Introduction to Composite Concrete Design

Eugene Washington, P.E.

Course Outline
1. Design for three stages of loadings
2. Design Prestressed girder for dead load only
3. Girder camber
4. Light weight concrete properties
5. Prestress losses
6. pply slab dead load weight
!. Girder diaphragms
". Differing material mod#l#s
$. pply li%e loadings
1&. 'hec( for shear
Learning Objectives
)his co#rse leads the reader thro#gh the step by step process re*#ired to design a
composite slab and beam system. )he basic form#las for design are gi%en with an
e+planation as why they are #sed and how they are applied. )he p#rpose of this co#rse is to
gi%e an insight and #nderstanding of the process of composite concrete design and
constr#ction proced#res.
Course Introduction
'omposite concrete str#ct#res are where different materials are bonded to the concrete to
form a combined str#ct#ral shape. )he most common e+ample is when a reinforced
concrete dec( slab is po#red on top of a prefabricated beam. )he beams are #s#ally
concrete girders or steel beams. ,ther e+amples incl#de timber- tr#sses and e%en polymer
materials. 'omposite applications are often seen in bridges- b#ildings and par(ing
str#ct#res. )his co#rse e+plains to the reader the ma.or steps and form#las needed to
design for composite beam constr#ction.
)here are se%eral ad%antages of composite str#ct#res. /y bonding the beam and dec(
together the str#ct#re can be designed lighter- stronger and stiffer than when the beam and
dec( act independently. )he cost sa%ings res#lt from a lighter str#ct#re and faster
constr#ction. ,ften the dec( slab soffit forms are attached to the beams- eliminating
e+pensi%e falsewor(. )he composite design techni*#e is #sed for bridges where traffic- deep
water- steep canyon or en%ironmental concerns ma(es falsewor( impractical. /ridge beams
can be precast- prestressed 01), concrete girders or steel girders. Par(ing str#ct#res are
often almost entirely precast e+cept for footing and topping slabs. 2%en the dec( soffit
forms can be eliminated by the #se of precast- prestressed do#ble tee girders.
Course Content
Girders m#st be designed for three ma.or stages. )he first stage is when the girders are
erected. )he second stage is the placing of the concrete dec( slab. )he third stage is
applying the li%e loads to the finished str#ct#re. )he internal stresses acc#m#late in the
girder from each stage of design.
,ften the girders m#st ha%e temporary lateral bracing installed so that they can be pic(ed
and crane erected witho#t collapsing before the permanent design bracing can be installed.
/oth long span concrete and b#ilt3#p steel girders are %#lnerable to wind loads and lateral
instability #ntil the design str#ct#re is completed. Prestressed concrete girders resist the
prestress load only by their dead weight. Prestressed girders m#st be crane pic(ed near the
e+treme ends and the s#spending cables m#st be %ertical. )he increased compression and
bending load ind#ced by a sling type rigging can ca#se a catastrophic r#pt#re of the girder.
)he girder m#st be (ept #pright and nearly le%el when being handled beca#se e%en a slight
mis3orientation of the dead load of the girder can ind#ce instant collapse of the girder. 0#ch
disasters #s#ally res#lt in ma.or pro.ect delays- cost o%err#ns and can res#lt in death. )he
same concerns apply to long span b#ilt #p steel girders.
)he merican 'oncrete 4nstit#te 5'46 p#blishes se%eral definiti%e man#als- incl#ding '4 3
31"- that define the concrete design proced#res and calc#lations. )heir g#idelines are the
res#lt of e+tensi%e st#dies- tests- theory and research. )he design engineer m#st be f#lly
cogni7ant of the ramifications and all the appropriate design chec(s needed to competently
design prestressed concrete girders. 8#rther reference is made to 0)9 and 001), for
material properties and design load criteria.
Prestressed concrete girders are a delicate design compromise where the prestress
compression and bending moment are .#st co#ntered by the dead weight of the girder. )he
added dead loads and li%e load s#bse*#ently will ca#se a tension in the bottom fiber nearly
e*#al to the ind#ced prestress compression. )he design allows the girder to remain in total
compression at all times.
: ; Girder Dead :eight- lb<in
P ; Prestress 8orce- lbs
)he stresses are combined to place the top concrete fiber of the girder at nearly 7ero stress
and the bottom concrete fiber compression .#st below the allowable concrete compressi%e
stress. 0e%eral points in the girder are chec(ed to ins#re the girder is not o%er stressed at
any point.
8pc ; P<- psi
8pm ; P=<0+- psi
8dm ; >:L?@2<2 3 :?@2<2A<0+- psi
8c ; 8pc B 8pm B 8dm- psi
; the concrete girder cross section area at the analysis section- s*in
L ; concrete girder clear span between s#pports- inches
P ; the prestress force at the analysis section- lbs
CoteD )he prestress force is red#ced d#e to the all of the %ario#s actions of bond length and
shortening reactions
0+ ; the 'oncrete girder 0ection 9od#l#s at the analysis section- cin
CoteD 4t is common for the girder section to be asymmetrical %ertically and that ca#ses the
#pper 0ection 9od#l#s to ha%e a different %al#e than the lower 0ection mod#l#s.
: ; concrete girder weight - lb<in
CoteD )he e*#ations shown here ass#mes a constant section for the entire girder length
= ; the prestress eccentricity from the girder ne#tral a+is at the analysis section- inches
? ; the distance from the s#pport to the analysis section- inches
0e%eral points in the girder are chec(ed to ins#re the girder is not o%er stressed at any
point. )he reason for this is the prestress is #s#ally harped strands that only appro+imates
the parabolic dead load c#r%e and the critical stress point will not be at the center of the
girder. )he top concrete fiber m#st be chec(ed to ma(e s#re no significant tension is
created. )he bottom concrete fiber is chec(ed to ins#re the concrete is not o%erstressed in
compression. )he harping of the prestress strands will ind#ce a significant shear in end
*#arter portions of the girder. )he sine of the slanted portion of the prestress force less the
dead load shear m#st be chec( to ins#re the concrete is not o%erstressed in shear.
)he prestressed girders will de%elop a %ery large %ertical camber. )his camber de%elops
from two so#rces. 8irst the prestress force is designed to s#pport the f#ll s#perstr#ct#re
dead load incl#ding the girder- dec(- diaphragms- bridge rails- sidewal(s- medians and
f#t#re toppings as well as traffic li%e loads- impact- and dynamic wind and earth*#a(e loads
pl#s all the associated safety factors. )his means the girder will nat#rally ass#me a
significant #pward camber as soon as the prestress force is applied.
)he second camber so#rce is creep. Es#ally the girders are cast with the prestress force
being resisted by str#ct#res that are e+ternal and independent of the girder. )he girder is
then steam c#red o%ernight at a temperat#re of abo#t 1"& degrees 8ahrenheit. )his high
heat will c#re the concrete to at least the 14 day normally c#red strength. )he prestress
tension is then released and the girder absorbs the prestress force thro#gh the bond
strength between the prestress strand and the concrete. s the girder contin#es to age and
c#re the ind#ced differential compressi%e stress ca#ses the lower portion of the beam to
shrin( or creep m#ch more than the lightly compressed #pper half of the girder. )his
increases the initial #pward camber and slightly rela+es the prestress force. )he creep effect
can easily do#ble the initial prestress ind#ced camber.
)he creep camber can be controlled by placing hea%y designed weights on the girder #ntil it
is shipped for erection. )he initial #pward deflection ca#sed by the prestress force can be
appro+imated by the e*#ationD
D ; 5>:p3:dAL@4<3"42c4+
D ; deflection at the girder center line- inches
L ; span length between s#pports- inches
2c ; 'oncrete 9od#l#s of elasticity- psi
4+ ; 'oncrete 9oment of 4nertia- *in 5inch@46
:d ; concrete girder weight- lb<in
:p ; "P=<L@2- lb<in )his con%erts the prestress moment to an e*#i%alent #niform load.
P ; the prestress force at the girder centerline- lbs
= ; the prestess force eccentricity from the ne#tral a+is at the girder centerline- inches
Lightweight concrete can be partic#larly s#sceptible to long term creep. 4 (now of a
lightweight post3tensioned concrete bridge in 'alifornia that had to be retrofitted with
e+tensi%e post3tensioning to correct a two foot sag. Lightweight concrete has the ad%antage
of a m#ch red#ced str#ct#ral dead load- b#t that red#ced weight is often offset by wea(er
strength- red#ced d#rability and high creep properties. Generally- lightweight concrete is not
commonly #sed in str#ct#ral bridge applications.
)he prestress losses are generated by fo#r phenomenon. 8irst- the strand rela+es as the
prestress force is transferred to the girder concrete. 0econd- the concrete girder shortens
#nder the prestress force- f#rther rela+ing the strand. )hird- the concrete shrin(s as it
contin#es to age and shortens the strand length. 8o#rth- the stress creep ca#ses the strand
to f#rther rela+ and lose tension. )hese action combine to significantly red#ce the initial
prestress forces.
)he girders and diaphragms are separated from the ab#tments and pier caps #sing
neoprene bearing pads- 0tyrofoam and e+pansion .oint filler. )his done to allow the
s#perstr#ct#re to freely rotate #nder differing load conditions. 4t also is designed to allow
the s#perstr#ct#re to e+pand and contract d#e to the anticipate e+tremes in temperat#re.
/oth ends of the girders are restrained laterally by concrete shear bloc(s. )he girders are
restrained only at one end by longit#dinal shear bloc(s. )his allows a free e+pansion and
contraction. 4n earth*#a(e prone areas the s#perstr#ct#re is often restrained by fle+ible
cable systems both longit#dinally and %ertically.
)he second step is to apply the dec( slab dead load. Es#ally it is ass#med that the dec(
soffit forms are s#pported by the girder. )hat means the slab concrete dead load weight will
be carried by the girder. ,nly after the dec( concrete is s#fficiently c#red will the dec( and
the girder act as a single str#ct#ral member to carry the li%e and dynamic loads. Enless the
soffit is a stay3in3place form- the form weight and constr#ction li%e loads can #s#ally be
ignored at this stage.
)he only constr#ction li%e load concern is the point loads generated from concrete finish
machines. )hese machines ride on pipe rails and finish the dec( s#rface to the defined grade
and slope. ,ften the dec( slab is cantile%ered a few feet past the o#tside girder. 4f the finish
machine rails are placed on the o#tside longit#dinal dec( edge forms- a tor*#e is introd#ced
to the o#tside girder by the weight of the finish machine. 'oncrete girders and steel beams
are %ery easily o%erstressed and deflected by tor*#e forces. ,ne sol#tion is to mo#nt the
finish rails on the %ertical centerline of the o#tside girders to eliminate any significant
tor*#e. nother sol#tion is to temporarily cross brace to the ne+t inside girder often eno#gh
to control tor*#e deflection. ny time the girders are anticipated to absorb tor*#e forces-
e%en fairly light loads- the tor*#e effect sho#ld be analy7ed for stress and twist deflection.
8or composite bridge designs intermediate diaphragms are cast between the girders and
below the dec( slab. )he diaphragms ser%e at least two p#rposes. )hey s#pport the bottom
flange of the girder to resist lateral loads s#ch as wind and earth*#a(e forces. )hey also tie
the girders together so that the girders will deflect as #nit when asymmetrical traffic loads
to some girders and not load the ad.acent girders. 8or long spans the girders can deflect
eno#gh to o%erstress the slab that has a short span between the girders. )he differential
deflections are analy7ed by ass#ming fi+ed end slab moments de%elop at the edge of the
girder. )he diaphragms are spaced to eliminate any significant differential girder deflection
#nder asymmetrical bridge loadings. 2nd diaphragms are cast to loc( the girders for lateral
stability.
)hese diaphragms are #s#ally cast before the dec( and allowed to ta(e at least an initial
set. )his proced#re is recommended to control the tendency for a shrin(age crac( to
de%elop between the interface between the dec( and diaphragm concrete.
)he dec( slab #niform weight is added to the freestanding girder and the res#lting stress
change is calc#lated. )he deflection d#e to the dec( slab concrete weight m#st also be
calc#lated and added to the finish dec( ele%ations.
8sm ; >:sL?@2<2 3 :s?@2<2A<0+- psi
8d ; 8c B 8sm- psi
L ; concrete girder clear span between s#pports- inches
0+ ; the concrete girder 0ection 9od#l#s at the analysis section- cin
CoteD 4t is common for the girder section to be asymmetrical %ertically and that ca#ses the
#pper 0ection 9od#l#s to ha%e a different %al#e than the lower 0ection mod#l#s.
:s ; concrete dec( slab weight - lb<in
CoteD )he e*#ations shown here ass#mes a constant section for the entire girder length
? ; the distance from the s#pport to the analysis section- inches
fter the dec( has s#fficiently c#red to design strength- the li%e loads can be applied to the
composite dec( girder str#ct#ral #nit. )he o#ter girders of a bridge #s#ally s#pport only
one3half of a traffic lane and a smaller slab section- b#t also carries the bridge barrier rail
and<or sidewal(. Es#ally the difference between the e+tra dead load on the e+terior girder
and the f#ll traffic loads on the interior is small eno#gh that separate girder designs are not
re*#ired.
)he third step in the design process is to determine the combined or composite section
properties and calc#late the li%e load stressesD
1 ; the girder height- inches
CoteD ,ften there is a positi%e ele%ation difference of abo#t three to si+ inches designed
between the dec( soffit and the high point of the girder camber. )his is to allow for the
inability to acc#rately predict creep camber.
0 ; the spacing of the girders and the contrib#ting dec( width- inches
CoteD Es#ally the dec( slab is thic( eno#gh and the girder spacing is small eno#gh that no
slab width red#ction is re*#ired- b#t reference to the '4331" criteria is pr#dent.
) ; the total thic(ness of the dec(- inches
CoteD )he thic(ness sho#ld be red#ced by the depth of e+pected wear. Fed#ction for the
rebar co%er is not necessary beca#se the slab will #s#ally be entirely in compression
longit#dinally by the li%e loads.
= ; the composite ne#tral a+is- inches
4n order to locate the ne#tral a+is the 9od#l#s of 2lasticity of the girder and the concrete
m#st be factored.
:hen the composite beam bends #nder load it is ass#med that the strain is linear- 7ero at
the ne#tral a+is with a fi+ed slope to the o#termost concrete fibers. )he compression force
m#st e*#al the tension force. 2%en prestressed girders can ha%e a different 9od#l#s of
2lasticity from the from the dec( slab concrete. )he reason is that the girder concrete my be
a 6-&&& psi mi+ design and the dec( slab concrete may be as low as a 3-&&& psi mi+ design.
8 ; Ds2<L- psi
Ds ; 0train- inches
2 ; 9od#l#s of 2lasticity- psi
8 ; tensile or compressi%e 8orce- psi
L ; 9ember length- inches
C ; 2g<2s
2g ; the girder 9od#l#s of elasticity- psi
2s ; the dec( slab 9od#l#s of elasticity- psi
C ; 9od#l#s factor the different material properties of elasticity- dimensionless
= ; >Cg=g Bs=sA<>Cg B sA
)his form#la con%erts the girder area to an e*#i%alent dec( slab concrete strength to
acco#nt for the different stress to strain relationships between the girder concrete and the
slab concrete.
g ; girder rea- s*in
s ; dec( slab area- s*in
= ; distance from the composite beam centroid from the bottom of the girder- inches
=g ; distance to the girder centroid form the bottom of the girder- inches
=s ; distance to the dec( slab centroid from the bottom of the girder- inches
Cow the 9oment of 4nertia can be calc#lated abo#t the composite beam ne#tral a+isD
4c ; 4g B 4s B g>=3=gA@2 B s>=s3=A@2
4c ; the composite beam 9oment of 4nertia- *in
4g ; the girder 9oment of 4nertia abo#t its own centroid- *in
4s ; the dec( slab 9oment of 4nertia abo#t its own centroid- *in
)he compression or #pper 0ection 9od#l#s and the tensile or lower 0ection mod#l#s of the
composite beam is calc#latedD
0c ; 4c<=c- cin
0t ; 4c<=- cin
=c ; the distance from composite beam centroid to the dec( slab top most fiber- inches
0c ; the compression 0ection 9od#l#s- cin
0t ; the tensile 0ection 9od#l#s- cin
)he li%e load ind#ced stresses are then calc#lated be the form#lasD
8c ; 9e<0c
8t ; C9e<0t
8c ; the li%e load ma+im#m compressi%e stress in the dec( slab- psi
8t ; the li%e load ma+im#m tensile stress in the girder- psi
CoteD C is #sed to con%ert the prestressed girder bac( from the dec( slab 9od#l#s of
2lasticity #sed to determine the composite beam 9oment of 4nertia and the 0ection
9od#l#s.
9e ; the %ario#s li%e load moments #sed for designing the str#ct#re- in3lbs
)he li%e load stress are now added to the concrete girder B dec( slab stress diagramD
)he final chec( is for shear loading. Es#ally the web of the girder is ass#med to carry all the
dead and li%e load shear to the bridge bearings. )he girder webs are often thic(ened and
stiffened near the ends to resist the high shear le%els. )he shear flow in the slab and the
interface between the dec( and the girder m#st be chec(ed. Es#ally additional stirr#ps or
shear st#ds are re*#ired to resist the shear forces. 8or the girder the shear is calc#lated by
the form#laD
% ; Gw
% ; the shear stress- psi
G ; the dead pl#s li%e load shear at the %ario#s points an analy7ed- lbs
w ; the girder web area- s*in
0hear flow for the dec( slab is calc#lated by the form#la
Gf ; GH<4c
4c ; the 9oment of 4nertia of composite beam cross section at the point #sed- *in
H ; s?c- cin
s ; the area of the slab o#tside the shear plane- s*in
?c ; the %ertical distance from the composite beam centroid to the centroid of s- inches
G ; the li%e load only shear at the cross section being analy7ed- lbs
Gf ; the li%e load shear flow- lbs<inch
)he area of shear reinforcement is calc#lated by the form#laD
r ; 0fGf0s<IpE8y
r ; the area of the steel st#d or stirr#p rebar- s*in
)he steel area can be the acc#m#lated area of se%eral bars placed in a trans%erse row.
Ip ; the shear load red#ction factor- '4331" recommends Ip ; &."5
8y ; the yield strength of the steel st#d or rebar- psi
0f ; the #ltimate stress safety factor- '4331" recommend at least 0f ; 1.!
0s ; the st#d or rebar longit#dinal spacing- inches
E ; the coefficient of friction between the girder and the dec( slab
)he coefficient of friction will %ary considerably depending on the girder material and
ro#ghness of the girder top s#rface- see '4 for the %ario#s recommended %al#es.
)he longit#dinal area of the slab cross section o%er girder sho#ld be chec(ed to ins#re the
trans%erse rebar or concrete area is s#fficient to resist the shear flow ind#ced by the li%e
load bending of the composite beam.
Course Summary
)his introd#ctory co#rse shows the basic proced#res necessary to de%elop a composite
beam design. )he primary e+ample #sed is the common 01), precast- prestressed
concrete girder. )he shown proced#res are also applicable to steel beams and girders by
#sing the steel properties. thoro#gh (nowledge of '4 recommendations for concrete and
concrete girders is re*#ired to completely design the concrete elements of the bridge. :hen
steel girders are #sed the recommendations of 40' 5merican 4nstit#te of 0teel
'onstr#ction6 m#st be followed. 8ederal- 0tate and local standards often m#st be employed.
/y following the step by step proced#re listed an acc#rate determination of the stresses that
occ#r can easily be calc#lated and the composite beam *#ic(ly designed. )his is especially
tr#e if a comp#ter design program is #tili7ed.
Additional Resources
1. /#ilding 'ode Fe*#irements for 0tr#ct#ral 'oncrete 5'4 31"3$56
2. Feinforced 'oncrete Design- 1$65 by 'h#3Iia :ang and 'harles G. 0almon
3. 1andboo( of 1ea%y 'onstr#ction- 2nd edition- 1$!1 2dited by John . 1a%ers and 8ran(
:. 0t#bbs- Jr.
4. 'oncrete 9an#al- 1$"1 E0 /#rea# of Feclamation
D40'L492FD )he materials contained in the online co#rse are not intended as a representation or warranty on the part of
PD1online.org or any other person<organi7ation named herein. )he materials are for general information only. )hey are
not a s#bstit#te for competent professional ad%ice. pplication of this information to a specific pro.ect sho#ld be re%iewed
by a registered professional engineer. nyone ma(ing #se of the information set forth herein does so at their own ris( and
ass#mes any and all res#lting liability arising therefrom.