Experimental Study on Flexural Fatigue Performance of Steel-Fiber-Concrete-Layered Beams

Fatigue cracking and stiffness degradation remain critical challenges for concrete flexural members used in bridge decks, crane beams, pavements, and other structures subjected to repeated loading. Layered beams that combine normal concrete in the compression zone with steel-fiber concrete in the tension zone offer a promising route to reduce self-weight while retaining crack resistance and ductility. However, the coupled influence of layer depth and fiber dosage on the flexural fatigue response of such members is still insufficiently quantified for reliable engineering design. Unlike previous studies that mainly focused on homogeneous SFRC members, UHPC-based members, or layered beams under static loading, the present study addresses a more practice-oriented but less explored problem, namely the flexural-fatigue behavior of cast-in-place layered beams composed of normal concrete in compression and steel-fiber concrete in tension. More importantly, the study does not examine fiber effect or layer geometry separately, but quantifies within one unified framework how lower-layer height ratio and fiber dosage jointly govern fatigue life, stiffness retention, crack development, and failure transition. A calibrated nonlinear finite-element model with damage-plasticity constitutive laws and cycle-block degradation was further established to reproduce the experiments and to conduct a broader parametric study. The results show that no horizontal crack formed at the cast interface and that the strain-deflection response preserved the typical three-stage fatigue evolution. Increasing either the steel-fiber volume fraction from 0.8% to 1.6% or the lower-layer height ratio from 0.5 to 0.7 markedly prolonged fatigue life and improved crack control. A practical fatigue-life relation, a stiffness-degradation law, and a numerical response surface are proposed, indicating that a height ratio of 0.6–0.7 combined with a fiber dosage of 1.2%–1.6% provides the best balance between fatigue durability, stiffness retention, and failure ductility.