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Load-Deflection Curve Specimen CB6

CB6 Cold-Formed Steel Only

___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

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Built-up ColdFormed Steel Section CB6

A typical built-up double cold-formed steel joists back to back screwed together. No metal deck and no concrete slab were used for this beam. As expected, the beam failed due to lateral and torsional buckling of the thin-wall cold-formed steel joists.

___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

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Neutral Axis Study of Composite Specimen CB4

Applied loads versus strain distribution at midspan for composite section CB4
___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

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Analysis and Design Methods

AISI has no specific design methodology for Composite floor systems. The shear design strength including tilting and bearing of fasteners can be determined based on Section E4.3 of the AISI Specifications (2002). The tension design strength of the fasteners including pull-out, and pull-over is based on Section E4.4 of the AISI Specifications (2001). The AISI specification requirements can be applied to fasteners with diameter between 0.08 in. (2.03 mm) up to 0.25 in. ( ) (6.35 mm). The flexural design procedures for non-composite section, by AISI Specifications (2001), are composed of two procedures: Procedure I - is named as the elastic state up to initiation of yielding. Procedure II - is named as the inelastic state beyond yielding. New Analysis and Design Method proposed by Hsu et. al (2012)
___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

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Basics of New Analysis and Design Method by Hsu et. al (2012)

Analysis and Design Similar to those for the built-up and composite sections described in the AISC Specifications (2010) with modifications. System bends in a plane parallel to the webs, and twisting effects ignored Procedure I is called as the Elastic Design up to yielding of steel Area of concrete transformed to equivalent area of steel joists. Total force equilibrium used to locate position of NA at steel yielding The flexural moment determined using the moment equilibrium equation. Procedure II is called the Inelastic Design beyond the yielding of steel Cold-formed steel joist assumed to reach their full yield stress when concrete reaches a maximum strain value of 0.003. The total force equilibrium used to locate plastic NA The flexural moment calculated from the sum of forces x their moment arms. Detailed analysis and design procedures can be found in Hsu, et al (2012) and Majdi and Hsu (2011).
___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

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Noncomposite
concrete steel deck CF steel joists
t= c

Composite
fc
C T
concrete steel deck CF steel joists
t c

Procedure I - ELASTIC up to yielding of steel

fc < 0.45 fc C
N.A. N.A. yt
y

yt

ft = fy

ft = fy

Procedure II INELASTIC beyond yielding of steel

concrete steel deck
c

fc < fy
N.A.

C T

concrete

c=

0.003

fc = 0.85fc
N.A.

C T

yt

steel deck CF steel joists

yt

CF steel joists

t>

ft = fy

>

fy

___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

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Comparison of Analysis and Test Results for CB1 and CB2

Maximum Analytical Load by computer program (lbs) (kN)

Test/ Analysis Mode of Failure

Specimen

Maximum Test Load (lbs) (kN)

Remark

Fasteners Shear

Proc. I

Proc. II Fasteners Proc. I Shear

Proc. II

Bending Bending

Bending Bending

CB1 No transverse reinforcement

9,950 (44.26)

7,607 (33.84)

8,573 (38.13) 1.31 1.16

Flexural and brittle failure

Longitudinal Shear crack in concrete slab make the structure become a noncomposite built-up section (Point Load Pattern)

CB2 No transverse reinforcement

11,300 (50.26)

10,215 (45.44)

8,973 (39.91)

14,334 (63.76) 1.11 1.26 0.79

Longitudinal shear crack in concrete slab and flexural failure

Longitudinal Shear crack in concrete slab make the structure become a noncomposite built-up section (Point Load Pattern)

___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

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Comparison of Analysis and Test Results for CB3, CB4, CB5, CB6
Maximum Analytical Load by computer program Test/ Analysis (lbs) Maximum (kN) Test Load Specimen (lbs) (kN) Fasteners Proc. I Proc. II Fasteners Proc. I Proc. II Shear 14,200 (63.16) 18,100 (80.51) 18,348 (81.61) 5,750 (25.58) Bending 8,053 (35.82) 10,084 (44.86) 10,084 (44.56) 5,125 (22.80) Bending 9,020 (40.12) 15,706 (69.86) 15,706 (69.86) 5,850 (26.02) 1.68 1.82 1.17 1.66 1.79 1.15 1.76 1.57 Shear Bending Bending Flexural failure Less Ductile Flexural and Ductile (Line Load Pattern) failure Flexural and Ductile failure

Mode of Failure

Remark

CB3

10,898 (48.48) 10,898 (48.48)

CB4

CB5

CB6

1.12

0.98

Lateral and torsional buckling

(Point Load Pattern)

___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

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CONCLUSIONS
Tests Results indicate that ultimate strength and ductility of proposed composite section increase by 14-38% and 56-80%, respectively, as compared to a non-composite section or built-up section. The shear connector and self-drilling fasteners allow transfer of horizontal shear forces between concrete slab and cold formed steel joists. After the concrete slab starts to crack, compression buckling of top flanges of steel joists was observed in the non-composite section, while the composite section was able to withstand additional loads without buckling of top flange and was able to reach its full flexural strength capacity. The cold-formed hat channel shear connector and screws proved to be an efficient transfer mechanism to distribute the horizontal shear forces. From the observations, the composite specimens failure is caused by the tilting and bearing of fasteners, and is then followed by the compression buckling of the compression flange of cold formed steel joists. AISI needs to provide the engineers and designers a comprehensive Analysis and Design method of Composite Cold Formed Floor Systems.
___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

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CONCLUSIONS
The proposed analysis and design methods were found to be capable to predict the ultimate strength capacity of the new composite beam and floor system in terms of both shear strength of fasteners and flexural strength of the tested cold-formed steel composite beams with concrete slab. The Elastic Analysis Approach (Procedure I) can be used to determine the flexural strength of the new composite system if the concrete slab has not been reinforced by the transverse bars, The Inelastic Analysis Approach (Procedure II) can be used to evaluate the flexural strength if the transverse bars have been provided to the composite floor system and are properly installed in the concrete slab. Further Research work is necessary to better estimate the shear capacity of the screws used to connect the new type of continuous shear connector to the metal deck and cold formed steel joists. The limitation of the AISI on the use of screw connectors up to 1/4 needs to be reevaluated to expand the use of larger diameter of screws for cold formed composite floor systems.
___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

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FIRST CCFFS BUILT IN LAWRENCE, MA February 2012

20x18 Storage Floor Span = 20 ft. - Live Load = 125 psf

CCFFS System: 4 concrete slab (3,000 psi), UF1X-24 ga galv. metal deck, 6x6 wire mesh (2)-1200S200-97 @ 4 o/c (40)-1/4 screws, Continuous 150F125-22Ga
___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

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QUESTIONS ???

hsuc@njit.edu prm4@njit.edu
___________________________________________________________ 21st International Specialty Conference by CCFSS October 24-25, 2012 on Cold-Formed Steel Structures St. Louis, MO

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