R-Group Finland Oy. RLA Lifting Inserts Technical Manual According to Eurocodes, EU Machinery directive 2006/42/EC and VDI/BV-BS 6205 CE Approved

Transcription

1 R-Group Finland Oy RLA Lifting Inserts Technical Manual According to Eurocodes, EU Machinery directive 2006/42/EC and VDI/BV-BS 6205 CE Approved

2 2 Table of Contents 1 DESCRIPTION OF THE SYSTEM Manufacturing markings Quality control LIFTING SYSTEM PARTS RLA lifting insert RLA Lifting Insert Dimensions Lifting insert materials and ordering code SAFE WORKING LOADS Design concept Safe working loads RLA lifting inserts safe working loads for wall elements RLA lifting inserts safe working loads for slab elements Concrete thickness and insert spacing in wall elements Slab thickness and insert spacing in slab elements Reinforcement of the pre-cast element RLA lifting insert reinforcement Axial pull reinforcement in wall elements Axial pull reinforcement in slab elements Diagonal pull reinforcement Tilting reinforcement Actions on lifting inserts General Number and actions of lifting inserts Statical system Load distribution for non-symmetrical insert layout Spread angle Self-weight Adhesion and form friction Dynamic actions

3 3 1 RLA lifting inserts systems manufactured by R-Group Finland Oy are lifting anchors consisting of studded end round steel bars and rapid release lifting keys. RLA lifting anchors enable lifting of slabs, columns, beams, walls and other pre-cast concrete elements. RLA lifting inserts can be used in all lifting directions and for lifting angles up to 90 degrees. RLA lifting inserts are designed and manufactured in accordance with EU Machinery Directive 2006/42/EC and VDI/BV-BS Lifting inserts meet the requirements for safe lifting and handling of concrete elements. 1.1 Manufacturing markings RLA lifting inserts are marked with R-Steel logo, type and load class of lifting insert and CE-marking. Products are delivered [in cardboard boxes] on a truck palette. Product package is equipped with an R-Steel Pallet Label, which contains the following information: product type, product name, quantity, ISO9001 and ISO14001 quality and environment system markings, and CE, FI and BY (Concrete Association of Finland) logo. 1.2 Quality control Quality control of the inserts is done according to the requirements of EN and the instructions according to quality and environment system of the R-Group Finland Oy (ISO9001 and ISO14001). R-Group Finland Oy has a quality control contract with Inspecta Sertifiointi Oy.

4 RLA lifting insert RLA Lifting Insert Dimensions Figure 1. RLA lifting inserts dimensions Table 1. RLA lifting inserts dimensions and tolerances Load group Lifting anchor RLA Diameter Dy Diameter Dv Diameter Da Length Lh ± ± ± ± Installation depth A Diameter H RLA RLA RLA RLA RLA RLA RLA RLA RLA

5 5 Load group Lifting anchor RLA Diameter Dy Diameter Dv Diameter Da Length Lh ± ± ± ± Installation depth A Diameter H RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA Lifting devices and recess formers are designed to be compatible with each load class and type of RLA lifting inserts.

6 Lifting insert materials and ordering code Part Ordering code Material Standard RLA S355J2+N EN RLAz S355J2+N EN Lifting anchor RLAez S355J2+N EN RLAr EN RLAh EN RLA lifting inserts are available in two surface finishes. Standard delivery surface finish is black (uncoated). Lifting inserts are also available as electro zinced. Ordering code RLA RLAz RLAez RLAr RLAh Type Plain Hot zinced Electro zinced Stainless Acid resistant Ordering code consists of type, size and length of RLA lifting anchor. Eg. RLA is plain 300 mm long lifting anchor. Eg. RLAz is hot zinced 300 mm long lifting anchor. Eg. RLAh is acid resistant 300 mm long lifting anchor. Marking on top of RLA lifting stud:

7 Design concept Safe working loads of RLA lifting inserts are calculated according to following standards and instructions: EN 1992: Eurocode 2 EN 1993: Eurocode 3 Machinery directive 2006/42/EC VDI/BV-BS 6205 Global safety factors used in calculation of safe working loads are Steel failure = 3,0 Concrete failure = 2,1 Global safety factor 2,1 for concrete failure assumes that the lifted pre-cast elements are produced under plant specific continuous supervision. In other lifting situations, global safety factor of 2,5 for concrete failure must be used and the given safe working loads must be multiplied reduction factor of 2,5 / 2,1 = 0,84. Safe working loads are based on concrete dimensions, anchor steel bars and lifting insert edge distances given in the following sections. Minimum concrete compressive strength at the moment of load application fck.cube.min = 15 MPa. Safety concept E SWL Where E = action placed on lifting insert SWL = safe working load of lifting insert Actions placed on lifting inserts must take into account all loads and load distribution to lifting inserts according to following sections.

8 8 3.2 Safe working loads RLA lifting inserts safe working loads for wall elements Figure 2. Lifting insert load directions in wall elements Safe working loads of RLA lifting inserts in wall elements are given in Table 2. Safe working loads are applicable with concrete strength and concrete thickness according to Table 2, insert spacing according to Table 4 and lifting insert reinforcement according to sections 3.6.1, and

9 9 Table 2. RLA lifting inserts safe working loads in wall elements Load group Lifting insert 1.3 RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA B Safe working loads (SWL) [kn] = 0-45 = 0-90 C12/15 C16/20 C20/25 C28/35 C12/15 C16/20 C20/ ,5 9,8 11,0 13,0 4,2 4,9 5, ,3 13,0 13,0 13,0 5,7 6,5 6, ,0 13,0 13,0 13,0 6,5 6,5 6, ,1 18,6 20,8 24,6 8,1 9,3 10, ,1 23,3 25,0 25,0 10,1 11,6 12, ,2 25,0 25,0 25,0 12,1 12,5 12, ,3 36,2 40,0 40,0 15,7 18,1 20, ,5 40,0 40,0 40,0 18,3 20,0 20, ,0 40,0 40,0 40,0 20,0 20,0 20, ,3 36,2 40,0 40,0 15,7 18,1 20, ,5 40,0 40,0 40,0 18,3 20,0 20, ,0 40,0 40,0 40,0 20,0 20,0 20, ,6 50,0 50,0 50,0 23,3 25,0 25, ,0 50,0 50,0 50,0 25,0 25,0 25, ,0 50,0 50,0 50,0 25,0 25,0 25, ,1 64,8 72,5 75,0 28,1 32,4 36, ,2 72,9 75,0 75,0 31,6 36,5 37, ,2 75,0 75,0 75,0 35,1 37,5 37, ,0 75,0 75,0 75,0 37,5 37,5 37, ,1 94,8 100,0 100,0 41,1 47,4 50, ,5 100,0 100,0 100,0 49,3 50,0 50, ,0 100,0 100,0 100,0 50,0 50,0 50, ,0 100,0 100,0 100,0 50,0 50,0 50, ,7 150,0 150,0 150,0 69,9 75,0 75, ,7 150,0 150,0 150,0 74,8 75,0 75, ,0 150,0 150,0 150,0 75,0 75,0 75, ,0 150,0 150,0 150,0 75,0 75,0 75, ,7 200,0 200,0 200,0 86,9 100,0 100, ,0 200,0 200,0 200,0 100,0 100,0 100, ,0 200,0 200,0 200,0 100,0 100,0 100, ,0 320,0 320,0 320,0 160,0 160,0 160, ,0 320,0 320,0 320,0 160,0 160,0 160, ,0 320,0 320,0 320,0 160,0 160,0 160, ,0 320,0 320,0 320,0 160,0 160,0 160, ,1 279,6 312,6 320,0 121,1 139,8 156, ,5 320,0 320,0 320,0 141,2 160,0 160, ,0 320,0 320,0 320,0 160,0 160,0 160,0 For lifting angle > 15, diagonal pull reinforcement according to section is always required. For lifting angle > 10, tilting reinforcement according to section is always required.

10 RLA lifting inserts safe working loads for slab elements Figure 3. Lifting insert load directions in slab elements Safe working loads of RLA lifting inserts in slab elements are given in Table 3. Safe working loads are applicable with concrete thickness and insert spacing according to Table 5 and lifting insert reinforcement according to sections 3.6.2, and Table 3. RLA lifting inserts safe working loads in slab elements Load group Lifting insert Tc Safe working loads (SWL) [kn] = 0-45 C12/15 C16/20 C20/25 C28/35 RLA ,3 8,4 9,4 11,1 RLA ,7 11,2 12,5 13,0 RLA ,0 13,0 13,0 13,0 RLA ,0 13,0 13,0 13,0 RLA ,0 13,0 13,0 13,0 RLA ,0 12,7 14,2 16,8 RLA ,7 15,8 17,7 20,9 RLA ,7 22,7 25,0 25,0 RLA ,0 25,0 25,0 25,0 RLA ,0 25,0 25,0 25,0 RLA ,8 20,6 23,0 27,2 RLA ,0 30,0 33,6 39,7 RLA ,0 38,0 40,0 40,0 RLA ,0 40,0 40,0 40,0 RLA ,0 40,0 40,0 40,0 RLA ,0 24,2 27,1 32,0 RLA ,3 28,0 31,4 37,1 RLA ,3 38,4 43,0 50,0

11 11 Load group Lifting insert Safe working loads (SWL) [kn] Tc = 0-45 C12/15 C16/20 C20/25 C28/35 RLA ,0 50,0 50,0 50,0 RLA ,0 50,0 50,0 50,0 RLA ,8 29,8 33,4 39,5 RLA ,1 38,2 42,7 50,6 RLA ,9 47,3 52,8 62,5 RLA ,5 59,4 66,4 75,0 RLA ,5 75,0 75,0 75,0 RLA ,0 75,0 75,0 75,0 RLA ,0 35,8 40,1 47,4 RLA ,7 44,7 50,0 59,1 RLA ,8 51,8 57,9 68,5 RLA ,4 61,7 69,0 81,6 RLA ,5 100,0 100,0 100,0 RLA ,0 100,0 100,0 100,0 RLA ,5 46,8 52,3 61,9 RLA ,0 58,9 65,9 77,9 RLA ,0 77,4 86,5 102,4 RLA ,1 138,7 150,0 150,0 RLA ,0 150,0 150,0 150,0 RLA ,8 77,1 86,2 102,0 RLA ,8 100,2 112,0 132,5 RLA ,0 106,2 118,8 140,5 RLA ,7 165,9 185,5 200,0 RLA ,0 200,0 200,0 200,0 32 RLA ,8 149,9 167,5 198,2

12 Concrete thickness and insert spacing in wall elements Figure 4. Minimum element thickness and lifting insert spacing in wall elements Safe working loads are valid only with minimum concrete thickness and minimum lifting insert spacing given in Figure 4 and Table 4. Table 4. Minimum element thickness and minimum lifting insert spacing in wall elements Minimum Minimum lifting Minimum lifting Lifting insert concrete insert edge insert centre thickness B spacing EL spacing CL RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA

13 Slab thickness and insert spacing in slab elements Figure 5. Minimum slab thickness and lifting insert spacing Safe working loads are valid only with minimum concrete thickness and minimum lifting insert spacing given in Figure 5 and Table 5. Table 5. Minimum slab thickness and minimum lifting insert spacing in slab elements Lifting insert Minimum lifting Minimum lifting Minimum slab insert edge insert centre thickness TC spacing EL spacing CL RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA

14 14 Lifting insert Minimum slab thickness TC Minimum lifting insert edge spacing EL Minimum lifting insert centre spacing CL RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA RLA Reinforcement of the pre-cast element The concrete element must have at least minimum reinforcement according to EN Concrete element must be reinforced to withstand all actions from lifting, tilting and transport including dynamic actions. This reinforcement must be designed by the structural designer.

15 RLA lifting insert reinforcement Additional reinforcement for lifting inserts B500B (K500C-T) Axial pull reinforcement in wall elements Figure 6. RLA lifting insert reinforcement for axial pull in wall elements RLA lifting inserts must always have reinforcement according to Figure 6 and Table 6. This reinforcement transfers the load from the lifting insert to the concrete. Stirrup reinforcement 1, additional surface reinforcement 2 and edge reinforcement 3 must be placed at the lifting insert area. Maximum distance for stirrup reinforcement 1 from the center of RLA lifting insert es1 is lifting insert height (es1.max = Lh). These reinforcements may be replaced by structural reinforcement in concrete element, providing the structural reinforcement has sufficient cross-section area and overlap lengths.

16 16 Table 6. RLA lifting reinforcement for axial pull in wall elements Load group n [pcs] Stirrup reinforcement 1 Diameter s1 Length s1 Mesh reinforcement 2 Both surfaces [mm 2 / m] Edge reinforcement 3 Diameter s (RLA ) 1700 (RLA ) Reinforcement given in this section covers only the load impact the lifting insert has on the concrete. Due to eccentricities and lifting angles the concrete element may be subject to bending. Due to loads placed on the concrete elements by the lifting actions the concrete element may be subject to cracking. Concrete element must be separately reinforced for bending and cracking. Diagonal pull reinforcement 4 see section

17 Axial pull reinforcement in slab elements Figure 7. Axial pull reinforcement in slab element RHA lifting inserts in slab elements must always have mesh reinforcement 2 according to Figure 7 and Table 7. This reinforcement may be replaced by structural reinforcement in concrete element, providing the structural reinforcement has sufficient cross-section area and overlap lengths. Diagonal pull reinforcement 4 see section and reinforcement 5 see section Table 7. RHA lifting reinforcement for axial pull in slab elements Mesh reinforcement 2 Load group Top surface [mm 2 / m]

18 Diagonal pull reinforcement In addition to axial pull reinforcement, the lifting inserts must be reinforced for diagonal pull if the lifting angle is greater than 15. Diagonal pull reinforcement 4 is given in Figure 6, Figure 7 and Table 8. Reinforcement given in Table 6 and Table 7 must always be present for diagonal pull. Diagonal pull reinforcement must be placed in direct contact with the recess former of the lifting insert according to Figure 6 and Figure 7. Bending diameter D should be same as the width a of the recess former for tight fit. Table 8. RLA lifting reinforcement for diagonal pull Diagonal pull reinforcement 4 Load Diameter Length group s4 s

19 Diagonal pull reinforcement for lifting angle < 30 For lifting angles smaller than 30 in slab elements diagonal pull reinforcement may be arranged from straight rebars. The reinforcement and placing are given in figure 8 and table 9. This reinforcement is placed in addition to mesh reinforcement 2. Number of rebars ns5 is given in table 9. This number of reinforcement bars must placed in both directions. Figure 8. RLA lifting reinforcement for diagonal pull, slab elements, lifting angle < 30 Table 9. RLA lifting reinforcement for diagonal pull, slab elements, lifting angle < 30 Diagonal pull reinforcement 5 Load group Diameter Number of rebars s5 s

20 Tilting reinforcement Long RLA lifting inserts can be used for tilting of concrete elements (load angle = 0-90 ). For tilting and lateral pull RLA lifting inserts must be reinforced with lateral pull reinforcement 4 according to Figure 9 and Table 10. Reinforcement given in Table 6 and Table 7 must always be present for lateral pull. Lateral pull reinforcement must be placed in direct contact with the recess former of the lifting insert. Direction of lifting force and tilting reinforcement must be according to Figure 9. If the direction of lifting force can be changed or there is a possibility of lifting force direction being according to Figure 10 it is recommended to install tilting reinforcement to both sides of RLA lifting insert, see Figure 10. Figure 9. RLA lifting insert tilting reinforcement

21 21 Figure 10. RLA lifting insert tilting reinforcement, lifting force both ways Table 10. RLA lifting reinforcement for lateral pull Lateral pull reinforcement 6 Load Diameter Length group s6 s

22 Actions on lifting inserts General The loads acting on a lifting insert shall be determined considering the following factors: - statical system - element self-weight - adhesion and form friction - dynamic effects - position and number of lifting inserts - type of lifting equipment and different load scenarios (tension, combined tension and shear, shear loading) Number and actions of lifting inserts The number of load bearing lifting inserts and the load acting on the lifting inserts shall be determined corresponding with the individual lifting situations. Statical system of lifting inserts must be accounted for in these calculations. Actions from all individual lifting situations must be calculated according to sections to After actions placed on lifting inserts are determined, the safe working load (SWL) in section 3.2 shall then be compared with the actions. The safety concept requires that the action E does not exceed the safe working load SWL. The following formula must be satisfied for all actions on lifting inserts where E action on lifting insert, see sections to , in kn SWL safe working load of lifting insert, see section 3.2, in kn The most unfavorable relation from action to resistance resulting governs the design Statical system Lifting equipment used in lifting of pre-cast elements shall allow determinate load distribution to all present lifting inserts. Figure 11 gives examples of statically indeterminate systems where only two lifting inserts carry the load. The load distribution is not clearly defined in these applications. Therefore these statically indeterminate systems shall be avoided.

23 23 Figure 11. Examples of statically indeterminate lifting systems which should not be used a) statically indeterminate system. Load bearing inserts n = 2. b) statical system without clearly defined load-bearing mechanism. Load bearing inserts n = 2. c) statically indeterminate load distribution to the lifting inserts of a wall element. Load bearing inserts n = 2. To ensure a statically determinate system and that all lifting inserts carry their required part of the load in case of applications with more than two lifting inserts transport aids such as sliding or rolling couplings or balancing beams shall be used. Figure 12. Transportation aids for the statically determinate lifting of slabs and wall elements a) balancing beam and rolling coupling. Load bearing inserts n = 4. b) sliding coupling. Load bearing inserts n = 4. c) rolling coupling. Load bearing inserts n = 4. In case of inclined lifting slings the lifting inserts are loaded by combined Figure 12 governs the level of combined tension and shear loads to be taken into account in the design.

24 24 If three lifting inserts are located in slab and situated in star pattern with same distance to the centre of gravity with equal inclinations of 120 (Figure 13) it is ensured that all three lifting inserts experience the same load. Figure 13. Statically determinate load distribution by means of lifting inserts in star pattern a) slab. Load bearing inserts n = 3. b) cover plate. Load bearing inserts n = Load distribution for non-symmetrical insert layout Figure 14. Load distribution for non-symmetrical insert layout using spreader beam If the inserts are not installed symmetrically to the loa load distribution to different inserts is

25 25 where FG weight of the pre-cast element, in kn a distance from insert to centre of gravity, in m b distance from insert to centre of gravity, in m If elements are lifted without spreader beam, the lifting inserts must be installed symmetrically with respect to the elements centre of gravity.

26 Spread angle Influence of spread angle on the actions for lifting inserts must be taken into account. Table 11. Spread angle factors Cable angle Spread angle Load factor z 0-1,00 7,5 15 1, ,04 22,5 45 1, ,15 37,5 75 1, ,41 Figure 15. Spread angle factors

27 Self-weight The self-weight FG of pre-cast elements shall be determined as where V volume of the pre-cast element, in m 3 G density of the concrete, in kn/m Adhesion and form friction Adhesion and form friction are assumed to act simultaneously during the lifting of the precast element from the formwork. The actions for demolding situations is where Fadh action due to adhesion and form friction, in kn qadh basic value of combined adhesion and form friction as per Table 12, in kn/m 2 Af contact area between concrete and formwork, in m 2 Table 12. Minimum values of adhesion and form friction q adh Formwork and condition a) b) qadh [kn/m 2 ] Oiled steel mold, oiled plastic coated plywood 1,0 Varnished wooden mold with panel boards 2,0 Rough wooden mold 3,0 a) Structured surfaces should be considered separately. b) The area to be used in the calculations is the total contact area between the concrete and the form. Note: The minimum values of Table 12 are valid only if suitable measures to reduce adhesion and form friction are taken e. g. casting on tilting or vibrating the formwork during the demolding process.

28 Dynamic actions During lifting and handling of the precast elements the lifting devices are subjected to dynamic actions. The magnitude of the dynamic actions depends on the type of lifting machinery. Dynamic effects shall be taken into account dyn dyn depending on the lifting machinery and characteristics of the terrain are given in Table 13. Table 13. Dynamic factor dyn Condition Tower crane, portal crane, mobile crane Dynamic factor dyn 1,3 Lifting and moving on flat terrain 2,5 Lifting and moving on rough terrain 4 dyn than given in Table 13 based on reproducible tests or verified experience can be used in the design. In case of other lifting and handling conditions than reported in Table 13 dyn shall be determined on the base of tests or engineering judgement nation with adhesion and Figure 16. Erection in combination with adhesion and form friction When pre-cast elements are lift from form according to Figure 16 the action FQ on lifting inserts is where

29 29 FQ FG Fadh z n load acting on individual lifting insert, in kn self-weight of the pre-cast element, section 3.7.6, in kn action due to adhesion and form friction, section 3.7.7, in kn factor for combined tension and shear, z = 1 / cos, angle in accordance with Figure 16. In case of only tension z = 1. number of lifting anchors carrying the load. Figure 17. Erection in combination with adhesion and form friction, lifting with balancing beam When pre-cast elements are lift from form according to Figure 17 the action FQ on lifting inserts is where FQ load acting on individual lifting insert, in kn FG self-weight of the pre-cast element, section 3.7.6, in kn Fadh action due to adhesion and form friction, section 3.7.7, in kn n number of lifting anchors carrying the load.

30 30 Figure 18. Erection in combination with adhesion and form friction, lifting with chains When pre-cast elements are lift from form according to Figure 18 the action FQ on lifting inserts is where FQ load acting on individual lifting insert, in kn FG self-weight of the pre-cast element, section 3.7.6, in kn Fadh action due to adhesion and form friction, section 3.7.7, in kn z factor for combined tension and shear z = 1 / cos, angle in accordance with Figure 18. n number of lifting anchors carrying the load.

31 It is assumed that the pre-cast element rests one-sided in the form or has been tilted up and forces from adhesion and form friction are no longer present. Figure 19. element erection with balancing beam Erection with balancing beam (Figure 19), action on lifting insert is where FQ shear load acting on individual lifting insert, in kn shear directed perpendicular to the longitudinal axis of the concrete component e. g. during lifting from the horizontal position with a beam FG self-weight of the pre-cast element, section 3.7.6, in kn dyn dynamic factor, section n number of lifting anchors carrying the load.

32 32 Figure 20. Element erection with chains For transverse shear (lifting according to Figure 20) action on lifting insert is where FQZ inclined shear load acting on individual lifting insert, in kn inclined and perpendicular to the longitudinal axis of the precast element e.g. during lifting from the horizontal position FG self-weight of the pre-cast element, section 3.7.6, in kn dyn dynamic factor, section z factor for combined tension and shear z = 1 / cos, angle in accordance with Figure 20. n number of lifting anchors carrying the load.

33 Figure 21. Lifting and handling under combined tension and shear presented in Figure 21. This is the most common lifting procedure. Action on lifting insert is where FZ load acting on the lifting insert in direction of the sling axis, in kn FG self-weight of the pre-cast element, section 3.7.6, in kn dyn dynamic factor, section z factor for combined tension and shear z = 1 / cos, angle in accordance with Figure 21. n number of lifting anchors carrying the load.