The aim of this paper is to investigate the flexural performance of a new steel–concrete composite beam system, which is required to carry higher loads when applied in flooring systems with less self-weight and cost compared with conventional composite beams. This new composite member is prepared by filling a single cold-formed steel C-section with concrete material that has varied lightweight-recycled aggregates. In addition, varied stiffening scenarios are suggested to improve the composite behavior of this member, since these cold-formed C-sections are of a slender cross-section and more likely to buckle and twist under high bending loads than those of hot-rolled C-sections. The influence of using four different lightweight-recycled aggregates that combine together in the infill concrete material was investigated. These recycled aggregates are recycled concrete aggregate (RCA), expanded polystyrene (EPS) beads, crumb rubber aggregates (CRA) and fine glass aggregates (FGA). For this purpose, 14 samples of cold-formed galvanized steel C-purlin were filled with concrete material (containing 0 to 100% recycled aggregates) which are experimentally tested under pure bending load, and 1 additional sample was tested without the filling material. Further numerical models were prepared and analyzed using finite element analysis software to investigate the effects of additional parameters that were not experimentally examined. Generally, the results confirm that filling the C-sections with concrete material that contains varied percentages of recycled aggregates offer significantly improved the flexural stiffness, bending capacity, and ductility performances. For example, using infill concrete materials with 0% and 100% recycled aggregate replacement increased the bending capacity of hollow C-section by about 11.4 and 8.6 times, respectively. Furthermore, stiffening of the concrete-filled C-sections with steel strips or screw connectors eventually improved the composite behavior of the specimens which led to an increase in their bending capacities accordingly, and this improvement enhanced more with an increased number of these strips and connectors.

In this study, the flexural performance of a new composite beam–slab system filled with concrete material was investigated, where this system was mainly prepared from lightweight cold-formed steel sections of a beam and a deck slab for carrying heavy floor loads as another concept of a conventional composite system with a lower cost impact. For this purpose, seven samples of a profile steel sheet–dry board deck slab (PSSDB/PDS) carried by a steel cold-formed C-purlins beam (CB) were prepared and named “composite CBPDS specimen”, which were tested under a static bending load. Specifically, the effects of the profile steel sheet (PSS) direction (parallel or perpendicular to the span of the specimen) using different C-purlins configurations (double sections connected face-to-face, double separate sections, and a single section) were investigated. The research discussed the specimens’ failure modes, flexural behavior, bending capacity, bending strain relationships, and energy absorption index of specimens. Generally, the CBPDS specimens with the PSS slab placed in a parallel direction achieved approximately a 13–40% higher bending capacity compared with the corresponding specimens with a perpendicular PSS direction (depending on the configuration of the beam). Fabricating the beam of the CBPDS specimen with double C-purlins (face-to-face) led to more effective concrete confinement behavior compared with the double separate C-purlins beam. The related specimen recorded a 10% higher bending capacity. Finally, the suggested composite CBPDS system exhibited a sufficient energy absorption capability of the static bending load because it demonstrated high strength and high ductility.

This study investigated the structural behavior of a beam–slab member fabricated using a steel C-Purlins beam carrying a profile steel sheet slab covered by a dry board sheet filled with recycled aggregate concrete, called a CBPDS member. This concept was developed to reduce the cost and self-weight of the composite beam–slab system; it replaces the hot-rolled steel I-beam with a steel C-Purlins section, which is easier to fabricate and weighs less. For this purpose, six full-scale CBPDS specimens were tested under four-point static bending. This study investigated the effect of using double C-Purlins beams face-to-face as connected or separated sections and the effect of using concrete material that contains different recycled aggregates to replace raw aggregates. Test results confirmed that using double C-Purlins beams with a face-to-face configuration achieved better concrete confinement behavior than a separate configuration did; specifically, a higher bending capacity and ductility index by about +10.7% and +15.7%, respectively. Generally, the overall bending behavior of the tested specimens was not significantly affected when the infill concrete’s raw aggregates were replaced with 50% and 100% recycled aggregates; however, their bending capacities were reduced, at −8.0% and −11.6%, respectively, compared to the control specimen (0% recycled aggregates). Furthermore, a new theoretical model developed during this study to predict the nominal bending strength of the suggested CBPDS member showed acceptable mean value (0.970) and standard deviation (3.6%) compared with the corresponding test results.