Table Of Contento
o
design
handbook
Precast and Prestressed Concrete
FIFTH EDITION
MNL 120-99
□
175 W. JACKSON BOULEVARD
CHICAGO, ILLINOIS 60604
312 786-0300 312 786-0353
Copyright © 1999
By Precast/Prestressed Concrete Institute
First edition, first printing, 1971
First edition, second printing, 1972
Second edition, first printing, 1978
Second edition, second printing, 1980
Third edition, first printing, 1985
Fourth edition, first printing, 1992
Fifth edition, first printing, 1999
All rights reserved. This book or any part thereof may not
be reproduced in any form without the written permission
of the Precast/Prestressed Concrete Institute.
ISBN 0-937040-60-6
Printed in U.S.A.
PCI Design Handbook/Fifth Edition
Precast and Prestressed Concrete
FIFTH EDITION
PCI Industry Handbook Committee
(,
A. Fattah Shaikh, P.E., Chairperson
Roger J. Becker, P.E. Phillip J. Iverson, P.E. Joseph A. Miller, P.E.
E. Fred Brecher, P.E. Daniel P. Jenny, Secretary Scott L. Muka, S.E., P.E.
Thomas J. D’Arcy, P.E. James E. A. King, P.E. Kurt L. Salm, S.E., R.A.
John D. Garlich, P.E. Rafael A. Magana, P.E. Kim Seeber, P.E.
Harry A. Gleich, P.E. Michael J. Malsom, S.E., P.E. Irwin J. Speyer, P.E.
Timothy A. Holien, P.E. Leslie D. Martin, S.E. Helmuth Wilden, P.E.
Mohammad Iqbal, P.E. Robert F. Mast, P.E.
Editor
Raths, Raths & Johnson, Inc.
PCI Design Handbook/Fifth Edition
FOREWORD
The Precast/Prestnessed Concrete - Institute, a Changes have beery made7 throughout the docu
non-profit- corporation, was founded-in T954 for the ment. Some of particular importance include:
purpose of advancing the design, -manufacture, and
use of structural precast and; prestressed concrete
• Updated to the ACI Building Code 318-95,
and architectural precast concrete in the United
other current PCI publications, and publica
States and Canada.
tions of other technical associations.
To meet this purpose, PCI continually dissemi
nates information on the latest concepts, techniques • New load tables for 12 ft. wide double tees
and design data to the architectural and engineering have been added.
professions through regional and national programs
• Prestressed column curves have been ex
and technical publications.
panded to include 9,000 and 10,000 psi con
The First Edition of the PCI Design Handbook was
crete strengths.
published in1971 with its primary focus on structural
• The Chapter 3 sections on structural integrity
products and buildings. To fill a void in the design of
and seismic design have been completely re
architectural precast concrete, the PCI Manual for
vised.
Structural Design of Architectural Precast Concrete
was published in 1977. In 1978, the Second Edition • Chapter 4 includes a new pocketed spandrel
of the PCI Design Handbookwas published. In keep beam design example.
ing with the tradition of continually updating informa
• Chapter 6 has been reorganized and materi
tion, an Industry Handbook Committee was formed in
al not specifically related to connections has
1979 to develop the Third Edition, which was pub
been moved to Chapter 4.
lished in 1985. That edition provided, in a single
source, information on the design of both architectur • The headed stud section (6.5.2) has been re
al precast concrete and structural precast and pre vised to incorporate the latest research and
stressed concrete. The Fourth Edition, published in coordination with ACI.
1992, continued to present both architectural and
• A new section 10.5 was added to explain
structural products and systems. This emphasis is
some design practices that require inter
maintained in the Fifth Edition.
pretation of ACI 318-95.
Since 1992, the committee has continued to moni
tor technical progress within the industry, with partic • The metric conversion section of Chapter 11
ular assistance from the many committees of PCI re has been expanded and includes a new ex
sponsible for a variety of specific topics. This Fifth ample problem.
Edition is the culmination of those efforts, and repre
sents current industry practice.
The members of the committee listed on the title Substantial effort has been made to ensure that all
page have made significant contributions of theirtime data and information in this Handbook are accurate.
and expertise. In addition, PCI committees have pro However, PCI cannot accept responsibility for any er
vided reviews of specific areas. Many individuals rors or oversights in the use of material or in the prep
within the industry have also provided advice and aration of engineering plans. The designer must rec
comment. The Institute offers alt involved in this pro ognize that no handbook or code can substitute for
cess a special note of recognition and appreciation. experienced engineering judgment. This publication
The final review phase consisted of a Blue Ribbon is intended for use by professional personnel compe
Review Committee, made up of Plant Engineers and tent to evaluate the significance and limitations of its
Consulting Engineers from each of the PCI Zones contents and able to accept responsibility for the ap
and from Canada. These individuals were Mike De- plication of the material it contains.
Sutter, P.E., Bill Fossing, P.E., Peter Kluchert, P.E., The Institute considers each new Edition of the
James Linskens, P.E., Robert H. Murray, P.E., Jo PCI Design Handbook to be a living document. The
seph W. Retzner, P.E., John Salmons, P.E., Timothy user is encouraged to offer comments to PCI on the
Salmons, P.E., Donald J. Smith, P.E., Victor 0. Stan- content and suggestions for improvement to be in
go, P.E., Ted Wolfstahl, P.E., and James Zusy, P.E. corporated in the next edition. Questions concerning
To them, PCI extends its appreciation for their very the source and derivation of any material in the Hand
important input. book should be directed to the Institute.
PCI Design Handbook/Fifth Edition
GUIDE TO CHAPTERS
Chapter 1—-Precast and Prestressed-Concrete:
Applications and Materials
1 - 1 to 1-36
Chapter 2—Product Information and Capability
2 - 1 to 2-56
Chapter 3—Analysis and Design of Precast,
Prestressed Concrete Structures
3-1 to 3-100
Chapter 4—Design ^3f Precast and Prestressed
Concrete Components
4 - 1 to 4-96
Chapter 5—Product Handling and Erection Bracing
5 - 1 to 5-36
Chapter 6—Design of Connections
6 - 1 to 6-74
Chapter 7—Selected Topics for Architectural Precast Concrete
7 - 1 to 7-24
Chapter 8—Tolerances for Precast and Prestressed Concrete
8 - 1 to 8-20
Chapter 9—Thermal, Acoustical, Fire and
Other Considerations
9 - 1 to 9-74
Chapter 10—Specifications and Standard Practices
10- 1 to 10-62
Chapter 11—General Design Information
11- 1 to 11-36
Index
PCI Design Handbook/Hfth-Edition
PCI Design Handbook/Fifth Edition
CHAPTER 1
PRECAST AND PRESTRESSED CONCRETE:
APPLICATIONS AND MATERIALS
1.1 General ..........................................,................................................................... 1-2
1.1.1 Background.......................................................................................... 1-2
1.1.2 Features and General Principles....................................................... 1-2
1.1.3 Common Products...................................................................,......... 1-3
1.2 Applications ......................................................................................................... 1-4
1.2.1 Building Structures ............................................................................. 1-5
1.2.1.1 Residential BuiJdings...................................... 1-5
1.2.1.2 Office Buildings ........................................ 1-9
1.2.1.3 Warehouses and Industrial Buildings ............................... 1-12
1.2.1.4 Other Building Structures.................................................... 1—13
1.2.2 Parking Structures............................................................................. 1-14
1.2.3 Justice Facilities................................................................................ 1-16
1.2.4 Precast Concrete Cladding ............................................................. 1-17
1.2.5 Stadiums/Arenas .............................................................................. 1-19
1.2.6 Bridges................................................................................................. 1-21
1.2.7 Other Structures.............................................................................,.1-22
1.3 Materials ............................................................................................................. 1-24
1.3.1 Concrete ............................................................................................ 1-24
1.3.1.1 Compressive Strength ........................................................ 1-24
1.3.1.2 Tensile Strength.................................................................... 1-25
1.3.1.3 Shear Strength...................................................................... 1-25
1.3.1.4 Modulus of Elasticity ............................................................ 1-25
1.3.1.5 Poisson’s Ratio...................................................................... 1-25
1.3.1.6 Volume Changes................................................................. 1-25
1.3.2 Grout, Mortar and Drypack ........................................ 1-26
1.3.2.1 Sand-Cement Mixtures....................................................... 1-26
1.3.2.2 Non-Shrink Grouts............................................................... 1-27
1.3.2.3 Epoxy Grouts ....................................................................... 1-27
1.3.3 Reinforcement................... 1-27
1.3.3.1 Prestressing Tendons......................................................... 1-27
1.3.3.2 Deformed Reinforcing Bars ................................................ 1-28
1.3.3.3 Structural Welded Wire Reinforcement............................. 1-28
1.3.4 Durability ............................................................................................ 1-28
1.3.4.1 Freeze-Thaw and Chemical Resistance ............................ 1-29
1.3.4.2 Protection of Reinforcement .............................................. 1 -30
1.3.4.3 Protection of Connections .................................................. 1 -32
1.3.4.4 Sulfate Attack .................................................., .................. 1 -34
1.4 References ......................................................................................................... 1-34
PCI Design Handbook/Fifth Edition 1 -1
PRECAST AND PRESTRESSED CONCRETE;
APPLICATIONS AND MATERIALS
1.1 General Development of standard-products was one ofthe.
major activities through the Y950s and the 1960s.
In the late 1970s 4©w relaxation .strand was
1.1.1 Background
introduced which reduced the loss of prestress force
The growth of precast and prestressed concrete rs due to creep in the strand, thus allowing more effi
a story of the vision and daring of a few notable linen. cient use of prestressing, resulting in longer spans or
These men took a new idea and maximized its poten smaller sections. Larger strand sizes have been
tial by modifying and improving existing methods, made available as well, such as 0.6 in. diameter
conceiving new methods, and inventing new de strand.
vices, all with a focus on mass production tech In the field of bridges there was the development
niques. An excellent portrayal of the beginnings and of spliced girders, segmental bridges, cable stayed
the growth of precast and prestressed concrete in bridges and cantilevered girder bridges.
North America and the early pioneers is given in a se During the 1980s it was recognized that durability
ries of papers developed to commemorate the is an important aspectof a structure. The precast and
25-Year Silver Jubilee of the founding of the Pre prestressed concrete industry responded by taking
stressed Concrete Institute which is now known as advantage of one of its natural strengths. Plant-cast
thePrecast/Prestressed Concrete Institute (PCI). concrete is more durable than site-cast concrete be
The single-most important event leading to the cause it can be cast with lower water/cementitious
launching of the precast/prestressed concrete indus materials ratios under controlled conditions. This
try in North America was the construction in 1950 of natural durability was enhanced with the develop
the famed Walnut Lane Memorial Bridge (Figure ment of admixtures that make the concrete matrix
1.1.1) in Philadelphia, Pennsylvania. From a technical more impermeable and that inhibit steel corrosion.
perspective it is surprising, and from a historical per Pretopped tees were developed for parking struc
spective it is fascinating, that the Walnut Lane Memo tures to maximize the benefits of the durability of pre
rial Bridge was constructed in prestressed concrete. cast, prestressed concrete at the wearing surface.
There was very little published information on the The past decade has seen the development of
subject and there was a total lack of experience with more complex architectural shapes and surface treat
linear prestressing in this country. Furthermore, the ments. The high demands of owners and architects
length of bridge spans involved would have been a for quality finishes has led to the development of new
daring venture in the late 1940s anywhere in the surface textures and surface treatments. Thin-set
world. The bridge became a reality through a fortu brick and stone-faced panels and textures and colors
nate sequence of events, and the vision, courage and of infinite variety have been developed.
persistence of a few extraordinary individuals [1].
1.1.2 Features and General Principles
Following completion of the Walnut Lane Memo
rial Bridge, American engineers and the construction Precasting concrete in PCI certified plants ensur
industry enthusiastically embraced prestressed con es manufacture of high quality architectural and
crete. Many of the early post-Walnut Lane Memorial structural products. Precasting also facilitates pro
Bridge applications remained in bridge construction, duction of a wide variety of shapes-and sizes, and the
such as the lower T ampa Bay crossing now known as use of prestressing substantially extends the span
the Sunshine Skyway. Simultaneously, American en capability of the products. These techniques enable
gineers and constructors were conceiving new de architects and engineers to achieve highly innovative
vices, improving techniques and developing new ma and economically competitive buildings and other
terials. structures.
The 1950s were the years that brought into focus This handbook serves as the primary reference for
the 7-wire strand, precasting, long-line beds (Figure the use and design of precast and prestressed con
1.1.2) , admixtures, high strength concrete, vacuum crete structures. This section enumerates some of
concrete, steam curing and many other innovations. the important and unique features of precast and pre
With these developments, coupled with the technical stressed concrete. These include the following:
and logistic support provided by the Prestressed
1. Construction speed.
Concrete Institute, which was chartered in 1954, the
industry grew and the applications of precast and
2. Plant-fabrication quality control.
prestressed concrete began to appear in an impres
sive variety of structures. 3. Fire resistance and durability.
1-2
PCI Design Handbook/Fifth Edition
