01 lfs technical and product manual

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01 lfs technical and product manual

  1. 1. PRODUCT GUIDE ANDPRECAST TECHNICAL MANUALThe professional choice for all your precast concrete anchors and accessoriesTel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk 1
  2. 2. LFS Product and Technical Manual Contents Page 3-4 Precast Concrete Lifting Design Page 5-22 Capstan Transport Anchor Systems Page 23—41 Threaded Lifting Systems Page 46—62 Spread Anchor System Page 63 Plastic AccessoriesTel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk 2
  3. 3. Precast Concrete Lifting DesignThe selection of lifting devices should be carefully made dependant on the type of lift or lifts that the unit willbe subject to once manufactured. It is vitally important to ensure both safe lifting and that no damage to theconcrete occurs. When assessing the lifting of a unit the following factors must be considered.The Weight of the UnitThe dead weight of a normal precast unit should be calculated using a concrete density of 2500kN/m2. Thetheoretical weight can be calculated either mathematically via the dimensions of the unit or through designpackages. The adhesion to the mould must also be included in the calculation of forces dependant on the typeof mould that the unit is cast in. The following can be used as a guide:Oiled steel mould = 1kN/m2Varnished timber mould = 2kn/m2Rough timber mould = 3kn/m2The value of adhesion to the mould is calculated by multiplying the area of the concrete in contact with themould by the adhesion factor = Area x Mould Adhesion FactorDouble T Beam should be calculated using 2 x deadweight and Coffered units should be 4 x deadweight.Dynamic LoadsThese should be calculated in most lifts of precast units, they are controlled by both the velocity and qualityof lifting equipment and the terrain being transported across.The following factors should be used: Demoulding = x 1.1 Turning = x 1.3 Site Transportation = x 1.5 (With a stationary crane) Site Transportation = x 1.65 (Over even ground)These are based on using overhead or static cranes at speeds of <=90m/min. For rough ground or when the siteinstallation details are not known, always use a factor of Dynamic Load ≥ x 2.The true mass of a precast unit for anchor specification is worked out as follows: (Demoulding) Mass = (Deadweight +Adhesion Factor) x Dynamic Load (Transportation) Mass = Deadweight x Dynamic LoadSling AngleThe angle is dependant on the length of chains / cables that are used to lift the unit. The shorter the chainsthe greater the tensile load becomes on each anchor point. The following table show the factors by which thepull factor should be calculated.Angle β Pull Factor (z)0º 1.00 β z15º 1.01 z30 1.0445º 1.0860 1.1690º 1.41(Consult LFS for angles above 90º)Tel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk 3
  4. 4. Calculation of Anchor Loads (1) 2No. Load Bearing AnchorsIt is imperative to ensure that the load is distributed as evenly as possiblewhen deciding on the number of anchors and lift design. z zThin walled panels and beams should be lifted and turned with two anchorseither with angled chains (1) or a spreader beam (2). This ensures evenload distribution across both anchors providing the anchors are set outsymmetrically either side of the centre of gravity. Please ensure that forturning units that the correct extra reinforcement is observed.For slab type units it is always advisable to use four anchors and a spreader zbeam (3) to ensure even weight distribution. It is not possible to calculateanchor loads for four anchors in panels as the exact distribution of load zcannot be guaranteed (4) . Where the unit necessitates such a lift it isessential to use an equalising device (5) that will distribute loads evenlyacross all four anchors. The use of such a system must not only be available (2) 2No. Loadat all areas that the unit is lifted, but also used only by trained and Bearing Anchorsexperienced persons. If any details of any part of the lift is not be availablethen it should be taken that two anchors will be load bearing. z βA three point lift as show in (6) will always provide an even distribution of zload providing the anchors are spaced evenly and correctly around the zcentre of gravity. zAll demoulding should take place with a minimum concrete strength of (3) 4No. Load15N/mm2 and ensuring that any load reduction factors are taken into Bearing Anchorsaccount. The safe working loads of all anchors are a minimum of threetimes and two times for the concrete.Anchor Loading z z βTo establish the actual anchor loadings, the following calculations are used:DemouldingForce / Anchor = (Dead Weight + Adhesion) x Dynamic Load x Pull Factor (4) 2No. Load No. Anchors Bearing AnchorsTransportationForce / Anchor = Dead Weight x Dynamic Load x Pull Factor β No. Anchors z z zExample – 5m x 1m x 1m Beam. Area = 5m2 Deadweight = 12500kg zFactory - Oiled steel mould, β = 15º, 2No. Anchors, Overhead Crane OnlySite Lift - β = 30º with Static Crane only (5) 4No. Load 2 Bearing AnchorsDemoulding = 12500kg + (5m x 1kN/m ) x 1.1 x 1.04 = 7436kg per Anchor 2Transportation = 12500kg x 1.5 x 1.04 = 9750kg per Anchor 2 β z z It is essential that the details in this literature are made available to all 120º production staff and that they are aware of and understand the installation instructions and safety regulations. z LFS offer a full technical support service including design calculations and on site pullout testing. Please contact us for further details. (6) 3No. Load Bearing AnchorsTel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk 4
  5. 5. Capstan Transport Anchor SystemThe Capstan Transport Anchor system is a simple and effective system for lifting most types of precast concreteunit. The anchors are forged from high grade steel and, provided the anchor is specified and installedcorrectly, provides safe and secure lifting, turning and transportation of units. Anchors are available in black,zinc plated, galvanised, 304 and 316 stainless steelEach anchor is stamped on the head with the manufacturers identification and maximum load rating of theanchor. Anchors are tested to a safety factor of at least three times their safe working load and 2.5 timesconcrete failure when installed to the guidelines that follow. Lifting Shackles are proof loaded to twice theirsafe working load and are supplied with a test certificate that is valid for six months from date of purchase.Capstan Anchors are designed for demoulding, transport and site fixing. They should not be used for repeatedlifting applications.Anchor TypesCapstan Transport Anchor Capstan Eye Anchor1.3t—32.0t load groups and are 1.3t—32.0t load groups and use with asuitable for large units such as reinforcement tail in thin walled units.staircases, slabs, wall units, beamsand pipes.Sandwich Panel Anchor Capstan Rod Anchor1.3t—20.0t load groups and are 2.5t—15.0t load groups and are suitablesuitable for large sandwich panels for very thin precast units.allowing vertical lifting.Double Head Capstan Anchor Capstan Plate Anchor1.3t—7.5t load groups and have 2.5t—10.0t load groups with abeen developed for automatic welded plate for production ofinstallation in concrete pipe thin slabs and demouldingmanufacture. These have also horizontally cast wall panels.proved very effective forHollowcore production.Tel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk 5
  6. 6. Capstan Transport Anchor SystemCapstan Anchor AccessoriesCapstan Rubber Recess Former Capstan Fixing Screw1.3t—32.0t load groups and are for 1.3t—32.0t load group and are for attachingattaching the anchor to the mould the former through the mould. The screwbefore casting. The former creates holds the anchor tightly to the formworka void in the precast to accept the when fastened with a washer and nut.Shackle and to allow lifting through360o.Capstan Magnetic Recess Former Capstan Steel Recess Former and Grommet1.3t—10.0t load groups and are forattaching the anchor to steel 1.3t—10.0t load groups and are formoulds before casting. The former attaching the anchor to steel mouldscreates a void in the precast to before casting. The former creates a voidaccept the Shackle and to allow in the precast to accept the Shackle andlifting through 360o. to allow lifting through 360o. This part requires a hole in the mould through which a fixing screw is inserted and fastened with a washer and nut.Double Head Capstan Magnetic Recess Former1.3t—10.0t load groups and are for attaching the anchor to the mould. Theformer creates a void in the precast to accept the Shackle and to allow liftingthrough 360o. They are available with either three or six magnets dependant onthe adhesion required. A rubber version for use in wooden moulds or for quickrelease floating applications such as hollow core flooring is also available.Capstan Lifting Shackle1.3t—32.0t load groups and are for lifting and turning concrete units withcorresponding anchors cast in. The shackle head surrounds the anchor and can rotatethrough 360o. Only the correct shackle for the anchor load group will fit.Tel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk 6
  7. 7. Capstan Transport Anchor SystemAnchor Use and Specification ConsiderationsThe LFS range of Capstan Transport Anchors are a simple and effective system for lifting most types of precastconcrete units. The anchors are manufactured from high grade steel and, provided the anchor is specified andinstalled correctly, provides safe and secure lifting.The anchors are designed as a method of demoulding, transportation and installation of precast units andshould not be used for repeated lifting. All anchors are tested by an independent institution to at least threetimes safe working load and are supplied with batch numbers and certification on request. All shackles areindividually proof loaded to twice safe working load and supplied complete with certification on delivery. Allload table data is based upon a safety factor of 2.5 to 1 against concrete failure.Anchor OperationThe Capstan Transport Anchor works by the distribution of load into the concrete via the tapered foot as shownbelow, this provides high load values with short embedments in the concrete. The forces can even betransferred into thin walled panels and safely lifted with the correct reinforcement.It is essential to specify the correct length of anchor relevant to Load Directionthe unit being lifted and the compressive strength of theconcrete at the time of lifting. This is a very importantconsideration as reduced anchor loadings are experienced in lowstrengths .InstallationThe anchors are installed in the formwork using one of a varietyof recess formers. These hold the anchors securely duringconcrete pouring and create a void in which the shackle fitsafter removal and once the concrete has cured. The anchor and Load transfers into the concrete in a conethe recess will only accept the corresponding shackle rendering pattern and will breakout in this manner ifmismatching load groups impossible. overloadedThe anchors are available in various lengths for use dependant on the application required. In general, longeranchors are to be used in thin panels or low strengths whereas short anchors are best in slabs and strongerconcrete.It is essential that consideration is taken to ensure that the anchors are equally positioned around the centre ofgravity and that loads are distributed evenly between each anchor.LFS offer a full technical support including calculations and on site pullout testing.Please contact LFS for further details.Tel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk 7
  8. 8. Capstan Transport Anchor SystemInstallation Instructions for Panels and BeamsFor vertical lifting of panels and beams the minimum edge distance required is as follows:Edge Distance F = (Anchor Length A + Recess Depth E) x 3These dimensions assume that the concrete is un-reinforced. Smaller edge distances are possible with suitablereinforcement.Walls and beams that contain only standard reinforcement shown overleaf should only be lifted at angles ofβ ≤ 30o. If the loading on the anchors is reduced then the amount of reinforcement can be reduced. E F C B A DAnchor Dimensions and Edge Spacing Required Head Length A Shank Dia. Foot Dia. D Head Recess Edge Distance F Load Group Diameter mm B mm mm Depth E mm mm C mm 1.3t 120 10 19 25 10 390 1.3t 240 10 19 25 10 390 2.5t 140 14 26 35 11 450 2.5t 170 14 26 35 11 450 5.0t 240 20 36 50 15 765 5.0t 340 20 36 50 15 765 5.0t 480 20 36 50 15 765 7.5t 300 24 47 60 15 945 7.5t 540 24 47 60 15 945 7.5t 680 24 47 60 15 945 10.0t 340 28 47 70 15 1100 10.0t 680 28 47 70 15 1100 15.0t 400 34 70 85 15 1250 20.0t 500 39 70 98 15 1550 20.0t 1000 39 70 98 15 1550 32.0t 700 50 85 130 23 2150 32.0t 1200 50 88 130 23 2150All other length variations have the same shank, foot and head dimensions. Special lengths are available toorder on request.Tel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk 8
  9. 9. Load Capacities for Angled Lifting in Panels and SlabsThe table below is the permissible loads for axial or angled lifting in panels or slabs using Capstan TransportShackles. The maximum angle of lift is β = 30o.10kn = 1 tonne of force Load DirectionThe table below assumes no edge reinforce- Cment and the edge distances can be reducedin reinforced concrete.Other lengths of anchor are available. ASlabs should be designed to accommodate Blifting moments during transportation. 10mm Min.Main reinforcement is not required. Min. Unit Edge Distance C Maximum Load Maximum Load Load Group Length A mm Thickness B mm mm 15N/mm2 25N/mm4 40 60 150 5 8 50 70 180 8 10 1.3t 65 85 225 13 13 85 105 285 13 13 2.5t 85 106 288 20 25 2.5t 120 155 393 25 25 85 110 300 24 36 5.0t 95 120 330 29 44 120 145 405 50 50 100 125 345 32 46 120 145 405 50 67 7.5t 140 165 465 68 75 165 190 540 75 75 115 140 390 44 65 135 160 450 62 77 10.0t 150 175 495 70 84 170 195 555 80 100 140 165 465 68 88 15.0t 165 190 540 78 111 200 225 645 113 150 200 225 645 113 150 20.0t 240 265 765 145 180 200 225 699 127 171 32.0t 250 283 819 180 210 280 313 909 220 240 β z zTel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk 9
  10. 10. Reinforcement Required for Axial LiftingMinimum concrete strength = 15N/mm2 15º Max. Please Note: Where possible lifting angle should not exceed 30o. Where mesh reinforcement is specified, an equivalent amount of reinforcement steel or smaller mesh with additional steel can be used. Edge reinforcement steel should be 460 grade 1.3t and 2.5t anchors only require one layer of mesh when minimum panel thickness is 60mmLoad Mesh Reinforcement Both Insert Stirrup Edge ReinforcementGroup Sides mm2/m Diameter mm No. Diameter L1 mm 1.3t A142 Consult LFS 2.5t A142 5.0t A142 6 8 700 8 7.5t A252 6 10 1160 8 10.0t A252 6 10 1160 12 15.0t B503 8 10 1240 12 20.0t B503 8 10 1240 12 32.0t 2 x B503 8 12 1400 16Tel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk 10
  11. 11. Load Capacities for Axial Lifting for Panels and Beams10kn = 1 tonne of force Min. Unit Length B Maximum Load Maximum Load Maximum LoadLoad Group Thickness mm 15N/mm2 20N/mm2 25N/mm2 d mm 60 13 1.3t 120 70 13 13 13 80 13 80 21 24 2.5t 170 100 24 25 25 120 25 100 43 49 5.0t 240 120 50 50 50 140 50 120 60 69 7.5t 300 140 67 75 75 160 75 10.0t 340 140 100 100 100 160 128 148 15.0t 400 180 142 150 150 200 150 160 166 191 180 182 20.0t 500 200 200 199 200 220 200 200 191 221 247 220 211 243 272 240 231 267 298 32.0t 700 260 253 292 280 275 318 320 300 299 320 320 320Tel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk 11
  12. 12. Capstan Transport Anchor SystemReinforcement Required for Angled LiftingMinimum concrete strength = 15N/mm2 45º Max. Please Note: Where possible lifting angle should not exceed 30o. Where mesh reinforcement is specified, an equivalent amount of reinforcement steel or smaller mesh with additional steel can be used. Edge reinforcement steel should be 460 grade 1.3t and 2.5t anchors only require one layer of mesh when minimum panel thickness is 60mm Diagonal Lift Insert Stirrup Mesh Rein- Reinforcement Edge Load forcement Reinf. Group Both Sides Diameter mm mm2/m Diameter B mm L mm No. Diameter L1 mm a mm ds mm 1.3t 142 10 40 1900 8 10 680 100 10 2.5t 142 10 40 1900 8 10 680 100 10 5.0t 142 10 48 2100 8 10 940 125 12 7.5t 257 12 64 2100 8 10 1160 125 12 10.0t 257 16 140 2200 8 10 1160 125 12 15.0t 513 20 140 3900 8 10 1240 125 14 20.0t 513 20 140 3900 8 10 1240 125 16 32.0t 1026 25 175 4500 8 12 1400 125 16Tel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk 12
  13. 13. Load Capacities for Angled Lifting for Panels and BeamsFor angles greater than 30o please contact LFS. 10kn = 1 tonne of force Min. Unit Maximum Load Maximum Load Maximum Load Load Group Length B mm Thickness d mm 15N/mm2 20N/mm3 25N/mm4 1.3t 120 95 13 13 13 100 25 2.5t 170 25 25 120 25 120 38 44 49 140 42 48 5.0t 240 160 46 50 50 180 50 140 42 48 54 160 47 54 60 180 52 60 67 7.5t 300 200 59 69 220 66 75 240 71 75 260 75 140 58 67 75 160 65 75 84 180 72 83 92 200 79 92 10.0t 340 220 84 98 240 90 100 260 95 100 280 100 160 79 91 102 180 88 102 113 200 97 112 125 220 107 124 138 15.0t 400 240 118 136 260 129 149 150 280 141 150 300 150 160 128 147 165 180 140 162 181 200 154 177 198 20.0t 500 220 168 194 240 182 200 260 198 200 280 200 200 147 170 190 220 167 187 209 240 178 206 230 260 195 225 251 280 212 245 247 32.0t 700 300 230 266 297 320 249 288 340 269 311 360 290 320 380 312 320 400 320Tel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk 13
  14. 14. Capstan Eye AnchorThe Capstan Eye Anchor is for use when the transfer of load is not possible through the foot of a standardanchor. This is usually for thin reinforced units or lightweight concrete. Reduced bond stress may need to beconsidered for lightweight concrete.The re-bar tail must be in close contact to the bottom of the hole to prevent concrete breakout when lifting. C H G B A F I 30o E J D Re-Bar Anchor Overall Anchor Load Length Shank Dia. Head Dia. Foot Dia. Hole Embedment Embedment Recess Group A mm B mm C mm D mm E mm F mm G mm H mm 1.3t 65 10 19 19 10 45 75 10 2.5t 90 14 26 27 13 64 101 11 5.0t 120 20 36 42 20 88 135 15 10.0t 180 28 47 57 25 136 195 15 20.0t 250 39 70 76 37 185 265 15 Reinforcement Specification Unbent Re-bar Length I mm Min. Unit Mesh Concrete Compressive StrengthLoad Group Thickness Reinforcement mm Each Side Re-Bar Dia. J mm 15N/mm2 25N/mm2 35N/mm2 1.3t 80 A142 8 900 700 550 2.5t 80 A142 10 1350 1050 850 5.0t 100 A252 12 1900 1500 1200 10.0t 140 A252 20 2650 2050 1700 20.0t 160 A252 28 3750 2950 2400Tel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk 14
  15. 15. Capstan Plate AnchorThe Capstan Plate Anchor is designed for reinforced concrete slabs too thin for a standard Capstan Anchorwhich are lifted at right angles to its greatest dimension and for de-moulding panels.The minimum panel thickness (J) is determined by the unit design by combining the anchor length, anchor headrecess and the specified cover. It is essential that not only the cover is observed but that the concrete can flowfreely under the base of the anchor to ensure corrosion resistance. C I A G A B J F H Cover DxE Overall Anchor Permissible Shank Head Plate Size Anchor Reinforcement BarsLoad Length Embed- Embed- Loads kN Dia. B Dia. C D x E x F RecessGroup A mm ment ment mm mm mm I mm G mm H mm Length K 15N/ 25N/ Dia. J mm mm mm2 mm2 2.5t 55 14 26 70 x 70 x 6 66 29 11 Dia. 8 x 4 200 10 15 2.5t 120 14 26 70 x 70 x 6 131 94 11 Dia. 10 x 4 300 25 25 5.0t 55 20 36 90 x 80 x 8 70 23 15 Dia. 12 x 4 450 30 40 5.0t 65 20 36 90 x 80 x 8 80 33 15 Dia. 12 x 4 450 40 50 5.0t 110 20 36 90 x 80 x 8 125 78 15 Dia. 12 x 4 450 50 5010.0t 115 28 47 90 x 90 x 10 130 71 15 Dia. 16 x 4 600 80 100 J LTel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk 15
  16. 16. Curved Capstan Transport AnchorThe Curved Capstan Transport Anchor is specifically designed for lifting, pitching and transporting sandwichpanels.After installing the anchor head is positioned in the centroidal axis of the panel with the foot being central inthe load bearing layer which ensures a proper load transference. Spalling of the concrete during erection andlifting is avoided with Curved Capstan Transport Anchors. A tilting table should be used to pitch units ifproduced with only a front layer on top. Using connector pins close to the anchor is advisable.These anchors should be used in conjunction with a spreader beam.10kn = 1 tonne of force Load Direction Load DirectionA B C Min.Unit Permissible Load Group Length A mm Offset B mm Thickness C Load Kn mm 1.3t 277 50 13 80 2.5t 268 50 25 100 5.0t 466 60 50 100 7.5t 664 70 75 120 10.0t 667 70 100 140 15.0t 825 70 150 180 20.0t 986 90 200 200Tel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk 16
  17. 17. Capstan Rod AnchorThe Capstan Rod Anchor is designed to pitch and lift very thin wall panels, reinforced girders or similar types ofunit as well as masonry wall units.The anchor consists of a ribbed steel bar with a forged Capstan lifting head. The load is transferred into theconcrete by the ribs of the steel bar.For special fabrications the bar can be bent in an offset manner to fit units such as sandwich panels.10kn = 1 tonne of force B A G C E D F Minimum Mesh Total Rod Bar AnchorLoad Length Anchor Head Panel Permissible Reinforcement Embedment Embedment Diameter RecessGroup A mm Dia. E mm Thickness Load kN Both Sides mm/ B mm C mm D mm G mm F mm m2 2.5t 400 411 374 14 26 100 11 25 188 2.5t 520 531 494 14 26 100 11 25 188 5.0t 580 595 548 20 36 140 15 50 257 5.0t 900 915 868 20 36 140 15 50 257 7.5t 750 765 706 24 46 140 15 75 257 7.5t 1150 1165 1106 24 46 140 15 75 257 10.0t 870 870 885 28 46 160 15 100 257 10.0t 1300 1315 1256 28 46 160 15 100 257 15.0t 1080 1095 1015 34 69 200 15 150 257 15.0t 1550 1565 1485 34 69 200 15 150 257Tel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk 17
  18. 18. Double Head Capstan Transport AnchorThe Double Head Capstan Transport Anchor has been specifically developed for use in pipe production whereanchor installation is automated. This permits high volume production by eliminating the manual operation offixing anchors.The second head of the anchor assists accurate positioning and ensures perpendicular installation as it sitstightly in the hollow of the former.This feature also benefits the production of high volume flooring where large amounts of anchors are installedon a regular basis. The rubber former is hard wearing and has a thread which allows quick removal and cleaningwith no requirement to remove excess concrete in the void. This anchor is lifted with the same shackle asstandard anchors. B Load Rating 1.3t 2.5t 4.0t 5.0t 40 85 95 95 50 120 170 100 Length (A) mm 65 - - 180 C 100 - - - A Head Diameter (B) mm 19 26 36 36 Shank Diameter (C) mm 10 14 18 20Permissible Loads for Double Head Capstan Transport AnchorThe concrete strength is for the time of first lifting. Load Group Length (A) mm 25N/mm2 35N/mm2 45N/mm2 40 0.7t 0.9t 1.0t 50 1.0t 1.0t 1.0t 1.3t 65 1.3t 1.3t 1.3t 100 1.3t 1.3t 1.3t 120 1.3t 1.3t 1.3t 85 2.5.t 2.5.t 2.5.t 2.5 120 2.5.t 2.5.t 2.5.t 95 4.0t 4.0t 4.0t 4.0t 170 4.0t 4.0t 4.0t 95 4.0t 5.0t 5.0t 5.0t 100 4.0t 5.0t 5.0t 180 5.0t 5.0t 5.0tRecess FormersThere are steel, magnetic and rubber formers available for Double Head Anchors. The steel formers aredesigned for welding to the mould and have a magnetic insert to keep the anchor in place when casting.Magnetic formers are also steel and have magnets in the base to securely attach to the formwork.Rubber formers work in the same manner but have a metric screw thread in the base to attach through woodenformwork for quick removal from cured concrete with a floating application.Magnetic Former The second head sits flush with the base of the former.Tel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk 18
  19. 19. Double Head Capstan Transport AnchorUse with Hollowcore Flooring ManufactureThe Double Head Capstan Transport Anchor is a very effective method of demoulding, lifting and installation ofmost types of Hollowcore flooring panels.The anchors are installed in extruded or slip formed Hollowcore by collapsing the cores at the required liftingpoints and back filling with a suitably wet mix of the same concrete to the top of the panel. Larger sizes ofcores may require the use of a Slab Cap or semi-dry mix inside the core either side of the lifting point. Theconcrete should be compacted well without damaging the webs, taking care that the recess is completelyfilled.The anchor should be worked down in the poured concrete until the former is flush with the top of the panelensuring no possibility of air gaps and trowel around the former for a neat finish.It is recommended that, where possible, demoulding Hollowcore should be carried out using clamps or ensuringthat the concrete is sufficiently cured to support the load required for the lift.With most Hollowcore applications, the edge distances that are achievable are less than would be expected forobtaining full lifting loads in unreinforced concrete. However, as the deadweight of the units are greatlyreduced by the cores or polystyrene, the loads on each anchor is reduced resulting in effective lifting withrelatively small edge distances. Because there are large variations in the concrete mixes, reinforcement strand patterns and lifting intentions, it is imperative to ensure that the anchor and installation is correct for each application. LFS offer a complete design and technical support service for customers wishing to implement the Double Head Anchor system into their production. This service includes load calculations, anchor specification, training and an on-site service to test the load capabilities in concrete panels. Our test unit has a 25.0t capacity for both proof and destructive loading of anchors. This testing includes both initial set up and periodically arranged visits to monitor the continuity of achievable loads. This test- ing is backed up by a full report of results and technical support for customers working in partnership with LFS.Lifting with Double Head AnchorsThe Double Head Anchor uses the same shackle as standard Capstan Anchors. LFS recommend that clients usingthis system should fully convey the permitted lifting design to their customers, for example, many installationsare intended for final positioning only. It is imperative that the installation teams are fully aware of sucharrangements.When all site lifting requires use of Double HeadAnchors, the use of a Safety Lifting Rig isrecommended. The rig is constructed as shownopposite and is designed to offer completesecurity with safety chains under the panels andexact load distribution between each anchor byuse of an equalising plate.Safety Lifting Rigs are designed for panels up to10.0t and can be manufactured specific tocustomer requirements. These are supplied withtest certificates and are available for both saleand hire at daily and weekly rates.Please contact LFS for all sale, hire and technicalinformation.Tel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk 19
  20. 20. Capstan Lifting ShacklesThe Capstan Shackle is the attachment used for lifting, turning and transportation of concrete units with thecorresponding anchors cast in. This is a manually operated device which is available in 1.3t—32.0t load groups.Each shackle is proof loaded to twice safe working load at a recognised independent test institution andsupplied certified and index numbered for traceability when supplied new. All health and safety regulationsand suitable risk assessments should be observed when using LFS lifting shackles and site lifting equipment. Crane Hole Width Crane Hole Height Anchor Aperture Load Group Overall Length (mm) (mm) (mm) (mm) 1.3t 188 40 68 11 2.5t 230 50 86 16 4.0t - 5.0t 283 70 88 21 7.5t - 10t 401 90 115 30 15.0t - 20.0t 506 140 135 41 32.0t 680 160 189 52Using Capstan Lifting ShacklesEngagingSelect the correct shackle and place the head opening over the anchorand lower the weighted lip down onto the concrete as show in Fig. 1.The shackle will now be ready for use.LiftingOnce the shackle is engaged the unit can be lifted. The direction of lipmust always be in the direction of the lift as this locks the shackle underload. The shackle is suitable for axial / angled lifting, turning, pitchingand swivelling of units providing the anchors have been suitablyreinforced. Please observe the maximum lifting angles per the designwhich should be supplied by the manufacturer or engineer.ReleasingOnce the lift has been completed and the load has been removed the Lift Directionshackle can be released by moving the lip towards the handle. Alwaysensure that the shackle is clear of the recess before withdrawing the Lift Directioncrane. FigMaintenanceShackles should be checked for damage prior to each lift and inspected Weighted lipby a qualified engineer every six months and recorded appropriately. must always be in the loadThe maximum life of a shackle under constant use is seven years directionprovided the limited dimensions are not exceeded. Any modifications orrepairs are strictly prohibited. Max Aperture Min. Aperture Load Group Width (mm) Thickness (mm) 1.3t 13 5.5 2.5t 18 6 4.0t - 5.0t 25 8 7.5t - 10t 32 12 15.0t - 20.0t 46 18 32.0t 58 24Tel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk 20
  21. 21. Capstan Recess FormersThe Capstan Anchor must be installed in the unit using the correct former for the anchor and application. Thiswill provide quick and secure installation and form a recess for the shackle. Only the correct former will fit theanchor and the load group is marked on each one. The former can be used by floating in the concrete or bybolting through the formwork or by magnets. The formers are available in recyclable rubber and steel in loadgroups from 1.3t to 32.0t.Rubber FormersThe rubber former is resistant to oil and retains its shape in temperatures up to 120 oC. The former is reusablemany times if correctly used and cleaned after each use. Mould oil should be applied to the former before theanchor is inserted.Short sided formers are also available and are for use when lifting thin panels.Floated InstallationWith this application the concrete is poured first and the anchor is installed once the fill level has beenachieved. The anchor is inserted into the concrete until the bottom of the former is touching the concretewhich should then be vibrated until the top is flush with the concrete. At its final position the anchor much beperpendicular to the base of formwork. It is advisable to use a fixing screw and a wooden block to ensure theformer is tightly shut to prevent any concrete ingress.Removal of FormerWhen the concrete has cured the former is simple to remove. If a fixing screw has been used, remove this firstand, with two pieces of reinforcement bar, use a scissors action to release the former from around the anchorand lift the former clear. If there is any excess concrete in the recess this should be removed before lifting.Installation with Fixing ScrewWhen installing through wooden formwork a fixing screw or nut is required. If thesides of formwork can be removed in a horizontal direction then a fixing screwcan be used. When this is not possible then a separate fixing nut and screw isrequired. These are available in all load groups.Tel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk 21
  22. 22. Steel Recess FormersThe Capstan Anchor can be installed in metal formwork by the use of a steel formers.These is used where the lifting anchors are not accessible when casting. They areavailable in load groups from 1.3t to 20.0t. All steel formers are zinc plated forcorrosion resistance.Using Steel FormersThe former is first attached to the mould by either its thread or by welding. Theanchor is then placed in the centre of the former and the rubber sleeve put aroundthe shank and pushed into the void, holding it tightly in position. The former andsleeve should be coated in mould oil before casting. When the unit is struck theformer remains on the mould with the anchor and sleeve coming away with the unit.The sleeve should then be removed and cleaned for reuse.When installing using steel formers, particularly when the anchors are horizontal to the formwork, provisionsshould be made to ensure it remains fixed during pouring. This can be done by tying the anchor to the form-work or by using spacers.Magnetic FormersThe steel formers are also available with magnets installed in the base to allow the attachment of anchors atany required point in a steel mould. These have either three or six magnets in the base and should be chosendependant on the adhesion required when casting. Larger units with a heavy concrete flow should use thehigher adhesion. The rubber sleeve should be used in the same manner as standard steel formers.Anchor Load Concrete Adhesion (kp) Ø (mm) (t) Cover (mm) 1.3 50 60 10 2.5 50 74 11 3.5 100 74 11 5.0 50 94 15 5.0 100 94 15 5.0 120 94 15 5.0 180 94 15 10.0 50 118 15 10.0 100 118 15 10.0 120 118 15 10.0 180 118 15Tel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk 22
  23. 23. Utility AnchorsThe Utility Anchor is designed for reinforced or unreinforced concrete units and are especially useful for coverslabs, pipes and culverts or any application where the construction site can benefit from an approved andtested lifting anchor that can be used with a crane hook and no other special lifting device.Benefits of Utility Anchors• Economical alternative for de-mould, handling and installing precast units.• Versatile system that can be used for most types of precast unit.• Lifting capacity of up to 7500kg.• Easy to install.Utility Anchor Components Fixing Screw Wet Setting PlateTel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk 23
  24. 24. Utility Anchors Installation Instructions for Precast UnitsPlacement of Utility AnchorsThis can vary dependant on the structural shape of the unitsand the manufactures or engineer’s preferences. UtilityAnchors are not designed for thin edge applications. Alwaysensure that the minimum edge distances are maintained andthat lifting design takes into consideration the minimumstrengths as noted in the capacity chart along with any otherdynamic forces.It is recommended that the formers should always be placed inline with the load direction of lifting chains.Typical InstallationsWet Setting1) Assemble the anchor, former and either a Fixing Screw or Wet Setting Plate2) If required, use grease or duct tape for an extra seal for the cavity in the former.3) Work the assemble into the wet concrete until the top surface of the former is flush to the concrete. Ensure that any air bubbles are removed before setting is complete.Fixing Screw Setting1) Assemble the anchor and former.2) If required, use grease or duct tape for an extra seal for the cav- ity in the former.3) Drill a hole in the formwork at the installation point and attach the assembly with the fixing screw and the thread cast into the former.4) Ensure that any air bubbles are removed before setting is complete via vibrating poker or similar method.Fixing Plate Setting1) Assemble the anchor and former.2) If required, use grease or duct tape to seal the cavity in the former.3) Screw or nail the fixing plate to the formwork at the installation point and place the assembly on the pins and push firmly into place.4) Ensure that any air bubbles are removed before setting is complete via vibrating poker or similar method.Tel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk 24
  25. 25. Utility Anchors Installation Instructions for Precast Units Min Panel Min Edge Product Tension Shear SWL A B C Thickness Distance Code SWL Kg Kg mm mmLF01UA08135 80 134 11 800 1300 102 160LF01UA20095 95 152 11 1800 2500 114 190LF01UA25120 120 181 11 2000 3000 140 240LF01UA35170 170 238 11 2500 3500 203 340LF01UA14080 80 135 17 1400 1800 102 160LF01UA35095 95 173 17 3500 5000 114 190LF01UA50120 120 188 17 5000 7000 140 240LF01UA75170 170 254 17 7500 8500 203 340 Utility Anchor Former Product Code C D E UAF200 203 76 89Tel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk 25
  26. 26. Utility Anchors Installation Instructions for Precast UnitsAngled LiftingThe safe working load figures on Page 25 are based on straight chains providing a pure tension lift. For angledlifting applications, please reduce the design lifting capacity by the figures quoted in the table below. Dynamicfactors for transport will also apply as detailed on Page 3 of this manual. Sling Angle Load FactorsSling Angle β 120o 105o 90o 75o 60o 45o 30o 15o Load Factor 2 1.64 1.41 1.26 1.16 1.08 1.04 1.01Adjusting Loads for Concrete StrengthThe safe working loads detailed on Page 25 are based on a concrete compressive strength of 25N/mm2 and isquoted for tensile applications. Please consult LFS for any special requirements in shear below this strength.To convert the allowable load in tension for an unreinforced anchor from a concrete strength of 25N/mm2 to agreater or lesser concrete strength, multiply the safe working load at 25N/mm2 by the applicable factor listedbelow. Concrete Strength Adjustment Factors Increased Concrete Strength 30N/mm2 Multiply SWL by 1.13 35N/mm3 Multiply SWL by 1.19 Increased Concrete Strength 20N/mm2 Multiply SWL by 0.92 15N/mm3 Multiply SWL by 0.75Tel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk 26
  27. 27. Lifting Sockets and InsertsFlat End and Cylindrical Lifting Sockets provide simple lifting and transporting for most kinds of precastconcrete units, particularly when casting into thin concrete panels. Flat End Lifting Inserts are available inboth high grade zinc plated carbon steel and 303 grade stainless with metric threads. Cylindrical Socketsare also available in both materials and also Rd and metric type threads. All installation instructions arebased on a 2:1 concrete safety factor at a strength of 15N/mm2 and 3:1 for steel inserts and are testedfor by a recognised institution. Flat End and Cylindrical Lifting Sockets can be used in conjunction withPlastic Nailing Plates or Magnetic Holding Plates to provide a 10mm recess that can be made good on site.Plastic Stopper Caps are also available to protect threads from weathering.Please contact LFS with any technical queries. F B H D A E Plastic Stopper to C prevent concrete ingress G Cylindrical Lifting Sockets Flat End Lifting Sockets Overall Usable Overall Axial Load Size (Thread x Rebar Hole Size (Thread x Rebar Hole Usable Thread Diameter Thread Load Rating Diameter Rating Length A) Size (C) Length E) Size (G) Length (H) (B) Length (D) (F) 500kg M/Rd 12 x 40 15 8 22 500kg M12 x 60 15 10 22 500kg M/Rd 12 x 48 18 10 25 1200kg M16 x 80 21 13 27 1200kg M/Rd 16 x 58 21 13 27 1200kg M16 x 100 21 13 27 2000kg M/Rd 20 x 70 27 16 35 2000kg M20 x 95 27 16 35 2500kg M/Rd 24 x 80 31 17 43 2500kg M24 x 110 31 18 43 4000kg M/Rd 30 x 101 39 22 56 4000kg M30 x135 39 22 56 6300kg M/Rd 36 x 125 47 25 69 4000kg M30 x150 38 22 56 8000kg M/Rd 42 x 140 54 30 80 - - - - 12500kg M/Rd 52 x 170 72 40 97 - - - -Anchor SpacingThe following should be observed for all anchor installations and should also have sufficient C/Lreinforcement as detailed on the next page. Axial Load Edge Distance Edge Distance Size Rating A mm B mm A B 500kg M/Rd 12 37 300 B/2 1200kg M/Rd 16 40 400 2000kg M/Rd 20 50 550 2500kg M/Rd 24 60 600 4000kg M/Rd 30 70 650 6300kg M/Rd 36 100 800 B 8000kg M/Rd 42 120 1000 A B/2 12500kg M/Rd 52 138 1200 3xATel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk 27
  28. 28. Lifting Sockets and InsertsAxial LiftingAll Sockets and Inserts must be reinforced for lifting with BSt500s reinforcement bar as per the table andsketches below. Reinforcement around the anchor can be in the form two layers of mesh or a re-bar cagebefitting the unit as specified by the design engineer. The socket reinforcement can be in the form of a 60ºangled bar (1) or with parallel ‘U’ bars (2). For slab type units the reinforcement can be cranked down fromthe ‘U’ bar to fit the thickness of the panel (3), straight bars must not be used and extra bars must be laidacross the flats of the bar. Mesh reinforcement is essential. Min. Mesh Axial Load Leg Length Leg Length Bar Diameter Internal Diameter Size Reinforcement Rating (L1) mm (L2) mm (BD) mm (ID1) mm (Two Layers) 500kg M/Rd 12 230 190 6 24 Q131 1200kg M/Rd 16 320 280 10 40 Q131 2000kg M/Rd 20 440 380 12 48 Q131 2500kg M/Rd 24 475 410 12 56 Q188 4000kg M/Rd 30 650 570 16 64 Q188 6300kg M/Rd 36 820 720 20 140 Q188 8000kg M/Rd 42 850 730 25 175 Q188 12500kg M/Rd 52 1200 1020 25 196 Q188 (2) (4) (1) ID1 ID2 L1 ID1 L2 BD (3) L3 BD 30º BDH 60º L3For angled lifts it is essential to reinforce the socket to ensure the load is distributed into the concrete unit,for angles of greater than β = 12.5º the following reinforcement should be observed and installed in the panelas in (5) with a re-bar hanger as detailed in (3). If this pattern is used straight bars should be laid over thecranked bars at right angles. The axial pull reinforcement must be in contact with the base of the socket (6). (5) InternalAxial Load Leg Length Bar Diameter Size Diameter β Rating (L3) mm (BDH) mm B (ID2) 10mm 500kg M/Rd 12 150 24 6 20º 1200kg M/Rd 16 200 32 10 (6) 2000kg M/Rd 20 300 32 12 2500kg M/Rd 24 300 40 14 4000kg M/Rd 30 400 48 16 6300kg M/Rd 36 550 56 20 8000kg M/Rd 42 600 64 25 12500kg M/Rd 52 750 140 28Tel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk 28
  29. 29. Lifting Sockets and InsertsPitching / TurningLifting Sockets and Inserts are designed to be used in thin panel applications for turning through 90º fromhorizontal to upright. All Sockets and Inserts must be reinforced for lifting with BSt500s reinforcement bar asper the table and must include the extra reinforcement as detailed below. InternalAxial Load Leg Length Leg Length Bar Diameter Bar Diameter Internal Diameter Height Size Diameter Rating (L1) mm (L2) mm (BD1) mm (BD2) mm (ID1) mm (h) mm (ID2) mm 500kg M/Rd 12 270 280 6 8 24 24 35 1200kg M/Rd 16 350 400 8 12 32 32 49 2000kg M/Rd 20 500 500 10 14 40 40 64 2500kg M/Rd 24 520 560 12 14 48 48 75 4000kg M/Rd 30 580 590 12 16 48 48 92 6300kg M/Rd 36 700 700 14 16 56 56 118 8000kg M/Rd 42 850 860 16 20 64 64 143 12500kg M/Rd 52 950 1000 20 20 140 140 174 L2 ID1 Lift Direction BD2 15º ID2 H BD1 L1For turning or erecting units through 90º as detailed below, only half the weight of the unit is being lifted andtherefore there is no reduction in the safe working load of the anchor and the same permissible loads andstandard sling angle reduction factors apply. However, for lifting at these angles the permissible load peranchor is half the axial load rating. Sling angle factors apply to the chains in the same manner as axial lifting.Combination Lifting Loops or Swivel Eyes should always be used for turning or pitching units. Load Direction z z βTel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk 29

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