Kiski Area High School Allegheny Township, PA FLOOR SYSTEM ANALYSIS

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1 FLOOR SYSTEM ANALYSIS Objective The objective of the following breadth study is to determine if an alternative floor system for Building N would be more advantageous than the existing floor system. The system that I am proposing to use is prestressed concrete planks. The parameters that will be considered during this analysis are: costs, schedule, site layout & access, and analysis of the plenum space. With the use of this proposed system, I am looking to increase the size of the span from 10ft O.C. to 20ft O.C. while keeping the thickness of the plank to a minimum. This may then reduce the overall tonnage of steel for Building N and save the Owner money as well as save the Contractor construction time. Existing Floor System The structural system of Building N was designed using Allowable Stress Design (ASD). However, the design consists of both A36 and A steel. This is because the designer wanted to use a cheaper grade steel for lighter loads and use a stronger grade for heavier loads. The steel structure is non-composite yield strength of structural steel at 36ksi and 50ksi. The system was designed to withstand earthquake loads and wind loads up to 70 MPH. The structural system also utilizes shear walls at either end of the building and several moment connections. Figure 3.1: Building N Floor Layout The second floor slab is a one-way slab system consisting of 3 concrete topping reinforced with 6x6/ W1.4xW1.4 W.W.F. on top of 3 x 20ga. galvanized composite metal deck; the total slab depth is 6. The beams supporting the slab are spaced at 10 O.C. A typical bay size for the first floor is approximately 40ft x 129ft; where as a typical bay size for the second floor is 40ft x 75ft. The picture to the right, Figure 3.1, shows the two floor layouts for Building N. The first floor is represented by the black striped-dotted lines, while the second floor is

2 represented by the red striped lines. Figures 3.2 and 3.3 are the cross section of Building N through line A-A. Figure 3.2: Cross Section through A-A line. Figure 3.3: Close-up of the Cross Section through A-A line. Proposed Floor System The floor system that I analyzed was with the use of prestressed concrete planks. The manufacturing catalog that I used was Nitterhouse Concrete Products, Inc. This company manufactures various precast and prestressed concrete products, such as wall panel systems, architectural precast concrete systems, and hollowcore planking.

3 Methodology To perform this analysis, several assumptions about the original design of the second floor system were made; the design was checked with these assumptions and then re-designed using prestressed concrete planks. Due to my technical knowledge of the Structural option, some assumptions were made about the structure. The first assumption made was the floor area to be analyzed; assuming a typical bay within the structure of the building. The W shapes with an asterisk (*) indicates that these members are A steel. All other shapes are A-36 steel. Below, Figure 3.4 is an AutoCAD drawing of the typical bay that was assumed. Figure 3.4: 40ft x 75ft Typical Bay Slab on Metal Deck Floor System The other assumptions that were made are as follows: No lateral load - wind or earthquake load No lateral bracing No moment connections Next, referencing the structural drawings for the design live loads of the second floor; I found that the Classrooms were designed to 60psf (40psf + 20psf - partitions) and the above ground floor Corridor was designed to 80psf. However, in all of my calculations a live load of 80psf was used because it was the worst case load to design for.

4 A reference to the manufacturing catalog United Steel Deck was done to determine the dead load on the second floor. Since the actual metal decking could not be found in this catalog, I chose one that was similar. I decided on N-Lok 20ga. metal deck with a slab thickness of 6, with normal weight concrete (145pcf) this gave me a dead load of 46psf. In my calculations I also added a dead load of 15psf for miscellaneous items, such as lights, ceiling, sprinklers, etc. The original design was checked after determining all of the loads for the floor system. The first beam checked was a W21x44 * (A572-50); I calculated the load on the classroom area, multiplied by the tributary area. Then found the uniformly distributed load (including the beams self-wt) atop of the beam. From this I was able to solve for the maximum moment imposed on the beam. Since the building was designed using ASD (A36 steel) and assuming it has compact sections, I used the Allowable Stress equation: F b = 0.66F y, where F b = M/S x. Knowing the beam resisting moment (M) and the reduction factor (F b ), I solved for the required elastic section modulus (S req ). I looked in the ASD Selection Tables (S x ) to find a beam with a value equal or greater than the section modulus that I solved for. Once I found the beam required for this condition, I found the most economical beam to use which was in fact a W21x44. Therefore, I continued with checking the original design of the system. The next beam checked was a W8x18 (A36); I performed the same calculations as the previous one and found a maximum moment imposed on the beam. When I looked in the ASD Selection Tables, I found that the most economical size beam to use was not W8x18 but rather W6x15. Since this calculation did not result with the same size beam that the designer had used, I looked into the reason why a designer would use W8x18. I found that most structural designers have a minimal size beam that they feel comfortable using on their projects and it just so happens that a W8x18 is the smallest size beam that they will use. After correctly determining the original size beams, the last check to make was the W30x99 girder. By taking half of the resultant shear force of each of the 3-W21x44 and each of the 3-W8x18, I was able to determine the maximum moment imposed on the girder. Once again, I referred to the Selection Tables in the ASD Manual and found that the most economical size beam to use was W30x90. However, W30x99 was listed as the most economical in the section above. Therefore, this is acceptable too. Since the assumptions that I had made resulted in approximately the same design of the typical bay, the next step was to find a prestressed concrete plank that could span further than 10ft O.C. yet keep the thickness of the slab to a minimum. The live load and 15psf dead load imposed on the structure will be the same; however, the dead load for the slab on metal deck will change because it will be based on the weight of the plank used. I began by determining which direction the plank would run and at what span length. After looking at the Nitterhouse Concrete Products catalog and deciding that the maximum plank

5 depth that I would use is 10 (8 hollowcore prestressed concrete plank + 2 CIP topping for an even surface), I ran calculations in order to determine whether the 5 or 8 plank would be capable of spanning a distance of 32-7 or 20. I found that the load of an 8 x 4 plank at a span of 20 can carry the imposed load for this system. Next, I calculated the new beam and girder sizes if an 8 (82.5psf) concrete plank was used. I assumed that the plank ends would set above a W21x44 beam. I calculated the load on the classroom area and multiplied by the tributary area. I found the uniformly distributed load (assumed beams self-wt) atop of the beam. From this I was able to solve for the maximum moment imposed on the beam. Designing to the same strength of steel as the original design (A572-50), I used the Allowable Stress equation: F b = 0.66F y, where F b = M/S x and solved for the required section modulus (S req. ). I looked in the ASD Selection Tables (S x ) to find a beam with this value or greater. Once I found the beam required for this condition, I found the most economical beam to use was W24x76. I performed the same calculations for the W8x18 beam; I assumed that was the beams self-weight supporting the plank at a span of 20 and found the maximum moment on the beam. Looking in the ASD Manual, I found that a W10x22 was the most economical size. Lastly, I sized the girder using the beams that I have calculated. By taking half of the resultant shear force of the W24x76 and of the W10x22, I was able to determine the maximum moment imposed on the girder. Once again, I referred to the ASD Selection Table and found that the most economical size beam to use was W30x108. All of the calculations for this analysis can be found in Appendix C. Results After completing the calculations for the prestressed concrete plank floor system, a new structural floor layout in AutoCAD was drawn. When laying out the 4-0 wide floor planks on the new structure, some areas of the bay were not able to fit a whole 4-0 section of plank on the floor. After contacting Mr. Mark Taylor at Nitterhouse Concrete Products, Inc. he responded by saying that they would make ripped planks which are 4-0 wide planks with a solid core. The next day they would cut through the solid core to create the narrow plank. He also stated that it would be possible to use a ripped plank as small as 1-7. Therefore, I have figured that there are a total of thirty-two (32) hollowcore planks, four (4) 3-0 solid core planks, four (4) 1-7 solid core planks, and two (2) 1-10 solid core planks. The AutoCAD drawing can be seen in Figure 3.5 on the following page.

6 Figure 3.5: 40ft x 75ft Prestressed Concrete Plank Floor System Cost Information There are several cost factors that need to be considered when determining if one structure is better than the other such as, the difference in the cost of the cranes, the cost of material, and the cost of labor. According to the steel erectors, Abate Irwin, the crane that was used on site was a 100-ton hydraulic crane with a reach of 164ft. However, if an 8 plank and larger beam sizes were to be erected, a hydraulic crane with a lifting capacity of 7200 lbs and a reach of 100ft would be needed. According to Maxim Crane, there is no difference in the cost of the cranes. Along with the information from Mr. Taylor about the ripped planks, he also included the costs associated with the 10 (8 w/ 2 CIP Topping) plank. For an 8 plank w/2 CIP topping, the cost is $5.95/sq.ft, this price includes plank fabrication, delivery, erection, and an allowance for a couple of rips in each bay. For a bay size of 40ft x 75ft which is an area of 3000sf, the cost for just the prestressed plank is $17,850. Another cost that needs to be included in the cost of the plank floor system is the cost of the 2 concrete topping, placing, and finishing.

7 However, the costs for the slab on deck can be determined by the cost of 4000psi concrete, placing, finishing, and the cost of labor. According to the project manager on the job from P.J. Dick, the cost of material was $65/CY plus $0.20/SF for miscellaneous materials. The placing cost was approximately $40/CY (including pump cost at $13/CY). Finishing the concrete was completed by troweling and sawcutting control joints, this was estimated at about $0.40/SF. Based on the cost information from the general contractor, the cost of the 40ft x 75ft bay is $6523. Using MC 2 to determine the cost of the existing structure versus the proposed structure, the existing structure for the 40ft x 75ft bay is $35,873 where as the proposed structure for the bay is $37,043. The MC 2 Estimates can be found in Appendix C. Total Costs Prestressed Plank Slab Floor Slab $17,850 $6532 Steel $37,043 $35,873 Total $54,893 $42,405 Figure 3.6: Total Cost for Bay Schedule For the Kiski Area High School project, the steel erectors, Abate Irwin started on August 4, However, they spent the first two days mobilizing by assembling the crane and unloading truckloads of steel from Amthor Steel. For the steel erection of the building, Abate Irwin used a 100-ton hydraulic crane with a reach of 164ft. It took approximately 15 days for the steel erection and a total of 30 days to complete the detailing work on the building which includes placing joists, bolting up, and installing decking. However, for the erection of the planks, the steel erectors need to erect steel up until the second floor level. Then the detailers will align and bolt the steel. Once the detailers have finished, then the prestressed concrete planks can be erected. After which, the steel located above the second floor can be erected followed by the detailers. This process will continue throughout the construction of building N.

8 Site Layout & Access To erect the structure and planks there must a large amount of planning. Due to the constrained site, there is only room for one crane to erect both the structure and the plank. On the following three pages (Figures 3.8, 3.9, and 4.0) show the steel erection sequence for Building N, the prestressed planks will also follow this same sequence. To erect the plank, the steel workers would erect steel up to the second floor then erect the prestressed planks off of the truck. After which, the steel workers could continue erecting steel to the roof of the structure. Notice that there are many obstacles which prohibit the use of the crane from other angles of the building. The only place to erect is from the side of the building and from the front of the building. The back of the building is not available due to construction of Building K which is located directly behind the building and is being constructed simultaneously with Building N.

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12 Plenum Space Analysis To analyze the effect that the prestressed planks and the deeper beams impose on the plenum space, three (3) AutoCAD drawings were created which illustrate the original design and the proposed design for Building N. In all of these cases, the floor elevation stays constant so that the floor-to-floor height of the building does not change. If the floor-to-floor height changed, then this would change the stair run from floor-to-floor in the building. Therefore, the plenum space decreased by a total of 7 due to the 8 precast plank with 2 topping and a deeper beam size. In Figure 3.9, the top picture shows the existing condition where a 66 x17 duct runs beneath a W21x44 beam which is supporting a slab on metal deck (6 depth). The bottom picture shows the proposed system with the new beam size. Figure 3.9: W24x76 Plenum Space

13 Notice that since the floor slab is thicker and the beam has a greater depth, the duct will no longer run above the ceiling height. A solution to this problem would be to lower the ceiling height, however, the architect or the owner may not approve of this decision. If they do not approve to lower the ceiling height, then this will require a lot of trade coordination from the contractor and engineers. In Figure 3.10, the top picture shows the existing condition where a 34 x12 duct runs beneath a W30x108 beam which is supporting a 6 slab on metal deck. The bottom picture shows the proposed system with the new beam size. Figure 3.10: W30x 108 Plenum Space

14 Notice that with the prestressed planks and the deeper beam size, the recessed light and the duct have very little room where as in the picture above there is more than enough room to install the recessed light fixture directly beneath the duct. Similarly to Figure 3.9, a solution to this problem would be to lower the ceiling height, however, the architect or the owner may not approve of this decision. If they do not approve to lower the ceiling height, then this will require a lot of trade coordination from the contractor. Figure 3.11: W10x22 Plenum Space

15 In Figure 3.11, the top picture shows the existing condition where a 16 x10 duct runs beneath a W8x18 beam. Although the precast plank and deeper beam size decrease the depth of the plenum space, in this instance it does not present any problems. Conclusions In conclusion, based on the site layout and cost, I would not recommend the use of prestressed concrete planks. As previously stated, the site is very limited due to the close proximity of the buildings and the construction of Building K behind the building. This then prohibits you from erecting at any other angle of the building but from the South and West ends. In this situation, it would be most favorable if slab on metal deck floor system was used. Although the planks increased the size of the beams, the cost difference between the original structure of the bay and the proposed structure of the bay was $1,170. The greatest cost difference was between the prestressed concrete planks and the slab on metal deck with an increased cost of $11,318 more for the planks. Further more, the money for this project comes from government funds which means that the money the school has to spend on the project is very limited. The school is interested in a structure that will get them more for their money. The use of slab on metal deck floor system fulfils that desire.

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