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Acknowledgements
Banagher Precast Concrete would like to thank the Concrete Bridge Development Group (CBDG) for asking us to present our Bridge Beam
Manual at their annual conference in Oxford. We would also like to thank Abhishek Das in MIDAS for his help with the initial bridge model and his
continued support throughout and a special thanks to our expert reviewers and researchers for their comments and help.
Irish Plant
UK Plant
Disclaimer
This manual gives Banagher Precast Concretes view on prestressed bridge beam design and in particular our W-beam which we developed in
2005. Please note that the calculations presented in this design manual are for information only. Banagher Precast Concrete Ltd. do not accept
any liability for the use of any presented material.
1. Introduction 2
2. Design standards required 2
3. Scheme design 3
4. Materials 4
4.1 Concrete 4
4.2 Prestressing Steel 4
4.3 Reinforcing Steel 4
4.4 Cement 4
4.5 Modular Ratio 4
5. Cover 5
6. Structural model and analysis 6
6.1 Modelling Assumptions 6
6.2 Loads 7
6.3 Boundary Conditions 7
6.4 Construction Stages 8
7. Section Properties 9
8. Calculation of Loads 10
9. Combinations of actions 13
10. Differential Shrinkage 14
11. Temperature Effects 15
11.1 Uniform Temperature Component 15
11.2 Temperature Difference Component 16
11.3 Non Linear Component 17
12. Prestress Design 18
13. Prestress Losses 20
13.1 Immediate Losses 20
13.1.1 Relaxation Loss 20
13.1.2 Elastic Shortening Loss 20
13.2 Time Dependent Losses 21
13.2.1 Relaxation Loss 21
13.2.2 Creep 21
13.2.3 Shrinkage 23
13.3 Summary of Long Term Prestressing Losses 24
13.4 Effective Prestressing Force 24
13.5 Transmission Length 24
14. Serviceability Limit State (SLS) 25
14.1 Decompression Check at Transfer of Prestress 25
14.2 Revised Stresses With Debonding 26
14.2.1 At End of Transmission Length 26
14.2.2 At End of Debonded Length 26
14.3 Stress Check at Construction Stage 26
14.4 Decompression and Stress Check at Service (midspan max) 27
14.5 Stress Check at Service (midspan min) 28
14.6 Decompression and Stress Check at Service (end of diaphragm) 29
14.7 Decompression and Stress Check at Service (end of transmission length) 30
14.8 Decompression and Stress Check at Service (end of different debonded lengths) 31
14.9 SLS Stress Summary 33
15. Ultimate Limit State (ULS) 35
15.1 Ultimate Limit State Flexure Check 35
15.2 Minimum Reinforcement Requirement Check 35
15.3 Global Vertical Shear Design (beam ends) 36
15.4 Shear at The Interface Between the Beam and The Slab 37
15.5 Shear Check Between The Web and The Flange of The Composite Section 39
16. Beam camber estimates 40
17 Creep Induced Sagging Moment at Supports 40
Appendix A 42
Appendix B 45
LIST OF SYMBOLS 46
Banagher Precast Concrete is pleased to introduce its bridge beam This manual gives Banagher Precast Concretes view of the new design
design manual. Prestressed concrete bridge beams are firm favourites process for Prestressed Bridge Beams to the Eurocode and it is hoped
in the short and medium span bridge market, of up to 50 metre spans will promote more use of Bridge Beams and a common and agreed
and have been in successful use for the last 60 years. understanding of the many new clauses in the codes. The manual
considers the design of the innovative Banagher W beam in a typical
The Bridges for which the industry and of course Banagher Precast two span road bridge. The internal beam is designed in detail and as
Concrete manufacture beams require considerable expertise in the loading code is also new, the approach to the use of this code is
design. The design is usually carried out with a Contractor employed also demonstrated.
Engineer taking the project from planning to working drawings
of the bridge for which the beams would be required. The design Other areas of the whole bridge design are commented upon,
of the beams may be carried out by this engineer, by the engineer particularly where they can have an important influence on beam
in cooperation with Banagher Precast Concrete the supplier or design. These are mentioned at appropriate places where they would
completely by Banagher Precast Concrete using the engineer’s naturally occur. Suggestions for further reading are also given. The
analysis output as the starting point. In the last few years, the design format is for the manual to have the commentary and the design
regulations have been harmonised throughout Europe as part of the information followed by the example calculations.
Common Market for Goods and Services with the introduction of a
suite of Eurocodes and European Product Standards. Each Member This design manual should be read in conjunction with our “Bridge
State of the EU has the responsibility for Structural Safety and the Beam Manual” which includes our full range of precast prestressed
Eurocodes therefore come with a National Annex in which National beams and their associated span tables along with all other relevant
preferences with respect to safety factors etc are given. The designs in information required by a bridge engineer in choosing
this manual have used the UK National Annexes which are very similar a precast section.
to the Irish National Annexes. Where the Irish regulation would be
different, it is noted in the text. The coherence of the new regulations
allow, with the use of Harmonised Product Standards,
a common approach which is used as the basis of the CE Marking
of Bridge Beams, in turn enabling them to be part of an open pan
European Market.
The following list contains the relevant standards that are required for 9. BS EN 13369 : 2013 Common rules for precast concrete products
the design of this bridge.
10. EN 10138 - Prestressing Steel
1. Eurocode - Basis of Structural Design - BS EN 1990 : 2002
Note:
2. Eurocode 1 Actions on structures - Part 1 and Part 2 - BS EN 1991-1
and BS EN 1991-2 The standards referenced in this design example are those relevant at
the time of print. Please make yourself aware of ammendments before
3. Eurocode 2 Design of concrete structures - BS EN 1992-1-1 : 2004 proceeding with this design example.
4. Eurocode 2 Design of concrete structures. Concrete bridges. Design
and detailing rules - BS EN 1992-2:2005
The design is for a two-span integral bridge, with each span having The foundations for the abutment are modelled as strip foundations
a length of 30.75m from centre of abutment to centre of pier giving 1m deep and 4m wide. The sizing of the foundations is taken from
an actual beam length of 30.50m as per fig 3.2. The bridge carries a experience and for this example will suffice as the W11 beams are
6.0m wide carriageway with 1.5m wide footways on either side as per all that is being looked at in detail not the supporting structure. The
fig 3.1. The superstructure consists of six Banagher Precast Concrete precast columns are fixed into place with dowel bars projecting up
prestressed W11-beams with a 230mm structural in-situ reinforced from the foundation below. The columns will need to be propped and
concrete deck slab 200mm over the top of the beam cast on ribbed the sleeves filled with non shrink grout which will then need to be left
fibre reinforced concrete (FRC) semi participating permanent shutter. to strengthen before placing of the precast crosshead.
There are in-situ diaphragms at the abutments and pier. A 500mm gap It is recommended that a number of transverse holes are located
between the precast beams is used at the pier to allow projecting links at various depths in the precast beam at the abutment and pier
from the crosshead. There is a 1500mm wide precast crosshead diaphragms. Whilst the number and position of these diaphragms will
spanning between two precast columns which makes up the pier. be at the discretion of the designer in conjunction with the precast
The bridge beams span from abutment to crosshead with 500mm manufacturer, a sufficient number of holes should be provided in
bearing/embedment and without the need for temporary support. order to ensure anchorage of the precast beams and that the pier
and / or abutment diaphragms act as a torsional beam.
10000
500 9000 500
1500 1500 1500
15
140
110
80
350
350
250
230
600
600
200
1466.624
1700
1500
1450
730
2000 3000 2000
3 NO. W11 BEAMS AT 3000mm CENTRES = 6000
Figure 3.1 - Section through bridge deck showing W-11 beams at 3.0m centres
30750 30750
Precast concrete
Characteristic cylinder strength fck 50.00 MPa
Characteristic cube strength fck cube 60.00 MPa
Mean compressive strength fcm 58.00 MPa
Mean value of axial strength fctm 4.06 MPa
Characteristic axial tensile strength of concrete fctk,0.05 2.84 MPa
Design tensile strength of concrete fctd 1.90 MPa
Modulus of elasticity Ecm 37.28 GPa
Age of beam at transfer 3.00 days
Characteristic cylinder strength at transfer fck @ transfer 28.00 MPa
Characteristic cube strength at transfer fck cube @ transfer 35.00 MPa
Mean compressive strength at transfer fcm @ transfer 36.00 MPa
Mean value of axial strength at transfer fctm @ transfer 2.77 MPa
Characteristic axial tensile strength of concrete at transfer fctk,0.05 @ transfer 1.94 MPa
Design tensile strength of concrete at transfer fctd @ transfer 1.29 MPa
Modulus of elasticity at transfer Ecm @ transfer 32.31 GPa
Insitu concrete
Characteristic cylinder strength fck 40.00 MPa
Characteristic cube strength fck cube 50.00 MPa
Mean compressive strength fcm 48.00 MPa
Mean value of axial strength fctm 3.51 MPa
Characteristic axial tensile strength of concrete fctk,0.05 2.46 MPa
Design tensile strength of concrete fctd 1.64 MPa
Modulus of elasticity Ecm 35.22 GPa
Coefficients and strains
Modular ratio m 1.00 -
Reinforcing steel:
Characteristic yield strength fyk 500.00 MPa
5. Cover
In the Republic of Ireland the National Roads Authorities (NRA) The diagram in figure 5.1 below shows the UK values with the NRA
version of BD57/10 “Design for Durability” December 2010 version is values in brackets where different.
a very useful booklet and has exposure class diagrams in Appendix
A. At present in the UK there are no such diagrams available in The exposure classes are specified in table 4.1 of BS EN 1992-1-1 and
any of the their documentation therefore use BS8500 “Concrete - also in other documents.
Complementary British Standard to BS EN 206-1”.
This bridge example is of a road over road bridge.
The nominal cover is worked out for the exposure class and the
concrete grade. The most severe result has been used so that the worst Please note ΔC is taken as 5mm for precast and 10mm for the insitu in
case scenario is taken, e.g in Ireland XD1 with concrete grade C50/60 this example.
is 35mm minimum cover plus 5mm ΔC for precast = 40mm nominal.
It is also worth noting figure 5.2 which shows the differences in Ireland
In the UK XD1 for the same concrete is 30mm minimum plus 5mm for and the UK in relation to exposure class when dealing with
ΔC = 35mm nominal. de-icing salts.
XC4/XD3 XC4/XD3
50mm 50mm
(55mm) (55mm)
XC3 - 40mm (35mm) (IF DECK IS WATERPROOFED)
XD3 - 50mm (55mm) (IF DECK IS NOT WATERPROOFED)
CONCRETE GRADES:
ALL RC PRECAST - C45/55
PRESTRESSED BEAMS - C50/60
INSITU - C40/50
Figure 5.1 - Exposure Class & Nominal Cover Diagram. Based on UK values with ROI values in brackets where different.
5000
Carraigeway Level Carraigeway Level
8000 10000
Modelling of the 2nr span continuous integral bridge was carried the slab on top of it. MIDAS composite section type beam elements
out in 3D using MIDAS Civil, with a grillage model representing the allow extraction of discrete force and stress results for both the slab
deck, line beams for intermediate piers and 2D FE plate elements for and the precast beams separately for a composite main beam section.
the abutments on either side of the bridge. Concrete diaphragms,
modelled as line elements are provided at the 2nr abutments and at For W beams it is common practice to provide one longitudinal
the central intermediate pier location. Use of beam elements for the grillage member per beam web (i.e. two per beam). Modelling a
deck ensures direct extraction of design forces for the single line per beam does not accurately model the load transfer from
longitudinal beams. deck slab to beam webs and does not accurately model load sharing
between adjacent beams. However for this example this action was
Longitudinal beams are modelled as composite sections with the not taken for simplicity.
effective width of the slab assigned to the composite section to take
care of the shear lag effects. For simplicity each longitudinal section of
the grillage consists of one precast beam and the effective width of
Figure 6.2 - Vehicle Position for gr5 for Max Sagging Moment
Figure 6.3 - Bridge Cross Section taken from MIDAS Civil showing tendon input locations
It is assumed that the slab will be poured in a single stage on the main accounting for all long term time dependant effects, including creep
precast beams. In a single analysis model, the following construction & shrinkage.
stages have been defined.
Time dependent analysis for concrete is done within the construction
Stage 1: All W11 precast beams are simply supported on the stages for both slab and beam. Creep and shrinkage behaviour is
abutments and crossheads with prestress and beam self weight only inputted as per Eurocode. Compressive strength gain of concrete is
considered. also applied as per Eurocode to account for short term and long term
elasticities. To keep the analysis simple, cracking in the deck is not
Stage 2: The in-situ wet concrete load is added to the precast beams assumed at the intermediate support.
with the beams again being simply supported.
Live Load Analysis: Highway Live Load Analysis was carried out based
Stage 3: The composite structure is completed in both spans and on MIDAS influence line analysis. 2nr Notional lanes and 2nr footway
the beams are now continuous. Grillage model is activated with all lanes were defined. The following live load combinations were
transverse elements, edge beams etc. Surfacing and parapet loads are analysed as per EN 1992-1-1 and its national annex.
applied when the slab attains the 28 days strength. Earth Pressure load
is also applied at this stage. 1. Gr1a: LM1 characteristic + 0.6 x Footway Characteristic
2. Gr5: LM1 frequent (Psi=0.75) + LM3 (SV196) straddling
Stage 4: Final stage, considering the bridge at the end of its design life between 2nr notional lanes
The W11 - beam has 40mm wide by 50mm deep recesses at the top from the W11 beam and a 3m rectangular slab.
of the webs, this is in order to facilitate the placing and positioning of
permanent shutter on site. This shutter is fibre reinforced concrete, The code permits stiffnesses to be represented on the gross concrete
FRC, and is manufactured by Banagher Precast Concrete. For this section ignoring the reinforcement or strand. This is the most
example FRC 50/20 will be used which has a 20mm bottom flange straightforward way since the reinforcement or prestressing strand has
(ignored in calculating the deck slab thickness) and 30mm upward not yet been calculated.
projecting ribs which participate structurally with the deck and is
included in the composite section properties. Composite section properties are used in the calculation of stresses
resulting from loads applied after the structure is made integral (e.g.
The overall height of the composite section is 1700mm. The composite traffic loads, surfacing, parapets, string courses, finishes etc.)
section properties are calculated by assuming the section is made up
8 22 98 50 148
R2
0
20
56
8
50
750
Figure 7.1 - Section through Banagher Precast Concrete FRC 50/20 shutter
BRIDGE BEAM
Figure 7.2 - Section showing Banagher Precast Concrete FRC shutter in place prior to in-situ deck slab pour
8. Calculation of Loads
Dead Loads: The carriageway must be divided into notional lanes as specified in BS
EN 1991-2, Table 4.1. For widths of 6.0 m and above, the carriageway
The weight of beam, deck slab and permanent shutter is divided into an integer number of 3.0 m wide lanes. Any excess
width is known as the ‘remaining area’. This example has a 6m wide
Superimposed Dead Loads: carraigeway split into 2nr notional lanes of 3.0m width.
The weight of the road surfacings & parapets. The variablility of All of this information is put into a computer programme, in this case
surfacing see EN 1991-1-1 Clause 5.2.3 (3) is ignored for simplicity. MIDAS Civil, and analysed for the worst load effect by positioning the
vehicles in the most onerous position on the bridge deck using
Live Loads: influence lines/surfaces. This design example has no remaining area.
Loads due to vehicular and pedestrian traffic, LM1 & LM3 SV196
Dead Load:
W11 Beam alone:
Area = 846920 mm2 (value taken from “BPC Bridge Beam Manual”)
Weight = 21.173 kN/m (value taken from “BPC Bridge Beam Manual”)
Composite section:
Area = 1521500 mm2
Weight = 38.04 kN/m
Superimposed dead load:
This loading is applied to the composite beam and slab structure
Notional Lanes
Carraigeway width, w = 6 m
Width of notional lanes, w1 = 3 m
Number of notional lanes, n1 = 2 nr
Width of remaining area, wr = 0 m
A double-axle load called the Tandem System is applied in each traffic Only one tandem system is applied to each lane, symmetrically
lane in conjunction with a uniformly distributed load called the around the centreline of the lane but no more than 0.5m from the TS
UDL System. in the opposite lane and in the position that causes the most severe
effect on the element being considered.
LM1 consists of two parts:
The tandem systems and UDL’s should only be applied in the
1. A double-axle loading, referred to as the tandem system, or TS. unfavourable parts of the influence surface, both longitudinally and
Each axle has a weight of αQQk, where αQ is a nationally determined transversely. The nationally determined adjustment factors for the
adjustment factor. UDL have been set by the UK NA so that a UDL of 5.5 kN/m2 is applied
to all lanes and the remaining area, irrespective of the number of
2. A uniformly distributed load (UDL) having a weight per square nominal lanes, simplifying the input of loading into the analysis model.
metre of αqqk, where αq is a nationally determined adjustment factor.
Load Model 1
Tandem system UDL system
Qik αQi αQiQik qik (or qrk) αqi αqi qik
(kN) (kN) (kN/m2) (or αqr) (kN/m2)
Lane 1 300 1 300 9 0.61 5.5
Lane 2 200 1 200 2.5 2.2 5.5
Table 8.2 - Load Model 1 results as per EN1991-2:2003 4.3.2 & Table 4.2
A single-axle load is applied anywhere on the carriageway. The UK The wheel contact shapes for LM1 and LM2 are 400mm square in the
use a 400kN axle load which includes a factor to allow for dynamic Republic of Ireland and the distribution through surfacing is 30° and
amplification effects. This load model is more predominant on short through the concrete slab is 45°. The UK national annex has a different
spans, < 7.0m and the transverse design of the deck slab. wheel size for LM1,2 & 3 and can be found in its NA.
Load Model 3 (LM3) - Clause 4.3.4 + NA.2.16 Load Model 4 (LM4) - Clause 4.3.5
In this example SV196 model vehicles will be used. The SV196 loading A uniformly distributed load of 5kN/m2 used to represent crowd
is combined with a reduced value of LM1, known as the ‘frequent’ loading and may be applied to both road bridges and footway/
value. Figure 8.1 below shows the SV196 vehicle from the UK national cycleway bridges.
annex to EN1991-2:2003, the only difference between the UK and the
ROI is that instead of the last 3nr loads being 180kN, 180kN & 100kN in
the ROI they are all 165kN.
Load Model 3
Basic axle load (kN) Dynamic amplification factor Design axle weight (kN)
Table 8.4 - Dynamic amplification factors for SV and SOV vehicles (Table NA.2 EN 1991-2:2003)
165 165 165 165 165 165 165 165 165 180 180 100
kN kN kN kN kN kN kN kN kN kN kN kN
1.2m 1.2m 1.2m 1.2m 1.2m 1.2m 1.2m 4.0m 1.6m 4.4m
Direction of Travel
0.35m
0.35m
Critical of
Overall Vehicle Width
1.2m
or
5.0m
3.0m
3.0m
or
9.0m
Groups of Traffic Loads (UK National Annex Table NA.3) Group gr5
9. Combinations of actions
There are three combinations of actions that must be considered at These are defined as follows:
the serviceability limit state(SLS):
EQU - Loss of static equilibrium of the structure or any part of it when
1. the characteristic combination, which can be considered the most considered as a rigid body.
severe loading to which the structure should be subjected to
STR - Internal failure or excessive deformation of the structure or
2. the frequent combination, which is the most severe load case to structural member.
which the structure should be subjected to on a regular basis
GEO - Failure or excessive deformation of the ground where the
3. the quasi-permanent loadcase, or the loading to which the structure strengths of soil are significant.
is subjected to most of the time.
FAT - Fatigue failure of the structure or structural members.
Four ultimate limit states (ULS) are defined in BS EN 1990, namely EQU,
STR, GEO and FAT.
gr5 SV vehicle 0 0 0
Table 9.1 - Values taken from the recommended values of Ψ for road bridges (Table NA.A2.1 EN 1990:2002)
Table 9.2 - Values taken from the design values for γ for road bridges (Table NA.A2.4(B) EN 1990:2002)
When the insitu slab is cast onto the precast W11 beams some of shrinkage will be reduced by creep. Allowance is made for this in the
the shrinkage of the beams has already occurred. Hence differential across sample calculation by using a reduction coefficent with a value
shrinkage occurs between the precast and the insitu concrete and this of 0.43. Note differential shrinkage is only considered in the SLS.
results in the development of internal stresses meaning the deck slab
itself will shrink by a relatively greater amount. This relative shrinkage A sample calculation for working out the differential shrinkage stress
will compress the top of the beam causing axial force and sagging in the top of the beam is shown across, using this logic the shrinkage
moment in it while generating tension in the deck slab. stress in the bottom of the beam, the bottom of the slab and the top of
the slab can all be worked out.
It is reasonable to assume that half of the beams shrinkage has
occurred at the time of casting the top slab. The effects of differential All of the answers are shown in table 10.1 below and fig 10.1 shows
them plotted in graph format.
Beam Btm (MPa) Beam Top (MPa) Slab Btm (MPa) Slab Top (MPa)
Beam Top Differential Shrinkage Stress = Force/Area of the composite section + Moment/Ztp = 1.10 MPa
where;
Restraining Moment = Force x eccentricity = 5.44E+08 Nmm
Restraining Force = 0.43 x differential shrinkage strain x Ecm x Total Area of insitu topping /Modular ratio = 1.51 N / mm2
Eccentricity = (area of top slab x lever arm / Total Area of insitu topping)-Height to the Centre of
Gravity of the Composite Section = 532.14 mm
Daily and seasonal fluctuations in shade air temperature, solar 11.1. Uniform Temperature Component, ΔTu:
radiation, etc. cause changes in the temperature of a bridge
superstructure, thereby causing movement of that structure. The first stage in determining the uniform temperature component
Depending on the restraint conditions, this movement can lead is to determine the minimum and maximum shade air temperatures
to stresses in the structure. This effect can be divided into for the location where the bridge is to be built. For the UK these can
three components; be determined from the maps of isotherms given in Figures NA.1 and
NA.2 of the National Annex to BS EN 1991-1-5, with an adjustment
1. the uniform temperature component which causes expansion or being made for the effect of altitude.
contraction of the deck
The minimum and maximum shade temperatures are then converted
2. the temperature difference component which leads to curvature of into minimum and maximum uniform bridge temperatures, Te,min and
the bridge and Te,max. For this example these values were taken as -9 ° C
and 29 ° C
3. the non-linear temperature component, which causes local stresses
within the structure. The maximum contraction that the bridge will experience will depend
on the difference between the minimum uniform bridge temperature
and the uniform bridge temperature at the time when the bridge is
first made continuous with its abutments, T0. As the temperature at
the time of construction cannot be known in advance the example
takes T0 to be 15°C when considering contraction and 5°C for
expansion as per the Irish National Annex, NA2.21.
Figure 11.1 - Diagrammatic representation of constituent components of a temperature profile (Fig 4.1 - EN1991-1-5:2003)
Surfacing = 120 mm
Altitude = 13.34 m
Fig NA.1 - Minimum shade air temperature = -9 ° C
Fig NA.2 - Maximum shade air temperature = 29 ° C
Annex A1 note 2 - The minimum shade air temperature may be reduced by 0.5 ° C per 100m above sea level
Annex A1 note 2 - The maximum shade air temperature may be reduced by 1.0 ° C per 100m above sea level
Fig 6.1 - Uniform minimum bridge temperature, Te,min = Tmin + 8 = -1.07 ° C
Fig 6.1 - Uniform maximum bridge temperature, Te,max = Tmax + 2 = 30.87 ° C
NA2.21 - T0,con = 15 ° C
NA 2.21 - T0,exp = 5 ° C
Maximum contraction range ΔTN,con = T0 - Te,min = 16.07 ° C
Maximum expansion range ΔTN,exp = Te,max - T0 = 25.87 ° C
Table C1 - Coefficent of linear expansion for concrete, α = 0.00001/ ° C
Length of beam = 30.5 m
No. of continuous spans = 2 nr
Maximum contraction = α.ΔTN,con.L = 9.80 mm
Maximum expansion = α.ΔTN,exp.L = 15.78 mm
Figure 11.2 - Temperature differences for bridge decks - Type 3: Concrete Decks
Table 11.2
The resulting restrained forces can be calculated using MIDAS:
Table 11.3
Table 11.4
The non-linear temperature difference component is self-equilibrating, temperatures are the difference between the original temperature
so it does not need to be included in the global model. However, it sets distribution and the uniform and linearly varying temperatures.
up local stresses that need to be assessed for SLS. The non-linear
Heating Cooling
ΔTE (°C) σE (MPa) Depth (mm) ΔTE (°C) σE (MPa) Depth (mm)
11.05 4.12 0 -6.8 -2.53 0
0.55 0.21 150 1.1 0.41 250
-2.45 -0.91 400 1.6 0.6 450
-1.04 -0.39 1480 1.43 0.53 1250
1.46 0.54 1700 0.43 0.16 1450
Table 11.6
The aim of prestress design is to limit tensile stresses and hence of the characteristic 0.1% proof stress.
flexural cracking in the concrete under normal working conditions.
The design is therefore based on the requirements of the serviceability The across W11 beam showing strand input is the preferred choice
limit state but the ultimate limit state for bending and shear must also however several iterations were performed:
be considered.
1. A 60nr strand layout:
Since concrete is strong in compression the material that is used in the
beam will be most efficently used if it can be kept in compression, this Pro’s - Lowest amount of strand required for beam to work
compression force is provided by means of high strength steel wired Con’s – In order to achieve decompression at the diaphragm face due
strand anchored against the concrete at either end of the stressing to the hogging moment stress 18nr strands (30% of total) would need
line. The concrete is cast around the strands in steel moulds and when to be debonded which exceeds the ACI 25% recommendation that
the required strength has been reached in the concrete (transfer Banagher Precast Concrete uses as a guide.
strength) the strand is released and the force is transferred into the
concrete by bond. 2. A 62nr strand layout – (adding 2nr at 1230mm above soffit):
The prestressing tendon layout, and the resulting calculation of Pro’s – Debonding can be reduced to 12nr strands(20% of total), 6nr
prestressing losses were initially based on an assumed layout less than the first design.
guestimated from previous experience with similar beams. Con’s - 2nr extra strands to be used compared to the first design
The tendon positions were selected from the standard positions
available for W beams. 3. A 64nr strand layout – (adding 2nr at 980mm above soffit):
Requirements for prestressing and the calculation of the effective Pro’s - Debonding can be reduced to 8nr strands(12.5% of total), 10nr
prestressing force are given in BS EN 1992-1-1, clause 5.10. The applied less than the first design.
prestress in the strands during tensioning should not exceed 80% of Con’s - 4nr extra strand to be used compared to the first design
the characteristic tensile strength or 90% of the characteristic 0.1%
proof stress, whichever is the lesser. This allows an applied prestress 4. A 66nr strand layout– (adding 2nr at 1430mm above soffit):
of up to 79% of the characteristic however we recommend a figure
of 75% in accordance with long standing practice. This gives a limit of Pro’s – No debonding required
1395 MPa for this example. Note that in pretensioning it is possible to Con’s - 6nr extra strand to be used compared to the first design and an
eliminate “draw - in” losses by extending the strand 5-10mm beyond increase in transfer strength from C28/35 to C35/45 plus an increase
the theoretical strand extension, this means that in practice the in 28day strength from C50/60 to C57/70 due to beam bottom
prestress applied will be slightly more than the 75% depending on the compression from the pier hogging moment.
length of the production line.
From an examination of the above designs a 62nr strand arrangement
The stress in the strands immediately after transfer is also limited – this was chosen as the preferred as it was both an extremely efficient
time to the lesser of 75% of the characteristic tensile strength or 85% design and suited factory production best as debonding strands is
150
B12-07
4 No. 15.7Ø
2 No. 15.7Ø
07 07 07 07
328
B12-02
1500
2 No. 15.7Ø
1430
250
B12-01
1230
1172
1115
2 No. 15.7Ø
880
B10-03-300
120x120 transverse holes
265
790
730
2 No. 15.7Ø
CL
540
480
12 No. 15.7Ø
210
28 No. 15.7Ø
110
60
40
70 42.5 42.5 52.5 52.5 52.5 50 50 50 50 50 50 50 50 75 50 50 50 50 50 50 50 50 52.5 52.5 52.5 42.5 42.5 70 Denotes fully bonded strand
Denotes partially debonded strand
CL 26mm O.D. Weephole
6000 6000
4000 4000
12 no. debonded
both ends
Length debonded
3000 3000
bottom row
2000 2000
1500 1500
1000 1000
8 2 @ 1115 mm
7 2 @ 880 mm
6 2 @ 730 mm
5 2 @ 480 mm
4 2 @ 340 mm
3 4 @ 210 mm
2 12 @ 110 mm
1 28 @ 60 mm
62 @ 348 mm
Class 2: Δσpr / σpi = 0.66 x ρ1000 x e9.1μ(t/1000)0.75(1-μ) = 8.79 MPa - (Exp 3.29)
= 0.63 % - (Cl 3.3.2(5))
where;
Ratio of initial prestress to tensile strength, μ = 0.75
time, t at transfer = 140 hrs
Relaxation of strand ( Class 2) - Mill Certs, ρ1000 = 1.5 %
The loss due to the elastic deformation of the concrete beam as a supported beam.
result of the action of the pre-tensioned tendons when they are
released from the anchorages. The methodology used in the “Designers Guide to EN 1992-2” by
Hendy & Smith has been adopted with particular reference to
The elastic loss at transfer is calculated at the centroid of the tendons equation D5.10-4. Using the denominator from this equation the
and is due to the compression arising from the prestressing force, after losses due to elastic deformation at a given time can be
the initial relaxation loss prior to transfer and the self weight of modified.
the beam. The latter is included because the beam cambers during
transfer and hence has to carry its selfweight as a simply
13.2. Time Dependent Losses prestressing force. The final prestress is usually about 25% less than
the initial prestress and it is the final value that must be used in the
Further losses of prestress occur with the passage of time. Long term long term SLS calculations for the beams.
prestressing losses are due to:
Relaxation Loss
Stage (days) Loss (MPa) Loss %
Transfer 3 7.76 0.56%
Construction 30 11.95 0.86%
Open to traffic 100 14.98 1.07%
Long term 20833 40.77 2.92%
13.2.2 Creep
Creep causes a number of effects that have to be considered at various BS EN 1992-1-1, clause 3.1.4 and Annex B describe how to calculate
stages in the design of prestressed concrete structures. Perhaps the creep and is outlined in the calculations below.
most significant is the loss of prestress that results from creep and the
effect that this will have on the SLS criteria.
Parameters required:
Relative Humidity of the ambient environment in %, RH = 80.00 %
α1 = 0.70 - (Exp B.8c)
α2 = 0.90 - (Exp B.8c)
α3 = 0.78 - (Exp B.8c)
h0 = 384.44 mm - (Exp B.6)
Mean compressive strength, fcm = 58.00 MPa
Curing period, Δti = 72.00 hrs
T(Δti) = 20.00 °C
Temperature adjusted age of concrete at loading in days, t0,T = 3 days
For cement class R, α = 1
Creep Coefficent:
φ(t,t0) = φ0 x βc(t,t0) = 1.46 - (Exp B.1)
Creep Strain:
εcc(∞,t0) = φ(∞,t0).(σc/Ec) = 5.25 x 10-1 - (Exp 3.6)
Creep Loss:
Long Term Creep loss = Ep. εcc = 104.9 MPa
= 7.52 %
Compressive Stress
Stage (days) P (N) Zc (mm3) σc (MPa)
Transfer 3 12051778 7.60E+08 15.58946219
Constr. 30 11880191 7.60E+08 15.09189229
Note:
σc = stress at centroid of the strands due to prestress, self weight and all other quasi permanent actions at the time
under consideration.
σc = P/A ± Pe/Zc ± MQP/Zc
where;
P = Prestress force less losses at time being considered.
A = Cross sectional area of beam.
e = eccentricity
Section modulus of centroid of strands about nuetral axis of section, Zc = Ixx / eccentricity
At transfer - 3 days At construction - 30 days At opening - 100 days Long term - 25550 days
NA
MQP/Zc
CENTROIDS
OF STRANDS
P Pe/Zc
Figure 13.1 - Calculating stress at the centroid of the strands (σc) due to prestress, self-weight and all other
quasi permanent actions at the time under consideration
13.2.3 Shrinkage
In the calculation of the shrinkage of a section, a notable difference Autogenous shrinkage is particularly important for high-strength
from previous practice is that the total shrinkage strain is decomposed concrete and high-performance concrete. Since autogenous
into a drying shrinkage component and an autogenous shrinkage is independent of the size of the concrete member and the
shrinkage component. relative humidity of the ambient environment, the shrinkage in bulk
concrete members exposed to humid environments is dominated by
autogenous shrinkage.
Stage (days) % of initial prestressing force after losses Effective prestressing force (N)
The transmission length of a tendon is the length over which the The calculations across are taken from clause 8.10.2.2 and in particular
prestressing force is fully transmitted to the concrete. It is assumed Exp(8.15),(8.16), (8.17) and (8.18) of BS EN 1992-1-1.
that the transfer of stress from the tendon to the concrete is via a
constant bond stress, fbpt such that there is a linear transfer of prestress For design purposes the transmission length is taken as being either
from the tendon to the concrete beam. 20% higher or lower than the calculated value, whichever is more
unfavourable for the given situation.
14.1 Decompression check at Transfer of Prestress The detailing of debonded prestressing strands should be carefully
(at end of transmission length) considered and recommendations from international codes should
be sought. In general, consideration should be given to debonding
The end of the transmission length is the critical location for the no greater than 25% of the total number of strands in a beam. No
decompression check at transfer as the moment due to self-weight, more than 40% of these debonded strands (or 4No. whichever is the
which is favourable to maintain compression in the top fibre, is at a lesser) should then be stopped off at any one location. In addition the
minimum towards the beam ends. exterior strands in any horizontal row should ideally not be debonded
and any strands anchoring a link (i.e. at a bend in a link) should never
As you can see that while the tension limit of 0.75fctm transfer is met the be debonded.
compression limit of 0.7fck transfer is not, therefore debonding is required.
These limits are interpolated from Cl.5.10.2.2(5)
Table 14.1
Moment due to self weight at 748.62 mm from beam ends = 228.12 kNm
P = 12051777.64 N
Table 14.2
12nr strands at 60mm above the beam soffit have been chosen to be prevents it transferring its force to the concrete along the debonded
debonded with the check re calculated, the section passes with the length. This allows the point of prestress transfer for debonded strand
revised strand layout. to be moved further into the span, to a point which tension in the top
flange is no longer an issue.
Debonding involves passing a plastic sheath around the strand to
prevent the strand bonding to the surrounding concrete and thereby See Appendix B for images of this.
Beam Top (MPa) Beam Btm (MPa) Beam Top (MPa) Beam Btm (MPa)
The construction stage involves the beam alone supporting the Beam Top (MPa) Beam Btm (MPa)
weight of wet slab and any applicable construction loading in a simply
P/A 13.61 13.61
supported condition.
Pe /Z -13.17 7.24
The limits here are 30MPa, (0.6fck) MDL /Z 17.82 -12.95
Σ 18.26 7.90
The prestressing force of 11527.8kN comes from the already worked
out effective prestressing force after all losses have been accounted for Limits 30.00 30.00
after 30nr days. Status OK OK
Table 14.5
P = 10207201 N
Heating
Frequent combination Characteristic combination
Beam Top Beam Btm Interface Slab Top Beam Top Beam Btm Interface Slab Top
(MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa)
Table 14.6
Cooling
Frequent combination Characteristic combination
Beam Top Beam Btm Interface Slab Top Beam Top Beam Btm Interface Slab Top
(MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa)
Table 14.7
Heating
Frequent combination Characteristic combination
Beam Top Beam Btm Interface Slab Top Beam Top Beam Btm Interface Slab Top
(MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa)
Table 14.8
Cooling
Frequent combination Characteristic combination
Beam Top Beam Btm Interface Slab Top Beam Top Beam Btm Interface Slab Top
(MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa)
Table 14.9
The bridge was modelled with a 500mm diaphragm and the check for
decompression and stress at service is shown below. The moments
due to self weight and dead load are worked out using an equation
along the length of the beam and the moments due to surfacing,
GR1a and GR5 are taken from MIDAS Civil.
Heating
Frequent combination Characteristic combination
Beam Top Beam Btm Interface Slab Top Beam Top Beam Btm Interface Slab Top
(MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa)
Status OK OK OK OK OK OK OK OK
Table 14.10
Status OK OK OK OK OK OK OK OK
Table 14.11
Distance from end of beam to end of the transmission length (most unfavourable) = 748.62 mm
e = 214.3 mm
Peff = 8231613.5 N
Characteristic and Frequent moments at the end of the diaphragm:
Status OK OK OK OK OK OK OK OK
Table 14.12
Cooling
Frequent combination Characteristic combination
Beam Top Beam Btm Interface Slab Top Beam Top Beam Btm Interface Slab Top
(MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa)
Status OK OK OK OK OK OK OK OK
Table 14.13
The following calculation for debonding has an input for “X” and an to self weight, moment due to permanent slab weight will all change
input for “Distance from beam end to end of debonded length”, when automatically, the rest of the moments are taken from MIDAS Civil.
input these locations are checked for decompression and stress at
service to see where debonding is required and where it can stop. This check is required at the end of each debonding zone, (1m,1.5m,
2m, 3m, 4m & 6m in this case).
When a value is input into the distance from beam end box the
effective prestressing force along with the eccentricity, moment due The check has the same form at each location, as such for simplicity
only one instance of the calulation is presented here.
Heating
Frequent combination Characteristic combination
Beam Top Beam Btm Interface Slab Top Beam Top Beam Btm Interface Slab Top
(MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa)
Status OK OK OK OK OK OK OK OK
Table 14.15
Cooling
Frequent combination Characteristic combination
Beam Top Beam Btm Interface Slab Top Beam Top Beam Btm Interface Slab Top
(MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa)
Status OK OK OK OK OK OK OK OK
Table 14.16
The following tables and graphs take the worst case scenario’s from
heating and cooling for both frequent and
characteristic combinations.
Frequent Combination
Beam Beam top Beam btm Compressive Decompression
Length (m) (MPa) (MPa) Limit Limit
0.00 30.00 -4.06
0.50 1.30 15.66 30.00 -4.06
0.75 3.01 19.52 30.00 -4.06
1.00 3.26 21.26 30.00 -4.06
1.50 4.31 20.95 30.00 -4.06
2.00 5.24 20.33 30.00 -4.06
3.00 7.28 18.43 30.00 -4.06
4.00 8.98 17.28 30.00 -4.06
6.00 12.16 14.81 30.00 -4.06
15.25 22.07 0.21 30.00 -4.06
24.50 12.16 14.81 30.00 -4.06
26.50 8.98 17.28 30.00 -4.06
27.50 7.28 18.43 30.00 -4.06
28.50 5.24 20.33 30.00 -4.06
29.00 4.31 20.95 30.00 -4.06
29.50 3.26 21.26 30.00 -4.06
29.75 3.01 19.52 30.00 -4.06
30.00 1.30 15.66 30.00 -4.06
30.50 30.00 -4.06
Table 14.17
Figure 14.1
Table 14.18
Figure 14.2
After the prestressed W beam has been designed to satisfy SLS 15.1 Ultimate Limit State Flexure Check
criteria, a check must be carried out to ensure the ultimate moment
of resistance and shear resistance are adequate to satisfy the The calculation of the ultimate moment capacity of the composite
requirements of the ultimate limit state, ULS. section is carried out below.
Seeing that the ultimate moment capacity is well in excess of the
ultimate moment due to loads a more rigourous calculation need not
be considered.
Row No. Strand @ Stress MPa Strain Force kN Lever Arm mm Moment kNm
10 4 1430 1038.29 5.19E-03 622.97 15.00 9.3
9 4 1230 1429.01 7.94E-03 857.41 215.00 184.3
8 2 1115 1440.00 9.51E-03 432.00 330.00 142.6
7 2 880 1462.45 1.27E-02 438.74 565.00 247.9
6 2 730 1476.78 1.48E-02 443.03 715.00 316.8
5 2 480 1500.67 1.82E-02 450.20 965.00 434.4
4 2 340 1514.04 2.02E-02 454.21 1105.00 501.9
3 4 210 1526.46 2.19E-02 915.88 1235.00 1131.1
2 12 110 1536.02 2.33E-02 2764.83 1335.00 3691.0
1 28 60 1540.79 2.40E-02 6471.33 1385.00 8962.8
Sum 13850.6 Sum 15622.2
Minimum area of reinforcement = As,min = Mrep /zs.fyk EN 1992-2 CL.6.1(109) - (Exp 101a)
where;
Mrep = fctm I / y = 2162.64 kNm
Zs = 1262.00 mm
fyk = fp0.1K = 1637.00 MPa
As, min = 1045.35 mm2
As, prov = 9300.00 mm2
Table 15.2
Table 15.3
Table 15.4
15.4 Shear at the interface between the beam and the slab
Rebar crossing shear plane to resist
Vertical shear forces in the beam always give rise to longitudinal longitudinal (interface) shear forces
(Interface) shear forces. The construction joint between the precast
beam and the insitu slab is the area under consideration for this
check. The following calculations will show if the shear reinforcement
for vertical shear is adequate for interface shear or if extra links are
required to deal with the interface shear. A solution for this is where
a design for vertical shear is carried out, the design links are added to
the beam and any additional interface shear links are added to make
up the difference as U-bars being anchored back into the web. This will Shear plane for
interface shear check
save a lot of additional vertical shear rebar as the interface shear links
are required only at the interface. For the calculations a rough surface
finish is used, which is very important as this has a large impact
on the area of reinforcement required. A lot of design programmes
are geared towards default values for c and μ and again highlights the
necessity to liaise with the precast beam manufacturer.
In calculating the shear load at the interface an average shear force Figure 15.1 - Interface Shear diagram
between 0 and 3m from the beam ends was taken. This value came to
1886kN, it was also checked at 3-6m and again from 6m to midspan.
Please note the following calculations are for the full beam end using The value for minimum shear interface links is taken from FIB Bulletin
the 2nr webs. In summary you will see that interface links are far more 65: Model Code 2010 Section 6.3.5 as:
severe than vertical shear links in this example. For the first 3m links are Minimum reinforcement ratio = 0.2(fctm/fyk)>0.001 where fctm is that of
required at 175mm centres to satisfy interface shear whereas 250mm the beam.
centres would have satisfied vertical shear.
Table 15.5
Table 15.6
This check is carried out looking specifically at the insitu slab. The rebar
is that crossing the failure/shear plane to resist longitudinal shear
forces as per fig 15.2 below.
Working out the camber of the prestressed beam due to the Note: We have taken the elastic modulus at transfer and the full
prestressing is shown below. This is an estimate as this is not an exact prestress force for working out the deflection due to prestress. For
science but it is sufficent for this eaxmple. The final deflection due to 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 elastic modulus which has come from
extensive factory testing and data. This modification factor is 1.2.
Formulae required:
Upward deflection due to full prestressing moment, δ = Ml2/8EI
Downwards deflections due to self weight and slab load, δ = 5Wl4/384EI
Beam Length Ecm Ecm I Mprestress Deflection Wself weight Deflection Wslab Deflection Ex Final
between (transfer) (GPa) (mm4x109) (kNm) due to (kN/m) due to (kN/m) due to works camber
supports (GPa) prestress self- wet slab camber after
(mm) (mm) weight (mm) (mm) slab pour
(mm) (mm)
Internal 30000 32.31 37.28 215.46 3676.65 59.42 21.17 -23.17 18.11 -19.81 36.25 16.44
Table 16.1
Figure 16.1
Beam end
PROJECTING STRAND
Figure 16.2
Appendix A1 - Bending Moment Diagram for gr5 Loading - internal beam - results taken from MIDAS
Appendix A2 - Bending Moment Diagram for gr1a Loading - internal beam - results taken from MIDAS
Appendix A4 - Shear Force Diagram for gr5 Loading - internal beam - results taken from MIDAS
Appendix A6 - Shear Force Diagram for surfacing Loading - internal beam - results taken from MIDAS
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 internal and external formers and fixed. The
operative is vibrating the concrete with the other operative pouring the next beam on the line.
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