Analysis and Design of Precast

Concrete Structures to Eurocode 2

Precast and Prestressed Floors
and Composite Floors
Precast & Prestressed Floors
and Composite Floors
• Hollow core floor units & slab fields
• Double tee units
• Half-slab (precast + in-situ topping)
• Composite floors
• Load vs. span data
Fixing Rates at 2000 m2 per week?
40  11 feet Wide HCU onto Precast Walls at
MGM Hotel, Las Vegas, 1992
Hollowcore Units

Daily production:
200 m2 – 1500 m2
Double Tee Units

Twice the price

but up to 4
capacity than
hollow core
 Prestressed Half Slab

Popular for
housing and
awkward shapes
 Prestressed Half Slab

Jetty at Pasir Gudang, Johor

Prestressed Half Slab

Propping required
for  5 m
 Prestressed Hollow Core Floor
Units
• 400 – 3600 mm wide; typically 1200 mm
• 90 – 730 mm deep; typically 150, 200, 250,
300 mm
• Self weight 1.5 to 5.0 kN/m2
• Void ratio 40 – 60 % of solid section
• Spans 6 – 20 m (economical range)
 Longitudinal No shear or 30 mm flanges
pretensioning strand torsion links and webs
or wire

Shear key
profile
Prestressed Hollow Core Floor Units

1195 mm
Prestressed Hollow Core Floor Units
 Splitting cracks due to
sawing restraints as
prestress in
transferred
Prestressed Hollow Core Floor Units
 Too much plasticiser!! in 450 deep units
Actually air-entrainment agent is used by
several producers as a plasticiser
Prestressed Hollow Core Floor Units
 Strand Pull-in:
An important indicator of
success
Should be about 1 mm,
irrespective of length
Prestressed Hollow Core Floor Units

Theoretical pull-in limit for

zero prestress:

𝑷𝑳
𝑨𝑬
* Use a linear scale between the
extremes
 Bearing onto neoprene
or mortar for spans
more than about 15 m
onto insitu or masonry
Prestressed Hollow Core Floor Units

20 m long HCU
 Section for Analysis for Prestressed
• Pretension and losses (about 18 – 25%)
• Service moment (bottom tension critical)
• Ultimate moment (usually  Msr  1.5)
Prestressed Hollow Core Floor Units

• Ultimate shear uncracked & flexurally cracked

• End bearing and transmission length
• Deflection and camber (long-term, creep)
• Live load deflection after installation
 Section for Analysis for Prestressed
• 𝑀𝑠𝑟 = 𝑓𝑏𝑡 + 𝑓𝑐𝑡 𝑍𝑏
• 𝑀𝑢𝑟 = 0.87𝑓𝑝𝑏 𝐴𝑝𝑠 𝑑 − 𝑑𝑛
Prestressed Hollow Core Floor Units

𝐼∙𝑏𝑤
• 𝑉𝑐𝑜 = 𝑓𝑐𝑡𝑑 2 + 𝛼𝑙 𝜎𝑐𝑝 𝑓𝑐𝑡𝑑
𝐴∙𝑦ത
 Prestressed Hollow Core Floor Units

Imposed load

Allowable span
Load vs Span Curve
 Load vs Span Curve
Bearing limit
Prestressed Hollow Core Floor Units

Imposed load

Handling limit
span/depth = 50

Allowable span
 Load vs Span Curve
Bearing limit
Prestressed Hollow Core Floor Units

Imposed load

Handling limit
span/depth = 50

Allowable span
 Load vs Span Curve

Shear
Prestressed Hollow Core Floor Units

Imposed load

Service
moment

Deflection
Handling

Allowable span
 Service moment
Possibly shear ? control

Deflection
Prestressed Hollow Core Floor Units

control
 Example 1
Calculate Msr for the 203 mm deep prestressed HCU shown below. The
initial prestressing force may be taken as 70% of characteristics strength
of the standard 7-wire helical strand. Take the final long-term losses as
24%. Geometric and data given by the manufacturer are as follows:

Ac = 135  103 mm2, I = 678  106 mm4, yt = 99 mm, fck = 50 N/mm2, Ec = 30

kN/mm2, fck (t) = 35 N/mm2, Eci = 27 kN/mm2, fp0,1k = 1750 N/mm2, Eps =
195 kN/mm2, Aps = 94.2 mm2 per strand ( = 12.5 mm) and cover = 40 mm.
 Example 1 - Solution
Section Properties
Zb = I/yb = 678  106/104 = 6.519  106 mm3
Zt = I/yt = 678  106/99 = 6.848  106 mm3

Eccentricity, e = 104 – 40 – 12.5/2 = 57.7 mm

Initial prestress in tendons, fpi = 0.70  1750 = 1225 N/mm2
Initial prestressing force, Pi = fpi  Aps = 1225  7  94.2  10-3 = 807.8
kN
 Example 1 - Solution
Check Stress at Transfer
fbc = (807.8  103/135  103) + (807.8  103  57.75/6.519 106)
= +13.14 N/mm2 (compression)  0.6fck (t) (21 N/mm2)
ftt = (807.8  103/135  103) − (807.8  103  57.75/6.848 106) OK
= − 0.83 N/mm2 (tension)  fctm (t) (−3.20 N/mm2)

Final Prestress in Bottom and Top

fbc = +13.14  (1 – 0.24) = +9.97 N/mm2 (compression)
ftt = −0.83  (1 – 0.24) = −0.63 N/mm2 (tension)
 Example 1 - Solution
Service Moment
At the bottom fibre, Msr is limited by the tensile stress limit of 0
N/mm2
Msr = (fbc)Zb = (9.97)  6.519  106 10-6
= 65.0 kNm

At the top fibre, Msr is limited by the compressive stress limit of

0.6fck = 30 N/mm2
Msr = (ftt + 0.6fck)Zt = (0.63 + 30)  6.848  106 10-6
= 209.7 kNm  65.0 kNm
 Example 2 - Solution
Calculate Mur for the section given in Example 1. Manufacturer’s
data gives the breadth of the top of the HCU as b = 1168 mm.

Effective depth, d = 203 – 40 – 12.5/2 = 156.75 mm

Stress in steel after losses = (1 – 0.24)  0.70  1750 = 931 N/mm2

𝑓𝑠 931
Therefore, strain in steel after losses = = = 0.0045
𝐸𝑠 205×103

which is less than y, the yield strain.

Example 2 - Solution

𝒇𝒑𝟎,𝟏𝒌 𝟏𝟕𝟓𝟎
= = 𝟏𝟓𝟐𝟐
𝜸𝒎 𝟏. 𝟏𝟓

𝟏𝟓𝟐𝟐
𝜺𝒚 = = 𝟎. 𝟎𝟎𝟕𝟒𝟐
𝟐𝟎𝟓 × 𝟏𝟎𝟑
 Example 2 - Solution
As a first attempt, try x = 75 mm, approximately equal to 0.5d
(a) Steel Strains
cc = 0.0035
Final stress strain, s = Prestress Strain + Bending Strain, ’s
Bottom layer at the tendon:
sb = 0.0045 + ’sb x

𝑑−𝑥 d
= 0.0045 + 𝜀𝑐𝑐
𝑥

156.75−75
= 0.0045 + × 0.0035 = 0.008315  y
75

 Take sb = 0.00742

’sb
 Example 2 - Solution
(b) Steel Stresses

Bottom layer at the tendon:

fsb = sb  Es
= 0.00742  205  103
= 1522 N/mm2

(c) Forces in Steel & Concrete

Steel tensile forces, Fst =fs.Aps = (fsb)  7  94.2 = 1003  103 N

Concrete compressive forces, Fcc= 0.567fckb  0.8x
= 0.567 50  1168  0.8  75 = 1987  103 N

Since Fcc  Fst, a smaller depth of neutral axis, x must be tried.

 Example 2 - Solution
Try x = 38 mm  28 mm (upper flange) and then carry out the
previous analysis.

Final Forces in Steel & Concrete

Steel tensile forces, Fst =fs.Aps = (fsb)  7  94.2 = 1003  103 N
Concrete compressive forces, Fcc= 0.567fckb  0.8x
= 0.567 50  1168  0.8  38 = 1006  103 N  Fst ➔ OK

Ultimate Moment of Resistance:

Mur = Fstz = Fst (d – 0.4x)
= 1003  103 (156.75 – 0.4 38)  10-6
= 142 kNm
 Shear Analysis
Shear failure in 400 deep units

Shear searches
out the weakest
web
 Example 3 - Solution
Calculate the uncracked shear capacity, Vco for the section in Example
1.

𝛾𝑐𝑝 𝜂𝑃𝑖 0.9×(1−0.24)×0.70×1750×7×94.2

𝜎𝑐𝑝 = = = 4.09 N/mm2  0.133fck (6.65 N/mm2)
𝐴 135×103
𝑓𝑐𝑡𝑘,0.05 2.90
𝑓𝑐𝑡𝑑 = = = 1.40 𝑁/𝑚𝑚2
𝛾𝑚 1.5
𝑙𝑥 800 + 203/2
𝛼1 = = = 0.94 ≤ 1.0
𝑙𝑝𝑡2 961
 Example 3 - Solution

𝜶𝟏 𝜶𝟐 ∅𝝈𝒑𝒎𝟎 𝟏. 𝟎 × 𝟎. 𝟐𝟓 × 𝟏𝟐. 𝟓 × 𝟏𝟐𝟐𝟓

𝒍𝒑𝒕𝟐 = 𝟏. 𝟐𝒍𝒑𝒕 = 𝟏. 𝟐 = 𝟏. 𝟐
𝒇𝒃𝒑𝒕 𝟒. 𝟕𝟖
= 𝟗𝟔𝟏 𝒎𝒎
1 = 1.0
2 = 0.25
pm0 = 0.70  1750 = 1225 N/mm2
 = 12.5 mm
lpt (transmission length) = 800 mm
𝑓𝑐𝑡𝑘,0.05 (𝑡) 2.20
𝑓𝑏𝑝𝑡 = 𝜂𝑝1 𝜂1 𝑓𝑐𝑡𝑑 𝑡 = 𝜂𝑝1 𝜂1 = 3.2 × 1.0 × = 4.78 𝑁/𝑚𝑚2
𝛾𝑚 1.5
 Example 3 - Solution
Total breadth at centroid, bw = 1168 – (6  150) = 268 mm
Area above the centroidal axis, A = 67500 mm2
y’ = 64.5 mm (calculate from geometry)

𝐼 ∙ 𝑏𝑤
𝑉𝑐𝑜 = 𝑓𝑐𝑡𝑑 2 + 𝛼1 𝜎𝑐𝑝 𝑓𝑐𝑡𝑑
𝐴 ∙ 𝑦ത
678 × 106 × 268 × 10−3
= 1.42 + 0.94 × 4.09 × 1.40
67500 × 64.5
= 113.1 kN
 Shear Analysis
Watch out for flexural-shear (Vcr) failure !
 Flexural-Shear Formula, Vcr
Prestressed Hollow Core Floor Units – Shear Analysis

Vco Decompression
point

Vcr

Vcr = [0.12k (100lfck)1/3 + 0.15cp] bwd

Vcr, min = [0.035k3/2 (fck)1/2 + 0.15cp] bwd
 Flexural-Shear Formula, Vcr
Prestressed Hollow Core Floor Units – Shear Analysis

UDL

SF diagram

Vcr failure
here
 Example 4 - Solution
Calculate the minimum value of Vcr for the slab in Example 1.
𝛾𝑐𝑝 𝜂𝑃𝑖 0.9×(1−0.24)×0.70×1750×7×94.2
𝜎𝑐𝑝 = = = 4.09 N/mm2  0.133fck (6.65
𝐴 135×103
N/mm2)

200 200
𝑘 =1+ =1+ = 2.12 ≤ 2.0 (From Example 2, d = 156.75
𝑑 156.75
mm)

From Example 3, cp = 4.09 N/mm2

Vcr, min = [0.035k3/2 (fck)1/2 + 0.15cp] bwd

= [0.0035(2.0)3/2 (50)1/2 + 0.15  4.09]  268  156.75  10-3
= 28.7 kN
 Bearing Capacity
Prestressed Hollow Core Floor Units – Bearing Capacity

• Refer to Cl. 10.9.5

• Refers to contact bearing pressure at the bearing ledge
• Non-isolated – components are connected to other
components with a secondary means of support
• Isolated – components rely entirely on their own bearing for
total support

Ultimate bearing capacity, FEd = fRd b1 a1

Prestressed Hollow Core Floor Units – Bearing Capacity
Bearing Definitions

𝒂 = 𝒂𝟏 + 𝒂𝟐 + 𝒂𝟑 + ∆𝒂𝟐 𝟐 + ∆𝒂𝟑 𝟐
 Net Bearing Length, a1 (Perpendicular to the
Floor)
Prestressed Hollow Core Floor Units – Bearing Capacity

a1 must NOT be less than the value

in Table 10.2
Prestressed Hollow Core Floor Units – Bearing Capacity
Limiting Value of a2
Prestressed Hollow Core Floor Units – Bearing Capacity
Limiting Value of a3
Prestressed Hollow Core Floor Units – Bearing Capacity
Limiting Value of a2 and a3
Prestressed Hollow Core Floor Units – Bearing Capacity
Net Bearing Width, b1
Prestressed Hollow Core Floor Units – Bearing Capacity
Ultimate Bearing Strength, fRd
 Example 5 - Solution
Calculate the bearing capacity of the HCU in Example 1. The unit has
an actual 75 mm dry bearing length onto a reinforced concrete.
Assumed that the unit is 6 m long and has secondary support on
steel beams.

50
Ultimate bearing strength, fRd = 0.4fcd = 0.4 × = 13.33 N/mm2
1.5

Net bearing width, b1 = 1200 mm  b1, max = 600 mm

Use b1 = 600 mm

Net bearing length for non-isolated component, a1:

From
a2 = 0 mm a2 = 10 mm a = 75 mm
a3 = 5 mm a3 = 2.4 mm
 Example 5 - Solution
 𝒂𝟏 = 𝒂 − 𝒂𝟐 − 𝒂𝟑 − ∆𝒂𝟐 𝟐 + ∆𝒂𝟑 𝟐

𝒂𝟏 = 𝟕𝟓 − 𝟎 − 𝟓 − 𝟏𝟎𝟐 + 𝟐. 𝟒𝟐 = 𝟔𝟎. 𝟑 𝒎𝒎 > 𝟐𝟓 𝒎𝒎

➔ Refer to Table 10.2 for the minimum values of a1

 The ultimate bearing capacity:

FEd = 13.33  60.3  600  10-3 = 482.3 kN > Vco (109.3 kN) ➔OK

Note:
𝑉𝑐𝑜 (𝐹𝑟𝑜𝑚 𝐸𝑥𝑎𝑚𝑝𝑙𝑒 4)
𝜎𝐸𝑑 = = 1.25 𝑁/𝑚𝑚2
1200 × 75
𝜎𝐸𝑑 1.25
= = 0.0375
𝑓𝑐𝑑 50ൗ
1.5
Composite Floors Required for Double Tee,
but Optional for Hollowcore
Surface Laitance due to Cutting Slurry
50 mm minimum at the highest point, increasing
(with slab and beam cambers) to about 80 mm
 Composite Construction
• Minimum thickness of topping  40 mm
• Average depth of topping allowances for camber should
be made – allowing span/300 will suffice
• Concrete grade – C25 to C30
• Minimum mesh reinforcement area = 0.13%  Concrete
area
 Composite Construction
• Advantages to composite construction:
(a) Increase bending resistance and flexural stiffness
(b) Improve vibration, thermal & acoustic performance
(c) Provide horizontal diaphragm action
(d) Provide horizontal stability ties across floors
(e) Provide a continuous and monolithic floor finish
with 75 mm
topping
Composite Design – 2 Stage Approach

Composite Design
 Composite Design -2 Stage Approach

Stage • Selfweight of slab + in-situ

concrete topping + construction
traffic allowance (1.5 kN/m2)
1 • Section properties = Precast unit
Serviceability – 2 Stage Approach

Stage • Superimposed load

• Section properties = Composite
2 section
 Stress Diagram at Serviceability

0.6fck limit
Topping + +
_
+
Serviceability – 2 Stage Approach

+ + =
Precast

fct limit
_ _
+ _

Prestress Imposed Imposed Total

Stage 1 Stage 2 stresses
stresses stresses
 Stage 1 – Service Moment, M1
Bottom fibre stress of the HCU:
𝑴𝟏
𝒇𝒃𝟏 = 𝒇𝒃𝒄 − < +𝟎. 𝟔𝒇𝒄𝒌 (𝒕) 𝒕𝒓𝒂𝒏𝒔𝒇𝒆𝒓 & 𝟎 (𝒔𝒆𝒓𝒗𝒊𝒄𝒆)
𝒁𝒃𝟏
Serviceability – 2 Stage Approach

Top fibre stress of the HCU:

𝑴𝟏
𝒇𝒕𝟏 = 𝒇𝒕𝒄 − < −𝒇𝒄𝒕𝒎 𝒕 𝒕𝒓𝒂𝒏𝒔𝒇𝒆𝒓 & + 𝟎. 𝟔𝒇𝒄𝒌 (𝒔𝒆𝒓𝒗𝒊𝒄𝒆)
𝒁𝒕𝟏
 Stage 2 – Service Moment, M2
Bottom fibre stress of the HCU:
𝑴𝟐
𝒇𝒃𝟐 = −
𝒁𝒃𝟐
Top fibre stress of the HCU:
𝑴𝟐
Serviceability – 2 Stage Approach

𝒇𝒕𝟐 = +
𝒁𝒕𝟐
Top fibre stress of the in-situ topping:
𝑴𝟐
𝒇′𝒕𝟐 = +
𝒁′𝒕𝟐

beff = b  Ec’/Ec where b is the full breadth

 Total Service Moment, Ms
Adding Stage 1 + Stage 2:
fb =fb1 + fb2 = fbc – M1/Zb1 – M2/Zb2  0
ft = ft1 + ft2 = ftc + M1/Zt1 + M2/Zt2  +0.6fck
f’t = f’t2 = + M2/Z’t2  +0.6fck, in-situ
Serviceability – 2 Stage Approach

Service Moment, Msr

Bottom of the slab:
Ms2 = M2  (fbc)Zb2 – [M1(Zb2/Zb1)]
Top of the slab:
Ms2 = M2  (0.6fck – ftc)Zt2 – [M1(Zt2/Zt1)]
 Example 6
Calculate the Stage 2 service bending moment that is available if the
HCU in Example 1 has a 50 mm minimum thickness structural
topping. The floor is simply supported over an effective span of: (a)
4.0 m; (b) 8.0 m. The precamber of the HCU may be assumed as
span/300 without loss of accuracy. Use fck, in-situ = 30 N/mm2 and Ec, in-
2 3
situ = 26 kN/mm . Self weight of concrete = 25 kN/m . Selfweight of
HCU = 3.24 kN/m run. What is the minimum imposed loading for
each span?
 Example 6 - Solution
Effective breadth of topping, beff = 1200  26/30 = 1040 mm
Total depth of composite section = 203 + 50 = 253 mm
Depth to neutral axis from top of composite section, yt2
1040×50×25 +(135000× 50+99 )
= = 114.5 mm
135000+(1040×50)

Second moment of area of composite section, I2 = 1266  106 mm4

 Example 6 - Solution
1266×106
𝑍𝑏2 = = 9.14 × 106 mm3
(253−114.5)

1266×106
𝑍𝑡2 = = 19.63 × 106 mm3
114.5

Zb2/Zb1 = 9.14  106 /6.519  106 = 1.40

Zt2/Zt1 = 19.63  106 /6.848  106 = 2.86
 Example 6 - Solution
(a) 4.0 m
4000
Precamber = = 13 mm
300

Maximum depth of topping at supports = 50 + 13 = 63 mm

(50+63)
Average depth of topping = = 57 𝑚𝑚
2

Self weight of topping = 0.057  25  1.2 = 1.71 kN/m run for 1.2 m
wide unit
Self weight of HCU = 3.24 kN/m run
(3.24+1.71)×42
Stage 1 moment, M1 = = 𝟗. 𝟗𝟎 𝒌𝑵𝒎
8
 Example 6 - Solution

Bottom of the slab:

𝑍𝑏2
𝑀𝑠2 > 𝑓𝑏𝑐 𝑍𝑏2 − 𝑀1
𝑍𝑏1
𝑀𝑠2 > 9.97 × 9.14 × 10−6 − 9.90 × 106 1.40 × 10−6
= 77.46 kNm
 Example 6 - Solution
Top of the slab:
𝑍𝑡2
𝑀𝑠2 = 𝑀2 > 0.6𝑓𝑐𝑘 − 𝑓𝑡𝑡 𝑍𝑡2 − 𝑀1
𝑍𝑡1
𝑀𝑠2 > 30 − (−0.63 ) × 19.63 × 106 − 9.90 × 106 2.86 × 10−6
= 573.35 kNm

The allowable maximum imposed load = 8  77.46/4.02 = 38.73 kN/m

* Additional notes:
Total Ms = Ms1 + Ms2 = 9.90 + 77.46 = 87.36 kNm
Ultimate Limit State - 2 Stage Approach
 Ultimate Limit State - 2 Stage Approach
Total area of reinforcement, Aps = Aps1 + Aps2
Effective breadth, beff = b  fcu in-situ/fcu

Stage 1
fpdAps1 = 0.567fck b(0.8X) ➔ but dn1 = 0.4X or X = dn1/0.4
then dn1 = fpdAps1/1.134fckb
then Mu1 = fpdAps1(d – dn1) ---------------- (1)
 Ultimate Limit State - 2 Stage Approach

Stage 2
Aps2 = Aps – Aps1
Mu2 = fpdAps2 (d + hs – dn2) ---------------- (2)
or by replacing (1) into (2):
Mu2 = fpd [Aps – Mu1/fpd(d – dn1)] (d + hs – dn2)

One Step Approach

Mu = fpdAps (d + hs – dn)
 Interface Shear Stress in Composite
Slabs (Cl. 6.2.5)
In the neutral axis is below the interface, X  hs
VEd = 0.567fckbeffhs

In the neutral axis is above the interface, X  hs,

VEd = 0.567fckbeff0.9X

The shear stress at the interface should satisfy:

vEdi  vRdi
 Interface Shear Stress in Composite
Slabs (Cl. 6.2.5)
𝛽𝑉𝐸𝑑
Design shear stress at the interface; 𝑣𝐸𝑑𝑖 =
𝑧𝑏𝑖

Design shear resistance at the interface;

vRdi = cfctd +n + fyd ( sin + cos )  0.5vfcd

If vEdi  vRdi ; provide shear reinforcement (per 1 m run) projecting

from the precast unit into the structural topping. The amount of
steel required:
𝟏𝟎𝟎𝟎𝒃𝝉𝒉
𝑨𝒇 =
𝟎. 𝟖𝟕𝒇𝒚𝒌
Interface Shear Stress in Composite
Slabs (Cl. 6.2.5)
Interface Shear Stress in Composite
Slabs (Cl. 6.2.5)
Interface Shear Stress in Composite
Slabs (Cl. 6.2.5)
Interface Shear Stress in Composite
Slabs (Cl. 6.2.5)
 Double Tee Floor Units

• 2400 – 3000 mm wide

• 300 – 2000 mm deep; typically 400 – 800 mm
• self weight 2.6 to 10 kN/m2
• void ratio 70 – 80 % of solid section
• spans 8 – 30 m (economical range)
 Double Tee Floor Units
Mostly prestressed, but RC if manufacturer
prefers

Bearing pads required 150 x 150 x 10 mm