Columns Product Catologue Rev D MK 2

Precast Columns
Design Guide & Product Catalogue
3
Precast Columns
Foreword
Explore Manufacturing is a subsidiary of Laing O’Rourke established to advance
the strategic objective of off-site manufacture or Design for Manufacture and
Assembly (DfMA).
This publication is the culmination of a body of work looking specifically at the

standardisation of precast concrete columns. A number of companies have co-
operated to develop the system described:
 Explore Manufacturing Ltd

 Laing O’Rourke PLC (delivery)
 Expanded Structures Ltd (assembly) Published by Explore Manufacturing Ltd
 Ramboll UK Ltd (design and analysis)
 Qube Design (UK) Ltd Dec 2012 | Ref. EXP/DG/PC | © Explore Manufacturing Ltd
 Modulus Structural Engineering Ltd
Copyright & Confidentiality
The proposed system has been peer reviewed by the following companies so that
Legal Notice: Proprietary Material. Strictly confidential. This document and
it can be confidently used to replace a typical insitu concrete column on a wide
associated texts, images, templates and programs are copyright. These materials
range of projects:
and the process they embody are trade secrets of Laing O’Rourke and should not
 Aecom be disclosed or made available outside the Laing O’Rourke group of companies
 Arup without authority. Laing O’Rourke gives no warranty (nor accepts any liability) to
 WSP Group PLC any third party under any circumstances as to the completeness or accuracy of
any content. Readers should note that all Laing O’Rourke publications are subject
The result is a system that harnesses the latest and most modern techniques for to revision from time to time and should ensure that they are in possession of the
the precast concrete column design, manufacture and assembly. latest version.
Revision History
Rev Date Status Revision summary

A 15 May 2012 Technical draft
B 10 Sep 2012 First issue C50/60 concrete adopted
C 18 Dec 2012 Second issue Rolltec® adopted
D 17 Jan 2013 Third issue Appendix A revised, minor revisions
2
Precast Columns Contents
6 How to specify columns 28
Contents 6.1 Column Performance Specification 28
1 Introduction 4 6.2 Columns reference system 29
1.1 The Explore Manufacturing column system 4 7 Design co-ordination 30
1.2 About this publication 4 References 32
1.3 Purpose and scope 4 Appendix A – Assembly 33
1.4 Further guidance and design standards 4 Appendix B – Design approach 43
2 Product features 5 Appendix C – Technical details 50
2.1 Key characteristics – square columns 5
Appendix D – Column Charts 54
2.2 Key characteristics – rectangular columns 6
2.3 Column sizes 7
2.4 Vertical arrangement of columns 9
2.5 Finishes 11
2.6 Column components 12
2.7 Lifters 18
2.8 Standard, standard+ and specials 18
3 Interfaces with other elements 19
3.1 Connection to foundations 19
3.2 Connection to in-situ columns 19
3.3 Slabs 21
3.4 Top of column detail 21
3.5 Beams 22
3.6 Wall interfaces 22
3.7 Attachments 23
4 Scheme design 24
5 Design charts 26
5.1 Introduction 26
5.2 Additional moment 26
5.3 Shear resistance 26
5.4 Example 26
3
Precast Columns Introduction
1.4 Further guidance and design standards
1 Introduction
This guidance assumes the design will be undertaken using the structural
1.1 The Explore Manufacturing column system Eurocodes and in particular Parts 1 and 2 of EN 19921,2 as read with their UK
National Annexes3,4; however, where appropriate, reference is made to other
The Explore optimised column system harnesses the latest and most modern applicable publications, including BS 8110-15,
techniques for precast concrete column design, manufacture and assembly.
This fully engineered system can be used in most cases where conventional The Institution of Structural Engineers publication Manual for the design of
concrete columns are considered. It has the added advantages of faster concrete building structures to Eurocode 2 6 and The Concrete Centre
construction, improved quality and a noticeable reduction in site based publication How to design concrete structures using Eurocode 27 are also
personnel and activity. The system has been developed to yield the highest recommended background reading.
holistic performance for the design and delivery of precast columns (see
Figure 1.1).
1.2 About this publication

This publication is intended to assist structural engineers commissioned to
design concrete structures using the system. It forms part of a suite of
publications and provides detailed guidance for precast concrete columns.
Guidance for other components of the structure is also available from Explore.
This document is intended to be read and used online. Users should always
refer to the latest online version to ensure they are using the latest information.
A revision history can be found on page 2.
1.3 Purpose and scope

This Explore Design Guide and Product Catalogue aims to provide the
designer with design aids to enable quick, accurate and consistent application
of the system from initial sizing to assembly. It also aims to assist in the
understanding of the design issues relating to the use of precast concrete
columns.
Figure 1.1
Explore Precast Column System
The advice contained within this publication assumes the use of precast
columns in hybrid concrete construction (i.e combining precast and insitu
concrete as well or all precast construction).
4
Precast Columns Product features
2 Product features
2.1 Key characteristics – square columns
Vertical bars (20, 25 or 32

Bent mesh link cage. Vertical steel
diameter) with centreline offset
in cage is ignored in design but
60mm from each face. B500
assists crack control.
steel. One bar located at each
corner.
Cast column shoe. Shoe locates

over threaded bar. Pocket in shoe
for tightening nut. Pocket must be
grouted.
Wavy-tail lifters cast into top &

bottom of column to assist de- Threaded bar.
moulding and installation.
Coupler at top of column.
Standard 20mm chamfer on

vertical edges. No chamfer on C50/60 concrete with 10mm
horizontal edges. calcareous aggregate. Minimum
cover to steel is 25mm.
5
2.2 Key characteristics – rectangular columns
Bent mesh link cage. Verticals in

Propping socket, if required. A single
mesh are ignored in design but
prop may be required to prevent
assist crack control.
rotation about the minor axis.
Vertical corner bars with 20, 25 or Secondary longitudinal bars (B16)

32 diameter, B500 steel. in order to satisfy requirement for
maximum spacing between vertical
bars of 400mm.
Cast shoe on one side only since
insufficient width in thin columns to
accommodate a shoe on each face. Coupler at bottom of vertical bar
Rebar continuity on opposite face where reinforcement continuity is
provided by grout sleeve. via a grout sleeve.
Threaded bars
Grout sleeve type coupler located
Wavy-tail lifters cast into top and within slab thickness.
bottom of column. Two lifters
each face on blade columns in
order to give better control during
handling C50/60 concrete with 10mm
calcareous aggregate. Minimum
cover to steel is 25mm.
Standard 20mm chamfer on
vertical edges. No chamfer on
horizontal edges.
6
2.3 Column sizes Please note that when b > 3h, a column made from a twinwall panel can be
a more economic solution than a solid precast column. Twinwall is available
2.3.1. Cross-sectional dimensions with 200 < h < 400. Please refer to the separate guide for further details.
Maximum cost efficiency is achieved by using standard cross-section Table 2.2

dimensions with standard longitudinal bar sizes. A large range of sizes are Standard column section sizes – rectangular
offered to suit the vast majority of project requirements. Figure 2.1 shows Column depth, h Column breadth, b Longitudinal bar
typical column sections. Tables 2.1 to 2.3 show the standard sizes for (mm) (mm) sizes (standard)
square, rectangular and circular columns.
200 400 20,25
200 600 20,25
200 800 20,25
225 450 20, 25, 32
225 675 20, 25, 32
225 900 20, 25, 32
250 500 20, 25, 32
250 750 20, 25, 32
250 1000 20, 25, 32
300 600 20, 25, 32
300 900 20, 25, 32
Figure 2.1 300 1200 20, 25, 32
Standard column cross-sections 350 700 20, 25, 32
350 1050 20, 25, 32
Table 2.1
Standard column sections - square 350 1400 20, 25, 32
400 800 20, 25, 32
Breadth b (mm) Longitudinal bar sizes (standard) 400 1200 20, 25, 32
300 20, 25, 32 400 1600 20, 25, 32
350 20, 25, 32 Notes:
400 20, 25, 32
1 200 mm depth columns are generally suitable for fire occurring on
450 25, 32
one side only.
500 25, 32
600 25, 32 2 Non-standard bar sizes will be Standard+.
700 25, 32 3 Column depths are fixed, however, variations in widths can be
800 25, 32 accommodated as Standard+. Contact Explore for details.
Notes: 4 Minimum bar diameter may be governed by As,min – see Appendix B
1. Non-standard bar sizes will be Standard+. for details.
2. Column depths are fixed, however, variations in widths can be
accommodated as Standard+. Contact Explore for details.
3. Minimum bar diameter may be governed by As,min – see Appendix B
7
2.3.2. Column Heights
Table 2.4 summarises the standard column height ranges that can be
Cast height of column

manufactured. The definition of the cast height is given in Figure 2.2.
Table 2.3
Standard column sections - circular 25mm deep recess in
Diameter, D (mm) Longitudinal bar sizes (standard) Floor level – taken slab (locally increasing
300 20, 25, 32 as top of slab to 40mm depth)
350 20, 25, 32
400 20, 25, 32
450 20, 25, 32 Slab soffit
500 25, 32
Slab
10
600 25, 32
Notes:
1. Explore hold a number of non-standard circular column moulds that
Floor to floor height

have been used on previous projects. These can be supplied as

Standard+. Check with Explore to confirm sizes and availability.
2. Non-standard diameters can be manufactured as a Special. Contact
Floor to slab
Explore for details.
Table 2.4
Available column heights
Cast height Comments
Shape
limit
Square 12 m Check ability to lift horizontally where L/h >
25
20
20 (e.g. 2-storey slender rectangular
Rectangular 12 m columns)
Greater height on some sizes, please Figure 2.2
Circular 5.0 m
check with Explore Dimensions for specifying precast columns
8
2.4 Vertical arrangement of columns Where there is a reduction in column dimension there are three possible
positional arrangements for each transition, (see Figure 2.4). Note that the
Columns are designed to be stacked vertically on top of each other (see diameter of the vertical reinforcing steel can also change. To limit the range of
Figure 2.3a)). Reductions in column section can be readily accommodated so potential transition arrangements Explore apply certain rules:
long as orientation remains the same (Figures 2.3b) and c)). Special designs
are required where the orientation of blade columns changes between floors  A column should normally transition by a maximum of 100mm in
(Figure 2.3d)). This detail should be avoided; if the detail must be used any dimension between floors;
contact Explore for advice.  Unless architectural requirements dictate otherwise, columns
should run for 3 or more storey’s at a given size before reducing
Typical
Typical
= offset = A offsets: A Typical offset
=
A= 50mm = 100 mm
50mm
B=100mm
= =
B
All 4 corners require 2 corners with L-bars; L-bars required

joggle only 2 corners joggle only on 3 corners
a) Centreline transition b) Edge transition c) Corner transition
Figure 2.4
Offset arrangements associated with column transitions
Column transitions are achieved by putting a joggle into the vertical bars, see
Figure 2.5. The following rules apply:
 Slope on joggle is 1 in 12 in accordance with BS EN 1992-1-1

cl 9.5.3(5).
 Where the joggle offset is greater than 75mm, an L-bar is inserted
into the column. The L is turned to face towards the column
centre. Cover to the top of the L is no greater than 25mm. The bar
diameter shall match the vertical bar diameter.
Figure 2.3
Column stacking  Where the joggle offset is greater than 150 mm use two
overlapping bars
9
Subject to these limitations, columns immediately below a transition will be cast shoe connection. Where access would prevent a nut being tightened, a
treated as standard+. grout sleeve connection can be used instead. Appendix C gives
details. Such a connection would be treated as a standard +.
In general the outermost bar of a corner column should be provided with a
h1 h1 b1
Terminator plate on
Where offset > 75mm, fit threaded bar
loose L-bar
Where offset < 75mm,
Cover = 25mm
no additional steel Where offset > 150mm,
required introduce additional bar.
Anchorage length
sufficient to take forces
(h2 – h1)/2<75 from upper column.
75 < (h2-h1) < 150
Link cages omitted (b2-b1) >150

for clarity
h2 h2 b2
Figure 2.5
Rules for joggles on columns with transitions
10
2.5 Finishes A number of specifications are used in the building construction for specifying
finishes for concrete cast against formwork. Table 2.5 provides a summary of
2.5.1. Chamfers the finishes that may be specified and guidance as to whether they can be
achieved as standard using steel formwork.
Rectangular columns come with a 20mm chamfer to long (vertical) edges as
standard. There is no chamfer on horizontal edges at the top or bottom of the A flow chart is provided (see Figure 2.6) to enable the most suitable casting
column. Any changes to the standard chamfer offer needs to be defined early arrangements to be determined. Since surface finish requirements can dictate
and will be subject to additional cost. method of manufacture and cost, client requirements and expectations need
to be defined and agreed at an early stage.
2.5.2. Surface finish
Table 2.5
The surface finish is dependent on the casting arrangement used. Since Available finish for concrete cast against a steel shutter.
standard square or rectangular columns are normally cast horizontally in open Finishes that can be Practicalities of
topped moulds, there will always be at least one face where the concrete is Specification achieved at no extra finished to be
not cast against formwork. This unformed surface will not be to the same document cost by casting against discussed with
standard as a formed surface, being either trowel- or power-floated. The steel shutter Explore
finishes available for columns are summarised in Table 2.4. BS 8110 – quality Class 1 Special
(Cl. 6.2.7.2) Class 2
Table 2.4 BS 8110 – surface Type A Type C
Finishes for various casting arrangements finish (Cl. 6.2.7.2) Type B
Cast National building 610 Basic 630 Fine smooth
Shape Finish Class
Orientation specification 620 Plain smooth
Steel plate Standard BS EN 13670 Basic Special
Circular Vertical
Steel plate + grit-blast Standard+ Ordinary
Steel plate: 1 x long face; 2 Plain
x short faces Standard
National structural Basic Special
Unformed: 1 x long face
concrete specification Ordinary
Horizontal Steel plate: 1 x long face; 2
Plain
Square of x short faces
Standard+ Civil Engineering Rough finish Fair worked finish
Rectangular Power floated(1): 1 x long
face Specification for the Fair finish
Steel plate all sides Special Water Industry
Vertical Steel plate +grit-blast all Specification for Class F1
Special highway works Class F2
sides
Note: Class F3
1. Power floating changes the surface colour on that face and may Class F4
therefore only be suitable for painted surfaces. Class F5
11
The steel formwork will give a finish that will be suitable for many applications. 2.6 Column components
However, if a higher quality of finish is required then an allowance should be
made in budgets for the additional costs. The efficiency of the precast column system is realised by standardising
components wherever possible and offering variable options only where
required for the design to suit particular requirements. In addition to adhering
to the range of sizes and finishes set out in section 2.2, a number of
restrictions are placed on the components used within a system. This section
describes the components and restrictions in use.
2.6.1. Concrete
The concrete in the columns is a Class C50/60. Further details on concrete

properties are given in Appendix B.
2.6.2. Reinforcement
The reinforcement is class B500, with a characteristic strength, fyk,of 500 MPa
and ductility class C for the longitudinal bars.
2.6.3. Columns connections
Each column has four cast column shoes; these are used to immediately
secure the column to the top of the lower column. They are also used to set
the column to level and plumb (see Appendix A). Adjusting the shoe is a
manual operation carried out by an operative positioned on the slab. Cast
shoes must be accessible from the slab.
Occasionally, when there is poor access to the shoes, Explore will substitute
one of the shoes with a grout sleeve. In this situation the column is considered
to be a standard+.
Figures 2.7 to 2.10 show column connections for square and blade columns,
note that circular columns are similar to square columns.
Figure 2.6:
Flow chart to determine casting arrangements to achieve desired finish
12
®
Rolltec locknut to preload thread.
Vertical column bar. This has a
®
Shoe access pocket. This must be Rolltec thread applied and is
grouted (C70 grout) once column screwed into the shoe.
has been set. Bottom cast surface of column is
nominally 5mm below the top
Threaded bar must project one full surface of the slab. A recess is
thread pitch above the nut. cast into the top of the slab.
5
Upper nut (Gr 8). These are
installed immediately after a column
Slab
has been placed. Nuts are not
tightened to a pre-defined torque,
but should be as tight as is
practically possible.
10
Lower nut (Gr 8). These should be
set to the correct height and level Top cast surface of column is
before a column is installed. A nominally 10mm below the soffit
recess is cast into the top of the of the cast slab.
slab to accommodate the nut.
®
Rolltec Coupler (adaptor to
Threaded bar (grade 8.8) screwed into take threaded bar). Flush with
coupler after slab steel has been placed top of cast concrete.
but before slab is cast.
Figure 2.7
Square column connection – components
13
Rolltec® locknut to preload thread.
®
Main vertical corner bar with Rolltec
thread at each end.
Upper nut (Gr 8). These are
installed immediately after a column
®
has been placed. Nuts are not Rolltec Coupler (adaptor to take
tightened to a pre-defined torque, threaded bar). Flush with bottom of
but should be as tight as it is cast concrete.
practically possible to make them.
Threaded bar (grade 8.8). Screwed
into coupler to form dowel for
inserting into grout sleeve.
Cast shoe on one side only since
insufficient width to accommodate Proprietary grout sleeve type connection.
two shoes. Shoe set 60mm in from Screwed to top of threaded bar (used
each face. where access is poor).
Threaded bar for connecting upper

Threaded bar (grade 8.8) screwed into coupler in column to grout sleeve.
coupler after slab steel has been
placed but before slab is cast.
B16 secondary longitudinal bar tied
in by transverse link in mesh cage.
®
Bar stops at top/bottom of column.
Rolltec Coupler (adaptor to take Bar not taken into account for
threaded bar). Flush with top of column moment capacity.
cast concrete.
Figure 2.8
Blade column connection – components
14
Upper column
Recess in slab such that column
base sits lower than slab surface
Upper nut – used to secure column.

Nut should be tightened as much as
Local recess to allow adjustment on practically possible.
lower nut
Lower nut – used to adjust upper

column to elevation and vertical.
Threaded bars pass through slab.
Lower column
Shear studs, lattices and other steel
in slab to be co-ordinated such that
threaded bars can pass through
slab zone
Figure 2.9
Square column connection – integration with slab
15
Corners fitted with cast shoes are

identical in dimension and assembly
to square columns. This includes an
additional recess to take the lower
nut. Recess formed in top of slab as for
square columns. There is no need to
form a secondary recess for the
grout sleeve connectors.
Top and bottom steel within the slab
is co-ordinated to avoid vertical steel
in the slab.
Grout sleeve locates within depth of

slab. Subject to grout sleeve type,
tubes will need to be attached to
sleeve filling ports prior to casting
slab.
Figure 2.10
Blade column connection – integration with slab
16
2.6.4. Longitudinal bars In some of the larger column sizes two or four 16 mm secondary bars are
introduced. This increases the area of reinforcement and if necessary may be
Main and secondary longitudinal bars may be used in the column section. considered when calculating the column capacity (see Appendix B). The
The location of the longitudinal bars for typical cross-sections is shown in secondary bars are not continuous through the floor slab and are not taken
Figure 2.11. into account in the design charts.
There are always four main longitudinal bars in a column section and they will 2.6.5. Transverse bars
always be the same bar size in an individual column. Bar sizes are restricted
to 20, 25 and 32 mm. Transverse steel is made from bent fabric. Vertical B8 stringers hold the mesh
together. These are positioned to suit the mesh bending machine. Transverse
Secondary longitudinal steel is introduced to ensure that vertical bar spacing steel spacing is a maximum of 200 mm. For columns where h < 300 mm,
is less than or equal to 400 mm. This secondary longitudinal steel dictates the spacing is reduced to 100 mm over the lower and upper b of height (BS
the plan layout of the cages, see Figure 2.11. EN 1992-1-1, Cl 9.5.3). Figure 2.12 shows the standard transverse steel
(links) arrangements used in the columns.
60 60
60
= Cage C1
Cage C2
Cage S1
Cage R1 Cage S2
60
200 100 < spacing <200

60
=
Cage R2
If > 400mm, introduce

60 secondary longitudinals 60
Cage R3
60
60
Figure 2.12
Standard tranverse reinforcement arrangements
Figure 2.11
Column section and elevation with typical dimensions
17
2.7 Lifters Table 2.6
Indicative classification of columns
Lifters are included in both the end faces of the columns and are required for Class Indicative Comments
two purposes: cost
increase
 To lift column out of the mould, by using the lifters at each end Standard Base cost Based on standard cross-sections in this
catalogue
 To upend a column and install it
Overall height within standard height range
Cast from standard C50/60 concrete
Up to two threaded lifters are cast into both of the top and bottom faces of
Standard+ 10-20% Combination of cast-shoes and grout sleeves
the column. Lifter sizes are selected by Explore to suit the column size and
within a column.
handling procedures adopted within the factory. Typical lifter sizes are given Columns accommodating change in size (see
in Appendix C section 0)
Non-standard breadth rectangular columns
2.8 Standard, standard+ and specials Note: Columns must still fully follow the standard
principles for all other aspects
Explore offer a range of standard column cross-sections. These are based Specials >25% Columns with enhanced concrete finishes (see
on popular sizes manufactured in the past. When necessary and to suit section 2.5)
Columns with cast-in components for beam
particular project requirements, Explore can enhance the standard columns.
attachment (see section 3.4)
These columns will be classified as ‘standard+’ or ‘specials’ depending on Columns accommodating change in orientation
the level of complexity. An indication of how columns are classified is given in (see section 0)
Table 2.6. Non-standard depth rectangular columns
Columns with non-standard edge chamfers (see
section 2.5.1)
Note:
Design charts in this catalogue are based on the standard columns only
18
Precast Columns Interfaces with other elements
3 Interfaces with other elements Template holding

threaded bars accurately Tolerance
 0.3 mm
Threaded bars forming
starter for standard pre-
to position and vertical. cast column
Template set accurately
Pre-cast columns can interface to a wide variety of other elements. In to position
general it is the responsibility of the Engineer to design and detail the
requirements working in collaboration with Explore. This chapter gives
guidance on some of the more common interfaces that can occur.
3.1 Connection to foundations

Starter bar are required at foundation level. These serve a number of
purposes: Threaded bar grouted into Wells
Wells void forming
void. Nut on end of bar
oversize pocket in slab
1. Accurately position and orientate a column improves anchorage.
2. To hold a column upright in its temporary condition Figure 3.1
3. To resist bending resulting from any lateral loads arising from table Two stage column starter assembly – shallow foundation
formwork
 The starter reinforcement at stage 2 must be located relative to
The accuracy required in 1 above is unlikely to be achieved by casting starter each other using a template. Positional accuracy should be  0.3
bars directly, and a two stage process may be required. mm – computer numerically controlled (CNC) production of the
template will be required, contact Explore for further details.
Figure 3.1 shows a typical two stage solution. Stage 1 does not require tight  The starters at stage 2 must be set so that they are vertical to
tolerances. Stage 2 is then accurately set after the foundation is cast. If within 1-in-100.
accurate control of tolerances can initially be achieved then stage 1 can be
omitted. It may be possible to cast the slab as normal and then drill and resin anchor
the threaded starter bars, see Figure 3.2. Note that the tolerances given
Key requirements of a two stage starter assembly are given below: above must still be achieved.
 Adjustment of template 2 must be greater than the positional
tolerance stage 1.
3.2 Connection to in-situ columns
 The strength of grout or concrete used to fix stage 2 must be Where the column below is formed of in-situ concrete (e.g. too large to make
greater than C50/60. precast), then it will be necessary to cast a column starter system into the top
 Sufficient tensile anchorage must be developed to provide of the column below. A suggested solution is illustrated in Figure 3.3.
temporary stability to the column. This criterion will be most
significant for rectangular columns about their minor axis and for
columns taking significant loads from formwork.
19
Tolerance to be increased in area or the insitu bars terminated in such a manner as to
Recess formed in slab. If Threaded bars –
recess not used, cast  0.3 mm these need to be set maintain a minimum reinforcement area.
column length should be accurately with a
reduced and bund used to template Vertical reinforcement
contain grout. continuous through slab
Slab internal steel and lapped into upper
omitted for clarity column
Holes drilled and

threaded bars resin
bonded in. Depth to suit
Pile or deep loads in accordance with
foundation anchor manufacturers
instructions
Insitu design intent Where insitu bars are
Figure 3.2 Accurate template to small enough, they may
Resin anchoring of column starters – for a pile position precast starters be bent into the slab,
and form slab recess. else cut-off.
Key requirements of the transition are given below:
 The threaded bars must be fully anchored into the column below
since they act as the vertical tying system. This will require them to
be cast into the column.
 The relative plan position of the bars to each other must be other Precast starter bar with
±0.3 mm. This will require the use of a CNC manufactured In-situ corner bars may
coupler at top. Lap
need to be moved slightly
template. length to insitu steel to
to permit positioning of
suit upper column
 The bars must be vertical to within 1 in 100 precast starters
requirements
 In order to get access to place and compact the in-situ column
concrete, access holes may need to be made in the precision
template.
The lap length in Figure 3.3 must be sufficient to transfer the load to the mid- Transition from insitu to precast
side bars of the insitu column. Where the in-situ column has a lower concrete Figure 3.3
strength than the pre-cast column, the insitu column steel may also be acting Transition from in-situ to pre-cast columns (CSCS)
as compression reinforcement. In such circumstances the lap bars may need
20
3.3 Slabs 3.4 Top of column detail
Figure 3.4 shows how the precast column system interfaces with the Explore At the top of columns there is usually a moment with limited axial
optimised lattice slab system. The interface with an insitu slab will be similar. compression. Proposed detail for transferring slab moment into the column is
shown in Figure 3.5. Terminator heads are used at the top of the column
Template used to set Threaded bars screwed in main longitudinal bars. These need to be located as close to the surface of
threaded bars accurately to after planks and top steel the slab as possible such that T1/T2 steel anchors into the compression zone
position and form recess have been placed.
High strength shrinkage

compensated grout under Square edge finish to
bearing slab and column
Figure 3.4
Interface of slab to Explore optimised slab system
The following should be noted in relation to the interface:
 Care is required when lowering planks over the upward facing shoe
components to ensure that they are not bent
 The nominal 20 mm lap between plank and column must be filled
with a high strength (>C60/75) grout or mortar
 Loose rebar or carpet mesh associated with the slab can be
placed between the upward facing components
 Prior to placing the slab concrete, the location of the upward facing
bars should be checked. Ideally they should be held in location
using a precision template, see Appendix A for further details.
 At edges and corners there will be additional U-bars and L-bars to
fit in. These are passed to the sides and between the vertically
facing components.
21
Terminator Plates able to transfer the forces from the top steel that are generating the
Top reinforcing steel
moments.
3.5 Beams
Threaded Bars
screwed into Beams may be attached to columns in a number of ways.
coupler
Proprietary beam fixings may be cast in, so long as they do not interfere with
the internal steel. This will generally be the case since the columns use only
Adapter coupler U-bars round threaded bar
at top of column four corner bars. Explore should be consulted to establish the feasibility of
and under terminator
head. U-bar sized manufacture. Such columns will be treated as specials.
(diameter and lap) to take
top bar tension Figure 3.6 shows a typical cast-in plate detail. Note that additional vertical
steel or links may be required to distribute the beam forces into the column.
Figure 3.7 shows how T-beams (e.g. as used to support hollowcore flooring
panels) are connected.
3.6 Wall interfaces

The recommended method for connecting a wall to a column is to use a
proprietary starter bar or connection product cast-in to the side of the
Terminator column. Such columns are treated as specials. Explore should be consulted
to establish the feasibility of manufacture for a given column/starter system
combination.
The depth of cover available to embed a starter product is given in Table 3.1.
Punching
reinforcement
Plan View
Figure 3.5
Top of column detail
beneath the head. In practice this will often be difficult to achieve. In such
circumstances a U-bar should be taken round the main bar and under the
terminator head. The U bar should be of sufficient length and diameter to be
22
Shear studs anchoring back into Table 3.1
body of column. Stud length such Available space in cover for mounting proprietary cast-in products
Steel plate that 45˚ cone intercepts tied vertical
sitting within Offset of vertical Link diameter
bars. bar centreline
cover zone of Bar Diameter Cover
column from column
face
20 60 8 42
25 60 8 39
32 60 8 36
3.7 Attachments
Additional or enlarged links mat be It is feasible to cast-in items such as threaded inserts or channels. They
required local to cast-in plate should be located to avoid the main vertical steel and within the cover zone
given in Table 3.1.
Figure 3.6
Cast-in steel plate It should be noted that the accurate positioning of apparently low-cost cast-
in items can significantly slow down the manufacturing process. This can
result in disproportionate increases in column cost. Explore should be
contacted for more information as to the impact of a particular proposal.
Threaded bars
pass through holes
in precast beams Precast
beam
All voids filled with

shrinkage
compensated high
strength grout
Figure 3.7
Interface to precast T-beams (L-beams similar)
23
Precast Columns Scheme design
4 Scheme design
Charts have been prepared to enable the efficient selection of the most
suitable column for particular applied actions. These charts are based on the
work undertaken to produce the detailed column charts presented in
Appendix D. As they consider the concrete strength and reinforcement
arrangements, they should provide a more appropriate initial sizing than more
general column sizing methods.
Column capacity is an interaction between axial forces and bending moment,

with the maximum moment resistance achieved when there is approximately
40% axial load. The column selection charts are therefore presented with
coloured bands indicating where maximum moment capacity can be
achieved. The actions should be based on the approach in the structural
Eurocodes. Note that the charts are presented for the minimum standard bar
diameter prepared for a given column. Figure 4.1 explains how the charts
have been derived.
The LOR precast column selection charts in Figure 4.2 can be used to
estimate column size and cost at scheme design stage.
Figure 4.1
Derivation of the column selector charts
24
Precast Columns Scheme design
Figure 4.2
Column selector chart
20000
325
15000
165
225
Axial Load, NEd (kN)
110 125
10000
865
210
85 340
590 70 85
130 200 250 120
55
5000 410 85
125 110 155
25 175 105
65 245 60 90 250
20 125
195 100
60 65
35 80 115 325 20 15 45 75 40
160
225 15 35 165 130
210 15 110 125 15 90
50
65 125 130 10 15 15 25 30 30 30 60 55
70 85 85 85 35 60 65 100 105 120
0 35 60 20 25 25
C300
C350
C400
C450
C500
C600
S300
S350
S400
S450
S500
S600
S700
R800
R200‐400
R200‐600
R200‐800
R225‐450
R225‐675
R225‐900
R250‐500
R250‐750
R250‐1000
R300‐600
R300‐900
R300‐1200
R350‐700
R350‐1050
R350‐1400
R400‐800
R400‐1200
R400‐1600
25
Precast Columns Design charts
5.4 Example
5 Design charts
A 600 mm column is required to support an axial load, NEd, of 7000 kN, and
5.1 Introduction first order moments of 500 kNm and 425 kNm about the y- and z-axes
respectively. Figure 4.2 suggests that for a 600 mm square column the
The LOR precast column ULS capacity plots in Appendix D can be used to maximum moment is 410 kNm, however, as the chart has been prepared for
assist in the detailed ULS design of the columns. The plots are similar to the minimum bar size and the moment is not considerably greater than
those in BS 8110-3:1985 in that they show curves of axial load capacity 410 kNm the 600 mm may still be appropriate.
against bending moment about the column’s y-axis. However, they have
been customised to the individual columns in Explore’s precast column The floor-to-floor height is 4000 mm and the slab is 300 mm thick. The
range. Each page corresponds to one section size, with a separate ULS detailed design is then carried out using the appropriate chart from Appendix
capacity plot for each of the standard levels of reinforcement available. D. The chart for a 600 mm square column is shown on the following page
complete with the method of working for the loading given above.
5.2 Additional moment
Only the four corner reinforcement bars are considered to be effective in
calculating the column capacity curves, as the side bars terminate at the end
of the column and cannot be continuous through the slab. However, away
from the ends of the column the side bars will contribute to the moment
capacity of the column at mid-height up the storey. A conservative allowance
for the additional moment, Madd, is given for columns with additional side
bars. The basis for this additional moment is given in Appendix B.
5.3 Shear resistance

Generally, the shear resistance of a column is not specifically checked in the
design of concrete columns in a braced building. There may be occasions
when shear should be checked, for example a column with a large bending
moment and low axial load such as a top corner column. Where shear in the
column is significant, additional link reinforcement may be required and
reference should be made to section 6.2 of BS EN 1992-1-1.
26
Precast Columns Design charts
Step 1: Fire Resistance Step 2: Second order moments
12000 12000
R30
600 Sq
R60
10000 10000
R90

R120
8000 8000
34
68
6000 6000 136
204
272
4000 4000 340
2000 2000
Step 3: Connection factor
0 0 Position Internal Edge Corner Madd
0 500 1000 1500 2 4 6 8 ϕNEd 1.1 1.2 1.4 (kNm)
Maximum moment (kNm) Effective Length, L0 (m) ϕMEd 1.0 1.0 1.3 41.9
Step 1
Step 4: Reinforcment selection Fire resistance. > 120 mins → OK
12000 12000
Step 2
25ϕ M
MEd,z MEd,y
Ed,z//MEd,y== 32ϕ M MEd,y
Ed,z//M
MEd,z Ed,y==
* * For effective length, L0 = 4.0 – 0.3 = 3.7 m
10000 0 10000 0 From graph, second order moment = 80 kNm
0.25 0.25
0.5 0.5 > 10% of 500 kNm → MED,y = 580 kNm
8000 0.75 8000 0.75 Step 3
1 1
NEd ΦNEd = 7000 x 1.1 = 7700 kN
6000 6000
MEd,y ΦMEd = 580 x 1.0 = 580 kNm
Step 4
4000 4000
MEd,z /MEd,y = 425/580=0.73
From 25ϕ graph MEd,y = 540 kNm
2000 2000
Insufficient, use Madd = 41.9 kNm
0 0 MRd,y = 540 + 41.9 = 581.9 > 580 kNm → OK

0 200 400 600 800 1000 1200 1400 1600 0 200 400 600 800 1000 1200 1400 1600 Specify S600-25-3690-300
Moment, MEd,y (kNm) Moment, MEd,y (kNm) (Alternatively use 32 ϕ bars)
27
Precast Columns How to specify columns
Ultimate limit state actions
6 How to specify columns Axial compression kN
My at top of column kNm It is assumed that forces supplied

The Engineer will always maintain responsibility for ensuring that the
take account of relative column/slab
performance requirements of a column have been correctly specified. Either Mz at top of column kNm stiffness. For double curvature give
the Engineer or Explore (as agreed in the contract) will determine column My,top the same sign as My,bottom.
sizes and steel areas in accordance with the standards in this document. My at bottom of column kNm Similarly for Mz.
Mz at bottom of column kNm
6.1 Column Performance Specification
Transitions
Where Explore are determining sizes and areas, the Engineer would be To enable transitions to be readily
Ref. No. of column above
expected to supply Explore with a column schedule containing the identified
information in Table 6.1. Ref. No. of column below
Table 6.1 Finishes

Information required by Explore from the designer How many long faces are 0,1 for circular
Requirement Units Comments visible? 0,1 or 2 for rectangular/square
Identification How many short faces are 1 for circular
Column schedule Must clearly identify to a unique column visible? 0,1 or 2 for rectangular/square
- Specify in accordance with NBS. If
reference No. type Required finish on visible
not, specified default is ‘as cast’ all
No. of columns - faces?
visible faces.
Geometry Fire requirements
Shape of column - Square, rectangular or circular. Default will be based on height of top
Cross-sectional Fire endurance requirement mins habitable floor above ground level in
mm b x h for rectangular; D for circular accordance with UK Building Regs.
dimensions
Either 1 face only or more than 1
Slab to soffit height mm No. of fire exposed faces - face. Default will be taken as fire on
Used to determine the length bars need to all sides.
Over column slab/drop
mm project out the top of columns. Slab to Reduction factor to apply to NEd
beam thickness
soffit + over column = slab to slab (design axial load) to give axial load
Fire reduction factor -
Slab at time of fire. Default will be taken
Required to determine appropriate slab as 0.7
Internal, edge or corner -
factor. Robustness
Slab concrete strength, Required to determine reductions to be To check minimum steel area
MPa Vertical tying force kN
fck applied where slab fck < 0.7 column fck through slab
28
Precast Columns How to specify columns
6.2 Columns reference system R250-850-20-2580-320X 250mm deep by 850mm wide rectangular
column with B20 main reinforcement bars, cast
Where the designer prescribes the column sizes and carries out the design, height 2580mm, slab 320mm. This is non-
standard aspect ratio and is therefore a standard
the following designations should be used for specifying precast columns.
+ and the designation is suffixed with an X.
Where a column incorporates a feature that makes it standard+, the
designation should be suffixed with an X. Where a column incorporates a
feature that makes it a special, the designation should be suffixed with XX.

Where a column has an X suffix additional information should be provided as
an attachment to the schedule.
Table 2.3
Column designations for specifying columns 25mm deep recess in
Shape 1st 2nd 3rd 4th 5th Floor level – taken slab (locally increasing
Shape as top of slab to 40mm depth)
Code Number Number Number Number Number
Cast
Main bar Slab
Circular C Diameter height of N/A
diameter thickness Slab soffit
column
Cast
slab
Side of Main bar Slab
10
Square S height of N/A
square diameter thickness
column
Maximum
Least plan Cast
Floor to floor height

plan Main bar Slab

Rectangular R dimension height of
dimension diameter thickness
(depth) column
(width)
Floor to slab
Note: All dimensions should be given in millimetres
6.2.1. Examples:
C400-25-3580-320 400mm diameter circular column with B25 main

reinforcement, cast height is 3580mm with
threaded bars dimension to pass through a
320mm slab.
25
20
S500-32-2760-280 500mm square column with B32 main
reinforcement bars, cast height 2760mm, slab
280mm Figure 6.1
Dimensions for specifying precast columns
29
Precast Columns Design co-ordination
The table below shows the major activities required in the delivery of
7 Design co-ordination columns. Activities are listed in approximate chronological order, noting that
overall programme and lead times may affect the sequence of activities.
Successful contract delivery requires understanding and agreement as to
how design responsibilities are apportioned between the delivery team. The
form of contract can influence this apportionment, but for the majority of
columns supplied by Explore the division of responsibility described herein
will apply. Note that for each new contract awarded, this section should be
reviewed and the applicability or otherwise of these responsibilities confirmed
as they may conflict with other more broadly based design responsibility
matrices in use on a project.
The design responsibilities matrix given in this section is on the basis that
Explore are responsible for determining the reinforcement levels etc. required
in a column. It assumes that a column performance specification (see
section 6.1) is provided by the Engineer.
The number of parties involved in design, detailing and manufacture can be
many. For the purpose of this guide, 4 main groups are considered:
 Architect. Overall responsibility for the coordination and approval
of the geometry. It is assumed the Architect looks after the Client
interests.
 Engineer. Responsible for the overall stability of any structures,
including ensuring that any pre-cast columns do not impact on
overall structural performance. This is achieved by specifying
column performance criteria.
 Explore Manufacturing. Responsible for ensuring that columns
delivered to a project meet the performance criteria set by the
Engineer. Responsible for working to the delivery schedule set by
the Contractor.
 Contractor. Responsible for installing columns in accordance with
the requirements specified by Explore such that the performance
criteria are not compromised. Also responsible for any special
access provisions or temporary works required for safe column
installation.
30
Precast Columns Design co-ordination
Table 7.1:
Design responsibility matrix
Activity Explore
Contractor
Architect
Engineer
Detailing
Planning
QA/QC
Design
Geometry, including basic column dimensions L s s
Defining finishes L s s
Production of column performance specification L s
Design package for Building Control (to be sent to
s L
Engineer)
Check design package to confirm requirements have
L s
been correctly interpreted
Production of manufacturing models/drawings s L
Checking of manufacturing models/drawings s L s
Sign-off of column package for manufacture L s
Identification of non-standard moulds, cast-ins etc.
s s L s
required to produce columns
Production of designers risk assessment/CDM
s L s
package for factory and site
Defining schedule for column delivery to site s L
Determining lead times and hence manufacturing
s s s L s
program
Recording and obtaining approval for non-
s s L
conformances
Calling-off columns for delivery to site s L
Installing columns and checking geometry etc. s L
Production of completion package including as-builts s s s s L
Sign-off that column supply is complete L
L = lead responsibility
s = supporting responsibility
31
Precast Columns References
References
1. British Standards Institution. BS EN 1992–1–1, Eurocode 2 – part 1–1:
Design of concrete structures – General rules and rules for buildings. BSI,
2004.
2. British Standards Institution. BS EN 1992–1–2, Eurocode 2 – part 1–2:

Design of concrete structures – Structural fire design. BSI, 2004.
3. British Standards Institution, UK National Annex to Eurocode 2 – part 1–1:

Design of concrete structures – General rules and rules for buildings. BSI,
2005.
4. British Standards Institution. UK National Annex to Eurocode 2 – part 1–2:

Design of concrete structures – Structural fire design. BSI, 2004.
5. British Standards Institution. BS 8110-1. Structural use of concrete – Part 1:

Code of practice for design and construction. BSI, 1997.
6. Institution of Structural Engineers. Manual for the design of concrete

structures to Eurocode 2, IStructE, 2006.
7. Brooker, O et al. How to design concrete structures using Eurocode 2, The

Concrete Centre 2006
8. British Standards Institution. BS 8500-1, Concrete – Complementary British

Standard to BS EN 206-1 – Part 1: Method of specifying and guidance for
the specifier. BSI, 2006
9. COMMUNITIES AND LOCAL GOVERNEMENT. Building regulations (England

and Wales) Approved Document A (2004). CLG, 2006
10. SCOTTISH BUILDING STANDARDS AGENCY. The Scottish building

standards technical handbook – Non-domestic. SBSA, 2007
32
Precast Columns Appendix A – Assembly
It should be noted that diametric tolerances are controlled to sub-millimetre

Appendix A – Assembly accuracy. The centre of the shoe hole should be within approximately 0.5 mm
absolute of its intended position.
Introduction
Once the cage assembly is complete, rubber formers are placed into the pockets
The columns have been developed so they can be manufactured and installed in to prevent them filling with concrete during production.
a particular way. This appendix describes the intent. Other methods may be
used, but they should take into account the tolerance controls described here. Placing in mould
Factory production using templates enables manufacture to millimetric accuracy. Figure A.4 shows the completed column cage assembly being lowered into a
This results in high quality column products. These can be assembled rapidly and mould. The key features required of the mould are shown. Release agent should
generally prop-free on site, but only if length and squareness is accurately set. be sprayed onto mould surfaces and the inside face of the end plates.
The system has been designed to make it straight forward to achieve the required
accuracy. Since careless manufacture will increase site installation time, it is Figure A.5 shows the column in the mould. The base of the column will end up
important that the tolerance requirements are understood. sitting on nuts which can be site adjusted to an vertical accuracy of 1-in-1000
using a good quality spirit level. If the bottom template of the column is to a
Manufacture similar or better accuracy, then the column should be able to be placed at site
with little or no further adjustment required. It is therefore important that this base
Vertical bar assembly plate is set square. Magnets attached to the side and base of the steel shutters
may be used to push/pull the plate to square if required. Note that it is not
The vertical bar elements and assembly sequence are shown in Figure A.1. The necessary for the top template to be square – tolerances will be taken up by
accuracy shown should be achievable with all straight bars. Where a bar has an subsequent grouting.
offset, the bar must be locked at a specific offset orientation. In this case the
tolerance on the length can be  (0.5 mm + thread pitch/2). Concrete filling and demoulding
Cage assembly The end plates are in general totally self-reacting against each other via the
longitudinal bars. No further supports are required for concrete filling. As a
Figure A.2 shows the components used to assemble a complete column cage. precaution against unbalanced forces distorting the cage, the concrete height
For a given standard column cross section the templates at top and bottom are should be brought up uniformly at the two ends.
the same regardless of bar sizes, however, the correct sized top and bottom
centralising spigots corresponding to the respective bar sizes must be used. Concrete should be allowed to cure until a cube strength of 15 MPa has been
achieved. At this stage the column may be demoulded. The column is lifted out
The components are initially assembled loose as shown in Figures A.3. The end of the mould using the cast-in wavy tail lifters. The column should be placed on
templates are then offered up and secured loosely at the bottom. The upper bar timbers. Whilst the concrete is young, care is required to ensure edges etc. are
assemblies are lifted and fastened each end at the top. All nuts/bolts are then not broken. This applies particularly when removing the rubber pocket formers.
tightened. Note that it should not be necessary to wire the cage to the bars.
33
Rolltec to Griptec adaptor – Assembly sequence:

screwed onto Rolltec thread. 1. Fix adaptor to top of bar
See Appendix C for further 2. Screw locknut to top of lower thread
details 3. Screw lower thread right into shoe
4. Place assembly between stops
5. Unscrew bar until touching each end
Standard reinforcing bar – 6. Screw in one turn to free assembly
diameter to suit vertical steel 7. Remove from between stops
requirements. Length of bar 8. Unscrew one turn to restore length
as per Appendix C. Length Rotate bar into thread at top of
9. Screw locknut down to lock thread
tolerance  3mm - saw cut to shoe. Use Stilson wrench or
length. similar to rotate bar if required.
DIFFERENTIAL LENGTH ON FINISHED VERTICAL

BAR ASSEMBLIES =  0.5mm
Rolltec lock nut screwed onto

Rolltec thread as far up as will
go. See Appendix C for
threaded length.
Accurately set stops on work

Newby cast iron column shoe bench. Use of same stops
with Rolltec female thread in top sets bars to identical lengths.
face. Bar screws into columns
shoe. See Appendix C for Wooden block to
specification details. hold bar level
Figure A.1
Vertical bar assembly
34
All bar assemblies

are initially inserted
Bent mesh cage
through and sat on
the bottom of the
mesh cage Steel templates laser profiled
M16 x 30 mm to give dimensional tolerances
long setscrew of 0.3 mm. Spigot holes to
be 16.2  0.2 mm. Bottom
template identical to top
template. Central hole for lifter
Shoe adaptor spigot attachment.
used to hold and
centralise the shoe to the
16 mm diameter
template location hole. M16 nuts to secure
An M16 x 30 mm long template to bar top
setscrew is used to assembly
secure the assembly.
Timber packer to hold cage

off ground so that end
templates can be fitted
M16 x 30 mm
long setscrew Threaded adaptor spigot
Shoe adaptor
reducing the relevant
spigot
Steel template Rolltec/Griptec thread to
an M16 male thread
Figure A.2
Assembly of link cage & vertical bars onto end plates
35
Cage Assembly Stage 1

Templates offered up to lower bars. M16 screws/nuts secured
loosely – plates at an angle. Mould sides have a fixed
Column cage assembly height, but can slide in-
complete with end plates out to vary the column
and pocket formers lifted as width. Top of mould side
a single item into the mould has inverted chamfer.
Cage Assembly Stage 2

Lift upper bars to top. Fasten M16 screw/nut. Tighten all
screws/nuts to hold assembly together. Since bars are matched
lengths, cage will be substantially square. Remove timber
supports. Fix in wavy tail lifters.
Chamfers on base insert and Insert into base of column

top of mould sides form mould sets both plan
vertical chamfer on column. dimensions of the column.
Figure A.4
Figure A.3 Insertion of completed column cage into mould
Assembly of link cage & vertical bars onto end plates
36
Installation
The bottom template
should be set square to the Introduction
mould sides and base. An
accuracy of 1 in 1000 will Installation of the next column up should be considered to start as soon as the
ensure the column will sit
lower column installation is complete. There are two key objectives to be
upright without requiring
adjustment at site achieved:
1. The upper column should locate easily over the threaded bars projecting out
of the top of the lower column;
2. The top of the upper column should be at the correct level and plan position.
During column development a number of different installation strategies have been

proposed. That presented here is considered the most straight-forward, but relies
on the individual steps being correctly executed.
Managing tolerances
Threaded bar locations
There are two requirements to ensure that the threaded bar locations are correct:
1. Bars must be vertical to within 1 in 100. In general the required verticality will
be achieved simply by screwing the threaded bar into the coupler at the top
of the lower column. However verticality should be checked, especially
where reinforcement in the slab may be pushing against the threaded bars.
Mould length is circa 12m. Depending on column height, a
number of columns can be cast in a single mould. 2. Bars must be in plan position relative to each other to an accuracy of
0.3 mm. This is achieved by using a 3mm thick steel laser profiled plate.
Such a plate may be re-used. For a 500mm square column such a plate
Figure A.5 should be circa £10. Contact Explore for further details.
Squaring of bottom plate to column axis
Figure A.6 summarises the tolerance requirements.
37
Laser profiled steel template Top plan position is more difficult to control. Even if a lower column is set-up so
Tolerance
holding threaded bars that the column top is initially perfectly in position, small movement due concrete
0.3mm
accurately in position curing (shrinkage), deflection under load (e.g., slab props being removed causing
relative to each other during bending) and deflection/settlement as a building is loaded can result in a drift in
slab casting. position. At each level this should not be more than a few millimetres. This
enables full recovery of top plan position for the column being placed whilst
Slab – contains slab remaining well within the allowable verticality tolerances. However it is essential
steel and punching that out of tolerances are chased out at each level. Poor tolerances should not be
reinforcement. Cast allowed to accumulate over several levels.
around threaded bars
Setting threaded bars
Threaded bars need to be The setting of threaded bars is illustrated in Fig A.7. The following should be
vertical to better than 1 in considered:
100 if they are to pass
through column shoes.  Couplers and threads will be protected by plastic caps, tape etc. Areas
being worked on should be cleaned of loose material prior to removing
thread protection. Thread protection should only be removed immediately
prior to the thread being required.
 Threaded bars should be screwed in as tight as possible. The length of
Figure A.6
Setting of threaded bars using template engagement should be monitored to ensure that the thread is fully engaged.
Thread engagement lengths are given in Appendix C.
Top of column position  Slab steel at column locations is often congested. Care should be taken to
ensure that a vertical path for the threaded bar through the slab steel is
When an individual column is installed, the location of its bottom end will be maintained. The slab steel should not be allowed to push against the
governed by the threaded bars projected out of the slab. These allow for limited threaded bars.
vertical movement, but only about 1.5mm lateral movement. Corrections to  Where carpet reinforcement is used in the slab, the threaded bars should be
column position are therefore made by ensuring that the TOP of each column is at screwed in after the reinforcement has been placed. Carpet reinforcement
the correct level and plan position. may need to be moved to provide the required access.
 On larger templates the provision of additional small holes in the template will
Correct top of column level is easily achieved due to the length accuracy of the
assist flow of concrete under the template.
precast columns. An adjustment of 10 mm is allowed for in the lengths of the
 The concrete surface under template forms part of the column. Any Laitance
threaded bars at the base, but this should rarely be required.
or poor material should be removed. This will subsequently be replaced by
high strength grout.
38
Slab recess former slotted

For Clarity slab steel is not shown
Top of lower column. over threaded bars. Steel
Lattice plank slab (if used) template on top. Assembly
boxes around column top secured with nuts.
Threaded bars screwed into Projecting threads should
upward facing couplers on be wrapped to protect from
lower column. Thixotropic concrete splash.
grout placed into box to
seal up nominal 10mm gap.
Grout also helps in securing
the lattice planks to the
column head.
Slab is cast. When

concrete solid, steel
template and slab recess
former are removed. Note
that concrete may not be
perfect under the former.
Grout should be Any loose material should
finished smooth with be removed, however, the
the edge of the subsequent grouting
column. Grout needs operation will fill any
to be free of voids. remaining voids.
Figure A.7
Procedure for forming slab recess
39
Setting lower nuts (support nuts)  Assuming the upper column will have a perfectly square base; determine the
correction in level required on the support nuts to correct the measured
Accurate pre-setting of the column support nuts can result in no or only negligible deviation. This will be a function of bar spacing, column height and plan
adjustment of the nuts being required after column installation, noting that it is correction required, see Figure A.9.
much easier to turn an unloaded nut. Figure A.8 shows the set-up proposed for  The correction will often only be a fraction of a millimetre. If the nuts are
setting the nuts. The recommended procedure is described below. accurately levelled relative to each other, then the adjustment can be made
by an appropriate rotation of the nut. For example, an M33 thread has a
 Provide a vertical datum point local to the column (e.g., a point on the slab pitch of 3.5mm. To adjust by 0.5mm requires a rotation of (0.5/3.5) x 360 =
immediately adjacent to the recess). The nuts can be set to the correct 51˚.
general level using a spirit level and tape measure.
 Survey the position of the threaded starter bars and determine the deviation
Bar
from true position in the two orthogonal grid directions.
spacing Plan
correction
Good quality engineers level of 0.5mm in a metre (1 in 2000mm) required
accuracy. Use level to set nuts to same level or, if survey dictates,
differential heights required to correct column top position.
Support nut correction =
Plan correction x Bar spacing
Column Height
Column Height
Identical length extension

tubes sitting on top of nuts
such that a level longer than
the recess may be used.
Support nuts for upper Support nut

column. Adjust so that top correction
of column is at correct level
Figure A.9
Support nut adjustment to correct for plan deviations
Figure A.8
Pre-setting of column support nuts
40
Installing
Column installation is illustrated in Figure A.10. The following should be

considered:
 If lifting the column to vertical by rotating about its base, ensure that there is
a soft board under the bottom corner edge.
 Upper nut tightness is not specified to a torque, but should be as tight as it is
possible to get. This is required to preload the connection so that the shoe
connection system is as rigid as possible.
 The column top must be confirmed as being in the correct position before
grouting occurs. Minor adjustment can be made if required.
 The strength of the grout should be confirmed using 40 mm grout cubes.
The grout forms part of the load bearing system of the column and should be
treated in a similar manner to structural concrete from a quality control
perspective – it is not just a filler material.
 Most columns are stable and do not require propping. Where propping is
required, this will be indicated (default: if a propping socket is provided, the
column requires propping)
 Columns will generally be able to take the temporary loads of an upper floor
without grouting, however it is recommended that grout be installed prior to
upper slab installation.
41
Lifter in wavy tail Column shoes are slotted over threaded bars
socket used to lift and a nut immediately screwed onto the
column to required threaded bar in the shoe pocket. At this stage Prior to grouting the top of
position. the crane may be disconnected the column is checked for
correct positioning. If
required adjustment can
be made using the
support nut. The upper
nut is then tightened as
tight as possible in order
to pre-load the threads.
The shoe pockets must be

grouted for compression strength
The recess is grouted using a 70 and fire protection. Corner
MPa high flow shrinkage moulds are used to contain the
compensated grout. Excess grout. The same grout as used
grout is removed. Note that the under the base may be used to
bottom of the column should be fill the shoe pockets.
5 mm into the recess.
Figure A.9
Column installation sequence
42
Precast Columns Appendix B – Design approach
Durability
Appendix B – Design approach
The durability of the precast concrete columns has been assessed using BS
This appendix describes the design assumptions that have been used in
8500-18. The following assumptions have been used:
preparation of the column charts in Appendix D, and the implications in their use.
It is intended that the column charts are used for the final design of the columns.  The axis distance from the column surface to the centre of the
reinforcement is 60 mm.
Assumptions  The allowance in design for deviation, Δc,dev = 5 mm
 The concrete Class is C50/60, with a cement content of 450 kg/m3
It has been assumed that the Explore precast columns will be used for internal,
and a minimum water:cement ratio of 0.39.
non-seismic situations, where the building does not rely on the column to slab
 The intended working life is 50 years.
connection for lateral stability.
 This gives a value for cmin,dur of 31 mm (60 – 32/2 – 8 – 5)
Cover The minimum cover for an internal environment (XC1) from Table A.4 of BS 8500
is 15 mm. The cover provided is also suitable for an XC3/4 environment (external
The minimum cover to the reinforcement is dependent on:
where no chlorides present).
 Bond
 Durability Accidental actions and provision of robustness
 Fire resistance
Accidental actions are covered by BS EN 1991-1-7; the accident actions may be
Each of these requirements has been considered in the design of the precast identified or unidentified. If accidental actions are identified (eg drifted snow), then
concrete columns. Bond and durability are covered immediately below and fire the structure should specifically be designed to resist them. Otherwise, the
resistance is covered in detail later in this appendix. structure should be designed for the consequences of localised failure from an
unspecified cause, which is addressed in Annex A of EN 1991-1-79. In England
Bond and Wales Approved Document A10 (AD-A) provides very similar guidance. Since
Annex A is “informative” the provisions of AD-A should be adopted. In Scotland
The minimum cover for bond requirements, cmin,b, has been taken as 32 mm. This the same guidance can be found in the Technical Handbook11.
is appropriate for 32 mm diameter bars, for smaller bar sizes this is conservative.
AD-A requires buildings to be divided into 4 classes depending on the
An allowance in design for deviations (tolerances), Δcdev, has been taken as 5 mm consequences arising from the unforeseen action. The precast concrete columns
since bars are accurately located and a quality assurance scheme is in place. and their connection details all assume a Class 2B structure, which should cover
the vast majority of building types. Where the building can be considered a Class
3 structure a risk assessment should be carried out by the design engineer, and if
necessary Explore should be informed if the tie forces should be increased.
43
The columns should be designed so there is a vertical tie from the lowest to the The column charts are derived based on the requirements of Cl.6.1 of EN 1992-1-
highest level capable of carrying the load in an accidental load situation acting on 1. The following limitations and assumptions are used:
the floor above the column accidentally lost (cl. 9.10.2.5(2) of EN 1992). The
accidental load is assessed using the Exp (6.11) of EN 1990, ie the unfactored  The concrete strength class is C50/60
permanent actions together with the variable actions reduced by the Ψ2 factor  αcc = 0.85
which depends on the type of imposed load (see Table B.1).  γc = 1.5
 design concrete compressive strength, fcd = 28.3 MPa
The maximum vertical tie force for the precast concrete columns is given in  The concrete is assumed to have no tensile strength.
Table B.1.  The concrete constitutive equations are:
Table B.1 σc = fcd [ 1 – (1 – εc / εc2)2 ] for 0 ≤ εc ≤ εc2

Ψ2 reduction factors for various imposed loads
σc = fcd for εc2 ≤ εc ≤ εcu2
Action category Ψ2 factor with εc2 = 0.0020 and εcu2 = 0.0031
Domestic, residential areas 0.3
Office areas 0.3  Class B500B or B500C reinforcement
Congregation areas 0.6  γs = 1.15
Shopping areas 0.6
 Design yield strength, fyd = 435 MPa
Storage areas 0.8
Traffic area, vehicle weight < 30 kN 0.6  The reinforcing steel constitutive equations are:
Table B.2 σs = Es x εs for 0 ≤ εs ≤ fyd / Es

Maximum tie force σs = fyd for εs ≥ fyd / Es
Bar diameter Maximum tie force (kN) with Es = 200 GPa
4 x 20 mm dia. bar 628
4 x 25 mm dia. bar 982 Only the four corner reinforcement bars are considered to be effective in
4 x 32 mm dia. bar 1608 calculating the column capacity curves, as the side bars terminate at the end of
the column and cannot be continuous through the slab. However, away from the
ends of the column the side bars will contribute to the moment capacity of the
Column charts column at mid-height up the storey. A conservative allowance for the additional
moment is calculated:
The Explore precast column ultimate limit state (ULS) column charts in Appendix D
can be used to assist in the detailed ULS design of the columns. These plots have Madd = As,add fyd t
been customised to the individual columns in Explore’s precast column range.
Each page corresponds to one section size, with a separate ULS capacity plot for Where As,add is the area of additional reinforcement on one side of the column and
each of the reinforcement bar diameters available. t is the distance between the reinforcement axes in the opposite faces:
t = h – 2a
44
A minimum reinforcement requirement, based on the axial load applied to the The design should also ensure that the design moment exceeds a minimum
column is given in Exp (9.12N) of EN 1992-1-1. Accordingly, some of the charts moment, Mmin:
identify the limits to axial load capacity based on the expression rearranged in
terms of axial load: Mmin = e0 NEd
Where
NEd < As fyd / 0.1 e0 = Max{h/400, 20}
h = depth of the section
For columns affected by this limit it may be possible to satisfy the As,min
requirement by taking account of extra steel either within the mesh cage or placed Slenderness
loose – see section 2.5.4 and 2.5.5.
‘Second order effects (see EN 19909 Section 1) shall be taken into account where
Biaxial bending they are likely to affect the overall stability of a structure significantly and for the
attainment of the ultimate limit state at critical sections’ (§5.1.4(1)P of EN 1992-1-
The biaxial bending in a column can be considered by applying Exp (5.39) of 1). Plots of second order moments are provided alongside the ULS capacity plots
Cl.5.8.9(4) of EN 1992-1-1. The ULS capacity plots allow for this by providing five in Appendix E to assist designers calculate the total moment in the column.
curves, each corresponding to a different level of bending about the column’s z-
axis. The levels of bending about the z-axis are expressed as proportions of the For the scheme design column selector charts, the plots provided are
bending about the y-axis. To make use of the plots, the designer should calculate conservatively the smallest reinforcement bar size level for each column section
the proportion, MEdz / MEdy size and are for the column bent about its weaker axis. The second order moment
for the weaker axis may also be used for the stronger axis. Whilst this will
Geometric Imperfections overestimate the second order moment for the strong axis, it is anticipated that
this will be insignificant for broad, thin rectangular section sizes used.
‘The unfavourable effects of possible deviations in the geometry of the structure
and the position of loads shall be taken into account in the analysis of members The graphs for second order moments are derived using Cl.5.8.8 ‘Method based
and structures’ (Cl.5.2 (1)P of EN 1992-1-1). The designer should consider these on nominal curvature’ of EN 1992-1-1. The following limitations and assumptions
effects in determining the first order moments for the column. If the effects of are used to prepare contours of M2 for varying l0 and NEd.
geometric imperfection have not been considered in a global analysis then an
additional moment, MGI should be calculated:  Concrete strength, fck ≥ 50 MPa
 Cement class is no worse than N
MGI = l0 NEd / 400  Significant loads are applied no earlier than 28 days after casting
 The columns will be in ‘inside conditions’ (relative humidity < 50%).
According to Cl.5.8.9 (2) of EN 1992-1-1, the additional moments due to
 φ(∞,t0) = 1.7 can be assumed
geometric imperfections ‘need to be taken into account only in the direction where
 The ratio of the first order bending moments of the serviceability
they will have the most unfavourable effect’; there is no need to consider them
limit state (SLS) quasi-permanent load combination to the ULS
about both axes.
45
design load combination is assumed to be limited to 1.35; M0Eqp / Where columns are subjected to high bending moments and low axial loads, the
M0Ed = 1.35 column and slab will fail due to yielding of the reinforcement. The strain in the
 The effective creep ratio of: φef = 1.26 can therefore be used lower strength concrete of the slab is insufficient to cause crushing and the full
 Constant cross-section is assumed, so the curvature distribution capacity of the column can be mobilised.
factor, c = 10
The situations in which the full capacity of the column cannot be mobilised are
If the second order moment, M2 from the chart is less than 10% of the design where the axial compressive stress is high enough to cause failure due to crushing
moment, M0Ed then the second order moments can be ignored (Cl.5.8.2 (6) of EN in the lower strength concrete. The axial load at which this change occurs,
1992-1-1.). assuming plane-sections remain plane is:
NEd = b d fcd,slab (εcu3,slab - εc3/2) / (εcu3,slab + fyd/Es) – As fyd

Effective Length
Above this axial load, where crushing of the concrete in the slab is critical, the load
In order to use the second order moment plots and calculate the additional
from the column will be treated as though it is a partially loaded area as defined in
moments due to geometric imperfections, the designer must first assess the
EN 1992-1-1:2004 Cl.6.7. The load is assumed to spread at a gradient of 2:1
effective length of the column.
through the slab.
The effective length of a column depends on the relative stiffness of the column
The capacity of the slab at mid-depth was calculated using the same plane-
and the members that restrain it in bending. Table 3.19 of BS8110-1 gives
sections-remain-plane analysis as used to calculate the column capacity.
approximate effective length to clear height ratios for a variety of restraint
However, the dimensions of this alternative column section were increased to
conditions. However, more detailed calculations can be made using BS EN 1992-
account for load spreading. A minimum slab depth of 250mm was assumed, so
1-1:2004 Cl.5.8.3.2(3). For columns braced top and bottom it is generally
that the dimensions of the section are:
conservative to use the floor to slab height as the effective length.
b’ = (b + 125mm) h’ = (h + 125mm)
Column/Slab Connection
This will be limited by the perimeter of the slab so that the equivalent section for
LOR precast columns are produced using Class C50/60 concrete, and the an edge column is:
capacity plots are based on the assumption that this full strength is available.
However, the columns typically bear onto structure cast from lower strength b’ = (b + 125mm) h’ = h
concrete. In certain cases this lower strength concrete could fail before the full
and for a corner column:
strength of the column is mobilised.
b’ = (b + 62.5mm) h’ = h
The behaviour of the connection between a floor slab and a supporting precast
column was investigated using 3D, non-linear finite element analysis. The capacities of these alternative sections were compared to the capacity of the
column and scaling factors produced so that any factored loads that fall within the
46
column capacity curves will also fall within the slab capacity curve when not minimum spacing of 60 mm. Only mesh steel within 150 mm of
factored (see Figure B.1Error! Reference source not found.). the axis of the corner bar shall be considered effective.
These scaling factors should be applied to the design moments Where the nominal bar area is not adequate for tying forces and bending, then
additional bars and shoes will be introduced mid-side. Such columns are specials
7 full column capacity since they will require a non-standard cage arrangement and end templates.
Example load case,
6 after factoring. column‐slab connection Efficiency is achieved by using the smallest sized column connections feasible.
Axial Load, NEd (MN)
capacity Note that the minimum area of steel passing through the slab can be less than the
5 column capacity ‐
minimum area of steel in the column.
factored down
4
Fire resistance
3 Example load
case, before
2 Endurance times
1 The tables in Annex B of BS EN 1992-1-2:2004 provide maximum axial load

capacities for varying endurance period, slenderness, reinforcement ratio, column
0
minimum dimension, axis distance (cover) and axial load to moment ratio. The
0 0.1 0.2 0.3 0.4
code notes that ‘linear interpolation between the different column tables… is
Bending Capacity, MEdy (MNm)
possible’ without explaining how the user can linearly interpolate on a non-planar
Figure B.1 surface. We have assumed that curve-fitting, rather than linear interpolation, is
Example of scaling factor for column to slab connection acceptable.
Minimum steel area Note 2 of Cl.5.3.3 (3) of BS EN 1992-1-2:2004 allows that 10 in fire may be taken
as 0.5l for intermediate floors, for endurance periods of >30 minutes. The majority
BS EN 1992-1-1 cl 9.5.2(2) has two requirements for minimum steel area. These of columns in fire are therefore likely to have a slenderness λ ≤ 30.
criteria are normally met by the 4 main corner bars provided within a column. On
larger columns four 32 mm diameter bars may not give enough area. Where the The data from Annex B were filtered for:
nominal bar area is adequate for tying forces and bending, the additional vertical
 λ = 30
steel required to satisfy this clause will be provided by one or both of the following:
 Reinforcement ratios of 0.1 and 0.5 (the typical range for the LOR
 Additional loose bars running vertically from bottom to top of columns).
column, positioned within 150mm of the axis of the corner bar;  Axis distances of 50-60mm (to give sufficient data points for the
 A concentration of vertical steel in the bent mesh cage, noting that regression).
the vertical cage bars have a maximum diameter of 12 mm and a
47
A relationship between axial load capacity, endurance period and reinforcement ( x / a )n + ( y / b )n = 1

ratio was found for each of the three levels of moment to axial load ratio using a
genetic algorithm. The relationship was then corrected so that it fitted below the Values of n, a and b were found at 30, 60, 90 and 120 minutes for each section
data points from Annex C, to give conservative results. For each column these so that the isotherms corresponded to those given in BS EN 1992-1-2:2004
three relationships were used to define three points for each of the fire endurance Annex A. The area of each superellipse was found using the equation:
levels.
Ac,fire = a b Γ(1+1/n)2 / Γ(1+2/n)
Annex C doesn’t give capacities for low axial loads. In order to complete this
Where Γ(x) is the gamma function.
analysis, the moment at zero axial load was calculated using ‘500°C isotherm
method’ in Annex B (see §4.2). It was assumed that linear interpolation was BS EN 1992-1-2:2004 Cl.B.1.2 1(b) allows the superelliptical section to be
possible between the four points for each endurance level to produce the capacity approximated by a rectangle of dimensions bfi by hfi. Figure B.1 appears to show
plots provided. that:
Bending capacity at low axial loads hfi for the rectangle = hfi for the superellipse
The bending capacity at zero axial load is derived using the ‘500°C isotherm It is assumed that bfi is chosen to give an equivalent area:
method’ in Annex B of BS EN 1992-1-2:2004. The following limitations and
assumptions are used: bfi = Ac,fire / hfi
Limitation or assumption Reference For the square sections the equivalent section was assumed to be square,
The column is subject to a standard fire BS EN 1992-1-2:2004 Cl. so that:
exposure and has a minimum width of cross- B.1.1
section of 200 mm. bfi = hfi ; bfi hfi = Ac,fire
The concrete strength class is C50/60 and the BS EN 1992-1-2:2004
actual characteristic strength of concrete is Cl.6.4.2.1 (3) note For the circular sections, the 500°C isotherm was taken from figures A.16 to A.19.
assumed not to be likely to be of a higher class These were taken to be 12 mm, 27 mm, 38 mm and 50 mm from the surface of
than that specified: The concrete is not treated the column at 30, 60, 90 and 120 minutes respectively.
as High Strength Concrete.
The axis distance from the column surface to Where the reinforcing bars are in the corners of the section, 60 mm from each
the centre of the reinforcement is at least; a = face, the temperature at the given time intervals and corresponding strengths
60 mm assumed are given in Table B.3 and for circular columns the values are given in
The reduction factor for forces and moments BS EN 1992-1-2:2004 Table B.4.
under fire conditions is assumed to be Ψfi = Cl.2.4.2
0.65. The factors for the steel strength were taken from figure 4.2 of EN 1992-1-2, with
The 500°C isotherm curves were assumed to be superelliptical in shape for the
Class N reinforcement, as required by the UK National Annex.
square and rectangular section, with the isotherm defined as:
48
The interaction plots were calculated for the reduced section size and steel Following this guidance, no further provision for explosive spalling needs to be
strengths using the same method described in Cl.2.2. taken where a column is to be used in a class X0 or XC1 environment.
Table B.3
Fire resistance properties for square and rectangular columns
Time Bar Strength Stiffness
Temperature
30 minutes 170°C 0.91fyk = 0.91Es = 1.87x105
455N/mm2 N/mm2
60 minutes 370°C 0.72fyk = 0.61Es = 1.25x105
360N/mm2 N/mm2
90 minutes 490°C 0.58fyk = 0.42Es = 0.86x105
290N/mm2 N/mm2
120 minutes 580°C 0.35fyk = 0.27Es = 0.55x105
175N/mm2 N/mm2
Table B.4
Fire resistance properties for circular columns
Time Bar Strength Stiffness
Temperature
30 minutes 110°C 0.98fyk = 0.99Es = 2.03x105
455N/mm2 N/mm2
60 minutes 250°C 0.80fyk = 0.79Es = 1.62x105
360N/mm2 N/mm2
90 minutes 380°C 0.71fyk = 0.59Es = 1.21x105
290N/mm2 N/mm2
120 minutes 480°C 0.59fyk = 0.43Es = 0.88x105
175N/mm2 N/mm2
Spalling
BS EN 1992-1-2:2004 Cl.4.5.1 (3) states that “It may be assumed that where
members are designed to exposure class X0 and XC1, the moisture content of
that member is less than k% by weight, where 2.5 ≤ k ≤ 3.0”. Paragraph (2) of the
same clause states, “Explosive spalling is unlikely to occur when the moisture
content of the concrete is less than k% by weight”. The UK National Annex
advises using the recommended value of 3% for k.
49
Precast Columns Appendix C – Technical details
Table C.1
Appendix C – Technical details Cast iron shoe assembly – component sizes
Bar dia. Dimension Dimension Coupler Thread
Assembly details (mm) A (mm) B (mm) length (mm) engagement
Threaded bar
20 175 115 55 27 M22x2.5

Upper column reinforcement
25 180 125 65 32 M27x3.0
Rolltec Locknut 32 190 140 85 42 M33x3.5
Re-bar = floor to floor – slab - A

Notes:
Cast Height = floor to floor – slab -5

1. Tolerances: Threads, threaded bars and nuts - threads 6g/6H; length (±1.0)
Hole (bottom of shoe) - (+0.2; -0.2)
2. Materials: Cast iron shoe - ADI800/8
Upper nut
Threaded bars and nuts - gr8.8
3. Finish: Black / natural
4. The M33 upper nut requires a special spanner to tighten due to reduced clearances.
Cast shoe This is available from Select.
5. The system is designed not to require washers
Lower nut
Table C.2
Cast shoe identifier
Newby Upper column Lower column
Code reinforcement reinforcement
Threaded bar
Thread bar = slab + B
(metric thread) Bar Thread Bar Hole

dia. identifier dia. identifier
1 20 M21 20 D25
2 20 M21 25 D30
3 20 M21 32 D36
4 25 M26 20 D25
5 25 M26 25 D30
Rolltec adaptor coupler 6 25 M26 32 D36
7 32 M33 20 D25
8 32 M33 25 D30
Lower column reinforcement 9 32 M33 32 D36
Note
1. Scrubbed out number on casting
indicates type.
Figure C.1 2. Shoe order code system: M21 – D25.
Cast iron shoe assembly details
50
Table C.2
Grout sleeve assembly details
Upper bar Threaded Dowel Length
Threaded Adaptor Bar Length (mm)
diameter (mm) (mm)
20 Sleeve Engagement + 47 Slab thickness + 12 - Lg + Aeng
Notes
1. Threaded dowel will have the same diameter as the upper bar. A Rolltec thread is
applied to one end of the bar. Length given includes threaded section.
2. Threaded dowel is screwed into downward facing coupler. Tighten to maximum
possible in order to pre-load threads
3. Grout sleeve type and length to be selected to suit the load requirements. Note that
Lg < (slab - 15)
4. The threaded adaptor bar connects between the top coupler/adaptor and the grout
sleeve. Depending on the grout sleeve used, the adaptor may need to be purpose
manufactured. In this case steel grade should be selected such that the adaptor
capacity based on the root area of the smallest thread is equivalent to the capacity of
the associated re-bar.
Figure C.2
Grout sleeve assembly details
51
Table C.3
Standard column details
b h Longitudinal Bars No. of B16 Cage Cage link Shoe Options4 Propping Column Lifter Lifter rating
Available1 midside shape spacing Sockets5 weight quantity6
B20 B25 B32 bars2 code3 Newby Grout (T/m) Length 4.5m < 8m <
sleeve < 4.5m Length < 8m Length <
12m
Circular
300 X X X 0 C1-2-30 200 4 0 0.18 2 RD24 RD24 RD24
350 X X X 0 C1-2-35 200 X X 0 0.24 2 RD24 RD24 RD36
400 X X X 0 C1-2-40 200 X X 0 0.31 2 RD24 RD36 RD36
450 X X X 0 C2-2-45 200 X X 0 0.40 2 RD24 RD36 RD36
500 X X 0 C2-2-50 200 X X 0 0.49 2 RD24 RD36 RD36
600 X X 0 C2-2-60 200 X X 0 0.71 2 RD36 RD36 RD52
Square
300 X X X 0 S1-2-30 200 X X 0 0.23 2 RD24 RD24 RD36
350 X X X 0 S1-2-35 200 X X 0 0.31 2 RD24 RD36 RD36
400 X X X 0 S1-2-40 200 X X 0 0.40 2 RD24 RD36 RD36
450 X X 0 S1-2-45 200 X X 0 0.51 2 RD24 RD36 RD36
500 X X 0 S1-2-50 200 X X 0 0.63 2 RD36 RD36 RD52
600 X X 4 S2-2-60 200 X X 0 0.90 2 RD36 RD52 RD52
700 X X 4 S2-2-70 200 X X 0 1.23 4 RD36 RD36 RD52
800 X X 4 S2-2-80 200 X X 0 1.60 4 RD36 RD52 RD52
Rectangular
200 400 X X 0 R1-1-2040 100 2 2 1 0.20 2 RD24 RD24 RD36
200 600 X X 2 R2-1-2060 100 2 2 1 0.30 4 RD24 RD24 RD24
200 800 X X 2 R2-1-2080 100 2 2 1 0.40 4 RD24 RD24 RD36
225 450 X X X 0 R1-1-2345 100 2 2 1 0.25 2 RD24 RD24 RD36
225 675 X X X 2 R2-1-2368 100 2 2 1 0.38 4 RD24 RD24 RD24
225 900 X X X 2 R2-1-2390 100 2 2 1 0.51 4 RD24 RD24 RD36
250 500 X X X 0 R1-1-2550 100 2 2 1 0.31 2 RD24 RD36 RD36
250 750 X X X 2 R2-1-2575 100 2 2 1 0.47 4 RD24 RD24 RD36
52
b h Longitudinal Bars No. of B16 Cage Cage link Shoe Options4 Propping Column Lifter Lifter rating
Available1 midside shape spacing Sockets5 weight quantity6
B20 B25 B32 bars2 code3 Newby Grout (T/m) Length 4.5m < 8m <
sleeve < 4.5m Length < 8m Length <
12m
250 1000 X X X 4 R3-1-25100 100 2 2 1 0.63 4 RD24 RD36 RD36
300 600 X X X 2 R2-2-3060 200 X X 0 0.45 2 RD24 RD36 RD36
300 900 X X X 2 R2-2-3090 200 X X 0 0.68 4 RD24 RD36 RD36
300 1200 X X X 4 R3-2-30120 200 X X 1 0.90 4 RD24 RD36 RD36
350 700 X X X 2 R2-2-35-70 200 X X 0 0.61 2 RD36 RD36 RD52
350 1050 X X X 4 R3-2-35105 200 X X 0 0.92 4 RD24 RD36 RD36
350 1400 X X X 6 R4-2-35140 200 X X 1 1.23 4 RD36 RD36 RD52
400 800 X X X 2 R2-2-4080 200 X X 0 0.80 2 RD36 RD52 RD52
400 1200 X X X 4 R3-2-40120 200 X X 0 1.20 4 RD36 RD36 RD52
400 1600 X X X 6 R4-2-40160 200 X X 1 1.60 4 RD36 RD52 RD52
Notes:
1. Available range based on exceeding minimum steel area and not exceeding maximum steel area.
2. Midside bars do not have shoes attached. Square columns have a midside bar on each face. Recatngular columns have the midside bars split between the two long faces.
Based on criteria (under discussion) that maximum spacing of longitudinal bars <400mm
3. First two characters cage plan form (see figure 2.12). Second part gives link spacing in 100 mm steps, i.e. 2 – 200 mm. Third part gives basic dimensions in centimetres,
smaller dimension first. Note the cages will also vary according to longitudinal bar diameter.
4. X denotes that shoe type is suitable for all locations. Standard would be 4 cast shoes, but a standard+ combination would be 3 cast + 1 Lenton. Where a number appears,
the standard offering is that number of shoes of each type, e.g., 2 x cast plus 2 x Lenton denotes a cast shoe and a Lenton sleeve at each end of a column. This is used
where the column thickness is insufficient to locate two cast shoes adjacent to each other. See sketch below.
5. Small dimension columns or very wide columns may require propping. This will vary according to specific site conditions. Socket estimate based on 4m column. No of
sockets is indicated. Assume 2T capacity.
6. Standard is based on a 4.5m column. For circular columns which are cast vertically, both lifters are in the top. For square or rectangular columns that are cast horizontally, if
quantity = 2 is one lifter top and bottom, if quantity = 4 is two lifters top and bottom.
53
Precast Columns Appendix D – Column Charts
Appendix D – Column Charts
54
Precast Columns Appendix D – Column charts
20000 20000 400
R30 x
18000 R60 18000
1600
16000 R90 16000

R120
14000 14000
12000 12000 81
162
10000 10000 324
486
8000 8000 648
6000 810
6000
4000 4000
2000 2000
0 500 1000 2 4 6 8 ϕNEd 1.1 1.2 1.5 (kNm)
Step 4: Reinforcment selection

21000 21000
25ϕ M
MEd,z MEd,y
Ed,z//M
MEd,z Ed,y==
* *
17500 0 17500 0
1 1
2 2
14000 3 14000 3
4 4
10500 10500
7000 7000
3500 3500
0 0
0 200 400 600 800 1000 1200 1400 1600 0 200 400 600 800 1000 1200 1400 1600
Moment, MEd,y (kNm) Moment, MEd,y (kNm)
* The dashed line indicates the maximum axial capacity based on the recommended minimum area of reinforcement 0.1 NEd/fyd from Exp (9.12)
55
Step 1: Fire Resistance Step 2: Second order moments 400
16000 16000
R30 x
14000 R60 14000 1200
R90

12000 R120 12000
10000 10000 61
122
8000 8000 244
366
6000 6000 488
610
4000 4000
2000 2000 Step 3: Connection factor

Position Internal Edge Corner Madd
0 0 ϕNEd 1.1 1.2 1.5 (kNm)
0 200 400 600 800 2 4 6 8 ϕMEd 1.0 1.0 1.5 48.9
Maximum moment (kNm) Effective Length, L0 (m)

15000 15000 15000
20ϕ M
MEd,z MEd,y
Ed,z//M
MEd,z Ed,y== 32ϕ M MEd,y
Ed,z//M
MEd,z Ed,y==
* * *
12500 0 12500 0 12500 0

0.75 0.75 0.75
1.5 1.5 1.5
10000 2.25 10000 2.25 10000 2.25
3 3 3
7500 7500 7500
5000 5000 5000
2500 2500 2500
0 0 0
0 110 220 330 440 550 660 770 880 0 110 220 330 440 550 660 770 880 0 110 220 330 440 550 660 770 880
Moment, MEd,y (kNm) Moment, MEd,y (kNm) Moment, MEd,y (kNm)
56
12000 12000 400 x 800
R30
R60
10000 R90 10000

R120
8000 8000
41
82
6000 6000 164
246
328
4000 4000 410
2000 2000
0 200 400 600 2 4 6 8 ϕNEd 1.1 1.1 1.4 (kNm)

12000 12000 12000
20ϕ M MEd,y
Ed,z//M
MEd,z Ed,y== 25ϕ M
MEd,z MEd,y
Ed,z//M
MEd,z Ed,y==
* * *
10000 10000 0 10000
0 0

0.5 0.5 0.5
1 1 1
8000 8000 1.5 8000
1.5 1.5
2 2 2
6000 6000 6000
4000 4000 4000
2000 2000 2000
0 0 0
0 80 160 240 320 400 480 560 640 0 80 160 240 320 400 480 560 640 0 80 160 240 320 400 480 560 640
57
Step 1: Fire Resistance Step 2: Second order moments 350
16000 16000
R30 x
14000 R60 14000 1400
R90

12000 R120 12000
10000 10000 64
128
8000 8000 256
384
6000 6000 512
640
4000 4000
2000 2000
0 200 400 600 800 2 4 6 8 ϕNEd 1.1 1.1 1.5 (kNm)

18000 18000 18000
20ϕ M
MEd,z MEd,y
Ed,z//M
Ed,z//M
MEd,z Ed,y==
* * *
15000 0 15000 0 15000 0

1 1 1
2 2 2
12000 3 12000 3 12000 3
4 4 4
9000 9000 9000
6000 6000 6000
3000 3000 3000
0 0 0
0 120 240 360 480 600 720 840 960 0 120 240 360 480 600 720 840 960 0 120 240 360 480 600 720 840 960
58
12000 12000 350 x 1050
R30
R60
10000 R90 10000

R120
8000 8000
50
100
6000 6000 200
300
4000 4000
400
500
ϕNEd 1.1 1.1 1.5 (kNm)
2000 2000
ϕMEd 1.0 1.0 1.4 40.2
0 0
0 200 400 600 2 4 6 8

12000 12000 12000
20ϕ M MEd,y
Ed,z//M
Ed,z//M
MEd,z Ed,y== 32ϕ M
MEd,z MEd,y
Ed,z//MEd,y==
* * *
10000 10000 10000 0
0 0

0.75 0.75 0.75

1.5 1.5 1.5
8000 8000 8000 2.25
2.25 2.25
3 3 3
6000 6000 6000
4000 4000 4000
2000 2000 2000
0 0 0
0 75 150 225 300 375 450 525 600 0 75 150 225 300 375 450 525 600 0 75 150 225 300 375 450 525 600
59
8000 8000 350 x 700
R30
7000 R60 7000
R90

6000 R120 6000
5000 5000 34
68
4000 4000 136
204
3000 3000 272
340
2000 2000
1000 1000
0 100 200 300 400 2 4 6 8 ϕNEd 1.0 1.1 1.4 (kNm)

9000 9000 9000
20ϕ M
MEd,z MEd,y
Ed,z//M
Ed,z//M
MEd,z Ed,y==
* * *
7500 0 7500 0 7500 0

0.5 0.5 0.5
1 1 1
6000 1.5 6000 1.5 6000 1.5
2 2 2
4500 4500 4500
3000 3000 3000
1500 1500 1500
0 0 0
0 60 120 180 240 300 360 420 480 0 60 120 180 240 300 360 420 480 0 60 120 180 240 300 360 420 480
60
10000 12000 300 x 1200
R30
9000 R60
R90 10000
8000

R120
7000 8000
6000 41
82
5000 6000 164
246
4000 328
4000 410
3000
2000 2000
1000 Step 3: Connection factor
0 100 200 300 400 2 4 6 8 ϕNEd 1.0 1.1 1.5 (kNm)

12000 12000 12000
20ϕ M
MEd,z MEd,y
Ed,z//M
Ed,z//M
MEd,z Ed,y==
* * *
10000 0 10000 0 10000 0

1 1 1
2 2 2
8000 3 8000 3 8000 3
4 4 4
6000 6000 6000
4000 4000 4000
2000 2000 2000
0 0 0
0 65 130 195 260 325 390 455 520 0 65 130 195 260 325 390 455 520 0 65 130 195 260 325 390 455 520
61
9000 300
8000
R30 x
R60 8000
7000 900
R90
7000

6000 R120
6000
5000 32
5000 64
4000 128
4000 192
3000 256
3000 320
2000 2000
1000 1000 Step 3: Connection factor

0 Position Internal Edge Corner Madd
0 ϕNEd 1.0 1.1 1.4 (kNm)
2 4 6 8
0 100 200 300 ϕMEd 1.0 1.0 1.4 15.7

12000 12000 12000
20ϕ M
MEd,z MEd,y
Ed,z//M
Ed,z//M
MEd,z Ed,y==
* * *
10000 0 10000 10000
0 0

0.75 0.75 0.75
1.5 1.5 1.5
8000 2.25 8000 8000
2.25 2.25
3 3 3
6000 6000 6000
4000 4000 4000
2000 2000 2000
0 0 0
0 50 100 150 200 250 300 350 400 0 50 100 150 200 250 300 350 400 0 50 100 150 200 250 300 350 400
62
6000 6000 300
R30 x
R60
5000 R90 5000 600

R120
4000 4000
23
46
3000 3000 92
138
184
2000 2000 230
1000 1000
0 50 100 150 200 2 4 6 8 ϕNEd 1.0 1.0 1.4 (kNm)

9000 9000 9000
20ϕ M MEd,y
Ed,z//M
Ed,z//M
MEd,z Ed,y== 32ϕ M
MEd,z MEd,y
Ed,z//MEd,y==
* * *
7500 7500 7500 0
0 0

0.5 0.5 0.5

1 1 1
6000 6000 6000 1.5
1.5 1.5
2 2 2
4500 4500 4500
3000 3000 3000
1500 1500 1500
0 0 0
0 40 80 120 160 200 240 280 320 0 40 80 120 160 200 240 280 320 0 40 80 120 160 200 240 280 320
63
7000 9000 250 x 1000
R30
R60 8000
6000
R90
7000

R120
5000
6000
24
4000 5000 48
96
4000 144
3000
192
3000 240
2000
2000
1000 1000
0 50 100 150 200 2 4 6 8 ϕNEd 1.0 1.0 1.5 (kNm)

9000 9000 9000
20ϕ M
MEd,z MEd,y
Ed,z//M
Ed,z//M
MEd,z Ed,y==
* * *
7500 0 7500 0 7500 0

1 1 1
2 2 2
6000 3 6000 3 6000 3
4 4 4
4500 4500 4500
3000 3000 3000
1500 1500 1500
0 0 0
0 40 80 120 160 200 240 280 320 0 40 80 120 160 200 240 280 320 0 40 80 120 160 200 240 280 320
64
6000 7000
R30
250 x750
R60 6000
5000 R90

R120
5000
4000
19
4000
38
3000 76
3000 114
152
2000 190
2000
1000 1000
0
0 (kNm)
2 4 6 8 ϕNEd 1.0 1.0 1.4
0 50 100 150 200
ϕMEd 1.0 1.0 1.4 11.3

9000 9000 9000
20ϕ M
MEd,z MEd,y
Ed,z//M
Ed,z//M
MEd,z Ed,y==
* * *
7500 0 7500 0 7500 0

0.75 0.75 0.75
1.5 1.5 1.5
6000 2.25 6000 2.25 6000 2.25
3 3 3
4500 4500 4500
3000 3000 3000
1500 1500 1500
0 0 0
0 30 60 90 120 150 180 210 240 0 30 60 90 120 150 180 210 240 0 30 60 90 120 150 180 210 240
65
4500
250
4500
R30 x
4000 4000 500
R60
R90 3500

3500
R120
3000 3000
13
2500 2500 26
52
2000 2000 78
104
1500 1500 130
1000 1000
500
0 50 100 150 2 4 6 8 ϕNEd 1.0 1.0 1.3 (kNm)
Maximum moment (kNm) Effective Length, L0 (m) ϕMEd 1.0 1.0 1.3 0

6000 6000 6000
20ϕ M
MEd,z MEd,y
Ed,z//M
Ed,z//M
MEd,z Ed,y==
* * *
5000 0 5000 0 5000 0

0.5 0.5 0.5
1 1 1
4000 1.5 4000 1.5 4000 1.5
2 2 2
3000 3000 3000
2000 2000 2000
1000 1000 1000
0 0 0
0 25 50 75 100 125 150 175 200 0 25 50 75 100 125 150 175 200 0 25 50 75 100 125 150 175 200
66
5000 7000 225 x 900
R30
4500 R60 6000
4000 R90

R120
3500 5000
3000 18
4000
36
2500 72
3000 108
2000 144
180
1500 2000
1000
1000
0 50 100 150 200 2 4 6 8 ϕNEd 1.0 1.0 1.4 (kNm)

9000 9000 9000
20ϕ M
MEd,z MEd,y
Ed,z//M
Ed,z//M
MEd,z Ed,y==
* * *
7500 0 7500 7500
0 0

1 1 1
2 2 2
6000 3 6000 6000
3 3
4 4 4
4500 4500 4500
3000 3000 3000
1500 1500 1500
0 0 0
0 30 60 90 120 150 180 210 240 0 30 60 90 120 150 180 210 240 0 30 60 90 120 150 180 210 240
67
4000 6000 225 x 675
R30
3500 R60
5000
R90

3000 R120
4000
2500 14
28
2000 3000 56
84
1500 112
2000 140
1000
500
0 0 ϕNEd 1.0 1.0 1.4 (kNm)
0 50 100 150 200 2 4 6 8 ϕMEd 1.0 1.0 1.4 3.17

6000 6000 6000
20ϕ M MEd,y
Ed,z//M
Ed,z//M
MEd,z Ed,y== 32ϕ M
MEd,z MEd,y
Ed,z//MEd,y==
* * *
5000 5000 5000 0
0 0

0.75 0.75 0.75

1.5 1.5 1.5
4000 4000 4000 2.25
2.25 2.25
3 3 3
3000 3000 3000
2000 2000 2000
1000 1000 1000
0 0 0
0 25 50 75 100 125 150 175 200 0 25 50 75 100 125 150 175 200 0 25 50 75 100 125 150 175 200
68
4000
3000
R30
225 x 450
R60 3500
2500 R90

R120 3000
2000
2500 10
20
1500 2000 40
60
1500 80
1000 100
1000
500
500
0 50 100 150 2 4 6 8 ϕNEd 1.0 1.0 1.3 (kNm)

6000 6000 6000
20ϕ M
MEd,z MEd,y
Ed,z//M
Ed,z//M
MEd,z Ed,y==
* * *
5000 0 5000 5000
0 0

0.5 0.5 0.5
1 1 1
4000 1.5 4000 4000
1.5 1.5
2 2 2
3000 3000 3000
2000 2000 2000
1000 1000 1000
0 0 0
0 20 40 60 80 100 120 140 160 0 20 40 60 80 100 120 140 160 0 20 40 60 80 100 120 140 160
69
4000 6000 200 x 800
R30
R60
3500
R90 5000

R120
3000
4000
2500 12
24
2000 3000 48
72
1500 96
2000 120
1000
1000
500
0 50 100 150 200 2 4 6 8 ϕNEd 1.0 1.0 1.4 (kNm)

6000 6000
20ϕ M
MEd,z MEd,y
Ed,z//M
MEd,z Ed,y==
* *
5000 0 5000 0
1 1
2 2
4000 3 4000 3
4 4
3000 3000
2000 2000
1000 1000
0 0
0 20 40 60 80 100 120 140 160 0 20 40 60 80 100 120 140 160
70
3000 4500
R30 200 x 600
R60 4000
2500 R90
3500

R120
2000 3000
9
2500 18
1500 36
2000 54
72
1000 1500 90
1000
500
500
0 50 100 150 2 4 6 8 ϕNEd 1.0 1.0 1.4 (kNm)

6000 6000
20ϕ M
MEd,z MEd,y
Ed,z//M
MEd,z Ed,y==
* *
5000 0 5000 0
0.75 0.75
1.5 1.5
4000 2.25 4000 2.25
3 3
3000 3000
2000 2000
1000 1000
0 0
0 15 30 45 60 75 90 105 120 0 15 30 45 60 75 90 105 120
71
2500 3000 200 x 400
R30
R60
R90 2500
2000

R120
2000
1500 7
14
1500 28
42
1000 56
1000 70
500 500
0 50 100 2 4 6 8 ϕNEd 1.0 1.0 1.3 (kNm)

6000 6000
20ϕ M
MEd,z MEd,y
Ed,z//M
MEd,z Ed,y==
* *
5000 0 5000 0
0.5 0.5
1 1
4000 1.5 4000 1.5
2 2
3000 3000
2000 2000
1000 1000
0 0
0 15 30 45 60 75 90 105 120 0 15 30 45 60 75 90 105 120
72
20000 20000
R30
18000 R60 18000
R90
800 Sq
16000 16000

R120
14000 14000
12000 12000 46
92
10000 10000 184
276
8000 8000 368
6000 460
6000
4000 4000
2000 2000
0 1000 2000 3000 2 4 6 8 ϕNEd 1.2 1.3 1.5 (kNm)

21000 21000
25ϕ M
MEd,z MEd,y
Ed,z//M
MEd,z Ed,y==
* *
17500 0 17500 0
0.25 0.25
0.5 0.5
14000 0.75 14000 0.75
1 1
10500 10500
7000 7000
3500 3500
0 0
0 350 700 1050 1400 1750 2100 2450 2800 0 350 700 1050 1400 1750 2100 2450 2800
73

16000 16000
R30
14000 R60 14000 700 Sq
R90

12000 R120 12000
10000 10000 40
80
8000 8000 160
240
6000 6000 320
400
4000 4000
2000
0 500 1000 1500 2000 2 4 6 8 ϕNEd 1.2 1.3 1.4 (kNm)

18000 18000
25ϕ M
MEd,z MEd,y
Ed,z//M
MEd,z Ed,y==
* *
15000 0 15000 0
0.25 0.25
0.5 0.5
12000 0.75 12000 0.75
1 1
9000 9000
6000 6000
3000 3000
0 0
0 250 500 750 1000 1250 1500 1750 2000 0 250 500 750 1000 1250 1500 1750 2000
74
12000 12000
R30
R60 600 Sq
10000 10000
R90

R120
8000 8000
34
68
6000 6000 136
204
272
4000 4000 340
2000 2000
0 500 1000 1500 2 4 6 8 ϕNEd 1.1 1.2 1.4 (kNm)

12000 12000
25ϕ M
MEd,z MEd,y
Ed,z//M
MEd,z Ed,y==
* *
10000 0 10000 0
0.25 0.25
0.5 0.5
8000 0.75 8000 0.75
1 1
6000 6000
4000 4000
2000 2000
0 0
0 200 400 600 800 1000 1200 1400 1600 0 200 400 600 800 1000 1200 1400 1600
75
9000 9000
R30
8000 R60 8000
R90 500 Sq
7000

7000
R120
6000 6000
27
5000 5000 54
108
4000 4000 162
216
3000 3000 270
2000 2000
1000
0 200 400 600 2 4 6 8 ϕNEd 1.0 1.1 1.4 (kNm)

9000 9000 9000
20ϕ M
MEd,z MEd,y
Ed,z//M
Ed,z//M
MEd,z Ed,y==
* * *
7500 0 7500 0 7500 0

0.25 0.25 0.25
0.5 0.5 0.5
6000 0.75 6000 0.75 6000 0.75
1 1 1
4500 4500 4500
3000 3000 3000
1500 1500 1500
0 0 0
0 120 240 360 480 600 720 840 960 0 120 240 360 480 600 720 840 960 0 120 240 360 480 600 720 840 960
76
7000 7000
R30
R60 6000
6000
R90 450 Sq

R120
5000 5000
25
4000 4000
50
100
3000 3000 150
200
250
2000 2000
1000 1000
0 200 400 600 2 4 6 8 ϕNEd 1.0 1.1 1.4 (kNm)

9000 9000
25ϕ M
MEd,z MEd,y
Ed,z//M
MEd,z Ed,y==
* *
7500 0 7500 0
0.25 0.25
0.5 0.5
6000 0.75 6000 0.75
1 1
4500 4500
3000 3000
1500 1500
0 0
0 70 140 210 280 350 420 490 560 0 70 140 210 280 350 420 490 560
* The dashed line indicates the maximum axial capacity based on the recommended minimum area of reinforcement 0.1 NEd/fyd from Exp (9.1
77
6000 6000
R30
R60
5000 R90 5000 400 Sq

R120
4000 4000
21
42
3000 3000 84
126
168
2000 2000 210
1000 1000
0 100 200 300 2 4 6 8 ϕNEd 1.0 1.1 1.4 (kNm)

6000 6000 6000
20ϕ M
MEd,z MEd,y
Ed,z//M
Ed,z//M
MEd,z Ed,y==
* * *
5000 0 5000 0 5000 0

0.25 0.25 0.25
0.5 0.5 0.5
4000 0.75 4000 0.75 4000 0.75
1 1 1
3000 3000 3000
2000 2000 2000
1000 1000 1000
0 0 0
0 55 110 165 220 275 330 385 440 0 55 110 165 220 275 330 385 440 0 55 110 165 220 275 330 385 440
*The dashed line indicates the maximum axial capacity based on the recommended minimum area of reinforcement 0.1 NEd/fyd from Exp (9.12
78
4500 4500
R30
4000 R60 4000 350 Sq
R90
3500

3500
R120
3000 3000
18
2500 2500 36
72
2000 2000 108
144
1500 1500 180
1000 1000
500
0 50 100 150 200 2 4 6 8 ϕNEd 1.0 1.0 1.3 (kNm)

6000 6000 6000
20ϕ M
MEd,z MEd,y
Ed,z//M
Ed,z//M
MEd,z Ed,y==
* * *
5000 0 5000 0 5000 0

0.25 0.25 0.25
0.5 0.5 0.5
4000 0.75 4000 0.75 4000 0.75
1 1 1
3000 3000 3000
2000 2000 2000
1000 1000 1000
0 0 0
0 40 80 120 160 200 240 280 320 0 40 80 120 160 200 240 280 320 0 40 80 120 160 200 240 280 320
79
3500 3500
R30
R60 300 Sq
3000 3000
R90

R120
2500 2500
14
2000 2000
28
56
1500 1500 84
112
140
1000 1000
500 500
0 50 100 150 2 4 6 8 ϕNEd 1.0 1.0 1.3 (kNm)

6000 6000
20ϕ M
MEd,z MEd,y
Ed,z//M
MEd,z Ed,y==
* *
5000 0 5000 0
0.25 0.25
0.5 0.5
4000 0.75 4000 0.75
1 1
3000 3000
2000 2000
1000 1000
0 0
0 25 50 75 100 125 150 175 200 0 25 50 75 100 125 150 175 200
80
10000 9000
R30
9000 R60 8000
R90
8000 7000

R120 600 ϕ
7000 6000
6000 26
5000 52
5000 104
4000 156
4000 208
3000 260
3000
2000
2000
1000
0 500 1000 2 4 6 8 ϕNEd 1.1 1.2 1.4 (kNm)

9000 9000
25ϕ M
MEd,z MEd,y
Ed,z//M
MEd,z Ed,y==
* *
7500 0 7500 0
0.25 0.25
0.5 0.5
6000 0.75 6000 0.75
1 1
4500 4500
3000 3000
1500 1500
0 0
0 70 140 210 280 350 420 490 560 0 70 140 210 280 350 420 490 560
81
7000 7000
R30
6000 R60 6000
R90 500 ϕ

R120
5000 5000
21
4000 4000
42
84
3000 3000 126
168
210
2000 2000
1000 1000
0 200 400 600 2 4 6 8 ϕNEd 1.0 1.1 1.4 (kNm)

9000 9000
25ϕ M
MEd,z MEd,y
Ed,z//M
MEd,z Ed,y==
* *
7500 0 7500 0
0.25 0.25
0.5 0.5
6000 0.75 6000 0.75
1 1
4500 4500
3000 3000
1500 1500
0 0
0 45 90 135 180 225 270 315 360 0 45 90 135 180 225 270 315 360
82
6000 6000
R30
R60
5000
5000 R90 450 ϕ

R120
4000 4000
18
36
3000 3000 72
108
144
2000 2000 180
1000 1000
0 100 200 300 400 2 4 6 8 ϕNEd 1.0 1.1 1.4 (kNm)

6000 6000 6000
20ϕ M
MEd,z MEd,y
Ed,z//M
Ed,z//M
MEd,z Ed,y==
* * *
5000 0 5000 0 5000 0

0.25 0.25 0.25
0.5 0.5 0.5
4000 0.75 4000 0.75 4000 0.75
1 1 1
3000 3000 3000
2000 2000 2000
1000 1000 1000
0 0 0
0 30 60 90 120 150 180 210 240 0 30 60 90 120 150 180 210 240 0 30 60 90 120 150 180 210 240
83
4500 4500
R30
4000 R60 4000
R90
400 ϕ
3500

3500
R120
3000 3000
15
2500 2500 30
60
2000 2000 90
120
1500 1500 150
1000 1000
500
0 100 200 300 2 4 6 8 ϕNEd 1.0 1.1 1.4 (kNm)

6000 6000 6000
20ϕ M
MEd,z MEd,y
Ed,z//M
Ed,z//M
MEd,z Ed,y==
* * *
5000 0 5000 0 5000 0

0.25 0.25 0.25
0.5 0.5 0.5
4000 0.75 4000 0.75 4000 0.75
1 1 1
3000 3000 3000
2000 2000 2000
1000 1000 1000
0 0 0
0 25 50 75 100 125 150 175 200 0 25 50 75 100 125 150 175 200 0 25 50 75 100 125 150 175 200
84
3500 3500
R30
3000
R60 3000 350 ϕ
R90

R120
2500 2500
12
2000 2000
24
48
1500 1500 72
96
120
1000 1000
500 500
0 50 100 150 200 2 4 6 8 ϕNEd 1.0 1.0 1.3 (kNm)

6000 6000 6000
20ϕ M
MEd,z MEd,y
Ed,z//M
Ed,z//M
MEd,z Ed,y==
* * *
5000 0 5000 0 5000 0

0.25 0.25 0.25
0.5 0.5 0.5
4000 0.75 4000 0.75 4000 0.75
1 1 1
3000 3000 3000
2000 2000 2000
1000 1000 1000
0 0 0
0 15 30 45 60 75 90 105 120 0 15 30 45 60 75 90 105 120 0 15 30 45 60 75 90 105 120
85
3000 3000
R30
R60
300 ϕ
2500 2500
R90

R120
2000 2000
8
16
1500 1500 32
48
64
1000 1000 80
500 500
0 50 100 150 2 4 6 8 ϕNEd 1.0 1.0 1.3 (kNm)

3000 3000 3000
20ϕ M
MEd,z MEd,y
Ed,z//M
Ed,z//M
MEd,z Ed,y==
* * *
2500 0 2500 0 2500 0

0.25 0.25 0.25
0.5 0.5 0.5
2000 0.75 2000 0.75 2000 0.75
1 1 1
1500 1500 1500
1000 1000 1000
500 500 500
0 0 0
0 10 20 30 40 50 60 70 80 0 10 20 30 40 50 60 70 80 0 10 20 30 40 50 60 70 80
86
Laing O’Rourke plc
Bridge Place
Anchor Boulevard
Admirals Park
Crossways
Dartford
Kent
DA2 6SN
T +44 (0)1322 296200
F +44 (0)1322 296262
E info@laingorourke.com
www.laingorourke.com

Columns Product Catologue Rev D MK 2

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Columns Product Catologue Rev D MK 2

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Precast Columns

Design Guide & Product Catalogue

This publication is the culmination of a body of work looking specifically at the

 Explore Manufacturing Ltd

Rev Date Status Revision summary

1.2 About this publication

1.3 Purpose and scope

Vertical bars (20, 25 or 32

Cast column shoe. Shoe locates

Wavy-tail lifters cast into top &

Coupler at top of column.

Standard 20mm chamfer on

2.2 Key characteristics – rectangular columns

Bent mesh link cage. Verticals in

Vertical corner bars with 20, 25 or Secondary longitudinal bars (B16)

Maximum cost efficiency is achieved by using standard cross-section Table 2.2

Cast height of column

Floor to floor height

Cast height of column

All 4 corners require 2 corners with L-bars; L-bars required

a) Centreline transition b) Edge transition c) Corner transition

 Slope on joggle is 1 in 12 in accordance with BS EN 1992-1-1

Where offset < 75mm,

75 < (h2-h1) < 150

Link cages omitted (b2-b1) >150

The concrete in the columns is a Class C50/60. Further details on concrete

2.6.3. Columns connections

Rolltec® locknut to preload thread.

Threaded bar for connecting upper

Upper nut – used to secure column.

Lower nut – used to adjust upper

Threaded bars pass through slab.

Corners fitted with cast shoes are

Grout sleeve locates within depth of

200 100 < spacing <200

If > 400mm, introduce

3 Interfaces with other elements Template holding

3.1 Connection to foundations

Holes drilled and

High strength shrinkage

The following should be noted in relation to the interface:

3.6 Wall interfaces

All voids filled with

Column capacity is an interaction between axial forces and bending moment,

5.3 Shear resistance

Axial Load, NEd (kN)

Axial Load, NEd (kN)

0 0 MRd,y = 540 + 41.9 = 581.9 > 580 kNm → OK

My at top of column kNm It is assumed that forces supplied

Table 6.1 Finishes

Cast height of column

Floor to floor height

Cast height of column

C400-25-3580-320 400mm diameter circular column with B25 main

2. British Standards Institution. BS EN 1992–1–2, Eurocode 2 – part 1–2:

3. British Standards Institution, UK National Annex to Eurocode 2 – part 1–1:

4. British Standards Institution. UK National Annex to Eurocode 2 – part 1–2:

5. British Standards Institution. BS 8110-1. Structural use of concrete – Part 1:

6. Institution of Structural Engineers. Manual for the design of concrete

7. Brooker, O et al. How to design concrete structures using Eurocode 2, The

8. British Standards Institution. BS 8500-1, Concrete – Complementary British

9. COMMUNITIES AND LOCAL GOVERNEMENT. Building regulations (England

10. SCOTTISH BUILDING STANDARDS AGENCY. The Scottish building