he Concrete CentrAcknowledgements “Ths authors would patel ke than thefllowng pple for ther upport inthe deveooment of hie design pce: Tony Jones an fanfeltham = up ‘The contributions and comments rom the Conerate Society Design Group and as rem the folowing people are gratefully acknowiedged John Stehle Laing ORouke Graham Hardwlek_Jotn Doyle Construction Lit Peter Kelly son Concrete Puts id Alex Davie Conslant David Appleton Hanson Concrete Products Kevin Laney Stongiecs Engineering [Norman Brown iishSrecart Concrete Faceration id Published by The Concrete Centre Riverside House, 4 Meadows Business Park, Station Approach, Blackwater, Camberley, Suey GUI7 9AB Tot +44 (0/1276 605800 Fax: 44 (0)1276 606801 ‘www.concretecentre.com ccp-030 Published January 2009 ISBN 978-1-904482-55-0, Price Group ? ©The Concrete Centre ‘Cement and Concrete Industry Publications (CCIP) are produced through an industry initiative to publish technical guidance in suppert of concrete design and construction. iP pubications ae aval rom the Concrete Bookshop at www.coneretebookshop.com Tob +44 (7008 607777 {Al aeornermston tom Te cones ene lzarly tarde ure nthe by those hn vaste ican tele of cress nds early ar fue plese, Nally hat x ne gee) (ecfigg wach taeser Heir aie Beco ta aan ear cael pyle acre ender shnld ote tat thebeats re Cancale Cane este evan rom net ie an shuld theeoreemue tat the ach pocesion oh best west ons pata: Caste Catal neat Prot by armaten Pes id Eyam UeDesign of Hybrid Concrete Buildings Contents 1.__ Introduction 5 11__ Single point of responsibility 5 1.2_Design considerations 6 1.3 Best practice procurement guidance 6 2. Overview of hybrid solutions 7 21 Type 1: Precast twin wall and lattice girder slab with in-situ concrete z 22 Type 2: Precast column with in-situ floor slab 9 2.3 Type 3: Precast column and floor units with cast in-situ beams 10 2.4 Type 4: In-situ colurnns or walls and beams with precast floor units 12 2.5. Type 5: In-situ column and structural topping with precast beams and floor units 3 2.6 Type 6: In-situ columns with lattice girder slabs with optional spherical void formers: 14 3. Overall structural design 15 3.1__ Robustness. 15 3.2_Stabilit 18 3.3_ Diaphragm action 18 3.4 Shear at interface of concrete cast at different times 19 3.5. Interface shear 22 3.6_Shear and torsion design 25 3.7_Long-line prestressing system. 26 3.8 Secondary effects of prestressing and the equivalent load method 29 3.9 Temperature effects 29 3.10 Differential shrinkage 29 3.111 Designing for construction 334, Bearings and movement joints 34 4. Horizontal forces at bearings 34 42. Restrained bearings 35 43 Movernent joints 36 4.4 Actions and restraints 36 4.5 _Design considerations 7 4.6 Allowance for anchorage of reinforcement at supports 37 4.7 Bearings that allow limited movernent 38 48 Connections between precast floors and in-situ concrete bears 42 5.__ Structural elements and connections 43 51_Twin wall construction (type 1) B 5.2. Precast columns, edge beams and in-situ slabs (type 2) 52 5.3. Biaxial voided stabs 55 5.4 Prestressed hollowcore units 58 5.5 Double tee beams 68 5.6 Stairs 74 5.7 Conbels, nibs and half joints 82 6._ Construction issues 87 6.1_Method of construction 87 6.2_Composite action between precast units and in-situ structural toppiny 89 6.3 Specially shaped standard units 89 6.4 Long and short units adjacent to each other 89 6.5. Differences of camber in double tees a1 6.6 Method of de-tensioning double tee units a 67_Checking strand or wire pull-in for hollowcore units a” 6.8 Placing hollowcore units into the correct position a1 69 Production tolerances 92 Z._ Special structures - case studies 93 71_Lloyd's of London 93 72_ Bracken House 700 References 104List of worked examples Worked example 1 Hollowcore floor acting asa diaphragm ‘Worked example 2 Interface shear between hollowcore slab and edge beam Worked example 3. Upwards camber on slab due to temperature gradient Worked example 4 Differential shrinkage Worked example 5. Bearing ofa hollowcore unit Worked example 6. Vertical tle Worked example 7 Anchorage length of longitudinal tie bar ‘Worked example 8 Dowel bar for connection of precast stairs Worked example 9 Corbel design 20 23 20 31 4 56 65 80 8411 Single point of ity Introduction 1 1. Introduction Hybrid construction allows the most appropriate use of different materials and methods of construction to produce a pleasing and effective form of structure. The search for greater economy, in terms of material costs and reduced construction time, has resulted In innovative approaches that seek to combine construction materials and methods to optimum effect. Hybrid concrete construction (HCC) is one such developrnent thet combines in-situ and precast concrete to maximise the benefits of both forms of concrete ‘construction. Further guidance on the benefits of HCC is given in Section 21 This design guide is aimed at the designer and considers a range of hybrid concepts and the overall structural aspacts It provides design and detaling information for some of the common systems used and structural elements involved. Where applicable the information isin accordance with 8S EN 1992-11, together with the UK National Annex (Eurocode 2 Isused to refer to BS EN 1992-1-1 throughout this guide unless noted otherwise). This Incorporates a section on the design of members by strut and the methods, whic particularly useful when considering ‘hybrid’ design details. Ths guide also considers and refers tothe following European Concrete Product Standards for precast concrete elements: BS EN 13369" Common Rules for Precast Concrete Products BSEN 1168! Precast Concrete Products —Hollowcore Slabs BS EN 13747* Precast Concrete Products Floor Plates fr Floor Systems BS EN 13224 Precast Concrete Products Ribbed Floor Elements BS EN 13225° Precast Concrete Procuicts— Linear Structural Elements BS EN 14992" Precast Concrete Products — Wall Elements BS EN 14843" Precast Concrete Products - Stas The use of precast and in-situ concrete may well lead to the design ofthe individual slements by designers working for ciferent companies Therefore, it is essential that there should be a single named designer or engineer who retains overall responsibility for the stability of the structure and the compatibility of the design and details of the parts and components, even where some oral ofthe design, including details, of those parts and components are not carried out by this engineer. This is particularly important forthe design of hybrid structures were misunderstandings as to who is responsible have occurred, Its the responsibilty of the designer, before incorporating any proprietary system as part of the structure, to ensure that the assumptions made in the design and construction of such are compatible with the design of the whole structure. This should include: 1 an adequate specication for that part. 1 ensuring that any standard product designed and detalled by the precast rmanifactuer, is suitable for that particular structure, 1 the design of any such parts reviewed by the designer to ensure that it satisfies the design intent and is compatible with the rest of the structure1 Introduction 1.2 Design considerations 1.3 Best practice procurement guidance ‘The design of each component should include consideration of; 1 ts performance in the permanent condition 1 the construction method and loading 1 any temporary supports required during construction. ‘The design should be carried out following the requirement of Eurocode 2, Cl 13, which 1 Structures are designed by appropriately qualified and experienced personnel 1 Adequate supervision and quality contro is provided in factories, in plants and on site "= Construction is carried out by personnel having the appropriate skill and experience 1 The construction materials and products are used as specified in Eurocode 2 or in the relevant material or product specifications The structure will be adequately maintained. ‘The structure will be used in accordance with the design brief 1» The requirements for execution and workmanship given in EN 73670" are complied with ‘The design assumptions should generally include the following construction related information: sequence of construction exposure requirements pour sizes assumed (iFappropriate) concrete strength at time of striking formvork and back-propping requirements breakdown of loading including allowance for construction loads loading history assumed It should be notes that some of the advice given in this design guide is a result of fallures that have occurred on completed structures Best Practice Guidance for Hybrid Concrete Construction”? looks atthe procurement process from concept stages through to design and construction, suggesting processes that allow the capture of best practice. Its supported by a number of case studies. The _Buidance explains the benefits that result from: 1 early involvement of specialist contractors Using a lead frame contractor Using best value philosophy hholding planned workshops measuring performance trust lose cooperation — with an emphasis on partnering. Its recommended that this guidance document is used to raximise the advantages of using HECOverview of h Table 21 Benefits of concrete. 2.1 Type 1: Precast twin wall and lattice girder slab with in-situ concrete 2. Overview of hybrid solutions This section considers a range of possible hybrid conerete construction (HCC), The ideal combination of precast and in-situ is influenced by the project requirements. There is a wide range of possible options, a selection of mhich i presented here as representative of curtent UK practice. This is not intended to be exhaustive, but to reflect the spectrum of possibilities, The planning and detailed design af hybrid structural systers wil almost always require the involvement of specialist precast concrete manufactures. These ‘manufacturers are willing and able to assist early inthe design process to produce an efficient design ‘There ae advantages to using bth precast and in-situ concrete summarised inTable 21; more detailed discussion on the benefits of concrete can be found in other publications", The key to maximising the benefits of HCC Isto use the most appropriate technique for each elernent to produce an economic structure ene ncrete_| in-situ concrete Economic Toreepettive elements Inherent fire esizance Fconomicfor bespoke areas Long dear enane Durabity Ccntiniy Speed fection Sustanabiity Inherent robustness usistity Acoustic peformance Fiesty High-qusity fishes ‘Theemalmassthat canbe utiled for Services coordination ater in fab energy scrape proararame Consistent 0.056 MPa -> OK) Check Vg, (Which fs unlikely to contrel);far this example the first and second terms are small and may be ignored as a first eotimate Vou = Ply Ht 0in a+ e080) s05Ul, where Ala, 08 (very omocth ourface) the design yield atrength of reinforcement: the area of reinforcement: enossing the interface the area of the joint 90" for reinforcement: perpendicular to the joint 06 (11,260) cea OED Eurocade 2,1 625 Eurocade 2, Exp (624) Eurocade 2, Figure 68 Eurocode 2, 010 9 &(12) Eurocade 2, Exp (6-25) Furocode 2, 1625 (2)3 Overall structural de: sign Hollowcare floor Qo Worked example 1 Sos OB a WETS eae RW = COPO0 acting a9 a diaphragm = O41s45MPs The Concrete Centre == ee Apaon For this example AL = 2x 24118 = 452 mat A, = 1200x200 =240 000 mnt Hence: 6 = 462/240 000 = 0.00188 acl Yea = 0.00188 x500x(05x1+ O11 $ 05x 0 G(1- 25/250) «1x 255 Use 2 No, hairpins (U bars) - 12 nm diameter This check demonstrates that. Exp. (6.25) | ‘The deeign would now normally continue to calculate the tensile eteel required in the edge beam to carry the diaphragm tenvile boom force, taking into account that this calculation must alse consider the other actions for the appropriate combination af actions ie not usually a iting control 3.5 Interface shear Figure 35 ‘Typlea interfaces between precast and in-situ Jolt For many beams in HCC there is an interface between concrete cast at diferent times, The interface may be between precast and in-situ, two precast elements or in-situ concrete with 2 construction joint All interfaces and critical sections in the composite section must be considered in accordance with Eurocade 2, 624 and 625 (see example in Section 3.4) ‘Typical interfaces are shown in the Figure 35, and typical calculations are presented in worked example 2 Intortace 3Overall structural design 3 CoIP-030 meee amor EW 8 Worked example 2 aos OB sone WEB The Concrete Centre’ oo Interface shear between hollowcore elab and edge beam tec ‘April 08 Consider Example 137 in the Precast Eurocade 2 Design Manual Interface shear check is between ‘the edge beam and in-situ concrete previded In the jer (see figure). ln this example the eonttbution of the horizontal eurface lo ignored. The shear reelatance of the interface between the upstand of ‘the precaot unit ana the msin body below should aleo be checked n-ne conorate ‘The flange over each hollowcore is cut out and therefore the unite should be temporarily propped 1No Hil6 Ubaris placed in each void ta interlock with projecting reinforcement in the edge beam 20 ehor Asoume that the compression flange of the edge beam Is G00 + 175 + 10 = B85 rom wide Check shear at interface according to Eurocode 2, C1625, ty = 35MPa f= 500MPa Maximum sagging moment, Me = 267 kNm Maximum design shear, Vqy = 2284N 6 = 200mm = 540mm Mydbl, =267 x 10000001(885x $40" x 36) = 0.0296 233 Overall structural design ey eae ey |" capo Qo Worked example 2 Goss OB mm Yeas Interface shear between hollowcore elab The Concrete Centre oe cage beam er toc | |" Apnlo8 From Figure Bt of the Precast Eurocade 2 Design Manua* find value of 2 (altemestively find z by calculation or uith any eultable design ald) Zz = 097 = BlyiZb, Eurocode 2, Exp (624) where B= ratlo of the longitudinal force in the new concrete and the teval longruudinal force width of new concrereitotal flange width ‘7781805 = 0.88 200 rst Ug = OBB 223. 10000 97 840 « 200) = 187 MPa Ven = Cha FHS, + Phy ona + cosa) < 05 ul, Eurocode 2, Exp (625) where © = 036.andy = 0.6 for a emooth ourface a= 0 a = 90° fy = 122115 2147 MPa uv = 06(1-35/250) = 052 Euracode 2, Exp (6 6N) 035x147 +0 +0x0.6xS00/116 < 05x 052x 1x 35/15(=607 MPa) Vea Yeu < 0516 +2609 p Hence p = (187- 05162609 = 0.005 Now e ASMA PA.= 0.005 1200x200 = 1200 mt Using 3 No. voide each containing 1No HIG U bar OK Fagus SK ERG THA = 1210 ri mu3.6 Shear and torsion design Figure 3.6 "Hang up steel requirement. Overall structural design 3 Shear and torsion are predominately critical at the ultimate limit state and the composite sections can be considered to be monolithic ifthe interface shear calculations have been carried out appropriately, as discussed in Section 3.4 (see Eurocode 2, Cl. 6.2.4 and 625). The variable strut inclination method used in Euracode 2 Is based on the shear load being _ppliod atthe top of the beam element. Whon itis applied near to the bottom, the load ‘must be ‘carried up’ to the top with vertical reinforcement additional to the vertical ‘einforcernent required by the shear calculation. Tis is sometimes called "hang up steel as ts effect isto hang up the applie load tothe top compression chord of the beam (Eurocode 2, Cl. 6.2118), see Figure 36. bean sana Sab eat svt “Hang up seat aattlonal to rainorcement requires to carry tear Eiacode 2.6.2.1 (8). ‘Types 2, 3 and 4 apply the floor permanent actions to the spine beams at the bottom of the section and this element ofthe load must be carried by hang up steel. Whether the subsequent variable actions should also be covered in this way depends on the form of the composite connection in any event, the load only needs to be carried up once to the ‘top of the truss and the extra link requirement is nat onerous. ‘Where type 5 is used a further check Is required for edge beams or where there Is out-of- balance loading on an intemal beam, The edge beam and internal spine beam with unequal loading inthis form of construction ‘must be designed to resist the torsion set up by the eccentric loading. Both the transient situation during construction and the ultimate limit state must be considered. The jaint between the bearn and its support must also be designed to take this torsion, see Figure 373 Overall structural design Figure 3.7 Design for torsional restraint. ‘cenite of reslarce tesa For the torsional design of the edge bear, the design torque is equal to the load multiplied by the distance from its line of action tothe shear centre of the edge element Vi, For the design of the temporary support system to give equilibrium, the overturning torque is ‘equal tothe torsional force multiplied by the distance from the line of action of the force to that ofthe restraining systern Yh, Many prestressed precast elements are produced by the long-line pre-tensioning system om prestressing beds of up to 200 m in length with built-in jack heads at each end, see Figure 3.8 The normal construction procedure is as follows: 1 The moulds are placed ina continuous Une along the bed (the number depending on the length of each unit) and end plates are fitted to the required dimensions of the units to be cast. 1 The tendons are laid out and stressed from fixed external ack heads. They pass through each unit as straight horizontal tendons. 18 The secondary reinforcement is then fixed within each mould 1 The conctete is poured into each mould 1 When the concrete reaches the required transfer strength (confirmed by test cubes), the stress is gradually released from the jack heads ands transferred into the concrete by anchorage bond ‘Atypical detail ofthe placing of moulds on the longzline system is shown in Figure 3.9Overall structural design 3 Figure3.8 ‘The Long-tnepre-tensioning system. Figure 3.9 ‘Typical deal of placing of moulds on the longline system. oes pleaton: Unit mould or eantiuousy es ck bleh ana ombeddes lover vprigt In tanarae eng ant Unit io mous stand Mould nd pate LV Detail ot gap betwoon moulds Debonding tendons The position of the strands in the section is normally determined by the length ofthe unit and the design loading at mid-span. Stress limits are set for the serviceability limit state ((or further inforrnation see Precast Eurocode 2: Design Manwal* and Post-tensioned Concrete Floors Design Handbook”) Since the tendons ae straight the prestrss isthe same at the end of the units as tis at rid-span (apart from within the transmission zone], but there is litle balance from the stresses due to permanent actions atthe ends, This creates high-tension stresses atthe top ofthe section that will be@ maximum immediately after transfer of prestress. In order to reduce these stresses locally some ofthe tendons are debonded by placing tubing over them at the end of the unit for the required length, see Figure 3.10. It should be noted that the bottom strand should not be debonded, as it ensures that the concrete near the end of the unit has less chance of being darnaged. It is advisable to provide two links just beyond the debonding point in the bear span to restrain anchorage stresses, Two 10 mm diameter links, the first at 100 mm from the debonding point and the second 40 mm beyond that, are typically sufficient. The proximity of the links to the bonding position ensures sufficient restraint to bursting even if the transmission zone is less than that assumed in design in accordance with Eurocode 2 23 Overall structural design 28 Figure 310 ‘Typlealdetall showing the debonding of strand Figure 311 Comparison betwean straight bonded, ‘debonded and deflected tendons. “plely 7-8 protrung is Fly bonded stresses rans Debonaea strand Debonding is used in double tee design because it is such a simple and cost-effective option. An altemative to debonding some of the tendons is to deflect them at the ends of the unit. This method is very seldom adopted, sit requires special features to be but into the Long-line system to take account of the vertical forces involved The difference between the effects of straight bonded and debonded tends is shown in Figure 311 — Fs wi stent sonses encore Bune winsteagt desonse tencens Memens rom presress SSeS falaneo of moments a Fsulling camberOverall structural design 3 3.8 Secondary effects of prestressing and the equivalent load method 3.9 Temperature effects 3.10 Differential shrinkage Prestressed units camber because ofthe hogging moment provided by the prestress. pre- tensioned prestressed beam with no camber, unless it has a very short span oris debonded, should be viewed with caution, Camber is equivalent tothe deflection of a reinforced ‘concrete beam: in fact fora permanent and variable action balanced by prestress, the Upwards camber would be less than the downward deflection ofthe reinforced section. This is because the prestressed section would be uncracked and stiffer than the cracked reinforced beam Thus, camber should not be a problem but should be allowed for when Setting loor levels. An estimate of camber should be obtained from the manufacturer of the prestressed unit. Ir willbe affected by the strength of concrete atthe time of transfer. Debonding has the advantage of reducing camber, as the debonded prestressed moment dlagram is closer to the permanent load diegram than the fully bonded one. The typical camber of a fully bonded 16 m double tee beam carrying car park loading is 35 to.45 mm and this can be reduced by debonding to the range of 10 to 25 mm. Debonding, however, reduces the net prestress at the support and this reduces the design shear strength, but for double tees this reduction is seldom a critical design issu. The occasions where secondary effects (sometimes refered to as parasitic effects) need to be considered relate to indeterminate frames and continuous beams/slabs. The most likely ‘example for HCC is where post-tensioned slabs are used, Section 5.6 ofthe Post-tensioned Concrete Floors Design Hanaboot describes the phenomena and the use of the equivalent load method. The defiection of a floor in response to a temperature gradient can be large and this can result in rotational movements at supports, which can produce unwanted local damage such as cracking and spaling. This problem is particularly acute in uninsulated roofs, often found in carparks. Te following simple calculation, worked example 3, gives an idea of the magnitude ofthe displacernents. Further guidance can be found in Movernent, Restraint and Cracking In Concrete Structures. ‘When an in-situ screed is added onto a fist stage cast floor of ether reinforced or pre- stressed construction, the shrinkage ofthe screed after its initial hydration will develop a compressive strain in the top ofthe fist stage cast and will induce a downwards deflection inthe span of the composite unit and, if the floors of continuous construction, a hogging moment at the supports. Note that these effects are of importance atthe serviceability lint state ony, as at the ultimate limit state these imposed strains wil have litle effect, Figure 312 shows how the strains are bull up through the height of the composite section fora given free differential shrinkage strain, «,. The final curvature, is constant across the saction. Design equations can be developed as follows: 23 Overall structural design “The effect of differential shrinkage across tection. Force equilibrium: EEA =6EA, E=6EAIE,A, Section equilibrium (gE/=M): PEG+E A= FEA Ue ted Strain equilibrium Eby HONE, 9a E+ EMO t¥n) PEE HEEALE AMY +¥) a) a 6) The Concrete Centre’| UPwarde camber on slab due to temperature gradient etc CaP-020 ae WE Ap 08 Calculate the upnarde deflection of a 16m epan 300 mm deep simply supported floor reeulting from a temperature gradient of 20°C nith the uzper ourface being the hotter Avoume that the gradient: lo linear and oteady otate, and that the temperature coefficient for concrete, 2, 10x 10% The curvature, g, from this Lemparature gradent ts = 20xa/300 20 x 10x 105/200 0.6710% ‘he curvature ie constant along the length of the unit: From the second moment ares theorem, the mid-opan deflection 8 pxke 0.67 8000 x 4000/0000 214 mn 30Overall structural design Combining (2) and (3) Wit Yor* (Eu EK+E, WW) (MEA + VE AM +) = Fe IEMA HE +E I) (META +E AMY, YA) a) Ene MFEA TEAL ty PEA NEL +E I) (5) EMF AIEA* YAY? EA NEL #E I) 6 From equations (4 to (6) al the stains, stresses and forces can be determined ‘Worked example 4 describes the method for determining the effect of differential shrinkage where in-situ concrete is placed on a precast concrete T section. rea amv py |=. dapeao Qo Worked example 4 ous op = WEAN Differential shrinkage rec | April o8 The Concrete Centre" cma Calculate the effect of differential ehrinkage in a beam contructed in two ptagee 0 ehowm below The element ie simply oupported and 20 m epan. The free differential shrinkage etrain io 0 0002, 95 men 2x9 mas Inst conreto 300 24 2No 7.9 apr strand rece concrete 160 B7B5 fabric in in-situ concrete B283 fabric In precast concreve flange 2x 2No. 79 mm euper etrand in precaot Hb3 Overall structural design ey aaner ew |" caP-0B0 Qo Worked example + eos 0B [Se WEAN _| Differential ehrinkage The Concrete Centre == yee |= Apatow In-situ concrete t 25MPa,{,,, = 3B MPa, creep coefficient, p =18 Eurocade 2, Table 31 Enno = 22 Ub pi/lOP3I1 + 9) and 1314 22x (BBN0)5/(1+ 15) 1259 GPa Section properties, including the reinforcement, are 29 follows A, 112 108 mat l, beB1t2 = 1000 x 10082 875% 10° me Yous = 521mm Zag = 1680x108 mm? Precast concrete fap = SO MPa. f= 58 MPa, Creep coefiient, @ =1 Eurocade 2, Table 31 Expy = 22x (SB/OP5/(1+ 1) and 314 1864 GPa Section propertice, including the tendons and reinforcement, are ae follows: 1015 « 108 mm 1220 «108 rum 2574 mm 1126 mem 10900 « 10° mr Curvature Using expression (4) above: Curvature: 1000 «0.0002 % "PEICT6 + ( (25819755 Ov BOs px (H28 «TEx IBEX IEA) 20+ 126 = 0.00088/m Deflection Defiection from differential shrinkage 8 = gle 0.00058 x 2048 29 mm 23.11 Designing for construction Overall structural design 3 Designers should take into account the stability of the structure during construction: 1 Precast elements are heavy. Bearings must be adequate and be robust enough to ‘withstand nommal unt fing operations including landing and ‘barring’ (see Section 6.7). 1 Beams must be securely fixed and have adequate safe beering at each end to avord ‘overtuming, excessive deflection or collapse when the precast elements are placed. 1 Consideration must be given to the unequal loading when precast elements are being, placed 1 Where precest elements are titted or twisted to allow them to be placed in their final position consideration should be given to ensuring there is sufficient clearance to place the unit and achieving the minimum end bearing required inthe final postion. 1 Special requirements, such as special fixing techniques, emporery measures or sequencing, should be cleery conveyed 3Cs -t-li la) -a- ale aaron (clan) 101 [Ol] u 41 Horizontal forces at bearings 4. Bearings and movement joints ‘The design of bearings and joints for hybrid concrete construction (HCC) is critical to the serviceability and lasting integrity of the structure. Careful design can avoid problems hich lead to deterioration of joints, which ultimately compromise the whole safety of the structure. ‘Where a bearing is introduced between precast elements or between precast and in-situ elements great care is required to take account of all the forces and movements that may be imposed on the elements connected tothe bearing. n addition consideration must be given to: hhow the robustness ofthe structure is attained eifects of composite action practical tolerances temperature changes shrinkage differential settlement effects of repeated changes in imposed deformations ensuring construction meets the assumption made in design. “The decision to design a fll continuity joint or one that allows some mavement is critical. ‘The design must then follow the decision to reach a practical and lasting solution, The joint detail rust be robust and must not deteriorate with time due to the effects of movernent. Joints that are designed to be monolithic ae considered in Chapter 5. Horizontal forces ata bearing can reduce the load carrying capacity of the supporting member considerably by causing premature splitting or shearing The forces may be due to creep, shrinkage and temperature effects or may result from misalignment, lack of plumb ‘or other causes. Allowance should be made for these forces in designing and detailing by the provision of: 2) bearings thet allow limited movernent or ») suitable lateral reinforcement in both the supporting and supported members or ©) sufficient continuity reinforcement through the joint to resist the lateral forces Where type a) bearings are used then conservatively the horizontal design force should be taken as 20 per cent of the vertical force. A more detailed assessment may show this force can be reduced. For ype b) and c) bearings the design horizontal force should be not less than half of the design vertical force on the bearing, Unless top and bottom continuty reinforcement is provided precast floor slabs, eg. hollweore slabs, spanning more than 8 m should be supported on elastomer bearings, eg neoprene.oer eee OMIA 4.2 Restrained bearings ‘These can normally be attached tothe support surface. They allove 1 the forces resulting from variation of bearing surfaces to be absorbed 1 any small horizontal movements to be absorbed without causing cracking and 1 limited rotation (as a result of cyclic upward and downward deflection) ofthe precast slab \Where top and bottom continuity reinforcement is provided, to make « homogenous Joint it may be acceptable not to provide elastomeric bearings. n this case great care ust be taken in construction to ensure that the precast element is not damaged during placing and that it can absorb the movements that take place during and after construction without damage For bearings that offer significant restraint to sliding or rotation, eg. dry bearing on concrete or mortar bedding, actions due to creep, shrinkage, temperature, misalignment, lack of plurnb and other things must be taken into account in the design of adjacent members. Further guidance on creep, shrinkage and temperature effects can be found in Movement, Restraint and Cracking in Concrete Structures* ‘The effectof such actions may require transverse reinforcement In supporting and supported members, and/or continuity reinforcement for tying elements together. They may also influence the design of the main reinforcement in such members, Such joints are not con- sidered suitable for extemal situations or for spans greater than 8 rm for internal situations, It should be notes that itis unlikely thata dry connection without bedding material will have a uniform contact surface and that concentrated loading wil result that may cause local cracking For joints with bedding material, e.g, mortar, concrete, polymers, relative movernent between the connected surfaces should be prevented during hardening of the material, ‘The bearing width should not be greater than 600 mm unless specific measures are taken to obtain a uniform distribution ofthe bearing pressure. Inthe absence of other specifications, the bearing strength, f, of dry connection should not exceed 0.4 f,and the average bearing stress between plane surfaces should not exceed 03 f, The bearing strength for joints with bedding material should not exceed the design strength of the bedding material, f,, < 0.85 f, where fi the lower of the design strengths for supported and supporting members. 35Cs -t-li la) -a- ale aaron (clan) 101 [Ol] 4.3 Movement joints itis possibie to deal with movernent at bearings using movernent joints, and care should be given to the design and construction, as for bridge decks, to minimise the risk of failures. In general ts recommended to seek solutions that do not require movement Joints. Figure 41 describes potential failure mechanisms that can occur even with a structural topping Figure 41 anne Examples of potential alures at movernent pacing mater = joints. pu ithe beering material creates lage fcton {forces (use neoprene or similar to avoid ‘tis, this can lead to large tension stresses in both the support and the precast slab orbeam 1 pl, tard terial can prevent rotation If the space between the precast slab or beam and the face ofthe supporting member fs not adaquate for the required ‘movement or iin time tit fills up with hard material, then cracking can occur. Ifthe effects of movement and/rotetion ‘cause the line of action to move too close tothe edge of the suppor, local spalling «an occur, 4.4 Actions and restraints 4.4. Action effects in addition to the effects of direct loading (imposed variable and permanent actions) the following action effects on the elements supported by the bearing must be considered 1 shrinkage (both long term and earty thermal) 1 temperature changes (both seasonal and short term) 1 creep. 36oer eee OMIA 4.4.2 Restraints 4.5 Design considerations 4.6 Allowance for anchorage of reinforcement at supports In addition to the above action effects the following restraints must be considered 1 intemal, eg from reinforcement, differential shrinkege 1 edge restraints 1 end restraints, For detailed consideration of these effects and restraints refer to Movement, Restraint and Cracking in Concrete Structures ‘When designing bearings the following details should be checked: calculation ofthe bearing area bearing layout the detail ofthe reinforcement in the end of the supported member the detail ofthe reinforcement in the supporting member tolerances construction issues — especially any additional forces imposed on the bearing through “parring’ the units into final position, see Section 6.8. The design and detailing of the reinforcement at supports is citcal. The supported member has to be designed to bear safely onto the support without spalling of the end cover and also to sustain any forces that may come from shrinkage ofthe floor, through stiortening of the floor, if prestressed, and from thermal, lve and further dead load movernents, see also Section 41 Prestressed members used for flooring ae commonly pre-tensioned and the main prestressed stael continues to the end of the member. Reinforcement in supporting and supported members should be detailed to ensure effective anchorage, allowing for deviations, see Figure 42 {6-4 4g, with horizontal loop bars 64+ Aa, + ith vertically bent bars nominal concrete cover a deviation (see Section 48) = radius of bend (see Table 4.1) 37Cs -t-li la) -a- ale aaron (clan) 101 [Ol] Figure 4.2 Effect of reinforcement on bearing ‘dimensions, Table 41 Minimum bend adi for reinforeament to avoid damage to reinforcement. 4.7 Bearings that allow imited movement 471 Design of the bearing area 4.72 Bearing layout 38 mo inimum radius of bend gs i6mm 2 > 16mm ase Bearings that allow limited movement, eg. neoprene pads, not only distribute the bearing forces over uneven supports but aso allow limited rotational and longftudinal movement of the supported member to take place. The bearing pad also defines the area of load transfer and thus has @ direct effect on the detailed design ofthe ends of the supporting, ‘and supported members. Inthe absence of other specifications, the bearing strength, f,, =f, = 0.85 f, where f_ i the design strength ofthe bearing material may be used. ‘The layout ofa bearing is critical to its successful execution The concrete surfaces must be separated in areas where load transfer isnot intended and must be bedded appropriatoly where load transfer is required. To ensure that spalling does not take place in the contact area at the end ofthe supported and supporting concrete, the provision of sufficient bearing length must be provided. This should allow for constructional tolerances and ensure the overlap of reinforcement between the supporting and supported concrete. The required allowances are shown in the Figure 4.3 and are described in Eurocode 2, CL 10.95.2. These vill lead to the design of minimum bearing shelf and nib sizesFigure 4.3 Critical dimensions for bearings Table 4.2 Minimum value ofa, (nm). oer eee OMIA ees =e ey The nominal length, a, of a simple bearing may be calculated as o=a,+0,+0,+ Who? +a) where a, = net bearing length with regard to bearing stress ~F,,/(b fg.) but not less than the values in Table 42 ‘¢_= design value ofthe support reaction = net bearing width fu, = design value of the bearing strength = 085), 4, = distance assumed inetfective beyond outer end of supporting member (seeTable 4.3) a, = distance assumed ineffective beyond outer end of supporting member (sve Table 4.4) ‘Aa, = allowance fr distance between supporting members (see Table 4.5) ‘Aa, = allowance for deviation ofthe length of the supported member £2500 length of member in men ore) Line supports (feers and rofs) 2B 30 0 tubes floors and purine ss 70 0 Concentrates supports (osame) 0 no 140 i 2 ayn eednip arg 39Es =x-t-1 Ala) = ale aaron (lanl 101 (OLIAT IS} Table 43 Distance a, (mm) assumed ineffective from ‘Suter end of supporting member, Table 4.4 Distancea, (rum) assumed ineffective from ‘outer end of supported member. Table 45, ‘Allowance for deviations forthe clear distance Detvesn the face ofthe supports, 5 Concentrated 10 15 & neers Une 10 6 % Concentrated | 2 25 3 Pelnea cers ‘Continuous bars over support ° 7 (restsinecer not) Straight bars, horizontal loops, 5 15, but nt less than end cover clove to end of member Tundons ot straight bars 5 5 exposed at endof member Vertical lop reinforcement 6 FE cover + one radus of bend Bina Ss Precast concrete 10-s//1200 <30 mm CCastn-sity concrete 1$5//1200+5240 mm ‘An example calculation is shown in worked example 5,oer eee OMIA meee eam RW PRL RE: Qo Worked example 5 wos 9p [= WESN i hol én The Concrete Centrer| Beating of a hollowcore unit = roc | Apnio8 12m wide hellowcare slab seated on a in-situ concrete nb, Created as a non-isolated member The length of holowcere unit is 9 m. The In-situ concrete beamis clase CAB/A5 concrete, Actions Self weight = 33S kNim* Variable load = 4 kN? Partitions = kN Finishes = O.7 Nir? Bearing stress Fog = Ox12x(135(S.33 +0.7)+15(441)¥2 = 699kN ‘Aeoume a 30 mm wide neoprene bearing, G4 = 699% 1000/(20 » 1200) =194MPa Se fy = 194/(0 85x 35/15) = 0 098 Geometry Minimum value of at from Table 4.1 for a line support le 25 rem Hence: a, = 30mm OK Simm Table 42 Simm Table 4S 1mm Table 44 200012500 = 4 mn say 5 mam The reinforcement in the in-situ concrete nib is assumed to be 20 men vertically bent with a nominal cover of 20 ran d= Gt th = 20418 +35x20 =105mm a, + Ba, 2 dy 4, +a, = 105 mm Allowance for clearance at end of unit Aa, + Oa, 2 15 +4 mm = 19 mm say 20 mm The bearing etress should also be checked for the holloweere unit. =e aCs -t-li la) -a- ale aaron (clan) 101 [Ol] Figure 4.4 ‘Typleal methods to aveld spalling of bearing 4.8 Connections between precast floors and in-situ concrete beams Spelling of the support is avoided if a large chamfer is provided on the outer comer or alternatively local part of the bearing shelf is lowered, see Figure 4.4 ‘This and the compressed thickness of any bedding material in the bearing must be sufficient ‘to avoid contact, taking into account any long-term movements, deflection, hogging and ifthe floor is laid toa fll for any reason, the difference in angle of the floor soffits at its end and that of the bearer beam. Neoprene is recommended as a suitable material for bearings but other materials may be used (see also PC! Design Handbook”) Inan HCC situation, the bearing may be in a diferent state when it caries construction actions and when i fully constructed and caries superimposed permanent actions and variable actions. These interactions should be considered and very soft bearing materials, may be inappropriate ifthe final objective fs to have a fully continuous connection, ‘Type 3and 4 systems that use precast floors with in-situ beams do not always have a direct bearing since the in-situ concrete is often cast against the precast unit, The floor i propped and the formwork for the edge beam is fled. The steel protruding from the floor Units is incorporated into the reinforcernent of the edge beorn that is then cast. The con- tinuity steel must be fully anchored in both the in-situ and precast concrete, Consideration should be given to the possibility of tension occurring in the bottom steel at the support. This can be caused by temperature and shrinkage effects. The design of the interface for shear requires the provision of ‘hang-up steet’ asthe shear load in the floors concentrated near to the bottom ofthe section This is described in Eurocode 2, Cl. 621 (9) and is also shown in Figure 3.6.Siew Troan lae eels cold (ol) 5.1 Twin wall construction (type 1) Figure 51 “Typleal example of atwin wall panel. Figure 5.2 Simple layout of atwin wall system. 5. Structural elements and connections Twin wall panels comprise two skins of precast concrete, connected by steel trusses, hich hold the precast skins apart at a constant spacing to produce a wall of a particular thickness. Figure 51 shows a typical view of a twin wall panel system, ‘The panels are supplied to site, erected and then filed with in-situ concrete to form @ solid concrete wall. The trusses, therefore, also act to hold the skins together against the pressure exerted by the in-situ concrete before ths has cured. typical layout is shown in Figure 52. The precast skins function as permanent formwork The precast skins contain the rain horizontal and vertical reinforcement for the wall, In the form ofa cross-sectional area of fabric or bas, which can be specified by the designer. However, starter bars and continutty reinforcement must be provided within the in-situ concrete The pocat ene ao Air poizontal an Vertical einiersement forthe al isfies tin the precast sins “aMBS Hive Cclan nee [alee a arene) a 5.11 Manufacturing process Figure 5.3 recasting sequence for twin wall ‘manufacture, ‘The twin wall system is often combined with a precast concrete permanent shuttering system, €g lattice giter slabs. This allows the minimum use of temporary formwork on site. The wall system is ideally combined with a precast lattice or composite slab floor, os, the in-situ element of both the wall and floor can be combined to produce a monolithic structure ‘The precast skin on one side ofthe panel is cast horizontally on a steel mould, with the ‘russes projecting. After curing, the assembly is rotated so that the trusses face down and can be cast into the pour forthe precast skin on the other sid, see Figure 53. AA A KK A a) One side of panel cast with outer face down with trusses projecting upwards NE NL NS NP NS 'b) Assembly then tur over andthe second side of panel cast with outer face down, Fabric reinforcernent, which can be specified by the designer is cast into each precast Skin, see Figure 5 4. A 60 rn thick precest skin could accommodate, for example: 1 25 mm cover to external face (or as appropriate to meet durability bond ard fire requirements) 16mm vertical bar 8mm horizontal bar 1§ 101mm cover to internal face (whilst not required for durability in the permanent condition, some cover here is advisable). Clearly, walls that require larger bar sizes to achieve required levels of reinforcement, or ‘walls in exposed conditions will in tum need thicker precast skins to achieve required covers. Overall panel thickness The final wall thickness can range typically ram 200 to 350 mrn in total width, although thicker walls are possible. typical 250 mm panel thickness may comprise: = 60 mm precast skin 15 130 mm gap for in-situ concrete, starter bars, continuity reinforcement = 60 mm precast skin.SSSgU Cot elms Ccaan\claycee-l Ceo) a preld (ola) Figure s.4 “Twin wall connection witha lattice girder slab Prova concrete Lattice rentoreement Se contorcemont In-stuconeete Lap lone erial enforcement Tie oinovooment With two layers of reinforcernent an overall wall thickness less than 250 mm is difficult to achieve. This is because the precast skin thickness is typically 50-70 mm each side (plus tolerance), and the thickness ofthe in-situ concrete in between must accommodate starter and continuity reinforcement with sufficient space for the concrete to flow around the bars, see Figure 55, With one layer of reinforcement it is possible to reduce the overall section thickness to 200 mm. tis worth noting that, due to the manufacturing process, tolerances on the inside faces of the precast skin are easily controlled and can reduce the space available for in-situ concrete or starter bars by 10-15 mm each side. Tolerance for the hybrid panel to be erected over the startersis a related issue and it is advisable to use 3 single row of starters, rather than one row each side as for a traditional in-situ wal. 45MBS Hive Cclan nee [alee a arene) a Figure 5 “The avalable space for vertical continuity reinforcement is restricted. Overall panel sizes Typically the maxienum panel dimensions are 10 m x 35 m as shown in Figure 5.6. These dimensions are often limited by the capacity ofthe lifting equipment, transportation or size of moulds. The minimum dimension of a panel is typically 1.20 m Figure 5.6 $sisi tiie aeSSSgU Cot elms Ccaan\claycee-l Ceo) a preld (ola) 511.2 Planning implications ‘Akey impact of introducing win well panels, as with many prefabricated forms of construction isto increase the amount of coordination required early in the programme. To assist in this planning ft is advised that the points below are considered. ‘Which walls are twin walls? ‘Agreement on the extent of twin walls is likely to involve architect, client, contractor, and structural and services engineers. Until fully define, this decision may have an impact on the design programme — en issue that should be communicated to the proposer of the system (often the contractor) Manufacturers’ requirements and their impact on co-ordination Often the twin wall manufacturer wil requir the following to be fully defined before commencing manufacture 1 dimensioned CAD wal alovations showing all was to be manufactured 1 locations of all cast-ins (eg, junction boxes, conduit) 1 locations and sizes ofall holes ané cut-outs (e.g. for services, drainage, builders work, windows, downstand beams) 1 reinforcement to be cast into the precast skins 1 locations and details of any bend-out bars required 1 information showing which side ofthe panel i tobe propped (to permit the prop attachments to be cast in). To produce CAD elevations showing this level of detail, the design ofthe services must be ‘well progressed (and any builders’ work holes assumptions agreed and recorded); the architect must have frozen the wall layout; all suspended and ground slab levels, soffit levels and upstands/downstands must be fully defined and frozen; and the contractor rust have defined a pour sequence so that the side to be propped can be identified. The designer should allow for the additional time required to coordinate the work Detailing continuity rebar at joints The catalogues of the twin wall manufacturer often show a number of typical joint dotals vihere fabric or loose bars are used, within the in-situ concrete, to provide reinforcement continuity. Its important to realise thatthe designers responsible for dealing and Scheduling such bers despite what may be implied in the catalogues. Checking of fabrication drawings Iris important that the designer checks the key panel layout drawings. The twin wall ‘manufacturer produces shop drawings for each panel They ae likely to be presented to the designer just asthe project begins on site. A plan for checking these should be set up Inadvance to avoid the confluence of site queries with panel drawing checking creating possible resourcing difficulties at a key project stage aMBS Hive Cclan nee [alee a arene) a 5113 Site erection and filling Figure 57 ‘Typical issues to considerin the layout design. ‘The panels are typically propped on one side only, using typically two ‘push-pull’ props to achieve verticalty, This requires a cast base slab on atleast one side ofthe wall if panels are being erected before the whole slab is cast, coordination with the contractors pour sequence will be required. Where no slab is adjacent, eg. walls inside lift shafts, there should be a clear method statement on how these panels wil be safely erected. “The methods of fixing the continuity reinforcement, particularly if the walls are ating as shear walls, should be clearly stated, The contractor should provide a method statement for the following: 1 At panel base level, how the panel fitted over the projecting reinforcement inthe lower slab taking account of the accepted tolerances. Figure 57 indicates other points that should be considered 1 At top of panel, how the vertical continuity reinforcement is fixed. One method may be to tie horizontal fixing bars onto the trusses (say two each side) and tie the vertical projecting bars onto those. The alternative proposal of pushing therm into the wet in-situ concrete isnot recommended A template forthe vertical bars should be considered to ensure that the next lift of well panel wil ft over them correctly. 1 For the fabric reinforcement at joints between adjacent panels at the same level, how this is held in postion within the pour (see Figure 5.8). Decide wien sae prope sould be post onad Dovid rom whieh oval ‘he wall seu ingSSSgU Cot elms Ccaan\claycee-l Ceo) a preld (ola) Figure 5.8 Plan view showing herzontal continuity reinforcement. Figure 5.9 Section showing typical lattice girder floor. eof baa a inks reconmenaes fo'enaieelnfocament tomar Ineareet postion during conersting Distance te tt tuse iyplouty aap oer ‘chook stent tp longtn With oinotcoment nsx [As the precast skins take up @ fair proportion ofthe overall width ofthe wall, the gap between them is often very narrow in comparison to thelr height. This may make it dificult to remove all the air when concreting (blowing out’) and the contractor should provide Specific proposal for this, Due to the very low volume of in-situ concrete required to fill the walls onsite, the contractor's preference may be to erecta large numberof wall panels atone level, before arranging a concrete pour to fill them. Asthe precast skins are functioning, as petmanent formwork, sisting the pressure of the wet in-situ concrete, the wall manu- facturer’s catalogue may have rate of rise limits typically less than 1 mv. Coupled with the low fill volume, this leads toa relatively slow filing process on site, and one that the operatives may be tempted to speed up! The operatives should be made aware of and respect the wall manufacturers rate of rise limits, The panels are typically erected on chocks to leave a gap atthe base of around 30 mm, This isthe principal means of checking thatthe in-situ concrete reaches the base ofthe pour. Timbers acting as grout checks are placed along each side at the base ofthe panel Precast lattice girder slab units Figure 59 showis atypical section ofa composite floor using precst lattice girder units, The lattice girder is cast into (usualy class C40/50) concrete reinforced with high-yield reinforcement. The width ofthe precast slab is typically 2.4 m with a depth of 50 mm or 75 mm They are used for spens of upto 10 m (lrger spans are possible with careful planning). Dsibution seo 49MBS Hive Cclan nee [alee a arene) a 50 Figure 510 ‘Typeal details of a atticegitder. 51.4 Design of panels ‘op bar 8 mm to 14 mmdia. ™ Diagonal tar 45 mm 107 mma Bottom bar typically S mda “The design of the lattice girdar is dependant on the thickness ofthe composite floor, final loading and propping system. Typical details of a lattice girder are shown in Figure S10, Figure 510 shows atypical layout of a 2.4 m wide unit containing four sets of lattice girders, Propping to support the self-weight and in-situ concrete can be reduced or eliminated by increasing the stifiness ofthe slabs through increasing the diameter of the reinforcement to the top of the lattices and/or reducing the spacing ofthe lattices, Unpropped spans of up +105 mean be achieved depending upon the design loads and the overall depth ofthe slab “Temporary propping is required where the end bearing is small. An example of tis is at end supports where the slab unt is seated on just one leaf ofthe wall. Nosmally the minimum caver tothe reinforcement willbe 20 mm; however, the cover to the reinforcement can be adjusted to meet the specific bond, durability and fire resistance requirernents for individual contracts. Design moments Design moments about the minor axis ofa wall should be considered even where central bars are placed in the joint, as these do not represent 2 hinge, Flexural, shear and axial design ‘When checking the strength of a section of a wall more than a full lap length from a joint ‘the full width of section may be included. Otherwise just the in-situ part should be considered, Ifthe whole section sin compression, itis reasonable to assure that the fll section can provide axlal resistance, Lap lengths At the top and bottom of the wall there wil be a lap between the main vertical reinforcement and the vertical continuity reinforcement, see Figure 5.4, When the distance between these bars is greater than 4g or 50 ram the lap length should be increased by a length equal to the space between the bars (Eurocode 2, CL. 872(3)}.SSSgU Cot elms Ccaan\claycee-l Ceo) a preld (ola) Figure sa Detail at an unrestrained horizontal panel jeintin compression. 5.1.5 Concrete and finishes Minor axis bending If the decision to use a single row of starters has been adopted, minor axis bending on such walls should be checked. If significant, the decision should be revisited — with potential impacts on wall thickness, as noted above, Horizontal joint between panels stacked one above the other (no slab adjacent) Horizontal ints commonly occur, for exemple, in it shaft walls, or in walls adjacent to risers, stars, or double-height spaces. AL the panel joint level, effective design to resist minor axis bucking moments would tend towards the use of two rows of vertical continuity reinforcement (one layer on each face) within the in-situ portion ofthe wall Due to the position ofthe continuity bar within the in-situ portion, and the possible tolerance and positional control issues, a realistic effective dapth should be used in assassng the moment capacity of the wal at this point, see Figure 511 c ‘Tre tondoney to buco undo compreson a2 Unresaines nesta <> Jom, laren by the ‘rerio continu rervorcamerts acing at ‘Trecuced lev am, wt Concrete mix The nature of the in-situ concrete mix used to fill the panels on site should be considered As the gap between the precast skins may be as litle as 100 mm for a 250 mm wall, and starters and continuity reinforcement may protrude into this gep, using a vibrator poker may be dificult or impossible. The use of selfcompacting concrete should be considered ‘smaller ageregate sie, for example 10 mm, may also be appropriate. Surface finish ‘Typically, the use of steel moulds gives the extemal faces ofthe panels a smooth finish The finish quality is suitable to receive a plaster finish or, on request, wallpaper. It should be noted, however, thatthe finish isnot ‘architectural’ concrete as colour is not consistent or easily spectied.MBS Hive Cclan nee [alee a arene) a 52 5:16 Detailing Figure 512 Horizontal continuity reinforcement to ft ‘with twin wall reinforcement. 5.2 Precast columns, edge beams and in-situ slabs (type 2) Vertical joints between adjacent panels at same level ‘At junctions between adjacent panels and at corner junctions, horizontal continuity reinforcement is recommended within the in-situ portion, Detailing this reinforcernent in the form of fabricor prefabricated cagesis likely to be the easiest way offing it within the Pour. As noted above, the designer should be responsible for detailing ths reinforcement It should be noted that the presence ofthe trusses at typical distance of 340 mm from the ends of each pane! effectively constrains the volume in which continuity reinforcement can be provided. If the forces applied to the wall are such that they cause significant shear ‘or tensile forces to develop at the vertical panel joints, the sultability of twin wall panels a5 a design solution may need to be revisited. Interface with reinforced concrete ground slab. Its important to obtain the contractor's pour sequence for the ground slab ~ at locations where the ground slab steps (changes level) this will often define the panel base level ‘Agree with the contractor whether the panel wil sit on the higher-Lovel slab, oron the lower-level slab with the higher-level slab poured up against the wall. Also agree details at the edge of slabs ora lit pits. Agree from which side the panels are to be propped. It is Likely that the twin wall panels will need to be installed over projecting starter bers cast into ‘the foundations, As well asthe use of a template and the consideration for using a single row of starters, as noted above, the starters wil need to-coordinate with the horizontal continuity reinforcement provided at locations of vertical joints between panels. This means five or sx layers of reinforcement locally overlapping within the gap betwreen the panels ~2 potential congestion issue, se Figure 512. Herizontal continu relniorcerent tomered into poation ator pacing ‘The type 2 system uses precast columns and edge beams, often with a prestressed in-situ floor siab. The complex fixing of steel and anchorages in the edge strips is more safely ‘and accurately carried out in the precast concrete factory. The use of precast concrete columns speeds up the time between the casting ofthe floor plates. The precast edge Strip Is supported on the same shutter systern that is used for the floor.SSSgU Cot elms Ccaan\claycee-l Ceo) a preld (ola) 5.21 Column to floor joint ‘The column to floor joint in this form of construction is assumed to be semi-monolithic, ie the in-situ concrete is cast up to the surface of the colurnn or fully routed connection ismmade. It may be desirable that leveling devices, for example nuts and wedges having no load bearing function in the completed structure should be slackened, released or removed as necessary Where this is necessary, the details should be such that inspection (to ensure that this has been done) can be carried out without undue difficulty ‘The design of the vertical continuity or tying reinforcement requires careful consideration, Three examples are shown in Figure 513. ‘Where a central dowel bar, as shown in Figure 513, fs also acting as a vertical tie, the load on the grouted connection between the slab and the dowel bar can be significant. The signer should ensure that the detail can carry this load either by design or through testing, Bearing under the precast column Inthe absence of more accurate inforation (derived from a comprehensive programme of suitable tests), the area of concrete that should be considered in calculating the strength of the joint should nat be greater than 90 percent of the area of column assured to be in contact with the joint, unless specific means are taken to ensure that no voids exist in the gout. The strength of the concrete in the precast column may be taken asf, (= 0.85/15) The area of any bar passing through the joint should be deducted from the bearing area. The design force of such a ber may be deducted from the applied force on the bearing when ‘calculating the capacity ofthe concrete provided that the bar has sufficient anchorage beyond the joint. Grouting The contractor should provide a method statement fr the grouting work. Ths should ensure that no pockets of air are trapped in the ducts and that the interface between the baso ofthe column and support is fully grouted, Trials may be necessary to demonstrate the method Maximum compression through floor For axial load with moment transfer Eurocode 2, CL. 6.7 limits the compression within the slab. Exp, (6.63) Is modified to: aes fas WA lpn) $3.0 fs Acar 09xA, area of precast column design strength ofthe slab 4 (hi2+ 6) (hi2+a) = depth of slab breadth of the precast colurnn , depth ofthe precast column >> wena 33MBS Hive Cclan nee [alee a arene) a ‘ostom of precast calur wth bar extending from botern Extension of bar dependent or capler dimensions 2) Column shoe 1) Colurmnbareoupler ed bere cng column ©) Central dowel bar Figure 513 ‘Typical column floor connections. 54Structural elements and connections 5 Figure 514 5.2.2 Vertical tie 5.3 Biaxial voided slabs Figure S15 ‘Typical layout of biaxial voided sab. ‘Where moment is transmitted through the joint A.,., should be reduced to 0.9 x the area of the stress block shown in Figure 514, where Any = 09 0, x2(d/2 ~e) ‘Get column 2x(ds2-@) For class 28 and 3 buildings (isk group 2B and 3 in Scotland) the vertical te must be ‘designed to take the full floor load in tension under ‘accidental’ loading conditions, The partial factors for the accidental combination of actions are equal to 1 {see 8S EN 1980, and UK National Annex, Table NA.A13), see worked example 6 Ifa central dowel bar system is considered for sucha flor, ie. span > 7, it should be effectively continuous throughout the height ofthe building Full tension mechanical ‘couplers should be used where joints are required Figure 515 shows atypical section ofa composite floor using precast lattice girder units with spherical void fomers (biaxial voided slabs).The lattice girder and the void former cages are cast intoa (usually class C40/50) concrete panel containing reinforcement in two directions. The width ofthe precast slab is typically 2.4 m with a depth of SO mm or 70 min. Normally the minimum cover tothe reinforcernent wil be 20 mm; however, the cover to the reinforcement can be adjusted to meet the specific bond durability and tre resistance requirernents for individual projects.MBS Hive Cclan nee [alee a arene) a oe cae gy J@™= capoao Qo Worked example 6 =e [== War The Concrete Centre| V2" teal He = ro | Apatow Consider a @ mx 9 m flat slab floor 300 tne thick with Inposed vartable load of 2 kNin? and finlohes of 1kNint Actions The totsl design force in vertical tie Fx G+Ay Eurocode, Table NA AIS = 9x9x{(25x03+10)+(05x4) = Resistance Using a colurm shoe eyster: 4 No 25 ren bars will provide a resistance of Fea = Waly 10500 x 25° 4x n/4/1000 = 981 kN Fea > Fag"? OR Use 4 No 25 vim bars 5.31 Slab geometry inital sizing can be determined from manufactures literature The manufacture literature will also advise the sie ofthe spheres avallabe, the spacing requirements and the general configuration ofthe slab. 5.3.2 Flexural design _The benefit of the reduced self-weight should be taken into account in the design. The design may assume a fat slab model, which has been demonstrated as appropriate through testing ofthe slabs. check should be caried out to ensue thatthe concrete compression 2zone remains outside ofthe depth of spherical old formers, Where this is not the case, as in heavily loaded slabs, the manufactures wil be able to offer appropriate guidance on determining the permissible compression zone that can be used inthe caluation of the flexural stength 5.3.3 Shear design Testing has been carried out to determine the shear strength ofthis type of lab, alongside a ‘theoretical assessment ofthe reduction in the shear plane due to the inclusion of the voids. ‘The manufacturers recommend that shear stength of a solid slab of the same depth should be reduced by a factor of between 0.55 and 0.6 to obtain the design shear resistance for the voided slab, se Figure 5.16 For punching shear itis recommended that the void formers are left out where the design shear stress exceeds the reduced shear resistance ofa voided slab, see Figure 516, Punching shear checks may then be carried aut on the solid slab areas around the columns 56Siew Troan lae eels cold (ol) Figure 5.16 ‘Typleal layout with final renforcemer 5.3.4 Deflection control 5.3.5 General considerations Manufacturers have carried out testing to determine the reduced stiffness ofthe slabs due to the voids. Conservatively the stifness of the woided slab may be taken as 0.87 times the stifiness of a solid slab, although in some configurations the factor may be increased to 0.96 The manufacturers have data available to take advantage of these situations, When using a finite element analysis, the stifness ofthe slab (by adjusting the modulus elasticity) can be reduced accordingly. The use of the span-to-effective depth rules of Eurocode 2 is not valid for this form of construction since itis not clear how the slab stifness is incorporated in the manufacturers design expressions Splice bars are used across the panel joints so thatthe slab may be designed as @ continuous ‘member. Figure 5.16 shows a typical layout including the final reinforcement. Buoyancy of voids ‘Whilst the concrete is being place and vibrate, the buoyancy force can reach the displaced ‘weight. The void formers are held in place by: 1 firm tying of the void former to the lower and upper reinforcement 1 casting of concrete in several stages (normally two, but three may be required where the voids ae larger than 360 mm) Slab edges Voids are not normally provided near slab edges to ensure a robust and continuous edge etal.MBS Hive Cclan nee [alee a arene) a 5.4 Prestressed hollowcore 58 units Figure 517 ‘Typical hollowcore unit production, 5.41 Anchorage of prestressing tendons Prestressed hollowcore units are produced by an extrusion or slipform process with a typical width of 1200 mrn, in lengths of up to 200 m, Each length is prestressed before casting. After curing, the units are sawn to the required length, Figure 517 shows atypical production layout. It should be noted tht where the only einforcement in the units isthe prestressing strands, as is common, it makes the support zone particularly vulnerable since this is where the maximum stresses due to bearing, shear and anchorage occur. The design should be in accordance with Eurocode 2 Hollowcore units have lateral edges provided with a longitudinal profile in order to make a shear key for transfer of vertical shear through joints between contiguous elements, For The cracking length, is the distance from the end of the unit to the point where the bottom fibre strass rsuiting from all actions (bending, prestress and horizontal forces at the bearings) equals, Figure 518 shows the components of actions and the net effect on the bottom fibre stress. Note that if i less than /,, the prestress is reduced, Figure 519 indicates the results from the example given in the Precast Eurocode 2: Worked Beomples™. The following points are of particular note 1 Consider all action effects to determine where the unit is likely to crack 1 Where dry or mortar bearings are used large horizontal forces may arise from temperature end shrinkage effects 1 In this exemple the horlzontal force at the bearing may cause cracking close to the end cof the unit, before I, is reached, see Figure 519(¢) IFcracking does occur close to the support, the shear resistance is likely to be exceeded. 305 Structural elements and connectio' Figure $19 Build-up of bottom fre stress in concrete from and of unit. 5.4.4 Total anchorage length 5.4.5 Tendon slip at ends of units ‘ sat srufi Baton on ‘tre tae Sree tress tol fa MZ ‘Support fan PARE 2) Stross duo laure 1b) Stes dus ta pretoxe e Sip orb ation | HASH Z ) Sess duoto hrzntal oan aspen Botton fore Posie ovorsioss Campresion fe ly 4) Net coton tor ares rong casting nat, ‘The total anchorage length, i. isthe distance from the end of the unit to the point beyond which the ull design resistance ofthe wires or strands can be obtained, as shown In Figure 518. ‘When the prestess is transferred from the anchor blocks to the hollowcore units, there is anchorage bond along the full length of the strand, apart from the transmission length at each end of the prestressng line. The concrete is then cut into the required lengths and at each end a further transmission length is introduced. Although expressions have been developed to determine the relationship between the end sip ofthe strands and the ‘transmission length, it has been shown that, for hollowcore units that have been sawn, there sno simple relationship between transmission length and initial sip at these positions, This is discussed further in Section 6.6.Structural elements and connections 5 ‘ea tense onion! iting eases creck Arenrapy Lage rack ap Sits f0 pve oy Ancoroge tan are | Shea tendon fale ch Heian sptitng race Figure 5.20 ‘Types of end failure. 5.4.6 Types of end failure Figure 520 shows the tree ypcal types of end failure that may occur t should be noted that types 4) and b) can interact, ane reducing the resistance of the other. 5.4.7 Anchorage bond failure Anchorage bond Failure, see Figure S 20a, may occur ue to cracking close tothe support hich doesnot allow the fll ancherage resistance to develop and strands start to sip ‘This couses the crack to grow until the unit fails. The most common cause of anchorage fale is when the end of the units subject to movement eltve to is bearing This may be the result of the effects of one or more of the following: 1 shrinkage 1 temperature changes 1 humidity changes 1 vertical loading Itis important that the designer considers each of these possible effects This is especialy important for units with spans greater than 8 m. Reference should be made to ‘Movement, Restraint and Cracking in Concrete Structures™ 5.4.8 Shear resistance Cracked sections ‘The cracked shear resistance should be checked at positions likely to be cracked at the Ultimate limit state. The position at which this check should be carried out i ata distance [, from the end of the unit, see Section 5.4.3, The shear tension resistance is calculated in accordance with Eurocode 2, Exp (6.2a and b) together with UK National Annex Vege = [OreK{ HOO, 2+ 095: with a minimum of Voac* (0.035K F124 0180, Jb.MBS Hive Cclan nee [alee a arene) a Figure 5.21 Critical section fr shear tension failure, where k = 14 2o0/d*<20 p, = A,/b,d= 0.02 (normally =0 since the distance to the end ofthe unit remporay 2nay ‘brace prope Note: itis important thatthe temporary braced props are supported by a permanent structure,SSSgU Cot elms Ccaan\claycee-l Ceo) a preld (ola) serev geer 4) Connection with dowel bar ely ‘Sree rebar via ner Seed ) connection wit hanging and comal ar Figure 5.38 Preferred arrangements of reinforcement for ‘connection with in-atu concrete, 5.6.3 Top and bottom supports with precast concrete Layout Figure 5.39 shows the preferred dimensions for the dataling ofthe top joint between @ precast stair light and a precast support ‘The design of the bearings shall be in accordance with Eurocode 2, Cl. 10.9.5 and due allowance shall be made for erection tolerances. Far the application of this rule, 6% classes of stair nibs are defined: Class A: The stair rib is manufactured with the design end cover in accordance with BS EN 14843, CL. 4311 Class B:The stair rib is similar to Cass A but with reduced end cover. In this case the full concrete covers achieved onsite with a non shrink mortar.The result shall be in accordence with Eurocode 2, Section 4 Recommended bearing type The recommended bearing type for precast stairs to precast concrete supports is a 10 mim thick mortar bedding,BSH fv loin Tc-1M (clan nn [glen @e) gla retnle lay 8) Lancing wth oping itertaxe i al L elle] 1) Landing with quar ntertace ae a —— Pree in ©) Wall with square inortace wn Figure 5.39 Preferred dimensions for top joint between, staiflght and precast support. 0 | 0 Design and supervision considerations ‘The following should be considered during the design and construction process 1 anallowance fora very generous impact factor on self-weight (say 2 or 3) of the precast ight '= checking the consequence ifthe support is assumed to be at the edge ofthe in-situ nib {or designing seating layer to even out the loading) fallure mode in shear and hanging tension behind the nib the construction procedure and temporary propping loads are property understood ensuring thatthe concrete reaches the required strength no shims are included the reinforcement is checked prior to concreting, Lapped horizontal connection Figure 5.40 shows @ preferred layout of reinforcement. This may not be the easiest way to construct an acceptable cage but ensures that the dimensions and the positioning of the loop and link reinforcement is correctSSSgU Cot elms Ccaan\claycee-l Ceo) a preld (ola) To entorcement in arustra topping “etentorcement in srustra topping Figure 5.40 Preferred layout of reinforeement for precast Joints FigureS.41 Dimensions te allow For dowel hole, 0 2 ia rue 542 basta area co enn * a5 8 — 2 ‘s,| a Dowel connection To provide sufficient room for a dowel hole the dimensions of the nib need to be as shown inFigure 5.41, Figure 5.42 shows the preferred layout of reinforcement for dowel connections, and ‘worked example 8 shows a typical calculation, npMBS Hive Cclan nee [alee a arene) a ey ane RW | caPoBo Qo Worked example & cous op pe WEB fi i - ie tee Centro" | DWE! bar for connection of precaot: otairo rec | Aprios Consider a 15 m vide stair fight spanning 4 m, with a vertical spacing between precast units of 10 een and using a 20 rt diameter bar for the dowel. The tying fares, F,, required ehould be st least the permanent. action of the etalr Fight: Actions Assume average vertical thickness of star fight is (150 + 100)V2 = 250 ram Self weight of star ght fy = 26x035418x4 =225K aesistance Is can be chown that the maxinum dowel force, Fe I0 Fea = GEM AE MVC 8) - of < ALB (ohear resistance ofthe dowel) Belt) « MEE) ‘equal to half the vertical spacing between the units @ = 10/2=Snen © = 34(6/20)x W(0.85x 4018)"(600N78); - 0171 208 40.85 x 40/15x 500/116) « {11+ O-7F) - 0.171000 = 3351N (70x 20°/4) x (00/1 15)/(5 x 1000) = 76 kN 2851N No read = 525/385 =157 Use 2No.20 mm dia, dowal bare] 5.6.4 Top and bottom steel angles are used to allow the star flight to rest crectly onto walls or floor units, see supports using steel angles Figure 5.43. Figure 5.43 ‘Support using steel angles.SSSgU Cot elms Ccaan\claycee-l Ceo) a preld (ola) Full strongtn wei to iforament (a angle, usta ’ Structural Feinoreement ‘Sruetra opping Stucural Felnorcement lll structure Fall strangth wold of rinforcomont to angie Lap with sustaraleinorcement Figure 5.44 totwom andtopsupportdetaeuingsteel The angle provides the bering onto the supporting structure but often doesnot have any srales Joint continuity reinforcement. The designer should ensure that the design ofthe precast Unit incorporating such a steel angle is adequate forthe particular situation and provides ‘an adequate te tothe structure. Gne method of achieving this sto weld reinforcement to the steal angle and anchor it to the structure through the screed, Typical top and bottom etails are shown in Figure 5.44. The tension forces transmitted from the angle to the reinforcement within the precast Uniti the top joint requires links welded to the bottom of the top angle. These should be designed to resist the forces from the angle with the force of the support at the worst possible position, Le. when the joint between units the widest permitted by the tolerances, ‘The stability of the staircase before the screed hes been cast is not normally considered by the manufacturer Iti essential to ensure that any temporary supports are provided and cleerly identified in the construction sequence. One example is to provide a positive tie between the fight and the landing by reinforcement welded to the bearing angle (at the precest factory] to lap withthe fabric in the structural topping, 5.6.5 Stairs with integral stair fights can be provided with an upper or lower integral landing as show in Figure 5.45 landings 1s important that an insert (typically 50 min s provided onthe top surface ofthe landing. Ths allows the top finish tobe laid unfermly over the whole ofthe landing surface, avoiding any steps, due to construction and installation tolerances. In order to establish an adequate tie to the supporting structure the reinforcement projecting from the precast unit should interlock with that of the support.