AS 3850.1-2015 Prefabricated Concrete Elements - General Requirements PDF

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AS 3850.1:2015
Part 1: General requirements

Prefabricated concrete elements
AS 3850.1:2015
This Australian Standard® was prepared by Committee BD-066, Tilt-up Construction. It was
approved on behalf of the Council of Standards Australia on 8 July 2015.
This Standard was published on 3 September 2015.
The following are represented on Committee BD-066:
• Australasian Fire and Emergency Service Authorities Council

• Australian Council of Trade Unions
• Australian Engineered Fasteners and Anchors Council
• Australian Institute of Building Surveyors
• Australian Steel Institute
• Building Designers Association of NSW
• Cement Concrete and Aggregates Australia
• Concrete Institute of Australia
• Concrete Pipe Association of Australasia
• Crane Industry Council of Australia
• Curtin University of Technology
• Engineers Australia
• Master Builders Australia
• National Association of Testing Authorities Australia
• National Precast Concrete Association Australia
• Steel Reinforcement Institute of Australia

• Sydney University
• WorkCover New South Wales
• WorkSafe Victoria
This Standard was issued in draft form for comment as DR2 AS 3850.1.
Standards Australia wishes to acknowledge the participation of the expert individuals that
contributed to the development of this Standard through their representation on the
Committee and through the public comment period.
Keeping Standards up-to-date

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using a current Standard, which should include any amendments that may have been
published since the Standard was published.
Detailed information about Australian Standards, drafts, amendments and new projects can
be found by visiting www.standards.org.au
Standards Australia welcomes suggestions for improvements, and encourages readers to

notify us immediately of any apparent inaccuracies or ambiguities. Contact us via email at
mail@standards.org.au, or write to Standards Australia, GPO Box 476, Sydney, NSW 2001.
AS 3850.1:2015
Australian Standard®

Originated as AS 3850.1—1990, AS 3850.2—1990 and AS 3850.3—1992.

AS 3850.1—1990, AS 3850.2—1990 and AS 3850.3—1992 revised,
amalgamated and redesignated as AS 3850—2003.
AS 3850—2003 revised and redesignated (in part) as AS 3850.1:2015.
COPYRIGHT
© Standards Australia Limited
All rights are reserved. No part of this work may be reproduced or copied in any form or by
any means, electronic or mechanical, including photocopying, without the written
permission of the publisher, unless otherwise permitted under the Copyright Act 1968.
Published by SAI Global Limited under licence from Standards Australia Limited, GPO Box
476, Sydney, NSW 2001, Australia
ISBN 978 1 76035 242 4
AS 3850.1:2015 2
PREFACE
This Standard was prepared by the Standards Australia Committee
BD-066, Tilt up Construction, to supersede, in part, AS 3850—2003, Tilt-up concrete
construction.
The AS 3850 series comprises the following parts:
AS
3850 Prefabricated concrete elements
3850.1 Part 1: General requirements
3850.2 Part 2: Building construction
The objective of this part of the Standard is to provide requirements for the materials,
components and equipment used in the manufacture of prefabricated concrete elements.
In this Standard where the word ‘shall’ is used, a mandatory requirement is implied; where
the word ‘should’ is used, a recommendation is implied.
Statements expressed in mandatory terms in notes to tables are deemed to be requirements
of this Standard.
The terms ‘normative’ and ‘informative’ have been used in this Standard to define the
application of the appendix to which they apply. A ‘normative’ appendix is an integral part
of a Standard, whereas an ‘informative’ appendix is only for information and guidance.
This document includes commentary on some of the clauses of the Standard. The
commentary directly follows the relevant clause, is designated by ‘C’ preceding the
clause number and is printed in italics in a box. The commentary is for information and
guidance and does not form part of the Standard.
3 AS 3850.1:2015
CONTENTS
Page
SECTION 1 SCOPE AND GENERAL

1.1 SCOPE ......................................................................................................................... 4
1.2 APPLICATION ........................................................................................................... 4
1.3 NORMATIVE REFERENCES .................................................................................... 4
1.4 DEFINITIONS............................................................................................................. 5
1.5 NOTATION ............................................................................................................... 10
SECTION 2 MATERIALS, COMPONENTS AND EQUIPMENT

2.1 GENERAL ................................................................................................................. 15
2.2 WORKING LOAD LIMIT (WLL) CALCULATION ................................................ 15
2.3 CONCRETE AND REINFORCEMENT ................................................................... 16
2.4 CURING COMPOUNDS AND RELEASE AGENTS ............................................... 16
2.5 LIFTING, BRACE AND FIXING INSERTS ............................................................ 17
2.6 LIFTING CLUTCHES............................................................................................... 20
2.7 BRACES .................................................................................................................... 21
2.8 LEVELLING PADS AND SHIMS ............................................................................ 22

2.9 CRANE AND RIGGING EQUIPMENT ................................................................... 23
2.10 DOCUMENTATION ................................................................................................. 23
APPENDICES
A TESTING OF MATERIALS AND COMPONENTS ................................................. 24
B CONCRETE CAPACITY DESIGN FOR CAST-IN LIFTING AND BRACE
INSERTS ................................................................................................................... 55
BIBLIOGRAPHY ..................................................................................................................... 69
AS 3850.1:2015 4
STANDARDS AUSTRALIA
Australian Standard
S E C T I O N 1 S C O P E A N D G E N E R A L
1.1 SCOPE
This Standard provides general requirements for the materials, components and equipment
used in the manufacture of prefabricated concrete elements.
1.2 APPLICATION
This Standard shall be read in conjunction with AS 3850.2 and AS 3600.
1.3 NORMATIVE REFERENCES

The following are the normative documents referenced in this Standard.
NOTE: Documents referenced for informative purposes are listed in the Bibliography.
AS
1012 Methods of testing concrete (series)
1110 ISO metric precision hexagon bolts and screws (series)
1111 ISO metric hexagon bolts and screws
1111.1 Part 1: Product grade C—Bolts
1199 Sampling procedures for inspection by attributes
1199.1 Sampling schemes indexed by acceptance quality limit (AQL) for lot-by-
lot inspection
1171 Non-destructive testing—Magnetic particle testing of ferromagnetic
products, components and structures
1379 Specification and supply of concrete
1391 Metallic materials—Tensile testing at ambient temperature
1733 Methods for the determination of grain size in metals
2193 Calibration and classification of force-measuring systems
2550 Cranes, hoists and winches—Safe use (series)
3600 Concrete structures
3799 Liquid membrane-forming curing compounds for concrete
3850 Prefabricated concrete elements
3850.2 Part 2: Building construction
4100 Steel structures
AS/NZS
4671 Steel reinforcing materials
© Standards Australia www.standards.org.au

5 AS 3850.1:2015
ABCB
NCC National Construction Code
ASTM
D618 Standard Practice for Conditioning Plastics for Testing
D695 Standard Test Method for Compressive Properties of Rigid Plastics
CEN/TR
15728:2008 Design And Use Of Inserts For Lifting And Handling Of Precast
Concrete—Elements
CEN/TS
1992 Design of fastenings for use in concrete
1992-4-2:2009 Part 4-2: Headed fasteners
ETAG
001 Metal anchors for use in concrete (series)
1.4 DEFINITIONS
For the purposes of this Standard, the definitions in AS 3600 and those below apply.
1.4.1 Axial insert loading
Load applied along the longitudinal axis of the insert.

1.4.2 Bending insert loading
Bending effect induced by a shear load applied with an eccentricity with respect to the
centroid of resistance.
1.4.3 Blow-out failure
Spalling of the concrete on the side face of the anchorage component at the level of the
embedded head, with no major breakout at the top concrete surface.
NOTE: This is usually associated with inserts with small side cover and deep embedment
[see Figure A5(e), Appendix A].
1.4.4 Bondbreaker
A chemical product used to prevent bonding of freshly poured concrete to a concrete
substrate.
1.4.5 Brace
A temporary support (which is usually inclined but may be horizontal in certain
circumstances) that provide stability for vertical prefabricated concrete elements to prevent
overturning, with both ends of the brace fitted with a pinned foot, allowing a degree of
freedom for variable fixing angles.
NOTE: Unless otherwise specified, a reference in this Standard to a brace means a primary brace.
1.4.6 Brace insert
A component or system cast or post-installed into the prefabricated concrete element, or
into a supporting member, for later attachment of a brace.
1.4.7 Bracing feet or shoes
The elements that connect braces onto a prefabricated concrete element or onto the bracing
support by way of pinned connections and inserts.
1.4.8 Characteristic spacing
Spacing required to ensure the characteristic resistance of a single insert.
www.standards.org.au © Standards Australia

AS 3850.1:2015 6
1.4.9 Characteristic value

The 5% fractile (value with a 95% probability of being exceeded, with a confidence of
90%).
1.4.10 Compatible
The coordinated use of two (or more) separate components without compromise to the
working load limit (WLL) or utility of either component.
1.4.11 Competent person
A person who has acquired through training, qualification or experience, or a combination
of these, the knowledge and skills to enable that person to perform the required task.
1.4.12 Component reinforcement
Reinforcement placed in conjunction with lifting, brace and fixing inserts and required to
achieve the nominated capacities of the inserts.
1.4.13 Concrete cone failure
Failure that corresponds to a wedge or cone of concrete surrounding the insert separating
from the base material.
NOTES:
1 See Figure A4, illustrations (a) and (b), Appendix A.

2 Concrete cone failure occurs when a load is applied to an insert embedded in concrete until
tensile failure of the concrete occurs and a ‘cone’ or ‘wedge’ of concrete is pulled from the
main body of the element, together with the insert See Figure A4(a) , Appendix A.
1.4.14 Concrete pry-out failure
Failure that corresponds to the formation of a concrete spall opposite to the loading
direction under shear loading.
NOTE: See Figure A5(b), Appendix A.
1.4.15 Drop zone
A designated restricted area in and around a building construction site where items may
potentially fall through or onto.
NOTE: The drop zone of each building site is determined by and detailed in the builders Safe
Work Method Statement.
1.4.16 Ductile material
A material that demonstrates plastic elongation after yielding.
1.4.17 Edge distance
Distance from the edge of the concrete element to the centre of the insert.
1.4.18 Edge lifting
A method of lifting prefabricated concrete elements with lifting inserts located within the
edges of the element.
NOTES:
1 For edge lifting, see Figure 2.4 of AS 3850.2.
2 For edge lifting inserts, see Figure C2.5.2.2.
1.4.19 Effective embedment depth
See Figure B2, Appendix B.

7 AS 3850.1:2015
1.4.20 Erection designer

A competent person who is an engineer and is responsible for the erection design of the
structure.
1.4.21 Erection platform (crane standing)
The base that supports the crane during erection of the prefabricated concrete elements.
1.4.22 Expansion anchors
Anchors placed in appropriately sized holes drilled in hardened concrete, which rely on
expansion devices interacting with the sides of the hole to prevent pull-out under design
load. The two types of expansion anchors are the following:
(a) Deformation-controlled—anchors that are expanded only during installation.
NOTE: Application of load to the anchor does not increase the expansion forces.
(b) Torque-controlled (also referred to as load-controlled)—anchors that have a wedge
and expansion-shield system where the wedge is directly connected to the applied
load.
NOTE: Increases in load above the retained preload (obtained from initial torque) will
increase the expansion force.
1.4.23 Face-lifting
A method of lifting a prefabricated concrete element using lifting inserts located in the ‘as
cast’ upper surface of the element.
NOTE: See Figure 2.4 of AS 3850.2.
1.4.24 Ferrule
A cast-in insert to accept a threaded bolt.
1.4.25 Fixing insert
A component or system cast or post-installed into the prefabricated concrete element and
subsequently used to bolt the structure together or support other architectural or structural
members.
1.4.26 Flat-lifting
A method of lifting a prefabricated concrete element where the orientation of the element
does not change throughout the lift.
NOTE: See Figure 2.2 of AS 3850.2.
1.4.27 Headed insert
A type of insert with an enlarged cast-in end that is installed before placing concrete, which
transfers load to the concrete by way of mechanical interlock at the insert head.
1.4.28 Innovative insert
Any insert that does not conform to the requirements of a reference insert.
1.4.29 Insert spacing
Distance between the centre-lines of the inserts.
1.4.30 In-service designer
A competent person who is an engineer and is responsible for design of the structure or
element to resist the load the building will experience in its lifetime subsequent to
completion of construction.
NOTE: The in-service engineer ensures that the design is constructible.

AS 3850.1:2015 8
1.4.31 Killed steel

Silicon or aluminium deoxidized steel.
1.4.32 Knee brace
An element, which is part of a secondary bracing system, that reduces the effective length
of a primary brace, with the secondary bracing system having a positive connection to each
end and usually connecting at mid-span of main brace.
NOTE: Cross-lacing may be incorporated to complete the system.
1.4.33 Levelling pad
A bearing area (e.g. a mortar bed or shims) used to provide support for a prefabricated
concrete element.
1.4.34 Lifting clutch
A re-usable device used to connect the crane rigging to a compatible lifting insert.
1.4.35 Lifting insert
A component or system cast or post-installed into the prefabricated concrete element for
later attachment of the lifting device.
1.4.36 Minimum element thickness
Minimum element thickness in which an insert can be installed.

1.4.37 Plate style edge lift insert
An insert, essentially planar in form, that is shaped to provide concrete interlock.
NOTE: For typical edge lift insert, see Figure C.2.5.2.2.
1.4.38 Precast element
A prefabricated concrete element.
1.4.39 Prefabricated concrete element
A concrete element manufactured at a place different from its final place of installation.
C1.4.39 Prefabricated elements may be manufactured on or off site, and essentially
include all concrete elements that are not cast in situ.
1.4.40 Progressive collapse
A continuous sequence of failures initiated by the local failure of one part of the structure.
1.4.41 Prop
Temporary supports for prefabricated concrete elements perpendicular to the surface of the
elements, primarily for supporting gravity and construction loads, and usually vertical.
1.4.42 Pull-out failure
A failure mode in which the insert pulls out of the concrete without development of a
concrete cone.
NOTE: For a depiction of pull-out failure, see Figure A4(d), Appendix A.
1.4.43 Reference insert
A round body headed insert with a minimum net bearing area of four times the
cross-sectional area of the body of the insert in accordance with Clause 13.1.4 of
AS 3600—2009, and a head diameter at least equal to 2.4 times the shaft diameter
(i.e. di, h > 2.4 di) in accordance with Clause 8.3.2 of CEN/TR 15728:2008.
NOTE: The bearing area is the head area less the shaft area (see Figure B1, Appendix B).

9 AS 3850.1:2015
1.4.44 Release agent

A chemical product used to prevent bonding of the freshly poured concrete to a substrate
other than concrete.
1.4.45 Re-usable lifting equipment
A device that connects the rigging directly to the element or a lifting insert.
NOTE: Examples are a lifting clutch, eye bolt, shackle and bolt-on brackets.
1.4.46 Shear insert loading
Shear induced by a load applied perpendicular to the longitudinal axis of the insert.
1.4.47 Splitting failure
A concrete failure mode in which the concrete fractures along a plane passing through the
axis of the insert or inserts.
NOTE: For a depiction of splitting failure, see Figure A4(f), Appendix A.
1.4.48 Stack casting
Casting one prefabricated concrete element on top of another.
1.4.49 Strongback
A temporary member used to provide localized strengthening, support or a suitable tilting

edge for prefabricated concrete elements.
1.4.50 Structural reinforcement
Reinforcement, including reinforcing steel and prestressing tendons, provided for crack
control or to resist forces caused by in-service loading and thermal and shrinkage
movements.
1.4.51 Supplementary reinforcement
Reinforcement, additional to the structural reinforcement, provided to resist forces caused
by manufacturer, handling, transport, construction and erection loads.
1.4.52 Temporary fixing
Fixing that is designed to transfer temporary loads during construction.
NOTE: Temporary fixings are not required to transfer loads in the permanent structure.
1.4.53 Tilt-up
A method of lifting a prefabricated concrete element from a horizontal to a vertical position
by rotation about one edge.
1.4.54 Tilt-up element
Prefabricated concrete elements lifted or erected by the tilt-up method.
1.4.55 Working load limit (WLL)
The maximum load that may be applied to an item, component or system.
NOTE: For design purposes, this is an unfactored load in terms of AS/NZS 1170.0 and not the
design load.

AS 3850.1:2015 10
1.5 NOTATION
For the purpose of this Standard, the symbols given in AS 3600 and the following apply:
Ac,N = actual projected area for concrete cone failure of single insert idealized as a
rectilinear pyramid of height hef
Ac,Nb = idealized projected area for concrete blow-out
Ac,V = idealized area of concrete cone at the lateral concrete surface for shear failure
Ah = loadbearing area of the head of the insert
As = stress cross-sectional area of brace insert bolt
As,re = cross-section area of the splitting reinforcement
Ac,0 N = projected concrete failure area of a single insert idealized as a rectilinear

pyramid of height hef and base length Si,cr,N = 3hef where the distance to an edge
is equal to or greater than 1.5hef
Ac,0 Nb = reference projected area for concrete blow-out
Ac,0 V = idealized area of concrete cone of an individual insert at the lateral concrete
surface not affected by edges, element thickness or adjacent inserts
a = spacing of stirrups or wire mesh

c = edge distance
ci = edge distance measured from the centre of an insert shaft to the edge of the
concrete
ci,cr,N = minimum edge distance required to achieve the characteristic tension load
resistance
ci,cr,N,mod= modified minimum value for edge distance to achieve characteristic resistance to
tension load
ci,cr,sp = minimum value for edge distance to achieve characteristic resistance to splitting
ci,max = maximum distance from centre of an insert to the edge of concrete element
ci,min = minimum value for edge distance to achieve characteristic resistance
ci,1 = edge distance to first edge
ci,1,mod = modified edge distance to first edge
ci,2 = edge distance to second edge
ci,2,max = largest of two edge distances parallel to the direction of loading
dcut,m = medium cutting diameter of drill bit
df = diameter of clearance hole in the shear test sleeve
di = diameter of the shank of insert
di,h = diameter of the head of insert
di,nom = nominal outside diameter of the insert
fbd = design bond strength
fcm = mean value of the in situ compressive strength of concrete at the relevant age
flift = compressive strength of concrete at the time of lifting
FoS = working load limit factor

11 AS 3850.1:2015
fsy = nominal yield strength of the reinforcing steel

fsu = characteristic ultimate strength of insert
f c′ = characteristic compressive (cylinder) strength of concrete at 28 days
f ct′ = characteristic uniaxial tensile strength of concrete
f c,′ age = characteristic compressive strength of concrete at the age of loading
H = concrete element depth

H min = minimum concrete element thickness requirements to avoid splitting failure
hef = effective embedment depth of the insert
hef,mod = modified effective depth of embedment for narrow elements
kcr = factor relating to condition of concrete (cracked/non-cracked)
ks = sampling factor
lf = loadbearing length of the insert in shear = hef in case of a uniform diameter of
the shank of the headed insert
Nd = design tensile strength of brace insert
N m,bas = mean tensile strength of the brace insert determined from basic tension tests
N m,c,bas = mean ultimate load of concrete cone failure based on basic tension tests
N m,p,bas = mean ultimate load of pull-out failure mode based on basic tension tests
N m,pcyc = mean ultimate tensile strength of the insert determined from post-cyclic slip
tension tests
N m,s,bas = mean ultimate load of steel based on basic tension tests
Ns = tension component of the applied load
Ns,lim tensile strength of the brace insert determined in accordance with AS 4100
Nu = characteristic tensile resistance of insert
Nult = ultimate load of a given test
Nuslip = load at uncontrolled slip of the brace insert
Nu,bas = characteristic ultimate tensile strength of the brace insert determined from basic
tension tests
Nu,c = characteristic tensile resistance of an insert in the case of concrete cone failure
Nu,c,bas = characteristic ultimate load of concrete cone failure based on basic tension tests
Nu,c,Inn = characteristic tensile resistance of an innovative insert to concrete cone failure
Nu,c,Ref = characteristic tensile resistance of a reference insert to concrete cone failure
Nu,c,β = basic concrete breakout strength of an insert loaded in tension, accounting for
the shape modification factor
Nu,cb = characteristic resistance of an insert in the case of blow-out failure
Nu,cb,Inn = characteristic tensile resistance of an innovative insert in the case of blow-out
failure
Nu,cb,Ref = characteristic tensile resistance of a reference insert in the case of blow-out
failure

AS 3850.1:2015 12
Nu,p = characteristic resistance of an insert in the case of pull-out failure

Nu,pcyc = characteristic tensile strength of the brace insert determined from post-cyclic slip
tension tests
Nu,p,bas = characteristic ultimate load of pull-out failure mode based on basic tension tests
Nu,p,Inn = characteristic tensile resistance of an innovative insert in the case of pull-out
failure
Nu,p,Ref = characteristic tensile resistance of a reference insert in the case of pull-out
failure
Nu,ref = characteristic resistance of an insert having predefined reference geometry
Nu,s,bas = characteristic ultimate load of steel based on basic tension tests
Nu,sp = characteristic resistance of an insert in the case of splitting failure
Nu,sp,Inn = characteristic tensile resistance of an innovative insert in the case of concrete
splitting failure
Nu,sp,Ref = characteristic tensile resistance of a reference insert in the case of concrete
splitting failure
N u,0 c = characteristic resistance of a single insert placed in cracked concrete and not
influenced by adjacent inserts or edges of the concrete element for concrete cone
failure/characteristic tensile pull-out strength of an insert when tested in
accordance with Paragraph A7, Appendix A
N u,0 cb.β = characteristic resistance of an insert to blow-out failure, not influenced by

adjacent inserts or free structural component edges placed in cracked concrete
including the shape modification factor
N1 = load corresponding to limit for uncontrolled slip
N* = design tension load applied to insert
N*s = design tension component of the applied load
n = accumulated sample size or total number of components tested to destruction
Ru = critical characteristic strength of an element or assemblage (limiting case of Nk,
Vk or a combination of these)
Ru,N = critical characteristic ultimate normalized tensile strength of the insert
considering the effects of slip due to cyclic loading
Ru,Ncp = characteristic ultimate tensile strength of post-installed brace insert normalised
to a concrete strength equal to 20 MPa for concrete cone failure or pull-out
failure
Ru,Ns = characteristic ultimate tensile strength of post-installed brace insert for steel
failure
Ru,V = critical characteristic ultimate normalized shear strength of the insert
Ru,Vc = characteristic ultimate shear strength of post-installed brace insert normalized to
a concrete strength equal to 20 MPa for concrete failure
Ru,Vs = characteristic ultimate shear strength of post-installed brace insert for steel
failure
s = standard deviation of a finite population of components tested to destruction
si = spacing of inserts

13 AS 3850.1:2015
si,cr,N = critical spacing to ensure adjacent inserts do not influence characteristic tensile
resistance of insert
si,cr,N,mod = modified critical spacing to ensure characteristic tensile resistance of insert in a
narrow element
si,cr,sp = critical spacing to ensure adjacent inserts do not influence characteristic splitting
resistance of insert
si,max = maximum centre to centre spacing of inserts in a group
si,min = minimum spacing required to avoid splitting failure
si,1 = spacing of inserts in direction 1
si,2 = spacing of inserts in direction 2
St = test load
T = torque
Tinst = installation torque
tfix = thickness of shear test sleeve
V = coefficient of variation
Vs = shear component of the applied load

Vs,lim = shear strength of the brace insert determined in accordance with AS 4100
Vu,bas = basic characteristic shear strength of the brace insert for concrete mode of failure
Vu,c = characteristic shear resistance of an insert
Vu,c,Inn = characteristic shear resistance of an innovative insert in the case of concrete
edge failure
Vu,c,Ref = characteristic shear resistance of a reference insert in the case of concrete edge
failure
Vu,0c = characteristic shear strength of a reference insert (R), being a round body, cast-in
headed insert with a minimum net bearing area of 4 times the cross-sectional
area of the body of the insert
Vu,0c,β = initial value of the characteristic resistance of an insert loaded perpendicular to

the edge in cracked concrete, including provision for a shape modification factor
V* = design shear load applied to insert
V*s = design shear component of the applied load
v = coefficient of variation of ultimate loads for tension tests
wk = width of crack
x = mean value of the test results of the accumulated sample of components
xi = test result of each individual component of the sample
Xk = characteristic value of the test values
z = internal lever arm of the concrete element
α = influencing factor based on the shape of the supplementary reinforcement
α0 = parameter used to reduce characteristic strength based on ratio of post-cyclic
tensile strength to basic tensile strength
α1 = parameter used to reduce characteristic strength based on basic tension tests

AS 3850.1:2015 14
α2 = parameter used to reduce characteristic strength based on post-cyclic slip tension

tests
α3 = reduction factor for uncontrolled slip for basic tension tests
α4 = reduction factor for uncontrolled slip for post-cyclic slip tension tests
βc,N = tension shape modification factor for concrete cone failure
βc,V = shear shape modification factor for concrete edge failure
βcb,N = tension shape modification factor for concrete blow-out failure
βp,N = tension shape modification factor for pull-out failure
βsp,N = tension shape modification factor for concrete splitting failure
Ø = capacity reduction factor
Øc = capacity reduction factor for fixings to concrete
Øs = capacity reduction factor for bolted connections in shear
ψc = factor to normalize brace insert strength according to concrete strength
ψh,sp = factor accounting for the effect of element thickness on splitting failure
ψh,V = factor accounting for the effect of element thickness on shear failure
ψre,V = a factor accounting for the effect of the state of the concrete and the type of
reinforcement at the edge
ψs,N = factor accounting for the disturbance of stresses in the concrete due to edges of
the concrete element for tension loading
ψs,Nb = factor accounting for the disturbance of the distribution of stresses in the
concrete due to a corner of the concrete element for break-out failure
ψs,V = factor accounting for the disturbance of the distribution of stresses in the
concrete due to a corner of the concrete element for shear failure
ψucr,N = factor relating to the state of the concrete (cracked/non-cracked) for tension
loading
σadm = admissible tensile stress for the definition of non-cracked concrete
σL = stresses in the concrete induced by external loads including insert loads
σR = stresses in the concrete due to restraint of intrinsic imposed deformations or
extrinsic imposed deformations

15 AS 3850.1:2015
S E C T I O N 2 M A T E R I A L S , C O M P O N E N T S A N D
E Q U I P M E N T
2.1 GENERAL
All materials, components and equipment shall comply with the relevant Australian
Standards and the requirements of this Section.
Verification that the various systems and items comply with these requirements shall be in
accordance with Appendix A.
For loadbearing proprietary products, the working load limit (WLL) shall be stated in the
product documentation.
All components to be used on site within the system shall be compatible. Different
proprietary components shall not be mixed without verification of compatibility.
Verification of compatibility shall be proved by testing, and such testing shall be
documented and certified by a competent engineer.
C2.1 Incompatibility of different types of inserts or sizes may lead to failure. This is
particularly relevant to lifting inserts, lifting clutches, bolts and ferrules. It should be
ensured that all components within a system are compatible.
2.2 WORKING LOAD LIMIT (WLL) CALCULATION

The working load limit shall be calculated as follows:
WLL = Ru / FoS
Where Ru is the critical characteristic load for the components listed in Table 2.2, it shall be
determined from one of the following methods:
(a) Testing in accordance with Appendix A.
(b) The CCD method and steel failure for headed inserts in accordance with Appendix B.
(c) The CCD method and steel failure with a shape modification factor for other inserts
in accordance with Paragraph A7, Appendix A, and Appendix B.
NOTE: The terms ‘CCD method’ (American approach) and ‘CC method’ (European approach) are
equivalent in this Standard.
FoS factors shall be as given in Table 2.1.
NOTE: These factors are appropriate for concrete, steel or aluminium alloy failure and may not
be applicable where other materials are used.

AS 3850.1:2015 16
TABLE 2.1
WORKING LOAD LIMIT (WLL) FACTOR
Component type FoS
Cast-in ferrules and brace inserts 2.25
Post-installed brace fixing 2.25
Cast-in lifting inserts 2.25
Lifting clutches 4.00
Levelling pads and shims 2.00
Steel or aluminium alloy temporary supports for 2.00
vertical elements—braces
Steel or aluminium alloy temporary supports for 2.00
horizontal elements—props and frames
2.3 CONCRETE AND REINFORCEMENT

Cementitious materials, aggregate, additives, reinforcement and tendons shall comply with
the appropriate clauses and materials Standards, as specified in AS 3600.
C2.3 Calcium chloride may corrode the reinforcement or cause increased shrinkage,
and should not be used as an additive in its own right to increase the rate of strength
gain of the prefabricated concrete element concrete, except as permitted in AS 1478.1.
2.4 CURING COMPOUNDS AND RELEASE AGENTS

Curing compounds shall comply with AS 3799.
Where curing compounds, bondbreakers and release agents are used together, they shall not
compromise the effectiveness of each to perform their respective functions.
C2.4 The strength, permeability and durability of concrete are dependent on it being
adequately cured. The ‘suction’ between the precast concrete element and the casting
bed should be kept to a minimum to reduce the stresses on the prefabricated concrete
element.
When selecting curing compounds, release agents and bondbreaker, considerations
should include the following:
(a) Effectiveness of bondbreaker and release agents The effectiveness of the
bondbreaker, release agents and the curing compound should not be compromised
by either compound. In the absence of previous experience, testing is highly
recommended.
(b) Tests Simple tests that check the effectiveness of the bondbreaker or release
agent after application should be available to the applicator. The supplier should
supply details of the test.
(c) Solubility Rain may affect the performance of release agents and bondbreakers.
They should be retested after rain in accordance with the supplier’s instruction.
(d) Discolouration Where a pigmented product is used, the pigmentation should
weather off within a reasonable time.
(e) Temperature effects The product should be suitable for the climate at the project
location, for example extreme temperatures may blister the product and cause it to
lose its properties.

17 AS 3850.1:2015
(f) Effect on finishes The adherence of applied finishes, including joint sealants,
should not be affected.
Products should be used in accordance with the supplier’s instructions.
2.5 LIFTING, BRACE AND FIXING INSERTS

2.5.1 General
All lifting inserts, brace inserts and ferrules shall be manufactured from ductile materials.
The washers used for all brace inserts and ferrules shall be of an appropriate size and
strength to transfer the load. When used with braces, they shall also be of sufficient size to
retain the attached fixing in the brace shoe.
Reinforcement and prestressing strands, bent to receive a hook or shackle and cast into the
prefabricated concrete element, shall not be used for lifting unless compliance with
Clauses 2.5.1 and 2.5.2 can be demonstrated.
A lifting system shall comply with Clause 2.5.2 unless it is not practicable for a particular
precast element (e.g. some types of lattice girder elements or odd-shaped elements), in
which case an analysis of the lifting system and the materials shall be conducted. Such
analysis shall be carried out and verified by a competent engineer.
C2.5.1 The strength of a given insert will be dependent on the embedded length and
inserts will need to be installed in accordance with the supplier’s requirements.
The slots in brace shoes are typically 22 mm to 24 mm wide and a heavy washer will be
required to transfer the brace load to the insert.
Where an insert projects from the surface of a prefabricated element, there is increased
risk of damage to the insert and the element. Provision should be made to protect the
integrity of such inserts and elements.
2.5.2 Lifting inserts
2.5.2.1 General
The WLL for lifting inserts shall be determined in accordance with Clause 2.2.
Lifting inserts shall be manufactured from ductile materials, with a total elongation of not
less than 20% for pearlitic steels and stainless steels, and not less than 15% for martensitic
steels, as determined in accordance with AS 1391.
Lifting inserts shall not be made from cast metals or materials that do not have reliable
homogenous mechanical properties.
Where lifting inserts are manufactured from steel, the steel shall be fully killed, have a
grain size of six or finer as determined in accordance with AS 1733, and have a chemical
composition not exceeding the limits given in Table 2.2:
Inserts made of materials other than steel shall provide mechanical performance not less
than those of steel inserts.
NOTE: Materials and manufacturing processes should ensure that the condition of inserts, as
supplied, are free from embrittlement, including temper, strain-age, hydrogen and liquid metal
embrittlement.
During the design validation, when lifting inserts are loaded in tension to ultimate failure—
(a) there shall be evidence of a ductile failure and plastic deformation of the material;
and
(b) the failure surface shall demonstrate a 100% fibrous structure consistent with ductile
failure.

AS 3850.1:2015 18
The insert assembly, which includes the void former, shall be marked with the
manufacturer’s name or symbol to ensure compatibility with other system components.
Lifting inserts may rely on component reinforcement to achieve their ultimate capacities.
Where such is the case, the Ru of the anchor shall be determined by testing the anchor and
component reinforcement together as a system in concrete.
C2.5.2.1 The requirements of Clause 2.5.2.1 are not intended to prevent the use of
other suitable metals that meet the performance requirements of this Standard. Some
guidance may be obtained by referring to CEN/TR 15728:2008.
TABLE 2.2
CHEMICAL COMPOSITION LIMITS
Carbon Phosphorus Sulfur
Maximum % by weight 0.25 0.05 0.05
2.5.2.2 Additional requirements for tension testing of lifting systems that require
component reinforcement
Where a plate style edge lift insert is used, it shall have component reinforcement (tension
bar) fitted and incorporate integral tension legs.

Edge lift inserts shall be tested in accordance with Appendix A, both with and without a
tension bar.
The ratio R u with tension bar/Ru without tension bar shall exceed 1.1 for a minimum
concrete strength of 25 MPa at the time of test.
Where component reinforcement is required, it shall be in accordance with AS/NZS 4671.
The bending of reinforcing bars shall be in accordance with AS 3600.
NOTES:
1 All edge lift inserts and some other inserts may require component reinforcement and details
should be obtained from the suppliers of these items.
2 If lifting inserts rely on component reinforcement, the size, shape and orientation of the bar
should be specified in the manufacturer’s documentation.

19 AS 3850.1:2015
C2.5.2.2 While the tension bar is part of the overall lifting system, the additional
anchorage provided by it into the element can act as an integral anchorage to the lifting
insert in circumstances where manufacturing error may not have properly anchored the
lifting insert into the element (see Figure C2.5.2.2).
A
Inte gr al
te n s i o n l e g s
A C o m p o n e nt
Ed g e lif t an c h or r e i nfor c e m e nt
w it h inte gr al te n s i o n l e g s
VIEW A-A
FIGURE C2.5.2.2 TYPICAL EDGE LIFT INSERTS WITH COMPONENT
REINFORCEMENT
2.5.3 Post-installed brace inserts

The WLL for post-installed brace inserts shall be determined in accordance with Clause 2.2.
Post-installed inserts shall satisfy the following:
(a) Mechanical fixings Mechanical fixings (such as undercut anchors) and drilled
through fixings shall be installed in accordance with the supplier’s instructions.
(b) Chemical anchors Chemical anchors relying solely on chemical adhesion shall not
be used for brace fixings unless each fixing is individually proof-tested to 120% of
WLL, and they shall be installed in accordance with the supplier’s instructions.
(c) Expansion anchors Expansion anchors for brace fixing inserts shall be of the
torque-controlled type and shall be installed in accordance with the supplier’s
instructions.

AS 3850.1:2015 20
NOTE: Expansion anchors should be installed, inspected and verified in accordance with the
supplier’s recommendations and special attention should be paid to the correct drilling of
holes and tightening to the correct installation torque and checking of the required residual
torque. Expansion anchors should also be torque-controlled, and of a type recommended by
the supplier for repetitive loads of combined tension and shear.
Deformation-controlled anchors, including self-drilling anchors and drop-in (setting) impact
anchors, shall not be used.
Post-installed brace inserts shall be stamped with the manufacturer’s name or symbol,
which shall be visible after installation.
C2.5.3 Deformation-controlled anchors should not be used because they—
(a) have no additional expansion (and hence additional load capacity) after the initial
setting process;
(b) fail without warning; and
(c) are highly sensitive to installation procedures.
Torque-controlled anchors may be used because after their installation the application
of load causes these anchors to behave elastically until a load is reached at which they
first begin to slip. After first slip, the anchor exhibits ‘ductile’ load behaviour.
Cyclic load conditions (e.g. wind loads) can result in failure of an expansion anchor
that has been loaded in excess of its first slip load, even if subsequent load cycles do not
exceed the first slip load.
2.5.4 Cast-in fixing and brace inserts (ferrules)
The WLL for cast-in fixing and brace inserts shall be determined in accordance with
Clause 2.2 and shall comply with the following:
(a) Where standard ISO metric threaded fixing inserts and bolts are used, they shall
comply with AS 1110 series.
(b) Where other types of fixings inserts are used, such as cast-in helical wire-coil inserts,
the fixing bolts used shall be compatible with the fixing inserts.
(c) The engagement length of the bolt in the insert shall be as specified by the supplier of
the system.
(d) Inserts, when used in tension, shall be designed with a steel capacity that exceeds that
of the class of the matching bolt and at a minimum, that of a Class 4.6 bolt in
accordance with AS 1111.1.
(e) Fixing inserts for the prefabricated concrete element connection to roof framing and
other structural members shall be designed to resist the forces imposed on the
connections, as determined by the appropriate Australian Standard and National
Construction Code (NCC), Volume 1, Building Code of Australia.
(f) Torque limits for cast-in components shall be provided in the erection documentation.
C2.5.4 It is important to ensure that the insert and bolt have matching threads and
have been checked by the user to be compatible.
2.6 LIFTING CLUTCHES

The WLL for lifting clutches shall be determined in accordance with Clause 2.2.
Lifting clutches shall be manufactured from ductile materials. During the design validation,
when loaded in tension to ultimate failure, lifting clutches shall comply with the following:
(a) Failure shall occur in a ductile manner away from any weld zone.

21 AS 3850.1:2015
(b) There shall be evidence of distortion and plastic deformation of the clutch assembly.
(c) All fracture faces shall demonstrate ductile failure mechanisms.
When tested in any orientation (as approved by the supplier) with a compatible anchor,
failure of the anchorage shall occur without fracture of any component of the lifting clutch.
All cast clutch components shall be 100% fluorescent magnetic particle tested in
accordance with AS 1171, and shall contain no linear indications.
Each lifting clutch shall be proof-tested, certified and uniquely identified prior to being
placed into service. The proof test shall subject the device to a load of 2.0 times its WLL.
Prior to each use, inspections of the lifting clutches shall be conducted to check for wear
and deformation to supplier’s specification. A proof test using a load equal to 1.2 times the
WLL shall be conducted and recorded for each lifting clutch at intervals of not more than
12 months commencing from the date of first use.
Each clutch shall be permanently marked with the following information:
(i) A unique identifier (traceable to the proof tests).
(ii) The manufacturer’s symbol or name.
(iii) Its WLL or compatible anchor identifier.
C2.6 Suitable identification of lifting clutches may be by permanent marking on the

clutch itself or attachment of a durable tag.
Following visual inspection of the lifting clutch, if there are any safety concerns, a
proof test and a fluorescent magnetic particle should be conducted.
2.7 BRACES
2.7.1 General
The WLL for braces shall be determined in accordance with Clause 2.2.
Brace adjustment mechanisms shall have stops on the threads to prevent over-extension,
and on retaining devices to prevent unintentional dislodgment of the shear pins, including
the telescopic adjustment pin and the brace foot pin. Shear pins shall be constructed so they
cannot be undone without the use of a tool.
The bracing foot or shoe shall be designed so as to prevent lateral displacement of the shoe
from the fixing insert after installation.
The following information, for all braces, shall be readily available at the erection site:
(a) WLL (in kilonewtons) for a fixed length brace and at minimum, maximum and
intermediate extensions for telescopic braces.
(b) WLL (in kilonewtons) when used with specified configurations of secondary bracing,
including knee bracing and stability bracing.
C2.7.1 The stability of a prefabricated concrete element in the temporary braced
condition may be jeopardized if shear pins on the braces are removed either
accidentally or as acts of vandalism. To minimize the risk of this occurring, site security
should be appropriate to reduce the risk of vandalism. Erection procedures should be
such as to ensure that a brace is not removed until the prefabricated concrete element is
secured to the structure. Shear pins on braces should be purpose-made, simple to install
and unable to be removed without appropriate equipment or deliberate force.

AS 3850.1:2015 22
2.7.2 Marking of braces

Braces shall be permanently marked with the following information:
(a) The supplier or manufacturer.
(b) The model type or designation.
(c) The load capacity of the braces, which shall be marked as follows:
(i) For fixed length braces, the WLL, in kilonewtons, on the permanent
identification plate.
(ii) For adjustable length braces, the WLL, in kilonewtons, at maximum and
minimum extension on the permanent identification plate.
2.7.3 Inspection and maintenance of braces
After each use, braces shall be inspected and maintained to ensure the following:
(a) There is no significant observable damage to components (no splits or cracks, no rust
that impairs strength or efficiency, no deformations/dents >4 mm or 1/15 of pipe
section width, and no pipe out-of-straightness >L/300 of individual length).
(b) Screw threaded length adjustments can be readily fully extended.
(c) Telescopic braces can be readily fully extended.
(d) All parts of the brace are as per the componentry specified by the supplier of the
brace.
Brace components not meeting these conditions shall be removed from service. Any
rework/repair of brace components to meet these limits and product specifications shall be
approved by a competent person.
2.8 LEVELLING PADS AND SHIMS

2.8.1 General
Levelling pads and shims for the temporary support of elements shall be qualified for use
by determining their compressive strength and creep characteristics. Shims shall be
manufactured from a material that will—
(a) deform elastically at full tested load;
(b) not continue to creep more than 5% of the shims’ average thickness up to 15 min
under full load;
(c) not continue to creep more than 3% of the shims’ average thickness after 15 min
under full load up to 48 h;
(d) resist corrosion stains or be adversely affected by cold weather, alkali, ground
chemicals at least that of polymeric materials; and
(e) not oxidize or expand when exposed to moisture.
Where levelling pads are intended to provide permanent support, they shall be capable of
safely carrying the design loads from the structure.
Levelling pads and shims shall be permanently marked to be traceable and have a marked
WLL.
The WLL shall be derived using statistical methods as set out in this Standard, and the
ultimate load shall be determined as the load at the onset of plastic deformation.

23 AS 3850.1:2015
2.8.2 Physical requirements of shims

The WLL of the shims shall be determined in accordance with Clause 2.2. The compressive
strength of the shim material shall be determined in accordance with Appendix A.
Unless otherwise designed and specified, the total height of the shim, or combination of
shims, shall not exceed 40 mm. The minimum width shall be 100 mm or, where the
thickness of the element is less than 100 mm, the thickness of the prefabricated concrete
element. The minimum length shall be 150 mm or, where the thickness of the element is
less than 150 mm, the thickness of the prefabricated concrete element.
2.9 CRANE AND RIGGING EQUIPMENT

Cranes shall be selected and operated in accordance with the appropriate parts of AS 2550
series, and rigging shall comply with the relevant rigging Standards.
2.10 DOCUMENTATION
Documentation shall set out the information required for the correct use of the component
or system. It shall include the following information, where applicable:
(a) Drawing or pictorial representation that clearly identifies the component or system to
which it refers.
(b) Adequate information to fully describe its intended use.

(c) Instructions for use, storage and maintenance, including all precautions to be
observed in its use.
(d) Criteria for rejection and reworking of the component or system.
(e) Detailed information including, where appropriate, the following:
(i) Part number.
(ii) Dimensions.
(iii) Section properties.
(iv) Self-weight.
(f) The WLL as calculated in accordance with Clause 2.2.
(g) A statement that the component or system depicted in the documentation complies
with this Standard.

AS 3850.1:2015 24
APPENDIX A
TESTING OF MATERIALS AND COMPONENTS
(Normative)
A1 SCOPE
This Appendix sets out the tests that are required for the development, testing and
verification of the products specified in this Standard.
Table A1 lists the sections that are relevant to the different tests that are required, by
product, for the following purposes:
(a) Design validation to determine Ru.
(b) Production validation—tests to ensure consistency of the production process.
TABLE A1
DETAILS OF THE TESTS REQUIRED
Product Test required Relevant Paragraphs

Design validation to determine R u A2, A3, A4, A6 and A7
Lifting inserts
Production validation A3, A4 and A5
Design validation to determine R u A3, A4 and A8
Lifting clutches
Design validation to determine R u A2, A3, A4 and A7
Cast-in inserts (ferrules)
Shims
Post-installed brace inserts
Braces
A2 CONCRETE TESTING
Where concrete strength or other concrete properties are referred to in this Appendix, these
shall be determined in accordance with the requirements of the appropriate parts of the
AS 1012 series.
Concrete used to construct test elements shall comply with the requirements of AS 1379.
Concrete test cylinders shall be manufactured in accordance with the requirements of
AS 1012 and all test cylinders shall be cured under identical conditions as the test blocks.
Verification tests of concrete strength shall be conducted on completion of the respective
tests. A minimum of 3 test cylinders shall be used to determine the concrete strength at the
time of the tests.
Features of the mix not common to normal grade concrete in accordance with AS 1379 shall
be specified.

25 AS 3850.1:2015
A3 TESTING OF COMPONENTS AND SYSTEMS

A3.1 General
Because of the mode in which failure can occur, it may be necessary to test complete
systems and not calculate values obtained from the group of components that make up the
system. The mode of failure of an individual component does not necessarily reflect the
mode of failure of the system.
The arrangement for the application of the test load(s) shall be made to simulate the field
use of the component or system.
A3.2 Record of tests
Test records shall be provided for all tests. The records shall be clearly identified by title,
description and report number, and provide the following information:
(a) The purpose of the test.
(b) The name and address of the testing facility.
(c) The date, time and environmental conditions at the time of the test.
(d) A detailed description of the component or system being tested, providing
identification of the specific type of component or system and including, where
appropriate, the name of supplier or the manufacturer (or both), the date of
manufacture, the batch number, etc.

(e) A detailed description of the geometry and material characteristics of the component
or system being tested, including, where appropriate, the dimensions, the materials,
the coating, the yield stress (fsy) and the ultimate strength (fsu).
(f) A detailed description of the test arrangement, including instrumentation layout and
fixture geometry, the geometric positioning of the component or assembly in the test
specimens, as illustrated by sketches or photographs.
(g) A description of the tools employed for the component or assembly installation
(where applicable).
(h) A detailed description of the test procedure.
(i) The names, positions and qualifications of the personnel carrying out or supervising
the test.
(j) The names, positions and qualifications of the witnesses, if any, to the test.
(k) The results of the test, covering the following, where relevant:
(i) The rate and direction of loading.
(ii) The load at failure in the case of destructive testing.
(iii) The mode of failure for each test.
(iv) Any specific observations concerning the application of load.
(v) A description of the progress of the test, including the mode of failure and any
permanent deformations.
(vi) The details of the load deformation curves, so proportioned that if there has
been any discontinuity or considerable departure from linearity during the
progress of increasing the loads then this will be clearly evident.
(vii) Any other relevant information such as signs of distress prior to failure.
(viii) The concrete strength at the time of test and the 28 days strength.
(l) The number of tests performed.

AS 3850.1:2015 26
(m) A detailed assessment and evaluation of the calculations, where appropriate.

(n) Confirmation of compliance with this Standard.
A3.3 Test reports
The test report shall be prepared from the test data evaluated in accordance with
Paragraph A4 and shall clearly demonstrate how the value of Ru has been determined.
A4 STATISTICAL EVALUATION OF TEST RESULTS

The test reports shall provide characteristic values based on statistical method to provide a
5% fractile at a 90% confidence level using a normal distribution and average values.
Characteristic values shall be calculated from test values.
The characteristic values shall correspond to the 5% fractile of the mean loads measured in
the test series, and shall be calculated according to statistical procedures for a confidence
level of 90%. A normal distribution and an unknown standard deviation of the population
shall be assumed unless an alternate probability distribution is justified, with the 5%-
fractile value calculated as follows:
Xk = x(1 − ksCOV) . . . A4
where
Xk = characteristic value of the test values

x = mean of test values
ks = sampling factor listed in Table A2
COV = coefficient of variation to the test sample
TABLE A2
SAMPLING FACTOR TO ESTABLISH
CHARACTERISTIC STRENGTH
No. of tests ks No. of tests ks No. of tests ks

5 3.400 10 2.568 40 2.010
6 3.091 15 2.329 50 1.965
7 2.894 20 2.208 ∞ 1.645
8 2.755 25 2.132
9 2.649 30 2.080
A5 PRODUCTION VALIDATION
A5.1 General
Testing shall be conducted to confirm ongoing verification of the standard of manufacture
of a component or system.
A5.2 Principle
Tests shall be conducted to confirm compliance with the critical specification requirements,
which may include the following where appropriate:
(a) Dimensions.
(b) Material properties including traceability.
(c) Loadbearing capacity, including proof testing where appropriate.

27 AS 3850.1:2015
A5.3 Statistical sampling

Statistical sampling is a procedure that enables decisions to be made about the quality of
batches of items after inspecting or testing only a portion of those items. This procedure
will only be valid if the sampling plan has been determined on a statistical basis and the
following requirements are met:
(a) The sample shall be drawn randomly from a population of product of known history.
The history shall enable verification that the product was made from known materials
at essentially the same time, by essentially the same processes and under essentially
the same system of control.
(b) For each different situation, a suitable sampling plan shall be defined.
NOTE: A sampling plan for one manufacturer of given capability and product throughput may
not be relevant to another manufacturer producing the same items.
In order for statistical sampling to be meaningful, there needs to be demonstrative proof of
how the above conditions have been satisfied. Sampling and the establishment of a
sampling plan shall be carried out in accordance with AS 1199.1.
NOTE: Guidance to AS 1199.1 is given in AS 1199.0.
A5.4 Acceptance criteria and evaluation
A5.4.1 Dimensions and material properties
The component or system shall be within the tolerances specified by the manufacturer.
A5.4.2 Test load
Where tests to destruction are being done to verify the capacity of an existing product,
sufficient tests shall be done to verify the resulting value of Ru exceeds the claimed value of
Ru for the product.
Where proof tests are being done, the tested item shall be loaded to 1.2 times the WLL.
This load shall be sustained without signs of failure or distortion.
A6 ADDITIONAL TESTING FOR MATERIALS OF LIFTING INSERTS

A6.1 General
In addition to the general requirements set out in Clause 2.5, lifting inserts shall also be
tested in accordance with Paragraph A6.2.
A6.2 Tension test of the manufactured insert
A6.2.1 General
This test is conducted to ensure the minimum strength has been achieved and that the
ductility has not been affected by the method of fabrication.
A6.2.2 Apparatus for tension testing of the manufactured insert
The following apparatus shall be required:
(a) A compatible lifting clutch for use with the insert.
(b) A tensile testing machine compliant with Class A of AS 2193, capable of applying a
destructive load to the insert using a uniform minimum crosshead travel speed of
20 mm/min.

AS 3850.1:2015 28
A6.2.3 Procedure
The procedure shall be as follows:
(a) Connect the lifting clutch to the insert.
(b) Using a constant crosshead travel speed of 20 mm to 50 mm/min, apply the load to
the insert until failure occurs.
(c) Examine the specimen for finite evidence of ductile fracture and plastic deformation
adjacent to the failure.
A7 ADDITIONAL TESTING FOR PULL-OUT CAPACITY OF CAST-IN LIFTING

AND BRACE INSERTS
A7.1 Introduction and scope
This Paragraph sets out the test and evaluation procedures for the determination of the
characteristic strength and shape modification factors for cast-in inserts used for lifting and
bracing of prefabricated elements during construction. Testing shall be undertaken to
achieve either of the following:
(a) Shape modification factors to be used in conjunction with the concrete capacity
method to establish the design capacity of the insert via the design procedure outlined
in Appendix B.
(b) Characteristic capacity determined from a comprehensive test program including tests
to evaluate the individual and combined effects of all influences shown in Table A3
to produce the design capacity of the insert as an alternative to Appendix B.

29 AS 3850.1:2015
TABLE A3
FACTORS TO BE CONSIDERED FOR ASSESSMENT
WITHOUT THE USE OF THE CONCRETE CAPACITY METHOD
Characteristic Factor to be investigated
Concrete strength
Material properties Regional variation in standard aggregates
Condition of concrete (cracked/non-cracked)
Tension failure modes:
(a) Steel failure
(b) Pull-out failure
(c) Concrete cone failure
(d) Splitting failure
Application of load (e) Blow-out failure
Shear failure modes:
(i) Steel failure
(ii) Concrete edge failure
(iii) Concrete pry-out failure

Combined tension and shear
Reduced edge distance
Multiple edges
Concrete element thickness
Geometric properties
Multiple embedment depths
Narrow element
Spacing of inserts
Bar type and diameter
Reinforcement
Bar geometry
NOTE: Additional testing may be undertaken to determine the characteristic
performance of an insert subject to factors not addressed in this Appendix. The test
parameters and material properties, the number of specimens for testing, and the test
procedure shall be based on this Appendix. The procedure for the assessment of
characteristic values shall remain the same.
A7.2 Shape modification factors

Shape modification factors may be developed for innovative inserts that do not rely on
component reinforcement to achieve their design capacity, provided the characteristic
capacity of the reference (R) and the innovative (I) inserts are identified.
The shape modification factors to be reported depend on the mode of failure of the
innovative insert. They shall include one or more of the following:
(a) Tension:
(i) Pull-out failure (βp,N).
(ii) Concrete cone failure (βc,N).
(iii) Concrete splitting failure (βsp,N).
(iv) Concrete blow-out failure (βcb,N).
(b) Shear—concrete edge failure (βc,V).
NOTE: Pry-out failure and steel failure of the insert are not covered in this test procedure.

AS 3850.1:2015 30
CA7.2 Where an insert contains component reinforcement that is integral to its

function, or if it is desired to measure directly the capacity of an insert without
interpolation using the concrete capacity method outlined in Appendix B, a modified
version of the test procedure outlined in this Appendix may be adopted to identify the
characteristic capacity. Data published by the manufacturer/supplier should be suitably
justified with results from experimental testing to address all of the following factors as
appropriate to the intended application. The minimum number of tests to be undertaken
should be consistent with Paragraphs A7.4.1 and A7.4.2 as appropriate. Table A3
contains a summary of key factors to be considered when developing the scope of the
proposed test program.
A7.3 Test parameters and material properties
A7.3.1 Concrete properties
The mean compressive strength of the concrete at the time of test shall be not less than
12 MPa, as applicable to the intended application. The compressive strength of the concrete
shall be determined in accordance with the test procedure outlined in the AS 1012 series.
Tests conducted in concrete with a lesser compressive strength shall be rejected.
A7.3.2 Size of concrete specimens
The minimum distance from the insert to any edge, discontinuity, or any part of the test
apparatus that transmits reaction forces to the concrete surface shall be not less than twice
the effective embedment depth of the insert, so as to allow the development of a complete
and unrestrained cone. In the event the effective embedment depth is unknown, it shall be
assumed to be equal to the maximum embedment depth of the insert for the purpose of
testing. Where a full concrete cone cannot develop due to nearby edges in the intended
application (e.g. the edge lift in a thin panel), the insert shall be positioned according to the
intended application.
The tolerances on placement of the insert, as published by the manufacturer/supplier, shall
be adhered to at all times.
When testing innovative inserts, reference inserts shall be placed in geometrically identical
elements cast from the same batch of concrete, and shall be placed, compacted and cured in
identical manner used to cast the elements for the companion innovative inserts. Any
reinforcement included in the test elements shall be placed outside of the actual failure
zone, unless such reinforcement is intended to be included as part of the insert assembly.
If the concrete element thickness (H min) nominated by the manufacturer/supplier is less than
twice the effective embedment depth (2hef) or 100 mm and the edge distance is less than
3hef, corner tests shall be undertaken in accordance with Paragraph A7.4.2 to determine the
characteristic edge distance corresponding to splitting failure (ci,cr,sp) for a given insert.
A7.3.3 Insert
The inserts supplied for the tests shall be statistically representative of the manufactured
product supplied in the market place. The insert shall be accompanied by installation
instructions.
A7.3.4 Installation
The casting and installation of the insert shall be undertaken according to the
manufacturer/supplier’s instructions. The minimum cover requirements shall be observed
for all inserts tested.
If multiple inserts are to be tested in a single concrete panel, the distance between inserts
shall be large enough that the effects of spacing on the insert performance are not
encountered.
The total depth of embedment shall be identical between the reference and innovative
inserts.

31 AS 3850.1:2015
A7.4 Number of specimens for testing

A7.4.1 General
The total number of tests to be conducted shall be dependent on the intended application of
the insert. Consideration shall be given to the following possible applications:
(a) Remote from the effects of edge distance and insert spacing (formation of a full
concrete cone possible).
(b) Reduced edge distance (partial formation of a concrete cone).
(c) Double-edged reduced concrete cone typical of a thin wall element (partial formation
of a concrete cone).
(d) Distance between inserts small enough that spacing effects influence insert capacity
(joining of two concrete cones).
(e) Manufacturer/supplier specified minimum panel depth that is less than 2hef or
100 mm.
The minimum number of tests shall be applicable to each variable as specified in
paragraphs A7.4.2 to A7.4.3.
A7.4.2 Tension tests
A minimum of 5 innovative inserts shall be tested.

In the event shape modification factors are to be established, a minimum of 5 reference
inserts shall be tested.
In the event that corner tests are required, a set of corner tests shall be conducted until a
minimum of 5 consecutive tests result in a mode of failure other than splitting failure.
A7.4.3 Shear tests
A minimum of 5 innovative inserts shall be tested.
In the event shape modification factors are to be established, a minimum of 5 reference
inserts shall be tested.
A7.5 Test procedure
A7.5.1 Test set-up
The reaction frame shall be situated at a minimum distance of twice the effective
embedment depth from the insert as shown in Figures A1 and A2.
The reaction frame shall be situated at a minimum distance of twice the effective
embedment depth from the insert in a corner test as shown in Figure A3.

AS 3850.1:2015 32
Load cylin d e r
Load c e ll D r awb a r
Reaction frame C o n n e c ti o n s h a c k l e
C o n c r e te s p e c i m e n
≥ 2 h ef ≥ 2 h ef
Insert
SIDE VIE W
TOP VIE W
(a) Basic test set-up
≥ 2 hef
hef
Reaction Reaction
≥ 2 hef ≥ 2 hef
Fo r c e
S c h e m a ti c vi ew
Ed g e i n s e r t te n s i o n hef
te s t i n a t h i n p a n e l
(b) Modified test set-up for thin panels
FIGURE A1 TEST SET-UP FOR THE DETERMINATION OF TENSILE CAPACITY OF

THE INSERT

33 AS 3850.1:2015
Fo r c e
Reaction Reaction
≥ 2 hef ≥ 2 hef
≥ 1. 5 h e f ≥ 1. 5 h e f
S c h e m a ti c vi ew
Ed g e i n s e r t s h e a r te s t
i n a thi n p a n e l
FIGURE A2 TEST SET-UP FOR THE DETERMINATION OF SHEAR CAPACITY OF THE

INSERT
3 2
c
LEGEN D:
1 te st m e m b er
c ≥ 2 hof
2 su p p or t of te st r i g
3 an c h or
≥ 2 hef
FIGURE A3 TEST SET-UP FOR A CORNER TEST
A7.5.2 Instrumentation
The load shall be recorded at a rate not less than 10 readings per second throughout the test.
The measuring error shall be not greater than 0.02 mm for displacement and 2% of the load
throughout the entire measuring range.
A7.5.3 Application of load
The tests shall be conducted in either load or displacement control. The load shall be
applied to the insert using the lifting clutch for the intended application.
The age at test (in hours) after casting shall be not greater than the minimum age for the
application of load in the intended application. The concrete specimen shall be removed
from any formwork prior to the commencement of testing.

AS 3850.1:2015 34
The load shall increase in such a manner that the peak load occurs 1 min to 3 min after the
commencement of loading. The application of load shall increase until failure is achieved,
denoted by a drop in the load-carrying capacity of the insert.
The shear test shall be conducted towards the closest concrete edge.
In the event the test is conducted in displacement control, the test shall be continued beyond
ultimate load until the load has reduced to at least 75% of the peak load.
For the corner test, the edge distance (c) shall be increased from a minimum initial distance
of 1.5hef and the test repeated until splitting failure is not encountered in five consecutive
tension tests at the same edge distance. The application of load shall occur in a manner
identical to tension tests (see Paragraph A7.4.2).
Testing shall be completed within ±4 h from the reported age at test.
A7.6 Assessment
A7.6.1 Integrity assessment
If the insert requires a torque prior to application of test load, the insert shall not fail by
breakage or cause failure of the concrete when the application of twice the specified
installation torque is applied. If this criterion is not met or if there are noticeable
abnormalities, the insert shall be deemed unsuitable and shall be retested. An insert that
fails to meet the criterion in the second test shall be deemed unsuitable.
A7.6.2 Determination of characteristic strength

If during a test series different failure modes occur, and one failure mode predominates and
other failure modes occur (and are of similar capacities), the failure modes and
corresponding failure loads of the tests shall be noted in the test report. The average failure
load shall be reported, taking into account all results as the failure load associated with the
predominant failure mode.
If no failure mode predominates in a test, additional inserts shall be tested to obtain at least
five samples for each failure mode and conduct a significant difference test to determine if
the capacities for the different failure modes are statistically different.
From the corner tests, ci,cr,sp shall be reported together with H min, as specified by the
manufacturer/supplier.
A7.6.3 Instrumentation
The characteristic strength shall be determined in accordance with Paragraph A4.
The characteristic tensile strength of the innovative and reference insert tests shall be
determined for each failure mode if multiple failure modes are observed. The possible
failure modes and notation for the innovative and reference inserts respectively are as
follows:
(a) Pull-out failure (Nu,p,Inn, Nu,p,Ref).
(b) Concrete cone failure (Nu,c,Inn, Nu,c,Ref).
(c) Concrete splitting failure (Nu,sp,Inn, Nu,sp,Ref).
(d) Concrete blow-out failure (Nu,cb,Inn, Nu,cb,Ref).
The characteristic tensile strength of the innovative and reference insert tests shall be
determined for each failure mode if multiple failure modes are observed. The failure mode
with the lowest characteristic value shall be decisive.
A7.6.4 Characteristic shear strength
Vu,c,Inn and Vu,c,Ref shall be determined for concrete edge failure.

35 AS 3850.1:2015
A7.7 Evaluation
A7.7.1 Characteristic values—Tension and shear
Extrapolation of values obtained from testing shall not be permitted. Interpolation between
two sets of data shall be permitted where the mode of failure between the two sets of data is
identical.
A7.7.2 Shape modification factors
The tensile shape modification factor shall be calculated for the respective modes of failure
encountered during testing from the following:
βp,N = Nu,p,Inn/Nu,p,Ref . . . A7.7.2(1)
βc,N = Nu,c,Inn/Nu,c,Ref . . . A7.7.2(2)
βsp,N = Nu,sp,Inn/Nu,sp,Ref . . . A7.7.2(3)
βcb,N = Nu,cb,Inn/Nu,cb,Ref . . . A7.7.2(4)
The shear shape modification factor shall be calculated for concrete edge failure as follows:
βc,V = Vu,c,Inn/Vu,c,Ref . . . A7.7.2(5)
A7.8 Test report
A test report shall be provided in accordance with the requirements of Paragraph A3.2.
Additionally, the following shall be reported as appropriate, for the innovative and
reference inserts:
(a) All details relating to concrete elements, including the following:
(i) Properties of concrete (composition, density, slump, 28 days strength).
(ii) Time of casting and testing of all specimens.
(iii) Compressive strengths of concrete as determined at the time of test.
(iv) Dimensions of test specimens.
(v) Nature and positioning of any reinforcement.
(b) All details relating to the installation of the insert, including the following:
(i) Depth of anchorage (effective and total).
(ii) Distance to edges.
(iii) Applied torque and statement on calibration of torque wrench (where
applicable).
(c) Measured values including the radius (maximum radius, minimum radius) and height
of a concrete cone produced in the test (where applicable).

AS 3850.1:2015 36
(a) Concrete cone failure (b) Concrete cone failure with (c) Concrete cone failure with
edge effects edge effects on two faces.
(d) Pull-out failure (e) Concrete blow-out failure (f) Splitting failure
FIGURE A4 POSSIBLE CONCRETE MODES OF FAILURE OBSERVED DURING

TENSILE LOADING
(a) Concrete edge failure (b) Pry-out failure
FIGURE A5 POSSIBLE CONCRETE MODES OF FAILURE OBSERVED DURING SHEAR

LOADING

37 AS 3850.1:2015
A8 TESTING OF LIFTING CLUTCHES

A8.1 General
In addition to the general requirements set out in Clause 2.6, lifting clutches shall also be
tested in accordance with Paragraph A8.2.
A8.2 Tension (axial) test of the lifting clutches
A8.2.1 General
Testing of lifting clutches shall be conducted to confirm the following requirements:
(a) Design validation to determine Ru—testing to ultimate load.
(b) Proof testing in accordance with Clause 2.6.
A8.2.2 Apparatus for tension testing of the lifting clutch
The following apparatus shall be required:
(a) A compatible lifting insert for use with the insert.
(b) A tensile testing machine compliant with Class A of AS 2193, capable of applying a
load to the lifting clutch using a uniform minimum crosshead travel speed of
20 mm/min.
A8.2.3 Procedure
(a) Connect the lifting clutch to the insert.
(b) Using a constant crosshead travel speed of 20 mm to 50 mm/min, apply the load to
the lifting clutch until—
(i) failure occurs when conducting a design validation test; or
(ii) proof-load when conducting proof testing.
(c) Examine the specimen for—
(i) finite evidence of ductile fracture and plastic deformation adjacent to the failure
when conducting a design validation test; and
(ii) no signs or failure or excessive distortion when conducting proof testing.
A9 ADDITIONAL TESTING FOR POST-INSTALLED BRACE INSERTS

A9.1 General
This Paragraph sets out the test and evaluation procedure for determining the design
capacities of torque-controlled expansion anchors (post-installed brace inserts) used in
bracing shoes (foot plates).
The test and evaluation procedures are limited to torque-controlled expansion anchors.
NOTE: These procedures are broadly based on the guideline for European technical approval
ETAG 001.
The additional testing specified in this Paragraph is limited to determining the design
capacities of post-installed brace inserts, free from the effects of edge distance, concrete
reinforcement and spacing, and excluding the splitting mode of concrete failure. The tests
in this Paragraph do not cover impact loading and seismic loading.
Testing shall be conducted in a controlled laboratory environment using representative
post-installed brace insert samples, installed in accordance with the supplier’s
specifications and applied to concrete specimens with minimum performance requirements,
as specified by this Paragraph.

AS 3850.1:2015 38
The procedures covered are the following:

(a) Torque testing and integrity assessment to ensure post-installed brace inserts and the
surrounding substrate are not compromised during installation.
(b) Testing and evaluation of post-installed brace inserts subject to tension (including
cyclic loading) to determine the design tension capacity and corresponding WLL.
(c) Testing and evaluation of post-installed brace inserts subject to shear to determine the
design shear capacity.
The post-installed brace inserts shall satisfy other relevant mandatory functionality
requirements as specified in this Standard and other regulations.
A9.2 Test parameters and material properties
A9.2.1 Concrete properties
Concrete specimens used for this test program shall have the following properties,
determined in accordance with AS 1379 and testing in accordance with the AS 1012 series:
(a) Series 1 (basic tension, cyclic and shear)—mean compressive strength ( f cm ) between
20–36 MPa at 7 days.
(b) Series 2 (torque)—mean compressive strength ( f cm ) between 32–40 MPa at an age of
28 days.
The concrete specimens for testing shall be in a non-cracked state.
A9.2.2 Size of specimens
The thickness of the concrete specimens in which the post-installed brace inserts that are to
be installed for tests shall be at least equal to 2hef, to avoid splitting failure during testing.
A9.2.3 Brace insert
The post-installed brace inserts supplied for the tests shall be statistically representative of
the manufactured product supplied in the marketplace.
The post-installed brace insert shall be accompanied by installation instructions, including
information about the required drill bit type, the drill bit diameter, maximum slot width in
fixture plate, the required hole depth, the maximum fixture thickness, the minimum
embedment depth and the setting torque of the brace insert.
A9.2.4 Drilling equipment
Holes shall be drilled perpendicular to the surface unless specifically specified otherwise by
the manufacturer’s instructions.
The holes shall be drilled with a drill bit having a medium cutting diameter (dcut,m) of the
specified tolerance range given in Table A4.
The diameter of the drill bit shall be checked every 10 drilling operations during testing to
ensure continued compliance.
A9.2.5 Installation
The test procedure described herein is based on carbide-tipped bits used with
rotary-hammer drill to form the hole for the post-installed brace insert. If multiple types of
drilling bits are used, the tests shall be conducted for each type of drill bit.
Installation shall be accomplished using tools readily available on site, except in special
cases as stipulated in the product instructions.
Post-installed brace inserts that do not have a specified installation torque shall be tested
following finger-tight installation only.

39 AS 3850.1:2015
TABLE A4
TOLERANCE ON CUTTING
DIAMETER OF HARD METAL
HAMMER-DRILL BITS
Nominal drill diameter Drill diameter (d cut,m ), mm

mm Max. Min.
12 12.35 12.25
14 14.35 14.25
15 15.35 15.25
16 16.35 16.25
18 18.35 18.25
20 20.40 20.30
22 22.40 22.30
24 24.40 24.30
NOTE: This Table is based on ETAG 001.
A9.3 Test specimens

A9.3.1 General
The required test specimens shall be as specified in Table A5 and Paragraphs A9.3.2 to
A9.3.5.
A9.3.2 Torque tests
A minimum of 5 post-installed brace inserts shall be installed in the concrete specimens of
Series 2.
A9.3.3 Tension tests
Series 1.
A9.3.4 Cyclic slip tension tests
Series 1.
A9.3.5 Shear tests
Series 1.
TABLE A5
TESTS FOR POST-INSTALLED BRACE INSERT.
Age at Age at test, Mean concrete Drill bit

No. of
Test Series installation, strength, diameter,
tests
days days MPa mm
Torque 2 28 28 32–40 d cut,m 5
Tension 1 7 7 20–36 d cut,m 5
Cyclic 1 7 7–9 20–36 at 7 days* d cut,m 5
Shear 1 7 7 20–36 d cut,m 5
* Adjustment for higher concrete strength shall be made based on square-root of strength.

AS 3850.1:2015 40
A9.4 Test procedure

A9.4.1 Torque tests
The specified torque moment shall be applied with a calibrated torque wrench until it
cannot be increased further, or at least to 1.3Tinst respectively.
The relation between the applied torque moment and the tension force in the bolt shall be
measured using a calibrated load cell with a measuring error <3% throughout the whole
measuring range.
NOTE: A typical illustration of the test set-up is depicted in Figure A6.
Brac e inser t Wa s h er
head
Double-sided
Fix ture a b r a s i ve p a p er
S p h er i c al seat
Load c e ll
C o n c rete
FIGURE A6 SET-UP FOR TORQUE TEST
A9.4.2 Basic tension tests

A9.4.2.1 General
The test rig shall permit the possible formation of an unrestricted rupture cone, as depicted
in Figure A7. The nominal thickness of the fixture plate shall be not less than the thickness
of the fixture plate for the intended application. The nominal slot width in the fixture plate
shall be 25 mm or depending on the slot width of the foot plate for the intended application.
The slot in the fixture plate [refer to Figure A7(b)] may be open or closed. The washer
under the bolt head shall be bearing on only two sides of the slot.
A9.4.2.2 Instrumentation
Direct measurement of the post-installed brace insert displacement shall be made relative to
basic point(s) at least 1.5hef from the centre of the brace insert. This may be achieved by
averaging two displacement transducers measuring a rigid bar directly attached to the head
of the post-installed brace insert, or by way of direct measurement by a single displacement
transducer at the head of the post-installed brace insert as depicted in Figure A7.
The load and displacement measurements shall be recorded at a rate not less than
10 readings per second throughout the test. The measuring error shall be not greater than
0.02 mm for displacement and 2% of the load throughout the entire measuring range.
A9.4.2.3 Application of load
The basic tension tests shall be conducted in either load or displacement control. The load
shall be applied concentrically to the post-installed brace insert.

41 AS 3850.1:2015
The tension tests shall commence between 1 h to 3 h after installation of the post-installed
brace insert. The load shall increase in such a manner that the peak load occurs 1 min to
3 min after the commencement of loading. The application of load shall increase until
failure is achieved, denoted by a drop in the load-carrying capacity of the post-installed
brace insert.
ultimate load until the load has reduced to at least 75% of the peak load (to allow the drop
of the load-displacement curve).
A9.4.3 Cyclic slip tension tests
The cyclic slip tension test set-up shall be prepared in accordance with Paragraph A9.4.2,
including the instrumentation. Cycling tension loading shall be applied in load control and
concentric to the post-installed brace insert. The load shall vary from a value not greater
than 0.02Ru,N to a load equal to 0.6Ru,N, established from basic tension tests, in a sinusoidal
manner. The test shall be conducted at a frequency between 1–2 Hz until 1000 tension load
cycles are achieved.
Upon completion of the cyclic slip tension test, the post-installed brace insert shall be
loaded in tension to failure in accordance with Paragraph A9.4.2.3.

AS 3850.1:2015 42
Load cy lin d er
Load c e ll
Univer sal joint D i s p l ac e m e nt

t r a n s d u c er
Sup p or t
Ad a pter
Fix ture
Brac e inser t
≥ 1. 5 h e f
Te st m e m b er
≥ 2 hef ≥ 2 hef
(a) Tension test rig
Pulling mem b er
Pulling fix ture
D i s p l ac e m e nt
t r a n s d u c er
t r a n s d u c er
su p p or t Fix ture p l ate
Brac e inser t
≥ t h i c k n e s s of t h e
fix ture p l ate for t h e
inte n d e d a p p li c at i o n
S l ot
width ≥1. 5 h e f
(b) Measurement of post-installed brace insert displacement
FIGURE A7 TEST SET-UP FOR TENSION TESTS

43 AS 3850.1:2015
A9.4.4 Shear tests

A9.4.4.1 General
The location of the post-installed brace insert shall be such that the edge distance, denoted
by ci,1 [refer to Figure A8(b)], is large enough that edge failure is avoided during
installation.
Following installation, the post-installed brace insert shall be connected to the test rig
(see Figure A8), without gap between the post-installed brace insert and the interchangeable
sleeve in the loading plate (see Figure A8). The load shall be applied parallel to the
concrete surface. A plate with interchangeable sleeves may be used for testing different
sized post-installed brace inserts (see Figure A8). The sleeves shall be made of quenched
steel and have radiused edges (0.4 mm) where they are in contact with the post-installed
brace insert. In general, the height of the sleeves shall be the same as the fixture plate, as
stated in Paragraph A9.4.2. The inner diameter of the shear test sleeve shall correspond to
the sizes given in Table A6.
To reduce friction, a smooth sheet (e.g. PTFE) with a maximum thickness of 2 mm shall be
placed between the concrete specimen and the loading plate and sleeve.
Where steel failure is expected, the clear distance may be reduced to less than 2ci,1
[see Figure A8(b), Appendix A and Figure B4, Appendix B].
A9.4.4.2 Instrumentation
The displacements of the post-installed brace insert relative to the concrete shall be
measured in the direction of the load application [see Figure A8(a)]. Direct measurement of
the post-installed brace insert displacement shall be made relative to a basic point at least
hef from the centre of the post-installed brace insert.
The load and displacement measurements shall be recorded at a rate not less than
10 readings per second throughout the test. The measuring error shall be not greater than
0.02 mm for displacement and 2% of the load throughout the entire measuring range.
A9.4.4.3 Application of load
The shear load shall be applied in such a manner that the peak load occurs 1 to 3 min after
the commencement of loading. The application of load shall increase until failure is
achieved, denoted by a drop in the load-carrying capacity.
ultimate load until the load has reduced to at least 75% of the ultimate load (to allow for the
drop of the load-displacement curve).

AS 3850.1:2015 44
A n c h or
D i s p l ac e m e nt Fix ture Load in g p l ate
t r a n s d u c er
Te st m e m b er
Univer sal joint Sup p or t Load c e ll Load cy lin d er
(a) Elevation
≥ 2c i ,1 ≥ 2c i ,1
t r a n s d u c er
C i ,1
(b) Top view
FIGURE A8 SHEAR TEST RIG SET-UP

45 AS 3850.1:2015
TABLE A6
DIAMETER OF CLEARANCE
HOLE IN THE SHEAR TEST SLEEVE (df)
External diameter d or Diameter df of clearance
d i,nom hole in the fixture
mm mm
12 14
14 16
16 18
18 20
20 22
22 24
24 26
27 30
30 33
Ødf
Load in g
p l ate
F
t fix
t f i x /2
P TFE, t ≤ 2 m m Inter c han g ea b l e

s l e eve
R ad i u s = 0.4
Ødf
F
t fix
t f i x /2
P TFE, t ≤ 2 m m
FIGURE A9 EXAMPLES OF SHEAR TEST SLEEVES WITH df ACCORDING TO

TABLE A6

AS 3850.1:2015 46
A9.5 Assessment
A9.5.1 Integrity assessment
During the installation process, post-installed brace inserts shall not fail by breakage of the
bolt, shank or threaded section, pull-through, or cause failure of the concrete. The
post-installed brace insert shall be capable of achieving the recommended installation
torque for the tension, shear and cyclic tests. If this criterion is not met or if there are
noticeable abnormalities, the post-installed brace insert shall be deemed unsuitable.
A9.5.2 Torque assessment
The 95% fractile of the tension force generated in the torque tests at a torque moment
T = 1.3Tinst shall be less than the nominal yield force (As fsy) of the post-installed brace
insert. After the test, the connection shall be capable of being unscrewed.
If the tension force generated in the post-installed brace insert is greater than the nominal
yield force at T = 1.3Tinst, the installation torque shall be reduced and the test repeated until
the tension force in the insert is less than nominal yield force (As fsy). All tests for Series 1
shall be repeated with the revised installation torque value.
A9.5.3 Strength in tension obtained from basic tension tests
A9.5.3.1 Mode of failure
The failure mode of each specimen shall be identified from the following:
(a) Steel failure.
(b) Concrete cone failure.
(c) Pull-out failure.
other failure modes occur and are of similar capacities, the failure modes and failure loads
of the tests shall be recorded in the test report. The average failure load, taking into account
all results as the failure load associated with the predominant failure mode, shall be
reported.
If no failure mode predominates in a test, additional post-installed brace inserts shall be
tested to obtain at least five samples for each failure mode and a significant difference test
shall be conducted to see if the capacities for the different failure modes are statistically
different.
The mean tensile strength determined from basic tests (N m,bas) and characteristic tensile
strength determined from basic tests (Nu,bas) shall be calculated for each failure mode if
more than one failure mode exists. The failure mode with the lowest characteristic value
shall be decisive as follows:
N m,bas = min (N m,s,bas, N m,c,bas, Nm,p,bas) . . . A9.5.3.1(1)
Nu,bas = min (Nu,s,bas, Nu,c,bas, Nu,p,bas) . . . A9.5.3.1(2)
where
N m,bas, = mean value or characteristic value of tensile strength determined from
Nu,bas basic tension tests
N m,s,bas, = mean value or characteristic value of ultimate load of steel failure
Nu,s,bas
N m,c,bas, = mean value or characteristic value of ultimate load of concrete cone failure
Nu,c,bas
N m,p,bas, = mean value or characteristic value of ultimate load of pull-out failure
Nu,p,bas

47 AS 3850.1:2015
A9.5.3.2 Load/displacement behaviour

To be acceptable, the tensile load-displacement behaviour of single post-installed brace
inserts shall be predictable. For each post-installed brace insert tested, a load plateau with a
corresponding slip greater than 5% of the displacement at ultimate load, or a temporary
drop in load, is not acceptable at load levels less than N1. For tests in non-cracked concrete,
N1 is taken as the smaller of 0.8Nult and As fsy.
NOTE: For examples of acceptable and unacceptable load-displacement curves for the
post-installed brace inserts, see Figure A10.
If this condition is not fulfilled in any test, the characteristic strength shall be reduced
according to Paragraph A9.6.1.
If the load at uncontrolled slip (Nuslip) is less than N1 and the deviation can be justified as
uncharacteristic of the brace insert behaviour as a result of a defect in the brace insert
tested, test procedure, etc., then the post-installed brace insert may be tested in an
additional series of 5 tests.
Nu
1
N1
LOAD, (N )
DISPL ACEM ENT
LEGEN D:
1 an d 2 Ac c e pt a b l e fun c t i o n
3 N o n - ac c e pt a b l e fun c t i o n
FIGURE A10 EXAMPLES OF ACCEPTABLE AND UNACCEPTABLE

LOAD/DISPLACEMENT CURVES
A9.5.3.3 Characteristic tensile strength based on basic tension tests

In order to identify the characteristic strength of the post-installed brace insert, the
following values shall be determined from the load-displacement curves:
(a) Mean ultimate loads The mean ultimate loads shall be determined from the
corresponding load-displacement curves.
(b) Coefficient of variation for ultimate loads The coefficient of variation of ultimate
loads (COV) shall be not greater than 15%.
NOTE: The initial sample size may be increased if its COV exceeds 15% to determine
whether the increase sample size reduces the COV to not greater than 15%.
(c) Characteristic values calculated from the ultimate loads determined by
tests Characteristic values shall be determined for the following (see Paragraph A4):
(i) Ultimate load for basic tension tests (Nu,bas).
(ii) Ultimate load for post-cyclic slip tension tests (Nu,pcyc).

AS 3850.1:2015 48
A9.5.4 Cyclic slip tension test assessment

The cyclic slip behaviour shall be determined as follows:
(a) Residual displacement behaviour Upon completion of the 1000 cycles and release of
load, the residual displacement of the brace insert shall be not greater than 0.25 mm.
In the event this condition is not met, the characteristic resistance shall be reduced
and the cyclic slip tension tests repeated for a new test series until this requirement is
fulfilled.
(b) Calculation of mean and characteristic strength based on cyclic slip tests The mean
ultimate tensile strength determined from post-cyclic slip tension tests (N m,pcyc) and
the characteristic tensile strength determined from post-cyclic slip tension tests
(Nu,pcyc) shall be calculated in accordance with Paragraphs A9.5.3.1 and A9.5.3.3.
(c) Comparison of measured ultimate loads with ultimate loads at installation An
assessment shall be made between the measured ultimate loads of the cyclic slip
tension test series, with the measured ultimate loads obtained from the basic tension
tests, as follows:
αo > req.α . . .A9.5.4(1)
where
αo
= ratio of post-cyclic slip tensile strength to basic tensile strength

⎛ N m, pcyc N u,pcyc ⎞
= min ⎜⎜ , ⎟
⎟
⎝ N m, bas N u,bas ⎠
N m,pcyc, = mean value of the characteristic ultimate strength measured
Nu,pcyc from the post-cyclic slip tension tests (refer to
Paragraph A9.4.3)
N m,bas, = mean value of the characteristic ultimate strength measured
Nu,bas from the basic tension tests
req.α = required significance level equal to 1.0 for cyclic tests
If the requirement of Equation A9.5.4(1) is not met (αo<1), the characteristic strength for
the post-installed brace insert shall be considered in Equation A9.6.1(1) in
Paragraph A9.6.1.
A9.5.5 Strength in shear
A9.5.5.1 Mode of failure
The failure mode of each specimen shall be identified from the following:
(a) Steel failure.
(b) Concrete failure.
other failure modes occur and are of similar capacities, the failure modes and failure loads
of the tests shall be recorded in the test report. The average failure load shall be reported,
taking into account all results as the failure load associated with the predominant failure
mode.
If no failure mode predominates in a test, additional post-installed brace inserts shall be
tested to obtain at least five samples for each failure mode, and a significant difference test
shall be conducted to see if the capacities for the different failure modes are statistically
different.

49 AS 3850.1:2015
A9.5.5.2 Characteristic shear strength

The characteristic shear strength of the post-installed brace insert shall be calculated for
each failure mode. The failure mode with the lowest characteristic value shall be decisive.
In order to identify the shear strength of the post-installed brace insert, the characteristic
value shall be calculated from the ultimate loads determined by tests. The basic
characteristic shear strength (Vu,bas) shall correspond to the 5% fractile of the mean loads
measured in the test series, and shall be calculated according to statistical procedures for a
confidence level of 90%. Values shall be calculated in a similar manner to characteristic
tensile values [see Paragraph A4 and Paragraph A9.5.3.3(c)].
A9.6 Evaluation
A9.6.1 Characteristic tensile strength of brace insert
A9.6.1.1 General characteristic tensile strength
The characteristic strength (Ru,N) shall be equal to the minimum value given in the
following equation:
Ru,N = min(Ru,Ncp, Ru,Ns) . . .A9.6.1.1
where
Ru,Ncp = characteristic ultimate tensile strength of post-installed brace insert
normalized to a concrete strength equal to 20 MPa for concrete cone failure

or pull-out failure
Ru,Ns = characteristic ultimate tensile strength of post-installed brace insert for
steel failure
A9.6.1.2 Characteristic tensile strength for concrete cone or pull-out failure mode
Where concrete cone or pull-out failure is decisive, the characteristic concrete cone or
pull-out strength (Ru,Nc) shall be the minimum value given in the following equation:
⎛ N u,basα 0 N u,basα 3 N u,pcycα 4 ⎞
Ru,Ncp = min ⎜⎜ , , ⎟
ψ c ⎟⎠
. . .A9.6.1.2(1)
⎝ ψc ψc
where
α0 = ratio of post-cyclic tensile strength to basic tensile strength [refer to
Paragraph A9.5.4(c)]
α3 = reduction factor for uncontrolled slip for basic tension tests
α1
= ≤ 1.0 . . . A9.6.1.2(2)
req.α
α4 = reduction factor for uncontrolled slip for post-cyclic slip tension tests
α2
= ≤ 1.0 . . . A9.6.1.2(3)
req.α
α1 = lowest ratio of Nuslip/Nult from basic tension tests (refer to
Paragraph A9.5.3.2)
α2 = lowest ratio of Nuslip/Nult from post-cyclic slip tension tests (refer to
Paragraph A9.5.3.2)
Nuslip = load at uncontrolled slip of the post-installed bracing insert
req.α = 0.8
ψc = (fcm/20)0.5 . . . A9.6.1(4)

AS 3850.1:2015 50
where
ψc = factor to normalize strength according to a concrete compressive strength
equal to 20 MPa
fcm = mean compressive strength of concrete at the relevant age
If no reduction for uncontrolled slip for the basic tension tests is necessary, α3 = 1.0.
If no reduction for uncontrolled slip for the post-cyclic slip tension tests is necessary,
α4 = 1.0.
A9.6.1.3 Characteristic tensile strength for steel failure
Where steel failure is decisive, the characteristic steel strength shall be determined from the
basic tensile strength (Nu,bas) and limited to the nominal tensile capacity of the brace insert
in accordance with AS 4100 as follows:
Ru,Ns = Nu,basα0 ≤ Ns.lim . . .A9.6.1.3
where
α0 = ratio of post-cyclic tensile strength to basic tensile strength (refer to
Paragraph A9.5.4(c)
Ns.lim = tensile strength of the brace insert determined in accordance with AS 4100
A9.6.2 Characteristic shear strength of the bracing insert

A9.6.2.1 General characteristic shear strength
The characteristic shear strength (Ru,V) shall be equal to the minimum value given in the
following equation:
Ru,V = min(Ru,Vc, Ru,Vs) . . . A9.6.2.1
where
Ru,Vc = characteristic ultimate shear strength of post-installed brace insert
normalized to a concrete strength equal to 20 MPa for concrete failure
Ru,Vs = characteristic ultimate shear strength of post-installed brace insert for steel
failure
A9.6.2.2 Characteristic shear strength for concrete failure
Where concrete failure mode is decisive, the characteristic concrete shear strength (Ru,Vc)
shall be determined from the basic characteristic shear strength (Vu,bas), and normalized to a
concrete strength equal to 20 MPa as follows:
Ru,Vc = Vu,bas/ψc . . . A9.6.2.2
where
Vu,bas = basic characteristic ultimate shear strength of post-installed brace insert for
concrete mode of failure
ψc = factor to normalize strength according to a concrete compressive strength
equal to 20 MPa (refer to Paragraph A9.6.1)
A9.6.2.3 Characteristic shear strength for steel failure
Where steel failure mode is decisive, the characteristic steel shear strength shall be
determined from the basic tensile strength (Vu,bas) and limited to the nominal shear capacity
of the brace insert in accordance with AS 4100 as follows:
Ru,Vs = Vu,bas ≤ Vs,lim . . . A9.6.2.2

51 AS 3850.1:2015
where
Vu,bas = basic characteristic ultimate shear strength of post-installed brace insert for
steel mode of failure
Vs,lim = nominal shear strength of the brace insert determined in accordance with
AS 4100
A9.6.3 Combined tension and shear
Where a post-installed brace insert is subjected to combined tension and shear the
post-installed brace insert shall conform to the interaction relationship included in the
following equation:
[N / (R
s u, N /F )]
1.5
[ (
+ Vs / Ru, V / F )]
1.5
≤ 1.0 . . . A9.6.3
where
Ru,N = characteristic ultimate tensile strength of brace insert
Ru,V = characteristic ultimate shear strength of brace insert
Ns = tension component of the unfactored applied load
Vs = shear component of the unfactored applied load
NOTE: If the applied load, or a component of it, is a wind load calculated from AS/NZS 1170.2
or AS/NZS 1170.0, it should be divided by 1.5 before being placed in this formula
(see Clause 2.5.6 of AS 3850.2).
A9.7 Test report
A test report shall be provided in accordance with the requirements of Paragraph A3.2.
Additionally, the following shall be reported:
(a) All details relating to concrete elements including the following:
(i) The properties of the concrete (composition, density, slump, 28 days strength).
(ii) The time of the casting and testing of all specimens.
(iii) Compressive strengths of the concrete as determined at the time of test.
(iv) The dimensions of test specimens.
(v) The nature and positioning of any reinforcement.
(b) All details relating to the installation of the brace insert including the following:
(i) The type of drill bit, the manufacturer’s mark and measured drill bit
dimensions, including the effective diameter of hard metal insert.
(ii) Information on the direction of drilling.
(iii) Information on the cleaning of the hole.
(iv) The depth of drill hole.
(v) The depth of anchorage (effective and total).
(vi) The distance to the edges.
(vii) The maximum width of slot in fixture.
(viii) The maximum thickness of the fixture.
(ix) The applied torque and a statement on calibration of torque wrench (where
applicable).

AS 3850.1:2015 52
(c) Measured values including the following:

(i) Displacement recording.
(ii) Displacements measured as a function of the applied load.
(iii) Residual displacement of post-installed brace insert head following cyclic test.
(iv) The radius (maximum radius, minimum radius) and the height of a concrete
cone produced in the test (where applicable).
A10 ADDITIONAL TESTING FOR BRACES

A10.1 General
This Paragraph applies only to braces that have a pinned connection at each end to
separately fabricated feet so they may be used at varying angles of inclination. The
principles expressed herein may be applied, where appropriate, to other brace designs.
A10.2 Procedure
(a) Test the bracing feet in compression and tension at angles of 0°, 30°, 45°, 60° and
90°, as shown in Figure A11. During the test, secure the foot to the testing bed in the
fixing slot provided.
(b) Test the brace pipes to peak load in compression as follows:

(i) At maximum and minimum extensions, and three intermediate and equally
spaced extensions (where telescopic).
(ii) Horizontally, suspended and clear spanning between the test supports unless
simulating restraint by way of secondary bracing.
(iii) As pin-connected to jacking supports having the same height as the intended
brace foot (see Figures A11 and A12, distance X), the reported test length of the
brace shall be the sum of the clearance between the pipe/foot pins + 2X.
(iv) With an axial test loading.
NOTE: Any adjustable threaded lengths at the end of braces should be at maximum
extension when tested.
(c) Test the brace pipes in tension at any length with the in-service pipe/foot pins but
without the brace feet. The connection of a tested brace pipe to the test equipment
shall be free to move only along the axis of the pipe brace.
(d) Determine the characteristic strength in both tension and compression from the test
results in accordance with Paragraph A4.

53 AS 3850.1:2015
90°
60°
4 5°
30°
D i st an c e X
FIGURE A11 ANGLES FOR TESTING BRACE FEET
J ac k w it h for c e g au g e
fi xe d i n p o s i t i o n
R e p o r te d l e n g t h of b r a c e
S o m e s h ear p in t hat
i s u se d w hil e in ser v i c e
A B
Pin n e d c o n n e c t i o n
u s e b o l t t h at i s u s e d
in ser v i c e
D i st an c e X
D i st an c e X
Fixe d p o s i t i o n
Jac k in line with
c e ntre of br ac e
DE TAIL A DE TAIL B
FIGURE A12 REPORTED LENGTH OF BRACE
A11 ADDITIONAL TESTING FOR LEVELLING SHIMS

A11.1 General
In addition to the general requirements set out in Paragraph A4, the compressive strength of
levelling shims shall be tested as set out in Paragraphs A11.2 to A11.5.
A11.2 Specimen
The specimen shall be a full sized sample of the finished saleable product.

AS 3850.1:2015 54
A11.3 Conditioning
The specimen shall be conditioned in accordance with ASTM D618, Procedure A.
A11.4 Procedure
The compression test shall be in accordance with ASTM D695.
A11.5 Expression of results
The compressive strength of the material shall be calculated as the stress, in megapascals,
required to either rupture or deform the specimen at a given percentage of its height. The
compressive strength shall then be expressed as the stress, in megapascals, either at rupture
or the specified deformation.
A11.6 Testing to establish the characteristic load of shims
Shims shall be tested by applying a constant load between parallel steel plates that have a
surface area exceeding the surface area of the shim, as follows:
(a) A load equal to the nominal WLL of the shim times FoS (see Table 2.1) shall be
applied for not less than 48 h at a temperature of 15°C–25°C. After 15 min of the load
application, the average deformation of the shim thickness shall not exceed 5% of the
nominal shim thickness, and after 48 h shall not exceed 8% of the nominal shim
thickness.
(b) A further test shall be conducted at 40°C for 12 h at a load equal to the nominal WLL
of the shim and the deformation shall not exceed the deformation recorded from the
test (a).
The characteristic load shall be the applied load, where:
Applied load = load applied in test (a) × (nominal surface area of the shim/load contact
area).
NOTE: The load contact surface area is the area of the shim that comes into contact with the steel
plates during the test. This contact surface area may be established by determining the
compressive capacity of the material using ASTM D695, the shim total cross-sectional area and
the characteristic ultimate load applied, or by marking the shim prior to testing and measuring the
full contact area after testing.

55 AS 3850.1:2015
APPENDIX B
CONCRETE CAPACITY DESIGN FOR CAST-IN LIFTING AND BRACE
INSERTS
(Normative)
B1 GENERAL
B1.1 Scope
This Appendix sets out a design procedure for cast-in headed inserts.
NOTE: This method is based on CEN/TS 1992-4-2:2009.
The procedure described herein may also be used for the design of individual inserts for
concrete failure modes under the following conditions:
(a) Tension accounting for pull-out failure, concrete cone failure, splitting failure and
blow-out failure.
(b) Shear accounting for concrete edge failure.
(c) Combined tension and shear.
This design procedure considers the variation in performance due to the condition of the
concrete (cracked/non-cracked), effects of edge distance, element thickness and the
direction of loading. The design procedure is based on the characteristic compressive
strength of concrete at 28 days ( f c′ ). If the concrete age is less than 28 days at the time of
loading, the design shall be based on the characteristic compressive strength at the age of
loading ( f c,′age ).
Design for group effects and steel failure are not covered in this design procedure.
An additional shape modification factor, determined by testing in accordance with
Paragraph A6, Appendix A, extends the design procedure for cast-in inserts with
configurations other than standard (reference) headed insert designs. Where the shape
modification factor is adopted, this design procedure may only be used for interpolation.
This design method does not account for any contribution made by component
reinforcement for headed inserts, including complementary and supplementary
reinforcement. Cast-in inserts that rely on supplementary reinforcement shall be designed in
accordance with the requirements of AS 3600. The consideration of the effects of a dense
layer of reinforcement on the characteristic resistance of a cast-in insert is omitted.
CB1.1 Each variation in innovative insert geometry should be considered as a
different insert requiring its own shape modification factor values.
B2 BASIS OF DESIGN
The installation instructions shall reflect the following:
(a) If the cast-in insert is intended to be installed prior to the pouring of the concrete, it
shall be fixed to the formwork or auxiliary constructions in a way that no movement
of the cast-in insert will occur during placing of reinforcement or during pouring and
compacting of the concrete.
(b) Adequate compaction of the concrete shall be achieved under the head of the cast-in
insert and under any fixture.

AS 3850.1:2015 56
(c) If the installation of the cast-in insert requires welding, the welding shall be
completed in accordance with the relevant Australian Standard.
(d) Inspection and approval of the correct installation of the cast-in inserts shall be
carried out by competent person.
B3 VERIFICATION OF ULTIMATE LIMIT STATE BY ANALYSIS

B3.1 General
This Paragraph applies when forces on the cast-in inserts have been calculated using
analysis.
B3.2 Tension capacity
B3.2.1 Required verification
The characteristic ultimate tensile strength of the cast-in insert (Ru,N) shall be determined
from the four possible tensile modes of failure as given in the following equation:
Ru,N = min (Nu,p, Nu,c, Nu,sp, Nu,cb) . . . B3.2.1
where
Nu,p = characteristic resistance of a cast-in insert in the case of pull-out failure
Nu,c = characteristic tensile resistance of a cast-in insert in the case of concrete

cone failure
Nu,sp = characteristic resistance of a cast-in insert in the case of splitting failure
Nu,cb = characteristic resistance of a cast-in insert in the case of blow-out failure
B3.2.2 Pull-out failure
B3.2.2.1 General
The characteristic resistance of an insert in the case of pull-out failure (Nu,p) of a single
cast-in insert shall be limited by the concrete stress under the head of the cast-in inserts
according to the following:
Nu,p = β p.N Ah f c,′ageψ ucr,N . . . B3.2.2.1
where
βp,N = tension shape modification factor for concrete pull-out failure
= 1.0 for a reference headed cast-in insert
= value determined from testing for other cast-in inserts (see Paragraph A7,
Appendix A)
Ah = loadbearing area of the head of the cast-in insert
= π 2
(d i,h − d i2 )
4
f c,′age = characteristic compressive strength of concrete at the age of loading
ψucr,N = factor relating to the state of the concrete (cracked/non-cracked) for tension
loading, (see Paragraph B3.2.2.2)
B3.2.2.2 State of the concrete
For all load cases where the stress in the concrete element (including external and intrinsic
loads) exceeds the characteristic uniaxial tensile strength of concrete ( f ct′ ) in the anchorage
zone determined in accordance with AS 3600, the cast-in insert shall be designed for a
cracked concrete condition.

57 AS 3850.1:2015
The factor ψucr,N depends on whether the insert is situated in cracked or non-cracked
concrete. The following factor shall be used:
ψucr,N = 1.0 for cast-in inserts in cracked concrete
= 1.4 for cast-in inserts in non-cracked concrete
B3.2.3 Concrete cone failure
B3.2.3.1 General
The characteristic resistance of a cast-in insert in case of concrete cone failure may be
obtained by the following equation).
Nu,c = Nu,c,β.(Ac,N/A0c,N).ψs,N . . . B3.2.3.1
where
Nu,c = characteristic tensile resistance of a cast-in insert in the case of concrete
cone failure
Nu,c,β = basic concrete breakout strength of a cast-in insert loaded in tension,
accounting for the shape modification factor (see Paragraph B3.2.3.2)
Ac,N = actual projected area for concrete cone failure of a single insert idealized as
a rectilinear pyramid of height hef (see Figures B2 and B3)
A0c,N = projected concrete failure area of a single insert idealized as a rectilinear

pyramid of height hef and base length si,cr,N = 3hef, where the distance to an
edge is equal or greater than 1.5hef (see Figure B4)
ψs,N = factor accounting for the disturbance of stresses in the concrete due to the
edges of the concrete element for tension loading (see Paragraph B3.2.3.4)
B3.2.3.2 Basic characteristic tensile resistance
The characteristic resistance to concrete cone failure for a single cast-in insert, placed at a
minimum distance 1.5hef from any edge, shall be as follows:
Nu,c,β = βc,N N0u,c . . . B3.2.3.2(1)
where
βc,N = tension shape modification factor for concrete cone failure
= value determined from testing for other cast-in inserts (see Paragraph A7)
1.5
N0u,c = k cr f c,′ age .hef . . . B3.2.3.2(2)
where
kcr = factor relating to the condition of concrete (cracked/non-
cracked)
= 10 for headed cast-in inserts in cracked concrete
= 13 for headed cast-in inserts in non-cracked concrete
f c,′age = characteristic compressive strength of concrete at the age of
loading
hef = effective embedment depth of the headed cast-in insert, in
millimetres

AS 3850.1:2015 58
B3.2.3.3 Effect of insert edge distance

The geometric effect of a cast-in insert spacing and edge distance on the characteristic
resistance shall be taken into account by the following ratio:
Ac,N/A0c,N
where
rectilinear pyramid of height hef
A0c,N = projected concrete failure area of a single insert idealized as a rectilinear
pyramid of height hef and base length si,cr,N = 3hef, where the distance to an
edge is equal or greater than 1.5hef
= si,cr,N . si,cr,N . . . B3.2.3.3
si,cr,N = critical spacing to ensure adjacent inserts do not influence
characteristic tensile resistance of insert
= 2ci,cr,N for headed inserts according to current experience
ci,cr,N = minimum edge distance required to achieve the characteristic
tension load resistance
= 1.5hef for headed cast-in inserts according to current

experience
S h af t of
inser t
A n g l e of h ead
of in ser t: 20 °- 3 0 °
H ead of
inser t
FIGURE B1 REQUIRED GEOMETRY FOR REFERENCE HEADED CAST-IN INSERT
di
hef
d i,h
FIGURE B2 EFFECTIVE EMBEDMENT DEPTH FOR A HEADED CAST-IN INSERT

59 AS 3850.1:2015
hef
s i,c r, N
0. 5 s i,c r, N
s i,c r, N
0. 5 s i,c r, N
A 0 c , N = s i,c r, N · s i,c r, N
FIGURE B3 IDEALIZED CONCRETE CONE AND AREA (A0c,N) OF CONCRETE OF AN

INDIVIDUAL CAST-IN INSERT

AS 3850.1:2015 60
A c,N
0. 5 s i,c r, N
s i,c r, N
0. 5 s i,c r, N
c i ,1 0. 5 s i,c r, N
If: c i ,1 < c i,c r, N

A c , N = (c i ,1 + 0 . 5 s i,c r, N ) s i,c r, N
FIGURE B4 ACTUAL PROJECTED AREA (Ac,N) OF THE IDEALIZED CONCRETE CONE

FOR A SINGLE CAST-IN INSERT AT THE EDGE OF A CONCRETE ELEMENT IN THE
CASE OF AXIAL TENSION LOAD
B3.2.3.4 Disturbance to the distribution of stresses

The factor ψs,N depends on the disturbance of the distribution of stresses in the concrete due
to edges of the concrete element. For cast-in inserts with several edge distances (e.g. cast-in
insert in a corner of the concrete element or in a narrow element), the smallest edge
distance (ci) shall be used in the following equation:
⎛ c ⎞
ψs,N = 0.7 + 0.3 ⎜⎜ i ⎟ ≤1
⎟ . . . B3.2.3.4
⎝ ci,cr,N ⎠
where
ci = edge distance measured from the centre of an insert shaft to the edge of the
concrete
ci,cr,N = minimum value for edge distance required to achieve the characteristic
tension load resistance

61 AS 3850.1:2015
B3.2.3.5 Effect of a narrow element

For cast-in inserts in an application with three or more edge distances less than ci,cr,N from
the cast-in inserts, the calculation according to Equation B3.2.3.1 will give conservative
results. To obtain more precise results for a single cast-in insert, the value hef shall be
substituted by the following:
ci,max
hef,mod = hef . . . B3.2.3.5(1)
ci,cr,N
where
hef,mod = modified effective depth of embedment for narrow elements
ci,max = maximum distance from centre of an insert to the edge of concrete element
< ci,cr,N
ci,cr,N = minimum value for edge distance to achieve characteristic resistance to
tensile load
The value hef,mod shall be inserted in Equation B3.2.3.2(2) and used for the determination of
A0c,N and Ac,N according to Figures B3 and B4, as well as in Equations B3.2.3.3 and
B3.2.3.4, where the values shall be as follows:
si,cr,N,mod = si,cr,N (hef,mod / hef ) . . . B3.2.3.5(2)

ci,cr,N,mod = ci,cr, N (hef,mod / hef ) . . . B3.2.3.5(3)
B3.2.4 Splitting failure
No verification for the splitting mode of failure is required if c > 3hef in all directions.
Otherwise, if H < 2hef and c < 3hef, the characteristic resistance of the cast-in insert to
splitting failure shall be calculated according to the following equation:
0 Ac, N
Nu,sp = N u β sp, N ψ s, Nψ h,sp . . . B3.2.4(1)
Ac,0 N
where
Nu,sp = characteristic resistance of an insert in the case of splitting failure
N u0 = min (Nu,p, N 0 )
u, c
Nu,p = determined in accordance with Paragraph B3.2.2.1
N u,0 c = determined in accordance with Paragraph B3.2.3.2, with the

values ci,cr,N and si,cr,N being replaced by ci,cr,sp and si,cr,sp, based
on an element thickness H min
βsp,N = tension shape modification factor for splitting
a rectilinear pyramid of height hef
Ac,0 N = projected concrete failure area of a single insert idealized as a rectilinear
pyramid of height hef and base length si,cr,N = 3hef where the distance to an
edge is equal or greater than 1.5hef

AS 3850.1:2015 62
ψs,N = modification factor accounting for the disturbance of the distribution of

stresses in the concrete due to edges of the concrete element
(see Paragraph B3.2.3.4) with ci,cr,N being replaced with ci,cr,sp, based on an
element thickness H min
H min = minimum concrete element thickness determined in accordance with
Paragraph A7.3, Appendix A
The factor ψ h,sp depends on the influence of the actual element thickness H on the splitting
resistance. For cast-in inserts, it shall be calculated using the following equation:
2/3 2/3
⎛ H ⎞ ⎛ 2h ⎞
ψh,sp = ⎜⎜ ⎟⎟ ≤ ⎜⎜ ef ⎟⎟ . . . B3.2.4(2)
⎝ H min ⎠ ⎝ H min ⎠
For cast-in inserts with several edge distances (e.g. cast-in insert in a corner of the concrete
element or in a narrow element), the smallest edge distance (ci) shall be used for the
calculation of Equation B3.2.4(1).
NOTE: If more than one concrete element depth (H) is given, the element depth corresponding to
the respective value of c i,cr,sp should be inserted in Equation B3.2.3.1.
If the edge distance is smaller than the value ci,cr,sp then a longitudinal reinforcement shall
be provided along the edge of the element.
B3.2.5 Blow-out failure

B3.2.5.1 General
Verification of blow-out failure shall not be required if the edge distance in all directions
exceeds ci = 0.5hef. If this condition is not met, the characteristic resistance in case of
blow-out failure shall be as follows:
0 Ac, Nb
Nu,cb = N u,cb,β ψ s, Nbψ ucr,N . . . B3.2.5.1
Ac,0 Nb
where
N0u,cb,β = characteristic resistance of a single cast-in insert, not influenced by
adjacent inserts or free structural component edges in cracked concrete
including the shape modification factor
Ac,Nb = idealized projected area for concrete blow-out (see Paragraph B3.2.5.3)
Ac,0 Nb = reference projected area for concrete blow-out (see Paragraph B3.2.5.3)
(see Paragraph B3.2.5.4)
ψucr,N = factor accounting for the state of the concrete (see Paragraph B3.2.2.2)
B3.2.5.2 Characteristic resistance of a single insert
The characteristic resistance of a single cast-in insert, not influenced by adjacent inserts or
free structural component edges placed in cracked concrete ( N u,0 cb,β ), shall be calculated
using the following equation:
N u,0 cb,β = 12 β cb, N ci.1 Ah f c,′ age . . . B3.2.5.2

63 AS 3850.1:2015
where
βcb,N = tension shape modification factor for blow-out failure
f c,′age = characteristic compressive strength of concrete at the age of loading
Ah = loadbearing area of the head of the cast-in insert (see Equation B3.2.2.1)
ci,1 = edge distance (see Figure B5)
c i ,1
A 0c,Nb
4 c i ,1 4 c i ,1
4 c i ,1
(a) C r o s s - s e c ti o n ( b) S i d e e l evati o n (s h owi n g i n s e r t)
FIGURE B5 IDEALIZED CONCRETE BREAK-OUT BODY AND AREA A0c,Nb OF AN

INDIVIDUAL CAST-IN INSERT IN CASE OF BLOW-OUT FAILURE
B3.2.5.3 Effect of insert spacing and edge distance

The geometric effect of cast-in insert spacing and edge distance on the characteristic
resistance shall be taken into account using the following value:
Ac, Nb / Ac,0 Nb
where
A0c,Nb = reference projected area for concrete blow-out
Ac,Nb = actual projected area for concrete blow-out, limited by edges of the
concrete element (ci,2 <2.ci,1) or the element depth.
NOTE: Examples for the calculation of Ac,Nb are given in Figure B5.
The factor ψ s,Nb depends on the disturbance of the distribution of stresses in the concrete
due to the proximity of a cast-in insert to a corner of the concrete element. For inserts with
several edge distances (e.g. insert in a corner of the concrete member), the smallest edge
distance (ci,2) shall be used in the calculation, as follows.
⎛ ci,2 ⎞
ψs,Nb = 0.7 + 0.3 ⎜⎜ ⎟ ≤1
⎟ . . . B3.2.5.4
⎝ c i,1 ⎠

AS 3850.1:2015 64
where
B3.3 Shear load
B3.3.1 Required verifications
The characteristic ultimate shear strength of the bracing cast-in insert (Ru,V) shall be
determined from the following equation:
Ru,V = Vu,c . . . B3.3.1
where
Vu,c = characteristic shear resistance of an insert
B3.3.2 Concrete edge failure
B3.3.2.1 General
If the edge distance in all directions for a single cast-in insert is greater than the minimum
of 10hef and 60di (i.e. ci ≥10hef or ci >60di), a check of the characteristic concrete edge
failure resistance may be omitted.
If an insert is influenced by more than one edge, the smallest resistance to edge effects shall
be decisive.
B3.3.2.2 Characteristic shear resistance
The characteristic resistance for a headed cast-in insert (including reference insert) or an
innovative insert that does not include supplementary reinforcement shall correspond to the
following:
0 Ac,V
Vu,c = Vu,c,β ψ s,V ψ h,V . . . B3.3.2.1
Ac,0 V
where
Vu,c = characteristic resistance of a single cast-in insert in shear
V0u,c,β = initial value of the characteristic resistance of an insert loaded
perpendicular to the edge in cracked concrete, including provision for a
shape modification factor
Ac,V = idealized area of concrete cone at the lateral concrete surface for shear
failure (see Figure B7)
A0c,V = idealized area of concrete cone of an individual insert at the lateral
concrete surface not affected by edges, element thickness or adjacent
inserts (see Figure B6)
ψs,V = factor accounting for the disturbance of the distribution of stresses for
shear failure (see Paragraph B3.3.2.5)
ψh,V = factor accounting for the effect of element thickness on shear failure (see
Paragraph B3.3.2.6)

65 AS 3850.1:2015
B3.3.2.3 Basic characteristic shear resistance

The characteristic resistance of a single headed insert (including reference insert) placed in
cracked or non-cracked concrete and loaded perpendicular to the edge shall satisfy the
following:
V0u,c,β = β c,VVu,0c . . .B3.3.2.3(1)
where
βc,V = shear shape modification factor for concrete edge failure for cast-in inserts
without supplementary reinforcement
= 1.0 for a reference headed insert
= value determined from testing for innovative cast-in inserts
(see Paragraph A7)
A
B 1.5
Vu,0c = 1.8d i,nom lf f c,′ age ci.1 . . .B3.3.2.3(2)
where
Vu,0c = characteristic shear strength of a reference cast-in insert (R), being a round-
bodied, cast-in headed insert with a minimum net bearing area of 4 times
the cross-sectional area of the body of the insert
0.5
⎛ l ⎞
A = 0.1 ⎜ i ⎟
⎜c ⎟
⎝ i,1 ⎠
0.2
⎛d ⎞
B = 0.1 ⎜ i,nom ⎟
⎜ c ⎟
⎝ i,1 ⎠
di,nom = nominal outside diameter of insert
= <60 mm
f c,′age = characteristic compressive strength of the concrete at age of loading, in
megapascals
ci,1 = edge distance to first edge (in the direction of the shear load), in
millimetres
li = hef in case of a uniform diameter of the shank of the headed insert, in
millimetres
= <8di,nom, in millimetres
B3.3.2.4 Effect of insert spacing, edge distance and element thickness
The geometrical effect of spacing as well as of further edge distances and the effect of
thickness of the concrete element on the characteristic resistance shall be taken into account
by the ratio Ac,V/A0c,V
where
Ac,0 V = idealized area of concrete cone of an individual insert at the lateral
concrete surface not affected by edges, element thickness or adjacent
inserts (see Figure B6)
= 4.5ci,12

AS 3850.1:2015 66
Ac, V = idealized area of concrete cone at the lateral concrete surface for shear
failure (see Figure B7)
1. 5 c i ,1
1. 5 c i ,1
1. 5 c i ,1 c i ,1
A 0 c ,V
A 0 c ,V = (2 x 1. 5 c i ,1) x 1. 5 c i ,1
= 4. 5 c i , l 2
FIGURE B6 IDEALIZED CONCRETE BREAK-OUT BODY AND AREA A0c,V FOR A

SINGLE CAST-IN INSERT
c i ,1
V
1. 5 c i ,1
A c ,V
c i,2
1. 5 c i ,1
A c ,V = 1. 5 c i ,1 (1. 5 c i ,1 + c i , 2 )
If: h > 1. 5 c i ,1
c 2 < 1. 5 c i ,1
FIGURE B7 ACTUAL PROJECTED AREA Ac,V OF THE IDEALIZED CONCRETE

BLOW-OUT BODY FOR A SINGLE CAST-IN INSERT AT A CORNER

67 AS 3850.1:2015

The factor ψs,V depends on the disturbance of the distribution of stresses in the concrete due
to the effects of additional edges of the concrete element on the shear resistance. For cast-in
inserts with two edges parallel to the direction of loading (e.g. in a narrow concrete
element) the smaller edge distance shall be shall be used in the calculation, as follows.
ci,2
ψs,V = 0.7 + 0.3 × ≤1 . . . B3.3.2.5
1.5ci,1
where
B3.3.2.6 Effect of the thickness of the structural component
The factor ψh,V depends on the fact that the concrete edge resistance does not decrease
proportionally to the element thickness as assumed by the ratio Ac, V / Ac,0 V :
0.5
⎛ 1.5ci,1 ⎞
ψh,V = ⎜⎜ ⎟⎟ ≥1 . . . B3.3.2.6
⎝ H ⎠
where
H = concrete element depth
B3.3.2.7 Effect of reinforcement and state of the concrete
The factor ψre,V depends on whether the insert is situated in cracked or non-cracked
concrete (see Paragraph B3.2.2.2) and edge reinforcement, as follows:
ψre,V = 1.4 for cast-in inserts in—
(a) non-cracked concrete
(b) cracked concrete with edge reinforcement and closely spaced stirrups
or wire mesh with a spacing a <100 mm and a <2ci,1
A factor ψre,V >1 for applications in cracked concrete shall only be applied if the
embedment depth (hef) of the insert is >2.5 times the concrete cover of the edge
reinforcement.
B3.3.2.8 Effect of a narrow element
For cast-in inserts in a narrow, thin element with ci,2,max <1.5ci,1 and H <1.5ci,1, the
calculation according to Equation B3.3.2.1 leads to conservative results. To obtain more
precise results for a single cast-in insert, ci,1 f shall be limited to the larger value of the
following:
ci,1,mod = max (ci,2,max/1.5,H/1.5) . . . B3.3.2.8
where
ci,2,max = largest of the two edge distances parallel to the direction of loading
The value ci,1,mod shall be included in Equations B3.3.2.3(2), B3.3.2.5 and B3.3.2.6 as well
as in the determination of the areas Ac,0 V and Ac, V according to Figures B6 and B7.

AS 3850.1:2015 68
B3.4 Combined tension and shear loading

Where a cast-in insert is subjected to combined tension and shear, the insert shall conform
to the interaction relationship given in the following equation:
[N / (R
s u, N /F )] + [V / (R
1.5
s u, V /F )]
1.5
≤ 1.0 . . . B3.4
where
Ru,N = characteristic ultimate tensile strength of cast-in insert
Ru,V = characteristic ultimate shear strength of cast-in insert
Ns = tension component of the applied load
Vs = shear component of the applied load

69 AS 3850.1:2015
BIBLIOGRAPHY
AS
1199 Sampling procedures for inspection by attributes
1199.0 Introduction to the ISO 2859 attribute sampling system
1478 Chemical admixtures for concrete, mortar and grout
1478.1 Part 1: Admixtures for concrete
AS/NZS
1170 Structural design actions
1170.0 Part 0: General principles
1170.2 Part 2: Wind actions
AS 3850.1:2015
70
NOTES
71
NOTES
AS 3850.1:2015
AS 3850.1:2015
72
NOTES
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Part 1: General requirements

The following are represented on Committee BD-066:

• Australasian Fire and Emergency Service Authorities Council

• Steel Reinforcement Institute of Australia

Keeping Standards up-to-date

Standards Australia welcomes suggestions for improvements, and encourages readers to

Prefabricated concrete elements

Part 1: General requirements

Originated as AS 3850.1—1990, AS 3850.2—1990 and AS 3850.3—1992.

SECTION 1 SCOPE AND GENERAL

SECTION 2 MATERIALS, COMPONENTS AND EQUIPMENT

2.8 LEVELLING PADS AND SHIMS ............................................................................ 22

Part 1: General requirements

1.3 NORMATIVE REFERENCES

© Standards Australia www.standards.org.au

Load applied along the longitudinal axis of the insert.

www.standards.org.au © Standards Australia

1.4.9 Characteristic value

1 See Figure A4, illustrations (a) and (b), Appendix A.

© Standards Australia www.standards.org.au

1.4.20 Erection designer

www.standards.org.au © Standards Australia

1.4.31 Killed steel

Minimum element thickness in which an insert can be installed.

© Standards Australia www.standards.org.au

1.4.44 Release agent

A temporary member used to provide localized strengthening, support or a suitable tilting

www.standards.org.au © Standards Australia

Ac,0 N = projected concrete failure area of a single insert idealized as a rectilinear

Ac,0 Nb = reference projected area for concrete blow-out

a = spacing of stirrups or wire mesh

© Standards Australia www.standards.org.au

fsy = nominal yield strength of the reinforcing steel

f ct′ = characteristic uniaxial tensile strength of concrete

f c,′ age = characteristic compressive strength of concrete at the age of loading

H = concrete element depth

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Nu,p = characteristic resistance of an insert in the case of pull-out failure

N u,0 cb.β = characteristic resistance of an insert to blow-out failure, not influenced by

© Standards Australia www.standards.org.au

Vs = shear component of the applied load

Vu,0c,β = initial value of the characteristic resistance of an insert loaded perpendicular to

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α2 = parameter used to reduce characteristic strength based on post-cyclic slip tension

© Standards Australia www.standards.org.au

ensured that all components within a system are compatible.

2.2 WORKING LOAD LIMIT (WLL) CALCULATION

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2.3 CONCRETE AND REINFORCEMENT

2.4 CURING COMPOUNDS AND RELEASE AGENTS

© Standards Australia www.standards.org.au

2.5 LIFTING, BRACE AND FIXING INSERTS

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bar) fitted and incorporate integral tension legs.

© Standards Australia www.standards.org.au

2.5.3 Post-installed brace inserts

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2.6 LIFTING CLUTCHES

© Standards Australia www.standards.org.au

C2.6 Suitable identification of lifting clutches may be by permanent marking on the

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2.7.2 Marking of braces