Академический Документы
Профессиональный Документы
Культура Документы
Senior Associate, Wiss, Janney, Elstner Associates, Inc., 14 Washington Road, Suite 501, Princeton
Junction, New Jersey 08550; Telephone: (609) 799-7799; Facsimile: (609) 799-7088;
E-mail: adolhon@wje.com
Abstract
This paper presents a literature search on the early developments in floor and roof
slabs constructed of “assembled concrete blocks” made from precast, lightweight
hollow core blocks, commonly referred to today as Dox Plank. This survey includes
period design guides, reference standards, United States patents, technical manuals,
product catalogs, plank manufacturers, design assumptions, design theory, and the
manufacture of planks. The findings will aid the architect/engineer in conducting a
performance evaluation by identifying the original design parameters, such as the
allowable unit stresses, area of embedded steel, material properties, etc., as well as by
identifying serviceability concerns. Assembled concrete block type planks are
formed by assembling a row of hollow core, lightweight concrete blocks into a
prestressed plank. The most common of the assembled concrete block systems was
the “Dox Plank,” initially known as “Doc’s Blocks.” It was named for its inventor
Bernhard A. “Doc” Vander Heyden, who patented improvements in the planks and
the methods of constructing them in 1954 (United States Patent No. 2,696,729), and
subsequent improvements in 1965 (United States Patent No. 3,172,932). Although
Dox Plank is just one variation on the assembled concrete block system, it came to
represent the industry.
Introduction
warranted, the analysis can be challenging, if not incomplete, without the basic
understanding of the original plank design, materials, and manufacture of the planks.
This paper presents a literature search on the early developments in floor and roof
slabs constructed of “assembled concrete blocks” made from precast, lightweight
hollow core blocks, commonly referred to today as Dox Plank. This survey includes
period design guides, reference standards, United States patents, technical manuals,
product catalogs, plank manufacturers, design assumptions, design theory, and the
manufacture of planks. The findings will aid the architect/engineer in the
performance evaluation by identifying the original design parameters, such as the
allowable unit stresses, area of embedded steel, material properties, etc., as well as by
identifying serviceability concerns.
Description
The planks are formed by assembling a row of hollow core, lightweight concrete
blocks, placed upside down on a work table, compressing the blocks together,
inserting steel reinforcing bars into aligned channels in the longitudinal direction of
the row of blocks, grouting the reinforcing into place, curing the assembled plank,
and then relieving the externally applied compression, thereby forming a prestressed
plank.
Once the plank has cured, it is then turned over and hoisted into position on the job
site to form a floor or roof slab. The tongue and grooved edges of the blocks allowed
the planks to be keyed with adjacent planks to provide shear transfer, thereby forming
a slab. Once the planks were in place, a thin concrete overlay may or may not be cast
on the supporting planks. If a topping is cast, it is intended to fill in the grooves
between planks resulting in greater strength through composite action.
The assembled concrete blocks had the advantages of being factory made with greater
supervision, control, and uniformity than would otherwise be available on the job
site. The planks could be quickly erected and once in place serve as a working
platform for other trades during construction and as a ceiling for the floor beneath the
platform. The hollow cores and lightweight aggregate reduced the overall weight of
the slab. The hollow cores had the added advantage of being used for utilities or as
air ducts. The underside of the planks formed a flat ceiling which may or may not
have been plastered.
Historical Background
Assembled concrete block systems gained popularity in the 1940’s and 1950’s as an
economical alternative to wood and light steel joists for relatively light loads. They
were not recommended for heavy loads or moving machinery, which could cause
impact and vibration.
Numerous variations have focused upon the clamping action using threaded rods and
end plates, grouting process, external tensioning, arching the row of blocks,
interlocking planks, shape of blocks, and the apparatus used in the manufacturing
process. Some of the variations and other improvements are described more fully in
United States Patent Nos. 1,891,597 (Jagdmann, 1932), 1,921,285 (Davis and Brush,
1933), 2,044,382 (Dunagan, 1936), 2,075,633 (Anderegg, 1937), 2,299,070 (Rogers
and Price, 1942), 2,631,450 (Lachaise, 1953), 2,645,115 (Abeles, 1953), 2,696,729
(Vander Heyden, 1954), and 3,172,932 (Vander Heyden, 1965). Most are structurally
indistinguishable. Cataloging these variations is beyond the scope of this paper.
The system that attracted the most attention was Dox Plank, initially known as
“Doc’s Blocks.” It was named for its inventor Bernhard A. “Doc” Vander Heyden,
who patented improvements in the planks and in the methods of constructing them in
1954 and subsequent improvements in 1965. He also founded the Dox Plank
Manufacturers Association, which licensed manufacturers across the eastern half of
the United States (Figure 2). Although Dox Plank is just one variation on the
assembled concrete block system, it came to represent the industry.
Minimum Standard Requirements for Precast Concrete Floor and Roof Units
Around the 1920’s, the American Concrete Institute (ACI) tasked its newly formed
Committee 711 to undertake a critical examination of precast concrete joist,
superimposed concrete floor systems, and construction methods on the state of the art
with recommendations for minimum standard requirements. Committee 711’s report
titled, “Precast Joist Concrete Floor Systems,” was submitted to ACI on
July 25, 1929. The report was later published by ACI in January 1940. It pertained
to three systems: 1) precast concrete joist with cast-in-place slab, 2) precast concrete
joist with precast concrete slab, and 3) independent precast joist with concrete slab
(i.e., precast slab that is not bonded to the joist).
The 1940 report of the ACI Committee 711 evolved into the “Proposed Minimum
Standard Requirements for Precast Concrete Floor Units,” which was later published
in 1944 (ACI, 1944) and revised again as proposed standards in 1946 (ACI, 1946).
In October 1946, ACI adopted the standard on “Minimum Standard Requirements for
Precast Concrete Floor Units (ACI 711-46)” as a supplement to the ACI “Building
Regulations for Reinforced Concrete (ACI 318-41).”
In November 1952, ACI Committee 711 first recognized the popularity of assembled
concrete block systems and specifically incorporated them into its proposed revision
of the standard (ACI, 1952) along with the revision to reference the updated ACI
standard, “Building Regulations for Reinforced Concrete (ACI 318-51).” By that
time, concrete block systems had been widely used and some types of planks and
manufacturing methods had already been patented. In the case of Dox Plank, the
application for the first of two patents had already been filed.
Initially, ACI Committee 711 (ACI, 1952) proposed subdividing the manufacture and
assembly of concrete blocks into essentially arched and prestressed systems. It
distinguished the two in stating those: 1) “With contact faces between units ground to
provide uniform bearing between units and to provide a slight camber to the
assembly,” and 2) “With contact faces parallel, but with a tension in the lower
moment bars sufficient to align and hold the assembly together and to provide slight
camber.” Subsequent, Dox Plank patents incorporated both the arching and
prestressing.
In 1953, ACI adopted the proposed revisions of Committee 711 (ACI, 1953). It
became the first ACI standard specifically devoted to assembled concrete blocks. It is
also devoted to segmental concrete, which includes tee-beam joists, concrete joists,
and I-beam joists. The Standard specifies concrete protection for reinforcement,
materials, manufacture, tests, and other requirements.
With the adoption of the “Building Code Requirements for Reinforced Concrete
(ACI 318-63),” which contained both Working Stress and Ultimate Strength Design
methods and also extensive changes in the treatment of shear and bond, ACI-ASCE
Committee 512 on Precast Structural Concrete Design and Construction was formed
to review ACI 711-58 and to recommend any necessary changes.
The result of ACI-ASCE Committee 512’s review was the proposed standard,
“Recommended Practice for Manufactured Concrete Floor and Roof Units,” which
supplemented ACI 318-63 and superseded ACI 711-58.
Most of the specifications given in ACI 711-58 are contained in the report by
ACI-ASCE Committee 512 (ACI-ASCE, 1966). The major additions concerned test
methods for strength design and ultimate strength design, minimum reinforcement
requirements, and quality requirements and acceptance procedures.
On June 19, 1944, Bernhard A. “Doc” Vander Heyden filed an application, which was
a continuation of an earlier application filed on May 17, 1943, with the United States
Patent Office for improvements in prestressed planks using concrete blocks and the
method of manufacture. A patent (Patent No. 2,696,729) was granted on
December 14, 1954.
The stated objective given in Patent No. 2,696,729 was, “To provide a strong but light
and porous cementitious plank combining great strength with a high thermal and
acoustical insulation factor, which together with its light weight, adapts it for making
of roofs and floors, and the like.” The patent identified 13 claims distinguishing it
from other patents using concrete and clay tile block and their manufacture.
Although the distinctions between Patent No. 2,696,729 and other patents pertaining
to planks with concrete blocks and their manufacture and also the distinction among
the 13 claims made by this patent maybe subtle, most important to the objective of
this paper is not the distinctions, but rather the insight it reveals into the details of the
planks and their manufacture.
The provisions of Patent No. 2,696,729 state that the planks are to be supported at
their ends and that the planks are manufactured by grouting reinforcing bars
throughout the length of the planks, so as to distribute the compressive stress to
individual blocks rather than concentrating it upon the end blocks. The reinforcing
bars are not threaded nor do they extend beyond the end blocks. The provisions also
state that the manufacture provides a means for grinding the face of individual blocks,
aligning the channels and hollow cores within a row of blocks, placing reinforcing
bars at predetermined positions in the plank, compressing the assembly of blocks,
grouting the reinforcing bars while the assembly of blocks remain in compression,
and transferring compressive stress in the blocks through bond with the reinforcing
bars thereby forming a prestressed plank. The provisions also provide a process for
adjusting a plank to correct sag or to create an arch.
On December 29, 1960, Mr. Vander Heyden filed an application for subsequent
improvements in the method of manufacturing a concrete plank. The patent was
granted on March 9, 1965 (Patent No. 3,172,932). It identified ten claims pertaining
to prefabricated or drilled access ports for pressure grouting in special blocks
provided at predetermined intervals along the length of the plank and to provide a
step-by-step process of grouting.
The standard specifications indicate that the design was performed in accordance
with ACI 711-46, ACI 711-53 or ACI 711-58 and the corresponding building
regulations given in ACI 318-41, ACI 318-51, or ACI 318-56, respectively. The
specifications also indicate that the concrete strength of the concrete block and
topping shall be 2,500 pounds per square inch or greater and 3,000 pounds per square
inch, respectively. For concrete toppings, the toppings shall be reinforced with
welded wire fabric. On roof slabs and other areas where no concrete topping is
required, a grout coat of 1 to 3 cement and sand mix shall be thoroughly swept into
the top surface of the plank after it is placed. The bearings shall provide a minimum
of 3 inches on masonry and concrete beams and 2-1/2 inches on structural steel.
1. The maximum tensile stress of reinforcing steel is 20,000 pounds per square
inch
2. The maximum compressive stress of concrete blocks is 1,125 pounds per
square inch (Table 1)
3. The maximum compressive stress of concrete toppings is 1,350 pounds per
square inch (Table 1)
4. The concrete topping slab weighs 145 pounds per cubic inch
5. The ratio of the net area to gross area of a typical plank is 0.55
The design for bending of simple span planks under uniformly distributed load using
the Working Stress Design method yields the following standard formula:
where the values of and have been derived from a T-beam section in accordance
with the ACI Reinforced Concrete Design Handbook and as illustrated in Figure 3,
The design summary for standard 8 x 16 plank section with topped and untopped
sections is tabulated in Tables 2 and 3, respectively. Applying basis engineering
principles for simple span beams, the available uniformly distributed load may be
computed. Tables 4 and 5 give the available uniform load for 8 inch x 16 inch planks
with various reinforcing bar sizes and span lengths.
loads from roof top mechanical units, or re-roofing over an existing roof may
change the load distribution and may decrease the available live load capacity.
Often the available live load is minimal and there is little margin for
additional loads.
4. The original design parameters, such as the allowable units stress, area of
embedded steel reinforcement, and material properties are provided herein.
5. Notable serviceability deficiencies, such as floor or roof sag, separation
between adjacent planks, differential deflection between adjoining planks,
separation of blocks within an assembled plank, water penetration through an
individual plank or between adjacent planks, corrosion of embedded steel
reinforcement, or cracking and spalling, cracks in the concrete topping
running parallel to the joint formed between side-by-side planks are indicators
of performance.
Conclusions
This paper raises the awareness of the performance evaluation of assembled concrete
blocks, and in particular Dox Plank, used in existing floor and roof construction.
Guidelines for the performance evaluation of Dox Plank are presented based up a
literature search.
This paper did not include a discussion of segmental concrete or cantilevered planks.
Although the original Dox Plank design did permit planks to be used as cantilevers,
only simple span construction is considered in this paper.
Notation
Acknowledgements
References
Jagdmann, Karl E. W. (1932). “Building Block and the Construction of Floors and
the Like.” United States Patent Office, Patent No. 1,891,597, Patented
December 20, 1932.
American Concrete Institute, Reported by ACI Committee 711 (1940). “Precast Joist
Concrete Floor Systems.” Proceedings of the American Concrete Institute,
Volume 36, Title 36-15, Journal of the American Concrete Institute, January 1940,
297-312.
Journal of the American Concrete Institute, Volume 18, No. 2, October 1946,
133-146.
Abeles, Paul William (1953). “Composite Structural Member and in the Manufacture
Thereof.” United States Patent Office, Patent No. 2,645,115, Patented July 14, 1953.
Flexure,
900 1,125 1,350 1,688
Extreme fiber stress in compression
Shear, , but
Flat slabs at distance, , from the edge of not to exceed 60 75 75 75
column capital or drop panel 75 psi
Tensile Moment
Effect. Controlling Controlling
Steel of
Depth Moments Shears
Area Inertia
Std.
Sect.
833T
834T
844T 0.40 8.81 0.212 0.930 4,097 10,286 3,254 5,792 4,913 170.6
845T 0.51 8.77 0.236 0.922 5,155 11,287 3,211 6,430 4,840 207.2
855T 0.62 8.75 0.258 0.917 6,218 12,067 3,187 7,088 4,810 242.0
856T 0.75 8.71 0.283 0.911 7,439 12,726 3,151 7,711 4,759 278.9
866T 0.88 8.69 0.306 0.908 8,680 13,295 3,134 8,366 4,733 314.1
867T 1.04 8.65 0.333 0.905 10,177 13,802 3,109 8,992 4,686 352.5
877T 1.20 8.63 0.357 0.902 11,676 14,186 3,091 9,629 4,674 389.1
a
Notes: Tabular data was compiled from Dox Plank catalogs.
Tensile Moment
Effect. Controlling Controlling
Steel of
Depth Moments Shears
Area Inertia
Std.
Sect.
833 0.22 6.88 0.241 0.927 1,754 5,588 2,533 3,381 98.9
834 0.31 6.83 0.290 0.923 2,443 6,064 2,504 3,899 127.9
844 0.40 6.81 0.332 0.919 3,129 6,371 2,485 4,424 153.7
845 0.51 6.77 0.378 0.917 3,958 6,600 2,465 4,936 180.1
855 0.62 6.75 0.418 0.916 4,792 6,765 2,455 5,462 203.5
856 0.75 6.71 0.459 0.915 5,756 6,882 2,438 5,967 225.8
866 0.88 6.69 0.494 0.914 6,726 6,974 2,428 6,483 245.8
867 1.04 6.65 0.532 0.913 7,893 7,027 2,411 6,974 265.2
877 1.20 6.63 0.564 0.912 9,070 7,074 2,401 7,480 282.8
a
Notes: Tabular data was compiled from Dox Plank catalogs.
833T
834T
833
834 91 71 55 42 31 22
844 83 66 53 41 32 24
845 95 78 64 52 42 34 26
855 87 73 61 50 41 34 27
856 96 81 70 59 50 42 34
866 88 75 65 56 50 44
867 95 82 71 61 54 47
877 88 76 65 58 50