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Fatigue Tests on Steel–Concrete Composite Beams

Subjected to Sagging Moments


Ayman El-Zohairy, A.M.ASCE 1; Hani Salim, M.ASCE 2; and Aaron Saucier 3
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Abstract: Current shear stud fatigue capacity recommended for design of shear connectors is based on experimental data from push-out
tests, and there is a need to experimentally evaluate the fatigue performance of shear connectors in steel-concrete composite beams. Therefore,
this paper presents the results of four composite beams tested under fatigue with different degrees of shear connection. The fatigue testing was
carried out to a million cycles under bending with two different amplitudes. The residual strength of steel-concrete composite beams was
evaluated by performing static tests until failure after the completion of the fatigue tests for each of the specimens. The testing measurements
included midspan deflection, slippage between the steel beam and concrete deck, shear connector strains, and strains in the concrete deck and
bottom steel flange. Based on the experimental results, degrees of the shear connection between the steel beam and the concrete deck played a
major role in controlling the longitudinal fatigue cracks in the concrete deck. The residual deflection and plastic slippage increased as the
fatigue of cycles increased. This is caused by the damage in the concrete deck that developed around the shear studs, which led to a reduction
in the composite stiffness. The shear connectors’ strain ranges gradually increased due to the accumulation of damage as the number of cycles
increased. Based on the results of this paper, it is concluded that the current shear stud fatigue design curve predicts a lower fatigue life for the
shear connectors. DOI: 10.1061/(ASCE)ST.1943-541X.0002326. © 2019 American Society of Civil Engineers.
Author keywords: Steel-concrete composite beams; Experimental tests; Fatigue; Shear connectors; Deflection; Residual strength;
Slippage.

Introduction and propagation of fatigue cracks in the concrete deck. Cyclic load-
ing causes the deflection of the composite beams to increase due to
Under service loads, steel-concrete composite bridge super- incremental slippage between the steel beam and concrete deck
structures may experience fatigue damage due to cyclic loads. (Taplin and Grundy 2000). Under a large number of cycles, the frac-
Therefore, fatigue testing is critical to evaluate existing design ture of the shear connectors and the concrete damage around the
methods. Push-out tests have been used by many researchers to shear connectors caused the failure of the composite beams in
study the fatigue performance of shear connectors. Slutter and tests performed by Hanswille et al. (2009). The fatigue failure of
Fisher (1966) performed the first fatigue tests on shear studs, simply supported composite beams first occurs at the end shear con-
and they concluded that fatigue failure occurred in the weld zone nector and spreads in a proper order (Li et al. 2015). Wang et al.
connecting the stud to the steel flange. Current design procedures (2014) and Dai and Richard Liew (2010) demonstrated that the shear
were developed using the push-out testing results of Slutter and stress range and the upper limit of the applied fatigue load signifi-
Fisher (1966) and Johnson (2000).
cantly affected the fatigue performance of concrete-steel composite
Semiempirical analytical procedures were developed by
beams. The upper limit of the applied fatigue load significantly
Hanswille et al. (2007) and Dogan and Roberts (2012) to predict
affected the fatigue performance of the shear connectors when the
the reduced fatigue life and strength of shear connectors subjected
load upper limit was much larger than the fatigue load range.
to unidirectional cyclic loading. According to Liu and Roeck
Sjaarda et al. (2017) experimentally evaluated the fatigue re-
(2009), stud spacing greatly affects the shear force developed in
sponse and failure of welded shear studs in precast composite
shear connectors, whereas concrete modulus effects are relatively
beams. The research provides valuable fatigue test data for precast
small. Results from push-out tests by Ovuoba and Prinz (2016) sug-
gested a fatigue endurance limit of 44.8 MPa, which is similar to and cast-in-place composite beams. The results showed that shear
the current AASHTO value of 48.3 MPa. studs in beams with precast slabs exhibited fatigue performance
Fatigue testing performed by Richard Yen et al. (1997) con- similar to those in beams with cast-in-place slabs. Steel-concrete
cluded that the failure of composite beams was due to the formation composite beams with different degrees of shear connection were
investigated by Wang et al. (2018). The results of the research
1
Adjunct Instructor, Dept. of Civil and Environmental Engineering, showed that all mechanical properties of the composite beams under
Univ. of Missouri, Columbia, MO 65211-2200. fatigue loads decreased as the degree of shear connection decreased.
2 The survey of the previous literature showed that most detailed
Professor, Dept. of Civil and Environmental Engineering, Univ. of
Missouri, Columbia, MO 65211-2200 (corresponding author). Email: studies of fatigue behavior of shear connectors were done using
SalimH@mail.missouri.edu push-out tests and addressed a lack of existing experimental data
3
Postdoctororal, Dept. of Civil and Environmental Engineering, based on steel-concrete composite beams. Push-out tests cannot
Univ. of Missouri, Columbia, MO 65211-2200.
fully represent the actual tensile or compressive stresses in the con-
Note. This manuscript was submitted on April 17, 2018; approved on
November 7, 2018; published online on February 27, 2019. Discussion per- crete deck and the steel beam that affect the fatigue behavior of the
iod open until July 27, 2019; separate discussions must be submitted for shear connectors, steel beams, and concrete decks. Current shear
individual papers. This paper is part of the Journal of Structural Engineer- stud fatigue capacity recommended for design of shear connectors,
ing, © ASCE, ISSN 0733-9445. such as AASHTO, is based on the experimental data from push-out

© ASCE 04019029-1 J. Struct. Eng.

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Table 1. Summary of the tested specimens
Fatigue load (kN)
Percentage of design
Specimen Composite level Test method Pmax Pmin Range Δτ (MPa) N fatigue lifea
RSB-1 Full (100%) Static only — — — — —
FSB-2 Full (100%) Fatigue þ static 160.1 13.3 146.8 77.0 1,000,000 100
FSB-3 Full (100%) Fatigue þ static 177.9 13.3 164.6 87.4 1,000,000 180
FSB-4 Partial (60%) Fatigue þ static 160.1 13.3 146.8 132.2 1,000,000 2,850
Note: Δτ = shear stress range; and N = number of cycles.
a
Based on AASHTO design S-N curve for shear stud fatigue capacity.
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Fig. 1. Details of the tested specimens: (a) cross-section; and (b) elevations showing shear connectors’ arrangements. Dimensions in millimeters.

tests, and there is a need to experimentally evaluate the fatigue the effect of predamage due to fatigue loading on both the ultimate
performance of shear connectors in composite beams. In addition, and serviceability limit states of composite beams, the number of
the effect of predamage due to fatigue loading on both the ultimate cycles was kept constant at the predicted one million cycles. Details
and serviceability limit states of composite beams is questionable of the tested specimens, material properties, test setup and loading
(Hanswille and Porsch 2008). Therefore, this paper adds valuable procedures, and instrumentation are described next.
fatigue test data for shear studs performed on large-scale com-
posite beam tests. The residual strength of steel-concrete composite
beams was evaluated by performing static tests until failure after the Details of the Tested Specimens
completion of the fatigue tests for each of the specimens.
Fig. 1 shows schematic details of the tested specimens. For all
tested specimens, the overall length was 4,572 mm, and the clear
Experimental Program

To investigate the fatigue performance and residual strength of steel- Table 2. Details of the shear connectors and steel reinforcement
concrete composite beams under constant fatigue loading, four
Shear connectors Reinforcing bars
steel-concrete composite beam specimens were tested (Table 1). spacing (mm) spacing (mm)
The specimens with full-shear connection and the associated applied
fatigue loads were designed according to the fatigue limit state of Connection Longitudinal Transverse Longitudinal
Specimen device spacing spacing bars Stirrup
AASHTO LRFD. The specimen with a partial shear connection was
designed using 60% of the required studs for full-composite require- RSB-1 Stud 122.2 63.5 215.9 122.2
ments. The design fatigue load was predicted to fail at one million FSB-2 Stud 122.2 63.5 215.9 122.2
cycles; thus, all specimens were designed to undergo the same num- FSB-3 Stud 122.2 63.5 215.9 122.2
FSB-4 Stud 209.5 63.5 215.9 104.8
ber of cycles. In addition, for comparative purposes, to investigate

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Table 3. Summary of the materials properties rows with variable longitudinal spacings, as described in Fig. 1
Component Property Value and summarized in Table 2. Bearing and transverse stiffeners were
used at supports and loading points. Bearing steel plates were also
Reinforcing bars f y (MPa) 294.2
used between the concrete deck and spreader beam to reduce con-
fu (MPa) 402.5
Es (GPa) 207.8
crete stress concentration at the loading points.
Concrete f c0 (MPa) 32.4
Steel beam (Grade A992)a f y (MPa) 345
fu (MPa) 450 Material Properties
Es (GPa) 204
Shear connectorsa f y (MPa) 351.6 Normal-weight concrete was used to cast all specimens. For each
fu (MPa) 448.2 specimen, concrete cylinders of 100 × 200 mm were tested, and
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Es (GPa) 206.5 the average nominal compressive strength of the concrete cylinders
a was 32.4 MPa. Tension tests on the steel rebars were performed
DeLong’s Inc. (Jefferson, Missouri).
following the ASTM A370 (ASTM 2013) standard, and the
mechanical properties of the steel materials are listed in Table 3.
span between supports was 4,419.6 mm. The concrete deck was
101.6 mm thick and 1,143 mm wide. The concrete decks were Test Setup and Loading Procedures
reinforced in the transverse and longitudinal directions using
10-mm-diameter deformed bars, as shown in Table 2. Concrete For fatigue testing, four-point loading was used with a spacing be-
confinement around the shear connectors was provided by trans- tween the loading points of 1,372 mm. Fig. 2(a) shows a schematic
verse rebars to prevent longitudinal shear failure and concrete of the loading setup, and Fig. 2(b) shows the spreader beam and
splitting. Shear connectors with a diameter and height of 15.875 roller support at the specimen end. The tests were conducted in
and 81 mm, respectively, were welded to the steel flange in two two stages, as illustrated in Fig. 2(c), where the fatigue test was

Load
Spreader beam

LVDT-2 LVDT-3

LVDT-1

(a)

LVDT-3
Loading points

Concrete strain gage

(b)
Load Fatigue test Static test
Pmax Failure

Pmin

Stage 1 Stage 2
Time
(c)

Fig. 2. Test setup: (a) schematic view of the fatigue tests; (b) spreader beam showing loading points and support; and (c) loading stages for the fatigue
specimens. Dimensions in millimeters.

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different locations were instrumented using strain gauges. To mon-
itor compressive and tensile strains in the shear connector, strain
gauges were attached to either side of the foot of the connectors.
In addition, strains were measured in the bottom flanges of the steel
beams and the concrete decks at midspans.

Fatigue Test Observations and Discussion


LVDT
String pot The fatigue response of the specimens was studied by monitoring
(LVDT-1) the fatigue cracks in the concrete decks, the residual deflections, the
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plastic slippages between the concrete deck and the steel beam, and
the cyclic strains in different components of the composite section.
The results of each are presented next.

Fig. 3. Static test setup showing the concentrated load at midspan over
the steel beam. Stiffness Response and Cyclic Deflection
During fatigue testing, it was observed that cracks initiated and
propagated in the concrete deck. Because the composite section
performed in Stage 1 at 4.0 Hz, and the subsequent final static load- was designed such that the neutral axis is below the concrete deck,
ing test was performed in Stage 2. The static tests were carried out no cracks were expected to initiate on the surface of the concrete
under a one-point load to monitor the residual behavior of the deck under such low load levels. However, when the number of
fatigue specimens, as shown in Fig. 3. The reference specimen cycles went beyond 50,000, minor cracks were observed on the
(RSB-1) was tested to failure under static loads to evaluate the top and side surfaces of the concrete deck. As the number of cycles
residual behavior of the fatigue specimens. increased, additional cracks formed, and the size of cracks grew, as
illustrated in Fig. 5, which shows that fatigue cracks were mostly
present in the shear span regions. For specimens with the full shear
Instrumentation connection, transverse cracks were formed and propagated as the
number of load cycles increased, whereas longitudinal cracks were
Three linear variable differential transformers (LVDTs) were used formed and propagated between rows of the shear connectors
to measure deformations: one LVDT was to measure the vertical through the shear span regions in the specimen with the partial
deflection at midspan, and two LVDTs at each end of the beam shear connection. This means that the degree of shear connection
were used to measure slippage of the concrete deck in relation to played a major role in controlling the longitudinal fatigue cracks in
the steel beam (Fig. 3). Ten strain gauges were installed on various the concrete deck. Compared to the results of Richard Yen et al.
parts of each specimen, as shown in Fig. 4. Four shear connectors at (1997) and Oehlers (1989), where longitudinal splitting occurred
in the concrete deck under fatigue, no failure in the concrete deck
was observed in specimens presented in this paper. This can be
attributed to the confinement provided by sufficient longitudinal
and transverse reinforcement in the concrete deck, which prevented
longitudinal splitting of the concrete deck.
The cyclic load-deflection behavior for specimens FSB-3 and
FSB-4 and the residual deflection of the fatigue specimens are
presented in Fig. 6. Initial fatigue crack propagation and the for-
mation of additional fatigue cracks resulted in increasing residual
Specimens with full shear connection deformations. As the number of load cycles increased, the damage
in the concrete around the shear connectors led to a decrease in
the composite stiffness, resulting in an increase in the residual de-
flection. This growth in the residual deflection increased with the
increase in the fatigue load range. In addition, the specimen with
partial shear connection demonstrated a rapid increase in the
residual midspan deflection in the early stages of the fatigue test.
Specimen with partial shear connection

Concrete-to-Steel Slippage
The plastic cyclic slippage, the residual slippage at the interface
between the steel flange and concrete deck, for the fatigued spec-
imens is illustrated in Fig. 7, which shows that the specimen with
partial shear connection demonstrated the highest level of such slip-
Strain gage Strain gage page. This incremental slippage can be attributed to the damage in
the steel-concrete shear connection under fatigue loading, which
Strain gages at either side of the foot of one of the shear connectors accumulated as the number of load cycles increased (Taplin and
Grundy 2000). Most of this damage occurred in the early fatigue
Fig. 4. Arrangements of strain gauges. Dimensions in millimeters.
life of the specimen with the partial shear connection.

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Fig. 5. Crack formation and distribution in the concrete flanges during the fatigue tests (numbers of cycles shown are in thousands).

Cyclic Incremental Strains in the Composite Section the relative slipping between the concrete deck and steel beam
along the beam length, which was maximum at the beam ends.
Fig. 8 shows the cyclic incremental strains in the shear connectors Albrecht and Lenwari (2008) demonstrated experimentally that a
for the specimen with a partial shear connection (FSB-4). Although sudden increase in displacement was associated with shear connec-
the residual deflection [Fig. 6(b)] and plastic slippage (Fig. 7) con- tor failure. Because no sudden displacements were recorded by any
firm damage in the steel-concrete shear connection, the results in of the LVDTs, this indicates that no shear stud failure occurred
Fig. 8(a) demonstrate the same behavior between the plastic slip- during fatigue testing. In addition, this was confirmed by inspecting
page and the residual strain in the shear connector at the beam ends. the shear connectors after completion of the static tests and removal
That coinciding behavior illustrates the compatibility between the of concrete around the shear connectors. Fig. 8(c) shows that shear
shear connectors and concrete deck. Higher incremental strains connectors in the specimen with partial shear connection experi-
were experienced in the shear connectors near the supports in com- enced higher levels of strain compared to the other specimens. This
parison to those around the quarter-spans during the fatigue tests higher strain levels might be responsible for the initiation of fatigue
[Fig. 8(b)]. This difference in the incremental strains correlates to cracks (Fig. 9).

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Fig. 6. Deflection response of fatigue tests: (a) cyclic load-deflection behavior for specimens FSB-3 and FSB-4; and (b) residual deflection.

cycles. In addition, only a static test was performed on the reference


specimen (RSB-1) for comparison with the residual behavior of the
fatigue specimens. The observed inelastic behavior for the refer-
ence specimen was governed by yielding in the bottom flange
of the steel beam followed by crushing in the concrete deck at
the midspan (Fig. 11). This mode of failure was also observed
for the static residual strength testing of the fatigue specimens.
Comparisons of deflection, slippage, and strain measurements
are presented in Figs. 12–14 and are summarized in Table 4 for
the reference and fatigue specimens.
The behavior of all specimens exhibited an elastic response up
to the emergence of nonlinear strain in the bottom flange of the
steel beam at the central zone, as illustrated in Fig. 12(a). At
Fig. 7. Plastic slippage between the concrete flange and steel beam.
the onset of steel flange yielding, the strain in the upper fiber of
the concrete deck was very low, around 0.05%, which indicates
that the concrete deck for all specimens did not exhibit damage
at that point. Crushing of the concrete deck in the central zone
The cyclic incremental strains in the concrete decks and bottom was observed as all specimens reached their ultimate capacities.
flanges of the steel beams at midspans are illustrated in Fig. 10 for Therefore, the overall static response and failure of all specimens,
the fatigue specimens. Due to damage accumulation in the steel- including the partial-shear-connection specimen, were controlled
concrete shear connection, the cyclic incremental strain increased
by yielding of the steel beam and crushing of the concrete deck
gradually during the fatigue tests. The higher the fatigue load level,
at midspan. Because the specimen with the partial shear connection
the higher the damage in the shear connection, which increased the
was able to crush the concrete deck without shearing the studs, this
cyclic incremental strains in the concrete decks and bottom flanges
suggests that the specimen behaved in a full-composite manner,
of the steel beams (Fig. 10). The specimen with partial shear con-
even after fatigue loading.
nection experienced the highest level of incremental strains due to
The damage in concrete around the shear connectors during
the original lack of a steel-concrete shear connection.
fatigue testing caused a loss of the composite interaction between
the steel beam and the concrete deck. This loss is evident in
Residual Static Capacity of Fatigued Specimens the load-slippage relationships, which occurred around 100 kN
[Fig. 12(b)]. Therefore, the slippage indicated in Table 4 occurred
Static tests were performed on the fatigue specimens up to failure to at 100 kN. Fig. 12(b) also shows that the effect of damage around
monitor the residual strength of composite beams after a million the shear connectors is less pronounced after the applied load

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Fig. 8. Cyclic strains in the shear connectors at supports for specimen FSB-4: (a) incremental strain and plastic slippage comparison; (b) incremental
strain comparison at different locations; and (c) total strain comparison at the beam ends.

exceeded the maximum fatigue load of 180 kN. Although the cyclic
loads caused a reduction in the composite interaction between the
concrete deck and steel beam, which decreased the strength of the
fatigue specimens, the full shear connection limited the strength
deterioration for the fatigue specimens, as demonstrated in the
change in capacities shown in Table 4.
Fig. 12(b) also shows that the specimen with a partial shear
connection experienced more damage in the concrete around the
Fatigue cracks initiation shear connectors during fatigue testing, which led to an increase
in the shear connectors’ strains relative to the strains in the refer-
Fig. 9. Fatigue crack initiation at the foot of both shear connectors ence specimen in Fig. 13. After the maximum fatigue loading of
located at beam end for specimen FSB-4. 150 kN, the trends for longitudinal slippages [Fig. 12(b)] and shear
connector strains (Fig. 13) for the fatigue specimens with full shear

Fig. 10. Cyclic incremental strains at midspans in the (a) concrete flange; and (b) bottom flange of the steel beam.

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Zone of crushing
Zone of yielding

Fig. 11. Typical mode of failure for the static tests.


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Fig. 12. Deformations of the tested specimens: (a) load-deflection relationship; and (b) slippage between the concrete flange and steel beam.

Fig. 13. Strain in the shear connectors: (a) near supports; and (b) near quarter-spans.

Fig. 14. Strains at midspans for the (a) concrete flange; and (b) bottom flange of the steel beam.

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Table 4. Static response comparisons of fatigued specimens
Capacity Yielding load Slippagea
b b
Specimen Composite type kN % change kN % change mm % changeb
RSB-1 Full 378.7 — 295.2 — 0.06 —
FSB-2 Full 363.8 −3.9 285.9 −3.2 0.10 þ66.7
FSB-3 Full 361.9 −4.4 277.3 −6.1 0.11 þ83.3
FSB-4 Partial 355.4 −6.2 240.6 −18.5 0.16 þ166.7
a
Slippage values at 100 kN load.
b
% change is calculated based on the reference specimen RSB-1.
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RSB-1 FSB-2

(a) Uplift
(b)

Compressive strain
Tensile strain

(c)

Fig. 15. Variation of strains on both sides of shear connectors located at supports for specimens: (a) RSB-1 and (b) FSB-2; and (c) schematic view of
the shear connector deformation under the applied forces.

connections became similar to the ones for the reference specimen. fatigue specimens. Although the shear stress ranges, presented in
The strains in the concrete deck and bottom flange of the steel Table 1, were designed according to the stress range versus number
beams for the fatigued specimens are compared in Fig. 14 with of cycles (S-N) curve in AASTHO (2012) for the shear stud fatigue
those for the reference specimen. The damage in the steel-concrete capacity to cause fatigue fractures in the shear connectors at a spe-
shear connection led to an increase in these strains compared to the cific numbers of cycles, as illustrated in Fig. 16, no fatigue failures
reference beam. were noted in any of the shear connectors for the fatigued speci-
The uplift forces developed between the steel beam and concrete mens. Only fatigue crack initiation at the foot of the shear connec-
deck at the beam ends caused a difference in strain readings re- tors at the beam ends was noticed after 1,000,000 cycles for the
corded on both sides of the shear connectors, especially at loads specimen with the partial shear connection, as described previously.
above the fatigue level (Fig. 15). Therefore, the average value of The current AASHTO shear stud design S-N curve was devel-
the two strain readings (tensile and compressive strains) can be oped using fatigue results from standard push-out tests, and these
used to represent the actual strain in the shear connectors at a types of tests cannot represent the actual tensile or compressive
low level of loading, as presented by Lin et al. (2013). On the other stresses in the concrete deck and top flange of the steel beam. Fur-
hand, the average value would underestimate the actual strain in the thermore, the fatigue behavior of shear connectors was significantly
shear connectors at higher loading levels.
affected by the stress state of the steel plate and concrete nearby.
Based on the basis of the AASHTO S-N curve and the experimental
Investigation of the Shear Connectors Fatigue Life results presented in this paper, the current AASHTO shear stud
design S-N curve predicted a lower fatigue life for the shear con-
After completion of the static tests, the concrete decks were nectors. Therefore, more fatigue tests on steel-concrete composite
removed to inspect the conditions of the shear connectors in all beams are required to be run until a complete fatigue fracture failure

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testing to failure on steel-concrete composite beams is needed to
Log (N) = 8.061 – 0.0266 ( ) improve current S-N curve to better predict the fatigue life of shear
connectors.
FSB-4

FSB-3 Acknowledgments

FSB-2 The financial support sponsored by the Ministry of Higher Educa-


tion of Egypt is gratefully acknowledged. In addition, the generous
donation of materials and services from DeLong’s Inc., USA, is
greatly appreciated.
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Fig. 16. AASHTO design S-N curve for shear stud fatigue capacity
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