A Study on Fatigue Durability of RC Slab with Metal-Grid

Instead of Steel Re-bar

Tadashi ABE1, Kazuhiko MINAKUCHI2, Ming-Chien HSU3 and Keisuke SHIOTA4

1
Dr. E, Prof., Nihon University, Dept. of Civil Engineering, 1-2-1, Izumi-cho,
Narasino-shi, Chiba 275-8575, Japan
2
Dr. E, Associate prof., Nihon University, Dept. of Civil Engineering 1-2-1, Izumi-
cho, Narasino-shi, Chiba 275-8575, Japan
3
Dr. E, Assistant prof., National Taipei University of Technology, Dept. of
Architecture, 1, Sec. 3, Zhongxiao E. Rd., Taipei 10608 Taiwan, R.O.C.
4
JFE Civil Engineering & Construction Corporation, Technical Development Dept.,
2-17-4, kuramae, taitou-ku, Tokyo 111-0051, Japan

ABSTRACT:
For this research, the new developed steel metal-grid has been used in RC slabs. The
practicality and the fatigue resistance has been verified by using wheel-running fatigue
load experiment. As the results, the steel metal-grid used as reinforcement in the RC
slabs has good constructability and shorten the construction time. Moreover,
comparing the results with the steel re-bars used in the RC slab, the equivalent number
of running times is similar by using wheel-running fatigue load experiment. Hence,
the fatigue resistance of steel metal-grid used in RC slabs is recognized. Therefore, the
steel metal-grid used in RC slab proposed in this paper has achieved the practicality of
rationalization and labor-saving construction.

INTRODUCTION

Page 1
 
 In recent years, rationalization and labor-saving construction materials aredesired
from a lack of workers in the construction business in Japan. Particularly in the
construction site of the concrete structure, insufficient of workers perform the
assembling and processing of steel re-bars. Therefore, two types of metal-grid material
have been developed as a substitute to the steel re-bars (K.Minakuchi, et al. 2015). The
first type is the steel metal-grid that the steel plate was cut slit shapes by a laser and
stretched out to form the grid shapes by hydraulic jack. The second type metal-grid is
cutting steel plate directly to form the grid shapes by laser. For using in the actual
concrete structure, these two types of metal-grid can be machining bended according
to the shape of the actual structure. Then, the formwork can be assembled around the
steel metal-grid before the concrete pouring. Hence, this steel metal-grid material can
be achieved the rationalization and labor reduction in construction site.
In this study, we have verified the load carrying capacity and the fatigue
durability of the steel metal-grid used in the RC slabs of Highway Bridge, and the steel
metal-grid has been shown the applicability of using in the actual bridge RC slabs.
Moreover, this experimental study is carrying out for verifying the load carrying
capacity and the fatigue durability under the load carrying wheel tracking machine.
Finally, for verifying the practicality, this study is going to compare the RC slab with
steel re-bars and the RC slab with steel metal-grids.

PREPARATION OF STEEL METAL-GRID

Outline of Steel Metal-Grid

Two types of steel metal-grid has been developed. The first type is that
checkered steel plate or steel plate is cut slit shapes by laser in the longitudinal
direction, and stretched to form a grid shape by hydraulic jack in axle direction.
(Hereinafter referred to as “stretched steel metal-grid”) The second type metal-grid is
cutting the checkered steel plate or the steel plate directly to form a grid shape by laser.
(Hereinafter referred to as “steel metal-grid”) Steel material can be used as SM400 or
SM490 types.

Fabrication of Steel Metal-Grid

Fabrication of the steel metal-grid is shown in the PIC 1. Fabrication method
of steel metal-grid is placed a checkered steel plate and used laser to cut the plate into

Page 2
 
the grid shape (PIC 1 (1)). The laser cut steel metal-grid is shown in PIC 1 (2). The
longitudinal direction of the steel metal-grid is seem as the main re-bars, and the axle
direction of the steel metal-grid is seen as the distribution re-bars. The cross section of
grid can be cut freely as according to the design. The steel metal-grid can be used as
the reinforced material. Therefore, the shape of the steel metal-grid can be bend
according to the structure that needed to be reinforced. For rust prevention, the anti-
rust inhibitor can be placed on the steel metal-grid as reinforced material (PIC 1 (3)).

(1) Laser cutting (2) Metal-grid (3) Preservative painting

PIC. 1. Method of fabrication of Metal-grid

As described above, unlike the steel metal-grid, the stretched steel metal-grid
is stretched to form a grid shape by hydraulic jack after the slit shape cut on the
checkered steel plate by laser. These two types of steel metal-grid have been tasted
with various materials and adhesion testing. Moreover, these two types have also been
tested in the structure experiment lab and adopted as reinforced material that sale as
commercial material.

MATERIALS APPLICATION AND SPECIMENS OVERVIEW

Material Used for Specimens

(1) RC slabs
Ordinary Portland cement with size of 5mm and below and coarse aggregate
with size of 5mm~20 mm were used for the concrete of RC slab test specimens. The
design criteria of concrete compression strength was 35N/mm2 and above that
specified in the concrete specification was used. The formula condition of concrete for
RC slab is shown in TABLE 1. Moreover, the D10 reinforcement-bars (re-bars) of SD
295A type were used. The physical properties of concrete and re-bars are listed in
TABLE 2.

Page 3
 
 Table 1. Formula condition of concrete for RC slab
Slump Air W/C s/a Unit weight(kg/m³)
(cm) (%) (%) (%) C W S G Ad
18 4.5 49.5 47.6 344 170 832 956 3.4

Table 2. Physical properties of concrete and re-bars

Concrete Reinforcing Bar (SD295A)
compressive Yield Tensile Young's
Specimen
strength strength strength modulus
(N/mm²) (N/mm²) (N/mm²) (kN/mm²)
RC slab 35 368 516 200

(2) Steel Metal-Grid

1) Material Specification
The SS400 material type of checkered steel plate was used as steel metal-grid
and had 4.5mm of thickness. The material properties of steel metal-grid are listed in
the TABLE 3. As shown in TABLE 3, the steel metal-grid had 337N/mm2 of yield
strength and 442N/mm2 of tensile strength. Furthermore, the yield strength and tensile
strength of checkered steel plate had been tasted in the laboratory (Test specification:
JIS Z 2241), and results were 327N/mm2 and 435N/mm2, respectively.

Table 3. Material properties of steel metal-grid

Yield Tensile Young's
Specimen strength strength modulus
(N/mm²) (N/mm²) (kN/mm²)
Metal-grid 337 442
Test value 327 435 200
Value of standard 245 and over 400 and over

2) Grid Dimension
The size of tensile re-bars in RC slab was D10 (The cross-section was
71.3mm2) that placed on axle and longitudinal direction with 100mm spacing. The
compression re-bars was half amount of the tensile re-bars with 200mm spacing.
Therefore, the steel metal-grid had 100mmx100mm grid spacing size in the tensile
side. The cross-section of steel metal-grid was 72mm2 that the thickness was 9.0mm

Page 4
 
and the width was 8.0mm. Moreover, it provided 2mm protrusion per 9mm spacing in
order to increase the adhesion of steel metal-grid. FIG 1 shows the dimension and
shape of steel metal-grid.

FIG. 1. Size of metal-grid

Outline of Specimen
(1) RC Slab Specimen
The design of the test specimen was from 2014 of the Highway Bridge
Specifications (Japan Road Association 2014). For this test, one half of the mode in
the Specifications was been designed. The figuration of RC slab specimen and re-bars
arrangement are shown in FIG 2 (1).
The RC slab specimens had a span of 1200mm between supports and had
135mm over hanging over the supports. The total length was 1470mm. Moreover, the
D10 of tensile re-bars were placed in axle and longitudinal direction with 100mm
spacing. The effective depths of tensile re-bars ware 95mm and 105mm for axle and
longitudinal direction, respectively. In the compression size, the compression re-bars
were half amounts of tensile re-bars and had 200mm in spacing. The effective depths
of compression re-bars ware 35mm and 25mm for axle and longitudinal direction,
respectively. Hereafter, the RC slab specimen is referred as RC-1.

(2) MG Slab Specimen

The figuration of steel metal-grid RC slab specimens (Hereinafter referred to
as “MG slab specimen”) were same as the RC slab specimen in total width, support
distance and thickness. FIG 2 (2) is shown the figuration of MG slab specimens.

Page 5
 
 For the arrangement of reinforcement in the MG slab specimens, the tension
side had placed a layer of the steel metal-grid with 100mm gird spacing dimension.
The effective depths of tension side was 105.5mm for both axle and longitudinal
direction. For compression side, the amount of reinforcement was half of the tension
side, and the effective depths was 24.5mm for both axle and longitudinal direction.
Hereafter, the MG slab specimens are referred as MG-1 and MG-2.

(1) RC slab (2) MG slab

FIG. 2. Specimen size and reinforcement arrangement

Assembling of Specimens
The assembling procedure of RC slab specimen is shown in FIG 3.1. As shown
in FIG 2, the main tensile re-bars were placed alone the longitudinal direction with
100mm spacing in the RC slab specimen. Next for the axle direction, the spacing of
re-bars was 100mm that same as the longitudinal direction. Future, assembling the axle
and longitudinal re-bars together to form a grid shape by using the steel wire (FIG
3.1.1). Assembling of the compression re-bars is shown in FIG 3.1.2. The compression
re-bars had same assembled method as the tensile re-bars, but the re-bars spacing was
200mm in axle and longitudinal direction. Next, the tensile and compression re-bars
were assembled together inside the formwork as shown in FIG 3.1.3. This whole
assembling process took approximately 60 mins to complete. At the end, the concrete
was poured into the formwork.

Page 6
 
 The assembling procedure of MG slab specimen is shown in FIG 3.2. The steel
metal-grid at tensile side had 100mm grid spacing dimension that was same as the RC
slab tensile re-bars’ spacing. The steel metal-grid had 200mm grid spacing dimension
at compression side that was same as the compression re-bars’ spacing in RC slab. For
rust prevention, the steel metal-grid had coated the anti-rust inhibitor on the surface in
the factory and before shopping out. FIG 3.2.1 and 3.2.2 are shown the tensile and
compression steel metal grid, respectively. On the job site, the steel metal grid and
formwork had assembled together and shown in FIG 3.2.3. This assembling process
took approximately 30 mins to complete. At the end, the concrete was poured into the
formwork.
As above, the assembling procedure of MG slab specimens had shorter time as
the RC slab specimens. That means the rationalization construction and cost down
could be happening by using the steel metal-grid.

FIG. 3. Assembling procedure of RC and MG slab

EXPERIMENTAL METHODS AND EQUIVALENT NUMBER OF RUNNING

TIMES

Page 7
 
Outline of Test Equipment
For evaluating the fatigue durability of RC slab and MG slab specimens, the
wheel-running fatigue load test had been carried out by using the wheel-running
vibration fatigue test equipment. As used for this research, the equipment had consisted
of a hydraulic structural vibration fatigue device (500kN) equipped with steel wheel
(dimension is 450mm and width is 250mm), fastened to the beam of a steel reaction
force frame. A truck which the test specimen was placed was moved laterally back and
forth by a motor and crank arm to simulate the running of vehicle. PIC 2 shows the
wheel-running fatigue test unit.

PIC. 2. Wheel-running fatigue test unit

Wheel-Running Fatigue Load Test

The wheel-running fatigue load test was that placed a steel wheel at center of
the slab specimens and running constantly along the axle direction with 450mm range
(PIC 2). Additionally, the slab specimens had 1200mm span and 130mm thickness;
when the loading applied onto the slab specimens, the loading would be distributed 45
degree down from the applied point at top of specimens. Furthermore, during this
450mm running range, the bottom of slab specimens would receive the loading
between the span.
For the wheel-running fatigue load test, the loading started at 80kN for the first
20,000 running cycle times. Then, the loading would increase 20kN for every 20,000
running cycle times until the slab specimens failed. The strain and deflection would be
measured at center of slab specimens. The strain and deflection measurements would
be record at running cycle times of 1, 10, 100, 1,000, and 5,000. After the 5,000
running cycle times, the measurement would be record every 5,000 running cycle

Page 8
 
times. Therefore, the fatigue durability evaluation of MG slab specimens could be
evaluated from the equivalent number of running times.

Equivalent Number of Running Times

In this research, the wheel-running fatigue load test had increased the loading
for every 20,000 running cycle times until the specimen failed. For fatigue durability,
the equivalent number of running times Neq is calculated from the basic loading, the
every increased loading and the experimental running cycle times. The calculation
equation for the equivalent number of running times Neq is shown in EQUATION 1.
In the equation, the m is 12.7 taken form Dr. Matsui’s S-N curve (S.Matsui 2007).
Moreover, the basic loading P is 60KN ((100KN/2)1.2) that calculated from the
Standard Specifications for Highway Bridge by using half of the T-load (truck load;
100kN) and considered the safety ratio by adding 20% of the half T-load.

∑ ⁄ (1)

Where, Neq is equivalent number of running times (times), Pi is loading (KN),

P is basic loading (60KN), ni is the experimental running cycle times (times),
m is from Dr. Matsui’s S-N curve (=12.7).

EXPERIMENTAL RESULTS AND DISCUSSION

Equivalent Number of Running Times

By using EQUATION 1, the equivalent number of running times are calculated
in TABLE 4 for the RC slab and the MG slab specimens.

Table 4. Experimental and equivalent cycles

Loading Total No. of No. of equivalent
Specimen
80 kN 100 kN equivalent cycles cycle ratio
Experimental cycles 20,000 8,400
RC-1 6,092,884 ―
No. of equivalent cycles 772,240 5,320,643
Experimental cycles 20,000 6,214
MG-1 6,027,197 0.99
No. of equivalent cycles 772,240 5,254,956
Experimental cycles 20,000 12,614
MG-2 6,684,066 1.10
No. of equivalent cycles 772,240 5,911,826

Page 9
 
(1) RC Slab Specimen
The e1uivalent number of running times (Neq) for RC slab specimen RC-1 has
6.09106 running times. This result of Neq will be used as reference to compare and
evaluate the fatigue durability of the MG slab specimens.

(2) MG Slab Specimen

The e1uivalent number of running times (Neq) for MG slab specimen MG-1 has
6.02106 running times, and this Neq result is close to the RC-1. Moreover, the Neq
results of MG-2 has 6.68106 running times that is 1.1 times larger than the RC-1. The
average result of Neq for MG-1 and MG-2 has 6.35106 running times that comparing
with RC-1 is 1.04 time lager. This means that the fatigue durability of MG slab
specimens are similar as RC slab specimens, and MG slab specimen is applicable as
the new slab.
From the above results, the MG slab specimens has similar results as the RC
slab specimen. Therefore, instead of using re-bars, the steel metal-grid can be
considered as reinforcement material in the concrete slab system.

Failure Condition
At failure, the cracking pattern of the RC slab and MG slab specimens are
shown in FIG 4.

(1) RC-1 (2) MG-1 (3) MG-2

FIG. 4. Cracking pattern of the RC slab and MG slab

(1) RC Slab Specimen

FIG 4.1 is shown the failure condition of RC slab specimen. By applying
wheel-running fatigue loading, the cracks are developed along with the tensile re-bars
in axle and in longitudinal direction at the bottom of RC slab specimen. Moreover, the

Page 10
 
failure of RC slab specimen is punching shear failure, the tensile re-bars has dowel
effect, and the clearance part of concrete is peeled off at bottom.

(2) MG Slab Specimen

FIG 4.2 and 4.3 are shown the failure condition of MG slab specimens. The
cracks are developed along with the steel metal-grid in axle and in longitudinal
direction at the bottom of MG slab specimens. Moreover, the failure of MG slab
specimens are punching shear failure, has dowel effect as the RC slab specimen, and
had concrete peeled off at bottom.

CONCLUSIONS

The practical usage of the steel metal-grid in the RC slab of Highway Bridge
is been verified under the wheel-running fatigue loading in this paper. The
constructability and the fatigue resistance have been also verified. The conclusions are
summarized as follows:
1. By substituted the steel re-bars, the checkered steel plate or steel plate has
been cut directly by laser to form steel metal-grid in the factory. The grid
spacing dimension, necessary cross-section, protrusion on the surface for
adhesion, and bending shape can be customized according to the
construction needs. The steel metal-grid can also assembled at
construction site. Moreover, for rust prevention, the epoxy paint or
galvanized process can be applied on the steel metal-grid after assembling.
Therefore, the rust prevented steel metal-grid can be effective material
using in salt damage regions.
2. Manufacturing the steel metal-grids at factory have good constructability.
Moreover, for making the RC slab specimens, the re-bars assembling takes
2 people in 60 mins. For the steel metal-grid, the assembling time reduce
to 30 mins for 2 people. This means that the construction time can be
reduced by using the steel metal-grid. Therefore, the usage of steel metal-
grid has significant contribution on the rationalization and labor-saving in
the construction.
3. Comparing the results of RC slab and MG slab specimens, the equivalent
number of running times by using wheel-running fatigue load test are

Page 11
 
 similar. Therefore, the fatigue resistance of steel metal-grid use in RC slab
has been recognized, and the steel metal-grid can be practical used in RC
slab.

REFERENCES
K.Minakuchi, et al. (2015). “Evaluation of reinforcing effects and fatigue resistance by
RC slabs bottom surface thickness increase method using two kinds of metal grid.”
JCI Annual Convention, Vol.37, No.2, pp.379-384.
Japan Road Association. (2014). “Japanese Specifications for Highway Bridge”
S.Matsui. (2007). “Design of Highway Bridge slab ・ Construction and
Maintenance.” Morikita Publishing Co.,Itd.

Page 12