Chapter 6 - Prestress Composite A Amended1

Chapter Six: Composite Strength of Prestressed Steel-Concrete Beams
Chapter Six
Composite Strength of Prestressed Steel-
Concrete Beams
6.1 Introduction
Composite beams strengthened with prestressed tendons display several failure
modes as mentioned in chapter 1. These failure modes include (i) compression
crushing of concrete (ii) yielding of steel beam web, (iii) shear failure, (iv) rupture of
steel tendons. Out of these four failure modes, the fourth mode can be eliminated by
providing special steel anchorages at the ends of and steel deviators along the tendons
to eliminate stress concentrations. Shear failure can be prevented by providing
sufficient shear studs on the steel beam, to be encased in concrete. The other two
failure modes, namely, compression crushing of concrete and yielding of steel beam
web is the main focus of this study. The tendon profile and amount of prestressing
force in the prestressing tendon are of particular interest since yielding of the steel
beam web is highly dependent on it.
This chapter studies the effects of the various tendon profiles of the prestressed
steel tendons for use between the steel beam and the concrete flange. The prestressing
tendon used in the present study is of diameter of 12.7mm. The experimental
programme involved 2-point and 4-point loading of the composite beams, each with a
different tendon profile but with the same prestressing force. The effects of different
profiles of the prestressing tendons on the ultimate load and deflection of the
composite beams were determined.
89
6.2 Test Programme
The experimental programme involved testing three simply-supported,
externally prestressed steel-concrete composite specimens of length 6m and one
continuously-supported 2-span externally-prestressed steel-concrete beam of length
9m. The first simply-supported composite beam, Beam SS4PT, having straight tendon
profile was tested under a 4-point load to simulate a uniform loading condition while
the other two beams, with trapezoidal (Beam SSTRAP) and triangular tendon profiles
(Beam SSTRIC), were both tested under a two-point load while simply-supported.
The continuous composite beam, Beam CTBD, had a point-load on each of its 4.5m
span, while resting on three supports. The three simply-supported composite beams
were subjected to positive moments at the sagging regions between the two external
supports, while Beam CTBD experienced hogging moments in the middle support.
The prestressing tendons were placed in steel brackets welded to the bottom flanges of
all the beams and maintained at a constant eccentricity using specially-designed steel
deviators. The deviators also served to maintain the profile of the steel tendons
throughout the duration of testing and act as stiffeners for the steel web. All other
components of the composite beams used in the test programme, such as the size of
steel sections, the strength of the concrete, the amount of prestressing force applied in
each tendon and the width of the concrete flange are all kept constant for these three
beams. Results from previous experiments (Wong, 1998) involving Beam CTB
(similar in configuration to CTBD except for the deviators) and Beam CT (without
bottom prestressing tendons) will also be used for discussion and comparision.
90
FIG. 6.1 Deviators to maintain the Tendon’s Eccentricity
6.2.1 Beam SS4PT
Beam SS4PT, of length 6.3m, consists of a rolled section UC 203 X 152 X 52,
grade 43 complying with BS4360. The beam had two rows of shear studs, 19mm
diameter and 100mm nominal height, welded to the top flange between the two
external supports at a spacing of 150mm. The Beam SS4PT is simply-supported, with
the supports spaced 6.0m apart from each other. Rockers were placed on one of the
external supports (FIG 6.8) while the other support is fixed.
91
hapter 6 Composite Strength of Chapter Six: Composite Strength of Prestressed Steel-Concrete Beams m
s
Deviator
Top Plan View
6300.0
72 Shear Studs, 2 per group @ 180mm, except the pair near both ends @156mm
Load Load Load Load
150.0
Chapter Six: Composite Strength of Prestressed Steel-Concrete

B A
92
20.0 203.0
1200.0 1200.0 1200.0 1200.0 1200.0 20.0

B A
30
6000.0
Shear Studs Diameter = 19 mm, Height = 75mm

50.0 50.0 50.0 50.0 J203 x 152 x 52
203.0 20.0
32.0
26.0
D16
Chamfer R8
203.0 20.0
32.0
26.0
D16
Chamfer R8
Grade 43 Steel
152.0 152.0
Section B-B Section A-A
Beam I
FIG 6.2 Configuration of Beam SS4PT
s
Left Deviators Right Deviators
Top Plan View
6300.0
Load Load
2000.0
24.0 24.0
156 180 180 156
C
150.0 150.0

D16
20.0 22.5
36 39.4
30.538.5
D36 D18
R8.0
R8.0
D36
20.0 203.0
93
20.0
Left Deviator Right Deviator 250.0
(Dwg 3) (Dwg 4) C
35.0
2000.0 2000.0
6000.0
A
J203 x 152 x 52
50.0 50.0 50.0 50.0 50.0 50.0
39.0
Inner D18
Outer Chamfer D36
49.0 38.5
30.5 22.5
Inner D18
Outer Chamfer D36
B
28.0
D16
Grade 43 Steel
26.0 26.0 26.0
203.0 20.0 203.0 20.0 203.0 20.0
Section C-C
152.0
Section B-B
152.0
B Section A-A
152.0
Beam II
FIG 6.3 Configuration of Beam SSTRAP
s
Centre Deviator
Top Plan View
6300.0
Load Load

150.0
24.0
C
D16
20.0 22.5
36 35.8
30.5
38.5
D36 D18
R8.0
R8.0
D36
20.0 203.0
20.0
250.0
94
3000.0 3000.0 C
35.0
6000.0
50.0 50.0 50.0 50.0

A
50.0 50.0
J203 x 152 x 52
Inner D18
Outer Chamfer D36
Inner D18
Outer Chamfer D36
B D16
203.0
35.0
20.0
26.0
49.0 39.0
203.0
31.0 22.0
20.0
26.0
203.0
28.0
20.0
26.0 Grade 43 Steel
A
152.0 152.0 152.0
Section C-C Section B-B B Section A-A

Beam III
FIG 6.4 Configuration of Beam SSTRIC
s
3400 2500 3400
62 shear studs, 2 per group, @110mm 8 shear studs, 1 per group 62 shear studs, 2 per group, @110mm
Steel Reinforcement
A Concrete B
24.5 Top Bracket 75.5 224.5 300 300 300 251 300 300 300 224.5 75.5 24.5
130
206.2
150 Bottom Bracket 150

Deviator
650 3500 500 500
A 3500
B 650
9300

UC 203 x 203 x 52
95
Grade 43 Steel
BEAM 3
Section B- Section A-
UC 203 x 203 x UC 203 x 203 x

Grade 43 Grade 43
Shear Studs Diameter = 19 mm, Height
FIG. 6.5 Configuration of Beam CTBD
hapter 6 Composite Strength of Chapter Six: Composite Strength of Prestressed Steel-Concrete Beams
___________________________________________________________________________________
Top Elevation
26.0 50.0 50.0 26.0
42.0 Chamfer R8.0

15.0
Deviator Design Used in Beam II 42.0
15.0
(All Round Welding, Weld Thickness = 10mm) 43.0 39.0
15.0 15.0
42.0
J203x152x52
20 72.0 72.0
42 15 42
42 15 42
39 128.0 156.0
50
50 43 50.0
R8
8
20 28 35 28.0
R8 R59.0 14.0
26.0 26.0
152.0
Front Elevation
Side Elevation
Right Deviator Design
Top Elevation
26.0 50.0 50.0 26.0
42.0
15.0
Deviator Design Used in Beam I and III 42.0
(All Round Welding, Weld Thickness = 10mm) 15.0
42.0
15.0
42.0
J203x152x52
20.0 72.0 72.0
42.0 15.0 42.0 42.0 15.0 42.0
128.0
50.0 50.0 156.0
28.0 28.0
R139.0 14.0
26.0 26.0
152.0
Front Elevation
Side Elevation
Central Deviator Design
Top Elevation
Deviator Design Used in Beam II

(All Round Welding, Weld Thickness = 10mm) 42.0
15.0 15.0
39.0 43.0
15.0
42.0
15.0
Chamfer R8.0 42.0
26.0 50.0 50.0 26.0
J203x152x52
20 72.0 72.0
42 15 42
42 15 42
39 156.0 128.0
50
43 50 50.0
R8
8
35 28 20 28.0
R59.0 R8
14.0
26.0 26.0
152.0
Front Elevation
Side Elevation
Left Deviator Design
FIG 6.6 Deviators Design used in Beams
96
___________________________________________________________________________________
FIG. 6.7 Overall View of Beam SS4PT Test Setup
FIG. 6.8 Side View of Beam SS4PT Test Setup
97
___________________________________________________________________________________
FIG. 6.9 Transverse Reinforcement Layout
FIG. 6.10 Prestressed Steel Tendons with Strain Gauge
98
___________________________________________________________________________________
The concrete flange was 1500mm wide and 130mm thick, with two rows of
transverse reinforcement bars spaced evenly throughout it at a distance of 110mm.
The cover distance for these two rows of rebars was 20mm for top and bottom surface.
Two 7-wire prestressing tendons, of diameter 12.7mm, were anchored to the
end plates welded to the both ends of the beam using barrel and chuck anchorages.
The two tendons were each prestressed in alternative sequence until the desired
prestressing force of 100kN was reached in each tendon. Four sets of deviators were
welded to the web of the steel beam to maintain the profile of the prestressing tendon.
FIG. 6.11 Deviator to maintain tendon’s eccentricity
Two pairs of stiffeners 20mm thick and 25mm wide are welded to the steel
beam at the end supports. This was to guard against the buckling of the steel web
under the applied loads, as the theoretical buckling capacity was not sufficient to
withstand the external loads to be applied without the stiffeners.
99
___________________________________________________________________________________
Two 2.4m long twin spreader beams were used to provide the desired four-
point loads on the composite Beam SS4PT in conjunction with a 4.5m long spreader
beam on top as shown in FIG 6.16. As the spreader beam was huge, it was not
advisable to rest it on rockers sitting on the composite beam as this would cause
punching shear failure at the region below the rocker. Hence, the rockers were placed
on top of a set of I-beams resting on the composite beam (FIG 6.12).
FIG. 6.12 I-Beams used to Transfer Load to Composite Beam
100
_________________________________________________________________________________________________
___________________________________________________________________________________

_________________________________________________________________________________________________
___________________________________________________________________________________
Rocker Support 4.5m Spreader Beam

2 .0 m S p re a d e r B e a m
101
UC203x152x52
Prestressed Tendons
FIG. 6.13 Front and Side View of Test Setup for Beam SS4PT
_________________________________________________________________________________________________
___________________________________________________________________________________
4.5m Spreader Beam

Rocker Support
102
UC203x152x52
Prestressed Tendons
FIG. 6.14 Front and Side View of Test Setup for Beam SSTRAP
_________________________________________________________________________________________________
___________________________________________________________________________________
4.5m Spreader Beam
Rocker Support

103
UC203x152x52
Prestressed Tendons
FIG. 6.15 Front and Side View of Test Setup for Beam SSTRIC
_________________________________________________________________________________________________
___________________________________________________________________________________
Rocker Support 4.5m Spreader Beam

Deviator
UC203x203x52
104
Prestressed Tendons
FIG. 6.16 Front and Side View of Test Setup for Beam CTBD
___________________________________________________________________________________
6.2.2 Beam SSTRAP
Beam SSTRAP, of length 6.3m, consisted of a rolled section UC 203 X 152 X 52,
grade 43 complying with BS4360. As shown in FIG 6.3, the basic configuration of the
beam is the same as Beam SS4PT except for the end supports, the tendon profile and
the deviator positions. Beam SSTRAP uses a trapezoidal profile for its prestressing
tendons, hence only two deviators were required to maintain its profile. (FIG.6.14) The
anchorage end plates for the tendons at the supports were adjusted to ensure maximum
contact between the chuck and the tendons. The simply-supported Beam SSTRAP is
subjected to a 2-point load as shown in FIG 6.17.
FIG. 6.17 Overall View of Beam SSTRAP Test Setup
105
___________________________________________________________________________________
FIG. 6.18 Side View of Beam SSTRAP Test Setup
FIG. 6.19 Left Deviator Maintain Trapezoidal Profile
106
___________________________________________________________________________________
FIG. 6.20 Trapezoidal Tendon Profile with Strain Gauges Attached
FIG. 6.21 Change in Beam Profile During Loading
107
___________________________________________________________________________________
6.2.3 Beam SSTRIC
Beam SSTRIC, of length 6.3m, also consisted of a rolled section UC 203 X 152 X 52,
grade 43 complying with BS4360. As shown in FIG 6.4, the basic configuration of the
FIG. 6.22 Overall Test Setup for Beam SSTRIC
beam is the same is the Beam SSTRAP except for the tendon profile and the deviator
position. Beam SSTRIC is using a triangular profile for its prestressing tendons, hence
only one deviator was required to maintain its profile on each side of the web.
(FIG.6.15) The anchorage end plates used to hold the tendons at the supports were
adjusted as for Beam SSTRAP to ensure maximum contact between the chuck and the
tendons. The simply-supported beam is also subjected to a 2-point load. (FIG 6.22)
108
___________________________________________________________________________________
FIG. 6.23 Front View of Beam SSTRIC Test Setup
FIG. 6.24 Triangular Tendon Profile with Strain Gauges Attached
109
___________________________________________________________________________________
FIG. 6.25 Central Deviator with Transducer
FIG. 6.26 Transducer to Measure Slippage at Support
110
___________________________________________________________________________________
FIG. 6.27 I-Beam used to Transfer Load to Beam SSTRIC
FIG. 6.28 Deviator to House Prestressed Tendon
111
___________________________________________________________________________________
6.2.4. Beam CTBD
Beam CTBD, of length 9.3m, consisted of a rolled section UC 203 X 203 X 52, grade
43A complying with BS4360. As shown in FIG.6.1, the beam had two rows of shear
studs, 19mm diameter and 100mm nominal height welded to the top flange between
the external support and the top bracket at a spacing of 110mm. Between the two top
brackets, a single row of shear studs of the same characteristics was welded to the
flange at a distance of 300mm from each other.(FIG.6.31). The beam had three
supports, spaced 4.5m apart from each other. Rockers were placed on the two external
supports while the middle support rested on a load cell to measure the load acting on it.
(FIG.6.35)
FIG.6.29. Bottom Bracket Design
112
___________________________________________________________________________________
The concrete flange was 1500mm wide and 130mm thick, with two rows of
transverse reinforcement bars spaced evenly throughout it at a distance of 110mm.
The cover distance for these two rows of rebars was 20mm for top and bottom surface.
Six 7-wire high strength tendons, of diameter 12.7mm, were anchored to the 3
brackets attached to the top and bottom flanges of the beam using barrel and chuck
anchorages. The top two tendons were each prestressed to 100kN while the bottom
two tendons each had a prestressing force of 50kN. The steel brackets were designed
and prefabricated by professionals to house the three pairs of tendons at their
designated location (FIG. 6.29 and FIG. 6.30), and intermediate deviators were also
spaced evenly throughout the two beam spans to maintain the eccentricity of the
tendons during loading. FIG. 6.33 For Beam CTBD, the bottom tendons were
prestressed before the top tendons.
Two pairs of stiffeners 20mm thick and 25mm wide are welded to the steel
beam at the supports and one pair at the middle support. This was to prevent the
buckling of the steel web under the applied load, as the calculated buckling capacity
was not sufficient to withstand the external load.(FIG. 6.32)
FIG.6.30. Top Bracket Design
113
___________________________________________________________________________________
FIG.6.31 Top Prestressing Tendon
FIG.6.32 Shear Studs Welded on Steel Beam with Reinforcement
114
___________________________________________________________________________________
FIG. 6.33. Steel Deviator to Hold Prestressing Tendon in Place
FIG. 6.34. Strain Gauges Attached to Bottom Tendon
115
___________________________________________________________________________________
FIG. 6.35 Steel Beam Resting On Load Cell
FIG. 6.36 Scaffolding for the Formwork
116
___________________________________________________________________________________
6.3. Material Properties
6.3.1 Concrete
The concrete used for the composite flange had a compressive strength of 40
MPa. The concrete was batched in a ready mix plant and transported to the laboratory
for casting.
An admixture by the tradename Rapidard was used to accelerate the strength
gain. Eight 100 mm cubes were prepared along with the beam specimens. The beam
specimens were moist cured for three days under wet gunny sacks covered with
polythene sheets after which they were kept in the laboratory under ambient indoor
laboratory conditions. Testing was carried out after 28 days after casting. The target
strength, compressive cube strength at 28 days and during the tests were consistent
with the required strength needed for the test program.
6.3.2 Steel Reinforcement
High-yield deformed T16 steel bars were prepared in the laboratory and used as
internal transverse reinforcement for the concrete flange to prevent cracking of the
concrete along the beam.
6.3.3 Steel Beam
The four steel sections, together with the steel anchorages, shear studs and
deviators, were all fabricated by a structural steel fabricator. The deviators also served
as stiffeners. For Beams I and II, the deviators sit directly below the loading points.
6.3.4 Instrumentation
The strain in the concrete and steel were monitored using strain gauges. For
steel, the base length of the strain gauge used is 5mm, type YFRA-5 while for the
117
___________________________________________________________________________________
concrete is the 60mm type PL60-11 were used. The strain gauges were mounted onto
the steel-concrete beams at locations shown in FIG. 6.37, 6.38, 6.39 and 6.40.
After the strain gauges are mounted, the formwork for the concrete flange was
assembled. The composite beams were then moved into the testing frame after the
concrete had reached the required strength.
After the formwork was assembled, the two rows of transverse rebars were
placed in the formwork and spot welded into place (FIG. 6.9). Next, the two tendons
on each side of the beam were prestressed alternatively in steps until the required
100kN prestressing force was reached in each tendon. Strain gauges wrere fixed on all
the prestressing tendons (FIG. 6.11). Using the data logger, the increase in the
prestressing force in the tendons during and after jacking could be monitored.
After preparation of the formwork, the casting of the concrete flange was
carried out with a curing period of 3 days using gunny sacks. Lastly, strain gauges are
fixed onto the concrete surfaces before the specimens are ready for testing.
118
hapter 6 Composite Strength
_________________________________________________________________________________________________
4
3
Legend
2
Type PL60-
11
1
Type YFRA-
0
26 25 24 23

13 6 19
14 7 Tendons
119
15 8
31
22
Suppor
21 20
27
5 11
12 18
29 28
30
9 10
16 17
FIG. 6.37 Strain Gauges and Transducers Layout for Beam SS4PT
_________________________________________________________________________________________________
4
3
Legend
2
Type PL60-11
1
Type YFRA-5
0
26 23
25 24

13 6
7
14 8 Tendo
15 19
120
22 31
21
Support
20 20
27
5 11
12 18
29 28
30
9 10
16 17
FIG. 6.38 Strain Gauges and Transducers Layout for Beam SSTRAP
_________________________________________________________________________________________________
4
3
Legend
2
Type PL60-
11
1
Type YFRA 0
22 21

13 14 6
15
7 Tendon
20 31
121
Suppo 19
27
5 11
12 18
29 28
30
9 10
16 17
FIG. 6.39 Strain Gauges and Transducers Layout for Beam SSTRIC
_________________________________________________________________________________________________
Legend 61
Tendons 56 51
Type PL60-11 52
62 46 46 46 57
Type YFRA-5 53
58
63 45 45 45
54
64 59
65 60 55
41 74 67
42 75 68

43 76 69
122
Support
83 82 81 80
Load
13 Cell
45 40
78 73 71 66
84
80
80
Tendons Tendons
85
46 44
79 77 72 70
37 36 32 31 30 25 24 21 20 14 12 11 8 7
39 38 27 26 23 22 10 9
29 34 33 17 16 15
FIG. 6.40 Strain Gauges and Transducers Layout for Beam CTBD
hapter 6 Composite Strength Chapter Six: Composite Strength of Prestressed Steel-Concrete Beams
___________________________________________________________________________________
6.3.5 Design Criteria
The design criteria for all three specimens are as follows:
1. To prevent buckling of the steel section during the prestressing state.
2. To prevent the punching failure of concrete due to the high stress concentration at
the point load positions.
3. To achieve a flexural mode of failure by development of plastic hinges at midspan.
4. To prevent flexure of the composite beam due to loss of composite action and
excessive slip.
5. To prevent failure in vertical shear.
6. To prevent local failure in concrete slab due to high stress concentration or local
failure in steel section due to local buckling.
7. To achieve yielding of prestressing tendons after the steel section has yielded and
before the crushing of concrete.
8. To achieve a ductile behaviour for the composite beam after the concrete had
crushed by further loading the beam beyond failure load.
123

Chapter 6 - Prestress Composite A Amended1

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Chapter Six: Composite Strength of Prestressed Steel-Concrete Beams

Composite beams strengthened with prestressed tendons display several failure

modes as mentioned in chapter 1. These failure modes include (i) compression

to eliminate stress concentrations. Shear failure can be prevented by providing

beam web is highly dependent on it.

tendon used in the present study is of diameter of 12.7mm. The experimental

composite beams were determined.

6.2 Test Programme

The experimental programme involved testing three simply-supported,

externally prestressed steel-concrete composite specimens of length 6m and one

continuously-supported 2-span externally-prestressed steel-concrete beam of length

FIG. 6.1 Deviators to maintain the Tendon’s Eccentricity

6.2.1 Beam SS4PT

external supports at a spacing of 150mm. The Beam SS4PT is simply-supported, with

external supports (FIG 6.8) while the other support is fixed.

Top Plan View

Chapter Six: Composite Strength of Prestressed Steel-Concrete

1200.0 1200.0 1200.0 1200.0 1200.0 20.0

Shear Studs Diameter = 19 mm, Height = 75mm

Section B-B Section A-A

Left Deviators Right Deviators

Top Plan View

Chapter Six: Composite Strength of Prestressed Steel-Concrete

203.0 20.0 203.0 20.0 203.0 20.0

Top Plan View

Chapter Six: Composite Strength of Prestressed Steel-Concrete

Shear Studs Diameter = 19 mm, Height = 75mm

50.0 50.0 50.0 50.0

Section C-C Section B-B B Section A-A

3400 2500 3400

150 Bottom Bracket 150

Chapter Six: Composite Strength of Prestressed Steel-Concrete

UC 203 x 203 x UC 203 x 203 x

26.0 50.0 50.0 26.0

42.0 Chamfer R8.0

Right Deviator Design

26.0 50.0 50.0 26.0

42.0 15.0 42.0 42.0 15.0 42.0

Central Deviator Design

Deviator Design Used in Beam II

26.0 50.0 50.0 26.0

Left Deviator Design

FIG 6.6 Deviators Design used in Beams

FIG. 6.7 Overall View of Beam SS4PT Test Setup

FIG. 6.8 Side View of Beam SS4PT Test Setup

FIG. 6.9 Transverse Reinforcement Layout

FIG. 6.10 Prestressed Steel Tendons with Strain Gauge

transverse reinforcement bars spaced evenly throughout it at a distance of 110mm.

Two 7-wire prestressing tendons, of diameter 12.7mm, were anchored to the

FIG. 6.11 Deviator to maintain tendon’s eccentricity

withstand the external loads to be applied without the stiffeners.

on top of a set of I-beams resting on the composite beam (FIG 6.12).

FIG. 6.12 I-Beams used to Transfer Load to Composite Beam

Chapter Six: Composite Strength of Prestressed Steel-Concrete Beams

Rocker Support 4.5m Spreader Beam

Chapter Six: Composite Strength of Prestressed Steel-Concrete Beams

4.5m Spreader Beam

Chapter Six: Composite Strength of Prestressed Steel-Concrete Beams

4.5m Spreader Beam

Chapter Six: Composite Strength of Prestressed Steel-Concrete Beams

Rocker Support 4.5m Spreader Beam

Chapter Six: Composite Strength of Prestressed Steel-Concrete Beams

6.2.2 Beam SSTRAP