Unilift Locking Klaw Concrete Lifting Systems

Design Guide

Unilift concrete lifting systems for the precast industry.

Unicon Systems is a division of Ancon Building Products. When Unicon Systems joined Ancon, it created a unique business with the customer in mind. We now offer an unrivalled service to the precast concrete industry of Australia. The combined technical and commercial strengths of the businesses, together with an extensive product range and nationwide operations, enable us to provide a customer-focused service that is second to none. Ancon is part of the Engineered Accessories division of CRH plc, an international building materials group with operations in over 35 countries and 80,000 employees. Our product portfolio of lifting, fixing and anchoring technologies includes market leading brands from across the CRH network. Service and Support
Ancon sales and technical support is available nationwide to offer advice, process orders and provide a one-to-one service. Choose your location to identify your nearest regional sales office. Sydney Brisbane Melbourne Perth Tel: 1300 304 320 Fax: +61 (0) 2 9675 3390 Tel: 1300 304 320 Fax: +61 (0) 7 3395 6693 Tel: 1300 304 320 Fax: +61 (0) 3 9311 1777 Tel: 1300 304 320 Fax: +61 (0) 8 9453 2300

Email: technical@ancon.com.au Web: www.ancon.com.au

Unilift Systems

Contents
Unilift Systems Locking Klaws Cone (foot) Anchors Reo (eye) Anchors Standard Recess Formers 4 6

Locking Klaws

8 9 10

Performance
Cone (foot) Anchors

Limit State Design of Concrete Serviceability Limit States Designing Concrete Lifting Anchors with AS3850:2003 Concrete Strength Limit State Design for Concrete Strength FAQ: Contribution of Panel Reinforcing Steel Concrete working load limit Design of Hanger bars for Reo (eye) Anchors FAQ: Hanger bars FAQ: Lifting loops Rigging Guide

11 12 14 17 20 21 22 27 28 29 31

Reo (eye) Anchors Standard Recess Formers

Ensure you have read and understood this manual before designing with Unilift Systems. Use Unilift Systems strictly in accordance with Ancons recommendations Do not modify any lifting component by welding or other means If in doubt contact our sales engineers who will be pleased to assist you For best results always specify genuine Unilift components

Performance

Unilift Systems
Unilift - the quickest, safest, most economical systems for lifting and handling a wide variety of precast concrete products, particularly for civil engineering applications.

How is Unilift used?

Specify the optimum Unilift system according to the loads, type of panel, and handling methods Choose a recess former to suit the casting method Insert Unilift anchors into the recess formers Attach the recess with the anchor to the mould Cast and cure the panel to the minimum strength required for lifting (normally 15MPa) Remove the moulds and recess formers to expose the anchor head Attach the Unilift Locking Klaw by rotating the Klaw and locking it over the anchor head Hoist slowly, removing the panel from the casting bed and avoiding impacts

Benefits
Versatile
Systems to suit all applications Standardised load range groups of 1.3, 2.5, 5, 10, 20 and 32 tonnes Working Load Limit (WLL) Fast, efficient handling of products in the factory, during transport and on the job-site

Safe
Engineered for safety. Anchor WLL includes a factor of 3 against ultimate failure Components of different load groups are not interchangeable Anchors and Locking Klaws are clearly marked with their performance (WLL) Locking Klaws safely and securely lock onto the anchor head

Easy to use
Simple and quick to install
Locking Klaw Safety clutch which locks to the anchor head

One click connection Easy to train operators in use and then minimal supervision required.

Efficient and Economical

Standardised components reduce costs Quick connections save labour and crane time Recessed anchors avoid remedial work
Anchor Forged anchor set below the concrete surface Recess Formed in the concrete by a recess former to permit attachment of the Locking Klaw to the Anchor head.

Efficient stacking with less product damage

Dependable Quality
Designed and tested to meet or exceed the requirements of AS3850: 2003 and OSH NZ Code of Practice ISBN 0-477-03658-9 May 2002 Recessed anchors resist damage in handling and transport Nothing to clog or jam Anchors are Hot-Dip Galvanised for superior corrosion resistance

Trusted
Well known, proven technology Engineered and tested for safety Backed by Ancon experience and comprehensive technical support

Unilift Systems

System Components
Locking Klaw
Ancons unique safety clutch. Safer, stronger, faster, lighter.

Cone Anchor
Classic spherical headed, forged foot anchor - the first choice for most applications.

Reo Anchor
Eye anchor used with hanger bar if concrete is too weak for cone anchors.

Steel Recess with rubber ring

Ideal for production precasting and permanent mould attachment.

Rubber Former
Flexible former suitable for most situations.

Articulated Steel Recess

Robust former for rigid anchor connection in production precasting.

Also available: Colletted Steel Recess

Rigid anchor connection for severe conditions e.g. pipemaking.

Plastic recess
One-trip recess.

Tilt-up Sets
For site casting, e.g. tilt-up anchors with support chairs.

Special products to meet individual applications, available on request.

Locking Klaws
Safer, faster, lighter, stronger clutches for all spherical head lifting anchors

These clutches are used for lifting a wide range of precast concrete products for building and civil engineering including panels, pipes, pits, manholes, box culverts, road barriers, bridge beams, planks, sound walls, culverts etc.
They meet the requirements of AS3850: 2003 and are compatible and interchangeable with standard clutches for 1.3t to 32t WLL anchor systems. Locking Klaws (LK) improve safety, performance and flexibility in all situations. LK Technologies fix the design flaws which have caused failures of other clutches.

Taperwall
Reinforced side walls. The unique tapered cantilever increases the strength when turning and side lifting. Lighter but stronger - more efficient metal distribution. Higher WLLs for 1LK and 2LK compensates for sling angles. Designed to fit spherical and reduced recesses.

CentriLok
Unique well in the curved lifting lips locates the anchor in its optimum, central position at the rear of the slot! Under load, the Klaw locks and resists rotation toward the disconnected position, locking the tail. The side of the well traps the anchor head and locks the Klaw at its position of maximum strength and safety. Safe for use in hanger applications (upside down). The locked Klaw protects against dangerous disconnections where there is a risk of fouling, a common problem when lowering precast drainage products in confined spaces (e.g. lowering products into trenches or past formwork).

FlushTail
Tail has clearance to the concrete surface. Less concrete damage when lifting toward the tail.

Compact-8
Lightweight and efficient figure-8 chain link design. Additional clearance when side lifting. Round links do not damage lifting hooks, links etc.

Unique well

Anchor in central position at rear of slot

Figure-8 shaped chain link design

Cw

Ch

Locking Klaws

Sw

SI

S, Smax

Nominal Dimensions, Working Load Limits

L W Ch Cw Sw SI S Smax 1LK 170 66 44 40 33 72 56 11 13 2LK 215 85 59 52 42 88 68 16 18 5LK 270 110 62 70 57 113 88 22 25 10LK 365 145 83 90 73 144 112 31 32 20LK 515 210 103 130 110 195 152 43 46 50LK 780 270 160 160 155 235 195 55 58

WLL t 0 sling angle 2 Annual Proof 24 Load kN WLL t 60 sling 1.7 angle Nominal 1.3 WLL anchor

3 36 2.6 2.5

5 60 4.3 5

10 120 8.6 10

20 240 17.2 20

50 590 43 32-45

Locking Klaws solve these critical problems, caused by traditional clutch designs

Anchor loses support from the rear of the sphere and the load spreads the lips of the clutch.

Side loading worsens the problem.

Standard clutch spheres rotate under load because nothing traps the anchor.

Spread lips cause pull-off failure and shearing of anchor heads.

And in severe cases, the side of the clutch bends and breaks.

Typical example of a standard clutch with lips spread by the anchor moving around the slot. This clutch is at the point of failing. 7

Cone (foot) Anchors

Classic spherical headed, forged foot anchor - the first choice for most applications

Hot dip galvanised, forged, high impact strength construction steel Genuine Unilift anchors are stamped with U on the head. Anchor Strength WLL and length stamped on the head of the anchor
Anchor Dimensions
WLL 1.3 2.5 5.0 10.0 20.0 32.0 H (mm) 19 26 36 47 70 88 S (mm) 10 14 20 28 39 50 F (mm) 25 35 50 70 98 135
H S F

Cone (foot) Anchors

Part Codes and Anchor Lengths

Other sizes are available for special order WLL 1.3 2.5 5.0 10.0 20.0 32.0 35 CA01035 45 CA01045 55 CA01055 CA02055 Standard Anchor Length L (mm) 65 75 85 95 CA01065 CA01085 CA02075 CA02085 CA05075 CA05095 120 CA01120 CA02120 CA05120 150 CA05150 CA10150 -

WLL 1.3 2.5 5.0 10.0 20.0 32.0

170 CA02170 CA05170 -

240 CA01240 CA05240 -

280 CA02280 -

Standard Anchor Length L (mm) 340 500 700 960 1200 CA05340 CA05960 CA10340 CA20340 CA20500 CA32700 CA321200

Reo (eye) Anchors

Eye Anchor used with hanger bar if concrete is too weak for cone anchors.

Hot dip galvanised, forged, high impact strength construction steel. Genuine Unilift anchors are stamped with U on the head. Anchor Strength WLL and length stamped on the head of the anchor. Ideal for thin panels and other applications where the concrete shear cone developed by the anchor is insufficient to provide the working load limit of the anchor (e.g. low strength concrete). A hanger bar, also known as a tension bar, is threaded through the hole in the anchor and embedded deep in the concrete. See below for the appropriate hanger detail.
Part Codes and Dimensions
Reo (eye) Anchors

WLL 1.3 2.5 5.0 10.0 20.0 32.0

50 RA01050 -

65 RA01065 RA02065 -

Standard Anchor Length L (mm) 90 120 180 RA02090 RA05120 RA10180 To suit D HL

250 RA20250 -

300 RA32300

S L D

Part Codes and Dimensions

WLL 1.3 2.5 5.0 10.0 20.0 32.0 H 19 26 36 47 70 88 L 65 90 120 180 250 300 S 10 14 20 28 39 50 Hanger / Tension HL Cut Hanger / Tension Bar Length Bar Dia D for 15MPa (AS3600 60mm cover) R8 700 N10 870 N16 1020 N20 1520 N28 2760 N40 5300

Standard Recess Formers

Used to accurately and reliably set the anchor into its recess in the concrete product. Recess formers are non-interchangeable between load groups, minimising errors. Available in a variety of types to meet the demands of different applications.

Semi-Spherical Rubber Recess Hard oil resistant, yet flexible, rubber For attachment to steel and timber forms or floats
Size Diameter (mm) Part Code 1.3 60 RRF01 2.5 74 RRF02 5 94 RRF05 10 118 RRF10 20 160 RRF20 32 214 RRF32

Steel Recess with Rubber Retaining Ring Economical recess for production precasting Long service life Uses a replaceable rubber retaining ring May be attached directly to the mould Available also with magnetic attachment
Size Diameter (mm) Recess Part Code Ring Part Code 1.3 60 SRF01 RR01 2.5 74 SRF02 RR02 5 94 SRF05 RR05

Standard Recess Formers

Articulating Steel Recess Former Similar in action to the semi-spherical rubber recess but manufactured from steel Long service life for production precasting
Size Diameter (mm) Part Code 1.3 60 SRF01A 2.5 74 SRF02A 5 94 SRF05A

10

Limit State Design of Concrete Lifting Systems

The designer must analyse all limit states and failure mechanisms.

Strength Limit States

Anchor strength: Will some part of the anchor or other component (e.g. hanger bar) on which the anchor depends for its load carrying capacity fail? Concrete strength: Will the concrete crack or fail? What are the consequences of cracking? If the concrete cracks does this cause complete failure (pull-out) of the anchor or is pull-out prevented by a secondary anchoring attachment (e.g. hanger bar)?

There are no Australian standards which provide the WLL for inserts in concrete, and no standard method for calculation of the tensile and shear capacities of thin concrete panels. These must be determined from tests. In this regard AS3850: 2003 says: 2.2 WORKING LOAD LIMIT (WLL) The WLL shall be derived from one of the following, as appropriate: (a) The relevant Australian Standard. (b) By dividing jRu, obtained from the relevant Australian Standard, by the limit state factor (LSF) (c) By dividing the multiple of the mean value of the test results (x) (see Appendix A of AS3850: 2003) and the capacity reduction factor (j), by the limit state factor (LSF) and the sampling factor, ks. Check the WLL of the concrete for its (compressive) strength at the time of lifting for each lifting situation (e.g. edge lifting from the mould, edge lifting while suspended, face lifting, handling in the factory and storage, loading and unloading on transport, erection). For well embedded anchors of given embedment depth, panel thickness, concrete tensile, flexural and compressive strengths, the concrete strength limit state (and therefore WLL) is independent of the anchor itself - it is a function of the load applied to the concrete. In Australia, the limit state design of concrete lifting systems for precast concrete elements is governed by the Australian Standard AS3850:2003.

Design for anchor strength

If the anchor is to be used without a hanger bar, select an anchor which has a WLL as specified to meet or exceed the factored anchor load. If the anchor is to be used with a hanger bar, check the WLL of the anchor and the WLL of the hanger bar (AS3850: 2003 and AS3600) is sufficient to meet or exceed the factored anchor load.

Design for concrete strength

Well embedded anchors transfer the applied loads to the concrete. If the applied load exceeds the concrete flexural, tensile or shear strength concrete cracking will occur. If cracking results in complete anchor pull-out, this defines the concrete strength ultimate limit state. A designer may choose to reinforce the anchor and/or concrete to control cracking and retain the anchor, preventing pull-out e.g. with a hanger bar. Serviceability may then limit the design.

Performance

11

Serviceability Limit States

The strength limit state is not the only consideration and not always the limiting factor. Serviceability limit states also control the selection of materials.

Impact strength limit state anchor toughness and resilience

Lifting anchors are subject to high load concentration, possible impact loads and extreme environmental conditions (temperatures, corrosion etc), requiring materials of high toughness. This has been recognised in AS3850: 2003 which specifies minimum toughness properties. Unilift anchors are forged from high toughness alloy steel (DIN 1.0570) with impact strength exceeding the requirements of AS3850: 2003.

Welding and welding embrittlement

Whilst Unilift anchors are manufactured from steels which are readily weldable, there are issues with zinc contamination, localised hardening (e.g. uncontrolled heat inputs), joint design, undercutting etc. Welding of Unilift components or indeed any type of lifting anchors is not recommended.

Strain age embrittlement

Unilift anchors are forged from alloy steels and metallurgical condition insensitive to SAE.

Fatigue and multiple lifting limit states

The WLL of Unilift anchors is ~60% of the 40,000 cycle fatigue limit for these steels and so fatigue is not a significant issue. On the other hand, mechanical damage, loss of metal, notching or corrosion pitting reduce both impact and fatigue strength.

Corrosion limit state

Unilift anchors are hot dip galvanised (coating thickness >50 micron) to provide resistance to atmospheric corrosion in most environments. Long term exposure to marine environments can be expected to result in eventual corrosive attack and possible rust staining of the concrete.

General guidelines
Undamaged anchors can be considered safe for multiple lifting for at least 100 lifts over at least the half-life of the galvanised coating from the corrosion table on page 13. Where anchors are designed for intentional longterm multiple lifting, the design factor should be increased from 2.5 to 5 to account for additional wear and tear. NB: Standards require a design factor of 5 for lifting equipment intended for long term multiple re-lifting operations to compensate for wear in service. Check for wear, mechanical or corrosion damage before attempting to lift with anchors after long term exposure which may have suffered corrosion or other damage.

12

The service life of Unilift galvanised anchor coatings depends on the environment in which it is used.

ISO 9223 category C1 C2

AS/NZS 2312 corrosivity Very low

C3

C4 C5

Typical AV Long Term Environmental corrosion rate External of steel Interior micron/year Alpine < 0.1 Dry interiors Low Arid/rural/urban 0.1 - 1.5 Interiors with occasional condensation Medium Coastal 50 metres to 1 km inland from sheltered seas or 1 km to 10-50 km from surf beaches depending upon prevailing winds and typography. Industrial e.g. dairies, food processing etc High Sea-shore calm Swimming pools Very high Sea-shore surf and offshore -

AV Long Term corrosion rate of Zinc < 0.1 0.1 - 1.7

Typical Service life 42 micron coating >50 years 40-50 years

14-40 years

7-14 years 5-7 years

* Source: Galvanisers Association of Australia

Stainless steel anchors are available for aggressive environments.

Is minor concrete cracking/spalling acceptable?

High Finish Building Panels Minor flexural cracking may be tolerable and controlled by reinforcing detailing to close the cracks to permissible crack widths. Generally severe cracking and spalling is not permissible and would require expensive patching and repair in the factory or in-situ. Where a high finish is required, typically visible and exterior walls, un-cracked design and systems which minimise cracking (e.g. EdjPro) should be specified. Panels and precast elements for civil and general applications In some cases minor cracking and spalling may not be a significant issue for the intended application e.g. pits, bridge planks, bunker walls for gravel storage, lids etc. Cracked and spalled products give the impression of poor quality. Reputable manufacturers, proud of their products seek to minimise cracking and damage around the anchor points of their otherwise well finished, high quality products. Where thin products are to be lifted from their edges, Unilift and similar systems can lead to damage around the recess and in these cases the Unicon EdjPro system offers users a superior performance with a unique recess, anchor and clutch design developed to eliminate cracking for Perfect Panels.

Performance

13

Designing Concrete Lifting Anchors with AS3850:2003

Historical Note:
Prior to the adoption of AS3850 in 1990, safe working loads for concrete lifting anchors were calculated using a factor of 3 between the working load and the minimum ultimate strength of the anchor. The AS3850 code committee chose to reduce this (Design Factor) from 3 to 2.5 for the Working Load Limit of anchors and applied a mandatory Load Factor of 1.2 (essentially a dynamic load factor) to the static load, thereby retaining the overall minimum factor of 3 (1.2 x 2.5 = 3.0).

Calculate the weight of the object

Volume x Density
e.g. Rectangular panel 10 x 2.5 metres x 150 mm thick, normal weight concrete (density 2.4) Weight in tonnes: = 10 x 2.5 x 0.150 x 2.4 = 9 tonnes

Calculate the factored load

Select the Load Factor

Design Lifting Condition Lifting from smooth, oiled steel moulds and casting beds, handling and erection with a crane Lifting from concrete casting beds, e.g. site-cast tilt up Lifting deep ribbed panels or objects where high suction and adhesion loads can be generated Lifting from moulds without removable side forms Travelling over rough ground whilst suspended Load Factor 1.2 1.5 2 3 4-5 AS3850: 2003 Requirement 1.2 1.5 -

Design guide for load factors, reference AS3850: 2003, Clause 3.5.2 Note: AS3850: 2003 always requires a minimum load factor of 1.2!

Calculate the total factored load

Weight x Load Factor

High impact loads - e.g. travel over rough ground
Bouncing whilst suspended can generate loads up to 5 times the static load at the anchor point. Where this type of loading cannot be avoided e.g. transporting pipe components with a backhoe, then increased dynamic factors must be applied when factoring the load to ensure that the anchors, locking klaws, chains attachments and lifting equipment are capable of withstanding these impact overloads.

14

Calculate the loads applied to the lifting system during lifting from the mould; and also when suspended during handling and panel erection.
Note! When a panel is supported on one edge and tilted from the horizontal position to the vertical, half of the panel weight may be used for the calculation of loads prior to final lift off. After lift off the full weight of the panel must be used for the calculation of factored loads.

Select the number of lifting points

Determine the minimum (normally 2 points) or required number of lifting points to ensure that the stresses from lifting do not exceed the strength of the object being lifted. e.g. a long thin panel lifted from its edge will normally require multiple lifting points so that the flexural stresses do not exceed the panel strength.

Select the method of rigging and apply a sling factor if required

NB: 1LK and 2LK Locking Klaws have increased WLLs (2t and 3t respectively) to enable these to be used at full nominal anchor capacity (1.3t and 2.5t) at sling angles up to 60 an advantage for slinging many small elements.

Included angle a between the slings 0 30 60 90 120

Sling Angle Factor 1 1.04 1.16 1.42 2

Check the factored load at each anchor

Factored anchor load = (factored load / number of anchors) x sling angle factor

Check the factored load in the clutch and sling components

Factored clutch load = (factored load / number of anchors) x sling angle factor

Performance

15

Designing Concrete Lifting Anchors with AS3850:2003

If the factored anchor load...
...exceeds the WLL of the Locking Klaw = Increase the number of lifting points or: Select a higher WLL Klaw and anchor group

...exceeds the WLL of the anchor strength = Increase the number of lifting points or: Select a higher WLL anchor group ...exceeds the WLLc for concrete strength = Select an eye anchor with hanger bar

Check whether the factored load exceeds the WLL of the concrete
Case 1: Cone anchor - uncracked concrete design Is the concrete strong enough to support the WLL without cracking the concrete? Check the WLL of the concrete - WLLc (fRuc /2.5), either by reference to the tables in this manual or by calculation. Consider a longer cone anchor or increase the concrete strength at the time of lift.

WLLct = fRuc / 2.5

Case 2: Reo (eye) anchor cracked concrete design If the concrete cracks at a load less than the WLL x 2.5 Use a Reo anchor with correctly designed and detailed hanger bar. The limit state is controlled by hanger bar failure Ruh.

WLLt = fsRuh / 2.5

AS3850:2003 does not provide full design methods for lifting inserts.
Refer: the following extracts: 1.5 Use of Limit States Design Tilt-up panels shall be designed for all phases of their design life, from casting to their service in the final structure. Where these aspects are covered by AS3600, the design shall be carried out using limit states design (LSD) procedures. C1.5 C2.2 Limit states design at this stage is under investigation and the committee is not in a position to recommend limit state procedures for insert design and erection stresses in panels. The WLL of a system will need to be assessed by a suitably experienced and competent person. It should be noted that the manufacturer of a device cannot determine the WLL of the device for each and every configuration that may be involved in a given system. Design of panels for manufacture and erection Panels may be designed

3.5.4

(a) to be uncracked; or (b) assuming they are cracked, in accordance with reinforced concrete design methods. When designing a panel on the basis of cracked sections, that is, using the assumptions of reinforced concrete design, sufficient reinforcement shall be used to provide the necessary design capacity. The designer shall ensure that the assumptions for effective depth are consistent with the reinforcement detailing. C3.5.4 Generally, panels will be designed for erection assuming they are uncracked and for the appropriate loads in the completed structure on the basis of reinforced concrete design. Cracks in panels, which occur during lifting, are difficult to repair and/or camouflage and therefore tilt-up panels are usually designed to remain uncracked during the erection process. In panels with large openings, designers need to make a judgement as to the position of reinforcement in the panel adjacent to the opening.

16

Concrete Strength Limit State: Ruc

For a Cone anchor the concrete failure load is dependent on: compressive strength f'c of the concrete depth of embedment h of the anchor in the concrete distance a from the anchor to any edge or face the spacing c between anchors
The geometry of Cone anchors efficiently transfers the full load from the foot of the anchor to the concrete. The anchor length defines the embedment depth (plus the set down from the surface). When the load causes concrete failure, it does so by a shear cone being pulled from the concrete with a depth equal to the embedment depth of the anchor. The strength limit state of the concrete is proportional to the area of shear cone.
h

Concrete cone failure

Embedment depth 3h

c Centre spacing a Edge distance

The fully developed shear cone has a diameter of approximately 6h. Where anchors are placed closer to an edge than a < 3h or with a spacing c < 6h between anchors, the area of the shear cone is reduced and so the pull-out capacity of the concrete is proportionally reduced. In thin panels where the edge distances to the faces are small, the shape of the shear cone is changed to that of a pie shape.

Zipper failure
Sometimes, in thin panels and short edge distances, when multiple anchors are embedded along a top edge of a thin panel, the failure surfaces link up and splits the concrete to each face and edge so that a strip of concrete equal to the embedment depth is zippered away from the rest of the panel.

Performance

17

Concrete Strength Limit State: Ruc

Prediction of Cone Anchor Failure and Ruc for design
Where Ruc (kN), h (mm), f'c (Mpa): Embedment greater than 120mm: Use the Haeussler equation to predict cone failure:

fRuc = kc . h2. f'c0.67 kc = 9.72 x 10-4

Embedment less than 120mm: Use the ACI CCD equation (better fit from tests less than 100mm):

fRuc = knc . h1.5. f'c0.5 knc = 1.55 x 10-2

Reduction factors for edge distances
A simple and effective method for calculation of the reduction of conic areas comes from the realisation that a full cone is developed at a diameter of 6h at an angle of ~30 and that the concrete strength limit state Ruc is directly proportional to the area of the pull-out cone. From trigonometry, the fully developed shear cone has a conic surface proportional to the hypotenuse of a triangle with sides h and 3h and since by Pythagoras' theorem the length of the hypotenuse (conic surface) varies by the square root of the two sides of the triangle, the ratio of the reduced area is as follows: for a = edge distance h = embedment depth so that

Reduced Conic Area a sin(30. a/h) Note when a = 3h this reduces to sin90 = 1 Ruc-reduced = Ruc . sin(30. a/h) This power equation may be extended to cater for anchors placed close to an edge and/or at anchor spacings less than 6h (3h + 3h). Ancon can assist designers to calculate Ruc for more complex anchor placements than the tables in this design guide cater for. The program includes the calculation of Ruc- reduced according to the geometry and strength of the product to be lifted.

18

Concrete Strength Limit State: Ruc

Other types of failure
Very short anchors Adhesion failure - where the force required to break the bond between the concrete and the anchor results in anchor pull-out without a cone. Long anchors in thin panels Side Blowout failure - where the embedment depth from the surface of the panel to the foot of the anchor controls cone failure.

Long anchors in the tops of columns Horizontal splitting failure where the force required to provoke splitting to each surface is less than to develop a shear cone. This is similar to zipper failure and most commonly seen where long anchors are placed in small piles.

Performance

19

Design for Concrete Strength

Factored concrete strength limit state:

fcRuc = 0.6 Ruc

WLL for concrete strength limit state:

WLLc = fcRuc / 2.5

From AS3850:2003
1. The factored ultimate load f Ruc is the predicted failure load of the concrete when it cracks and can no longer support the load. It includes the capacity reduction factor fc = 0.6 for concrete.

This is defined as follows in Appendix A of AS3850: 2003 f Ru where f Ru x ks and WLL NB! i) ii) The concrete will crack at Ruc. At this load a cone anchor (foot anchor) will pull-out. If an eye anchor is used with a hanger bar then after cracking the load is transferred to the hanger. If the hanger is not strong enough it will fail by shearing at the connection point (hole in the anchor) or tensile failure of the bar or pull-out from the concrete. = f Ru /2.5 = strength limit state capacity = mean value of test data (Paragraph A4.4) = sampling factor, Table A2 = 1.3 (more than 5 tests) = x/ks . . A4.6

iii) If the hanger has been correctly designed (see section on hanger bar design) then this shall be capable of providing an ultimate failure load not less that 2.5 times the WLL of the hanger bar or the WLL of the anchor, whichever is the lower. 2. If the design anchor load is less than the WLL of the concrete then the anchor can be used without additional reinforcing or panel cracking. Shear reinforcing over the anchor and recess can assist in controlling cracking where serviceability requires. The factored ultimate load (f Ru) for edge shear (loading toward the edge) is the load at which the panel edge is predicted to crack, regardless of whether a shear bar is present. If a shear bar is present it should control the crack and minimise the risk of spalling. Ancon recommends sufficient anchors be installed so that the design anchor load is less than f Ru or some spalling may occur.

3.

20

FAQ: Contribution of panel reinforcing steel

Can the failure strength be improved by the panel reinforcing steel?

Contrary to a popular misconception, the presence of reinforcing steel in the panel cannot be assumed to increase the failure strength! Steel designed to elastically control cracking for shrinkage and in-place loads does not necessarily increase the failure load sufficiently to meet the requirements for lifting! The purpose of reinforcing an anchor against ultimate failure is quite different from adding steel to control cracking in normal concrete design. The limit state for crack control steel is the elastic limit i.e. steel yield. The limit state for lifting anchor reinforcement is steel failure i.e. breaking load, divided by a design factor of 2.5. Lifting loads are not expected to exceed the design WLL and most don't! However higher loads can occur accidentally and for this reason the design factor is required. The most likely accidental overloads are impact loads. Concrete subjected to impact loads tends to fail explosively; whilst the same load applied slowly may not lead to more than cracking, the additional forces generated within the concrete from impact cause spalling, delamination and loss of bond and confinement of the reinforcing steel. If the impact load is sufficient to exceed both the WLL and cone failure strength concrete, then the reinforcing steel must be capable of resisting the factored lifting load. After the concrete has cracked only fully confined steel is capable of reinforcing the concrete in the anchorage zone.

Additional steel may be designed to specifically transfer lifting loads but in doing so it becomes part of the lifting system and must be designed to AS3850: 2003 accordingly. Designers must ensure that effective shear reinforcing steel (e.g. closely spaced stirrups) encloses the concrete in the anchorage zone and the steel to which the loads are to be transferred to prevent spalling, loss of bond and anchorage. If it is necessary to reinforce the cracking in and around the anchor zone, the area of steel required to transfer the lifting load must be designed to meet the requirements of AS3850: 2003 i.e. f Ru / 2.5 S* and development, confinement etc according to AS3600.

Performance

21

Concrete working load limit WLLc design tables

The design tables provide WLLc for the failure of the concrete (concrete strength limit state). 1. WLLc is calculated for products with shrinkage reinforcing. As the presence of unconfined reinforcing makes no difference to the WLLc the effect of other steel must be disregarded unless it has been specifically designed for lifting and has been detailed accordingly. 2. WLLc in these tables includes the design factor of 2.5 required by AS3850: 2003. 3. Where the factored load exceeds the WLLc eye anchors must be used with a hanger bar designed in accordance with AS3850: 2003 and AS3600 (see tables). 4. If the factored shear load toward a free edge exceeds the ultimate shear capacity, the edge is likely to fail. Initial cracking may commence from about 50% of the ultimate capacity. Ancon does not recommend Unilift systems for edge lifting thin products toward a face because compression of

the concrete by the clutch may cause edge cracking and spalling. Ancon EdjPro systems have been specifically designed for this type of lifting and offer solutions for the production of Perfect Panels. 5. Shear bar reinforcing over the recess may help control, but cannot prevent cracking! 6. When panels are rotated about a supporting edge (e.g. from mould), with hanger bars fitted to anchors to prevent them pulling out, shear cracking does not limit the anchor WLL but could result in panel damage. Loads should be limited to the ultimate edge shear capacity of the concrete and/or shear bars used to control cracking. 7. Ancon recommends a minimum concrete compressive strength fc=15MPa at time of lifting. Ancon has expressed the values for the WLLs in tonnes force (rather than kN) to avoid confusion because most lifting equipment is specified in Australia for WLL in tonnes.

Preferred length and short Cone anchors

Special care must be taken when designing with foot anchors shorter than the preferred lengths shown in the table below for each load range which have been designed to develop the WLL of the anchor when placed at the minimum edge distance in concrete of at least 10MPa. Load Group WLL t Preferred Anchor Length (mm) Part Code

1.3 120 CA01120

2.5 170 CA02170

5 240 CA05240

10 340 CA10340

20 500 CA20500

32 700 CA32700

22

Concrete Strength WLLc of anchors with minimum edge distance a3h and spacing s6h
Embedment mm 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 160 170 185 190 240 280 340 400 500 700 Min Edge Distance 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360 375 390 405 420 435 450 480 510 555 570 720 840 1020 1200 1500 2100 Min Anchor Spacing 180 210 240 270 300 330 360 390 420 450 480 510 540 570 600 630 660 690 720 750 780 810 840 870 900 960 1020 1110 1140 1440 1680 2040 2400 3000 4200 WLLc = Ruc / 2.5 tonnes Force 15MPa 20MPa 30MPa 0.40 0.46 0.57 0.51 0.59 0.72 0.62 0.72 0.88 0.74 0.85 1.05 0.87 1.00 1.23 1.00 1.15 1.41 1.14 1.31 1.61 1.28 1.48 1.82 1.44 1.66 2.03 1.59 1.84 2.25 1.75 2.02 2.48 1.92 2.22 2.72 2.09 2.42 2.96 2.27 2.62 3.21 2.45 2.83 3.47 2.64 3.04 3.73 2.83 3.26 4.00 3.02 3.49 4.27 3.51 4.25 5.58 3.80 4.61 6.05 4.12 4.99 6.55 4.44 5.38 7.06 4.77 5.79 7.59 5.12 6.21 8.15 5.48 6.64 8.72 6.23 7.56 9.92 7.04 8.53 11.20 8.33 10.11 13.26 8.79 10.66 13.99 14.03 17.01 22.32 19.09 23.15 30.37 28.15 34.13 44.79 38.96 47.24 61.99 60.88 73.82 96.86 119.32 144.68 189.84

10MPa 0.33 0.41 0.51 0.60 0.71 0.82 0.93 1.05 1.17 1.30 1.43 1.57 1.71 1.85 2.00 2.15 2.31 2.47 2.67 2.90 3.14 3.38 3.64 3.90 4.18 4.75 5.36 6.35 6.70 10.69 14.55 21.45 29.69 46.39 90.93

40MPa 0.66 0.83 1.01 1.21 1.41 1.63 1.86 2.10 2.34 2.60 2.86 3.14 3.42 3.70 4.00 4.31 4.62 4.93 6.76 7.34 7.94 8.56 9.21 9.88 10.57 12.03 13.58 16.08 16.96 27.06 36.83 54.31 75.17 117.45 230.20

Performance

23

Concrete working load limit WLLc design tables

Concrete Strength WLLc for preferred length anchors when the anchor is placed closer to one edge, less than the critical edge distance: a1 < 3h, and the remaining edge distances exceed the critical edge distance: a2, a3, a4 3h
Anchor WLL Length 1.3 x 120 Effective Embedment mm hef 125 Edge Distance mm a 30 40 50 40 50 75 50 75 100 75 100 150 100 150 200 100 200 250 WLLc = Ruc / 2.5 tonnes Force 15MPa 20MPa 30MPa 1.35 1.63 2.14 1.55 1.88 2.47 1.73 2.10 2.76 2.62 3.18 4.17 2.93 3.55 4.66 3.58 4.34 5.69 4.92 5.97 7.83 6.02 7.30 9.58 6.94 8.41 11.04 9.98 12.10 15.88 11.52 13.96 18.32 14.07 17.06 22.39 20.28 24.59 32.26 24.81 30.08 39.47 28.60 34.68 45.50 33.32 40.40 53.01 47.06 57.06 74.87 52.56 63.73 83.62

2.5 x 170

177

5 x 240

250

10 x 340

350

20 x 500

510

32 x 700

710

10MPa 1.03 1.18 1.32 2.00 2.23 2.73 3.75 4.59 5.29 7.61 8.78 10.72 15.45 18.90 21.80 25.39 35.86 40.05

40MPa 2.60 3.00 3.35 5.06 5.65 6.90 9.49 11.61 13.39 19.26 22.22 27.15 39.12 47.86 55.17 64.28 90.78 101.40

Bolded values: Concrete WLLc exceeds the nominal WLL of the anchor steel.

WLL Concrete Tension a3 3h a2 3h a4 3h a1 < 3h

24

Concrete working load limit WLLc design tables

Concrete Strength WLLc for preferred length anchors placed in the centre of thin panel when the panel thickness t < 6h (a1, a2 < 3h) and the remaining edge distances exceed the critical edge distance: a3, a4 3h
Anchor WLL Length 1.3 x 120 Effective Panel Embedment Thickness mm hef mm t = 2a 120 60 80 100 177 80 100 150 250 100 150 200 350 150 200 300 510 200 300 400 710 200 400 500 WLLc = Ruc / 2.5 tonnes Force 15MPa 20MPa 30MPa 0.50 0.60 0.79 0.66 0.80 1.05 0.82 1.00 1.31 0.90 1.09 1.43 1.12 1.36 1.79 1.68 2.04 2.67 1.59 1.93 2.53 2.38 2.89 3.79 3.16 3.84 5.03 3.34 4.05 5.31 4.45 5.39 7.07 6.64 8.05 10.56 6.49 7.87 10.33 9.72 11.78 15.46 12.91 15.66 20.55 9.04 10.97 14.39 18.04 21.87 28.70 22.50 27.29 35.80

2.5 x 170

5 x 240

10 x 340

20 x 500

32 x 700

10MPa 0.38 0.50 0.63 0.69 0.86 1.28 1.21 1.81 2.41 2.55 3.39 5.06 4.95 7.40 9.84 6.89 13.75 17.15

40MPa 0.96 1.27 1.59 1.74 2.17 3.24 3.07 4.59 6.10 6.44 8.58 12.81 12.52 18.74 24.91 17.45 34.80 43.41

Bolded values: Concrete WLLc exceeds the nominal WLL of the anchor steel.

WLL Concrete Tension

a4 3h a3 3h

a1, a2 = t/2 < 3h

Performance

25

Concrete working load limit WLLc design tables

Concrete Shear Strength WLLc.shear for anchors loaded toward a free edge
Where the edge distance is substantially less than 3h care must be exercised in selecting anchor systems to avoid cracking and spalling of the panel edge. Ancon recommends EdjPro systems, specifically designed for edge lifting thin panels, for the production of Perfect Panels. The following table shows that the full working load limit of preferred length anchors is not supported by the shear capacity of the concrete when loaded toward the free edge until the edge distance approaches 3h. Typically, minor cracking commences from about 50% of the limit state strength fRuc.s. Shear bar reinforcing may help control cracking but shear bars cannot prevent cracking!

WLL Concrete Tension

fRuc.shear and WLLc.shear = Ruc.shear / 2.5 tonnes Force Anchor WLL Length 1.3 x 120 Edge Distance mm a 50 75 100 300 75 100 125 400 100 125 150 540 150 175 200 770 200 300 400 1050 500 1250 10MPa 15MPa 20MPa 30MPa 40MPa fRuc.s WLLc.s fRuc.s WLLc.s fRuc.s WLLc.s fRuc.s WLLc.s fRuc.s WLLc.s 0.36 0.66 0.97 3.45 0.85 1.29 1.73 6.54 1.65 2.27 2.89 12.53 3.75 4.61 5.48 25.20 7.23 12.28 17.32 50.09 29.69 82.34 0.14 0.27 0.39 1.38 0.34 0.52 0.69 2.62 0.66 0.91 1.15 5.01 1.50 1.84 2.19 10.08 2.89 4.91 6.93 20.04 11.88 32.94 0.44 0.81 1.19 4.22 1.05 1.58 2.12 8.01 2.02 2.78 3.53 15.34 4.59 5.65 6.71 30.87 8.86 15.03 21.21 61.35 36.36 100.85 0.17 0.33 0.48 1.69 0.42 0.63 0.85 3.21 0.81 1.11 1.41 6.14 1.84 2.26 2.68 12.35 3.54 6.01 8.48 24.54 14.54 40.34 0.50 0.94 1.38 4.87 1.21 1.83 2.45 9.25 2.33 3.21 4.08 17.72 5.30 6.52 7.75 35.64 10.23 17.36 24.49 70.84 41.99 116.45 0.20 0.38 0.55 1.95 0.48 0.73 0.98 3.70 0.93 1.28 1.63 7.09 2.12 2.61 3.10 14.26 4.09 6.94 9.80 28.34 16.79 46.58 0.62 1.15 1.69 5.97 1.48 2.24 3.00 11.33 2.86 3.93 5.00 21.70 6.49 7.99 9.49 43.65 12.53 21.26 30.00 86.77 51.42 142.62 0.25 0.46 0.67 2.39 0.59 0.90 1.20 4.53 1.14 1.57 2.00 8.68 2.60 3.20 3.79 17.46 5.01 8.50 12.00 34.71 20.57 57.05 0.71 1.33 1.95 6.89 1.71 2.58 3.46 13.08 3.30 4.54 5.77 25.05 7.49 9.22 10.95 50.41 14.47 24.55 34.64 100.19 59.38 164.68 0.28 0.53 0.78 2.76 0.68 1.03 1.38 5.23 1.32 1.81 2.31 10.02 3.00 3.69 4.38 20.16 5.79 9.82 13.85 40.08 23.75 65.87

2.5 x 170

5 x 240

10 x 340

20 x 500

32 x 700

26

Design of Hanger bars for Reo (eye) anchors

AS3850: 2003 requires hanger bars (being part of the anchor system) be designed as follows: Clause 2.2 Working Load Limit (WLL) The WLL shall be derived from one of the following, as appropriate: (a) The relevant Australian Standard. (b) By dividing f Ru, obtained from the relevant Australian Standard, by the limit state factor (LSF). (c) By dividing the multiple of the mean value of the test results (x) (see Appendix A of AS3850: 2003) and the capacity reduction factor (f), by the limit state factor (LSF) and the sampling factor, ks. Note: option (a and b) are determinative because (c) is not appropriate. It is not possible to guarantee that the strength of the bar which is used for testing is the same as, or representative of, every bar delivered for making the hanger bars in practice. The characteristic strength of reinforcing bars specified in AS4671 and AS3600 should be used in the design of hanger bars made from standard grade reinforcing steels. Example: 500N grade hanger bars. AS4671 specifies an ultimate/yield strength ration of 1.08 (minimum). ultimate strength in tension = Ab x 1.08 x 500 N = Ab x 1.08 x 500 / 1000 (kN) = 0.54 x AAb (kN) where Ab = cross sectional area of the bar Now the WLL of lifting inserts (including the hanger reinforcing bar which is part of the anchor) WLL = f Ru /LSF ...... Cl. 2.2 (b) AS3850: 2003 fs = 0.8 ...... table 2.3 (a) (i) AS3600 LSF = 2.5...... Cl 2.4.2 AS3850: 2003 Therefore WLL = 0.8 x 0.54 x Ab / 2.5 = 0.173 x Ab (kN) Since a hanger bar has 2 legs in tension, the capacity of the bar in tension is double this force: Ru = 2 x Ab x 0.54 / 9.8 (tonnes Force) WLLhanger bar = 2 x Ab x 0.173 / 9.8 (tonnes Force) Ru

The following table shows the calculated loads and development lengths according to the requirements of AS4671, AS3850: 2003 and AS3600 for a hanger bar with two legs centrally located with a minimum of 60mm cover either side.The recommended hanger bar lengths shown in this table have been calculated conservatively, for concrete compressive strength f'c =10MPa. This is to provide effective hanger reinforcement when demoulding. Shorter lengths may be used at higher concrete strengths.

Hanger db Rebar N12 N16 N20

Area Ab Area 113 201 314

Total Area 2 x Ab 226 402 628

Ru Ultimate Tensile Strength for 2 legs tonnes Force 12.45 22.15 34.60

WLL Tension Limit State AS3850: 2003 f*Ru / 2.5 tonnes Force 4.0 7.1 11.1
Performance

The development length of the hanger bar is calculated from AS3600 to develop Ru.

27

FAQ: Hanger bars

Why use a hanger bar?

Thin concrete panels cannot support a high load when they are lifted by their edges. If the concrete were to crack, a pie shaped segment including the anchor would be torn from the panel. A hanger bar is a reinforcing bar which improves the load capacity of the anchor beyond the load at which the concrete would otherwise fail.

What is a hanger bar?

A reinforcing bar bent in an inverted V shape which is passed through a hole in the anchor. The lifting load is therefore transferred by the hanger bar, deep into the concrete panel.

When are hanger bars required?

When the concrete cracking load is less than 2.5 times the required WLL. Hanger bars are always required for edgelift anchors of any type in 150mm thick panels when the Anchor Lifting Load is greater than about 2.3tonnes. This is because most panels are lifted from the mould when the concrete is only 10-15MPa. At 10MPa, the cracking strength is only 5.7tonnes which provides a 2.3tonne Working Load Limit (including the Design Factor of 2.5 required by AS3850: 2003).

Will a horizontal bar e.g. edge trimmer work?

NO! Horizontal bars do not transfer vertical load they zipper out of the edge.

Does panel mesh improve the lifting load?

NO! Panel mesh is only designed for shrinkage forces. It must NEVER be relied upon to improve the lifting load capacity of anchors in panels!

Can the lifting load be improved by the other panel reinforcing bars?
Maybe, but ONLY if that reinforcing steel has been especially designed to accept the lifting load! This is NOT normal! Normal panel reinforcing steel is only designed for in-service structural loads. It must NEVER be relied upon to improve the lifting load capacity of anchors in panels.
28

FAQ: Lifting Loops

What is the problem with lifting loops?

Lifting loops of smooth round bars can be made of steels which meet lifting code requirements BUT they have significant disadvantages compared to Unilift systems. In the end they cost more. Every loop must be engineered and installation supervised to control quality Bending the steel results in internal stresses which can sensitise the material to strain age embrittlement after heating e.g. galvanising or high environmental temperatures Kinking occurs unless lifted with a pin diameter at least 6 times the loop steel diameter, degrading strength, ductility and toughness. They are only suitable for straight lifts. Angled lifting creates stress points and damage. There is no visual confirmation of the WLL of the loop nor indication to users of lifting restrictions/ requirements e.g. minimum pin diameter. Loops are exposed to mechanical damage, prevent easy stacking, slow production and increase crane costs in the factory and on site.

What makes reinforcing steels unsuitable for lifting?

Fitness for purpose Steels for lifting inserts are required to be both ductile and tough and to meet the impact strength of AS3850: 2003 they need at least 12% uniform elongation and typically exhibit 20% or more. Reinforcing steels are designed to be fit for one purpose: concrete reinforcing! They excel as uni-axial strength elements subject to continuous loading within their elastic range.They are steels of low ductility, without specified impact properties because concrete reinforcing requires no more. They are divided into three principal classes: Hot rolled N class bars which have sufficient ductility (5%) to enable them to be bent (but not re-bent) to shape and to provide moment redistribution capacity when required. Hot rolled or drawn L class wires which can be bent but have insufficient ductility (1.5%) for moment re-distribution. Hard drawn, high carbon wires and strands for prestressing and never intended to be bent. These have anisotropic properties in the drawn direction of high tensile strength (~1800MPa) but low ductility 3.5%. They are notch sensitive making them susceptible to localised embrittlement from corrosion pitting, mechanical damage or martensitic hardening from metal abrasion or localised heating (e.g. weld spatter).

Why are lifting loops made of reinforcing steels not suitable - or allowed?
Just because a loop is designed to be strong enough does not mean it is safe to lift with! Reinforcing materials do not have the required properties for lifting and combined with the disadvantages of exposed loops projecting from precast products they present a high risk of failure. Do they meet the requirements of standards and construction codes? No! AS3850:2003 specifically excluded - Cl. 2.4.1. Properties do not meet Cl. 2.4.2. National code of Practice, Precast. Feb 2008: Cl. 5.1.4 prohibited. What about design rules? There are none. Since they are not supported by standards there are no rules for design.

Performance

29

Prestressing strands and cables are sometimes engineered for heavy lifting so why are they particularly unsuitable for lifting loops?
Lifting with cables made of straight lengths of strand can be safe. This is quite different to a loop! Strand is spun from seven large diameter, hard drawn, stiff, low ductility spring wires. They are ideal tension members but not designed to resist shear or bending loads. When a loop of strand is bent over a small diameter (e.g. around a hook or shackle with a radius of less than about six times the strand diameter), the wires tend to birdcage and separate. The strand no longer functions as a whole but as a collection of individual wires, each with a different loop diameter (because of the unravelled helix). Not only is there an increase in the stress in the wires because of being looped but since some wires are now longer than others, the loads are concentrated in the shorter wires. "Bunching" strands cannot increase carrying capacity because the shortest strands and wires take the load first. In order for load re-distribution to occur, these short wires must plastically deform before the others can accept their full share of the load. However prestressing wires have low ductility and are designed not to deform significantly before they break and so reliance on load re-distribution must be considered very hazardous. Some have suggested that load equalisation can be achieved by covering the strands with a sleeve (e.g. a steel pipe). This is not possible. The sleeve deforms but the load is only transferred to the shortest strand or wire within the sleeve. Crumpling of the tube also causes stress concentrations. Worse, wire breaks are hidden from view and failure can occur without warning. There are other OHS hazards with PC strands and wires; removal by cut-off saw or gas cutting causes the strands to violently fly apart and or "flick" the operator with (hot) splinters of hardened steel and or broken saw blade pieces; corrosion and mechanical damage have severe implications as these materials are easily embrittled by notches and corrosion pitting.

30

Rigging Guide

Regulatory Requirements
AS3850: 2003 and the National Code of Practice for Precast and Tiltup Construction require that rigging systems be designed to distribute loads equally between all anchors in precast components. If loads are not equally distributed, damage or failure can occur to the precast components, the rigging components or both. Rigging Geometry affects the loads in the rigging equipment and the precast components being lifted. Common rigging errors can result in loads of twice the design loads. A common mistake is to lift a component designed with four equally loaded points with four fixed length slings attached to a ring or hook. The small variations in the lengths of the rigging result in the load in this case only being shared by two of the slings, resulting in double the load applied to the anchors and the concrete surrounding the anchor. When lifting thin precast panels this has been the cause of many failures. Rigging with multiples of three lifting points (except for the special case shown) is not recommended by codes.

Rigging Diagrams for Equalised Loading

Correct rigging for equalised anchor loading 2 points
2 fixed length Equal loads in each 2 sheaved slings Equal loads in each

3 points Only for special cases!

T T
T

T c.g.

T
2T 2T 2T

P=3T
Special Case! 3 fixed leg slings equally distributed around the centre of gravity

P=2T

P=2T P=2 2T 2T

P=6T

4 points

TT

TT

Flat lift - equalised

Flat lift - equalised

P=4T

P=4T

Flat lift - equalised

Flat lift - equalised

c.g.

Always ensure that the centre of gravity (centroid) of the object being lifted lies below the centre of lift of the lifting anchors to avoid instability and toppling during lifting.

Performance

31

Rigging Guide
Recommended Rigging Configurations when Facelifting with Unilift QwikTilt systems
Minimum C + 300mm Minimum 2D Minimum 3C + D

C q D D The maximum sling angle q should be specified in the lifting design.

2x1

2x2

4x2

Minimum 4.5D or 4.5E whichever is the greater

Minimum 3D

E D 2x4 Minimum 3D

4x2

Recommended Rigging Configurations when Edge-lifting panels with EdjPro systems

2 point edge lifting:
For tilting up panels by their long edge, e.g. from the casting bed. For typical 150mm thick panels less than 5 metres long.

Preferred 4 point equalised edge lifting:

With load equalising beam and sheaved slings. For typical 150mm thick panels 5 - 10 metres long.
Sheave Sheave

Non-preferred 4 point equalised edge-lifting: With sheaved slings

Sheave

Sheave

32

Transporting in the factory, handling and erection by top-lifting from the edge
2 point 4 point

Mid-air Panel Rotation Spin-up and Erection using EdjPro anchors and clutches
Main Winch:
Connect two standard EdjPro clutches or EdjPro Hammerlock clutches to the EdjPro top-lift erection anchors.

Auxiliary Winch:
Connect an EdjPro clutch with locking ring arm away from the point of lift to the spin-up, or tail-lift EdjPro anchor which is located at approximately of the long edge.

Standard EdjPro clutches

Auxiliary Winch Main Winch Spin-up EdjPro Anchor

EdjPro Hammerlock clutches

Top-lift EdjPro Anchors

Remove the spin-up clutch. Hoist the panel into position and disconnect the top lift clutches, preferably with the aid of an elevated work platform.

Turn the panel by transferring the load to the main hoist.

Performance

33

Rigging Guide
Rigging diagrams showing unequal loading
Many accidents and failures have occurred with these rigging configurations because of the difficulty of ensuring that the loads are evenly distributed.

4 point rigging with fixed length slings develops unequal loads i.e. load is shared on two slings only

T 0

0 T 0

0T 0

0 2T

Flat lift 4 x fixed slings no equaliser

Fixed leg slings can lead to indeterminate loading

P=2T

P=2T

4 equal length slings unequal loads. Panel tries to bend to equalise the loads. This overstresses the panel causing cracking.

Rigging with multiples of 3 slings is particularly difficult and not recommended

Flat lifting with three points is possible when they are equi-distant from the centre of gravity.

T 2T 2T 2T 2T

This can be OK but it is generally safer for stability to lift with 4 fixed leg slings and design for sharing the load on 2 of the 4 points.

T c.g.

P=6T Equal Load

P=4T Central Anchor Double Loaded

Special Case! 3 fixed leg slings equally distributed around the centre of gravity

34

Performance

NOTES

35

Masonry Support Systems Windposts and Lintels Wall Ties and Restraint Fixings Channel and Bolt Fixings Tension and Compression Systems Stainless Steel Fabrications Flooring and Formed Sections Shear Load Connectors Stainless Steel Reinforcement Reinforcing Bar Couplers Reinforcement Continuity Systems Punching Shear Reinforcement Precast Concrete Accessories

Ancon Building Products 114 Kurrajong Avenue Mount Druitt Sydney NSW 2770 Australia Tel: 1300 304 320 Fax: +61 (0) 2 9675 3390 Ancon Building Products 4/31 Archimedes Place Murarrie Brisbane QLD 4172 Australia Tel: 1300 304 320 Fax: +61 (0) 7 3395 6693 International Enquiries: +61 (0) 2 8808 1111 Email: info@ancon.com.au Web: www.ancon.com.au Overseas Offices: Ancon Building Products Sheffield United Kingdom www.ancon.co.uk Ancon Building Products GesmbH Vienna Austria www.ancon.at
These products are available from:

Ancon Building Products 7-9 Second Avenue Sunshine Melbourne VIC 3020 Australia Tel: 1300 304 320 Fax: +61 (0) 3 9311 1777 Ancon Building Products 82 Chisholm Crescent Kewdale Perth WA 6105 Australia Tel: 1300 304 320 Fax: +61 (0) 8 9453 2300

Ancon (Schweiz) AG Ried bei Kerzers Switzerland www.ancon.ch Ancon GmbH Nuremberg Germany www.anconbp.de

Ancon (Middle East) FZE Dubai United Arab Emirates www.ancon.ae

The construction applications and details provided in this literature are indicative only. In every case, project working details should be entrusted to appropriately qualified and experienced persons. Whilst every care has been exercised in the preparation of this document to ensure that any advice, recommendations or information is accurate, no liability or responsibility of any kind is accepted in respect of Ancon Building Products. With a policy of continuous product development Ancon Building Products reserves the right to modify product design and specification without due notice.

Ancon Building Products 2012