Hilti HIT-HY 70. Setting depth [mm] M6 M8 M10 M12 M8 M10 M12. Clay common (Dry pressed) f b b) 25 N/mm² L x H x B [mm] 230 x 110 x 76

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1 Hilti HIT-HY 70 Recommended loads a) F rec for brick breakout and pull out in [kn] Solid masonry: HIT-HY 70 with HIT-V, HAS, HAS-E and HIT-IC HIT-V, HAS, HAS-E Anchor size HIT-IC Base material Setting depth [mm] M6 M8 M10 M12 M8 M10 M12 Clay common (Dry pressed) f b b) 25 N/mm² L x H x B [mm] 230 x 110 x N rec [kn] - 2,5 3,0 4,0 2,5 3,0 4,0 Australia V rec [kn] - 2,0 2,0 2,0 2,0 2,0 2,0 Calduran Solid sand-lime brick f b b) 22 N/mm² L x H x B [mm] 437x198x100 Netherlands 80 N rec [kn] - - 2,5 c) 3,0 c) 3,0 c) 3,0 c) 4,0 c) V rec [kn] - - 3,0 4,0 3,0 3,0 4,0 Calduran Solid sand-lime brick f b b) 22 N/mm² L x H x B [mm] 437x298x N rec [kn] - - 2,5 c) 3,0 c) 3,0 c) 3,0 c) 4,0 c) Netherlands V rec [kn] - - 3,0 4,0 3,0 3,0 4,0 a) Recommended load values with consideration of a global safety factor γ global = 3,0: F rec = F Rk / γ global b) f b = brick strength c) The minimum value of brick break out and/or pull out given in the table and of pull out of one brick is decisive. 722

2 Hilti HIT-HY 70 Recommended loads F rec for brick breakout and pull out in [kn]: Hollow masonry: HIT-HY 70 with HIT-SC and HIT-V, HAS, HAS-E and HIT-IC HIT-V, HAS, HAS-E HIT-IC Anchor size M6 M8 M10 M12 M8 M10 M12 Base material Settin g depth [mm] HIT-SC 12x HIT-SC 16x HIT-SC 16x HIT-SC 18x HIT-SC 16x HIT-SC 18x HIT-SC 22x HIT-SC 22x Wienerberger Powerbrick f b b) 41 N/mm² L x H x B [mm] 285x135x135 Belgium N rec [kn] 1,0 1,25 1,25 1, V rec [kn] 1,5 2,0 2,0 2, N rec [kn] 1,5 1,75 1,75 2,0 1,75 2,0 2,0 2,0 V rec [kn] 1,5 3,0 3,0 3,0 3,0 3,0 4,0 4,0 Wienerberger Thermobrick f b b) 21 N/mm² L x H x B [mm] 285x135x138 Belgium Concrete hollow brick f b b) 6 N/mm² L x H x B [mm] 600x500x N rec [kn] 0,5 0,75 0,75 1, V rec [kn] 1,0 1,25 1,25 1, N rec [kn] 1,5 1,75 1,75 1,75 1,75 1,75 1,75 1,75 V rec [kn] 1,5 2,0 2,0 2,0 2,0 2,0 2,5 2,5 N rec [kn] 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 (Shell thickness 15 mm) Finland V rec [kn] 0,5 0,75 0,75 0,75 0,75 0,75 1,0 1,0 Leca typ 3 EN f b 3,0 N/mm² 80 N rec [kn] - 2,0 2,0 2,0 2,0 2,0 2,0 2,0 Sweden V rec [kn] - 1,2 1,2 1,2 1,2 1,2 2,0 2,0 a) Recommended load values with consideration of a global safety factor γ global = 3,0: F rec = F Rk / γ global b) f b = brick strength 723

3 Hilti HIT-HY 70 Recommended loads F rec for brick breakout and pull out in [kn]: Hollow masonry: HIT-HY 70 with HIT-SC and HIT-V, HAS, HAS-E and HIT-IC Values in brackets: mean ultimate loads F u,m [kn]: HIT-V, HAS, HAS-E HIT-IC Anchor size M6 M8 M10 M12 M8 M10 M12 Base material Concrete block f b b) 23 N/mm² L x H x B [mm] 390 x 190 x 120 (Shell thickness 25 mm) Japan Spancrete (Hollow Core Slab) f b b) 83 N/mm² L x H x B [mm] 1000 x1000 x125 Settin g depth [mm] N rec [kn] V rec [kn] N rec [kn] V rec [kn] N rec [kn] HIT-SC 12x 1,25 (8,1) 1,25 (6,7) 1,25 (9,0) 1,25 (7,1) 1,25 (8,5) HIT-SC 16x HIT-SC 16x HIT-SC 18x 1,5 1,5 2,0 1,5 (11,4) 1,5 (10,3) 1,5 1,5 HIT-SC 16x 1,5 2,0 1,5 (9,2) 1,5 1,5 1,5 1,5 (11,4) 2,0 (15,0) 2,0 2,5 2,5 (13,9) HIT-SC 18x HIT-SC 22x HIT-SC 22x ,0 2,0 2,0 (12,1) 1,5 2,0 2,0 (15,9) 2,5 2,5 (19,3) - (Shell thickness 27,5 mm) Japan V rec [kn] 1,25 (7,0) 2,5 (12,0) 2,5 2,5 2,5 (21,3) 2,5 3,0 (28,1) - Aereted concrete block f b b) 6 N/mm² L x H x B [mm] 1900 x 600 x 100 Special application: through fastening HIT-SC HIT-SC x85 x N rec [kn] 1,25 (8,1) 1,75 (8,6) 1,75 2, V rec [kn] 0,75 (6,3) 1,00 (9,2) 1,00 1, Japan a) Recommended load values with consideration of a global safety factor γ global = 3,0: F rec = F Rk / γ global b) f b = brick strength 724

4 Hilti HIT-HY 70 Recommended loads a) F rec for brick breakout and pull out in [kn] Solid masonry: HIT-HY 70 with HIT-V, HAS, HAS-E and HIT-IC Values in brackets: mean ultimate loads F u,m [kn]: HIT-V, HAS, HAS-E Anchor size Base material Aereted concrete block f b b) 6 N/mm² L x H x B [mm] 1900 x 600 x 100 Japan Setting depth [mm] HIT-IC M6 M8 M10 M12 M8 M10 M12 N rec [kn] , V rec [kn] ,0 - - N rec [kn] - - V rec [kn] - - 1,5 (7,3) 0,75 (4,2) 1,75-1,0 (4,7) - 1,75 (7,4) 1,0 (4,6) a) Recommended load values with consideration of a global safety factor γ global = 3,0: F rec = F Rk / γ global b) f b brick strength 0,75 (4,0) 1,0 (8,6) 1,75 (8,0) 1,0 (5,8) Design Influence of joints: If the joints of the masonry are not visible the recommended load N rec has to be reduced with the factor α j = If the joints of the masonry are visible (e.g. unplastered wall) following has to be taken into account: The recommended load N rec may be used only, if the wall is designed such that the joints are to be filled with mortar. If the wall is designed such that the joints are not to be filled with mortar then the recommended load N rec may be used only, if the minimum edge distance c min to the vertical joints is observed. If this minimum edge distance c min can not be observed then the recommended load N rec has to be reduced with the factor α j = The decisive resistance to tension loads is the lower value of N rec (brick breakout, pull out) and N max,pb (pull out of one brick). Pull out of one brick: The allowable load of an anchor or a group of anchors in case of pull out of one brick, N max,pb [kn], is given in the following tables: Clay bricks: N max,pb [kn] brick length l brick [mm] brick breadth b brick [mm] All other brick types: brick breadth b brick [mm] N max,pb [kn] ,1 1,6 2,7 3,3 4,1 4,9 brick 240 0,8 1,2 2,1 2,5 3,1 3, ,4 2,1 3,4 4,1 5,1 6,2 length 300 1,0 1,5 2,6 3,1 3,9 4, ,3 3,4 5,7 6,9 8,6 10,3 [mm] 500 1,7 2,6 4,3 5,1 6,4 7,7 l brick 725

5 Hilti HIT-HY 70 N max,pb = resistance for pull out of one brick l brick = length of the brick = breadth of the brick b brick l brick b brick N max,pb For all applications outside of the above mentioned base materials and / or setting conditions site tests have to be made for the determination of load values. Due to the wide variety of natural stones site tests have to be made for determine of load values. Materials Material quality HAS Part Threaded rod HAS-(E) Threaded rod HAS-(E)R Washer ISO 7089 Nut EN ISO 4032 Material Strength class 5.8, A 5 > 8% ductile steel galvanized 5 µm Stainless steel grade A4, A 5 > 8% ductile strength class 70, ; ; ; ; ; Steel galvanized, Stainless steel, ; ; ; ; ; Strength class 8, steel galvanized 5 µm Strength class 70, stainless steel grade A4, ; ; ; ; ; Strength class 70, high corrosion resistant steel, ; Material quality HIT-A Part Material HIT-AC rod Carbon steel strength 5.8; galvanized to min. 5 µm HIT-ACR rod Stainless steel, grade A4-70; ; ; HIT-AN rod Carbon steel strength 3.6; galvanized to min. 5 µm Material quality sleeves Part Material HIT-IG sleeve Carbon steel ; galvanized to min. 5 µm HIT-IC sleeve Carbon steel; galvanized to min. 5 µm HIT-SC sleeve PA/PP 726

6 Hilti HIT-HY 70 Setting Installation equipment Anchor size M6 M8 M10 M12 Rotary hammer TE2 TE16 Other tools blow out pump, set of cleaning brushes, dispenser Setting instruction in solid base materials 727

7 Hilti HIT-HY 70 Setting details: hole depth h 0 and effective anchorage depth in solid base materials Setting details HIT-AC, HIT-V, HIT-V, HAS, HAS-E, HAS-R Anchor size HIT-V HIT-V, HAS, HAS-E, HAS-R M8 M10 M12 M8 M10 M12 M16 Nominal diameter of drill bit d 0 [mm] Effective anchorage depth h ef [mm] Hole depth h 0 [mm] Minimum base material thickness h min [mm] Diameter of clearance hole in the fixture d f [mm] Minimum spacing a) s min [mm] Minimum edge distance a) c min [mm] Torque moment T inst [Nm] Filling volume [ml] a) In case of shear loads towards a free edge: c min = 200 mm A distance from the edge of a broken brick of c min = 200 mm is recommended, e.g. around window or door frames. HIT-IC HIS-N/RN 728

8 Hilti HIT-HY 70 Setting details HIT-IC Anchor size HIT-IC HIS-N/RN M8 M10 M12 M8 M10 M12 Nominal diameter of drill bit d 0 [mm] Effective anchorage depth h ef [mm] Hole depth h 0 [mm] Minimum base material thickness Diameter of clearance hole in the fixture Length of bolt engagement h min [mm] d f [mm] h S [mm] min. 10 max. 75 min. 8 max.20 min. 10 max.25 min 12 max.30 Minimum spacing a) s min [mm] Minimum edge distance a) c min [mm] Torque moment T inst [Nm] Filling volume [ml] a) In case of shear loads towards a free edge: c min = 20 cm A distance from the edge of a broken brick of c min = 20 cm is recommended, e.g. around window or door frames. 729

9 Hilti HIT-HY 70 Setting instruction in hollow base material using 330 ml foil pack 730

10 Hilti HIT-HY 70 Setting details: hole depth h 0 and effective anchorage depth in hollow base materials HAS / HIT-V with HIT-SC HIT-V, HAS Setting details HIT-V / HAS with sieve sleeve Anchor size M6 M8 M10 M12 Sieve sleeve HIT SC 12x50 12x85 16x50 16x85 16x50 16x85 18x50 18x85 22x50 22x85 Nominal diameter of drill bit d 0 [mm] Effective anchorage depth h ef [mm] Hole depth h 0 [mm] Minimum base material thickness h min [mm] Diameter of clearance hole in the fixture d f [mm] Minimum spacing a) s min [mm] Minimum edge distance a) c min [mm] Torque moment T inst [Nm] Filling volume [ml]

11 Hilti HIT-HY 70 Setting details: hole depth h 0 and effective anchorage depth in hollow base materials HIT-IC with HIT-SC HIT-IC Setting details HIT-IC with sieve sleeve Anchor size HIT-IC M8 M10 M12 Sieve sleeve HIT SC 16x85 18x85 22x85 Nominal diameter of drill bit d 0 [mm] Effective anchorage depth h ef [mm] Hole depth h 0 [mm] Minimum base material thickness h min [mm] Diameter of clearance hole in the fixture d f [mm] Length of bolt engagement h S [mm] min. 10 max. 75 Minimum spacing a) s min [mm] Minimum edge distance a) c min [mm] Torque moment T inst [Nm] Filling volume [ml] a) In case of shear loads towards a free edge: c min = 20 cm A distance from the edge of a broken brick of c min = 20 cm is recommended, e.g. around window or door frames. 732

12 Hilti HIT-HY

13 HRT-WH Rail anchor with Hilti HVU or Hilti HIT-RE 500 HRT-WH Rail anchor with Hilti HVU or Hilti HIT-RE 500 Fastening system Benefits Hilti HRT-WH Hilti HIT-RE ml foil pack (also available as 500 ml and 1400 ml foil pack) Hilti HVU foil capsule - for fastening rails to concrete slab track - for bottom-up (post-installed) construction method - verified for axle loads up to 250 kn - high electrical insulation values concerning stray currency - corrosion resistance -- additional sizes and accessoiries available - chisel point - setting through rib plate possible - different support stiffness - complete installation and system portfolio - 2 and 4 anchor configuration Approvals / certificates Description Authority / Laboratory No. / date of issue Rail anchor testing Technical University of Munich Report no / Application field covered Selection of Hilti rail anchors for fastening rails to concrete track slab, based on axle load (A), stiffness (c) and thickness (t) of elastic pad Anchor * Elastic pad, t (mm)** Tramway A = 100 kn Metro A = 135 kn Commuter A = 170 kn Full Size A = 250 kn HRT-WH M22x V max 60 km/h 80 km/h 120 km/h 250 km/h Criteria R min (V max )*** 70 m (25 km/h) 200 m (60 km/h) 350 m (80 km/h) 3000 m Support spacing 750 mm 750 mm 700 mm 650 mm * Configuration of base plate (support): -> = Anchors per support ** Stiffness of elastic pad: t = 10mm -> c = kn/mm t = 20mm -> c = kn/mm *** Indicative value: V max is a function of the existing superelevation (cant) and the lateral acceleration. 734

14 HRT-WH Rail anchor with Hilti HVU or Hilti HIT-RE 500 Setting details HRT WH 22x200 Hilti mortar type HVU M20x110 HIT-RE 500 Nominal diameter of drill bit d 0 [mm] Nominal drilling depth h 1 [mm] Embedment depth h nom [mm] Minimum member thickness h min [mm] Length of anchor l [mm] Maximum fixing height t fix [mm] Spring deflection S inst [mm] Spring length L st [mm] Wrench size S inst [mm] Curing time for general conditions HVU capsule Temperature of the base material Curing time before anchor can be fully loaded t cure 20 C to 40 C 20 min 10 C to 19 C 30 min 0 C to 9 C 1 h -5 C to - 1 C 5 h Curing time for general conditions HIT-RE 500 Temperature of the base material Curing time before anchor can be fully loaded t cure 40 C 4h 30 C to 39 C 8h 20 C to 29 C 12h 15 C to19 C 24h 10 C to 14 C 48h 5 C to 9 C 72h 735

15 HRT-WH Rail anchor with Hilti HVU or Hilti HIT-RE 500 Specification HRT-WH Rail Anchor Stopnut (M22-SW32) Material: 5S (DIN 985,EN ISO 7040,DIN 267), blue zinc plated: Fe/Zn 5B (DIN 50961) Fixing device: Nylon, torque force 68 Nm Service temperature: -50 C up to 120 C Washer (24/39/3 mm) Material: Steel grade 4.6 (DIN 126), blue zinc plated: Fe/Zn 5B (DIN 50961) Double coilspring Fe 6 Material: Spring steel, Int. Ø= 24 mm, Ext. Ø= 44 mm, original height: 22 mm, compressed height: 17 mm, cathaphoretic coating 7 μ Collar Bush (Sealing Lip) Material: Plastic, int. Ø= 22 mm, ext. Ø= 36 mm Volume resitivity: 1.2 x Ω cm Flexible lower portion of collar bush to prevent any excess injection mortar HIT-RE or foilcapsule (HVU) from restricting managed system compression Anchor Body (Ø 22 mm) High grade steel (DIN/ISO 898/1) Blue zinc plated: Fe/Zn 10B (DIN 50961) Designed to withstand high axle loads of 250 kn, cone heads fits setting tool TE-Y-E M20 to set the anchor with the HVU foil capsule Thread (M22) To provide adequate bonding with foil capsule HVU or HIT-RE 500 mortar and transfer tension loading to the lower part of the concrete slab Chisel Point To provide adequate mixing of the HVU foil capsule and to transfer the torsionloading via the mortar to the concrete 736

16 HRT-WH Rail anchor with Hilti HVU or Hilti HIT-RE

17 HRT Rail anchor with Hilti HIT-RE 500 HRT Rail anchor with Hilti HIT-RE 500 Fastening system Benefits Hilti HRT Hilti HIT-RE ml foil pack (also available as 500 ml and 1400 ml foil pack) - for fastening rails to concrete slab track - for bottom-up (post-installed) construction method - verified for axle loads up to 170 kn - high electrical insulation values concerning stray currency - corrosion resistance - for diamond core drilled holes with roughening - additional sizes and accessoiries available - setting through rib plate possible - different support stiffness - complete installation and system portfolio - 2 and 4 anchor configuration Approvals / certificates Description Authority / Laboratory No. / date of issue Rail anchor testing Technical University of Munich Report no. 1584a / Report no / Application field covered Selection of Hilti rail anchors for fastening rails to concrete track slab, based on axle load (A), stiffness (c) and thickness (t) of elastic pad Anchor * Elastic pad, t (mm)** Tramway A = 100 kn Metro A = 135 kn Commuter A = 170 kn Full Size A = 250 kn HRT M22x V max 60 km/h 80 km/h 120 km/h 250 km/h Criteria R min (V max )*** 70 m (25 km/h) 200 m (60 km/h) 350 m (80 km/h) 3000 m Support spacing 750 mm 750 mm 700 mm 650 mm * Configuration of base plate (support): -> = Anchors per support ** Stiffness of elastic pad: t = 10mm -> c = kn/mm t = 20mm -> c = kn/mm t = 30mm -> c = 5-10 kn/mm *** Indicative value: V max is a function of the existing superelevation (cant) and the lateral acceleration. 738

18 HRT Rail anchor with Hilti HIT-RE 500 Setting details HRT WH 22x200 Anchor size M22 Hilti mortar type HIT-RE 500 Nominal diameter of drill bit d 0 [mm] Nominal drilling depth h 1 [mm] Embedment depth h nom [mm] Minimum member thickness h min [mm] Length of anchor l [mm] Maximum fixing height t fix [mm] Spring deflection S inst [mm] Spring length L st [mm] Wrench size S inst [mm] Curing time for general conditions HIT-RE 500 Temperature of the base material Curing time before anchor can be fully loaded t cure 40 C 4h 30 C to 39 C 8h 20 C to 29 C 12h 15 C to19 C 24h 10 C to 14 C 48h 5 C to 9 C 72h 739

19 HRT Rail anchor with Hilti HIT-RE 500 Specification Hilti HRT Rail Anchor Stopnut (M22-SW32) Material: 5S (DIN 985,EN ISO 7040,DIN 267), blue zinc plated: Fe/Zn 5B (DIN 50961) Fixing device : Nylon, torque force 68 Nm Service temperature: -50 C up to 120 C Spring 35mm Wire grade: C7 (DIN 2076), yellow zinc plated: Fe/Zn 7C (DIN 50961) Spring rate: 373 N/mm Deformation: 8mm 3.0 kn compression Collar Bush (Sealing Lip) Material: Plastic, int. Ø= 22 mm, ext. Ø= 36 mm Volume resitivity: 1.2 x Ω cm Flexible lower portion of collar bush to prevent any excess injection mortar from restricting managed system compression Anchor Body (Ø 22 mm) Material: High grade carbon steel (DIN/ISO 898/1) Yellow zinc plated: Fe/Zn 10C (DIN 50961) Designed to withstand high dynamic loads resulting from train axle loads up to 170 kn Knurling To provide adequate bonding with HIT-RE 500 mortar and transfer tension and torsion loadings to the lower part of the concrete slab Centering Bush To centrally locate the anchor within the cored hole to provide an uniforme wrapping of the anchor rod with the injection mortar. To avoid the contact between the concrete slab reinforcement and the anchor body 740

20 HRT Rail anchor with Hilti HIT-RE

21 HRC / HRC-DB Rail anchor with Hilti HIT-RE 500 HRC / HRC-DB Rail anchor with Hilti HIT-RE 500 Fastening system Hilti HRC Hilti HRC-DB Hilti HIT-RE ml foil pack (also available as 500 ml and 1400 ml foil pack) Benefits - for fastening rails to concrete slab track - for bottom-up (post-installed) construction method - verified for axle loads up to 250 kn - high electrical insulation values concerning stray currency - corrosion resistance - additional sizes and accessoiries available - horizontal adjustment when used with ex-center collar bush - different support stiffness - complete installation and system portfolio - 2 and 4 anchor configuration Approvals / certificates Description Authority / Laboratory No. / date of issue Rail anchor testing Technical University of Munich Report no. 1584b / Report no. 1584d / Report no / EBA approval a) German Federal Railway Office lozb (561/00) / a) EBA approval (HRC-DB), shimming up to 25mm to take account of settlement Application field covered Selection of Hilti rail anchors for fastening rails to concrete track slab, based on axle load (A), stiffness (c) and thickness (t) of elastic pad Anchor * Elastic pad, t (mm)** Tramway A = 100 kn Metro A = 135 kn Commuter A = 170 kn Full Size A = 250 kn HRC M22x HRC-DB M22x mm shim V max 60 km/h 80 km/h 120 km/h 250 km/h Criteria R min (V max )*** 70 m (25 km/h) 200 m (60 km/h) 350 m (80 km/h) 3000 m Support spacing 750 mm 750 mm 700 mm 650 mm * Configuration of base plate (support): -> = Anchors per support ** Stiffness of elastic pad: t = 10mm -> c = kn/mm t = 20mm -> c = kn/mm t = 30mm -> c = 5-10 kn/mm *** Indicative value: V max is a function of the existing superelevation (cant) and the lateral acceleration. 742

22 HRC / HRC-DB Rail anchor with Hilti HIT-RE 500 Setting details HRC M22x215 / HRC-DB M22x225 Anchor HRC M22 HRC-DB M22 Hilti mortar type HIT-RE 500 Nominal diameter of drill bit d 0 [mm] Nominal drilling depth h 1 [mm] Embedment depth h nom [mm] Minimum member thickness h min [mm] Length of anchor l [mm] Maximum fixing height t fix [mm] Spring deflection S inst [mm] Spring length L st [mm] Wrench size S inst [mm] Curing time for general conditions HIT-RE 500 Temperature of the base material Curing time before anchor can be fully loaded t cure 40 C 4h 30 C to 39 C 8h 20 C to 29 C 12h 15 C to19 C 24h 10 C to 14 C 48h 5 C to 9 C 72h 743

23 HRC / HRC-DB Rail anchor with Hilti HIT-RE 500 Specification Hilti HRC Rail Anchor Stopnut (M22-SW32) Material: 5S (DIN 985,EN ISO 7040,DIN 267), blue zinc plated: Fe/Zn 5B (DIN 50961) Fixing device : Nylon, torque force 68 Nm Service temperature: -50 C up to 120 C Spring 35mm Wire Grade: C7 (DIN 2076), Yellow Zinc Plated: Fe/Zn 7C (DIN 50961) Spring Rate: 373 N/mm Deformation: 8mm 3.0 kn compression Collar Bush (Sealing Lip) Material: Plastic, int. Ø= 22 mm, ext. Ø= 36 mm Volume Resitivity: 1.2 x Ω cm Flexible lower portion of collar bush to prevent any excess injection mortar from restricting managed system compression Anchor Body (Ø 22 mm) Material: High grade carbon steel (DIN/ISO 898/1), yellow zinc plated: Fe/Zn 10C (DIN 50961) Designed to withstand high dynamic loads resulting from train axle loads up to 250 kn Knurling To provide adequate bonding with HIT-RE/HY mortar and transfer tension and torsion loadings to the lower part of the concrete slab Centering Bush To centrally locate the anchor within the cored hole to provide an uniforme wrapping of the anchor rod with the injection mortar. To avoid the contact between the concrete slab reinforcement and the anchor body 744

24 HRC / HRC-DB Rail anchor with Hilti HIT-RE

25 HRA Rail anchor with Hilti HIT-RE 500 or HVU-G/EA glass capsule HRA Rail anchor with Hilti HIT-RE 500 or HVU-G/EA glass capsule Fastening system Hilti HRA, type a Hilti HRA, type b Hilti HIT-RE ml foil pack (also available as 500 ml and 1400 ml foil pack) Hilti HVU-G/EA glass capsule Benefits - for fastening rails to concrete slab track - for bottom-up (post-installed) construction method - verified for axle loads up to 250 kn - high electrical insulation values concerning stray currency - corrosion resistance -- with spring or double coil spring - additional sizes and accessoiries available - different support stiffness - complete installation and system portfolio - 2 and 4 anchor configuration Approvals / certificates Description Authority / Laboratory No. / date of issue Rail anchor testing Technical University of Munich Report no. 1584c / Report no. 1584d / Application field covered Selection of Hilti rail anchors for fastening rails to concrete track slab, based on axle load (A), stiffness (c) and thickness (t) of elastic pad Anchor * HRA M22x220a M22x220b M22x270 M22x310 Elastic pad, t (mm)** Tramway A = 100 kn Metro A = 135 kn Commuter A = 170 kn Full Size A = 250 kn V max 60 km/h 80 km/h 120 km/h 250 km/h Criteria R min (V max )*** 70 m (25 km/h) 200 m (60 km/h) 350 m (80 km/h) 3000 m Support spacing 750 mm 750 mm 700 mm 650 mm * Configuration of base plate (support): -> = Anchors per support ** Stiffness of elastic pad: t = 10mm -> c = kn/mm t = 20mm -> c = kn/mm t = 30mm -> c = 5-10 kn/mm *** Indicative value: V max is a function of the existing superelevation (cant) and the lateral acceleration. 746

26 HRA Rail anchor with Hilti HIT-RE 500 or HVU-G/EA glass capsule Setting details HRA M22 Anchor HRA M22 220a 220b Hilti mortar type HIT-RE 500 HVU-G/EA glass capsule Nominal diameter of drill bit d 0 [mm] 35 Nominal drilling depth h 1 [mm] Embedment depth h nom [mm] Minimum member thickness h min [mm] 160 Length of anchor l [mm] Maximum fixing height t fix [mm] Spring deflection S inst [mm] Spring length L st [mm] Wrench size S inst [mm] 38 Curing time for dry conditions HVU-G/EA glass capsule Temperature of the base material Curing time before anchor can be fully loaded t cure 30 C 20 min 20 C to 29 C 30 min 10 C to19 C 1,5 h -5 C to 9 C 6 h The curing time data for water satutated anchorage bases must be doubled Curing time for general conditions HIT-RE 500 Temperature of the base material Curing time before anchor can be fully loaded t cure 40 C 4h 30 C to 39 C 8h 20 C to 29 C 12h 15 C to19 C 24h 10 C to 14 C 48h 5 C to 9 C 72h 747

27 HRA Rail anchor with Hilti HIT-RE 500 or HVU-G/EA glass capsule Specification Hilti HRA Rail Anchor, type a Stopnut (M22-SW38) Material; 5S (DIN 982), Zinc plated Fe/Zn 7C (DIN 50961) Spring (35mm/55mm) Wire Grade: C7 (DIN 2076), yellow zinc plated: Fe/Zn 7C (DIN 50961) Spring Rate: 373 N/mm Washer (W 24 x39 x 3 mm) Zinc plated Fe/ZN 5B (DIN 50961) Collar Bush Material; Plastic, int Ø= 28 mm, ext Ø= 35.5 mm Electrical Insulation; 3.5 x Ω Plastic Wrapping Designed to eliminate stray current loss. Ext Ø= 32 mm Anchor Body High grade carbon steel. Designed to withstand high dynamic loads resulting from train axle loads up to 250 kn Bonding Ribs To provide adequate bonding with injection mortar HIT-RE 500 mortar and HVU-G/EA capsule Chisel Point To provide torsional resistance and ensure mixing of HVU-G/EA capsule 748

28 HRA Rail anchor with Hilti HIT-RE 500 or HVU-G/EA glass capsule Hilti HRA Rail Anchor, type b Stopnut (M22-SW38) Material; 5S (DIN 982), Zinc plated Fe/Zn 7C (DIN 50961) Double coilspring Fe 6 (22 mm) Spring steel, Int = 24mm, Ext = 44 mm, Original Heigth: 22mm Compressed Heigth: 17mm, Cathaphoretic coatings 7 µ Washer (W 24 x39 x 3 mm) Zinc plated Fe/ZN 5B (DIN 50961) Collar Bush Material; Plastic, int Ø= 28 mm, ext Ø= 35.5 mm Electrical Insulation; 3.5 x Ω Plastic Wrapping Designed to eliminate stray current loss. Ext Ø= 32 mm Anchor Body High grade carbon steel. Designed to withstand high dynamic loads resulting from train axle loads up to 250 kn Bonding Ribs To provide adequate bonding with injection mortar HIT-RE 500 mortar and HVU-G/EA capsule Chisel Point To provide torsional resistance and ensure mixing of HVU-G/EA capsule 749

29 HRT-I Rail anchor with Hilti HIT-RE 500 HRT-I Rail anchor with Hilti HIT-RE 500 Fastening system Hilti HRT-I (rigid) Hilti HRT-I (elastic) Hilti HIT-RE ml foil pack (also available as 500 ml and 1400 ml foil pack) Benefits - for fastening rails to concrete slab track - for bottom-up (post-installed) construction method - verified for axle loads up to 250 kn - high electrical insulation values concerning stray currency - corrosion resistance - with spring (elastic) or spring washer (rigid) - additional sizes and accessoiries available - bolt removable - different support stiffness - complete installation and system portfolio - 2 and 4 anchor configuration Approvals / certificates Description Authority / Laboratory No. / date of issue Rail anchor testing Technical University of Munich Report no / Report no / Application field covered Selection of Hilti rail anchors for fastening rails to concrete track slab, based on axle load (A), stiffness (c) and thickness (t) of elastic pad Anchor * Elastic pad, t (mm)** Tramway A = 100 kn Metro A = 135 kn Commuter A = 180 kn Full Size A = 250 kn HRT- I M22 HRT- I M V max 60 km/h 80 km/h 120 km/h 250 km/h Criteria R min (V max )*** 70 m (25 km/h) 200 m (60 km/h) 300 m (80 km/h) 3000 m Support spacing 750 mm 750 mm 700 mm 650 mm * Configuration of base plate (support): -> = Anchors per support ** Stiffness of elastic pad: t = 10mm -> c = kn/mm t = 20mm -> c = kn/mm t = 30mm -> c = 5-10 kn/mm *** Indicative value: V max is a function of the existing superelevation (cant) and the lateral acceleration. 750

30 HRT-I Rail anchor with Hilti HIT-RE 500 Setting details HRT-I-M22x190/HRT-I M27x240 Anchor HRT I M22 HRT I M27 Hilti mortar type HIT-RE 500 Nominal diameter of drill bit d 0 [mm] Nominal drilling depth h 1 [mm] Embedment depth h nom [mm] Minimum member thickness h min [mm] Length of anchor l [mm] Maximum fixing height t fix [mm] Spring deflection S inst [mm] Spring length L st [mm] Wrench size S inst [mm] Curing time for general conditions HIT-RE 500 Temperature of the base material Curing time before anchor can be fully loaded t cure 40 C 4h 30 C to 39 C 8h 20 C to 29 C 12h 15 C to19 C 24h 10 C to 14 C 48h 5 C to 9 C 72h 751

31 HRT-I Rail anchor with Hilti HIT-RE 500 Specification Hilti HRT-I (elastic) Rail Anchor Bolt (M22, SW32) Material: 10.9 (DIN 931,EN ISO 4014,), hot dipped galvanized Head: Hexagonal Bolt (M27, SW41) Material: 8.8 (DIN 931,EN ISO 4014), blue zinc plated: Fe/Zn 10B (DIN 50961) Head: Hexagonal Spring (35 mm) Wire Grade: C7 (DIN 2076), Yellow Zinc Plated: Fe/Zn 7C (DIN 50961), spring Rate: 373 N/mm, deformation: 8mm Spring (40 mm) Wire Grade: C7 (DIN 2076), yellow zinc plated: Fe/Zn 7C (DIN 50961), spring Rate: 300 N/mm, deformation: 10mm 3.0 kn compression Collar Bush (Sealing Lip) Material: Plastic, Int. Ø= 23 mm, Ext. Ø= 36 mm Volume resitivity: 1.2 x Ω cm Flexible lower portion of collar bush to prevent any excess injection mortar HIT-RE on the anchor shaft Sealingwasher (22.0/36.0/5.0) To prevent any excess injection mortar HIT-RE on the anchor shaft. Insert Body Ø 28 mm Material: carbon steel (DIN/ISO 898/1), blue zinc plated: Fe/Zn 10B (DIN 50961), designed for an embedment of 120 mm Collar Bush (Sealing Lip) Material: Plastic, int. Ø= 28 mm, ext. Ø= 36 mm Volume Resitivity: 1.2 x Ω cm Flexible lower portion of collar bush to prevent any excess injection mortar HIT-RE on the anchor shaft Sealingwasher (27.0/36.0/5.0) To prevent any excess injection mortar HIT-RE on the anchor shaft. Insert Body Ø 33 mm Material: carbon steel (DIN/ISO 898/1), blue zinc plated: Fe/Zn 10B (DIN 50961), designed for an embedment of 150 mm 752

32 HRT-I Rail anchor with Hilti HIT-RE 500 Hilti HRT-I (rigid) Rail Anchor Bolt (M22, SW32) Material: 10.9 (DIN 931,EN ISO 4014,), hot dipped galvanized Head: Hexgonal Spring washer (22.5/35.9/4.0) Wire Grade: C7 (DIN 2076), blue zinc plated: Fe/Zn 10B (DIN 50961), deformation: 4mm Washer (23.0/44.0/4.0) Material: 4.8 (DIN 125), blue zinc plated: Fe/Zn 10B (DIN 50961) Int. Ø= 23 mm, Ext. Ø= 44 mm Collar Bush Material: Plastic, int. Ø: 22.2 mm, ext. Ø: 24.2 mm; collar Ø: 44 mm, height: 2/12/14 mm to provide insulation against stray current. Sealingwasher (22.0/36.0/5.0) PE-Hard foam LD29, black, to prevent any excess injection mortar HIT-RE on the anchor shaft. Insert Body (Ø 28 mm) Material: carbon steel (DIN/ISO 898/1), blue zinc plated: Fe/Zn 10B (DIN 50961), designed for an embedment of 120 mm Bolt (M27, SW41) Material: 8.8 (DIN 931,EN ISO 4014), blue zinc plated: Fe/Zn 10B (DIN 50961) Head: Hexgonal Spring washer (27.5/41.5/5.0) Wire Grade: C7 (DIN 2076), blue zinc plated: Fe/Zn 10B (DIN 50961), deformation: 4mm Washer (28.0/49.0/4.0) Material: 4.8 (DIN 125), blue zinc plated: Fe/Zn 10B (DIN 50961) Int. Ø= 28 mm, Ext. Ø= 49 mm Collar Bush Material: Plastic, int. Ø: 27.2 mm, ext. Ø: 30.5 mm; collar Ø: 49 mm, height: 2/12/14 mm to provide insulation against stray current. Sealingwasher (27.0/36.0/5.0) PE-Hard foam LD29, black, to prevent any excess injection mortar HIT-RE on the anchor shaft. Insert Body (Ø 33 mm) Material: carbon steel (DIN/ISO 898/1), blue zinc plated: Fe/Zn 10B (DIN 50961), designed for an embedment of 150 mm 753

33 HRT-IP Rail Anchor for cast-in/top down construction method HRT-IP Rail Anchor for cast-in/top down construction method Fastening system Hilti HRT IP (elastic) Hilti HRT-IP (rigid) Benefits - for fastening rails to concrete slab track - for top-down (cast-in) construction method - verified for axle loads up to 250 kn - high electrical insulation values concerning stray currency - corrosion resistance - with spring (elastic) or spring washer (rigid) - additional accessoiries available different support stiffness - fixing plate to support assembling - bolt removable - identical system for postinstalled/bottom up construction method available (HRT-I) Rehabilitation - 2 and 4 anchor configuration Approvals / certificates Description Authority / Laboratory No. / date of issue Rail anchor testing Technical University of Munich Report no / Report no /

34 HRT-IP Rail Anchor for cast-in/top down construction method Application field covered Selection of Hilti rail anchors for fastening rails to concrete track slab, based on axle load (A), stiffness (c) and thickness (t) of elastic pad Anchor * Elastic pad, t (mm)** Tramway A = 100 kn Metro A = 135 kn Commuter A = 180 kn Full Size A = 250 kn HRT- IP M HRT IP M27 30 V max 60 km/h 80 km/h 120 km/h 250 km/h Criteria R min (V max )*** 70 m (25 km/h) 200 m (60 km/h) 300 m (80 km/h) 3000 m Support spacing 750 mm 750 mm 700 mm 650 mm * Configuration of base plate (support): -> = Anchors per support ** Stiffness of elastic pad: t = 10mm -> c = kn/mm t = 20mm -> c = kn/mm t = 30mm -> c = 5-10 kn/mm *** Indicative value: V max is a function of the existing superelevation (cant) and the lateral acceleration. - Setting details HRT-IP M22x190/HRT-IP M27x240 Anchor HRT IP M22 HRT IP M27 Embedment depth h nom [mm] Minimum member thickness h min [mm] Length of anchor l [mm] Maximum fixing height t fix [mm] Spring deflection S inst [mm] Spring length L st [mm] Wrench size S inst [mm]

35 HRT-IP Rail Anchor for cast-in/top down construction method Specification Hilti HRT-IP (elastic) Rail Anchor Bolt (M22, SW32) Material: 10.9 (DIN 931,EN ISO 4014,), hot dipped galvanized Head: Hexgonal Spring (35 mm) Wire Grade: C7 (DIN 2076), yellow zinc plated: Fe/Zn 7C (DIN 50961), Spring rate: 373 N/mm, deformation: 8mm Bolt (M27, SW41) Material: 8.8 (DIN 931,EN ISO 4014), Blue Zinc Plated: Fe/Zn 10B (DIN 50961) Head: Hexgonal Spring (40 mm) Wire Grade: C7 (DIN 2076), Yellow Zinc Plated: Fe/Zn 7C (DIN 50961), spring Rate: 300 N/mm, deformation: 10mm 3.0 kn compression Collar Bush Material: Plastic, int. Ø= 27 mm, ext. Ø= 36 mm Volume resitivity: 1.2 x Ω cm Collar Bush Material: Plastic, int. Ø= 28 mm, ext. Ø= 36 mm Volume resitivity: 1.2 x Ω cm Sealingwasher (22.0/36.0/5.0) To prevent any excess concrete on the anchor shaft Fixing plate (26.2/50.0/2.0) To fix the rigid pad (HDPE) and elastic pad to the support assembling during concrete slab pouring. Insert Body (Ø 28 mm) Material: carbon steel (DIN/ISO 898/1), blue zinc plated: Fe/Zn 10B (DIN 50961), designed for an embedment of 120 mm Sealingwasher (27.0/36.0/5.0) To prevent any excess concrete on the anchor shaft Fixing plate (31.2/50.0/2.0) To fix the rigid pad (HDPE) and elastic pad to the support assembling during concrete slab pouring. Insert Body (Ø 33 mm) Material: Carbon steel (DIN/ISO 898/1), blue zinc plated: Fe/Zn 10B (DIN 50961), designed for an embedment of 150 mm 756

36 HRT-IP Rail Anchor for cast-in/top down construction method Hilti HRT-IP (rigid) Rail Anchor Bolt (M22, SW32) Material: 10.9 (DIN 931,EN ISO 4014,), hot dipped galvanized Head: Hexgonal Spring washer (22.5/35.9/4.0) Wire Grade: C7 (DIN 2076), blue zinc plated: Fe/Zn 10B (DIN 50961), deformation: 4mm Washer (23.0/44.0/4.0) Material: 4.8 (DIN 125), blue zinc plated: Fe/Zn 10B (DIN 50961) Int. Ø= 23 mm, Ext. Ø= 44 mm Collar Bush Material: Plastic, int. Ø: 22.2 mm, ext. Ø: 24.2 mm; collar Ø: 44 mm, height: 2/12/14 mm to provide insulation against stray current. Sealingwasher (22.0/36.0/5.0) PE-Hard foam LD29, black, to prevent any excess injection mortar HIT-RE on the anchor shaft. Fixing plate (26.2/50.0/2.0) To fix the rigid pad (HDPE) and elastic pad to the support assembling during concrete slab pouring. Insert Body (Ø 28 mm) Material: carbon steel (DIN/ISO 898/1), blue zinc plated: Fe/Zn 10B (DIN 50961), designed for an embedment of 120 mm or Bolt (M27, SW41) Material: 8.8 (DIN 931,EN ISO 4014), Blue Zinc Plated: Fe/Zn 10B (DIN 50961) Head: Hexgonal Spring washer (27.5/41.5/5.0) Wire Grade: C7 (DIN 2076), blue zinc plated: Fe/Zn 10B (DIN 50961), deformation: 4mm Washer (28.0/49.0/4.0) Material: 4.8 (DIN 125), blue zinc plated: Fe/Zn 10B (DIN 50961) Int. Ø= 28 mm, Ext. Ø= 49 mm Collar Bush Material: Plastic, int. Ø: 27.2 mm, ext. Ø: 30.5 mm; collar Ø: 49 mm, height: 2/12/14 mm to provide insulation against stray current. Sealingwasher (27.0/36.0/5.0) PE-Hard foam LD29, black, to prevent any excess injection mortar HIT-RE on the anchor shaft. Fixing plate (31.2/55.0/2.0) To fix the rigid pad (HDPE) and elastic pad to the support assembling during concrete slab pouring. Insert Body (Ø 33 mm) Material: carbon steel (DIN/ISO 898/1), blue zinc plated: Fe/Zn 10B (DIN 50961), designed for an embedment of 150 mm 757

37 Post-installed rebar connections 758

38 Post-installed rebar connections Post-installed rebar connections Basics, design and installation Injection mortar systems for post-installed rebars 759

39 Post-installed rebar connections Basics, design and installation of post installed rebars Content 1 Basics of post installed rebar connections Definition of rebar Advantages of post-installed rebar connections Application examples Anchorage and Splice Bond of Cast-in Ribbed Bars Specifics of Post-Installed Reinforcing Bars Design of Post-Installed Reinforcement Loads on Reinforcing Bars Approval Based ETA/EC2 Design Method Application Range Design of Development and Overlap Length with Eurocode Design Examples General information for design example HIT-Rebar Design Method Splitting Design Strut and Tie Model for Frame Nodes Design Examples Load Case Fire Fatigue of bonded-in reinforcement for joints Seismic design of structural post-installed rebar Corrosion behaviour Design Programme PROFIS Rebar References Installation of Post-Installed Reinforcement Joint to be roughened Drilling Standard Drilling Hole cleaning Injection and bar installation Installation instruction Mortar consumption estimation for post-installed rebars

40 Basics, design and installation of post-installed rebars 1 Basics of post installed rebar connections 1.1 Definition of rebar Reinforcement anchorages or splices that are fixed into already cured concrete by Hilti HIT injection adhesives in drilled holes are called Post-installed rebar connections as opposed to normal, so called cast-in reinforcement. Many connections of rebars installed for good detailing practice will not require specific design considerations. But post-installed rebars which become part of the structural system have to be designed as carefully as the entire structure. While European Technical Approvals prove that in basic load situations, post-installed rebars behave like cast-in bars, a number of differences needs to be considered in special design situations such as fire or load cases where hooks or bends would be required for cast-in anchorages. The following chapters are intended to give the necessary information to safely design and specify post-installed reinforcement connections. structural rebar situations: anchorage node in equilibrium and splice anchor situation This section of the Fastening Technology Manual deals with reinforcement connections designed according to structural reinforced concrete design principles. The task of structural rebars is to take tensile loads and since concrete failure is always brittle, reinforced concrete design assumes that concrete has no tensile strength. Therefore structural rebars can end / be anchored in only two situations: - the bar is not needed anymore (the anchorage is a node in equilibrium without tensile stress in concrete) - another bar takes over the tensile load (overlap splice) Situations where the concrete needs to take up tensile load from the anchorage or where rebars are designed to carry shear loads should be considered as rebar used as anchors and designed according to anchor design principles as given e.g. in the guidelines of EOTA [3] Unlike in anchor applications, reinforcement design is normally done for yielding of the steel in order to obtain ductile behaviour of the structure with a good serviceability. The deformations are rather small in correlation to the loads and the crack width limitation is around w k ~0.3mm. This is an important factor when considering resistance to the environment, mainly corrosion of the reinforcement. In case of correct design and installation the structure can be assumed as monolithic which allows us to look at the situation as if the concrete was poured in one. Due to the allowed high loads the required embedment depth can be up to 80d (diameter of rebar). 1.2 Advantages of post-installed rebar connections With the use of the Hilti HIT injection systems it is possible to connect new reinforcement to existing structures with maximum confidence and flexibility. design flexibility reliable like cast in horizontal, vertical and overhead form work simplification defined load characteristics simple, high confidence application 761

41 Basics, design and installation of post-installed rebars 1.3 Application examples Post installed rebar connections are used in a wide range of applications, which vary from new construction projects, to structure upgrades and infrastructure requalifications. Post-installed rebar connections in new construction projects Diaphragm walls Slab connections Misplaced bars Vertical/horizontal connections Post-installed rebar connections in structure upgrades Wall strengthening New slab constructions 762

42 Basics, design and installation of post-installed rebars Joint strengthening Cantilevers/balconies Post-installed rebar connections in infrastructure requalifications Slab widening Structural upgrade Slab strengthening Sidewalk upgrade 763

43 Basics, design and installation of post-installed rebars 1.4 Anchorage and Splice Development Length Reinforced concrete is often designed using strut and tie models. The forces are represented by trusses and the nodes of these trusses have to be in equilibrium like in the figure to the left: the concrete compression force (green line), the support force (green arrow) and the steel tensile force (blue). The model assumes that the reinforcing bar can provide its tensile force on the right side of the node while there is no steel stress at all on the left side, i.e. the bar is not needed any more on the left side of the node. Physically this is not possible, the strut and tie model is an idealization. The steel stress has to be developed on the left side of the node. This is operated by bond between steel and concrete. For the bar to be simple support able to develop stress it needs to be extended on the left side of the node. This extension is called development length or anchorage length. The space on the left side of the node shown in the figure above is not enough to allow a sufficient development of steel stress by bond. Possible approaches to solve this problem are shown in the figure below: either an extension of the concrete section over the support or a reduction of the development length with appropriate methods. Typical solutions are hooks, heads, welded transverse reinforcement or external anchorage. Typical solutions for anchoring of the reinforcement Overlap Splices Overlap splices In case that the equilibrium of a node cannot be established without using the tensile capacity of the concrete, the tensile force of a (ending) bar must be transmitted to other reinforcement bars. A common example is starter bars for columns or walls. Due to practical reasons foundations are often built with rebars much shorter than the final column height, sticking out of the concrete. The column reinforcement will later be spliced with these. The resulting tension load in the column reinforcement due to bending on the column will be transferred into the starter bars through an overlap splice. Forces are transmitted from one bar to another by lapping the bars. The detailing of laps between bars shall be such that: - the transmission of the forces from one bar to the next is assured - spalling of the concrete in the neighbourhood of the joints does not occur - large cracks which affect the performance of the structure do not develop 764

44 Basics, design and installation of post-installed rebars 1.5 Bond of Cast-in Ribbed Bars General Behaviour For ribbed bars, the load transfer in concrete is governed by the bearing of the ribs against the concrete. The reacting force within the concrete is assumed to be a compressive strut with an angle of 45. For higher bond stress values, the concentrated bearing forces in front of the ribs cause the formation of cone-shaped cracks starting at the crest of the ribs. The resulting concrete keyed between the ribs transfer the bearing forces into the surrounding concrete, but the wedging action of the ribs remains limited. In this stage the displacement of the bar with respect to the concrete (slip) consists of bending of the keys and crushing of the concrete in front of the ribs. Load transfer from ribbed bars into concrete The bearing forces, which are inclined with respect to the bar axis, can be decomposed into directions parallel and perpendicular to the bar axis. The sum of the parallel components equals the bond force, whereas the radial components induce circumferential tensile stresses in the surrounding concrete, which may result in longitudinal radial (splitting / spalling) cracks. Two failure modes can be considered: Bond Failure Bond failure is caused by pull-out of the bar if the confinement (concrete cover, transverse reinforcement) is sufficient to prevent splitting of the concrete cover. In that case the concrete keys are sheared off and a sliding plane around the bar is created. Thus, the force transfer mechanism changes from rib bearing to friction. The shear resistance of the keys can be considered as a criterion for this transition. It is attended by a considerable reduction of the bond stress. Under continued loading, the sliding surface is smoothed due to wear and compaction, which will result in a further decrease of the bond stress, similar to the case of plain bars. Bond failure of ribbed bars Splitting failure: Bond splitting failure is decisive if the radial cracks propagate through the entire cover. In that case the maximum bond stress follows from the maximum concrete confinement, which is reached when the radial cracks have penetrated the cover for about 70%. Further crack propagation results in a decrease of the confining stresses. At reaching the outer surface these stresses are strongly reduced, which results in a sudden drop of the bond stress. Influence of spacing and cover on splitting and spalling of concrete Splitting In most cases the reinforcement bars are placed close to the surface of the concrete member to achieve good crack distribution and economical bending capacity. For splices at wide spacing (normally in slabs, left part of figure left), the bearing capacity of the concrete depends only on the thickness of the concrete cover. At narrow spacing (normally in beams, right part of figure above) the bearing capacity depends on the spacing and on the thickness of the cover. In the design codes the reduction of bearing capacity of the cover is taken into account by means of multiplying factors for the splice length. Load Transfer in Overlap Splices Load transfer at lap splices The load transfer between bars is performed by means of compressive struts in the concrete, see figure left. A 45 truss model is assumed. The resulting perpendicular forces act as splitting forces. The splitting forces are normally taken up by the transverse reinforcement. Small splitting forces are attributed to the tensile capacity of the concrete. The amount of the transverse or tie reinforcement necessary is specified in the design codes. 765

45 Basics, design and installation of post-installed rebars 1.6 Specifics of Post-Installed Reinforcing Bars General Behaviour The load transfer for post-installed bars is similar to cast in bars if the stiffness of the overall load transfer mechanism is similar to the cast-in system. The efficiency depends on the strength of the adhesive mortar against the concentrated load near the ribs and on the capacity of load transfer at the interface of the drilled hole. In many cases the bond values of post-installed bars are higher compared to cast in bars due to better performance of the adhesive mortar. But for small edge distance and/or narrow spacing, splitting or spalling forces become decisive due to the low tensile capacity of the concrete. Post-Installed Reinforcement Approvals There are European Technical Approvals for post-installed rebar connections. Systems getting such approvals have to be assessed according to the EOTA technical guideline TR023 [2] (available in the EOTA website). Requirements for a positive assessment are an installation system providing high installation quality for deep holes and an adhesive fulfilling the test requirements of the guideline TR023. Obtaining the approval is basically the proof that the post-installed rebars work at least as well as cast-in rebars (with respect to bond strength and displacement); consequently, the design of the rebar anchorage is performed according to structural concrete design codes, in the case of Europe this is Eurocode 2 [1]. High Quality Adhesives Required Assessment criteria EOTA TR023 [2] specifies a number of tests in order to qualify products for post-installed rebar applications. These are the performance areas checked by the tests: 1. bond strength in different strengths of concrete 2. substandard hole cleaning 3. Wet concrete 4. Sustained load and temperature influence 5. Freeze-thaw conditions 6. Installation directions 7. Maximum embedment depth 8. Avoidance of air bubbles during injection 9. Durability (corrosion, chemical attack) Approvals with or without exceptions If an adhesive fulfills all assessment criteria of EOTA TR023, rebar connections carried out with this adhesive can be designed with the bond strength and minimum anchorage length according to Eurocode 2 [1] as outlined in section 2.2 of this document. Adhesives which do not fully comply with all assessment criteria can still obtain an approval with exceptions. - If the bond strength obtained in tests does not fulfil the specified requirements, then bond strengths lower than those given by Eurocode 2 shall be applied. These values are given in the respective ETA. - If it cannot be shown that the bond strength of rebars post-installed with a selected product and cast-in rebars in cracked concrete (w=0.3mm) is similar, then the minimum anchorage length l b,min and the minimum overlap length l 0,min shall be increased by a factor

46 Basics, design and installation of post-installed rebars 2 Design of Post-Installed Reinforcement There are two design methods which are supported by Hilti: 1. Based on the approval (ETA) for the mortar system qualified according to EOTA TR023 [2] which allows to use the accepted structural code Eurocode 2 EN :2011 [1], chapters 8.4: anchorage of longitudinal reinforcement and 8.7 Laps and mechanical couplers taking into account some adhesive specific parameters. This method is called ETA/EC2 Design Method paragraph 2.2 gives an overview of the design approach and design examples, technical data from the rebar approvals can be found in section For applications which are not covered by ETA/EC2 Design Method, the design approach of Eurocode 2 has been extended on the basis of extensive internal as well as external research [6-8] as well as assessments [9]. This method is called Hit Rebar Design Method which offers an extended range of applications (please see section 2.3 for an overview of the design approach as well as design examples. 2.1 Loads on Reinforcing Bars Strut and Tie Model Strut-and-tie models are used to calculate the load path in reinforced concrete members. Where a non-linear strain distribution exists (e.g. supports) strut-and-tie models may be used {Clause 6.5.1(1), EC2: EN :2011}. Joint to be roughened Crack limitation Strut-and-tie models consist of struts representing compressive stress fields, of ties representing the reinforcement and of the connecting nodes. The Tension cord Tension ties forces in the elements of a strut-and-tie Strut-and-tie-model model should be determined by maintaining the equilibrium with the applied loads in ultimate limit state. The ties of a strut-and-tie model should coincide in position and direction with the corresponding reinforcement {Clause 5.6.4, EC2: EN :2011 Analysis with strut and tie models}. In modern concrete design codes the strut angle θ can be selected within certain limits, roughly between 30 and 60. Many mod ern concrete design codes show a figure similar to the following: The equilibrium equations in horizontal direction gives the force in the reinforcement: Compression cord and strut (concrete) F sl M y N x Vz = + + z 2 cotθ 2 truss model in modern codes 767

47 Basics, design and installation of post-installed rebars 2.2 Approval Based ETA/EC2 Design Method Application Range The principle that rebars are anchored where they are not needed any more (anchorage) or where the force is taken over by another bar (splice) and the fact that only straight rebars can be post-installed lead to the application range shown by the figures taken from EOTA TR023 [2]: Application range according to EOTA TR

48 Basics, design and installation of post-installed rebars All other applications lead to tensile stress in the concrete. Therefore, the principle works like cast-in would not be true any more. Such cases must be considered with specific models exceeding the approval based approach to post-installed rebar connections Design of Development and Overlap Length with Eurocode 2 The following reflect the design relevant sections from EOTA TR023, chapter 4 Assumptions under which the fitness of use is to be assessed and from the specific European Technical Approvals: Design method for post-installed rebar connections - The post-installed rebar connections assessed according to this Technical Report shall be designed as straight cast-in-place rebars according to EC2 using the values of the design bond resistance f bd for deformed bars as given in the relevant approval. - Overlap joint for rebars: For calculation of the effective embedment depth of overlap joints the concrete cover at end-face of the post-installed rebar c 1 shall be considered: l v l 0 + c 1 with: l 0 = required lap length c 1 = concrete cover at end-face of bonded-in rebar - The definition of the bond region in EC2 is valid also for post-installed rebars. - The conditions in EC2 concerning detailing (e.g. concrete cover in respect to bond and corrosion resistance, bar spacing, transverse reinforcement) shall be complied with. - The transfer of shear forces between new and old concrete shall be designed according to EC2 [1]. Additional provisions - To prevent damage of the concrete during drilling the following requirements have to be met: Minimum concrete cover: c min = ,06 l v 2d s (mm) for hammer drilled holes c min = ,08 l v 2d s (mm) for compressed air drilled holes The factors 0,06 and 0,08 should take into account the possible deviations during the drilling process. This value might be smaller if special drilling aid devices are used. Furthermore the minimum concrete cover given in clause , EC2: EN : 2004 shall be observed. Minimum clear spacing between two post-installed bars a = 40 mm 4d s - To account for potentially different behaviour of post-installed and cast-in-place rebars in cracked concrete, in general, the minimum lengths l b,min and l o,min given in the EC 2 for anchorages and overlap splices shall be increased by a factor of 1.5. This increase may be neglected under certain conditions. The relevant approval states under which conditions the factor can be neglected for a specific adhesive. Preparation of the joints - The surface of the joint between new and existing concrete should be prepared (roughing, keying) according to the envisaged intended use according to EC2. - In case of a connection being made between new and existing concrete where the surface layer of the existing concrete is carbonated, the layer should be removed in the area of the new reinforcing bar (with a diameter d s +60mm) prior to the installation of the new bar. Transverse reinforcement front cover c 1 The requirements of transverse reinforcement in the area of the post-installed rebar connection shall comply with clause 8.7.4, EC2: EN :

49 Basics, design and installation of post-installed rebars Design Examples a) End support of slab, simply supported h = 300 Slab: l n = 4,50m, Q k = 20 kn/m 2, h = 300 mm, d = 260 mm Wall: h = 300 mm d = 260 h = 300 Concrete strength class: C20/25, dry concrete Reinforcement: f yk = 500 N/mm2, γ s = 1,15 a 1 = 130 a l = d = 260 Loads: G k = 25 kn/m 3 h = 7,5 kn/m²; S d = (1,50 Q d + 1,35 G k ) = 40,1 kn/m² l n = 4,50 m Structural analysis (design forces): 2 M Ed = S d l n / 8 V Ed = S d l n / 2 = 102 knm/m = 90,3 kn/m Bottom reinforcement required at mid span: A s,rqd,m = (M sd γ s ) / (0,9 d f yk ) = 998 mm²/m Reinforcement provided at mid span: 16, s = 200 mm A s,prov,m = 1005 mm²/m Bottom reinforcement at support: Tension force to be anchored: F E = V Ed a l /(0,9d) = 100 kn/m {Clause (2), EC2: EN :2004} Steel area required: A s,rqd = F E γ s / f yk = 231 mm²/m Minimum reinforcement to be anchored at support: A s,min = k c k f ct,eff A s /σ s = 0,4 1 2, /500 = 264 mm²/m {Clause 7.3.2(2), EC2: EN :2011} A s,min = 0, = 499 mm 2 /m {Clause (1), EC2: EN :2011} A s,min = 0, = 251 mm²/m {Clause (1), EC2: EN :2011} Decisive is 499 mm²/m reinforcement provided: 12, s = 200 mm A s,prov = 565 mm²/m; Installation by wet diamond core drilling: Hilti HIT-RE 500 is suitable adhesive (see Tech data, sect ) Basic anchorage length {EC2: EN :2004, section 8.4.3}: l b,rqd = (d s / 4) x (σ sd / f bd ) with: d s = diameter of the rebar = 12 mm σ sd = calculated design stress of the rebar = (A s,rqd / A s,prov ) (f yk /γ s ) = (231 / 565) (500 / 1,15) = 177 N/mm² f bd = design value of bond strength according to corresponding ETA (= 2,3 N/mm²) l b,rqd = (12 / 4) x (177 / 2,3) = 231 mm Design anchorage length {EC2: EN :2011, section 8.4.4}: l bd = α 1 α 2 α 3 α 4 α 5 l b,rqd l b,min with: l b,rqd as above α 1 = 1,0 for straight bars α 2 = 1 0,15(c d ø)/ø (0,7 α 2 1,0) α 2 is for the effect of concrete cover, in this case half the clear spacing: c d =(200-12)/2=94mm α 2 = 0,7 Straight bars, c d = min (a/2, c 1, c) α 3 = 1,0 because of no transverse reinforcement α 4 = 1,0 because of no welded transverse reinforcement α 5 = 1,0 influence of transverse pressure is neglected in this example l bd = 0,7 231 = 162 mm 770

50 Basics, design and installation of post-installed rebars minimum anchorage length {Clause 8.4.4(1), EC2: EN :2011}: l b,min = max {0,3l b,rqd ; 10φ; 100mm} = 120 mm l bd controls drill hole length l ef = 162 mm Top reinforcement at support: 300 d = 260 a 1 = 130 a l = 260 l n = 6.50 m h = 300 Minimum reinforcement: 25% of bottom steel required at mid-span {Clause (2), EC2: EN :2004} A s,req = 0,25 x 988 = 247 mm 2 /m A s,min = 0,4 x 1 x 2,2 x 150 x 1000 / 500 = 264 mm 2 /m {Clause 7.3.2(2), EC2: EN :2004} Decisive is 264 mm²/m reinforcement provided: 12, s = 333 mm; A s,prov = 339 mm²/m As the design stress is 0, the minimum anchorage length applies for the upper reinforcement. As in the above calculation for bottom reinforcement: l b,min = max {0,3l b,rqd ; 10φ; 100mm} = 120 mm Therefore, drill hole length l ef = 120mm If wet diamond core drilling is used {Clause 8.4.4(1), EC2: EN :2011}: l b,min = max {0,3l b,rqd ; 10φ; 100mm} 1,5 = 180 mm (as wet diamond core drilling is used, the minimum values according do EC2 have to be multiplied by 1,5, see tech data) -> in this case the minimum length will control, drill hole length l ef = 180mm for upper and lower layers 771

51 Basics, design and installation of post-installed rebars b) splice on support General information for design example l v l 0 M Ed = 80kNm/m V Ed = 50kN/m h = 300 Bending moment: M Ed =80 knm/m; shear: V Ed = 50 kn/m Slab: cover cast-in bars c c = 30 mm (top, bottom); cover new bars: c n = 50mm h = 300 mm; Top reinforcement (new and existing): φ16, s = 200 mm; A s,prov = 1005 mm 2 /m; cover to face c 1 = 30 mm Bottom reinforcement: φ10, s=200 mm; A s,prov =393 mm 2 /m Concrete strength class: C25/30 w = 250 Properties of reinforcement: f yk = 500 N/mm 2 Fire resistance: R60 (1 hour), Light weight plaster for fire protection: t p =30 mm; maximum steel stress in fire σ Rd,fi = 322 N/mm 2 Hilti HIT-RE 500 Cast-in reinforcement top l 0,ci = α 1 α 2 α 3 α 5 α 6 l b,rqd,ci l 0,min η 1 = (d- φ/2 > 250mm) 0.7 poor bond condition z ci = 239 mm (from static calculation) A s,req = (MEd/z) (γs/fyk)=(80/0.239) (1.15/0.5) = 770 mm 2 /m σ sd = (A s,rqd / A s,prov ) (f yk /γ s ) = (770 / 1005) (500 / 1.15) = 333 N/mm 2 f bd = 2.25 η f 2/3 ck /γ c = /3 /1. 5= 1.89 N/mm 2 (ETA-08/0105) l b,rqd,pi = (φ / 4) (σ sd / f bd ) = (16 / 4) (333 / 1,89) = 705 mm α 1 = 0,7 hooked end of cast-in bars α 2 = (1 0,15(c d ø)/ø 0.7) = (30-16)/16 = 0,87 α 3 = 1,0 no transverse reinforcement α 5 = 1,0 no transverse pressure α 6 = 1,5 splice factor l 0,min = max{0,3 1,5 705; 15 16; 200} = 317 mm l 0,ci = 0,70 0,87 1,5 705 = 643 mm Post-installed reinforcement top The required design lap length l 0 shall be determined in accordance with EC2: EN :2004, section 8.7.3: l 0,pi = α 1 α 2 α 3 α 5 α 6 l b,rqd,pi l 0,min d = h-c n -φ/2 = /2 = 242 mm η 1 = (d- φ/2 < 250mm) 1,0 good bond condition z = 228 mm (from static calculation) A s,req = (MEd/z) (γs/fyk)=(80/0.228) (1,15/0,5) = 807 mm 2 /m σ sd = (A s,rqd / A s,prov ) (f yk /γ s ) = (807 / 1005) (500 / 1,15) = 349 N/mm 2 f bd = design value of bond strength according to = 2,7 N/mm 2 (ETA-08/0105) l b,rqd,pi = (φ / 4) (σ sd / f bd ) = (16 / 4) (349 / 2,7) = 516 mm 772