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Development of Design Charts For Concrete Pavements and Industrial Ground Slabs
Development of Design Charts For Concrete Pavements and Industrial Ground Slabs
2.1. Introduction
This chapter describes the development of a design procedure for concrete pavements
and ground slabs subjected to various forms of vertical applied loading, with particular
reference to industrial floors. The procedure is based on solutions from the theory of
elasticity, where the supporting soil is characterised by equivalent values of Young’s
modulus and Poisson’s ratio, and where the primary design criterion is the allowable
flexural tensile stress in the slab.
Three types of loading are considered, namely wheel loads, post loads and distributed
strip loads. In each case, design charts are provided for both interior and edge loading.
These charts are based on an extensive series of elastic finite element analyses in which
the slab is modelled by a thin plate and the soil is idealised as an equivalent homoge-
neous isotropic layer underlain by a rigid base [2.1]. A standard set of parameters was
selected for the main analyses, and then correction factors were derived to take account
of variations from the standard values of soil stiffness and layer depth, and from the
standard loading.
There are four main steps in the design process:
Examples illustrating the design procedure are also given. The charts form the basis of
the current design guidelines for industrial pavements published by the Cement and
Concrete Association of Australia [2.2]. In particular, they avoid many of the shortcom-
ings of a previous document T34 [2.3] that was based on modelling the soil as a uniform
series of unconnected (Winkler) springs to give a modulus of subgrade reaction.
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40 D ESIG N AP PLIC A TIO NS OF RA FT FOU N DA TIO N S
Concrete slab
Loading
Ec,νc
Soil layer
H Es,νs
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DE VEL OPM ENT OF DE SIG N CH AR TS FO R CO NC RET E PA V EMEN TS 41
S S
b
b b b b
b S
b b b b
b
Figure 2.2. Representation of wheel loading: (a) interior loading; (b) edge loading,
case 1; (c) edge loading, case 2
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42 D ESIG N AP PLIC A TIO NS OF RA FT FOU N DA TIO N S
Slab edge
y y
b y b y
b b
x x x x
(a) (b)
Figure 2.3. Representation of post loading: (a) interior loading; (b) edge loading
W W W
Figure 2.4. Representation of distributed loading: (a) interior loading; (b) edge loading,
case 1; (c) edge loading, case 2
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DE VEL OPM ENT OF DE SIG N CH AR TS FO R CO NC RET E PA V EMEN TS 43
(a) computer program FLEA (Finite Layer Elastic Analysis), which can analyse the
behaviour of an extensive slab on a layered soil profile [2.5], and can therefore
be used for interior loadings;
(b) analytical solutions presented by Selvadurai [2.6] for concentrated loading
within an extensive raft, and also near the edge of an extensive raft.
For the two cases illustrated in Figure 2.5, solutions have been compared for the
maximum bending moment Mmax and maximum deflection qmax beneath the loaded area.
Typical comparisons are listed in Tables 2.1 and 2.2. For the case of interior distributed
loading (case A), there is reasonably close agreement between the solutions from FLEA
and FEAR. For interior dual wheel loading (case B), the slab flexure given by FEAR,
FLEA and Selvadurai agree well. As shown in Figure 2.5(c), the distributions of
bending moment from the FEAR and Selvadurai solutions for case B also agree very
well; here Mx denotes the moment per unit length in the x-direction, and similarly for
My .
Zhang and Small [2.7] have carried out a series of comparisons between solutions for
a loaded raft foundation, and have concluded that the FEAR analysis gives results which
agree well with previously published solutions. These comparisons, together with those
presented herein, suggest that the program FEAR is capable of producing results of
adequate accuracy for most practical purposes. This program has therefore been selected
as the tool for obtaining the solutions which are used in this chapter to develop the design
charts for industrial ground slabs.
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44 D ESIG N AP PLIC A TIO NS OF RA FT FOU N DA TIO N S
Ec = 30 000 MPa
νc = 0·16 W=2m
t p = 1 MPa
Es = 20 MPa
H=6m
νs = 0·3
(a)
S =1·2 m
Ec = 30 000 MPa
νc = 0·16
D = 0·3 m D = 0·3 m
t p =1 MPa p =1 MPa
Es = 20 MPa
H=6m
νs = 0·3
(b)
CL
0·028
Selvadurai
0·024 } Results from FEAR
Moment per unit length: MNm/m
y
0·020
x
Centre CL
0·016 of
wheel
0·012 Loaded My
diameter
0·008
Mx
0·004
t = 0·3 m
0
0 0·2 0·4 0·6 0·8 1·0 1·2 1·4 1·6 1·8 2·0
Distance from centre line: m
(c)
Figure 2.5. Accuracy check on flexure of extensive ground slab: (a) uniform strip
loading, case A; (b) uniform circular loading, case B; (c) bending moment distribution,
case B
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DE VEL OPM ENT OF DE SIG N CH AR TS FO R CO NC RET E PA V EMEN TS 45
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46 D ESIG N AP PLIC A TIO NS OF RA FT FOU N DA TIO N S
3. From the maximum bending moment so computed, the maximum stress in the
slab was calculated. For the cases of distributed and post loading, the maximum
stress was expressed in dimensionless form by dividing by the applied loading.
4. A plot of maximum stress F, against slab thickness was prepared.
5. The problem was re-analysed for the ‘standard’ parameters and for a typical slab
thickness (usually 200 mm), varying in turn:
(a) soil Young’s modulus;
(b) soil layer depth;
(c) loading details.
6. For each parameter varied, a correction factor was obtained by dividing the
computed stress for the ‘standard’ value of the parameter by the computed stress
for the value of that parameter used in the analysis. For example, the correction
factor FE for the soil Young’s modulus Es was computed as
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DE VEL OPM ENT OF DE SIG N CH AR TS FO R CO NC RET E PA V EMEN TS 47
In some cases, an assessment of the deflections may also be required e.g. for long-term
distributed loading. The design procedure is summarised in Figure 2.6. Each stage of
assessment is discussed in detail in the following sections.
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48 D ESIG N AP PLIC A TIO NS OF RA FT FOU N DA TIO N S
Consideration is not given herein to combined loading, although there may be circum-
stances where, for example, a combination of distributed loading and wheel loading
could occur. In that case, however, the effects of the two loadings are likely to be
compensating rather than additive. In other cases e.g. a combination of post loads with
wheel loads, the two loadings may have a cumulative effect on ground slab stresses. In
such cases, the designer should exercise appropriate judgement in selecting the magni-
tude and configuration of design loading.
As stated previously, the design charts in this chapter are for the case of a single axle
with single wheels; for a given axle load, this representation of loading will be slightly
conservative if dual wheels are present.
Hodgkinson [2.8] provides details of axle configurations and wheel loads for vehicles
using public roads. Table 2.3, reproduced from document T34, gives details of a 1983
survey of manufacturers’ data for forklift trucks.
WS WC
Front axle load: Approx. rated
tonnes capacity: tonnes WC TC
4 2 750
6 2.5 800
8 3.5 850
10 4.5 900 1450 250
20 9 1050 1750 300
30 13 1150 2000 350
40 17 2200 400
50 22 2350 450
60 26 2450 500
70 30 2550 550
80 35 2600 550
90 40 2600 550
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DE VEL OPM ENT OF DE SIG N CH AR TS FO R CO NC RET E PA V EMEN TS 49
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50 D ESIG N AP PLIC A TIO NS OF RA FT FOU N DA TIO N S
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DE VEL OPM ENT OF DE SIG N CH AR TS FO R CO NC RET E PA V EMEN TS 51
100
80
Long-term Young's modulus Es: MPa
60
40
20
0
1 2 4 6 8 10 20 40 60 80 100
CBR: %
Figure 2.7. Approximate correlation between CBR and long-term Young’s modulus
Appropriate laboratory testing usually requires triaxial testing of soil samples with a
stress history, and over a range of stress, similar to that to be experienced by the soil
under field conditions; see, for example, Davis and Poulos [2.9].
The most useful geotechnical data with which to correlate Young’s modulus are:
(a) California Bearing Ratio (CBR), which is readily measured for compacted soil
samples;
(b) standard penetration test (SPT) data;
(c) static cone penetration test (CPT) data.
Document T34 reproduces a correlation between CBR and subgrade reaction modulus,
derived by Austroads [2.10]. Assuming that the subgrade reaction modulus values corre-
spond to a 760 mm diameter plate, the foregoing correlation can be re-interpreted (via
elastic theory) to produce a correlation between CBR and soil Young’s modulus; the
correlation so obtained is shown in Figure 2.7.
The values of Young’s modulus from this figure are generally lower than simple linear
correlations commonly used for pavement design e.g. Es (MPa) = 5 to 10 times CBR. It
is recommended that the values of Es derived from Figure 2.7 be considered as long-term
modulus values. In the case of wheel loadings, it is generally appropriate to use a
short-term value of Es. The relationship between the short-term and long-term values can
be expressed as
Es (long-term) = b Es (short-term) (2.5)
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52 D ESIG N AP PLIC A TIO NS OF RA FT FOU N DA TIO N S
Gravel 0.9
Sand 0.8
Silt, silty clay 0.7
Stiff clay 0.6
Soft clay 0.4
Typical presumptive values of CBR are reproduced in Table 2.6, from Austroads
[2.10], where USC refers to the Unified Soil Classification system; see, for example,
Lambe and Whitman [2.11]. Ideally, the CBR values should be selected on the basis of
local experience.
Based on the work of Stroud and Butler [2.12], Figure 2.8 presents a correlation
between short-term Young’s modulus, SPT-value, and soil plasticity index PI. The ratio
Es/N (in MPa) ranges from 3.5 for sands and gravels (PI = 0) to about 0.5 for heavy
clays, where N denotes the standard penetration resistance (blows/300 mm). It is recom-
mended that, when applied to clays, Figure 2.8 be used only for relatively stiff clays and
not for very soft clays. It has been suggested that an approximately linear correlation can
be derived between the short-term Young’s modulus and the static cone penetration
resistance qc, namely
Es = aqc (2.6)
Recommended values of the correlation factor a are shown in Table 2.7 as a function of
soil type.
Both Figure 2.8 and Table 2.7 refer to the soil Young’s modulus for short-term
loading. If long-term loading is being considered, the long-term value may be derived
from the short-term value, via equation (2.5), using the correction factor b shown in
Table 2.5. Finally, typical values of soil Poisson’s ratio vs are shown in Table 2.8.
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DE VEL OPM ENT OF DE SIG N CH AR TS FO R CO NC RET E PA V EMEN TS 53
3
Es/N : MPa
0
0 20 40 60 80
Plasticity index: %
Figure 2.8. Suggested correlation between short-term Young’s modulus, N-value and
plasticity index
Sand – loose 5
– medium dense 8
– dense 10
Silt 12
Silty clay 15
Clay – highly plastic 20
Poisson’s ratio vs
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54 D ESIG N AP PLIC A TIO NS OF RA FT FOU N DA TIO N S
Soil surface
zi
Layer n hn Esn
(a) (b)
Figure 2.9. Assessment of equivalent uniform soil layer: (a) actual layered soil profile;
(b) equivalent uniform soil layer
∑Wi =1
fi hi
Ese = n (2.7)
∑W
i =1
fi hi / Esi
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DE VEL OPM ENT OF DE SIG N CH AR TS FO R CO NC RET E PA V EMEN TS 55
Weighting factor: Wf
Wheel loading
(X = S )
2
Distributed loading
(X = W )
4
Post loading
(X = x )
Relative depth: z /X
10
12
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56 D ESIG N AP PLIC A TIO NS OF RA FT FOU N DA TIO N S
where k1 = material factor, which accounts for differences between site and laboratory
strengths, etc; k2 = load repetition factor; f ct′ = characteristic flexural tensile strength of
concrete.
The value of k1 typically ranges between 0.7 and 1.0. For wheel loading, values of k2,
based on document T34, are shown in Table 2.9.
Unlimited 0.50
400 000 0.51
300 000 0.52
200 000 0.54
100 000 0.56
50 000 0.59
30 000 0.60
10 000 0.64
2 000 0.70
1 000 0.73
As outlined in AS 3600 [2.13], f ct′ may be estimated from the characteristic compres-
sive strength of the concrete, f c′, as follows:
For post loading, the recommendations of document T34 for the design tensile strength
are less specific, the decision being left to the design engineer.
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DE VEL OPM ENT OF DE SIG N CH AR TS FO R CO NC RET E PA V EMEN TS 57
P P
t
Es H
600 1·3
400 600
1·1
400 FE1
1·0
200
200 0·9
100
0·8
0 0·7
0 1 2 3 4 5 10 15 0 10 20 30 40 50
F1 Soil Young's modulus Es: MPa
1·2 1·1
FS1
FH1
1·0 1·0
0·8 0·9
1 1·5 2 3 0 5 10 20
Wheel spacing S : m Soil layer depth H : m
The factors FE1, FS1 and FH1 are plotted on Figures 2.11 and 2.12, noting that the
short-term value of Es is usually appropriate.
Once the factor F1 has been computed from equation (2.10), the required slab thick-
ness t for the given axle load can be determined from the main plot of t versus F1 in
Figures 2.11 and 2.12.
The case of edge loading requires a greater slab thickness than does interior loading.
For this case, the critical edge-loading pattern occurs when the axle is perpendicular to
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58 D ESIG N AP PLIC A TIO NS OF RA FT FOU N DA TIO N S
P P
t
Es H
600
1·5
Slab thickness t : mm
FE1
800
600 1·0
200 400
200
100
0 0·5
0 1 2 3 4 5 10 15 20 0 10 20 30 40 50
F1 Soil Young's modulus Es: MPa
1·2 1·1
FH1
FS1
1·0 1·0
0·8 0·9
1 1·5 2 3 0 5 10 20
Wheel spacing S : m Soil layer depth H : m
the edge of the slab i.e. case 1 in Figure 2.2. Consequently, if edge loading is likely to
occur, the slab thickness in the vicinity of the edge will need to be increased. Guidelines
for the distance over which such an increase should occur are given in section 2.8.4.
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DE VEL OPM ENT OF DE SIG N CH AR TS FO R CO NC RET E PA V EMEN TS 59
1. Changing the modulus of the slab by ± 10 000 MPa (from the adopted value of
30 000 MPa) causes the F1 factor to change by about 5%.
2. Changing the tyre pressure by ± 200 kPa from the adopted value of 700 kPa
causes the F1 factor to change by about 1.5%.
3. If the wheel print is changed from a square to a 1:1.5 rectangular shape, the factor
F1 is decreased by about 5%.
Within the uncertainty of the estimation of design loads and soil properties, the three
factors considered above do not appear to be of major importance.
f all
F2 = 1000 FE2 FS2 FH2 (2.11)
P
where fall = design tensile strength of concrete (see section 2.7), in MPa
FE2 = factor for soil Young’s modulus, Es (of equivalent uniform layer)
FS2 = factor for post spacing in x-direction
FH2 = factor for depth of soil layer, H
P = magnitude of loading on each post (in kN).
The factors FE2, FS2, FH2 are plotted in Figure 2.13, and are similar for both edge and
interior loading. In most cases, use of the long-term value of Es is appropriate.
The factor F2 is relatively insensitive to the area of the base plate below each post. The
curves in Figure 2.13 have been computed for a base plate area of 25 000 mm2, but a
reduction of 5000 mm2 only reduces F2 by about 6%, while an increase in area to
50 000 mm2 leads to an increase in F2 of about 7%.
For post spacings which are not equal in both the x- and y-directions, an average value
of spacing can be used, with sufficient accuracy, to obtain the factor FS2 in Figure 2.13.
From the value of F2 computed from equation (2.11), the required thickness can be
read from Figure 2.13.
f all
F3 = F F F (2.12)
p E3 W3 H3
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60 D ESIG N AP PLIC A TIO NS OF RA FT FOU N DA TIO N S
x x
P P P t
Es H
600
1·5
Slab thickness t : mm
FE2
Interior 1·0
200 loading Edge loading
0 0·5
0 10 20 30 40 50 75 100 125 0 10 15 20 30 40 50
F2 Soil Young's modulus Es: MPa
1·5 1·2
FH2
FS2
1·0 1·0
0·5 0·8
1 1·5 2 3 0 5 10 20
Average spacing between posts S : m Soil layer depth H : m
and where the long-term value of Es is usually appropriate. Using the value of F3
computed from equation (2.12), the required thickness slab t can be read from Figure 2.14.
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DE VEL OPM ENT OF DE SIG N CH AR TS FO R CO NC RET E PA V EMEN TS 61
p t
Es H
600
1·5
Slab thickness t : mm
400
FE3 1·0
200
0 0·5
30 50 70 90 110 0 10 20 30 40 50
F3 Soil Young's modulus Es: MPa
1·8 1·3
1·6 1·2
1·4 1·1
FW3
FH3
1·2 1·0
1·0 0·9
0·8 0·8
0 1 2 2·5 3 4 5 0 5 10 20
Width of aisle or loaded area W : m Soil layer depth H : m
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62 D ESIG N AP PLIC A TIO NS OF RA FT FOU N DA TIO N S
1·8
W
1·6
p t
Ec, νc
1·4 Es, νs H
1·2
1·0
ωs
H: m
20
0·8
10
0·6
5
0·4
2·5
0·2
0
0 2 4 6 8 10 12 14
Characteristic length lc: m
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DE VEL OPM ENT OF DE SIG N CH AR TS FO R CO NC RET E PA V EMEN TS 63
Table 2.10. Distance (e) from edge of slab at which slab thickening should commence
(t denotes thickness of slab required for internal loading)
For distributed loading, as discussed previously, the interior loading case is generally
the critical one, and therefore edge thickening is not necessary.
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64 D ESIG N AP PLIC A TIO NS OF RA FT FOU N DA TIO N S
Concrete slab t
Sand N = 12 2·5 m
Stiff clay N = 22 2m
Shale
Figure 2.16. Soil profile used in worked example of slab design for wheel loading
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65
Table 2.11. Assessment of Young’s modulus of equivalent soil layer used in worked example of slab design for wheel loading
Young’s Depth zi to
Thickness hi modulus Esi layer centre Weighting
Soil layer (m) CBR (%) SPT (MPa) (m) zi /X(1) factor Wf i(2) Wfi hi Wfi hi /Esi
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Sand 2.5 – 12 42 2.75 1.53 0.52 1.30 0.0310
Stiff clay 2.0 – 22 37.4 5.0 2.78 0.34 0.68 0.0182
Very stiff clay 3.0 – 35 59.5 7.5 4.17 0.25 0.75 0.0126
Total 4.02 0.1263
t = 385 mm
From Table 2.10, for stiff soil support, e/t = 8. Therefore, the 385 mm thick edge
of the slab needs to grade to a thickness of 270 mm at a total distance
8 × 270 = 2160 mm from the edge.
It is interesting to compare the above slab design with that derived from document
T34. For an average Young’s modulus of 31.8 MPa, the equivalent CBR value would be
about 13. Hence, for a single wheel forklift truck with an axle load of 200 kN, the slab
thicknesses required would be 235 mm and 370 mm for interior and edge loading,
respectively. These values are slightly less than the values of 270 mm and 385 mm
obtained from the present design charts.
f all
F2 = FE2 FS2 FH2
P
Assuming that the concrete compressive strength is 30 MPa and that the factors k1 and k2
in equation (2.8) are 0.8 and 1.0 respectively, the design tensile strength from equations
(2.8) and (2.9) is 2.62 MPa.
From Figure 2.13, the various factors for interior loading are as follows:
Thus, for a post loading of P = 70 kN, substitution into the above equation gives
F2 = 54.2; and from the main graph in Figure 2.13, the required slab thickness is about
205 mm.
For the purpose of comparison with the design charts from document T34, a
soil Young’s modulus of 30 MPa is equivalent to a modulus of subgrade reaction k
(for a 0.76 m diameter plate) of approximately 58 kPa/mm. Thus the required thick-
ness is found to be 200 mm, which is almost identical to the value obtained from the
present chart.
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DE VEL OPM ENT OF DE SIG N CH AR TS FO R CO NC RET E PA V EMEN TS 67
1. Assessment of loading
The specified distributed loading is 50 kPa, and it is assumed that, over the life of
the structure, there may be 1000 load repetitions. It will be necessary to consider
stresses both beneath the rolls and in the unloaded aisles, to find the more critical
case. Only the case of interior loading need be considered, as the slab stresses due
to edge loading are less severe (see section 2.8.3).
f ct′ = 0.6 f c′
= 4.24 MPa, and
f all = k1 k 2 f ct′
= 0.85 × 0.73 × 4.24
= 2.63 MPa.
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68 D ESIG N AP PLIC A TIO NS OF RA FT FOU N DA TIO N S
pW (1 − 2
s)
q= zs
Es
Using document T34, the relationship between required slab thickness and modulus of
subgrade reaction k is shown in Figure 2.17 for the case of variable storage layout. For a
760 mm diameter plate and a soil Young’s modulus of 20.7 MPa, the modulus of
subgrade reaction would be about 48 kPa/mm. The use of this value with document T34
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DE VEL OPM ENT OF DE SIG N CH AR TS FO R CO NC RET E PA V EMEN TS 69
800
600
400
0
0 10 20 30 40
Modulus of subgrade reaction k : kPa/mm
Figure 2.17. Relation between slab thickness and modulus of subgrade reaction
would give a slab thickness of only 90 mm, substantially less than the 440 mm computed
from the present charts. To obtain the same thickness as that computed from the present
design charts, the value of k would need to be about 8 kPa/mm. The relationship between
k and Young’s modulus of the soil is, at best, uncertain for distributed loadings. Clearly
the volume of soil influenced by the distributed loading is larger than for wheel and post
loadings, and therefore a smaller value of k than the value for a 760 mm diameter plate
would be appropriate for the distributed loading case.
The use of the present design charts removes the need to assess k-values for different
types of loading, by using a more fundamental measure of soil compressibility, the
Young’s modulus.
Acknowledgements
The author is grateful to the Cement and Concrete Association of Australia for
permission to publish the material in this chapter. The support of R. Potter is
particularly appreciated.
2.12. References
2.1. POULOS, H. G. and SMALL, J. C. Development of new design charts for concrete industrial slabs.
Proc. Int. Conf. Concrete 95, Toward Better Concrete Structures, Brisbane, Australia, Sept.
1995, 2, 615–624. Concrete Institute of Australia, 1995.
2.2. CEMENT AND CONCRETE ASSOCIATION OF AUSTRALIA. Industrial pavements: guidelines for design,
construction and specification. C&CAA, Sydney, T48, 1997.
2.3. CEMENT AND CONCRETE ASSOCIATION OF AUSTRALIA. Concrete industrial floor and pavement
design. C&CAA, Sydney, T34, 1985.
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70 D ESIG N AP PLIC A TIO NS OF RA FT FOU N DA TIO N S
2.4. SMALL, J. C. Computer program FEAR (Finite Element Analysis of Rafts). Sydney Univ.,
Australia.
2.5. SMALL, J. C. Computer program FLEA (Finite Layer Elastic Analysis). Sydney Univ., Australia.
2.6. SELVADURAI, A. P. S. Elastic analysis of soil–foundation interaction. Elsevier, Amsterdam, 1979.
2.7. ZHANG, B. and SMALL, J. C. Analysis of rafts on foundations of variable stiffness. Proc. 7th Int.
Conf. Comp. Meth. Adv. Geomech., Cairns, Australia, May 1991, 2, 1103–1108. A. A. Balkema,
Rotterdam, 1991 (eds G. Beer, J. R. Booker and J. P. Carter).
2.8. HODGKINSON, J. R. Thickness design for concrete road pavements. Cement and Concrete Associ-
ation of Australia, 1982, Tech. Note TN46.
2.9. DAVIS, E. H. and POULOS, H. G. The use of elastic theory for settlement prediction under
three-dimensional conditions. Géotechnique, 1968, 18, 1 (Mar.), 67–91.
2.10. AUSTROADS. Pavement design: a guide to the structural design of road pavements. Austroads,
Sydney, 1992.
2.11. LAMBE, T. W. and WHITMAN, R. V. Soil mechanics, SI Version. Wiley, New York, 1979.
2.12. STROUD, M. A. and BUTLER, F. G. The Standard Penetration Test and the engineering properties
of engineering materials. Proc. Symp. Engng Behaviour of Glacial Materials, Univ. Birmingham,
England, 1978, 117–128.
2.13. STANDARDS AUSTRALIA. Concrete structures. Standards Australia, Sydney, 1994, AS 3600.
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