Plate 60 ArmourMate. Joint Edge Protection INDUSTRIAL SLAB ON GROUND. Plate 60 AmourMate. Joint Edge Protection

Transcription

1 Plate 60 AmourMate Plate 60 ArmourMate INDUSTRIAL SLAB ON GROUND Accommodates large concrete shrinkage Facilities thermal movement Prevents spalling on construction joints Extends the life-cycle of the floor and the asset

2 Plate 60 ArmourMate Product Description Plate 60 ArmourMate is designed to be installed at the construction joints in Post Tension slab applications or where large shrinkage joints are expected to occur. The plate that bridges over the gap provides a smooth ride for traffic travelling over the joint, minimising wheel damage and impacts and allows for up to 60 mm expansion in the joints. Plate 60 ArmourMate is a cover plate type armour edging solution and is designed for applications where the wear surface must withstand materials handling traffic with small hardwheels carrying high-loads on a daily basis, in particular semi-automated and automated materials handling environments. Plate 60 ArmourMate systems are designed to provide the total joint system solution by incorporating 3 systems in the one solution, being the Plate 60 ArmourMate steel angles and plates as the armour edging, the Square Dowels and Flanged Dowel Boxes as the load transfer system and the galvanised formwork plate as the sacrificial formwork that takes the place of the traditional wooden formboard. Plate 60 ArmourMate is made to customer specification. Range Options Full Joint Systems specifications Black or hot-dip galvanized steel to AS/NZS 4680 Multiple dowel options Infill lengths available on request Intersections available on request Made to custom configurations Post tension fabrication available Features 1. Used with high capacity Grade 300 square dowels and Flanged Dowel Boxes. 2. Shear Studs tested at 34 kn breaking strain, shears at shank. 3. The cover plate covers the joint gap between slabs preventing debris from filling the joint gap. 4. Patented twist and lock stake bracket system for easy setup. 5. Pre-fabricated Intersections and infill s available by request. Advantages Expands large post-tension slab joint gap widths of up to 60 mm. Incorporates the joint cover, edge protection, load transfer device and formwork in a single system. Smooth wheel transition over larger gap openings. The cover plate remains supported either side of the gap once the joint has opened up. Can be made to match on-site PT specifications (optional). Galvanised formwork plate on all systems. Danley Plate 60 ArmourMate provides slab edge protection to prevent concrete spalling. Benefits Concreter Benefits Full system configuration eliminates formboards. Staking system eliminates Hot Work (on-site welding). Twist and lock stake system provides fine height and level adjustment. Provides a straight edge and screed rail. Prefabricated PT holes and grout holes for easy on-site installation (optional). Asset Protection Benefits Reduces concrete spalling damage at the joints. Provides a safer operating environment for tenant employees. Extends the life-cycle of the asset by protecting the floor. Reduces floor maintenance and downtime costs over the lifecycle of the facility. Increased tenant satisfaction and return on investment. Engineering Benefits Provides a bridge across the construction joint. Provides accurate PT tendon positioning and spacing. Facilitates movement while maintaining cover over joint gap. Transfers load across the joint and into the slab panel. Accuracy of dowel placement ensures the most effective load transfer performance. ( 1 )

3 Plate 60 AmourMate Joint Section - After Sab Shrinkage Permanent sliding cover plate 60 mm max. recommended movement due to slab shrinkage Armoured edge Cover plate covers joint gap eliminating the need for fillers 60 mm max. joint gap due to slab shrinkage Field and Product Support We pride ourselves on our ability to provide on-site product and installation support. Our field sales and support teams are available to advise and work side by side with the industry when on site clarification or problem solving is required. Joint Section - At Install Material Technical Data COMPONENT DIMENSION (mm) MATERIAL TYPE MATERIAL STANDARDS STEEL GRADE EQUIVALENT YIELD STRESS (MPa) TENSILE STRENGTH (MPa) STANDARDS COMPLIANCE Large Angle 75 x 50 x 6 Hot Rolled Steel AS/NZS Grade AS/NZS Small Angle 40 x 40 x 6 Hot Rolled Steel AS/NZS Grade AS/NZS Large Top Plate 110 x 10 Hot Rolled Steel AS/NZS Grade AS/NZS Small Top Plate 20 x 10 Hot Rolled Steel AS/NZS Grade AS/NZS Shear Stud 100 x 10 Cold Drawn DIN C AS1443 Formwork 1.95 Galv G2 Z275 AS1365 Grade AS1397 Square Dowel 20 x 20 x 400 Mild Steel Bar AS/NZS Grade AS/NZS Flanged Dowel Box 0.77 Galv G2 Z275 AS1365 Grade AS1397 Manufacturing Tolerances OVERALL LENGTH ±2 mm OVERALL HEIGHT ±1 mm ( 2 )

4 Plate 60 ArmourMate Installation Process Step 1. INSTALLATION TOOLS REQUIRED: Danley Stakes (Six Per Length) Hammer Small Shifter Spirit Level String Line Extra Bracing And Stakes As Required (Customer To Supply) Cordless Drill 3.5 mm X 20 mm Self-Tapping Screws Drill Bit Step 4. INSTALLATION Installation Install the separately supplied Flanged Dowel Boxes using the self-tapping screws at the provided dowel cut-outs, ensuring the flange is facing towards the top of the joint. Step 2. INSTALLATION The ArmourMate lengths are flush on the ends. They need to be joined together with the supplied joiner plate and fixing bolts. Ensure a 5 mm gap is left between each length. This allows for the lateral movement of the joint. Repeat the process for each section until the desired length is achieved. Step 5. INSTALLATION Check sub-grade for levelness and grade. Set a string line along the joint path and position the first length of ArmourMate. Ensure the sleeves go on the side of first concrete pour will occur. Insert stakes (six per length) through the stake brackets attached to the ArmourMate separation plate. Hammer the stakes into the ground until they are 50mm below the top of the joint. Additional staking and bracing may be required to keep sections steady during the concrete pour. Step 3. INSTALLATION Apply any concrete reinforcing (including PT tendons and grout tubes) into the required pre-punched positions. Pour the concrete ensuring to vibrate along the joint at regular intervals. The top of the ArmourMate rails can be used to screed along. Step 6. INSTALLATION Adjust the height of the joint until it is level and at the required slab depth. Turn the stakes 90 degrees using the shifter to lock the joint in place. After the first pour has set remove any additional staking. Place the dowels through the separation plate slots into the sleeves in the first pour before pouring the second pour. Dowels should be placed within 36 hours of the first pour. After second pour is completed the top tack welds need to be ground off to allow the joint to open. ( 3 )

5 Plate 60 AmourMate Joint Placement For Mesh Reinforced Slabs Correct Mesh Placement - The following points are recommended when placing mesh at the joint 1. The mesh should be located externally of stud position. 2. The mesh should be supported by bar chairs to rest approximately ⅓ of the slab height. 3. The mesh should never rest on the dowel or the dowel cover. Mesh Reinforced Slab Design - Typical Install 4. The mesh edge should be located approximately 50 mm from the formwork plate (on either side). 5. Continuous mesh wire should be broken at the edge of the sheet to prevent cracking. Failing to do so may induce a crack in-line with the edge of the mesh. 6. Dowel sleeves should always be located on the stake bracket side of the joint. Mesh to be spaced a minimum of 50 mm from the joint (either side) Slab height Reinforcing mesh supported by bar chairs (⅓ the slab cover) ½ Slab height (±5%) Thermal Movement Gap Movement Gap - Plan Detail Please Note: During installation a 5 mm min. gap must be provided between lengths to allow for any thermal movement of the joint. 5 mm min. ( 4 )

6 Plate 60 ArmourMate IMPORTANT - Replacing anchors on-site cut lengths If Danley ArmourMate rails are cut to length on-site, and the remaining anchors on the rails are in excess of 100 mm from the cut, it is the responsibility of the contractor to secure an anchor or anchors onto the rail to be cast into the concrete, before pouring concrete. The replacement anchor or anchors may be removed from the off-cut, or a device similar to the anchor on the off-cut may be used; and should be tack welded to the rail within 75 mm of the cut end. Similarly, it is the responsibility of the contractor, when setting out the ArmourMate rails prior to pouring concrete, to examine the location of any saw-cut contraction joint that may pass through the ArmourMate rails, and add additional anchors within 75 mm each side of the proposed saw-cut on each side of the rail. Both these actions will ensure that the ends of the Danley ArmourMate rails are anchored appropriately when the concrete is poured. Plate 60 ArmourMate Typical Stud Placement (Plan View) Max mm from soff saw-cut (both sides) Max mm from cut infill end (both sides) Cut infill end Soff saw cut Weld loose stud to rail on-site Typical Companion Product Flanged Dowel Boxes Flanged Dowel Boxes are multi-directional metal sleeves with high capacity square dowels. They are attached to metal or wooden formwork with integral nailing flanges and location marks. They allow for both contraction and expansion at the joint, as well as having a large lateral movement capacity. They are designed for construction joints in both ground and elevated slabs and are available in a number of different standard sizes. Square dowel inserted into Flanged Dowel Box after first pour ½ dowel length Second pour First pour Compressible foam in sleeve allows for expansion capacity ( 5 )

7 Plate 60 AmourMate Post Tensioned Slabs Plate 60 ArmourMate is designed to be used on post tensioned (PT) slab projects. The high movement joint is suitable for the expected large gaps associated with PT slabs. Joints can be made with PT cut-outs and grout tube holes punched in the separation plates at specified centres. Cut-out size and grout tube size can be varied dependent upon customer requirements. Please note that the minimum slab height for a PT Plate 60 ArmourMate joint is 220 mm. Post Tensioned (PT) Slab For post tensioned slab a full set of technical drawings needs to be supplied for take off, quoting and manufacturing. Plate 60 ArmourMate - Post Tensioning Features PT live end hole Grout tube hole Min. 220 mm 60 mm Specified dowel holes within min. and max. centres tolerance As specified ( 6 )

8 Plate 60 ArmourMate APPLICATION HYPER PLATE 60 INSERT PLATE Small, hard wheeled traffic (pallet jacks) Cushioned wheel traffic (forklifts & trucks) Heavy loads Warehouse internal slabs External slabs, pavements & carparks Durability Testing Our in-house test rig is on the job consistently running cycle testing for durability of our Plate 60 ArmourMate. Large slab shrinkage & movement at joint (PT) High FF & FL floors JOINT STOCKED POUR THROUGH EXPANSION JOINTS POST TENSIONING DIAMOND DOWEL FLANGED DOWEL BOX INFILLS INTERSECTIONS Hyper Armourmate (Full Joint) Hyper Armourmate (top rail) Plate 60 Armourmate Insert Plate Armourmate ( 7 )

9 Plate 60 AmourMate Plate 60 ArmourMate Pre-Fabricated Intersections Plate 60 ArmourMates prefabricated intersections allow for easy onsite installation and continuation of joints. Manufactured to suit the slab height and dowel specification of the connecting Plate 60 ArmourMate joint. The design of the intersection allows the joint to match the orientation of the joints in the pour ensuring the plates are inline and matching. Caution must be taken to install the intersections in there correct orientation onsite. Available in three standard configurations, 2-Way, 3-Way and 4-Way the Intersections can be a great labour saving component to any project. 2-Way Intersection 3-Way Intersection 4-Way Intersection Plan View At Intersection On-site Butted Intersections 2000 mm width SP* On-site butted intersections can be used when a prefabricated intersection is not required or cost effective. It is the process of forming an intersection with standard 3 m lengths on-site or running a soff saw-cut through the joint. The top plate section of the ArmourMate must be cut to allow the joint to open up effectively on all sides of the intersection. SP* SP* 2000 mm length Caution must be taken not to cut too deep, cutting into the dowels (load transfer system) will weaken the joint. Studs should be no further than 100 mm from the cut to effectively anchor the separate pieces. If this is not the case a stud will need to be welded onto the rail on-site within this range. SP* Please Note: SP* refers to separation plate side ( 8 )

10 Plate 60 ArmourMate How to write a (custom) specification Product specification for custom Plate 60 ArmourMate consists of a standard full joint system (see below for requirements) with additional requirements for Post Tension, if required (see below). In order for Danley to help with your project requirements please have the following information available for when you contact your sales representative. Specification REQUIRED INFORMATION FOR QUOTATION Slab Height Joint Finish (Blk/Galv.) Dowel Type Dowel Size Dowel Centres Stand or Stakes (If Required) QTY & Type Of Pre-Fabricated Intersections x x x x x x x Post Tensioned Slabs (Additional Information) PT Cut-Out Length (L) PT Cut-Out Width (W) Grout Tube Size Grout Tube Spacing PT Centres Min. & Max. Allowable Dowel Movement x x x x x x Section At Joint - When Poured Plate 60 ArmourMate (Full Formwork Systems) - Dimension Details Dowel centres as specified Grout tube hole size 3000 mm overall length PT length ('L') Grout tube spacing Slab height ½ Slab height Slab height Specified roadbase (10 mm typical) Dowel type/ size PT centres PT width ('W') ( 9 )

11 Plate 60 AmourMate Local Manufacture We pride ourselves in being a local manufacturer of Edge Protection Systems in Australia with all systems being fabricated and assembled at our QLD manufacturing facility in Morningside, Brisbane. Maintaining local manufacture and growth in Australia generates local employment and ensures we are able react quickly to providing non-standard design solution for tough applications. Danley Plate 60 ArmourMate Panel Layout Construction Joints ArmourMate or loose dowels (Flanged Dowel Box) positioned around the perimeter of each concrete pour. Contraction Joints Square Dowel Cradles positioned at the soffcut joint lines. Typical 30 x 30 meter slab panel. ( 10 )

12 Companion Products Flanged Dowel Box Flanged Dowel Boxes are multi-directional metal sleeves with high capacity square dowels. They are able to be attached to metal or wooden formwork with ease there integral nailing flanges and location marks. They allow for both contraction and expansion at the joint, as well as having a large lateral movement capacity. They are ideal for construction joints in both ground and elevated slabs and are available in a number of different standard sizes. 2. Square Dowel Cradle 2. Square Dowel Cradles are designed to provide a total contraction joint system solution by incorporating two systems in the one solution. The square dowels act as the load transfer system with the dowel sleeves to provide lateral and longitudinal movement capabilities and reduces the risk of restraint. The wire cage acts as a chair and spacer to ensure the dowels are aligned and maintained at the correct height and spacing during the pouring of the slab. 3. Crack-A-Joint As an option to saw cutting, place Crack-A-Joint into the wet concrete along the joint line (above the centre of the Dowel Cradle), to induce a crack for the full depth of the concrete. The Crack -A-Joint is available in standard 3 m lengths formed from galvanised sheet steel to a height of 25 mm. It can be supplied as a plain joint or with a permanent Rip-A-Strip capping in three different colour options (Black, Grey or Sandstone) Ground Crack Inducer An inverted V-shaped PVC extrusion, 3 m long and available in 25 mm and 50 mm heights. It is positioned on the sub-grade before the Dowel Cradles are placed. It produces a weakening in the slab that initiates a crack from the bottom up. Ground Crack Inducer is optional and should only be used when Crack-A-Joint is used, or when saw cuts are to made in the slab on the same day as the slab is poured. 5. Cradle Hold Down Hook 4. A small optional wire hook that allows you to anchor the base of your Cradles into the site sub-base. It prevents the Dowel Cradles from moving during the pour process. They hook over the bottom wire of the Cradles securing them to the ground DANLEY ( ) sales@danley.com.au 5. Other related ITW Construction Systems brands Rev 1 - April 2015 Innovative engineered solutions for the concrete construction industry with specialty in the design of precast and tilt-up. Market leading brands that include Swiftlift TM Concrete Lifting solutions, Reidbar TM Threaded Reinforcing, Nirvana TM Insulated Panel System and a range of Architectural Concrete products. Expansion Joint systems for civil and architectural specification that includes Floor, Wall, Roof, Facade, and Seismic engineered solutions for Retail Centres, Multi-level Carparks, Hospitals, Bridges and most other suspended slab environments. Manufacturing one of the largest ranges of plastic concrete accessories, bar chairs and spacers, as well as components for formwork and precast. Working closely with end users, Modfix has continued to assist in the development of new, cost effective solutions for the building and construction industries. info@itwcsanz.com Disclaimer: The information contained in this publication is intended to give a fair description of the products and their capabilities. No responsibility or liability by the manufacturers will be accepted for misuse, misreading or deviation from the recommended guidelines of these products. As new technology is introduced, or industry standards are altered, ITWCS reserves the right to alter the information without notice.