R-118-64 ertwriters Laboratories, Inc.| Uy tolg cay PRECAST-PRESTRESSED CONCRETE, HOLLOW CORE FLAT SLABS, FORMING A FLOOR AND CEILING ASSEMBLY ARCHITECTURAL PRESTRESSED CONCRETE INSTITUTEs 20 N. Wacker Drive Chicago, III. 606060 National Board of Fire Muderwriters UNDERWRITER’S LABORATORIES, INC. REPORT R4123-11 ON Precast-Prestressed Concrete Hollow Core Flat Slabs, Forming A Floor And Ceiling Assembly PCI COMMITTEE ON FIRE RESISTANCE RATINGS HOWARD R. MAY, Chairman FRANK ERSKINE STEVEN GALEZEWSKI DAVID LaGUE SAM SELVAGGIO GEORGE VAUGHT ADOLPH WALSER ARCHITECTURAL C PRESTRESSED CONCRETE INSTITUTE. Copies are available at $2.00 each ($1.40 to PCI members) from PRESTRESSED CONCRETE INSTITUTE, 20 N. WACKER DRIVE, CHICAGO, ILLINOIS 60606. Copyright by the PRESTRESSED CONCRETE INSTITUTE, 1964.» ih fhe f * ‘Boor Service - Not for Fruit i Diy. Notional Board of Sire Underwriters File R4123-11 Assignment 63C2571 September 27, 1963 REPORT ON PRECAST-PRESTRESSED CONCRETE HOLLOW CORE FLAT SLABS, FORMING A FLOOR AND CEILING ASSEMBLY Prestressed Concrete Institute Chicago, Illinois Editors Note: This report on fire testing of precast-prestressed concrete hollow core flat slabs, forming a floor and ceiling assembly, was conducted at Underwriters’ Laboratories at Chicago, Illinois, and resulted in the grant- ing of 3 hour label service for this assembly by U.L. This is the eleventh test to be conducted on prestressed concrete assemblies in the current Prestressed Concrete Institute series which is under the direction of the PCI Committee on Fire Resistance Ratings. Reports are also available on floor and roof con- struction consisting of prestressed concrete single tee slabs (Report R4123- 5-7-8) and floor and roof construction consisting of prestressed concrete dou- ble tee slabs (Report R4123-1). These reports are published as a service to the membership of the Prestressed Concrete Institute, who sponsored the work, and to others interested in the behavior of prestressed concrete when under exposure to fire. 94 PCI JournalGENERAL The subject of this report is a precast-prestressed concrete hollow core flat slab used to form a roof or Hoor test assembly as shown on Fig. 1. Three full width flat slabs and two filler slabs used in the assembly were made of sand-limestone concrete. Similar aggregate to that employed in the flat slabs was used in the placing of the concrete topping to form a roof or floor assembly as shown on Fig. 1. To permit drying outside of the test frames, the concrete topping normally placed on the assembled slabs at the job site was placed on the individual slabs shortly after the manufacture of the slabs. This permitted the topping to dry with the slabs. ‘The purpose of this investigation was to establish a fire resistance classi- fication for the floor or roof assembly, consisting of prestressed slabs when tested in accordance with the Standard for Fire Tests of Building Construc- tion and Materials of Underwriters’ Laboratories, Inc, UL 263 (NEPA Pamphlet No. 251, ASTM Pamphlet No, E119), The fire test was supple- mented by other tests and examinations to determine the physical proper- ties of the material used, and the practicability of handling, shipping, and installing. DESCRIPTION The materials used in the assembly are described below in the order of use. Supporting Members—The members used to support the ends of the concrete slabs were 8 in. deep, 6 in. wide structural steel angle members on the top of which rested 3 in. wide by 1 in, thick steel bars which provided the recommended minimum bearing surface of 3 in. Precast-Prestressed Concrete Hollow Core Slabs—The hollow core slabs were manufactured at a plant chosen by the submittor and were of the shape and design shown on Fig. 1 and were prestressed using seven % in. nominal diameter seven-wire tendons. The prestressing tendons had 1%e in. of concrete bottom cover. At the time of test the concrete developed compressive strengths, as meas- ured on representative 6 x 12 in, test cylinders made at the same time as the slabs, ranging from a minimum of 5512 psi to a maximum of 6095 psi with an average of 5823 psi. Other properties of the slabs are considered of a proprietary nature and are on file at Underwriters’ Laboratories, Inc. for future use in the Factory Inspection Program. ‘The 2 in, thick limestone aggregate concrete topping placed on the hollow: core flat slab eight days after casting the slabs was in the approximate pro- portions of one part portland cement, 3.25 parts fine sand aggregate, and 5.0 parts coarse limestone aggregate by weight. The compressive strength of the topping as determined from representative 6 by 12 in. test cylinders, ranged from a minimum of 1555 to 2180 psi with an average of 1862 psi at the time of test. ERECTION OF TEST ASSEMBLY: The precast-prestressed flat slabs were provided so that three full width units and two 11% in. wide units completely filled the test furnace allowing April 1964 953 in, minimum bearing on supports at the ends. The clear span between the supports was approximately 16 ft. 9 in, The sides of the units were spaced such that there was a % to 4s in. gap between the lower portions of the slabs. The matching weld plates on the top of the slabs were then tied together by welding a reinforcing bar to each weld plate for each slab as shown on Fig. 1. A high early strength, low water content grout was used to tightly All the gaps between the ends of the slabs and the restraining frame, as well as the joints between the slabs and along the side walls of the test frame. The grout was prevented from flowing into the space between the lower portions of the slabs by placing corrugated paper in these spaces and then removing the paper after the grout had set. The appearance of the exposed surface of the test assembly after erection +in the restraining frame is shown on Fig. 2, and the appearance of the un- exposed surface of the test assembly is shown on Fig. 3. TEST RECORD NO. 1 FIRE ENDURANCE TEST: This test was conducted in accordance with the Standard for Fire Tests of Building Construction and Materials of Underwriters’ Laboratories, Inc., UL 263 (NFPA Pamphlet No. 251, ASTM Pamphlet No, E119). DESCRIPTION OF SAMPLE The test assembly was as described in “erection of test assembly,” and as shown on Fig. 1, 2, and 3, The precast concrete units were 231 days old, and the conerete topping 298 days old when the assembly was subjected to the fire test. The individual precast-prestressed concrete slab-topping combination were cured at elevated temperatures by blowing hot air across and through the core areas of the slabs which were stored in an insulated cell. The slabs were cured in this manner intermittently for a period of approximately five months. The relative humidity, as determined by electronic moisture sensing cle- ments placed in a representative full slab that was cured and stored in the same manner as the test slabs, was 61 per cent for the highest reading and 48.0 per cent for the lowest reading. The average was 55.9 per cent. These determinations were made 22 days before the fire test. The relative humidity at the time of fire test of a spare test slab, which was not the slab described above, was 75.0 per cent for the high, and 66.0 per cent for the low, The average was 69.4 per cent. METHOD The load applied to the test assembly was arranged to provide a uni- formly distributed load of 250 psf. This load was specified by the submittor, and calculated in accordance with ACI 318-63 and the ultimate moment criteria described in ACT 318-63 indicated that the floor should be loaded using that criteria, Fourteen hours after the floor was loaded, the furnace fire was started, exposing the assembly to flames of controlled extent and severity in accord- ance with the Standard Time-Temperature Curve as shown on Fig. 4. The unexposed floor surface temperatures were measured by thermo- 96 PCI Journalcouples, each covered with a 6 by 6 in. dry asbestos pad, located as shown on Fig. 5. The temperatures of the prestressing tendons were measured by means of thermocouples affixed to the tendons during the casting of the slab. The location of these thermocouples is shown on Fig. 6. The deflection of the floor was observed through a surveyor’s level, placed on one side of the furnace, and sighted on three vertical targets, each grad- uated in 0.10 in. and located at the center of the spans as shown on Fig. 5. Throughout the test, observations were made of the character of the fire, its control, the condition of the surfaces, and all developments pertinent to the performance of the assembly with reference to stability. RESULTS Observations During Application Of Load—During the loading a maximum deflection of 0.13 in. occured at target No. 2. An additional deflection of 0.01 in. occured prior to the start of the fire test. Character and Distribution Of The Fire—The furnace fire was luminous and well distributed throughout the test. The temperatures developed con- formed to the Standard Time-Temperature Curve as shown on Fig. 4. Observations Of The Exposed Surface—At 9 minutes a hairline crack ap- peared under the east core of the west full slab for two-thirds of the slab Iength and at 10 minutes approximately 1 sq ft of conerete had spalled away from the northeast comer of the west full slab. By 16 minutes there were two cracks on the west full slab for its entire length, 2 and 3 ft from its east edge. At 19 minutes a piece of concrete fell away from the east side of the center slab, 2 ft from the south end, exposing the eastern-most tendon of the center slab, By 20 minutes additional pieces of concrete fell away from the east edge of the center slab exposing the eastern-most tendon for about two- thirds of its length. At 24 minutes the east half of the west full slab had a relative deflection of approximately 1 in. more than the center slab. By 31 minutes it appeared as if the second, third, and fourth web from the east of the west full slab had split, and the relative deflection for the cast half of the west full slab was 1% in. greater than the center slab. By 115 minutes there was a tendon exposed and sagging in the east part of the west full slab and some pieces of concrete had fallen away from the sagging portion of this slab. ‘The relative deflection for the east half of the west full slab was 6 in. greater than the center slab and the second and third core openings from the east edge of the west full slab were visible. At 119 minutes a piece of concrete fell from the sagging portion of the west full slab. The face shell section had deflected approximately 11 in. at this time. By 142 minutes the exposed tendon at the east edge of the center slab appeared to be sagging approximately % in. and at 155 minutes a large piece of conerete fell away from the sagging portion of the west full slab. By 164 minutes a large piece of concrete fell away from the south end of the sagging portion of the west full slab knocking over furnace thermocouple No. 2. It was noted at 176 minutes that one of the tendons in the sagging portion of the west full slab had broken in two and it was hanging from the slab. April 1964 oT‘There were no further changes throughout the remainder of the fire test. Observations Of The Unexposed Surface—Hairline cracking occurred at the south end of the assembly at 7 minutes and at the north edge of the assembly at 15 minutes. At 17 minutes a hairline crack occured parallel to the joint on the west full slab and on the center slab at the north end. Steaming occurred from a crack at the north end of the west full slab at 27 minutes, The crack along the south edge of the assembly opened to ap- proximately % in. and heavy steaming came from this crack at 35 minutes. ‘A crack opened up at the east and west edge of the assembly to about ¥% in. at 40 minutes. These cracks were approximately 4s in. wide before the test. By 50 minutes very heavy steaming occurred from the north crack. At 60 minutes there was a relative deflection between the west filler slab and the “west full slab with the filler slab being higher by 1 in. By 82 minutes the deflection at the center caused the ends of the slabs to raise up approximately Linch. At 120 minutes the steaming appeared to have diminished somewhat and toa lesser amount at 180 minutes. There were no further changes through the remainder of the test. The furnace fire was extinguished at 185 minutes at the request of the submittor. Deflection Of The Floor—The following table shows the deflection of the assembly during the fire test and excess load test. DEFLECTION—IN. Target No. rT 2 Time, Min West Center East No load 0. 0 Full load 0.13 0.10 5 029 021 10 0.61 0.50 15 0.98 0.69 20 193 1.01 25 141 16 30 153 1.26 40 172 1.40 50 185 1:50 60 199 1.60 5 219 173 90 234 182 105 2.47 191 120 262 1.99 140 282 2.09 155 2.96 2.19 170 BL 226 185 325 2.36 After hose stream 384 2.40 20 br 335 2.96 Excess load 3.96 2.79 All load removed 369 177 ‘Temperature Of The Unexposed Surface—The initial average temperature 98 PCI Journalof the unexposed surface was 69 F, therefore, the average limiting tempera- ture was 319 F, and the maximum limiting individual temperature was 394 F. Review of Fig. 5 shows that the average temperature was 252 F and the maximum temperature was 338 F at 180 minutes. The temperature recorded by the thermocouple No. 1 at about 60 min- utes was checked and found to be incorrect. However, after checking this thermocouple for other readings after 60 minutes the recorder was function- ing properly for this thermocouple. ‘Temperature Of The Prestressing Tendons—Temperatures of the prestress- ing tendons, while not,required for classification purposes were recorded and are shown on Fig. 6. Thermocouple Nos. 3 and 4 were checked and found not to be functioning properly after 20 minutes. HOSE STEAM TEST: Description Of Sample—The sample previously described under the head- ing “Bre endurance test” was used for this test. ‘Method—Immediately after the fire endurance test the assembly was sub- jected to the impact and eroding action of a 30 psi water stream impinging on the sample through a nozzle diameter of 1% in, and held at an angle of 70 degrees to the normal for a period of 4 minutes. Results—The action of the hose stream eroded away about 70 per cent of the concrete softened in the fire test but did not penetrate the assembly. EXCESS LOAD TEST: Description Of Samples—The sample previously subjected to the “fire endurance and hose stream tests” was subjected to an additional live load of 250 psf, 24 hr after the fire endurance test was completed. Results—The assembly successfully carried the excess live load with a maxi- mum deflection of 3.96 in. recorded at the midpoint of the span at the cen- ter slab. Aside from some flaking away of the softened concrete there were no significant changes in the assembly due to the application of the excess load. OBSERVATIONS AFTER TESTS: After the sample had cooled and the double live load had been removed, it was noted that the assembly had deflected 3.69 in. below its original posi- tion before loading and tests, as shown by target No. 2. Figures 7 and 8 show a view of the exposed and unexposed surface, respectively, after- all tests were completed. On the exposed side, it was observed that the first four webs from the east side of the west full slab were split and the first two tendons from the east in that same slab had broken and were hanging down. There were several longitudinal hairline cracks in the center full slab and a few in the east full slab. There were three transverse cracks in the west full slab. The surface of the exposed concrete, crumbled readily to the touch. In the unexposed surface there was cracking in the grout only. Strength tests conducted on tendons having thermocouple Nos. 2, 7, April 1964 99and 10 attached to them, indicated that approximately 45 per cent of the original strength of the tendons remained after the fire endurance, hose stream, and excess load tests were completed. CONCLUSIONS FIRE RETARDANT PROPERTIES: Floor and roof assemblies constructed of precast-prestressed hollow core flat slabs of the design and cross-sectional dimensions as described herein when used with a 2-in, thick cast-in-place limestone concrete topping, are judged to afford a 3 hr protection against passage of flame and danger- ous heat transmission, provided: 1. The assemblies are restrained at the edges. 2. Bearing on the supports is 3 in. minimum, The assembly, as tested, carried the live load for 3 hours, 5 minutes, during fire exposure and the slabs remained intact and prevented passage of flame or dangerous heat transmission for a period of 185 minutes of fire exposure. The assembly successfully withstood the action of a hose stream applied for the length of time required for a 3 hr classification and carried the excess load without visible signs of distress. PRACTICABILITY: These precast-prestressed concrete slabs can be readily erected in the field by workmen familiar with such installations. The installation must have the provision for minimum bearing and re- straint as used in the test assembly. CONFORMITY: This construction was tested in accordance with the Standard for Fire Tests of Building Construction and Materials of Underwriters’ Laboratories, Inc., UL 263 (ASTM Pamphlet No, E119, NFPA Pamphlet No. 251). This construction is judged to be noncombustible, in accordance with that Standard. FOLLOW-UP PROGRAM: Precast-prestressed hollow core flat slabs conforming to the cross-sec- tional dimensions, design, and properties given herein and on file, made like those investigated and found acceptable, and produced under Under- writers’ Laboratories, Inc. Factory Inspection Program will bear a label with the following statement: UNDERWRITERS’ LABORATORIES; IN LISTED PRECAST CONCRETE UNITS FIRE RESISTANCE CLASSIFICATION FLOOR OR ROOF CEILING DESIGN NO. 55—3 HR 100 PCI JournalRECOMMENDATION TO THE FIRE COUNCIL OF UNDERWRITERS’ LABORATORIES, INC.: We recommend promulgation of listing cards in the forms presented below whenever a manufacturer of precast-prestressed hollow core con- crete slabs demonstrates that his product conforms with the design, dimen- sions, and specifications as set forth for the products as used in these tests. Guide No. 40 U18.17. September 27, 1963 File R4123-11 Precast Concrete Units. Prestressed Concrete Institute, Chicago, Illinois Prestressed concrete hollow core slabs for use in: Floor or Roof and Ceiling Design No. 55-3 Hr Chicago, Iinois Label Service—See General Information Card of above guide number. See Guide No. 40 U18 for illustration of design numbers and fire resistance classification. Guide No. 40 U18. September 27, 1963 Floor or Roof and Ceiling Construction and Beam Protection. Guide No, 40 UI Floor ar Roof and Ceiling Construction ‘ond Beam Pratection Part | - See Port 2 for Description of Numbered items Class C - 3 Designs Design No. 55 - 3 Hr. F Part 2—Description of Numbered Items. Class C-3 Design Design No. 55-3 Hr. 1. Limestone Coarse Aggregate Reinforced Concrete Topping-2 in. mini- mum thickness, 1500 psi, one part cement, 3.25 parts fine sand aggre- April 1964 101gate, 5.0 parts coarse aggregate by weight. Minimum size of rein- forcement should be a 6/4-10/10 welded wire mesh. 2. Precast Concrete Units—Listed by Underwriters’ Laboratories, Inc., Guide No. 40 U18.17. 3. Minimum Bearing—3 in. 4. Sand Cement Grout—3500 psi. 5. Cardboard Spacers~3% in, high, full length of slabs, used to keep grout from bottom of joint, also spaces slabs %s to % in, apart. Spacer re. moved after grout has set. Report by: Reviewed by: J. H. SABO/Signed B. A. ZIMMER/Signed Project Engineer, Fire Assoc. Managing Engineer Protection Department Fire Protection Department SUBMITTED: JACK BONO/Signed Managing Engineer, Fire Protection Department The foregoing Recommendation has been accepted Nov. 4, 1963. UNDERWRITERS’ LABORATORIES, INC. W. S, AUSTIN/Signed Vice President and Secretary JHS:LL 103, PCI Journalrisen stan Neer 2 ne" & o4-0 o ” ud Fo we weto pare SoutH age ees ey 43 R 4123-1 Fig. Ra123—11 April 1964 103Fig. 3-Unexpotad surface before tents los PCT JournalApril 1964 i Hea i 105eur a‘April 1964 7—-Expor Fig. 8—Unoxposed surface after tests surface after taste 107