Lessons from the design of the GLA building RC core

Andy Pye BG4

September 2000

This overview of the design and construction of the GLA core is given as a set of learnt points. Looking at these points now, some seem terribly obvious. However, I am still close enough to the beginning of the process to know that having had this list then would have saved a lot of time and money. I originally made the list as a personal record to prompt better design the next time that I designed a core. However, despite being specific to the GLA building several people have found these notes useful for their projects. It is important to remember that the notes are not a statement of how things should be done. The are just a record of what I thought was appropriate to my problem. Accordingly we can expand and correct this note to cover other aspects of core design and to include other people's views. Over to you.

1 1.1

CONCEPT DESIGN Check the core section elastically using a reduced I-value Calculate the I-value of the core at a typical cross-section allowing for doorways and major service penetrations. (If the arrangement of penetrations at the base of the core is significantly different, for example if there are additional service penetrations, then calculate the I-value here.) The additions of holes in a core mean that plane sections do not remain plane. A judgement needs to be made about how this will affect the stiffness. On the GLA building the core, as finally analysed, was 20 percent less stiff than the Ivalue of the typical cross-section. A core should be designed to work elastically at ultimate loads in order to limit cracking. Therefore the extreme fibre stresses should be calculated assuming a linear stress distribution and the reinforcement calcula ted accordingly. At this stage it is probably best to keep the reinforcement below 2% of the cross sectional wall area.

f =

N ult M ult y A 80% I

Extreme fibre stress Axial force Typical cross-sectional area Overturning moment Distance from centroid to outside face of furthest wall Value of second moment of area at typical cross section, reduced to take account of penetrations

N ult
A

M ult
y

80%I

1.2

Ignore walls with a very large number of penetrations such as lift lobby walls, Figure 1.1. These walls may be built from blockwork. Even if they are built in concrete you will not realise the stiffness predicted by a simple I-value calculation.

1.3

Ignore out-stand walls that you will not be able to stabilise Out-stand walls with service openings either side can prove very difficult to stabilise, so think twice before relying on them for stability, Figure 1.2.

1.4

Check the lateral deflections with the lift designer Determine the core deflections early on. Conventional lifts are very sensitive to verticality and contractors will be concerned if the core moves appreciably after the lifts have been installed. Note that the elastic modulus of cracked sections is less than the default values given in GSA.

1.5

Consider how the position of slab edges and cladding are specified If your core has a permanent imposed deflection consider how this affects the setting out of the cladding and floorplates. Are your co-ordinates absolute, with reference to a fixed mark on the ground, or relative, with reference to the core?

Wall is likely to be slender in compression

Wall stabilised by diaphragm action of floor

Left: Figure 1.1, Lift lobby walls should be omitted from I-value calculations at concept design. Above: Figure 1.2 Ignore out-stand walls that will be difficult to stabilise. 1.6 Where possible keep services outside the core This will drastically reduce the number of penetrations and will improve the structural efficiency of the core. This is of particular benefit where there is a lag between the design of the structure and the services. It will also help to avoid late changes on site. However, if you need to mobilise the diaphragm action of a floorplate make sure that there are not so many service penetrations around the core that you cannot achieve the requisite connectivity. 1.7 Do not position openings at the corners of the core walls as this reduces the stability of the wall adjacent to the opening.

Poor Figure 1.3, Do not position openings at the corners of core walls. 1.8 Where possible avoid transfer beams

Good

If you cannot avoid a transfer beam ensure that it is deep enough to transfer the forces and remember to pay special attention to its design during the analysis stage.

Figure 1.4, Where possible avoid transfer beams 1.9 Watch what happens at the top of lift shafts What happens will depend on the type of lift you have. As a general rule lift contractors will want to sit lift steels on, or in, the core wall. A single lift could have up to four lift steels each requiring two oversize holes, perhaps 500 square. If the top of your core supports any other structure, such as a roof or a terrace floor, then make sure that this is co-ordinated with the requirements of the lift contractor. 2 2.1 ANALYSIS Build the analysis model as late as possible However you build and post-process the core model it is likely to take a considerable amount of time. Making large numbers of changes could take even longer though! At the time you build the model you must have a full set of co-ordinated elevations. Develop a numbering system that will allow you to identify where particular nodes and elements are and, where absolutely necessary, will allow you to make changes. 2.2 Incorporate small holes by inspection Basically do anything to make building your model easier. Omit small holes, move holes and combine holes. Use your engineering judgement and where necessary produce a small study on a local area. What constitutes small will depend on the geometry of your core. On the GLA building holes smaller than 750 mm were either omitted or were combined with a nearby hole. 2.3 Use a stick model (Personal Preference) There are two basic methods available to analyse a core. A stick model describes the core as a series of column and spandrel elements and uses stiff beams to connect them together. A description of this technique can be found in Analytical Modelling of Structural Systems (Macleod 1990). Care must be taken where there is a deep beam. Also make sure that wall elements take no torsion or out of plane bending. The benefit of this method is that post-processing the model is a simple case of designing beams in combined bending and compression, see note 2.4.

The second method of analysis is to use 2D plate elements. This technique has the benefit of looking realistic, this makes checking the geometry easy. How easy it is to construct will depend on the modelling software used. It is important that the mesh is adequately fine and as a general rule better results will be obtained from using a small number of parabolic, 8 node, elements than a greater number of linear, 4 node, elements. The most difficult part of this method comes in converting the pattern of stresses to a pattern of reinforcement. Some software will do this for you, otherwise you could use RC2D developed by AR&D. Either way you would be well advised to read Ian Felthams note on Reinforcing concrete for in-plane forces, 1989NST_7. 2.4 Design walls elastically to the IStructE/ICE green book (stick model method) Reinforce walls for the extreme fibre stress, see note 1.1. The green book suggests that you place all the reinforcement necessary to carry the tension triangle in the first half of the tension zone.
As .req = 1 ft l b 2 0. 95 y

Distribute As.req over a length 0.5l.

Figure 2.1, Design walls elastically to the IstructE/ICE green book If compression steel is required this can be designed in a similar manner. Minimum reinforcement will extend for the full length of the wall. This calculation could be incorporated into a spreadsheet. Although it would be unusual to have a problem you should also check beam shear. Note that this method of analysis will result in heavier reinforcement than the equivalent 2D element analysis. 2.5 Produce at least one fully worked through hand calculation of your post-processed results Your results will inevitably be post-processed in a spreadsheet or using some specialist software. Include a full printout of the results in your calculations, label all entries, do not hide any cells and produce at least one fully worked through hand calculation. You should also make several spot checks, especially if you are using a spreadsheet. 2.6 Beware of walls in permanent tension, E may be <<14N/mm2 ADSEC is very useful for calculating the stiffness of cracked sections. Make sure you use ICE Tech Note 372, see Sarah Meldrums note on ADSEC, 1989NST_13. Using this as a basis you could reduce E globally or else re-model walls in permanent tension as a different material with a lower E.

2.7

Use the CIRIA deep beam guide The guide is very good at giving an overview of deep beam design. However, I have found it lacking in the common case of a deep beam with indirect supports. I have developed the following method; based upon the notes in the guides.

h a is the lesser of 1.2l 0 and l 0 +

c1 + c2 2

Calculate the midspan moment assuming a simple support,

M ult = ( Top + Bottom Load) l2 8

Tie force =

M ult , calculate As .tie .steel 0. 6 ha

Consider equilibrium at supports,

Assume tie force to indirect supports acts over a width of 0.2h a . Therefore calculate As.indirect.support. This should be placed horizontally and vertically to a height of 0.5h a . Calculate the area of steel necessary to suspend the bottom load, As.vert.tie. Now check the compression in the arch and in the indirect support. The reinforced section will look something like;

3 3.1

REINFORCEMENT DETAILING Specify long lap lengths In the bar-bending schedule add an extra 100 mm to the required lap lengths. This gives the fixers some tolerance on site and avoids your being asked to accept a short lap length.

3.2

Do not vary bar sizes unnecessarily Try to use the same size bar for the full length of a wall. Changing bar size every few metres makes fixing more difficult and leads to mistakes on site.

3.3

Make sure your detailing accommodates the need of the jump form/slip form system The contractors system for supporting the formwork and the working platforms may need cast-in bolts or pockets. It is easier to incorporate these at detail design than on site.

3.4

Specify the detail you require at the intersection between walls The contractor may chose to fabricate reinforcement cages on the ground and then lift them into place. If this is the case it will be more difficult to place four vertical bars inside the horizontal reinforcement, see Figure 3.1a. More likely you will get what is shown in Figure 3.1b and if you ask for the four bars inside the knuckle it will be achieved by adding extra bars, Figure 3.1c.

3.5

Watch Kwikastrip on external corners Kwikastrip, also known as Conner Bar, is a proprietary system of pre-bent pullout bars, commonly used at the junction between walls and slabs. Note that because of the U-bar,

which should extend into the full depth of the wall, you cannot have Kwikastrip on both faces of an external corner. In this scenario consider whether 1 you can manage without a pullout bar on one face, 2 you want to use a loose pullout bar that will fit inside the U-bar on the adjacent face (this is awkward and the contractor will not like it), 3 you should use a resin grouted, post-fixed, starter bar (a) (b) (c)

Figure 3.1, Reinforcement details at intersections of walls. 3.6 Watch out for short lengths of Kwikastrip It is not possible to supply Kwikastrip in very short lengths because of the way it is folded, Figure 3.2. Use loose pullout bars or use an overlong length of Kwikastrip and once the wall is cast cut off the bars not used and make good. Figure 3.2, Kwikastrip is supplied in minimum lengths 3.7 Meet the detailer early on Whether you are using the Arup detailing group or contractor detailing meet the detailer early on. A misunderstanding in your instructions will result in a considerable amount of abortive work if not caught straight away. Ask if you can see the very first drawing rather than waiting to see the whole core! 3.8 Ensure good information flow Make sure that your detailer has the very latest information as soon as possible. That could be your detailing instructions or the core GAs. If it is not your direct responsibility to issue the information to the detailer then give them a telephone call and make sure that they have received it. If you have a construction manager, a concrete contractor and a subcontractor-detailer the information flow can take a very long time. 3.9 Use larger diameter bars adjacent to openings and at corners and free ends This is good detailing practice and gives additional robustness, see Figure 3.3.

Figure 3.3, Large diameter bars at corners, door openings and ends 3.10 Bend spandrel steel up above openings and down below openings The compression forces that occur behind the bend in the spandrel steel are better confined in this arrangement. If this is not possible then consider using a terminator, see Figure 3.4.

Figure 3.4, Develop an appropriate anchor detail for spandrel steel. Never anchor spandrel steel into column strip adjacent to an opening. 3.11 Be aware that the contractor will prefer to reinforce from the inside out This gives the steel fixers more room to work and makes lifting materials easier. The use of particularly large cast-in plates that need to be bolted to the external shutter may make this impractical. 3.12 Beware of placing Unistrut on the closing face of a wall It is very difficult to guarantee the position of Unistrut, Halfen Channel, etc. when on the closing face of a wall. If tied to the reinforcement the Unistrut can be knocked when offering up the closing shutter and the Unistrut may not sit flush against the face of the shutter. Nailing the Unistrut to the closing shutter is equally difficult because the cast-in legs will invariably clash with the placed reinforcement making it impossible to close the shutter. 3.13 Watch out for areas of water tight concrete Whilst most of your concrete construction will be conventional watch out for any areas in the basement that may need to be water tight construction. 3.14 Allow for bending tolerances Allow something like a bar diameter when checking the reinforcement in heavily reinforced sections. 3.15 Make sure that the architect has the chance to check any dimensions and levels on detailing drawings Architects will often ignore, or not even be given reinforcement drawings. This is unfortunate because architects are often very good at spotting setting out errors and it is

well worth asking them to check the drawings. It also signals that you are very nearly at construction and that changes are not welcome. 3.16 Allow extra time for checking the first set of drawings The first set of drawings will most likely take a long time to check. You may be out of the practice of checking reinforcement drawings and it may take time to become accustomed to the detailers drawing style. Most importantly errors not caught here will be reproduced throughout the whole core. 4 4.1 CONNECTIONS TO THE CORE Check that the connection to all slabs, beams, etc. have been detailed At the time the core is being detailed the connecting slabs, beams, etc. may not have been designed. You must check for all likely connections and request details from the designers of those elements. Post-fixing T12s might be a possibility, post-fixing T25s is definitely not! 4.2 Use threaded couplers for connecting large diameter bars If you cannot drill through the shuttering, fairly normal, then threaded couplers are a very good way of connecting main bars for beams. It is better to use a few large diameter bars rather than a lot of smaller diameter bars because couplers are difficult install. Make due allowance for the diameter of the coupler, which will be considerably larger than the bar. The threaded coupler needs to be plugged to make sure that it is not filled with concrete and must be placed hard against the shutter. 4.3 Double -up reinforcement in areas of post-fix bolted connections If you know that you will be using post-fixed bolted connections in a particula r location then double-up the reinforcement. This way you can design for drilling through a certain amount of reinforcement. 4.4 Ensure sufficient anchorage behind cast-in plates Most modelling techniques will not be sufficiently refined to model the reality of what happens behind a cast-in plate. In the absence of further guidance ensure that there is sufficient reinforcement to transfer any horizontal forces to the opposite end of the wall. On the GLA building we assumed that bars falling within a 45 cone of the anchors bars would be mobilised provided that the horizontal reinforcement was closed by a horizontal U-bar, see Figure 4.1. Vertical forces need to be carried by an identified column strip and the moment resulting from the eccentricity of the cast-in plate and the centre of the column strip should be allowed for.

Figure 4.1, Anchorage behind cast-in plates 4.5 Draw all details. Describing details as handed might be quick in the office but can lead to mistakes on site. 5 5.1 CONSTRUCTION Request that stock steel be kept on site When you have to issue a late detailing instruction sourcing steel from site-stock will save your client a considerable amount of money. If appropriate you could also request that the contractor have a bar-bending machine available. This is feasible for bars up to T20 and should allow you to detail yourself out of most problems. 5.2 Watch that concrete wagons properly mix their load before concrete is placed At the batching plant the concrete wagon will spin at mixing speed for ten minutes but during travel it only spins at idling speed. As a result it is possible that some segregation may occur and the wagon should be spun at mixing speed for a further two minutes before any concrete is dispatched. This is not always done because it lengthens the turnaround time and causes wear on the wagon. 5.3 Do not discharge grout used to prime the concrete pump into the wall A concrete pump has to be primed before concrete can be pumped through it. This is normally done with a mixture of cement and water. This mix should be discharged into a skip on the working platform. 5.4 Do not allow concrete to fall from the pumping pipe If falls it may segregate on impact. A flexible hose that extends to the bottom of the pour should always be used. 5.5 Ensure sufficient vibration Unless you are using self-compacting concrete it will be necessary to vibrate the concrete to ensure good compaction. The number of pokers used to vibrate the concrete will depend on the concrete mix and the type of poker used. However, for most concrete pours on the GLA, for slabs as well as walls, we had three or four vibrators per 8m3 wagon load of concrete. The pokers should be continually moved around the whole pour. They should not be left dropped in one location for five minutes. If there is a break between concrete wagons it is not necessary to continue vibrating the concrete during the waiting period. However, it is important that the concrete continues to be

vibrated for a few minutes after the last concrete has been pumped to ensure that this concrete is suitably compacted. 5.6 Agree benchmark panels for reinforcing and concrete finish This should be done at an early stage on a good, but reproducible, area of work. Benchmarks can also be agreed for complex reinforced details. Our only concern is the structural performance and integrity of the wall, the architect may wish to establish benchmarks for other reasons. 5.7 Arrange inspections the day before the pour This requires some discipline but it makes the inspection far more relaxed and increases the chances of your getting necessary remedial work done to your satisfaction. 5.8 Write a checking list for inspections There can be quite a few things to check on inspections. Most mistakes are likely to be made at the beginning of the job, unfortunately this is the time when you are least up to speed on what needs checking. Also try to look at the drawings before you go onto site. Make time to note what is different in this pour and then check that it has been properly executed. 5.9 Record inspections with a digital camera You should keep a notebook with the date, location and observations made in each inspection. It is also useful to have a digital camera with you too. If you need to write a note about something it is very useful to include a picture of what you are talking about. 5.10 Decide your requirements for testing post-fixed re -bar before you are asked Whether it is your fault or not, somebody will want to resin fix re-bar into the core at some point. If installed properly these anchors are very effective but you need to test a sample to establish the workmanship. It is also worth noting that the contractor can buy the testing equipment needed to perform these tests for about the same price as having a Hilti engineer on site for a day. If the contractor can perform the test they are more likely to agree to your testing regime. However, you should make sure that the load cell has been recently calibrated and you should witness some of the tests. 5.11 Do not allow welding of re -bar As a general rule re-bar should not be welded because of the way that the heat modifies the metallurgic structure of the bar. Re-bar should not be flame cut for the same reasons. If re-bar is to be welded there should be a full method statement and a certified welder must carry out the welding. 5.12 Consider the use of water jetting for remedial works Water jetting is a good method of removing bad concrete without damaging reinforcement. The weaker the concrete the easier it will be to water jet. However, water jetting is dangerous and nobody other than the operator can work in area of demolition. Also water jetting is very noisy.

5.13 Consider the use of self-compacting concrete for awkward repairs Self-compacting mixes have a very watery consistency and will flow and carry aggregate to all parts of the pour. The admixture used for self-compacting concrete increases the cost of a typical metre cube of concrete by 10. 5.14 Allow the use of plastic spacers in none water retaining concrete Circular plastic spacers, sometimes called wagon wheels, are very easy to fix and give a definite cover. They give you greater confidence and because they are so easy to fix your are likely to get enough to give you the cover you want. 5.15 Insulate freshly poured concrete in cold weather Normally the shutters and the hydration of cement will be enough to maintain the concrete temperature above 5C whilst curing. However, if the programme necessitates the jumping of the shutters before the concrete has had three or four days cure it should be insulated to keep the temperature above 5C. 5.16 How do you check a bar in a threaded coupler? Threaded couplers are very good apart from the fact that you cannot tell how much thread is in the coupler! Where possible get the couplers factory threaded. If not, inspect the threaded bars on site and insist that the length of thread on all bars is the same. Perform some spot checks by getting the contractor to remove some threaded bars and checking the threaded length. Make sure that the couplers and the threaded bars are kept as clean as possible. That way the threads will not be damaged. 5.17 Be aware that the contractor will aim to prefabricate walls on the ground This is good and should increase the speed and quality of erection. Just watchout for the points 3.1 and 3.4. 5.18 Ensure that the contractor has inspected the reinforcement before you make an inspection The contractor will be required to make a check of any work before it is offered up. You are not there to do their work for them. If a contractor repeatedly makes the same mistakes or if they offer you unfinished or untidy reinforcement you should refuse to inspect it. 5.19 Minimise the number of site inspections Make sure that the contractor understands that your time is valuable and that you have several aspects of the construction to monitor. Try to limit inspections to one a day and co-ordinate inspections so that you can see as much as possible on one visit. 5.20 Beware of bars in the next pour which are anchored in the pour below Occasionally there may be bars in the next pour that need to be anchored in the current pour. These are unusual but that makes them all the easier to forget. The most common case of this are diagonal bars around doorways.