Figure 1.

Details of corrugated arch reinforcement, showing

V-rib at the base of corrugations. Photo shows how concrete
comes through openings to inner face of the arch; inner
arch surfaces are usually protected later with a thin layer of
shotcrete Sheets of the reinforcement are approximately 3

Design information
for concrete arch system
Useful for earth-sheltered Se ve ral earth-sheltered homes using this system have
been built in the United States (see Concrete Construc -
or cut-and-cover construction tion, January 1982, page 43). Construction of these
homes has resulted in cost savings in labor and materi-
BY JAMES I. DANIEL als, as well as long-term energy savings that go along
ASSOCIATE STRUCTURAL ENGINEER with earth-sheltered construction. Howe ve r, lack of ac-
CONSTRUCTION TECHNOLOGY LABORATORIES tual strength information has led to a conservative ap-
PORTLAND CEMENT ASSOCIATION
AND
proach in structural design.
BRAD BURNSIDE This article reports new strength data for the system
FIELD MARKETING MANAGER and discusses how they can be applied to achieve opti-
UNDERGROUND SUPPORT SYSTEMS mum structural design with minimum concrete thick-
UNITED STATES GYPSUM COMPANY ness and adequate safety. The test program was con-
ducted at the Construction Technology Labora t o ri e s
(CTL).

A n arch system that combines concrete with modular

steel sheets has been introduced recently for both
e a rt h - s h e l t e red and cut-and-cover construction. The
steel sheets function as both formwork and reinforce-
ment for the concrete. This form i n g - a n d - re i n f o rc i n g
system originated in Switzerland for use as tunnel lining
in about 1968. Since that time it has been used success-
fully for many applications including highway bridge
construction, transit system tunneling and mining.
DESCRIPTION OF FORMING-AND-
REINFORCING SYSTEM
Precurved interlocking steel sheets are linked togeth-
er on site to form an arch. Details of the sheet are shown
in Figure 1. Sheets are approximately 3 1/2x4 feet, made
of 14-gage steel and weigh 46 pounds each. They are
manufactured with ribbed corrugations to contribute
strength for forming. The continuous steel needed for

The arch is assembled by linking together precurved
interlocking steel sheets.
development of flexural strength is provided by the V-
ribs. Sheets are assembled so that the continuous V-ribs
are toward the inner surface of the arch and run parallel
to the arch perimeter. A temporary shoring system is
used at center span.
Once assembled, the steel form is covered with low-
slump concrete or shotcrete. When the arch is complet-
ed, the temporary supports are removed leaving a clear
span. A thin layer of shotcrete is usually applied later to
the underside of the arch for protection of the steel. The
arch is finished using conventional construction tech-
niques.
STRENGTH INFORMATION
An experimental program investigated strength prop-
erties of concrete specimens using this steel forming sys-
tem as the only flexural reinforcement. Details of the test
program are given later. Test results verified that Section
10.2 of the ACI Building Code Requirements for Rein-
forced Concrete1 or Article 1.5.31 of the AASHTO Stan-
dard Specifications for Highway Bridges2 can be used to
determine capacities of concrete structures using this
forming-and-reinforcing system.
Test results
Test data for bending moment versus axial thrust are
shown in Figure 2 using dashed lines. These data are
based on a 14-inch-wide section as tested.
Diagrams of calculated moment versus axial thrust in-
teraction are also plotted in Figure 2. Calculated data
are shown as crosshatched zones with upper and lower
bounds representing steel areas equal to 0.60 and 0.44
square inch respectively. A steel area of 0.44 square inch
represented the cross-sectional area of the three V- ri b s
contained within each specimen. A steel area of 0.60
square inch is shown for comparison.
Calculated values were based on nominal strength fol-
1
lowing the ACI Building Code or the AASHTO Specifi-
 2
cations. Calculated nominal strength of a section in
pure compression was taken as 80 percent of the calcu-
lated maximum strength following the ACI Code, Section
10.3.5. Strength reduction factors were not applied to the
calculated data.
For the test configuration shear strength did not con-
trol. For each specimen tested, shear strength was high-
er than bending strength. This behavior would be ex-
pected with the amount of flexural reinforcement
provided by the steel sheets. When the ratio of moment
to shear divided by the effective section depth is greater
than 2, shear strength design can be based on the shear
strength provided by the concrete, ignoring any contri-
butions by the steel.
Implication of test results
An arch subjected to a specific loading condition has
different combinations of bending moment, axial thrust
and shear force at each point around its perimeter.
Based on given applied loads and specified arch bound-
ary conditions, the forces can be calculated. Calculated
forces must be resisted by the structure. With the appro-
priate calculated values of bending and thrust, the re-
quired thickness can be determined using the informa-
tion supplied in Figure 2. The shear strength also must
be checked.
HOW THE TESTS WERE CONDUCTED
Specimens were tested under different combinations
of bending moment, shear and axial thrust. The objec-
tive was to develop criteria for design of concrete struc-
tures using this system. One part of the program deter-
mined bending moment-axial thrust interaction, and
the other part determined bending moment-shear in-
teraction.
In Part 1, eleven specimens were tested with the steel
sheets located at the bottom of the cross section to es-
tablish positive bending-axial thrust interaction dia-
g ra m s. Nominal effective depth to the centroid of the
steel V-ribs was 3.3, 5.3, or 7.3 inches. Throughout each
test axial thrust was maintained constant. Howe ve r,
since the ratio of bending to thrust varies around an
arch, different ratios of axial thrust to concrete compres-
sive strength were used to establish interaction diagrams
for each specimen thickness.
Depending on support conditions for the arch, high
negative bending moments could exist at the supports.
Therefore, three specimens were tested with steel sheets
located at the top of the cross section to establish a neg-
ative bending moment-axial thrust interaction diagram.
Nominal effective depth to the steel was 3.3 inches.
These specimens were similar to the others but were
tested upside down.
In Part 2 tests were conducted to investigate bending-
shear interaction. Specimens were tested with the steel
sheets located at the bottom of the cross section. Nomi-
nal effective depth to the centroid of the steel V-ribs was
3.3 or 5.3 inches. The ratio of shear span to effective
depth was maintained constant at 2.
Test specimens
The configuration of test specimens is illustrated in
Figure 3. Each specimen was approximately 14 inches
wide to include three complete waves of sheeting. Spec-
imens were approximately 6 feet long and of va ry i n g
thickness. Specimens subjected to axial load had 1-inch-
thick steel plates welded to the ends of the steel sheets
before casting. This prevented premature end failures by
evenly distributing axial load into the steel and concrete.
Specimens were cast in groups of 12 in gang forms
made for the purpose. Steel sheets in all specimens were
supported off the floor to simulate field casting condi-
tions. After the concrete hardened, the specimens were
turned over and a 1-inch-thick concrete cover was cast
on the original underside. Specimens were stored at 73
F and 50 percent relative humidity at least one month
prior to testing.
Average concrete compressive strength at time of test-
ing was approximately 6000 psi. Yield stress and tensile
strength of the steel sheet were 45,000 psi and 55,000 psi,
respectively.
CONCLUSIONS
1
Section 10.2 of the ACI Building Code or Article 1.5.31
of the AASHTO Specifications2 can be used to determine
capacities of concrete structures using this forming-and-
reinforcing system. For determination of flexural capac-
ity the effective steel area should be taken as the actual
cross-sectional area of the V-ribs alone. Shear strength
design can safely be taken as the shear strength provid-
ed by the concrete, ignoring any contribution by the
steel.
Test results now allow optimum design of these con-
crete structures for earth-sheltered applications, using a
minimum concrete thickness while ensuring adequate
safety.
References
1. ACI Committee 318, Building Code Requirements for
Reinforced Concrete, ACI Standard 318-77, American Con-
crete Institute, Detroit, 1977, 99 pages.
2. Standard Specifications for Highway Bridges, American
Association of State Highway and Transportation Officials,
Washington, D.C., Twelfth Edition, 1977.
Acknowledgement
The test program described in this article was performed by
Construction Technology Laboratories, a division of the
Portland Cement Association, under contract to Metal Prod-
ucts Division, United States Gypsum Company, Chicago,
Illinois.
PUBLICATION #C820581
Copyright 1982, The Aberdeen Group
All rights reserved