4

FRIMEDA RAPID LIFT SYSTEM

Description of the system Description of the system FRIMEDA's Rapid Lift System consists of a steel anchor set in the concrete and a lifting hook (ring clutch). The precast concrete element is raised and transported by means of a ring clutch which locks into the cast-in anchor. The design of the ring clutches and anchors permits a pulling load from any direction. The ring clutches can be released either by hand directly at the clutch head, or by remote control.

Fig. I System type designation F Anchor type S = Spread anchor Z = Two hole anchor P = Plate anchor A = Erection anchor E = Unilateral erection anchor G = Garage anchor F = Flat foot anchor D = Double ended column anchor X = Sandwich panel anchor U = Universal anchor Anchor length length = 13 cm

Load range [t]

Manufacturers sign FR

Fig. 2 The ring clutch can move in any direction

The load groups The FRIMEDA Rapid Lift System components are classified by load groups. Each load group corresponds to the load limit of a ring clutch to which anchors with various rated loads are allocated. The allocation of rated loads to load groups and ring clutches is shown in the adjacent table. Anchors and ring clutches cannot be mismatched, that is to say that a ring clutch cannot be assembled with an anchor of a different load group.

Load group Load group ring clutch [t] Load range anchor [t]
0.7 2.5 1.4 2.0 2.5 3.0 5.0 4.0 5.0 5.3 10.0 7.5 10.0 12.5 14.0 26.0 17.0 22.0

26.0

FRIMEDA RAPID LIFT SYSTEM

System components The anchors The anchors are manufactured from special-grade steel strip St 52/3. The foot of the anchor varies, and is described individually below. The hole in the anchor head is designed to receive the appropriate ring clutch. Each anchor bears clearly visible stamped markings with the name of the manufacturer FRIMEDA, the description of the system (F), the anchor type (S), the anchor length in centimetres (13) and the load range in tons (2.0) (Fig. I)

TPA-FS

TPA-FZ

TPA-FA

TPA-FE

TPA-FX

TPA-FD

TPA-FP

TPA-FF

TPA-FG

The ring clutches

The ring clutch is inserted into the recess of the cast-in anchor and the locking bolt is closed by hand. The ring clutch is thus secured to the anchor in a matter of seconds. The ring clutch can now be subjected to loads in any direction: turning, rotating and tilting can all be carried out easily.

There is no preferred direction of pull (Fig. 2). To disengage, the locking bolt is simply opened to free the ring clutch. If the access is more difficult ring clutches with pneumatic or manual remote-control release can be used (TPA-F1, TPA-F2).

TPA-R1

TPA-R2

TPA-R3

TPA-F1

TPA-F2

FRIMEDA RAPID LIFT SYSTEM

Anchor types Spread anchor TPA-FS Load range 0.7 t to 22.0 t The spread anchor is very versatile. It provides an efficient anchorage in both thin panels and slabs. For special applications additional reinforcement can be combined with the spread anchor by utilising the extra hole. Main applications: Columns, Beams, Trusses, Wall units, Double T-slabs Design considerations: Component thickness Concrete grade Reinforcement Details p.14 - 18

Two hole anchor TPA-FZ

Load range 1.4 t to 26.0 t The head of the two hole anchor is identical to the head of the spread anchor. The anchorage in concrete is achieved by means of a reinforcement tail. Longer anchors with additional holes can be produced on request.

Main applications: Prestressed concrete trusses, Thin walled elements, low strength concrete (e.g. lightweight concrete) Design considerations: Component thickness Concrete grade Reinforcement Details p.19 - 21

er

er
Load range 1.4 t to 22.0 t The special shaped anchor head means that the pitching/turning loads are taken by the anchor and not to the concrete. This helps prevent spallation of the concrete. The anchors are notched to assist with the placement of additional reinforcement required in the pitching/turning operation. Main applications: Thin-walled concrete elements, being lifted from a horizontal to a vertical position (pitching). Design considerations: Component thickness Concrete grade Reinforcement Details p.22 - 25

Erection anchor TPA-FA and Unilateral erection anchor TPA-FE (fig.)

Double ended column anchor TPA-FD

Load range 2.5 t to 22.0 t This anchor is identical to the head of the two hole anchor. It was specially developed for the erecting of columns or similar construction elements. Special lengths can be made to order.

Applications: Columns Design considerations: Component thickness Concrete grade Reinforcement Details p.30 - 31

FRIMEDA RAPID LIFT SYSTEM

Anchor types Flat foot anchor TPA-FF Load range 0.7 t to 22.0 t This anchor is a variant of the plate anchor TPA-FP. The main uses are in elements with a concrete strength, at lifting, in excess of 20 N/mm2. Reinforcement tails are essential. Main applications: Demoulding panels Lifting thin slabs Concrete pipes

Design considerations: Component thickness Concrete grade Reinforcement Details p.26 - 27

Plate anchor TPA-FP

Load range 1.4 t to 10.0 t This anchor is mainly used for slabs. Reinforcement tails are essential.

Main applications: Very thin slabs Design considerations: Component thickness Concrete grade Reinforcement Details p.28

Garage anchor TPA-FG

Load range 4.0 t This special anchor is used for heavy precast concrete system buildings, such as garages. It is similar to the plate anchor TPA-FP.

Main applications: Very thin slabs, e.g. precast concrete garages, casting in floor or roof slab Design considerations: Component thickness Concrete grade Details p.29

Sandwich panel anchor TPA-FX

Load range 2.5 t to 17.0 t This anchor is specially designed for use with precast sandwich panels. Its suspension point is close to the gravity axis thus allowing the element to be transported and erected in an upright position.

Main applications: Sandwich panels Design considerations: Component thickness Concrete grade Reinforcement Details p.32

Universal anchor TPA-FU 1.25

Load range 1.25 t only (Special light duty system with light duty ring clutch, not part of load range system). This anchor combines the advantages of Spread, Two hole and Erection anchor with a very small recess in the precast element. Available ex-stock in stainless steel.

Main applications: see TPA-FS, TPA-FZ and TPA-FA Small precast units Design considerations: Component thickness Concrete grade Reinforcement Details p.33

FRIMEDA RAPID LIFT SYSTEM

Calculation Safety rules A lift system consists of a cast-in anchor and a ring clutch. The ring clutch is only attached to the anchor when required for lifting. The ring clutch is a strong, high quality product and subject to checks may be stored in the yard and be used for many jobs. The safety rules require the following safety against breaking: Breaking of the steel compon: g = 3 Breaking of concrete: Breaking of cable wires: g = 2.5 g=4 Deadweight The mass (G) of a precast reinforced concrete unit can be determined using a density of g =25 kN/m3. G = Total mass of the precast unit Adhesion to mould Adhesion forces between the mould and the concrete vary according to the type of mould used. The following may be taken as a guide: Oiled steel mould q = 1 kN/m2 Varnished timber mould q = 2 kN/m2 Rough timber mould q = 3 kN/m2 The value (Ha) of adhesion to the mould is thus calculated by the following equation: Ha = q x A
1

Dynamic forces When a precast unit is moved by lifting gear, dynamic forces which depend considerably on the type of lifting gear used are generated. These are taken into account in the calculation using the lifting load coefficient f, in the following table.

Lifting class
H1 H2 H3 H4

Lifting load coefficient f at lifting speed VH

up to 90 m/min over 90 m/min 1.1 + 0.0022 VH 1.3 1.6 1.2 + 0.0044 VH 1.9 1.3 + 0.0066 VH
1.4 + 0.0088
VH

To guarantee a safe application of the FRIMEDA Rapid Lift System, this manual must be available to all operators using the system. Load capacity The load capacity of the anchor depends on: - The strength of the concrete at the time of lifting/transporting - The embedded depth of the anchor - The edge distance and spacings of the anchors - The load direction - The arrangement of reinforcement The force acting on the anchor is determined according to the following load assumptions:

2.2

Higher adhesion to the mould is to be expected for double T-slabs and coffered units. For ease of calculation, a multiple of the mass is used: Double T-slabs Coffered units Ha = 2 x G Ha = 4 x G

Lifting load coefficients of f = 1.1 to 1.3 are to be expected for cranes with precision lifting, such as those used in manufacturing plants and on construction sites. The application of a lifting load coefficient for lifting out of the mould at the manufacturing plant is unnecessary if a suitably cautious approach is adopted. Care must be taken when transporting suspended precast units over uneven terrain. In the interests of safety, a lifting load coefficient of f > 2 should be used. Total load The total load of the precast unit for calculating the anchor is determined as follows: 1. When demoulding: V1 = G + Ha

Adhesion to the mould should be minimised before lifting out of the mould by removing as many parts of the mould as possible.

A is the area of contact between the mould and the unit when starting the lift.
1

2. When transporting: V2 = G x f

FRIMEDA RAPID LIFT SYSTEM

Calculation Asymmetrical anchor arrangement If the arrangement of the anchors is asymmetrical in relation to the centre of gravity, the load of the individual anchors must be calculated using the rod method. Transport without lifting beam If no lifting beam is used, the cable angle depends on the length of the suspending cable. Halfen recommend that, where possible, should be kept to a minimum - 300 is always preferred. The resulting horizontal component increases the tensile force on the anchor by a further factor: z = 1/ cos Note: To avoid tilting of the unit during transport, the load should be suspended from the lifting beam such that its centre of gravity S is directly below the crane hook. If no lifting beam is used during transport, the anchors must be cast in symmetrically to the load.

Unequal anchor loads when the suspension points are not symmetrical in relation to the centre of gravity:

V tot Lifting beam F

Vtot

Fa Fb

S = centre of gravity

=2x

The load will always balance under the crane hook. If the anchors are in an asymmetrical arrangement, the load of each anchor is calculated as follows:

Cable angle 0 7.5 15.0 22.5 30.0 37.5 45.0 52.5 60.0

Cable angle factor z 1.00 1.01 1.04 1.08 1.16 1.26 1.41 1.64 2.00

F a = V tot x

b a+b a a+b

F b = V tot x

For a symmetrical arrangement, the tensile force on the anchor is: F = z x Vtot / n n = number of load bearing anchors (see also section "Multiple slings", page 10)

FRIMEDA RAPID LIFT SYSTEM

Multiple slings For a beam with more than two suspension points and for a panel with more than three, it is impossible to work out the load per anchor precisely, even if the anchors are arranged symmetrically to the load centre. As a result of unavoidable tolerances in the suspension system and in the position of the anchors, it can never be determined whether the load on each anchor is equal. The use of tolerance-compensating suspension systems (e.g. articulated lifting beam combinations, multiple slings with compensating rig, etc.) permits exact load distribution, but should only be used by experienced specialists; moreover, bearing in mind that such a system must be used both in plant and on site. In case of doubt, only two anchors should be assumed to be load bearing bearing. The use of two anchors is recommended for beams and panels, and four anchors installed symmetrically to the load centre is recommended for slabs and demoulding panels.

Examples: The use of three anchors ensures that the static load is shared evenly. For an arrangement of four independent cable runs or continuous diagonal cable runs, only two anchors can be assumed to be load bearing. A perfect static weight distribution can be obtained by the use of a lifting beam and two pairs of anchors set out symmetrically.

Vtot
Number of load bearing anchors: n=3

Vtot

Vtot F d F b F F
Number of load bearing anchors: n = 2

b F 120

b F

d G

G
Number of load bearing anchors: n = 4

F G

The system with compensating rig makes it possible to distribute the load evenly over 4 anchors.

A perfect static weight distribution can be obtained using a crossed spreader beam, which avoids angle pull.

Vtot F b F F
Number of load bearing anchors: n = 4

Vtot F F F F

G
Number of load bearing anchors: n = 4

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FRIMEDA RAPID LIFT SYSTEM

Calculation example: slab unit When selecting the anchor, a distinction can be made between the situation in the manufacturing plant and on the construction site.

Example slab unit Lifting, transporting in the plant and on site

Example Slab unit G A q f

Mass Mould area Adhesion to mould Lifting load coef.

Manufacturing plant Demoulding Transport

10.0 t (~ 100 kN) 20 m2 2 kN/m2 1.0 1.04 ( b= 15) 15 N/mm2 1.1

On site
10.0 t (~ 100 kN) 1.4 1.41 ( b = 45) 35 N/mm2

z Cable angle factor Fcu Concrete strength

With 2 supporting anchors, the angled pull force F per anchor is as follows: Demoulding at the plant:

F = (G + q x A) x f x z/n
Transport at the plant:

F = (100 kN + 2 kN/m2 x 20 m2 ) x 1.0 x 1.04/2 = 72.8 kN

F = G x f x z/n
Transport on site:

F = 100 kN x 1.1 x 1.04/2 = 57.2 kN

F = G x f x z/n

F = 100 kN x 1.4 x 1.41/2 = 98.7 kN

An anchor in the 10 t load range is just within the capacity required. If all factors were applied, the result would be

F = (100 kN + 20 m2 x 2 kN/m2 ) x 1.4 x 1.41/2 = 138 kN

i.e. an anchor in the load range 14.0 t would have to be used.

The loads occurring on site are often greater than those in the plant as cable angle and lifting load coefficients may be greater. At this stage the concrete strength is usually higher resulting in a greater load capacity of the anchor.

Adhesion to mould

11

FRIMEDA RAPID LIFT SYSTEM

Calculation examples

Double T beam
Lifting and transporting at the manufacturing plant: Concrete strength when demould: fcu 25 N/mm2 Cable angle: = 30 Cable angle factor: z = 1.16 Lifting load coefficient (transporting): f = 1.1 Lifting load coefficient (demoulding): f = 1.0 Loads: Deadweight: G = (0.1 x 3.0 + 2 x 0.32) x 8.7 x 25 = 104.4 kN Adhesion to mould: Ha = 2 x G = 208.8 kN Total load: Q = Ha + G = 313.2 kN Load per anchor when demoulding: F = 1.16 x 1.0 x313.2 = 90.8 kN 4 Load per anchor when transporting: F = 1.16 x 1.1 x104.4 = 33.3 kN 4 Anchor selected: TPA-FS 10.0-30 (acc. to table p. 16) 10 30

30

75

25 15 0 25 75

87

Note: no additional reinforcement required

Dimensions in cm

Wall panel
Pitching and transporting on the construction site Concrete strength when pitching: fcu 15 N/mm2 Lifting load coefficient of the crane: f =1.1 (pitching) f =1.3 (transporting on site) Loads: Dead weight: G = 0.16 x 7.0 x 2.5 x 25 = 70.0 kN Adhesion to mould: Ha = 2.5 x 7.0 x 1 = 17.5 kN Total load: = 87.5 kN Q = G + Ha Load per anchor when pitching: F1 = 1.1 x 87.5 x 0.5 = 24.1 kN 2 Load per anchor when transporting: F2 = 1.3 x 70 = 45.5 kN 2 Anchor selected: TPA-FA 5.0-29 (acc. to table p. 24) Fperm, pitching
16 0

25 kN > 24.1 kN Fperm, transporting 50 kN > 45.5 kN

70 25 0

Reinforcement tail:

16 l = 1500 mm Dimensions in cm

Pitching reinforcement: 16 l = 1000 mm Note: in most cases it is advisable to demould before pitching 12