30/9/2013

Analysis and Design of Precast

Concrete Structures to Eurocode 2
Precast and Prestressed Floors
and Composite Floors

www.civil.utm.my

Precast & Prestressed Floors

and Composite Floors

www.civil.utm.my

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• Hollow core floor units & slab fields

• Double tee units
• Half-slab (precast + in-situ topping)
• Composite floors
• Load vs. span data

Fixing Rates at 2000 m2 per week?

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40  11 feet Wide HCU onto Precast Walls at

MGM Hotel, Las Vegas, 1992

Hollowcore Units

Daily production:
200 m2 – 1500 m2

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Double Tee Units

Twice the price

but up to 4
capacity than
hollow core

Prestressed Half Slab

Popular for
housing and
awkward shapes

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Prestressed Half Slab

Jetty at Pasir Gudang, Johor

Prestressed Half Slab

Propping required
for  5 m

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Prestressed Hollow Core Floor

Units
• 400 – 3600 mm wide; typically 1200 mm
• 90 – 730 mm deep; typically 150, 200, 250,
300 mm
• Self weight 1.5 to 5.0 kN/m2
• Void ratio 40 – 60 % of solid section
• Spans 6 – 20 m (economical range)

Longitudinal No shear or 30 mm flanges

pretensioning strand torsion links and webs
or wire

Shear key
profile
Prestressed Hollow Core Floor Units

1195 mm

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Prestressed Hollow Core Floor Units

Splitting cracks due to

sawing restraints as
prestress in
transferred
Prestressed Hollow Core Floor Units

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Too much plasticiser!! in 450 deep units

Actually air-entrainment agent is used by
several producers as a plasticiser
Prestressed Hollow Core Floor Units

Strand Pull-in:
An important indicator of
success
Should be about 1 mm,
irrespective of length
Prestressed Hollow Core Floor Units

Theoretical pull-in limit for

zero prestress:

𝑷𝑳
𝑨𝑬
* Use a linear scale between the
extremes

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Bearing onto neoprene

or mortar for spans
more than about 15 m
onto insitu or masonry
Prestressed Hollow Core Floor Units

20 m long HCU

Section for Analysis for Prestressed

• Pretension and losses (about 18 – 25%)
• Service moment (bottom tension critical)
• Ultimate moment (usually  Msr  1.5)
Prestressed Hollow Core Floor Units

• Ultimate shear uncracked & flexurally cracked

• End bearing and transmission length
• Deflection and camber (long-term, creep)
• Live load deflection after installation

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Section for Analysis for Prestressed

• 𝑀𝑠𝑟 = 𝑓𝑏𝑡 + 𝑓𝑐𝑡 𝑍𝑏
• 𝑀𝑢𝑟 = 0.87𝑓𝑝𝑏 𝐴𝑝𝑠 𝑑 − 𝑑𝑛
Prestressed Hollow Core Floor Units

𝐼∙𝑏𝑤 2
• 𝑉𝑐𝑜 = 𝑓𝑐𝑡𝑑 + 𝛼𝑙 𝜎𝑐𝑝 𝑓𝑐𝑡𝑑
𝐴∙𝑦

Load vs Span Curve

Prestressed Hollow Core Floor Units

Imposed load

Allowable span

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Load vs Span Curve

Bearing limit
Prestressed Hollow Core Floor Units

Imposed load

Handling limit
span/depth = 50

Allowable span

Load vs Span Curve

Bearing limit
Prestressed Hollow Core Floor Units

Imposed load

Handling limit
span/depth = 50

Allowable span

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Load vs Span Curve

Shear
Prestressed Hollow Core Floor Units

Imposed load

Service
moment

Deflection
Handling

Allowable span

Service moment
Possibly shear ? control

Deflection
Prestressed Hollow Core Floor Units

control

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Example 1
Calculate Msr for the 203 mm deep prestressed HCU shown below. The
initial prestressing force may be taken as 70% of characteristics strength
of the standard 7-wire helical strand. Take the final long-term losses as
24%. Geometric and data given by the manufacturer are as follows:

Ac = 135  103 mm2, I = 678  106 mm4, yt = 99 mm, fck = 50 N/mm2, Ec = 30

kN/mm2, fck (t) = 35 N/mm2, Eci = 27 kN/mm2, fp0,1k = 1750 N/mm2, Eps =
195 kN/mm2, Aps = 94.2 mm2 per strand ( = 12.5 mm) and cover = 40 mm.

Example 1 - Solution
Section Properties
Zb = I/yb = 678  106/104 = 6.519  106 mm3
Zt = I/yt = 678  106/99 = 6.848  106 mm3

Eccentricity, e = 104 – 40 – 12.5/2 = 57.7 mm

Initial prestress in tendons, fpi = 0.70  1750 = 1225 N/mm2
Initial prestressing force, Pi = fpi  Aps = 1225  7  94.2  10-3 = 807.8
kN

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Example 1 - Solution
Check Stress at Transfer
fbc = (807.8  103/135  103) + (807.8  103  57.75/6.519 106)
= +13.14 N/mm2 (compression)  0.6fck (t) (21 N/mm2)
ftt = (807.8  103/135  103)  (807.8  103  57.75/6.848 106) OK
=  0.83 N/mm2 (tension)  fctm (t) (3.20 N/mm2)

Final Prestress in Bottom and Top

fbc = +13.14  (1 – 0.24) = +9.97 N/mm2 (compression)
ftt = 0.83  (1 – 0.24) = 0.63 N/mm2 (tension)

Example 1 - Solution
Service Moment
At the bottom fibre, Msr is limited by the tensile stress limit of 0
N/mm2
Msr = (fbc)Zb = (9.97)  6.519  106 10-6
= 65.0 kNm

At the top fibre, Msr is limited by the compressive stress limit of

0.6fck = 30 N/mm2
Msr = (ftt + 0.6fck)Zt = (0.63 + 30)  6.848  106 10-6
= 209.7 kNm  65.0 kNm

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Example 2 - Solution
Calculate Mur for the section given in Example 1. Manufacturer’s
data gives the breadth of the top of the HCU as b = 1168 mm.

Effective depth, d = 203 – 40 – 12.5/2 = 156.75 mm

Stress in steel after losses = (1 – 0.24)  0.70  1750 = 931 N/mm2

𝑓 931
Therefore, strain in steel after losses = 𝐸𝑠 = 205×103 = 0.0045
𝑠

which is less than y, the yield strain.

Example 2 - Solution

𝒇𝒑𝟎,𝟏𝒌 𝟏𝟕𝟓𝟎
= = 𝟏𝟓𝟐𝟐
𝜸𝒎 𝟏. 𝟏𝟓

𝟏𝟓𝟐𝟐
𝜺𝒚 = = 𝟎. 𝟎𝟎𝟕𝟒𝟐
𝟐𝟎𝟓 × 𝟏𝟎𝟑

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Example 2 - Solution
As a first attempt, try x = 75 mm, approximately equal to 0.5d
(a) Steel Strains
cc = 0.0035
Final stress strain, s = Prestress Strain + Bending Strain, ’s
Bottom layer at the tendon:
sb = 0.0045 + ’sb x

𝑑−𝑥 d
= 0.0045 + 𝜀𝑐𝑐
𝑥

156.75−75
= 0.0045 + × 0.0035 = 0.008315  y
75

 Take sb = 0.00742

’sb

Example 2 - Solution
(b) Steel Stresses

Bottom layer at the tendon:

fsb = sb  Es
= 0.00742  205  103
= 1522 N/mm2

(c) Forces in Steel & Concrete

Steel tensile forces, Fst =fs.Aps = (fsb)  7  94.2 = 1003  103 N

Concrete compressive forces, Fcc= 0.567fckb  0.8x
= 0.567 50  1168  0.8  75 = 1987  103 N

Since Fcc  Fst, a smaller depth of neutral axis, x must be tried.

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Example 2 - Solution
Try x = 38 mm  28 mm (upper flange) and then carry out the
previous analysis.

Final Forces in Steel & Concrete

Steel tensile forces, Fst =fs.Aps = (fsb)  7  94.2 = 1003  103 N
Concrete compressive forces, Fcc= 0.567fckb  0.8x
= 0.567 50  1168  0.8  38 = 1006  103 N  Fst  OK

Ultimate Moment of Resistance:

Mur = Fstz = Fst (d – 0.4x)
= 1003  103 (156.75 – 0.4 38)  10-6
= 142 kNm

Shear Analysis
Shear failure in 400 deep units

Shear searches
out the weakest
web

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Example 3 - Solution
Calculate the uncracked shear capacity, Vco for the section in Example
1.

𝛾𝑐𝑝 𝜂𝑃𝑖 0.9×(1−0.24)×0.70×1750×7×94.2

𝜎𝑐𝑝 = = = 4.09 N/mm2  0.133fck (6.65 N/mm2)
𝐴 135×103
𝑓𝑐𝑡𝑘,0.05 2.90
𝑓𝑐𝑡𝑑 = = = 1.40 𝑁/𝑚𝑚2
𝛾𝑚 1.5
𝑙𝑥 800 + 203/2
𝛼1 = = = 0.94 ≤ 1.0
𝑙𝑝𝑡2 961

Example 3 - Solution

𝜶𝟏 𝜶𝟐 ∅𝝈𝒑𝒎𝟎 𝟏. 𝟎 × 𝟎. 𝟐𝟓 × 𝟏𝟐. 𝟓 × 𝟏𝟐𝟐𝟓

𝒍𝒑𝒕𝟐 = 𝟏. 𝟐𝒍𝒑𝒕 = 𝟏. 𝟐 = 𝟏. 𝟐
𝒇𝒃𝒑𝒕 𝟒. 𝟕𝟖
= 𝟗𝟔𝟏 𝒎𝒎
1 = 1.0
2 = 0.25
pm0 = 0.70  1750 = 1225 N/mm2
 = 12.5 mm
lpt (transmission length) = 800 mm
𝑓𝑐𝑡𝑘,0.05 (𝑡) 2.20
𝑓𝑏𝑝𝑡 = 𝜂𝑝1 𝜂1 𝑓𝑐𝑡𝑑 𝑡 = 𝜂𝑝1 𝜂1 = 3.2 × 1.0 × = 4.78 𝑁/𝑚𝑚2
𝛾𝑚 1.5

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Example 3 - Solution
Total breadth at centroid, bw = 1168 – (6  150) = 268 mm
Area above the centroidal axis, A = 67500 mm2
y’ = 64.5 mm (calculate from geometry)

𝐼 ∙ 𝑏𝑤
𝑉𝑐𝑜 = 𝑓𝑐𝑡𝑑 2 + 𝛼1 𝜎𝑐𝑝 𝑓𝑐𝑡𝑑
𝐴∙𝑦
678 × 106 × 268 × 10−3
= 1.42 + 0.94 × 4.09 × 1.40
67500 × 64.5
= 113.1 kN

Shear Analysis
Watch out for flexural-shear (Vcr) failure !

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Flexural-Shear Formula, Vcr

Prestressed Hollow Core Floor Units – Shear Analysis

Vco Decompression
point

Vcr

Vcr = [0.12k (100lfck)1/3 + 0.15cp] bwd

Vcr, min = [0.035k3/2 (fck)1/2 + 0.15cp] bwd

Flexural-Shear Formula, Vcr

Prestressed Hollow Core Floor Units – Shear Analysis

UDL

SF diagram

Vcr failure
here

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Example 4 - Solution
Calculate the minimum value of Vcr for the slab in Example 1.
𝛾𝑐𝑝 𝜂𝑃𝑖 0.9×(1−0.24)×0.70×1750×7×94.2
𝜎𝑐𝑝 = 𝐴
= 135×103
= 4.09 N/mm2  0.133fck (6.65
N/mm2)

200 200
𝑘 =1+ 𝑑
=1+ 156.75
= 2.12 ≤ 2.0 (From Example 2, d = 156.75
mm)

From Example 3, cp = 4.09 N/mm2

Vcr, min = [0.035k3/2 (fck)1/2 + 0.15cp] bwd

= [0.0035(2.0)3/2 (50)1/2 + 0.15  4.09]  268  156.75  10-3
= 28.7 kN

Bearing Capacity
Prestressed Hollow Core Floor Units – Bearing Capacity

• Refer to Cl. 10.9.5

• Refers to contact bearing pressure at the bearing ledge
• Non-isolated – components are connected to other
components with a secondary means of support
• Isolated – components rely entirely on their own bearing for
total support

Ultimate bearing capacity, FEd = fRd b1 a1

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Bearing Definitions
Prestressed Hollow Core Floor Units – Bearing Capacity

𝒂 = 𝒂𝟏 + 𝒂𝟐 + 𝒂𝟑 + ∆𝒂𝟐 𝟐 + ∆𝒂𝟑 𝟐

Net Bearing Length, a1 (Perpendicular to the

Floor)
Prestressed Hollow Core Floor Units – Bearing Capacity

a1 must NOT be less than the value

in Table 10.2

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Limiting Value of a3
Limiting Value of a2
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 Prestressed Hollow Core Floor Units – Bearing Capacity Prestressed Hollow Core Floor Units – Bearing Capacity

Net Bearing Width, b1

Limiting Value of a2 and a3
30/9/2013

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Prestressed Hollow Core Floor Units – Bearing Capacity

Ultimate Bearing Strength, fRd

Example 5 - Solution
Calculate the bearing capacity of the HCU in Example 1. The unit has
an actual 75 mm dry bearing length onto a reinforced concrete.
Assumed that the unit is 6 m long and has secondary support on
steel beams.

50
Ultimate bearing strength, fRd = 0.4fcd = 0.4 × 1.5 = 13.33 N/mm2

Net bearing width, b1 = 1200 mm  b1, max = 600 mm

Use b1 = 600 mm

Net bearing length for non-isolated component, a1:

From
a2 = 0 mm a2 = 10 mm a = 75 mm
a3 = 5 mm a3 = 2.4 mm

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Example 5 - Solution
 𝒂𝟏 = 𝒂 − 𝒂𝟐 − 𝒂𝟑 − ∆𝒂𝟐 𝟐 + ∆𝒂𝟑 𝟐

𝒂𝟏 = 𝟕𝟓 − 𝟎 − 𝟓 − 𝟏𝟎𝟐 + 𝟐. 𝟒𝟐 = 𝟔𝟎. 𝟑 𝒎𝒎 > 𝟐𝟓 𝒎𝒎

 Refer to Table 10.2 for the minimum values of a1

 The ultimate bearing capacity:

FEd = 13.33  60.3  600  10-3 = 482.3 kN > Vco (109.3 kN) OK

Note:
𝑉𝑐𝑜 (𝐹𝑟𝑜𝑚 𝐸𝑥𝑎𝑚𝑝𝑙𝑒 4)
𝜎𝐸𝑑 = = 1.25 𝑁/𝑚𝑚2
1200 × 75
𝜎𝐸𝑑 1.25
= = 0.0375
𝑓𝑐𝑑 50
1.5

Composite Floors Required for Double Tee,

but Optional for Hollowcore

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Surface Laitance due to Cutting Slurry

50 mm minimum at the highest point, increasing

(with slab and beam cambers) to about 80 mm

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Composite Construction
• Minimum thickness of topping  40 mm
• Average depth of topping allowances for camber should
be made – allowing span/300 will suffice
• Concrete grade – C25 to C30
• Minimum mesh reinforcement area = 0.13%  Concrete
area

Composite Construction
• Advantages to composite construction:
(a) Increase bending resistance and flexural stiffness
(b) Improve vibration, thermal & acoustic performance
(c) Provide horizontal diaphragm action
(d) Provide horizontal stability ties across floors
(e) Provide a continuous and monolithic floor finish

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with 75 mm
topping

Composite Design
Composite Design – 2 Stage Approach

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Composite Design -2 Stage Approach

Stage • Selfweight of slab + in-situ

concrete topping + construction
traffic allowance (1.5 kN/m2)
1 • Section properties = Precast unit
Serviceability – 2 Stage Approach

Stage • Superimposed load

• Section properties = Composite
2 section

Stress Diagram at Serviceability

0.6fck limit

Topping + +
_
+
Serviceability – 2 Stage Approach

+ + =
Precast
fct limit

_ _
+ _

Prestress Imposed Imposed Total

Stage 1 Stage 2 stresses
stresses stresses

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Stage 1 – Service Moment, M1

Bottom fibre stress of the HCU:
𝑴𝟏
𝒇𝒃𝟏 = 𝒇𝒃𝒄 − < +𝟎. 𝟔𝒇𝒄𝒌 (𝒕) 𝒕𝒓𝒂𝒏𝒔𝒇𝒆𝒓 & 𝟎 (𝒔𝒆𝒓𝒗𝒊𝒄𝒆)
𝒁𝒃𝟏
Serviceability – 2 Stage Approach

Top fibre stress of the HCU:

𝑴𝟏
𝒇𝒕𝟏 = 𝒇𝒕𝒄 − < 𝒇𝒄𝒕𝒎 𝒕 𝒕𝒓𝒂𝒏𝒔𝒇𝒆𝒓 & + 𝟎. 𝟔𝒇𝒄𝒌 (𝒔𝒆𝒓𝒗𝒊𝒄𝒆)
𝒁𝒕𝟏

Stage 2 – Service Moment, M2

Bottom fibre stress of the HCU:
𝑴𝟐
𝒇𝒃𝟐 = −
𝒁𝒃𝟐
Top fibre stress of the HCU:
𝑴𝟐
𝒇𝒕𝟐 = +
Serviceability – 2 Stage Approach

𝒁𝒕𝟐
Top fibre stress of the in-situ topping:
𝑴𝟐
𝒇′𝒕𝟐 = +
𝒁′𝒕𝟐

beff = b  Ec’/Ec where b is the full breadth

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Total Service Moment, Ms

Adding Stage 1 + Stage 2:
fb =fb1 + fb2 = fbc – M1/Zb1 – M2/Zb2  0
ft = ft1 + ft2 = ftc + M1/Zt1 + M2/Zt2  +0.6fck
f’t = f’t2 = + M2/Z’t2  +0.6fck, in-situ
Serviceability – 2 Stage Approach

Service Moment, Msr

Bottom of the slab:
Ms2 = M2  (fbc)Zb2 – [M1(Zb2/Zb1)]
Top of the slab:
Ms2 = M2  (0.6fck – ftc)Zt2 – [M1(Zt2/Zt1)]

Example 6
Calculate the Stage 2 service bending moment that is available if the
HCU in Example 1 has a 50 mm minimum thickness structural
topping. The floor is simply supported over an effective span of: (a)
4.0 m; (b) 8.0 m. The precamber of the HCU may be assumed as
span/300 without loss of accuracy. Use fck, in-situ = 30 N/mm2 and Ec, in-
2 3
situ = 26 kN/mm . Self weight of concrete = 25 kN/m . Selfweight of
HCU = 3.24 kN/m run. What is the minimum imposed loading for
each span?

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Example 6 - Solution
Effective breadth of topping, beff = 1200  26/30 = 1040 mm
Total depth of composite section = 203 + 50 = 253 mm
Depth to neutral axis from top of composite section, yt2
1040×50×25 +(135000× 50+99 )
= = 114.5 mm
135000+(1040×50)

Second moment of area of composite section, I2 = 1266  106 mm4

Example 6 - Solution
1266×106
𝑍𝑏2 = (253−114.5) = 9.14 × 106 mm3

1266×106
𝑍𝑡2 = = 19.63 × 106 mm3
114.5

Zb2/Zb1 = 9.14  106 /6.519  106 = 1.40

Zt2/Zt1 = 19.63  106 /6.848  106 = 2.86

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Example 6 - Solution
(a) 4.0 m
4000
Precamber = = 13 mm
300

Maximum depth of topping at supports = 50 + 13 = 63 mm

(50+63)
Average depth of topping = = 57 𝑚𝑚
2

Self weight of topping = 0.057  25  1.2 = 1.71 kN/m run for 1.2 m
wide unit
Self weight of HCU = 3.24 kN/m run
(3.24+1.71)×42
Stage 1 moment, M1 = = 𝟗. 𝟗𝟎 𝒌𝑵𝒎
8

Example 6 - Solution

Bottom of the slab:

𝑍𝑏2
𝑀𝑠2 > 𝑓𝑏𝑐 𝑍𝑏2 − 𝑀1
𝑍𝑏1
𝑀𝑠2 > 9.97 × 9.14 × 10−6 − 9.90 × 106 1.40 × 10−6
= 77.46 kNm

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Example 6 - Solution
Top of the slab:
𝑍𝑡2
𝑀𝑠2 = 𝑀2 > 0.6𝑓𝑐𝑘 − 𝑓𝑡𝑡 𝑍𝑡2 − 𝑀1
𝑍𝑡1
𝑀𝑠2 > 30 − (−0.63 ) × 19.63 × 10 − 9.90 × 106 2.86 × 10−6
6

= 573.35 kNm

The allowable maximum imposed load = 8  77.46/4.02 = 38.73 kN/m

* Additional notes:
Total Ms = Ms1 + Ms2 = 9.90 + 77.46 = 87.36 kNm

Ultimate Limit State - 2 Stage Approach

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Ultimate Limit State - 2 Stage Approach

Total area of reinforcement, Aps = Aps1 + Aps2
Effective breadth, beff = b  fcu in-situ/fcu

Stage 1
fpdAps1 = 0.567fck b(0.8X)  but dn1 = 0.4X or X = dn1/0.4
then dn1 = fpdAps1/1.134fckb
then Mu1 = fpdAps1(d – dn1) ---------------- (1)

Ultimate Limit State - 2 Stage Approach

Stage 2
Aps2 = Aps – Aps1
Mu2 = fpdAps2 (d + hs – dn2) ---------------- (2)
or by replacing (1) into (2):
Mu2 = fpd [Aps – Mu1/fpd(d – dn1)] (d + hs – dn2)

One Step Approach

Mu = fpdAps (d + hs – dn)

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Interface Shear Stress in Composite

Slabs (Cl. 6.2.5)
In the neutral axis is below the interface, X  hs
VEd = 0.567fckbeffhs

In the neutral axis is above the interface, X  hs,

VEd = 0.567fckbeff0.9X

The shear stress at the interface should satisfy:

vEdi  vRdi

Interface Shear Stress in Composite

Slabs (Cl. 6.2.5)
𝛽𝑉𝐸𝑑
Design shear stress at the interface; 𝑣𝐸𝑑𝑖 = 𝑧𝑏𝑖

Design shear resistance at the interface;

vRdi = cfctd +n + fyd ( sin + cos )  0.5vfcd

If vEdi  vRdi ; provide shear reinforcement (per 1 m run) projecting

from the precast unit into the structural topping. The amount of
steel required:
𝟏𝟎𝟎𝟎𝒃𝝉𝒉
𝑨𝒇 =
𝟎. 𝟖𝟕𝒇𝒚𝒌

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Interface Shear Stress in Composite

Slabs (Cl. 6.2.5)

Interface Shear Stress in Composite

Slabs (Cl. 6.2.5)

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Interface Shear Stress in Composite

Slabs (Cl. 6.2.5)

Interface Shear Stress in Composite

Slabs (Cl. 6.2.5)

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Double Tee Floor Units

• 2400 – 3000 mm wide

• 300 – 2000 mm deep; typically 400 – 800 mm
• self weight 2.6 to 10 kN/m2
• void ratio 70 – 80 % of solid section
• spans 8 – 30 m (economical range)

Double Tee Floor Units

Mostly prestressed, but RC if manufacturer
prefers

Bearing pads required 150 x 150 x 10 mm

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