Holding down systems for steel stanchions

Published by:

The Concrete Society

The British Constructional Steelwork Association (BCSA)

Constructional Steel Research and Development Organisation (Constrado) in whom the copyright is jointly vested

Contents

1. Introduction

1.1 Performance requirements 1.2 Responsibility for design

2. Types of holding down systems 2.1 General

2.2 Comparison of the systems

3. Design considerations 3.1 Column base plates

3.2 Load transfer mechanism 3.3 Access and tolerance

3.4 Bolt forces

3.5 Bolt dimensions 3.6 Embedded lengths 3.7 Corrosion

3.8 Cementitious bedding

4. Work on site

4.1 The traditional system 4.2 Bolts set in drilled holes 4.3 The recessed base system

5. Conclusion

6. Recommendations 6.1 Responsibility

6.2 Design and specification 6.3 Foundation construction 6.4 Steelwork erection

6.5 Filling and bedding

FOREWORD by A. C. L. Blake

Between a steel structure or machine and its concrete support, there is a boundary surface which separates two designers with separate skills, two contractors, two engineering disciplines; often two complete contracts.

The surface is crossed by the bolts which secure the steel to the concrete. It often happens that one end of a bolt is designed by the supplier of the steel, while the other is designed by the concrete technologist. Alternatively, the steelwork designer may have to make highly conservative assumptions regarding the strength of the 'grout' on which his structure will stand. His worst fears may come true; the word 'grout' means many things to many people. At any rate, it is common experience that bolts mean waste, or trouble, or both.

This is no figure of speech. Representatives from the British Constructional Steelwork Association and from the Concrete Society served on the working party which has produced this document; both of these organisations sent questionnaires to their members, and the replies clearly indicated the widespread extent of the problems which are almost universally experienced. The members of the working party express their grateful thanks to all those who replied to the questionnaire; the information which was so freely made available in this way was of tremendous value.

This document is intended to draw attention to the problems, and to indicate methods by which they may possibly be overcome. The subject is an extensive one, as the working party found to its cost, and it was felt to be inappropriate to prepare formal recommendations for standardisation at this stage. Similarly, although the working party gave consideration to the problems of fixing plant and machinery, and to the range of general purpose bolts and fasteners, this document relates only to holding down boIts for columns. Even in this restricted context, there is no general consensus. These notes are therefore in the hope that they will stimulate further discussion, arid will remind designers of steelwork and concrete of their interdependence.

2

1. Introduction

1.1 Performance requirements

Holding down systems are intended to meet two separate sets of requirements; under service conditions they must transmit tension and shear from the column to the foundations, and during construction they may also be called upon to stabilise the column until after other structural elements have been erected. This erection condition can sometimes represent the worst case for the design of the bolts, and its importance should not be overlooked.

The duties which the holding down system is commonly designed to perform include:

The acceptance of the loadings imposed by the column, and their transfer to the foundation, in a manner which will be consistent with the intentions of the designers of both of these structural elements.

The provision of a system of packing, filling and bedding which will be compatible with the design requirements for the column and the foundation.

The provision of sufficient freedom of movement, tolerances, and accessibility to allow the design requirements to be achieved in practice.

The provision of protective methods which ensure that the strength of the holding down system will remain suitable for its purpose throughout its intended life.

1.2 Responsibility for design

There is a widespread practice by which holding down bolts are designed separately from, or with little or no reference to, the supporting concrete.

This should be discontinued; the design of the bolts and the foundation should be prepared under the direction of a single engineer, with a knowledge and appreciation of the different problems of the steelwork designer, the steelwork erector, and the civil engineering contractor. Where assumptions are unavoidable they should be clearly stated on the drawings, and care should always be taken to ensure that all the information needed by both the steelwork erector and the civil engineering contractor is incorporated on all drawings related to the bolts and foundations. When this unified approach is not possible it is essential that the steelwork designer and concrete designer work in close cooperation at this important interface of their respective disciplines,

2. Types of holding down systems

2.1 General

The traditional type of holding down system is shown in Fig. 1 (for a heavy industrial column) and Fig. 2 (for a lighter type of building column). In this system, the bolt heads bear against suitable load spreading devices which are embedded within the base concrete. The main length of each bolt is surrounded by a protecting tube, to ensure freedom of movement, and the threaded ends project through distances sufficient to allow the nuts to be fully engaged on the threads. The column base plates are set at some distance above the foundation, the gap being eventually fllled with bedding

material. '

A variation of this system is the use of high yield steel for the bolts; another is the use of prestressed high tensile steel bars (Fig. 3).

Two further systems are also considered in these notes. In one, drilled holes are formed in the foundations once the concrete has hardened, and the holding down bolts are set in position using cementitious or resinous bonding materials; examples are shown in Figs. 4, 5 and 6, and a variation in the form of a self-levelling system is sketched in Fig. 7. Lastly, a recessed base system, which can completely eliminate the need for holding down bolts altogether, is shown in Figs. 8 and 9.

2.2 Comparison of the systems

2.2.1 The traditional system

It is usual for mild steel bolts to be employed, though high yield steel may be used when advantage

3

can be gained from the reduction in diameter. While it is quite possible to set the bolts into position with sufficient accuracy to enable them to be embedded directly in the concrete, it is widely found in practice that this accuracy is not achieved. The bolts are therefore surrounded by tubes, with diameters of about three times the bolt diameter, to overcome the positioning errors which are normally expected. In large anchor systems, using bolts of 50 mm diameter or more, the tubes are commonly of steel; with smaller bolts, tubes of sheet steel, timber, plastic or expanded metal may be employed. Expanded metal tubes often cause unsatisfactory results as a consequence of the passage of fines into the tubes during the vibration of the concrete, even when a small sized mesh is chosen. Void formers of polystyrene or other expanded plastic are also used; these keep the holes free from water and rubbish, but they tend to float upwards during concreting, and can also be difficult to remove clearly.

An anchor is provided at the head of the bolt, in the form of a separate plate for each bolt or a single member common to two or more bolts. Steel tubes are often welded to these anchor plates, but are not normally considered to contribute to the designed strength of the system. The whole of the bolt loading is designed to be transmitted to the anchor, which in turn is designed to. transmit the loading to the foundation. Special provisions may be needed for the transmission of shear; in many designs this is transmitted through the filling material, the strength of which is often doubtful. The head of the bolt may be encased in a plastic or metal cap, or wrapped with tape, to prevent it from being trapped by the concrete. A keep flat or other device should be provided to prevent rotation during tightening. Square shanked bolts are also available; or square washers can be welded to the bolts to prevent rotation. Bolt threads should be protected against damage by the provision of suitable guards, which should be shown on the drawings. The thread length should extend from the top of the tube to the top end of the bolt.

The tops of the tubes should be plugged to prevent the accumulation of water and rubbish, the plugging detail being included on the drawings. The exclusion of water can be particularly important; the forces due to the freezing of water in pockets of this type have been known to split pile caps.

In large holding down systems, the provision of bolts of different lengths can simplify the problem of passing the base plate over the bolts as the column is lowered into position. Reusable conical extensions, made of plastic, can also be employed. Generously sized clearance holes through the base plate also help to speed erection.

The advantages of the system include its design flexibility (it can be adapted to almost any size of column), its familiarity (which may sometimes be more apparent than real), and its capacity for adjustment when wrongly installed. It provides a positive system of load transfer, by means of direct mechanical devices of known suitability.

Its drawbacks include its high cost, in terms both of initial outlay and of remedial costs when things go wrong, as they often do (see section 4.1).

It also offers less security against corrosion than is commonly supposed. The main problem however, is not inherent in the system as such; it lies in the tendency of designers to treat the system as a standardised method of dealing with a problem of detail, and thus to give it less than the attention which its cost and importance both warrant.

2.2.2 Variations on the traditional system

The use of high yield bolts in place of mild steel bolts, causes no additional design problems; except that care should be taken to use weldable steel in case site modifications are necessary.

Prestressed bolts make use of cold worked high tensile steel bars which should not be welded or heated in any way; the bolts must be protected from accidental weld splash and accidental local heating. Erection of the columns proceeds in the usual way. Thereafter, predetermined forces are applied to the bolts, by means of jacks, and the bolts must be free to move in accordance with these forces; it is therefore usual to encase them in a sheathing system which permits this movement. Burst" ing and splitting forces in the concrete local to the anchor plates may need to be resisted by local reinforcement.

The advantages of prestressing usually include a substantial cost economy, resulting from the efficient use of smaller quantities of high grade material, and a more accurate knowledge of the forces acting on the holding down system. As a result of the prestressing, the whole anchor system is also proof tested; though the mode of behaviour at service load conditions may differ from that at ultimate load. The drawbacks include the need for a two-stage procedure, and the possibility that subsequent modifications might be attempted in ignorance of the existence of the prestress.

4

2.2.3 Bolts set in drilled holes

The difficulties commonly encountered with the traditional system have led to the development of bolts which are set into drilled holes by means of bonding agents.

The system offers a number of advantages: problems associated with the setting out and temporary support of the bolts are eased or eliminated; the setting of the bolts can be delayed until shortly before (even, in some cases, after) the positioning of the column, thereby reducing the chance of site damage; and the use of a higher grade bedding material improves both the overall economy of the system and the resistance to corrosion. Drawbacks may include the employment of an additional subcontractor for the drilling (though this is commonly a matter of choice, not of necessity); the need for more accurate setting out of the reinforcement in the foundation (to avoid damaging the reinforcement and slowing down the drills); and some uncertainty over the creep behaviour of resinous bonding material, under sustained high stress. In some cases it may be necessary to prop the column during

erection. .

The bonding materials are of two main types: cementitious and resinous.

(a) Cementitious bonding agents.

These consist mainly of sand and cement mixtures, with admixtures to provide slight expansive properties to ensure the close contact of the filling with the bolt and the sides of the hole. A number of such admixtures are marketed under various brand names, and the advice of the manufacturer should be sought before use. Some proprietary mortars are also available.

J

1'1

~i

J.I

~i

1'1 III

1,1

Steel anchorage framework

D = (3 or 4) x d ----+1

DETAIL AT LOWER END OF BOLT

Nut welded to shank or forged head.

Do not weld nut

to washer plate.

"Keep" flat to prevent rotation

Cap from gauge metal, polystyrene, etc to ensure bolt freedom

Fig. 1 Heavy industrial building column

5

;)Fll;)UO;) uounpunoj JO dOl (3
.J::J,___
--. - ....
Q) '"
C 2.0
E </l>,
Q) 0
;::l ,,,d, ,u'PP''; I ~~
(3
o C u
Q) '"
G) .... ;:;:::
Q) ~~
tl
J
Ali.
-- -
I 11 - 2 ..'2 0..

:!:::JfF~~~(]

c

E

;::l

(3

s»

G)

Q)

tl

0; .~

....

"0

.5 c >.~

u 0

o~

.J::J </l

2 '" cO; o .~ .;: c

'" 0 u u

o .... ....l 0

6

z; -< ....l 0...

7

8

o

c: o

:~ §

<l) 0-

e

U.l {/J

<t: iJ:)

Z o z

j

0..

Expansive properties are generally introduced by the addition of micro-fine particles of metallic elements which oxidise in contact with the mixing water. It is occasionally possible for oxidation to continue in wet conditions, with a consequent breakdown of material before the filler attains sufficient strength to accept the load from the bolts.

(b) Resinous bonding agents.

These can themselves be sub-divided into polyester based and epoxy based formulations. The former are better able to sustain adverse conditions such as damp and are more widely used than epoxies for filling and bedding materials. Epoxies possess slightly better strength, shrinkage and creep characteristics, but require more attention to be paid to the environment in which they are used.

Both types of resin are exothermic, but under normal circumstances the temperatures generated are not high enough to affect ordinary concrete. Resinous materials have some advantages over the cementitious types. Their combination of high strength and low viscosity make it possible to use less material; they may be stressed after a smaller time interval; and they are largely immune from attack by normal lubricants and hydraulic fluids. Their drawbacks include a higher unit cost, and a greater tendency to creep under load.

(c) Types of bolts

(i) The simplest form of bolt is made from deformed bar; hot rolled high yield reinforcement baris suitable being easier to thread than cold worked steel because of the softer surface of the former. Such a bolt is shown in Fig. 4.

/

This type of bolt has the advantage of being able to be passed through the hole in the base plate after the column has been positioned. The hole in the concrete should be no larger than is necessary to accommodate the shank of the bolt. Its disadvantages include the need to grind or turn off the deformations before threading; and problems can also arise because the bond is present throughout the whole of its embedded length. This in turn means that the load is transferred from the bolt to the bonding material over only a small part of the length, in a manner analogous to the transmission length of a pre tensioned prestressing tendon. As a result progressive strain failures proceeding downwards from the concrete surface have been known to occur.

(ii) The 'block-ended' bolt illustrated in Fig. 5 works on the principle that the bolt loading is transferred to the bonding material by compression from the block, and thence into the concrete by means of the bond between the column of bonding material and the walls of the hole. By debonding the shank of the bolt a greater length is available to accept the strain and to provide a degree of resilience which is particularly advantageous in the case of shock loading.

The larger hole provides a greater area for the distribution of the load into the concrete, and allows more tolerance for the positioning of the column; it also has the obvious drawbacks of more expensive drilling and a greater volume of bonding material. This type of bolt is usually suspended into the hole from the column while it is being positioned; the bonding material is injected after the column has been placed.

(iii) A third type of bolt has been developed for the case in which adjustable bolts are needed to support the column during erection (Fig. 6). The force in the bolt is transferred through the tube into the concrete by bond between the walls of the tube, the bonding material and the walls of the hole.

(iv) The use of expanding bolts is sometimes considered for small loads, but these fixings are not recommended for heavy duty holding down bolts.

2.2.4 Recessed base system

The types of bases shown in Figs. 8 and 9 can lead in many cases to overall economy particularly when some degree of fixity is required between the column and the base. When bolted systems are used, the lengths of the bolts can often determine the depths of concrete (and thus the volume of excavation); with recessed bases, the depth of the pocket is often less than the equivalent bolt lengths.

In design a check is needed to ensure that the embedded length is sufficient to transmit the moments and forces into the concrete by bearing and bond; the bond may be enhanced by the adddition of studs or cleats to the column. It may also be necessary to specify an erection procedure, and to call up any props or guys that may be required to ensure stability. Temporary bolts may also be used for this purpose; these can be set in drilled holes using a cementitious or resinous bonding agent, or may simply be one of the many types of expanding bolts now available.

9

The advantages of the system include the overall economy mentioned in the foregoing; the elimination of permanent holding down bolts as such, and the setting out problems associated with them; and the elimination also of problems associated with bolt corrosion. The drawbacks include the possible increase in foundation depth and the lack of inherent stability during erection, though this can be improved by the provision of temporary bolts and temporary outriggers. It may also be more difficult to achieve true lines, levels and plumbs when the setting out is to be related to the bottoms of deep recesses.

3. Design considerations

3.1 Column base plates

Most base plates are presently designed on the assumption that the supporting pressure will be uniform or linear, and will be applied over the whole area of the plate; the steelwork designer must also decide, or assume, the maximum working stress which the bedding material can safely withstand. On the other hand, many - perhaps most - columns are erected using permanent packs through which the column loads tend to be transferred. In some cases this can have an important effect on the performance of the base plate; the steelwork drawings should clearly state whether packs are to be permanent or temporary, the positions in which they are to be provided, the characteristics required of the bedding material, and the extent to which contact between the base plate and the bedding is relied upon to transmit the loading.

3.2 Load transfer mechanism

The designer should satisfy himself of the security of all the components of the system by which the load is transferred from the column to the foundation. In particular, reliance should never be placed on the ability of 'grout' (often of unspecific nature) to act as a bonding agent connecting the bolts to the foundation or to resist shear (see also section 3.8). A quantitive check should be made on all load bearing components and their constituents, and quality control procedures should be properly specified.

3.3 Access and tolerance

The two are not the same. Steelwork manufacturers and civil engineering contractors can both work to close tolerances when necessary, though sometimes at increased cost. Closer tolerances than needed should not be called for; but on the other hand designers should not be inhibited by the mistaken belief that close tolerances cannot be achieved. When proper precautions are taken, civil engineering contractors should have little difficulty in placing bolts to line and level, to vertical and horizontal tolerances of ± 5 mm; and tolerances of ± 10 mm should prove adequate for most purposes.

The steelwork designer should specify the tolerances required; it may also be necessary on occasion to consider the provision of special aids such as templates.

The degree of access provided will have a direct effect on the quality of the bedding material. It is clearly unreasonable to call for a bedding of high strength, with a 95% contact between the base plate and the bedding, and then expect this material to be inserted under a plate with an area of several square metres through an access gap of 15 mm; yet such requirements have sometimes been called for in practice. The bedding space under the base plate should not be less than 25 mm (for grout), 50 mm (for mortar) or 75 mm (for concrete). The diameters of bolt sleeves should be at least 75 mm or three times the bolt diameter, whichever is greater.

The foundation designer should also allow for the provision of access and cleaning facilities appropriate to the standard of performance expected of the contractor. (See also section 3.8).

3.4 Bolt forces

Holding down bolts are often sized on the assumption that the whole of their strength will be available to resist the upward forces applied by the structure - that is, that the initial stress in the bolt, on completion of erection, is negligibly small. Guidance should be given to the erector, on the drawings, with respect to the amount of tightening which is permissible when this is of importance. Thread damage should be guarded against. If locknuts are used, care must be taken to ensure that the main nut supports the load. Large horizontal and vertical forces may be imposed on the members of statically indeterminate frames, and on the bolts, if the frames have to be distorted to fit badly placed bolts.

10

3.5 Bolt dimensions

The basic bolt force and hence the diameter should be determined by the steelwork designer, since this is derived from the loading imposed by the column. The bolt diameter is sometimes increased to allow for possible corrosion; this practice may be unreliable, and better methods may be available (see section 3.7), but where it is adopted it should be clearly noted on the drawings. By contrast the length of the bolt is determined primarily to suit the properties of the foundation, and thus its magnitude should be determined by the foundation designer. When the responsibility for the design of the steelwork and the foundation is divided, full provision should be made for the interchange of information between the respective designers.

3.6 Embedded lengths

In the traditional system, the embedded length of the tube (and thus of the bolt) is determined by the properties of the concrete in which it is cast, and by the magnitude of the load applied to the bolt ..

A simple method of assessing the embedded length required is to assume that the upward force applied by a bolt is resisted by a conical surface of concrete, though this may be an over-simplification. Values for the surface areas of two overlapping cones are given in Table 1; when multiplied by the permissible shear stress, this gives the loading which can be resisted by the concrete. The provision of appropriate reinforcement may increase the permissible loading; the use of a 90° cone may also be conservative.

Embedment lengths for other bolt systems are considered in CIRIA Technical Note No. 75 based upon tests on expanding bolts, resin capsules and cast in sockets - all up to 20 mm diameter.

3.7 Corrosion

Inspections of holding down bolts taken from demolished structures have shown that, within the design life of the building, corrosion has significantly reduced the cross sectional area of the bolt. In very severe cases the load carrying capacity of the bolt has disappeared within 50 years. The critical position is often in between the hole in the base plate and the bolt and just below the base, in the filling. Demolition contractors confirm that it is not uncommon in old structures to find the bolts to be so severely corroded as to be structurally useless (see photographs A to D).

This problem should be carefully considered at the design stage, especially in exposed structures and in those where the working environment is very aggressive. Where necessary, protective tapes or sleeves should be specified, or a corrosion resistant material should be provided. In some cases a corrosion allowance when determining the size of the bolts may be sufficient; but this practice is often inadequate by itself.

When prestressed bolts are used, even greater importance should be attached to the prevention of corrosion.

Where the column is buried below the floor level, severe corrosion of the steelwork has been found to occur just below the concrete surface. In this case it is good practice to introduce a small timber fillet round the perimeter of the steel shaft when the concrete is cast. On removing the timber fillet, the resulting groove is then filled with a non-setting mastic.

No information has been received of any serious problems traceable to corroded holding down bolts. However, it is true to say that buildings now being demolished were designed to much greater factors of safety than is currently the case. Thus it is important to note that the change toward lighter and more economical structures, operating at higher stress levels, is safe only when all parts of the structures are designed accordingly. The extrapolation of past experience with foundation bolts to the present design of holding down bolts may therefore be unsound.

It should be noted also that experience appears to indicate that cementitious bedding and filling materials cannot be relied on to provide protection against corrosion. These materials are often placed in difficult conditions; they often shrink and crack; and gaps may open between the bolts and the surrounding material, because of small movements due to vibration or other loading. In a number of cases these conditions have encouraged corrosion, rather than prevented it.

3.8 Cementitious bedding ('grout')

The words 'grout' and 'grouting' are commonly used to describe the bedding material which is placed between a steel member and a concrete surface. They are often misleading, in that they mean different things to different people; and rarely does the designer indicate the duties that he expects the material to perform.

11

Photograph A

75mm diameter H. D. bolts, part of the anchorage for a steel furnace installed in 1918. Maximum reduction in cross sectional area is 61 %.

These bolts passed through a large steel casting haunched with concrete.

A.M.S.: 7S MM: 1918

Photograph B

45 mm diameter H. D. bolts from a building column adjacent to the steel furnace mentioned in 'A'. Maximum reduction in cross sectional area is 27%. These bolts were also installed in 1918.

A.M.S.: 4S MM: 1918

12

Photograph C

50 nun diameter H. D. bolt from a building column located in a melting shop structure. Reduction in cross sectional area reached approximately 50% and subsequent mechanical damage had reached a level such that the bolt had failed at the time of demolition. Date of installation 1917-1920.

R.M.S.: 50 MM: 1917

Photograph D

5 mm diameter H. D. bolt, date of installation and exact location not known. It did, however, originate from the same general area as Bolts A, Band C and is no older.

All the bolts A, B, C and D were obtained in the Scunthorpe area from a steelworks environment. They demonstrate that only at discrete positions are all the conditions for corrosion fulfilled and at these points corrosion is severe. It is expected that investigations in other areas would produce similar results.

13

This section relates only to cementitious materials; resin-based materials are also available, often with better properties bu t at higher cost.

3.8.1 Terminology

The following definitions are used throughout the document:

GROUT: A mixture of cement (usually Portland Cement) and water, in the proportions of about 2:1 or more by weight. The high water content is intended to produce a fluid suspension, which can be poured into holes and under base plates. After setting, the material is usually porous, of relatively low strength, and liable to shrink to an extent which causes significant cracking of the hardened paste. It is suitable for use as a non-load-bearing filler.

SANDED GROUT: A mixture of cement, sand and water in approximately equal proportions by weight. It is intended to be used in much the same way as grout, and suffers from similar drawbacks, though the strength is usually higher and the shrinkage is slightly smaller.

MORTAR: A mixture of cement, sand and water in proportions of about 1 :3:0.4 by weight. It is intended for placing or packing rather than pouring and is often placed below the base plates where the designer requires that a significant proportion of the load shall be transferred through the bedding to the concrete.

FINE CONCRETE: A mixture of cement, sand, coarse aggregate and water, in proportions of about 1:1 t:2:0.4 by weight. The aggregate has a maximum size of about 10 mm. It is intended for use where the bedding material must transfer most or all of the load from the steel to the concrete.

3.8.2 The function of the material

The bedding and filling material is often expected to perform several different duties, some of which may be clearly incompatible. These may include:

FILLING: Pockets, sleeves, and so on for holding down bolts need to be filled with an inert material which ideally should possess fluidity during pouring (often with poor accessibilityj.isubstantial resistance to lateral movement after hardening, no hardening shrinkage, and the ability to protect the embedded bolts from corrosion. Grout and sanded grout usually provide the fluidity required, but rarely meet the remaining requirements in full. Where these are of particular importance, more positive methods should be employed; for example epoxy resins can provide markedly higher strengths than grout or sanded grout. The use of an additive can reduce or eliminate shrinkage, and corrosion may be inhibited by the use of a suitable bolt material or protective coatings.

BEDDING: It has already been noted that the steel erection packs under base plates are usually not removed. Transfer of the load to the foundations in this case must be mainly through the packs. Since the bedding material will only perform a nominal role, the use of grout or sanded grout would appear to be acceptable.

It has been argued that under load the steel packs are driven into the foundation concrete thus transferring the load to the bedding. In practice, however, the shrinkage of the grout may well exceed the settling of the packs and this mode of action may not be achieved.

This inherently haphazard procedure can be justified only when the consequences of a failure are both minor and predictable. In the case of large structures transmitting substantial loads and moments through extensive base plates, this may not be so. Whilst grout or sanded grout may be satisfactory for filling the bolt sleeves or tubes, the bedding space under such base plates should be packed with mortar or fine concrete.

3.8.3 Placing the material

The achievement of good placing conditions requires positive action by the designer and detailer, particularly in the following respects:

Provision of unimpeded access to allow proper cleaning of pockets, and direct placing and good compaction of the infilling material.

Provision of adequate space below base plates (preferably 50 mm to 150 mm, depending on the size of the plate), to permit unsegregated and direct compaction of the infilling material.

Appropriate openings in the base plate should be provided where necessary; these may be used for pressure grouting (in conjunction with proper shuttering), escape of entrapped air, placing of concrete (through openings not less than 150 mm diameter), inspection, or direct compaction.

14

The properties required of the infilling material must be specified, preferably on the civil engineering drawings, and the attention of the inspectorate and the contractor focused on actions expected of them in order that the design parameters may be achieved.

Requirements or restrictions on the use, positioning, or removal of temporary wedges, packs, or other levelling devices associated with the erection of the structure should also be specified.

3.8.4 Other design considerations

STRENGTH: Unless better values can be relied upon, the following are suggested as reasonable for design purposes:

Cube strength Working stress (N/mm2)
Material at 28 days
(N/mm2) at 3 days at 7 days
Grout 12-15 1.5-2.0 2.0 -3.0
Sanded grout 15-20 2.0-2.5 3.0 -3.5
Mortar 20-25 3.0-4.0 4.0 -6.0
*Fine concrete *30-50 *7.0-10.0 *10.0-15.0 *The strength of fine concrete will depend critically on the degree of compaction which can be achieved. Higher strengths and working stresses can be obtained using hammered or dry packed fine concrete, up to about 20 Njrnm" at 3 days and 25 Njrnm" at 7 days if required.

Unless proper provision is made for the placing and compaction of good quality mortar or concrete, the working stresses appropriate to grout or sanded grout should be adopted in the design. In the common case where grout is required to be introduced into bolt pockets under a column base plate, the access space. is often between 25 and 50 mm; thus placing conditions are poor and correspondingly low working stresses should be assumed.

3.8.5 Admixtures

Some admixtures may help to achieve the proper placement of the infilling material, where adequate provision has been made in the design; or contribute towards achieving specific design requirements. Expanding admixtures for example, may help to counteract the otherwise inevitable setting shrinkage. It should be noted, however, that expanding admixtures can operate correctly only when the filling material is restrained from free expansion in every direction. Mortar plasticisers can also make it easier to obtain proper placing, and superplasticisers can improve the early strength as well. NO ADMIXTURE CAN COMPENSATE FOR POOR MIXING, PLACING OR COMPACTION.

Two or more admixture should not be used at the same time, since the different chemical and physical reactions are often incompatible. The effectiveness of both the admixtures may be reduced, to the disadvantage of the bedding material as a whole.

No admixture containing calcium chloride as an active constituent should be used. This compound can exacerbate the problem of corrosion.

It-is also worth repeating that no cement based infilling material has been found to provide a completely reliable safeguard against corrosion and this should be recognised by designers.

4. Work on site

For convenience, the work on site is considered in the squence in which it commonly occurs, and in which it is often contractually divided; the work, that is, of the foundation contractor, the steelwork erector, and the foundation finishing contractor.

4.1 The traditional system

4.1.1. Setting bolts in position

With the traditional system and its variants it is usually the responsibility of the foundation contractor to ensure that the bolts are set to the correct lines and levels; and it became very clear to the working party that this requirement is honoured more in the breach than in the observance. The

15

problem is that of setting and holding heavy assemblies of bolts, anchor frames and tubes in three dimensions within shutters into which reasonably large volumes of concrete have to be poured; and maintaining them accurately in position, level, and plumb while this operation proceeds. It is by no means trivial, though in other contexts it is met and solved regularly, with success. Thus it seems that the commonly reported nuisance of misaligned bolts, bolts set too high or low, and bolts set solid are largely due to the failure of the foundation contractor and the inspectorate to give the attention to the work which its importance warrants.

Typically, substantial structures of steel or timber have to be erected to span the shutters, which themselves often require strengthening to sustain this loading; and the bolt assemblies must be suspended from this structure in such a way that they can be adjusted in position and level, yet firmly fixed after these factors have been agreed. Thorough checking is required to reach this agreement, and since these operations generally take place at a fairly early stage of construction when accurate lines and levels are difficult to establish and maintain, this is a time consuming exercise. Programmers rarely allow sufficient time for it to be done properly, and this in turn often causes delayin the pouring of the concrete. Rationalisation of cross centres, diameters and levels can help to reduce the amount of setting out, but this is not always possible because of variations in base plate sizes and other factors.

Even when the positions and levels of the tops of bolts have been agreed there is still the problem of fixing the lower ends of the assemblies to prevent movement during the concrete pour. There is no established way of doing this; commonly the assembly is wired either to the reinforcement cage or to shutter bolts, or occasionally lengths of angle or channel are welded in position.

Unless care is taken in placing the concrete, the bolts become displaced to some degree, requiring either some remedial work to replace them in their proper position or a considerable degree of tolerance in the item to be fixed to them; particularly is this so if the projection of the bolts from the concrete is large; for example where the bolts are required to pass through a deep fabricated bedplate, or both flanges of a steel beam.

These difficulties are largely overcome when the foundation contractor treats the problem as a serious one, requiring the allocation of adequate resources and skilled setting out personnel; the programmer encourages him to do so by the allocation of sufficient time; and the inspector carefully checks the work and insists on proper provisions being made.

4.1.2 Steelwork erection

With the traditional system it is normal for the steelwork erector to check the bolt positions when he arrives on site; if this were to be done at the time the bolts were being placed, many of the following problems would be avoided,

With misplaced bolts the remedial measures commonly adoped include slotting or extending the bases, and bending the bolts. The time honoured practice of 'warming up' with a burning torch bending in position is not one to be encouraged.

When large discrepancies are encountered the offending bolts may be cut off and new ones set in drilled holes. When the bolts are too low, screwed ferrules or butt-welded stubs may be used to extend them; in the second method, care should be taken to use suitable weld preparations and procedures. When the bolts are too high, the usual remedy is the employment of washers or ferrules under the nuts. Bolts which are set solid - perhaps the most common of all these errors - are usually bent into their correct position. None of these expedients is desirable; and the extent of the remedial work which is often required causes considerable extra expense and delay.

Before the erection of the steelwork masks the holes from view, it is necessary to check that the bolt holes are clean and clear.

During erection it is normal to use the holding down bolts to stabilise the column; the column base is supported prior to grouting on pre-levelled laminated steel packs, folding wedges, or levelling bolts. The areas of the packs should be determined by the designer, and should be related to the dead loading from the structure and the strength of the base concrete. The preferred positions are shown in Fig. 10.

Laminated packs are difficult to remove after bedding is completed, and are commonly left in position, thereby possibly causing an undesirable distribution of load (see section 3.1). Folding wedges and levelling bolts can be extracted and reused.

When prestressed bolts are used, the packs should be removed after the bedding has reached an adequate strength and before the load is jacked into the bolts.

The degree of bolt tightening required should be specified on the drawings (see section 3.5).

16

With light columns, temporary props and guys are sometimes used to stabilise the columns during erection, to enable lighter bolts to be used. Often, also, a single central pack is used, the plumbing of the column being effected by tightening and slackening the bolts. This procedure is widely used; but with insensitive application it can lead to distortion of the base plate, bowing of the steel structure, and overloading of the bolts.

4.1.3 Filling and bedding

The properties expected of the filling and bedding materials should be specified in the contract document and drawings; and both the filling contractor and the inspectorate should ask for clear instructions when these have been omitted. Bases up to about 0.75 m2 in area should have a bedding space of 25-50 mm; above this size a space of 75 mm or more should be provided. Care should be taken to ensure that the design requirements are known and understood by the site staff, and that sufficient supervision is available for their implementation. When problems arise over the implementa-. tion of these requirements they should be resolved before the filling and bedding is placed. Tolerances and clearances should be carefully observed.

/After tightening the bolts, the (cleaned) tubes are first filled with grout; this should be carefully done

.> both to minimise subsequent corrosion and to ensure that the bolts can help to transfer shear loading to the base concrete. This is followed by the bedding of the main base plate; under large bases a stiff bedding of mortar or fine concrete should be rammed, either by hand or (preferably) by mechanised hammers. Holes in the base plate assist this operation in several ways (see section 3.8). With light columns and small bases the filling and bedding can be done in a single-stage operation; grout is gravity fed into the location tubes and bedding space, and is contained within a temporary bund or

I

,

I ---t-~~

,

I I

Erection packings shown hatched

PLAN ON HEAVY BUILDING COLUMN BASE SHOWING SUGGESTED POSITIONS OF ERECTION PACKINGS

Base plate

DETAIL OF FOLDING WEDGES WHICH CAN BE REMOVED AND RE-USED ON SUCCESSIVE BASES 7:'</m~r;:x;r;zy,~r;zy,r;:xm7J"'{_mmmm7J':7j~~

Site concrete

PLAN ON LIGHT BUILDING COLUMN BASE SHOWING SUGGESTED POSITIONS OF ERECTION PACKINGS

Note: Often a single packing is located at the centre of the base plate

Fig. 10 Erection packs

17

shutter. Again, holes in the base plate are helpful, and the spread of the bedding can be assisted by drawing a rope or chain underneath the base plate.

Grout or sanded grout should preferably be mixed in proper grout mixers, of the type generally used for pressure grouting. These small mixers produce a colloidal mix with the solids held in suspension, thereby facilitating the placing of the infilling material. Mortar is best mixed in a standard mortar mixer, and fine concrete (in the relatively small quantities necessary for proper placing and compaction) is preferably mixed in a small pan mixer, though small drum mixers are also adequate.

The mixer should be sited as closely as practicable to the placing location. Trial mixes should be prepared and tested, and the mix proportions should be agreed and strictly maintained. Ease of placing should be a major factor in assessing the suitability of a mix.

Where admixtures are employed details of the proprietary brands which the contractor proposes to use should be approved by the designer. The admixtures should be incorporated in the trial mixes in the agreed proportions, and the designer should satisfy himself that the intended results are obtained without detriment to the required characteristics of the material.

With prestressed bolts the sequence is similar, but there is the additional step of stressing the bolts. This is carried out after the bedding has gained sufficient strength and the steel erection packs have been removed. Since the bolts must be free to extend during stressing, they are installed complete with a plastic sheath within which grease is contained between the sheath and the bolt. A typical detail is shown in Fig. 3.

4.2 Bolts set in drilled holes

With this system the sequence is broadly similar to that for the traditional system, but the problems are often simplified. When casting the foundations for example it is necessary only to ensure that the reinforcement is positioned clear of the bolt locations.

When conditions permit, it is usually advantageous to leave the drilling and setting of the bolts until a week or two before they are required by the steelwork erector. In this way it is possible to ensure to the satisfaction of all parties concerned, that the setting out for the drilling and placing is accurate. Plastic rods can be set in the concrete, to facilitate subsequent drilling.

Holes up to 100 mm diameter can be rapidly drilled by means of rotary/percussion drills using tungsten carbide tipped bits. The holes thus formed need no more treatment than a thorough clearing out, generally with a combined compressed air and water jet. Under-reamed holes can also be drilled, to obtain additional security if required.

Above 100 mm diameter, and sometimes when obstructions may be met, diamond coring can be employed. This is not an unduly expensive operation; its main drawback is that the hole is very smooth sided, and the action of the water used to cool the bit with the dust tends to form a layer of slurry on the wall of the hole, which is difficult to remove and would be a surface of weakness if left. To overcome this it is necessary to scarify the sides of the hole after diamond coring; this can be accomplished by using a tungsten bit of smaller diameter and allowing it to travel from side to side of the hole. For holes of 150 mm diameter and above, 'flail' bits are available which act by centrifugal force to roughen the sides of the hole. These measures should of course be followed by a thorough cleaning of the hole.

The resinous material may be introduced into the hole in an encapsulated form, with the resin and hardener separated. Mixing of the two constituents is then usually accomplished by inserting the bolt and rotating it by means of a drill. Alternatively the resin and the hardener can be mixed in their correct proportions before injection into the hole.

Whichever method is adopted, the advice of the manufacturer should be sought and any specific requirements regarding environment, curing time, and so on should be discussed with him.

Once the bolts have been set, the erection and bedding procedures are similar to those described for the traditional system.

4.3 The recessed base system

Little further needs to be said about this method since it poses virtually no site problems. The foundation contractor forms the recess (preferably with roughened sides) in the normal manner, and the steelwork erector has freedom to position the column in its required position without restriction. Any temporary supports required at this stage should be included in the design. On completion of erection the recess is cleaned and concreted in the conventional manner.

18

5. Conclusion

Holding down systems have been designed and installed on a semi-empirical basis for decades, and practice has remained largely static despite major changes in the general philosophy of structural design and clear evidence that the traditional holding down systems provide a common source of trouble, expense and delay.

The reasons for this are not inherent in the systems; they appear to arise primarily from a lack of attention to this quite important aspect of structural engineering. In part this may be due to a detrimental division of responsibility; in part also, the problems seem simply to have been overlooked.

Most designers have their own ideas about the way in which these systems should be designed and installed; and these often vary quite widely. This document is produced in the hope that it will serve as a focus for the discussion which is needed before a consensus can be achieved.

6. Recommendations

Full and definitive recommendations are not considered possible at this time. The following recom mendations are abstracted from the body of the report and are believed to represent the current concensus of opinion. On certain aspects where they may not be universally accepted they will serve as a basis against which alternative or contrary procedures can be measured.

Recommendations are cross referenced to the earlier sections so the reasoning behind them may be identified.

6.1 Responsibility

6.1.1 Steelwork designer

The determination and specification of the following shall be the responsibility of the steelwork designer:

3.5 forces in the bolts

3.5 diameters of bolts

3.1 nature, size and position of packs

3.4 degree of tigh tening of bolts

3.1 characteristics required of the bedding and filling materials

3.3 setting out of the bolts and the permitted tolerances

3.7 degree of corrosion protection required

and he shall ensure that all information relevant to the design and installation of the bolts is transmitted to the foundation engineer.

6.1.2 Foundation engineer

The design, specification and detailing of the following shall be the responsibility of the foundation engineer:

1.2 length and type of bolts and ancillary fittings

3.8.3 type, quality and testing of bedding and filling materials

3.7 method of achieving corrosion protection

4.1.1 measures for maintaining the assemblies in their correct position during concreting

2.2.1 temporary protection of bolts and open holes

all materials relevant to the provision and proper installation of the anchorage assemblies

and shall ensure that this information is transmitted to the steelwork designer, the steelwork erector

1.2 and the foundation contractors.

6.1.3 Steelwork erector

The steelwork erector shall be responsible for transmitting to the foundation contractor all information which may affect the installation of the bolts, including any temporary forces due to erection. His duty to check the setting out will be best and most economically discharged if the major checks

4.1.2 are made before concreting.

6.1.4 Foundation contractor

The foundation contractor shall be responsible for the correct setting out, installation and protection

4.1.1 of the holding down bolts assembly.

19

6.2 Design and specification

All information required by both the steelwork erector and the civil engineering contractors should be given on all drawings related to holding down bolts and foundations. As recommended in 6.1.2 all

1.2 information including temporary works and protection should be shown on the foundation drawings.

6.2.1 Forces

The pressure distribution beneath the base plate, and thus the bolt force, will be affected by the "flexibility" of the base plate and the size and position of any permanent packs. No positive recommendations can be made but uniform or linear pressure can only be expected with fairly rigid base

3.1 plates. \

6.2.2 Shear

Special provision should be made to resist shears in excess of those which can be carried by friction. This may be done by shear keys or other anchorages bearing against the foundation concrete or encasement of the base plate in reinforced concrete.

3.2 No reliance should be placed on the bedding or sleeve filling to resist shear forces.

6.2.3 Bolts

Preferred diameters should be used.

Bolt sizes and/or material can be influenced by the risk of corrosion.

Embedment lengths may be determined assuming a conical shear surface as in Table 1 with, for

3.6 traditional holding down bolts, the whole force applied at the apex (see 6.2.6).

Pending further research a conservative value of concrete shear stress should be used.

Table 1 Embedded lengths of holding down bolts based on conical pull out

DEPTH DISTANCE BETWEEN CENTRES Xmm
D nun
75 100 125 150 200 225 300 450 600 750 1000
EFFECTIVE CONICAL SURFACE AREA (allowing for overlap) ern?
75 402.1 445.1 479.9 499.8 499.8 499.8 499.8 499.8 499.8 499.8 499.8
100 651.3 714.9 773.2 824.5 888.6 888.6 888.6 888.6 888.6 888.6 888.6
125 955.3 1038.1 1117 1191 1316 1362 I 1388 1388 1388 1388 1388
150 1315 1416 1514 1608 1780 1855 ! 1999 1999 1999 1999 1999
200 2199 2337 2473 2605 2859 2979 3298 3554 3554 3554 3554
225 2724 2880 3034 3186 3479 3619 4006 4498 4498 4498 4498
300 4633 4843 5052 5258 5664 5862 6434 7420 7997 .~~1?27 .... 7997 ~"',.
450 9950 10267 10583 10897 11521 11831 12743 14476 16022 17277 17994
600 17266 17689 18112 18533 19373 19790 21032 23448 25735 27837 30715
750 26581 27111 27640 28168 29221 29746 31312 34392 37371 40211 44507
1000 46550 47256 47962 48667 50076 50779 52882 57048 61141 65134 71486 Values to the right of the heavy zig-zag line are for two non-intersecting cones.

20

Bolt centres, sizes, lengths and levels should be standardised as far as possible to reduce and simplify

4.1.1 the setting out.

Different bolt projections or re-usable conical plastic extensions should be specified for large assern-

2.2.1 blies to simplify erection.

3.4 The degree of bolt tightening should be shown on the drawings.

6.2.4 Packs

The size and position of packs should be considered in designing the base plate and be specified on 3.1 the drawings, stating also whether permanent or temporary.

The positioning of the packs and whether they should only be temporary may be influenced by the 3.8.3 . proximity of a concrete edge.

4.1.2 Except near edges the smallest packs possible will generally be preferable.

6.2.5 Corrosion

The likelihood and probable severity of corrosion must be carefully considered and bolts, bedding

3.7 and filling materials specified accordingly.

3.7 Protective sleeves or tape may be adequate, or in some cases over-sized bolts.

3.7 Generally, cementitious bedding and filling materisls should not be relied upon to prevent corrosion.

Where the encased shaft of a stanchion is buried or externally exposed a seal should be introduced

3.7 between shaft and concrete.

6.2.6 Anchors and sleeves

For the traditional system an anchor plate adequate to transfer the bolt force to the concrete in bearing must be provided. Reliance should not be placed on bond between bolt/grout/foundation in

2.2.1 assessing the bolt embedment length.

2.2.1 The anchor should be provided with keep flats or other means to prevent rotation of the bolt head.

2.2.1 The internal diameter of the sleeves should be about three times bolt diameter and not less than

3.3 75mm.

Choice of material for the sleeves should take into account the method of fixing the assembly and the

2.2.1 chance of intrusion of concrete or grout.

6.2.7 Debonding

2.2.2 Prestressed bolts should normally be sheathed to break bond.

2.2.3 Consideration should also be given to debonding the upper part of bolts grouted into drilled holes.

6.2.8 Bedding and filling

The choice of bedding material should be based on the size of base, the level of stress and the type of

3.3 packing and, if predetermined, the space available.

3.8.3 Bedding space should preferably be between 50 mm and 150 mm and not less than:

25 mm for grouting

50 mm for mortar bedding

3.3 75 mm for concrete bedding

The design should provide adequate access for cleaning and filling pockets or sleeves, and air or access

3.8.3 holes through the base plates, where necessary.

4.1.3 Filling and bedding should be specified as separate operations.

The types and properties of fillings and bedding materials should be specified, together with require-

4.1.3 ments for trial mixes and control testing procedures.

21

6.2.9 Recessed base

2.2.4 Any temporary supports, restraints or bolts required should be considered in the design and shown on

4.3 the drawings.

6.2.10 Location of assemblies

The tolerances on position and level of bolts must be specified and should generally be between

3.3 ± 5 mm and ± 10mm

3.3 The drawings should indicate the means, whether permanent or temporary, of setting and maintaining

4.1.1 the bolt assemblies in the correct position during concreting.

6.2.11 Protection

Guards or, on trafficked areas, temporary encasement should be specified as protection to bolts and

2.2.1 their threads.

Details of plugging to the top of sleeves or drilled holes to prevent ingress of water or rubbish should

2.2.1 also be given.

6.3 Foundation construction

6.3.1 Preliminary

Before foundation work is commenced the contractor should study all drawings and specification items relating to holding down systems, satisfying himself as to their practicality and the adequacy of

4.1.1 his labour and temporary works resources, and of his skilled setting out personnel.

Section 6.2. makes recommendations of items to be specified and detailed by the foundation designer. The contractor should ensure these are issued to him or are agreed and recorded.

6.3.2 Setting out

Setting out shall be carried out by skilled personnel leaving, wherever possible, permanently marked

4.1.1 lines, profiles and level datum for subsequent checking.

The methods used for setting out should be agreed with the designer, engineer and the steelwork erector.

6.3.3 Checking setting out

The contractor should make arrangements for the employer's inspectors and the steel erectors to

4.1.1 check the setting out before concreting.

6.3.4 Fixing assemblies

After agreement of position and level the bolt assemblies must be firmly fixed using permanent restraints to the lower part within the foundation and for the top substantial temporary supports

4.1.1 between rigid abutments.

6.3.5 Placing concrete

4.1.1 Care must be taken to avoid displacement of the bolt assemblies during concreting.

Relevant tradesmen should be present during concreting to correct the positions of any assemblies which have moved.

6.3.6 Drilled holes

Care should be taken to ensure reinforcement is clear of the bolt positions; these can be marked with plastic rods which also facilitate drilling.

22

4.2 The sides of cored holes must be scarified.

4.2 All drilled holes must be thoroughly cleaned out.

6.3.7 Protection and cleaning

6.2 Open holes and bolts must be protected as recommended. Holes should be cleaned out before erec-

4.1.2 ting steelwork.

6.4 Steelwork erection

6.4.1 Preliminary

4.1.1 6.2·10

The steel erector should study all drawings relating to the holding down system and ensure any special requirements to suit his method of erection are transmitted to the foundation contractor.

Positons and levels of holding down bolts should be checked and agreed before and after concreting.

6.4.2 Misplaced bolts

If any bolts are misplaced, the remedial measures should be agreed with steelwork and foundation

4.1.2 designers.

6.4.3 Packs

The sizes and positions of packs must be as specified.

4.i.2 Where specified as temporary, folding wedges or levelling bolts should be used, not laminated packs.

6.4.4 Bolt tightening

4.1.2. Bolts shall not be tightened beyond the limit specified.

6.5 Filling and bedding

6.5.1 Materials

Cementitious filling and bedding materials must be mixed in grout, mortar or small concrete mixers

4.L3 as appropriate and as close as possible to the placing location. Other materials must be mixed and

42 used strictly in accordance with the manufacturers' instructions.

6.5.2 Filling

After checking the bolt sleeves are clean they should be carefully grouted, excluding pockets of air

4.1.3 or water.

6.5.3 Bedding

Bedding should be carried out in the specified material taking care that the means of placing and

4.1.3 compaction will ensure contact over the whole area of the base plate.

23