bridge beam manual

Precast concrete specialists

Bridge Beam Manual2nd Edition

Introduction 2

Brief History of Prestressed Bridge Beams 3

Banagher Precast Concrete Bridge Beam Types 4

M & UMB Edge Beam - for Beam and Slab Construction 8

MY & MYE Edge Beam - for Solid Slab Construction 10

Solid Box Beam 12

SY & SYE Edge Beam 14

T Beam - for Solid Slab Construction 16

TB Beam - for Solid Slab Construction 18

TY & TYE Edge Beam - for Beam and Slab Construction 20

TY & TYE Edge Beam - for Solid Slab Construction 22

U & SU Beam 24

W Beam 28

Y & YE Edge Beam 32

Fibre Reinforced Concrete Permanent Shutter 34

Precast Parapet, Coping and Edge Beam details 36

Lifting and Handling Details 42

Delivery and Installation 44


Contents

1Precast concrete specialists

Precast concrete specialists Precast concrete specialists

Introduction Brief History of Prestressed Bridge Beams

Banagher Precast Concrete is the largest precast concrete manufacturer in Ireland and the UK. Our track record in the field of precast concrete manufacture is exceptional. We have established an internationally recognised reputation for innovation in design, manufacture and installation of precast components.

The Banagher Precast Concrete team, comprising of experienced chartered structural engineers, graduates and technicans, is continually working on enhancing our range of products to meet the latest demands. We also offer early stage design assistance to consultant engineers and contractors.

• Trusted and experienced supply partner with vast experience. Bridge beams have been manufactured in Banagher for over 60 years

• Largest Bridge beam manufacturing facility in Ireland and the UK with capacity to manufacture 2Km of bridge beams per week.

• All beams are designed to British and Eurocode standards by our Design Team

• All beam sections and profiles are available in BIM format.

• All Precast elements including Bridge Beams have CE marking and concrete is certified to EN 206. We operate and maintain ISO 9001 Quality Assurance standards.

• All our Bridge beam sections including the W beam and MY Beams (designed and developed by Banagher) are recognised and used in Computer Bridge Beam design packages.

pretensioned prestressed concrete bridge beams were introduced into many countries in the period 1948 to 1995. in the period after the War, infrastructure which had been damaged or neglected had to be replaced. the newly developed pretensioning technique was put to use in the manufacture of beams which could be used for a variety of bridging and decking problems.

At first, manufacturers rushed in competition to develop their own sections, which provided choice but only at the provisional layout stage. In some countries this was seen as a major disadvantage, compared with standard steel sections which could be specified and bought freely and competitively at the time of construction. Industry groups, with the blessing of National Authorities, removed this disincentive by developing a series of beam sections which could be made by any manufacturer. The Standard Bridge Beam was born.

In Ireland the first prestressed concrete bridge beam project was the “OB56 Dublin to Cork Line at Sallins” in 1952. It consisted of 15 number I Beams, 11430mm long weighing 4.5 tonne. The beams were 560mm deep and 460mm wide with a prestressing force of 950 kilonewtons and 4 number prestressing bars per beam.

In the UK the first Standard beams were developed by the PCBDG (Prestressed Concrete Bridge Development Group) and were an Inverted T beam for a solid slab deck, an I beam for a beam and top slab deck and a Box Beam for a voided deck. In the USA an I beam, a Box beam and a Bulb T were similarly developed. The PCBDG Inverted T beam is still made today, after 60 years of excellent service.

In the UK and Ireland by 1973, the M Beam, a larger version of the Inverted T for beam and slab and voided decks and a U Beam which provided a voided deck of more elegant appearance had been introduced.

By the mid 1980’s, it became clear that although bridge beams were performing well, the joints between decks and their supporting abutments tended to leak and winter road salt was being allowed to penetrate down to bearing shelves and substructures causing corrosion damage. This problem applied to bridges of all forms of construction, insitu concrete and steel included.

The way forward was to provide continuity in decks over supports of multi span bridges and at abutments.

For this and other reasons a new beam the Y Beam was introduced with variants for Solid Slab - TY, Beam and slab - Y and for spans up to 40 metres – SY. At the same time, experience in the USA with a compromise form of continuity, Integral Construction, was brought across the Atlantic. This was followed by back up research and finally a presumption that Integral Construction should be used for all bridges of

any material up to lengths of 60 metres.

Transport and crane capabilities have now increased to the extent that spans in excess of 45 metres can now be delivered and erected with beams weighing 150 tonnes. The Banagher Precast Concrete W Beam was brought to the market in 2005 and has successfully taken advantage of this change in scope.

The W Beam bridge beam was designed and developed exclusively by Banagher Precast Concrete. The first ever W Beam was produced by Banagher Precast Concrete in 2005 and was manufactured for the Kinsale Road Flyover on the outskirts of Cork City.

There was considerable research, design and investment required to bring this new and unique Bridge Beam to the UK and Irish markets. The W Beam was developed by Banagher Precast Concrete as a more economical solution to traditional bridge beam types existing in the market. It is also capable of spanning in excess of 45m, which is beyond the range of other beam types.

As well as these benefits the W Beam is inherently more stable during transportation and erection on site, thus providing for better Health and Safety on sites.

A couple of years later in 2007 the MY Beam bridge beam was designed and developed by Banagher Precast Concrete. The MY Beam was developed as a more economical solution to traditional ‘Inverted T Beam’ and ‘TY Beam’ type bridge beams which existed in the market place. For spans up to approximately 15m the MY Beam provides a more efficient solution than tradition beams, reducing the amount of precast concrete required. The MY Beam is a more environmentally friendly beam with a smaller carbon footprint than other beam types for similar spans.

The Pretensioned Prestressed Bridge Beam has been with us for nearly 70 years and with its original sound engineering background still has proven excellent durability to this day.

2 3


Typical Applications Advantages Typical Construction Details Photo

Provides a voided bridge deck with a closed soffit for beam and slab construction for medium and long span bridges

Solid slab construction for short and medium span bridges. road and railway overbridges.

Very Efficent Span - Weight Ratio. The UMB beam acts as an edge beam giving a fair faced precast finish to the bridge deck.

A more economical solution to traditional T Beam and TY Beam Bridge Construction which exist in the market place. Provides a flat soffit with no need for formwork.

Solid slab construction for short span bridges, railway over bridges, jetties, marine docks and loading bay construction.

A very robust bridge construction. No need for formwork. Very goog resistance In marine environments. Can be easily designed for continuity.

Beam and slab construction for long span bridges.

Solid slab construction for short and medium span bridges, jetties, marine docks and loading bay construction.

Underside of deck and surfaces of beams and bridge bearings are fully visible for inspection and maintenance. Good capacity for negative bending at supports. Followed on from the successful Y Beam when the need for longer spans arouse. Practical and economical solution for spans up to 45m.

A very robust bridge construction. No need for formwork. Very goog resistance In marine environments. Can be easily designed for continuity

970

970

495 - 1500

750

495

750

970

640

- 136

030

0 - 6

00

1500

- 20

00

1500

- 20

00

380

- 815

300

- 100

0

300

- 600

640

- 136

0

970

M Beam

MY Beam

solid Box Beam

sY Beam

t Beam

sYe Beam

UMB Beam

MYe Beam


Bridge Beam Type Span Ranges

1 2 3 4 5 6 7 8 9 10 11 12 13 14 1615 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

1 2 3 4 5 6 7 8 9 10 11 12 13 14 1615 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

1 2 3 4 5 6 7 8 9 10 11 12 13 14 1615 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

1 2 3 4 5 6 7 8 9 10 11 12 13 14 1615 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

1 2 3 4 5 6 7 8 9 10 11 12 13 14 1615 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

M & UMB Edge BeamFor Beam and Slab Construction

MY & MYE Edge Beam For Solid Slab Construction

Solid Box Beam

SY & SYE Edge Beam

T BeamFor Solid Slab Construction

The information provided below will enable our customers to make a preliminary assessment of the suitability of one or more beam types for a particular bridge design requirement. The detailed cross sections, section properties, notional load span tables and normal methods of use are given in the following pages.

The chart below gives a guide to the span range of all of the Banagher Precast Concrete Bridge Beam types, designed to the new Eurocode loading outlined in the technical section for each beam. The final choice of beam and the detailed design will be determined by the relevant performance specification.

11 - 21.75m

16 - 45m

10 - 35m

9 - 19m

16 - 35m

Banagher Precast Concrete Bridge Beams

Designed &

Developed by

BanagherPrecast

Concrete

4 5


Typical Applications Advantages Typical Construction Details Photo


Beam and slab construction for short and medium span bridges.


Beam and slab construction for long span bridges. major motorway schemes.

Beam and slab construction for long span bridges. major motorway schemes.

Beam and slab construction for short and medium span bridges.


Underside of deck and surfaces of beams and bridge bearings are fully visible for inspection and maintenance. Good capacity for negative bending at supports.


Suitable for skew decks and where torsion is high. Visually pleasing.

The W Beam was developed by Banagher Precast Concrete as a more economical solution to traditional bridge beam types existing in the market. It is also capable of spanning in excess of 45m, which is beyond the range of other beam types. As well as these benefits the W Beam is inherently more stable during transportation and erection on site, thus providing for better Health and Safety on sites.

Underside of deck and surfaces of beams and bridge bearings are fully visible for inspection and maintenance. Good capacity for negative bending at supports.

495

750

750 750

970

1500

750 750

970

750

375

- 825

400

- 900

400

- 900

400

- 900

1500

- 16

00

800

- 230

0

700

- 140

0

700

- 140

0

600

- 160

0

400

- 900

tB Beam

tY Beam

tY Beam tYe Beam

sU Beam

W Beam

Y Beam Ye Beam

U Beam

tYe Beam


Bridge Beam Type Span Ranges

TB Beam For Solid Slab Construction

TY & TYE Edge BeamFor Beam and Slab Construction

TY & TYE Edge BeamFor Solid Slab Construction

U & SU Beam

Y & YE Edge Beam

W Beam

Banagher Precast Concrete Bridge Beams

1 2 3 4 5 6 7 8 9 10 11 12 13 14 1615 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

1 2 3 4 5 6 7 8 9 10 11 12 13 14 1615 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

1 2 3 4 5 6 7 8 9 10 11 12 13 14 1615 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

1 2 3 4 5 6 7 8 9 10 11 12 13 14 1615 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

1 2 3 4 5 6 7 8 9 10 11 12 13 14 1615 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

1 2 3 4 5 6 7 8 9 10 11 12 13 14 1615 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

11 - 23m

12 - 26.5m

13 - 41.5m

17 - 50m

16 - 40m

12 - 26m

Designed &

Developed by

BanagherPrecast

Concrete

Designed &

Developed by

BanagherPrecast

Concrete

6 7

Section

M1M680

M2M3M4M5M6M7M8M9

M10UMB1

UMB680UMB2UMB3UMB4UMB5UMB6UMB7UMB8UMB9

UMB10

Depth

(mm)

640680720800880960

10401120120012801360640680720800880960

10401120120012801360

Area

(mm²)

284650300650316650348650380650355050387050419050393450425450457450345675360475375275404875434475464075493675523275552875582475612075

Ht. centroidover so�tYc (mm)

220.1242.9265.4309.8353.4357.0409.2459.6454.1512.3568.0243.4260.1276.9311.4346.5382.3418.6455.4492.4529.8567.4

Top �breZ t

24.7230.1435.6446.9658.7659.3975.3991.5287.39

108.09128.6529.3433.2537.4146.4256.3767.2278.9591.56

105.03119.36134.52

Bottom �breZ b

47.1754.2461.0474.3287.56

100.33116.23131.53143.57161.96179.3647.7953.7059.8572.8686.78

101.56117.19133.64150.92169.00187.90

Second Momentof Area

I xx (mm4 x 109)

10.38113.17316.20223.02030.94435.81347.55960.44665.18782.977

101.88011.63513.96416.57322.68530.07138.83049.05960.85674.31889.540

106.620

Approximateself-weight

(kN/m)

7.127.527.928.729.528.889.68

10.489.84

10.6411.448.649.019.38

10.1210.8611.6012.3413.0813.8214.5615.30

Web Height

H (mm)

200200200200200440440440680680680

-----------

Section modulus - (mm3 x 106)


M & UMB Edge Beam for Beam and Slab Construction

M & UMB-BEAM - BEAM AND SLAB SPAN CHART - BASED ON ACTUAL BEAM LENGTH AND 1300mm BEAM SPACINGCOVERING GENERAL APPLICATIONS FROM 1000mm TO 1600mm c/c's

MetresM1

M680M2M3M4M5M6M7M8M9

M10

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 3516

The above span table is for guideline purposes only and is based on the below criteria, please contact Banagher Precast Concrete with job speci�c information for a more accurate evaluation.

» Tra�c loading as per Eurocode 1» Design to Eurocode 2» Simply supported bridge beam structure » Beams spaced at 1.3m centres» C40/50 Insitu deck slab 200mm over beam

» C50/60 precast concrete grade @ 28 days with up to C32/40 @ transfer - see» C57/70 precast concrete grade @ 28 days with up to C45/55 @ transfer - seeNote: » The above �gures are for actual beam length» The clear span will be 1m less than the �gues given above» The centre to centre of bearing in a simply supported structure will be 500mm less than the above �gures» The pier to abutment centres will be perhaps 500mm greater than the above �gures» M-Beams can be poured to any beam depth from 640mm to 1400mm deep if it is found necessary to match the depths to those of other beams like Y-Beams, W-Beams etc..» This table also covers UMB-Beams

Alternative Spacings & Spans:» To determine the beam length "Ladj" for a beam spacing "S" other than 1.3m adjust the actual beam length "L" above using the following formula. Ladj = L(1.3/S)0.5

» To determine the required beam spacing for a given beam length "Lg" and beam size use the following formula where L = beam length for a 1.3m spacing from the above chart. S=1.3(L/Lg)2

» In order to keep control of deck slab moments, beam interface shear links and to use standard 50/20 ribbed FRC shutter BPC recommends a general beam spacing in mm of 1350+0.28D for M-beams where D= beam depth.

Beam spacings greater than this may be used but the permanent shutter will have to be either 75mm deep ribbed FRC or prestressed wide slab with a corresponding increase in deck slab thickness over the beam up to 250mm.» If using prestressed 75mm wideslab permanent shutter the outside beam face shutter rebates will have to be increased in size from the standard 40mm wide x 50mm deep to 60mm wide x 75mm deep. This also requires the shear links to be narrowed and some adjustment of the top strand locations.

M Beam showing all possible strand locations UMB Beam showing all possible strand locations

Full M Beam range Full UMB Beam range

M1

= 64

0

M2

= 72

0M

3 =

800

M4

= 88

0M

5 =

960

M6

= 10

40M

7 =

1120

M8

= 12

00

M9

= 12

80

M10

= 1

360

M68

0 =

680

B10-02

B12 LINK

50

40

40

505050505050 75 75 505050 505050 11011040

40

2525

01 01

02 02

01 01

80

B10-01

2No. @ 12302No. @ 11802No. @ 11302No. @ 10802No. @ 1030

2No. @ 9802No. @ 9302No. @ 8802No. @ 8302No. @ 7802No. @ 7302No. @ 6802No. @ 6302No. @ 5802No. @ 5302No. @ 4802No. @ 4302No. @ 3802No. @ 330

2No. @ 1280

4No. @ 16014No. @ 110

15No. @ 60

2No. @ 12302No. @ 11802No. @ 11302No. @ 10802No. @ 1030


2No. @ 1280

4No. @ 200

16No. @ 11015No. @ 60

505050505050 75 75 505050 505050 110110

400600135

25

25970

2545

18530050

X X

45

160

Yc

Yc

Y970

Y Y

Y

XX

UM

B1 =

640

UM

B2 =

720

UM

B3 =

800

UM

B4 =

880

UM

B5 =

960

UM

B6 =

104

0

UM

B7 =

112

0U

MB8

= 1

200

UM

B9 =

128

0U

MB1

0 =

1360

UM

B680

= 6

80

8 9

Section

MY1MY2MY3MY4MY5MY6MY7

MYE1MYE2MYE3MYE4MYE5MYE6MYE7

Depth (mm)

300350400450500550600300350400450500550600

Area (mm²)

170000188500208000228500250000272000294000230190263690297690332190367190402440437690

Ht. centroidover so�t Yc

(mm)

111.7132.6155.4179.6205.0230.9256.6136.0160.1184.6209.6234.9260.3285.6

Dist. centroid tovertical face Xc

(mm)

485.0485.0485.0485.0485.0485.0485.0399.1391.0385.2381.0378.0375.8373.9

Top �breZ t

6.399.05

12.3116.1820.6725.6130.8310.7814.8419.5825.0131.1337.8545.11

Bottom �breZ b

10.7814.8419.3924.3729.7435.4041.2612.9917.6122.8528.6935.1342.1349.66


I xx (mm4 x 109)

1.20331.96813.01234.37536.09728.142510.5871.76672.81864.21806.01288.2517

10.966114.1830


(kN/m)

4.254.715.205.716.256.807.355.756.597.448.309.18

10.0610.94

Top FlangeWidth Wf (mm)

360.0380.0400.0420.0440.0440.0440.0665.0675.0685.0695.0705.0705.0705.0



Designed &

Developed by

BanagherPrecast

Concrete

MY & MYE Edge Beam for Solid Slab Construction

MY BEAM SOLID SLAB SPAN CHART - BASED ON ACTUAL BEAM LENGTHFOR GENERAL APPLICATION OF 985mm SPACING

MetresMY1MY2MY3MY4MY5MY6MY7

17 18 19139 10 11 12 14 15 16


» Tra�c loading as per Eurocode 1» Design to Eurocode 2» Simply supported bridge beam structure » Beams spaced at 985mm centres» C40/50 Insitu in�ll solid slab deck to 150mm over the beam

» C50/60 precast concrete grade @ 28 days with up to C32/40 @ transfer - see» C57/70 precast concrete grade @ 28 days with up to C45/55 @ transfer - see

Note: » The above �gures are for actual beam length» The clear span will be 1m less than the �gues given above» The centre to centre of bearing in a simply supported structure will be 500mm less than the above �gures» The pier to abutment centres will be perhaps 500mm greater than the above �gures» Longer spans can be achieved by propping the beams while pouring the insitu concrete» MY-Beams have been designed speci�cally for solid slab construction. The bottom �ange thickness and link shape are not su�cent for beam and slab construction.» If beam and slab construction is preferred please use the TY-Beam version.» This table also covers MYE-Beams, but please note that when dealing with MYE-Beams the prestressing force should be centred on the lateral (transverse) centroid Xc

section through MYe Beam rangeshowing all strand locations

5No. @ 550

5No. @ 500

5No. @ 450

5No. @ 400

5No. @ 350

5No. @ 300

3No. @ 250

2No. @ 200

6No. @ 15011No. @ 10517No. @ 60

75 50 50 55 55 55 55 55 55 55 55 55 6555 45 45 45 45

970

60 150 173 102 102 118

B12 LINK

B16 female coupler

section through MY Beam rangeshowing all strand locations

3No. @ 550

3No. @ 500

3No. @ 450

3No. @ 400

3No. @ 350

3No. @ 300

3No. @ 250

5No. @ 105

17No. @ 60

102

30

102

342

250

150

454557

25 2565 55 55 55 55 55 55 55 55 55 55 55 55 6545 45 45 45

920

970

57

B10 LINK

Full MY Beam range Full MYe Beam range

970 970

440

Transverse holes @ 800mm centres

705

MY7

= 6

00

MYE

7 =

600

MY6

= 5

50

MYE

6 =

550

MY5

= 5

00

MYE

5 =

500

MY4

= 4

50

MYE

4 =

450

MY3

= 4

00

MYE

3 =

400

MY2

= 3

50

MYE

2 =

350

MY1

= 3

00

MYE

1 =

300

Wf Wf

Y

Y

Y

Y

X XXX

plan of transverse Holes @ 800mm c/c’s elevation of transverse Holes @ 800mm c/c’s

65 125

250

150

10 11

Section

SD1 (1)SD2 (1)SD3 (1)SD4 (1)SD5 (1)SD6 (1)SD7 (1)SD8 (1)SD1 (2)SD2 (2)SD3 (2)SD4 (2)SD5 (2)SD6 (2)SD7 (2)SD8 (2)SD1 (3)SD2 (3)SD3 (3)SD4 (3)SD5 (3)SD6 (3)SD7 (3)SD8 (3)SD1 (4)SD2 (4)SD3 (4)SD4 (4)SD5 (4)SD6 (4)SD7 (4)SD8 (4)

Depth

(mm)

300400500600700800900

1000300400500600700800900

1000300400500600700800900

1000300400500600700800900

1000

Area

(mm²)

127625168125208625249125289625330125370625411125204125270125336125402125468125534125600125666125270125358125446125534125622125710125798125886125429350570350711350852350993350

113435012753501416350


145.0194.0244.0294.0343.0393.0443.0493.0147.0196.0246.0296.0346.0396.0446.0496.0148.0197.0247.0297.0347.0397.0447.0497.0148.4198.2248.1298.1348.0398.0448.0497.9

Top �breZ t

6.3311.2317.5025.1134.0844.4056.0869.1010.1718.0528.1340.4354.9271.6290.52

111.6213.4723.9237.3056.6372.9095.09

120.23148.2921.4438.0859.4385.48

116.23151.69191.85236.71

Bottom �breZ b

6.7911.9018.3826.2033.3845.9157.7971.0210.6218.7129.0041.5056.2173.1192.22

113.5213.9224.5838.1754.7074.1796.58

121.92150.1921.9138.7660.3386.59

117.56153.23193.6

238.67


(kN/m)

3.194.205.226.237.248.259.27

10.285.106.758.40

10.0511.7013.3515.0016.656.758.95

11.1513.3515.5517.7519.9522.1510.7314.2617.7821.3124.8328.3631.8835.41



Solid Box Beam

SOLID BOX BEAMS SPAN CHART - BASED ON ACTUAL BEAM LENGTHFOR GENERAL APPLICATIONS SPACED SIDE BY SIDE

MetresSD 1 300mm DeepSD 2 400mm DeepSD 3 500mm DeepSD 4 600mm DeepSD 5 700mm DeepSD 6 800mm DeepSD 7 900mm Deep

SD 8 1000mm Deep

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 3510 11 12 13 14 15

The above span table is for guideline purposes only and is based on the below criteria, please contact Banagher Precast Concrete with job speci�c information for a more accurate evaluation. NOTE: Beam depths from 350mm to 950mm in 100mm steps are also available and can be produced - contact Banagher Precast Concrete for further details.

» Tra�c loading as per Eurocode 1» Design to Eurocode 2» Simply supported bridge beam structure » Beams spaced at 510mm, 770mm and 990mm centres depending on beam width» C40/50 Insitu in�ll between beams - 75mm topping assummed

» C50/60 precast concrete grade @ 28 days with up to C32/40 @ transfer - see» C57/70 precast concrete grade @ 28 days with up to C45/55 @ transfer - seeNote: » The above �gures are for actual beam length» The clear span will be 1m less than the above �gures» The centre to centre of bearing in a simply supported structure will be 500mm less than the above �gures» The pier to abutment centres will be perhaps 500mm greater than the above �gures» Longer spans can be achieved by propping the beams while pouring the insitu concrete

sD8(2) Beam showing all possible strand locations




SD1

= 30

0SD

2 =

400

SD3

= 50

0SD

4 =

600

SD5

= 70

0SD

6 =

800

SD7

= 90

0SD

8 =

1000

45 45

910

30

3525

2525

SDX(1) = 405, SDX(2) = 660, SDX(3) = 880, SDX(4) = 1410

SDX(1) = 495, SDX(2) = 750, SDX(3) = 970, SDX(4) = 1500

soliD Box BeaM (Generic)

50505050505050

50 50 50 50 50 505050 50 50 50 50 50 50 50 65 95505050

45

95 65

5050 50 50 50 50 50 50 50 50 5050707070

70 70 70

1500

70

70 115115

50 50265 265240 240300

50

50115970

11550 50 50 50 50 50 50 50 50 50 50

507095 9570

70 70

70 7050 50 50 5050 505050

50 50270 240B10-01

B10-01

B10-02

B10-01

B10-01270

454545454545 112.5112.5495

52.5 52.5300 50 50215 130 215

50 50 50 50 50 50 50 110750

110 50

50 5065 65 65 6550 50 50 5050 50

65 65

2No. @ 9302No. @ 8802No. @ 8302No. @ 7802No. @ 7302No. @ 6802No. @ 6302No. @ 5802No. @ 5302No. @ 4802No. @ 4302No. @ 3802No. @ 3302No. @ 2802No. @ 230

7No. @ 1607No. @ 1107No. @ 60


11No. @ 16011No. @ 11011No. @ 60


25No. @ 16025No. @ 11025No. @ 60


15No. @ 16015No. @ 11015No. @ 60

B10-02 B10-02

B10-02

12 13

Section

SY1SY2SY3SY4SY5SY6

SYE1SYE2SYE3SYE4SYE5SYE6

Depth

(mm)

150016001700180019002000150016001700180019002000

Area

(mm²)

550090582090614090646090678090710090837240890740944240997740

10512401104740


597.6649.2700.7752.1803.3854.4700.2751.0801.7852.4903.0953.5

Dist. centroidto vertical face

Xc (mm)

------

287.7286.5285.4284.4283.6282.8

Top �breZ t

132.69154.09176.30199.35223.28248.10211.91242.10273.90307.36342.49379.30

Bottom �breZ b

200.39225.66251.41277.77304.82332.65242.05273.68306.88341.70378.17416.30


I xx (mm4 x 109)

119.750146.510176.170208.910244.870284.220169.490205.540246.040291.260341.470396.940


(kN/m)

13.7514.5515.3516.1516.9517.7520.9322.2723.6124.9426.2827.62



SY & SYE Edge Beam

SY-BEAM-BEAM AND SLAB SPAN CHART - BASED ON ACTUAL BEAM LENGTH AND 1200mm BEAM SPACINGCOVERING GENERAL APPLICATIONS FROM 800mm TO 1600mm c/c's

MetresSY1SY2SY3SY4SY5SY6

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 4516



» C50/60 precast concrete grade @ 28 days with up to C32/40 @ transfer - see» We do not normally recommend using C57/70 concrete with high levels of prestress in SY-beams due to their slenderness in handling and transportationNote: » The above �gures are for actual beam length» The clear span will be 1m less than the above �gures» The centre to centre of bearing in a simply supported structure will be 500mm less than the above �gures» The pier to abutment centres will be perhaps 500mm greater than the above �gures» This table also covers SYE-Beams, but please note that when dealing with SYE-Beams the prestressing force should be centred on the lateral (transverse) centroid Xc



» In order to keep control of deck slab moments, beam interface shear links and touse standard 50/20 ribbed FRC shutter BPC recommends a general maximum beam spacing in mm of 1600mm for SY-beams.

» Beam spacings greater than this may be used but the permanent shutter will either have to be 75mm deep ribbed FRC or prestressed wide slab with a corresponding increase in deck slab thickness over the beam up to 250mm.» If using prestressed 75mm wideslab permanent shutter the outside beam face shutter rebates will have to be increased in size from the standard 40mm wide x 50mm deep to 60mm wide x 75mm deep. This also requires the shear links to be narrowed and some adjustment of the top strand locations.

sY Beam showing all possible strand locations sYe Beam showing all possible strand locations

Full sY Beam range Full sYe Beam range

SY1

= 15

00

SYE1

= 1

500

SY2

= 16

00

SYE2

= 1

600

SY3

= 17

00

SYE3

= 1

700

SY4

= 18

00

SYE4

= 1

800

SY5

= 19

00

SYE5

= 1

900

SY6

= 20

00

SYE6

= 2

000

2No. @ 1830

2No. @ 1730

2No. @ 1630

2No. @ 1530

2No. @ 1430

2No. @ 1330

2No. @ 1230

2No. @ 1130

2No. @ 1030

2No. @ 930

2No. @ 830

2No. @ 730

2No. @ 630

2No. @ 1930

2No. @ 400

2No. @ 310

14No. @ 21014No. @ 16014No. @ 11013No. @ 60

2No. @ 1830

2No. @ 1730

2No. @ 1630

2No. @ 1530

2No. @ 1430

2No. @ 1330

2No. @ 1230

2No. @ 1130

2No. @ 1030

2No. @ 930

2No. @ 830

2No. @ 730

2No. @ 630

5No. @ 400

2No. @ 1930

3No. @ 400

5No. @ 3108No. @ 26014No. @ 21014No. @ 16014No. @ 11013No. @ 60v

60 160 50 90 150 85

B12-01

75 45454550 50 65 65 50 50454545 1575 4545455050 65 65

345

75

5050454545 15

150

B12-01

B12-02

750Xc Y

YY

Y

XX

XX

Yc

Yc

750

495240 4040

5050

14 15

Section

T1T2T3T4T5T6T7T8T9

T10

Depth

(mm)

380420535575615655695735775815

Area

(mm²)

98000106200114275122475130675138875147075155275163475171675


139.9160.0196.0220.0243.6266.7289.5311.9334.2356.2

Top �breZ t

5.186.769.57

11.9214.3016.7319.2021.7424.3326.99

Bottom �breZ b

8.8910.9816.5519.2321.8124.3626.9129.4832.1034.77


I xx (mm4 x 109)

1.24431.75723.24404.23105.31266.49597.78789.195410.72612.385


(kN/m)

2.452.662.863.063.273.473.683.884.094.29

Web HeightH (mm)

8585

240240240240240240240240

FlangeHeightF (mm)

55955595

135175215255295335



T Beam for Solid Slab Construction

T-BEAMS SOLID SLAB SPAN CHART - BASED ON ACTUAL BEAM LENGTHFOR GENERAL APPLICATION OF 510mm SPACING

MetresT1T2T3T4T5T6T7T8T9

T10

16 17 18 19 20 21 221211 13 14 15




t Beam range From t3 to t10

t Beam showing all possible strand locationsthis option Will Give 40mm cover With 12.9mm

Dia. strand & B8 links only

t Beam showing all possible strand locationsthis option Will Give 35mm cover With 12.9mm

Dia. strand & B8 links only

205Y

X

T1 =

380

T3 =

535

T4 =

575

T5 =

615

T6 =

655

T7 =

695

T8 =

735

T9 =

775

T10

= 81

5

T2 =

420

X

Y

F50

5040

Yc

25

25 25Y

Y

205

XX

25

25 25

2575

4050

50F

240

Yc

495

495

445

495

25

8575

t Beam range From t1 to t2

1No. @ 780

1No. @ 730

1No. @ 680

1No. @ 630

1No. @ 580

1No. @ 530

1No. @ 480

1No. @ 430

1No. @ 380

1No. @ 340

1No. @ 300

1No. @ 260

1No. @ 1158No. @ 90

9No. @ 55

1No. @ 770

1No. @ 730

1No. @ 690

1No. @ 650

1No. @ 610

1No. @ 570

1No. @ 530

1No. @ 490

1No. @ 450

1No. @ 4101No. @ 3801No. @ 350

1No. @ 3001No. @ 2701No. @ 240

9No. @ 90

9No. @ 50

45 4545 4540 4040 40

40 35

72.5 72.572.5 72.510

0

100

205 205

445

495

105105

102.5 102.5102.5 102.5

205 205

35 45

B8-01 B8-01

TRANSVERSE HOLES @ 610MM CENTRES TRANSVERSE HOLES @ 610MM CENTRES

NOTE: The centre strand @ 115mm mustnot be used along with the 2nrinner strands @ 90mm.

45 4525 25

45 4545 4545 45

16 17

Section

TB1TB2TB3TB4TB5TB6TB7TB8TB9

TB10

Depth

(mm)

375425475525575625675725775825

Area

(mm²)

99875110125120375130625125375135625145875156125166375176625


135.70160.3

184.90209.7215.5

244.60273.0

301.10328.7

356.10

Top �breZ t

4.856.848.97

11.2311.6914.7317.8521.0424.3427.74

Bottom �breZ b

8.5511.3014.0716.8919.5022.9226.2729.6333.0436.53


I xx (mm4 x 109)

1.15991.81162.60103.54084.20145.60457.17328.9212

10.862013.0080


(kN/m)

2.502.753.013.273.133.393.653.904.164.42

FlangeHeightF (mm)

4090

14019085

135185235285335

WebHeightH (mm)

85858585

240240240240240240



TB Beam for Solid Slab Construction

TB-BEAMS SOLID SLAB SPAN CHART - BASED ON ACTUAL BEAM LENGTHFOR GENERAL APPLICATION OF 510mm SPACING

MetresTB1TB2TB3TB4TB5TB6TB7TB8TB9

TB10

16 17 18 19 20 21 22 23 241211 13 14 15




tB Beam range From tB1 to tB4 tB Beam range From tB5 to tB10

tB Base Detail

tB Beam showing all possible strand locations

25

25 25

8540

5085

50 240

5050 Yc

4085

2525

F

F

X

X

X

X

Y Y

495 495

25TB

1 =

375

TB2

= 42

5

TB3

= 47

5

TB4

= 52

5

TB5

= 57

5

TB6

= 62

5

TB7

= 67

5

TB8

= 72

5

TB9

= 77

5

TB10

= 8

25

Yc

Y

Y

205

205

Designed &

Developed by

BanagherPrecast

Concrete

72.5

205

105

102.5 102.5

205

45

B8 LINK

825

7525

25

5

10

110

72.545 45 45 45 454540 40

2No. @ 780

2No. @ 730

2No. @ 680

1No. @ 630

1No. @ 580

1No. @ 530

1No. @ 480

1No. @ 430

1No. @ 380

1No. @ 340

1No. @ 300

1No. @ 260

9No. @ 100

9No. @ 60

18 19

Section

TY3TY4TY5TY6TY7TY8TY9

TY10TY11TYE3TYE4TYE5TYE6TYE7TYE8TYE9

TYE10TYE11

Depth

(mm)

500550600650700750800850900500550600650700750800850900

Area

(mm²)

208050221460235880251320267770285230303710323210343710291210316670342630369100396070423550451540480040509040


173.31193.6216.0240.2266.1293.4322.0351.7

382.24222.9246.8271.3296.4321.9347.8374.0400.6427.4


Xc (mm)

---------

304.1300.0296.9294.5292.8291.6290.8290.4290.3

Top �breZ t

10.86313.9617.7122.1327.2433.0639.6146.9154.9621.8728.8732.4838.7045.5553.0261.1369.8979.30

Bottom �breZ b

20.47725.6931.4837.7444.4151.4458.8

66.4774.4427.1933.0139.3446.1753.5061.3169.6278.4187.69


I xx (mm4 x 109)

3.54894.97426.79919.067011.81915.09518.93523.37528.4546.05988.145910.67413.68517.22221.32526.03931.40837.476


(kN/m)

5.2015.5375.8976.2836.6947.1317.5938.0808.5937.287.928.579.239.90

10.5911.2912.0012.73

Top FlangeWidth

Wf (mm)

157.7178.0198.3218.6238.9259.1279.4299.7320.0453.9464.0474.2484.3494.4504.6514.7524.9535.0



TY & TYE Edge Beam for Beam and Slab Construction

TY-BEAMS BEAM & SLAB SPAN CHART - BASED ON ACTUAL BEAM LENGTH AND 1200mm BEAM SPACINGCOVERING GENERAL APPLICATIONS FROM 800mm TO 1600mm c/c's

MetresTY3TY4TY5TY6TY7TY8TY9

TY10TY11

17 18 19 20 21 22 23 24 25 26 271312 14 15 16



» C50/60 precast concrete grade @ 28 days with up to C32/40 @ transfer - see» C57/70 precast concrete grade @ 28 days with up to C45/55 @ transfer - seeNote: » The above �gures are for actual beam length» The clear span will be 1m less than the above �gures» The centre to centre of bearing in a simply supported structure will be 500mm less than the above �gures» The pier to abutment centres will be perhaps 500mm greater than the above �gures» This table also covers TYE-Beams, but please note that when dealing with TYE-Beams the prestressing force should be centred on the lateral (transverse) centroid Xc



» In order to keep control of deck slab moments, beam interface shear links and to use standard 50/20 ribbed FRC shutter BPC recommends a general maximum

beam spacing in mm of 1300+0.4D where D= beam depth.Beam spacings greater than this may be used but the permanent shutter will have to be either 75mm deep ribbed FRC or prestressed wide slab with a corresponding increase in deck slab thickness over the beam up to 250mm.» If using prestressed 75mm wideslab permanent shutter the outside beam face shutter rebates will have to be increased in size from the standard 40mm wide x 50mm deep to 60mm wide x 75mm deep.

tY Beam showing all possible strand locations for 15.7mm diameter strands

tYe Beam showing all possible strand locations for 15.7mm diameter strands

2No. @ 850

2No. @ 800

2No. @ 750

2No. @ 700

2No. @ 650

2No. @ 600

2No. @ 550

2No. @ 500

2No. @ 450

2No. @ 400

2No. @ 350

1No. @ 217

7No. @ 160

11No. @ 110

13No. @ 60

5No. @ 850

5No. @ 800

5No. @ 750

5No. @ 700

5No. @ 650

5No. @ 600

5No. @ 550

5No. @ 500

5No. @ 450

5No. @ 400

5No. @ 3503No. @ 3053No. @ 2607No. @ 2171No. @ 1759No. @16012No. @ 110

13No. @ 60

40

25 25

2581 49 49 49 45 45 45 45 49 49 49 56

750Note: For a 12.9mm diameter strand layout please see appendix A

750

57 57

B10 LINK B10 LINK

44 m

in. c

over

70

60

45 45 50 63 45 57

42

50 100

50

25 4956 49 49 45 45 45 45 49 49 49 8157 57

Full tY Beam range Full tYe Beam range

Wf Wf

Y Y

Y

750

Yc Yc

X X X

Y

X

750Xc

TY3

= 50

0

TYE3

= 5

00

TY4

= 55

0

TYE4

= 5

50TY5

= 60

0

TYE5

= 6

00TY6

= 65

0

TY7

= 70

0

TY8

= 75

0TY

9 =

800

TY10

= 8

50TY

11 =

900

TYE6

= 6

50TY

E7 =

700

TYE8

= 7

50TY

E9 =

800

TYE1

0 =

850

TYE1

1 =

900

(TY11 and TYE11 shown above, for all other TY beam links please contact the technical department)

20 21

Section

TY1TY2TY3TY4TY5TY6TY7TY8TY9

TY10TY11TYE1TYE2TYE3TYE4TYE5TYE6TYE7TYE8TYE9

TYE10TYE11

Depth

(mm)

400450500550600650700750800850900400450500550600650700750800850900

Area

(mm²)

188790200170212560225970240390255830272280289740308220327710348220244080268520293470318920344880371350398330425810453800482290511300


145.5161.4179.7200.2222.7247.0272.9300.2328.6358.2388.6179.2201.6224.8248.8273.3298.4323.9349.8376.0402.6429.4


Xc (mm)

-----------

317.3310.6305.4301.4298.2295.8294.1292.8292.0291.6291.5

Top �breZ t

7.699.71

12.3515.6219.5424.1429.4235.4142.1149.5657.7614.2318.0722.5427.6233.3139.6246.5454.0962.2771.1080.59

Bottom �breZ b

13.4617.3522.0027.2833.1039.3846.0453.0660.4068.0576.0117.5422.2827.6033.4539.8146.6854.0461.8870.2179.0388.33


I xx (mm4 x 109)

1.95812.80113.95385.46307.37309.726612.56515.92619.85124.37529.5393.14204.49056.20358.320710.88213.92917.50321.64626.40131.81437.928


(kN/m)

4.725.005.315.656.016.406.817.247.718.198.716.106.717.347.978.629.289.96

10.6511.3512.0612.78

Top FlangeWidth

Wf (mm)

217.5237.7258.0278.3298.6318.9339.2359.4379.7400.0420.3483.7493.9504.0514.2524.3534.4544.6554.7564.9575.0585.1



TY & TYE Edge Beam for Solid Slab Construction

TY-BEAMS SOLID SLAB SPAN CHART - BASED ON ACTUAL BEAM LENGTHFOR GENERAL APPLICATION OF 765mm SPACING

MetresTY1TY2TY3TY4TY5TY6TY7TY8TY9

TY10TY11

17 18 19 20 21 22 23 24 25 261312 14 15 16



» C50/60 precast concrete grade @ 28 days with up to C32/40 @ transfer - see» C57/70 precast concrete grade @ 28 days with up to C45/55 @ transfer - seeNote: » The above �gures are for actual beam length» The clear span will be 1m less than the above �gures» The centre to centre of bearing in a simply supported structure will be 500mm less than the above �gures» The pier to abutment centres will be perhaps 500mm greater than the above �gures» Longer spans can be achieved by propping the beams while pouring the insitu concrete» This table also covers TYE-Beams, but please note that when dealing with TYE-Beams the prestressing force should be centred on the lateral (transverse) centroid Xc

tY Beam showing all possible strand locations for 15.7mm diameter strands

tYe Beam showing all possible strand locations for 15.7mm diameter strands

2No. @ 850

2No. @ 800

2No. @ 750

2No. @ 700

2No. @ 650

2No. @ 600

2No. @ 550

2No. @ 500

2No. @ 450

2No. @ 400

2No. @ 350

1No. @ 217

7No. @ 160

11No. @ 110

13No. @ 60

5No. @ 850

5No. @ 800

5No. @ 750

5No. @ 700

5No. @ 650

5No. @ 600

5No. @ 550

5No. @ 500

5No. @ 450

5No. @ 400

5No. @ 350

3No. @ 305

3No. @ 260

7No. @ 217

1No. @ 1759No. @16012No. @ 110

13No. @ 60

57

25 25

25

42

81 49 49 49 45 45 45 45 49 49 49 56

750 750

57 57

73B10 LINK

TRANSVERSE HOLES @ 600mm centres

B10 LINK

44 m

in. c

over

60 50 100

50

25

4956

190

70 45 45 50 63 45 5757

49 49 45 45 45 45 49 49 49 8157 57

Full tY Beam range Full tYe Beam range

Wf Wf

Y Y

Y

750

Yc Yc

X X X

Y

X

750Xc

TY1

= 40

0TY

2 =

450

TY3

= 50

0TY

4 =

550

TY5

= 60

0TY

6 =

650

TY7

= 70

0TY

8 =

750

TY9

= 80

0TY

10 =

850

TY11

= 9

00

TYE1

= 4

00

TYE2

= 4

50

TYE3

= 5

00TY

E4 =

550

TYE5

= 6

00TY

E6 =

650

TYE7

= 7

00TY

E8 =

750

TYE9

= 8

00TY

E10

= 85

0TY

E11

= 90

0

Note: For a 12.9mm diameter strand layout please see appendix A


22 23

Section

U600U700

U1U3U5U7U8U9

U10U11U12

SU11SU12

Depth

(mm)

600700800900

100011001200130014001500160015001600

Area

(mm²)

377100431740489180509650543170576690610210643730677250710770744290772730806250


248.4298.0350.0396.3442.7489.5536.7584.1631.8679.8727.9681.0728.8

Top �breZ t

33.2047.4264.5883.29

101.27120.60141.23163.14186.29210.66236.24231.22259.28

Bottom �breZ b

47.0063.9783.05

105.88127.50150.42174.58199.95226.49254.21283.07278.08309.96


I xx (mm4 x 109)

11.67419.06329.06541.95856.44173.62893.687

116.790143.100172.800206.040189.37225.89


(kN/m)

9.4310.7912.2312.7413.5814.4215.2616.0916.9317.7718.6119.3220.16

Overall WidthW1 (mm)

1118.41146.41174.41202.41230.41258.41286.41314.41342.41370.41398.41370.41398.4

Inner WidthW2 (mm)

600.0600.0600.0558.0586.0614.0642.0670.0698.0726.0754.0682710

W3 (mm)

194.2208.2222.2242.2242.2242.2242.2242.2242.2242.2242.2264264

Beam Top DimensionsSection modulus - (mm3 x 106)


U & SU BEAMS - BEAM AND SLAB SPAN CHART - BASED ON ACTUAL BEAM LENGTH AND 2000mm BEAM SPACINGCOVERING GENERAL APPLICATIONS FROM 1600mm TO 2400mm c/c's

MetresU600U700

U1U3U5U7U8U9

U10U11 (SU11)U12 (SU12)

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 4213 14 15 16



» C50/60 precast concrete grade @ 28 days with up to C32/40 @ transfer - see» C57/70 precast concrete grade @ 28 days with up to C45/55 @ transfer - see» SU11 & SU12 = C57/70 precast concrete grade @ 28 days with up to C45/55 @ transfer - seeNote: » The above �gures are for actual beam length» The clear span will be 1m less than the �gues given above» The centre to centre of bearing in a simply supported structure will be 500mm less than the above �gures» The pier to abutment centres will be perhaps 500mm greater than the above �gures

Alternative Spacings & Spans:» To determine the beam length "Ladj" for a beam spacing "S" other than 2m adjust the actual beam length "L" above using the following formula. Ladj = L(2/S)0.5

» To determine the required beam spacing for a given beam length "Lg" and beam size use the following formula where L = beam length for a 2m spacing from the above chart. S=2(L/Lg)2

» In order to keep control of deck slab moments, beam interface shear links and to use standard 50/20 ribbed FRC shutter BPC recommends a general maximum beam spacing in mm of 2200+0.28D where D= beam depth.


applies to Beams U600-U1

U & SU Beam

970

970

930

930

20

25

20

600W1

40

20

25

5020

VARI

ES

VARI

ES

Yc

Yc

25

50

40 40W3W1W2

X

X X

Y

Y

X

Y

Y

applies to Beams sU11 & sU12

W3

applies to Beams U3-U12

970930

20 20 20

VARI

ES

Yc

50

2540 40W3

W1W2

Y

Y

X X

24 25


U Beam range From U3 - U12

U Beam range For U600, U700 & U1 Beam

section showing transverse Holes& scabbling Details

elevation showing transverse Holes& scabbling Details

U & SU Beam

Note: The above shows the preferrable strand positions available for U beams in Banagher Precast Concrete. The below shows how many strand positions are available at a given height over the soffit, please be aware that you must match the below data with the above diagram to get the correct design strand and their locations.

18 @ 60mm over soffit18 @ 110mm over soffit8 @ 160mm over soffit6 @ 210mm over soffit2 @ 340mm over soffit2 @ 380mm over soffit2 @ 430mm over soffit2 @ 480mm over soffit2 @ 530mm over soffit2 @ 560mm over soffit2 @ 580mm over soffit2 @ 630mm over soffit



U12 - 1600

U11 - 1500

U10 - 1400

U9 - 1300

U8 - 1200

U7 - 1100

U5 - 1000

U3 - 900

Hatched area to bescabbled as shown

Transverse HolesTransverse Holes

Line of Scabbling

U12 - 1600

U11 - 1500

U10 - 1400

U9 - 1300

U8 - 1200

U7 - 1100

U5 - 1000

U3 - 900

U1 - 900

U700 - 7000

U600 - 600

SU12 - 1600

SU11 - 1500

Full sU Beam range

930

20 20

210

B10-03

1080

60 110 16

0 210

340 48

0 530 56

0 580 63

0 660 68

0 730 76

0 780 83

0 860 88

0 930 96

0 980 10

30 1060 10

80

2020

160

970

930

20 20 20

970930

1130

1160

1180

1230

1260

1280

1330

1380

1430

1530

B12-02

B12-01B10-04

U Beam showing all strand locations

160

26 27

Section

W1W3W5W7W8W9

W10W11W12W13W14W15W16W17W18W19

Depth

(mm)

800900

10001100120013001400150016001700180019002000210022002300

Area

(mm²)

572360606880641400692030726550761070812400846920881440933470975150

10160601057970110268011501901213750


305.3345.9387.5440.2484.2528.7585.2631.3677.6736.7790.6844.3898.6954.5

1011.81081.1

Top �breZ t

71.8889.54

108.76136.21159.46184.11219.51248.01277.84321.13362.63405.70451.09499.74551.68622.31

Bottom �breZ b

116.46143.43171.88204.15235.73268.56305.62341.33378.23419.90462.97507.30552.89599.75647.82701.68


I xx (mm4 x 109)

35.55649.61466.61089.871

114.140142.000178.850215.460256.280309.340366.030428.300496.830572.450655.490758.560


(kN/m)

14.3115.1716.0417.3018.1619.0320.3121.1722.0423.3424.3825.4026.4527.5728.7530.34

Overall WidthW1 (mm)

1704.41732.41760.41788.41816.41844.41872.41900.41928.41956.41984.42012.42040.42068.42096.42124.4

W2 (mm)

243.2243.2243.2250.2250.2250.2257.2257.2257.2264.2278.2292.2306.2320.2334.2348.2

W3 (mm)

1058108611141128115611841198122612541268126812681268126812681268

Web

100200300350450550600700800850950

10501050105010501050

S

220220220220220220220220220220248276276276276276

F

707070

12012012017017017022019216413610880

100

V

------------

128256384464

Beam Top DimensionsSection modulus - (mm3 x 106)


W BEAMS-BEAM & SLAB SPAN CHART - BASED ON ACTUAL BEAM LENGTH AND 3000mm BEAM SPACINGCOVERING GENERAL APPLICATIONS FROM 2200mm TO 3200mm c/c’s

MetresW1W3W5W7W8W9

W10W11W12W13W14W15W16W17W18W19

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

The above span table is for guideline purposes only and is based on the below criteria, please contact Banagher Precast Concrete with job speci�c information for a full design.


» C50/60 precast concrete grade @ 28 days with up to C32/40 @ transfer - see» C57/70 precast concrete grade @ 28 days with up to C45/55 @ transfer - see » Modi�cation to internal shutter to create a "Super-W-Beam" - see Note: » The above �gures are for actual beam length» The clear span will be 1m less than the �gues given above» The centre to centre of bearing in a simply supported structure will be 500mm less than the above �gures» The pier to abutment centres will be perhaps 500mm greater than the above �gures

Alternative Spacings & Spans:» To determine the beam length "Ladj" for a beam spacing "S" other than 3m adjust the actual beam length "L" above using the following formula. Ladj = L(3/S)0.5

» To determine the required beam spacing for a given beam length "Lg" and beam size use the following formula where L = beam length for a 3m spacing from the above chart. S=3(L/Lg)2

» In order to keep control of deck slab moments, beam interface shear links and to use standard 50/20 ribbed FRC shutter BPC recommends a general maximum beam spacing in mm of 2750+0.28D where D= beam depth.


Designed &

Developed by

BanagherPrecast

Concrete

applies to Beams W1-W15 applies to Beams W16-W19

W Beam

Building Information Modelling (BIM)Banagher Precast Concrete are operating in BIM – we can produce drawings in 3D to Autodesk Revit 2014.The BIM concept envisages virtual construction of a project prior to its actual physical construction, in order to reduce uncertainty, improve safety, work out problems, and simulate and analyse potential impacts. Banagher Precast Concrete can input critical information into the model before beginning construction, resulting in a more efficient end product.

W1

W3

W3

W2

W2 W2

W240

40

50

50 S

S

VW

EB

WEB

VARI

ES

VARI

ES

YcYc

Y

Y

XXX

14601460 2015001500

X

YY

F

F

W1

20

28 29


Full W Beam range

section showing transverse Holes& scabbling Details

elevation showing transverse Holes& scabbling Details

W Beam

section through W11 Beam showing strand location

Note:This is the strand and link arrangement for a W11 beam based on certain design criteria. Please contact a member of the Banagher Precast Concrete bridge design team for further information on general strand and link arrangements for all W-beams.

W19 - 2300

W18 - 2200

W17 - 2100

W16 - 2000

W15 - 1900

W14 - 1800

W13 - 1700

W12 - 1600

W11 - 1500

W10 - 1400

W9 - 1300

W8 - 1200

W7 - 1100

W5 - 1000

W3 - 900

W1 - 800

Hatched area to bescabbled as shown

Transverse Holes

Transverse Holes Transverse Holes

Line of ScabblingLine of Scabbling

Please see OUr

desIgN MaNUal

fOr a fUll set Of

CalCUlatIONs ON

thIs BeaM

1500

20 20

160

Prestressing strand Parameters

Diameter (mm)

Cross sectional area

(mm2)

Ultimate strength (MPa)

%Ultimate strength applied

(%)

Cracteristic value of max

Force (kN)

Initial force applied (kN)

Initial prestress applied (MPa)

Elastic modulus (GPa)

Relaxation of strand

(%)

15.7 150 1860 75 279 209.25 1395 200 1.5

42.570 42.5 52.5 52.5 52.5 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 52.5 52.5 52.5 42.5 42.5 705075

CL

4 No. 15.7Ø

2 No. 15.7Ø

2 No. 15.7Ø

60 110 21

034

048

073

0

880

1115

1230

1430

2 No. 15.7Ø

2 No. 15.7Ø

2 No. 15.7Ø

4 No. 15.7Ø

4 No. 15.7Ø & 2B12-05

B12-07

B12-01

12 No. 28 No.

6000 6000

4000 4000

3000 3000

2000 20001500 15001000 1000

B10-04CL

B12-02

40

92

07 0707 07

71.571.5 194

5015

032

832

8

1500

250

1172

265

275

Leng

th d

ebon

ded

bott

om ro

w

540

790

200

120x120 transverse

100x100 transverse holes

B10-03-300

Denotes fully bonded strandDenotes partially debonded strand26mm O.D. Weephole

12 no. debondedboth ends

Debonding both endsDebonding symmetrical about centreline

Initial Prestressing Force = 12973500 NEccentricity = 283.4 mmMoment = 3677000000 Nmm

30 31

Section

Y1Y2Y3Y4Y5Y6Y7Y8

YE1YE2YE3YE4YE5YE6YE7YE8

Depth

(mm)

700800900

10001100120013001400700800900

10001100120013001400

Area

(mm²)

310140340830374420410880450230492460537580585580417260470100524400580130637300695920755980817480


255.0298.4346.8399.3455.2514.0575.0637.8315.0363.4413.4464.6516.8569.8623.6678.0


Xc (mm)

--------

309.5304.4300.9298.7297.5297.1297.3298.0

Top �breZ t

24.8835.0747.9563.6382.19

103.73128.35156.1244.4359.2876.6196.45

118.85143.86171.55201.98

Bottom �breZ b

43.4258.9676.5195.72

116.40138.45161.83186.5654.3171.2190.18

111.15134.13159.10186.08215.10


I xx (mm4 x 109)

11.07317.59326.53038.22052.99071.16093.052

118.99017.10625.87937.27851.64169.31690.659

116.040145.830


(kN/m)

7.758.529.36

10.2711.2612.3113.4414.6410.4311.7513.1114.5015.9317.4018.9020.44

Top FlangeWidth

Wf (mm)

198.1227.0255.8284.7313.5342.3371.2400.0474.1488.5502.9517.3531.8546.2560.6575.0



Y & YE Edge Beam

Y-BEAM - BEAM AND SLAB SPAN CHART - BASED ON ACTUAL BEAM LENGTH AND 1200mm BEAM SPACINGCOVERING GENERAL APPLICATIONS FROM 800mm TO 1600mm c/c's

MetresY1Y2Y3Y4Y5Y6Y7Y8

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 4016



» C50/60 precast concrete grade @ 28 days with up to C32/40 @ transfer - see» C57/70 precast concrete grade @ 28 days with up to C45/55 @ transfer - seeNote: » The above �gures are for actual beam length» The clear span will be 1m less than the above �gures» The centre to centre of bearing in a simply supported structure will be 500mm less than the above �gures» The pier to abutment centres will be perhaps 500mm greater than the above �gures» This table also covers YE-Beams, but please note that when dealing with YE-Beams the prestressing force should be centred on the lateral (transverse) centroid Xc



» In order to keep control of deck slab moments, beam interface shear links and to use standard 50/20 ribbed FRC shutter BPC recommends a general maximum

beam spacing in mm of 1350+0.28D for Y-beams where D= beam depth.Beam spacings greater than this may be used but the permanent shutter will either have to be 75mm deep ribbed FRC or prestressed wide slab with a corresponding increase in deck slab thickness over the beam up to 250mm.» If using prestressed 75mm wideslab permanent shutter the outside beam face shutter rebates will have to be increased in size from the standard 40mm wide x 50mm deep to 60mm wide x 75mm deep. This also requires the shear links to be narrowed and some adjustment of the top strand locations.

Y Beam showing all possible strand locations Ye Beam showing all possible strand locations

Full Y Beam range Full Ye Beam range


2No. @ 480

2No. @ 1330

2No. @ 3502No. @ 310

10No. @ 21014No. @ 16014No. @ 11013No. @ 60

2No. @ 12302No. @ 11802No. @ 11302No. @ 10802No. @ 10302No. @ 9802No. @ 9302No. @ 8802No. @ 8302No. @ 7802No. @ 7302No. @ 6802No. @ 6302No. @ 5801No. @ 5302No. @ 4801No. @ 430

2No. @ 13301No. @ 1280

2No. @ 3502No. @ 3101No. @ 26010No. @ 21014No. @ 16014No. @ 11013No. @ 60

310

280

250

220

190

310

280

250

220

190

160

130

100

70

190

160

130

100B12-01

B12-0270

190

70 50 45 45

45 45 45 50 50 65 65 50 50 45 45 45 757575 45 45 45 50 50 65 65 50 50 4545 45 75

B12-01

750

Y1 =

700

Y2 =

800

Y3 =

900

Y4 =

100

0Y5

= 1

100

Y6 =

120

0Y7

= 1

300

Y8 =

140

0

750

B12-02

YE1

= 70

0YE

2 =

800

YE3

= 90

0YE

4 =

1000

YE5

= 11

00

YE6

= 12

00YE

7 =

1300

YE8

= 14

00

Wf

Y

Y Y

YY

XXX X

Xc

Yc Yc

Wf

32 33


Fibre Reinforced Concrete Permanent Shutter

FRC is a flat or ribbed product designed to facilitate the pouring of in-situ deck slabs between prestressed bridge beams. The shutter is designed to carry the immature concrete and associated construction loadings. It is intended that the shutter will be left in place following completion of the bridge. Banagher Precast Concrete FRC shutter is made from 50N self-compacting concrete

with 5 kg/m3 of synthetic fibre and glass fibre reinforced polymer bars. These products were chosen for their structural properties and long-lasting durability. Specifications for all of the components can be sought from Banagher Precast Concrete.

Design loads:- Live load – 1.5 kN/m2 Dead load – Thickness of insitu slab * 24 kN/m3

load span tables

design

Introduction

Product

30mm Flat50/2075/20

Maximum Span (mm)

75013501800

Max deck thickness including FRC shutter (mm)

300300300

148

6mm GFRP rod

6mm GFRP rod

6mm GFRP rod

50

750

50

30

6no. 6mm GFRP rod @ 130c/c = 650

148 148

750

750

148148

56

509822 R208

15

50

20

138 148

148

138

148

56

103chamfer 10x10

MAX

DEC

K

FRC

SHU

TTER

PERMANENT SHUTTER

SPAN SPAN

BRIDGE BEAM

SPAN

PERMANENT SHUTTER PERMANENT SHUTTER

chamfer 10x10

45

138 15

15

8

19.5

R20

8

15 138

8

Frc 75/20

Frc 50/20

Frc Flat 30

20

• Cutting altering of frC panels may cause structural failure and is not permitted without written approval from Banagher Precast Concrete ltd.• frC should always be placed with arrows/ribs directed transversely across the span –see figure.• FRC products must not be subjected to excessive point loads (live load not to exceed 150 Kg/m2) • FRC Products should be inspected for damage. • All surfaces to receive FRC should be cleaned to remove all loose material and inspected for damage.

• The bearing should be no less than 25mm at each side of the FRC, and must be level with the underside of the FRC- See figure. • FRC product must not be subject to shock loading. • FRC is only suitable for intended use. • Spacers should always be placed on the beams not the FRC. • Concrete must not be heaped on the FRC. • Material must not be stacked or elements must not be propped on the FRC. • Storage of materials on deck must be supported by beams not FRC.

Material safety data

WarNINg

25MMMINIMUMBEARING

34 35


Precast Parapet, Coping and Edge Beam Details

section through MY Beam showing cast on parapet(this Detail can also Be Used With the tY & Y Beams)

Precast Parapet Cast on Beam

Transverse Hole

Projecting Link

Precast Prestressed MY Beam Projecting steel for tie in with Deck

section through W Beam showing precast coping(this Detail can also Be Used With the U Beam)

Cast in craddles for Crash Barrier System

Precast Prestessed W Beam

BPC In-House Connection Detail

Precast Coping Beam

Drip Detail Level

More and more contractors are using the option of factory manufactured concrete cast on or individually cast parapets, copings and edge beams. Banagher Precast Concrete parapets, copings and edge beams can be any profile, we do carry standard sizes and we would offer these first but bespoke sizes can also be catered for.

Cast on parapets, copings and edge beams are typically precast onto our standard range of prestressed bridge beams as a secondary process which can be seen here and on the next five pages.

Banagher Precast Concrete also design holding down details for contrac-tors so that the use of precast parapets, copings and edge beams can be used on site. They make for a better finished product and a much safer product as straight away the contractor has edge protection and they also act as formwork for the deck pour.

36 37


section through tY Beam showing cast on precast coping(this Detail can also Be Used With the MY & Y Beam)

Cast in craddles for Crash Barrier System

Cast on Coping Beam

Drip Deatil Incorporated

Precast PrestressedTY Beam

Projecting steel for tie in with Deck

section through tY Beam showing precast parapet(this Detail can also Be Used With the MYe & Ye Beam)

Precast Parapet Beam


Precast Prestressed TYE Beam


Typical advantages of precast concrete parapets, copings and edge beams:

1. Factory produced2. Ensure a quick erection process3. Alternative finishes and profiles available to suit local conditions4. Can take cast in items for light fixings and crash barrier systems.

Banagher Precast Concrete manufacture parapets like below for use over Railways where a steeple top is required to prevent people being able to stand on top of the parapet. These units can have an F4 finish on both faces or a U4 finish on one.

38 39


section through tY & tYe Bridge Deck showing precast parapet(this Detail can also Be Used With the MY & Y Beam)

Precast Parapet Cast on Beam

Precast Prestessed TYE Beam


section through W Beam showing precast coping(this Detail can also Be Used With the U Beam)

Cast in craddles for Crash barrier System

Drip Detail Incorporated

Precast Coping BeamBPC In-House Connection Detail

Precast Prestessed W Beam


Banagher Precast Concrete can offer pattern profiled finishes, exposed aggregate finishes, brick sandwich panels and as shown below curved panels as well. Whatever your criteria please give our technical team a call for a precast solution.

There are many forms of connection details for the parapet to the deck. Banagher Precast Concrete pride themselves on offering the client the best and most user friendly solution for on site conditions. A precast seating and a stitch detail can help in the temporary case and give the client edge protection at an early stage allowing work on the deck to start straight away.

40 41


Lifting and Handling Details

Sufficient clearancerequired to avaoid Beambearing along its span

U and W Beams

W Beam manufacture is identical to U Beam manufacture but due to the larger section, extra care must be taken in lifting and stacking of W Beams. The units are manufactured with two sets of lifting anchors (see Fig. 1). The lifting anchors positioned closest to the ends are used at the manufacturing yard and should not be used on site, except in special agreed circumstances. The site lifting anchors are positioned further in along the beam. The location and Lifting Angle for these positions are noted on the relevant production drawing.

When lifting the beams at the production yard, a spreader beam is used. This spreader beam has been manufactured, tested and certified for this specific task and lifts straight up causing no inward or outward stress to the beam. This

system is used for lifting the beam from the production line into storage.Typical support arrangement for temporary storage is shown in Fig. 3. The beam must be supported under the end lifting anchor and the supports should provide sufficient ground clearance to avoid any bearing along its length. Bearing should only take place at these two points, no further bearing should be provided along the length of the beam. Support should be provided either across the full width of the W Beam soffit (see Fig. 4a) or directly under thetwo webs (see Fig. 4b) and NOT be positioned along the centre line of the beam (see Fig. 4c). When transporting to site a temporary brace is positioned between the two site lifting anchors (Fig. 2). This is an adjustable steel frame that is easily fixed and removed when the beam is in position. The brace must remain in place when lifting on site and slings can be attached as normal. Once the beam has been landed on its support this brace can be removed easily andreturned to the yard. Site work may commence.

xall Other Beams

elevation

fig 1.

fig 2.

sectionsection

elevation

elevation

section

section

prestressed Bridge Beam lifting Details

prestressed Bridge edge Beam lifting Details

section

fig 4a. fig 4b.

fig 3.

fig 4c.

SupportPoint

SupportPoint

W Beam

D-Shackle to be used when lifting on site

D-Shackle to be used when lifting on site

15.7mm superstrandto be used for lifting.

Specified characteristicsBreaking load = 279kn

3 No. Strand each end

4No. StrandFor lifting both ends

15.7mm superstrandto be used for lifting.

Specified characteristicsBreaking load = 279kn

Strands to be splayed in Beamto provide anchorage

Spreader Beam usedfor lifting in yard

D Shackleused for lifting

D Shackleused for lifting

Yard lifting anchor

Yard lifting anchor

Site lifting anchor

Site lifting anchor

Temp. lifting bracepositioned betweenwebs @ site liftinganchor locations

Temp. lifting bracepositioned betweenwebs @ site liftinganchor locations

Direction of site lift

Min. Liftangle

45°Dire

ction of si

te lift

W Beam

W Beam

15.7 DiaSuperstrand usedfor lifting anchors279kn breakingload

15.7 DiaSuperstrand usedfor lifting anchors279kn breakingload

Strands to be splayed in Beamto provide anchorage

Site lifting

Site lifting

Yard lifting

Yard lifting

Nominal 50mm pin to be used

Nominal 50mm pin to be used

Inclined Lift on site

Inclined Lift on site

See DWGS

See DWGS

60°

60°

60°

60°

15°

15°

45°

45°

Liftin

g sling

Liftin

g sling

42 43


transportation to site:In almost all cases it is the responsibility of Banagher Precast Concrete to deliver the bridge beams to site. The handling of the units on site, preparation of suitable access roads, cranage and further site operations is the responsibility of the contractor. Banagher Precast Concrete are on hand to advise in relation to any of the points above.

The precast beams are delivered to site on special vehicles with the load supported and restrained appropriately. On site, the access road to the point of

unloading must be appropriate for road vehicles, i.e. adequate hardstanding to be provided for by the main contractor.

Roadways with crossfalls or corners with severe changes of level should be avoided as these may impose torsional stresses on the beams. The unloading area should be on level ground and appropriate space for turning should be available.

handling and erection on site:Lifting and handling operations must be reviewed by a competent person. Cranes should be positioned such that the erection of the beams can take place safely, within the safe working load and radius of the crane. Beam weights for lifting are given on the Banagher Precast Concrete production drawings. The angle of lift is also defined on the drawings. Bridge beam lifts are often critical with respect to road or rail closures, it is recommended therefore that the crane has some additional capacity. The contractor should allow for an additional 10% of weight to that on the production drawings, if necessary, Banagher Precast Concrete can weigh the beams. The bridge beams have lifting strands cast in, these again are identified clearly on the production drawings. It is up to the crane supplier to provide all of the lifting gear.

Bridge beams should be placed in position as soon as they are delivered to site but often this is not possible as large numbers of beams may take days to be delivered in full if the haulier doesn’t have adequate numbers of trailers therefore it may be required to store a number of beams until all of the beams have been delivered and then can be placed at the same time. Storage areas should be cordoned off and beams should be supported on timber skids with appropriate foundation strips, Banagher Precast Concrete are available to liaise on the type and size of timbers that need to be used, often these timbers will be on the delivery wagon and can be kept and used on site. Tall beams should be stabilised with props and all beams should be supported only under the lifting points as shown in our section on “Lifting and Handling Details” in this brochure.

Delivery and Installation


Appendix A

TY & TYE Edge Beam for Solid Slab Construction

TY & TYE Edge Beam for Beam and Slab Construction


tY Beam showing all possible strand locations for 12.9mm diameter strand

tY Beam showing all possible strand locations for 12.9mm diameter strand

tYe Beam showing all possible strand locations for 12.9mm diameter strand

tYe Beam showing all possible strand locations for 12.9mm diameter strand

60

50 45 4544 4456 56590

50 50 50 50 50

73

60

B10 Link

60

21070

50 50 50 50 50 5044 44590

56 5645 45

45 45 50 65 44 56

193

60 50 100

13No.@ 6013No.@ 1009No.@ 1405No.@ 1801No.@ 220

2No.@ 3502No.@ 4002No.@ 4502No.@ 5002No.@ 5502No.@ 6002No.@ 6502No.@ 7002No.@ 7502No.@ 8002No.@ 850

13No.@ 6013No.@ 10011No.@ 1409No.@ 1807No.@ 2203No.@ 2703No.@ 3105No.@ 3505No.@ 4005No.@ 4505No.@ 5005No.@ 5505No.@ 6005No.@ 650

5No.@ 7005No.@ 7505No.@ 800

13No.@ 6013No.@ 10011No.@ 1409No.@ 1807No.@ 2203No.@ 2703No.@ 3104No.@ 3504No.@ 4004No.@ 4504No.@ 5004No.@ 5504No.@ 6004No.@ 650

4No.@ 7004No.@ 7504No.@ 800

13No.@ 6013No.@ 1009No.@ 1405No.@ 1801No.@ 220

2No.@ 3502No.@ 4002No.@ 4502No.@ 5002No.@ 5502No.@ 6002No.@ 6502No.@ 7002No.@ 7502No.@ 8002No.@ 850

B10-01 LinkB8-01 Link

50 50 50 50 50 5044 4456 5645 45

590

50

45.5

45 4544 4456 56

590

80

60

100120140

160180

200

50 50 50 50 50

B8-01 Link

44 45


Notes Notes

46 47


For a copy of the

Bridge Beam Design Manual please contact our technical department.

48 Precast concrete specialists


Banagher precast concrete ltd, Banagher, Co. Offaly, IrelandT(IRL) +353 (0)57 9151417 T(UK) +44 (0)161 300 0513 F +353 (0)57 9151558 E [email protected] W www.bancrete.com

Produced by studio93.ie

all rights reserved. except as permitted under current legislation no part of this work may be photocopied, stored in a retrieval system, published, performed in public, adapted, broadcast, transmitted, recorded or reproduced in any form or by any means, without the prior permission of the copyright owner. enquiries should be addressed to Banagher Precast concrete.

bridge beam manual

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