Lean production in the precast concrete components’ industry

Proceedings IGLC-19, July 2011, Lima, Perú

Optimisation and design of post-tensioning anchorage corner blisters in concrete box girder bidges

The design of anchorage blisters of internal continuity post-tensioning tendons of bridges built by the cantilever method, presents some peculiarities, not only because they are intermediate anchorages but also because these anchorages are located in blisters, so the prestressing force has to be transferred from the blister the bottom slab and web of the girder. The high density of steel reinforcement in anchorage blisters is the most common reason for problems with concrete cast in situ, resulting in zones with low concrete compacity, leading to concrete crushing failures under the anchor plates. A solution may involve improving the concrete compression and tensile strength. To meet these requirements a high-performance fibre reinforced self-compacting mix- ture (HPFRC) was used in anchorage corner blisters of post-tensioning tendons, reducing the concrete cross-section and decreasing the reinforcement needed. To assess the ultimate capacity and the adequate serviceability of the local anchorage zone after reducing the minimum concrete cross-section and the confining reinforcement, specified by the anchorage device supplier for the particular tendon, load transfer tests were performed. To investigate the behaviour of anchorage blisters regarding the transmission of stresses to the web and the bottom slab of the girder, and the feasibility of using high performance concrete only in the blister, two half scale models of the inferior corner of a box girder existing bridge were studied: a reference specimen of ordinary reinforced concrete and a HPFRC blister specimen. The design of the reinforcement was based in the tensile forces obtained on strut-and-tie models. An experimental program was carried out to assess the models used in design and to study the feasibility of using high performance concrete only in the blister, either with casting in situ, or with precast solutions. A non-linear finite element analysis of the tested specimens was also performed and the results compared.

Prestress losses in NSM-CFRP flexurally strengthened RC beams

The use of prestressed near surface mounted fibre reinforced polymers (NSM-FRP) has been long acknowledged to be a suitable approach to strengthen and retrofit existing reinforced concrete structures. The application of a certain amount of prestress to the FRP prior to its installation provides a number of benefits, mainly related to crack width and deflection requisites at serviceability limit state conditions. After transferring the prestress to a structural element, some of the existing cracks can be closed, decreasing the vulnerability of the element to corrosion and, a certain amount of deflection can be recovered due to the introduced negative curvature. However, these benefits can only be assured if the prestress is properly preserved over time. In this context, three series of reinforced concrete beams, in a total of 10 beams, were strengthened with a prestressed carbon FRP laminate (CFRP) and monitored for about 40 days. The data obtained from these tests is in this paper presented and analysed. The observed losses of strain in the CFRP laminate were found to be mainly located in the extremities of the bonded length, while in the central zone most of the initial strain was well-preserved over time. Additionally, the highest CFRP strain losses were observed in the first 6 to 12 days after prestress transfer, suggesting that the benefits of prestressed NSM-FRP will not be considerably lost over time.

Embedded Through-Section shear strengthening technique using steel and CFRP bars in RC beams of different percentage of existing stirrups

The Embedded Through-Section (ETS) technique is a promising technique for the shear strengthening of existing (RC) elements. According to this technique, holes are drilled through the beam section, and bars of steel or FRP material are introduced into these holes and bonded to the concrete with adhesive materials. An experimental program was carried out with RC T-cross section beams strengthened in shear using the ETS steel bars and ETS CFRP rods. The research is focused on the evaluation of the ETS efficiency on beams with different percentage of existing internal transverse reinforcement (ρsw=0.0%, ρsw=0.1% and ρsw=0.17%). The effectiveness of different ETS strengthening configurations was also investigated. The good bond between the strengthening ETS bars and the surrounding concrete allowed the yield initiation of the ETS steel bars and the attainment of high tensile strains in the ETS CFPR rods, leading to significant increase of shear capacity, whose level was strongly influenced by the inclination of the ETS bars and the percentage of internal transverse reinforcement.

Transfer zone of prestressed CFRP reinforcement applied according to NSM technique for strengthening of RC structures

This study presents an experimental program to assess the tensile strain distribution along prestressed carbon fiber reinforced polymer (CFRP) reinforcement flexurally applied on the tensile surface of RC beams according to near surface mounted (NSM) technique. Moreover, the current study aims to propose an analytical formulation, with a design framework, for the prediction of distribution of CFRP tensile strain and bond shear stress and, additionally, the prestress transfer length. After demonstration the good predictive performance of the proposed analytical approach, parametric studies were carried out to analytically evaluate the influence of the main material properties, and CFRP and groove cross section on the distribution of the CFRP tensile strain and bond shear stress, and on the prestress transfer length. The proposed analytical approach can also predict the evolution of the prestress transfer length during the curing time of the adhesive by considering the variation of its elasticity modulus during this period.

Plastic-damage smeared crack model to simulate the behaviour of structures made by cement based materials

This work proposes a constitutive model to simulate nonlinear behaviour of cement based materials subjected to different loading paths. The model incorporates a multidirectional fixed smeared crack approach to simulate crack initiation and propagation, whereas the inelastic behaviour of material between cracks is treated by a numerical strategy that combines plasticity and damage theories. For capturing more realistically the shear stress transfer between the crack surfaces, a softening diagram is assumed for modelling the crack shear stress versus crack shear strain. The plastic damage model is based on the yield function, flow rule and evolution law for hardening variable, and includes an explicit isotropic damage law to simulate the stiffness degradation and the softening behaviour of cement based materials in compression. This model was implemented into the FEMIX computer program, and experimental tests at material scale were simulated to appraise the predictive performance of this constitutive model. The applicability of the model for simulating the behaviour of reinforced concrete shear wall panels submitted to biaxial loading conditions, and RC beams failing in shear is investigated.

Influence of casting condition on the anisotropy of the fracture properties of Steel Fibre Reinforced Self-Compacting Concrete (SFRSCC)

Identification of the tensile constitutive behaviour of Fibre Reinforced Concrete (FRC) represents an important aspect of the design of structural elements using this material. Although an important step has been made with the introduction of guidance for the design with regular FRC in the recently published fib Model Code 2010, a better understanding of the behaviour of this material is still necessary, mainly for that with self-compacting properties. This work presents an experimental investigation employing Steel Fibre Self-Compacting Concrete (SFRSCC) to cast thin structural elements. A new test method is proposed for assessing the post-cracking behaviour and the results obtained with the proposed test method are compared with the ones resulted from the standard three-point bending tests (3PBT). Specimens extracted from a sandwich panel consisting of SFRSCC layers are also tested. The mechanical properties of SFRSCC are correlated to the fibre distribution by analysing the results obtained with the different tests. Finally, the stress-crack width constitutive law proposed by the fib Model Code 2010 is analysed in light of the experimental results.

Metric Short Course for the Office of Bridges and Structures, HR-378, 1995

This metric short course was developed in response to a request from the Office of Bridges and Structures to assist in the training of engineers in the use of metric units of measure which will be required in all highway designs and construction after September 30, 1996 (CFR Presidential Executive Order No. 12770). The course notes which are contained in this report, were developed for a half-day course. The course contains a brief review of metrication in the U.S., metric units, prefixes, symbols, basic conversions, etc. The unique part of the course is that it presents several typical bridge calculations (such as capacity of reinforced concrete compression members, strength of pile caps, etc.) worked two ways: inch-pound units throughout with end conversion to metric and initial hard conversion to metric with metric units throughout. Comparisons of partial results and final results (obtained by working the problems the two ways) are made for each of the example problems.

A Ten Year Performance Summary of Fibrous PC Concrete Overlay Research in Greene County, Iowa, HR-165, 1984

The Greene County, Iowa, overlay project, completed in October, 1973, was evaluated in October, 1978, after five years of service and most recently in October, 1983, after ten years of service. The 33 fibrous concrete sections, four CRCP sections, two mesh reinforced and two plain concrete sections with doweled reinforcement were rated relative to each other on a scale of 0 to 100. The rating was conducted by original members of the Project Planning Committee, Iowa DOT, Iowa County, Federal Highway Administration, University of Illinois and industry representatives. In all, there were 23 and 24 representatives who rated the project in 1978 and 1983 respectively. The 23 or 24 values were then averaged to provide a final rating number for each section or variable. All experimental overlay sections had performed quite well in the period from five through 10 years, experiencing only limited additional deterioration. Based upon this relatively good performance through 10 years, the sections will be maintained for further research with another evaluation at 15 years. The 4" thick nonfibrous mesh reinforced continuous reinforced concrete pavement overlay sections provided the best performance in this research project. Another nonfibrous 5" thick bar reinforced overlay section performed almost as well. The best performance of a fibrous reinforced concrete section was obtained with 160 pounds of fiber per cubic yard.

Strength and serviceability performance of beams reinforced with GFRP bars in flexure

Glass fiber reinforced polymer (GFRP) rebars have been identified as an alternate construction material for reinforcing concrete during the last decade primarily due to its strength and durability related characteristics. These materials have strength higher than steel, but exhibit linear stress–strain response up to failure. Furthermore, the modulus of elasticity of GFRP is significantly lower than that of steel. This reduced stiffness often controls the design of the GFRP reinforced concrete elements. In the present investigation, GFRP reinforced beams designed based on limit state principles have been examined to understand their strength and serviceability performance. A block type rotation failure was observed for GFRP reinforced beams, while flexural failure was observed in geometrically similar control beams reinforced with steel rebars. An analytical model has been proposed for strength assessment accounting for the failure pattern observed for GFRP reinforced beams. The serviceability criteria for design of GFRP reinforced beams appear to be governed by maximum crack width. An empirical model has been proposed for predicting the maximum width of the cracks. Deflection of these GFRP rebar reinforced beams has been predicted using an earlier model available in the literature. The results predicted by the analytical model compare well with the experimental data

Flexure-shear Analysis of Concrete Beam Reinforced with GFRP bars

This paper gives the details of flexure-shear analysis of concrete beams reinforced with GFRP rebars. The influence of vertical reinforcement ratio, longitudinal reinforcement ratio and compressive strength of concrete on shear strength of GFRP reinforced concrete beam is studied. The critical value of shear span to depth ratio (a/d) at which the mode of failure changes from flexure to shear is studied. The fail-ure load of the beam is predicted for various values of a/d ratio. The prediction show that the longitudinally FRP reinforced concrete beams having no stirrups fail in shear for a/d ratio less than 9.0. It is expected that the predicted data is useful for structural engineers to design the FRP reinforced concrete members.

Seismic behavior of capacity designed masonry walls in low seismicity regions

Eurocode 8 representing a new generation of structural design codes in Europe defines ‎requirements for the design of buildings against earthquake action. In Central and ‎Western Europe, the newly defined earthquake zones and corresponding design ground ‎acceleration values, will lead in many cases to earthquake actions which are remarkably ‎higher than those defined so far by the design codes used until now in Central Europe. ‎ In many cases, the weak points of masonry structures during an earthquake are the corner ‎regions of the walls. Loading of masonry walls by earthquake action leads in most cases ‎to high shear forces. The corresponding bending moment in such a wall typically causes a ‎significant increase of the eccentricity of the normal force in the critical wall cross ‎section. This in turn leads ultimately to a reduction of the size of the compression zone in ‎unreinforced walls and a high concentration of normal stresses and shear stresses in the ‎corner regions. ‎ Corner-Gap-Elements, consisting of a bearing beam located underneath the wall and ‎made of a sufficiently strong material (such as reinforced concrete), reduce the effect of ‎the eccentricity of the normal force and thus restricts the pinching effect of the ‎compression zone. In fact, the deformation can be concentrated in the joint below the ‎bearing beam. According to the principles of the Capacity Design philosophy, the ‎masonry itself is protected from high stresses as a potential cause of brittle failure. ‎ Shaking table tests at the NTU Athens Earthquake Engineering Laboratory have proven ‎the effectiveness of the Corner-Gap-Element. The following presentation will cover the ‎evaluation of various experimental results as well as a numerical modeling of the ‎observed phenomena.‎

Zur Druck-Querzug-Festigkeit von Stahlbeton und stahlfaserverstärktem Stahlbeton in scheibenförmigen Bauteilen

Am Fachgebiet Massivbau (Institut für Konstruktiven Ingenieurbau – IKI) des Fachbereichs Bauingenieurwesen der Universität Kassel wurden Bauteilversuche an zweiaxial auf Druck-Zug belasteten, faserfreien und faserverstärkten Stahlbetonscheiben durchgeführt. Dabei wurden die Auswirkungen der Querzugbeanspruchung und der Rissbildung auf die Druckfestigkeit, auf die Stauchung bei Erreichen der Höchstlast sowie auf die Drucksteifigkeit des stabstahl- und faserbewehrten Betons an insgesamt 56 faserfreien und faserverstärkten Beton- und Stahlbetonscheiben untersucht. Auf der Grundlage der experimentell erhaltenen Ergebnisse wird ein Vorschlag zur Abminderung der Druckfestigkeit des gerissenen faserfreien und faserbewehrten Stahlbetons in Abhängigkeit der aufgebrachten Zugdehnung formuliert. Die Ergebnisse werden den in DIN 1045-1 [D4], Eurocode 2 [E3, E4], CEB-FIP Model Code 1990 [C1] und ACI Standard 318-05 [A1] angegebenen Bemessungsregeln für die Druckstrebenfestigkeit des gerissenen Stahlbetons gegenübergestellt und mit den Untersuchungen anderer Wissenschaftler verglichen. Die bekannten Widersprüche zwischen den Versuchsergebnissen, den vorgeschlagenen Modellen und den Regelwerken aus U.S.A., Kanada und Europa können dabei weitgehend aufgeklärt werden. Für nichtlineare Verfahren der Schnittgrößenermittlung und für Verformungsberechnungen wird ein Materialmodell des gerissenen faserfreien und faserbewehrten Stahlbetons abgeleitet. Hierzu wird die für einaxiale Beanspruchungszustände gültige Spannungs-Dehnungs-Linie nach Bild 22 der DIN 1045-1 auf den Fall der zweiaxialen Druck-Zug-Beanspruchung erweitert.

Study of bond behaviour between FRP reinforcement and concrete

El uso de barras de materiales compuestos (FRP) se propone como una alternativa efectiva para las tradicionales estructuras de hormigón armadas con acero que sufren corrosión en ambientes agresivos. La aceptación de estos materiales en el mundo de la construcción está condicionada a la compresión de su comportamiento estructural. Este trabajo estudia el comportamiento adherente entre barras de FRP y hormigón mediante dos programas experimentales. El primero incluye la caracterización de la adherencia entre barras de FRP y hormigón mediante ensayos de pull-out y el segundo estudia el proceso de fisuración de tirantes de hormigón reforzados con barras de GFRP mediante ensayo a tracción directa. El trabajo se concluye con el desarrollo de un modelo numérico para la simulación del comportamiento de elementos de hormigón reforzado bajo cargas de tracción. La flexibilidad del modelo lo convierte en una herramienta flexible para la realización de un estudio paramétrico sobre las variables que influyen en el proceso de fisuración.

Modeling of interfaces in two-dimensional problems using solid finite elements with high aspect ratio

Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)