HALFEN HEK PRECAST COUPLER Z_HEK 02/18-E CONCRETE

Transcription

1 HALFEN HEK PRECAST COUPLER Z_HEK 02/18-E CONCRETE

2 HALFEN HEK PRECAST COUPLER General note Use of third-party products This approval only applies to original HALFEN products manufactured by HALFEN. The specifications in this approval are not transferable to other products. Users are fully liable for personel injuries and material damage caused by third-party products used instead of HALFEN products.

3 This translation of the original German version of the National Technical Approval is not authorized by the Deutsches Institut für Bautechnik. Technical assessment institute for construction products and methods: Deutsches Institut für Bautechnik (DIBt) (National and Federal State approved statutory public body) Member of the EOTA, UEAtc and WFTAO National Technical Kolonnenstrasse 30 B, D Berlin, Germany Tel.: Fax: Date Ref no.: Approval /16 Approval number: Z Period of validity: Valid from: Applicant: Liebigstraße Langenfeld Expires on: 30 th January 2023 Approved product: The aforementioned construction product is herewith granted a general building authority approval. This general building authority approval comprises seven pages and eleven annexes.

4 page 2 of 7 I. GENERAL PROVISIONS 1. This national technical approval verifies the usability and applicability of the aforementioned construction product in accordance with the Landesbauordnungen (Regional Building Codes of the German Federal States). 2. The national technical approval does not replace any permits, approvals and certificates legally required for the execution of building projects. 3. The granting of this national technical approval does not affect the legal rights of any third party; in particular those pertaining to private protection laws. 4. The manufacturer and distributor of the aforementioned construction product must make copies of the national technical approval available to the purchaser i.e. the end-user irrespective of further regulations as stated in the Specific Provisions, and must give notice that the national technical approval for the product must be available at the point of application. Copies of the national technical approval must be made available to the respective authorities on request. 5. Reproductions or copies of this national technical approval must always be in full. Reproduction in extracts requires the consent of the Deutsches Institut für Bautechnik. Text and illustration used in advertising material must not contradict this national technical approval. Translations of the national technical approval must include a disclaimer as follows "This translation of the original German version is not authorized by the Deutsches Institut für Bautechnik (Vom Deutschen Institut für Bautechnik nicht geprüfte Übersetzung der deutschen Originalfassung). 6. This national technical approval can be revoked at any time. The provisions of this national technical approval may be subsequently amended or modified, especially if technical progress makes this necessary. 7. This approval also includes a general building authority approval. The general type approval provided by this certificate may also be regarded as a general building authority design approval certificate. 8. This approval is based on the specifications and documents submitted by the applicant. Any change to these basic specifications are to be made available to the the Deutsches Institut für Bautechnik without delay.

5 page 3 of 7 II. SPECIFIC PROVISIONS 1.1 Object of approval and intended use The object of this national technical approval is the, which is used to connect two concrete precast elements together. The precast coupler consists of a symmetrically shaped steel bracket (Types HEK2 T-100 and HEK2 L-100) and a square counterplate made of hot-dip galvanized or stainless steel material. The HEK Precast coupler is cast in, flush with the concrete surface with a recess for installation in a precast concrete element. Counterplates and bolts in the installation recess are used together with anchorage elements (for example, sleeve anchors or anchor channels) in the second precast component to positively lock the elements. The is shown in an installed state in annex Area of application The may be used as anchorage in connections under static or quasi-static load in reinforced and non-reinforced normal concrete of strength class of at least C20/25 and at most C50/60 according to DIN EN 206-1: : Concrete - Part 1: "Specification, performance, production and conformity". The HEK Precast coupler may only be used in the installation applications as shown in Appendix 5. The Precast coupler may be anchored in cracked and non-cracked concrete. The hot-dip galvanized steel precast coupler may only be used in dry indoor conditions, e. g. in residential buildings, offices, schools, hospitals, and in retail facilities; with the exception of wet rooms. The stainless steel HEK Precast coupler is produced in material of corrosion resistance class CRC III and can therefore be used in accordance with DIN EN : with DIN EN /NA: The application of the HEK Precast coupler is in accordance with DIN EN : and with DIN EN /NA: , if all the steel parts are subsequently completely embedded with grouting mortar cement in the recess and joint in accordance with the DAfStb* Guideline, Preparation and application of cement based grouting concrete and grouting mortar. * DAfStb Deutscher Ausschuss für Stahlbeton = (German Committee for Structural Concrete) Provisions for the construction product Properties and materials The must be consistent with the drawings and specifications in the annexes of this document. The material properties, dimensions and tolerances for the precast coupler not specified in this general building authority s approval must correspond to the specifications deposited with the German Institute for Structural Engineering, the certification body and the third party inspection authority.

6 page 4 of Marking The packaging, enclosed documents or shipping documents for the precast coupler (HEK2 T-100 and the HEK2 L-100; steel element and counterplate) must be marked by the manufacturer with the conformity mark (Ü-mark) in accordance with the conformity mark regulations of the Federal states. In addition, the manufacturer's identification mark, the approval number and the complete name of the precast coupler must be declared. The marking may only be used if the conditions in accordance with section 2.3 are met. Each precast coupler must be marked as illustrated in annex Verification of conformity General information Confirmation of conformity with the specifications for the precast coupler (HEK2 T-100 and HEK2 L-100; steel element and counterplate) with the specifications of this approval must be provided for each manufacturing location with a declaration of conformity based on a factory production control. The certificate of conformity must be issued by a recognized body; also required is regular third party monitoring by an approved inspection body in accordance with the following provisions: The manufacturer of the construction product must contract an approved certification body for independent inspection and to issue a certificate of conformity as well as an approved inspection body for relevant product testing. The manufacturer is required to mark the precast coupler with a conformity mark (Ü-mark) including a declaration of the intended use. A copy of the certificate of conformity issued by the certification body must be submitted to the Deutsches Institut für Bautechnik. The Deutsches Institut für Bautechnik must also be provided with a copy of the initial test report Factory production controls Each manufacturing plant must set up and implement an in-house, factory production control. Factory production control is understood as the continuous internal monitoring of the production process, implemented by the manufacturer, to ensure the precast coupler (HEK2 T-100 and HEK2 L-100; steel element and counterplate) manufactured by them are in conformity with the provisions of this national technical approval. The extent, type and frequency of factory production control is determined by the inspection plan deposited with the Deutsches Institut für Bautechnik and the third-party certification body. The results of the factory production control must be documented and evaluated and must include at minimum the following: identification of the construction product, raw material or components method of test or inspection production date, test date of the construction product, raw material or components results of the inspection and tests, and evaluation against the requirements signature of the person responsible for factory quality control plan The documents must be kept for at least five years and be submitted to the inspection body responsible for thirdparty inspection. On request, these records must be made available to the Deutsches Institut für Bautechnik and to the responsible building authority (obersten Bauaufsichtsbehörde).

7 page 5 of 7 In case of unsatisfactory test results the manufacturer must take immediate action to resolve the deficiency. Construction products which do not comply with the requirements must be handled in a manner to ensure they cannot be mistaken for products complying with the requirements. After a problem has been resolved, the respective test must be repeated immediately; as far as this is technically feasible and necessary to verify that the deficiency has been eliminated Third-party controls In each manufacturing plant for the precast coupler (HEK2 T-100 and HEK2 L-100; steel element and counterplate), factory production control must be reviewed at regular intervals by an independent body, at least once a year. Independent inspection must include an initial test of the precast coupler and samples taken for random inspections. The respective approved inspection body is responsible for taking samples and testing. The extent, type and frequency of third-party control is as recorded in the document deposited with the Deutsches Institut für Bautechnik and the third-party monitoring authority. The results of the certification and third-party control must be kept for at least five years. On request, they must be made available by the appointed certification or inspection body to the Deutsches Institut für Bautechnik and to the responsible building authority (obersten Bauaufsichtsbehörde) Specifications for application of the object of approval Design and dimensioning General information The precast connection must be planned and dimensioned according to standard engineering practices. Verifiable calculations and construction drawings must be prepared taking the loads to be anchored into account. The design drawings must include the exact location of the precast coupler and information on the allowable bolts. When designing, the is to be regarded as similar to a double fastening using headed anchors. Details for the possible directions of loading (actions) for types HEK2 T-100 and HEK2 L-100 can be found in annex 2 and 3. The design of the precast coupler should be in accordance with DIN SPEC : " Design of fastenings for use in concrete" Part 4-2: Headed fasteners; (German version CEN/TS :2009) considering the following notes and additions. Verification of the immediate local force transfer to the concrete has been provided. Verification of the transfer of the loads to be anchored to the building component must be provided separately. Additional stresses that may occur in the precast coupler, in the connected component or in the component in which the precast coupler is anchored caused by constrained deformation must be taken into account (for example: temperature fluctuations). The load-bearing capacities of the precast elements and the anchoring elements in the second precast concrete element (e. g. sleeve anchor and bolt) are not subject of this approval and must be verified separately. The installation specifications and dimensions of the precast connector can be found in annex 5, table 6. (Spacing and edge distances, concrete component thickness and dimensions of the installation recess).

8 page 6 of Verification according to DIN SPEC : The characteristic values provided for verifications according to DIN SPEC : given in the tables in annexes 6 to 9 must be used. The provisions and illustrations of projected areas in annexes 6 to 10 must be observed for verification of concrete failure. Weakening of the concrete cross-section caused by the installation recess for the precast coupler must be taken into account in the verification. Supplementary reinforcement according to DIN SPEC : When supplementary reinforcement is used, it is not required to provide verification for concrete cone failure or concrete edge failure in the event of tensile or shear stress. The requirements of DIN SPEC : , sections and apply for supplementary reinforcement. Annex 11 must also be observed when detailing the supplementary reinforcement Application instructions Introduction The assembly and installation of the precast coupler must be in accordance with the design drawings prepared in accordance with section Installation of the precast coupler in the precast concrete element The precast coupler must be installed in accordance with the manufacturer's installation instructions and the information provided in annex 5. The required recesses for installation must be kept free by using the correct recess formers when pouring concrete. These are removed after the concrete has cured and hardened. The precast coupler must be securely fixed to the formwork to ensure it cannot move when installing the reinforcement or when pouring and compacting the concrete. The serration (see annexes 2 and 3) in the precast coupler must be protected from concrete. Extra care is required when compacting the concrete to avoid significant voids, particularly under the anchor flanges of the precast coupler Connection and fixing of the second precast concrete element Always observe the installation instructions provided by the manufacturer of the precast coupler for connection of precast concrete elements. The precast coupler counterplate is inserted into the installation recess together with the bolt. The counterplate must have full contact with the serrated area of the precast coupler, must engage properly with the serration and be secured by turning the bolt. The bolt may only be screwed into an approved anchor sleeve. Shimming is required under the precast coupler connector in accordance with annex 1 if a construction joint is planned between the precast concrete elements. The tightening torques for the bolts as specified in annex 5, table 5 must be observed.

9 page 7 of Checking the installation The responsible contractor or a designated site manager or a designated competent representative must be present when installing the precast coupler, and also on site for final assembly of the concrete elements. It is their responsibility to ensure the work is carried out properly and document the installation and assembly. They are also responsible for checking the position of the precast coupler and the optional supplementary reinforcement. The documentation must remain available on site during the construction period and submitted to inspection personnel on request. The documentation, with the delivery notes, must be kept by the contractor for at least five years after completion of the project. Beatrix Wittstock Referatsleiter (Head of Division)

10 Concrete element Connection joint Concrete element Shim/washer Counterplate Bolt br sef Sef Sleeve anchor Installation recess h ef h nom hr h h h R h nom h ef t 1,fix t 2,fix s ef b R = Concrete element thickness = Height of the installation recess = Embedment depth = Effective anchoring depth = Connection joint width = Clamping thickness, precast coupler with counterplate = Effective axial spacing of the anchorage bracket = Width of the installation recess Annex 1 Product description. Installed state D Langenfeld Fax:

11 HEK2 T-100 Precast coupler Serration Serration The serration can also be on both sides of the precast coupler. Table 1: Counterplate dimensions Thread sizes Ød f [mm] M16 17 M20 21 M24 25 Annex 2 Product description Dimensions, labels and load directions; HEK2 T-100 D Langenfeld Fax:

12 HEK2 L -100 Precast coupler Serration Serration The serration can also be on both sides of the precast coupler. Table 2: Counterplate dimensions Thread sizes Ød f [mm] M16 17 M20 21 M24 25 Annex 3 Product description Dimensions, labels and load directions; HEK2 L-100 D Langenfeld Fax:

13 Identification: Identification Example: HEK L -100 HEK: Article name L-100: Size Table 3: Identification and materials Part Element Material 1 Precast coupler (S235JR) acc. to DIN EN : , hot-dip galvanized 1) or / / / with f yk 240 N/mm² / f uk 500 N/mm² according to Z or DIN EN : Counterplate (S235JR) according to DIN EN : , hot-dip galvanized 1) or / / / with f yk 240 N/mm² / f uk 500 N/mm² according to Z or DIN EN : ) Zinc coating thickness 45 μm according to DIN EN ISO 1461: Table 4: Identification and materials of fasteners / supplementary reinforcement (not part of the approval) Element Material Bolts Washer and shims for joint installation Supplementary reinforcement Steel according to DIN EN ISO 898-1: , galvanized 1) or hot-dip galvanized 2), strength class 4.6, 5.6 or 8.8 Stainless steel / / / / / / / / / / / / / according to DIN EN ISO : , strength class A4-50, A4-70 or A (S235JR) acc. to DIN EN : , hot-dip galvanized 3) or mechanically plated 4) or / / / with f yk 240 N/mm² / f uk 500 N/mm² according to Z and DIN EN : B500A, B500B or stainless steel reinforcement B500NR 1) Zinc coating thickness 5 μm according to DIN EN ISO 4042: ) Zinc coating thickness 40 μm acc. to DIN EN ISO 10684: ) Zinc coating thickness 40 μm acc. to DIN EN ISO 1461: ) Zinc coating thickness 40 μm acc. to DIN EN ISO 12683: Layout/dimensions according to DIN SPEC : Annex 4 Product description, identification, material D Langenfeld Fax:

14 Table 5: Installation specifications Thread size d [mm] M16 M20 M24 Tightening torque T inst [Nm] Clamping thickness precast coupler and counterplate Bolt hole in washer or shim for joint installation as in annex 1 t 2,fix [mm] Ød f1,fix [mm] Table 6: Minimum edge distance, Minimum spacing to other precast couplers, minimum element thickness, dimensions of the installation recess, characteristic values of the precast couplers Minimal edge distance c 1,min [mm] 50 c 2,min [mm] 225 Minimal axial spacing s 1,min [mm] 250 s 2,min [mm] 450 Minimal element thickness h min [mm] 100 Maximum installation recess depth h R,max [mm] 125 Installation recess width b R [mm] 74 Depth of the recess for installation of the precast coupler t R [mm] 72 Effective anchoring depth h ef [mm] 83 Effective axial spacing of the anchor bracket s ef [mm] 200 Annex 5 Installation specifications and position in the precast concrete element D Langenfeld Fax:

15 Table 7: Characteristic values for tension loads Steel failure precast coupler Characteristic resistance N Rk,s [kn] 40.4 Respective partial safety factor ϒ Ms [-] 1.84 Pull out failure Characteristic resistance N Rk,p [kn] not relevant Concrete cone failure Factor to take into account the influence of load transfer mechanism in cracked and uncracked concrete k cr [-] 6.46 k ucr [-] 9.04 Characteristic spacing s cr,n [mm] 250 Characteristic edge distance c cr,n [mm] 125 Actual projected area of the idealized concrete cone, after deduction of the projected area of the installation recess. A c,n [mm²] See figure 1 Partial safety factor ϒ Mc [-] 1.50 Splitting failure Characteristic spacing s cr,sp [mm] 250 Characteristic edge distance c cr,sp [mm] 125 Factor to account for element thickness Ψ h,sp [-] Gl. 1 ) Partial safety factor ϒ Msp [-] ) h 2 h ef h ef c 1 2 h ef 2/3 2/3 Ψ h,sp = ( ) max { 1; ( ) } 2 Blow-out failure Factor to take into account the influence of load transfer mechanism in cracked and uncracked concrete Actual projected area of the idealized concrete cone, after deduction of the projected area of the installation recess. Ψ cr;n [-] 0.76 Ψ ucr;n [-] 1.06 A c,nb [mm²] See figure 2 Partial safety factor ϒ Mc [-] 1.50 Annex 6 Characteristic values for tension loads D Langenfeld Fax:

16 Table 7 (continued): Characteristic values for tension loads A c,n = (2 c cr,n + s ef ) (2 c cr,n ) A R,N (1) with A R,N = b R t R (2) ef A c,n = (2 c cr,n + s ef ) (c 1 + c cr,n ) A R,N (3) with A R,N = b R (c 1 + t R / 2) if c 1 < c cr,n (4) ef A c,n = (2 c cr,n + s ef ) 2 c 1 A R,N with A R,N = b R (c 1 + t R / 2) (5) (6) if c 1 < c cr,n ef Figure. 1: Examples of actual projected areas A c,n of the idealized concrete cone, including the projected area of the installation recess A R,N for different arrangements of precast couplers under tension loads. Annex 7 Characteristic values for tension loads D Langenfeld Fax:

17 Table 7 (continued): Characteristic values for tension loads ef A c,nb = (2 c 1 + h ef ) (s ef + 4c 1 ) A R,Nb (7) with A R,Nb = h R b R (8) if h R h ef 2c 1 h R h ef ef A c,nb = h (s ef + 4c 1 ) A R,Nb with A R,Nb = h R b R (9) (10) if h h ef < 2 c 1 h R h ef Figure. 2: Examples of actual projected areas A c,nb of the idealized concrete cone, including the projected area of the installation recess A R,Nb for different precast coupler arrangements in case of blow-out failure. Annex 8 Characteristic values for tension loads D Langenfeld Fax:

18 Table 8: Characteristic values for shear loads Steel failure Group factor k 2 [-] 1.0 Characteristic resistance V 1) Rk,s [kn] 43.2 Corresponding partial safety factor ϒ Ms [-] ) with a spacing between shear load and concrete surface of e 1 30 mm Concrete edge failure Effective anchor length under shear load l f [mm] 83 Effective outside diameter d nom [mm] 60 Factor to account for existing edge and stirrup reinforcement in cracked concrete Ψ re,v [-] 0.76 Factor to account for existing edge reinforcement ( Ø12mm) in cracked concrete. Ψ re,v [-] 0.91 Factor to account for existing edge and stirrup reinforcement with small axial spacing, dense mesh reinforcement or anchorings in non-cracked concrete Ψ re,v [-] 1.06 Actual projected area of the idealized concrete cone, after deduction of the projected area of the installation recess. A c,v [mm²] See figure 3 Partial safety factor ϒ Mc [-] 1.50 Concrete pry-out failure Factor k 3 [-] 1.0 Characteristic resistance with concrete cone failure N Rk,c [kn] Acc. to table 7 Partial safety factor ϒ Mc [-] 1.50 Annex 9 Characteristic values for shear loads D Langenfeld Fax:

19 1.5 c1 National technical approval Table 8 (continued): Characteristic values for shear loads A c,v = (3c 1 + s ef ) 1.5c 1 A R,V with A R,V = b R 1.5c 1 (11) (12) if h 1.5c c1 Sef 1.5 c1 s ef 3c 1 h R h 1.5 c1 A c,v = (3c 1 + s ef ) h A R,V with A R,V = b R h R (13) (14) if h 1.5c c1 s ef 3c 1 h R h Sef A c,v = (3c 1 + s ef ) 1.5c 1 A R,V with A R,V = b R 1.5c 1 (15) (16) if h 1.5c c1 s ef 3c 1 Sef 1.5 c1 h R 1.5c c1 Figure. 3: Examples of available projected areas A c,v of the idealized concrete breakout cone, including the projected area of the installation recess A R,V for different arrangements of precast couplers under shear loading. Annex 10 Characteristic values for shear loads D Langenfeld Fax:

20 Supplementary reinforcement under tensile load Installation recess Supplementary reinforcement under shear load Recess Installation recess Design value for anchorage length l bd according to DIN EN : in combination with DIN EN /NA: Annex 11 Detailing of supplementary reinforcement D Langenfeld Fax:

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