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Fatigue Behavior of Fasteners in case of Concrete Failure: Numerical and

Experimental Investigations

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FATIGUE BEHAVIOR OF FASTENERS IN CASE OF CONCRETE
FAILURE: NUMERICAL AND EXPERIMENTAL INVESTIGATIONS

Máté Tóth1 Joško Ožbolt1 Werner Fuchs1 Jan Hofmann1

1
Institute of Construction Materials, University of Stuttgart, Stuttgart, Germany

ABSTRACT
Repeated actions due to, for instance, mechanical actions of machines with rotary parts, guide rails of
elevators or cranes can cause fatigue failure of fasteners. If fasteners are exposed to such repeated loads,
the verification of the fatigue resistance is needed. The behavior of fastenings is well known under static
and quasi-static load conditions. In contrast to their fatigue behavior, which was investigated only in a
relatively few studies (Fuchs 1985, Lotze 1993, Maruyama et al. 1997, Block 2001, Fares et al. 2006,
Lazzarin et al. 2010, Majzoobi at al. 2005, Kunz 2003). Consequently, the EN 1992-4 provisions for the
fatigue design of fasteners are rather conservative and cover fatigue applications of fasteners under
pulsating tension and pulsating or alternating shear loads only up to 2x106 loading cycles. Within the
scope of this article the concrete fatigue behaviour with respect to fastening technology is investigated. A
new method is proposed, which is capable to predict the fatigue life of concrete based on experimentally
obtained results from fatigue tests, performed only for a limited number of loading cycles. The method
combines the energy dissipation, obtained numerically, Paris law (Paris and Erdogan 1963) and
experimentally obtained test data. It has the advantage of capturing the fatigue behaviour of fastenings in
the case of concrete failure without having the risk of steel failure. As for validation, the proposed fatigue
model was calibrated using different test results from the literature and the resulting fatigue curves were
compared with the corresponding experimental data and empirical formulas of the authors. The presented
validations show that the new fatigue model provides robust and reliable results.

Keywords: Fastening technology, fatigue, concrete failure, Paris law, numerical analysis

1. Introduction
Post-installed anchoring and cast-in systems, such as headed fasteners and anchor channels, have gained
greatly in importance and their application in the fields of structural engineering increased enormously. In
the fastening technology, the loads are transferred by means of fasteners into the concrete via mechanical
interlock, friction, bond or a combination of these load transfer mechanisms determining the governing
verification in design. If the fasteners are subjected to fatigue actions, the fatigue verification must be
carried out. The detailed knowledge of the fatigue behavior of all the materials and parts involved in the
load-transfer is required for the prediction of the fatigue life of a fastening system. Moreover, when
predicting the fatigue life of a fastener, all possible failure modes have to be considered. This includes the
different failure modes of concrete and steel failure, but also bond or pull-out (friction) failure. The
product dependent fatigue resistances must be included in the corresponding European Technical Product
Specifications. The failure modes under fatigue loading are steel failure, pull-out failure, concrete cone,
concrete edge- or breakout, concrete splitting and blow-out and correspond to the failure modes under
static loading. In the recent provisions of EN 1992-4, the characteristic concrete fatigue resistance is
verified with 50% of the corresponding static reference loads at 2x106 number of loading cycles. The
tested steel and pull-out fatigue resistances are to be taken from the European Technical Product
Specifications.
Multiple theoretical and experimental studies show that the concrete fatigue curve crosses the steel fatigue
curve once in the low cycle fatigue range as depicted by Block (2001) and shown in Fig. 1. Based on the
available data on fatigue of plain concrete under tension and concrete fatigue of fasteners, it is assumed
that the concrete fatigue curve may cross the steel fatigue curve also in the high to very-high cycle fatigue
range. By plotting the assumed fatigue curves of steel, concrete and pull-out failures (bond, pull-out, pull-
through) into the same Wöhler-diagram, the fatigue behavior of fastenings with the decisive failure modes
can be schematically demonstrated (see Fig. 1).

Concrete
Product dependent
Stress amplitude
? Steel

Product dependent failure

modes (Pull-out/Pull-
through/Bond failure)
Concrete Steel Concrete
failure failure failure

Number of cycles N

Figure 1: Wöhler-curve for the different failure modes of fasteners under tension observed under fatigue
loading – example
The second crossing point of steel and concrete fatigue curves is of particular interest in case of fasteners
with relatively small embedment depths and stress amplitudes but very large number of loading cycles. In
this case the steel fatigue may be not the decisive failure mode but concrete fatigue failure. The available
test results on concrete fatigue of fasteners in the literature are not suitable to determine this point with
sufficient accuracy. However the determination of this crossing point could extend the provisions of EN
1992-4 in case of concrete fatigue for larger number of load cycles and therefore could cover also
applications in the very high cycle fatigue range.
This study focuses primarily on the concrete fatigue failure modes of fastenings, and therefore the
conclusions of the earlier experiments on plain concrete and concrete fatigue in the fastening technology
are summarized briefly in the following paragraph. Subsequently the proposed model and its verification
is discussed.

2. Fatigue behavior of concrete

In order to investigate the concrete fatigue behavior for fasteners, the experimental data on plain concrete
fatigue under uniaxial loading was studied. Principally, the Wöhler-curves of plain concrete under
pulsating tension and pulsating compression show similar behavior. Beside the large scatter of results,
from the literature review can be seen that the upper tension stress at N = 2x106 is reduced to
approximately 60% of the short term value. But the knowledge on plain concrete fatigue cannot be
directly applied to the concrete fatigue behavior of fastenings without additional considerations. In
contrast to the uniaxial loading of concrete, the load transfer mechanisms of fasteners generate relatively
complex three-dimensional (3D) stress-strain conditions and high stress concentrations in the load transfer
zone. These stress concentrations cause micro-cracks and the local damage of concrete. The micro-cracks
are considered as small notches, which decrease the fatigue life significantly. Experiments show, that in
case of fastenings already small relative static loads (0.3Nu) provoke micro-cracks in the concrete, which
cause irreversible damages (Eligehausen & Sawade, 1989). With respect to the discussed differences, the
fatigue resistance of concrete failure of fastenings should be verified by taking into account all concrete
failure modes under fatigue loading. Results of the experimental work of Block (2001), Maruyama et al.
(1997) and Lotze (1993) on concrete fatigue of fastenings are summarized in Fig. 2.
The presented experimental database contains results of fatigue tests performed with undercut anchors,
bonded anchors and headed studs with different diameters and embedment depths and two loading
directions to obtain concrete cone and concrete edge failure, respectively. However, the experimental
range is limited to 4x106 in all cases and the tests were carried out for a concrete class C20/25. The results
were compared with the empirical formulas for plain concrete proposed by Cornelissen (1984a,b).
The aim of the present research project is to develop a new method, which is capable to predict the
concrete fatigue life of fasteners using available experimental data sets as input parameter and predicting
the fatigue resistance of fasteners over the entire loading range.
100
Block (tension) UC

relative stress range Fu/Nu,m [%]

Block (shear) UC
80
Maruyama (tension) HS

60 Lotze (1993) Tension

Block (shear) BA
40 Block (tension) BA
Cornelissen (dry)
20 Cornelissen (sealed)
Flower=0,1*Nu
HS: Headed stud
0 BA: Bonded anchor
1,E+01 1,E+03 1,E+05 1,E+07 1,E+09 UC: Undercut anchor
number of cycles [-]

Figure 2: Comparison of the experimental data on concrete fatigue failure caused by fasteners (concrete
cone (tension) and concrete edge failure (shear)) and Wöhler-curves of plain concrete under pulsating
tension (Cornelissen, 1984)

3. Proposed fatigue model

Based on numerous experimental and theoretical investigations, concrete does not exhibit an endurance
limit, thus the concrete fatigue may be decisive in the high-cycle fatigue range (N>108) in case of
fasteners with smaller embedment depths and small applied upper loads, where steel fatigue is unlikely to
occur. However, capturing the fatigue behavior of the concrete - particularly in the targeted fatigue range -
requires extensive testing. The crossing point of steel and concrete curves in the high cycle fatigue range
might be beyond the experimentally possible range. Therefore, a new method is proposed, which is
capable to predict the fatigue behavior of concrete for the entire loading range. The method is based on the
Paris law in combination with available experimental data and a set of numerical results obtained for the
problem in question. Instead of working with stress intensity factor like the Paris law, the proposed model
uses the dissipated energy (entropy) in order to account for degradation of structural resistance as a
consequence of cycling loading.
The Paris law (see Eq. 1) defines the crack-extension rate as a function of the stress amplitude. It was
introduced primarily to describe the fatigue life of ferrous materials. Multiple experiments demonstrated
that the law may also be applicable for cementations materials (Schwarz and Go 1984, Suresh et al.1989).
m
da  K 
 C   (1)
dN  KC 
where a = crack length, N = number of load cycles, ΔK = Kmax-Kmin, KC = critical stress intensity factor for
static (monotonic) loading, Kmax = stress intensity factor related to the crack at lower load, Kmin = stress
intensity factor related to the crack at upper load and C, m = material empirical constant (dependent on
material type, stress ratio, stress range).
In the proposed model the critical number of loading cycles N is assumed to be a power function of the
ratio between dissipated energy at peak load (Glim) and the difference in dissipated energies that
correspond to the upper and lower load applied in cyclic loading (Gmax-Gmin):
m
 
m
G  Glim
N  C  lim   C   (2)
 G   G max  G min 
where C and m are material dependent constants, which are obtained from the fitting of available test data.
Essentially Eq. 2 is based on the relative energy dissipation. According to Eq. 2 the increase of energy
dissipation between upper and lower load levels, the number of load cycles at failure decreases with the
power of m. This principally agrees well with the expected fatigue behavior for fasteners, since the
reduction of the upper load level decreases the loading amplitude on the fastener, which results in the
progressive increase of loading cycles. It is obvious that the progression of the calculated curve will
always converge to the lower load (Fl) at higher number of cycles. When the upper load approaches to the
lower load and thus the amplitude is close to zero, the anchor is subjected to a constant load. Therefore,
the anchor would exhibit a nearly infinite fatigue life. However, this requires further considerations
because the durability of anchors under static loads is generally characterized with time to failure curves,
which is not discussed within the scope of this paper. Once the material dependent model parameters C
and m are determined the model is able to predict the number of loading cycles to failure for a given upper
and lower load levels.
The calibration of the model is done by the determination of the material dependent parameters C and m
from Eq. 2. To calibrate the model, S-N values are required from experimental investigations, at least for a
certain limited range of N. For each calibration curve two failure points (Fupper.1; N1) and (Fupper.2; N2)
should be selected from the available experimental basis. The points have to be taken from different load
or stress levels in order to get reasonable results, i.e. Fupper.1 ≠ Fupper.2. Furthermore the energy dissipation
for Eq. 2 should be obtained from a numerical analysis, i.e. for a given problem the load should be applied
up to the three required load levels (peak load, upper and lower applied load levels). After reaching the
required load level, the specimen should be unloaded to zero and using numerically predicted load-
displacement curves the energy dissipations Gmax1(Fupper.1), Gmin1(Flower.1), Gmax2(Fupper.2), Gmax2(Fupper.2) can
be calculated (see Fig. 3). By inserting the chosen S-N value pairs with the corresponding calculated
energy dissipations into Eq. 2, the two unknown parameters (C, m, see Eqs. 4 and 5) can be obtained by
solving Eq. 3.

G_lim
Load

G_min
G_max
G_min

Displacement

Figure 3: Numerically obtained hysteresis areas (Glim, Gmax, Gmin)

m m m m
G   Glim  and N  C  Glim   Glim 
N 1  C  lim   C    G   C   (3)
 G1   G max .1  G min .1   G max .2  G min .2
2
 2  
N1
ln
N2 (4)
m
 G 2 
ln  
 G1 
m m
G  G 
C  N 2  lim   N 1  lim  (5)
 G2   G1 
After the material dependent constants C and m are determined, the fatigue life up to the targeted cyclic
range can be evaluated using Eq. 2. Note that two S-N pairs are required for each calibration curve. That
means, that the calibration of the model can be made by choosing all mathematically possible S-N
combinations by using failure points from different load levels and each calibration would result different
fatigue curves. However, it is expected that the best choice of the two sets of data should be taken for a
possibly small and possibly large number of loading cycles.
4. Validation of the proposed method

4.1 General
In order to validate the functionality of the proposed numerical method, the calibrations of the new model
on two examples are presented in this paper. The experimental data sets for the calibrations are taken from
the literature. For the numerical analysis, the finite element models of the investigated problems were
performed and a cyclic analysis was made to obtain the required dissipative energies, as discussed above.
Finally, the predicted fatigue curves were plot and were compared with the corresponding experimental
data.

4.2 Validation with results on undercut anchors (Block 2001)

For the first calibration, the experimental data of Block (2001) on undercut anchors was used. The anchors
were set close to the edge with edge distance c = 0.5cmin and were subjected to pulsating shear load to
obtain concrete edge failure. The tests were carried out according to the interactive test method proposed
by Block (2001). The schematic of the test setup and the results of fatigue tests are shown in Fig. 4.
120

100
relative load - Vu/Vu,m [%]

80

60

40

20
Vlower=0,1*Vu
0
1,E+00 1,E+02 1,E+04 1,E+06 1,E+08
number of cycles [-]

(a) Schematic of the test setup (b) Test results of fatigue tests with regression line

Figure 4: Fatigue behaviour of an undercut anchor loaded in pulsating shear load towards the edge (Block
2001)
To compute the required energy dissipation, the above geometry was discretized with 3D finite elements.
To capture the concrete edge failure under shear load, modeling of a headed stud with the given diameter
and edge distance was sufficient since undercut fasteners and headed studs close to the edge indicate
similar load carrying behavior under shear load towards the edge. For the spatial discretization of the
concrete, four node solid finite elements were used and the steel was modelled with eight node solid
elements. The contact between the anchor and concrete was modeled using 1D contact elements, which
can take up only compressive forces. The location of the constraints corresponded to the applied clear
support distance as in the experiments. The load was applied by controlling the displacement of the
anchor. The material properties of the concrete were the same as in the experiments: uniaxial compressive
strength fc = 28 N/mm2, tensile strength ft = 2.5 N/mm2 and an elastic modulus Ec = 30000 N/mm2. Steel
behavior was assumed linear elastic with an elastic modulus Es = 200000 N/mm2. The numerical
analysis was performed using 3D finite element code MASA, which was developed at the University of
Stuttgart, Institute of Construction Materials (Ožbolt et al., 1999). As a constitutive law for concrete, the
microplane model was employed (Ožbolt et al., 2001). The numerically predicted peak load showed only
1% deviation from the experimentally obtained value. It should be noted, that the applied relative load
during the numerical analysis referred always to the numerically obtained reference peak load in order to
eliminate the deviation of the peak loads obtained from the numerical and experimental investigations.
Three different S-N data pairs were selected from the experimental basis, and consequently three
independent calibrations resulting in three fatigue curves were determined. The three fatigue curves are
shown in the S-N diagram (Fig. 5b) and the fatigue life was evaluated up to 1018. The value of the
exponent m varies from 7 to 10, which agrees well with the m values 8-10 reported by Bažant & Xu
(1991) and Bažant & Schell (1993) for high and normal strength concrete. Furthermore, the proposed
regression curve by Block (2001) fits well the model prediction. The progression of the predicted fatigue
curves corresponds well to the conclusions of the previous experimental and theoretical investigations,
which claim that the concrete may not show an endurance limit. This indicated that for fasteners a
concrete fatigue failure is expected even at low load levels in the high cycle fatigue range.

(a) FE-discretization of anchor close to the edge (b) Fatigue behavior of an undercut anchor loaded in pulsating shear

Figure 5: Calibration of the new fatigue model with the test results of Block (2001) (Bošnjak et al., 2014)

4.3 Validation with fatigue test results on plain concrete (Cornelissen, 1984)
The validation of the proposed model was also carried out using fatigue test results on plain concrete
specimens under uniaxial pulsating tension and alternating tension-compression. Since there are no results
available on reversed loading of fastenings, the following example on the plain concrete shall demonstrate
that the model is able to predict the behavior of concrete under fatigue loading and may be applicable to
fasteners as well. The calibration was done with the experimental data of Cornelissen.
100

80

Tension-
60
Ϭu / fctm [%]

tension [B45]

Tension-
40
compression
[B45]
20
Ϭmin / fcm = 0,025 – 0,1

0
1,E+00 1,E+02 1,E+04 1,E+06 1,E+08 1,E+10
number of cycles [-]

(a) Schematic of test setup and the FE-discretization of the concrete (b) Test results of fatigue tests on Ø120 mm, 300 mm height concrete
cylinder cylinders (dry and sealed specimens)

Figure 6: Fatigue behaviour of plain concrete cylinders loaded in pulsating tension and alternating
tension-compression (Cornelissen, 1984)
Cornelissen (1984) performed fatigue tests on concrete cylinders (Ø120 mm, 300 mm height). They were
subjected to pulsating tension and alternating tension-compression. Only the results performed with dry
concrete were used to calibrate the model. The compressive strength of the concrete was fc = 47 N/mm2,
the tensile strength was ft = 2.7 N/mm2 and the elastic modulus was Ec = 35000 N/mm2. The test setup and
the finite element discretization are shown in Fig. 6a. The finite element analysis was performed at the
macro and meso-scale, i.e. the aggregate and the mortar were modeled explicitly based on the microplane
model (Bošnjak at al., 2014). The experimental results of Cornelissen are shown in Fig. 6b. Note that in
case of tension-compression loading the applied relative compression stress was varied between 2.5% to
10% of the compressive strength. The test results show the influence of reversed loading on the fatigue
behavior (see Fig. 6b).
For the calibration of the numerical model, the results of the empirical formulas proposed by Cornelissen
were used. Three -N pairs were calculated using Eq. 6 for tension-tension loading and Eq. 7 for tension-
compression loading:
 max  min (6)
log N  14 .81  14 .52  2,79
f ctm f ctm

 max  min (7)

log N  9.36  7.93  2,59
f ctm f cm

The calibration of the model was carried out using the S-N pairs summarized in Table 1 and 2.

Tension-tension (using Equation 6)

max/fctm min/fctm N (calc) max/fctm min/fctm N (calc)
1 0,5 0,0 35481339 0,7 0,0 44259
2 0,5 0,0 35481339 0,8 0,0 1563
3 0,6 0,0 1253141 0,8 0,0 1563
Table 1: Used calculated calibration points for tension-tension

Tension-compression (using Equation 7)

max/fctm min/fcm N (calc) max/fctm min/fcm N (calc)
1 0,5 0,05 184289 0,7 0,05 4780
2 0,5 0,05 184289 0,8 0,05 770
3 0,6 0,05 29682 0,8 0,05 770
Table 2: Used calculated calibration points for tension-compression

The determination of the parameters C and m was carried out as described in the section before. The
comparison of the determined calibration curves with the experimental data and the proposed empirical
model of Cornelissen is shown in Figure 7a,b. The calibration curves fit well to the experimental data as
well as with the proposed empirical model by Cornelissen up to 108 in case of pulsating tension and until
106 number of cycles in case of alternating tension-compression respectively. This confirms the general
applicability of the proposed new model, even in case of alternating compression-tension. It can be seen,
that the empirical formulas proposed by Cornelissen (Eqs. 6-7) provide more conservative results in the
high cycle fatigue range (>106). Furthermore, the effect of alternating tension-compression on the fatigue
life is much more pronounced at higher number of cycles (see Fig. 7a,b). It can be seen, that in case of
alternating tension-compression, the application of already small relative compressive stress
(Ϭmin/fcm=0,05) reduces the fatigue life significantly. According to the new prediction method, the
expected number of loading cycles is 1016 for tension-tension at 20% relative upper stress level. For only
alternating cycling loading the expected number of loading cycles is only 109, if 0,05fcm is applied. The
determined exponent m is between 4 and 9 in both cases, which agrees well with the exponent reported by
Bažant & Xu (1991) and Bažant & Schell (1993).
(a) Fatigue behavior of the concrete under pulsating tension (b) Fatigue behavior of concrete under alternating tension-
compression
Figure 7: Calibration of the new fatigue model with the test results of Cornelissen (1984) (Bosnjak et al.
2014)

5. Conclusions
If fasteners are subjected to repeated actions, the fatigue resistance must be verified. When predicting the
fatigue life of fasteners, all possible failure modes must be taken into account. Since, the fatigue behavior
of steel is well known for fasteners, a special attention should be devoted to the fatigue of concrete.
Numerous studies and the fatigue curves presented in this paper show, that the concrete fatigue can be
decisive in case of high cycle fatigue loading, particularly if the load amplitude is selected such, that it is
below the endurance limit of steel. Since the experimental verification of the fatigue life in the high-cycle
fatigue range for fasteners would require extensive testing, a new method is proposed to predict the fatigue
curves of concrete failure based on Paris law. The model requires experimentally obtained test data and a
set of numerical results related to energy dissipation. The presented validations of a fastener loaded in
shear and a concrete specimen show that the proposed model provides reliable results. It seems that the
model is able to capture the concrete fatigue behavior of fastenings with sufficient accuracy even at very
high number of cycles. In case of fasteners, no endurance limit can be observed, which corresponds to the
expected concrete fatigue behavior. The proposed model should be verified for the high-cycle fatigue
range and calibrated using new test results or using available experimental data sets from the literature,
thus covering all concrete failure modes of fastenings.
The alternating cyclic loading may be used for fasteners if the concrete surface is compressed by the
fixing plate. However no results are available on reversed cyclic loading of fasteners. Based on the test
results on plain concrete specimen under reversed loading (Cornelissen, 1984), the significant reduction of
the fatigue life of fasteners is expected, even when relatively small compressive stresses are applied. The
presented validation in this paper shows that the proposed fatigue model may be capable to handle the
reversed loading case as well. Once the proposed fatigue model has been calibrated for different loading
cases and all concrete failure modes, the concrete fatigue resistance of fastenings even with different
upper and lower loads could be evaluated and crossing point of the steel and concrete fatigue curves can
be determined.

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