Precast Concrete Structures

Alfred Steinle (1936-2017) turned the lecture notes of Prof. Dr.-Ing. Volker Hahn, which dated from the early 1970s, into a manuscript that became the starting point for this book. After a number of years in bridge-building, Alfred Steinle also became heavily involved in precast concrete construction at Züblin. His theoretical work covered bridge-building with torsion and section deformations in box-girder bridges and in precast concrete structures within the scope of the 6M system with corbels, notched beam ends and pocket foundations. In addition, he was a key figure in many precast concrete projects such as the 6M schools, the University of Riyadh, schools with foamed concrete wall panels in Iraq, Züblin House and the construction of a modern automated precasting plant. Alfred Steinle retired in 1999 and by that time he had risen to the post of authorised signatory in the engineering office at Züblin's head office. Hubert Bachmann (b. 1959) began his career in a precasting plant in 1976 as an apprentice for concrete and precast concrete construction. After studying structural engineering and completing his doctorate at the University of Karlsruhe, he accepted a post in the structural engineering office of Ed. Züblin AG in Stuttgart in 1993, where he has worked ever since. His duties have included the detailed design of structures of all kinds plus research and development in the civil and structural engineering sectors. He has been presenting the series of Hahn lectures on precast concrete structures at the University of Stuttgart since 2003. Mathias Tillmann (b. 1970) has been an engineering and standards consultant at Fachvereinigung Deutscher Betonfertigteilbau e.V. (FDB) since 2007 and technical director since 2008. He specialised in structural engineering during his studies at RWTH Aachen University. After attaining his diploma, he worked as a project engineer, structural engineer and designer. Mathias Tillmann has written numerous brochures, advisory documents and specialist articles on the subject of precast concrete. All three authors have been or still are verymuch involved in construction industry organisations, many technical boards and national and international standards committees concerned with precast concrete construction.

• Introduction 1References 161 General 171.1 The Advantages of Factory Production 171.2 Historical Development 191.3 European Standardisation 21References 292 Design of Precast Concrete Structures 312.1 General 312.2 Tolerances and Calculations for Fit 352.2.1 General 352.2.2 Tolerance Standards 362.2.3 Calculations for Fit 402.3 Production 422.4 Transport and Erection 462.4.1 General 462.4.2 Transport 482.4.3 Erection 512.5 Sustainability 532.6 Design Examples 54References 573 Stability of Precast Concrete Structures 593.1 General 593.2 Loads on Stability Components 593.2.1 General 593.2.2 Wind Load Case 603.2.3 Out-of-Plumb Load Case 633.2.4 Seismic Load Case 643.2.5 Restraint Load Case (Shrinkage and Temperature) 693.3 Shear Walls for Stability 703.3.1 Typical Stability Elements 703.3.2 Arrangement of Stability Elements 743.4 Distribution of Horizontal Loads 803.4.1 General Procedure 803.4.2 Equations for Rough Preliminary Design 813.5 Analysis of Stability Components 843.6 Construction Details 863.6.1 Floor Diaphragms 863.6.2 Shear Walls 86References 884 Precast Concrete Elements 914.1 General 914.2 Floor and Roof Elements 914.2.1 General 914.2.2 Solid Slabs 914.2.3 Hollow-Core Slabs 914.2.4 Precast Floor Plates With In Situ Concrete Topping 954.2.5 Ribbed Elements 984.2.6 Other Floor Systems 1004.3 Beams 1014.3.1 Purlins, Frame Beams, Downstand Beams 1014.3.2 Roof Beams 1014.4 Columns 1034.5 Walls 1094.5.1 General 1094.5.2 Precast Concrete Wall Elements 1094.6 Foundations 1114.6.1 General 1114.6.2 Monolithic Foundations 1114.6.3 Pocket and Pad Foundations 1144.6.4 Other Types of Foundation 118References 1195 Connections for Precast Concrete Construction 1235.1 General 1235.2 Purlin Supports 1245.3 Roof Beam Supports 1255.4 Floor Slab Supports 1265.4.1 Ribbed Elements 1265.4.2 Prestressed Hollow-Core Slabs 1285.5 Downstand Beam Supports 1285.6 Wall Element Supports 1305.7 Balcony Slabs 1335.8 Stair Supports 1345.9 Column/Foundation 135References 1376 Individual Design Issues 1396.1 General 1396.2 Partially Loaded Areas 1396.3 Supports 1406.3.1 General 1406.3.2 Elastomeric Bearings 1416.3.3 Technical Codes of Practice for Elastomeric Bearings 1436.3.4 Design Methods for Elastomeric Bearings 1446.3.5 Horizontal Forces 1456.3.6 Sizing the Bearing 1466.3.7 Design of and Details for Supports 1476.4 Column Butt Joints 1516.4.1 General 1516.4.2 Column Butt Joints with Bed of Grout (Hard Support) 1526.4.3 Column Butt Joints with Deformable Joint Materials 1556.4.4 Rigid Joints 1566.4.5 Column Joints with High-Strength Steel Reinforcement 1566.5 Wall/Floor Connections 1606.6 Shear Dowels 1616.6.1 General 1616.6.2 Large Edge Distances a|| ≥8∅B or a⟂ ≥8∅B 1636.6.3 Small Edge Distances a|| <8∅B or a⟂ <8∅B 1646.6.4 Further Advice Concerning Shear Dowels 1656.7 Welded Connections 1666.8 Bolted Connections and Screw Couplers 1716.9 Other Forms of Connection 1736.10 Transport Anchors 1736.10.1 General 1736.10.2 Actions 1746.10.3 Determining the Permissible Ultimate Resistance 1766.10.4 Further Advice for Design 1786.10.5 Consequences of the ‘Machinery Directive’ 1796.10.6 Incompatibility of Transport Anchor Systems 1796.11 Shear at the Interface Between Concrete Cast at Different Times 1806.11.1 General 1806.11.2 Design 1806.11.3 Surface Categories 1846.11.4 Construction Details 1866.11.5 Fatigue 1876.12 Floor Diaphragms and Shear Walls 1886.12.1 General 1886.12.2 Floor Diaphragms 1896.12.3 Shear Walls 1926.12.4 Miscellaneous 1956.13 Shear Forces in Floor Elements 1956.14 Half Joints 2006.14.1 General 2006.14.2 Design 2006.15 Corbels 2046.15.1 General 2046.15.2 Design 2056.15.3 Construction Details 2136.15.4 Beam Nibs 2146.15.5 Retrofitted Corbels 2156.16 Analysis of Lateral Buckling 2176.16.1 General 2176.16.2 Simplified Lateral Buckling Analysis 2176.16.3 Numerical Analysis 2186.16.4 Analysis of Supports 2266.17 Design for Fire 2286.17.1 General 2286.17.2 Principles of Design for Fire 2296.17.3 Reinforced and Prestressed Concrete Beams 2336.17.4 Reinforced Concrete Columns 2346.17.5 Reinforced Non-Braced Columns 2376.17.6 Fire Walls 2376.17.7 Plaster and Render Finishes 2386.17.8 Junctions, Joints, and Connections 2386.18 Pretensioning 2426.18.1 General 2426.18.2 Concrete Cover 2436.18.3 Level of Prestress 2436.18.4 Loss of Prestress 2446.18.5 Decompression 2466.18.6 Stress Limitation 2476.18.7 Transferring and Anchoring the Prestress 2476.18.8 Tensile Splitting Forces and end Face Tension 249References 2527 Precast Concrete Façades 2577.1 General 2577.2 Conceptual Design 2577.3 Surface Finishes 2607.3.1 General 2607.3.2 Surface Finishes Produced by the Moulds 2617.3.3 Concrete Surface Treatments 2617.3.4 Weathering Behaviour 2637.4 Joint Waterproofing 2667.5 Concrete Sandwich Panels 2687.5.1 General 2687.5.2 Dimensions and Leaf Thicknesses 2687.5.3 Connectors 2697.5.4 Actions 2737.5.5 Design 2787.5.6 Deformations 2817.5.7 Cracking 2817.5.8 Construction Details 2827.6 Suspended Façade Panels 2847.6.1 Large-Format, Suspended Façade Panels 2847.6.2 Small-Format, Suspended Façade Panels 2877.7 Further Developments for Concrete Façades 2897.7.1 Textile-Reinforced Concrete 2897.7.2 Photoconcrete 2907.7.3 Translucent Concrete 2907.7.4 Concrete with Glass Aggregate 2907.7.5 Glass–Concrete Composite 2927.8 Building Physics 2927.8.1 Energy Considerations and Thermal Performance 2927.8.2 Moisture Control 3007.9 Examples 3007.9.1 Züblin House 3007.9.2 Community Centre in Mannheim 3027.9.3 Ohligsmühle Office Building 3027.9.4 Tour Total 3037.9.5 ROC Mondriaan in The Hague 305References 3068 Production 3118.1 Production Methods 3118.1.1 General 3118.1.2 Production Using Fixed Moulds 3118.1.3 Pallet Circulation Systems 3158.2 Concretes for Precast Concrete Elements 3178.2.1 General 3178.2.2 Fresh Concretes 3208.2.3 Hardened Concretes 3218.2.4 Ultra-High Performance Concretes 3228.2.5 Self-compacting Concretes 3248.2.6 Fibre-Reinforced Concretes 3268.3 Heat Treatment and Curing 3278.4 Reinforcement 3298.4.1 General 3298.4.2 Materials 3308.4.3 Reinforcement Drawings 3308.4.4 Bending and Assembling Reinforcement 3328.5 Pretensioning in Prestressing Beds 3348.5.1 General 3348.5.2 Materials 3358.5.3 Construction Documents 3358.5.4 Production 3388.6 Quality Assurance 3428.6.1 General 3428.6.2 Factory Production Control 3428.6.3 External Monitoring 3448.6.4 Certification and Labelling 344References 345Index 351