a-beam s - anstar oy · 2.2 composite beam applications 2.2.1 a-beam s in a building frame system...

A-BEAM S

Design Manual 2

Design Manual A-BEAM S Revision 6/2017

Finland

A-BEAM S

Design Manual 3


TABLE OF CONTENTS 1 A-BEAM S ................................................................................................................................................................... 4 2 A-BEAM S STRUCTURE ............................................................................................................................................ 4

2.1 Composite beam manufacturing programme .................................................................................................. 4 2.2 Composite beam applications ......................................................................................................................... 5

2.2.1 A-BEAM S in a building frame system .............................................................................................. 5 2.2.2 Using a composite beam in a hollow-core slab floor ........................................................................ 5

2.3 Structural dimensions of the beam .................................................................................................................. 7 2.3.1 Intermediate beam ............................................................................................................................. 7 2.3.2 Edge beam ......................................................................................................................................... 8

3 PRODUCT APPROVAL AND MANUFACTURING .................................................................................................. 9 4 DESIGN CRITERIA FOR THE A-BEAM S ................................................................................................................ 9

4.1 Design and manufacturing standards ............................................................................................................. 9 4.2 A-BEAM S composite beam design quid for the main design designer ......................................................... 10

4.2.1 Applications for the beams .............................................................................................................. 10 4.2.2 Selecting the beam as the building’s floor beam ............................................................................. 10

4.3 Load bearing structure of the A-BEAM S composite beam ........................................................................... 11 4.3.1 Load bearing cross-section of the structure .................................................................................... 11 4.3.2 Loads and load combination ........................................................................................................... 13 4.3.3 Structural design of the A-BEAM S composite beam ...................................................................... 14

5 DESIGNING THE A-BEAM S .................................................................................................................................. 17 5.1 Design-and-build deal ................................................................................................................................... 17 5.2 ABeam software for composite beams ........................................................................................................... 18 5.3 Joint action of the A-BEAM S composite beam and hollow-core slab .......................................................... 21

5.3.1 Placement of the hollow-core slab .................................................................................................. 21 5.3.2 Addition steel for the beam .............................................................................................................. 22 5.3.3 Grouting for the structure ............................................................................................................... 23 5.3.4 Surface casting of the hollow-core slab .......................................................................................... 23

5.4 A-BEAM S composite beam’s connections .................................................................................................... 25 5.4.1 Standard connections of the beam ................................................................................................... 25 5.4.2 Hidden bracket connection to a concrete column ........................................................................... 25 5.4.3 Hidden bracket connection to a composite column ......................................................................... 26 5.4.4 Beam coupler connection in the field .............................................................................................. 26 5.4.5 End plate connection to the side of another beam ........................................................................... 27 5.4.6 Bolt connection on top of a column or wall .................................................................................... 27 5.4.7 Welded connection to a mounting plate on top of a column or wall ............................................... 28 5.4.8 Building services lead-throughs and equipment fastenings ............................................................ 29

5.5 Fire protection of the beam and connections ................................................................................................ 29 5.6 Service life design of the structure ................................................................................................................ 29

6 DESIGN-AND-BUILD DEAL DELIVERY DOCUMENTS....................................................................................... 30

Revision A. 31 May 2018

Minor corrections to the text. English version published.

Revision 0. 26 June 2017

Anstar Oy’s new composite beam type is A-BEAM S.

Separate design and erection instructions have been prepared for the beam.

The beam’s product approval is CE marking according to EN 1090-1.

The software for the beam has been updated.

The new software version, ABeam 4.7, was published on 31 Mai 2018.

A-BEAM S

Design Manual 4


1 A-BEAM S

The beam acts as the load-bearing composite structure of a low intermediate floor. The housing is

made of steel plate, and its bending resistance is adjusted by means of plate thickness. The beam is

delivered without grouting inside, and the grouting is performed on the site. In the final stage, the

beam acts as a composite structure with the hollow-core slabs and the surface casting. The bending

resistance of the beam is sufficient for the loads on the hollow-core slabs during erection. The beam

is used as both a single-span and continuous-span structure and designed without separate fire

protection up to fire resistance class R180. The standard connection is the AEP hidden bracket to a

reinforced concrete column and the AEL hidden bracket to a composite column. A connection

library has also been prepared for the beam for typical connections to various frame structures.

Presentation material on the beam is available on our website.

Figure 1. A-BEAM S composite beam in a building frame

2 A-BEAM S STRUCTURE

2.1 Composite beam manufacturing programme

Anstar Oy’s manufacturing programme for composite beams includes two cross-section types:

- A-BEAM W The beam housing is filled with concrete at the machine shop.

- A-BEAM S The beam housing is grouted after erection on the site.

These design instructions apply to A-BEAM S-type beams grouted on the site, in Figure 2.

Figure 2. Structure of composite beams. Beam types W and S

A-BEAM S

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The manufacturing programme for beam type S has been adapted for standard dimensions in

accordance with the hollow-core slab height and composite column width. Beams with different

dimensions are manufactured for demanding applications.

Table 1. A-BEAM S. Standard intermediate and edge beams

2.2 Composite beam applications

2.2.1 A-BEAM S in a building frame system

A-BEAM S is a composite beam designed for low intermediate floors. Together with the hollow-

core slab and grouting concrete, it forms a composite structure whose bending resistance is adjusted

by means of the housing’s plate thickness. The pieces of rebar inside the housing act in designed for

fire situations. The web widths for an intermediate beam have been specified according to the

standard dimensions of the steel composite column tube and, for an edge beam, there is a narrower

application for a one-sided hollow-core slab.

The beam is connected to a reinforced concrete or composite column or a concrete wall using either

AEP or AEL hidden brackets, or on top of a support using normal connection methods. The beam

can be used as a multi-span Gerber beam hanger going over supports, in which case the coupler

connection is located in the field.

2.2.2 Using a composite beam in a hollow-core slab floor

The beam is used to implement a floor structure with no structures hindering building services under

the floor. The beam acts as a composite structure that enables the use of longer, more slender

structures.

1. Floor structures

The beam is used as the load-bearing structure for hollow-core slabs. The slab can be used

without a surface structure, with a 10–30 mm layer of filler or with reinforced concrete topping.

The minimum thickness of concrete topping acting as a composite structure is 40 mm, and it can

be implemented in the roof with a concrete bay located in the insulation space. The reinforced

concrete topping significantly increased the bending resistance of the structure and also protects

the upper flange against corrosion and fire. In other cases, the upper flange must be protected

separately in accordance with the exposure class.

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Design Manual 6


Figure 3. Intermediate floor structure, reinforced surface slab and surface filler

2. Level difference between slabs

Hollow-core slabs of different heights are levelled with an intermediate beam where an

elevation part is welded on top of the other lower flange. The elevation part does not change the

structural function of the beam, and the elevation part is filled with concrete. The resistance of

the beam can be increased, and deflection reduced by elevating both flanges. The beam can also

be used to implement slight level differences in the top surface of the slab as necessitated by

various surface materials, for example.

Figure 4. Roofing structure, reinforced surface casting bay and hollow-core slabs of different

heights

3. Edge of the floor

The beam is located at the edge of the floor, and an edge bay can be cast up to the surface of the

exterior wall. Flange elevation parts can be used to increase the resistance of the structure and

reduce deflection in floors with the necessary space. The beam can also be used to implement

slight level differences in the top surface of the slab as necessitated by various surface materials,

for example. Thicker surface structures required by wet rooms can also be implemented

according to this principle.

Figure 5. Floor edge structure and level difference at the top surface of the slab

Below is a conceptual rendering of an A-BEAM S beam erecteded on a round composite

column using an AEL hidden bracket.

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Design Manual 7


2.3 Structural dimensions of the beam

2.3.1 Intermediate beam

An intermediate beam is used for a line where there are hollow-core slabs on both sides of the beam.

The web width is selected according to the column width and the height according to the hollow-core

slab height. With long span lengths or high loads, the housing can be elevated using an L-profile

welded to the lower flange. The bracket is located on the centre line of the profile (and column).

There are lifting holes in the upper flange and vent holes in the top corner of the web.

Figure 6. Intermediate beam structure

Table 2. Intermediate beam dimensions

Beam H A B C D E θ F M

type mm mm mm mm mm mm mm mm mm

A200S-200 200 395 200 97.5 130 100 90 – 100

A200S-300 200 495 300 97.5 230 100 90 – 150

A200S-400 200 660 400 130 330 100 90 – 200

A265S-300 265 495 300 97.5 205 165 90 60 150

A265S-400 265 660 400 130 305 165 90 60 200

A265S-500 265 760 500 130 405 165 90 60 250

A320S-300 320 495 300 97.5 185 215 90 70 150

A320S-400 320 660 400 130 285 215 90 70 200

A320S-500 320 760 500 130 385 215 90 70 250

A370S-400 370 660 400 130 270 230 150 70 200

A370S-500 370 760 500 130 370 230 150 70 250

A400S-400 400 660 400 130 260 250 150 70 200

A400S-500 400 760 500 130 360 250 150 70 250

A500S-500

A500S-600

500

500

760

860

600

600

130

130

325

425

350

350

150

150

70

70

250

300

Legend: H = Housing height = hollow-core slab height

A = Lower flange width

B = Web width at bottom

C = Flange projection width

D = Web width at top

E = Grouting hole distance from top surface of lower flange

θ = Grouting hole opening diameter

d = Grouting hole c/c spacing = 400 mm standard spacing

M = Beam centre line = standard positioning dimension of hidden bracket

connection

F = Torsional hole distance from top surface of lower flange

The torsional steel hole is 55*80, spacing 1200 mm in the hollow-core slab joints.

A-BEAM S

Design Manual 8


2.3.2 Edge beam

An edge beam is used for a line where there is a hollow-core slab on one side of the beam only. If

there will be a reinforced bay on the other side of the beam, an intermediate beam can be used. The

web width is selected according to the column width and the height according to the hollow-core

slab height. With long span lengths or high loads, the housing can be elevated using an L-profile

welded to the lower flange. The bracket is located on the centre line of the profile (and column).

There are lifting holes in the upper flange and vent holes in the top corner of the web.

Figure 7. Edge beam structure

Table 3. Edge beam dimensions

Type H A B C D E θ F M

mm mm mm mm mm mm mm mm mm

AR200S-200 200 300 180 100 145 100 90 – 100

AR200S-250 200 350 230 100 195 100 90 – 125

AR265S-250 265 350 230 100 183 165 90 60 125

AR265S-300 265 400 280 100 233 165 90 60 150

AR320S-300 320 400 280 100 224 215 90 70 150

AR320S-350 320 450 330 100 274 215 90 70 175

AR370S-350 370 480 330 130 265 230 150 70 175

AR370S-400 370 530 380 130 315 230 150 70 200

AR400S-350 400 480 330 130 259 250 150 70 175

AR400S-400 400 530 380 130 309 250 150 70 200

AR500S-400

AR500S-450

500

500

530

580

380

430

130

130

292

342

350

350

150

150

70

70

200

225

Legend: H = Housing height = hollow-core slab height

A = Lower flange width

B = Web width at bottom

C = Flange projection width

D = Web width at top

E = Grouting hole distance from top surface of lower flange

θ = Grouting hole opening diameter

d = Grouting hole c/c spacing = 400 mm standard spacing

M = Beam centre line = standard positioning dimension of hidden bracket

connection

F = Torsional hole distance from top surface of lower flange

The torsional steel hole is 55*80, spacing 1200 mm in the hollow-core slab joints.

A-BEAM S

Design Manual 9


3 PRODUCT APPROVAL AND MANUFACTURING

ANSTAR Oy has entered into a quality control agreement with Inspecta Oy regarding the

manufacture of steel parts for composite beams. Manufacture according to EN 1090-2 in execution

class EXC2 or EXC3. CE marking according to EN 1090-1. The certificates can be found on the

company website.

Quality control of the concrete grouting inside the housing and the joint grouting is carried out in

accordance with the quality control instructions for cast-in-place concrete prepared for the site by the

main structural designer. These grouting tasks require a quality control procedure for a load-bearing

concrete structure.

1. Manufacturing

markings

The beams feature manufacturing markings:

- CE marking according to EN 1090-1 for steel parts.[1]

- ANSTAR Oy’s code

- Beam code and weight

2. Materials

The manufacturing materials used meet the following EN standards:

- Web and flange plates EN 10025 S355J2+N

- Reinforcement EN 10080 B500B

- Concrete grouting inside the housing minimum C30/37 class 2

3. Manufacturing

method

- Beams are manufactured according to EN 1090-2 in execution classes EXC2

and EXC3. [2]

- Welding class C, EN ISO 5817. [11]

- Rebar welding EN 17760-1. [16]

4. Surface

treatment

- The lower flange, 50 mm of the web and the end plate are painted.

- Painting: EN ISO 12944-5 A60 machine shop priming – FeSa2.5. [12]

- By special order only, hot-dip galvanisation according to EN-ISO 1461. [13]

- Service life design more specifically in Section 5.6

4 DESIGN CRITERIA FOR THE A-BEAM S

4.1 Design and manufacturing standards

1. Finnish European standards:

The beams are designed according to the following standards:

SFS-EN 1991-1+NA Actions on structures. Part 1-1: General actions. [5]

SFS-EN 1992-1+NA Design of concrete structures. Part 1-1: General rules and rules for

buildings. [6]

SFS-EN 1993-1-1+NA Design of steel structures. Part 1-1: General rules and rules for buildings.

[7]

Concrete Code Card No. 18EC (EN 1992-1-1) 31 July 2012. Designing a hollow-core slab floor

system supported by a beam. [20]. (Finnish national quire)

2. Other countries in the European Standards area

The beams are designed according to the following EN standards:

Basic Eurocode EN-1992-1-1:2004/AC:2010

Sweden SS-EN 1992-1-1:2005/AC:2010+A1/2014

Germany DIN-EN 1992-1 +NA/2013-04

3. Beam manufacture

Manufacture according to EN 1090-2 in execution class EXC2 or EXC3. CE marking according

to EN 1090-1, with CE marking certificate 0416-CRP-7247-03.

The standards followed in manufacture and erection are:

EN 1090-1 Execution of steel structures. Part 1: Requirements for conformity

assessment of structural components. [1]

EN 1090-2 Execution of steel structures. Part 2: Technical requirements for steel

structures. Execution classes EXC2 and EXC3. [2]

A-BEAM S

Design Manual 10


EN 13670 Execution of concrete structures. Execution class 2 or 3. [17]

EN ISO 5817 Welding. Fusion-welded joints in steel, nickel, titanium and their alloys.

Weld classes. [11]

EN 17760-1 Welding. Welding of reinforcing steel. Part 1: Load-bearing welded joints.

[16]

4.2 A-BEAM S composite beam design quid for the main design designer

4.2.1 Applications for the beams

The beams are used as load-bearing structures for hollow-core slab floors in office, commercial,

public and industrial buildings as well as multi-storey car parks. Connections to the side of vertical

structures are made using AEL and AEP hidden brackets. Typical applications include the following

frame systems:

1. Concrete element and multi-frame systems

The columns are multi-storey reinforced concrete columns, and the floors are made of hollow-

core slabs. The beam is designed as a single-span structure and connected to a concrete column

using an AEP bracket. In roofs, a multi-span, continuous structure going past the column can be

used, in which case the coupler connection is located in the field. Similarly, a continuous or

cantilever structure can be used in mezzanine floors when the column ends below the floor.

Connections through the column are not recommended.

2. Composite frame systems

The columns are multi-storey composite tubular columns, and the floors are made of hollow-

core slabs. The beam is designed as a single-span structure and connected to a composite

column using an AEL bracket. In roofs, a multi-span, continuous structure going past the

column can be used, in which case the coupler connection is located in the field. Similarly, a

continuous or cantilever structure can be used in mezzanine floors when the column ends below

the floor. Connections through the column are not recommended.

There may be a structurally reinforced surface casting on top of the hollow-core slab, or the surface

may be created using filler or without a surface structure. The bending resistance of the structure can

be significantly increased by design a reinforced surface slab to produce a composite effect as part of

the load-bearing structure of the beam.

4.2.2 Selecting the beam as the building’s floor beam

The beam is selected as the load-bearing structure for the building’s hollow-core slab floor for a

design-and-build query as follows:

1. Hollow-core slab

The hollow-core slab is designed according to the loads on the floor and the span length of the

slab, taking into account that it is supported on a flexible lower flange.

2. Beam cross-section

The cross-section dimensions are selected according to the hollow-core slab height and column

width. Preliminary design is carried out using the ABeam software, which can be downloaded

from Anstar website. The software performs preliminary design of the cross-section according

to the hollow-core slab selected. The software also calculates the shear resistance of the slab’s

ribs according to Concrete Code Card 18EC.

3. Hidden bracket suitable for the beam

Connections to concrete columns are made using AEP hidden brackets and connections to

concrete-filled composite tubular columns using AEL hidden brackets. The software selects the

hidden bracket suitable for the purpose.

A-BEAM S

Design Manual 11


Connections transferring reactive moment cannot be formed using AEP and AEL hidden

brackets. Structurally, it is not allowed to create a situation in which a hidden bracket

connection transfers reactive moment. Vertical angle change must be allowed for the hidden

bracket connection after joint grouting and surface casting such that the top surface of the

bracket’s tongue acts as the pivot point of the connection. The space between the end plate and

the column must not be grouted full.

4.3 Load bearing structure of the A-BEAM S composite beam

4.3.1 Load bearing cross-section of the structure

Together with the concrete of the housing, the joint grouting and the concrete of the surface slab and

hollow-core slab’s top rib, the housing structure forms a composite structure whose load bearing

cross-section includes the following parts:

1. Surface slab ≥40 mm with sufficient transverse reinforcement

When the surface slab has sufficient reinforcement, the load bearing cross-section consists of

the concrete structures in the hatched area of the figure. Filling of the hollow core is not

included in calculating the load bearing cross-section. It is used for calculating the shear

resistance of the hollow-core slab’s ribs. The surface slab reinforcement spreads the splitting

caused by floor deflection and slab end torsion to a wider area, preventing uncontrolled splitting

of the surface slab.

Figure 8. Load bearing cross-section of the structure, reinforced surface slab

2. Surface slab ≥ 40 mm without transverse reinforcement

When the surface slab has no transverse reinforcement, the load bearing cross section consists

of the concrete of the surface slab between the ends of the hollow-core slabs. In this case, it

must be taken into account that the load deflection of the hollow-core slab causes splitting in the

surface slab in the area between the end of the slab and the web. In particular, this must be

considered when selecting the floor surface material.

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Design Manual 12


Figure 9. Load bearing cross-section of the structure, non-reinforced surface slab

3. Surface slab with 10–30 mm filler

The load bearing cross-section of the structure consists of the concrete of the joint in an area the

width of the ends of the hollow-core slabs. In this case, it must be taken into account that the

load deflection of the hollow-core slab causes splitting in the filler of the slab in the area

between the end of the slab and the web. This must be considered when selecting the floor

surface material.

Figure 10. Load bearing cross-section of the structure with a 10–30 mm filler layer

4. Hollow-core slab floor without surface structure

The load bearing cross-section of the structure consists of the concrete of the joint in an area the

width of the ends of the hollow-core slabs. In this case, it must be taken into account that the

load deflection of the hollow-core slab causes splitting in the filler of the slab in the area

between the end of the slab and the web.

Figure 11. Load bearing cross-section of the structure without a surface structure

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Design Manual 13


4.3.2 Loads and load combination

The resistance values of the structure are calculated taking into account the development of the load

history from erection to the final stage. It is also taken into account that structures are connected to

the load-bearing cross-section at different times. The nominal loads and load combination are

specified according to the following principles:

1. Consequence class and execution classes

The consequence class and reliability class are the same as for the building frame, and the

manufacture execution classes are accordingly determined as follows:

Table 4. Consequence and reliability classes as well as manufacture execution classes

Consequence class/

reliability class

Steel structure’s

execution class

EN 1090-2

Concrete structure’s

execution class

EN 13670

Note:

CC1/RC1 EXC2 Execution class 2

CC2/RC2 EXC2 Execution class 2 Standard delivery

CC3/RC3 EXC3 Execution class 3

2. Load during erection

The design load during the erection stage is the dead load of the hollow-core slab with joint

grouting and a live load of 0.5 kN/m2. Other loads during erection are possible, and information

on these must be specified in the design-and-build deal drawings. The moment during the

erection stage: The joints and housings have been grouted but the grouting has not hardened yet.

3. Erection support

The beam can either be erected without erection support or be supported for hollow-core slab

loads during erection. Erection support is provided according to the following principles:

1. No erection supports

The beam and its connections and load-bearing vertical structures withstand loads during

erection as well as the torsional moment from the hollow-core slabs and the additional

torsion caused by the play of the brackets.

2. Erection supports at the end of the beam

The erection support eliminates torsion to the connection during erection and prevents

additional torsion caused by the play of the brackets.

3. Erection supports on the beam span

Deflection and torsion of the beam during erection are limited by means of erection

supports placed at the third-points to reduce the torsion transferred to the end

connections.

Erection support is presented in more detail in Section 3.3 of the erection instructions. Anstar

also provides project-specific instructions for beam-specific erection support on the site.

4. Design for the final stage

The beam acts as a composite structure for loads during the final stage. The design takes into

account that the various structures (including the surface slab) and loads are connected to the

load bearing cross-section at different times. The design is performed using software.

5. Design for fire situations and suspension and torsional steel

Beams can be designed up to fire resistance class R180 without fire protection of the lower

flange. For fire situations, the hollow-core slab is tied with additional steel through the housing.

This steel also ties the final stage torsion caused by the supporting of the hollow-core slab to the

housing. The torsional steel goes directly through the housing on the intermediate line and is

anchored inside the housing on the edge line.

6. Design for accident situations

If necessary, a design analysis for accident situations can be performed according to EN 1992-1-

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Design Manual 14


1, Section 2.4.2.4, by using the partial safety factors in accident situations indicated in Table

2.1N of the standard to determine the resistance of the structure in exceptional situations. [6]

7. Dynamic loads and earthquake loads

Loads including dynamic effects are taken into account according to EN 1990-1, Section 4.1.5,

with the corresponding increased partial safety factors for loads. Earthquake is taken into

account in the load combination according to EN 1991-1[5]. The partial safety factor level is

selected in accordance with the European standard.

8. Fatigue actions

The beam has not been designed for fatigue actions. Fatigue is performed separately on a case-

specific basis according to the principles in EN 1990-1, Section 4.1.4. [4]

9. Using the beams at low temperatures

The impact strength of standard materials is tested at –20 oC. At operating temperatures lower

than this, the material requirement must be increased in the reference plans.

4.3.3 Structural design of the A-BEAM S composite beam

The following principles must be taken into account in the structural design details:

1. Circular reinforcement

The hollow-core slab floor is stiffened into a load bearing plate structure using circular

reinforcement. The circular reinforcement is designed according to EN 1991-1-7. It is designed

by the main structural designer.

The reinforcement is located in the joint between the web and slab, above the torsional steel.

The reinforcement transfers the loads from the plate stiffening to the vertical stiffeners. AEP

and AEL hidden bracket connections have been designed for horizontal load during erection.

This longitudinal resistance of the connection is intended for exceptional erection stage loads

when the circular reinforcement is not functioning yet. In the final stage, the brackets must not

be included in calculating the load bearing horizontal stiffening.

At the same time, the pieces of torsional steel act as part of the circular reinforcement, tying the

hollow-core slabs to each other through the housing. The design is performed according to EN

1991-1-7. [5] The torsional reinforcement calculated by the software does not include the

catastrophe design required by the standard.

2. Ensuring the joint action of the hollow-core slab with the A-BEAM S composite beam

The ABeam software designs the shear resistance of the hollow-core slab’s ribs according to

Concrete Code Card 18EC. The joint action can also be checked using the Flexibl software

available from the Elementtisuunnittelu.fi website. The final resistance analysis of the hollow-

core slabs always belongs to the slab supplier.

3. Filling of the hollow core

The resistance of the profile does not normally require additional filling of the hollow cores

other than for the minimum length required by Concrete Code Card 18EC. Additional filling of

the hollow cores is required in order to increase the shear resistance of the slab’s ribs; the slab

designer provides instructions for this.

With additional filling of the hollow cores, the shear resistance of the hollow-core slab’s ribs

can be significantly increased compared to standard filling, resulting in substantial savings in

the slab’s structure. The additional filling can be designed with the ABeam software.

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Design Manual 15


4. Surface slab reinforcement

Reinforcing the surface slab significantly increases the bending resistance of the structure. The

surface slab is designed to produce a composite effect together with the rest of the structure

when the slab thickness is at least 40 mm. Transverse reinforcement is placed in the surface

slab, also evening out the cracks in the surface slab and ensuring the composite effect. The

surface slab reinforcement significantly improves the shear resistance of the hollow-core slab’s

ribs.

5. Splitting of the surface slab

Deflection of the hollow-core slab causes torsion at the slab’s support, causing cracks in the

joint grouting between the end of the hollow-core slab and the housing. The effect of the cracks

must be taken into account in selecting the surface structures. The cracks cannot be prevented,

but they can be limited by using, for example, a reinforced surface slab or flexible floor surface

materials, allowing for splitting of the surface slab at the end of the hollow-core slab.

6. Vertical separation of the surface slab

The surface slab tends to move away from the upper flange due to the deformation caused by

the slab’s loads and deflection. To eliminate this phenomenon, vertical separation steel parts are

welded to the upper flange, tying the surface casting to the flange. This phenomenon also occurs

in slabs with filler, so its effect must be taken into account for them as well.

7. Removing moisture from inside the housing

After erection, the housing is grouted on the site such that it is filled with concrete, and moisture

runs out through the web holes and the vent holes at the top edge of the web. However, the final

drying of the inner parts of the housing must be taken into account in scheduling the

manufacture of the surface structures.

8. Structure’s service life and durability

Service life and durability design is performed according to the instructions in EN 1992-1. The

surface treatment and protection requirements are specified in Section 5.7 of this manual.

Durability design must be performed separately for the upper and lower structures of the

housing if they have different exposure classes.

9. Division of responsibilities and allocation of tasks in designing connections

The following allocation of tasks, division of responsibilities and information transfer methods

are followed in designing connections connected to load-bearing structures of the building.

Table 5. Division of responsibilities and allocation of tasks relating to connections

Connections to

load-bearing frame

Main structural designer’s

tasks and responsibilities

Anstar Oy’s tasks and

responsibilities

1. Bracket

connection to

concrete column

- Selects the connection type and

preliminary bracket type and

size.

- Responsible for placement of

the bracket’s column

component as well as the

bracket’s supplementary

reinforcement in the concrete

column.

- Responsible for fire protection

of the bracket.

- Calculates the bracket’s final

forces during the erection stage

and final stage and confirms the

size of the bracket selected.

- Specifies the erection supports

necessary.

- Provides load data for the

connection.

2. Bracket

connection to

composite column


preliminary bracket size.

- Responsible for placement of

the bracket’s column

component in the composite

column, supplementary

reinforcement and welding the

- Calculates the bracket’s final

forces during the erection stage

and final stage and confirms the

size of the bracket selected.

- Specifies the erection supports

necessary.

- Provides load data for the

A-BEAM S

Design Manual 16


bracket to the column surface. connection.

3. Bolt connections

on top of a

column or wall


preliminary bolt dimensions.

- Performs final design of the

connection using forces

received from the beam design

unit.

- Responsible for bolt design in

the concrete structure.

- Calculates the final forces on the

connection during the erection

stage and final stage.

- Provides the main structural

designer with data on the forces

on the connection.

- Designs the necessary provisions

for the beam.

4. Welded

connection to a

mounting plate on

top of a column or

wall


mounting plate dimensions.

- Performs final design of the

connection using forces

received from the beam design

unit.

- Responsible for design of the

mounting weld of the mounting

plate and end plate in the

concrete structure.

- Calculates the final forces on the

connection during the erection

stage and final stage.

- Provides the main structural

designer with data on the forces.

- Designs the necessary connection

provisions for the beam.

5. Coupler

connection in the

field, secondary

beam connection

- Preliminary placement of

coupler connections.

- Connections are taken into

account in designing the rest of

the floor structure.

- Designs and implements the

connections on the beams.

6. Other special

connections

- The division of responsibilities

must always be agreed case-

specifically in the detail design

phase.

- If necessary, Anstar delivers data

on the forces loading the

connection.

- Anstar manufactures the

connection pieces needed for the

beam.

10. Ensuring the joint action of the hollow-core slab with the A-BEAM S composite beam

The beam cross-section produces a composite effect together with the joint grouting and the end

of the hollow-core slab. Structures producing a composite effect are presented in figures 8–11.

Anstar designs the composite effect of the beam using preliminary hollow-core slab data. The

final design of the shear resistance and composite effect of the slab’s end belongs to the hollow-

core slab supplier.

The beam’s joint action with the hollow-core slab can be confirmed with the Flexibl 8.37

software version, which includes the latest beam profiles of the A-BEAM S and A-BEAM W

types. If necessary, during the project implementation phase, Anstar can check the joint action

of the hollow-core slab using the final material and cord data received from the slab supplier.

11. AOK-Support for hollow-core slab floor openings

A new support structure has been made of the S-type beam for supporting the end of a hollow-

core slab in a floor opening. The new AOK support is a composite column application to be cast

in connection with the slab’s joint grouting. The length of the support can be selected freely

according to the width of the floor opening, and the span lengths of the bracket are within the

range of 1200–4800 mm. The resistance of the bracket is sufficient for normal hollow-core slab

loads and span lengths, and its fire resistance without protection can be implemented up to

R180.

A-BEAM S

Design Manual 17


5 DESIGNING THE A-BEAM S

5.1 Design-and-build deal

Design phases:

Anstar Oy is responsible for designing and manufacturing the beams as part of a design-and-build

deal. Our technical support will provide assistance with questions arising in various phases of the

design process.

The design responsibilities in the design-and-build deal are as follows:

1. Allocation of design tasks in the bidding phase

Main structural designer Anstar Oy

- Comparing frame options

- Preliminary design of floor structures

- Preliminary design of the beam

- Preliminary design of the hidden bracket

type

- Preliminary detail design

- Preliminary connection design

- Service life design

- Query material for the design-and-build

deal

- ABeam software

- Anstar Oy’s technical support

- Technical assistance in design the beam

- Hidden brackets and their operating instructions

- Connection type details

- TS components

- Bid calculation and preliminary inspection of the

floor’s joint action

2. Allocation of design tasks in the implementation phase


- Updating structural plan drawings

- Designing the circular reinforcement of

the slab

- Updating detail drawings

- Designing beam connections to concrete

structures

- Service life and durability design

- Beam design and strength calculation

- Manufacturing drawings

- Data for the hollow-core slab designer

- Information about structural and connection

detail updates

- Providing concrete structure design with data on

the forces on the connections

3. Preparation and construction


- Having plans approved by building

control

- Supplementing the erection plan

- Quality control plan

- Beam manufacture and delivery

- Erection Manual, A-BEAM S [23]

- Additional instructions for erecting the beams

- Instructions for providing the beams with

erection supports

4. Initial data for design as part of the design-and-build deal

For implementation planning, Anstar needs the following information from the main structural

designer:

1. Structural plan

drawings

- Structural plan drawings and preliminary beam codes

- Design standard and reliability and consequence class

- Execution class according to EN 1090-2

- Structure class of concrete structures according to EN 1992-1-1

- Floor loads, provisions, fire resistance class information and floor

openings

- Floor surface structure types and wall connection data to floor, structure

sections

- Column locations, materials and final dimensions

- Preliminary connection detail data and connection types

2. Initial data for

the beam

- Service life and durability data as well as surface treatment requirements

- Any special manufacturing tolerances

- Jaw removals: length, width and location

- Other perforation: size and location

A-BEAM S

Design Manual 18


- Equipment suspensions and other mounting provisions

- Other special requirements

5.2 ABeam software for composite beams

The ABeam software for preliminary design can be downloaded from our website. The software can

be used for designing the beam for a design-and-build deal query. The software can be used on

Windows 7, 8 and 10. The user interface structure of the software is shown in Figure 12.

1. Software user interface

In the main window, the software shows the beam’s cross-section according to the initial data

provided. The Cross-section data buttons are used to select the initial data windows below the

figure.

The following initial data is specified for the calculation:

Select the general calculation data, location of the beam on the

intermediate or edge line and erection support of the beam. Also specify

the load range of the beam.

Select the hollow-core slab type and materials to be used as well as the

erection support of the slabs on the beam flange.

Select the surface structure and materials of the hollow-core slab. Select

the weight class and cross-section of the beam to be calculated from the

standard profile library.

Figure 12. User interface structure of the ABeam software

The Results buttons are used to view the results of the calculation. A green check mark in the

button means acceptable utilisation rates for all the quantities, and a red check mark means that

the utilisation rate has been exceeded for some calculation value. The calculation results are

presented in the following situations:

A-BEAM S

Design Manual 19


The window shows the power quantities during the erection stage and their

utilisation rates when the joint grouting of the floor has been performed but

has not hardened yet.

The window shows the power quantities in the ultimate limit state,

deflection in the serviceability limit state, design for fire situations and the

utilisation rates of the quantities. Loads at the final stage.

The software calculates the shear resistance of the ribs at the hollow-core

slab’s end according to Concrete Code Card 18EC.

The utilisation rates of the most important quantities for bending moment

and shear resistance of the hollow-core slab’s ribs are shown at the bottom

of the window. If these are green, all resistance values are OK. The

deflection must be checked separately.

2. Selecting the calculation standard

At the beginning of the calculation, create a project folder in the File/Project folder menu.

When creating a project folder, you select the calculation standard used by the software for the

folder. When you perform a new calculation later and select this project folder, the calculation

standard copied to the folder will be used. To change the standard, create another project folder.

The calculation standard is shown as an icon in the bottom left corner. The software remembers

the folder and standard last used.

The following standards are available:

EN 1992-1-1:2004 Basic Eurocode

SFS-EN 1002-1-1:2005+NA Finnish Eurocode + NA

SS-EN 1992-1-1:2005/AC:2010+A1/2014 Swedish Eurocode + NA

DIN-EN 1992-1-1:2011-01+A1/2014 German Eurocode + NA

3. General data of beam

By selecting General data of beam, you can provide general data for the calculation. Figure 13.

1. Location of beam Select either intermediate beam or edge beam. The structure of the top

window changes correspondingly.

2. Span of beam Specify the span length to be calculated. This is usually the distance

between the beam’s end plates.

3. Spans of slabs/

distance to edge

Specify the distance to the centre of the adjacent line or to the outer edge

of the floor. This determines the beam’s load range.

4. Erection support Specify the use and location of erection supports and the erection order of

hollow-core slabs. There are three options available:

1. No erection supports

2. Erection supports are located under the jaw at the ends of the beam.

The torsion to the bracket and the torsion of the connection are

eliminated.

3. Erection supports are located on the beam of the span and the

distance of the support is specified. This reduces deflection and

torsion during erection.

4. Floor system

This window is used to specify the data of hollow-core slabs separately for each side of the

beam. The hollow-core slab material selections are used for calculating the composite effect of

the structure as well as the shear resistance of the slab’s ribs in accordance with Concrete Code

Card 18EC.

A-BEAM S

Design Manual 20


Figure 13. Information on the hollow-core slab

5. Beam cross-section

This window is used to select the surface slab type, materials and possible reinforcement and the

cross-section to be used. The structure of the window changes according to the surface slab type

selected. This window is used to check that the selected cross-section fits the structure being

designed.

1. Type of top slab There are four surface structure options to choose from.

2. Structure of top

slab

Select the thickness and materials of the surface slab and specify whether

the surface slab is taken into account in the calculation as a composite

structure.

3. Transverse

reinforcement

Select the surface slab reinforcement.

4. Height of the beam Only one height option is available for the S type.

5. Type of the beam There are three different weight classes to choose from. The cross-section

– light L, normal N or heavy H – determines the bending resistance of the

profile.

6. Choose cross-

section of beam

The cross-section is selected from the database according to the height and

width. The window shows the structure of the cross-section with the

hollow-core slabs.

7. Elevation parts Elevation parts are used to adjust the beam height for hollow-core slabs of

various heights.

8. Joint concrete Select the strength of the concrete of the joint and housing.

Figure 14. Surface slab and profile cross-section data

A-BEAM S

Design Manual 21


6. Loads

Figure 15 shows the dead and live loads specified for the slab. The software calculates the dead

loads of all the structures displayed in the top window, so these are not specified. The load can

be either uniform or trapezoidal and for either part of the slab or the entire slab.

Figure 15. Loads on the slab

7. Design the beam cross-section

The software performs the following design for the beam:

1. Erection stage For the erection stage, the software calculates the ultimate limit state

resistance before hardening of the housing and joint grouting as well as the

bracket resistance at the erection stage, which can be influenced by means

of erection support.

2. Final stage For the final stage, the software calculates the ultimate limit state

resistance as well as the bracket utilisation rate for final loads. The

software selects the smallest AEL hidden bracket according to the loads

specified and the dimensions of the beam. In the beam design, Anstar

checks the final resistance of the bracket.

3. Fire situation Fire situation resistance is calculated using the fire situation loads

specified in the load data, with the lower flange no longer acting in the

structure.

4. Shear resistance of

the ribs at the

hollow-core slab’s

end

The software calculates the shear resistance of the ribs at the hollow-core

slab’s end in composite effect with the beam according to Concrete Code

Card 18EC. The resistance can be increased by filling of the hollow cores,

concrete strength and reinforcement of the surface slab. This preliminarily

determines the suitability of the hollow-core slab for the case. The

software does not calculate the bending resistance of the hollow-core slab

or determine the final cording required.

5.3 Joint action of the A-BEAM S composite beam and hollow-core slab

5.3.1 Placement of the hollow-core slab

The following must be taken into account in designing the connection between the housing profile

and the hollow-core slab:

1. Supporting the hollow-core slab on the lower flange

The theoretical clearance of the end of the hollow-core slab from the web is 20 mm with the S-

type beam. The slab’s support surface has the following values: Also see Figure 16.

- For hollow-core slabs OL200–OL370, the support surface is 80 mm, minimum value 65

mm.

- For hollow-core slabs OL400–OL500, the support surface is 110 mm, minimum value 100

mm.

A-BEAM S

Design Manual 22


In the support surface width, the manufacturing tolerances of the hollow-core slab’s length must

be taken into account as a factor reducing the support surface. Figure 16 shows the standard for

placing the hollow-core slab on the lower flange.

2. Concrete filling of the hollow cores and shear resistance of the ribs

In terms of strength engineering, the functioning of the structure does not require concrete

filling of the hollow cores for a length greater than the basic value indicated in the Concrete

Code Card. Additional filling of the hollow cores is required when the shear resistance of the

slab’s concrete ribs is not sufficient in the joint action analysis in accordance with Concrete

Code Card 18EC.

In connection with the final design, Anstar checks the shear resistance of the slab’s ribs,

ensuring acceptable joint action of the housing and hollow-core slab. The ultimate responsibility

for design the slab rests with its supplier, who performs the calculations using the final

structural values of the hollow-core slab.

Figure 16. Dimensions for placing the hollow-core slab on the lower flange

3. Hollow-core slabs of different heights and elevations

The software can also be used for calculating hollow-core slabs of different heights whose top

surfaces are not level with each other. The design is performed for all surface slab options. With

long span lengths, the profile can also be elevated using elevation parts on the lower flange.

5.3.2 Addition steel for the beam

Torsional steel in accordance with Figure 17 is placed in the cross-section for the joint action of the

housing profile and hollow-core slab.

1. Torsional steel

For fire situations, the hollow-core slabs are suspended using pieces of torsional steel placed in

the slab joint through the housing. These pieces of steel also tie the torsional moment caused by

the hollow-core slabs’ eccentric support to the housing. On the centre line, the pieces of steel go

straight through the housing in every joint of the hollow-core slab. On the edge line, the steel is

bent into a hook inside the housing. These pieces of torsional steel are designed by Anstar and

are part of the site acquisitions.

Figure 17. Torsional reinforcement of the centre and edge line

A-BEAM S

Design Manual 23


2. Circular steel for the hollow-core slab floor

Pieces of circular steel are placed in the joint grouting between the hollow-core slab and the

housing and are designed to combine the hollow-core slab floor into a plate stiffening the

building, transferring the horizontal loads to the vertical stiffening.

Figure 18. Torsional reinforcement of the edge line

The hidden bracket and other standard connections transfer the horizontal force on the frame

before the hardening of the joint grouting by their horizontal force resistance, and this can be

used to ensure the stability of the frame during erection. During the final stage, all horizontal

forces are transferred using these pieces of circular steel. The circular steel is designed by the

main structural designer.

5.3.3 Grouting for the structure

The housing acts as a composite structure with the hollow-core slab when all grouting has hardened.

The joint action of the housing profile and slab as a composite structure is influenced by the

following concrete grouting:

1. Grouting inside

the housing

The housing is filled with concrete in connection with joint grouting of the

hollow-core slab. The housing grouting acts as part of the load-bearing structure,

and quality control of the concrete must be carried out according to the

requirements for structural concrete.

2. Grouting of the

joint between the

hollow-core slab

and housing

Joint grouting of the hollow-core slab is performed once the pieces of additional

steel have been erected. Grouting is performed by simultaneously grouting the

housing, the longitudinal joints of the slab and the joint between the housing and

slab up to the top surface of the floor.

3. Surface casting of

the hollow-core

slab

The surface or filler casting of the hollow-core slab floor is performed after the

joint grouting has hardened and dried.

5.3.4 Surface casting of the hollow-core slab

Structurally, there are four different ways of performing the surface casting of the hollow-core slab

floor, and this influences the structural function of the beam. The surface casting options are:

1. No surface casting

Such structures include roofs and parking deck floors, where water and thermal insulation layers

are placed on top of the slab. In this case, corrosion and fire protection of the upper flange must

be carried out separately.

A-BEAM S

Design Manual 24


Figure 19. Joint grouting of the structure in the roof without a surface slab or bay

2. Surface structure consists of 10–30 mm filler casting

Such structures include intermediate floors of residential buildings and other structures only

requiring a thin layer of filler on top of the slab. Light floor surface structures are placed on top

of the filler. The filler must also protect the upper flange against fire and corrosion.

Figure 20. Joint grouting of the structure in the intermediate floor with 10–30 mm surface filler

3. Surface structure is at least 40 mm reinforced concrete

Such structures include intermediate floor slabs of office and public buildings, where the span

lengths are long, and the floor requires surface casting for the floor surface structures.

Reinforcement mesh is placed in the surface casting to even out cracks caused by deflection of

the hollow-core slab.

Figure 21. Joint grouting of the structure in the intermediate floor with a structural surface slab

4. Surface structure is a bay on top of the beam

A reinforced concrete topping bay can be used in the roofs of buildings to significantly increase

the bending resistance of the structure. The bay is located in the thermal insulation space of the

structure, also protecting the upper flange of the beam against fire and corrosion.

A-BEAM S

Design Manual 25


Figure 22. Joint grouting of the structure in the roof with a reinforced surface casting bay

5.4 A-BEAM S composite beam’s connections

5.4.1 Standard connections of the beam The beam can be connected to the side of a concrete and composite column and on top of a concrete

wall and column using hidden bracket and anchor bolt products. There is a library of standard

connections that can be used to implement the most common types of connections. Standard

connections to load-bearing vertical structures are described below.

5.4.2 Hidden bracket connection to a concrete column

The beam’s standard connection to a concrete column or concrete wall is the AEP hidden bracket.

The resistance values and more detailed design instructions for the brackets are provided in the user

manual for AEP hidden brackets.[21]

1. Dimensions for placing the A-BEAM S composite beam and AEP hidden bracket in a

concrete column

The web width of the beam must be selected for intermediate and edge beams such that the

bracket is located on the centre line of the round column. In the beam, the hidden bracket is

always located on the centre line. The bracket acts as a swivel joint, and it is not allowed

structurally to create a situation in which the connection transfers bending moment.

The height of the AEP bracket’s column component is determined such that the bottom surface

of the bracket’s front plate is level with the top surface of the lower flange.

Compatibility of the AEP hidden bracket with the A-BEAM S standard beam by size class A200 A265 A320 A370 A400 A500

AEP400

AEP600

AEP800

AEP1100

Figure 23. AEP bracket connection to a concrete column

A-BEAM S

Design Manual 26


5.4.3 Hidden bracket connection to a composite column

The standard connection of the A-BEAM S composite beam to the side of a composite tubular

column is the AEL hidden bracket. The resistance values and more detailed design instructions for

the brackets are provided in the user manual for AEL hidden brackets.[22]

1. Dimensions for placing the beam and AEL hidden bracket in a composite column

The bracket is placed on the side of a steel column such that the connection is centred on the

column. The elevation of the AEL bracket’s column component is +45 mm from the bottom

surface of the hollow-core slab (= top surface of the lower flange). If using an elevated profile,

the bracket’s column component is placed at an elevation of +45 mm from the top surface of the

lower flange. For more information, refer to the user manual for the AEL hidden bracket.

Anstar Oy manufactures the AEL brackets and delivers them to the machine shop that

manufactures the composite column, where the bracket is welded to the surface of the

composite column. The AEL hidden bracket has been designed in the R60 fire resistance class

and has two dowel pins, which are placed in the concrete core of the composite column through

the tube. The composite column must be reinforced for the fire resistance class required.

Compatibility of the AEL hidden bracket with the A-BEAM S standard beam by size class A200 A265 A320 A370 A400 A500

AEL250

AEL400

AEL600

AEL900

AEL1200

AEL1500

Figure 24. AEL bracket connection to composite column

5.4.4 Beam coupler connection in the field

The beam is designed as a continuous structure going over the column in the roof, meaning that the

coupler connection is located in the field near the origin of the bending moment. The coupler

connection in the field is made using a connection type in accordance with the AEL bracket. The

connection forms a swivel joint at the ends of the beam, and the connection clearance is 20 mm. The

connection requires normal fire protection according to the user manual for the AEL bracket. [22]

A-BEAM S

Design Manual 27


Figure 25. Beam coupler connection in the field

5.4.5 End plate connection to the side of another beam

When the load-bearing direction of a hollow-core slab changes in the adjacent field, a secondary

beam can be connected to the

side of a primary beam using an end plate connection. The beam is designed as a single-span

structure, and the connection transfers the shear force and torsional moment but not the bending

moment. After mounting, the connection is ready to be loaded. Anstar designs and delivers these

connection pieces. Figure 26 shows the connection principle.

Figure 26. End plate connection to a primary beam

5.4.6 Bolt connection on top of a column or wall

The beam can be connected on top of a column or wall using two AHP rebar bolts. The following

must be taken into account in designing the connection:

- The height of the connection is adjusted using fitting pieces made of neoprene or steel plate, and

they must allow for vertical torsion at the bolt and end plate.

- The vertical support reaction of the connection is transferred from the end plate through the

fitting pieces to the column.

- The grouting of the connection must not be performed such that the front edge of the column

starts transferring the shear force on the beam. No concrete is allowed under the lower flange.

The joint must be sealed with fire-resistant sealant.

- The connection can be used for transferring the beam’s torsional moment.

Force is applied to the bolt.

Nd = Vd /2 ± Mvd /p, where

Vd = Beam’s shear force

Mvd = Beam’s torsional moment

A-BEAM S

Design Manual 28


p = Distance between bolts

- The design values and reinforcement instructions for AHP rebar bolts are provided in the bolt

user manual [24].

Figure 27. Bolt connection on top of a column or wall with two bolts

5.4.7 Welded connection to a mounting plate on top of a column or wall

The beam can be connected on top of a column or wall by welding its end plate to a mounting plate

on the column. The following must be taken into account in designing the connection:

- If necessary, the height of the connection can be adjusted using fitting pieces made of steel

plate, which must first be welded to the mounting plate.

- The vertical support reaction of the beam is transferred from the end plate through the fitting

pieces to the mounting plate and the column.

- The joint grouting of the connection must not be performed such that the front edge of the

column starts transferring the shear force on the beam. No concrete is allowed under the lower

flange. The joint must be sealed with fire-resistant sealant.

- The connection transfers torsional moment, and the weld is designed for the following forces.

Forces acting on the mounting plate weld:

Nd = Vd /2 ± Mvd /p, where

Vd = Beam’s shear force

Mvd = Beam’s torsional moment

p = Effective length of the weld, or if there are two welds, the distance between them.

The weld is designed according to EN 1993-1-8.

- The connection solution is selected according to the dimensions of the load-bearing vertical

structures and the space available.

Figure 28. Welded connection to a mounting plate on top of a column or wall

A-BEAM S

Design Manual 29


5.4.8 Building services lead-throughs and equipment fastenings

Additional fastenings can be made to the beam on the site for erections required by building services.

However, heavy equipment suspensions are implemented through beam design to provide the

structure with safe fastening points. Equipment suspensions can be welded on the lower flange, in

the area between the webs. Weld fastenings of equipment supports can also be made on the upper

flange.

Small pipes and other installations required by building services can be taken through the housing.

However, information about this must be delivered to detail design. Lead-throughs implemented on

the site are not possible except through the housing’s grouting opening. However, the grouting

opening cannot be closed completely or cut to make it larger, and permission must be obtained for

using it. Figure 29 shows the allowable fastening areas of the beam in green.

On an edge beam, fasteners can be made for temporary handrails if necessary.

Figure 29. Allowable lead-through and fastening areas of the beam

5.5 Fire protection of the beam and connections

The beam and its connections are designed for the same fire resistance class as the frame. The beam

is designed up to fire resistance class R180 without external fire protection of the lower flange. In a

fire situation, the load-bearing structure consists of the concrete of the housing with the stirrups and

the bottom surface rebar. In a fire situation, the suspension and torsional steel transfer the hollow-

core slab’s loads to the housing profile when the lower flange has no load-bearing capacity left. Fire

protection details for the beam and its standard connections are presented in Section 6 of the Erection

Manual. [23]

5.6 Service life design of the structure

Service life and durability design for concrete structures is performed according to the principles of

EN 1992-1. The requirements of EN ISO 12944 are applied for steel structures [12]. The analysis

must be performed separately for the top and bottom of the structure, particularly if they have

different exposure classes.

1. Durability of concrete and rebar

The concrete and pieces of rebar inside the housing have sufficient protection in each exposure

class. The nominal value for the concrete cover outside the housing is specified according to the

exposure class for the structural and rebar parts of the housing.

2. Durability of steel parts

Surface treatment of the steel parts left outside the concrete is carried out according to EN

12944-2 [12] by applying the instructions to the exposure classes of EN 1992-1. The

atmospheric corrosivity category according to EN 12944-2 and its requirements are only taken

A-BEAM S

Design Manual 30


into account in the surface treatment of the visible lower flange and the web against the exterior

wall.

The standard delivery is machine shop priming of the lower flange surfaces and the web at a

height of 50 mm. The other protection requirements are specified in the reference plans.

Table 6 shows the nominal value Cnom for the concrete cover of the structure’s supplementary

reinforcement or steel parts by exposure class according to minimum value Cmin,cur in EN 1992-1.

The nominal value for the concrete cover of the steel parts is Cnom = Cmin,cur + Δcdev (= 10 mm). Table

6 also shows the recommended minimum surface treatments and protection methods in various

exposure classes.

Table 6. Nominal value Cnom for the steel parts’ concrete cover and surface treatment methods

Exposure

class EN

1992-1

Concrete

Codes

50-year

service

life

Cnom

mm

100-year

service

life

Cnom

mm

Surface treatment options and protection methods recommended

for the beam

Minimum requirement for

lower flange surface

treatment

Upper flange surface treatment

or other protection method

X0 20 20 Machine shop priming. Finish

painting only for visible parts as

necessary. Specified in the

structural plans.

No surface treatment.

Minimum concrete cover requirement

for top surface steel parts or machine

shop priming for the upper flange.

XC1 20 30 Machine shop priming.

Necessary finish painting specified

in the structural plans.

No surface treatment.

Minimum concrete cover requirement

for top surface steel parts or machine

shop priming for the entire beam.

XC3 35 45 Machine shop priming.

Necessary finish painting specified

in the structural plans.

Machine shop priming. Minimum

concrete cover requirement for top

surface steel parts. Structural concrete

topping and waterproofing prevents

water from getting inside the beam.

XD1–XD3 50 60 The beams are hot-dip galvanised

according to the standard [13].

Torsional and suspension

reinforcement as well as circular

steel are hot-dip galvanised.

Beams are hot-dip galvanised.

Structural concrete topping and

waterproofing prevents water from

getting inside the beam.

XS1–XS3 XA1–XA3

XF1–XF4

– – The beams may only be used on the basis of site-specific special analyses. The

beam’s surface treatment, protection methods and concrete cover’s nominal

value are specified according to the site requirements.

6 DESIGN-AND-BUILD DEAL DELIVERY DOCUMENTS

The standard delivery includes the following beam manufacturing documents and design data for

updating the structural plans:

Table 7. Documents included in the beam delivery

Documents and other design data

delivered to the main structural designer

Contents and purpose of the documents

1. Manufacturing drawings For building control

2. Beam strength calculations For building control

3. Beam table Data for updating structural plan drawings

4. Forces on bracket connections Final bracket and force data for designing adjoining concrete

structures.

5. Forces on other connections Final connection and force data for designing connections to

the beam and concrete structures.

6. Product approval information This information can be found on our website

- CE marking certificate

- Quality control certificates

A-BEAM S

Design Manual 31


REFERENCES [1] EN 1090-1 Execution of steel structures and aluminium structures. Part 1:

[2] EN 1090-2, Execution of steel structures and aluminium structures. Part 2: Technical requirements for steel structures.

[3] EN ISO 3834. Quality requirements for fusion welding of metallic materials. Part 1: Criteria for the selection of the

appropriate level of quality requirements, and parts 2–5.

[4] EN 1990, Eurocode. Basis of structural design.

[5] EN 1991-1, Eurocode 1. Actions on structures, parts 1–7.

[6] EN 1992-1-1, Eurocode 2. Design of concrete structures. Part 1-1: General rules and rules for buildings.

[7] EN 1992-1-2, Eurocode 2. Design of concrete structures. Part 1-2: General rules. Structural fire design.

[8] EN 1993-1, Eurocode 3. Design of steel structures. Part 1-10: General rules and rules for buildings.

[9] CEN/TS 1992-4-1 Design of fasteners in concrete – Part 4-1: General.

[10] CEN/TS 1992-4-2 Design of fasteners use in concrete – Part 4-2: Headed Fasteners.

[11] EN ISO 5817, Welding. Fusion-welded joints in steel, nickel, titanium and their alloys. Weld classes.

[12] EN ISO 12944, Paints and varnishes. Corrosion protection of steel structures by protective paint systems. Part 1: General, and

parts 2–7.

[13] EN ISO 1461. Hot dip galvanized coatings on fabricated iron and steel articles.

[14] EN 10025, Hot rolled products of structural steels. Part 1: General technical delivery conditions.

[15] EN ISO 1684 Fasteners. Hot dip galvanized coating.

[16] EN 17760-1 Welding. Welding of reinforcing steel. Part 1: Load-bearing welded joints.

[17] EN 13670 Execution of concrete structures.

[18] EN 13225 Precast concrete products. Linear structural elements.

[19] EN 13369 Common rules for precast concrete products.

[20] Concrete Code Card No. 18EC (EN 1992-1-1) 31.7.2012

[21] Anstar Oy. AEP Bracket User Manual.

[22] Anstar Oy. AEL Bracket User Manual.

[23] Anstar Oy. A-BEAM S Erection Manual

[24] Anstar Oy. ATP Rebar Anchor Bolts

LIST OF TABLES Table 1. A-BEAM S. Standard intermediate and edge beams ....................................................................................................... 5 Table 2. Intermediate beam dimensions ....................................................................................................................................... 7 Table 3. Edge beam dimensions ................................................................................................................................................... 8 Table 4. Consequence and reliability classes as well as manufacture execution classes ........................................................... 13 Table 5. Division of responsibilities and allocation of tasks relating to connections ................................................................. 15 Table 6. Nominal value Cnom for the steel parts’ concrete cover and surface treatment methods .............................................. 30 Table 7. Documents included in the beam delivery .................................................................................................................... 30

PICTURES

Figure 1. A-BEAM S composite beam in a building frame ............................................................................................................ 4 Figure 2. Structure of composite beams. Beam types W and S ....................................................................................................... 4 Figure 3. Intermediate floor structure, reinforced surface slab and surface filler ......................................................................... 6 Figure 4. Roofing structure, reinforced surface casting bay and hollow-core slabs of different heights ...................................... 6 Figure 5. Floor edge structure and level difference at the top surface of the slab ......................................................................... 6 Figure 6. Intermediate beam structure ........................................................................................................................................... 7 Figure 7. Edge beam structure ....................................................................................................................................................... 8 Figure 8. Load bearing cross-section of the structure, reinforced surface slab ........................................................................... 11 Figure 9. Load bearing cross-section of the structure, non-reinforced surface slab ................................................................... 12 Figure 10. Load bearing cross-section of the structure with a 10–30 mm filler layer ................................................................... 12 Figure 11. Load bearing cross-section of the structure without a surface structure ...................................................................... 12 Figure 12. User interface structure of the ABeam software ........................................................................................................... 18 Figure 13. Information on the hollow-core slab ............................................................................................................................ 20 Figure 14. Surface slab and profile cross-section data .................................................................................................................. 20 Figure 15. Loads on the slab .......................................................................................................................................................... 21 Figure 16. Dimensions for placing the hollow-core slab on the lower flange ............................................................................... 22 Figure 17. Torsional reinforcement of the centre and edge line .................................................................................................... 22 Figure 18. Torsional reinforcement of the edge line ...................................................................................................................... 23 Figure 19. Joint grouting of the structure in the roof without a surface slab or bay ..................................................................... 24 Figure 20. Joint grouting of the structure in the intermediate floor with 10–30 mm surface filler ................................................ 24 Figure 21. Joint grouting of the structure in the intermediate floor with a structural surface slab ............................................... 24 Figure 22. Joint grouting of the structure in the roof with a reinforced surface casting bay ......................................................... 25 Figure 23. AEP bracket connection to a concrete column ............................................................................................................. 25 Figure 24. AEL bracket connection to composite column .............................................................................................................. 26 Figure 25. Beam coupler connection in the field ........................................................................................................................... 27 Figure 26. End plate connection to a primary beam ...................................................................................................................... 27 Figure 27. Bolt connection on top of a column or wall with two bolts ........................................................................................... 28 Figure 28. Welded connection to a mounting plate on top of a column or wall ............................................................................. 28 Figure 29. Allowable lead-through and fastening areas of the beam ............................................................................................ 29

A-BEAM S

Design Manual 32


Anstar Oy

Erstantie 2

FI-15540 Villähde, Finland

Tel. +358 3 872 200

Fax +358 3 872 2020

www.anstar.fi

[email protected]

Anstar Oy is a Finnish family business established in 1981. We offer concrete structure connections and composite structures manufactured in Finland for our customers worldwide. Created through innovative development work and using modern production

technology, our extensive product range speeds up construction and saves on costs. We take pride in our high-quality products and quick deliveries. Our products have the necessary official approvals, and external quality control is carried out

by Inspecta Sertifiointi Oy. We have been granted the ISO 9001 and ISO 14001 quality and environmental certificates. Our production is certified according to EN 1090-1 and EN 3834-2.

Joint solutions since 1981

JOINT SOLUTIONS FOR CONSTRUCTION