rea and technical reaslim lifting manual...

THESTRONGESTIN FINLAND

TechnicalManualTechnical changes and errors reserved

According to Eurocodes, EU Machinery directive 2006/42/EC and VDI/BV-BS 6205 CE Approved

Version 30.11.2018

REA andREAslim LiftingInserts

2 www.repo.eu Technical Manual - REA and REAslim Lifting Inserts v30.11.2018

1. DESCRIPTION OF THE SYSTEM 3

1.1 Manufacturing markings 3

1.2 Quality control 3

2. LIFTING SYSTEM PARTS 4

2.1 Lifting insert 4

2.1.1 REA Lifting Insert Dimensions 4

2.1.2 REAslim Lifting Insert Dimensions 5

2.1.3 Lifting insert materials and ordering code 6

2.2 Quick lift clutch 6

2.2.1 Use of quick lift clutch 7

2.3 Rubber recess former bayonet 8

2.4 Holding plate 9

2.5 Holding screw 9

3. SAFE WORKING LOADS 10

3.1 Design concept 10

3.2 Safe working loads 11

3.2.1 REA and REAslim lifting inserts safe working loads 11

3.3 Concrete thickness and insert spacing in wall elements 12

3.4 Reinforcement of the pre-cast element 13

3.5 REA and REAslim lifting insert reinforcement 13

3.5.1 Axial pull reinforcement 13

3.5.2 Diagonal pull reinforcement 15

3.5.3 Tilting reinforcement 15

3.6 Actions on lifting inserts 17

3.6.1 General 17

3.6.2 Number and actions of lifting inserts 17

3.6.3 Statical system 17

3.6.4 Load distribution for non-symmetrical insert layout 19

3.6.5 Spread angle 20

3.6.6 Self-weight 21

3.6.7 Adhesion and form friction 21

3.6.8 Dynamic actions 21

Table of Contents

3Technical Manual - REA and REAslim Lifting Inserts v30.11.2018www.repo.eu

1. DESCRIPTION OF THE SYSTEM

1.1 Manufacturing markings

1.2 Quality control

REA and REAslim lifting inserts systems manufactured by R-Group Finland Oy are lifting anchors consisting of flat steel inserts, ribbed steel anchor bars and rapid release lifting keys. REA and REAslim lifting anchors enable lifting of columns, beams, walls and other pre-cast concrete elements. REA and REAslim lifting inserts can be used in all lifting directions and for lifting angles up to 90 degrees.

REA and REAslim lifting inserts are designed and manufactured in accordance with EU Machinery Directive 2006/42/EC and VDI/BV-BS 6205. Lifting inserts meet the requirements for safe lifting and handling of concrete elements.

REA and REAslim lifting inserts are marked with R-Steel logo, type and load class of lifting insert and CE-marking.

Product package is equipped with an R-Steel Pallet Label, which contains the following information: product type, product name, quantity ISO9001 and ISO14001 quality and environment system markings, CE marking and product picture.

Quality control of the inserts is done according to the requirements of the Finnish Code of Building Regulations and the instructions according to quality and environment system of the R-Group Finland Oy (ISO9001 and ISO14001). R-Group Finland Oy has a quality control contract with Inspecta Sertifiointi Oy.

3.6.9 Load condition “erection in combination with adhesion and form friction” 22

3.6.10 Load condition “erection” 24

3.6.11 Load condition “lifting and handling under combined tension and shear” 26


2. LIFTING SYSTEM PARTS

2.1 Lifting insert

2.1.1 REA Lifting Insert Dimensions

BD

CONCRETE SURFACE LEVEL T

E

H

C

Figure 1. REA lifting inserts dimensions

Load group Lifting insert

H[mm]

B[mm]

D[mm]

T[mm]

C[mm]

E[mm]

2.5REA 1.4 200 55

146

1045

REA 2.5 230 55 10 45

5.0REA 4.0 270 70

1812

1066

REA 5.0 290 70 15 66

10.0REA 7.5 320 95

2615

1588

REA 10.0 390 95 20 88

26.0

REA 12.5 500 148

35

20

15

89

REA 17.0 500 148 25 89

REA 22.0 500 148 30 89

Table 1. REA lifting inserts dimensions


Figure 2. REAslim lifting inserts dimensions

Load group Lifting insert H[mm]

B[mm]

D[mm]

T[mm]

C[mm]

E[mm]

REAslim 2.5 230 55 14 10 10 46

5.0REAslim 4.0 270 70

1812

1066

REAslim 5.0 290 70 15 66

10.0REAslim 7.5 320 95

2615

1588

REAslim 10.0 390 95 20 88

26.0

REAslim 12.5 486 148

35

20

15

89

REAslim 17.0 486 148 25 89

REAslim 22.0 488 148 30 89

Table 2. REAslim lifting inserts dimensions

Lifting devices and recess formers are designed to be compatible with each load class and type of REA lifting inserts. Compatible lifting devices and recess formers see following sections.

Lifting devices and recess formers are designed to be compatible with each load class and type of REAslim lifting inserts. Compatible lifting devices and recess formers see following sections.

2.1.2 REAslim Lifting Insert Dimensions

H H

B BT T

REAslim 2.5 - 10.0 REAslim 12.5 - 22.0

D D

C C

CONCRETE SURFACE LEVEL CONCRETE SURFACE LEVEL


Lifting insert type Material Standard

REAS355J2 EN 10025

REAslim

2.1.3 Lifting insert materials and ordering code

Figure 3. Quick lift clutch

REA and REAslim lifting inserts are available in two surface finishes. Standard delivery surface finish is black (uncoated). Lifting inserts are also available as electro zinced.

Ordering codes:

REA 2.5 Standard lifting insert (uncoated)REAZ 2.5 Electro zinced lifting insert

REAslim 2.5 Standard lifting insert (uncoated)REAZslim 2.5 Electro zinced lifting insert

The lifting clutch is made of special steel casting. The lifting bolt of the quick lift clutch is inserted into the hole of the lifting insert and can be easily and quickly removed after lifting.

2.2 Quick lift clutch


Part no (Ordering code) Load group

2.5

5.0

10.0

26.0

Table 3. Quick lift clutch

2.2.1 Use of quick lift clutch

1. Engagement 2. Lifting

3. Release

A

A

A

A

Figure 4. Use of quick lift clutch


Engagement

Lifting

Release

Marking

2.3 Rubber recess former bayonet

Quick lift clutch in inserted into the recess formed in the concrete and the locking bolt A is closed manually. When closing the locking bolt it must be ensured that the quick lift clutch is fully engaged and the locking bolt is flush with concrete surface.

The quick lift clutch system can be subjected to loads in any direction and no extra or special parts are required for angled lifts and tilting. It is essential to follow the instructions regarding rebars in concrete in section 3. Once the ring clutch has been engaged in the anchor, the shackle can move in any direction, even under load.

To release the quick lift clutch from the lifting insert, shift the locking bolt back by hand. This will release the lifting clutch.

Every quick lift clutch is marked with the load capacity and a serial number. Clutches should be examined regularly and re-tested annually.

Recess former fort fixing with holding screw for mounting plate or bayonet fixing.

Figure 5. Rubber recess former bayonet

b

c

a

Part no (Ordering code) Load group a[mm]

b[mm]

c[mm] Thread

2.5 43 104 45 M8

5.0 49 126 59 M8

10.0 67 188 85 M12

26.0 112 223 121 M16

Table 4. Rubber recess former ordering codes and dimensions


Part no (Ordering code) Load group a[mm]

b[mm]

c[mm]

2.5 73 15 4

5.0 85 30 4

10.0 128 40 6

26.0 178 65 8

Table 5. Rubber recess former ordering codes and dimensions

2.4 Holding plate

For fastening of the recess former onto the formwork.

i

m

Figure 7. Holding screw

Figure 6. Holding plate

c

a

b

2.5 Holding screw

For fastening of the recess former through the formwork.


3. SAFE WORKING LOADS

3.1 Design concept

Safe working loads of REA and REAslim lifting inserts are calculated according to following standards and instructions:

EN 1992EN 1993Machinery directive 2006/42/ECVDI/BV-BS 6205

Global safety factors used in calculation of safe working loads are

Steel failure γ = 3,0Concrete failure γ = 2,5

Safe working loads are based on concrete dimensions, anchor steel bars and lifting insert edge distances given in the following sections. Minimum concrete compressive strength at the moment of load application fck.cube.min = 15 MPa.

Safety concept

E ≤ SWL

Where E = action placed on lifting insert SWL = safe working load of lifting insert

Actions placed on lifting inserts must take into account all loads and load distribution to lifting inserts according to following sections.

Part no (Ordering code) Load group I[mm]

m[mm]

2.5 160 M8

5.0 160 M8

10.0 160 M12

26.0 180 M16

Table 6. Holding screw ordering codes and dimensions


3.2 Safe working loads

3.2.1 REA and REAslim lifting inserts safe working loads

Lifting insertSafe working loads (SWL)

[kN]

β = 0° - 15° β = 15° - 45° γ = 0° - 10° γ = 10° - 90°

1.4 14 14 14 7

2.5 25 25 25 12.5

4.0 40 40 40 20

5.0 50 50 50 25

7.5 75 75 75 37.5

10.0 100 100 100 50

12.5 125 125 125 62.5

17.0 170 170 170 85

22.0 220 220 220 110

Table 7. REA and REAslim lifting inserts safe working loads

Figure 8. Lifting insert load directions

Safe working loads of REA and REAslim lifting inserts are given in Table 7. Safe working loads are applicable with concrete thickness and insert spacing according to section 3.3 and lifting insert reinforcement according to section 3.5.


3.3 Concrete thickness and insert spacing in wall elements

Safe working loads are valid only with minimum concrete thickness and minimum lifting insert spacing given in Figure 9 and Table 8.

Figure 9. Minimum element thickness and lifting insert spacing

Table 8. Minimum element thickness and minimum lifting insert spacing in wall elements

TC

EL

CL

Lifting insertMinimum concrete

thickness TC

[mm]

Minimum lifting insertedge spacing EL

[mm]

Minimum lifting insert centre spacing CL

[mm]

1.4 100 250 500

2.5 120 300 600

4.0 150 350 700

5.0 160 375 750

7.5 175 600 1200

10.0 240 600 1200

12.5 260 750 1500

17.0 300 750 1500

22.0 360 750 1500


3.4 Reinforcement of the pre-cast element

The concrete element must have at least minimum reinforcement according to EN 1992-1-1. Concrete element must be reinforced to withstand all actions from lifting, tilting and transport including dynamic actions. This reinforcement must be designed by the structural designer.

REA and REAslim lifting inserts must always have anchoring reinforcement 1 according to Figure 10 and Table 9. This reinforcement transfers the load from the lifting insert to the concrete. Anchoring reinforcement must be installed in to the hole in the lifting insert and it must be in direct contact with lower edge of the reinforcement hole in lifting insert, see Figure 11.

Figure 10. REA and REAslim lifting insert reinforcement for axial pull

3.5 REA and REAslim lifting insert reinforcement

3.5.1 Axial pull reinforcement

3

1

3

5

5

4

4

4

2

2

= 00 - 150

= 150 - 450

> 450

Not Allowed

Ls4

Ls3

Mesh reinforcement

With Reinforcement

Ls1

1


Reinforcement in directcontact with lifting insert

Additional surface reinforcement 2, stirrup reinforcement 3 and edge reinforcement 5 must also be placed at the lifting insert area. These reinforcements may be replaced by structural reinforcement in concrete element, providing the structural reinforcement has sufficientcross-section area and overlap lengths.

Reinforcement given in this section covers only the load impact the lifting insert has on the concrete. Due to eccentricities and lifting angles the concrete element may be subject to bending. Due to loads placed on the concrete elements by the lifting actions the concrete element may be subject to cracking. Concrete element must be separately reinforced for bending and cracking.

Figure 11. Placing of REA and REAslim lifting insert reinforcement in hole

Lifting insert

Anchor reinforcement 1

Meshreinforcement 2 Stirrup reinforcement 3 Edge

reinforcement 5

Diameterøs1

[mm]

LengthLs1

[mm]

Both surfaces[mm2 / m]

n[pcs]

Diameterøs3

[mm]

LengthLs3

[mm]

Diameterøs5

[mm]

1.4 10 400131

2 6 300 8

2.5 12 500 4 6 300 8

4.0 16 650131

4 8 450 10

5.0 16 700 4 8 450 10

7.5 20 900188

4 10 500 12

10.0 25 1000 4 10 500 12

12.5 28 1200

257

4 12 550 16

17.0 28 1450 6 12 550 16

22.0 28 1550 6 12 550 16

Table 9. REA and REAslim lifting reinforcement for axial pull


3.5.2 Diagonal pull reinforcement

3.5.3 Tilting reinforcement

In addition to axial pull reinforcement the lifting inserts must be reinforced for diagonal pull if the lifting angle β is greater than 15°. Diagonal pull reinforcement 4 is given in Figure 10 and Table 10. Reinforcement given in Table 9 must always be present for diagonal pull.

Diagonal pull reinforcement must be placed in direct contact with the recess former of the lifting insert according to Figure 10. Bending diameter D should be same as the width a of the recess former for tight fit.

REA and REAslim lifting inserts can be used for tilting of concrete elements (load angle γ = 0° - 90°). For tilting and lateral pull REA and REAslim lifting inserts must be reinforced with lateral pull reinforcement 5 according to Figure 12 and Table 11. Reinforcement given in Table 9 must always be present for lateral pull.

There are semi-circular notches on both sides of REA and REAslim lifting inserts which help with the placement of lateral pull reinforcement. Lateral pull reinforcement must be placed in direct contact with the lifting insert.

Lifting insert

Diagonal pullreinforcement 4

Diameterøs4

[mm]

LengthLs4

[mm]

1.4 6 400

2.5 8 500

4.0 10 650

5.0 12 700

7.5 16 900

10.0 16 1000

12.5 20 1100

17.0 20 1350

22.0 28 1600

Table 10. REA and REAslim lifting reinforcement for diagonal pull

Ls4

D

4


Reinforcement in directContact with lifting insert

Height according toelement thickness

= 00 - 900

≤ 900

6 6

Ls6

Figure 12. REA and REAslim lifting insert tilting reinforcement

Lifting insert

Lateral pull reinforcement 6

Diameterøs6

[mm]

LengthLs6

[mm]

1.4 10 700

2.5 12 800

4.0 14 900

5.0 16 1000

7.5 20 1200

10.0 20 1500

12.5 25 1500

17.0 25 1800

22.0 25 1800

Table 11. REA and REAslim lifting reinforcement for lateral pull


3.6 Actions on lifting inserts

3.6.1 General

3.6.2 Number and actions of lifting inserts

3.6.3 Statical system

The loads acting on a lifting insert shall be determined considering the following factors: - statical system - element self-weight - adhesion and form friction - dynamic effects - position and number of lifting inserts - type of lifting equipment and different load scenarios (tension, combined tension and shear, shear loading).

The number of load bearing lifting inserts and the load acting on the lifting inserts shall be determined corresponding with the individual lifting situations. Statical system of lifting inserts must be accounted for in these calculations. Actions from all individual lifting situations must be calculated according to sections 3.6.3 to 3.6.11.

After actions placed on lifting inserts are determined, the safe working load (SWL) in section 3.2 shall then be compared with the actions. The safety concept requires that the action E does not exceed the safe working load SWL. The following formula must be satisfied for all actions on lifting inserts

E ≤ SWL

where E action on lifting insert, see sections 3.6.3 to 3.6.11, in kN SWL safe working load of lifting insert, see section 3.2, in kN

The most unfavorable relation from action to resistance resulting governs the design.

Lifting equipment used in lifting of pre-cast elements shall allow determinate load distribution to all present lifting inserts. Figure 13 gives examples of statically indeterminate systems where only two lifting inserts carry the load. The load distribution is not clearly defined in these applications. Therefore, these statically indeterminate systems shall be avoided.


Figure 13. Examples of statically indeterminate lifting systems which should not be used a) statically indeterminate system. Load bearing inserts n = 2. b)staticalsystemwithoutclearlydefinedload-bearingmechanism.Loadbearing inserts n = 2. c) statically indeterminate load distribution to the lifting inserts of a wall element. Load bearing inserts n = 2.

Ftotal

FG

F

ɑF

a) b) c)Ftotal Ftotal

To ensure a statically determinate system and that all lifting inserts carry their required part of the load in case of applications with more than two lifting inserts transport aids such as sliding or rolling couplings or balancing beams shall be used.

In case of inclined lifting slings the lifting inserts are loaded by combined tension and shear loads. The inclination β according to Figure 14 governs the level of combined tension and shear loads to be taken into account in the design.

Figure 14. Transportation aids for the statically determinate lifting of slabs and wall elements a) balancing beam and rolling coupling. Load bearing inserts n = 4. b) sliding coupling. Load bearing inserts n = 4. c) rolling coupling. Load bearing inserts n = 4.

Ftotal

Ftotal

Ftotal

ɑɑ

ß

FGFG

a) b) c)


Figure 15. Statically determinate load distribution by means of lifting inserts in star pattern a) slab. Load bearing inserts n = 3. b) cover plate. Load bearing inserts n = 3.

Figure16.Loaddistributionfornon-symmetricalinsertlayoutusingspreaderbeam

If three lifting inserts are located in slab and situated in star pattern with same distance to the centre of gravity with equal inclinations of 120° (Figure 15) it is ensured that all three lifting inserts experience the same load.

Ftotal Ftotal

FG

FZ

a) b)

FZFZ

FZ

FZ

FG

FZ

ß ß

F

3.6.4 Load distribution for non-symmetrical insert layout

FG

FG

FBFA

ɑ b


If the inserts are not installed symmetrically to the load’s centre of gravity, the load distribution to different inserts is

FA + FG . b/(a+b)FB + FG . a/(a+b)

where

FG weight of the pre-cast element, in kNa distance from insert to centre of gravity, in mb distance from insert to centre of gravity, in m

If elements are lifted without spreader beam, the lifting inserts must be installed symmetrically with respect to the elements centre of gravity.

3.6.5 Spread angle

Influence of spread angle on the actions for lifting inserts must be taken into account.

Cable angleβ

Spread angle α

Load factorz

0° - 1,00

7,5° 15° 1,01

15° 30° 1,04

22,5° 45° 1,08

30° 60° 1,15

37,5° 75° 1,26

45° 90° 1,41

Table 12. Spread angle factors

FGT

FG

> 900 Not ALLOWED

900

600

450

300

F Z=0,

5FG

F Z=0,

5FG

=0,52FG

=0,5

2FG

=0,5

4FG

=0,5

8FG

=0,7F

G

=0,54FG

=0,58FG

=0,7FG

ß

Figure 17. Spread angle factors


3.6.6 Self-weight

3.6.7 Adhesion and form friction

The self-weight FG of pre-cast elements shall be determined as

FG = V . ρG

whereV volume of the pre-cast element, in m3

ρG density of the concrete, in kN/m3

Adhesion and form friction are assumed to act simultaneously during the lifting of the precast element from the formwork. The actions for demolding situations is

Fadh = qadh . Af

whereFadh action due to adhesion and form friction, in kNqadh basic value of combined adhesion and form friction as per Table 13, in kN/m2

Af contact area between concrete and formwork, in m2

Formwork and conditiona) qadhb)

[kN/m2]

Oiled steel mold, oiled plastic-coated plywood ≥ 1,0

Varnished wooden mold with panel boards ≥ 2,0

Rough wooden mold ≥ 3,0

Table 13. Minimum values of adhesion and form friction qadh

a) Structured surfaces should be considered separately.b) The area to be used in the calculations is the total contact area between the concrete and the form.

Note: The minimum values of Table 13 are valid only if suitable measures to reduce adhesion and form friction are taken e. g. casting on tilting or vibrating the formwork during the demolding process.

3.6.8 Dynamic actions

During lifting and handling of the precast elements the lifting devices are subjected to dynamic actions. The magnitude of the dynamic actions depends on the type of lifting machinery. Dynamic effects shall be taken into account by the dynamic factor ψdyn. For further guidance values of ψdyn depending on the lifting machinery and characteristics of the terrain are given in Table 14.


Condition Dynamic factor ψdyn

Tower crane, portal crane, mobile crane 1,3

Lifting and moving on flat terrain 2,5

Lifting and moving on rough terrain ≥ 4

Table 14. Dynamic factor ψdyn

Note: Other values of ψdyn than given in Table 14 based on reproducible tests or verified experience can be used in the design. In case of other lifting and handling conditions than reported in Table 14 the factor ψdyn shall be determined on the base of tests or engineering judgement.

3.6.9 Load condition “erection in combination with adhesion and form friction”

Figure 18. Erection in combination with adhesion and form friction

Ftotal

Ftotal

ɑ

FG

FQ

FQ

b)a)ß

When pre-cast elements are lift from form according to Figure 18 the action FQ on lifting inserts is

FQ = (FG + Fadh) . z/n

whereFQ load acting on individual lifting insert, in kNFG self-weight of the pre-cast element, section 0, in kNFadh action due to adhesion and form friction, section 3.6.7, in kNz factor for combined tension and shear, z = 1 / cos β , angle β in accordance with Figure 18. In case of only tension z = 1.n number of lifting anchors carrying the load.



where

FQ load acting on individual lifting insert, in kNFG self-weight of the pre-cast element, section 0, in kNFadh action due to adhesion and form friction, section 3.6.7, in kNn number of lifting anchors carrying the load.

Figure 19. Erection in combination with adhesion and form friction, lifting with balancing beam

Ftotal

FQ

FQFG

2

FQ = ( + Fadh) /nFG

2

Figure 20. Erection in combination with adhesion and form friction, lifting with chains

Ftotal

FG

2

ß



whereFQ load acting on individual lifting insert, in kNFG self-weight of the pre-cast element, section 0, in kNFadh action due to adhesion and form friction, section 3.6.7, in kNz factor for combined tension and shear z = 1 / cos β , angle β in accordance with Figure 20.n number of lifting anchors carrying the load.

3.6.10 Load condition “erection”

It is assumed that the pre-cast element rests one-sided in the form or has been tilted up and forces from adhesion and form friction are no longer present.

Figure 21. element erection with balancing beam

Ftotal

FQ

FQ

FG

2

FQ = ( + Fadh) . z/nFG

2

Erection with balancing beam (Figure 21), action on lifting insert is

whereFQ shear load acting on individual lifting insert, in kN shear directed perpendicular to the longitudinal axis of the concrete component e. g. during lifting from the horizontal position with a beamFG self-weight of the pre-cast element, section 0, in kNψdyn dynamic factor, section 0n number of lifting anchors carrying the load.

FQ = ( ) . ψdyn/nFG

2


Figure 22. Element erection with chains

For transverse shear (lifting according to Figure 22) action on lifting insert is

FQZ = FG . ψdyn . z/n

whereFQZ inclined shear load acting on individual lifting insert, in kN inclined and perpendicular to the longitudinal axis of the precast element e.g. during lifting from the horizontal positionFG self-weight of the pre-cast element, section 0, in kNψdyn dynamic factor, section 0z factor for combined tension and shear z = 1 / cos β , angle β in accordance with Figure 22.n number of lifting anchors carrying the load.

Ftotal

FQ

FQ

FG

2

ß


The load condition “lifting and handling under combined tension and shear” is presented inFigure 23. This is the most common lifting procedure. Action on lifting insert is

FZ = FG . ψdyn . z/n

whereFZ load acting on the lifting insert in direction of the sling axis, in kNFG self-weight of the pre-cast element, section 0, in kNψdyn dynamic factor, section 0z factor for combined tension and shear z = 1 / cos β , angle β in accordance with Figure 23.n number of lifting anchors carrying the load.

Figure 23. Lifting and handling under combined tension and shear

Ftotal

FZ

FZ

ß

3.6.11 Load condition “lifting and handling under combined tension and shear”


Notes CREATE A NOTE

AboutR-Group is a leading provider of steel connections for precast and cast-in- situ construction around the globe.

With over three decades of our participation in huge projects, we don’t compromise on quality or customer satisfaction and we create connections for a lifetime.

Our customer-oriented service, excellent and reliable network of suppliers plus our extensive product portfolio ensure that we are able to offer professional and flexible solutions for any kind of projects.

In our operations we comply with the ISO 9001 and 14001 standards

R-Group

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© 2019 R-GROUP BALTIC OÜ. All rights reserved.This brochure may not be reproduced in wholeor in part without the prior written approval ofR-GROUP BALTIC OÜ

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