IIE Annual Conference Presentation

IIE Annual Conference, Parramatta, 30 November 2012 1
AS/NZS 5100.6 the New Joint Bridge Design Standard on

Steel and Composite Construction

Dr Stephen Hicks
New Zealand Heavy Engineering Research Association (HERA),
General Manager Structural Systems
Forms of construction for highway bridges
Span Ranges for highway bridges
Bridge Form Span
10m 20m 20m 50m 50m-100m 100m-300m 300m +
RC slab
Precast prestressed
beams
Up to 35m
Prestressed
concrete box

Composite plate
girders
From 15m Up to 90m
Composite box
girders
Up to 150m

Steel box girders
Tied arch bridges
Cable supported
bridges

Composite plate
girders
From 15m Up to 90m
Medium-span Composite Bridges: Multi-girder
Bridges

Images courtesy of Eastbridge
Medium-span Composite Bridges: Ladder Deck
Bridges

Images courtesy of Eastbridge
AS 5100 Bridge Design series and the proposed joint AS/NZS
5100.6 for steel and composite construction
AS 5100 revision
Standards Australia project with a duration of 3-years
Project kick-off November 2010
Initial scope of project:
General reviewing and updating all Parts.
Updating Part 2 to be aligned to AS 1170.4 (earthquake actions in Australia)
Updating Part 4 to address new bearing and expansion joint materials.
Updating Part 5 in line with changes to AS 3600.
Following acceptance of proposals submitted to Standards Australia in
February 2012, two new parts are being developed in parallel with the revision
of existing AS5100
From NZ stakeholder consultation that included the Steel Bridge Development
Group, in the interests of Closer Economic Relations (CER) between New
Zealand and Australia, confirmation from Standards New Zealand to revise
Part 6 as a joint AS/NZ Standard
AS/NZS 5100.6
Kick-off meeting March 2011
Draft for Public Comment document expected early 2013
Proposed suite of AS5100 parts
Standard Committee
responsible
Description
AS 5100.1 to .9 BD-090 Bridge Design
AS 5100.1 BD-090-01 Scope and General Principles
AS 5100.2 BD-090-02 Design Loads
AS 5100.3 BD-090-03 Foundations (DPC ended 5 March 2012)
AS 5100.4 BD-090-04 Bearings and Deck Joints
AS 5100.5 BD-090-05 Concrete
AS/NZS 5100.6 BD-090-06 Steel and Composite Construction
AS 5100.7 BD-090-07 Rating
AS 5100.8 BD-090-08 Rehabilitation
AS 5100.9 BD-090-09 Timber Bridges
Scope and Application
Sets out minimum requirements for design of structural steelwork in
bridges (wrought and cast iron structures may be checked in
accordance with this Standard using appropriate capacity reduction
factors)
Standard applies to the design of other steel components of bridges
including steel piers, steel railings and sign structures.
Does not cover the following structures, members and materials:
Bridges with orthotropic plate decks.
Cold-formed members other than those complying with AS/NZS 1163.
Steel members for which the value of yield stress f
y
used in design exceeds
690 MPa (previously 450 MPa).
Steel elements, other than packers, less than 3 mm thick.
Aligns with AS 5100.5 and is applicable to the following characteristic
compressive strengths for concrete: 20 MPa, 25 MPa, 32 MPa,
40 MPa, 50 MPa, 65 MPa, 80 MPa and 100 MPa.
p
f
10
-
Basis of Load and Strength capacity reduction
factors

Normal distribution usually taken
Characteristic value
Mean value if variability small
Upper value (normally 95% fractile) if variability
is not small
Design value based on probability of failure
Log-normal distribution usually taken
(resistance doesnt have negative values)
Characteristic (or nominal) value for resistance
based on lower value (5% fractile)
Design value based on probability of failure.
For large sample of data and a normal
distribution
5% fractile = 1.64
R

Design value = 0.8 x 3.8
R
= 3.04
R
( 1 in 845 =
0.12% probability of observing lower value)
Loads Material and product properties
S
S
k
S
d
o
S

S
R
R
d
R
k
-o
R

R
FORM sensitivity factors for
actions o
S
and resistance o
R
from
AS 5104 (ISO2394)
|=1/
R
S
R
k
/ R
d
=
R
= 1/|
p
f
10
-6
10
-5
10
-4
10
-3
10
-2
10
-1
|
4.75 4.27 3.72 3.09 2.32 1.28
p
f
= 7.210
-5
|=3.8 (typically used for ULS considerations).
ULS SLS
Headed stud connectors
Reinforcememt:
Ribbed bars 10 mm
resulting in a high bond
with 450 f 500 N/mm
Steel section:
HE 260 B or
254 x 254 x 89 UC
Cover 15
150 260 150
150
250
250
35
150
150
150
100
35
200 200 200
180 180 180
100
P
30 recess
optional
Bedded in mortar or gypsum
s
sk
s
600
P
Rk
L
o
a
d

p
e
r

s
t
u
d

P

(
k
N
)
Slip (mm) o
o
u
o
uk
= 6 mm
Standard Push Test
EN 1994-1-1 &
EN 1994-2 (Eurocode 4)
AS 5100.6 &
AS 2327.1
ANSI/AISC 360-10
c
1
c
2
0,80
0,37o
0,63
0,31
1,00
0,50
where c
1
and c
2
are calibration factors based on the analysis of test
results, A
sc
is the cross-sectional area of the shank of the stud and f
u
is the
ultimate tensile strength of the shear connector material, f
ck
is the
characteristic compressive concrete strength and E
cm
is the secant
modulus of elasticity of the concrete.

Resistance of Headed Stud Connectors
failure] [stud
1 u sc Rd
f A c P | =
failure] [concrete f
ck 2 cm sc Rd
E A c P | =
4 for 00 . 1 for ; 4 3 for 1 2 . 0 > = s s |
.
|
\
|
+ =
d
h
d
h
d
h
sc sc sc
o o
In the development of Eurocode 4, the two key studies that
considered the performance of the equations for stud
resistance were undertaken by Roik et al. (1989) and later by
Stark & van Hove (1991)
By removing suspect push test data, the Eurocode 4
equations are based on reliability analyses of 75 results, which
demonstrated that | = 0.8 appropriate for studs embedded in
solid concrete slabs or encasement with f'
c
35MPa.
The present HERA study was undertaken:
to harmonize the Australian and NZ equations for stud resistance; and
to provide alignment with AS 5100.5 and AS 3600 and include equations that
were valid for f'
c
100 MPa.
The present study expanded the sample size in this
investigation to include 113 results from a variety of
international sources
Motive for HERA Study
The data that is considered is the correction factor:

where r
ei
is the experimental resistance for specimen i and r
ti
is
the theoretical resistance predicted from the design model using
a set of mean measured basic variables that are included in a
report from a laboratory test on specimen i.

Comparison of experimental data with theoretical
model
ti ei i
r r b =
b
i
vs. stud height to diameter ratio for concrete
failure according to EC4
4 for 00 . 1
4 3 for 1 2 . 0
> =
s s |
.
|
\
|
+ =
d
h
d
h
d
h
sc
sc sc
o
o
Source: Hicks, S. & Jones, A.: Statistical evaluation of the design resistance of headed
stud connectors embedded in solid concrete slabs, SEI, IABSE, (in publication)
For the design fractile factor k
d,n

as n , k
d,
= o
R
| = 3,04
For the characteristic fractile factor k
n

as n , k
n,
= 1,64

If log-normal distribution is taken (which is desirable as it falls to zero at
the origin, so there are no negative resistances)

where o
rt
and is the weighting factor for Q
rt
, Q
rt
is a coefficient for variation
of the variables in the resistance function, o
o
is the weighting factor for Q
o
,
Q
o
is a coefficient for variation of the error term o and Q is a coefficient for
variation of the resistance.

Corrected partial factor

where r
n
is the nominal resistance evaluated from the theoretical
resistance equation using nominal values for the basic variables and k
c
=
r
n
/ r
k

( ) ( )
2
5 , 0 exp Q Q k Q k X bg r
n rt rt m rt k
=
o o
o o
( ) ( )
2
, ,
5 , 0 exp Q Q k Q k X bg r
n d rt rt d m rt d
=
o o
o o
Evaluation of partial safety factor
M
d
k
c M c M
r
r
k k = =
*
Coefficient of
variation
Eurocode 4 AS2327.1 & AS
5100.6
NZS 3404.1
V
d
= 0,4/(1,64 d
m
) = 0,34/(1,64 d
m
)
V
fc
= 8/(1,64 f
cm
)

= 10.9% = 10.4%
V
Ec
= 14.65% = 12.25%

-
V
fu
= 4%
2 2 2
16
2
1
Ec fc d rt
V V V V + + =
2 2
4
d fu rt
V V V + =
( ) | |
( )

= =
|
|
.
|
\
|
c
c
=
|
|
.
|
\
|
c
c
~ =
j
i
j
i m rt
i
i
rt
i
i
rt
m rt m rt
rt
rt
X g X
g
X
g
X g X g
X g VAR
V
1 1
2 2
2 2
2
) ( ) (
1 o
o
Coefficients of variation for the basic variables
Performance of current international standards

Eurocode 4
AS 2327.1 and
AS 5100.6
NZS 3404.1 ANSI / AISC 360-10
Stud Concrete Stud Concrete Stud Concrete Stud Concrete
n 53 55 53 55 45 63 94 14
r
e
175,21 110,81 175,21 110,81 178,93 116,34 148,18 103,73
r
t
134,06 88,54 134,42 94,65 137,26 104,78 118,40 105,35
0,882 0,798 0,882 0,798 0,847 0,777 0,804 0,696
b 1,31 1,23 1,31 1,15 1,31 1,10 1,26 0,973
V
rt
4,66% 11,54% 4,48% 8,49% 4,49% 6,94% 4,51% 8,20%
V
12,41% 13,33% 12,41% 13,33% 14,53% 13,70% 18,47% 14,07%

V
r
13,26% 17,63% 13,20% 15,80% 15,21% 15,36% 19,01% 16,28%
*
M
1,15 1,28 1,15 1,28 1,19 1,41 1,27 1,33
Recommended design equations and limits to the
basic variables
Eurocode 4
AS2327.1 and
AS5100.6
NZS 3404.1 ANSI / AISC 360-10
Eq. (1)
c
1
= 0,88
V
= 1,25
c
1
= 0,87
V
= 1,24
c
1
= 0,87
V
= 1,24
c
1
= 1,33R
g
R
p
V
= 1,25
Eq. (2)
c
2
= 0,36
V
= 1,24
c
2
= 0,38
V
= 1,24
c
2
= 0,38
V
= 1,23
c
2
= 0,41
V
= 1,25
f
ck

12 MPa f
ck
80
MPa
16 MPa f
ck
80 MPa 16 MPa f
ck
80 MPa
E
40 MPa
> 40 Mpa
f
u
f
u
500 MPa f
u
500 MPa f
u
450 MPa
3 . 0
10
22 |
.
|
\
|
=
cm
cm
f
E
cm cm
f E 043 , 0
5 . 1
=
12 . 0 024 , 0
5 . 1
+ =
cm cm
f E
ck ck
f E 043 , 0
5 . 1
=
V
u
Rd
d f
c P
t 4
2
1
=
V
ck
Rd
E f d
c P
t 4
2
2
=
(1) (2)
The following recommended design equations are appropriate for concrete with a
density not less than 2200 kg/m, an overall nominal height for the stud of 65 mm
h
sc
95 mm and a shank diameter of 16 mm d 25 mm:
Combined shear and tension
Where headed stud connectors are subject
to both tension and shear the following
rules apply:
if N*
u
0.1|f
ks
, the tensile force may be neglected;
if N*
u
> 0.1|f
ks
the following interaction between the design
shear and design tension shall be satisfied.
0 . 1
85 . 0
3
5
* 3
5
*
s
(
+
(
ks
L
ks
u
f
V
f
N
| |
Horizontally lying studs examples
Failure modes due to stud position
Detailing & Design Equations for horizontally lying
studs
Steel types that comply with AS/NZS 5100.6
Australia/New Zealand
AS/NZS 1163 Hollow sections 250 MPa < f
y
450 MPa
AS/NZS 1594 Plate, strip, sheet floorplate 170 MPa < f
y
380 MPa
AS/NZS 3678 Plate and floorplate 200 MPa < f
y
450 MPa
Includes weathering steel AS/NZS 3678-WR350 f
y
= 340 MPa for t 50mm
AS/NZS 3679.1 Flats and sections 280 MPa < f
y
360 MPa
AS/NZS 3679.2 Welded sections 280 MPa < f
y
340 MPa
AS 3597 Plate 500 MPa < f
y
690 MPa

Overseas Steels
Due to successfully using overseas structural steels over the
last 35-years, coupled with an existing market share of 50% for
steel in construction, it was required by New Zealand
designers that the overseas steel currently permitted by NZS
3404.1 should be supported in AS/NZS 5100.6.
Concern was expressed that the use of overseas steels may
be causing an erosion of safety margins required by AS/NZS
1170.0.
In response to these concerns, a structural reliability
investigation was undertaken between UWS and HERA to
evaluate appropriate capacity factors for structural steel
conforming with:
EN 10025-1 to EN 10025-6 275 MPa < f
y
690 MPa
JIS G 3106, JIS G 3114 and JIS G 3136 245 MPa < f
y
460 MPa

Structural reliability analyses of beams in bending by UWS
and HERA
Analyses on beam tests that
have compact, not-compact
and non-compact cross-
sections show:
capacity factor of 0.90 given in AS
4100 and AS 5100.6 for beams in
bending are on the conservative side
for EN and JIS manufacturing
Standards.
Design practice that has been
adopted in NZS 3404.1 for the last
35-years is supported.
Proposed to introduce
overseas steels appendix in
AS/NZS 5100.6 with minimum
standards of workmanship
that are required to ensure
that the design assumptions
are valid

Parameter EN10034: 1993 JIS G 3192
AS 5100.6
AS/NZS 1365
Depth (h)
(mm)
h180
180<h400
400<h700
h>700
-2
-2
-3
-5
h<400
400h600
h600
-2
-3
-4
-h/50
Width (b)
(mm)
b 110
110<b210
210<b325
b>325
-1
-2
-4
-5
b<100
100b<200
b200
-2
-
2.5
-3
-b/100
Web
thickness
(t
w
) (mm)
t
w
<7
7 t
w
<10
10 t
w
<20
20 t
w
<40
40 t
w
<60
t
w
>60
-0.7
-1
-1.5
-2
-2.5
-3
t
w
<16
16 t
w
<25
25 t
w
<40
t
w
40
-
0.7
-
1.0
-
1.5
-
2.0 4.5 < t 6
6 < t 10
-0.85
-0.9
Flange
thickness
(t
f
) (mm)
t
f
<6.5
6.5 t
f
<10
10 t
f
<20
20 t
f
<30
30 t
f
<40
40 t
f
<60
t
f
>60
-0.5
-1
-1.5
-2
-2.5
-3
-4
t
f
<16
16 t
f
<25
25 t
f
<40
t
f
40
-
1.0
-
1.5
-
1.7
-
2.0
Use of steel with f
y
420 MPa
A
B
C
(C) PNA in
web
M
Rd
= | M
pl,Rd
Composite columns
More generous width-to-thickness ratios
permitted for composite column design cf.
other international Standards
Higher concrete strengths permitted: 100
MPa cf. 50 MPa in EN 1994-2 (Eurocode 4)
Bond strengths given for longitudinal shear
connection
Type of cross section t
bond
(MPa)
Completely concrete encased steel sections 0.30
Concrete filled circular hollow sections 0.55
Concrete filled rectangular hollow sections 0.40
Flanges of partially encased sections 0.20
Webs of partially encased sections -
cross-section o
b
0
0.5
-0.5
0
0
0
% 3
s
s
% 6 % 3
s
s <
q
20 100
1,0
0,8
0,6
0,4
0,2
60 140
-0.5
0
0.5
c c r y r y s u s
f A f A f A N
'
+ + = | v | |
180
buckling about
strong axis
buckling about
weak axis
85 , 0 = v
00 , 1 = v
85 , 0 = v
85 , 0 = v
00 , 1 = v
00 , 1 = v
Composite columns verification for axial
compression

For k
f
= 1.0
b
o
N
M
2
*
N
*
N
Rd , pl
M
Rd max,
M
us
N
A
B
D
As a simplification, the interaction
curve may be replaced by a
polygonal diagram given by the
points A to D.
C
Determination of interaction curve
Corrosion resistance and protection
New Zealands first weathering steel bridge (State Highway 1
Mercer to Longswamp Off-ramp) Image courtesy of Eastbridge
Rigorous Structural Analysis
No
Material
behaviour
Geometric
behaviour
Imperfections

Example of use
1 linear linear no elastic shear lag effect, elastic
resistance
2 non linear linear no plastic resistance in ULS
3 linear non linear no critical plate buckling load
4 linear non linear yes elastic plate buckling resistance
5 non linear non linear yes elastic-plastic resistance in
ULS
Type of
imperfection
Component
global member
with length

global
longitudinal
stiffener with
length a

local panel or
subpanel

local stiffener
or flange
subject to twist

Model
with yielding
plateau

with strain-
hardening

Web stiffeners
Corrugated Web Girders
Transverse reinforcement Option of using strut &
tie modelling
S-N curves simplified
S-N Curve for Normal Stress S-N Curve for Shear Stress
Functional and Essential Tolerances
Areas worthy of future research
Confirm/extend the current combined bending and tension
rules for shear studs in high strength concrete.
Develop more competitive capacity factors through bending
tests on Australasian-produced steel sections.
Push test performance of other shear connectors, such as the
perfobond connector.
Fatigue performance of headed stud connectors in high
strength concrete.
Reconsideration of brittle fracture provisions, in particular,
weld locations and stress concentration factors.
Corrosion rates for Australia
Conclusions
Bridge design Part 6: Steel and composite
construction, only part of AS 5100 suite being
revised as a joint AS/NZS Standard
Proposed that overseas steels currently recognized
in NZS 3404.1, together with weldability and brittle
fracture provisions, to be covered in an appendix.
Following the international trend of using less
natural resources, rules for higher strength steel
and concrete given.
New design rules provide greater alignment with
international best practice and, in some cases,
improvements are given (particularly for composite
construction).
Where can I get further information?
http://www.standards.org.au
Where can I get further information?
stephen.hicks@hera.org.nz
http://www.hera.org.nz/
Thank you for your attention
(Te Rewa Rewa Bridge, image courtesy of Novare Design, Wellington, NZ)

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IIE Annual Conference, Parramatta, 30 November 2012 1

AS/NZS 5100.6 the New Joint Bridge Design Standard on

12,41% 13,33% 12,41% 13,33% 14,53% 13,70% 18,47% 14,07%

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