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Natural hazards and resulting technological disasters are currently becoming regular. In these conditions, the creation of emergency shelters is a foremost task of the government to provide the harmed population with housing units in a short time. In the framework of the integration of advanced materials and technologies into steel structures to create safe emergency shelters, experimental research is conducted into adhesively bonded steel-to-steel connections based on epoxy resin laminate. Such connections are interesting for prefabricated modular construction of emergency shelters, as they allow avoiding sectional weakening and stress concentrators common to welding and screw connections. Young’s modulus and shear modulus determined for the epoxy adhesive, are crucial parameters for accurate design. The paper studies the strain distribution in epoxy bonded steel-to-steel connections, identifies strain stages and strain concentration zones, leading to a combined cohesive-adhesive fracture. The obtained results can be used to transfer form empirical building to theoretically substantiated strength analysis of safe and reliable assemblies of prefabricated adhesively bonded steel structures.
The paper presents integrated experimental research into epoxy bonded steel-to-steel connections based on FibArm Resin Laminate+. Tensile strain distribution is identified along the sample longitudinal axis. Four strain stages (elastic, yield plateau, plastic and pre-fracture) are determined together with the evolution of localized elastoplastic strain regions on the surface of the steel plate.
Identified are a nonuniform strain distribution with alternating compressive and tensile strain regions that correlates with transitions on strain-stress curves. The maximum primary relative strain in the epoxy adhesive reaches 3.38 % and concentrates along the adhesive–steel interface
In accordance with GOST 25717-83 requirements, the shear modulus of 236 MPa and Young’s modulus are determined for the epoxy adhesive by B method and the t distribution with the confidence level of 5%. These parameters are used for a transition from empirical building to theoretically substantiated finite element analysis of the stress-strain state of the steel-to-steel connection.
The obtained results help to optimize the design of epoxy bonded steel-to-steel connections in engineering, promoting more continuous load, reduced weight and defects as compared to conventional techniques (welding and screw connections). This work confirms the efficiency of sanding of the steel surface in gaining the best adhesion and resistance to environmental impacts, which is relevant for the iron, aerospace and construction industries.
The paper presents integrated experimental research into epoxy bonded steel-to-steel connections based on FibArm Resin Laminate+. Tensile strain distribution is identified along the sample longitudinal axis. Four strain stages (elastic, yield plateau, plastic and pre-fracture) are determined together with the evolution of localized elastoplastic strain regions on the surface of the steel plate.
Identified are a nonuniform strain distribution with alternating compressive and tensile strain regions that correlates with transitions on strain-stress curves. The maximum primary relative strain in the epoxy adhesive reaches 3.38 % and concentrates along the adhesive–steel interface
In accordance with GOST 25717-83 requirements, the shear modulus of 236 MPa and Young’s modulus are determined for the epoxy adhesive by B method and the t distribution with the confidence level of 5%. These parameters are used for a transition from empirical building to theoretically substantiated finite element analysis of the stress-strain state of the steel-to-steel connection.
The obtained results help to optimize the design of epoxy bonded steel-to-steel connections in engineering, promoting more continuous load, reduced weight and defects as compared to conventional techniques (welding and screw connections). This work confirms the efficiency of sanding of the steel surface in gaining the best adhesion and resistance to environmental impacts, which is relevant for the iron, aerospace and construction industries.
1. Chandramohan D.L., Roy K., Taheri H., et al. A State of the Art Review of Fillet Welded Joints. Materials. 2022. 15. P. 8743. DOI: 10.3390/ma15248743
2. Shen B., Liu M., Wang Y., Zhuge H. Research on Fatigue Strength Evaluation Method of Welded Joints in Steel Box Girders with Open Longitudinal Ribs. Crystals. 2025. 15. P. 646. DOI: 10.3390/cryst15070646
3. Chandramohan D.L., Roy K., Taheri H., Zhiyuan Fang, Lim J.B.P. A State of the Art Review of Fillet Welded Joints. Materials. 2022. 15. P. 8743. DOI: 10.3390/ma15248743
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5. Marchione F. Structural Adhesive Joints: State of the Art, Challenges, and Future Perspectives. International Journal of Engineering. 2025. 38 (5). DOI: 10.5829/ije.2025.38.09c.01
6. Kowatz J., Teutenberg D., Meschut G. Experimental failure analysis of adhesively bonded steel/CFRP joints under quasi-static and cyclic tensile-shear and peel loading. International Journal of Adhesion and Adhesives. 2021. 107. P. 102851. DOI: 10.1016/j.ijadhadh.2021.102851
7. Maiheu T., Kassem H., Roig A., Kolb N., Azzawi A., Prez F.E.D. Debondable polyurethane-inspired adhesives using malonate-formed amide chemistry. European Polymer Journal. 2025. 239. 7 November. P. 114286. DOI: 10.1016/j.eurpolymj.2025.114286
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9. Romanowicz P., Szybinski B., Wygoda M. Fracture Mechanism of Adhesive Layers in Fatigue-Loaded Steel Structures Reinforced by the CFRP Overlays. Applied Sciences. 2025. 15. P. 3435. DOI: 10.3390/app15073435
10. Sługocka M., Grochała D., Kwiatkowski K., Grzejda R., Zmarzły P. Study of the Impact of Surface Topography on Selected Mechanical Properties of Adhesive Joints. Coatings. 2024. 14(8). P. 944. DOI: 10.3390/coatings14080944
11. Zheng X., Hu N., Zhang D., Da Z., Shu L., Li Z., Cang X. Sci Prog. Study on the interface and failure characteristics of joints between epoxy adhesive and duralumin alloy. 2025. Apr-Jun. 108 (2). 00368504251348966. DOI: 10.1177/00368504251348966
12. Rudawska A. Mechanical Properties of Selected Epoxy Adhesive and Adhesive Joints of Steel Sheets. Appl. Mech. 2021. 2. P. 108 – 126. DOI: 10.3390/applmech2010007
13. Mulcahy K.R., Kilpatrick A.F.R., Harper G.D.J., Walton A., Abbott A.P. Debondable adhesives and their use in recycling. Green Chem. 2022. 24. P. 36 – 61. DOI: 10.3390/coatings14080944
14. Dachev D., Kazilas M., Alfano G., Omairey S. Towards Reliable Adhesive Bonding: A Comprehensive Review of Mechanisms, Defects, and Design Considerations. Materials. 2025. 18 (12). P. 2724. DOI: 10.3390/ma18122724
15. Anasiewicz K., Kuczmaszewski J. Apparent Young’s Modulus of Epoxy Adhesives. Materials. 2022. 15. P. 8060. DOI: 10.3390/ma15228060
16. Akkasali N.K., Biswas S., Sen S. Numerical failure load analysis and prediction (ANN technique) of AA2014 adhesively bonded single lap joint: An experimental validation. International Journal of Adhesion and Adhesives. 2025. 143. P. 104157. DOI: 10.1016/j.ijadhadh.2025.104157
17. Mousavi S.R., Estaji S., Paydayesh A., Arjmand M., Jafari S.H., Nouranian S., Khonakdar H.A. A review of recent progress in improving the fracture toughness of epoxy-based composites using carbonaceous nanofillers. Polym. Compos. 2022. 43. P. 1871 – 1886. DOI: 10.1002/pc.26518
18. Klopotov A., Slobodyan M., Smirnov A., Ababkov N., Popova N., Kurgan K., Ustinov A., Abzaev Y., Nikonenko E. Effect of deformation-induced martensitic transformations in a SMAW butt joint of the 304 stainless steel on its strain field distributions. 2022. 53A. P. 942 – 960. DOI: 10.1007/s11661-021-06566-1
19. Klopotov A.A., Ivanov Yu.F., Ustinov A.M., Teresov A.D., Abzaev Yu.A., Litvinova V.A., Influence of Modification of the Surface of a Metal Matrix on the Mechanical Properties of Silumin/CFRP Layered Composites. Journal of Surface Investigation: X-ray, Synchrotron and Neutron Techniques, 2023. 17 (3). P. 548 – 555. DOI: 10.1134/S1027451023030072
20. Machikhin A., Poroykov A., Bardakov V. et al. Combined Acoustic Emission and Digital Image Correlation for Early Detection and Measurement of Fatigue Cracks in Rails and Train Parts under Dynamic Loading. Sensors. 2022. 22. P. 9256. DOI: 10.3390/s22239256. URL: https://www.mdpi.com/journal/sensors
21. Demiral M. Strength in Adhesion: A Multi-Mechanics Review Covering Tensile, Shear, Fracture, Fatigue, Creep, and Impact Behavior of Polymer Bonding in Composites. Polymers. 2025. 17. P. 2600. DOI: 10.3390/polym17192600
22. Ustinov A.A., Babayevsky P.G., Kozlov N.A., Salienko N.V. Numerical Evaluation of Subcritical Crack Growth Kinetics in Structural Adhesive Joints under Long-Term Static Loads Using Cohesive Zone Model and Experimental Data. Inorganic Materials: Applied Research. 2022. 13(2). P. 580 – 587. DOI: 10.1134/S2075113322020411
23. Potekaev A.I., Klopotov A.A., Plyaskin A.S., Ustinov A.M., Volokitin O.G. Strength and deformation properties of some building materials, structural elements, buildings and structures. Tomsk: NTL, 2022. 256 p.
2. Shen B., Liu M., Wang Y., Zhuge H. Research on Fatigue Strength Evaluation Method of Welded Joints in Steel Box Girders with Open Longitudinal Ribs. Crystals. 2025. 15. P. 646. DOI: 10.3390/cryst15070646
3. Chandramohan D.L., Roy K., Taheri H., Zhiyuan Fang, Lim J.B.P. A State of the Art Review of Fillet Welded Joints. Materials. 2022. 15. P. 8743. DOI: 10.3390/ma15248743
4. Croccolo D., De Agostinis M., Fini S., et al. Optimization of Bolted Joints: A Literature Review. Metals. 2023. 13. P. 1708. DOI: 10.3390/met13101708
5. Marchione F. Structural Adhesive Joints: State of the Art, Challenges, and Future Perspectives. International Journal of Engineering. 2025. 38 (5). DOI: 10.5829/ije.2025.38.09c.01
6. Kowatz J., Teutenberg D., Meschut G. Experimental failure analysis of adhesively bonded steel/CFRP joints under quasi-static and cyclic tensile-shear and peel loading. International Journal of Adhesion and Adhesives. 2021. 107. P. 102851. DOI: 10.1016/j.ijadhadh.2021.102851
7. Maiheu T., Kassem H., Roig A., Kolb N., Azzawi A., Prez F.E.D. Debondable polyurethane-inspired adhesives using malonate-formed amide chemistry. European Polymer Journal. 2025. 239. 7 November. P. 114286. DOI: 10.1016/j.eurpolymj.2025.114286
8. Sullivan K., Peterman K.D. A review of adhesive steel-to-steel connections for use in heavy construction. Journal of Constructional Steel Research. 2024. 213. P. 108405. DOI: 10.1016/J.JCSR.2023.108405/
9. Romanowicz P., Szybinski B., Wygoda M. Fracture Mechanism of Adhesive Layers in Fatigue-Loaded Steel Structures Reinforced by the CFRP Overlays. Applied Sciences. 2025. 15. P. 3435. DOI: 10.3390/app15073435
10. Sługocka M., Grochała D., Kwiatkowski K., Grzejda R., Zmarzły P. Study of the Impact of Surface Topography on Selected Mechanical Properties of Adhesive Joints. Coatings. 2024. 14(8). P. 944. DOI: 10.3390/coatings14080944
11. Zheng X., Hu N., Zhang D., Da Z., Shu L., Li Z., Cang X. Sci Prog. Study on the interface and failure characteristics of joints between epoxy adhesive and duralumin alloy. 2025. Apr-Jun. 108 (2). 00368504251348966. DOI: 10.1177/00368504251348966
12. Rudawska A. Mechanical Properties of Selected Epoxy Adhesive and Adhesive Joints of Steel Sheets. Appl. Mech. 2021. 2. P. 108 – 126. DOI: 10.3390/applmech2010007
13. Mulcahy K.R., Kilpatrick A.F.R., Harper G.D.J., Walton A., Abbott A.P. Debondable adhesives and their use in recycling. Green Chem. 2022. 24. P. 36 – 61. DOI: 10.3390/coatings14080944
14. Dachev D., Kazilas M., Alfano G., Omairey S. Towards Reliable Adhesive Bonding: A Comprehensive Review of Mechanisms, Defects, and Design Considerations. Materials. 2025. 18 (12). P. 2724. DOI: 10.3390/ma18122724
15. Anasiewicz K., Kuczmaszewski J. Apparent Young’s Modulus of Epoxy Adhesives. Materials. 2022. 15. P. 8060. DOI: 10.3390/ma15228060
16. Akkasali N.K., Biswas S., Sen S. Numerical failure load analysis and prediction (ANN technique) of AA2014 adhesively bonded single lap joint: An experimental validation. International Journal of Adhesion and Adhesives. 2025. 143. P. 104157. DOI: 10.1016/j.ijadhadh.2025.104157
17. Mousavi S.R., Estaji S., Paydayesh A., Arjmand M., Jafari S.H., Nouranian S., Khonakdar H.A. A review of recent progress in improving the fracture toughness of epoxy-based composites using carbonaceous nanofillers. Polym. Compos. 2022. 43. P. 1871 – 1886. DOI: 10.1002/pc.26518
18. Klopotov A., Slobodyan M., Smirnov A., Ababkov N., Popova N., Kurgan K., Ustinov A., Abzaev Y., Nikonenko E. Effect of deformation-induced martensitic transformations in a SMAW butt joint of the 304 stainless steel on its strain field distributions. 2022. 53A. P. 942 – 960. DOI: 10.1007/s11661-021-06566-1
19. Klopotov A.A., Ivanov Yu.F., Ustinov A.M., Teresov A.D., Abzaev Yu.A., Litvinova V.A., Influence of Modification of the Surface of a Metal Matrix on the Mechanical Properties of Silumin/CFRP Layered Composites. Journal of Surface Investigation: X-ray, Synchrotron and Neutron Techniques, 2023. 17 (3). P. 548 – 555. DOI: 10.1134/S1027451023030072
20. Machikhin A., Poroykov A., Bardakov V. et al. Combined Acoustic Emission and Digital Image Correlation for Early Detection and Measurement of Fatigue Cracks in Rails and Train Parts under Dynamic Loading. Sensors. 2022. 22. P. 9256. DOI: 10.3390/s22239256. URL: https://www.mdpi.com/journal/sensors
21. Demiral M. Strength in Adhesion: A Multi-Mechanics Review Covering Tensile, Shear, Fracture, Fatigue, Creep, and Impact Behavior of Polymer Bonding in Composites. Polymers. 2025. 17. P. 2600. DOI: 10.3390/polym17192600
22. Ustinov A.A., Babayevsky P.G., Kozlov N.A., Salienko N.V. Numerical Evaluation of Subcritical Crack Growth Kinetics in Structural Adhesive Joints under Long-Term Static Loads Using Cohesive Zone Model and Experimental Data. Inorganic Materials: Applied Research. 2022. 13(2). P. 580 – 587. DOI: 10.1134/S2075113322020411
23. Potekaev A.I., Klopotov A.A., Plyaskin A.S., Ustinov A.M., Volokitin O.G. Strength and deformation properties of some building materials, structural elements, buildings and structures. Tomsk: NTL, 2022. 256 p.
Ustinov A.M., Klopotov A.A., Prishchepa I.A., Popov A.V., Samchenko S.V., Kudyakov K.L. Adhesive bond integration into steel structures of emergency shelters. Construction Materials and Products. 2025. 8 (6). 4. https://doi.org/10.58224/2618-7183-2025-8-6-4