DESIGN INFORMATION WAFFLE-CRETE. FOR MORE INFORMATION, WRITE OR CALL International, Inc.

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1 WAFFLE-CRETE DESIGN INFORMATION STRUCTURAL PRECAST PRECAST CONCRETE CONCRETE BUILDING BUILDING SYSTEMS SYSTEMS FOR MORE INFORMATION, WRITE OR CALL WAFFLE-CRETE International, Inc. P.O. BOX 1008 Hays, Kansas USA Ph: Fx: Web: waffle-crete.com & picturetrail.com/wafflecrete1

2 WAFFLE-CRETE STRUCTURAL PRECAST CONCRETE BUILDING SYSTEMS NOTICE Design Information for WAFFLE-CRETE panels has been prepared by WAFFLE-CRETE International, Inc. to provide fabricators, designers, and contractors with suggested uses and practical applications of the WAFFLE-CRETE panels in building construction. The structural capacities and characteristics described herein are to be used as guidelines only. The included information is not to be considered as a final structural design. WAFFLE-CRETE International, Inc. recommends that a qualified structural engineer evaluate each application of WAFFLE-CRETE panels. The engineer shall be directed to determine the actual loads and limitations of the panels under each specific application. Materials, codes and manufacturing methods peculiar to the particular operation and market area shall be considered. WAFFLE-CRETE molds are covered by: U.S. PATENT NO. 5,667,192; CANADA PATENT NO. 1,109,653; JAPAN PATENT NO. 1,364,341. WAFFLE-CRETE is a registered trademark of WAFFLE-CRETE International, Inc. of Hays, Kansas. Reg. U.S. Pat. Off., Reg. No. 1,116,050. Canadian Trade Mark Office Registration No. 241,383. Other foreign patents pending. WAFFLE-CRETE panels are recognized by the I.C.B.O. (International Conference of Building Officials). See I.C.B.O. Research Report Number PFC Copyright WAFFLE-CRETE International, Inc All rights reserved.

3 MATERIALS Material properties and criteria used in the design information contained herein are as follows: A. Normal Weight Precast Concrete ( #/cubic foot) day compressive strength f c = 5000 psi (34,416 KN/m 2 ) or 4000 psi (27,533 KN/m 2 ) 2. Maximum shear strength v c =.75 (2) f c 3. Modulus of elasticity e = w (1.5) 33 f c B. Reinforcing Steel 1. Deformed Billet Steel Bars, ASTM A-615, Grade 60 fy = 60 ksi (412,992 KN/m 2 ) or 40 ksi (275,328 KN/m 2 ) 2. Welded wire fabric, ASTM A-185 fy = 60 ksi (412,992 KN/m 2 ) or 40 ksi (275,328 KN/m 2 ) DESIGN A. Code 1. Uniform Building Code, 1991 Edition 2. American Concrete Institute Building Code B. Spans 1. The spans are in 2 and 4 foot intervals to best utilize the WAFFLE-CRETE form dimensions. Lengths other than those shown may be obtained through the use of headers in the forms during fabrications. 2. Panels were designed in accordance with ultimate strength design methods for maximum allowable stresses. 3. All panels are designed for yield of reinforcing steel prior to concrete failure. C. Loading 1. Panel loading was calculated with dead load and superimposed loads. The dead load included only the panel weight. All superimposed weight, such as partitions, toppings, and live loads shall be considered superimposed loads. 2. Design loading was calculated in conformance with ACI Ultimate strength load factors as follows: U = 1.4D + 1.7L D = dead load or L= live load U =.75 (1.4D + 1.7L W) W = wind load D. Deflections 1. Live load deflections were calculated by: = 5WL El W = uniform live load L = span length E = modulus of elasticity I = effective moment of inertia 2. Deflections shown are elastic short duration only. Upper limit of span lengths do not consider deflection limits for varying applications. General deflection limits are L/240 for roofs and L/360 for floors. E. Transportation and Erection 1. Handling designs assumes Swift Lift anchors cast in the top edge of walls and top of floors. 2. Panels 16 feet and longer require two Swift Lifts for walls and four for floors to be located in top surface of panel in ribs 4 feet from each end. -1-

4 REINFORCING AND DEFLECTION U.S. TABLES 6 FLOOR/ROOF PANEL -- f c = 5000 psi fy = 60,000 psi (grade 60 steel) Superimposed Load 20 psf 30 psf 40 psf 50 psf 100 psf FLOOR AND ROOF SPAN Reinforcing #3 #4 #5 #6 #8 Defl. (inches) Reinforcing #3 #4 #5 #7 #8 Defl. (inches) Reinforcing #3 #4 #6 #8 Defl. (inches) Reinforcing #4 #5 #6 Defl. (inches) Reinforcing #4 #6 Defl. (inches) FLOOR/ROOF PANEL -- f c = 5000 psi fy = 60,000 psi (grade 60 steel) Superimposed Load 20 psf 30 psf 40 psf 50 psf FLOOR AND ROOF SPAN Reinforcing #4 #4 #5 #6 #7 Defl. (inches) Reinforcing #4 #4 #5 #6 #7 Defl. (inches) Reinforcing #4 #4 #5 #6 #8 Defl. (inches) Reinforcing #4 #5 #6 #7 #8 * Defl. (inches) psf Reinforcing #4 #5 #7 #8 * Defl. (inches) * - Indicates shear reinforcement is required. DESIGN NOTES: 1. Design assumes fy = 60 ksi for all reinforcing. Area of reinforcing may be approximated at 1.5 times that shown if fy = 40 ksi. 2. Reinforcing shown above is for span direction only. 3. All panel designs require 6x6 W1.4xW1.4 welded wire fabric at middle of skin, and #3 bar at bottom of each non-span rib in 6 thick panels and #4 bar in non-span ribs of 8 panels. 4. Deflection design in chart is for superimposed loads only. Design assumes all loads other than panel weight are superimposed loads. 5. Panels over 12 feet long should be pre-cambered to minimize deflection. 6. Design information in these charts was derived utilizing ACI-SP and Defl

5 REINFORCING AND DEFLECTION U.S. TABLES 6 FLOOR/ROOF PANEL -- f c = 4000 psi fy = 40,000 psi (grade 40 steel) Superimposed Load 20 psf 30 psf 40 psf 50 psf 100 psf FLOOR AND ROOF SPAN Reinforcing #3 #5 #6 #8 Defl. (inches) Reinforcing #3 #5 #6 Defl. (inches) Reinforcing #3 #5 #7 Defl. (inches) Reinforcing #3 #6 #7 Defl. (inches) Reinforcing #3 #7 Defl. (inches) FLOOR/ROOF PANEL -- f c = 4000 psi fy = 40,000 psi (grade 40 steel) Superimposed FLOOR AND ROOF SPAN Load psf 30 psf 40 psf 50 psf Reinforcing #4 #4 #6 #7 #8 Defl. (inches) Reinforcing #4 #5 #6 #7 #9 Defl. (inches) Reinforcing #4 #5 #6 #8 Defl. (inches) Reinforcing #4 #6 #7 #8 * Defl. (inches) Reinforcing #4 #6 #8 * 100 psf Defl. (inches) Indicates shear reinforcement is required. DESIGN NOTES: 1. Design assumes fy = 40 ksi for all reinforcing. Area of reinforcing may be approximated at 0.67 times that shown if fy = 60 ksi (grade 60 steel). 2. Reinforcing shown above is for span direction only. 3. All panel designs require 6x6 W1.4xW1.4 welded wire fabric at middle of skin, and #3 bar at bottom of each non-span rib in 6 thick panels and #4 bar in non-span ribs of 8 panels. 4. Deflection design in chart is for superimposed loads only. Design assumes all loads other than panel weight are superimposed loads. 5. Panels over 12 feet long should be pre-cambered to minimize deflection. 6. Design information in these charts was derived utilizing ACI-SP and Defl

6 REINFORCING AND ALLOWABLE AXIAL LOAD U.S. TABLES 6 WALL PANEL -- f c = 5000 psi fy = 60,000 psi (grade 60 steel) Wind Speed Exposure Mph UBC Pressure UNBRACED WALL HEIGHT psf C C C D D Reinforcing B-#4 B-#4 B-#4 B-#5, T-#4 B-#5, T-#4 B-#6, T-#5 Load/plf 13,500 13,500 13,500 13,200 12,700 12,050 Reinforcing B-#4 B-#4, T-#3 B-#4, T-#4 B-#5, T-#4 B-#6, T-#5 Load/plf 13,500 13,500 13,200 12,700 12,050 Reinforcing B-#4 B-#5, T-#4 B-#5, T-#4 B-#6, T-#5 Load/plf 13,500 13,500 12,700 12,050 Reinforcing B-#5,T-#4 B-#6, T-#5 B-#6, T-#5 Load/plf 12,700 12,700 12,050 Reinforcing B-#5, T-#4 B-#6, T-#5 Load/plf 12,700 12,700 8 WALL PANEL -- f c = 5000 psi fy = 60,000 psi (grade 60 steel) Wind Speed Exposure Mph UBC Pressure UNBRACED WALL HEIGHT psf C C C D 66.4 Reinforcing B-#4 B-#4 B-#4 B-#5, T-#4 B-#5, T-#4 B-#6, T-#5 Load/plf 15,500 15,500 15,500 13,200 12,700 12,050 Reinforcing B-#4 B-#4 B-#4 B-#5, T-#4 B-#6, T-#5 B-#6, T-#5 Load/plf 15,500 15,500 15,500 12,700 12,050 15,200 Reinforcing B-#4 B-#4 B-#4 B-#6, T-#5 B-#6, T-#5 B-#7, T-#6 Load/plf 15,500 15,500 15,500 12,050 15,200 14,600 Reinforcing B-#5,T-#4 B-#5, T-#4 B-#5, T-#4 B-#6, T-#5 B-#7, T-#6 Load/plf 15,500 15,500 15,500 15,200 12, D T - Refers to reinforcing at skin side of each vertical rib. B Refers to reinforcing at bottom of each vertical rib. DESIGN NOTES: Reinforcing B-#5, T-#4 B-#5, T-#4 B-#6, T-#5 B-#7, T-#6 Load/plf 15,500 15,500 15,200 12, Design assumes fy = 60 ksi for all reinforcing. Area of reinforcing may be approximated at 1.5 times that shown if fy = 40 ksi. 2. All panel designs require 6x6 W2.9xW2.9 welded wire fabric at middle of skin, and #4 bar at bottom of each horizontal rib. 3. Allowable axial load assumes concentric loading with maximum.84 inch eccentricity from centroid of panel. 4. Design information in these charts was derived utilizing ACI-SP and

7 REINFORCING AND ALLOWABLE AXIAL LOAD U.S. TABLES 6 WALL PANEL -- f c = 4000 psi fy = 40,000 psi (grade 40 steel) Wind Speed Exposure Mph UBC Pressure UNBRACED WALL HEIGHT psf C C C D D Reinforcing B-#4 B-#4 B-#5, T-#4 B-#6, T-#5 B-#7, T-#6 B-#8, T-#7 Load/plf 10,600 10,600 10,600 10,600 9,700 9,300 Reinforcing B-#4 B-#5, T-#4 B-#5, T-#4 B-#6, T-#5 B-#7, T-#6 Load/plf 10,600 10,600 10,600 9,700 9,300 Reinforcing B-#5, T-#4 B-#5, T-#4 B-#6, T-#5 B-#7, T-#6 Load/plf 10,600 10,600 9,700 9,300 Reinforcing B-#5,T-#4 B-#6, T-#5 B-#7, T-#6 Load/plf 10,600 9,700 9,300 Reinforcing B-#6, T-#5 Load/plf 9,700 8 WALL PANEL -- f c = 4000 psi fy = 40,000 psi (grade 40 steel) Wind Speed Exposure Mph UBC Pressure UNBRACED WALL HEIGHT psf C C C D 66.4 Reinforcing B-#4 B-#4 B-#5, T-#4 B-#5, T-#4 B-#6, T-#5 B-#7, T-#6 Load/plf 12,800 12,800 12,800 12,800 12,800 11,700 Reinforcing B-#4 B-#5, T-#4 B-#5, T-#4 B-#6, T-#5 B-#6, T-#5 B-#7, T-#6 Load/plf 12,800 12,800 12,800 12,800 11,700 11,000 Reinforcing B-#4 B-#5, T-#4 B-#5, T-#4 B-#6, T-#5 B-#8, T-#7 Load/plf 12,800 12,800 12,800 11,700 11,000 Reinforcing B-#5,T-#4 B-#5, T-#4 B-#6, T-#5 B-#7, T-#6 Load/plf 12,800 12,800 11,700 11, D Reinforcing B-#6, T-#5 B-#6, T-#5 B-#7, T-#6 Load/plf 12,800 11,700 11,000 T - Refers to reinforcing at skin side of each vertical rib. B Refers to reinforcing at bottom of each vertical rib. DESIGN NOTES: 1. Design assumes fy = 40 ksi for all reinforcing. Area of reinforcing may be approximated at.67 times that shown if fy = 60 ksi (greade 60 steel). 2. All panel designs require 6x6 W2.9xW2.9 welded wire fabric at middle of skin, and #4 bar at bottom of each horizontal rib. 3. Allowable axial load assumes concentric loading with maximum.84 inch eccentricity from centroid of panel. 4. Design information in these charts was derived utilizing ACI-SP and

8 REINFORCING AND DEFLECTION METRIC TABLES 6 FLOOR/ROOF PANEL -- f c = 34,416 KN/m 2 fy = 412,992 KN/m 2 (grade 60 steel) Superimposed Load FLOOR AND ROOF SPAN Reinforcing 10 mm 12 mm 16 mm 20 mm 25 mm 1.0 KN/m 2 Defl. (cm) Reinforcing 10 mm 12 mm 16 mm 20 mm 25 mm 1.5 KN/m 2 Defl. (cm) Reinforcing 10 mm 16 mm 20 mm 25 mm 2.0 KN/m 2 Defl. (cm) Reinforcing 12 mm 16 mm 20 mm 2.5 KN/m 2 Defl. (cm) Reinforcing 12 mm 20 mm 5.0 KN/m 2 Defl. (cm) FLOOR/ROOF PANEL -- f c = 34,416 KN/m 2 fy = 412,992 KN/m 2 (grade 60 steel) Superimposed Load FLOOR AND ROOF SPAN KN/m 2 Reinforcing 12 mm 12 mm 16 mm 20 mm 25 mm Defl. (cm) KN/m 2 Reinforcing 12 mm 12 mm 16 mm 20 mm 25 mm Defl. (cm) KN/m 2 Reinforcing 12 mm 16 mm 16 mm 20 mm 25 mm Defl. (cm) KN/m 2 Reinforcing 12 mm 16 mm 20 mm 25 mm 25 mm * Defl. (cm) Reinforcing 16 mm 16 mm 20 mm 25 mm 5.0 KN/m 2 Defl. (cm) * - Indicates shear reinforcement is required. DESIGN NOTES: 1. Design assumes fy = 412,992 KN/m 2 for all reinforcing. Area of reinforcing may be approximated at 1.5 times that shown if fy = 275,328 KN/m 2 (grade 40 steel). 2. Reinforcing shown above is for span direction only 2. All panel designs require 6x6 W1.4xW1.4 welded wire fabric at middle of skin, and 10 mm bar at bottom of each non-span rib in 6 thick panels and 12 mm bar in non-span ribs of 8 panels. 3. Allowable axial load assumes concentric loading with maximum 2.2 cm eccentricity from centroid of panel 5. Panels over 3.7 meters long should be pre-cambered to minimize deflection. 6. Design information in these charts was derived utilizing ACI-SP and Defl

9 REINFORCING AND DEFLECTION METRIC TABLES 6 FLOOR/ROOF PANEL -- f c = 27,533 KN/m 2 fy = 275,328 KN/m 2 (grade 40 steel) Superimposed Load FLOOR AND ROOF SPAN Reinforcing 10 mm 16 mm 20 mm 25 mm 1.0 KN/m 2 Defl. (cm) Reinforcing 10 mm 16 mm 20 mm 1.5 KN/m 2 Defl. (cm) Reinforcing 10 mm 16 mm 25 mm 2.0 KN/m 2 Defl. (cm) Reinforcing 16 mm 20 mm 25 mm 2.5 KN/m 2 Defl. (cm) Reinforcing 16 mm 25 mm 5.0 KN/m 2 Defl. (cm) FLOOR/ROOF PANEL -- f c = 27,533 KN/m 2 fy = 275,328 KN/m 2 (grade 40 steel) Superimposed FLOOR AND ROOF SPAN Load Reinforcing 12 mm 12 mm 20 mm 25 mm 25 mm 1.0 KN/m 2 Defl. (inches) Reinforcing 12 mm 16 mm 20 mm 25 mm 1.5 KN/m 2 Defl. (inches) Reinforcing 12 mm 16 mm 20 mm 25 mm 2.0 KN/m 2 Defl. (inches) Reinforcing 12 mm 20 mm 20 mm 25 mm * 2.5 KN/m 2 Defl. (inches) Reinforcing 12 mm 20 mm 25 mm * 5.0 KN/m 2 Defl. (inches) Indicates shear reinforcement is required. DESIGN NOTES: 1. Design assumes fy = 275,328 KN/m 2 for all reinforcing. Area of reinforcing may be approximated at 0.67 times that shown if fy = 412,992 (grade 60 steel). 2. Reinforcing shown above is for span direction only. 3. All panel designs require 6x6 W1.4xW1.4 welded wire fabric at middle of skin, and 10 mm bar At bottom of each non-span rib in 6 thick panels and 12 mm bar in non-span ribs of 8 panels. 4. Deflection design in chart is for superimposed loads only. Design assumes all loads other than Panel weight are superimposed loads. 5. Panels over 3.7 meters long should be pre-cambered to minimize deflection. 6. Design information in these charts was derived utilizing ACI-SP and Defl

10 REINFORCING AND ALLOWABLE AXIAL LOAD METRIC TABLES 6 WALL PANEL -- f c = 34,416 KN/m 2 fy = 412,992 KN/m 2 (grade 60 steel) Wind Speed Exposure Km/h UBC Pressure UNBRACED WALL HEIGHT N/m C C C D D Reinf. (mm) B-12 B-12 B-12 B-16, T-12 B-16, T-12 B-20, T-16 Load (KN/m) Reinf. (mm) B-12 B-12, T-10 B-12, T-10 B-16, T-12 B-20, T-16 Load (KN/m) Reinf. (mm) B-12 B-16, T-12 B-16, T-12 B-20, T-16 Load (KN/m) Reinf. (mm) B-16, T-12 B-20, T-16 B-20, T-16 Load (KN/m) Reinf. (mm) B-16, T-12 B-20, T-16 Load (KN/m) WALL PANEL -- f c = 34,416 KN/m 2 fy = 412,992 KN/m 2 (grade 60 steel) Wind Speed Exposure Mph UBC Pressure UNBRACED WALL HEIGHT psf C C C D Reinf. (mm) B-12 B-12 B-12 B-12, T-10 B-16, T-12 B-20, T-16 Load (KN/m) Reinf. (mm) B-12 B-12 B-12 B-12, T-10 B-16, T-12 B-20, T-16 Load (KN/m) Reinf. (mm) B-12 B-12 B-12 B-16, T-12 B-20, T-16 B-25, T-20 Load (KN/m) Reinf. (mm) B-12 B-16, T-12 B-16, T-12 B-20, T-16 B-25, T-20 Load (KN/m) D T - Refers to reinforcing at skin side of each vertical rib. B Refers to reinforcing at bottom of each vertical rib. DESIGN NOTES: Reinf. (mm) B-16, T-12 B-16, T-12 B-20, T-16 B-25, T-20 Load (KN/m) Design assumes fy = 412,992 KN/m 2 for all reinforcing. Area of reinforcing may be approximated at 1.5 times that shown if fy = 275,328 KN/m 2 (grade 40 steel). 2. All panel designs require 6x6 W2.9xW2.9 welded wire fabric at middle of skin, and 12 mm bar at bottom of each horizontal rib. 3. Allowable axial load assumes concentric loading with maximum 2.2 cm inch eccentricity from centroid of panel. 4. Design information in these charts was derived utilizing ACI-SP and

11 REINFORCING AND ALLOWABLE AXIAL LOAD METRIC TABLES 6 WALL PANEL -- f c = 27,533 KN/m 2 fy = 275,328 KN/m 2 (grade 40 steel) Wind Speed Exposure Km/h UBC Pressure UNBRACED WALL HEIGHT N/m C C C D D Reinf. (mm) B-12 B-12 B-16, T-12 B-20, T-16 B-25, T-20 B-25, T-20 Load (KN/m) Reinf. (mm) B-12 B-16, T-12 B-16, T-12 B-20, T-16 B-25, T-20 Load (KN/m) Reinf. (mm) B-16, T-12 B-16, T-12 B-20, T-16 B-25, T-20 Load (KN/m) Reinf. (mm) B-20, T-16 B-20, T-16 B-25, T-20 Load (KN/m) Reinf. (mm) B-20, T-16 Load (KN/m) WALL PANEL -- f c = 27,533 KN/m 2 fy = 275,328 KN/m 2 (grade 40 steel) Wind Speed Exposure Mph UBC Pressure UNBRACED WALL HEIGHT psf C C C D Reinf. (mm) B-12 B-12 B-16, T-12 B-16, T-12 B-20, T-16 B-25, T-20 Load (KN/m) Reinf. (mm) B-12 B-16, T-12 B-16, T-12 B-20, T-16 B-20, T-16 B-25, T-20 Load (KN/m) Reinf. (mm) B-12 B-16, T-12 B-16, T-12 B-20, T-16 B-25, T-20 Load (KN/m) Reinf. (mm) B-16, T-12 B-16, T-12 B-20, T-16 B-25, T-20 Load (KN/m) D Reinf. (mm) B-20, T-16 B-20, T-16 B-25, T-20 Load (KN/m) T - Refers to reinforcing at skin side of each vertical rib. B Refers to reinforcing at bottom of each vertical rib. DESIGN NOTES: 1. Design assumes fy = 275,328 KN/m 2 for all reinforcing. Area of reinforcing may be approximated at.67 times that shown if fy = 412,992 KN/m 2 (grade 60 steel). 2. All panel designs require 6x6 W2.9xW2.9 welded wire fabric at middle of skin, and 12 mm bar at bottom of each horizontal rib. 3. Allowable axial load assumes concentric loading with maximum 2.2 cm inch eccentricity from centroid of panel. 4. Design information in these charts was derived utilizing ACI-SP and

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24 FOR MORE INFORMATION, WRITE OR CALL WAFFLE-CRETE International, Inc. P.O. BOX 1008 Hays, Kansas USA Ph: Fx: Web: waffle-crete.com & picturetrail.com/wafflecrete1