Foundation and Anchor Design Guide for Metal Building Systems Alexander Newman, PE., F.ASCE\ Publication Data is on file with the Library of Congress Copyright © 2013 by The McGraw-Hill Companies, Inc. AU rights reserved. Printed in the ‘United States of America. Except as permitted under the United States Copyright Act of 1976, no part of this publication may be reproduced or distributed in any form ot by any means, or stored ina data base or retrieval system, without the prior written permission of the publisher. 1234567890 DOC/DOC 18765432 ISBN 978-0-07-176635-7 MHID 0-07-176635-9 Sponsoring Editor Acquisitions Coordinator Proofreader Larry 8. Hager Bridget L. Thoreson Surencira Nath Shivam, Cenveo Publisher Services Editing Supervisor Piojedt Manager ‘Stephen M. Smith Robini Deb Art Director, Cover Cenveo Publisher Services Jeff Weeks Production Supervisor Richard C. Ruzycka Copy Editor Composition Rachel Hockett Cenveo Publisher Services Printed and bound by RR Donnelley. McGraw-Hill books are available at special quantity discounts to use as premiums and sales promotions, or for use in corporate training programs. To contact a representative, please e-mail us at bulksales@megraw-hill.com. This book is printed on acid-free paper. Information contained in this work has been obtained by The McGraw-Hill Companies ine. (*McGraw-Hil’) fom sources beloved to be rellble, However neither McGraw-Hill nor is authors guarantee the accuracy or completeness of any Information published heels, and neither McGraw-Fill nor its authors call be resporsibe for any exors, omissions, ot damages erting out of se ofthis information, This work s published wih dhe understanding that McGraw-Hill and its futhows ene supplying information but ae not tempting reer enginesring or other profesional serves. If such services fe required, the asatance of an appropriste profesional should be soughtAbout the Author Alexander Newman, RE., ASCE, is a forensic and structural consultant in Needham, Massachusetts. During more than 30 years of professional practice, he has been involved with the structural design, renovation, and failure investigation of numerous structures around the country. His areas of expertise indude design and failure analysis of pre-engineered metal buildings, metal roofs, and other structures. He is one of the country’s foremost experts on metal buildingsystems. Hehas served asan expert consultant for litigation involving metal building systems and other structures, ‘Mr. Newman's diverse engineeringand managerial experience includes positions as principal structural engineer with a large architectural and engineering firm, manager of a steel fabrication shop, and engineer with light-gage metal and precast-concrete manufac- turers. Most recently, he has been a managing engineer with Exponent Failure Analysis Associates, the country’s premier construction failure and accident investigation firm, Mr. Newman’s many publications include a number of award-winning articles that appeared in leading engineering magazines. His definitive reference book Structural Renovation of Buildings: Methods, Details, and Design Examples was published by McGraw-Hill in 2001. He is the author of another authoritative book from McGraw-Hill, Metal Building Systems: Design and Specifications, now in its Second Edition and translated into Chinese. ‘Mr. Newman has led numerous educational semi- nars around the country for design professionals, building officials, owners, and contractors. He has, conducted training programs for the employees of the US. State Department, NASA, the US. Air Force, the Iraq Reconstruction Team, and many educational and professional groups. He has taught a number of courses at Northeastern University.Contents Preface ....cccceeeessereeee Introduction to Metal Building Systems ........060eeee0 1.1 Two Main Classes of Metal Building Systems ..... : 1.2 Frame-and-Purlin Buildings: Primary and Secondary Framing 1.2.1 Primary Frames: Usage and Terminology 2. Single-Span Rigid Frames 1.23 Multiple Span Rigid Frames 1.24 Tapered Beam 1.2.5 Trusses 1.2.6 Other Primary Framing Systems 1.2.7 Endwall and Sidewall Framing .... 1.3 Frame-and-Purlin Buildings: Lateral-Force Resisting Systems 1.4 Quonset Hut-Type Buildings «=... References. eeeeeeeeeeeees oo Foundation Design Basics 21 Soil Types and Properties 21.1 Introduction 212 Some Relevant Soil Properties 21.3 Soil Classification ..... 214 Characteristics of Coarse-Grained Soils 2.1.5 Characteristics of Fine-Grained Soils 2.4.6 The Atterberg Limits ...... 2.1.7 Soil Mixtures att. 2.1.8 Structural Fill 21.9 Rock 22. Problem Soils : wale 2.2.1 Expansive Soils: The Main Issues ......+. 2.2.2. Measuring Expansive Potential of Soil .. 2.2.3 Organics .. : : 224 Collapsing Soils and Karst 23. Soil Investigation .. | 23.1. Types of Investigation 2.3.2 Preliminary Exploration... 2.3.3 Detailed Exploration: Soil Borings and Other Methods 2.34 Laboratory Testing 24 Settlement and Heave Issues 2.4.1 What Causes Settlement? 242. Settlement in Sands and GravelsContents 25 26 References 24.3. Settlement in Silts and Clays 24.4 Differential Settlement 24.5 Some Criteria for Tolerable Differential Settlement 7 Determination of Allowable Bearing Value 25.1 Why Not Simply Use the Code Tables? 252. Special Provisions for Seismic Areas... 25.3 What Constitutes a Foundation Failure? 7 254 Summary ....... Staliow ve. Deep Foundations Foundations for Metal Building Systems: The Main Issues ....... aa 32 33 34 35 References ........... ‘The Differences between Foundations for Conventional Buildings and Metal Building Systems 3.1 Light Weight Means Large Net Uplift 3.1.2. Large Lateral Reactions : 3.13 Factors of Safety and One-Third Stress Increase. seeveeees 3.14 In Some Circumstances, Uncertainty of | Reactions Estimating Column Reactions... 3.2.1 Methods of Estimating Reactions 3.2.2. How Accurate Are the Estimates? Effects of Column Fixity on Foundations 33.1 Is There aCost Advantage? : 33.2. Feasibility of Fixed-Base Columns in MBS 33.3 Communication Breakdown General Procedure for Foundation Design 3.4.1 Assign Responsibilities 342 Collect Design Information... 3.4.3 Research Relevant Code Provisions and Determine Reactions. 344 Determine Controlling Load Combinations 3.4.5 Choose Shallow or Deep Foundations 3.446 Establish Minimum Foundation Depth 34.7 Design the Foundation. Reliability, Versatility, and Cost 35.1 Definitions. 35.2. Some Examples Column Pedestals (Piers) eleseals 3.6.1 The Area Inviting Controversy. 3.6.2. Two Methods of Supporting Steel Columns in Shallow Foundations .. 3.63. Establishing Sizes of Column Pedestals (Piers) 364 Minimum Reinforcement of PiersContents 4. Design of Isolated Column Footings 59 4.1 The Basics of Footing Design and Construction cece 59 4.1.1 Basic Design Requirements ron - 9 4.1.2 Construction Requirements 60 413 SeismicTies ...... aad 60 414 Reinforced-Concrete Footings... ....s..-- 60. 4.15. Plain-Conerete and Other Footings ce 60 4.1.6 Nominal vs. Factored Loading Gt 42 The Design Process... a 62 4.21 General Design Procedure e 4.2.2 Using ASD Load Combinations 62 4.23. Using Load Combinations for Strength Design bee 8 4.24 What is Included in the Dead Load? 63 4.2.5 Designing for Moment 6 4.2.6 Designing for Shear 6 42.7 Minimum Footing Reinforcement 68 4.28 Distribution of Reinforcement in Rectangular Footings 68 4.2.9 Designing for Uplift 6 42.10 Reinforcement at Top of Footings References ...eescees botdeete estar 70 7 titttssteeseesereeee 79 hee 79 5 Foundation Walls and Wall Footings .. 5.1 The Basics of Design and Construction... 5.1.1 Foundation Options for Support of Exterior Walls... feledenledantaden| 5.1.2 Design and Construction Requirements for Foundation Walls eel ee 80 5.1.3 Construction of Wall Footings 83 5.1.4 Design of Wall Footings 84 References ae 87 6 Tie Rods, Hairpins, and Slab Ties 89 61 TieRods ...... 89 64.1 The Main Issues 0... 89 6.1.2 Some Basic Tie-Rod Systems 90 6.1.3. AReliable Tie-Rod Design 92 614 Development of Tie Rods by Standard Hooks 95 6.1.5 Design of Tie Rods Considering Elastic Elongation ........ 6.1.6 Post-Tensioned Tie Rods 617 TieRodGtid ....... = 6118 Which Tie-Rod Design Is Best? 62 Hairpins and Slab Ties 62.1 Haigpins: The Essence of the System 6.2.2 Hairpins in Slabs on Grade =x Contents 623 624 625 6.2.6 References 7 Moment-Resisting Foundations .. 71 The Basic Concept Jad 712 Hairpins: The Design Process Development of Straight Bars in Slabs Slab Ties (Dowels) Using Foundation Seats ‘A Close Relative: Cantilevered Retaining Wall Advantages and Disadvantages 7.2. Active, Passive, and At Rest Soil Pressures 721 72.2 723 73 Lateral Sliding Resistance 731 73.2 74. Factors of Safety against Overtuing and Sliding 74d 742 743 75 The Design Procedures... 754 752 753 75.4 755 References 8 Slab with Haunch, Trench Footings, a and Mats .....0..ss065 81 Slab with Haunch : 811 812 813 82 Trench Footings 83 Mats 831 83.2 833 834 References ‘The Nature of Active, Passive, and At-Rest Pressures... How to Compute Active, Passive, and AtRest Pressure ‘Typical Values of Active, Passive, and AtRest Coefficients ‘The Nature of Lateral Sliding Resistance Combining Lateral Sliding Resistance and Passive Pressure Resistance ‘No Explicit Factors of Safety in TBC Load Combinations ..... Explicit Factors of Safety for Retaining Walls How to Increase Lateral Siding Resistance Design Input ...... Design Using Combined Stresses Acting on Soil ...... : ‘The Pressure Wedge Method General Design Process Moment Resisting Foundations in Combination with Slab Dowels General Issues... The Role of Girt Inset an Resisting the Column Reactions Common Uses ..... ‘The Basics of Design ‘Typical Construction in Cold Climates Using Anchor Bolts in Mats 105 107 109 i im 13 113 3 us us us uy uy 19 9 120 1 124 11 12 122 122 123 126 127 iar ui 143 164 165 165 167 168 Ww 1729 Deep Foundations ....... 10 O41 92 References ....-2.2200e see Anchors in Metal Building Systems ..... 101 102 103 104 105 Introduction Deep Piers 9.2.1 ‘The Basics of Design and Construction 9.22 Resisting Uplift and Lateral Column Reactions with Deep Piers ......... : : Piles... be 934 The Basic Options 9.3.2. The Minimum Number of Piles : 9.33 Using Structural Slab in Combination with Deep Foundations : 9.34 Resisting Uplift with Piles 935. Resisting Lateral Column Reactions with Piles General Issues pee 10.1.1 Terminology and Purpose 10.12. The Minimum Number of Anchor Bolts Anchor Bolts: Construction and Installation ...... 10.2.1 ‘Typical Construction . : 10.2.2 Field Installation ....... 10.2.3 Placement Tolerances vs, Oversi Column Base Plates .. 10.2.4 Using Anchor Bolts for Column Leveling 10.2.5 Should Anchor Bolts Be Used to Transfer Horizontal Column Reactions? .........++5 Design of Anchor Bolts: General Provisions ............. 10321 Provisions ofthe Intemational Building Code 103.2 ACI318-08 AppendixD ......... Design of Anchor Bolts for ‘Tension per ACT 318-08 AppendixD ... : 104.1 Tensile Strength of Anchor Bolt vs. Tensile Strength of Concrete for a Single Anchor 10.4.2 Tensile Strength of an Anchor Group 10.4.3 Tensile Strength of Steel Anchors 10.44 Pullout Strength of Anchor in Tension. 10.4.5 Concrete Side-Face Blowout Strength of Headed Anchors in Tension ...... 104.6 Concrete Breakout Strength of Anchors in Tension 104.7. Using Anchor Reinforcement for Tension Design of Anchors for Shear per ACI 318-08 Appendix D set 10.5.1 Introduction 10.5.2 Steel Strength of. ‘Anchors in Shear 10.5.3 Concrete Breakout Strength in Shear: General 10.5.4 Basic Concrete Breakout Strength in Shear V,, 10.5.5 Concrete Breakout Strength in Shear for Anchors Close to Edge on Three or More Sides. Contents 173 173 173 173 74 17%6 176 wr 178 181 181 185 185 185 186 186 186 187 188 190 191 193, 193, 196 198 198xii n A tents 10.56 Concrete Breakout Strength in Shear: Modification Factors 7 22 1057 Using Anchor Reinforcement for Concrete Breakout Strength in Shear .....2..02000ee00eeeee 224 10.58 Using a Combination of Edge Reinforcement and Anchor Reinforcement for Concrete Breakout Strength in Sheer ..... peleele 27 1059 Concrete Pryout Strength in Shear 227 105.10 Combined Tension and Shear 105.1 Minis Bdge Distances an Spacing of Anchors ve 228 105.12 Concluding Remarks = ceecevee “BBB References ...eeeeeeeee : Concrete Embedments in Metal Building Systems 11.1 The Role of Concrete Embedments I111 Prior Practices vs. Today's Code Requirements... 235 11.1.2 ‘Two Options for Resisting High Horizontal Column Reactions ele deabetentedeatad 235 11.13 Transfer of Uplift Forces to Foundations: No Alternative to Anchor Bolts? ... seeee 236 112 Using Anchor Bolts to Transfer Horizontal Column Reactions to Foundations... Tedeokedawladanhad 237 11.21 Some Problems with Shear Resistance of Anchor Bolts besseeees 237 11.22. Possible Solutions to Enable Resistance of Anchor Bolts to Horizontal Forces ......-+ 238 11.23 Design of Anchor Bolts for Bending 240 113. Concrete Embedments for the Transfer of Horizontal ‘Column Reactions to Foundations: An Overview wee MAD M14 Shear Lugs and the Newman Lug. ...... 243 114.1 Construction of Shear Lugs cee 243 1142 Minimum Anchor Bolt Spacing and Column Sizes Used with Shear Lugs... : -. 285 1143. Design of Shear Lugs: General Procedure 2.2... 247 1144 Determination of Bearing Strength 249 TAS Determination of Concrete Shear Streng 249 M46 The Newman Lug 115 Recessed Column Base 115.1 Construction 1152 Design .... 11.6 Other Embedments a 116.1 CapPlate .......0. a 11.6.2 Embedded Plate with Welded-On Studs 2.00.02... 260 References 7 261 Frame Reaction Tables Index. 293,Preface the design of foundations for metal building systems, also knownas pre-engineered metal buildings, is a subject of much controversy and misunderstanding. The primary reason: Reliable foundations for these structures might be more difficult to design and more expensive to construct than the foundations for conventional Duildings. And yet the building owners and contractors, who tend to perceive metal building systems as inexpensive structures, are rarely aware of the foundation challenges. Their main efforts are usually directed to getting the best price on the steel superstructure; the foundations arean afterthought. Asa result, these owners and contractorsare sometimes alarmed by the cost of their metal building foundations and might even question the competency of the foundation designers. After a few such experiences, the engineers who design these foundations might start to question their own design methods and settle for the cheapest solutions ‘What makes the foundations for metal building systems difficult to design? The design complexities stem from two main issues. First, the most popular types of the primary frames used in metal building systems tend to exert significant horizontal column reactions on the foundations. While some conventional building foundations also resist Jateral forces generated by wind and seismic loading, those forces are generally smaller than the typical frame reactions in metal buildings. Second, metal building systems are extremely lightweight, which means that their supports are routinely subjected to a net uplift loading caused by wind. It follows that metal building foundations are usually designed to resist a combination of lateral and vertical (either downward or uplift) forces. When the primary frame columns are fixed at the bottom, rather than pinned, still more complications arise for the foundation design. These unique challenges and complexities might not be familiar to the engineers accustomed to designing foundations for conventional buildings. Unfortunately, little authoritative design guidance exists on the subject, which undoubtedly adds to the controversy. At present, only one chapter in the author’s book Metal Building Systems: Design and Specifications, 24 ed. (McGraw-Hill, 2004), provides some guidance about this area of design. in the past, some metal building manufacturers used to publish their own brochures dealing with the subject, but no longer do so, perhaps because the manufacturer's scope of work normally excludes the building foundations, ‘The lack of clear design procedures naturally results in uneven design solutions. Some foundation designs for metal buildings have been overly complicated. But morex Preface ‘commonly in the author's experience, they have been barely adequate for the imposed loads (or not adequate at all). This book is intended to fill the knowledge void by exploring the complexities of designing foundations for metal building systems and providing clear design procedures for various foundation types. The book covers the most common foundation systems used for metal buildings and illustrates their design through step-by-step examples. It describes a variety of possible solutions, ranging ftom the most reliable (and often the most expensive) to the less reliable (and typically less expensive) approaches. ‘The book is intended to serve as a desk reference soutce for structural engineers, bothinsideand outside the manufacturers’ offices, and for other design and construction professionals, such as architects, facility managers, building officials, and technically inclined contractors. It will help these professionals in the selection of the most appropriate and cost-effective system for their projects and in developing tealistic cost expectations. Alexander Newman, PE., EASCEFoundation and Anchor Design Guide for Metal Building SystemsCHAPTER 1 Introduction to Metal Building Systems 1.1. Two Main Classes of Metal Building Systems ‘The purpose of this chapter is to introduce the reader to metal building systems (MBS) and to explain how they work, These structures, also known as pre-engineered metal buildings and sometimes abbreviated as PEMBs, are both designed and manufactured by their suppliers. In this book the terms metal building systems, metal buildings, pre- engineered buildings, and pre-engineered metal buildings are used interchangeably. ‘Metal buildings are extremely popular in the United States. Many, if not most, low-rise nonresidential buildings there contain pre-engineered structures. Reasons for the popularity of these systems include their cost-effectiveness, speed of construction, single-source responsibility for the superstructure, ease of maintenance, and the ability. to span long distances without intermediate supports. ‘Metal building systems can be found in all types of buildings. Approximately one-third of them are used in conunercial applic:tions, such as office buildings, retail stores, and garages. Another one-third include manufacturing uses, such as factories, production plants, and material recycling facilities (see Fig. 1.1). The rest are used in community buildings (schools, churches, municipal), agricultural, and storage occu- pancies (Newman, 2004). ‘The two main classes of metal building systems are frame-and-purlin and Quonset hut-type buildings. Both are described in this chapter, but our main focus is on the former. From the foundation designers’ point of view, there is a fundamental difference between the two classes of metal buildings. 1.2 Frame-and-Purlin Buildings: Primary and Secondary Framing As the name suggests, this class of metal building systems includes separate primary frames and secondary members. The primary frames (also called main frames) can be of various types. The foundation design is greatly influenced by the type of primary frame selected for the building, For example, some frame types tend to exert significant lateral reactions on the supports and others donot.2° Chapter One Faure 1.4 Metal building system used in an industrial tacit. ‘The primary frames carry secondary roof members called purlins and secondary ‘wall members called girts. At the intersection of the roof and wall panels typically exists the third type of secondary member, known by the names of eave girt, eave purlin, or eave strut, The Various names reflect the versatile nature of this important element that can wear three hats: a gitt, a purlin, and an axially loaded structural member. Axial loading, comes into play when the strut resists lateral forces as part of the cross-bracing, assem- bly in the wall. ‘The secondary members support metal panels or other roof and wall cladding. In pre-engineered buildings, endwalls are at the ends of the building parallel to the pri- mary frames, while sidewalls are perpendicular to the frames. The typical components of the frame-and-purlin system are shown in Fig. 1.2. Root system ool putin Eave strut Endwall frame Rigi frame Poop column = Fraune 1.2 ypleal Components of the frame-and-pariin system.Introduction to Metal Building Systems ‘The Metal Building Manufacturers Association (MBMA) is the trade group that includes most major manufacturers of pre-engineered metal buildings. Metal Building System Marual (MBMA, 2006) provides a wealth of information related to the design, fabrication, and procurement of frame-and-purlin pre-engineered metal buildings. 1.2.1 Primary Frames: Usage and Terminology Primary frames are the backbone of the frame-and-purlin metal building system. The available primary frame systems vary significantly in their design assumptions, struc- tural behavior, column configuration, and, perhaps most important for the reader, in the magnitude of the horizontal column reactions exerted on the foundations. Some of the considerations involved in the selection of the primary frames inchude: ‘Width, length, and height of the building * Acceptability of tapered columns Slope of the roof + Clear-span requirements Wall and roof materials Each frame consists of a rafter and at least two columns. The joint between an exterior column and the rafter is called the knee. A clear span is the distance between the inside faces of the frame columns. Each of the primary frame types has an optimum range of clear spans. The clear span can be measured between the frame knees, as shown in Fig. 1.2, but it can also be measured between the inside faces of the col- tums at the base. A similar term, frame width, refers to the distance between the outside faces of the wall girts,a plane that is called the sidewall structural line. Looking at Fig. 1.2, please also note that for a single-story building the clear height is the distance between the floor and the lowest point of the frame at the roof level. Also, the eve height is the distance between the bottom of the column base plate and the top of the eave strut, ‘The rafter is usually spliced, with the dimensions of the individual segments fine- tuned for the applied bending moments and shears at those locations. The variability of the frame cross-section tends to complicate the analysis but saves metal by improv ing the framing efficiency. The splices are typically made at the peak, at the knees, and at the intermediate locations determined by the manufacturer's preferences. Certain types of frames, such as a single-span rigid frame, can resist lateral (wind and seismic) forces acting in the direction parallel to the frames. Others require separate vertical and horizontal lateral-force-resisting elements in addition to the frames, as discussed in Sec. 1.3. 1.2.2 Single-Span Rigid Frames ‘The single-span rigid frame system is perhaps the most familiar and versatile type of pri- mary framing used in pre-engineered buildings. These frames can be found in a wide variety of applications, from warehouses to churches. The frame profile is tapered to approximate the shape of the frame's moment diagram. A single-span rigid frame can be of either two- or threeshinge design. An example of two-hinge rigid frame can be found in Fig, 1.2;a three-hinge frame design is shown in Fig. 132. 34 Chapter One © @ Ficone 1.2 Common types of primaty frames used in metal bullding systems and the gravityload reactions they generate: (a) Single-span rigid frame; (6) multiple-span rigid frame; (c) tapered beam; ia) uss. ‘The knee is typically the deepest point of the tapered frame profile, making this system appropriate for the buildings where the clear height at the exterior walls is not critical. In this type of construction, the tallest equipment can be placed near the middle of the span or between the frames. ‘The single-span rigid frame provides a significant column-free area and the maxi- mum flexibility for the user. The most economical frame width for this system lies between 60 and 120 ft, although frames over 200 ft wide have been produced. The most common range of the eave heights is from 10 to 24 ft. ‘The degree of rafter slope depends on the type of the roof used in the building. ‘The low-slope frames, with a pitch from 4:12 to 1:12, are appropriate for waterproof (hydrostatic) metal and nonmetal roofs. The medium-slope frame profile has a pitch of about 2:12, which works well with “waterproof” metal roofs in the regions where heavy snow accumulation is common. And finally, the high-profile frames, with a pitch of 3:12 or 4:12, are used with steep-slope (hydrokinetic) roofing systems. The different types of ‘etal roofing are discussed in Newman (2004) and in Roofing Systems Design Manual (MBMA, 2000). ‘A single-span rigid frame typically exerts significant horizontal reactions on the foundations under gravity loading. The smaller the eave height, the larger these hori- zontal reactions tend to become. 1.2.3 Multiple-Span Rigid Frames When the frame width of the building exceeds the limitations of the single-span rigid. frame system, intermediate columns can be added. The resulting system is called the