Arup - PT Design Notes
Arup - PT Design Notes
Design Guide
Post Tensioned Floor Construction
REP/0001
Issue | January 2011
Arup
Arup Pty Ltd ABN 18 000 966 165 This report takes into account the particular
Arup instructions and requirements of our client.
Level 10 It is not intended for and should not be relied
201 Kent Street upon by any third party and no responsibility is
Sydney undertaken to any third party.
NSW 2000
Australia
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2 Scheme Design 4
2.1 Selection of Concrete Sizes 4
2.2 Determination of load to be balanced 8
2.3 Selection of Level of Prestress 9
2.4 Practical design approach 9
6 References 18
1 Advantages and Disadvantages of Post-
Tensioned Concrete Floors
The use of post-tensioned (PT) concrete in buildings has been consistently growing over
the past three decades in Australia and has become the most common form of
construction for the floors and roofs of buildings. The main advantages of post-tensioned
concrete floors over conventional reinforced concrete (RC) in-situ floors include the
following:
Floor construction cycle time reduced - due to less tonnage of steel craned, less
labour and early stripping of formwork.
Reduced floor depth for a given span, resulting in reduced storey height and hence
savings in building height and façade costs.
Larger spans achievable providing greater flexibility for architectural planning.
Construction of lighter buildings overall with smaller columns and substantial
savings in foundations.
Better control of cracking under service conditions.
More permanent floor joints and façade joints required in comparison to similar
size RC floor and extra temporary joints or pour strips required during
construction stage - resulting in higher costs.
PT floors are potentially less flexible in accommodating future penetrations
through the floor.
PT floor design may not be economical in the case of large floor plates with
multiple stiff elements (e.g. lift cores, staircases etc).
2 Scheme Design
2.1 Selection of Concrete Sizes
Initially the trial depth for slabs and band beams may be selected by means of simple
span to overall depth ratios (L/D).
For prestressed slabs in order to fit anchorages within the depth of the slab and eliminate
eccentricity of prestressing force, a minimum depth of 150mm or an edge thickening is
required.
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For banded slab systems, the clear span (L) is taken as the distance from edge to edge of
the band tapers plus the thickness of the slab except in end spans where it is measured
from the discontinuous column centerline to the band taper plus slab thickness. (see
diagram below)
For all other systems, use L as the distance between centerline of the supports. It is not
uncommon to thicken the slab in end spans. The most economical design will be
achieved if the end span length is reduced to about 80% of the length of the internal spans
and all slab depths made equal.
Band beams are commonly proportioned by using L/D = 25-30 where L is the larger of
the span lengths in either direction. An increase in these ratios may be obtained by
stiffening up the band beam across the support. This is done by providing a "drop-panel"
like deeper beam section extending, say L/6, each way into the span (L based on the
longer span). For ease of construction, keep the width of the thickening the same width as
that at the soffit of the beam. Whilst this system is structurally efficient it should be noted
that drop-panels are becoming less popular as they complicate the formwork and are
therefore labour intensive.
The web width of the band, measured at the slab soffit, is sized as 0.20-0.25 times the
transverse span width. This dimension is rationalized to suit standard plywood sheets i.e.,
1200, 1800, or 2400 mm. For long span bands (in either Direction) consideration should
be given to introducing a taper on the sides of the band beam. The width of the taper
should also suit standard plywood sheets (600 or 1200). Again, whilst tapers are efficient
they are labour intensive and are becoming less popular with builders.
The flange width of bands may be calculated from the smaller of:
The effective flange width formula for beams even though the band is designed
more as a wide slab than a beam.
The columns strip width as if it were a two-way slab.
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Prestressed beams may have their depth initially be proportioned by: L/D = 25 to 30 and
width calculated according to strength requirements.
A set of typical span/depth ratios for a variety of types of multi span floors has been
reproduced below from the Post-tensioned Concrete Floors – Design Handbook,
Technical Report No 43 by the Concrete Society. However it should be noted here that
the ratios for band beams are too conservative and the 25-30 ratio given above provides a
better, more competitive guidance for band beams.
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2.2
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Determination of load to be balanced
The selection of the load to be balanced is an important factor in the economics of
prestressed slab systems. One of the major advantages of prestressing is that it
reduces the long-term deflection of the concrete floor system. However, selection
of too high a load to balance may incur excessive prestressing costs reducing
economy.
A combination of a lower level of "balanced load" and the addition of normal bar
reinforcement at peak moment regions will prove to be the most economical
solution in most applications.
The load to be balanced should be that which is just sufficient to give limiting
tensile stresses in the chosen section under full working load.
If the intention of the design is to produce a level floor under long-term loading
then the load to balance should be the self-weight plus a proportion of the long
term applied loading. Over balancing, i.e. balancing self-weight plus a large
superimposed loading may result in problems at transfer. In this instance the full
prestress is present (accentuated by the as yet not realized long-term losses) and
the live load is yet to be applied. Generally the load to be balanced in the
following table will prove satisfactory as an initial estimate:
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2.3 Selection of Level of Prestress
The level of prestress (the total effective force divided by the net concrete area) serves as
a useful check on the economics of the design and the serviceability of the structure:
Average
Prestress Comments
__________________________________________________________
1.4 – 3.5 MPa Generally accepted "proper" range for post tensioned slabs with
optimum range being 2.0 to 2.5 MPa. Check for very stiff vertical
elements and very long distances between expansion joints or stiff
elements, but for typical conditions ~ slabs stressed in this range
will perform well with respect to cracking and shortening. Will
usually mean that no extra reinforcement is required for ultimate
flexure at positive regions (except in end spans) but may be
required for negative flexure.
Above 3.5 MPa Slabs stressed in this range will undergo excessive shortening due
to axial elastic shortening and long term effects of creep and
shrinkage. Check all connections to vertical elements limit pour
size to as small as practicable, pour walls after slab is stressed (if
possible). Take every available precaution to avoid shortening
problems. This normally indicates that an increase in depth is
required.
Watch significant moments going into columns (therefore column
design) generated by long term effects of creep & shrinkage of
large floors, particularly on the first two suspended floors.
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3 Detailed Design
3.1 Design Process
The following procedure contains all the steps required when designing PT slabs and
beams manually. Whilst design is typically carried out via computer software, the
following flowchart has been presented for the purposes of understanding the step by step
process that is carried out via the software. Normally steps 2-11 & 13-14 are carried by a
PT design program like RAPT (or similar) on the basis of the engineers input.
1. Choose slab/beam depth – normally set by preliminary design and forms an input
to the program run (like on RAPT)
2. Ideally - select load to be balanced, i.e. load at which there will be near zero
deflection (can be entered into RAPT). Practically - select the trial amount of PT
based on preliminary design or on the basis of experience (see also 2.4) as an
input for first run on RAPT.
3. Determine the maximum effective drape allowing for haunches or drop panels -
normally calculated automatically by RAPT on the basis of geometry and covers
entered as input.
6. Carry out frame analysis for a unit loading and compute moments at transfer,
working load and ultimate load (including secondary effects) – carried out by
RAPT on the basis of user input.
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9. Check ultimate strength of section at transfer. This should not be a problem unless
very high levels of prestress are used (i.e. average compression in the range of 5-
10 MPa). - This is part of RAPT standard procedures and output.
10. Check elastic stresses at working load, as per AS3600 – automatically carried out
by RAPT.
11. If permissible stresses are exceeded, carry out a cracked section analysis -
automatically done by RAPT and when the extra passive reinforcement is
required – it is displayed in the Service section of output.
12. Revise section if necessary and repeat. – When working on RAPT, of course, this
step must be done by user – RAPT does not make any decisions for the designer.
15. Check anchorage – for typical band beams and slabs there are 2 sheets of typical
details on the Office System, which should be sufficient for most design
situations. For special cases (i.e. prestressed precast elements) and for cases where
a multi-strand system is used – anchorage reinforcement must be designed
manually. No local software is available for this aspect of design at this stage.
Where the permissible tensile stresses are exceeded, AS 3600 calls for a cracked
section analysis which involves limiting the incremental stress in the tendons and
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reinforcement after decompression. Calculation by hand is tedious, and is
automatically done by RAPT.
The computer program RAPT is recommended for the final design of either fully
or partially stressed slabs. However, the designer must carry out hand checks to
verify the final results. As a general rule, if under working stresses the beam/slab
is not in tension, then extra reinforcement for ultimate capacity is generally not
required.
The jacking force for the mono strand system normally taken as 85% of the
tendon breaking load. The average effective prestressing force is then taken as
75% of breaking load at transfer and 60% of breaking load at full load. The stress
losses should be considered for long ducts. As a general rule, tendons longer than
30m should be stressed from both ends to limit losses in prestress force.
Sometimes we accept ducts longer than 30m (up to 40 m max) if the last span is
not critical in the design (i.e. is much shorter). For tendons stressed from both
ends (bonded or unbounded) – 60 m is considered to be maximum, however this
value also can be stretched slightly if middle span is not critical in the design.
Effective force in tendon below 40% of UTS (ultimate tensile strength) is
considered to be not very economical and the design should be re-examined for
possible alternative solutions to arranging stressing of tendons.
Tendon profiles are typically parabolic. Allowance should be made for the
reversal of curvature at the supports where most stress losses occurs (RAPT
accounts for it automatically in calculation of losses)
Dynamic effects should be considered for thin slabs i.e. L/D > 40.
At both the live and dead ends of stressing tendons, local effects produce quite
large tensile forces. These forces only occur in the immediate region around the
anchorage, and result from the prestress force spreading out to produce a uniform
stress across the section.
Refer to the RAPT manual or “Prestressed Concrete” by Warner and Faulkes - for
more information, and a design examples.
Checks are required to ensure the section does not fail under the reverse loading
(particularly for transfer beams), so it is important that a realistic resisting dead
load is used (RAPT carries it out).
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The same reasoning also applies for transfer beams, where stage stressing may be
required to limit stresses at transfer. RAPT also works this distinction with dead
loads, and superimposed dead loads as separate load cases, however does not have
provision for stage stressing and individual RAPT runs would have to be created
for each stage.
At present no guidelines are available for this form of construction and engineers are
currently ignoring the contribution of profiled sheeting in their design.
Unfortunately, this approach is not conservative as the presence of the steel sheeting
completely alters the post-tensioning effects on the floor slab at both service and ultimate
conditions and, therefore, cannot be ignored.
It is essential to point out that the structural response of post-tensioned composite slabs
is different from the one of post-tensioned concrete members (without steel decking) and
from the one of conventional composite slabs (without post-tensioning) and, therefore the
results of previous studies and the methodologies behind them cannot be utilized for this
form of construction. Furthermore, the presence of the steel decking changes the
occurrence of the time dependent behavior of the concrete due to lack of moisture egress
at the bottom of slab. This leads to occurrence of shrinkage warping, for which no clear
guidance are currently available.
Furthermore, the combined effects of post-tensioning and shrinkage warping may induce
premature and significant de-bonding or even separation between the slab and steel
decking already at service conditions.
The large cross-sectional area of steel decking will act as excessive amount of tension
steel and cause tension cracking in the vicinity of decking (to satisfy compatibility of
strains between sheeting and concrete) resulting in comparatively larger deflections than
the post-tensioned slabs without the steel decking. Importantly, a theory has yet to be
proposed and proven that can be used confidently by structural engineers. The recently
launched, new version of RAPT program utilizing Fielders’ formwork steel profiles in PT
design appears to be addressing the above outlined design issues. However, until proven
by the currently undertaken research work it should be treated with caution, particularly
when the steel decking other than Fielder’s is used for the design.
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Arup is currently collaborating with The University of Sydney and some of the steel
decking manufacturers to research this issue.
4 Practical Considerations
4.1 Strand
Use low relaxation super grade strand. Two sizes, 12.7mm and 15.2mm, are available.
12.7mm strands, maximum 5 per tendon and placed in flat ducts (monostrand system) are
the preferred method of construction in Australia. However it should be noted that 15.2
mm dia strands are potentially more economical provided that the prices are not
artificially higher than 12.7 mm dia strands as they require less workmanship, less
cranage and they are quicker to install (less ducts involved).
The contractor and Quantity Surveyor should be consulted regards which duct size is
preferred and most efficient for a particular project.
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4.3 Tensioning
Early application of part prestress, usually 25% at between 24 to 48 hours helps to
control shrinkage cracking.
Extensions should be calculated and checked against measurements made on site
before permission to cut tendons and grout the ducts is given. The stressing
Subcontractor should provide the expected extensions well before the first pour
and these should be checked against the extensions calculated by the Design
Engineer (on basis of RAPT runs). Any differences should be discussed with the
stressing Subcontractor prior to first pour. The achieved extensions on site should
be verified against agreed with stressing Subcontractor, calculated extensions. An
allowance of ± 10% in calculated/actual extensions is allowed. Anything outside
this range requires an explanation why the difference occurs. Care should be
taken when restressing (if required) to ensure that the wedges do not clamp at the
same point on the strands.
Beware of large clearances required for stressing when multistrand system and large
jacks are used (particularly when stressing from within the floor plate).
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4.6 Reinforcement
Stirrups should be open at the top to allow installation of the tendon (except at
anchorages). If the stirrups must be closed use separate closer bars.
Where the pure torsion is present (or the edge beams are designed for torsion to
limit slab end span deflections) closed links should be used.
Sometimes closed links are used around columns heads in the case when torsion
is small in the middle section of the edge beam.
Terminate bottom slab steel before it runs into the beam and fouls tendon profiles.
Failures may occur at anchorages due to omitted anchorage reinforcement or poor
compaction of concrete around slab anchorages. However failures shall not occur
around multistrand anchors as the forces are big and the potential failure is very
difficult to rectify. The “end block” reinforcement around multistrand anchorages
shall be always carefully designed and inspected on site that the design intent has
been met.
The strand content in PT floors may vary anything between 22 to 75 kg/m3, depending if
we talking about content in the slab or beam. Of course it is also dependent on the level
of loading.
Similarly the bar content may vary anything between 30 to 75 kg/m3 – depending on
loading, how tight are the concrete profiles sized and the complexity of the concrete
floor. More steps, recesses, edges and openings – the higher will be the bar content. The
prediction of strand and reinforcement ratios are a very important part of pre-tender
documentation and getting it right is very important aspect of Structural Consultant input
to the project. Very often incorrect reinforcement ratios (in either direction) may be the
subject to disputes between the Contractor and Structural Consultant and in some cases
ending up in very costly legal procedures to resolve these matters. The reinforcement
ratios will be subject of separate guidance note dealing in more detail with the various
aspects of this complicated issue.
4.7 Concrete
A concrete strength of 40MPa is normally used in post tensioned floors to enable the final
stressing as early as possible (requiring 22 or 25 MPa concrete strength minimum) and to
avoid mushrooming of high strength concrete around columns, which is not well
accepted by Contractors.
Control of shrinkage cracking can be improved by ensuring that slabs are cured correctly
and cements containing excessive fly ash are avoided.
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4.8 Designing Layout
Be careful in the initial planning stage that the prestressed elements do not lie between
stiff elements, e.g. core walls or stiff columns. If this cannot be avoided, then pour strips
or cobles with sliding bearings may be required.
Isolating every single structural stiff element with permanent joints may not always be
feasible. Between two stiff elements (like lift shafts or stairs) high tensile forces will
develop, particularly on the first suspended floor. In such situations a layer of passive
reinforcement should be used between stiff points to control and distribute cracking of
concrete. In assessing the amount of reinforcement required, the effects of long term
concrete creep and shrinkage due to prestress should be carefully examined.
It should be noted that in beams and slabs the loss of prestress will only effect
serviceability and not the ultimate capacity of the section (provided the ducts have been
grouted).
4.9 Haunches
Minimizing the floor-to-floor heights of buildings is critical in keeping costs
down. The penalty in this is that there is often not enough space in the ceiling for
both mechanical ductwork and beams.
Haunches or reductions in beam depths are then used to allow ductwork to pass
under beams at certain agreed locations.
It is recommended that haunches in the beams be placed adjacent to edge
columns, where bending moments are smaller. Section capacity problems will
arise if they are placed next to internal columns.
As a general rule, haunches extend 1000 - 1500mm from the edge, and a 33%
reduction in beam depth can usually be accommodated in the haunch.
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Advise the client that these provisions will not "guarantee" a watertight slab and
that a ponding test should be conducted. Provision should be made to apply a
membrane if the test proves unsuccessful. Design should allow for 50-75 mm
thick concrete topping screed.
4.11 Penetrations
Penetrations through existing post-tensioned slabs require careful construction. Wherever
possible, it is recommended that the tendon locations be permanently marked on the
underside or top of the slab. Future penetrations that have been included in the design
should be located clearly to the underside (or on top of) of the slab (e.g. a 3mm x 5mm
recess around the perimeter of the future opening). Coring should be preceded by a pilot
hole drilled to verify clearance from tendons.
Most of the post tensioning contractors have recommended standard procedures for
cutting holes in existing slabs. They should be contacted if holes are required in any
slabs.
5 Transfer Beams
The design of transfer beams requires special consideration of the loading history.
Strength and serviceability checks must be carried out at each stage of loading.
Deflection will only govern when the transfer beam is undersized. Shear strength is likely
to be critical in the final condition.
In heavily loaded transfer beams the bending stress at transfer is likely to govern and may
require staged stressing of tendons. If staged stressing is used, make provision for
grouting of individual tendons rather than partial stressing and restressing of all tendons.
Design is best undertaken from first principles rather than by the load-balancing method
and the notes given above on beam depth selection, balancing load and level of prestress
may not be appropriate.
If compressive stress governs the design then consideration should be given to increasing
the section size.
6 References
6.1 Post-Tensioned Concrete Slab Construction. Chris Gildersleeve & John Mennis -
Arup Design Guidance Notes – September 1990
6.2 Post-tensioned Concrete Floors –Design Handbook, Technical Report No 43 of
Concrete Society
6.3 AS 3600-2010 "Concrete Structures" Standards Association of Australia
6.4 "Prestressed Concrete" (2nd Edition). Warner and Faulkes
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6.5 "RAPT Manual" PCDC
6.6 VSL Slab System Manual
6.7 OAP Feedback Notes: Notes on Structures: 18 and 23 "Prestressed
Concrete in Buildings: Secondary Effects
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