R-Group Finland Oy REA Lifting Inserts Technical Manual According to Eurocodes, EU Machinery directive 2006/42/EC and VDI/BV-BS 6205 CE Approved 10.2.2017
2 Table of Contents 1 DESCRIPTION OF THE SYSTEM... 3 1.1 Manufacturing markings... 3 1.2 Quality control... 3 2 LIFTING SYSTEM PARTS... 4 2.1 Lifting insert... 4 2.1.1 REA Lifting Insert Dimensions... 4 2.1.2 Lifting insert materials and ordering code... 5 2.2 Quick lift clutch... 5 2.2.1 Use of quick lift clutch... 6 2.3 Rubber recess former bayonet... 7 2.4 Holding plate... 8 2.5 Holding screw... 8 3 SAFE WORKING LOADS... 9 3.1 Design concept... 9 3.2 Safe working loads... 10 3.2.1 REA lifting inserts safe working loads... 10 3.3 Concrete thickness and insert spacing in wall elements... 11 3.4 Reinforcement of the pre-cast element... 11 3.5 REA lifting insert reinforcement... 12 3.5.1 Axial pull reinforcement... 12 3.5.2 Diagonal pull reinforcement... 13 3.5.3 Tilting reinforcement... 14 3.6 Actions on lifting inserts... 15 3.6.1 General... 15 3.6.2 Number and actions of lifting inserts... 15 3.6.3 Statical system... 15 3.6.4 Load distribution for non-symmetrical insert layout... 18 3.6.5 Spread angle... 19 3.6.6 Self-weight... 20 3.6.7 Adhesion and form friction... 20 3.6.8 Dynamic actions... 21 3.6.9 Load condition erection in combination with adhesion and form friction 21 3.6.10 Load condition erection... 24 3.6.11 Load condition lifting and handling under combined tension and shear... 26
3 1 DESCRIPTION OF THE SYSTEM REA lifting inserts systems manufactured by R-Group Finland Oy are lifting anchors consisting of flat steel inserts, ribbed steel anchor bars and rapid release lifting keys. REA lifting anchors enable lifting of columns, beams, walls and other pre-cast concrete elements. REA lifting inserts can be used in all lifting directions and for lifting angles up to 90 degrees. REA lifting inserts are designed and manufactured in accordance with EU Machinery Directive 2006/42/EC and VDI/BV-BS 6205. Lifting inserts meet the requirements for safe lifting and handling of concrete elements. 1.1 Manufacturing markings REA lifting inserts are marked with R-Steel logo, type and load class of lifting insert and CE-marking. 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, CE marking and product picture. 1.2 Quality control Quality control of the inserts is done according to the requirements of the Finnish Code of Building Regulations 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 2 LIFTING SYSTEM PARTS 2.1 Lifting insert 2.1.1 REA Lifting Insert Dimensions Figure 1. REA lifting inserts dimensions Table 1. REA lifting inserts dimensions Load group 2.5 5.0 10.0 26.0 Lifting insert H B D T C E [mm] [mm] [mm] [mm] [mm] [mm] REA 1.4 200 55 6 45 14 10 REA 2.5 230 55 10 45 REA 4.0 270 70 12 66 18 10 REA 5.0 290 70 15 66 REA 7.5 320 95 15 88 26 15 REA 10.0 390 95 20 88 REA 12.5 500 148 20 89 REA 17.0 500 148 35 25 15 89 REA 22.0 500 148 30 89 Lifting devices and recess formers are designed to be compatible with each load class and type of REA lifting inserts. Compatible lifting devices and recess formers see following sections.
5 2.1.2 Lifting insert materials and ordering code Lifting insert type Material Standard REA S355J2 EN 10025 RHA and REA lifting inserts are available in two surface finishes. Standard delivery surface finish is black (uncoated). Lifting inserts are also available as electro zinced. Ordering codes: REA 2.5 REAZ 2.5 Standard lifting insert (uncoated) Electro zinced lifting insert 2.2 Quick lift clutch Figure 2. Quick lift clutch The lifting clutch is made of special steel casting. The lifting bolt of the quick lift clutch is inserted into the hole of the lifting insert and can be easily and quickly removed after lifting. Table 2. Quick lift clutch Part no (Ordering code) Load group 2.5 5.0 10.0 26.0
6 2.2.1 Use of quick lift clutch Figure 3. Use of quick lift clutch Engagement Quick lift clutch in inserted into the recess formed in the concrete and the locking bolt A is closed manually. When closing the locking bolt it must be ensured that the quick lift clutch is fully engaged and the locking bolt is flush with concrete surface. Lifting The quick lift clutch system can be subjected to loads in any direction and no extra or special parts are required for angled lifts and tilting. It is essential to follow the instructions regarding rebars in concrete in section 3. Once the ring
7 clutch has been engaged in the anchor, the shackle can move in any direction, even under load. Release To release the quick lift clutch from the lifting insert, shift the locking bolt back by hand. This will release the lifting clutch. Marking Every quick lift clutch is marked with the load capacity and a serial number. Clutches should be examined regularly and re-tested annually. 2.3 Rubber recess former bayonet Recess former fort fixing with holding screw for mounting plate or bayonet fixing. Figure 4. Rubber recess former bayonet Table 3. Rubber recess former ordering codes and dimensions Part no (Ordering code) Load a b c Thread group [mm] [mm] [mm] 2.5 43 104 45 M8 5.0 49 126 59 M8 10.0 67 188 85 M12 26.0 112 223 121 M16
8 2.4 Holding plate For fastening of the recess former onto the formwork. Figure 5. Holding plate Table 4. Rubber recess former ordering codes and dimensions Part no (Ordering code) Load group a [mm] b [mm] c [mm] 2.5 73 15 4 5.0 85 30 4 10.0 128 40 6 26.0 178 65 8 2.5 Holding screw For fastening of the recess former through the formwork. Figure 6. Holding screw Table 5. Holding screw ordering codes and dimensions Part no (Ordering code) Load group l [mm] m [mm] 2.5 160 M8 5.0 160 M8 10.0 160 M12 26.0 180 M16
9 3 SAFE WORKING LOADS 3.1 Design concept Safe working loads of REA lifting inserts are calculated according to following standards and instructions: EN 1992 EN 1993 Machinery directive 2006/42/EC VDI/BV-BS 6205 Global safety factors used in calculation of safe working loads are Steel failure γ = 3,0 Concrete failure γ = 2,5 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.
10 3.2 Safe working loads 3.2.1 REA lifting inserts safe working loads Figure 7. Lifting insert load directions Safe working loads of REA lifting inserts are given in Table 6. Safe working loads are applicable with concrete thickness and insert spacing according to section 3.3 and lifting insert reinforcement according to section 3.5. Table 6. REA lifting inserts safe working loads Lifting insert Safe working loads (SWL) [kn] β = 0-15 β = 15-45 γ = 0-10 γ = 10-90 REA 1.4 14 14 14 7 REA 2.5 25 25 25 12.5 REA 4.0 40 40 40 20 REA 5.0 50 50 50 25 REA 7.5 75 75 75 37.5 REA 10.0 100 100 100 50 REA 12.5 125 125 125 62.5 REA 17.0 170 170 170 85 REA 22.0 220 220 220 110
11 3.3 Concrete thickness and insert spacing in wall elements Figure 8. Minimum element thickness and lifting insert spacing Safe working loads are valid only with minimum concrete thickness and minimum lifting insert spacing given in Figure 8 and Table 7. Table 7. Minimum element thickness and minimum lifting insert spacing in wall elements Lifting insert Minimum concrete thickness TC [mm] Minimum lifting insert edge spacing EL [mm] Minimum lifting insert centre spacing CL [mm] REA 1.4 100 250 500 REA 2.5 120 300 600 REA 4.0 150 350 700 REA 5.0 160 375 750 REA 7.5 175 600 1200 REA 10.0 240 600 1200 REA 12.5 260 750 1500 REA 17.0 300 750 1500 REA 22.0 360 750 1500 3.4 Reinforcement of the pre-cast element The concrete element must have at least minimum reinforcement according to EN 1992-1-1. 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.
12 3.5 REA lifting insert reinforcement 3.5.1 Axial pull reinforcement Figure 9. REA lifting insert reinforcement for axial pull REA lifting inserts must always have anchoring reinforcement 1 according to Figure 9 and Table 8. This reinforcement transfers the load from the lifting insert to the concrete. Anchoring reinforcement must be installed in to the hole in the lifting insert and it must be in direct contact with lower edge of the reinforcement hole in lifting insert, see Figure 10. Figure 10. Placing of REA lifting insert reinforcement in hole Additional surface reinforcement 2, stirrup reinforcement 3 and edge reinforcement 5 must also be placed at the lifting insert area. These reinforcements may be replaced by structural reinforcement in concrete element, providing the structural reinforcement has sufficient cross-section area and overlap lengths.
13 Table 8. REA lifting reinforcement for axial pull Lifting Anchor reinforcement Mesh Edge Stirrup reinforcement 3 insert 1 reinforcement 2 reinforcement 5 Diameter Length Diameter Length Diameter Both surfaces n øs1 Ls1 [mm [mm] [mm] øs3 Ls3 øs5 / m] [pcs] [mm] [mm] [mm] REA 1.4 10 400 2 6 300 8 131 REA 2.5 12 500 4 6 300 8 REA 4.0 16 650 4 8 450 10 131 REA 5.0 16 700 4 8 450 10 REA 7.5 20 900 4 10 500 12 188 REA 10.0 25 1000 4 10 500 12 REA 12.5 28 1200 4 12 550 16 REA 17.0 28 1450 257 6 12 550 16 REA 22.0 28 1550 6 12 550 16 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. 3.5.2 Diagonal pull reinforcement In addition to axial pull reinforcement the lifting inserts must be reinforced for diagonal pull if the lifting angle β is greater than 15. Diagonal pull reinforcement 4 is given in Figure 9 and Table 9. Reinforcement given in Table 8 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 9. Bending diameter D should be same as the width a of the recess former for tight fit. Table 9. REA lifting reinforcement for diagonal pull Lifting Diagonal pull insert reinforcement 4 Diameter Length Ls4 øs4 [mm] [mm] REA 1.4 6 400 REA 2.5 8 500 REA 4.0 10 650 REA 5.0 12 700 REA 7.5 16 900 REA 10.0 16 1000 REA 12.5 20 1100 REA 17.0 20 1350 REA 22.0 28 1600
14 3.5.3 Tilting reinforcement REA lifting inserts can be used for tilting of concrete elements (load angle γ = 0-90 ). For tilting and lateral pull REA lifting inserts must be reinforced with lateral pull reinforcement 5 according to Figure 11 and Table 10. Reinforcement given in Table 8 must always be present for lateral pull. There are semi-circular notches on both sides of REA lifting inserts which help with the placement of lateral pull reinforcement. Lateral pull reinforcement must be placed in direct contact with the lifting insert. Figure 11. REA lifting insert tilting reinforcement Table 10. REA lifting reinforcement for lateral pull Lifting Lateral pull insert reinforcement 6 Diameter Length Ls6 øs6 [mm] [mm] REA 1.4 10 700 REA 2.5 12 800 REA 4.0 14 900 REA 5.0 16 1000 REA 7.5 20 1200 REA 10.0 20 1500 REA 12.5 25 1500 REA 17.0 25 1800 REA 22.0 25 1800
15 3.6 Actions on lifting inserts 3.6.1 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). 3.6.2 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 3.6.3 to 3.6.11. 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 E SWL where E action on lifting insert, see sections 3.6.3 to 3.6.11, 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. 3.6.3 Statical system Lifting equipment used in lifting of pre-cast elements shall allow determinate load distribution to all present lifting inserts. Figure 12 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.
16 Figure 12. 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 13. 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 tension and shear loads. The inclination β according to Figure 13 governs the level of combined tension and shear loads to be taken into account in the design.
17 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 14) it is ensured that all three lifting inserts experience the same load. Figure 14. 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 = 3.
18 3.6.4 Load distribution for non-symmetrical insert layout Figure 15. Load distribution for non-symmetrical insert layout using spreader beam If the inserts are not installed symmetrically to the load s centre of gravity, the load distribution to different inserts is F A = F G b/(a + b) F B = F G a/(a + b) 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.
19 3.6.5 Spread angle Influence of spread angle on the actions for lifting inserts must be taken into account. Table 11. Spread angle factors Cable angle β Spread angle α Load factor z 0-1,00 7,5 15 1,01 15 30 1,04 22,5 45 1,08 30 60 1,15 37,5 75 1,26 45 90 1,41 Figure 16. Spread angle factors
20 3.6.6 Self-weight The self-weight FG of pre-cast elements shall be determined as F G = V ρ G where V volume of the pre-cast element, in m 3 ρg density of the concrete, in kn/m 3 3.6.7 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 F adh = q adh A f 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.
21 3.6.8 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 by the dynamic factor ψdyn. For further guidance values of ψdyn depending on the lifting machinery and characteristics of the terrain are given in Table 13. Table 13. Dynamic factor ψ dyn Condition Tower crane, portal crane, mobile crane Dynamic factor ψdyn 1,3 Lifting and moving on flat terrain 2,5 Lifting and moving on rough terrain 4 Note: Other values of ψdyn 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 the factor ψdyn shall be determined on the base of tests or engineering judgement. 3.6.9 Load condition erection in combination with adhesion and form friction Figure 17. Erection in combination with adhesion and form friction When pre-cast elements are lift from form according to Figure 17 the action FQ on lifting inserts is F Q = (F G + F adh ) z/n where
22 FQ FG Fadh z n load acting on individual lifting insert, in kn self-weight of the pre-cast element, section 0, in kn action due to adhesion and form friction, section 3.6.7, in kn factor for combined tension and shear, z = 1 / cos β, angle β in accordance with Figure 17. In case of only tension z = 1. number of lifting anchors carrying the load. Figure 18. Erection in combination with adhesion and form friction, lifting with balancing beam When pre-cast elements are lift from form according to Figure 18 the action FQ on lifting inserts is F Q = ( F G 2 + F adh)/n where FQ load acting on individual lifting insert, in kn FG self-weight of the pre-cast element, section 0, in kn Fadh action due to adhesion and form friction, section 3.6.7, in kn n number of lifting anchors carrying the load.
23 Figure 19. Erection in combination with adhesion and form friction, lifting with chains When pre-cast elements are lift from form according to Figure 19 the action FQ on lifting inserts is F Q = ( F G 2 + F adh) z/n where FQ load acting on individual lifting insert, in kn FG self-weight of the pre-cast element, section 0, in kn Fadh action due to adhesion and form friction, section 3.6.7, in kn z factor for combined tension and shear z = 1 / cos β, angle β in accordance with Figure 19. n number of lifting anchors carrying the load.
24 3.6.10 Load condition erection 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 20. element erection with balancing beam Erection with balancing beam (Figure 20), action on lifting insert is F Q = ( F G 2 ) ψ dyn/n 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 0, in kn ψdyn dynamic factor, section 0 n number of lifting anchors carrying the load.
25 Figure 21. Element erection with chains For transverse shear (lifting according to Figure 21) action on lifting insert is F QZ = F G ψ dyn z/n 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 0, in kn ψdyn dynamic factor, section 0 z factor for combined tension and shear z = 1 / cos β, angle β in accordance with Figure 21. n number of lifting anchors carrying the load.
26 3.6.11 Load condition lifting and handling under combined tension and shear Figure 22. Lifting and handling under combined tension and shear The load condition lifting and handling under combined tension and shear is presented in Figure 22. This is the most common lifting procedure. Action on lifting insert is F Z = F G ψ dyn z/n 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 0, in kn ψdyn dynamic factor, section 0 z factor for combined tension and shear z = 1 / cos β, angle β in accordance with Figure 22. n number of lifting anchors carrying the load.