Background and Discussion

PCI DESIGN HANDBOOK

PRECAST AND PRESTRESSED CONCRETE

7th Edition PCI Industry Handbook Committee

Greg Force, P.E.,FPCI, Chairman Neal S. Anderson, P.E., S.E., FPCI, FACI Ned M. Cleland, PhD, P.E., FPCI, FACI Harry A. Gleich, P.E., FPCI, FACI Gary A. Householder, P.E. Pat Hynes, P.E., FPCI Phillip J. Iverson, P.E. Walter Korkosz, P.E., S.E. Jason Krohn, P.E. Karen Laptas, P.E. David J. Larsen, P.E., S.E Jason P. Lien, P.E. Rafael A. Magana, P.E. Michael I. Owings, P.E., S.E. Stephen Pessiki, PhD, FPCI, FACI Steven H. Peterson, P.E. Courtney B. Phillips, P.E., S.E. Timothy R. Salmons, P.E., S.E. Kim E. Seeber, P.E., FPCI Larbi Sennour, PhD, P.E., FPCI, FACI Fattah Shaikha, PhD, P.E., FPCI Irwin J. Speyer,P.E., FPCI, FACI Peter G. Troiani, P.E., S.E. Helmuth Wilden, P.E., FPCI Charles E. Wynings, P.E. a. Deceased January 10, 2008 Prepared by PCI Industry Handbook Committee

Foreword
The Precast/Prestressed Concrete Institute (PCI) updates and publishes the PCI Design Handbook: Precast and Prestressed Concrete1 in cycles coincident with publication of the American Concrete Institutes (ACIs) Building Code Requirements for Structural Concrete (ACI 318-05) and Commentary (ACI 318R-05).2 The seventh edition of the PCI Design Handbook, published in 2010, continues that tradition. Each update of the PCI Design Handbook reflects the modifications adopted by ACI 318 as well as the most recent research and experience of designers regularly engaged in the design of precast and prestressed concrete structures.

Introduction
The publication of the seventh edition of the PCI Design Handbook continues to meet the goals set forth by the Precast/Prestressed Concrete Institute, which was established in 1954 as the Prestressed Concrete Institute. The current name was adopted in 1989 to better reflect the interests of both prestressed concrete producers and those that manufacture nonprestressed precast concrete components. The goal is to advance the design, manufacture, and use of precast and prestressed concrete. The seventh-edition PCI Design Handbooks primary objective remains the same as it was with the first edition, published in 1971; that is, to make it easier for architects and engineers to use prestressed and precast concrete. It is intended to be a working tool, assisting the designer in achieving optimum solutions in minimum time. The seventh edition of the PCI Design Handbook background and discussion paper is the sixth document of its type. The first was published for the second-edition PCI

Consulting Members
Robert F. Mast, P.E., S.E., FPCI, HACI Jagdish C. Nijhawan, P.E., FPCI J. Robert Norris, P.E.

Editor
Helmuth Wilden, P.E., FPCI

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Design Handbook and was an authored paper titled Background and Discussion on PCI Design Handbook, Second Edition. It was published in the JanuaryFebruary 1980 issue of the PCI Journal. Subsequent papers with the same intent and similar titles were published as follows: For the third-edition PCI Design Handbook: May June 1988, PCI Journal

It includes the correction of errors in the sixth edition that were published as errata in the MayJune 2007 issue of the PCI Journal. It incorporates comments by the sixth-edition PCI Design Handbook Blue Ribbon Review Committee that could not be included in the sixth edition. It includes updated information based on current standard practices of the industry. It includes updated information based on results of recent research in the industry. It expands text of selected topics to provide morecomprehensive discussion. Selected text, figures, tables, Design Aids, and examples are rewritten, modified, and edited for improved clarity.

For the fourth-edition PCI Design Handbook: NovemberDecember 1996, PCI Journal For the fifth-edition PCI Design Handbook: JulyAugust 1998, PCI Journal For the sixth-edition PCI Design Handbook: March April 2006, PCI Journal

Purpose
The main purpose of the background and discussion of the seventh edition of the PCI Design Handbook is to identify significant changes from the sixth edition on a chapter-bychapter basis and explain the rationale for these changes. Other purposes are to describe current work in progress toward the eighth edition of the PCI Design Handbook and to establish goals for future work.

The user of the PCI Design Handbook will observe several somewhat subtle differences from the sixth edition: Equations are numbered consecutively in each chapter. For example, Eq. 6.5.2.1 in the sixth edition is now Eq. (6-2) and Eq. 6.12.1.1 is now Eq. (6-93). A complete list of design examples is included at the end of the foreword to the handbook. Previous charts shown as figures are now Design Aids, and a complete list is included at the end of the foreword to the handbook. All figures and tables are identified with a three-digit number. For example, Table 6.6.5.2 in the sixth edition is now Table 6.6.3 and Fig. 6.7.3.1 is now Fig. 6.7.1. The first digit refers to the chapter, the second digit refers to the main section in which the figure or table appears, and the third digit represents the consecutive order in the main section. Chapters are identified on each page with a tab box at the edge of the page for easy reference. The term member, representing a precast concrete unit, has been changed to component throughout the handbook. This was done to be consistent with the title for chapter 5 of the seventh-edition PCI Design Handbook. For the most part, American Concrete Institute nomenclature and formatting has been used.

Synopsis of changes from the sixth-edition PCI Design Handbook

Some things in the seventh-edition PCI Design Handbook remain unchanged from the sixth edition. The number of chapters has been increased from 11 to 15 as a result of the PCI Industry Handbook Committees intent to provide more emphasis on some topics, including fire endurance and vibrations. Chapter 9, Precast and Prestressed Concrete: Materials, is totally new and compiles discussions of materials that were in individual chapters in previous editions. Chapter 2 is also totally new and includes the notation used throughout the entire handbook on a chapter-by-chapter basis. Table 1 outlines the differences from the sixth edition to the seventh edition of the PCI Design Handbook. The seventh edition of the PCI Design Handbook, while similar to the sixth edition in many ways, incorporates modifications that generally fall into one of the following categories: It includes updated information reflecting changes from ACI 318-02 to ACI 318-05, incorporating new and revised provisions. Note that changes related to ACI 318-08 are identified in the appendix to the seventh edition.

The user will also observe that some sections of the sixth edition have been omitted from the seventh edition. They are:

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Table 1. Comparison of 6th and 7th editions of the PCI Design Handbook Sixth edition Chapter 1 2 3 4 5 6 7 8 9 10 Ch. 5 in 6th New Sect. 9.3 in 6th Sects. 9.1 and 9.2 in 6th Sect. 9.7 in 6th Ch. 8 in 6th Ch. 10 in 6th Ch. 11 in 6th New New Ch. 2 in 6th Ch. 3 in 6th Ch. 4 in 6th Pages 32 n.a. 58 124 132 102 22 36 n.a. 26 Figures 58 n.a. 8 20 25 39 15 27 n.a. 19 Tables 5 n.a. 32 2 8 5 3 4 n.a. 13 Design examples n.a. n.a. n.a. 19 43 23 n.a. 6 n.a. 5 Design Aids n.a. n.a. 8 26 14 15 n.a. n.a. n.a. n.a. Pages 28 18 64 98 152 116 36 28 42 26 Figures 63 n.a. 8 34 38 39 18 27 22 17 Seventh edition Tables n.a. n.a. 32 4 8 11 4 4 10 13 Design examples n.a. n.a. n.a. 13 48 26 3 4 n.a. 4 Design Aids n.a. n.a. 11 26 15 14 n.a. n.a. n.a. n.a.

11

23

15

n.a.

26

15

n.a.

12 13 14 15 Appendix Totals

8 34 36 58 n.a. 691

2 6 n.a. n.a. n.a. 223

3 13 n.a. n.a. n.a. 103

3 2 n.a. n.a. n.a. 105

n.a. n.a. n.a. 31 n.a. 94

10 34 36 62 22 776

2 6 n.a. n.a. 6 278

3 11 n.a. n.a. 8 115

3 2 n.a. n.a. n.a. 107

n.a. n.a. n.a. 37 n.a. 103

Section 9.5, Quality Assurance and Control. The committee felt that this section was redundant because three major PCI quality-control manuals already exist. They are MNL-1163 for structural precast concrete, MNL-1174 for architectural precast concrete, and MNL-1305 for glass-fiber-reinforced concrete. Section 9.9, Precast Segmental Construction. This topic is outside the area of building construction, which is the emphasis of the handbook, and more up-to-date

information is available in other publications. Section 9.10, Coordination with Mechanical, Electrical and Other Sub-Systems. At the time of publication of the seventh edition, it was the intent of PCI to develop a recommended practice and guidelines for total precast concrete structures and the committee considered that this new publication would provide more information than could be included in the handbook.

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The handbook committee process

It is of interest to review the process by which the seventh edition of the PCI Design Handbook was created. As soon as the sixth edition was published in 2004, a new Industry Handbook Committee was established. It consisted of 25 full members and 3 consulting members. Eighteen of these people served on the previous sixth-edition committee. They represent various interests within the industry and include 15 specialty engineers, 9 plant engineers, 2 tradeassociation engineers, and 2 academics. The process used was as follows: 1. The committee used the sixth edition as the baseline, with the understanding that ACI 318-05, American Society of Civil Engineers (ASCE) 7-05,6 and International Building Code 2006 (IBC 2006)7 would be the relevant references for the seventh edition. The committee agreed on a new arrangement, increasing the number of chapters from 11 to 15, as described later in this article. A subgroup of three to seven members (including a chairperson) was established for each chapter. The objective of each chapter subgroup was to perform a detailed review of the existing chapter and an exhaustive review of research and publications relevant to the subject of the chapter subsequent to the sixth edition. After analysis of information discovered in the subgroups reviews and discussion regarding improved and/or updated content, each subgroup developed a draft of its respective chapter. Each chapter was then edited by the editor, and a committee-ballot version was created. Each chapter was balloted by the committee, and all comments were resolved during meetings of the full committee. This process included 14 face-to-face meetings and 9 web-based teleconferences over the four-year course of development. The intensity peaked during 2009 with two face-to-face meetings and all nine of the teleconferences. In addition, hundreds of individual telephone calls and thousands of emails between members and to and from the editor took place. Additional editing was done, and a Technical Activities Council (TAC) ballot version was created. Each chapter was balloted by TAC with resolution of all comments by both TAC and the Industry Handbook Committee.

9.

Based on these approved versions, a blue-ribbon-review version was created. This final review phase consisted of the Blue Ribbon Review Committee, made up of plant engineers, specialty engineers, consulting engineers, academics, and associate members. Each member of the Blue Ribbon Review Committee is a recognized leader in the analysis and design of precast and prestressed concrete structures or an expert in a closely related field. The members of the Blue Ribbon Review Committee are noted in the foreword to the handbook. After a six-week review period, this group met for three days and offered valuable comments that were considered by the Industry Handbook Committee. Most were accepted as improving the publication. Others will be considered as new business for the eighth edition.

10. A final version of each chapter was then created and reviewed thoroughly by the original chapter subgroup. This review resulted in a few corrections and further improvement. 11. In addition, a comprehensive editorial and technical review of the handbook was carried out by the PCI Publications Department, led by Emily Lorenz, editorin-chief of the PCI Journal, as well as Jason Krohn, PCIs Managing Director of Technical Activities. It is commendable that the seventh edition of the PCI Design Handbook was created primarily through the volunteer efforts of the committee members and many others. Thousands of hours were devoted to its development, which, at normal consulting rates, would easily exceed a value of $2 million. The following presents a chapter-by-chapter review of the contents, outlining the general content and emphasizing changes from the sixth edition as well as the rationale behind these changes.

2.

3.

4.

5. 6.

Chapter 1Precast and Prestressed Concrete: Applications

This chapter is intended to provide the user of the handbook with a general understanding of the many applications of precast and prestressed concrete used in buildings and other structures. (For bridges, a separate publication by PCI, the Precast Prestressed Concrete Bridge Design Manual,8 should be consulted.) As is typical with each new edition of the PCI Design Handbook, the photographs have been updated to illustrate the current state of the art. As a result of the newer photographs, captions and text referring to the photographs have been updated. Although the handbook is not intended for bridges, a photograph of the Walnut Lane Memorial Bridge (Fig. 1) has been retained to remind the user of the beginning of

7. 8.

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the prestressed concrete industry in the United States. For additional information related to the history of the industry, refer to Reflections on the Beginnings of Prestressed Concrete in America,9 published in 1981, and PCI Visions Taking Shape,10 published in 2004. These documents commemorate the 25th and 50th anniversaries of PCI, respectively. The sixth-edition figure of typical products has been replaced with a collage of photographs to better illustrate the variety of products available (Fig. 2). Because of the growing emphasis on sustainability, section 1.1.3, Sustainability and LEED Considerations, has been added to describe the benefits of precast and prestressed concrete in achieving long-lasting and energy-efficient structures. A new section 1.2.1.7, Educational Facilities, has been added to better illustrate the importance of these applications and to present to the user of the handbook the superior solutions that precast and prestressed concrete offers to the owners of these facilities. The sixth-edition section 1.3, Materials, was completely removed from chapter 1. It was extensively expanded and has become the new chapter 9 of the PCI Design Handbook, seventh edition. See the discussion in this article on chapter 9 for further details of the changes and additions on the subject of materials.

Figure 1. Walnut Lane Memorial Bridge.

stairs, and section 3.3.12 and Design Aid 3.12.11, which provides guidelines for stadium riser sections. Design Aid 3.12.7 has been added to assist in preliminary sizing of non-load-bearing wall panels.

Chapter 4Analysis and Design of Precast/ Prestressed Concrete Structures

This chapter was chapter 3 in the sixth edition. The chapter on the analysis and design of precast and prestressed concrete structural systems has been updated to reflect the requirements of ACI 318-05, IBC 2006, and ASCE 7-05. There has been an update of the discussion on precast concrete lateral systems, which reflects the more-severe treatment in ASCE 7-05 of cantilevered column systems. The ASCE 7-05 update for seismic systems includes an alternate equation for the determination of the approximate building period for shear-wall structures. The change to the requirements and factors for redundancy for high-seismic design categories is discussed. The discussion of recommended loads for diaphragm design has been updated in an effort to clarify the difference between a diaphragm overstrength factor and the system overstrength factor 0. The new, more prescriptive requirement for a positive horizontal connection force parallel to supported components in ASCE 7-05 section 12.1.4 is discussed as part of updated information on structural integrity. Some advanced results from the PCI-sponsored volumechange study have also been included.11 The design examples for moment-resisting frames are covered in more detail in the PCI Seismic Design Manual,12 published in 2007, and are no longer repeated in the handbook.

Chapter 2Notations
This chapter is completely new and includes the notations for the entire handbook. This is the result of the PCI Industry Handbook Committees intention to make the handbook similar to ACI 318-05. It was the original intention to include definitions in this chapter, but the committee considered it more user friendly to include definitions either at the beginning of each chapter or in the text where a term is used. It is important to recognize that notations identical to those used in ACI 318-05 are identified with (ACI) after the definition.

Chapter 3Preliminary Design of Precast/Prestressed Concrete Structures

This chapter was chapter 2 in the sixth edition. The load tables in the chapter have been updated to meet the latest ACI 318-05, IBC 2006, and ASCE 7-05 provisions. Load capacities have not changed significantly, except for short-span components where reduced phi factors in the prestressed transfer zone govern the design. Preliminary Design Aids for several new products have been added to the seventh edition, including section 3.3.11 and Design Aid 3.12.10 for use in sizing precast concrete

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Figure 2. Typical products of the industry.

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bays at
Elevator

Collector force demand

typical

typical

Ramp up

Stair well

Figure 3. Collector force demand diagram for shear walls in a parking garage. See note a in Postpublication Notes at the end of this article.

Examples for shear-wall buildings and for precast concrete diaphragms have been updated to clarify diaphragm and collector design procedures. Diaphragm design has been expanded, and more detail is provided for collectors.

Figures 3 and 4 illustrate the intent of ASCE 7-05 and IBC 2006. An entirely new section (section 4.9) on blast-resistant design has been added to the chapter. This section discusses the special considerations of large-magnitude,

Shear wall Connection to shear wall

Collector reinforcement in line with shear wall Cast-in-place topping

Collector reinforcement in topping

Double-tee deck

Figure 4. Perspective view of shear wall and collectors. PCI Journal | Fa l l 2010 135

bays at

Shear walls

Ramp down

Table 2. Recommended shear-friction coefficients (6th edition) Crack interface condition 1. Concrete to concrete, cast monolithically 2. Concrete to hardened concrete, with roughened surface 3. Concrete to concrete 4. Concrete to steel Recommended 1.4 1.0 0.6 0.7 Maximum e 3.4 2.9 2.2 2.4 Maximum Vu = Vn 0.302f ' Acr 10002Acr c 0.252f ' Acr 10002Acr c 0.202f ' Acr 8002Acr c 0.202f ' Acr 10002Acr c

Table 3. Recommended shear-friction coefficients (7th edition) Case 1 2 3 4 Crack interface condition Concrete to concrete, cast monolithically Concrete to hardened concrete, with roughened surface Concrete placed against hardened concrete not intentionally roughened Concrete to steel a 1.4 1.0 0.6 0.7 Maximum e 3.4 2.9 Not applicableb Not applicableb
c

Maximum Vu / 0.30f 'c Acr 1000Acr 0.25f 'c Acr 1000Acr 0.20f ' Acr 800Acr c 0.20f ' Acr 1000Acr c

a. In accordance with ACI 318-05 Section 11.7.4.3. b. The use of e is not applicable for concrete placed against hardened concrete not intentionally roughened or against steel. c. The handbook shows this as 0.30f ' Acr 1000Acr. This is incorrect. It should be 0.20f ' Acr 1000Acr. c c

short-duration loads on precast concrete systems with large mass and inertia. Topics include blast loads, dynamic material properties, and blast-design methods. A blast-design example for a cladding panel is also included.

Chapter 5Design of Precast and Prestressed Concrete Components

This chapter was chapter 4 in the sixth edition. Section 5.2.3 and example 5.2.3.2 have been revised to allow for the use of an interpolated phi factor for underdeveloped strand in accordance with ACI 318-05 section 12.9.1. This section and the example show that for the flexural analysis of a section with fully and partially developed strand, the partially developed strands will maintain their load when strained beyond the slipping strain. See note b in Postpublication Notes at the end of this article. Section 5.2.5 has been significantly expanded to increase design guidelines and provide a complete design example for stadium-seating components. Based on a review of the original research,13 section 5.3.6 has been revised to correct the equation for the effective shear friction coefficient (Eq. [5-33]) to include the phi factor in the numerator. Also, based on this review of
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the original research, use of the effective coefficient of friction with concrete placed against hardened concrete not intentionally roughened and concrete-to-steel interfaces has been disallowed, and the formulas for maximum shear stress (right column of Table 4.3.6.1 in the sixth edition) have been revised to remove the squared from the lambda terms. Other sections using shear friction have been updated to be consistent with these revisions. A comparison of the sixth-edition and seventh-edition tables is shown in Tables 2 and 3. Based on recent experience with self-consolidating concrete (SCC) in which the surface remained slick after curing, a warning has been included regarding selection of the appropriate interface condition when corbels are cast on the up face of components cast using SCC. In section 4.5 of the sixth edition, Beams with Ledges, the table for ledge design m factors has been removed because the committee felt that solving Eq. (5-52) of the seventh edition is as easy as looking up a value for m in the chart. Also, Fig. 5.5.3 includes corrections for determining the m factor for an inverted-tee beam based on the original research.14

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Concerns raised by PCI Professional Members suggested the need for better clarity of the detailing requirements for dap-ended members. Accordingly, the committee modified Fig. 5.6.3 by enlarging the alternative dap reinforcement detail to clarify and emphasize the importance of dap reinforcement detailing and placement. Section 5.8, Camber and Deflection, was expanded, primarily to provide guidance for the use of ACI 318-05 Table 9.5(b) Maximum Permissible Computed Deflections (PCI Design Handbook Table 5.8.1). Section 5.9, Compression Components, contains several significant revisions. In section 5.9.1, the section allowing elimination of lateral ties in certain instances based on Recommended Practice for the Design of Prestressed Concrete Columns and Walls15 has been removed because the reference no longer contains these exceptions. In Example 5.9.1.1, the interaction curve has been modified to better show its actual shape. In Example 5.9.3.1, the stiffness-reduction factor has been changed to K = 0.85, as suggested by ACI 318-05 section R10.11.1. Section 5.9.4, Concrete Brackets or Corbels, has been moved into this chapter from chapter 6, Design of Connections, in the sixth edition, on the basis that this is part of the component design rather than a connection. Section 5.10, Shear Walls, is a completely new section. It provides an introduction to the design of precast concrete shear walls, including a design example. Section 5.11, Sandwich Panels, was moved into this chapter from chapter 9 of the sixth edition, Thermal, Acoustical, Fire and other Considerations, because it is an important aspect of many precast concrete structures and is more appropriate with a discussion about component design. Section 5.12.1, Point Loads on Double-Tee Flanges, is a new section, though the design example was in the Analysis Using Strain Compatibility subsection of the Flexure section of the sixth edition. Determination of the effective resisting width for a point load has been revised to more accurately reflect load test data.16 Section 5.12.7, Warping of Deck Components, is a completely new section. It addresses the warping of doubletees, especially in parking structures, to obtain desired drainage patterns. Recommendations are based on experience and relatively recent research.17 Design Aid 5.14.15 now provides updated corbel capacities and more clearly illustrates whether the capacity is limited by flexure, shear, or maximum Vu.

Chapter 6Design of Connections

Section 6.2.3 has been added to differentiate IBC 2006 requirements from recommended PCI values for seismic overstrength factors for lateral-force-resisting systems. Tables 4 and 5 (Tables 6.2.1 and 6.2.2 in the seventhedition PCI Design Handbook) have been added to clarify overstrength factors applicable for diaphragms and collector systems, respectively. Section 6.4.3.1, Reinforcing Bars in Conduit, has added requirements for supplemental reinforcement based on the previous research.18 Table 6.5.5, Summary table of HCA (headed concrete anchors) group concrete shear strength equations, has been added to conveniently show the appropriate design factor for each failure mode. Design Example 6.5.5.4, Design of Bearing Seat with Headed Concrete Anchors (Example 6.5.8.1 in the sixth edition), has been modified to include the weld requirements for the bearing seat, and a table has been added that shows all of the component design strengths. Further explanation of the interaction of tension and shear for headed concrete anchors has been added to section 6.5.8, Interaction of Tension and Shear. Examples 6.6.5.1(a) and 6.6.5.1(b) are new and illustrate the design procedure for an unstiffened connection angle using headed concrete anchors and bolts, respectively. Section 6.7.2.1, Fillet Welds, has been modified to more accurately represent the nominal design strength of a fillet weld element. This section now includes the effect of the angle of loading with respect to the axis of the weld element. Enhancement has been added to the Instantaneous Center Method (ICM) for weld design in section 6.7.5.2 to more clearly demonstrate the design approach. Chapter 5 modified the calculation of effective shear friction, and this revision has been applied to the chapter 6 design examples, where appropriate. Cazaly Hanger, section 6.9.1, has been modified to reflect recent research indicating that previous editions may not have been adequately conservative. While the procedure is essentially the same, an additional requirement for anchor reinforcement has been introduced to avoid a concrete breakout failure (Fig. 5). This is illustrated below.

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Table 4. Diaphragm overstrength factorsa factor table design element A Diaphragm to SFRS connection Bearing-wall systems Building-frame systems Moment-resisting systems Dual system with special moment frames Dual system with intermediate moment frames Inverted pendulum system and cantilevered-column systems Diaphragm chord element Bearing-wall systems Building-frame systems Moment-resisting systems Inverted-pendulum system and cantilevered-column systems DiaphragmDESIGN OF CONNECTIONS joint shear connection Bearing-wall systems Building-frame systems 1 1 1 1 1 1 1 1 1b 1b 1b 1b 2 2 1 1 2 2 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1b 1b 1b 1b 2 2 1 1 2 2 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2.5a 2.5a 2.5a 2.5a 2.5a 2.5a 2.5a 2.5a 3a 2.5a 2.5a 2 2.5a 2.5a 3a 2.5a 2.5a 2 2.5a 2.5a 3a 2.5a 2.5a 2 B Seismic design category C D E F

Design of the bar or HSS is then accomplished so that:

nded when xamhave ances cy in

The size of the bar must be such that for combined Moment-resisting systems the actual stress 0.9Fy flexure and tension
Inverted-pendulum system and cantilevered-column systems For flexure:

Zrequired = Mu the y = [Vu(lp + g + c + 0.5S a. The tabulated value of /Fdiaphragm overstrength factor w) may be reduced by subtracting 0.5 for structures with flexible diaphragms but shall not be taken as less than + Nfor any structure. 2.0 u (0.5)Y]/Fy (Eq. 6-81)
b. For seismic design categorytrial section check that the actual the maximum distributed design force at that level is used. Then based on a C diaphragms, it has been assumed that

stress due to combined flexure and tension is 0.9Fy For shear: Actual shear stress is 0.9(0.6Fy) 4. Provide anchor reinforcement distributed uniformly over 0.8d as illustrated in Fig. 6.9.2(b) to resist 1.33 Vu. Section 6.13, Typical Connections, has been added to represent typical connection details used in total precast concrete structures. Example 6.13.6, Wall-to-Wall Shear Connection with Combined Loading, is new and illustrates a combined shear and tension connection and the interaction equations for each component and the capacity region of the assembly. Example 6.13.8, Deformed Bar or Reinforcing Bar Connection Plate Supporting Steel Beam, is new and illustrates a typical connection for a steel, wide-flange beam connected to a plate with deformed bar anchors. See note c in Postpublication Notes at the end of this article. Design Aids 6.15.4 and 6.15.5 no longer show weld size and minimum plate thickness requirements for welds using E70 electrodes for ASTM Grade 60 reinforcing bars because this is no longer allowed by AWS D1.4.19

nents lows

that The yield

Au Av =

1.33Vu fy

(Eq. 6-82)

-79)

Check minimum area required: where: b s A = 0.75 fc' w fy not less than 50bw

flexstartments

s fy

(Eq. 5-24)

bw = width of component (see Fig. 6.9.2(b)) s 5. = 0.8d The conservative and simplifying assumption that strap weld forces are concentrated at the strap centerline is implicit in the 0.5Sw factor in the value of a in Eq. 6-80. Fall 2 0 1 0 | PCI Journal

face rm is nd of ment 138 t this

Table 5. Seismic overstrength factorsa o factor table design element A Collectors (drag-ties) Bearing-wall systems Building-frame systems Moment-resisting systems Dual system with special moment frames Dual system with intermediate moment frames Inverted-pendulum system and cantilevered-column systems Collectors (drag-tie) transfer to vertical resisting element Bearing-wall systems Building-frame systems Moment-resisting systems Dual system with special moment frames Dual system with intermediate moment frames Inverted-pendulum system and cantilevered-column systems a. Table shown is condensed from ASCE 7-05, Table 12.2-1. b. The tabulated value of the system overstrength factor o may be reduced by subtracting 0.5 for structures with flexible diaphragms but shall not be taken as less than 2.0 for any structure. 1 1 1 1 1 1 1 1 1 1 1 1 2.5 2.5 3 2.5 2.5 1.25 2.5 2.5 3 2.5 2.5 1.25 2.5 2.5 3 2.5 2.5 1.25 2.5 2.5 3 2.5 2.5 1.25 1 1 1 1 1 1 1 1 1 1 1 1 2.5 2.5 3 2.5 2.5 1.25 2.5 2.5 3 2.5 2.5 1.25 2.5 2.5 3 2.5 2.5 1.25 2.5 2.5 3 2.5 2.5 1.25 B Seismic design category Cb Db Eb Fb

1 1

/2b d b An Nu d h bw b

/2p

3a s = 0.8d

Y Cantilever bar or HSS Dowels Steel hanger strap Support Vu Av

Nu

p g c

d Strap, Sw

Avf Outline of component (b)

Main reinforcement

(a)

Figure 5. Cazaly hanger. PCI Journal | Fa l l 2010 139

Deflected position of grid Column lines Floor level

Spandrel panel in translated position Seismic reaction

Seismic reactions C.G.

Seismic force

C.G.

Seismic force Window

Floor level Seismic reactions (a) Wall panels Note: Gravity and out-of-plane loads to connectors not shown; C.G. = center of gravity

Spandrel panel (b) Spandrel panels Bearing connection

Tie-back connection

Allowed movement direction

Figure 6. Cladding panel connection conceptsseismic drift effect (translating panels).

Chapter 7Structural Considerations for Architectural Precast Concrete

This chapter is very much like its counterpart in the sixth edition, with several noteworthy additions: It includes material from the third edition of PCIs Architectural Precast Concrete,20 published in 2007, that is particularly important for a structural engineer designing architectural precast concrete to know. Three examples have been added. All three use the same cladding panel on the same building but consider different load conditions. The load cases are: Example 7.5.1.1, Use of ASCE 7 Method 1 for Wind-Load Determination. This is an extension of Example 4.2.3.1, which uses ASCE 7-05 to calculate wind loads on a building to design for the lateral-load-resisting-system. The example in this chapter covers the individual panels as a cladding component. Example 7.5.2.1, Use of ASCE 7 Method 2 for Wind-Load Determination. This example was added because Method 1 has a building height restriction of 60 ft (18 m) and many architectural cladding components are used on taller buildings.

Example 7.5.3.1, Architectural Precast Concrete Panel with Earthquake Loading. This example is the same as Example 3.2.4.2 in the sixth edition, but has been expanded to reflect appropriate seismic factors. It includes comparisons of critical loads from the two previous wind-load examples to illustrate the actual design procedure that an engineer would use. Seismic drift considerations have been added to illustrate the need for some connections to move in different directions to avoid unintended forces acting on the cladding and/or the supporting structure. This is illustrated in Fig. 6. The chapter has added recommendations for where to locate connections on cladding panels to provide predictable behavior. This is illustrated in Fig. 7.

Chapter 8Component Handling and Erection Bracing

This was chapter 5 in the sixth edition. The new section 8.3.3, Spreader Beams, has been added to provide guidance for the design of spreader beams used in handling precast concrete components. Section 8.6, Erection Handling, has been revised to address uncontrolled rolling when erecting wall panels with three-point pick using rolling blocks between the two bottom lifting points. Some erectors and engineers have

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Column cover options (b) (c)

(a) Wall panel

Bearing connection Tieback connection

(d) Spandrel panel

2 b2 e> a 2 2
Optional for long panels Figure 8. Stability during erection.

Figure 7. Typical cladding connection locations.

observed firsthand that the equation shown in Fig. 5.6.2 of the sixth edition for the distance from the lower rolling block to the center of gravity is incorrect. This is shown in Fig. 8. A paper written by Don Logan, P.E., in the Winter 2010 PCI Journal21 explains in detail the potential risks associated with using this equation. As a result, the Industry Handbook Committee has recommended the rigging arrangement illustrated in Fig. 9 to avoid this condition. Section 8.7, Erection Bracing, was reduced to an abbreviated version, and design examples were removed. This was a topic that was debated significantly by the Industry Handbook Committee, primarily as a result of the difference between the experiences of the committee members and the requirements of ASCE 37-02 Design Loads on Structures During Construction.22 It was concluded that because ASCE 37-02 is not a mandatory code, the loads imposed on precast concrete structures during erection should be the responsibility of the experienced precast concrete designer. With that responsibility must go the authority to define the loading requirements during this temporary stage.
Figure 9. Stability during erection.

Center of gravity

tion, reinforcement, waterproofing, and in-service repairs. The chapter also includes a number of new figures, graphs, and tables to augment the text. Because the handbook is often used as a textbook at the university level and many students have not been exposed to typical materials used in the industry, several photographs have been includedfor example, prestressing strand (Fig. 10) and standard reinforcement (Fig. 11). Section 9.2, Concrete, covers the constituent materials of the concrete matrix, consisting of cement, supplementary cementitious materials (SCMs), aggregates, admixtures, and pigments. Detailed descriptions are provided with relevant references to ASTM standards. Physical properties of concrete are introduced, such as compressive and tensile strength, modulus of elasticity, volume changes, and durability. Tables presenting common material parameters are given and photographs of good concrete and common deterioration mechanisms are presented, as illustrated in Fig. 12 and 13, respectively.

Chapter 9Precast and Prestressed Concrete: Materials

Chapter 9 is a new chapter dealing exclusively with materials affecting and used in precast and prestressed concrete construction. Chapter 9 represents a consolidation of several material sections that were contained in various chapters of past handbook editions. Major topics include concrete, grouts, connection materials, corrosion protec-

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Figure 10. Wire prestressing strand of various sizes. Figure 13. Planar cracking marking freezing and thawing damage.

viding protection against deterioration are covered within the context of waterproofing with coatings, joint sealant types and issues, and expansion joint sealant systems. In the event that a precast concrete component is damaged during transportation or erection, in-service repairs are reviewed. Other in-service conditions are also examined, and suggested maintenance and strengthening means are provided. The chapter concludes with section 9.9, Relevant Standards and Publications, which is a comprehensive listing of reference standards and publications relevant to materials. These standards may also appear in project specifications prepared by the engineer of record or architect of record.

Figure 11. Reinforcing bars of various sizes, from no. 18 to no. 3.

Chapter 10Design for Fire Resistance of Precast and Prestressed Concrete

This was section 9.3 in the sixth edition and is now a standalone chapter to emphasize the many benefits of precast concrete in fire protection. Section 10.6.2, Continuous Components (section 9.3.7.2, Continuous Members, in the sixth edition), has been shortened by eliminating other loading conditions beyond the two-span case discussed. Refer to PCI MNL-124-8923 for additional load case discussion. Example 9.3.7.1, Fire Endurance for Hollow-Core Slab with Topping, from the sixth edition has been eliminated because most applications for residential use do not use topping and still satisfy fire-endurance requirements. Example 10.8.1, Fire Endurance by Code Tables, for a double-tee with topping, has been updated to reflect IBC 2006.

Figure 12. Example of good air-void system.

Section 9.4, Connection Materials, reviews the common steel sections, bearing pads, and bolts used in connections. This is followed by a discussion on the galvanic series and its importance in examining service life and protection of connections. Protection means are discussed, including painted systems, galvanized steel, and stainless steel, and the proper means of specifying them. Section 9.6, Reinforcement, describes various systems for precast and prestressed concrete components and the various deterioration mechanisms that can occur. Different means of embedded steel protection are presented to mitigate common deterioration problems. Other means of pro-

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A new section 10.8, Requirements for Parking Structures, has been added to assist the user in applying the requirements and tables in IBC 2006 to the design of precast and prestressed concrete components typically used in parking structures. Several paragraphs that outline recent research at Lehigh University are included in this section. This research was performed to evaluate realistic vehicle-fire loads (time-temperature or time-heat flux relationships) for precast concrete parking structures. This work investigated the influence of the structural geometry and fire characteristics on the resulting fire load.

Chapter 12Vibration Design of Precast/Prestressed Concrete Floor Systems

This was section 9.7 in the sixth edition and is now a standalone chapter to demonstrate the importance of vibration control in certain types of facilities. There are no significant changes; however, a minor change is the addition of three double-tee sections to Fig. 12.4.1 (Fig. 14). They are 12DT28+2, 12DT30, and 15DT34.

Chapter 11Thermal and Acoustical Properties of Precast Concrete

The topics of chapter 11 comprise sections 9.1 and 9.2 from the sixth edition. The chapter provides updated information on both topics, as well as adding design guidelines for calculating the thermal resistance of sandwich panels using metal ties between concrete wythes.

Chapter 13Tolerances for Precast and Prestressed Concrete

Chapter 13 in the seventh edition was chapter 8 in the sixth edition. It was moved to accommodate other major changes in the layout of the PCI Design Handbook. The only other changes are editorial and correction of some minor errors.

Chapter 14Specifications and Standard Practices

This chapter was chapter 10 in the sixth edition. The most significant change from the previous edition was the reorganization of the sections. PCI Standard Design Practice (section 14.1) has been placed first because it is believed to be the most important information for the

12 11 10 9

10

DT

With 10 lb/ft superimposed load f c = 5000 psi, normalweight Ed = 1.2 33 1501.5 f c

32

Natural frequency fn, Hz

8D
2 2+

T2

4+

12
2

+2

4H

DT

28

+2

15

6 FS +2

DT

+ C8 4H 2

C1

34
30

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DT

Use of values below 3 Hz is not recommended

Span, ft
Figure 14. Natural frequency of selected floor units. PCI Journal | Fa l l 2010 143

designer in the chapter. It has been updated to reflect ACI 318-05 and has had extensive review by the PCI Building Code Committee and TAC. Sections 14.2 and 14.3 are brief descriptions of the guide specifications for structural and architectural precast concrete, respectively. They have both been updated to the latest ACI 301 and AIA Masterspec.24,25 The full guide specifications are on the CD in the front jacket pocket of the PCI Design Handbook and are in a usable word-processing format. Section 14.4, Standard Operations Practice Recommendations for Precast Concrete, has been updated to reflect current practices in the industry. Section 14.5, Recommendations on Responsibility for Design and Construction of Precast Concrete Structures, remains essentially the same as in the sixth edition.

AppendixImpact of ACI 318-08 on this Handbook

The appendix is totally new and is the result of PCIs TAC directing that the impact of ACI 318-0827 be included in the seventh edition. It is based entirely on four papers written by S. K. Ghosh and published as a supplement to separate issues of the PCI Journal.2831 The PCI Industry Handbook Committee reviewed those papers and included in the appendix those portions that have an impact on sections of the handbook.

Conclusion
Most of the goals established by the PCI Industry Handbook Committee for the seventh edition have been accomplished. However, several were not and will remain goals for the eighth edition, as noted in the following paragraphs. Chapter 2, Notations, was intended to include definitions used throughout the handbook, as well as other terms typically used in the industry that might not be specifically used in the handbook. Terms such as down-in-form, chuck, stripping, dunnage, and the like are used in everyday conversation in plants and may be helpful for the inexperienced designer or student using the handbook. A review of chapter 2 also resulted in the observation that the notation used in the handbook could be improved with a complete overhaul. Many of the same notations have different meanings, which can cause confusion. Examples include the notation R, which is the response modification factor for seismic design in chapter 4 and the thermal resistance of a precast concrete component in chapter 11. There are numerous less-critical topics and suggested changes brought forward for consideration, but the decision to incorporate them was postponed because of timing and publishing constraints. Similar thoughts occurred during the blue-ribbon review. The committee has gathered these items for future consideration and has provided them to the next PCI Industry Handbook Committee, to be chaired by Tim Salmons, P.E., S.E. The list of items for the eighth edition of the PCI Industry Handbook Committee to address also includes: ACI 318 intends a major revision in 2013, with only an interim revision in 2011. PCIs TAC will direct the PCI Industry Handbook Committee as to which versions of ACI 318, IBC, and ASCE will be used for the eighth edition. Consider making the publication a two-volume set, with one including material that does not necessarily change with the code cycles. Use 3 in. (75 mm) topping for double-tee load tables instead of 2 in. (50 mm).

Chapter 15General Design Information

This chapter was chapter 11 in the sixth edition. The following is a listing of the most significant changes in this chapter: All Design Aids have been reorganized to better reflect the topic. All Design Aids have been updated to reference the current model codes and standards. Numerical values have been modified where required. For example, the uniform floor loading in passenger-car parking structures was revised from 50 lb/ft2 (244 kg/m2) to 40 lb/ft2 (195 kg/m2). The sixth-edition Design Aid 11.2.1 has been omitted from the seventh edition because it is easy to calculate the values that are a function of the concrete strength. The sixth-edition Design Aid 11.2.2 has been updated in the seventh edition as Design Aid 15.2.1 to include the recommended curves using two recognized equations for the modulus of elasticity of concrete. The new seventh-edition Design Aid 15.4.2 has been added and includes typical bent reinforcing bar configurations and designations. The source for this information is ACIs publication Details and Detailing of Concrete Reinforcement.26 The new seventh-edition Design Aid 15.5.4 has been added and illustrates common styles of welded-wire reinforcement (WWR) shear reinforcement used in the ends of double-tee stems.

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Reintroduce material related to erection bracing and include examples. Create a uniform format for all examples and all figures. Consider providing a final draft of the eighth edition to the entire engineering community for public comment. While the seventh edition has had a very intense review process, it cannot be considered a consensus document. Responding to public comments would allow the document to achieve this status. Update the handbook to reflect ongoing research.

3.

PCI Plant Certification Committee. 1999. Manual for Quality Control for Plants and Production of Structural Precast Concrete Products. MNL-116-99. 4th ed. Chicago, IL: PCI. PCI Architectural Precast Concrete Services Committee and Plant Certification Committee. 1996. Manual for Quality Control for Plants and Production of Architectural Precast Concrete Products. MNL-117-96. 3rd ed. Chicago, IL: PCI. PCI Glass Fiber Reinforced Concrete Panels Committee. 2009. Manual for Quality Control for Plants and Production of Glass-Fiber Reinforced Concrete Products. MNL-130-09. Chicago, IL: PCI. American Society of Civil Engineers (ASCE). 2005. Minimum Design Loads for Buildings and Other Structures. Structural Engineering Institute (SEI)/ ASCE 7-05 and Supplement No. 2. Reston, VA: ASCE. International Code Council. 2006. International Building Code 2006. Falls Church, VA: ICC. PCI Bridge Design Manual Steering Committee. 1997. Precast Prestressed Concrete Bridge Design Manual. MNL-133-97. 1st ed. Chicago, IL: PCI. PCI. 1981. Reflections on the Beginnings of Prestressed Concrete in America. Chicago, IL: PCI.

4.

5. As stated in the foreword, the PCI Design Handbook is a living document. Comments related to any aspect of the handbook are encouraged and much appreciated. This handbook has had a very intensive review at several levels. It must be understood, however, that all errors may not have been observed and corrected during these reviews. PCI therefore intends to publish errata based on input of the users of the handbook over the next several months. The errata will also be posted on PCIs website at www.pci.org. Address all comments to PCIs Managing Director of Technical Activities at PCI, Jason Krohn, 200 West Adams Street, Suite 2100, Chicago, IL 60606.

6.

7. 8.

Postpublication Notes
After publication of the handbook, several errata that affect this article were observed as follows. These and other errata will be published in a future issue of the PCI Journal. a. Figure 4.8.4 of the seventh edition is not correct in that the horizontal line just above the lower shear wall on the right side of the plan should line up with the end of that shear wall. Figure 3 in this article is correct. Example 5.2.3.2 does not correctly reflect the text of the seventh edition in that it does not properly account for load in the partially developed strands. Use of E70 electrodes has been a common practice in the industry for years. The statement that this is no longer allowed by AWS D1.4 is incorrect. Refer to the sixth-edition PCI Design Handbook, which is correct. 9.

10. Schutt, Craig, ed. 2004. PCI 50 Years: Visions Taking Shape. Chicago, IL: Cherbo Publishing Group Inc. 11. Klein, G. J., and R. J. Lindenberg. 2009. Volume Change Movement and Forces in Precast Concrete Buildings. Research report, PCI, Chicago, IL. 12. Cleland, Ned and S. K. Ghosh. 2007. Seismic Design of Precast/Prestressed Concrete Structures. MNL140-07. Chicago, IL: PCI. 13. Mattock, A. H., W. K. Li, and T. C. Wang. 1976. Shear Transfer in Lightweight Reinforced Concrete. PCI Journal, V. 32, No. 1 (JanuaryFebruary): pp. 2039. 14. Klein, G. J. 1986. Design of Spandrel Beams. PCISFRAD project no. 5. PCI Journal, V. 31, No. 5 (SeptemberOctober): pp.76124. 15. PCI Committee on Prestressed Concrete Columns. 1988. Recommended Practice for the Design of Prestressed Concrete Columns and Walls. PCI Journal, V. 33, No. 4 (JulyAugust): pp. 5675. 16. Aswad, Alex, and George Burnley. 1991. Point Load

b.

c.

References
1. PCI Industry Handbook Committee. 2010. PCI Design Handbook: Precast and Prestressed Concrete. MNL120-10. 7th ed. Chicago, IL: PCI. American Concrete Institute (ACI) Committee 318. 2005. Building Code Requirements for Structural Concrete (ACI 318-05) and Commentary (ACI 318R-05). Farmington Hills, MI: ACI.

2.

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Tests of Double-Tee Flanges. PCI Journal, V. 36, No. 4 (JulyAugust): pp. 6673. 17. Mack, P., G. Force, C. Magnesio, and K. Bryan. 2003. The Practice of Warping Double-Tees. PCI Journal, V. 48, No. 1 (JanuaryFebruary): pp. 3248. 18. Concrete Technology Associates (CTA). 2000. Ductile Pullout Connections. CTA Technical Bulletins, Vol. II. Chicago, IL: PCI. 19. American Welding Society (AWS). 2002. Structural Welding CodeReinforcing Steel. AWS D1.4-02. Miami, FL: AWS. 20. PCI Architectural Precast Concrete Committee. 2007. Architectural Precast Concrete. MNL-122-07. 3rd ed. Chicago, IL: PCI. 21. Logan, D. 2010. Erecting Long, Vertical Precast Concrete Members with One Crane and Two Operating Lines. PCI Journal, V. 55, No. 1 (Winter): pp. 118136. 22. American Society of Civil Engineers (ASCE)/Structural Engineering Institute (SEI). 2002. Design Loads on Structures During Construction. SEI/ASCE 37-02. Reston, VA: ASCE. 23. PCI Fire Committee. 1989. Design for Fire Resistance of Precast Prestressed Concrete. MNL-124-89. 2nd ed. Chicago, IL: PCI. 24. American Institute of Architects. 2006. Masterspec 2004. Salt Lake City, UT: ARCOM. 25. ACI Committee 301. 2010. Specifications for Structural Concrete. Farmington Hills, MI: ACI. 26. ACI. 1999. Details and Detailing of Concrete Reinforcement. ACI 315-99. Farmington Hills, MI: ACI. 27. ACI Committee 318. 2008. Building Code Requirements for Structural Concrete (ACI 318-08) and Commentary (ACI 318R-08). Farmington Hills, MI: ACI. 28. Ghosh, S. K. 2008. Significant Changes to ACI 318-08 Relative to Precast/Prestressed Concrete: Part 1. PCI Journal. Suppl. no. 53-2. 29. Ghosh, S. K. 2008. Significant Changes to ACI 318-08 Relative to Precast/Prestressed Concrete: Part 2. PCI Journal. Suppl. no. 53-3. 30. Ghosh, S. K. 2008. Significant Changes to ACI 318-08 Relative to Precast/Prestressed Concrete: Part 3. PCI Journal. Suppl. no. 53-5.

31. Ghosh, S. K. 2009. Significant Changes to ACI 318-08 Relative to Precast/Prestressed Concrete: Part 4. PCI Journal. Suppl. no. 54-3.

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