nl Pee Onc Pee eo meen for precast and prestressed concrete construction Pe te agar Cree tratteny Dc eRe CutsPCI Connections Manual for precast and prestressed concrete construc o o i 7 | Prepared by PCI Connection Details Committee Latbi Sonnour, PhD, P-E,, Chair Rashid Ahmed, P-E. Looi Bacreddino, PE, S.E, Lyle Bowman, P.E., S.E. Thomas Camp, P.E, Harry A, Chambers: Thomas J. DiAtcy, PE, SE Paul M. Douglas," P.E. James R. Gerla P-E. Robert Grosz, PE Pot Connections Manual Mohammad §. Habib, P-E, X, (Sharon) Huo, PhD, P.E, Hussam Faik Kakish, PhD, P.E, Kovin Kirkloy, PLE, Kenneth 8. Kowall,P.E., S.E, Fagjar |. Kusumo-Rahardjo,” Karen Laptas,* PLE, David Larsen, SE, “Jason P. Lien, PE ‘Andrew EN, Osborn, PE Gordon Samuelson," P.E, ‘Jerald A. Schneider, PE, SE ‘A Fatlah Shaikh, PhO, PE Kim Sorenson," PE. Sergio G. Lozada, PE, ‘Charles Magnesio, P.E. Todd G. McCoy, P.E, Barry N. McKinley, PE. Bradley E. Means," P.E. David Nasser," PE Irwin J. Speyer, PLE. Scott Winch, P.E. ‘Jagdish C. Nijnawan, PE ‘Michael G. Ova, PAD, PE David W. Omdortt, PE. ~ Past Chair *onaptr Chairo'o MINE 138-08 Copyright © 2008 By PrecasyPrestressed Conerete Institute All eights reserved, ‘This book or any part thereof may not be reproduced in any form without the writen ponnission of the PrcastPrestressed Concrete fate ‘Susana effort has been made to ensue that all data and information in this manual are accurate. However, PCI cannot accept esponsibility for any errs or oversights a the use of material or in the proparation of engineering plans. This publication is intended For use by personne! competent to evaluate the significance and linitations a ts contents and able to accept responsibility for the aplication of the material it contain. Special conditions on a project may equire more specific evaluation of practical engineering Judgement. While every effort has been made to prepare this publication asthe national standards for the industry, iti possible that dhere may be some conflicts between the material herein and local pructices. First Editon, 2008, ISBN 978.0.937040-76-8 Printed in the United States of America PI Connostions ManualTable of Contents CHAPTER 1—Introduction to Connections Ll to 1-22 1.1 Scope of Repott 3 TE I Gar eserere-e 484444 EAEEEEEEE E18 EOEE 9g EESEREE CEE SEnEE CEE SSS SPEECH cxeveo ace: mh a O 1.2 Standardization 13 1.3 Organization of Connections 13 1.4 Format 13 1.6 Connection Design Criteria 1.7 Erection Considerations 1.8 Protection of Plates 9 Connection Materials 1.1.9.1 General 1.1.9.2 Mechanical Couplers 1.1.9.3 Dowels 1.1.9.4 Welded Headed Studs and Deformed Bar Ai 1.1.9.5 Bolts and Threaded Connectors 1.1.9.5.1 Standard Bolts 1.1.9.5.2 High-Strength Bolts 1.1.9.5.3 Threaded Steel Rods 1.1.9.5.4 Coil Bolts and Rods 1.1.9,5.5 Post-Tensioning Rods 1.1.96 Iaserts (1.9.6.1 Primary Inserts 1.9.6.2 Secondary Inserts 1.1.9.7 Expansion Inserts 1.1.9.8 Resin Capsule Inserts 1.1.9.9 Structural Steel 1.1,9.9.1 Welding of Structural Steel 1.1.9.9.2 Galvanized Steel 1.1,9.9.3 Stainless Steel 1.19.94 Reinforcement 1.1.9.9.5 Welding Electrodes 1.19.10 Post-Tensioning Steel 1.19.11 Bearing Pads 1.1.9,12 Other Lond Transfer Materials 1.1.9.12.1 Cast-la-Place Concrete 1.1.9.12.2 Grout 1.1.9.12.2.1 Sand-Cement Grout Dry-Pack 1.1.9,12.2.2 Flowable Grout 1.1.9.12.2.3 Non-Shrink Grout 1.1.9.12.24 Epoxy Grouts 1,1.9.12.2.5 Epoxy Compounds 1.1.10 Structural Integrity [.2 Referenced Organizations 1.3 Referenced Standards 1.4 Quality Assurance LS Materials 1 L L 1.1.5 Limitations, IL 1 1 1 PCI Connections Manual 0-3eects ah *Q CHAPTER 2—Foundation Connections 2.1 Column to Footing Connection (Pinned/Partial Fixity) 2.2 Column to Footing Connection (Moment) 2.2.1 Mechanical Splice Connection 2.2.2 Socketed Connection 2.3 Double-Tee Wall to Continuous Footing 24 Double-Pee Wall to Stem Wall 2.5 Solid Wall Panel to Continuous Foundation 2.6 Solid Wall Panel to Stem Wall 2.7 Spandtel Wall to Continuous Foot 2.8 Spandret Wall to Continuous Footing (Moment) 2.9 Double Tee to Foundation Wall (No Topping) 2.10 Douible Tee to Foundation Wall (With Topping) CHAPTER 3—Beam to Colum, Double Tee to Spandrel Connections. 3.1 Inverted-Tee Beatn to Column (No Corbel) 3.2 Inverted-Tee Beam to Column (Corte) 3.3 Spandrel to Column (Loadbearing or Non-Loadbearing) 3.4 Column to Column (Splice Steeve) 3.5 Column to Column (Anchor Bolted) 3.6 Double Tee to tnverted-Tee Beum Connection (With Topping) 3.7 Protopped Tee to Inverted-Tee Beam (With Topping) 3.8 Double Tee to Steel Beam Connection 3.9 Double Tee to Spandrel (Loadbearing) 3.10 Double Tee to Spancrel (Bolted and Non-Loadbearing) 3.11 Double Tee to Spandire! 3.12 Double-Tee Flange to Flange CHAPTER 4—Double Tee to Wall Connections 4.1 Double Tee to Solid Wall (Londbearing/Welded), 4.2 Double Tee to Solid Wall (Non-Loadbearing/Sloted) 4.3 Double Tee to Solid Wall (Non-Loadbearing/Welded) 4.4 Double Tee to Double-Tee Wall 4.5 Double Tee to Masonry Wall (Loadbearing/Grouted) 4.6 Double Tee to Masonry Wall (Non-Loadbearing/Stotted) 4.7 Double Tee to Solid Wall With Pockets CHAPTER 5—Wali Pane! to Wall Panel Connections 5.1 Precast Concrete Wall to Wall (Inside Comer, Recessed Angie) 5.2 Precast Concrete Wall to Wall Inside Comer, Recessed Plate) 5.3 Precast Concrete Wall to Wall (Vertical Joint) 5.4 Precast Concrete Wall to Wall (Recessed Flat Plate Embed) 5.5 Precast Concrete Wall to Wall (Recessed Angle Embed) 5.6 Precast Conerete Double-Tee Wall to Double-Tree Wall (Inside Cornet) CHAPTER 6—Architectural Connections 6.1 Knife-Bage Support at Concrete or Steel Beam 6.2 Conerete Corbel at Concrete or Steel Beam 46.3 Adjustable Beating (Inverted Angle) at Concrete or Stee! Beam 644 Adjustable Bearing (Gusseted Angle) at Concrete or Steel Beam 6.5 Bolted Tieback to Concrete or Steel Beam 6.5.1 Bolted Tieback to Concrete 6.5.2 Bolted Tieback to Steel Beam 66 Steel Corbel at Conerete or Steel Beam 2-1 t0 2-108, 417 427 35 441 447 5-1 t0 5-68 S17 5.27 5.35 5-43 5-59 6-1 to 6-44 63 69 IS 6-21 6.27 6.29 633 637 ‘Pct Connections tanvalCHAPTER 7—Miscellancous Connections TA to 7-42 7.1 Double Tee to Double Tee (Steel/Conerete Beam Bearing) 13 7.2 Double Tee to Cast-in-Place Ramp ng 7.3 Double Tee to Masonry Wal 7.4 Grouted Dowel to Foundation Sleeve 723 7.8 Steel Joist 19 Double-Tee Wall 3.29 7.6 Expansion Joint, Pretopped Double-Tee-Flange Support 737 CHAPTER 8—General Design Information 81 0 8.68 8.1 Design Information 8.1.1 Dead Weights of Floors, Ceilings, Roofs, and Walls 8.1.2 Recommended Minimum Uniformly Distributed and Concentrated Live Loads 8.1.3 Beam Design Equations and Diagrams 8.14 Camber (Deflection) and Rotation Coefficients fer Prestress Force and Loads 8.1.5 Momtents in Beams with Fixed Ends 8.1.6 Torsion Diagrams, Reactions, and Rotations 8.1.7 Moving Load Placement for Maximum Moment and Shear 8.1.8 Moments, Shears, and Deflections in Beams with Overhangs 8.2 Material Properties 8.2.1 Table of Concrete Stresses. 8.2.2 Concrete Modulus of Elasticity as Affected by Unit Weight and Strength 8.2.3 Properties and Design Strengths of Presiressing Strand and Wire 8.24 Properties and Design Stronaths of Prestressing Bars 8.2.5 Typical Stress-Strain Curve, 7-Wire Low-Relaxation Presiressing Strand 8.26 Transfer and Development Lengths for 7-Wire Uncotted Strand 8.27 Reinforcing Bar Data 8.2.8 Location of Reinforcement Confined by Stirrups or Ties 8.2.9 Required Development Lengths for Reinforcing Bars 8.2.10 Common Styles of Structural Welded-Wire Reinforcement 8.2.11 Wire Used in Structural Welded-Wire Reinforcement 8.2.12 Bar Area Equivalents in a One-Foot-Wide Section 8.2.13 ACI Required Minimum Reinforcement Areas Fer Foot Width of Section 8.3 Standard Bolts, Nuts, and Washers 83.1 Dimensions of Nuts and Bolts 8.3.2 Dimensions of Standard Washers 8.4 Welding Information 8.4.1 Weld Symbols Commonly Used in Precast Conerete Construction 8.4.2 Typical Welded Joints in Precast Concrete Construction 8.4.3 Properties of Weld Groups Treated as Lines 8.5 Section Properties 8.5.1 Properties of Geometric Sections 8.5.2 Plastic Section Moduli and Shape Factors 8.6 Metric Conversion 8.6.1 Metric Calculations and Example 8.6.2 Conversion from U.S. Customary Uni 8.6.3 Preferred SI Units and U.S, Custom 8.6.4 Concrete Stress Cocfficients 8.7 Design Aids 8.7.1 Allowable and Desiga Stress for Fillet and Partial Penetration Welds 8.7.2 Strength of Fillet Welds for Building Construction 8.7.3 Minimum Length of Weld to Develop Full Strength of Bar Weld Parallel to Bar Length 8.7.4 Size of Fillet Weld Required to Develop Full Strexgth of Bar, One Side 8-65 8.755 Sice of Fillet Weld Required to Develop Full Streigth of Bar, Both Sides _ 8-66 8.7.6 Strength of Bolts and Threaded Fasteners 8-67 suico ones a sO to International System ry Equivalents Pi Connaatons Manuel 0-8wecctmene mh 8.7.7 High-Strength Coil Bolt and Coil-Threaded Rod Selection Chart 8.7.8 Strength of Connection Angles 8.7.9 Strength of Connection Angles 8.67 8-68 8-68 Pot conn tons MenuChapter 1 Introduction to Connections LL Scope of Report 1.1 General so 13 1.1.2 Standardization : 13 1.1.3 Organization of Conneetions 1.14 Format 1.15 Limitations i \ 1 1 1.6 Connection Design Criteria 1.7 Brection Considerations 1.8 Protection of Plates 1.9 Connection Materials 1.1.9.1 General oe 1.1.9.2 Mechanical Couplets «0 16 L193 DOWE!S eran eee 16 1.1.9.4 Welded Headed Studs and Deformed Bar Anchors 7 sew 1.9.5 Bolts and Threaded Connectors : ‘ \7 1.9.5.1 Standard Bolts : ia a La 1.1.9.52 High-Strength Bolts ee la 1.19.53 Threaded Steel Rods a o seowl-T 4 Coil Bolts and Rods La 1.9.5.5 Post-Tensioning ROWS wren sen sntinninnnnnninanenenel 1.1.9.6 Insests : : senntnnnnnnnmnane 1.1.9.6.1 Primary Inserts ... 7 1.1.9.6.2 Secondary Inserts -enenanan aa le aetna 1.1.9.7 Expansion Inseris 18 1.1.9.8 Resin Capsule Inserts nnn — 19 1.1.9.9 Structural Steet : re ee dD 1.1.9.9.1 Welding of Structural Stee! 19 1.1.9.9.2 Galvanized Stel .. eet teeaeeas 1-10 1.1.9.9.3 Stainless Steet 1 [1.9.9.4 Reinforcement Siren 12 1.9.9.5 Welding Electrodes ee ete 1-13 [1.9.10 Post‘Tensioning Steel 116 L911 Beating Pads... See eee penn AAT 1.9.12 Other Load Transfer Materials... LT L.9.12.1 Castin-Place Concrete sesyinnsnnnnn a ns 17 1.6.9.12.2 Grout Sete 7 7 Lit 1.1,9.12.2.t Sand-Cement Grout Dry-Pack Lay 1.1,9.12.2.2 Plowable Grout .. ny i i wna tHT 1.1,9.12.2.3 Non-Shrink Grout Lis 1.1.9.12.2.4 EpOKY GrOUS snnnnnin 7 118, 1.1,9.12.2.5 Epoxy Compounds 18 [1.10 Structural Integrity 19 1.2 Referenced Organizations 1.3 Referenced Standards 1.4 Quality Assurance 1.5 Materials Connections Manvel O.m sup1n9009 «4 vouCO. Pcl Connections ManuIntroduction to Connections LL Scope of Report 1.1.1 General Conneotions ave fundamental to all building and construction ‘ng matter what material is used. The purpose of a connection is to transfer load and provide stability, which means the design of connections is one of the most important steps in tho engincoring of precast/prestressed concrote structures, Standard precast concrete connections are the subject of {his report. Although the connections are noted as “typical precast concrete connections,” the manual does not limit ‘the designer or precast concrete producer to using oaly the connections shown in this report as long as the alternate connection satisties the objective of the design. ‘The designer must be well versed in all of the Factors that influence the determination of applied Joads and thus in the design of various connections. This roport takes a typical connection and establishes a nominal connection capacity. It is the responsibility of the designer to verify that the applied Toauls do nat exceed the given connection capacity under the given design assumptions, This report should be used by ‘an engincer who is familiar with structural mechanies ancl ‘who uses engineering judgment in applying these standard ‘connections to a specific structure. Note the term “designed by others” means designed by the engineer of record oF the ‘contractor—not the precaster. A typical desiga example is presented with each connection detail table in order to iMlostrate the design method used to arrive at a particular connection capacity. The capacities shown are maximum for the direction shown and the etfect of interaction should be considered where appropriate, jtandardization During the evolution of the precast/prestressed concrete \dustry, certain approaches for making connections have been found to satisfy the objectives of owners, contracto! precast/prestressed concrete manufacturers, and designers, ‘The objectives of a good connection combine practicality ‘and economy with sound desiga and therefore require an understanding of factors such as strength, serviceability, ductility, production techniques, erection techniques, aesth “This report categorizes and deseribes connections that the Committee believes have satisfied all the noted objectives ver several years of construction and use, ‘The connections shown in this epott perform well in seismic design categories A, B, and C. Special detailing and design C1 Connections Manual considerations will be required in seismic design categories D, E,and voscujoccoss am a mh 1.1.3 Orgai jon of Connections ‘The connections presented in this report are given in the following general categories: + Foundation Connections + Beam-Column, Double Tee-Spandret + Double Tee-Wall Connections + Wall Pane!-Wall Connections + Architectural Claddings Connections + Miscellaneous Connections + Scismic Connections Refer to the Table of Contents for a more detailed breakdown, within these groups. Although these categories are very broad, the members of the committes believe that the general layout of the text should be familiar to most readers. 1.1.4 Format ‘The connections depicted in this report show a simplified graphic schematic of the connection in the middle of a typical page with design assumptions on the upper left hand side, followed by the connection capacity table. Sample problems are presented with examples. 1.1.5 Limitations Some of the most important considerations in building design, such as building layout, configuration, and selection of types of precast members, are discussed in the PCI Design Handbook (6th edition). This report shovld be used as @ roference for the reader in determining which approaches to cerain connections are considered standaed by the ‘Committee. For any particular project, the designer should analyze the conditions specific to that project and determine if the standard connections shown in this report are desirable ‘or applicable, There may be several successful solutions to each connection problem, and the design methods and ‘examples included in this report are not the only acceptable ‘ones. The connections presented inthis repost, however, hhave satisied the noted objectives over several years of constiuetion and use Disclaimer: The Committee wants fo reiterate that this report is intended for use by those with an understanding of ‘engineering mechanics and structural design, and in no case should it replace good engineering judgment.ahh ‘Scape ot epact 1.1.6 Connection Design Criteria ‘The PCI Design Handbook (6th edition) is an aid for designing, fabricating, and constructing precast! prestressed concrete structures. Chapter 6, titled “Design of | Connections,” contains the following notable topics: + Loads and Load Factors + Connection Design Criteria + Connection Hardware and Load Transfer Devices: + Headed Conerote Anchor Design + Structural Steel Design + Welding Precast conerete connections must meet a variety of design and performance criteria, and not all connections are required to meet the same criteria, These criteria are: 1, Strength: A connection must have the strength to transfer the forces to which it wil be subjected during its lifetime, ineluding those caused by volume change and those required to maintain stability. Connections are usually designed with factored loads determined from the building analysis, Starting with the 2002 edition, ACI 318 has adopted load factors from ASCE 7, Chapter 2. Additionally, it is recommended that bearing connections be designed for a minimum horizontal tensile force acting parallel to the span of 0.2 times the factored dead load transferred at the bearing, unless a smaller value can be justified by using, properly designed bearing pads. To ensure that the overall safety of the connection is adequate, additional Over Load Factors (OLF) have historically been used by the industry. ‘The overload factors range trom 1.0 to 1.33. The need and magnitude of the overload! factor depends on the engineer's judgment and consideration of the mode of failure, the consequences of failure, sensitivity of the ‘connection to tolerances, and the requirements of focal codes. These overload factors are typically employed ‘on the welds and embeded anchors. Sirengrh reduction factor @ shall be as follows: Except for concrete anchorages and conerete corbels @ actors from ACI 318-02, seetion 9.3, are used: ‘Members designed as: Flexural controlled sn 0.90 Compression controled. 0.65 Shear and torsion, 0.75 Beating one 0.65 Strut-and:-tie models and struts, ties, nodal zones, and bearing areas in such models. son 05 ‘The phi factor for conerete corbels designed by the cantilever beam method as specified in ACI 318-02 section 11.9.3.1 sence OFS Conerete corbels designed in accordance with the ACT 318-02 section 119 vaso 095 ‘The phi factors for concrete anchorages are specified in seetion D4.4 of ACI 318-02, Headed Studs Tension nnnns OTS Shears 0.65 Post-installed anchors are required to be designed with phi factors that range from 0.45 to 0.75 ‘depending on sensitivity to installation and reliability ‘The phi factors for steel construction are specified in the AISC Manual for Steel Construction-Load and Resistance Factor Design (3rd edition). Structural Steel Sections: ‘Tension and Shear..n.n 0.90 Welds sn OTS, ‘Bolts and Threaded Fasteners... 075 Ductlity: This is the ability to undergo relatively large inelastic deformations prior to failure. In steuctures, ductility is usually measured by the amount of Adcformation between first yield and failure. Duetilty in the overall structure may result from the ductility of the stoctural members and/or their connections. In precast/ prestressed concrete structures, connection ductility ‘can be effectively used to contribute to the overall structure ductility. The connection ductility is achieved ‘by ensuring that various load transfer elements —such a deformed bar and headed stud anchors, welded ‘wire reinforcement, and other inserts—are adequately anchored in the concrete. In certain situations, such. as where member depth is limited, where inserts are located close to concrete member edges, and/ for where inserts ae located close 10 each other, ‘concrete failure may precede insert material failure. In such cases consideration should be given to provide supplementary reinforcement around the inserts, ‘Connection failures resulting From failure in concrete are typically britle and, as a general rule, should be avoided. Regarding calculations, capacity governed by concrete must be greater than capacity governed by steel when ductile connections are required Voiume Change Accommodation: Restcaint of ereep, shrinkage, and temperature change strains can cause large stresses in precast concrete members and their cornections, Much of the creep and sbrinkage will hhave typically taken place prior to making the final connection of precast concrete members; however, temperature change can also be pavticularly damaging in exposed structures such as parking structures, AU of| these Formations must be considered in the design. It is preferable if the connection allows some movement take place, thus relieving the stresses. Connections Manuel5. Durability: When exposed to weather, or used ‘corrosive environment, steel elements should be adequately covered by concrete oF be painted, epoxy coated, or galvanized, Stainless steel is sometimes used in corrosive environments, 6. Fire Resistance: Connections that could jeopardize the structure's stability if weakened by fire, should be. protected to the same degree as that requived for each, of the members they connect 7. Constructability: Phe following procedures should be followed when designing connections: + Standardize products or connections. + Avoid reinforcement and hardware congestion. + Check material and size availability + Avoid penetration of forms where possible. + Reduce post-stripping work. + Be aware of material sizes and limitations. + Consider clearances and tolerances. + Avoid non-standatd production and erection tolerances. + Use standard hardware items and as few different sizes as possible. + Use repetitive details. + Plan forthe shortest possible hoist hook-up time. + Provide for field adjustment. + Provide accessibility. + Use connections that are not susceptible to «damage in handling. + Consider how to to prevent shims or pads that transfer loads from “walking.” + Allow for adjustment after product is unhooked trom the crane, + Minimize weld heat buildup in the surrounding conerete, or allow for embed expansion, + Determine if special inspection is required For the ‘material and welding process 8. Acsiheties: The final appearance of the connection ‘must be kept in mind when designing. Designers should incorporate a visually pleasing final product into the design by keeping in mind production practices and erection methods, 9. _Seixmie Requirements: Connections located in regions ofthe structure where large inelastic displacements will develop during aseismic event are classified as seismic connections. Seismic design procedures assume enetgy dissipation by the formation of plastic mocha ‘When these mechanisms occur at inter-element joints connected by seismic connections, energy nustbe dissipated through inelastic deformations of these connections. Seismic engineering of structures may even be necessary in regions of low seismic mensity because the mass ofthe concrete stuctuees Pt Connections Manus! can generate significant lateral forces. Proper design of seismic conncetions is requiced to ensure the satisfactory performance of commonly used lateral loud resisting systems, 10. Tolerances: Tolerance may be defined asthe permitted variation from a specified dimension or quantity Tolerances are specified to allow controlled leeway in the fabrication of products and their installation due to economical and practical production, erection, and interfacing considerations. The designer must realize that normal fabrication, erection, and interfacing tolerances proclude the possibility ofa perfect fit in the field. The connection must satisfy structural integrity conceras to atccommodlte the specified project tolerances. 1 1 i i 1.1.7 Erection Considerations Designers should consider erection procedures when designing precast concrete connections. This is best done by consultation with the erection contractor early inthe design process. If more than one connection detail satisties structural requirement, the selected detail should be the one that expedites both production and erection, Details that are best suited for erection may require compromise of some production considerations. [f possible, the same onnection methods should be used throughout the project. For example, if some spandrols are botted tothe columns, all spandrels—loadbearing and non-Ioadbeating—should be bolted, Also the numberof different sizes of field connection hardware should be minimized. Pate sizes, weld sizes, and bolt sizos should be standardized as much as possible Connections should be designed so that a member can be tunlooked from the erane in the shortest amount of time. The following procedures pertaining to erection should be kept in mind when designing connections: + Plan for the shortest possible hoist hook-up time. + Provide for field adjustment. + Provide accessibility + Use connections that are not susceptible to damage from handling. Identily proper design, location, use, and restraint of shims. + Determine when to shim and when to dry-pack.. + Consider unbalanced loading due to loading on one side of member. + Determine temporary bracing/erection stability + entify location of welds. Practice has shown that when beating plates are welded to the support, excess stresses can build up due to shrinkage, creep, or loading. If this can affect stability, one must pay tention to detailing the welded members; that is, weld alternate ends of alternate tecs if the ends have to be welded to the supportoh oh seope of Reno 1.1.8 Protection of Plates Plates exposed on the surface of precast concrete units, particularly in parking decks where deicing salts ate used, should be protected by special coatings such as epoxy, zine- enriched paints, or galvanizing, Stainless steel may also be Utilized in corrosive environments, particularly in flange t0 flange connections in pretopped double-tee systems, Note that special care should be taken when galvanized assemblies are used in conjunction with mild steel reinforcement. When galvanized assemblies used, strict adherence to the practices given in ASTM A1S3 is mandatory to avoid possible strain-age embritdlement and hydrogen embrittlement 1.9 Comnection Materials 1.1.9.4 General A variety of hardware, including deformed bar and headed stud anchors, plain wire and coil inserts, structural shapes, bolts and threaded rods, and other materials are used in connections of members in precast concrete structures. In| ‘ordec to achieve specified strength, these picces of hardware must be properly anchored in the concrete. The anchorage is Figure 1.1.9.1. Mechanical Coupl. achieved by bond and/or bearing between the embed and the adjacent concrete. Some pieces of the more commonly used connection hardware are discussed in this section. 1.1.9.2 Mechanical Couplers Coupleis are mostly proprietary in nature and are available {or use in precast conerete connections. Typical examples are shown in Figure 11.9.1, Some couplers ate suitable for compression splices, while others ean be used as tension splices as well. Designs using these deviees should be based on the manufacturer's recommendations and applicable codes. 1.1.9.3 Dowels Reinforeing bars or stecl rods are frequently used as dowels ‘o connect precast concrete components. These dowels may be cast in one member and field placed and grouted into a preformed or predrilled hole in another member, or they may be field placed in both members. tn many applications, these dewels are placed vertically and used only for alignment, o to resist nominal shear loads, and thus may not require full tensile strength development. Occasionally, 8 dowel willbe required to resist tension. Tn this ease, the bar mus be sufficiently anchored o develop the equited High Strength dn Song Grout Packing Grout-Filled Sleeve ‘Thread-Detormed Bar Coupler Cola swaged See boas - Reducer Insert Metal-Filled Sleeve ~ Li extruded Wedge-Locking Coupler Tapered-Threaded Coupler steal Soper C1 Coanestions Manualtensile stength. However, the bond of the grout to the ‘concrete may control the embedment length. For most situations, ordinary sand-cement grout in drilled holes is unreliable under ditect tension loads. Therefore, larger preformed sleeves or special grouts such as epoxy mixtures are required 1.1.9.4 Welded Headed Studs and Deformed Bar Anchors Both of these materia are welded in a semiautomatic process. This process is an efficient and economical method by which anchorage of steel shapes to concrete can be achieved. The most common type of fastener for use in this process is the headed stud. The anchorage 0 conerete is provided by conerete bearing under the head of the stud. Deformed bar anchors are made from the same type of sicel as headed studs. Anchorage to concrete is achieved by deformations on the bar similar to reinforcing bars, except that the deformations are indentations rather than projections. Bond properties of deformed bars ate those of reinforcing bars. 1.1.9.5 Bolts and Threaded Connectors rious types of bolts and other threaded connectors are used in connections of precast concrete. The primary advantage of these devices is that they facilitate quick assembly and erection. The primary disadvantage is the close tolerance required for the placement of the connector and its receptacle, ‘The majority of the connections in precast concrete structures tend to be of the bearing type, where transfer is achieved with fasteners acting essentially as ‘dowels. On the other hand, friction-type connections transfer the load by the friction between the interconnected pacts, ‘The friction resistance capability is produced by the normal compressive force, which is in cur due to tensioning of the threaded fasteners, 1.1.9.5.1 Standard Bolts ‘Standard bolts are defined as those conforming to ASTM A307 specifications. Threads comply with the "Coarse ‘Thread Series” specification of ANSI BI.1(31). 119s. High-Strength Bolts High-strength bolts (ASTM A325 or A490) have been developed primarily for frition-type connections between stevetural steel members. They have more than 1wo times. the tensile strength of ASTM A307 bolts. Their application requires controlled tensioning of the fastener to develop sufficient force to prevent slipping of the connected pars Ci Connections Manval 1.1.95.3 Threaded Steel Rods ‘Threaded steel rods of various sizes are also used in precast cconciete connections. The most common application is for anchor bolts at column bases, yesccg mh mh 1.1.95. Coll Bolts and Rods Coil bolts and continuously threaded coil rods are popular items for both temporary and permanent connections of precast concrete. The threads are designed to fit the contour ofa elically wound wire coil insert, Because the threads are very coarse, they are not easily clogged or damaged, Coil bolts and rods are available in many sizes and lengths ‘up (020 fL (6 m), Because coil bolts and rods are not covered by standard specifications, itis suggested that the manufacturer's recommendation be used in desiga. 1.1.9.5 Post-Tensioning Rods Post-tensioning rods (usually conforming to ASTM A722 specilications) are also used to connect precast concrete ‘members. They can be used simply as bolts, or preferably prestessed, to resist uplift and/or shear forces created by lateral loads 1.1.96 Inserts A large variety of inserts are commercially avaiable For use ir precast concrete construction. Their strengths and application procedures are generally well defined. For discussion in this document, these are roferred to-as primary Inserts, Other types of inserts are used for temporury conditions, such as lifting and handling, or light loads, sueh as various shelf angle inserts. These are labeled as secondary insert ie 1 Primary Inserts Basically, these inserts include a receptacle to engage a connector, such as a bolt, and an element, such as a wire loop, for anchorage to concrete. Examples of these inserts are shown in Figure 1.1.9.2 and [1.9.3 ‘These inserts use one of the following three basic types of receptacles (Figure (1.9.4): 1, Standard Coil: A helically wound coil of wire that nut” into which a coil bolt or rod is threaded. forms a 2. Tapped Coil: The standard coil may be tapped to accept standard machine bolts, Due to the difficulties inherent in the tapping process, the cost of tapped coils ‘ends to be high, thus their use is infrequent, 3. Pernule or Welded Nut; This is for use with bolts ot rods with standard threads, The nuts are weldable and are of sufficient length to ensure that design loadoh oh Seace of Repo transfer to the anchor wires, The wires provide for the anchorage to concrete ‘The anchorage of wire inserts to concrete is achieved by engagement of the Loop in concrete (loop-type wire inserts, Figure 1.1.9.2) or by bond with concrete (open wire inserts, Figure 1.1.9.3). Failure of an insect may be due to either conerete failure or insert material failure. The lesser of the toro is taken as the in-place design strength, Ifthe insert is adequately anchored into the conerete and the anchorage wires are properly welded to the receptacle, the in-place strength of the insert is governed by the strength of, the wires or the receptacle capacity. Again, itis desirable to have the bolt or the wires govern the connection strength, because such failures are more predictable and ductile. For the open wire inserts, manufacturer's data including. the recommended safety Factors should be used in design, ‘The loop-type wire inserts may also be designed by using ‘manufacturers’ data. Alternately, the loop-type wire inserts can be investigated in a manner similar to that for the welded hheaded studs, wherein the strength governed by concrete failure is based on a shear cone. 1.1.9.6.2 Secondary Inserts A variety of inserts have been devised for lifting and handling of precast concrete members, suspension of ceilings, and for attachment of shelf angles. These inserts Figure 1.1.9.2 Loop-Type Wire Inserts are intended for temporary loads or for supporting light permanent loads. Their use for structural applications in primary connections is not recommended. Because ofthe large variety of inserts available, i is not feasible to include a comprehensive coverage inthis document, Reference to insert manufacturers’ catalogues is recommended for various applications and estimating loxd camying capabilities. 1.1.9.7 Expansion Inserts Expansion inserts are devices placed into hotes drilled in. hhardened conerete. The insert develops tensile and shear capacity when expanding parts of the insert are forced against the sides of the hole. This is usually done by tightening the connector bolt into the insert. All expansion anchors are propriety and examples are shown in Figute 1.1.9.5. Manufacturers have established the tensile and shear strengths of their devices by testing. At a ‘minimum, recommended embedment depth and the tensile ‘capacity agree well with the “shear cone” concept. However, due to the slip of the anchor inthe hole, deeper embediment ‘depth does not proportionally increase the anchor’s capacity. Because the expansion inserts thrust against the sides of the: installaton hole producing lateral pressures, the spacing between inserts and location with respect to edges of the member is critical. Manufacturer's recoramendations and —} mS = SP SP ae PCI Connections ManaICC Legacy or Evaluation Service repotts should be used in this regard, 1.1.98 Resin Capsule Inserts Resin capsule anchors or epoxy anchors are also used for attachment to hardened concrete. Like expansion anchors, they are placed in a hole drilled in the hardened co Resin anchors consist of two parts: crete. 1. A scaled glass capsule containing a premeasured amount of an aggregate suspended in synthetic resin and a separate vial within the eapsule containing the catalystinardener. AA threaded rod stud with a washer and nut. During the instalation the capsule is placed in the predrlled hole and the stud is driven into the capsule, thus breaking, it The resulting chemical reaction among resin, aggregate, crushed glass, and hardener forms a thick symthetic mortar that hones the stud to the conerete, Because the pullout strength is developed by resistance long the entire depth of the anchor, the strengths of these anchors are typically higher than those of similar si expansion anchors. Also, because of the full depth bonding, the resin capsule anchors are less likely to work loose under shock or vibration conditions than the expansion anchors. Resin capsule inserts are recommended for use as a threaded fastener only. They are not recommended for applications Figure 1.1.8.3 Open Wire Inserts where they are installed and welded to a steel shape. The hheat caused by the welding operation may cause degradation in the resin, which could affect the holding value and possibly cause the anchor to fail 1.1.99 Structural Steel Structural steel plates, angles, wide-flange beams, und other shapes are often used! in connections, 1.1.9.9.1 Welding of Structural Steet Welded connections are structurally efficient and easily adjust to varying field conditions, The strength of a welded connection depends on reliable quality and the compatibility of welding materials to the metals to be joined. Welding in temperatures below 32°F (0°C) may require preheating of materials to be joined because of the possibility of fractured welds. Surfaces to be welded, and surfaces adjacent to a Weld, should be uniform, free from fins, tears, cracks, and other discontinuities, and free from loose or thick seale, slag, rust, moisture, grease, or other foreign material that would preveat proper welding or produce objectionable fumes, Provide for expansion of cast-in plates caused by heating luring welding, ‘There are two types of group weld designs, These weld ‘group designs are described as: ‘The Flastie Vector Method (FVM) caleutates the resultant stress on a weld group due to applied loads. Typically, Figure 1 Standard Coil ‘Tapped Coll ‘Wold Nut (Ferrule) 'Pc1Conections Manual vodssjocdeag aml aahi three-dimensional configurations are evaluated against 1wo- dimensional weld geometry. The stress is calculated using a traditional mechanics of materials approach. This approach is typically used for out-of-plane loading. ‘The Instantaneous Center Method (ICM) calculates the resullant foad based on strength design. The weld stresses are functions of the rotational displacement about an instantaneous center. This analysis procedure is typically used for in-plane loading, Where deformations are a ‘concern, such as bearing, care should be used due to the nature of the analysis procedure. Depending on the geometry, the calculated capacity can be significantly greater than that provided by the EVM, “The Committee recognizes tne EVM to be conservative, and thus recommends the analysis of weld groups using this method. This recommendation should not deter an experienced designer from utilizing the ICM, as long as the designer recognizes the conditions that may cause aetual capacities to be less than calculated capacities. Refer to the PCI Design Handbook (6th edition for design methodology for both methods. 1.1.9.9.2 Galvanized Steel Galvanized metal is a material in which proper surface treatment must be used. One of the two following procedures should be used for ‘welding galvanized stec!: 1. Removal of galvanizing on mating surfaces and the use of standard welding procedures, The zine should be removed at least 2 10 4 inches from either side of the intended weld zone and on both sides of the workpiece, i possible, When galvanized stee! is welded, some of the zine is volatilized on each side of the weld and, while thin layer of zine-iron alloy remains, there is a loss in cor‘osion resistance. In the cases of zinc-rich painted stesl, welding causes decomposition ofthe paint film thal is burned off for some distance on each side of the ‘weld. The width of the damaged zone will depend on the heat input and preheat. Removal of the zine, where weld is to be placed, is the most conservative approach in welding galvanized steel. Welding procedures will then be the same as 1 Connections Mantfor uncoated steel. Zine ean be removed by burning with a carbon are or an acetylene torch while using. an oxidizing flame, by shot blasting with portable equipment, ot grinding with silicone carbide abrasive dlsks, 2. Leave the galvanized coating on the surface of the plates and weld using galvanized base metal with the thickest coating anticipated and qualified by test in accordance with ANSUAWS D1. | or AWS D1. ‘This welding procedure specification (WPS) will permit welding over surfaces with coatings equal to ‘or less than the coating used in qualification testing In general, to avoid zine penetration of the welds, this procedure should involve greater root openings in the joimts, electrodes with low silicon content, and slower welding speeds Ineither ease, the weld areas should be given a coat of zine rich pant (95% zinc) or epoxy paint immediately after welding and chipping of slag to replace the removed galvanizing. Hardware should be propesly cleaned prior to applying protective treatment, Special care shoutd be taken when welding in the vicinity of a bearing pad to avoid damage to the pad. Tn general, manual metal are welding procedures for galvanized stee! are similar to welding uncoated steel. However, welding galvanized steel generally requires that the welder receive specialized training, In addition, ‘qualifications of the welder and welding procedure using the thickest coating anticipate is strongly recommended. [Note the following points when welding galvanized steel: The welding electrode EXX10 and EXX 1S. should be applied slower than usual with a whipping action which moves the electrode Forward ‘to cinch along the seam in the direction of progression and then back into the molten pool. All volatilization of the galvanized coating should be complete before the bead progresses. This will prevent zine entrapment in the weld metal b. A short are length is recommended for welding. in all positions to give better control of the weld ‘pool and to prevent either intermittent excess penetration or undercutting. Slightly wider gaps, up 10 Ye inch, are required! in Du joints ora 15* angle on the edge of a standing. plate in order to give complete penetration. The Bap also allows for the zine and its pases to escape, and reduces cracking caused by restraint a tho coating thickness increases. Po} Connactions Manual 4. Weaving and multiple weld beads should be avoided. Heat input into the joint should be Kept 10 a minimum (o avoid undue damage to the adjacent coating. When welding galvanized steel, hydrogen-induced eracking ‘of the heat-affected rone may occur inthe base plate aujacent to the weld. The precautions necessary to avoid cracking include such measures as reduction in cooling rate ‘of the joint by the use of preheat or the use of large diameter clectiodes at high currents, The hydrogen content of a weld can be increased when it is deposited on galvanized or zine- rich primed stet, This extra hydrogen originates from the pickling process in galvanizing or from the decomposition products of primers. It may be necessary to cither remove primers from the vicinity of the joint before welding oF use higher preheating temperature than would be used on uncoated steel, vodayjoadcog muh om oath Zine-tich paints are available that have been specially Formulated such that it i not necessary to remove the coating from the weld path prior to welding. A letter should bbe obtained from the coating manufacturer stating it fo be “weldable.” Porosity will occur in certain weld joint designs in galvanized steel, depending on coating thickness, due to volatization ofthe zinc in the coating and entrapment of gas in the weld. The type of joint affects porosity formation because gases cannot readily escape from tee joints or from bute pints in thick materials In the ease of tee or butt joints, vee edge preparation or provision of a gap between the plates facilitates the escape of gases, minimizing porosity. Pore “ormation is also influenced by the thickness of the galvanized coating relative to the base material 1.1,9.9.3 Stainless Steel Wher welding stainless steel plates to other stainless steel pilates or to low-carbon steel, the general procedure For ‘welding low-carbon steels should be followed, taking into ‘account the stainless steel characteristics that differ, such as hhigher thermal expansion and lower thermal conductivity Welding of stainless steel should be done by qualified ‘welders familiar with the weld requirements of these alloys. Austenitic stainless steels are best welded without preheat ‘except to reduce shrinkage stresses on sections over If inch thick or on restrained joints. No peeleat, interpass temperature below 350° F (177° C), or a stinger-beud technique reduce the time the heat-etfected zone isin the sensitizing range (800 to 1400" F (30" C), thereby reducing the amount of carbide precipitation and warpage. Preheating will be necessary when earbon steel is to be welded or {cmperature of components to be welded is less than 32° F wo, 1-1oh "oh ‘Scope of Repo 1-12 Stainless welds are generally not as penetrating as those in ‘carbon steels and the weld metal is a bit more sluggish. This ‘means that the weld joints in stainless have to be a bit more ‘open to obtain penetration and fusion, For vertical and overhead positions, electrodes should be he in, (4mm) in diameter or less. For vertical welds on Ys in. (5 smi) thick plate or less, the weld should be vertically down using small beads; otherwise, on thicker plates, the tiangular ‘weave technique should be used welding vertically up Because of the relatively high coefficient of thermal expansion and lower thermal conductivity of austenite stainless steet, precautions should be taken to avoid weld bead eracking, minimize the distortion of stecl, and avoid cracking ofthe concrete. The following procedures may be used to minimize these problems Lower weld current consistent with sufficient penetration to reduce the heat input othe work b. Use skip-weld techniques to minimize heat concentration. Apply other cooling techniques to dissipate heat Use tack welding to hold the parts in alignment during welding &. Vary sequence of welding. 1. Keep edges of eastin stainless steel connection plates free from adjacent concrete to allow expansion during ‘welding without any spalling ofthe concrete. Surfaces to be welded should be sanded smooth, not ground, and all blue heat tint removed, Joints should be clean and diy. Moisture should be removed by heating oF by blowing with dry ai. Propared surfaces on which weld metal i 9 be deposited should be fice from organie contaminants, surface oxides or material discontinuities (for example, tears, Jaminations) that would affect the strength ofthe weldment; additionally the surface discontinuity limitations of AWS. D1. should be used asa guide In joining austenitic stainless steels to carbon steels or low- alloy steels, a stainless steel welding rod that is sufficiently high in total alloy content, such as Type 309 or 309L or other highty alloyed electrodes should be used. Buttering may he ‘an unnecessary and costly procedure. However, when joining austenitic stainless steel and carbon steel, it may be a good practice to butter the carbon stecl surface with a layer of ASTM Type 309 or other suitable stainless steel weld metal, such as ASTM Type 312, prior to actually joining it to the stainless steel. The portion of the joint where difficulties are most likely to oceuris buttered while there is little restraint ‘on the weld metal, Following the deposition and inspection of the buttered layer or layers, the joint between the stainless steel member and the buttered layer will be a conventional stainless steel to stainless steel joint. The welding electrode in this case cam be the type normally used to weld the stainless tee! member ofthe joint (.e., Type ASTM 308 iF the stainless steel membor is Type ASTM 304), Carbon steels with less than 0.20% carbon can normally be welded with austenitic fillers without preheat; but when the carbon is greater than 0.30%, temperature control is necessary. As alloy content increases, like, in the case of | ow-alloy steets, preheat control is usually essential, ‘The deposition of carbon steel or low alloy stee! weld metal ‘on stainless can result in hard, brittle weld deposits that frequently crack when deposited and woul likely fail in service. Weld procedure qualifications should be conducted ‘on all proposed combinations of base metal and electrodes to termine the extent to which this is a problem. When welds are made using tick electrodes (SMAW method), some spatter is normal, However, its easily removec by light grinding (alurinum oxide) or wire brushing, Spatter resistant compounds applied before welding reduces this annoyance. Cleaning time is reduced ot climinated when welding is dane using the inert gas process Welds and the surrounding area on stainless steel should be cleaned 2f weld spatter, lus, oF scale to avoid impairment ‘of corrosion resistance. Most welding flux or slag ean be chipped off, but itis beter to grind the ux off using lean grinding wheels. Sandblasting with clean silica sand is also an effective and economical way to remove slag. Stainless steel brushes and clean grinding wheels (wheels not contaminated with earbon stecl particles) should be used to clean stainless steel welds. A small piece of carbon steel), scale, copper, or foreign material lodged on stainless steel may become sufficient to destroy passivity atthe point of contact and eause rust staining and increased corrosion. Slag shal also be cleaned off to ascertain proper weld size and quantity 1.1.9.9.4 Reinforcement ‘When welding of reinforcement is used to make a connection, weldabilty characteristics of the reinforcement shouldbe considered, Ifrequied, minimum preheating and interpass temperatures for welding of reinforcing bars should consider the highest carbon equivalent numberof the base metal. The weldablity of stool established by its chemical analysis determines the applicable welding procedure and sets prea and iterpass temperature requirements. Staking an are outside ofthe weld area ofthe einfreing bar should be awoided, One practical method of preheating reinforcing bars and insert plates is to use an oscillating torch while measuring the preheat with a temperature level or heat-sensitive chalk. By using the torch, a localized preheated area can be obiaired simplifying the welding process. The entire plate or bar does nat need to be heated. Heat-sensitive Pt Connections Manualchalk is designed to change color or melt when the desired temperature is reached, If preheating is required, the reinforcing bar should be heated until the eross section of the bar is at or above the siniwum temperature for atleast 6 in. (150 men) on either ide ofthe joint. Surfaces of reinforcing bars to be welded and surfaces. adjacent to a weld should be free from loose or thick seale, slag, rust, moisture, grease, epoxy coating, or other foreign ‘material that would prevent proper welding or produce objectionable fumes. Mill scale that withstands vigorous wire brushing, «thin rust inhibitive coating, or anti-spatter compound, may remain, The ends of reinforcing bars in dlitect butt joints should be shaped to Form the weld groove by oxygen cutting, air carbon are cutting, sawing, or other ‘mechanical means. Bars for difect butt joints that have sheared ends should be trimmed back beyond the area deformed by shearing. Welding galvanized reinforcing bars, without prior removal of the coating, should be performed in accordance with AWS D4. Welding of galvanized metal may also be done after removing all coating from within 2 in, (50 mm) of the ‘weld joint. The galvanized coating should be removed with oxyfuel gas flame, abrasive shot blasting, or other suitable ‘When welding or preheating epoxy-coated base material, the epoxy coating should be removed from the surfaces to be heated. After welding, suitable protective coating (zine rich oF epoxy paint) should be applied to the finished joint to restore the corrosion resistance properties of the coated bars When reinforcing steel is welded to structural steel ‘members, the project specification for structural steel should apply. When joining different grades of stee, the filler metal should be selected for the lower streneth base metal Reinforcing bars shall not be welded within two bar diameters of the beginning point of tangency of a cold bend, ‘Typical reinforcing bar welds are shown in Figure 1.1.9.6, and improper and proper methods of welding reinforcing boars are shown in Figure 1.1.9.7. 1.1.9.9.5 Welding Electrodes Electrodes for shielded metal are welding (SMAW) should conform to the requirements on ANSVAWS DI.1, Section 4 or AWS DI, Seotion 5 (AWS A5.1 of AS.5). All clectrodes should be of a type suitable for the chemistry of the steel being welded. ‘The electrodes and the shielding for gas metal arc welding, (GMAW) or ux-cored are welding (CAW), for prod ‘weld metal with minimum specified yield strengths of 60 1% PC Connections Manus! ksi (415 MPa) or less should conform to the requirements of AWS A5.20 oF A5.29. Weld metal having a minimum specified yield strength ‘greater than 60 ksi (415 MPa) should conform to the following requirements: 1. The electrodes and shielding for GMAW for produ weld metal with a minimum specified yield strength ‘greater than 60 ksi (415 MPa) should conform to AWS 5.28, ng 2, ‘The electrodes and shiclding gas for FCAW for producing weld metal with a minimum specified strength greater than 60 ksi (415 MPa) should conform 1 AWS A5.20 and A5.29. Electrodes similar to those used for are welding uncoated steel san be used for welding galvanized steel, along with the same electrode size and eurrent. The major difference ‘when manval are welding galvanized steel compared 10 uncoated stel arises from the need for higher heat input to remove the zine from the weld pool and lower welding speed to bum oft as much ofthe zine coating as possible in ont of the weld pool. All low hydrogen electrodes conforming to AWS AS.1 should be purchased in hermetically sealed containers or should be cred for at least 2 hours at temperature between 500" F (260" C) anc 800° F (430° C) before they are used, if the container is damaged. Storage temperatures for 66010 and E6011 (high cellulosic type) electrodes are not critical but temperatures exceeding 125" # (52° C) should be avoided because these electrodes depend on a high percentage of moisture (6 to 7%) for favorable are characteristics. Over-baked or dried-out cellulosic electrodes result in low are force, low penetration, incomplete slag coverage, and porosity Of the various standard electrode covering types, low- hhydregen coverings are the most resistant to hydrogen induced cracking. These types of organic electrodes are produced with a minimum moisture content in theie coatings and ae given a high-temperature bake before packaging in hermetically sealed containers designed to provide adequate protection ftom exposure under normal conditions. Electrodes that have been in physical content with water, _gfease, or oil should not be used, and itis not recommended to re-bake these electrodes. These electrodes should be scrapped, ‘Condensation on covered electrodes will occur when cans ‘or cartons are opened prematurely ina relatively warm area after removal from storage in a welatively coo! atea ‘Containers should be allowed! to warm up to ambient temperature before opening in the welding location, Cartons, vodeycedoss mlb mahsooe ot Revert gull aah Figure 1.1.9.8 Typical Reinforcing Bar Welds — e2y__y¢ INS iO BAL ye oy aot Single-V-Groove Weld Double-V-Groove Weld Full Penetration Welds Note: AAs shown for no. 9 and larger reinforcing bars, no. 8 and smaller bars require appropriate backing, 1" = 1 in, = 25.4 mm AX Som Fillet Welds, eA Flare-V-Groove Welds 0.28, Section Flare-Bevel-Groove Welds PI Connections ManualFigure 1.1.9.7 Improper and Proper Methods of Welding Reinforcing Bars, Note: 1" = 1 in. =25.4mm, Pol of Ctatzabon Reinforcement Bar —/- r ZZ. (A) Improper 2x Bar Diameter | 2" Minimum (3" Preferred) Reinforcement Z Bars | |-— Point of Tangency (8) Proper ‘wil require more time than cans to equalize temperature due to the insulating effect of the cardboard. Welding with moist low-hydrogen electrodes leads to hydrogen-induced cracking, increased arc voltage, spatter loss, undescutting, and poor slag removal, in addition 19 porosity, underbead cracking, and general rough welds. ‘Therefore, all low hydrogen and stainless stool SMAW electrode coverings should be protected from moisture pickup. Electrodes packaged in hermetically sealed containers can be stored for several months without deterioration. However, electrodes should be dried as specified prior to use ifthe hermetically-sealed containers are damaged, improperly stored, ot for any reason the clectrodes are exposed ta high moisture conditions. Immediately after removal from hermetically-sealed containers or rom drying ovens, electrodes should be stored Jn holding ovens and held at emperatures of 250° F (120° C), Redry £70 electrodes that are not used within 4 hours, ERO series within 2 hours, E90 series electrodes 1 hour, or E100 series within 's hour, after removal led containers or from a deying or storage oven, in a drying oven before use. The manufactures of electrodes may warrant longer exposure periods based on tests, Blectrodes should be dried only once for any reason. Blectrodes that have boon wet should not be used, witi ‘When drying clectrodes, stack them in a maximum of three layers. The following methods of reconditioning works best: 1. Load electrodes into a preheated oven that does not exeeed 200° F (93° C). 1 Connsetions Manual 2. Increase to recommended temperature for conditioning (see Table 1.1.9) and hold for about ‘one hour. When oven temperature exceeds 500° F (260° ©), the heating rate should not exceed 300° F (150° ©) per hour, 3, Cool the oven to 150 to 200" F (66 10 93°C) before unloading electrodes. Table 1.1.9.4 Store as follows: Storage of Electrode Contents, we CPOeen | Reconditioning Cartons TMi Stool Diy atroom | Not (6010,6011) temp. Recommended ile Steel 100-175 F | 250-800" F (60°2,6013, (98-80"0) | (121-149" c) 7014,7024), ‘Milg Stee! 215-450" F | 700-800" F (Low Hydrogen, Low | 102-233" 0) | (371- 427° C) Alloy, EXX15,EXX16, Exx18) Stainless Steel AG! | 215-260" F | 400-600" F DO|AWS-16), (102-127° ¢) | (205-16" c) DC Lime(AWS-15) Steling(AWS-17) | 215-260" F | 350-425" F (102-127" cy | (177-219" 6) ‘The bond between the covering of the electrode and th wire can loosen if electrodes are loaded or unloaded at, or core 1 1 g :mh oh Seone of Report 1-16 close t, the baking temperate or ifthe baking cyel repeated indefinitely Only low hydrogen welding rods (EXX-X5, 6, or 8) should be Kept in an oven once removed from their air-tight container. Although they must not get wet, the coating of other rods (60-11) will be damaged if heated All tainfess steel SMAW electrode coverings are of the Jow-hydrogen type and must be protected from moisture Electrodes should be purchased in hermeticaly-sealed containers, which can be stored for several months without deterioration. ‘The hazacd of moisture pick-up isnot as great with cored wites as i is with covered electrodes. The low-hydrogen fill ingredients of cored wires are toa considerable extent protecied from nir by the tight wrapping ofthe steal sheath Novertheles, it is possible to damage the low-hydrogen character of cored wires by excessive exposure to moisture laden air. This is most likely o occur by overnight exposure to high humidity, Returning the partially used coil or spool of wire to its plastic bag when the wire will not be used for a period of time (for example, 8 hours oF more) is a siraple but effective means of preventing excessive exposure. When joining different grades of steel, the electrode should be selected for the lower strength base metal If the weld joint in @ low carbon, unalloyed steel cannot be ‘completely cleaned of scale, rust, paint, moisture, or dirt, an 6010 oF E601 | electroce should be used, except for steels having yields strengths in excess of 70 ksi. The E6010 and ODI electrodes are sources of large amounts of hydrogen and in high-strength steels, hydrogen-induced cracks may occur. ‘When welding stainless stel, itis necessary to select a welding rod that provides weld filler metal having corrosion resistance properties as nearly identical to the base metal as possible, or better. The characteristics of the weld metal are primarily dependent on the alloy content ofthe filer metal and to a lesser extent on the degree to which the molten weld ‘metal is protected from the environment, This protection is provided by the shielding gasses used in certain welding processes or by the action of chemical fluxes applied to welding rods. The greater amount of chromium and nickel in certain alloys, Type 308 for example, is useful in welding ‘Types 302 and 304 base metals and hence is standard for all the lower chromium-nickel base metals, While the same principal applies to Type 316, in thatthe miniryumn chromium is higher in the weld metal than the base metal, the designation of the filler metal isthe same, ‘The maxinwum diameter of electrodes should be + qin. (8 mm) for all welds made in the flat position, except root passes. + ‘Win. (6 mm) for horizontal fillet welds, + ‘Win. (6 mm) for root passes of fillet welds made in the flat position and groove welds made in the flat position ‘with backing and with a root opening of in. (6 mm) + ‘pin. (4 mm) for welds made with low hydrogen electrodes in the vertical and overhead positions. + fein, (5 mm) for root passes of groove welds and for allother welds not included above. DC electrodes (EXXX-15) operate on DC only, have good. penetration, produce fillets with a slightly convex profile, and are -ecommended for + Vertical and overhead welding and all-position applications such as pipe. The slag has a fast Jreeze characteristic, Root passes on heavy plate. ‘The larger throat section of the convex bead helps prevent cracking, + Austenitic stainless welds that cannot contain any ferrite. AC-DC electrodes (EXXX-16) ae always used on DC ‘when this type of power is available, The fillet profile is flat to slightly concave, the weld surface is smoother, and the penetration i less than with EXXX-15 (DC only) electrodes. ‘The larger amount of slag requires more care to avoid slag, inclusions. These electrodes are recommended for horizontal fillets and forall fat position welding. EXXX-16 electrodes te also used in all positions by skilled welders If ASTM Type 304 stainless stels are thick enough to require multiple pass welds, carbide precipitation, which can cause intergranular corrosion, is likely to occur. Extra low-carbon plate (less than 0.03%) ASTM 304L., and electrodes such a5 308L should be used to minimize carbide precipitation, One of the most common dissimilar metal weld ‘combinations is Type 304 stainless to a low carbon or mild steel. High alloy filler metal such as Type 309 or Type 312 should be used so as to resist cracking or fissures. Electrodes for welding copper silicon (silicon bronze) ancl ‘copper aluminum (aluminum bronze) should conform to AWS AS.6 0F AST, 1.1.9.10 Post-Tensioning Steel Post-tensioning is often used in connections, particularly those that are subjected fo high tensile Forces, such asthe ‘comections in moment resisting frames. Post-tensioning, is accomplished using either 7-wire sand (ASTM A416) cor bars (ASTM A722). Typically, a 15 to 20 f length is desirable for this purpose, although shorter lengths can be Pet Connections Manus!