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Design Guide
March 2015
Brisbane
Perth
Email: info@ancon.com.au
Web: www.ancon.com.au
Unilift Systems
Contents
4
Locking Klaws
Locking Klaws
Unilift Systems
10
Performance
Serviceability Limit States
12
14
17
20
21
22
27
28
Anchor Installation
29
Rigging Guide
32
11
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.
Benefits
Versatile
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
Dependable Quality
Designed and tested to meet or exceed the
requirements of AS3850 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
4
Unilift Systems
System Components
Locking Klaw
Cone Anchor
Reo Anchor
Classic spherical
headed, forged foot
anchor - the first choice
for most applications.
Rubber Former
Articulated Steel
Recess
Also available:
Colletted Steel
Recess
Rigid anchor connection
for severe conditions e.g.
pipemaking.
Plastic recess
Tilt-up Sets
One-trip recess.
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 and are
compatible and interchangeable with standard clutches for
1.3t to 32t WLL anchor systems.
Locking Klaws improve safety, performance and flexibility
in all situations.
LK Technologies* fix the design flaws which have caused
failures of other clutches.
CentriLok
Unique well in the curved lifting lips locates the
anchor in its optimum, central position at the rear of
the slot!
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.
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
Cw
Ch
SI
Locking Klaws
Sw
S, Smax
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
20LC*
506
180
135
106
110
195
152
41
46
32LC*
680
272
189
172
160
300
180
52
58
WLL t
0 sling
angle
2
Annual Proof
24
Load kN
WLL t
60 sling
1.7
angle
Nominal
1.3
WLL anchor
10
20
32
36
60
120
240
384
2.6
4.3
8.6
17.2
27.6
2.5
10
20
32
Locking Klaws solve these critical problems, caused by traditional clutch designs
Typical example of a
standard clutch with lips
spread by the anchor
moving around the slot.
This clutch is at the point
of failing.
Anchor Dimensions
H
(mm)
19
26
36
47
70
88
WLL
1.3
2.5
5.0
10.0
20.0
32.0
S
(mm)
10
14
20
28
39
50
F
(mm)
25
35
50
70
98
135
35
CA01035
-
45
CA01045
-
55
CA01055
CA02055
-
120
CA01120
CA02120
CA05120
-
WLL
1.3
2.5
5.0
10.0
20.0
32.0
170
CA02170
CA05170
-
200
CA10200
-
240
CA01240
CA05240
-
960
1200
CA05960
CA321200
150
CA05150
CA10150
-
65
RA01065
RA02065
-
250
RA20250
-
WLL
1.3
2.5
5.0
10.0
20.0
32.0
300
RA32300
To suit
D
HL
H
S
L
D
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
1.3
60
RRF01
2.5
74
RRF02
5
94
RRF05
10
118
RRF10
20
160
RRF20
32
214
RRF32
Size
Diameter (mm)
Recess Part Code
Ring Part Code
1.3
60
SRF01
RR01
2.5
74
SRF02
RR02
5
94
SRF05
RR05
1.3
60
SRF01A
2.5
74
SRF02A
5
94
SRF05A
10
130
PRFC10
20
175
PRFC20
Performance
11
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
C3
C4
C5
Typical
AV Long Term
Environmental
corrosion rate
External
of steel
Interior
micron/year
Alpine
< 0.1
Dry interiors
Arid/rural/urban
0.1 - 1.5
Low
Interiors with occasional
condensation
Coastal
Medium
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
-
AS/NZS
2312
corrosivity
Very low
AV Long Term
corrosion rate
of Zinc
< 0.1
Typical
Service life 42 micron coating
>50 years
0.1 - 1.7
40-50 years
14-40 years
7-14 years
5-7 years
Performance
13
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).
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
Load Factor
1.2
AS3850 Requirement
1.2
1.5
1.5
3
4-5
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.
Included angle a
between the slings
0
30
60
90
120
1
1.04
1.16
1.42
2
Performance
15
...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
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.
C2.2
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.
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
Embedment depth
c
Centre spacing
3h
a
Edge distance
The fully developed shear cone has a diameter of approximately 3h. 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
Performance
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.
17
a = edge distance
h = embedment depth so that
18
Performance
19
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.
= x/ks
. . A4.6
where
f Ru
ks
and
WLL
= f Ru /2.5
NB!
i)
The concrete will crack at Ruc. At this load a cone anchor (foot anchor) will pull-out.
ii)
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.
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.
3.
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.
20
Performance
21
22
1.3
2.5
10
20
32
120
170
240
340
500
700
CA01120
CA02170
CA05240
CA10340
CA20500
CA32700
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
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
Effective
Embedment
mm hef
125
2.5 x 170
177
5 x 240
250
10 x 340
350
20 x 500
510
32 x 700
710
Edge
Distance
mm a
30
40
50
40
50
75
50
75
100
75
100
150
100
150
200
100
200
250
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
Bolded values: Concrete WLLc exceeds the nominal WLL of the anchor steel.
a4 3h
a1 < 3h
a2 3h
24
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
2.5 x 170
5 x 240
10 x 340
20 x 500
32 x 700
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
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.
a4 3h
a3 3h
Performance
25
Anchor WLL
Length
1.3 x 120
2.5 x 170
5 x 240
10 x 340
20 x 500
32 x 700
26
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
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
AS3850 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) 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
Ru
=
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
fs
=
0.8 ...... table 2.3 (a) (i) AS3600
LSF
=
2.5...... Cl 2.4.2 AS3850
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)
The following table shows the calculated loads and development lengths according to the requirements of
AS4671, AS3850 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
The development length of the hanger bar is calculated from AS3600 to develop Ru.
27
7
7
7
Anchor Installation
2. Pass the setting bolt through the formwork and fasten with wing nut
29
Anchor Installation
Installation of Steel Round Void against formwork
Formwork
Rubber
Ring
Anchor
SettingFormwork
Bolt
Steel Round
Void Former
The Anchor is
secured by
insertion of the
rubber ring
Setting
Bolt
Unilift
Anchor
Articulated
Recess Former
30
Anchor Installation
Installation of Colleted Void against formwork
Tension Bar
35-45
Tension Bar
Concrete cover
Performance
31
Rigging Guide
Regulatory Requirements
AS3850 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.
3 points
Only for special cases!
2 sheaved slings
Equal loads in each
2 fixed length
Equal loads in each
T
T
T
c.g.
T
T
T
2T 2T
2T
P=3T
P=2T
P=2T
P=6T
4 points
2T
TT
P=4T
c.g.
32
2T
TT
P=4T
Rigging Guide
Recommended Rigging Configurations when Facelifting with Unilift QwikTilt systems
Minimum 3C + D
Minimum 2D
Minimum
C + 300mm
C
q
C
D
D
The maximum sling
angle q should be
specified in the
lifting design.
2x1
2x2
Minimum 4.5D or
4.5E whichever is
the greater
4x2
Minimum 3D
E
D
Minimum 3D
2x4
4x2
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.
0 T
0T
T
0
0
Flat lift
4 x fixed slings
no equaliser
P=2T
2T
P=2T
T
2T 2T
2T
P=6T
Equal Load
T
2T
T
c.g.
P=4T
Central Anchor
Double Loaded
P=3T
Special Case! 3 fixed leg slings equally
distributed around the centre of cravity
34
NOTES
35
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