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State of the Arts of Hybrid structures consisting of steel and concrete in Japan

Kazuo OHGAKI * Dr. Engineer, Kawasaki Heavy Industries, Ltd., Tokyo, Japan; ohgaki_kazuo@khi.co.jp

Abstract Hybrid structures consisting of steel and concrete have been adopted for the construction of various structures. The composite construction in Japan has not only been adopted for the roadway bridges but also been adopted for various structures such as the foundation, the vessel, the harbor structure and so on. This reason is an economic advantage of them. Furthermore, hybrid structures consisting of CFT has been studied recently. This structural type is now increasing for the pursuit of the economy, rationalization of structures and efficiency of construction now. In this paper, the present state of hybrid structures consisting of steel and concrete in Japan is introduced, and particularly the joint system in each structure is focused on. Keywords: Hybrid structure, Shear connector, CFT girder

1. Introduction The composite construction in Japan has not only been adopted for the roadway bridges but also has been adopted for various structures such as the foundation, the vessel, and the harbor structure, etc. This reason is an economic advantage obtained from its lightness compared to the concrete structure. Therefore, it is said that these composite structures are rational ones under earthquake attack. Another reason is that the composite structures are more advantageous than steel structure from a viewpoint of economic. Around a half of the contents of this paper consists of the citation from the report of the committee of "Recent Progress of Hybrid Structures set up by Committee on Hybrid Structures of JSCE. Primarily I show composite structures, in which there are two plate girder bridges that has wide span pre-stressed concrete slab, and PC box girder bridges with the steel corrugated web. A characteristic part explained is joint systems between the corrugated steel web and the concrete slab for these composite bridges. Next I explain, as an application example, the PC hybrid truss bridge consisting of the steel pipes used for the web member. Moreover, as the joint system between concrete slab and steel pipe, the system consisting of the double tube is explained.

The investigation result of each structural type for the joint systems between steel and concrete slab are shown in this paper. This investigation includes the shear connectors being used for various kinds of composite structure. Finally, the steel deck plate girder with CFT for the lower flanges is shown as an example. The limit state design method was applied to this bridge. These are presented in this paper. . 2. Recent hybrid structures and joint systems 2.1 Composite two girder bridge The target is squeezed to the roadway bridges where the hybrid structures were developed, and preferably being used in Japan. The trend is described about the construction case for the recent hybrid structures and the joint systems between steel and concrete. In the roadway bridges, there are a lot of cases that the hybrid structures are adopted, especially in the expressway, and the one that steel and concrete were combined in a structural cross section is called a composite structure, and on the other hand, the one that steel and concrete were combined in a structural member is called a mixed structures, and generally these are called hybrid structures. The most general hybrid structure in the

2 expressway bridge is a two plate girder bridge that has wide span (6-11m) in the concrete slab. For the composite plate girder bridges, in the latter half of 1990's, the steel rational plate girder bridges come to be adopted as a standard structural form of the steel bridges by rationalizing construction and so on. For the concrete slabs, PC slabs are adopted with the increase of the span of the concrete slabs, and for the durability of the concrete slabs. In this kind of bridge, the headed stud has been adopted for the connection between steel and concrete, and the composite action is generally expected under the live load. The examples are shown in Figure1 and Figure2. Figure1 indicates the case of 6m in span length of concrete slab, and Figure2 indicates the case of 11m in span length of concrete slab. the first time in 1999 in Japan, and around 100 bridges have been constructed so far. The construction cases of this type bridge are shown in Figure 4 and Figure 5.

Concrete upper slab

Inner PC cable

Corrugated steel web Deviator

Corrugated steel web Outer PC cable Inner PC cable

Concrete lower slab

Figure 3. Structure of PC box girder with corrugate steel web

Figure 1. OTSURO River Bridge (Slab span length 6m)

Figure 4. KOKAWAUCHI River Bridge

Figure 2. WARASHINA River Bridge (Slab span length 11m) 2.2 PC box girder bridges with the corrugated steel web The technology of PC box girder bridges with the corrugated steel web shown in Figure3 was introduced from France, and it was adopted in the expressway for

Figure 5. TOYOTA C-Ramp Bridge

3 2.3 Extradosed PC box girder bridge In recent years, application has been extended to Extradosed PC box girder bridge and cable-stayed PC bridge that especially used the corrugated steel for the web, and it leads to the span extension by lightening of the superstructures. The typical cases are shown in Figure 6 and Figure 7.
Reinforcement Hole for reinforcement

Corrugated Corrugated steel web

steel web

Penetrated reinforcement Penetrated reinforcement

(a) Direct embedding in concrete

U-formed reinforcement
U-formed reinforcement

Penetrated reinforcement

Flange Flange plate

Angle Angle

Figure 6. HIMI-YUME Bridge

Corrugated steel web

(b) Angles welded to the flange plate

Perforated steel plate

Perforated

steel

Penetrated

Penetrated hole

Penetrated Penetrated reinforcement

reinforcemen Flangeplate Flange rlate

Corrugated steel web Corrugated steel web

(c) Twin perforated steel plate

Flask formed perforated steel plate

Figure 7. OMI-OTORI Bridge

Penetrated Penetrated reinforcement

reinforcement

2.4 Joint systems between the corrugated steel web and the concrete slab A characteristic part is a joint system between the corrugated steel web and the concrete slab for these composite bridges. In this structure, it is necessary to transfer the shear force acting at the interface between the corrugated steel and the concrete slab. Therefore the joint system between the corrugated steel and the concrete slab is basically important to attain the complete composite performance for this structure. In the first stage into which the technology of the bridge structure to

Headed Headed stud

stud

(d) Flask formed perforated steel plate and headed stud

Figure 8. The type of joint system of the composite PC box girder bridge with the corrugated steel web

4 use the corrugated steel web was introduced from France, the headed stud was used for the joint system between the corrugated steel web and the concrete slab. In the expressway bridge in Japan, the horizontal shear force acting on the interface between the corrugated steel and the concrete slab in the longitudinal direction of the bridge is large, and also the influence of fatigue by the wheel load increases. Therefore, the joint systems shown in Figure8 have been employed recently. As a result of these examinations, the perforated-bond plate of flask type was developed in the lower slab. In recent years, the twin perforated-bond plate has been adopted for the upper slab, otherwise the directly embedding system is adopted for the lower slab pursuing further economy. 2.5 PC hybrid truss bridge Next, PC hybrid truss bridge developed is introduced. This type of bridge is shown in Figure 9 and Figure 10. 2.6 Joint systems between the steel pipe and the concrete slab These bridges are adopted for the continuous rigid frame type structure for the first time in the world, and the maximum span length is 119m, and the bridge scale is the world's largest as the PC hybrid truss bridge. The steel pipe is used for the web truss member, and lightening is attempted. Moreover, as the joint systems between concrete slab and steel pipe, the joint system consisting of the double tube and that consisting of twin gusset shown in Figure11 and Figure12 were developed.

Holed steel pipe with rib

Steel pipe with rib

Connection plate

Steel pipe

Figure 11. Joint system consist of the double tube

Gusset plate

Figure 9. Outside view of hybrid truss bridge (SARUTA River Bridge)

Steel truss member

Penetrated reinforcement and Perforated steel plate

Figure 12. Joint system consist of twin gusset

Figure 10. Inner view of hybrid truss bridge (TOMOE River Bridge)

The joint system using the double tube is composed of the steel pipe with rib on the outside surface, the holed steel pipe with rib on the inside and outside surface which is arranged on that outside, and the steel plate that is connected with that both outside steel pipes. On the other hand, the joint system having two gussets structurally leads to a big joint system because the gusset plate is so big. Two friction joint systems with the high

5 tension bolts were used for connection systems between truss members and the upper chord slabs. By this system, the height of gusset plates was reduced, resulting in the decrease of the number of the bolt. The gusset part was arranged in a concrete beam with a combination of shear mechanisms such as PBL. In this bridge, two gusset systems was adopted in the joint part where the high axial force for the truss member is subjected, and the double tube joint system is adopted in other joint parts. the block dowel (Section steel shear connector) is adopted in the railway bridges. There are various joint systems for the composite slab, because these slabs were developed in each company.
0 .Cost performance .Constructability .Seismic performance 46 46 56 36 29 17 68 10 20 30 40 50 60 70 80 90 91 100

3. Investigation result of hybrid structures This investigation for establishing the design technique was carried out by Subcommittee on the Recent Progress of Hybrid Structures in JSCE. The questionnaire survey was requested from the subcommittee to the engineer or the designer of these hybrid structures. With respect to the content of the questionnaire, it was an outline of the structure, merits of adoption of the hybrid structures, a design method and so on. In addition, the opinion of a structural problem and the performance-based design method being advanced in JSCE was expressed. The classification of the investigated each structural form is shown in Table1. In this investigation, the number of the hybrid rigid frame type bridge, the composite plate girder bridge (The PC box girder bridge using corrugated steel web is included) and the composite slab bridges is comparatively large. In these investigations, the merits of the adopted hybrid structures are shown in Figure13. The reason for a lot of merits that are given from Figure13 is the economy. The resistance of the earthquake increases by improvement of the structure. Furthermore, a construction period of these hybrid structures can be shortened. The investigation result of each structural type for the joint systems between steel and concrete slab are shown in Figure14. Various joint systems in various structures were adopted. This reason is the one basically adopted in consideration of a structural characteristic, construction, and the economy, etc. In the composite plate girder bridge, it is understood that the headed stud is generally used. The perforated-bond plate is preferably used to PC box girder bridges using the corrugated steel web Table 1. The investigated each structural form
Classification
Composite girder bridge (corrugated steel web bridge ) Composite slab bridge Hybrid structure(truss bridge , arch bridge) Hybrid structure(cable stayed bridge) Mixed structure, Steel reinforced concrete girder Hybrid structure(rigid ramen bridge) Fiber reinforced plastics girder , Steel stiffened timber bridge Others

.Lightness .Shortening .Maintenance .Sosio economic impact .Others

Figure 13. Merits of hybrid structures

10

15 15

20

Headed studs Perforated-bond plate Block dowel Bond, Friction Others

1 2 5 8

(a)Composite plate girder bridge (PC box girder bridge using corrugated steel web is included)
0 5 7 3 5 4 6 10 15 20

Headed studs Perforated-bond plate Block dowel Bond, Friction Others

(b)Composite slab bridge

0 5 10 9 11 1 3 8 15 20

Headed studs Perforated-bond plate Block dowel Bond, Friction Others

included in the composite plate girder bridge. Moreover,

(c)Hybrid structure(rigid ramen bridge) Figure 14. Joint system of each hybrid structures

6 4. CFT girder bridge 4.1 Structural summary The CFT girder bridge developed by Kawasaki Heavy Industries is the new type of composite structure. CFT is used for the lower flange of the steel deck plate girder bridge, as can be seen in Figure15. CFT is a concrete filled steel tube and has superior plastic deformation properties in a compression stress state. Hence, we used CFT for a lower flange subjected to compressive force. The stiffness of the main girder increases and a long span construction can be attained compared to the normal plate girder. 4.2 The comparison with the conventional bridge form I assumed the 3-span continuous girder bridge with a span length 100+125+100m to examine the economy of this bridge. Three types of structures designed are a steel deck plate box girder bridge, composite truss bridge and steel deck plate girder bridge with CFT. These designed bridges for comparison are shown in Figure16. A comparison result with respect to steel weight, deadweight and the number of steel plates is given in Table2. The steel deck plate girder bridge with CFT has smaller steel weight and the number of steel plates compared to those of steel deck plate box girder bridges, and it will give an advantage in economy. 4.3 The design method of main girder The limit state design method was applied to the design of the steel deck plate girder bridge with CFT. In the limit state, it was defined that CFT member reaches plasticity as shown in Figure17. With respect to the ultimate strength of this newly developed bridge system, it has been confirmed by an experiment.

Steel deck plate

CFT Steel tube Concrete

Table 2. The comparison with the conventional bridge

Item Steel weight deadweight number of steel plates Steel deck plate box girder bridge 1,650tf 2,700tf most composite truss bridge 1,250tf 5,100tf many CFT girder bridge 1,500tf 2,900tf few

Figure 15.

The CFT girder bridge

(a) Steel deck plate box girder bridge

(b) Composite truss bridge

CFT

CFT

(c) Steel deck plate box girder bridge with CFT Figure 16. Compared design bridges

7 4.4 An application example to Kobe new transportation system The CFT girder bridge shown in Figure18 was designed for the construction for the second stage of the Kobe new transportation Port Island Line. On the occasion of construction, the wind-resistant stability was examined by the wind tunnel test, the concrete filling performance was examined and confirmed and the inspection method of the filling degree confirmation system by infrared photography was established. 5. Concluding remarks Examples of steel-concrete composite structures were introduced. The continuous composite two girder bridges, the PC box girder bridges with the corrugated steel web, the extradosed PC box girder bridges and PC hybrid truss bridge were shown as construction example of hybrid structures. Furthermore, I explained the joint systems between the steel members and the concrete slabs. In addition, the investigated result on shear connectors that have been adopted for various composite structures were shown. The shear connector design document of various composite structures was also offered. Finally, I introduced an application example of the CFT girder bridge. The result of comparative design, the application of limit state design method to the main girder and the adoption of this type of bridge for Kobe new transportation system were introduced.

steel deck plate

t

Tension

web plate plastic CFT Full plastic

c y

Compression Using limit state Ultimate limit state

6. Acknowledgment The first half of this paper is from the result obtained in The Present Conditions Investigation Subcommittee of The Hybrid Structure Committee of Japan Society of Civil Engineering. I thank these cooperators very much.

Figure17. The design method of main girder

CFT

CFT

(a)side view

References JSCE Subcommittee on the Recent Progress of Hybrid Structures; (2008). Survey and Analysis on the Current Situation of Hybrid Structures(Toward the Advance of Performance-Based Design Method of Hybrid Structures), Hybrid Structures Reports 02 Uehira K., Ito S. (2008). Recent Progress of HybridStructures and Its Design Methods in Japan, EASEC-11, Building a Sustainable Environment, Taipei, TAIWAN Kawasaki Technical Review; (2005). New Style Bridge: First Steel Deck CFT Girder Bridge in Japan, No.157, pp.10-15.

(b)photograph Figure18. The CFT girder bridge in Kobe new transportation system