University Of Central Florida

Big Beam Competition 2012

Design Team 1 Mohamed Alrowaimi Nader Mehdawi Walid Hamad

Faculty Advisor Dr. Hae-Bum Yun

Sponsoring Producer

Finfrock Industries Inc.

TABLE OF CONTENTS

Cover Page..

1 2 3 4 5 6 7 7 8 8 8 9 10 11 11 11 13 14

ii Table of Contents iii Acknowledgements. 1 2 3 4 The Beam Configuration Cross Section Drawings Design Parameters. Beam Predictions 4.1 Crack Prediction. 4.2 Deflection Prediction.. 5 6 7 8 9 Stress in pre-stressing strands Partial Losses.. Flexural Design and Analysis .... Shear Design and Analysis. Anchorage Design...

10 Concrete Mix Design Criteria..... 11 Cost Estimation... 12 Conclusion. 12 Appendix.

ACKNOWLEDGEMENTS

The Project Team extends his gratitude to Dr. Hae-Bun Yun for introducing us to this contest, guiding and advising us to have a good design. Next, we would like to thank Joseph Lord, Executive Director of the Florida Pre-stressed Concrete Association (FPCA) for helping us to participate in the big beam contest for the first time. Also, we would like to thank Mr. Allen R Finfrock, Vice President of FINFROCK Industries Inc., in Orlando, Fla., for their support and sponsoring our prestressed beam. Last but not least, we thank the Precast/Prestressed Concrete Institute (PCI) for organizing and sponsoring the 2012 PCI Big Beam Contest.

1. The Beam Configuration with the shear and the moment diagram

2. Cross Section Drawings

10.00" 6.00" 1'-3.00" 9.00" 4.45" 6.00"

6.55"
N.A

4.00"

#3 Stirrups ,JYP 1/2" , 270K Law lax STRANDS N.A

10.00"

4.00"
2.95"
2" 2" 2"

3"

1'-3.00"

Section

#3 Stirrups ,JYP

9.05"

3" 2.95"

2'

2'

2'

4'
Elevation
5

2'

2'

2'

3. Design Parameters

(4)

Section Properties and Parameters

4. Beam Predictions
All the beam predictions were computed either manually or by using a Excel spreadsheet. A few numbers of rectangular and T beam sections were checked on the cracking load. So, the design was initially dominated by the restriction of that the beam shall not crack under the total applied service load of 20 kips. Then the selected T-beam section was designed for the flexural load at transfer and service. A detailed calculation and checks for the flexural bea

m Design and analysis will be presented in Section 7. 4.1. Crack Prediction It is important to evaluate the first cracking load. Hence, the moment due to the applied live load (20 kip) and the self-weight of the T-beam were calculated. Then this moment were compared to the cracking moment to get the exact cracking applied service load. The predicted design cracking load = 20 kip

As assumed above, the beam will crack at 20 kips or more. The detailed calculations are shown in appendix. 4.2 Deflection Prediction The deflection calculation was done based on uncracked prestressed section since the assumptions of elastic behavior are more applicable than the cracked section. So, the deflection was calculated at transfer due to the beams self-weight and at service due to the total load, beams self-weight and the live load. Also, the camber due to the prestressing force was calculated and subtracted from the calculated deflections. A summary of the deflections at transfer and service is shown in the next table. Loading Stage At transfer (midspan) At service (midspan) Deflection (in) 0.05 0.43

The predicted max. deflection = 0.43 in at the Midspan . The detailed deflection calculation is presented in the appendix.

5. Stress in Prestressing Strands

The initial prestressing stress: Hence, the initial prestressing force The effective prestressing stress: Hence, the effective prestressing force

6. Partial Losses
The Partial Losses were calculated for the pretension tendon and the results are shown in the following table: Stress Level at various Stages After tensioning (0.7 Fpu) Steel Stress (psi) 189,000 8 % 100

Elastic shortening loss Creep loss Shrinkage loss Relaxation loss Final Net Stress (FPe)

-10325 -6757.95 -3690 -3126.81 165100.24

-5.5 -3.6 -1.95 -1.65 87.3

The percentage of total losses = 12.7 % for this pre-tensioned beam.

7. Flexural Design and Analysis

The following prestressed beam was designed to carry at least total factored load of 32 kips. In this design, the service load design method was used. A several section trails were studied with: Different shapes and dimensions (rectangular and T-Beam) Different tendon numbers Different eccentricities

All these sections were checked to choose the best section in weight, cost and strength. The following spread sheet table shows the most effective Beam. Also, the stresses for the selected T-Beam were checked on both transfer and service stage as shown in the following table. The design was for number of 4 e

Spreadsheet Calculation of the most effective beam

Calculation Sheet
Trial Section # 5 I-Beam Section Properties N# Area (sq in) I (in^4) Ct (in) Cb (in) r^2 (sq in) St (cu in) sb (cu in) Eccentricity e (in) 4 114 2143.184 6.5526 8.4474 18.79986 327.0739 253.7093 Number of Tendons 4
N.A

10.00" 6.00" 1'-3.00" 9.00" 4.45" 6.00"

6.55" 4.00"

Prestressing Force 12.70 Losses % 115668 Pi (psi) 100978.164 Pe (psi)

Support Ft Transfer Load

399.948 -2838.26

Midspan
260.5299 -2658.53

Psi Psi

Loading Moments Md (in-lb) Ml (in-lb) Mt (in-lb) 45600 720000

Fb Ft Service Load Fb

349.1546 -2477.8

-1991.6 179.3647

Psi Psi

765600

8. Shear Design and Analysis

10

The shear reinforcement was deigned to carry the shear due to the external load. In this design, it is found that the shear due to the external load Vu is bigger than half of the shear capacity Vc.

Hence, the shear reinforcement was taken to be the min as Per ACI, (Min Av/S), which came to 2 # 3 closed tie stirrups, spaced at 2 in center to center.

9. Anchorage Design
The anchorage was reinforced based on the empirical expression by Mattock. This was found to be 2 #3 closed tie stirrups.

10.Concrete Mix Design Criteria

In our design we will adopt the concrete mix design done by Finfrock Industries Inc. since they will produce the concrete at their plant. Self-compacted concrete Type 3 cement for high early strength Water cement ratio is 0.38 According to Finfrock the mix will give concrete comprehensive strength of 6000 psi after two weeks.

11.Cost Estimation
11

The major challenge in the design is how to design a safe member with the least cost and build an economically competitive structure of suitable strength performance which would satisfy the requirements. The need for the most efficient cost design solution has led to the need to carry out accurate cost estimation and a structural cost optimization. Self-manufacturing costs are proposed to be defined as a sum of: - The material costs, - The power consumption costs - The labor costs. In our contest will be responsible of just the material costs. So, we have to break down the material in the beam. Our beams materials are:

Concrete volume (yd) 4 strands 0.5 in dia. Length (ft) #3 stirrups length (ft) #3 reinforcement weight (lb/ft)

0.469135 64 8.7 0.376

Using cost price given in the Big Beam contest specifications, we can give a good predicted as shown:

Material Concrete Pre-stressing Strand Steel: A615/A706

Unit Cost $100/cu yd $0.30/ft $0.45/lb

Amount 0.469135 (cu yd) 64 (ft) 3.2712 (lb)

Cost ($) 46.9135 19.2 1.472 67.59

Total Cost

12

12.Conclusion
During the design of the big beam, our team has tried several sections with different shapes, dimensions, number of tendons and eccentricities to come with the most effective design. The beam in this report was designed to carry a total factored live load of 32 kips and must not have a total peak applied load more than 39 kips. Also, this beam was designed to have the first crack at load equal or bigger than 20 kips (the total applied service load). The selected T-section was found to be the most effective section that meets all the requirements of the contest: Self-weight =118.7 plf with total weight of 1899.2 lb Material cost = $ 67.59 4e e

13

Appendix
Five Trial Sections:Trial #1 Calculation Sheet
Trial Section # 1 Rectangular 15*10 Section Properties Area (sq in) I (in^4) Ct (in) Cb (in) r^2 (sq in) St (cu in) sb (cu in) Eccentricity e (in) 4 150 2812.5 7.5 7.5 18.75 375 375 Prestressing Force 12.70 Losses % 115668 Pi (psi) 100978.16 Pe (psi) Number of Tendons 4 N#

Support Ft Transfer Load

462.672 -2004.912

Midspan
302.672 -1844.912

Psi Psi

Loading Moments Md (in-lb) Ml (in-lb) Mt (in-lb) 60000 720000

Fb Ft Service Load Fb

403.91266 -1750.288

-1676.0873 75.088

Psi Psi

780000

14

Trial #2

Calculation Sheet

Trial Section # 2 Rectangular 15*6 Section Properties Area (sq in) I (in^4) Ct (in) Cb (in) r^2 (sq in) St (cu in) sb (cu in) Eccentricity e (in) 4 90 1687.5 7.5 7.5 18.75 225 225 Number of Tendons N# 4

Prestressing Force 12.70 Losses % 115668 Pi (psi) 100978.2 Pe (psi)

Support Ft Transfer Load

771.12 -3341.52

Midspan
611.12 -3181.52

Psi Psi

Loading Moments Md (in-lb) Ml (in-lb) Mt (in-lb) 36000 720000

F b Ft

673.1878 -2917.15

-2686.81 18.48

Service Load
756000

Psi Psi

F b

15

Trial #3

Calculation Sheet
Trial Section # 3 I-Beam Section Properties Area (sq in) I (in^4) Ct (in) Cb (in) r^2 (sq in) St (cu in) sb (cu in) Eccentricity e (in) 4 150 5312.5 7.5 12.5 35.41667 708.3333 425 Number of Tendons N# 4

Prestressing Force 12.70 Losses % 115668 Pi (psi) 100978.2 Pe (psi)

Support Ft Transfer Load

-117.936 -1859.76

Midspan
-202.642 -1718.58

Psi Psi

Loading Moments Md (in-lb) Ml (in-lb) Mt (in-lb) 60000 720000

Fb Ft Service Load Fb

-102.958 -1623.57

-1204.13 -24.4659

Psi Psi

780000

16

Trial #4

Calculation Sheet

Trial Section # 4 I-Beam Section Properties N# Area (sq in) I (in^4) Ct (in) Cb (in) r^2 (sq in) St (cu in) sb (cu in) Eccentricity e (in) 4 110 2734.924 6.5909 8.4091 24.86295 414.9546 325.2339 Number of Tendons 4

Prestressing Force 12.70 Losses % 115668 Pi (psi) 100978.16 Pe (psi)

Support Ft Transfer Load

63.46702 -2474.11

Midspan
-42.5687 -2338.82

Psi Psi

Loading Moments Md (in-lb) Ml (in-lb) Mt (in-lb) 44000 720000

Fb Ft Service Load Fb

55.40671 -2159.9

-1785.76 -125.031

Psi Psi

764000

17

Trial #5

Calculation Sheet
Trial Section # 5 I-Beam Section Properties N# Area (sq in) I (in^4) Ct (in) Cb (in) r^2 (sq in) St (cu in) sb (cu in) Eccentricity e (in) 4 114 2143.184 6.5526 8.4474 18.79986 327.0739 253.7093 Number of Tendons 4

Prestressing Force 12.70 Losses % 115668 Pi (psi) 100978.164 Pe (psi)

Support Ft Transfer Load

399.948 -2838.26

Midspan
260.5299 -2658.53

Psi Psi

Loading Moments Md (in-lb) Ml (in-lb) Mt (in-lb) 45600 720000

Fb Ft Service Load Fb

349.1546 -2477.8

-1991.6 179.3647

Psi Psi

765600

18

Check for stresses for our selected beam section at 32, and 39 kips

For applied 32 kip load, the stresses are:

For applied 39 kip load, the stresses are:

19

Partial Losses of Pre-stressed Beam

1. Elastic Shortening: FPES = n . FCS Where, FCS = e = 4 in so, FCS =-1687.1 psi Modular Ratio n = so, FPES = n . FCS = 6.12 * 1687.1 = 10325 psi 2. Creep Losses: FPCR = Ct Where; Ct = Cu = *2 = 0.655 * 1687.1 = 6757.95 psi FCS = = 6.12 )+ and n =

and MD = 45600 in-lb

FPCR = 0.655 * 3. Shrinkage Losses: Time-dependent method FPSH = SH * ES Where: SH = = (SH)u * 820*10-6

20

= 1.37*10-4 So, FPSH = 1.37*10-4 * 10-6 = 3690 psi

4. Relaxation: ACI-ASCE method FPR = {kre - J(FPES + FPCR + FPSH )}C = {5000 0.04(10325+6757.95+3690)}*0.75 = 3126.81 psi

Total Losses FPT = FPES + FPR+ FPCR + FPSH FPT = 10325+6757.95+3690+3126.81 = 23899.76 psi

Stress Level at various Stages After tendioning (0.7 Fpu) Elastic shortening loss Creep loss Shrinkage loss Relaxation loss Final Net Stress (FPe)

Steel Stress (psi) 189,000 -10325 -6757.95 -3690 -3126.81 165100.24

% 100 -5.5 -3.6 -1.95 -1.65 87.3

The percentage of total losses = 12.7 % for this pre-tensioned beam based on 14 days.

21

Shear Design Calculation

Calculate Vu due to factored loads Pl= 10 kips Pu=16 kips WD=0.118 kips/ft Wu=0.1425 kips/ft Calculate Vu at 1/2dp From shear force diagram Vu= 17.062 Kips Nominal shear strength Vc :

Use ACI alternate method ( )

( )

22

Defection Calculation
Transfer Stage Deflection due to Dead load (Self weight)

Camber due prestreesing force:

At service load of uncracked beam

The maximum deflection at the midspan

Crack Calculation
Mcr = fr * Sb + Pe ( e + r2/cb ) Mcr = 7.5 (6000)1/2 *253.709 + 100978.2 (4+18.8/8.45) Mcr = 775965.97 in-lb Mcr/MT = 775965.97/765600 Mcr/MT = 1.01 O.K.

23