THE DESIGN OF CAST-IN PLATES THE DESIGN OF CAST-IN PLATES SCI PUBLICATION P416 THE DESIGN OF CAST-IN PLATES J.R. Henderson BSc, PhD, CEng, MIStructE i SCI (The Steel Construction Institute) is the leading, independent provider of technical expertise and disseminator of best practice to the steel construction sector. We work in partnership with clients, members and industry peers to help build businesses and provide competitive advantage through the commercial application of our knowledge. We are committed to offering and promoting sustainable and environmentally responsible solutions. Our service spans the following areas: Membership Consultancy Individual & corporate membership Development Product development Advice Engineering support Members advisory service Sustainability Information Assessment Publications SCI Assessment Education Events & training Specification Websites Engineering software © 2017 SCI. All rights reserved. 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To report any errors, contact: Although care has been taken to ensure, to [email protected] the best of our knowledge, that all data and information contained herein are accurate to the extent that they relate to either matters of fact or accepted practice or matters of opinion at the time of publication, SCI, the authors and the reviewers assume no responsibility for any errors in or misinterpretations of such data and/or information or any loss or damage arising from or related to their use. Publications supplied to the members of the Institute at a discount are not for resale by them. British Library Cataloguing‑in‑Publication Data. A catalogue record for this book is available from the British Library. ii FOREWORD Comment The use of steel plates cast into concrete elements to connect steel beams to is a common constructionSteel method constructionwhere a steel frame surrounds a concrete core. Despite the frequency theof providing smart lateral choicestability to a steel frame in this way, hitherto there has been no design guide available in the UK to suggest a common approach. Consequently there may be discussions between project participants with limited The steel construction sector was well placed to respond to the government’s objectives to make the common basis about designuse of Building assumptions, Information Modelling the(BIM) widespread division across of the responsibility construction industry, as and it had the already been making strong use of digital methods of construction for many years. Players in some necessary arrangementother of parts the of the connection construction sector toare reportedlyachieve struggling the to design keep up with intent. the introduction The of purpose digital methods of construction like BIM; and the signs are that they will have to run a lot faster to of this guide is to providekeep up such in future. a basis and identify issues that should be addressed in As we see in this month’s Headline Sponsor article by Trimble, digital methods of construction are the design and constructionbeing taken process.to a new level with the introduction of mixed reality and holographic technology. The Nick Barrett - Editor pace of change in the technologies available to the sector is dramatic. The guide was preparedMixed by realityRichard creates a Hendersoncollaborative work environment, of the givingSCI designerswith guidance and construction andteams input the ability to blend real world objects with digital content in real time, and interactively. Physical and from a working party madedigital information up of is the shared, following allowing users to individuals. interpret and use physical Their and digitalcontribution information is about real world objects – or what are to become real world objects once designed and constructed. gratefully acknowledged.The technology spans the virtual and physical environments. The promise being held out by this technology is reduction in poor quality, cost overruns and disrupted construction programmes – all holy grails of the construction industry. Steelwork ▪ David Brown contractorsSCI can use this technology in the workshop, improving quality even further and enhancing the already extensive offsite benefits of steel construction. ▪ Gordon Deuce Mixed realityMA andCE other new technologies are being adopted across industries, in a drive towards smart factories and machines that has been called the fourth industrial revolution, or Industry 4.0. ▪ Chris Dolling There hasBCSA always been a lot of advanced thinking in evidence in steel construction design and on site, but that isn’t to say things won’t be improved further. Even the highest quality steel-framed ▪ Andy Gardner buildings likeAru Bloomberg’sp new European HQ in the City which has just opened, and which achieved a ▪ Will Haley BREEAM 98.5%Hale scorey atEngineering the design stage (a record for a major office development), will be more easily and efficiently designed and built using advanced mixed reality technologies. ▪ Craig Horsley Many sayKie that rthese Professional technologies will change Services our working Ltd world in ways that we can’t foresee. The evidence so far suggests however that steel will remain the smart choice in the new world of smart ▪ Alessandro Maccionifactories andExpe ever smarterdition buildings. Engineering ▪ Gary Simmons William Hare Ltd This guide was commissioned and funded by the BCSA and Steel for Life. Headline sponsors: BARRETT STEEL LIMITED Gold sponsors: AJN Steelstock Ltd | Ficep UK Ltd | Kingspan Limited | National Tube Stockholders and Cleveland Steel & Tubes | ParkerSteel | Peddinghaus Corporation | voestalpine Metsec plc | Wedge Group Galvanizing Ltd Silver sponsors: Hadley Group | Jack Tighe Ltd Bronze sponsors: BAPP Group of Companies | Barnshaw Section Benders Limited | Hempel | Joseph Ash Galvanizing | Jotun Paints | Kaltenbach Limited | Kloeckner Metals UK | Sherwin-Williams | Tension Control Bolts Ltd | Voortman Steel Machinery For further information about steel construction and Steel for Life please visit www.steelconstruction.info or www.steelforlife.org Steel for Life is a wholly owned subsidiary of BCSA NSC Nov/Dec 17 5 iii CONTENTS FOREWORD iii 6 CONSTRUCTION DETAILS AND HEALTH AND SAFETY ISSUES 23 SUMMARY vii 6.1 Welding: Studs and Reinforcement 23 1 INTRODUCTION 1 6.2 Thermal Expansion of the Cast-in Plate 23 6.3 Cast-in Plate Material Grade 24 2 FUNCTIONAL REQUIREMENTS 6.4 Installation 24 AND BEHAVIOUR 3 6.5 Painting and Fire Protection 24 2.1 Nominally pinned connections in simple construction 4 7 CONCLUSIONS 27 2.2 Nominally pinned connections with REFERENCES & CREDITS 29 coincident shear and axial forces 6 2.3 Alternative detailing to provide resistance APPENDIX A: to coincident shear and axial forces 8 DESIGN CALCULATIONS FOR CAST-IN PLATE 31 3 PROPOSED DESIGN MODEL 11 A.1 Resistances of shear studs and reinforcement 31 4 CONTRACTUAL ARRANGEMENTS A.2 Calculations 32 AND DESIGN RESPONSIBILITY 15 5 CONSTRUCTION TOLERANCES AND THEIR IMPLICATIONS 19 v SUMMARY This publication provides guidance for the design of cast-in steel plates for connecting structural steel beams to concrete core walls. The guidance can be extended to connections of other elements (eg support brackets for services). The guide provides a model for the design of simple connections that transfer shear force due to permanent and variable loads and a non-coincident axial tie force resulting from an accidental load case. It points out additional issues which must be considered where coincident shear forces and axial forces are to be dealt with. A sample design of a simple connection for a 610 serial size UB is presented. The design of punching shear reinforcement for the wall is included. The guide discusses the responsibilities of the building structural engineer and the steelwork contractor and suggests where the responsibilities are best divided. It also considers the impact of deviations between the theoretical positions of the parts of the connection and their as-erected positions. Issues relating to construction are discussed and some recommendations made. vii INTRODUCTION A common form of building construction in the UK is to choose concrete cores to provide the lateral stability to steel framed buildings. The steel frames often consist of steel-concrete composite slabs and beams supported on steel columns using simple connections. Loads are transferred through the floor structure to the concrete cores as: ▪ vertical forces from the permanent and variable actions on the floor; ▪ horizontal forces from wind on the building façade or the horizontal component of force from inclined columns; ▪ tie forces for robustness (independent of other forces). Such force