fatigue6_en

From: TPFkj
TWU-TPF-06a/02-d Date: October 31, 2002
Corporate Research Page: 1/7

Hilti HIT-Rebar

Design of bonded-in reinforcement

(post-installed rebar connections)
using Hilti HIT-HY 150 or Hilti HIT-RE 500
for predominantly cyclic (fatigue) loading

Author: Dr. Jakob Kunz (TPFkj)

mailto:kunzjak@hilti.com

Designation: TWU-TPF-06a/02-en

Version / Date: 1.0-d / FL-9494 Schaan, 2002-05-28

Release: Marcel John (TPF)

Keywords: Anchor technology, fastening systems, fatigue, re-

inforcement

Confidentiality: - Intranet
- Selected customers, on request

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fatigue6_en

From: TPFkj
TWU-TPF-06a/02-d Date: October 31, 2002
Corporate Research Page: 2/7

Contents

Management summary __________________________________________________ 3

1. Introduction _______________________________________________________ 4
2. Fatigue behavior of bond _____________________________________________ 4
2.1 Tests __________________________________________________________ 4
2.2 Fatigue of concrete under compressive loading in standards _______________ 5
3. Splitting of concrete under fatigue loading 5
3.1 Tests __________________________________________________________ 5
3.2 Fatigue of concrete under tensile loading in standards ____________________ 5
4. Verification of fatigue strength of bonded-in rebars _______________________ 6
4.1 Verification of steel fatigue strength ___________________________________ 6
4.2 Simplified verification of bond fatigue and concrete splitting ________________ 6
4.3 Verification of fatigue strength with Weyrauch diagram _______________________ 7
4.4 Verification of fatigue strength with S-N diagram (Wöhler) __________________ 7
Reference literature _____________________________________________________ 8

Management Summary
This report gives the complete background information needed for the design of rebar connections under fa-
tigue loading, as proposed in the corresponding Hilti manuals. The fatigue behavior of cast-in and post-
installed reinforcement bars during the concrete splitting and bond failure modes is analyzed. Fatigue test
results from literature and those carried out in our own laboratories are presented and commented for both
types of adhesives. The treatment of fatigue in different codes is shown in a second step. Based on the test
results and the provisions in codes, a design concept for rebar connections subjected fatigue loading is de-
veloped. The design can be carried out at three levels of accuracy: a simplified method with reduction factors
for fatigue, a design with Weyrauch diagrams as given in Eurocode 2 or a design with the actual S-N curves
(Wöhler).

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 fatigue6_en

From: TPFkj
TWU-TPF-06a/02-d Date: October 31, 2002
Corporate Research Page: 3/7

1. Introduction
Post-installed (bonded-in) rebar connections subjected to considerable stress fluctuations must be designed
on the basis of the fatigue strength. When doing so, the steel, bond and concrete fatigue strengths must be
verified separately. Simplified design processes, which are on the safe side, may also be used. The load
combinations and the partial safety factors in the relevant codes (standards) covering reinforced-concrete
construction have been taken over.
The European codes (standards) ENV 1992-2:1996 (EC 2-2) [4] and the Model Code 90 [3] provide the ba-
sis for the following design principles. The design values were determined during in-house fatigue tests with
bonded-in bars, and tests in pertaining literature about cast-in bars were taken into account.
When the fatigue strength is verified, three different modes of failure can be decisive: steel failure, bond fail-
ure and concrete splitting. Bond failure can more likely be attributed to concrete fatigue behavior under com-
pressive loading. Where concrete splitting is concerned, the tensile strength of the concrete is decisive which
is why, in this case, the fatigue behavior of concrete under tensile loading is used. An evaluation of the tests
shows the values for both bond failure and concrete splitting to be higher than those given in the code (stan-
dard).

2. Fatigue behavior of bond

2.1 Tests
Fig. 1 is a plot of the results of testing the bond fatigue behavior. When evaluating tests of this kind, it is
usual to plot the ratio of mean static bond strength from comparison tests to max. load, F1/Fmax , against the
logarithm of the number of load cycles at failure, N. In this way, the bond behavior of cast-in and post-
installed bars can also be compared with various concrete strengths and different bond strengths. In Fig. 1,
the regression lines for the individual test series with the additional condition Fmax/F1 = 1 for N = 0 have been
entered along with the plotted test readings.
1
The fatigue tests were those carried out with
0.9
cast-in bars by Eligehausen [2], with Hilti HIT-
HY 150 also by Eligehausen [6] and in-house
0.8 tests with bars installed in diamond-drilled
holes in saturated concrete using Hilti HIT-RE
0.7 500. The tests were arranged in such a way
Fmax/F1

that failure was by pull-out (no concrete split-

0.6
RE 500 (DIA, nass) ting and, as far as possible, no steel failure).
HY 150
0.5 einbetoniert
The ratio of min. stress to the reference bond
Linear (RE 500 (DIA, nass)) stress from static loading tests, Fmin/F1, was
0.4 Linear (HY 150) always smaller than 0.1. The tests with cast-in
Linear (einbetoniert)
bars were run with the diameters, ds , of 8, 14
0.3
0 1 2 3 4 5 6 7
and. 28 mm, but no significant difference in
log N behavior of the various sizes was ascertained
[2].
Fig. 1: Bond fatigue and regression lines
The tests with Hilti HIT-HY 150 were carried
out with rebars of the diameter, ds, of 10 mm (lv =50 mm = 5ds) which were installed in clean, dry, drilled
holes. With only one exception, failure took the form of bond fatigue (pull-out). Fig. 1 shows that the results
from the cast-in bar series hardly differ from those with bars bonded in using Hilti HIT-HY 150 [7].
Several test series were conducted using Hilti HIT-RE 500 and rebars with a diameter, ds , of 12 and 20 mm
[5]. Despite very short bond lengths, lv , of 3ds in dry, drilled holes, it was not possible to produce a bond fail-
ure either at room temperature or -40°C. During all tests, the steel failed or the test was stopped. In the case
of bars installed in diamond-drilled holes in water saturated concrete, several fatigue failures of the bond oc-
curred. As would be expected in these conditions, the scatter was relatively wide. The regression line for
HIT-RE 500 in Fig. 1 also lies somewhat lower than that for cast-in bars or bars installed with HY 150, but,
as already mentioned, it is a matter of the relative behavior with much higher reference bond stresses.

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From: TPFkj
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2.2 Concrete fatigue under compressive loading in codes (standards)

Eurocode 2, part 2 [4], provides a simplified design diagram (Weyrauch diagram) for concrete subjected to
fatigue loading. The fatigue strength, i.e. the range of stress without failure after more than 106 load cycles,
can be quickly read from this diagram, but it does not contain any data concerning the fatigue strength for fi-
nite life (over given number of load cycles).

1 1 σ c , min
0.9 0.9 f ck , fat

0.8 0.8 0.8

0.7 0.7 0.6
0.4
σ c,max/fcd

0.6 0.6
0.2
0.5 0.5

σ c,max/fck,fat
0
0.4 0.4
0.3 0.3
0.2 0.2
0.1
0.1
0
0
0 0.2 0.4 0.6 0.8 1
0 1 2 3 4 5 6 7
σ c,m in/fcd
log N

Fig. 2: Fatigue strength as per EC2 Fig. 3: S-N diagram (Wöhler) for concrete under compressive loading

If the load is pulsating with a min. load of 0, the permissible range of stress is thus 50% of the static max.
load. This diagram corresponds to the lowest S-N diagram (Wöhler) (Sc,min = 0) of MC90. (See Fig. 3.)
The CEB Model Code 90 (MC90) [3] provides an analytical process for the computation of concrete fatigue
behavior. Fig. 3 shows the S-N (Wöhler) diagrams corresponding to MC90 for various ratios of max. load to
static comparison load. It can be seen that the MC90 diagram, unlike the S-N diagram (Wöhler) depicted in
Fig. 1, comes from tests that tended to be more on the safe side, e.g. in Fig. 1 the strength for Fmin/F1 ≤ 0.1 at
106 load cycles is still 65% of the initial strength, whereas according to MC90 the strength for Sc,min = 0.1 af-
ter 106 load cycles is only 55% of the original strength, while at Sc,min = 0 it is even down to 50%.

3 Concrete splitting under fatigue loading

3.1 Tests
For concrete to split, its tensile strength is decisive. In [6], Tep-
fers tested cast-in rebars for fatigue as a result of concrete split-
ting. The results are shown in Fig. 4. After 106 load cycles, when
the ratio of min. load to max. load, R = Fmin/Fmax, was 0.43, a
strength of still 80% of the initial strength was measured, and
Fmax/F1

when the ratio of Fmin/Fmax was 0.34, it was still approx. 70%.
No such test with bonded-in bars were carried out.

Fig. 4: Cast-in bars during failure due to concrete splitting

3.2 Fatigue behavior of concrete under tensile loading according to codes (standards)
MC90 [3] provides the S-N diagram (Wöhler) in accordance with Fig. 7 for tensile-stressed concrete. To re-
main on the safe side, a purely pulsating load (static load = 0) is assumed. When number of load cycles is
less than 106 , this diagram is identical to the S-N diagram (Wöhler) for compressive-stressed concrete un-
der a purely pulsating load (Sc,max = 0). If the number of load cycles is higher, the plot does not becomes flat-
ter in the case of tensile loading, but keeps the same gradient. According to this plot, the resistance of con-
crete under tensile loading decreases to 50% after 106 load cycles. The correspondingly evaluated Wey-
rauch diagram is depicted in Fig. 6.

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Eurocode 2 offers no information about the fatigue of concrete under tensile loading.
1 1
0.9 0.9
0.8 0.8
0.7 0.7
σ c,max/fck,fat

σ c,max/fck,fat
0.6 0.6
0.5 0.5
0.4 0.4
0.3
0.3
0.2
0.2
0.1
0.1
0
0
0 0.2 0.4 0.6 0.8 1
0 1 2 3 4 5 6 7
σ c,m in/fcd
logN

Fig. 6: Weyrauch diagram for tension as per MC 90 Fig. 7: S-N diagram (Wöhler) for tension as per MC 90

4. Verification of fatigue strength of bonded-in rebars

Adequate resistance to fatigue may be regarded to exist if formula 3.1 is satisfied:
Fsd , fat ≤ N Rd ⋅ f fat formula 3.1
Fsd,fat: design anchorage force from the applicable load model for fatigue
NRd: design anchorage resistance from static loading
f fat : fatigue influencing factor

4.1 Verification of fatigue strength of steel

Verification of the fatigue strength of reinforcing steel is carried out in keeping with currently valid codes
(standards) for reinforced-concrete construction. The fatigue behavior of reinforcing steel is not impaired
when forces are transferring with Hilti HIT-HY 150 or Hilti HIT-RE 500 injectable adhesive mortar.

4.2 Simplified verification of bond fatigue strength and concrete splitting due to fatigue
In many cases, it is sufficient to carry out simplified verification of the fatigue strength, and thus to be on the
safe side, using a global influencing factor. If the minimum loads are known, greater utilization of the connec-
tion can be verified with the Weyrauch diagram according to section 4.3 or, if the number of load cycles is
known as well, by means of the S-N (Wöhler) diagrams according to section 4.4.

4.2.1 Global influencing factor for bond behavior and concrete splitting:
According to Figs. 2 and 3, the lowest influencing factor, ffat , for compressive-stressed concrete subjected to
purely pulsating loads is 0.5. This figure may be assumed with sufficient accuracy for the bond and concrete
splitting.
0
f fat = 0,5 formula 3.2

4.2.2 Different influencing factor for bond behavior and concrete splitting:
An evaluation of the tests (Fig. 1) resulted in the resistance of a connection made with cast-in bars, or rebars
bonded in with HIT-HY 150, after 106 load cycles with a low min. load (smaller than 10% of the static com-
parison load) still being 65% of the resistance determined during static tests. When the bars are installed in
diamond-drilled holes in saturated concrete using HIT-RE 500, the figure is still 55%. If conditions are nor-
mal, the same influencing factor for fatigue can, therefore, be assumed for bonded-in rebars as for cast-in

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bars. The influencing factors have been reduced for the favorable case of purely pulsating loads (min. load =
0). This leads to the following global influencing factors for fatigue:
Bond decisive, bonded-in bars, general case (without formula 3.4):
0
f fat = 0.63 formula 3.3

Bond decisive, rebar set with Hilti HIT-RE 500 in diamond-drilled hole in saturated concrete:
0
f fat ,b = 0.53 formula 3.4

Concrete splitting decisive:

0
f fat ,sp = 0.5 formula 3.5

4.3 Verification of fatigue strength using Weyrauch diagram

The Weyrauch diagram permits better utilization of the anchorage if the load, Fsd,fat, consists of a permanent
min. load, F0d, and cyclic component, ∆Fd, (Fsd,fat = F0d + ∆Fd).
4.3.1 Bond
Both Weyrauch diagrams, Figs. 5a and 5b, give somewhat higher values than the diagram according to
Eurocode 2 (Fig. 2). Simplifying and remaining on the safe side, the Weyrauch diagram from Eurocode 2
may be taken over for both cases with this in mind.

1 1
0.9 0.9
0.8 0.8
0.7 0.7
0.6 0.6
fat,b
fat,b

0.5 0.5
1
f
1
f

0.4 0.4
0
0.3 ffat=0.63 0.3 0
ffat=0.53
0.2 0.2
0.1 0.1
0 0
0 0.2 0.4 0.6 0.8 1 0 0.2 0.4 0 0.6 0.8 1
0
F d/NRd F d/NRd

Fig. 5: Weyrauch diagrams for fatigue failure of bond based on tests (section 2.1)
a) In general b) Rebar with HIT-RE 500 in diamond-drilled hole in saturated concrete

4.3.2 Concrete splitting

1 Fig. 6: Weyrauch diagram for concrete splitting as per
0.9 Tepfers [6]
0.8
0.7
The Weyrauch diagram for concrete under tensile load-
0.6
ing according to MC90 may also be used on the safe
fat,sp

0.5 side (Fig. 2).

1
f

0.4
0.3
0.2
0.1
0
0 0.2 0.4 0 0.6 0.8 1
F d/NRd
4.4 Verification of fatigue strength using S-N
(Wöhler) diagrams
If the number of load cycles is known, the fatigue strength can be verified with the aid of the S-N (Wöhler)
diagrams.

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4.4.1 Bond
By adapting the S-N (Wöhler) diagrams from MC90 to suit the test results under section 2.1, the S-N
(Wöhler) diagrams can be developed for the bond in Fig. 7. Once again and also simplifying, the S-N
(Wöhler) diagrams from MC90 can be taken over (Fig. 3).
1 0 1
F d/NRd 0
F d/NRd
0.9 0.9
0.8 0.8 0.8
0.6 0.8
0.7 0.4 0.7 0.6
0.2 0.4
0.6 0 0.6 0.2
fat,b

fat,b
0.5 0.5 0
2

2
f

f
0.4 0.4
0.3 0.3
0.2 0.2
0.1 0.1
0 0
0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7
logN logN

Fig. 7: S-N (Wöhler) diagrams for fatigue failure of bond based on tests (section 2.1)
a) In general b) Rebars with HIT-RE 500 in diamond-drilled holes in saturated con-
t
4.4.2 Concrete splitting
In the case of concrete under tensile loading, only the
1 diagram for purely pulsating loads (static load = 0, on
0.9 the safe side) is available. The evaluation according to
0.8 the tests by Tepfers [6] is given in Fig. 8. Here too, the
0.7 diagram according to MC90 (Fig. ) may be used on the
0.6 safe side.
fat,sp

0.5
0.4
2
f

0.3
0.2
0.1
0
0 1 2 3 4 5 6 7 Fig. 8: S-N diagram (Wöhler) for concrete splitting
logN due to fatigue

Reference literature
[1] Bond of Reinforcement in Concrete. State-of-the-art report. Fib bulletin 10. Lausanne, 2000. ISBN 2-88394-050-9
[2] Eligehausen R.: Übergreifungsstösse von gerippten rebars mit geraden Enden. Deutscher Ausschuss für Stahlbe-
ton. Heft 301, 1979.
[3] CEB-FIP Model Code 1990. Thomas Telford Services Ltd. London 1993.
ISBN 0 7277 1696 4
[4] Eurocode 2: Planung von Stahlbeton- und Spannbetontragwerken. Teil 2: Betonbrücken. ENV 1992-2 : 1996.
[5] Hilti HIT-RE 500 Mörtel unter dynamischer Belastung. TWU-IFF-17/99. Hilti AG, Schaan, 2002.
[6] Tepfers, R.: A theory of bond applied to overlapped tensile reinforcement splices for deformed bars. Chalmers Uni-
versity of Technology, Goteborg, Pobl. 73/2, 1973.
[7] Eligehausen, R.: Gutachtliche Stellungnahme zur Frage der Eignung des Mörtels HIT-HY 150 zum Vermörteln von
gerippten rebars BSt 500S. Institut für Werkstoffe im Bauwesen, Universität Stuttgart, 1999.

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