Addendum To The Top GRC Fixation - Design of The Halter-R01

One Limassol, Cyprus
Structural Calculation
Addendum to Top GRC fixation
Design of the Halter- R01
Document No. Revision Date Done By Checked By

---- A Feb 1 , 2021 R.B B.BH
----- B Feb 9, 2021 R.B B.BH
11 February 2021 Addendum to top GRC fixation
Comment/reply table:
Item Comment Reply
01 Revise the area contributing to the tension of each halter from the Noted. Kindly refer to reply on page
inside skin to 0.8mx0.4m instead of 0.6x0.4m and in accordance to 6.
the spacing of the halters actually placed on site.
02 Clarify the number of halters contributing to the support of the Noted. Kindly refer to reply on pages
GRC weight in the direction perpendicular to gravity. 7, 8 and 9.
03 Consider nominal transverse load on the halters due to friction Noted. Kindly refer to reply on page
10.
04 Revise sizing of halters and/or drilling screws as necessary. Noted. Kindly refer to pages 11 till
22.
05 Include halter design anchors and fixings and standing seam Noted. Kindly refer to pages 23 till
calculation for façade access and industrial climbing supports 26.
(abseiling brackets locations).
2
The aim of this report is to design the aluminum halter and the self-drilling screws supporting the halter.
Figure 1: Section view for the GRC panels and the aluminium halter
The halter is of aluminium material whose characteristics are shown in the extract below.
3
1. Wind suction loads:
As shown in the figure above, there are two skins: first skin is the GRC which is a permeable outside skin and a second
inside skin which is an impermeable skin. The extract from the Eurocode EN 1991-1-4 shown below shows the
distribution between the wind loads between the outside and the inside skin:
But conservatively, a full wind load will be taken on the outside skin and a 2/3 of the full wind load will be applied on
the inside skin.
Wind load due to the outside skin (GRC):
Each GRC panel is fixed on six positions. Each bracket is fixed on a single halter. The figure below shows as well the
dimensions of the GRC 2.5mx1.2m.
Figure 2: Section for the GRC and the halter
4
The wind load applied on one halter due to the outside skin is: 1.5* 1.2m * 2.5m *4.6KN/m2 /6=3.45 KN
Where 1.5 is the safety factor, 4.6KN/m2 is the wind load
Wind load on the inside skin seemed roofing: (reply to comment #1)
The maximum tributary area supported by the halter is 0.8m x 0.4m as shown in the figure below:
5
The wind load applied on one halter due to the inside skin is 2/3 * 1.5 * 0.4m *0.8m * 4.6 KN/m2 = 1.472 KN
Where 2/3 is the conservatively taken as the percentage share by the inside skin, 1.5 is the safety factor, and
4.6KN/m2 is the wind load.
Thus, the total wind load on the halter is : (3.45 KN +1.472 KN)/2= 4.92 KN /2=2.461 KN on each side of the halter as
shown in the figure below extracted from inventor.
6
2. Dead loads:
The halter is supporting the weight of the GRC. (refer to the figure below to see the components of the vector=weight
of the GRC)
Weight of the GRC supported by one halter : B= (1.35 * cos 45 * 1.2m * 2.5m * 0.87 KN/m2 )/3= 3KN /3= 0.83KN
Where 1.35 is the factor of safety, 1.2 m x2.5m is the dimension of the GRC, 0.87KN/m2 is the weight of the GRC.
The second vector (A) of the GRC is ignored since it will act in the direction opposite to the wind suction force.
Thus, conservatively it will not be included in the design of the halter.
Figure 3: Plan view showing the weight of the GRC
7
The two below are extracts from DS-AR-98 showing how the panel is slotted for thermal movement and it clearly
shows that the dead load is only divided by three brackets. (reply on comment #2)
8
9
3. Friction forces: (reply on comment #3)
Ffr=Cfr * qp(Ze) *Afr ( EN 1991-1-4, Section 5.3, equation 5.7)
Where Cfr =0.04 ( friction coefficient derived fromEN 1991-1-4, Section 7.5) but will be taken 5% conservatively.
qp (Ze) (peak velocity pressure at referenced height Ze ) but since we don’t have this value, we will use the value of the
wind load on the halter calculated previously
Thus, Ffr=0.05 * 3.45=0.1725 KN=172.5 N
10
4. Inventor model of the Halter:
The halter is supported on the steel tube 100x100x4mm through 4 self drilling screws.
Figure 4: 3D view of the halter on the Inventor program
11
Figure 5: Pinned connection (self-drilling screws position)
Figure 6: Wind suction load applied on one side of the halter
12
Figure 8: Wind suction load applied on the other side of the halter
Figure 7: Dead load of the GRC
13
Figure 9: Friction force applied on the halter

Stress check:
Figure 10: Maximum stress reached in the aluminium halter
Where maximum stresses reached in aluminum transoms is 196.3MPa which is less than the ultimate stress for
aluminum alloy EN AW-6063 or EN AW-6060 of fo = 195MPa where resistance for yield criteria for a critical point of a
cross section is as per below:
14
σx,ED / (f0/γM1) =196/(1.5*195/1.1) = 0.74< 1 (reference EN 1999-1-1 section 6.2) where:
f0 = 195MPa yield strength for aluminum alloy AW-6063 or AW-6060 as per specs below
γM1 = 1.1 partial safety factor
15
Design of the self-drilling screw:
The halter is connected to the steel tube through 4 self drilling screws grade A4-70.
The maximum forces applied on the self drilling screw are taken from the inventor model shown below.
Figure 11: Maximum forces applied on the self-drilling screw
Fy=2.25 KN (tension force on the screw) taken from the above figure
Fz= 0.83 KN/4=0.21 KN (shear force on the screw) Where 0.83 KN is the dead load of the GRC as calculated previously
Shear force due to the friction force 0.17 KN /4= 0.04 KN
Thus, the total forces applied on the screw are:
Ft= 2.25 KN
Fs= √( 0.212 + 0.042)=0.21 KN
16
Figure 12: Maximum forces applied on the M6 Ejot self-drilling screw
17
18
Thus, the four self drilling screw M6 are safe and can withstand the applied forces.
19
Thus, the four self drilling screws are safe for shear as well.
20
If the tolerance is greater than 15mm and less than 20mm, two screws will be added to increase the characteristic
strength of the screw. Thus, we will have six screws instead of four.
Thus, the shear force on one screw will be divided among the six screws as follows: (√( 0.832+ 0.172))/6=0.141 KN
Where 0.83 KN is the shear force due to weight and 0.17KN is the shear force due to friction force.
The moment due to this force is 0.141*1000 N *0.02 *1000mm=2820 N.mm Where 20mm is the distance between
the top of the screw and the fixed part as shown in the figure below.
21
Figure 13: Forces applied on the M6 screw

MED = 2820 N.mm
MC,RD = Wply x Fy / γM0 = 7.07 mm3 x 450 N/mm2 / 1 = 3181 N.mm (eq 6.14 as per EN 1993-1-1)
Where, Fy is the yield strength for A4-70 screw and Wely is the elastic section modulus of the section taken
conservatively. Wely= π * r 3 /4= 3.14 * 2.0813 mm3/4= 7.07 mm3
MED/MC,RD = 2820/3181 = 0.88< 1 (eq 6.12 as per EN 1993-1-1)
Thus, the 6 A4-70 screw M6 are safe to withstand applied loads.
22
Halter for abseiling bracket 60cm long:
Design will be carried on using inventor and using manual calculations.
 Simulation using Autodesk Inventor:
Figure 14: 3D view for the halter, tube, and the abseiling bracket
Figure 15: Pinned connection for the bolts between the halter and the tube
23
Figure 16: Load applied on the halter
24
Figure 17: Maximum stresses reached in the halter
Where maximum stresses reached in aluminum transoms is 265MPa.
The ultimate stress for aluminum alloy EN AW-6063 or EN AW-6060 of fo = 195MPa where resistance for yield criteria
for a critical point of a cross section is as per below:
σx,ED / (f0/γM1) =265/(1.5*195/1.1) = 0.9 < 1 where:
f0 = 195MPa yield strength for aluminum halter
25
 Manual design as per the engineer’s recommendation:
The force applied on one halter is 7.5KN.

The moment due to this force is M= f*a where f is the force and a is the distance between the top of the halter and
the base as shown in the figure below:
M=7.5*1000 N* 67mm=502,500 N.mm
26
b=600mm (length of the halter)

h=3.2mm (thickness of the halter)
Wel= b* h2/6= 600 * 3.22 /6= 1024 mm4 (elastic section modulus)
Wpl= b* h2/4= 600* 3.22 /4=1532 mm4 (plastic section modulus)
Mc,RD= α * Wel * f0/ γM1 (EN 1999-1-1 section 6.2, equation 6.2.5)
Where α=Wpl/Wel
Thus, Mc,Rd= Wply* f0 / γM1= 1532 mm4 * 195 N/mm2 /1.1= 271581 N.mm > 502,500 N.mm Not Ok
F0= 195MPa yield strength for aluminum halter

Accordingly, 600mm halter alone is not enough, at least 5 frames should be connected (6 halters) to be able to
resist the load safely which will be similar to the site testing.
Each haler will be connected to the main steel tube by 20 screws, 10 from the left and 10 from the right.
27

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One Limassol, Cyprus

Document No. Revision Date Done By Checked By

11 February 2021 Addendum to top GRC fixation

Item Comment Reply

11 February 2021 Addendum to top GRC fixation

11 February 2021 Addendum to top GRC fixation

1. Wind suction loads:

Wind load due to the outside skin (GRC):

Figure 2: Section for the GRC and the halter

11 February 2021 Addendum to top GRC fixation

Where 1.5 is the safety factor, 4.6KN/m2 is the wind load

11 February 2021 Addendum to top GRC fixation

11 February 2021 Addendum to top GRC fixation

Thus, conservatively it will not be included in the design of the halter.

Figure 3: Plan view showing the weight of the GRC

11 February 2021 Addendum to top GRC fixation

11 February 2021 Addendum to top GRC fixation

11 February 2021 Addendum to top GRC fixation

3. Friction forces: (reply on comment #3)

Ffr=Cfr * qp(Ze) *Afr ( EN 1991-1-4, Section 5.3, equation 5.7)

Thus, Ffr=0.05 * 3.45=0.1725 KN=172.5 N

11 February 2021 Addendum to top GRC fixation

4. Inventor model of the Halter:

Figure 4: 3D view of the halter on the Inventor program

11 February 2021 Addendum to top GRC fixation

Figure 5: Pinned connection (self-drilling screws position)

Figure 6: Wind suction load applied on one side of the halter

11 February 2021 Addendum to top GRC fixation

Figure 7: Dead load of the GRC

11 February 2021 Addendum to top GRC fixation

Figure 9: Friction force applied on the halter

Figure 10: Maximum stress reached in the aluminium halter

11 February 2021 Addendum to top GRC fixation

σx,ED / (f0/γM1) =196/(1.5*195/1.1) = 0.74< 1 (reference EN 1999-1-1 section 6.2) where:

γM1 = 1.1 partial safety factor

11 February 2021 Addendum to top GRC fixation

Design of the self-drilling screw:

Figure 11: Maximum forces applied on the self-drilling screw

11 February 2021 Addendum to top GRC fixation

Figure 12: Maximum forces applied on the M6 Ejot self-drilling screw

11 February 2021 Addendum to top GRC fixation

11 February 2021 Addendum to top GRC fixation

11 February 2021 Addendum to top GRC fixation

11 February 2021 Addendum to top GRC fixation

11 February 2021 Addendum to top GRC fixation

Figure 13: Forces applied on the M6 screw

MED/MC,RD = 2820/3181 = 0.88< 1 (eq 6.12 as per EN 1993-1-1)

Thus, the 6 A4-70 screw M6 are safe to withstand applied loads.

11 February 2021 Addendum to top GRC fixation

Halter for abseiling bracket 60cm long:

Design will be carried on using inventor and using manual calculations.

 Simulation using Autodesk Inventor:

11 February 2021 Addendum to top GRC fixation

Figure 16: Load applied on the halter

11 February 2021 Addendum to top GRC fixation

Figure 17: Maximum stresses reached in the halter

Where maximum stresses reached in aluminum transoms is 265MPa.

σx,ED / (f0/γM1) =265/(1.5*195/1.1) = 0.9 < 1 where:

f0 = 195MPa yield strength for aluminum halter

γM1 = 1.1 partial safety factor

11 February 2021 Addendum to top GRC fixation

 Manual design as per the engineer’s recommendation: