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Fabrication Design
PresentationOutline
Planning Discussion
Stripping Process Design and Analysis
Prestress / Post Tension Effects
Handling Devices
Stripping Stress Examples
Storage Discussion
Transportation Discussion
Erection Discussion
Introduction
The loads and forces on precast and prestressed
concrete members during production,
transportation or erection will frequently require a
separate analysis
Concrete strengths are lower
Support points and orientation are usually
different from members in their final position
PrePlanningPieceSize
The most economical piece size for a project is
usually the largest, considering the following
factors:
Stability and stresses on the element during
handling
Transportation size and weight regulations and
equipment restrictions
PrePlanningPieceSize
Available crane capacity at both the plant and
the project site.
Position of the crane must be considered, since
capacity is a function of reach
Storage space, truck turning radius, and other
site restrictions
PlanningandSetup
Once a piece has been fabricated, it is necessary to remove it
from the mold without being damaged.
Positive drafts or breakaway forms should be used to allow a
member to lift away from the casting bed without becoming
wedged within the form
Adequate draft also serves to reduce trapped air bubbles.
PlanningandSetup
Lifting points must be located to keep member stresses within limits and
to ensure proper alignment of the piece as it is being lifted
Members with unsymmetrical geometry or projecting sections may
require supplemental lifting points and auxiliary lifting lines to achieve
even support during handling
Come-alongs or chain-falls are frequently used for these auxiliary
lines
PlanningandSetup
When the member has areas of small cross
section or large cantilevers, it may be necessary
to add a structural steel strongback to the piece
to provide added strength
PlanningandSetup
Members that require a secondary process prior to
shipment, such as sandblasting or attachment of
haunches, may need to be rotated at the production
facility. In these cases, it may be necessary to cast in
extra lifting devices to facilitate these maneuvers
PlanningandSetup
When developing member shapes, the designer
should consider the extra costs associated with
special rigging or forming, and pieces requiring
multiple handling
Stripping:General
Orientation of members during storage, shipping and final in-place position is
critical in determining stripping requirements
They can be horizontal, vertical or some angle in between
The number and location of lifting devices are chosen to keep stresses within the
allowable limits, which depends on whether the no cracking or controlled
cracking criteria is to be used
Stripping:General
It is desirable to use the same lifting devices for
both stripping and erection; however, additional
devices may be required to rotate the member to
its final position
Stripping:General
Stripping:General
When panels are stripped this way, care
should be taken to prevent spalling of
the edge along which the rotation
occurs
A compressible material or sand bed
will help protect this edge
Stripping:General
Stripping:General
In some plants,
tilt tables or
turning rigs are
used to reduce
stripping
stresses
Stripping:General
Stripping:General
RiggingConfigurations
Stresses and forces occurring during
handling are also influenced by the type
of rigging used to hook up to the
member
RiggingConfigurations
Lift line forces for a two-point lift using
inclined lines are shown
RiggingConfigurations
When the sling angle is small, the components of
force parallel to the longitudinal axis of the
member may generate a significant moment due
to secondary effects
RiggingConfigurations
While this effect can and should be accounted
for, it is not recommended that it be allowed to
dominate design moments
RiggingConfigurations
Consideration should be
given to using spreader
beams, two cranes or
other mechanisms to
increase the sling angle
Any such special handling
required by the design
should be clearly shown
on drawings
RiggingConfigurations
Using a spreader beam can also eliminate the use of
rolling blocks
Note that the spreader beam must be sufficiently
stiffer than the concrete panel to limit panel
deflections and cracking
Lifting hook locations, hook heights, and sling
lengths are critical to ensure even lifting of the
member
For analysis, the panel acts as a continuous beam
over multiple supports
StrippingDesign
StrippingDesign
PCI provides a table of typical values
FactorofSafety
When designing for stripping and handling, the
following safety factors are recommended:
Use embedded inserts and erection devices with a
pullout strength at least equal to four (4) times the
calculated load on the device.
For members designed without cracking, the
modulus of rupture (MOR) , is divided by a safety
factor of 1.5.
7.5
StressLimits&CrackControl
Stress limits for prestressed members during
production are discussed in Section 4.2.2.2 of
the the PCI Handbook
ACI 318-02 does not restrict stresses on nonprestressed members, but does specify
minimum reinforcement spacing, as
discussed in Section 4.2.2.1. (PCI chapter 4
member design)
StressLimits&CrackControl
Members which are exposed to view will generally be
designed for the no discernible cracking criteria (see
Eq. 4.2.2.2), which limits the stress to
.
In the case of stripping
fci should be
5 stresses,
substituted for fc
Whether or not the members are exposed to view, the
strength design and crack control requirements of ACI
318-02, as discussed in Chapter 4 of this Handbook,
must be followed.
BenefitsofPrestressing
Panels can be prestressed, using either
pretensioning or post-tensioning.
Design is based on Chapter 18 of ACI 31802, as described in Chapter 4 of this
Handbook. Further, tensile stresses should be
restricted to less
, must be
5 than
followed.
BenefitsofPrestressing
It is recommended that the average stress due to
prestressing, after losses, be within a range of 125 to
800 psi
The prestressing force should be concentric with the
effective cross section in order to minimize camber,
although some manufacturers prefer to have a slight
inward bow in the in-place position to counteract
thermal bow
It should be noted that concentrically prestressed
members do not camber, hence the form adhesion
may be larger than with members that do camber
StrandRecomendation
In order to minimize the possibility of splitting
cracks in thin pretensioned members, the
strand diameter should not exceed that
shown in the table below
Additional light transverse reinforcement may
be required to control longitudinal cracking
StrandRecommendations
When wall panels are post-tensioned, care must be
taken to ensure proper transfer of force at the
anchorage and protection of anchors and tendons
against corrosion
Straight strands or bars may be used, or, to reduce
the number of anchors, the method shown may be
used
StrandRecommendation
HandlingDevices
Since lifting devices are subject to dynamic
loads, ductility of the material is a requirement
Deformed reinforcing bars should not be used
as the deformations result in stress
concentrations from the shackle pin
Also, reinforcing bars may be hard grade or
re-rolled rail steel with little ductility and low
impact strength at cold temperatures
HandlingDevices
Strain hardening from bending may cause
embrittlement
Smooth bars of a known steel grade may be
used if adequate embedment or mechanical
anchorage is provided
The diameter must be such that localized
failure will not occur by bearing on the
shackle pin
AircraftCableLoops
For smaller precast members, aircraft cable can be
used for stripping and erection purposes
Aircraft cable comes in several sizes with different
capacities
The flexible cable is easier to handle and will not leave
rust stains on precast concrete
AircraftCableLoops
For some small precast members such as coping, the
flexible loops can be cast in ends of members and
tucked back in the joints after erection
Aircraft cable loops should not be used as multiple
loops in a single location, as even pull on multiple
cables in a single hook is extremely difficult to achieve
User should ensure that the cable is clean and that
each leg of the loop is embedded a minimum of 48 in.
PrestressingStrandLoops
Prestressing strand, both new and
used, may be used for lifting loops
The capacity of a lifting loop
embedded in concrete is dependent
upon the strength of the strand, length
of embedment, the condition of the
strand, the diameter of the loop, and
the strength of the concrete
PrestressingStrandLoops
As a result of observations of lift loop behavior
during the past few years, it is important that
certain procedures be followed to prevent
both strand slippage and strand failure
Precast producers tests and/or experience
offer the best guidelines for the load capacity
to use
A safety factor of 4 against slippage or
breakage should be used
StrandLoopsRecommendations
StrandLoopsRecommendations
Continued:
The diameter of the hook or fitting around
which the strand lifting eye will be placed
should be at least four times the diameter
of the strand being used
Do not use heavily corroded strand or
strand of unknown size and strength.
StrandLoopsRecommendations
In the absence of test or experience, it is
recommended that the safe load on a
single 1/2 in. diameter 270 ksi strand
loop satisfying the above
recommendations not exceed 8 kips
The safe working load of multiple loops
may be conservatively obtained by
multiplying the safe load for one loop by
1.7 for double loops and 2.2 for triple
loops
StrandLoopsRecommendations
StrandLoopsRecommendations
ThreadedInserts
Threaded inserts can have NC
(National Course) or coil threads
Anchorage is provided by loop, strut
or reinforcing bar
Inserts must be placed accurately
because their safe working load
decreases sharply if they are not
perpendicular to the bearing surface,
or if they are not in a straight line
with the applied force
ThreadedInserts
Embedment of inserts close to an edge will greatly
reduce the effective area of the resisting concrete
shear cone and thus reduce the tension safe working
load of the embedded insert
When properly designed for both insert and concrete
capacities, threaded inserts have many advantages
However, correct usage is sometimes difficult to
inspect during handling operations
ThreadedInserts
In order to ensure that an embedded insert acts
primarily in tension, a swivel plate as indicated in
should be used
It is extremely
important that
sufficient threads
be engaged to
develop the
strength of the bolt
ThreadedInserts
For straight tension loads only, eye bolts or wire
rope loops provide a fast method for handling
precast members.
Do not use either device if shear loading conditions
exist.
ProprietaryDevices
A variety of castings
or stock steel
devices, machined
to accept
specialized lifting
assemblies are used
in the precast
industry
ProprietaryDevices
These proprietary devices are usually recessed (using a pocket former)
to provide access to the lifting unit. The recess allows one panel to be
placed against another without cutting off the lifting device, and also
helps prevent spalling around the device
Longer devices are used for edge lifting or deep precast concrete
members
Shallow devices are available for thin precast concrete members.
ProprietaryDevices
ProprietaryDevices
These units have a rated capacity as
high as 22 tons, with reductions for thin
panels or close edge distances
Supplemental reinforcement may be
required to achieve these values
Shallow units usually have a spread
foot or base to increase pullout capacity
ProprietaryDevices
Reinforcing bars are required in two directions over the base to fully develop the lifting unit, as
shown in Figure below
ProprietaryDevices
WallPanelExample
WallPanelExample
Given:
A flat panel used as a loadbearing wall on a two-story
structure, as shown on next slide
Section properties (nominal dimensions are used for
design):
Solid panel
Panel with openings
A = 960 in2
A = 480 in2
Sb = St = 1280 in3
Sb = St = 640 in3
Ix = 5120 in4
Ix = 2560 4 in4
Unit weight @ 150 pcf = 100 psf = 0.100 ksf
Total weight = 35.2 kips (solid panel)
= 29.2 kips (panel w/ openings)
WallPanelExample
WallPanelExample
Stripping method:
Inside crane height prevents panel from being
turned on edge directly in mold, therefore, strip flat
Handling multipliers:
Exposed flat surface has a smooth form finish with
false joints. Side rails are removable. Use
multiplier of 1.4
WallPanelExample
fci at stripping = 3000 psi
Allowable tensile stresses at stripping and lifting:
Problem:
Check critical stresses involved with stripping. Limit stresses
to 0.274 ksi.
Compare Simple Solution to Mechanics Solution
SolutionSteps
Step 1 Determine section properties
Step 2 Select number of pick points and
determine maximum stress
Step 3 Determine stress from mechanic
approach
Step 4 Check panel with opening
Step 5 Check rolling block solution
Step 6 Check transverse bending
Step 7 Check secondary effects
Step1DetermineSectionProperties
Step24pointpick
Figure 5.36.1.1(a) (page 5-5)
My
Step2CheckStresses
4 Point Stresses
ft
Step28PointPick
Figure 5.3.1.1(b) (Page 5-5)
My
Step2CheckStresses
8 Point Stresses
ft
Step3MechanicsofMaterials
Step4PanelWithOpenings
ft
Step5RollingBlocks
If using a rolling block for handling as shown below,
the panel cannot be analyzed with the previous
method
Each leg of continuous cable over a rolling block
must carries equal load
Step5RollingBlock
w
Step6TransverseBending
Consider lower portion of panel with openings
Note that Figure Without the concrete in the area of the
opening, the weight is reduced and unevenly distributed.
Also, the resisting section is limited to a width of 4.7 ft.
Step6TransverseBending
Section through lifters:
w2
Step7SecondaryEffects
Check added moment due to sling angle
Using recessed proprietary lifting anchor
e = 3.5 in
sling angle
Step7SecondaryEffects
Resisting Section
Therefore Section is OK
PrestressedWallExample
Given:
Same wall
panel as
previous
example
PrestressedWallExample
Problem:
Determine required number of 1/2 in diameter, 270 ksi
strands pulled to 28.9 kips to prevent cracking in window
panel. Assume 10% loss of prestress.
From previous example, tensile stress is 0.431 ksi. The
desired level of tensile stress is 5 3000 psior 0.274 ksi
SolutionSteps
Step1AdditionalCompressive
Step2#OfStrandsBasedOnStress
From previous the max moment/stress occurs at lifting
points (-M). This results in tensile stresses on the top
face.
Step3NumberofStrands
Storage
Storage
If support is provided at more than two points,
and the design is based on more than two
supports, precautions must be taken so that
the element does not bridge over one of the
supports due to differential support settlement
Storage
Warpage in storage may be caused by
temperature or shrinkage differential between
surfaces
creep
storage conditions
Storage
By superposition, the total instantaneous deflection,
ymax , at the maximum point can be estimated by:
ymax
Ic , Ib = moment of
inertia of
uncracked section
in the respective
directions for 1
in. width of panel
Storage
yt
Storage
= amplification due to creep and shrinkage as a
function of (reinforcement ratio for non-prestressed
compression
reinforcement,
As/bt)
Transportation
The method used for transport can affect the
structural design because of size and weight
limitations and the dynamic
Except for long prestressed deck members, most
products are transported on either flatbed or lowboy trailers
Trailers deform during hauling
Size and weight limitations vary from one state to
state
Loads are further restricted on secondary roads
The common payload for standard trailers
without special permits is 20 tons.
Transportation
Transportation
Erection is simplified when members are transported in the same orientation they will have in the
structure
For example, single-story wall panels can be transported on A-frames with the panels upright
A-frames also provide good lateral support and the desired two points of vertical support
Transportation
Longer units can be transported
on their sides to take advantage
of the increased stiffness
compared with flat shipment
Transportation
In all cases, the panel support locations should be consistent with the panel design
Panels with large openings sometimes require strongbacks, braces or ties to keep
stresses within the design values
Transportation
For members not symmetrical with respect to the bending axis, the following
expressions can be used for determining the location of supports to give equal
tensile stresses for positive and negative bending moments
Transportation
For one end cantilevered
Where
yb = distance from the bending axis to the bottom fiber
yt = distance from the bending axis to the top fiber
Transportation
For two ends cantilevered
Where
yb = distance from the bending axis to the bottom fiber
yt = distance from the bending axis to the top fiber
Erection
Precast concrete members frequently must be
reoriented from the position used to transport
to its final construction position
The analysis for this tripping (rotating)
operation is similar to that used during other
handling stages
In chapter 5 in the PCI handbook, maximum
moments for several commonly used tripping
techniques are illustrated
TrippingDesignGuide
Erection
When using two crane lines, the center of
gravity must be between them in order to
prevent a sudden shifting of the load while it
is being rotated
To ensure that this is avoided, the stability
condition shown must be met:
Erection
The capacities of lifting devices must be checked
for the forces imposed during the tripping
operation, since the directions vary
When rotating a panel with two crane lines, the
pick points should be located to prevent the panel
from an uncontrolled roll on the roller blocks can
be done by slightly offsetting the pick point
locations to shift the weight toward the upper
crane line lift points, or by using chain drags on
the rolling block
ErectingWallPanelsExample
Given:
The wall panels with
openings used on
previous examples
Problem:
Determine appropriate
procedures for erecting
the wall panels with
openings, panel will be
shipped flat
ErectingWallPanelsExample
Assumptions
Limit stresses to 5 f 'c (0.354 ksi).
Crane has main and auxiliary lines.
A telescoping man lift is available on site.
Solution:
Try three-point rotation up using stripping inserts and
rolling block: To simplify, conservatively use solid panel
(no openings) to determine moments.
ErectingWallPanelsExample
W
ErectingWallPanelsExample
R T
In Horizontal Position
MMAX
ErectingWallPanelsExample
Knowing from the stripping analysis
that a four-point pick can be used,
the configurations shown here may
be used
However, this rigging may become
unstable at some point during
tripping, i.e., continued rotation
without tension in Line A
Therefore, the lower end of the
panel must stay within inches of the
ground to maintain control.
ErectingWallPanelsExample
ErectingWallPanelsExample
ErectionBracingIntroduction
This section deals with the temporary bracing which
may be necessary to maintain structural stability of a
precast structure during construction
When possible, the final connections should be used
to provide at least part of the erection bracing, but
additional bracing apparatus is sometimes required
to resist all of the temporary loads
ErectionBracingIntroduction
These temporary loads may include wind, seismic,
eccentric dead loads including construction loads,
unbalanced conditions due to erection sequence
and incomplete connections Due to the low
probability of design loads occurring during
erection, engineering judgment should be used to
establish a reasonable design load
ErectionBracingResponsibilities
Proper planning of the construction process is essential for
efficient and safe erection
Sequence of erection must be established early, and the
effects accounted for in the bracing analysis and the
preparation of shop drawings
The responsibility for the erection of precast concrete may
vary as follows:
(see also ACI 318-02 Section 10.3)
ErectionBracingResponsibilities
ErectionBracingResponsibilities
The products are purchased by an independent erector who
has a contract to furnish the complete precast concrete
package.
Responsibility for stability during erection must be clearly
understood.
Design for erection conditions must be in accordance with all
local, state and federal regulations. It is desirable that this
design be directed or approved by a Professional Engineer
ErectionBracingResponsibilities
It is desirable that this design be directed or approved by a
Professional Engineer
Erection drawings define the procedure
on how to assemble the components into the final structure
The erection drawings should also address the stability of
the structure during construction and include temporary
connections
ErectionBracingResponsibilities
When necessary, special drawings may be required
to include shoring, guying, bracing and specific
erection sequences
It is desirable that this design be directed or
approved by a Professional Engineer
Erection drawings define the procedure
on how to assemble the components into the final
structure
ErectionBracingResponsibilities
The erection drawings should also address the stability of the structure
during construction and include temporary connections
When necessary, special drawings may be required to include shoring,
guying, bracing and specific erection sequences
ErectionBracingResponsibilities
HandlingEquipment
The type of jobsite handling equipment
selected may influence the erection sequence,
and hence affect the temporary bracing
requirements
Several types of erection equipment are
available, including truck-mounted and crawler
mobile cranes, hydraulic cranes, tower cranes,
monorail systems, derricks and others
The PCI Recommended Practice for Erection
of Precast Concrete provides more information
on the uses of each.
SurveyingandLayout
Before products are shipped to the jobsite, a field check of the project is recommended to ensure that prior
construction is suitable to accept the precast units
This check should include location, line and grade of bearing surfaces, notches, blockouts, anchor bolts,
cast-in hardware, and dimensional deviations
Site conditions such as access ramps, overhead electrical lines, truck access, etc., should also be checked
SurveyingandLayout
Any discrepancies between actual conditions and those shown on drawings should be addressed before erection is
started
Surveys should be required before, during and after erection:
Before, so that the starting point is clearly established and any potential difficulties with the support structure are determined early.
During, to maintain alignment.
After, to ensure that the products have been erected within tolerances.
LoadsonStructure
The publication Design Loads on Structures During Construction (SEI/ASCE 37-02) provides
minimum design loads, including wind, earthquake and construction loads and load
combinations for partially completed structures and structures used during construction
In addition to working stress or strength design using loads from the above publication, the
designer must consider the effect of temporary loading on stability and bracing design
TemporaryLoadingExamples
Columns with eccentric loads from other framing
members produce sidesway which means the
columns lean out of plumb
A similar condition can exist when
cladding panels are erected on one
side of a multistory structure
TemporaryLoadingExamples
TemporaryLoadingExamples
Some solutions are:
Install wood wedges
between flange of tee
and top of beam
Use connection to
columns that prevent
rotation
Erect tees on both
sides of beam
Prop tees to level
below
TemporaryLoadingExamples
Rotations and deflections of framing members may
be caused by cladding panels. This may result in
alignment problems and require connections that
allow for alignment adjustment after all panels are
erected
TemporaryLoadingExamples
FactorsofSafety
Reusable hardware
Lifting inserts
BracingEquipmentandMaterials
For most one-story and
two-story high
components that require
bracing, steel pipe
braces similar to those
shown are used
BracingEquipmentandMaterials
Proper anchoring of the braces to the precast
members and deadmen must be considered
When the pipe braces are in tension, there may
be significant shear and tension loads applied
to the deadmen
Properly designed deadmen are a requirement
for safe bracing
Cable guys with turnbuckles are normally used
for taller structures
BracingEquipmentandMaterials
Since wire rope used in cable guys can resist only
tension, they are usually used in combination with
other cable guys in an opposite direction
Compression struts, which may be the precast
concrete components, are needed to complete
truss action of the bracing system
A number of wire rope types are available
Note that capacity of these systems is often
governed by the turnbuckle capacity
GeneralConsiderations
Careful planning of the erection sequence is important
This plan is usually developed by a coordinated effort
involving the general contractor, precast erector,
precaster production and shipping departments and a
structural engineer
A properly planned erection sequence can reduce
bracing requirements
For example, with wall panel systems a corner can first
be erected so that immediate stability can be achieved
GeneralConsiderations
Similar considerations for shear wall structures can
also reduce bracing requirements
All parties should be made aware of the necessity of
closely following erection with the welded diaphragm
connections
This includes the diaphragm to shear wall connections
GeneralConsiderations
Questions?