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Minimum Cost Design of One-Way TRC RC Composite Slabs
Minimum Cost Design of One-Way TRC RC Composite Slabs
I, ICTRC 165
ABSTRACT: The present study presents the outline and the results of an optimum (minimum
cost) design procedure for one-way RC slabs cast on top of prefabricated Textile Reinforced
Concrete (TRC) Stay-in-Place (SiP) formwork elements. The SiP element is considered to
participate to the load-bearing behaviour of the composite slab. Such slabs may be used as
superstructure systems for short and medium-span bridges and industrial or marine buildings
(for example, used transversely spanning between longitudinal girders). The procedure is
decomposed in two design states: a temporary and a permanent one. During the temporary
state the TRC element is designed to undertake construction loads, as well as the self-weight
of the fresh cast in-situ concrete. During the permanent state the design addresses the
behaviour of TRC/RC composite slab. Design equations conform largely to Eurocode 2.
Materials’ cost functions (for textiles, steel, formwork’s micro-concrete and cast in-situ
concrete) have been derived and are presented in the paper. The design variables vector
includes the geometry of the TRC formwork (different cross-sections are examined), the fibre
and steel reinforcement ratios, the fibre material for the textile reinforcement (grids
considered are of rovings’ orthogonal configuration) and the flexural strength of the micro-
concrete in the SiP formwork. The optimum determination of the design variables leads to the
minimum production cost of the composite slab, while fulfilling simultaneously: (i)
Serviceability Limit State (SLS) and Ultimate Limit State (ULS) design criteria (for both
design states); (ii) Geometric constraints based on construction rules and anthropometric data;
and (iii) General design rules (e.g. desirable mode of failure). Preliminary results indicate that
(the over-conservative) SLS governs the optimum design. Cap-shaped TRC formwork cross-
sections with micro-concretes of moderate tensile strength seem to be favoured.
1 INTRODUCTION
from the implementation of the presented optimization procedure are given, indicating the
critical design parameters.
For polymer-coated textiles coefficients kb and ks, are close to unity. Therefore, the maximum
tensile force taken up by the textile reinforcement is given by Equation 2.1.
Filaments’ failure strain εf,max is taken equal to 85% (depending on the material [Pap10]) of
the nominal failure strain of the fibrous material and is computed according to Equation 2.2.
f ft
ε f, max = C t (2-2)
Ef
The shear capacity of the TRC element is calculated following the proposed model by Vos06.
The main criterion for the selection of a design variable is the degree of its participation in the
total cost of the element. The global design variables can be classified into two categories:
– The first one includes the parameters that define the section geometry, namely the ratio of
the effective depth of the textile reinforcement (df – measuring from the reinforcement
layer level to the full height of the composite member) to the thickness of the TRC
element, t, and the ratio the effective depth of the textile reinforcement (dff – measuring
from the reinforcement layer level to the height of the TRC element) over t. Local
(geometrical) design parameters are assigned for each type of cross-section considered.
Fig. 3.1 illustrates some sections for use as a SiP TRC formwork element.
– The second category of design variables includes the flexural strength of the fine-grained
concrete and the reinforcement ratios (textile and steel).
In this design process the total cost of the element is the sum of four individual cost
components and is given by the following equation.
International RILEM Conference on Material Science – MATSCI, Aachen 2010 – Vol. I, ICTRC 169
⎡ A A ⎤
C = bd f ⎢C c c + C m m + C s γ s ρ s + C tex γ f ρ f ⎥ (3-1)
⎣ bd f bd f ⎦
where A s the steel reinforcement area, A f the textile reinforcement area parallel to the
length of the element, ℓ, and b the width of slab.
The cost of cast in-situ concrete of normal strength-class (up to C30/37) can be expressed as a
second order polynomial function of its compressive strength. Although the cost of fine-
grained concrete is assumed to be a function of mainly the ratios of polymers (if used) and
fine particles (cementitious or not) in the mix, in this study (and in sake of simplicity) it is
regarded as being dependent solely on the polymer content. Polymer–modified fine–grained
concrete mixes are opted in this work based on their favourable properties, such as improved
workability (self-levelling ability) at low plasticizer contents, reduced shrinkage potential and
enhanced bonding to the textile reinforcement and to other cement-based substrates. Thus, a
relation between the flexural strength of the fine-grained concrete and its cost can be
established. The cost functions for the fine-grained and in-situ concrete are given from
Equations 3.2 and 3.3 respectively. The derivation of equation 3.2 was based on polymer–
modified fine–grained concrete mixes obtained from a pertinent literature review [ASTM].
Equation 3.3 was derived from the current Greek ready-mix concrete market.
The cost of the textile reinforcement is dependent on a large number of parameters such as:
fibre material (e.g. carbon. glass, aramid, basalt), fibre treatment (sizing, fibre coating), textile
geometry (grid spacing, TEX, rovings’ stitching material and pattern, etc.). The derivation of
a cost function for the textile reinforcement that includes all the above-mentioned parameters
does not lie within the scope of the current study and is against the robustness of the
optimization process. Considering textile structures with orthogonal grid and the 2/3 of the
total fibre mass per square meter in the warp direction the cost relation between different
textile structures, in terms of materials, is given in Table 3.1.
170 PAPANTONIOU, PAPANICOLAOU: Minimum Cost Design of one-Way TRC/RC Composite Slabs
Table 3.1. Relative costs of 2D orthogonal textiles based on limited market data
Carbon AR-Glass Basalt
Relative 5.80*Ctex_ref Ctex_ref 2.20* Ctex_ref
where Ctex_ref Cost per unit weight of AR-Glass textile reinforcement (≈ 0.0192 €/gr).
3.3 Constraints
The mathematical constraints are posed by the demand that all calculated values derived from
the Ultimate Limit State and Serviceability Limit State analyses are lower than or equal to the
ones that cause failure, or are unacceptable in terms of users’ comfort. Geometric-specific
constraints are also imposed on individual cross-sections due to anthropometric restrictions
(that take into account the on-site constructability and site safety).
⎡d d A A ⎤
X opt = ⎢ f , ff , α, c, f , s , f t ⎥ (4-1)
⎣ t t bt bt ⎦
Section 1 Section 2
α α
c c
Fig. 4.1. Cross sections under examination: Closed (Section 1) and Open (Section2).
The thickness of the TRC element was assumed to be equal to 25 mm (to avoid premature
failure due to accidental actions, e.g. impact) and the width of the slab equal to 1.0 m. In the
present study cracking of the TRC element in the TS was not allowable and a single-span
structural system was considered. Analysis was carried out for one-way slabs with a span
equal to 2.5, 3.0, 3.5 and 4.0 m and for live loads equal to 2.5, 5.0 and 7.5 kN/m2. Also, a
dead load of 2.0 kN/m2 was considered. Material safety factors for concrete and steel were
taken into account according to Eurocode 2. The compressive strength of concrete and the
yield stress of steel were taken equal to 20 MPa and 500 MPa, respectively. Polymer-based
coated textile structures made of carbon, AR-glass and basalt were considered. Coefficients kb
and ks were taken equal to 0.90 and 1.0, respectively. Finally, full composite behaviour of the
slabs was assumed (i.e. interfacial shear slippage was taken equal to zero).
All results presented in this section are the product of the optimization procedure applied for a
given set of conditions, namely span, fibrous material and live load. In Fig. 4.2 the effective
depth of the textile reinforcement in the composite slab for different spans and load levels is
presented. The span to effective depth ratios for the composite slab and the formwork element
in different live load levels are presented in Fig. 4.3. Fig. 4.4 presents the shape of the AR-
Glass-TRC cross section and the effective depth for different spans and a live load equal to
5.0 kN/m2. In Table 4.1 the minimum production cost per running meter of the slab, for the
three types of textiles and for a live load equal to 5.0 kN/m2 is presented. For the same
analysis parameters the textile and steel reinforcement ratios which lead to the minimum cost
solutions are presented in Table 4.2. The respective optimum flexural strength of the
cementitious mortar is presented in Table 4.3.
172 PAPANTONIOU, PAPANICOLAOU: Minimum Cost Design of one-Way TRC/RC Composite Slabs
220 220
Carbon Carbon
Q=7.5
45 45
Closed Section Carbon Open Section Carbon
AR-Glass AR-Glass
Basalt Basalt
40
ℓ/dff
40 ℓ/dff
35 35
25 25
ℓ/df Composite Slab ℓ/df Composite Slab
20 20
15 15
2 3 4 5 6 7 8 2 3 4 5 6 7 8
2 2
Live Load (kN/m ) Live Load (kN/m )
Fig. 4.3. Ratio of span to effective depth of textile reinforcement for the composite slab and the
TRC formwork element.
International RILEM Conference on Material Science – MATSCI, Aachen 2010 – Vol. I, ICTRC 173
140 140
Closed Section Open Section
Effective Depth of Textile Reinforcement dff (mm)
130 130
Htot=200 mm,α=225 mm,c=300 mm,C=47.9 €/m Htot=196 mm,α=230 mm,c=337 mm,C=41.6 €/m
120 120
110 110
Htot=181 mm,α=319 mm, c=300 mm,C=43.6 €/m
100 100
Htot=176 mm,α=224 mm,c=350 mm,C=41.8 €/m
90 90
70 70
Htot= 138 mm,α =75 mm,c=300 mm,C=37.4 €/m
Htot=138 mm,α=160 mm,c=350 mm,C=33.7 €/m
60 60
2500 3000 3500 4000 2500 3000 3500 4000
Span (mm) Span (mm)
Fig. 4.4. Effective depth and cross section of formwork element as obtained by the optimization
procedure for Q = 5.0 kN/m2 and AR-glass textile reinforcement.
Table 4.1. Minimum production cost per running meter of slab for Closed and Open Sections (Live
load = 5.0 kN/m2)
Span Closed Section Open Section
Carbon AR-Glass Basalt Carbon AR-Glass Basalt
(mm) €/m €/m €/m €/m €/m €/m
2500 75.1 37.4 54.4 57.0 33.7 47.9
3000 77.2 40.3 57.1 74.7 36.8 54.7
3500 84.5 43.6 59.2 72.9 41.8 63.8
4000 82.3 49.9 66.4 76.6 41.6 68.2
Table 4.2. Optimum steel and textile reinforcement ratios (Live load = 5.0 kN/m2)
Span Closed Section Open Section
Carbon AR-Glass Basalt Carbon AR-Glass Basalt
1
ρs ρf ρs ρf ρs ρf ρs ρf ρs ρf ρs ρf
(mm) ‰ ‰ ‰ ‰ ‰ ‰ ‰ ‰ ‰ ‰ ‰ ‰
2500 1.60 1.80 1.60 1.70 1.60 1.80 1.60 1.30 1.60 1.80 1.60 1.60
3000 1.50 1.50 1.40 1.40 1.40 1.40 1.50 1.70 1.40 1.70 1.50 1.80
3500 1.30 1.60 1.20 1.40 1.20 1.40 1.30 1.30 1.20 1.30 1.20 1.30
4000 1.10 1.20 1.30 1.00 1.10 1.30 1.30 1.10 1.20 1.00 1.40 1.50
1 ρf=Af/bdf, ρs=As/bdf
174 PAPANTONIOU, PAPANICOLAOU: Minimum Cost Design of one-Way TRC/RC Composite Slabs
Table 4.3. Optimum flexural strength of the cementitious mortar (Live load = 5.0 kN/m2)
Span Closed Section Open Section
Carbon AR-Glass Basalt Carbon AR-Glass Basalt
(mm) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa)
2500 5.5 5.5 5.5 5.5 5.6 5.6
3000 5.8 6.3 6.5 6.8 7.2 7.2
3500 6.5 6.7 6.7 7.7 7.0 7.3
4000 6.8 6.5 7.1 8.0 7.3 7.9
4.2 Discussion
The derived results indicate that for the specific set of conditions examined:
• For spans higher than 3.0 m and for all load levels considered the total deflection
(deflection at TS + deflection at PS), was the critical performance criterion, which
determined the effective depth of the textile reinforcement not only for the composite slab
but also for the TRC element.
• Another decisive design constraint, which determined mainly the height of the TRC
element, was the demand for the minimum in-situ concrete topping thickness (at least 50
mm of concrete between the top flange of the TRC element and the top surface of the
composite slab so that smooth load distribution and avoidance of stress concentration
phenomena is ensured).
• Open TRC formwork sections lead to lower production costs compared to closed ones.
• Formwork elements of Open section profiles comprising AR-glass textile reinforcement
lead to an overall minimum cost solution.
• The use of AR-glass textile reinforcement leads to the deepest TRC cross sections, in
comparison to other types of textile materials, regardless of the section type selected (i.e.
Closed or Open).
• Larger spans are accommodated through higher flexural strength of the cementitious
mortar in the TRC.
5 CONCLUSIONS
This study presented the outline of an optimization (minimum cost) procedure for one-way
RC slabs cast on top of prefabricated Textile Reinforced Concrete (TRC) Stay-in-Place (SiP)
formwork elements. The design for all sets of conditions examined in this work (spans, loads
and textile materials) was proved to be deflection-controlled. Sensitivity analysis (dependent
on different cost functions or propping existence) has to be conducted in order to determine
which design parameters or performance criteria are of crucial importance for the design
procedure. Future work should be focused on the experimental investigation of the degree of
composite behavior of TRC/RC composite slabs (using different types of shear connectors)
and the supplementation of the optimization procedure with durability criteria and long-term
mechanical behaviour constraints.
International RILEM Conference on Material Science – MATSCI, Aachen 2010 – Vol. I, ICTRC 175
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