Structural Engineering & Statics
where the load goes
Concept

Tolerance — where it appears

The permitted departure of a manufactured dimension from its nominal value. In a statically indeterminate assembly it is not a cosmetic quantity: a millimetre of difference between two nominally identical members redistributes force between them in proportion to their stiffness.

Named by 16 essays across 6 fields — each of them below, with the objects they name alongside it.

One coefficient, and nothing else in it. The deflected shapes of one beam under four load cases, each scaled so that its mid-span deflection is the same, with the tangent at the left-hand support drawn on each. The end rotation is that deflection times a coefficient that depends only on the shape of the load: 3.20 for a uniform load, 3.00 for a load at mid-span, 2.99 for a triangular load, 3.60 for a load on half the span. Every material property, every second moment and the span itself cancel out of the ratio θL/δ, so a beam at any deflection limit has an end rotation that is known before anything about it is: at L/360 it is 8.89 milliradians, or 0.51 of a degree.

The angle nobody limits

Every serviceability rule in this collection limits a displacement. What a bearing, a joint and a cladding gap actually have to accommodate is an angle — and the angle is locked to the displacement by a coefficient that contains no material, no section and no span.

deflection · End rotation At thirty degrees each leg carries the whole load. A 100 kN lift on two legs at 60 degrees to the horizontal. Each leg is a two-force member, so its force is the vertical share it carries divided by the sine of its angle: T = W/(2 sin β) = 57.7 kN, which is 0.58 times the whole load in each. The curve on the right is that division, and it is the reason the rule about sling angles exists rather than a convention: at sixty degrees a leg carries 0.58 W, at forty-five 0.71, at thirty exactly 1.00, and at fifteen 1.93. And the horizontal components do not disappear — they run through the thing being lifted, which here carries 57.7 kN of compression between the two pick points. That is what a spreader beam is for: it takes the compression as a designed strut so the legs above it can stand up.

The angle that doubles the force

A crane hook takes the weight and nothing else. What holds the load is a set of legs running down to it at an angle, and each leg is a two-force member — so at thirty degrees from the horizontal each of two legs carries the entire load, and the difference goes into the thing being lifted as compression.

equilibrium · Rigging The dimension the capacity rides on is not a drawn dimension. Moment capacity of a 225 mm slab against the cover to the reinforcement. The line is very nearly straight, because capacity is A_s·f_yd·z and z is about 0.9d — so the capacity is proportional to a dimension that is not on the drawing. What is on the drawing is the overall depth, and the effective depth is what the cover, the link and half a bar diameter leave of it: 225 − 30 − 0 − 8 = 187 mm here. Every one of those three is a site tolerance rather than a design decision. Ten millimetres of bar position is 5.7% of this slab's capacity and 1.8% of a 600 mm beam's — the same workmanship costs 3.0 times as much in the shallow member, and the shallow member is the one whose steel is walked on before the pour.

The dimension nobody can measure

Every flexural capacity in reinforced concrete is proportional to the effective depth, and the effective depth is not on the drawing. It is what is left of the thickness after a cover, a link and half a bar diameter have been taken off it — and each of those is a site tolerance. In a slab, ten millimetres of workmanship is six per cent of the strength.

sections · Effective depth The gap is a sum of five things and only one of them is computed. What a 30 mm movement joint is asked to accommodate, by three combination rules. The top bar is every term at its extreme, added: 33.2 mm, which assumes the hottest day, the fullest floor, the whole of the shrinkage and the worst-placed wall arrive together. The chance of that is about 1.5%. The bottom bar treats them as independent and asks for 16.0 mm. The middle bar is the rule used for actions and almost never for movements — one term at its full value and the rest at their coincidence factors — and gives 25.5 mm. The segments across the top bar are the terms themselves, and the ordering is the finding: the largest is tolerance at 10.0 mm, which is not a structural quantity at all, and the smallest is deflection at 3.2 mm — the only one anybody computes carefully, and 10% of the total.

The gap nobody computed

A movement joint is sized by adding up everything the structure will do to it, and the deflection calculation — the only term anybody computes carefully — is usually the smallest one in the list. The largest is a construction tolerance, which is not a structural quantity at all, and the sum of the extremes is nearly twice what treating them as independent would ask for.

deflection · Movement budget Five millimetres short, and a hundred kilonewtons in every member. An X-braced bay 6 m by 4 m in which one diagonal was fabricated 5 mm short, with the force that leaves in every member. Nothing is applied to this frame. The forces are the self-stress state the frame's one redundancy supports, scaled so that the diagonal is pulled back to the length it should have been: tension in both diagonals at 100 kN, compression in the four members round the outside, and the whole set in equilibrium with nothing. That is 25% of the force the diagonal was sized to carry, and it is there for the life of the structure. Take one diagonal out and the frame becomes determinate: the short member then simply puts the joint somewhere else, and the structure is in the wrong place instead of under stress. Redundancy is bought, and this is the price.

Built to the wrong length

A redundant structure's members do not have independent lengths. Choose all but one and geometry decides the last, so a member made a different length has to be pulled or pushed into place — and the force required stays in the structure for as long as the structure does. Nothing has been applied to it, there is no load case and no factor, and the members are carrying real force.

connections · Fit-up Three specimens cannot see the tail. The factor k applied to the sample's own scatter when a characteristic value is estimated from n specimens. With the scatter known in advance it is z·sqrt(1 + 1/n) and barely moves; with the scatter estimated from the same n results it is the Student t quantile instead, and it runs from 7.73 at two specimens to 1.73 at 30. At n = 4 the characteristic strength comes out at 23.8 N/mm² against 27.9 for a population known exactly — 15% lower, for a material that is identical. A small test programme does not report a worse estimate of the strength; it reports a worse strength.

The strength that belongs to the test programme

A characteristic strength is a fractile of a distribution, and a distribution estimated from four specimens is not the same object as one known exactly. The same material tested four times reports a strength 15 per cent below what it reports when its scatter is known — and nothing about the material differs.

materials · Characteristic strength A preloaded joint, before and after it slips. Four preloaded bolts at 172 kN each, on one friction face at μ = 0.5. The joint carries 344 kN by friction with the bolts in tension and not in shear at all; past that it slips into bearing and carries 362 kN with the bolts now in shear. Two different mechanisms, one joint.

The hole made bigger so the steel would fit

A preloaded joint carries load by friction, and the friction is reduced by the shape of the hole the bolt passes through — not by how much steel the hole removes, but by a coefficient in a table. An oversize hole costs fifteen per cent of the resistance; a long slot costs thirty-seven. Both are provided because the steel would not otherwise line up.

connections · Slip-critical Three fasteners, three completely different clocks. What each of three shear fasteners carries against how far the joint has moved. A 400 kN fillet weld is linear to 0.4 mm and then gone — it is stiff and it is not ductile. A 380 kN bolt in a hole 2 mm larger than itself carries nothing until the hole closes and then rises over several millimetres of hole elongation. A 250 kN preloaded bolt is at its slip resistance in under a tenth of a millimetre and holds it until it slips. Two of these in one joint are at the same displacement, so the one that gets there first carries the load — and the weld gets there 23 times sooner than the bearing bolt does.

Two fasteners that never arrive together

Every steel code forbids adding a weld's capacity to a bolt's in one shear joint, and states it as a rule rather than deriving it. It is derivable. Two fasteners in parallel are at the same displacement rather than the same force, and a weld has ruptured at four tenths of a millimetre while a bolt in a standard hole has not yet touched the side of it.

connections · Weld group Nine-tenths of a tightening torque stretches nothing. Where the torque applied to the nut of an M20 grade 10.9 bolt goes, against the coefficient of friction in its thread and under its nut, taken as equal. The bottom band is the thread's lead — the only part of the work that stretches the bolt — the middle band is friction in the thread and the top band is friction under the nut. At μ = 0.14 the lead takes 11% of the torque, the thread 39% and the nut face 50%. At μ = 0.06 the lead's share is 22% and at 0.24 it is 6%, so a coefficient nobody measured decides how much of a specified torque arrives in the bolt as preload.

The torque that goes into the thread

A preload specified as a torque is a preload specified through two coefficients of friction that nobody measures. Nine-tenths of the torque on a bolt is spent turning against its own thread and the face of its nut, so a change in the grease moves the clamping force by half — and the one method that escapes it does so by yielding the bolt on purpose.

connections · Slip-critical Two pencil lines, and where they cross. Two lines drawn with a pencil 0.2 mm wide are two bands, drawn here much wider than a pencil so the shape can be seen, and they cross not at a point but in a parallelogram. At 60° apart the parallelogram's long diagonal is 2.0 pencil widths — 0.40 mm; at 12° apart the parallelogram's long diagonal is 9.6 pencil widths — 1.91 mm. The crossing's uncertainty along the bisector is the width divided by twice the sine of half the angle, so it grows without limit as the lines turn parallel, and a construction that finds a point by crossing two lines inherits it.

How wrong a drawing is

A pencil line is a band, and two bands cross in a parallelogram that grows as they turn parallel. The accuracy of a graphical construction is therefore a property of the angles it makes, not of the hand that made it — and the worst case is the shallow arch, the structure the method was most used on. Measured properly, the drawing's error there is the size of the builder's, and the check draughtsmen relied on cannot see it.

equilibrium · Graphic statics The rotation a bearing sees is made before it arrives. The end rotation of a 12 m pretensioned beam, 300 mm wide and 700 mm deep, with a 160 mm in-situ slab 1.2 m wide, in 60 per cent humidity, from the prestress's release at three days to thirty years, with sagging positive. Release turns each end 4.8 milliradians upward; creep takes it to 7.9 by day 28, when the beam is set on its bearings. The slab brings it back by 0.9, the surfacing by 0.1, and thirty years of creep take it to 8.1 upward. The band after erection is the imposed load (0.9 down) and a night with the top cooler (0.6 down) above the line, and a sunny day with the top warmer (1.0 up) below it. Every value in the band is below zero: under every load it will carry, the beam's ends still point up, and a level bearing is turned the same way for its whole life.

The angle made in the casting yard

A bridge bearing is designed for the rotation of the beam it carries, and the rotation is listed as a sum of load, temperature, creep and a tolerance. Followed through the life of a pretensioned beam, the largest term is none of those. It is the upward turn the prestress gives the beam's ends in the casting yard, before any bearing exists, and under every load the beam will ever carry its ends still point up.

deflection · End rotation The yard's schedule has no room for the beams above. For the 12 m pretensioned beam, 300 × 700 mm, with eight strands, stored on bearers 1.0 m in from each end, debonded for the bed and the yard, with two beams stacked on it: the top fibre's stress along half the beam, N/mm², compression positive, with the stack lined up and landing 100 and 250 mm outside its bearers; dotted, the yard's limit of −3.0. Lined up, the worst is −2.98; 100 mm out, −3.24; 250 mm out, −3.63. Every beam above costs the top fibre 0.13 N/mm² for every 100 mm, at every section between the bearers.

The beam at the bottom of the stack

A precast yard stacks pretensioned beams to save space, each on bearers resting on the one below. If the bearers line up, the weight above goes straight down through them and the bottom beam never knows it is there. If they land outside its own bearers, the stack hogs the bottom beam at every section between them and takes from its top fibre relief that its debonding schedule had already spent. A schedule built for the yard leaves the bearers of a stack of three seven millimetres to be out of line. A bottom beam with a schedule of its own can be given half a metre.

sections · Prestress limits A core drilled into a slab the studs were laid out for without it. One column of a 260 mm flat slab (d = 225 mm) carrying 12 kN/m² on 400 × 400 mm columns, the shear 300 mm off centre, on a 10.0 m bay, to scale, its studs laid out for the slab without a hole — six rings of 14 mm studs on twelve rails, the last ring 4.25d from the face — and a 150 mm core 225 mm (1.00d) from the face. Its shadow from the column's centre takes 20.3 degrees of every perimeter. The studs' outer perimeter stands where the last ring leaves it, 5.75d out (solid); with the core the slab needs it at 5.74d (dashed), so the outer check is at 1.00 of its capacity, and the control check's studs at 0.79. No rail runs into it.

The core drilled after the slab was built

A building in use acquires new services, and a core drilled through a flat slab beside a column is a routine instruction. The studs round the column were laid out for a slab without the hole, and the drill finds whatever is there. Whether it cuts a stud matters less than it looks. What decides is the outer perimeter, which the hole pushes outward while the studs stay where they are, and whether the slab survives is set by a margin nobody chose: the room left when the studs were rounded up to a stock size and the rings to a whole number.

internal-forces · Punching shear The best compensation is less than the prediction. For every floor of a 40-storey building of 3.6 m storeys, its perimeter columns at 12 N/mm² and its core at 6 under the finished load, cast a floor every seven days, with 25 per cent of the load arriving as finishes 90 days after the frame is complete and creep coefficient 2.2, from its fit-out to thirty years, with the creep anywhere within ±30 per cent of the design value: the largest amount any floor stands high (dashed) and stands low (light), and the worse of the two (solid), against the share of its predicted thirty-year movement each floor is set high by. Uncompensated, a floor ends 31.9 mm low; compensated in full, a floor stands 16.0 mm high at its fit-out; the worst is smallest, 11.0 mm, at 0.79 of the prediction, where level 40 standing high 0 days after its fit-out under creep ×0.70 balances level 33 standing low after thirty years under creep ×1.30.

The floor that is level on one date

Each floor of a tall concrete building is set high by the amount its columns are predicted to drop against the core, so that it arrives level. Counted in time, the drop does not peak at mid-height and stop at the roof: the worst floor of a forty-storey building is level 31, the roof moves 24 mm, and half the movement is still to come when the floors are fitted out. Set high by all of the prediction, a floor is level on one date thirty years away and 16 mm high at handover. With the creep known to ±30 per cent, setting it high by about four fifths of the prediction makes the worst floor's error 11 mm instead of 16. And none of it changes what the partitions see.

deflection · Differential shortening An old joint passes the bolts that have lost their preload. The chance that an M20 grade 10.9 bolt holds the inspection torque of 647 N·m without its nut turning, against the tension actually in it as a fraction of the minimum preload, for a joint new and 1 year old, 5 years old and 20 years old. New, a bolt at half the minimum preload passes 0% of the time and one at the minimum 83%; 20 years old, the bolt at half passes 80% of the time and one at a quarter 9%.

The wrench that reads the rust

The obvious check on a preloaded joint that has been in service for years is a wrench on the nut, and it measures the wrong thing. The nut holds against the bolt's tension times a friction bracket, and twenty years of rust raise the bracket until a bolt with half its preload passes four times in five. The washer that could have said more remembers only the day it was crushed.

connections · Slip-critical The survey knows the creep once most of the floors are set. The doubt about the creep of a 40-storey building cast a floor every seven days, its creep known to ±30 per cent, as the half-width of its 95% band, after a survey of every floor set by then — each read to a standard error of 1.0 mm — against the floor it is made after: from the survey alone (drawn at 100% where it is larger), and combined with the design's ±30%; beside them, the share of the building's floors still to be cast, which are all a survey can correct. The survey alone beats the design's doubt only after floor 25, with 38% of the floors still to cast; the combined doubt halves after floor 31, with 23% still to cast.

The survey that arrives after the floors

A tall building's lower storeys start shortening months before its upper floors are cast, so a survey every ten floors should tell the creep the building really has and let the floors still to come be set for it. It does tell it, to a millimetre's precision, after the twenty-fifth floor. By then most of the floors whose height it was meant to correct are already set, and the floor that ends furthest from level is the one no survey can help.

deflection · Differential shortening

Named alongside it

The objects these essays reach for when they reach for this one.

ServiceabilityBearingCreepPreloadSlip resistanceCamberCoefficient of frictionConnectionEffective depthErectionFrictionImposed deformation

All concepts