BANAGHER Cy PRECAST CONCRETE Bridge Beam Design Manual doco IS) fares PRECAST CONCRETE SPECIALISTSBANAGHER (qe PRECAST CONCRETE Banagher Precast Concrete would like to thank the Concrete Bridge Development Group (CBDG) for asking us to present our Bridge Bear ‘Manual at their annual conference in Oxford We would aso lke to thank Abhishek Das in MIDAS for his help with th inital bridge model and his, ‘continued support throughout and a special thanks to our expert reviewers and researchers for thelr commentsand help. ish Plant Try Disclaimer “This manual gives Banagher Precast Concretes view on prestressed bridge lam design and in articular our W-beam which we developedin 2005, Please note that the calculations presented inthis design manual ae for information only. Banagher Precast Concrete Ltd. do not accept any lability for the use of any presented mateta PRECAST CONCRETE SPECIALISTSBANAGHER PRECAST CONCRETE reo J.INTRODUCTION.____ - 2. DESIGN STANDARDS REQUIRED 3. SCHEME DESIGN ‘4. MATERIALS 41 Conerete 4.2 Prestossing Stee! {43 Reinforcing Stee! 44Cement 45 Modular Ratio 5.COVER 6. STRUCTURAL MODEL AND ANALYSIS. 6.1 Modeling Assumptions 62 Loads {63 Boundary Coneitions 6.4 Construction Stages 7.SECTIONPROPERTIES Oo 8. CALCULATION OF LOADS 10 9. COMBINATIONS OF ACTIONS. 3 10. DIFFERENTIAL SHRINKAGE 1“ 11. TEMPERATURE EFFECTS 16 11.1 Unifotm Temperature Component. . 11.2 Temperature Difference Component. 16 113 Non Linear Component - ce 12. PRESTRESS DESIGN 18 13. PRESTRESS LOSSES. 20 13.1 Immediate Losses 2 13.1.1 Relaxation Loss 20 13.1.2ElastieShorteningLess 13.2 Time Dependent Losses 2 132.1 Relaxation Loss 2 1322Creep. 13.23 Shrinkage 133 Summary of Long Term Prestressing Losses 13.4Effective Prestressing Force 135 Tranemisson Length - 14. SERVICEABILITY LIMIT STATE (SiS) 14.1 Decompression Check t Transfer of Presress Ce 14.2 Revised Stresses With Debonding 142.1 At End of Transmission Length 1422At End of Debonded Length 143 Stress Check at Construction Stage 144 Decompression and Stress Check at Service (midepan max) 14.9 Stress Checkat Service (midspanimin) 146.Decompression andl Stress Check at Service (end of ciaphragm) 147 Decompression and Stress Checkat Service (end of transmission length) _ 148 Decompression and Stress Checkat Service (end of cifferent debonded lengths) 149515 Sttess Summary 15. ULTIMATE LIMIT STATE (ULS) 15.1 Urtimate Limit State Flexure Check 15.2 Minimum Reinforcement Requirement Check. 153 Global Vertical Shear Design (beam ends). 154ShearatThe interface GetweentheBeam andTheslab 15.5 Shear Check Between The Web and The Flange of The Composite Section 16. BEAM CAMBER ESTIMATES 17 CREEP INDUCED SAGGING MOMENT AT SUPPORTS APPENDIX A, APPENDIXE USTOF SYMBOLS eaNVoauese esau BRSSSYSSE EMSS SUR R RR ROBE EEO PRECAST CONCRETE SPECIALISTS 1BANAGHER PRECAST CONCRETE 1, INTRODUCTION Banagher Precast Concrete s pleased to introduce is bridge bear ‘design manual, Prestrescad conerete bridge beams ate fr favourites Inthe short and medium span bridge market. of upto 50 metre pans ‘and have been in successful use forthe last 60 years “The Bridges for which the industry and of course Banagher Precast Concrete manufacture beams requir considerable expertise in design, The design is usually caried out with a Contractor employed Engineer taking the project from planning to working drawings of the bridge for which the beams would be required. Thedesign of te beams may be cantied outby this engineer, by the engineer incooperation with Banagher Precast Concrete the supplier or ‘completely by Banagher Precast Concrete using the engineers ‘analysis output as the starting point n the last few yeas, the design regulations have been harmonised throughout Europeas part of the ‘Common Matket for Goods and Services withthe Introduction of 2 suite of Eurocodes and European Product Standards. Each Member State ofthe EU has the responsibility for Structural Safety and the Eurocades therefore come witha National Annex in which National preferences with respect to safety factors etc are given. The designs in ‘this manual have used! the UK National Annexes which ate very similar tothe lish National Annexes. Where the rsh regulation would be lfferent itisnoted inthe text. The coherence the new regulations allow, withthe use of Harmonised Product Standards, ’ commen approach which is used a the basis ofthe CE Marking cof Bridge Geams in turn enabling them to be part ofan open pan European Market. Tey Gre RED ‘The following list contains the relevant standards that are required for the design of this ridge, | .Burocode Basis of Structural Design BS EN 1990 2002, 2.Eurocode 1 Actions on sructures-Part 1 and Part 2-85 EN 1991-1, and BS EN 1991-2 3,Eurocodte 2 Design of concrete structures -BSEN1992-1-1 : 2004 4. Eurocode 2 Design af concrete structures, Concrete bridges, Design and detailing rules BSEN 1992-22005 5.8SEN 206-1 :2000 Concrete Pat I: Specification, performance, procluction and conformity 6,85 8500-1 :2006 - Concrete - Complementary British Standard to BS EN 206-1 ~ Par I: Method of specifying and quidance for the specifier 7.PD 6694-1 Recommendations for the design of structures subjectto ttafficloading to BSEN 1997-1 2004 £8. BS EN 15050-20074 A : 2012 Precast concrete products Bridge elements 2 PRECAST CONCRETE SPECIALISTS ‘This manual gives Banagher Precast Concretes view of the new design proces for Prestressed Brldge Beam to the Eurocode andit shoped ‘wll promote more use of Bridge Beams and a common and agreed Understanding ofthe many new clausesin the codes The manwal ‘considers the design ofthe innovative Banagher W beam ina typical ‘two span road bridge. The internal beam is designed in detail and as ‘the lading code i also nevs, the approach ta the use ofthis cade I ‘also demonstrated. ‘Other ares ofthe whole bridge design are commented upon, parciculaty where they can have an importantinfiuence on beam design. These are mentioned at appropriate places where they would naturally occur. Suggestions for further reaging are aso given. The Tormatifor the manual tahave the commentary and the design information followed by the example calculations. “This design manual should be readin conjunction with our"Beidge ‘Beary Manual which incluces our full ange of precast prestressed beans and their associated span tables along with all other relevant information require by abridge engineerin choosing ‘aprecast section. 9. BSEN 13369:2013 Common rules for precast concrete products 10.EN 10128-Prestessing Stel Note: ‘The standards referenced this design example are those relevant the time of print Please make yourself aware of ammendments before proceeding with this design example.“The design is fora two-span integral bridge, with each span having length of 20.75m from contre of abutment to centre of pier giving {anactual beam length of 30 50m as per ig 32 The bikige canes a 6.0m wide carriageway with 1m wide footways.on ether ideas per fig 3.1. The superstructure consists of sx Banagher Precast Concrete prestressedW/ I-beams with 230mm structural in-situ reinforced onerete deck slab 200mm aver the top af the beam cast on ribbed ‘ibte reinforced concrete FRC) seml participating permanent shutter, “There areinstu diaphragms at the abutments and pet. S00mm gap ‘between the precast beams Is used atthe plerto allow projecting links from the crosshead. There isa 1500mm wide precast crosshead spanning beeen to precast columns which makestup the piet ‘The bridge beams span from abutment to crosshead with SOOmm ‘bearing/embedment and without the need for temporary support. BANAGHER PRECAST CONCRETE yy ‘The foundations for the abutment are modelled as stip foundations ‘im deep and Am wide. The sizing of the foundations taken from ‘experience and for this example wil suffice as the WT beams are allthatsbeing looked atin detail not the supporting structure. The precast columns ae fixed into place wth dowel bars projecting up ‘rom the foundation below The columns wllnced to be propped and ‘the deeves filed with non shrink grout which wl then need t be aft ‘strengthen before pacing ofthe precast crosshead. Itis recommended that a numberof transverse holes are locate _atvarious depths nthe precast beam atthe abutment and pier ‘diaphragms. Whit the number and position of these diaphragms will beat the clscretion ofthe designerin conjunction with the precast ‘manufacturer asuficent numiser of holes should be provided in order to ensure anchorage ofthe precast beams and that the pier {and /or abutment diaphragms acts a torsional beam. y LJ | y Figure 3.1 - Section through bridge deck showing We11 beams at3.0m centres Figure 3.2-Elevation of bridge PRECAST CONCRETE SPECIALISTS 3BANAGHER PRECAST CONCRETE CON ey ‘1 Concrete ‘Accumed properties of concrete are given in BS EN 1992-1-1, clause 3.1. BS EN 1982 usescylinder strengths throughoutbutTable 3.1 gives the cortesponding cube strengths, allowing the continued use of cubes as contro specimens. The concrete strength class used inthis design is C50/60 forthe precast beams, (40/50 for the in-situ deckslab and diaphragms and C45/55 for the precast columns and crosshead. 4.2 Prestressing Steel ‘The proposed! European standard for prestessing steels prEN 10138- 3 andit soften referredto in BSEN 1992-1-1.prEN 10138-3, however, has since been voted down, though itis key thatit wil be rewritten and published a afuture date. In the meantime, 5 5896: 1980 has bbeen amended to cover those products currently on the market for which no specification would othenise exist. PRECAST CONCRETE Characteristic cylinder strength Characteretie cube strength Mean compressive strength Mean value of axial strength Characteristic axial tensie strength of concrete Design tensile strength of concrete Modulus of elasticty ‘Age of beam. at transfor Characteristic cylinder strength ot transfer Characteristic cube strength at transfer Mean compressive strength at transfer Mean value of axial strength at transfer Characteristic axial tensile strength of concrete at transfer Design tensile strength of concrete at transfer Modulus of elasticity at transfer INSITUCONCRETE Characteristic cylinder strength Characteristic cube serength Mean compressive strength Mean value of axial strength Characteristic axial tensile strength of concrete Design tensile strength of concrete Modulus of elasticty (COEFFICIENTS AND STRAINS Modular vatio PRESTRESSING STEEL TYPE: Diarneter Arta per strand Uleimate strength 4% Utimate strength applied Characteristic value of max Force 4 PRECAST CONCRETE SPECIALISTS 43 Reinforcing Steel ‘The European standard for relnforcing steel for concrete 8S EN, 10080, However 85 EN 10080 does net define steel grades and rather Inconveniently leaves itto the designer to specif its properties. In the UK this oid is iled by 85 4449:2005 which specifies the required properties fr standardised grades. 4ACement (Cement type lass Ris used by Banagher Precast Conctetein the {design calculations as rapid hardening cementis generally used in production. 45 Modular Ratio ‘Amodlular ato of 10s used for this example in accordance with ‘common UK practice (85 5400} which alowed a modula ratio of 10, ifthe diffetence between the precast strength &uin-situ strength does notexceed 10 MPa f 5000 MPa aoe 6000 MPa ie 52.00 MPa a 4.06 MPa ioe 2.84 MPa i 3.40 MPa z. 3728 GPa 3.220 days Farce 28.00 MPa focuses 35:00 MPa area 36.00 MPa (ae 277 MPa Fccoctemte 284 MPa Eee 3.20 Mra Bee 32.2 GPa f 4000 MPa aan 5000 MPa. Ee 42.00 MPa my 355 MPa oe 246 MPa ie 2.64 MPa =. 3522 Gra ” 3.00 - dia 35:70 mom Ae 350.00 mon? ie 3860.00 N/mont i 75.00% F 27400 kNBANAGHER PRECAST CONCRETE Initial force applied Fr 20425 kN Initial prestress applied & 2395.00 N/mm Elastic modulus 5 200.00 KN/nans? Relaxation of strand ¢ Class 2) - Mill Certs Cazes 250% REINFORCING STEEL: Character'stic yidd strength 50000 MPa OVER Inthe Republic of rela! the National Roads Authorities INRA) ‘The diagram in igure 1 below shows the UK values with the NRA version of 8057/10"Design for Durablity’ December 2010 versions values in brackets where diferent 4 very useful booklet and has exposure class iagramsin Appendix ‘A.At present in the UK there arena such diagrams available in ‘The exposure classes are speciiedin table 4.1 of BS EN 1962-1-1 and any ofthe their documentation therefore use B58500"Concrete- alsin atherdocuments, ‘Complementary British Standar to 8S EN 206-1" ‘Thisbridge example of atoad over road beg. “Thenominal coveris worked out forthe exposure class and the conetete grade. The most severe esulthas been used so thatthe worst Please note A, taken as Sm for precast and 1Omm for the insituin case scenarios taken, eginleland XDI with concrete grade C50/60 this example. |s 35mm minimum cover plus 5mm A for precast = 40mm nominal. Itisalso worth noting figure 5.2 which shows the differences in reland Inthe UKXD1 forthe same concrete is 30mm minimum plus Smm for and the UKin elation to exposure class when dealing with 4, =35mmnomina. deicing sats. 3S Sn CES NCTA ———] Figure 5.1 - Exposure Class & Nominal Cover Diagram Based on UK values with ROI values in brackets where cifferent PRECAST CONCRETE SPECIALISTS 5BANAGHER PRECAST CONCRETE Figure 5.2 - Exposure Class due to de-icing salts aCe val Ta UPN 6-1 Modeling Assumptions “Modeling ofthe 2nrspan continuous integral bridge was carted ‘utin 3D using MIDAS Civil, with agrilage model representing the deck, line beams for intermeciate piers and 2D FE plate elements for the abutments on either sce ofthe bridge. Concrete diaphragms, ‘modelled a ine elements are provided atthe 2nr abutments and at the central intermediate pir location. Use of beam elements forthe deck ensures direct exaction of design forces forthe longitudinal bears Longitudinal beams are modelled as composite sections with the effective width ofthe slab assigned tothe composite section to take «are ofthe shear lag effects Fr simpikity each longitudinal section of ‘the gillage consists of one precast bear and the effective width of| ‘the slab on top oft MIDAS composite section type beam elements allow exaraction of discrete force and sess results for both the slab ‘and the precast beams separately fora composite main beam section, For\W beams tis common practice to provide one longitucinal ‘grilage member per beam web (ie two per bear), Modeling a single line per bear does not accurately model the load transfer from ‘deck slab to beam webs and does not accurately model load sharing between adjacent beams. However for this example this ation was ‘ot taken for simplicity Figure 6.1 -FullFleshed Modet 6 PRECAST CONCRETE SPECIALISTSBANAGHER PRECAST CONCRETE 6.2Loads er Eas Permanent Selfieightof bears ‘Auto self weight feature Insta concrete slab ‘Element Beam Load (UBL) 18.75kNm per precast beam Parapet Element Beam Load (VDL) 75kNimon the edge beams Surfacing Element Beam Load (VDL) {828 KN/m per precast beam Earth Pressure on abutmens Hydrostatic Pressure 13.661 KN¢ntoptobottom Pretensioning | Tendon Prestess| 75% = 209.25 KN pertendon Variable Temperature Difference Element Temperature 2Odegrees Variable Traffic Actions Load Model Standard Eurocode Vehicle Tandem system and co-existent UL Load Model3 Standard Eurocode Vehicle sv196 Footway Standard Eurocode Vehicle SiN Table 6.1 - Mida¢ Chl Input Parameters Figure 6.3 - Bridge Cross Section taken from MIDAS Civil showing tendon input locations 6.3 Boundary Conditions: Fined supports under piers and vertial soll springs below the abutments PRECAST CONCRETE SPECIALISTS 7BANAGHER PRECAST CONCRETE Ce Figure 64 Skeletal Model showing Boundary Coneitions 6.4 Construction Stages: Itisassumed that the slab willbe poured in single stage on the main precast beams Ina singleanalyis model, the following construction stages have been defined Stage 1: AIWH precast beams are simply supporteden the abutments and crossheads with prestress and beam self weight only considered. Stage 2:The instuwiet concrete load is aelded tothe precast beams with the beams again being simpy supported, Stage 3:The composite structures completedin both spansand the beams are now continuous. Grilage madelfsactvated with all ‘transverse elements, edge beams etc Surfacing and parapetloads are applied when the slab atains the 28 days strength. Earth Pressure load 'salso applied at this stage. Stage 4: Fina stage, considering the bridge atthe end ofits designlife _accounting for alllong term time dependant effects including creep shrinkage, Time dependent analysis for concrete s one within the construction stages for both slab and beam. Creep and shrinkage behaviour s inputted as perEurocode. Compressive strength gain of concrete is ‘also applied as per Eurocode to account for short term andilong term elasticities, Tokeep the analysis simple, crackingin the deck s not assumed at the intermediate support. Live Load Analysis: Highway Live Load Analysis was carried out based, ‘on MIDAS influence line analysis. 2nr Notional lanes anc 2nr footway lanes were defined. The following lve load combinations were ‘analysed as pet EN 1992-I-1 and itsnational annex. 1. Grla: Lat characteristic +06x Footway Characteristic 2. GIS: LMT frequent (Psi20 75) + LM3 (S196) stradating betwen 2nr notional lanes Figure 65 - MIDAS Civil Screenshot Showing Construction Stages Input 8 PRECAST CONCRETE SPECIALISTS“The WIT - beam has 40mm wide by SOmm deep recesses atthe top BANAGHER PRECAST CONCRETE Baraat} ‘of the webs this sin order to facilitate the placing and positioning of permanent shutter on site. This shutters fibre reinforced concrete, FRC, andis manufactured by Banagher Precast Concrete-For this ‘example FRC 50/20 vllbe used which hasa 20mm bottom flange ‘from theW11 beam and a 3m rectangular sab, “The code permits stiffnesses tobe represented onthe gtoss concrete section ignoring the reinforcement or strand.Thisis the most (ignored in calculating the deck lab thickness) and 30mm upward not yet been calculated. projecting ribs which participate structurally withthe deckand Included in the composite section properties “The overall height of the composite sections 1700mm. The composite straightforware way since the reinforcement or prestressing strand has ‘Composite section properties are usedin the calculation of stresses resulting ftom loads applie after the structures made inceoral (2. section properties are calculated by assuming the section is made up trafic loads, surfacing, parapets string courses, finishes eit) ieee Station | Depth ‘Arta ¥ Z, 2, im SUF Weight | Overall W (mm) enemy | conn) | Conentzory | (ommeasor) | Conmrczo | ckN/m) | Comm) wae 2500 | eeqo | e220 | 24ec2 | 2423 | aasae | 22a7 | aeo040 Table 71-11 Beam Section Properties Masiinuen height above bean Rekate depth less Forraworke Total depth of slob Beam centres ‘The depth of carviagway surfacing has bean taken as: =, (slab\/E, (beam) Modular ratio 200 mm 2O mm 230 mm 3000 mm ‘Composite Section Properties section. Bp A e tae Zaman Frais Zou ie (oan) (vo0ee) conn) | oanncesor) | (wnmeezo) | (momteso%) | (ramneeso%) | (enn'ezo?) Comp. 3700 | aszxs00 | sosszs | szez2s | ssaz0e | svove | szezes | sezs2 Table 7.2-W1 1 Beam and Slab Composite Section Properties Figure 7.1 - Section through Banagher Precast Concrete FRC 50/20 shutter PRECAST CONCRETE SPECIALISTS 9BANAGHER PRECAST CONCRETE Figure 7.2 - Section showing Banagher Precast Concrete FRC shutter in place prior to in-situ deck lab pour 8. CALCULATION OF LOADS Eurocode I: Actions on stuctures Part 2: Trafic loads on bridges is the main document usedto calculate loadings on bridges in ireland {and the UK. This document is to be used along with ts national annex. Definitions: Dead Loads: ‘The weight of beam, deck slab and permanent shutter ‘Superimposed Dead Loads: ‘The weight ofthe road surfacings & parapets. The variability of surfacing see EN 1991-1-1 Clause 52.3 (3) isignored for simply. Live Loads: Loads due to vehicular and pedestrian traffic, LMT & LM SV196 Dead toad! Wa Beam alone: Transient Loads: Tempertue, shrinkage andi creep Notional Lanes: ‘The carriageway must be divided into notional lanes as specified in BS EN 1991-2, Table 4.1, For vieths of 60m and above, the cariageway 'slvded into an integer number of 3.0m wide lanes. Any excess With is known as the temaning area Thisexample hasa 6m wide Catraigevray spit into 2nr notional anes of 3.0m with. Allof this information is putinto a computer programme, in this ease [MIDAS Civil and analysed forthe worst load effect by positioning the \ehices in the most onerous postion on the bridge deck using influence lines/surfaces. This design example has no remaining area. Area = 246920 sana? (value taken from BPC Bridge Gearn Manual") Woight = 23.273 KN/m (value taken from “BPC Bridge Bean Manual”) Composite section: Arta = 2522500 mn? Weight = 38.04 kN/m Superimposed dead load: This landing (s applied to the corapasite bean and slab structure 10 PRECAST CONCRETE SPECIALISTSCarraigewey: BANAGHER PRECAST CONCRETE yy Asphalt surfacing - for simplicity assume maxioune thickness of 20mm over whole carriageway. This includes allowance for waterproofing SDL gy = 022m x 23KN/on* = 2.76 KN/ea? To get this value in kN/ea length of beam it iS multiplied by beam centres, in this case Bm. = 2.T6kN/m? x 3.0m = 8.28 kN/en per beam SDL jug =O.2A WA DSLN/ ea? = 6 kN/ow? (with 240mm being the average thickness of the footway) Canrnigeway width we e[m Width of notional lanes, w= 3 [ma Nunnber oF notional lanes, wi = 2 [nr With oF remaining area, wr = o[m Table 8.1 -Notional ane results as per EN1991-2:2003 4.24 Load Model 1 (LMI) -Clause 4.3.2 +NA212 ‘A double-anle load calle the Tanclem Systems applied in each traffic lane in conjunction witha uniformly distributed load called the UDLSystem. LUM consists of wo parts: 1-Adouble-axe loading, refered to asthe tandem system, oF. Each anlehasa weight ofa,0, where a, isanationaly determined, adjustment factor 2.A uniformly distributed load (UDU having aweight per square ‘mete ofa, where a, isanationally determined adjustment factor. Only one tandem systemis applied to each lane, symmetically around the centeline ofthe lane but no moce than 0.5m fom the TS inthe opposite lane and in the positon that causes the most severe effect on the element being considered. ‘The tanclem systems and UDL should only be applied inthe Lnfavaurable parts the influence surface, bath longitudinally ane transversely The nationally determined adjustment factors forthe UD have been set by the UKNA so that a UDL of 5SkN/m'isappled toalllanes and the remaining area respective of the number of "nominal lanes, simplifying the input ofloading nto the analysis mode! ec Tandem system UBL system a. He Ae 44 (07 4) 4, a4 city (kN) (RNA nee) (or o,,) (KN/ re?) Lanes 300 2 200 @ one 55 Lone 2 200 2 200 2s 22 55 Table 8.2-Load Model results a per EN1991-22002 422 Table 42 Load Model 2(LM2)-Clause 4.3.3-+NA215 Asingleae loads applied anywhere on the carriageway. The UK ‘use a 400KN axle load which inchides a factor to allow for dynamic amplification effects. Tis load modes more predominant on short spans, <7.0m and the transverse design of the deck lab, ‘The wheel contact shapes for LM and LMZare 400mm squarein the Republic of eland and the disiibution through surfacing i 30° and ‘tough the concrete slab is 45 The UK national annex hasa diferent ‘hee! size for LMI,2 3 and can be found in its NA, PRECAST CONCRETE SPECIALISTS 11BANAGHER PRECAST CONCRETE yY ‘Ade Whight, Qu = 400 kN Aadjustenent Factor, 8 3 Applied axle weight, 8,04 20 WN Table 83 -Load Wodel? results as per EN1991-22003 433 ‘Load Model 3 (LM3) -Clause 4.3.4-+NA2.16 Inthis example SV196 mace! vehicles willbe used. The SV196 loading is combined witha reduced value of LM, knownas the frequent’ value. Figure 8.1 below shows the SV196 vehicle from the UK national annex toEN1991-2:2003, the only lifference between the UK and the ROI sthat instead ofthe lat 3 loads being TBOKN, TBOKN & TOOKN in the ROI they ae ll 1654N, Load Model 4 (LIA) Clause 4.3.5 ‘A uniformly distibute load of N/m? used to represent crowed loading and may be applied to both road bridges and footway! ‘oyceway bridges. Basic ade load (kN) Dynamic amplification factor Design axle weigh (EN) 200) 22 230) 226 280. a 7S 248 225 207 24075 Table 8.4 - Dynamic amplification factors for SV and SOV vehicles (Table NA2 EN 1991-2:2003), Figs, ‘Groups of Traffic Loads (UK National Annex Table NA.3) Load Madels 1 to 4 may be combined to form ‘Groups of trafic loads ‘The Groups are referenced grla, grb, gr2, 9F3, gr grS and gré and the load mode's usedin each group are listed inTable NA3 of the UK NA this verte Eurocode EN1991-2 Table 44a) Forthis example gra & gS have been looked at. Group grla LMI7 is combined with footway loading, The footway loading fs reducedto 3/m (06 xSkN/m’) 12 PRECAST CONCRETE SPECIALISTS ts | tan | tae on | vim ” | Ba I a HOoOOA Ba ~5V 196 vehicle Fig NAT SV 196 vehicle -EN1991-22003) Group 95 ‘The Frequent’value of Load Mode! 1 combined withthe ‘Characteristic’ value of Load Model 3. The Frequent value of Li i ‘obtained by muttpiying axe loads and UDL by 0.75 (¥1 = 0.75 from Table NAAZ.1 in NA to BSEN 1990:2002+A1:2005).Tanclem Systerns can be interchanged ia worse load effects achieved, Loading from LMI is omitted from the lane or lanes, occupied by LMB fora distance within 5 metres ofthe front and rea anes This loading arrangementis shown figure NAS of the UKNA to EN 1991-2. “The vehicle load optimiser in MIDAS Civ places the LMT and LM3. Vehicles on the bridge and gives sults for the west possible position ofsame.BANAGHER (7 icin ae oer] ee ae Vert ores as ert Fores ae rho qa aa rae | a Zs m cs Enuaton (53) ass ry cme Te oe Braking aad | Conrfagal | Unto (rand ut) |(singe ale) | (specid | (Oru acelaration | de transverse | dstriuted vehiaes) —_lloading) [feces [fores | oad ms an tae Hee Cheractertic ie aaa | Paunta) Characins | Charo ca Cane a Characters Character os |e Characters ins Characters Giaratiats| hana ea a (6 er Sa Ai] rp OT ei Reena a Wise ara ek eet an ee gs aed ced cone tT erro ene chaste she arate ceed eer ameter eden feces na Recline el se anol i endo (a) Tew, factors shold be taken fram the UK National Ani to BS EN 3490 Table 8.5 Assessment of groups of traffic loads (Table NA.3 EN 1991-2:2008) Neo ee Valery ‘There are three combinations of actions that must be considered at the serviceability imi tateSLSr J-the characteristic combination, which can be considered the most These are defined as follows: QU -Loss of static equilbyium ofthe structure orany part ofit when severe loading to hich the structure should be subjected to 2 the frequent combination, which isthe most severe oad case to consideredas.a righ body. 'STR- Internal failure or excessive deformation of the structure or Which the structure should be subjected toon a regular basis 3. the quasi-permanentloadcase or the loading to wiich the structure lcsubjected to mastofthetime. structural member. (GEO -Foilure orexcessive deformation ofthe ground where the strengths of sollare significant. FAT-Fatigue flue of the structure or structural members. Four ultimate imi states (ULS) are defined in BSEN 1990, namely EQU, STR,GEO anctFAT, Serviceability limit state (SLS) Aetion Groups of loads Coad componént % % % Thermal actions o6 o6 os Traffic actions grea Tanda system 7s ors o UE O75 ors ° Pedestrian loads o-4 4 ° oe SV vehidle @ 2 o 9:1 - Values taken from the recommended values of '/for road bridges (Table NA.A2.1 EN 1990:2002) PRECAST CONCRETE SPECIALISTS 13BANAGHER PRECAST CONCRETE Ultimate limit state (ULS) Group oF loads i Yer ta Dead load 23s 225 o Superinaposed DL 32 Oa ° Terwp. dif, 35 ° ° Prestress 33 oO 2 “Tralfe groups 235 ° NA Table 9.2- Values taken from the design values for 7 for road bridges (Table NA.A2.4(8) EN 1990:2002), Saas Uva Lech When theinsity slab fscast onto the precast W711 bears some of shrinkage wil be reduced by creep. Allowance is made for thi in the the shrinkage ofthe beamshas already occurred Hence differential across sample calculation by usinga reduction coefficent with a value shrinkage occurs between the precast and the insitu concrete and this of 43, Note cfferential shrinkage only considered inthe SLS. results in the development of internal tresses meaning the deck slab tcl wil shrink by a elatvely greater amount: This telative shrinkage A sample calculation for working out the ciferential shrinkage stress wll compress the top ofthe beam causing axialforce anc/sagging_inthe top of the bears show across, using this logic the shrinkage ‘moment in while generating tension inthe deck dab. stessinthe bottom of the bear, the bottom ofthe slab and the top of the slab canall be worked out Itis reasonable to assume that half ofthe beams shrinkage has ‘occurred atthe time of casting the top slab The effects of cfferentlal _Allof the answers are shown in table 10.1 helow and ig 10.1 shows them plottedin graph format. Bean tea (MPa) ‘Beam Top (MPA) Slab Bem (MPA) Slab Tap (MPa) Value 255 ae “On ~e22 H (mon) e 2500) 3500) 2700) Table 10.1 -Long Term Differential Shrinkage Stresses Differential Shrinkage Figure 10.1 - Differential shrinkage diagram 14 PRECAST CONCRETE SPECIALISTSExample calculation forthe stress in the top of the beam: BANAGHER PRECAST CONCRETE Beam Top Differential Shrinkage Stress = Force/Area of the compasite stction + Moment/Z,, = 2.30 MPa wheres Restraining Moment oree x eccentricity AAELOB New Restraining Force = O43 x differential shiinkage strain x E,,.« Total Arca of insitu topping /Modular ratio = 2.53 N / mon® 2 top precast beam = 2:36:09 mun? Arta of the composite section = 2.525406 mmm? Eccentricity = (area of top slab x lever aren / Total Area of insitu topping)-Height to the Centre of Gravity of the Composite Section = 53234 enn Daly and seasonal fuctuationsin shade air temperature solar radiation etc. cause changes inthe temperature ofa bridge superstructure, thereby causing movement ofthat structure, Depending on the restraint concitions this movement can lead tostresses in the structure. This effect can be divided into. three components; 1. the uniform temperature component which causes expansion or contraction ofthe deck 2 the temperature ciference component which leads to curvature of. the bridge and 3. the nor-inear temperature component, which causes local stresses ‘within the stecture SPR as ae say n Inform Temperature Component, AT, “The frst stage in determining the uniform temperature component Isto determine the minimum and maximum shade air temperatures {forthe location vere the biige fs tobe built Forthe UK thesecan be determined fiom the maps of isotherms given in Figures NA. and, NA2ofthe National Annex to BS EN 1991-15, with an adjustment being made forthe effectof altitude, ‘The minimum and maximum shade temperatures are then converted into minimum ang maximum uniform bridge temperatures and T gg Fortis example these values were taken a5-9°C and29°C “The maximum contraction that the bridge will experience will depend ‘onthe difference between the minimum uniform bridge temperature and the uniform bridge temperature atthe time when the bridae is first made continuous with ts abutments, TAs the temperature at ‘the time of construction cannet be known i advance the example takesT, tobe 15°C when considering contraction and 5° for ‘expansion as per the rsh National Annex, NA2.21. Figure 11 - Diagrammatic representation of constituent components of a temperature profile (Fig 4.1 -EN1991-1-5:2003) PRECAST CONCRETE SPECIALISTS 15BANAGHER PRECAST CONCRETE BS EN 3993-3-5 Ce3.2(2) - Bri Surfacing = 220 men Altitude = 2334 m Fig NAS - Minium shade Fg NA2 - Maximum shade air temperature temperature = -9 °C ane Annex AS note 2 ~ The minimuen shade air temperature may be reduced by 0.5 * C per 500% above sea level Annex Ab note 2 ~The maxinum shade air temperature ency be reduced by 3.0°C per 200m above sea level Fig 6.2 ~ Uniform enininnuna bridge temperature, Tons, Fig 62. ~ Uniform enaximum bridge temperature, Toya. NAZ2E. ~ Tyo = 25°C NA222 ~Tyy25°C Tat 8= 307°C Tut 2=3087°C Maginuon contraction range AT yan To ~ Tom seor'c Maximuen expansion range AT. = Tiyy ty = 25.87°C “Table C3. ~ Coeficent of linear expansion for conorete, Length of bean = 20.5 m No.of continuous spans = 2 nr Masiimuen contraction = OAT, ad = 9.80 eam Maxinuen expansion = CAT gl = 25.78 mann c0008/* C 11.2.Temperature Difference Component, AT,; (-integral bridges only) ‘As wellas uniform temperature changes, which cause uniform Comections to fg 11.2are givenin clause changes in length, variations in temperature through the thickness NA29ofBSEN 1991-15 the deck must be considered. Both heating and cooling temperature dlferences are considered, The values for ernperature difference lstibutions given in Figure 6.2c of 8 EN 1991-1-5 assume a depth of ened aon ‘Temperature Difference (7) Type of Construction (a) Heating {b) Cooling ona L s i} Be nei Yar, Eeeceesed ‘h.-0 button eh =a ante, sere, weet it ee ae JZ | Ee Sinaia Figure 11.2- Temperature citferences for bridge decks ~Type 3: Concrete Decks 16 PRECAST CONCRETE SPECIALISTSBANAGHER yy rs —_ —_ —_ —_ = 280 -OS 250 ° 400 ° 450 2 3700, 2 2450) “The resulting restrained forces can be calculated using miDas: Table 112 a a a Table 11.3 “The uniform temperature components and linearly varying teenperature difference components may be colculated as follows AT, = (N/A) / Ea) AT, = (Mh /1) (Ea) ATCO) ATCO) Heating 275 3ad Cooling =a52 ~o27 Table 11.4 11.3.Non linear temperature component, AT,: ‘The nontinear temperature lfference componentisselfequiliorating, _ternperatues are the difference between the orginal temperature soit does not need to be includedin the global model, However it sets _cstibution and the uniform andiinearly varying temperatures. Uuplocal stresses that need to be assessed forSLS.The non-linear a7.) a.(MPa Depth nn} ATCO, 4, (MPa) Depth (nom) 33.05 458 5 =68 “255 2 oss oat 350 3 ont 250 “Bas 7 400 ze 36 450 ot ~o54 3480 3A5 3350 a as 2700 ons 3ASO Table 11.5 S87) Bae) Table 116 Design value of thermal loading: For the characteristic combination of actions; Wa, = O60 For the frequent and quasi-permanent combination of actions: VW, = 2.50 PRECAST CONCRETE SPECIALISTS 17BANAGHER PRECAST CONCRETE Heating Cooling Stess Pa stress MPa 2600 -1.000 6.009 1.000 2000 3.000 4000 5.0% 3.000 2.000 1.000 © cm —«1.000 — naan “ Depth mm Figure 11.3 - Heating and cooling graphs for temerature stresses. 12. PRESTRESS DESIGN “The aim of prestess design sto limit tensle stresses and hence ‘egural cracking in the concrete under normal working conditions. “The design is therefore based on the requirements ofthe serviceability limitstate but the ulimatelimit state fr bending and shear must also beconsered. Since concretes strong in compression the material thats used inthe beam willbe most efficently used ifitcan be keptin compression this ‘compression force is provided by means of high strength steel wired strand anchored against the concrete a either end of the stressing line-The concrete is cast around the strands in steel moulds and when the requited strength has been reached inthe concrete (transfer strength the strand! release! and the force is transfered into the concrete by bond. “The prestessing tendon layout and theresuting calculation of prestressing losses were inital based on an assumed layout .uestimated from previous experience wth similar beams. ‘The tendon positions were selected from the standard positions available for W beams. Requirements for prestessing and the calculation ofthe effective Drestressing force are given in 85 EN 1992-1-1, clause 5.10. The applied Drestressin the svands during tensioning should not exceed 802% of the characteristic toni strength or 90% of the characteristic 0.196 proof tress, whichever i the lesser. Ths alos an apolied prestess ‘of upto 79% of te characteristic however ve recommend afiqure .0f75% in accordance with long standing practice This gives a limit of 1395 MPa for this example. Note thatin pretensioningitis possible to eliminate “draw -in"losses by extending the strand 5-10mm beyond ‘the theoretical strand extension, this means thatin practice the prestrss apple willbe sightly more than the 75% depending en the length ofthe production tne, “The tres inthe strands immediately after transfer i aso limited this time to the lesser of 75% ofthe characteristic tensile strength or 85% 18 PRECAST CONCRETE SPECIALISTS ‘ofthe characteristic 0.1% proof stress. ‘The across W/11 beam showing strand inputis the prefered choice however several iterations were performed: 1.A60nr strand layout: Pros Lowest amount of strand requited for beam to work CCon's~ In orderto achieve decompression atthe diaphragm face due to the hogging moment stress 18h strands (30% of total) would need. ‘tobe debonded which exceeds the ACI 25% recommendation that Banagher Precast Concrete uses asa gulde, 2.A62nr strand layout -(adding 2nr at 1230mm above soffit): Pros -Debonding can be reduced to 12 strands{20%6 of total), nr lessthan the fst design. CCon’s-2nr extra strands to be used! compared tothe frst design 3.A Ane strand layout (adding 2nr at 980mm above soffit): Pros - Debonding can be reduced to Bn strands(12.5% of total), Ton less than the frst design. CCon’s- nr extta strand tobe used compared tothe ist design 4. AG6nr strand layout- (adding 2nr at 1430mm above soffit: Pros—No debonding required CCon’s- Gor extra strand tobe used compared tothe frst design and an increase in transfer strength from C28/35 to C35/45 plus an increase in 28cay strength from C50/60 to C57/70 cue to beam bottom ‘compression from the pier hagging moment, From an examination ofthe above desions 2 62nr strand arrangement ‘was chosen a the preferred asit was both an extremely efficient {design and suited factory procucton best as debonding strands.BANAGHER PREGAST CONCRETE ‘relatively inexpensive and aity straightforward factory controlled envionment once the quantity isnot excessive. This is why thought and several iterations shouldbe carried out by the bridge designer plusinput from the precaster to achieve the best ft Te fst selection ‘that a computer programme comes up with isnot always the bastona, Prestressing Strand Parameters Diameter | Cross | Utimate | SUttimate | Craceritic | intial force | tnd | elastic | Relacation (im) | sectional area| strength | strangth | value of max | applied | prestrss | modules | of strand (rane) (MPa) applicd Force (kN) applied (GPa) (a) @) (kN) (MPa) as7 aso | aeeo [7s | ava | aoeas | aes | amo | 2s | yo. SS = sweeper ie Figure 12.1 - Section through W11 beam showing strand layout. PRECAST CONCRETE SPECIALISTS 19BANAGHER PRECAST CONCRETE end No. strand used H/0 soffit Row 4 @3420 mm 4 @3220 mm 203325 mm 2@ 880 mm 2@ 750 mm 2 e480 mm 2e =o mm 4 @20 mm 32 220 mm wlefofalafe|afe| o 28 @60 mm 62 @=48 mm Table 12.2- Strand Layout. Initial Prestressing Force = 32473500 N Eccentricity = 2824 man ‘Monnent = 3677000000 Nim 13. PRESTRESS LOSSES: 13.1.lmmediate Losses ‘The prestessing force does not actually achieve ts intial value The prestress transferred to the beams after they are casts ess than the force initialy jacked into the strands. Prestess losses which occur ator before wansfer are duet: |. Relaxation ofthe strands 2. Blastic shortening ofthe beam under the prestressing force ass 2: Ab, / 6, = O66 X Prony X Ct EODO}2 where: Ratio of initial prastress to tensile strength, yu = O75 time, t at transfer = 240 hrs Relacation of strand ¢ Class 2) ~ Mill Certs, Csose 25% 13.1.2.Elastie Shortening Loss “The oss due tothe elastic deformation of the concrete beam asa result ofthe action ofthe pre-tensioned tendons when they are released from theanchorages ‘The elastic oss at transfers calculated atthe centroid ofthe tendons and is due tothe compression arising fiom the prestessing force, after ‘the initia relaxation loss prorto transfer anc the self weight of ‘the beam, The later is included hecause the beam cambers ung ‘transfer and hence has to cary its selfveight asa simply 20 PRECAST CONCRETE SPECIALISTS 2.79 MPa 0635 13.1.1.RelaxationLoss ‘The loss due tothe relaxation ofthe tendons during the period which lapses between the tensioning ofthe tendon and the prestressing of ‘the concrete bear, - (Exp 324) = (A335) supported beam, ‘The methodology used in theDesigners Guide to EN 1992-2" by Hendy & Smith has been adopted with particular reference to ‘equation DS. 104, Using the denominator rom this equation the losses due to elastic deformation ata given time can be modifiedBANAGHER PRECAST CONCRETE Using the denominator from D530~¢ we can work out the elastic deformation modification factor (ME) as Follows: Mi where; Modulus of elasticity of the prestressing steel, E, = 200 GPa ‘Short term modulus of olasticity for the conorete, E, (t) Gross sectional area of the tendons, A, ‘Arca of concrete section, A, = 840920 mon Second moment of area of the concrete section, |,= 23546 x0" mm? Eccentricity of the tendons,2, = 2824 mm + ESE OK A/A. &BHA/ x28, = 2.0894 Prestress at Centroid of section, 0, = 35.54 MPa as per tale 32.2 Loss of prestres = 6{E, /Emg)/MF = 88:72 MPa 636% 13.2.Time Dependent Losses prestresing force. The final prestres is usually about 25% ess than ‘the intl prestress adits thefnal value that must be used in the Further losses of prestress occur withthe passage oftime,Longterm Jong term sLS calculations fr the bears prestressing losses are due to: Further relaxation of the strands 13.2.1. Relaxation Loss. ‘croop of the concrete due to the permanent compressive stesses Shrinkage ofthe concrete as it cures ‘Thess due to the relaxation of the tendons checked at ifferent times. The code sets out checks at transfer, construction, open to trafic ‘These lozsesneed to be evaluated to find the final (long term) and long term. Allo these are checked across and tabulated, Relaxation Loss Stage (days) Loss (MPa) Loss Transfer 3 176 osen Construction. 30 2385 anon Open to traffic 300) 2498 2oTs Long term. 208s 4077 242% Table 13.1 -Reloxation Loss Summary. 13.22Greep ‘Creep causes a number of effects that have te beconsideredat various 85 EN 1992-1-1,clause3.14 and Annex describe how to calculate stagesin the design of prestressed concrete structures Perhaps the creep andi outlined n the calculations below. ‘most sgnifieant isthe loss of prestess that results from creep and the effect that this willhave on the SLS criteria Parameters required Relative Hunnidity of the ambient environment in, RH = 2000 % ~ Gap 3.8) - Gap B82) - Gap B82) 32444 mm - Cap 8.6) Mean. compressive strength, f,, = 5800 MPa Curing period. At, = 72.00 hrs Tat) = 20.00°C “Temperature adjusted age of conerete. at loading in days, t= % days For exment dass R, = 5 PRECAST CONCRETE SPECIALISTS 21BANAGHER PRECAST CONCRETE t= emompmetanisen ae = 3.00 days Bf) = 26.8/f,,22 = 2.22 ‘Age of concrete at loading in days, t, = t(9/2Ht,.2* +3) 20S 773 dys Factor to allow for the effect of concrete age at loading, A(t.) = 2/(03+t,299 = 062 5 = dan Koad x been Creep Coeficent: ae) =, x Bitt) = 246 Creep Strain: e,outy) = Hat ModE) = 525% 30% Creep Loss: Long Term Creep los = 5,8, = 2088 MPa ~ (exp 830) - ep 84) ~ Gp 8.) ~ ap 85) ~ Gap 82) - ep 82) - (ep Bs) - p36) Stage (des) Pw) Ze (enn?) 2. (MPa) Transfer 3 32052778 7.608:08 ysseenena4 Constr 30 Beano 7:608:08 soued22@ Open to trafic 300, 33749674 T60EO8 Tae8035587 Tong terme 25550 3as0383e e088 saonoz0687 Table 13.2 -Compressive Stress Results Note: 1, = stress at centroid of the strands due to prestress, self weight and all other quas! permanent actions at the time under consideration. A + PU/Z, 4MfZ, where; = Prestress farce less losses at time being considered. A= Crass sectional area of beam. = eccentricity ‘Section modulus of centroid of strands about wuetral ais of section, Z, =, / eccentricty ‘Ab transfor — 3 dogs ‘AE construction ~ 50 days AE opening ~ 200 days Long term ~ 25550 days Mae = Ma Moat Macs Mm, ten = M, Mae = Met M, Figure 13.1 - Calculating stress at the centro of the strands (.) due to presttess, self-weight and all other {quasi permanent actions atthe time under consideration 22 PRECAST CONCRETE SPECIALISTSBANAGHER PRECAST CONCRETE Stage (days) fa (OP0) 4 4 Es un Trane > 2 ase are one 226 Constr Be 38 aro as are 208 ‘Open to tralfe 200 38 aro aro ore 208 Tong tern 25550 38 aro as are a8 ‘Summary Table Calculation of Creep Coefficent Continue ‘Stage (dag) Bed) 8, Beet) @ ots) Trance 3 280 200878 000 220 000 Constr. 30 Bat 2047AS O28 248 one ‘Open to trafic 200 Bat 2047As one 248 are Tong term S550 Bat 2Ot7AS one 248 246 Table 13.3 -Creep Calculation parameters Gees Stage (days) E, % eee) ® Greep toss ] Creep (GPs) (ray ray Lass Transfer 5 3a2, 35:59 o0e | acckeo | oo 0.00% Construction 30 Bast 3504 ong | zaceoo | S709 272% Open to traffic 300) Bask 2489 ors | 2eer-cn | sse2 S68 Tong tern 25500, Base pre sat | s25E-0n | 20490 1528 Table 13.4- Creep Loss Summary Table Long term, of 1401 MPa exceeds 0.45F,(t0), 126MPa therefore non linear cteep should have been taken into account as per (Exp 37) from 1.3.14 which ill nerease the creep coetficent and therefore the creep losses by a factor of expl1S(K,O45)) = 1.0785, 13.23 Shrinkage In the calculation ofthe shrinkage ofa section anotablecifference _Autogenous shrinkage is particularly important for high-strength ‘rom previous practice thatthe total shrinkage stain decomposed concrete and high-performance concrete. Since autogenous into.2 drying shrinkage component anc an autogenous shrinkage independent ofthe size ofthe concrete member and the shrinkage component relative humidity of the ambient environment the shrinkage in bulk ‘concrete members exposed tohumid envronmentsis dominated by ‘autogenous shrinkage Drying shrinkage strain: Fay = OB S(22013 3 Ot A4K Agha! fa JIIO “Buy = 292 X 30-6 - xp 822) wheres cadss (based on Class R coment) ads2 (based on Class R cennent) = 032 Bo, = 2.5513 -(RH/RH) = 07564 = xp 832) where: RH is the ambient relative hum'dty (&) = 20% far outdoor exposure based on irish and UK meteorological date, RH, & 200% = 300% Atogencous shrinkage strain: S(f,-30}20" = 3000 420-6 = (exp 522) f,=50MPa PRECAST CONCRETE SPECIALISTS 23BANAGHER Ce PRECAST CONCRETE Drying shrinkage strain ££) = Blt tie, p29) wheres K, i a coefficent depending on the notional size, h, according to table 333 = 0.7289 A= 3a44 mmm - (xp 8) Nate: The general fornaulae for working aut « For W Beams is: 252542,02(Depth-T0) in eam. Note: Internal void not included as ft not exposed to the atmosphere. Butts Total shrinkage strain: 6,7 044 6, = 235 x 20-6 Shrinkage loss: Long Term Shrinkage lass = Ep.c, = 63.07 MPa 525 13.3 Summary of Long Term Prestressing Losses: “The design stresses in the precast W beam are the stresses due to the final presres afterall losses have been taken into account The table below tabulates these losses. The design stresses when worked out re ‘then compared o the allowable tense and compressive stesses from the Eurocode to see they meet the limits set out par Prestressing Losses Relacation. Shrinkage Elastic Shortening Creep Total LesMPa | Loss | tossMPa | tos® | tos MPa | Loss | Los MPa | boss | LosMPa | Loss sort | 20a | es07 | 452 | eae 626 | 0800 | 752 | 2974s | 2220 Table 13.5 - Long Term Prestressing Losses Note: (Exp 5.46) from C1.5.10.6 may be applied to reduce the time dependent losses, (relaxation, shrinkage and creep), further. 13.4 Effective Prestressing Force: “The effective prestressng force i shown below before any losses at ‘tansfer, during construction, opening to taficand long tem. The diferent losses are subtracted each time to givea new force. The long ter force corresponds to the longterm loss. as calculated earlier. ‘These forces are used later inthe calculations, Stage (days) 2 oF inal prestressing Force after losses fective prestressing Force (N) Before Losses o 30000) 22973500) Transfer = a0) 22052778 Construction = 3886 23827845) Opening 280 867 zanaazay Long toro 25550 7368 20207203, Table 13.6 - Effective Prestressing Force Summary Table. 135 Transmission Length “The transmission length ofa tendonis the length over which the prestresing forcefully tranemited to the canerete. Its assumed thatthe transfer of stress fromthe tendon tothe concreteis viaa constant bond stress, such that there isa linear transfer of prestress from the tendon tothe concrete beam, 24 PRECAST CONCRETE SPECIALISTS. “The calculations across are taken from clause 810.22 and in particular Expy8.19),8.16, (8.17) and (18) of BS EN 1992-71. Fordesign purposes the vansmisson lengths taken as being either 20M higher or lawer than the calculated value, whichever ismore Lnfavourable forthe given situationfigs = Ms Ms fal) = 43 MPa where; Nga = 22 For 3 ond 7 wire strands 1%. fff) = 3.29 MPa “The basic value of the transeaision length & given by: p= et 296 6 / fag = 935.77 mam. 029 for 3 and 7 wire strands 3,295.80 MPa t BANAGHER PRECAST CONCRETE - Exp 825) for depths greater than 250mm where good bond conditions are likely = (Gp 326) - Gp 826) “The design transmision length i calculated as the more unfavourable of the below: |, =O), = 742.62 mm (=a, = 232260 mm 14.1 Decompression check at Transfer of Prestress {atend of transmission length) ‘The end of the transmission length s the erica location forthe decompression check at tansfet asthe moment due to self weight, hich is favourable to maintain compression inthe top fibre sata minimum towards the beam ends, [As youcan see that while the tension limitof0.75Fsyanu is met the compression limit of0.7,,4, 15 ot, therefore debonding is required “These limits are interpolated from CL5.102.26) Beans Tap (Pa) | Beam Bem (MPA) A 3423 7423 RUZ 3577 300% MZ on2. “O67 z 2.38 2357 Limits =207 3960 Status OK Not OK Table 14.1 ‘Therefore debonding required ot bears ends ~ (ep 82.7) - E—p 228) Peale NM a AeA cS) ‘The detaling of debonded prestessing strands should be carefully ‘considered and! recommendlations fiom international cade should bbe sought. In general, consideration should be given to debonding no greater than 259% of the total numberof stands in a bear. No mote than 40% ofthese debonded strands (or 4No. whichever isthe lesser) should then be stopped off at any one location. In addition the ‘exterior strands in any horizontal row should iceally not be debonded and any strands anchoringa link ie. ata bendin alink) should never bedebonded. Moment due to self weight at 742.62 men froen beam ends = 22832 kim P=2205377704N PRECAST CONCRETE SPECIALISTS 25BANAGHER gq PRECAST CONCRETE Ray Inatial Prestressing Force, P, Eccentricity = 224.3 ram Row No. strand used de H/0 soffit Moment = 2242333750 Newn 30 423430 men 4 43230 men 222335 men 26880 mm 26720 mm 28480 mm 2as1o mm 4 azo mm wfufafalefate 32 330 ram 36 @ comm ‘50 .@ 437 rama Table 14.2 14.2 Revised Stresses with Debonding 12nr strand at 6Omm above the beam soffthavebeen chosen tobe _ prevents ttansfering its force to the concrete along the debonded debonded with the checkre calculated, the section passeswwith the length. Thsallows the point of prestress transfer for debonded strand revised strand layout. ‘tobe moved further into the span to.a point which tension inthe top Mange sno longer anissue Debonding invalves passing aplastic sheath around the strandto prevent the strand bonding tothe surrounding concrete and thereby See AppendheBfor images of this. 14.2.1. AtEnd of Transmission Length 14.2.2.AtEnd of Debonded Length P= o7s9n75.52 2 TIES W Moment due to self weight at 64 9e6200m From beann ends = 3597.54 P= 2208277764 N Beara Top (MPa) | Beam Bema (MPA) Bears Top (MPo)_ | Beara Btrn (MPa) PA 2248 32A8 PIA 3425 2423 Piz “840 620 az 3377 2003 MZ ona. 067 MZ eae “£68 = 400 3682, s 620) 34.56 Linmite “207 2460 inns “207 2460 Status oK K Status OK OK Table 14.3 Table 14.4 14.3 Stress Checkat Construction Stage 527894.8 N ‘The construction stage involves the beam alone supporting the ‘Beam Top (MPa) | Beam Stim (MP2) \eightofwetslaband any applicable constuction leading in 3 simply a a supported condition. cues ace sae: Piz 3327 724 Theliits here are 30MPa (0.64) M/Z 3782 “3205 ‘Te prstessing force of 11527 kN comes fom the already worked Es BEE Es outeffecive prestressing force ater allosses have been accounted for Linas 3000 3000 after30n days, Status oK ok Table 145 26 PRECAST CONCRETE SPECIALISTSBANAGHER yy PRECAST CONCRETE 144 Decompression and Stress Checkat Service (midspan max) The stress check at service includes the ive moment inaction to sreszes resuiting from differential shrinkage and temperature effects, The check k repeated fr heating and cooling conditions (cooling is _morecitcal for tensile stresses at the extreme bottom ft) P= 20207202 N —_ — Tame eae nae Se ae ee ee ey Pe | ee es ee es ee SoS HS + HS SSS ES se ee ESS ES SF | ee ee ee eee EEEEEE EE Se a ee meee ee ee ere ee a oa ane SS ES eS EES ESE EE EES re SES SES SS ee ee oe ee Tape SS SE EES PRECAST CONCRETE SPECIALISTS 27BANAGHER PRECAST CONCRETE 145 Stress Check at Service (midspan min) This check isas per 144 only now minimum moments.t midspan arebeing checked, which ate taken ftom the MIDAS Chil model and shown below. Minimum lve characteristic moment at midspan = ~6255 kNm (MIDAS) Minimum live frequent moment at snidspan =-423 thine (MIDAS) Fretunt cont ation Charan comtaton Bia Top | Beam btm | terface | Sb Tp | Geum Top | Beam Bim | tntrace | Slab Tp (ora | uray | “arn | wray | cwray” | cara | ray | cue) Pa | saos | vans | eno | oa | sao | saos | ono | ono pz | sees | ay | aco | ooo | see | ear | aco | ono Maf@ | sven | sees | 000 | eco | staz_| aes | azo | aco cas | ons [ons | ean | ons | own | ons | aaa “om | ore | ose | on | one | 227 | eae] ove Difsiridage | 220 | oss | -oas | ose | sao | oss | ons | asa Temp fess | 020 | 087 [020 | ace | ose | oan | oss | a7 = zea | 720 25 oa? | aa Tints | 3000 | 000 3400 2400 | 2400 Tobie 148 a Fretunt combination haraceritie combination Bea Top | Beam Blm | Iierface | Sab Top | Geom Top | Bean tm | Interface | Slab Top (MPa) (MPa) (MPa) (MPa) (MPa) (MPa) 0001 whee stato thebeom PRECAST CONCRETE SPECIALISTS 37BANAGHER PRECAST CONCRETE Dasign value of interface shear stress: Vag = PV /(2b) = 234 MPa - exp 6.24) wheres B is the ratio of the longitudinal Force th the news concrete arva and the total longitudinal Foves either in the compression or tension zone, both calculated for the section considered Va is the transverse shear force = 2.650.72 kN 2 the lever arms of the composte section = 2737.08 mm 6, i the width of the interface = 52.4 vam 2 = VAG = 2737633427 mm where: |= 562.5309206 mot A= 600000 naw? 7 = 584.9492508 mm Design shear resistance at the interface: -@25 (a) ‘Arta of interface = 524000 mam. Angle of reinforcement to interface: « = 40 deg Stresses resulting from forces normnal to surface: 0, = 0 MPa Surface roughness: = (6.2.5 (2)) Rovgh e204 peor Note: Do nat set 2=0 as shown in 1423 except when using specie [oad cases for fatigue Mo value of intertace Sre8S: Veja, = OS, = 6.72 MPa ~ p(6.25) Aa WAI - fad / wha wheres c= 040 2.90 MPa for C50/60 f,= 435.00 MPa b= 534.00 mm Note: Use f,, value appropriate to the concrete grade of the precast beam not the insitu concrete as advised in 014.32.8 of EN 2.5050. Poe een x Shear due to | Shear dueto | Shear due on surfacing parapet to grs co) cen es) Oma 278s 234 2225 eer 2453 332 2006 e-Midepan 50 334 eee Table 15.5 mc * ‘Average Shear Asi/s min | Chosen | Asv/s prov (on) | Force per beann end] Crna) rapa) | (owme/anns) | Spacing | Crann2/enen) cen) (ona) 3m aeee72 Ey 4 234 Bas 275 258 2m 354548 32. 4 375 2.67 250 282 e-Midepan 46208 a2 4 ea o8e ‘S00 080 Table 15.6 38 PRECAST CONCRETE SPECIALISTSBANAGHER PRECAST CONCRETE 155 Shear Check Between The Web and The Flange of The Composite Section ‘This checkis carted out looking specifically atthe insitu slab The rebar {sthatcroscing the fallure/chear plane to resist longitudinal shear forces. perfig 152 below. ENA COSSNG HEFL HEAP TOES ONGTUDNAL SHER FORCES Figure 15.2. Shear between Web and Flange diagram Design shear force per beam end = 2887 kN “Thiceness of web at junction with Range, b= 554 wim “Thicleness of ange at junction with web, b= 200 mm d= 3440 enn 2 = 2206 mm “Total shear force transmitted from web to Flange: Ve/= = 2456N/enen length Proportion of shear force transmitted to Hange : (2-b,/b¥2 = 042 Longitudinal shear stress aarass janction: (V,,/2)%(2-b,/OY/2\"3/h) = 3.02 MPa Permissible sheor stress = O46 4 = O76 MPa £3.02 MPa - (62.46) “Therefore transverse reinforcennent is required Required amount of transverse reinforcement: 8 = 0.ssin= (aV,/it,) = 14.06 ° = (exp 622) Strut angle & limited to 26.5< 8 <45 ‘therefore @ = 26.5 ° “Transverse reinforcennont por unit lengthe Agae = vejhy/E,COB = 6.92.4 vaani/an ~ (Exp 622) As the lab i also subject to transverse bending, the area of transverse steel should equal the greater of - (62.45) 625.4 wnm:/ma or half this value plus the area required to rest transverse bending, Arta of reinforcennent required for transverse bending 2686.07 wiwni/nn Arta of transveese reinforcement provided 2680.83 must/an “Therefore transverse reinforcement provided is oe PRECAST CONCRETE SPECIALISTS 39BANAGHER PRECAST CONCRETE SSeS} Working out the camber of the prestressed beam due tothe Note: We have taken the elastic modulus at transfer and the fll prestresing sshown below. This k an estimateas thisienotanexact _prestess force for working out the deflection ue to prestess For science butitis surficent for this eaxrple. he fina deflection duet _working out the deflection due to self weight and wet slab weight the wet concrete being poured on the beam is also given, ‘we have used an increased elasticrmodiulus which has come from ‘extensive factory testing and data, Thismodification factors 1.2. Formulae required: Upmard defection due to full prestrassing mowsnt, = ME/3E1 Downwards defections due to lf weight and slab load, = sWit/s24EI Beam | tegth] =, | Ey ' Myon | PAREEION | Waray [DeAection] Way [Deflection] Ex | Final between | transfer) | (GPa) | (mon'es09 | (Een) | due to | (kN/on)| due to | (kN/m)| due to | works | carnber supports | (GPa) prestress sof wet slab | camber | after Coane) (eam) weight ones) | Conn) | slob pour (ona) (onen) Internal | 30000 | 2222 [2728| azsae [zerees| saaz | 2237 | -2227 | 3002 | -2082 | zeas | 2644 Table 16.1 ete (ord a brAe saa uae Cel OME ae ed Because ofthe delayed restraint between continuous spans, even inthe absence of variable load.a bending moment will arse in the connection, sagging iFptestressis prevaling over permanent load, hogging f not The evaluation of delayed bending moment can be performed by means ofa suitable creep analysis method, Net moment = M pana” M estas ~M pgp lt M sans = 20230KN X TOT25en0n = 7223kNeA (Che above is the long terms force multiplied by the eccentricity From the contre of gravity of the conaposite stction to the centre of gravity ofthe strana) M cana 44S SENN 40 PRECAST CONCRETE SPECIALISTS= s20kNm. ringed ke et Moment = 22824Nm Prastress provats - wil ease sagging @ the support Sagging restraint monnent = 2282(2-€°9) where; $2347 M, = 2282(3-€597) 1M, =5757kNen Place Gnv strands spaced ot 360M over the soft. Fens = litt fy £0.05 Shy (05 Per Mattock) = 38604075 = 3345MPa F, “amg = FB4SKESO = 209.251N d= 5700-260 = 154mm 2 =095d = 3463 snag = 2082S 6 x EAGB = 2836.8 > 3757 kNed OK ‘Adopt nr untensianed strand at +60nnm above the bear soffit as per the below sketch. eemuno ProcnnstRaND Figure 16.2 ‘Note: We fee that leaving stra’ projecting is notnecessary with 4 precast dovmstand crosshead a the pier and when builtinto an abutment wall ute have carried out the check for completeness,Be UE INe a ENaa aha oe [Appendix A1 - Bending Moment Diagram for g15 Loading - Internal beam-results taken from MIDAS ‘Appendix A2 - Bending Moment Diagram for grla Loading - intemal beam - results taken from MIDAS 42 PRECAST CONCRETE SPECIALISTS‘Appendix A3 - Bending Moment Diagram for surfacing Loading - internal beam - results taken from MIDAS Seviat an ‘ites 1 [Appendix A4- Shear Force Diagram for gr5 Loading - intemal beam - results taken from MIDAS,= a | [Appendix AS - Shear Force Diagram for grt Loading- Internal beam -results taken from MIDAS. Wwe [Appendix AG - Shear Force Diagram for surfacing Loading - Internal Beam - results taken from MIDAS,BANAGHER @@ PRECAST CONCRETE Appendix B1 - Photo showing W Beam end with transverse hole formers, lifting strand, prestressed strand, spacers links, stopends and debonding all visible. ‘Appendix B2 - Photo showing W/Beam being poured. The intemal and external formers and fixed. The ‘operative lc vibrating the concrete with the other operative pouring the next beam on the lin. PRECAST CONCRETE SPECIALISTS 45BANAGHER PRECAST CONCRETE Pr Cel N71) A Cross sectional area {Characteristic tensile strength of reinforcement A, Cross sectional area of concrete f _Yieldstrenath of reinforcement A Area ofa presressing tendon or tendons £, Design yild strength of reinforcement a Cross sectional area of reinforcement Characteristic yeld strength of reinforcement A... minimum cross sectional area of reinforcement £., Design yield of shear reinforcement AL” Crosssectional area of shear reinforcement RY Heicht D” Diameter Overall depth ofa cross-section E, £28) Tangent modulus of elasticity ofnormal weightconcrete i Radiusof gyration ata stress of, = Oand at 28 days k Coefficient Factor E_, Effective modilus of elasticity of concrete IorlorLiLengthy Span £” Desig value of modulus of elasticity of concrote © Radius E-_Secant modulus of elasticity of concrete t Thickness Ef) Tangent modulus of elasticity ofrormalweightconcrete —t_—_Timetbeing considered atastress of, = and attimet t, __Theage of concrete a the time ofoading £, _Designvalueof modulus ofelasticty of prestressing steel -—=—_—erimeter of concrete cross-secton, having area A, E —_Desigavalueofmedulus of lastity ofreinforcing steel x ———_Neutralaxis depth Ei Bending stifness xyz Coordinates QU Staticequilbrium Z——_Leverarm of internal forces F Action F, Design value ofanaction a Angletratio, F Characteristic value ofanaction B Angler ratio; coeficient Characteristic permanentaction Y Partial factor r Second moment of area of concrete section Ye Partial factor for concrete L Length YE Partial factor for actions, F M Bending moment Ye Partial factor for permanent actions, G M,, _Desiga value ofthe applied internal bending moment Compressive trainin the concrete N° Axil force &, Compressive strain nthe concrete a the peakstress N,, Design value ofthe applied axial force €, _Utimate compressive strain in the concrete (tension or compression) €) Strain of reinforcement or prestessing ste! at P——_Prestessing force ‘maximum load P, ——Inialfrce atthe activeend ofthe tendon immediately -«&, Characteristic strain of reinforcement or prestrossing afer stressing steel at maximumtoed Characteristic variable action 8 Angle Q, Characteristic ftiquelead A Slendemass ratio. R” Resistance 1 Coefficient offrction between the tendons and SIS Servceabity mit state theirducts ULS Ultimate limit state vPoissonisratio VY Shearforce Strength eduction factor for concrete cracked in shear Vig Design value ofthe applied shear force & __Ratloofbond strength of prestessing and reinforcing stel b Overall with of cross-section oractualflangewidthin p= Ovene-dry density ofconcreteinkg/mm> aTorl. beam Pixe _Valiueofrelaxation loss in 9), at 1000 hours after b, — Widthofthe web onT, Lor L beams tensioning and ata mean temperature of 20°C Diameter: Depth », Reinforcement ratio for longitudinal reinforcement 4 Effective depth ofa cross section Reinforcement rato for shear reinforcement 4, Largest nominal maximum aggregate size ©, Compressvastressin the conerate e” Eccentricity Sy Compressive stress in the concrete ftom axtal oad {Compressive strength of concrete orprestessing £, Design value of concrete compressive strenath 4 Compressive stress in the concrete atthe ultimate f Characteristic compressive cylinder strength of concrete ‘compressive strain €,, at 2B days + Torsional shear stress f,, _ Meanvalue of concrete cyinder compressive strength © Diameter of reinforcing bar or ofa prestessing duct 1) Characteristic axial tensile strength of concrete It) Creep coefficient, defining creep between times tand t, £5 Mean value of axial tensile strength of concrete related to alastic deformation at 28 days £” Tensile strength of prestressing steel let.) Final value of creep coefficient é Characteristic tensile strength of prestressing steel ¥ Factors defining representative values of variable actions £5, 0,1%proof stress of prestressing steel Y, _ forcombination values fo Characteristic 0,1% proof-stress of prestressing steel ¥. ——forfrequent values {2° Characteristic 0.2% proof-stress of reinforcement. for quasi permanent values Tensile stength of reinforcement 46 PRECAST CONCRETE SPECIALISTSBanagher Precast Concrete Ltd, B 353 (0 417 wyucbancrete.com —- t 8 (Zee MS Uy ote empowered by Achilles PRECAST CONCRETE SPECIALISTS