PCI 6th Edition

Fabrication Design
 Presentation Outline

Planning Discussion
Stripping Process Design and Analysis
Prestress / Post Tension Effects
Handling Devices
Stripping Stress Examples
Storage Discussion
Transportation Discussion
Erection Discussion
 Introduction

The loads and forces on precast and prestressed

concrete members during production,
transportation or erection will frequently require a
separate analysis
Concrete strengths are lower
Support points and orientation are usually
different from members in their final position
 Pre-Planning Piece Size

The most economical piece size for a project is

usually the largest, considering the following
factors:
Stability and stresses on the element during
handling
Transportation size and weight regulations and
equipment restrictions
 Pre-Planning Piece Size

Available crane capacity at both the plant and

the project site.
Position of the crane must be considered, since
capacity is a function of reach
Storage space, truck turning radius, and other
site restrictions
 Planning and Setup

Once a piece has been fabricated, it is necessary

to remove it from the mold without being
damaged.
Positive drafts or breakaway forms should be
used to allow a member to lift away from the
casting bed without becoming wedged within the
form
Adequate draft also serves to reduce trapped air
bubbles.
 Planning and Setup

Lifting points must be located to keep member

stresses within limits and to ensure proper
alignment of the piece as it is being lifted
Members with unsymmetrical geometry or
projecting sections may require supplemental
lifting points and auxiliary lifting lines to achieve
even support during handling
Come-alongs or chain-falls are frequently
used for these auxiliary lines
 Planning and Setup

When the member has areas of small cross

section or large cantilevers, it may be necessary
to add a structural steel strongback to the piece
to provide added strength
 Planning and Setup

Members that require a secondary process prior

to shipment, such as sandblasting or attachment
of haunches, may need to be rotated at the
production facility. In these cases, it may be
necessary to cast in extra lifting devices to
facilitate these maneuvers
 Planning and Setup

When developing member shapes, the designer

should consider the extra costs associated with
special rigging or forming, and pieces requiring
multiple handling
 Stripping: General

Orientation of members during storage, shipping

and final in-place position is critical in determining
stripping requirements
They can be horizontal, vertical or some angle in
between
The number and location of lifting devices are
chosen to keep stresses within the allowable
limits, which depends on whether the no
cracking or controlled cracking criteria is to be
used
 Stripping: General

It is desirable to use the same lifting devices for

both stripping and erection; however, additional
devices may be required to rotate the member to
its final position
 Stripping: General

Panels that are stripped

by rotating about one
edge with lifting devices
at the opposite edge will
develop moments as
shown
 Stripping: General

When panels are stripped this way, care

should be taken to prevent spalling of
the edge along which the rotation
occurs
A compressible material or sand bed will
help protect this edge
 Stripping: General

Members that are

stripped flat from
the mold will
develop the
moments shown
 Stripping: General

In some plants,
tilt tables or
turning rigs are
used to reduce
stripping
stresses
 Stripping: General

Since the section modulus with respect to the

top and bottom faces may not be the same, the
designer must select the controlling design
limitation:
Tensile stresses on both faces to be less than that which
would cause cracking
Tensile stress on one face to be less than that which would
cause cracking, with controlled cracking permitted on the
unexposed face
Controlled cracking permitted on both faces
 Stripping: General

If only one of the faces is exposed to

view, the exposed face will generally
control the stripping method
 Rigging Configurations

Stresses and forces occurring during

handling are also influenced by the type
of rigging used to hook up to the
member
 Rigging Configurations

Lift line forces for a two-point lift using

inclined lines are shown
 Rigging Configurations

When the sling angle is small, the components of

force parallel to the longitudinal axis of the
member may generate a significant moment due
to secondary effects
 Rigging Configurations

While this effect can and should be accounted

for, it is not recommended that it be allowed to
dominate design moments
 Rigging Configurations

Consideration should be
given to using spreader
beams, two cranes or
other mechanisms to
increase the sling angle
Any such special handling
required by the design
should be clearly shown
on drawings
 Rigging Configurations

Using a spreader beam can also eliminate

the use of rolling blocks
Note that the spreader beam must be
sufficiently stiffer than the concrete panel to
limit panel deflections and cracking
Lifting hook locations, hook heights, and sling
lengths are critical to ensure even lifting of
the member
For analysis, the panel acts as a continuous
beam over multiple supports
 Stripping Design

To account for the forces on the member

caused by form suction and impact, it is
common practice to apply a multiplier to the
member weight and treat the resulting force
as an equivalent static service load.
The multipliers cannot be quantitatively
derived, so they are based on experience
 Stripping Design

PCI provides a table of typical values

 Factor of Safety

When designing for stripping and handling, the

following safety factors are recommended:
Use embedded inserts and erection devices with a
pullout strength at least equal to four (4) times the
calculated load on the device.
For members designed without cracking, the
modulus of rupture (MOR) , is divided by a safety
factor of 1.5.

7.5 f 'c
5 f 'c
1.5
 Stress Limits & Crack Control

Stress limits for prestressed members during

production are discussed in Section 4.2.2.2 of
the the PCI Handbook
ACI 318-02 does not restrict stresses on non-
prestressed members, but does specify
minimum reinforcement spacing, as
discussed in Section 4.2.2.1. (PCI chapter 4
member design)
 Stress Limits & Crack Control

Members which are exposed to view will

generally be designed for the no discernible
cracking criteria (see Eq. 4.2.2.2), which limits
the stress to 5 f ' .
c
In the case of stripping stresses, fci should be
substituted for fc
Whether or not the members are exposed to
view, the strength design and crack control
requirements of ACI 318-02, as discussed in
Chapter 4 of this Handbook, must be followed.
 Benefits of Prestressing

Panels can be prestressed, using either

pretensioning or post-tensioning.
Design is based on Chapter 18 of ACI 318-
02, as described in Chapter 4 of this
Handbook. Further, tensile stresses should
be restricted 5to
less
fthan
'c , must be
followed.
 Benefits of Prestressing

It is recommended that the average stress due

to prestressing, after losses, be within a range
of 125 to 800 psi
The prestressing force should be concentric
with the effective cross section in order to
minimize camber, although some manufacturers
prefer to have a slight inward bow in the in-
place position to counteract thermal bow
It should be noted that concentrically
prestressed members do not camber, hence the
form adhesion may be larger than with
members that do camber
 Strand Recomendation

In order to minimize the possibility of splitting

cracks in thin pretensioned members, the
strand diameter should not exceed that
shown in the table below
Additional light transverse reinforcement may
be required to control longitudinal cracking
 Strand Recommendations

When wall panels are post-tensioned, care must be

taken to ensure proper transfer of force at the
anchorage and protection of anchors and tendons
against corrosion
Straight strands or bars may be used, or, to reduce
the number of anchors, the method shown may be
used
 Strand Recommendation

It should be noted that if an unbonded tendon

is cut, the prestress is lost. This can
sometimes happen if an unplanned opening
is cut in at a later date
 Handling Devices

Since lifting devices are subject to dynamic

loads, ductility of the material is a
requirement
Deformed reinforcing bars should not be used
as the deformations result in stress
concentrations from the shackle pin
Also, reinforcing bars may be hard grade or
re-rolled rail steel with little ductility and low
impact strength at cold temperatures
 Handling Devices

Strain hardening from bending may cause

embrittlement
Smooth bars of a known steel grade may be
used if adequate embedment or mechanical
anchorage is provided
The diameter must be such that localized
failure will not occur by bearing on the
shackle pin
 Aircraft Cable Loops

For smaller precast members, aircraft cable can

be used for stripping and erection purposes
Aircraft cable comes in several sizes with
different capacities
The flexible cable is easier to handle and will not
leave rust stains on precast concrete
 Aircraft Cable Loops

For some small precast members such as

coping, the flexible loops can be cast in ends
of members and tucked back in the joints
after erection
Aircraft cable loops should not be used as
multiple loops in a single location, as even
pull on multiple cables in a single hook is
extremely difficult to achieve
User should ensure that the cable is clean
and that each leg of the loop is embedded a
minimum of 48 in.
 Prestressing Strand Loops

Prestressing strand, both new and

used, may be used for lifting loops
The capacity of a lifting loop
embedded in concrete is dependent
upon the strength of the strand, length
of embedment, the condition of the
strand, the diameter of the loop, and
the strength of the concrete
 Prestressing Strand Loops

As a result of observations of lift loop

behavior during the past few years, it is
important that certain procedures be followed
to prevent both strand slippage and strand
failure
Precast producers tests and/or experience
offer the best guidelines for the load capacity
to use
A safety factor of 4 against slippage or
breakage should be used
 Strand Loops Recommendations

In lieu of test data, the recommendations

listed below should be considered when
using strand as lifting loops.
Minimum embedment for each leg of the loop
should be 24 in.
The strand surface must be free of contaminants,
such as form oil, grease, mud, or loose rust, which
could reduce the bond of the strand to the
concrete
 Strand Loops Recommendations

Continued:
The diameter of the hook or fitting around
which the strand lifting eye will be placed
should be at least four times the diameter
of the strand being used
Do not use heavily corroded strand or
strand of unknown size and strength.
 Strand Loops Recommendations

In the absence of test or experience, it is

recommended that the safe load on a
single 1/2 in. diameter 270 ksi strand
loop satisfying the above
recommendations not exceed 8 kips
The safe working load of multiple loops
may be conservatively obtained by
multiplying the safe load for one loop by
1.7 for double loops and 2.2 for triple
loops
 Strand Loops Recommendations

To avoid overstress in one loop

when using multiple loops, care
should be taken in the fabrication to
ensure that all strands are bent the
same
Thin wall conduit over the strands in
the region of the bend has been
used to reduce the potential for
overstress
 Strand Loops Recommendations

When using double or

triple loops, the
embedded ends may
need to be spread apart
for concrete
consolidation around
embedded ends without
voids being formed by
bundled strand
 Threaded Inserts
Threaded inserts can have NC
(National Course) or coil
threads
Anchorage is provided by loop,
strut or reinforcing bar
Inserts must be placed
accurately because their safe
working load decreases sharply
if they are not perpendicular to
the bearing surface, or if they
are not in a straight line with the
applied force
 Threaded Inserts

Embedment of inserts close to an edge will

greatly reduce the effective area of the
resisting concrete shear cone and thus
reduce the tension safe working load of the
embedded insert
When properly designed for both insert and
concrete capacities, threaded inserts have
many advantages
However, correct usage is sometimes difficult
to inspect during handling operations
 Threaded Inserts

In order to ensure that an embedded insert acts

primarily in tension, a swivel plate as indicated in
should be used
It is extremely
important that
sufficient threads
be engaged to
develop the
strength of the bolt
 Threaded Inserts

For straight tension loads only, eye bolts or

wire rope loops provide a fast method for
handling precast members.
Do not use either device if shear loading
conditions exist.
 Proprietary Devices

A variety of castings
or stock steel
devices, machined
to accept
specialized lifting
assemblies are used
in the precast
industry
 Proprietary Devices

These proprietary devices are usually

recessed (using a pocket former) to provide
access to the lifting unit. The recess allows
one panel to be placed against another
without cutting off the lifting device, and also
helps prevent spalling around the device
Longer devices are used for edge lifting or
deep precast concrete members
Shallow devices are available for thin precast
concrete members.
 Proprietary Devices

The longer devices

usually engage a
reinforcing bar to
provide greater pullout
capacity, and often have
holes for the bar to pass
through as shown to the
left
 Proprietary Devices

These units have a rated capacity as

high as 22 tons, with reductions for thin
panels or close edge distances
Supplemental reinforcement may be
required to achieve these values
Shallow units usually have a spread foot
or base to increase pullout capacity
 Proprietary Devices

Reinforcing bars are required in two

directions over the base to fully develop the
lifting unit, as shown in Figure below

These inserts are

rated up to 8 tons
 Proprietary Devices

Some lifting eyes do not swivel, so rotation

may be a concern
In all cases manufacturer recommendations
should be rigorously followed when using any
of these devices
 Wall Panel Example

This example and others in Chapter 5

illustrate the use of many of the
recommendations in this chapter
They are intended to be illustrative and
general only
Each manufacturer will have its own preferred
methods of handling
 Wall Panel Example

Given:
A flat panel used as a loadbearing wall on a two-story
structure, as shown on next slide
Section properties (nominal dimensions are used for
design):
Solid panel Panel with openings
A = 960 in2 A = 480 in2
Sb = St = 1280 in3 Sb = St = 640 in3
Ix = 5120 in4 Ix = 2560 4 in4
Unit weight @ 150 pcf = 100 psf = 0.100 ksf
Total weight = 35.2 kips (solid panel)
= 29.2 kips (panel w/ openings)
Wall Panel Example
 Wall Panel Example

Stripping method:
Inside crane height prevents panel from being
turned on edge directly in mold, therefore, strip flat
Handling multipliers:
Exposed flat surface has a smooth form finish with
false joints. Side rails are removable. Use
multiplier of 1.4
 Wall Panel Example

fci at stripping = 3000 psi

Allowable tensile stresses at stripping and lifting:

5 (1.0) 3000psi
5 f 'c 0.274ksi
1000
Problem:
Check critical stresses involved with stripping.
Limit stresses to 0.274 ksi.

Compare Simple Solution to Mechanics Solution

 Solution Steps

Step 1 Determine section properties

Step 2 Select number of pick points and
determine maximum stress
Step 3 Determine stress from mechanic
approach
Step 4 Check panel with opening
Step 5 Check rolling block solution
Step 6 Check transverse bending
Step 7 Check secondary effects
 Step 1 Determine Section Properties

Solid panel dimensions

a = 10 ft, b = 35.2 ft, a/2 = 5 ft = 60 in.

S for resisting section (half of panel width)

b h2 60 in (8 in)2
640 in3
6 6
 Step 2 4-point pick

Figure 5.36.1.1(a) (page 5-5)

My 0.0107 w a b2

121.4 223kip in
2
0.0107 0.10 10 35.2ft
 Step 2 Check Stresses

4 Point Stresses
223 kip in
ft fb 3
0.348 ksi 0.274 ksi
640 in

Not Good try 8 point pick

 Step 2 8 Point Pick

Figure 5.3.1.1(b) (Page 5-5)

My 0.0027 w a b2

121.4 56.2kip in
2
0.0027 0.10 10 35.2ft
 Step 2 Check Stresses

8 Point Stresses

56.2 kip in
ft fb 3
0.088 ksi 0.274 ksi
640 in
 Step 3 Mechanics of Materials

2
w l 2 1.0 3.65
Mmax
2 2
6.7ft kip
Mmax area under shear diagram
1

6.7 5.15
2
10.3ft
2
6.7kip ft

ft

6.7 1.4 12
1280
0.088 ksi 0.274 ksi
 Step 4 Panel With Openings

ft

6.8 1.4 12
1280
0.089ksi

or ft

5.9 1.4 12
640in3
0.155 ksi 0.274 ksi O.K.
 Step 5 Rolling Blocks

If using a rolling block for handling as shown below,

the panel cannot be analyzed with the previous
method
Each leg of continuous cable over a rolling block
must carries equal load
 Step 5 Rolling Block

w 29.2kips

RL
13.9 kips
29.2 8.4
9.3 8.4
13.9
R1 R 2 7.0 kips
2
R R 29.2 13.9 15.3 kips
15.3
R1 R 2 7.6 kips
2
 Step 6 Transverse Bending

Consider lower portion of panel with openings

Note that Figure Without the concrete in the area of the
opening, the weight is reduced and unevenly distributed.
Also, the resisting section is limited to a width of 4.7 ft.
 Step 6 Transverse Bending

Section through lifters:

w2 4.7 0.67 0.15 0.47 kips
ft
From continuous beam
analysis, load carried by
bottom two anchors is 7.2
kips, therefore:

w1
0.97 kips
7.2 0.47 5
2 2.5 ft

Mmax 2.1 ft kips 25.2 in kips

 Step 7 Secondary Effects

Check added moment due to sling angle

Using recessed proprietary lifting anchor
e = 3.5 in
sling angle 60o
7.2 kips
P 3.6 kips
2
3.5
Mz 3.6 o
7.3 kips
tan 60
Mtotal 25.3 7.3 32.5 in kips
 Step 7 Secondary Effects

Resisting Section

2
bt2 56 8
S 597in3
6 6

f

Mtotal handling mult.

32.5 1.4
S 597in3
0.08 ksi 0.274 ksi

Therefore Section is OK
 Prestressed Wall Example

Given:
Same wall
panel as
previous
example
 Prestressed Wall Example

Problem:
Determine required number of 1/2 in diameter, 270 ksi
strands pulled to 28.9 kips to prevent cracking in window
panel. Assume 10% loss of prestress.
From previous example, tensile stress is 0.431 ksi. The
desired level of tensile stress is 5 3000 psi or 0.274 ksi
 Solution Steps

Step 1 Determine additional

compressive Required
Step 2 Determine the number of strands
required based on stress
Step 3 Calculate the number of strands
 Step 1 Additional Compressive

Compressive stress required

0.431 0.274 = 0.157 ksi
 Step 2 # Of Strands Based On Stress

From previous the max moment/stress occurs at lifting

points (-M). This results in tensile stresses on the top
face.

A 2 30 7.25 435 in2

2 30 7.25
2

3
St 526 in
6
P

0.060 no. of strandksi
no. of strand 28.9 0.90
A 435in2
7.25
M

no. of strand 28.9 0.90
2
4


S 526

0.019 no. of strand ksi
 Step 3 Number of Strands

0.060(no. of strands) 0.019(no. of strands) = 0.157 ksi

No. of strands = 3.8

Add four strands to panel (two on each side of opening)

 Storage

Wherever possible, a member should be

stored on points of support located at or near
those used for stripping and handling
Where points other than those used for
stripping or handling are used for storage, the
storage condition must be checked
 Storage

If support is provided at more than two points,

and the design is based on more than two
supports, precautions must be taken so that
the element does not bridge over one of the
supports due to differential support settlement
 Storage

Warpage in storage may be caused by

temperature or shrinkage differential between
surfaces
creep
storage conditions
Warpage can only be minimized by providing
Where feasible, the member should be
oriented in the yard so that the sun does not
overheat one side
 Storage

By superposition, the total instantaneous

deflection, ymax , at the maximum point can
be estimated by:

y max

1.875 w sin a4 l 4

Eci Ic Ib

Ic , Ib = moment of inertia
of uncracked section in
the respective directions
for 1 in. width of panel
 Storage

This instantaneous deflection should be

modified by a factor to account for the time
dependent effects of creep and shrinkage
ACI 318-02 suggests the total deformation
yt, at any time can be estimated as:

y t y max 1
 Storage

= amplification due to creep and shrinkage as a

function of (reinforcement ratio for non-prestressed
compression
reinforcement,
As/bt)
 Transportation

The method used for transport can affect the

structural design because of size and weight
limitations and the dynamic
Except for long prestressed deck members,
most products are transported on either flatbed
or low-boy trailers
Trailers deform during hauling
Size and weight limitations vary from one state
to state
Loads are further restricted on secondary roads
The common payload for standard trailers
without special permits is 20 tons.
 Transportation

Low-boy trailers permit the height to be

increased to about 10 to 12 ft.
However they have a have a shorter bed
length.
This height may require special routing to
avoid low overpasses and overhead wires
 Transportation

Erection is simplified when members are transported

in the same orientation they will have in the structure
For example, single-story wall panels can be
transported on A-frames with the panels upright
A-frames also provide good lateral support and the
desired two points of vertical support
 Transportation

Longer units can be transported

on their sides to take advantage
of the increased stiffness
compared with flat shipment
 Transportation

In all cases, the panel support locations should be

consistent with the panel design
Panels with large openings sometimes require
strongbacks, braces or ties to keep stresses within
the design values
 Transportation

For members not symmetrical with respect to

the bending axis, the following expressions
can be used for determining the location of
supports to give equal tensile stresses for
positive and negative bending moments
 Transportation

For one end cantilevered

yb yb
1
x 1 1
2 yt yt

Where
yb = distance from the bending axis to the bottom fiber
yt = distance from the bending axis to the top fiber
 Transportation

For two ends cantilevered

1
x
yt
2 1 1
yb

Where
yb = distance from the bending axis to the bottom fiber
yt = distance from the bending axis to the top fiber
 Erection

Precast concrete members frequently must

be reoriented from the position used to
transport to its final construction position
The analysis for this tripping (rotating)
operation is similar to that used during other
handling stages
In chapter 5 in the PCI handbook, maximum
moments for several commonly used tripping
techniques are illustrated
Tripping Design Guide
 Erection

When using two crane lines, the center of

gravity must be between them in order to
prevent a sudden shifting of the load while it
is being rotated
To ensure that this is avoided, the stability
condition shown must be met:

2 2
l l b
e a
2 2
 Erection

The capacities of lifting devices must be

checked for the forces imposed during the
tripping operation, since the directions vary
When rotating a panel with two crane lines,
the pick points should be located to prevent
the panel from an uncontrolled roll on the
roller blocks can be done by slightly offsetting
the pick point locations to shift the weight
toward the upper crane line lift points, or by
using chain drags on the rolling block
 Erecting Wall Panels Example

Given:
The wall panels with
openings used on
previous examples

Problem:
Determine appropriate
procedures for erecting
the wall panels with
openings, panel will be
shipped flat
 Erecting Wall Panels Example

Assumptions
Limit stresses to 5 f 'c (0.354 ksi).
Crane has main and auxiliary lines.
A telescoping man lift is available on site.

Solution:
Try three-point rotation up using stripping inserts and
rolling block: To simplify, conservatively use solid panel
(no openings) to determine moments.
 Erecting Wall Panels Example

W 1.0kips / ft
35.17

35.17 1
2
RB
0.292
35.17 0.604
2
23.4 kips
R B R B 11.7 kips
1 2
 Erecting Wall Panels Example

R T 35.17 1 23.4kips 11.8kips

In Horizontal Position

MMAX 69.6kip ft 835.2kip in

1.2(835.2kip in)
f 1.58 ksi 0.354 ksi
635

Therefore, 3 point pick not adequate

 Erecting Wall Panels Example

Knowing from the stripping analysis

that a four-point pick can be used,
the configurations shown here may
be used
However, this rigging may become
unstable at some point during
tripping, i.e., continued rotation
without tension in Line A
Therefore, the lower end of the
panel must stay within inches of the
ground to maintain control.
 Erecting Wall Panels Example

Because the previous configuration

requires six rolling blocks and can be
cumbersome, the method shown on the
following slide may be an alternative
Erecting Wall Panels Example
 Erection Bracing Introduction

This section deals with the temporary bracing

which may be necessary to maintain
structural stability of a precast structure
during construction
When possible, the final connections should
be used to provide at least part of the
erection bracing, but additional bracing
apparatus is sometimes required to resist all
of the temporary loads
 Erection Bracing Introduction

These temporary loads may include wind,

seismic, eccentric dead loads including
construction loads, unbalanced conditions
due to erection sequence and incomplete
connections Due to the low probability of
design loads occurring during erection,
engineering judgment should be used to
establish a reasonable design load
 Erection Bracing Responsibilities

Proper planning of the construction process is

essential for efficient and safe erection
Sequence of erection must be established
early, and the effects accounted for in the
bracing analysis and the preparation of shop
drawings
The responsibility for the erection of precast
concrete may vary as follows:
(see also ACI 318-02 Section 10.3)
 Erection Bracing Responsibilities

The precast concrete manufacturer supplies

the product erected, either with his own
forces, or by an independent erector
The manufacturer is responsible only for
supplying the product, F.O.B. plant or jobsite
Erection is done either by the general
contractor or by an independent erector
under a separate agreement
 Erection Bracing Responsibilities

The products are purchased by an

independent erector who has a contract to
furnish the complete precast concrete
package.
Responsibility for stability during erection
must be clearly understood.
Design for erection conditions must be in
accordance with all local, state and federal
regulations. It is desirable that this design be
directed or approved by a Professional
Engineer
 Erection Bracing Responsibilities

It is desirable that this design be directed or

approved by a Professional Engineer
Erection drawings define the procedure
on how to assemble the components into the
final structure
The erection drawings should also address
the stability of the structure during
construction and include temporary
connections
 Erection Bracing Responsibilities

When necessary, special drawings may be

required to include shoring, guying, bracing
and specific erection sequences
It is desirable that this design be directed or
approved by a Professional Engineer
Erection drawings define the procedure
on how to assemble the components into the
final structure
 Erection Bracing Responsibilities

The erection drawings should also address

the stability of the structure during
construction and include temporary
connections
When necessary, special drawings may be
required to include shoring, guying, bracing
and specific erection sequences
 Erection Bracing Responsibilities

For large and/or complex projects, a pre-job

conference prior to the preparation of erection
drawings may be warranted, in order to
discuss erection methods and to coordinate
with other trades
 Handling Equipment

The type of jobsite handling equipment

selected may influence the erection sequence,
and hence affect the temporary bracing
requirements
Several types of erection equipment are
available, including truck-mounted and crawler
mobile cranes, hydraulic cranes, tower cranes,
monorail systems, derricks and others
The PCI Recommended Practice for Erection
of Precast Concrete provides more information
on the uses of each.
 Surveying and Layout

Before products are shipped to the jobsite, a

field check of the project is recommended to
ensure that prior construction is suitable to
accept the precast units
This check should include location, line and
grade of bearing surfaces, notches,
blockouts, anchor bolts, cast-in hardware,
and dimensional deviations
Site conditions such as access ramps,
overhead electrical lines, truck access, etc.,
should also be checked
 Surveying and Layout

Any discrepancies between actual conditions

and those shown on drawings should be
addressed before erection is started
Surveys should be required before, during
and after erection:
Before, so that the starting point is clearly
established and any potential difficulties with the
support structure are determined early.
During, to maintain alignment.
After, to ensure that the products have been
erected within tolerances.
 Loads on Structure

The publication Design Loads on Structures

During Construction (SEI/ASCE 37-02)
provides minimum design loads, including
wind, earthquake and construction loads and
load combinations for partially completed
structures and structures used during
construction
In addition to working stress or strength
design using loads from the above
publication, the designer must consider the
effect of temporary loading on stability and
bracing design
 Temporary Loading Examples

Columns with eccentric loads from other framing

members produce sidesway which means the
columns lean out of plumb
A similar condition can exist when
cladding panels are erected on one
side of a multistory structure
 Temporary Loading Examples

Unbalanced loads due to partially complete

erection may result in beam rotation
The erection drawings should address these
Conditions
 Temporary Loading Examples

Some solutions are:

Install wood wedges
between flange of tee
and top of beam
Use connection to
columns that prevent
rotation
Erect tees on both
sides of beam
Prop tees to level
below
 Temporary Loading Examples

Rotations and deflections of framing members may

be caused by cladding panels. This may result in
alignment problems and require connections that
allow for alignment adjustment after all panels are
erected
 Temporary Loading Examples

If construction equipment such as concrete

buggies, man-lifts, etc., are to be used,
information such as wheel loads and spacing
should be conveyed to the designer of the
precast members and the designer of the
erection bracing
 Factors of Safety

Suggested safety factors are shown

Bracing inserts cast into precast members 3
Reusable hardware 5
Lifting inserts 4
 Bracing Equipment and Materials

For most one-story and

two-story high
components that
require bracing, steel
pipe braces similar to
those shown are used
 Bracing Equipment and Materials

Proper anchoring of the braces to the precast

members and deadmen must be considered
When the pipe braces are in tension, there
may be significant shear and tension loads
applied to the deadmen
Properly designed deadmen are a
requirement for safe bracing
Cable guys with turnbuckles are normally
used for taller structures
 Bracing Equipment and Materials

Since wire rope used in cable guys can resist

only tension, they are usually used in
combination with other cable guys in an
opposite direction
Compression struts, which may be the
precast concrete components, are needed to
complete truss action of the bracing system
A number of wire rope types are available
Note that capacity of these systems is often
governed by the turnbuckle capacity
 General Considerations

Careful planning of the erection sequence is

important
This plan is usually developed by a coordinated
effort involving the general contractor, precast
erector, precaster production and shipping
departments and a structural engineer
A properly planned erection sequence can
reduce bracing requirements
For example, with wall panel systems a corner
can first be erected so that immediate stability
can be achieved
 General Considerations

Similar considerations for shear wall

structures can also reduce bracing
requirements
All parties should be made aware of the
necessity of closely following erection with the
welded diaphragm connections
This includes the diaphragm to shear wall
connections
 General Considerations

In order for precast erection to flow smoothly:

The site access and preparation must be ready
The to-be-erected products must be ready
Precast shipping must be planned
The erection equipment must be ready
Bracing equipment and deadmen must be ready
Questions?