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Concrete Electrical Duct Bank Test Report

The purpose of the testing was to analyze the structural strength of a precast concrete duct bank
to determine that it is equivalent and/or superior to the cast-in-place duct bank installation.
Seven different tests were performed to analyze and evaluate the internal reactions to different
loading cases.

The first test was an end shear test on the joint. The results showed that the PVC conduit did not
shear instead the bearing forces from conduit deformation and shear forces applied into the
section spalled the concrete and failed the joint. This test was a success.

Test #2 was very similar with the exception that there was a gap in-between the joint. The test
result showed a predictably weakened joint in comparison to test #1, but was sufficient.

Test #3 was a flexural strength test to determine the moment capacity of the precast section. It
showed that the conduit bonded to the concrete and acted like a reinforcing component to the
section which exceeded our expectations.

Test #4 had a very similar layout and also tested the flexure. The results were even better than
test #3.

Test #5 was another joint strength test. The test load was moved farther away from the end than
in test #1 and #2. The goal was to produce a shear failure, but the section actually broke in
flexure. The section failed with a value lower than expected because the conduit slipped and the
force was not transferred into the conduit. This scenario of conduit slippage would have the
same result whether a precast duct bank system or cast-in-place duct bank system were used.

The objective of test #6 was comparable to test #5, evaluating the shear strength of a precast
section. The outcome produced two cracking planes. The first was shear cracking and the
second was a flexure failure of the beam. The flexural force in the duct bank failed as predicted.
This was the only piece that had a shear crack. These findings for the precast duct bank system
would meet or surpass that of the cast-in-place.

The last test was set up similar to test #3 & #4 to assess the flexural strength of the section. The
results were lower than predicted, but again the PVC slipped during testing. The end results
would be comparable with both the precast and cast-in-place methods of duct bank installation.

The determination of the seven tests was overwhelmingly positive. The precast concrete duct
bank systems’ internal reactions to various loading cases met and/or exceeded expectations. The
abundant evidence provided in this report is significant and shows the sufficiency needed while
using precast concrete electrical duct banks.
Page #001

Test #1 Joint Shear

The goal of test #1 was to determine possible failure modes at the joint between
precast duct bank sections. Section #1 was connected to section #2 by six PVC conduits
and two concrete shear keys. The conduits were not cemented between their tongue and
groove joints, which is atypical of in-field installation procedure. This was done to be
conservative. In addition, the ends opposite of the tested joint were not confined as
would be the case for standard installations. A layout of the test is shown in drawing TR-
1.
During test loading, shear keys became engaged at initial vertical deflection of the
joint. As the load increased a small gap in the joint was opened due to lack of lateral
restraint. Near failure load the gap was 1/4” at the top of the joint and 3/8” at the bottom.
As the vertical deflection grew between the two pieces, the top shear key developed a
crack prior to the bottom key. The concrete cracked as shown in Fig. 2 at joint failure
and appeared to model a shear failure at the end of the piece. When load was released
and the pieces were separated as shown in Fig. 3 it became apparent that the failure was a
combination of the internal shear stresses and the horizontal bearing stress caused by the
PVC as the conduit deformed.

Shear Strength Computed Shear Strength Computed Actual Maximum Shear


as Unreinforced Section as Steel Reinforced Section Reaction
14,737.8 pounds 22,106.64 pounds 70,928.7 pounds

The maximum internal shear force experienced by the duct bank was 70,928.7
pounds at end D of section #1 as shown in chart 1 assuming a simply supported beam.
The shear strength of an unreinforced concrete section neglecting effects of PVC would
be 14,737.8 pounds. The shear strength of a steel reinforced section neglecting effects of
the PVC would be 22,106.64 pounds.
The section failed well above the shear strength of the concrete. With the load
placed within half the member depth from end there was an introduction of compression
and bearing forces which added to the strength of the joint. The results of this test show
that an improperly bedded duct bank on one side of a joint will perform well to loading
near that joint. The results show the precast duct banks would meet or exceed the current
casting method.
LOAD
9'-0 1/4' i.J2ll- 1'~"
c I ol 1 o E
~
FULL BEARING
ON SUPPORT
BLOCK

CD 0 FULL BEARING
ON SUPPORT BLOCK
FULL BEARING
6wX6N NOMINAL 9'-5 1/4" ON SUPPORT BLOCK
WOOD BLOCKS 6wX6" NOMINAL
WOOD BLOCKS
r 4" DIA. SCHEDULE
40 PVC* NOTES:
1'-6" -LOADED ON TONGUE SIDE OF JOINT
-MOLDED JOINT WITH TIGHT FIT
-2X8 NOMINAL WOOD BLOCK UNDER 6" WIDE LOADING BEAM
~ 0 ~- -FIRST TEST FOR PIECES 1 AND 2
-AT FAILURE JOINT SEPARATED 1/8"
0 0 B~
.!..§'! -INTERNAL Sf-lEAR REACTION NOT PERFECT DUE TO INTRODUCTION
OF COMPRESSION FORCES INDUCED FROM BEAM LOADING APPLIED AT
.I
~
~"" END OF PIECE
~ o o ~r
-PVC OBLONGED DURING TESTING WHERE LOAD WAS APPLIED AND
SPALLED OUT THE CONCRETE IN THE FAILURE PLANE
13·1 4~. 13·1 4~. I 3·1 P @ FAILURE = 72,510#
L = 9'-8"
X-SECTION Fe' = 5069 psi
WT = 3120 pounds
*4" DIA. SCHEDULE 40 PVC 10' LG. comply with NEMA TC 2 TEST DATE: 11/30/2010
(Approved PVC manufacturers - Carlon, PW Pipe, Western Plastics) POUR DATE: 11/18/2010
TrT1.£
I ~Cretex Concrete Products Midwest, Inc.
DRAWING NUMBER
PRECAST ELECTRICAL DUCT
':-: ~ Maple Grove, MN BANK JOINT TEST #1 TR-1 of 7
- Phone:(763) 545-7473 Fax:(763) 545-8399 REVISIONS BY I DATE
Page #002

PLANT: oa I scALE: 3/4"=1'-o" I DATE: 12-13-10 TEST DESCRIPTION AND FINAL LAYOUT AS 11/11/2011
R/S APPROVED BY; ADAM
CONTR. STENBERG
.: ' (l'
I I f
't' .•
Page #003
JOINT VIEW FROM EAST TEST #1 FIGURE 1
Page #004

JOINT VIEW FROM EAST POST-TEST #1 FIGURE 2


Page #005
PIECE #1 POST-TEST #1 FIGURE 3
Page #006

Shear Diagram SS Test #1

80000

70000

60000
Shear Reaction (lbs.)

50000

40000

30000

20000

10000

0
-10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0
-10000
Length of Beam (ft.)

Vn1(#)= 14737.8 Vn2(#)= 22106.6

Moment Diagram SS Test #1

30000

25000
Moment Reaction (lb.-ft.)

20000

15000

10000

5000

0
-10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0
Length of Beam (ft.)

Mn1(#-ft)= 33208.9 Mn2(#-ft)= 67501.2

CHART 1
Page #007

DISPATCHING CENTERS
Central & Southern, MN
and Western, WI
Maple Grove, MN - 763-694-3260
Concrete Products
Red River Valley & Northeastern
Northwestern Minnesota Minnesota
www .cretexconcreteproducts .com Fargo, ND -701-237-9800 Duluth, MN- 218-624-4891

i : i
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Cretex Concrete Products - The Shape of Solutions


Page #008

DISPATCHING CENTERS
Central & Southern, MN
and Western, WI
Maple Grove, MN- 763-694-3260

Red River Valley & Northeastern


Northwestern Minnesota Minnesota
www .cretexconcreteproducts .com Fargo, ND -701-237-9800 Duluth, MN- 218-624-4891

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Cretex Concrete Products - The Shape of Solutions


Page #009

DISPATCHING CENTERS
Central & Southern, MN
and Western, WI
Maple Grove, MN- 763-694-3260
Concrete Products
Red River Valley & Northeastern
Northwestern Minnesota Minnesota
www.cretexconcreteproducts .com Fargo, ND- 701-237-9800 Duluth, MN- 218-624-4891

ic,. K~
~- b
:_ ·~"·--1·"
....,_,
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,
1.
. X . l ...

(see appendix for calculations)


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Cretex Concrete Products - The Shape of Solutions


Page #010

Test #2 Joint Shear

The goal of test #2 was to determine possible failure modes at the joint between
precast duct bank sections with an initial 7/8” gap. This gap was large enough to ensure
that the joint shear keys would not make contact. Section #2 was connected to section #1
by six PVC conduits. The conduits were not cemented between their tongue and groove
joints, which is atypical of in-field installation procedure. This was done to be
conservative. In addition, the ends opposite of the tested joint were not confined as
would be the case for standard installations. A layout of the test is shown in drawing TR-
2.
During testing, the joint differential peaked at failure loading and there was a 3/4”
vertical deflection between joints (Fig. 4). The conduit had pulled slightly out of the
section #1 by ½”. At joint failure the concrete cracked as shown in Fig. 6 and appeared
to model a shear failure at the end of the piece. When testing was completed and the
pieces were separated the visible failure was a combination of the internal shear stresses
and the horizontal bearing stress caused by the PVC as the conduit deformed.

Shear Strength Computed Shear Strength Computed Actual Maximum Shear


as Unreinforced Section as Steel Reinforced Section Reaction
14,737.8 pounds 22,106.64 pounds 52,749.3 pounds

The maximum internal shear force experienced by the duct bank was 52,749.3
pounds at end E of section #2 as shown in chart 2 assuming a simply supported beam.
The shear strength of an unreinforced concrete section neglecting effects of PVC would
be 14,737.8 pounds. The shear strength of a steel reinforced section neglecting effects of
the PVC would be 22,106.64 pounds.
The section failed well above the shear strength of the concrete. With a 7/8” joint
gap there was an additional moment component acting in the conduit which allowed
greater deformation of the PVC than a tight fitting joint. This deformation has a negative
impact on the strength of the joint. The joint strength was also decreased by the shear
keys not transferring load. The concrete shear strength was increased by the effect of the
load being placed within half the member depth from end. This introduces compression
and bearing forces to which the concrete has a higher resistance. The results of this test
show that an improperly installed duct bank joint left with a significant gap will perform
solidly to loading near that joint. This testing showed the precast duct banks would meet
or exceed the current casting method.
CONCRETE DAMAGE
FROM PRIOR TEST
M
D c CONCRETE DAMAGE
FROM PRIOR TEST
CD
FULL BEARING
ON SUPPORT BLOCK

0 FULL BEARING
ON SUPPORT BLOCK
j .. ~ 6uX6u NOMINAL
WOOD BLOCKS

FULL BEARING
ON SUPPORT BLOCK
CL OF JOINT

8'-9 3/4" 6"X6u NOMINAL


WOOD BLOCKS
NOTES:
1'-6" -LOADED ON TONGUE SIDE OF JOINT
I I -NON-MOLDED JOINT WITH 7/8" GAP IN JOINT
00 ~.
-2X8 NOMINAL WOOD BLOCK UNDER 6" WIDE LOADING BEAM
-END D OF PIECES 1 AND 2 PREVIOUSLY TESTED
-BLOCKS MOVED IN FROM ENDS TO ACHIEVE PROPER BEARING
tl 00 B:
~
~""

SURFACE
-INTERNAL SHEAR REACTION NOT PERFECT DUE TO INTRODUCTION
OF COMPRESSION FORCES INDUCED FROM BEAM LOADING APPLIED AT
oo ~r
END OF PIECE
-PVC OBLONGED DURING TESTING WHERE LOAD WAS APPLIED AND
SPALLED OUT THE CONCRETE IN THE FAILURE PLANE
13·1 4~. 13·1 4~. I 3·1 P @ FAlLURE = 54, 083#
L = 9'-8"
X-SECTION Fe' = 5069 psi
WT = 3120 pounds
*4" DIA. SCHEDULE 40 PVC 10' LG. comply with NEMA TC 2 TEST DATE: 11/30/2010
(Approved PVC manufacturers - Carlon, PW Pipe, Western Plastics) POUR DATE: 11/18/2010
mt£ DRAWING NUMBER
~Cretex Concrete Products Midwest, Inc. PRECAST ELECTRICAL DUCT
TR-2 of 7
= :..-: Maple Grove, MN BANK JOINT TEST #2
Phone:(763) 545-7473 Fax:(763) 545-8399 REVISIONS BY I DATE
Page #011

PLANT: 08 SCALE: 3/4"=1'-o" I DATE: 12-13-10 TEST DESCRIPTION AND FINAL LAYOUT AS 11/11/2011
R/S APPROVED BY; ADAM
CONTR. STENBERG
Page #012 PVC DEFLECTION TEST #2 FIGURE 4
Page #013

JOINT VIEW FROM EAST TEST#2 FIGURE 5


Page #014
JOINT VIEW FROM EAST POST TEST #2 FIGURE 6
Page #015

Shear Diagram SS Test #2

60000

50000
Shear Reaction (lbs.)

40000

30000

20000

10000

-10000
0 1 2 3 4 5 6 7 8 9 10
Length of Beam (ft.)

Vn1(#)= 14737.8 Vn2(#)= 22106.6

Moment Diagram SS Test #2

25000

20000
Moment Reaction (lb.-ft.)

15000

10000

5000

0
0 1 2 3 4 5 6 7 8 9 10

-5000
Length of Beam (ft.)

Mn1(#-ft)= 33208.9 Mn2(#-ft)= 67501.2

CHART 2
Page #016

DISPATCHING CENTERS
Central & Southern, MN
and Western, Wl
Maple Grove, MN- 763-694-3260
Concrete Products
Red River Valley & Northeastern
Northwestern Minnesota Minnesota
www .cretexconcreteproducts .com Fargo, ND- 701-237-9800 Duluth, MN- 218-624-4891

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Cretex Concrete Products- The Shape of Solutions


Page #017

DISPATCHING CENTERS
Central & Southern, MN
and Western, WI
Maple Grove, MN - 763-694-3260
Concrete Products
Red River Valley & Northeastern
Northwestern Minnesota Minnesota
www .cretexconcreteproducts .com Fargo, ND- 701-237-9800 Duluth, MN- 218-624-4891

·,E4~ ~
' . ~

.I

!.
Page #018

DISPATCHING CENTERS
Central & Southern, MN
and Western, WI
Maple Grove, MN- 763-694-3260
Concrete Products
Red River Valley & Northeastern
Northwestern Minnesota Minnesota
www .cretexconcreteproducts .com Fargo, ND -701-237-9800 Duluth, MN- 218-624-4891

(see appendix for calculations)

i
'• 1 , ... j

Cretex Concrete Products - The Shape of Solutions


Page #019

Test #3 Flexure

The goal of test #3 was to determine the flexural strength of precast duct banks.
This test was completed on section #2 which was previously tested at both joints. There
is damage at both ends that should minimally affect its flexural capacity. In addition,
both ends of the piece were not confined and the PVC was not cemented to adjacent
pieces as would be the case for standard installations. This may affect the flexural
capacity if the end of the conduits slip, and loose bond to the concrete. A layout of the
test is shown in drawing TR-3.
During testing there was no sign of conduit slippage from either end of the PVC,
so it appears that the conduit fully developed its tensile strength through its bond to the
concrete. At failure the concrete cracked as shown in Fig. 7 and modeled a flexural
failure at the mid-span as the PVC yielded.

Flexural Strength Computed Flexural Strength Computed Actual Maximum Flexural


as Unreinforced Section as PVC Reinforced Section Reaction
33,208.9 pound-feet 67,501.2 pound-feet 74,289.9 pound-feet

The maximum internal flexural force experienced by the duct bank was 74,289.9
pound-feet at mid-span of section #2 as shown in chart 3 assuming a simply supported
beam. The flexural strength of an unreinforced concrete section neglecting effects of
PVC would be 33,208.9 pound-feet. The flexural strength of a conduit reinforced section
assuming the PVC has developed full yield strength would be 67,501.2 pound-feet.
The section failed well above the strength of a hollow unreinforced concrete
section and slightly above the strength of a concrete section using the PVC as
reinforcement. This result was positive showing that the PVC could be used as
reinforcement. The result of this test shows that an improperly bedded duct bank at mid-
span will perform well when under direct loading. In addition, the PVC can be
considered when analyzing flexural stresses from lifting and handling of precast concrete
duct banks. The results show the precast duct banks would meet or exceed the current
casting method.
LOAD @MIDSPAN
4'-7" ~ 4'-7"
!. -~· ·I
~
E D
CL SUPPORT
0 FULL BEARING
ON SUPPORT BLOCK
FULL BEARING
ON SUPPORT BLOCK 9'-2 1/2" I 'I 6"X6w NOMINAL
2J.w
r- WOOD BLOCKS
4
.--- 4" DIA. SCHEDULE
40 PVC* NOTES:
1'-6" -LOADED AT MIDSPAN
-2X8 NOMINAL WOOD BLOCK UNDER 6" WIDE LOADING BEAM
~ 0 ~-
-BOTH ENDS PREVIOUSLY TESTED
-BLOCKS AT OUTSIDE EDGE
0 0 B~
.!..§'!
.I
~
~""
~ o o ~r
13·1 4~. 13·1 4~. I 3·1 P @ FAlLURE = 31,71 0#
L = 9'-8"
X-SECTION Fe' = 5069 psi
WT = 3120 pounds
*4" DIA. SCHEDULE 40 PVC 10' LG. comply with NEMA TC 2 TEST DATE: 11/30/2010
(Approved PVC manufacturers - Carlon, PW Pipe, Western Plastics) POUR DATE: 11/18/2010
1 ~Cretex
mt£ DRAWING NUMBER
Concrete Products Midwest, Inc. PRECAST ELECTRICAL DUCT
TR-.3 of 7
= :..-: Maple Grove, MN BANK FLEXURAL TEST #3
Phone:(763) 545-7473 Fax:(763) 545-8399 REVISIONS BY I DATE
Page #020

PLANT: oa I scALE: 3/4"=1'-o" I DATE: 12-13-10 TEST DESCRIPTION AND FINAL LAYOUT AS 11/11/2011
R/S APPROVED BY; ADAM
CONTR. STENBERG
Page #021

MID-SPAN VIEW FROM WEST POST-TEST #3 FIGURE 7


Page #022

Shear Diagram SS Test #3

20000

15000

10000
Shear Reaction (lbs.)

5000

-5000

-10000

-15000

-20000
0 1 2 3 4 5 6 7 8 9 10
Length of Beam (ft.)

Vn1(#)= 14737.8 Vn2(#)= 22106.6

Moment Diagram SS Test #3

80000

70000
Moment Reaction (lb.-ft.)

60000

50000

40000

30000

20000

10000

0
0 1 2 3 4 5 6 7 8 9 10
Length of Beam (ft.)

Mn1(#-ft)= 33208.9 Mn2(#-ft)= 67501.2

CHART 3
Page #023

DISPATCHING CENTERS
Central & Southern, MN
and Western, WI
Maple Grove, MN- 763-694-3260
Concrete Products
Red River Valley & Northeastern
Northwestern Minnesota Minnesota
www .cretexconcreteproducts .com Fargo, ND- 701-237-9800 Duluth, MN- 218-624-4891

··;t:~--- +· .'

:t:
T~Y"4J·
I i i ,.
---~---------

.i.
Page #024

DISPATCHING CENTERS
Central & Southern, MN
and Western, WI
Maple Grove, MN - 763-694-3260
Concrete Products
Red River Valley & Northeastern
Northwestern Minnesota Minnesota
www .cretexconcreteproducts .com Fargo, ND -701-237-9800 Duluth, MN- 218-624-4891

l '111I!?ali

l
I

!
1.

'i .

Cretex Concrete Products- The Shape of Solutions


Page #025

DISPATCHING CENTERS
~
Central & Southern, MN
and Western, W1
Maple Grove, MN -763-694-3260
Concrete Products
Red River Valley & Northeastern
Northwestern Minnesota Minnesota
www .cretexconcreteproducts .com Fargo, ND- 701-237-9800 Duluth, MN- 218-624-4891

:hfC~ {)eL ..,..,


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l . q-€,...
' ' . (see appendix for calculations). . I,
I

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Cretex Concrete Products - The Shape of Solutions
Page #026

Test #4 Flexure

The goal of test #4 was to determine the flexural strength of precast duct banks.
This test was completed on section #1 which was previously tested at both joints. There
is damage at both ends that should minimally affect its flexural capacity. In addition,
both ends of the piece were not confined and the PVC was not cemented to adjacent
pieces as would be the case for standard installations. This may affect the flexural
capacity if the end of the conduits slip, and loose bond to the concrete. A layout of the
test is shown in drawing TR-4.
During testing there was no sign of conduit slippage from either end of the PVC,
so it appears that the conduit fully developed its tensile strength through its bond to the
concrete. At failure the concrete cracked as shown in Fig. 8 and modeled a flexural
failure at the mid-span as the PVC yielded.

Flexural Strength Computed Flexural Strength Computed Actual Maximum Flexural


as Unreinforced Section as PVC Reinforced Section Reaction
33,208.9 pound-feet 67,501.2 pound-feet 79,911.72 pound-feet

The maximum internal flexural force experienced by the duct bank was 79,911.72
pound-feet at mid-span of section #1 as shown in chart 4 assuming a simply supported
beam. The flexural strength of an unreinforced concrete section neglecting effects of
PVC would be 33,208.9 pound-feet. The flexural strength of a conduit reinforced section
assuming the PVC has developed full yield strength would be 67,501.2 pound-feet.
The section failed well above the strength of a hollow unreinforced concrete
section and slightly above the strength of a concrete section using the PVC as
reinforcement. This result was positive showing that the PVC could be used as
reinforcement. The result of this test shows that an improperly bedded duct bank at mid-
span will perform well when under direct loading. In addition, the PVC can be
considered when analyzing flexural stresses from lifting and handling of precast concrete
duct banks. The results show the precast duct banks would meet or exceed the current
casting method.
!.
4'-r
-~·
w LOAD @ MIDSPAN
4'-7"
·I
~
c D
FULL BEARING ON
SUPPORT BLOCK
3" FROM END

CD CL SUPPORT
6"X6" NOMINAL 8'-8 1/2" FULL BEARING ON
WOOD BLOCKS SUPPORT BLOCK
H .3" FROM END
5 J/4 5 .3/4"
.--- 4" DIA. SCHEDULE
40 PVC* NOTES:
1'-6" -LOADED AT MIDSPAN
-2X8 NOMINAL WOOD BLOCK UNDER 6" WIDE LOADING BEAM
-BOTH ENDS PREVIOUSLY TESTED
~ 0 ~- -BLOCKS MOVED IN FROM ENDS TO ACHIEVE PROPER BEARING
SURFACE
0 0 B~
.!..§'!
.I
~
~""
~ o o ~r
13 • I 4~. 13·1 ~. I 3·1
4
P @ FAILURE = 36,420#
L = 9'-8"
X-SECTION Fe' = 5069 psi
WT = 3120 pounds
*4" DIA. SCHEDULE 40 PVC 10' LG. comply with NEMA TC 2 TEST DATE: 11/30/2010
(Approved PVC manufacturers - Carlon, PW Pipe, Western Plastics) POUR DATE: 11/18/2010
1 ~Cretex
mt£ DRAWING NUMBER
Concrete Products Midwest, Inc. PRECAST ELECTRICAL DUCT
TR-4 of 7
= :..-: Maple Grove, MN BANK FLEXURAL TEST #4
Phone:(763) 545-7473 Fax:(763) 545-8399 REVISIONS BY I DATE
T
Page #027

PLANT: oa 1 scALE: .3/4"=1'-o" DATE: 12-u-10 TEST DESCRIPTION AND FINAL LAYOUT AS 11/11/2011
R/S APPROVED BY; ADAM
CONTR. STENBERG
Page #028
MID-SPAN VIEW FROM WEST POST-TEST #4 FIGURE 8
Page #029

Shear Diagram SS Test #4

25000

20000

15000
Shear Reaction (lbs.)

10000

5000

-5000

-10000

-15000

-20000

-25000
0 1 2 3 4 5 6 7 8 9 10
Length of Beam (ft.)

Vn1(#)= 14737.8 Vn2(#)= 22106.6

Moment Diagram SS Test #4

90000

80000

70000
Moment Reaction (lb.-ft.)

60000

50000

40000

30000

20000

10000

0
0 1 2 3 4 5 6 7 8 9 10
-10000
Length of Beam (ft.)

Mn1(#-ft)= 33208.9 Mn2(#-ft)= 67501.2

CHART 4
Page #030

DISPATCHING CENTERS
~
Central & Southern, MN
and Western, WI
Maple Grove, MN -763-694-3260
Concrete Products
Red River Valley & Northeastern
Northwestern Minnesota Minnesota
www.cretexconcreteproducts.com Fargo, ND _ 701-237-9800 Duluth, MN- 218-624-4891

Project P~ f!-{.r.-.._. 1 Date ---1.--J'-->!..L-t--=---""'--L-.ti--

~ ll,"~~c •.6r~.._~ at!"o'01n~? 1"f'1Aj .-··•-


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i : I
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·······!···

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Cretex Concrete Products- The Shape of Solutions


Page #031

DISPATCHING CENTERS
Central & Southern, MN
and Western, WI
Maple Grove, MN -763-694-3260
Concrete Products
Red River Valley & Northeastern
Northwestern Minnesota Minnesota
www .cretexconcreteproducts .com Fargo, ND- 701-237-9800 Duluth, MN- 218-624-4891

. r 1 :· ·-:-· r· ·: ~ · 1 I : • T ~ ~ · · ~ : ~ ! 1· 1

r-·-+, -~j~~-~---j_ -it·V\·-:·lLn~~---··:[t;-~~t-t.·::tt:-~--Fc:~_-_·.·····:·~-~~~-~~--~" s._._-N·~-ci·ej:_······· .


~ nc~ ; ; ~ I ' : I
!
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--:-----~~:·----.---·- --~ : i i·

tt ~::;;-ltJ~:z,3i.~~~-k =~-±ira§ ,s~et ~~ -c;it.'t;- ioe~!~~-~•••Mt-- t-__


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---~-----~----------:---·T-- L ...... '· - -·-· -······-· I ·'-- -·· .. :.

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I ! I I ' I ' i
":i
i....

I
i I I .. . '
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.:±&o~- fl~x~rG?J .lc~J.c:.t5 .
I I I
!

(see appendix for calculations)


I
r

Cretex Concrete Products - The Shape of Solutions


Page #032

Test #5 Joint Shear/Flexure

The goal of test #5 was to determine possible failure modes at the joint between
precast duct bank sections. Section #5 was connected to section #6 by six PVC conduits.
This is the first test for either of these pieces. The conduits were not cemented between
their tongue and groove joints, which is atypical of in-field installation procedure. This
may affect the flexural capacity if the end of the conduits slip, and loose bond to the
concrete. This was done to be conservative. In addition, the ends opposite of the tested
joint were not confined as would be the case for standard installations. A thin layer of
foam was applied around the bell end of the conduit prior to concrete placement. This
will act as a bond breaker and could reduce flexural capacity of this section. A layout of
the test is shown in drawing TR-5.
The tested joint C-B was not a matched molded joint so there was a varying gap
between the two pieces (Fig. 9). This joint mismatch would not be an issue for further
products with our new forming system. During testing a flexural failure occurred as
shown in Fig. 10 near the loading point at the maximum moment. The PVC at end C, the
tongue end of section #5, slipped at failure of the piece.

Shear Strength Computed Shear Strength Computed Actual Maximum Shear


as Unreinforced Section as Steel Reinforced Section Reaction
15,545.7 pounds 23,318.5 pounds 22,107.61 pounds

Flexural Strength Computed Flexural Strength Computed Actual Maximum Flexural


as Unreinforced Section as PVC Reinforced Section Reaction
35,029.43 pound-feet 67,766.68 pound-feet 42,706.73 pound-feet

The maximum internal flexural force experienced by the duct bank was 42,706.73
pound-feet near the end of section #5 as shown in chart 5 assuming a simply supported
beam. The flexural strength of an unreinforced concrete section neglecting effects of
PVC would be 35,029.43 pound-feet. The flexural strength of a conduit reinforced
section assuming the PVC has developed full yield strength would be 67,766.68 pound-
feet.
The section failed in flexure so the Shear forces are shown simply as observation.
The maximum flexural force in the duct bank section at failure was well below the
strength of a section with the conduit analyzed as reinforcement. This low failure value
was to be expected since the conduit lost bond and slipped during testing. This conduit
slippage would take place regardless whether these duct banks were poured continuously
in place or a system of precast sections. The slippage that occurred during this testing
would have been reduced or eliminated if PVC joints were cemented. The results show
the precast duct banks would meet or exceed the current casting method.
LOAD CENTERED @ 24• FROM JOINT
7'-5 1/4u 1'-9 1/4"
I
I I
~ sl·~
A c I B A
2
FULL BEARING
ON SUPPORT BLOCK Cl SUPPORT
® ®
FULL BEARING
ON SUPPORT BLOCK
6"X6" NOMINAL 9'-5 1/4" I
WOOD BLOCKS • FULL BEARING 6•X6" NOMINAL
ON SUPPORT BLOCK WOOD BLOCKS
.--- 4" DIA. SCHEDULE
40 PVC* NOTES:
1'-6" -RED CONCRETE
-LOADED ON TONGUE SIDE OF JOINT
-NON-MOLDED JOINT MIDDLE AND BOTTOM TIGHT SMALL GAP IN TOP
~ 0 ~. OF JOINT
-6X6 NOMINAL WOOD BLOCK UNDER 6" WIDE LOADING BEAM
-FIRST TEST FOR PIECES 5 AND 6
0 0 B~
.!..§'!
.I
~
~""
~ o o ~r
13 • I 4~. 13·1 ~. I 3·1
4
P @ FAlLURE = 26,200#
L = 9'-8"
X-SECTION Fe' = 5640 psi
WT = 3120 pounds
*4" DIA. SCHEDULE 40 PVC 10' LG. comply with NEMA TC 2 TEST DATE: 12/16/2010
(Approved PVC manufacturers - Carlon, PW Pipe, Western Plastics) POUR DATE: 12/15/2010
1 ~Cretex
mt£ DRAWING NUMBER
Concrete Products Midwest, Inc. PRECAST ELECTRICAL DUCT
TR-5 of 7
= :..-: Maple Grove, MN BANK JOINT TEST #5
Phone:(763) 545-7473 Fax:(763) 545-8399 REVISIONS BY I DATE
Page #033

PLANT: oa I scALE: 3/4"=1'-o" I DATE: 12-13-10 TEST DESCRIPTION AND FINAL LAYOUT AS 11/11/2011
R/S APPROVED BY; ADAM
CONTR. STENBERG
Page #034 JOINT VIEW FROM WEST PRE-TEST #5 FIGURE 9
Page #035 JOINT VIEW FROM WEST POST-TEST #5 FIGURE 10
Page #036

Shear Diagram SS Test #5

25000

20000
Shear Reaction (lbs.)

15000

10000

5000

-5000

-10000
-10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0
Length of Beam (ft.)

Vn1(#)= 15545.7 Vn2(#)= 23318.5

Moment Diagram SS Test #5

45000

40000

35000
Moment Reaction (lb.-ft.)

30000

25000

20000

15000

10000

5000

0
-10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0
Length of Beam (ft.)

Mn1(#-ft)= 35029.4 Mn2(#-ft)= 67766.7

CHART 5
Page #037

DISPATCHING CENTERS
Central & Southern, MN
and Western, WI
Maple Grove, MN -763-694-3260
Concrete Products
Red River Valley & Northeastern
Northwestern Minnesota Minnesota
www .cretexconcreteproducts .com Fargo, ND -701-237-9800 Duluth, MN- 218-624-4891

.I.

:
. i

- ,.i
:

Cretex Concrete Products- The Shape of Solutions


Page #038

DISPATCHING CENTERS
Central & Southern, MN
and Western, WI
Maple Grove, MN- 763-694-3260
Concrete Products
Red River Valley & Northeastern
Northwestern Minnesota Minnesota
www .cretexconcreteproducts .com Fargo, ND -701-237-9800 Duluth, MN- 218-624-4891

Project ~·\llc.,.} be411~ ls Test iS P1'ece+S


. T . . l- <: _::· ~ ~-f- 1.·_~- j.·.·.- . ___ .__ _::.,. ____ · ~-·- -~- Rt_ - -.,- . - ,- 1,t _ _ . . ·,: __ _~_.- ----1____
1

,1 ___ __
··--~----·····--:-.--·

. . . . . , ! J .1 in fe-r:na 1
' I i I
. i6J>if:C)e: ,_ :e.~~ j tl\ Vl 6: :2-t
l . !
1

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: '

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l

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:

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ots,:qu,h].J:--.-r
i I i : '

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~· __ J..._·-···;· .. J. • " I . . -- - • -• .. . . ;_ ···•· . .----···'-· ...•. -.I ....

(see appendix for calculations)

- \

,. '

\-·

Cretex Concrete Products- The Shape of Solutions


Page #039

Test #6 Joint Shear/Flexure

The goal of test #6 was to determine possible failure modes at the joint between
precast duct bank sections. Section #3 was connected to section #4 by six PVC conduits.
This is the first test for either of these pieces. The conduits were not cemented between
their tongue and groove joints, which is atypical of in-field installation procedure. This
may affect the flexural capacity if the end of the conduits slip, and loose bond to the
concrete. This was done to be conservative. In addition, the ends opposite of the tested
joint were not confined as would be the case for standard installations. A thin layer of
foam was applied around the bell end of the conduit prior to concrete placement. This
will act as a bond breaker and could reduce flexural capacity of this section. A layout of
the test is shown in drawing TR-6.
The tested joint B-B was a molded tight fitting joint, so there was almost no
separation between the two pieces (Fig. 11). Two failures happened during testing the
initial cracking was a shear failure which took place at a load of 37,410#. Section #3
continued to handle loading until a final flexural failure occurred with a load of 44,830#;
Fig. 12 shows both failure modes.

Shear Strength Computed Shear Strength Computed Actual Maximum Shear


as Unreinforced Section as Steel Reinforced Section Reaction(@ shear cracking)
16,360.86 pounds 24,541.29 pounds 31,972.51 pounds

Flexural Strength Computed Flexural Strength Computed Actual Maximum Flexural


as Unreinforced Section as PVC Reinforced Section Reaction(@ Final Failure)
36,866.27 pound-feet 67,985.65 pound-feet 66,201.61 pound-feet

The cracking internal shear force experienced by the duct bank was 31, 972.51
pounds near the end of section #3 as shown in chart 6 assuming a simply supported beam.
The shear strength of an unreinforced concrete section neglecting effects of PVC would
be 16,360.86 pounds. The flexural strength of a conduit reinforced section assuming the
PVC has developed full yield strength would be 24,541.29 pounds.
The maximum internal flexural force experienced by the duct bank was 66,201.61
pound-feet near the end of section #3 as shown in chart 7 assuming a simply supported
beam. The flexural strength of an unreinforced concrete section neglecting effects of
PVC would be 36,866.27 pound-feet. The flexural strength of a conduit reinforced
section assuming the PVC has developed full yield strength would be 67,985.65 pound-
feet.
The initial shear cracking occurred well above the computed shear strengths. This
was the only pure shear cracking experienced throughout all tests see Fig. 13 and Fig. 14.
It was a difficult situation to test since the depth to span ratio was relatively high.
The maximum flexural force in the duct bank section failed very near the
predicted value within 2.7%. This value would probably have been slightly larger had
the shear cracks not propagated so deeply. The results show that shear in general is not
the controlling factor for design of this section. This heavily reinforces that precast duct
banks would meet or exceed the current casting method.
LOAD CENTERED @ 21.5" FROM END
7'-7 3/4"
A B
FULL BEARING
ON SUPPORT BLOCK

0 Q)
6"X6" NOMINAL FULL BEARING
I~ g·-a· ~I 6"X6" NOMINAL
WOOD BLOCKS
WOOD BLOCKS ON SUPPORT BLOCK
NOTES:
1'-6" -LOADED ON GROOVE SIDE OF JOINT
I I -MOLDED JOINT WITH TIGHT FIT
-6X6 NOMINAL WOOD BLOCK UNDER 6" WIDE LOADING BEAM
00 ~.
-FIRST TEST FOR PIECES 3 AND 4
-TWO FAILURE MODES OBSERVED; INITIAL SHEAR FAILURE FROM
tl 00 B:
~
~""

SHEAR KEYS UP TO SURFACE, THEN A SECOND FLEXURAL FAILURE


BELOW FOCAL POINT OF LOAD
oo ~r P @ INITIAL SHEAR = 37,410#
13 • I 4~. 13·1 ~. I 3·1
4
P @ FLEXURAL FAlLURE = 44,830#
L = 9'-8"
X-SECTION Fe' = 6247 psi
WT = 3120 pounds
*4" DIA. SCHEDULE 40 PVC 10' LG. comply with NEMA TC 2 TEST DATE: 12/29/2010
(Approved PVC manufacturers - Carlon, PW Pipe, Western Plastics) POUR DATE: 11/18/2010
mt£ DRAWING NUMBER
~Cretex Concrete Products Midwest, Inc. PRECAST ELECTRICAL DUCT
TR-6 of 7
= :..-: Maple Grove, MN BANK JOINT TEST #6
Phone:(763) 545-7473 Fax:(763) 545-8399 REVISIONS BY I DATE
Page #040

PLANT: 08 SCALE: 3/4"=1'-o" I DATE: 12-1.3-10 TEST DESCRIPTION AND FINAL LAYOUT AS 11/11/2011
R/S APPROVED BY; ADAM
CONTR. STENBERG
Page #041
JOINT VIEW FROM WEST TEST #6 FIGURE 11
Page #042 JOINT VIEW FROM WEST POST TEST #6 FIGURE 12
Page #043 FAILED PIECE #3 FIGURE 13
Page #044 FAILED PIECE #3 FIGURE 14
Page #045

Shear Diagram SS Initial FailureTest #6

35000

30000

25000
Shear Reaction (lbs.)

20000

15000

10000

5000

-5000

-10000

-15000
0 1 2 3 4 5 6 7 8 9 10
Length of Beam (ft.)

Vn1(#)= 16360.9 Vn2(#)= 24541.3

Moment Diagram SS Initial FailureTest #6

60000

50000
Moment Reaction (lb.-ft.)

40000

30000

20000

10000

0
0 1 2 3 4 5 6 7 8 9 10
Length of Beam (ft.)

Mn1(#-ft)= 36866.3 Mn2(#-ft)= 67985.7

CHART 6
Page #046

Shear Diagram SS Final FailureTest #6

50000

40000
Shear Reaction (lbs.)

30000

20000

10000

-10000

-20000
0 1 2 3 4 5 6 7 8 9 10
Length of Beam (ft.)

Vn1(#)= 16360.9 Vn2(#)= 24541.3

Moment Diagram SS Final FailureTest #6

70000

60000
Moment Reaction (lb.-ft.)

50000

40000

30000

20000

10000

0
0 1 2 3 4 5 6 7 8 9 10
Length of Beam (ft.)

Mn1(#-ft)= 36866.3 Mn2(#-ft)= 67985.7

CHART 7
Page #047

c
Concrete Products
DISPATCHING CENTERS
Central & Southern, MN
and Western, WI
Maple Grove, MN- 763-694-3260

Red River Valley & Northeastern


Northwestern Minnesota Minnesota
www .cretexconcreteproducts .com Fargo, ND -701-237-9800 Duluth, MN- 218-624-4891

)/t7/9_0I J
(

i' ·-.

;····

'
-- i ..

i
. i
l

:.E~ 'i\{!( li.: ·.. R1.-:;.w~


.. ht tvc.tv l£~- Rct ~ R\ r -:t?.. 017.?5 M·
'

*$;~ 5~eql'~ M~"'~


: I""r ...} ..... : C'!\_ '-/
1. ..

R?-= W ~(~rt~)+ ~~.,4,"- ?- _ ~~ iOS, ~~~


.~. , Lf:> ~ l , •. · . · : :57 Dl~r-Qt\' +e~ .i:l=fG
Cretex Concrete Products - The Shape of Solutions
Page #048

DISPATCHING CENTERS
~
Central & Southern, MN
and Western, Wl
Maple Grove, MN -763-694-3260
Concrete Products
Red River Valley & Northeastern
Northwestern Minnesota Minnesota
www .cretexconcreteproducts .com Fargo, ND- 701-237-9800 Duluth, MN- 218-624-4891

i~0
- .f-1~ I .0 WI• . i.F lev/:'..u.. r:. .~(..1...
.

(see appendix for calculations)

-··-····J ...... .

Cretex Concrete Products- The Shape of Solutions


Page #049

Test #7 Flexure

The goal of test #7 was to determine the flexural strength of precast duct banks.
This test was completed on section #4 which was previously tested. There is damage at
both ends that should minimally affect its flexural capacity. In addition, both ends of the
piece were not confined and the PVC was not cemented to adjacent pieces as would be
the case for standard installations. This may affect the flexural capacity if the end of the
conduits slip, and loose bond to the concrete. A thin layer of foam was applied around
the bell end of the conduit prior to concrete placement. This will act as a bond breaker
and could reduce flexural capacity of this section. A layout of the test is shown in
drawing TR-7.
During testing all 6 conduits slipped at section failure especially the bottom 4, see
Fig. 16 and Fig. 17. At failure the concrete cracked as shown in Fig. 15 and modeled a
flexural failure at the mid-span as the PVC to concrete bond broke.

Flexural Strength Computed Flexural Strength Computed Actual Maximum Flexural


as Unreinforced Section as PVC Reinforced Section Reaction
36,866.27 pound-feet 67,985.65 pound-feet 55,077.8 pound-feet

The maximum internal flexural force experienced by the duct bank was 55,077.8
pound-feet at mid-span of section #4 as shown in chart 8 assuming a simply supported
beam. The flexural strength of an unreinforced concrete section neglecting effects of
PVC would be 36,866.27 pound-feet. The flexural strength of a conduit reinforced
section assuming the PVC has developed full yield strength would be 67,985.65 pound-
feet.
The section failed well above the strength of a hollow unreinforced concrete
section and well below the strength of a concrete section using the PVC as reinforcement.
These results are misrepresentative of the flexural strength computed as a PVC reinforced
section because the bond between the conduit and concrete failed. This means that the
PVC never reached its yield strength as this method assumes. This conduit slippage
would take place regardless whether these duct banks were poured continuously in place
or a system of precast sections. The slippage that occurred during this testing would have
been reduced or eliminated if the PVC joints were cemented at each end of this section to
provide lateral stability. The results show the precast duct banks would meet or exceed
the current casting method.
LOAD CENTERED @ MIDSPAN
4'-7" ~ 4'-7"
!. . . .!
~
A 8
0
9'-B"
6~X6" NOMINAL 6wX6" NOMINAL
WOOD BLOCKS WOOD BLOCKS
r 4" DIA. SCHEDULE
40 PVC* NOTES:
1'-6" -LOADED AT MID-SPAN OF PIECE
-6"X1" RUBBER PAD UNDER 6" WIDE LOADING BEAM
-END B WAS PREVIOUSLY TESTED
~ 0 ~- -NO ~SUAL CRACKS OR DAMAGE TO END B
-BOTTOM 4 CONDUIT SUD IN FROM TONGUE END B AS FLEXURAL
0 0 B~
FAlLURE OCCURED IN BEAM
.!..§'!
.I
~
~""
~ o o ~r
13·1 4~. 13·1 4~. I 3·1 P @ FAILURE = 21,860#
L = 9'-8"
X-SECTION Fe' = 6247 psi
WT = 3120 pounds
*4" DIA. SCHEDULE 40 PVC 10' LG. comply with NEMA TC 2 TEST DATE: 12/29/2010
(Approved PVC manufacturers - Carlon, PW Pipe, Western Plastics) POUR DATE: 11/18/2010
TrT1.£
I ~Cretex Concrete Products Midwest, Inc.
DRAWING NUMBER
PRECAST ELECTRICAL DUCT
':-: ~ Maple Grove, MN BANK FLEXURAL TEST #7 TR-7 of 7
- Phone:(763) 545-7473 Fax:(763) 545-8399 REVISIONS BY I DATE
Page #050

PLANT: oa I scALE: 3/4"=1'-o" I DATE: 12-13-10 TEST DESCRIPTION AND FINAL LAYOUT AS 11/11/2011
R/S APPROVED BY; ADAM
CONTR. STENBERG
Page #051 VIEW FROM WEST POST-TEST #7 FIGURE 15
Page #052
END B VIEW TEST #7 POST-SLIP PIECE #4 FIGURE 16
Page #053 END B VIEW TEST #7 POST-SLIP PIECE #4 FIGURE 17
Page #054

Shear Diagram SS Test #7

15000

10000
Shear Reaction (lbs.)

5000

-5000

-10000

-15000
0 1 2 3 4 5 6 7 8 9 10
Length of Beam (ft.)

Vn1(#)= 16360.9 Vn2(#)= 24541.3

Moment Diagram SS Test #7

60000

50000
Moment Reaction (lb.-ft.)

40000

30000

20000

10000

0
0 1 2 3 4 5 6 7 8 9 10
Length of Beam (ft.)

Mn1(#-ft)= 36866.3 Mn2(#-ft)= 67985.7

CHART 8
Page #055

DISPATCHING CENTERS
~
Central & Southern, MN
and Western, WI
Maple Grove, MN -763-694-3260
Concrete Products
Red River Valley & Northeastern
Northwestern Minnesota Minnesota
www.cretexconcreteproducts .com Fargo, ND- 701-237-9800 Duluth, MN- 218-624-4891

'
... ·~··· St:e: . ~hear-. +--lllo\'1'1-mf ?5 D,'et~l'~~ T~.;±:lt '7

Cretex Concrete Products - The Shape of Solutions


Page #056

DISPATCHING CENTERS
Central & Southern, MN
and Western, WI
Maple Grove, MN- 763-694-3260
Concrete Products
Red River Valley & Northeastern
Northwestern Minnesota Minnesota
www .cretexconcreteproducts .com Fargo, ND -701-237-9800 Duluth, MN- 218-624-4891

Project----~:.,BL!L!li\W=CLLt---..!..~..LJ· 1\ -=-p'-=-·
fJ:!l!)h:...!-- _T-l-.-./,--=-t!.>--'e;!__-}+-.··_·~_·fj_: ;.·_7_·_ ;p:. . Lt'-l. f.-~C~.e.- =- . :.t- - L~ _ _ _Date 1/17/?Oil
f I

.!

(see appendix for calculations)

'. -----·-1

i...

Cretex Concrete Products - The Shape of Solutions


Page #057

DISPATCHING CENTERS
retex
Concrete Products
Central & Southern, MN
and Western, WI
Maple Grove, MN -763-694-3260

Red River Valley & Northeastern


Nmthwestern Minnesota Minnesota
www .cretexconcreteproducts .corn Fargo, ND- 701-237-9800 Duluth, MN- 218-624-4891

Project._ _.,::::S:,.!h_!,!e=, ~~c.LC-.. . .~.,.(,.<.l~a8. . -=-l~c-'-.


'....Jsl.._.___;,JJ=e==-?.!....,a!!q"_:_n;,_#_·_,
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APPENDIX 1

Cretex Concrete Products- The Shape of Solutions


Page #058

DISPATCHING CENTERS
Central & Southern, MN
and Western, WI
Maple Grove, MN- 763-694-3260
Concrete Products
Red River Valley & Northeastern
Northwestern Minnesota Minnesota
www .cretexconcreteproducts .com Fargo, ND- 701~237-9800 Duluth, MN- 218-624-4891

j.
;
i
.j

-- .: .....

APPENDIX 2
. I

Cretex Concrete Products - The Shape of Solutions


/
Page #059

DISPATCHING CENTERS
Central & Southern, MN
and Western, Wl
Maple Grove, MN -763-694-3260
Concrete Products
Red River Valley & Northeastern
Northwestern Minnesota Minnesota
www .cretexconcreteproducts .com Fargo, ND -701-237-9800 Duluth, MN- 218-624-4891

Project

I '
'
'.

··•··""i··--·---i-·-· ··-'-····--···' ·-·····!.......... ...... •· ·-· ····-· :_ I ______ I ---...' ....•. , .... - j ________ :___ - . _.1_

J +--l}s~ ~ ~.s Co"' cc:«te..c z,+r~6 ~ ~¥ ;fhou+ re,'t1-h>nce. l"'e ~VI~


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.! . bd. 5:ec±rev1 _ __, ~. ' .

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!.

!.

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I.

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i

APPENDIX 3

Cretex Concrete Products - The Shape of Solutions


Page #060

DISPATCHING CENTERS
~
Central & Southern, MN
and Western, WI
Maple Grove, MN- 763-694-3260
Concrete Products
Red River Valley & Northeastern
Northwestern Minnesota Minnesota
www .cretexconcreteproducts .com Fargo, ND -701-237-9800 Duluth, MN- 218-624-4891

.. iI

I £53 ·£~=. b1LfiH-p7;, > lf,~od: : .


. . --: IA~e.-~ ~r 5; '~ ';7
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:
. . i

<;. I ..
1
!
APPENDIX 4
: 1 I f • • I : ,

Cretex Concrete Products - The Shape of Solutions

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