European Technical Approval ETA 11/0281

Transcription

1 Istituto per le Tecnologie della Costruzione Consiglio Nazionale delle Ricerche Via Lombardia San Giuliano Milanese Italy tel: Telefax: Autorizzato e notificato conformemente all articolo 10 della Direttiva 89/106/CEE del Consiglio del 21 dicembre 1988, relativa all avvicinamento delle disposizioni legislative, regolamentari ed amministrative degli Stati membri, relativa ai prodotti da costruzione. Membro EOTA European Technical Approval ETA 11/0281 (English language translation; the original version is in Italian) Nome commerciale Trade name Beneficiario Holder of approval Tipologia del prodotto da costruzione ed utilizzo Generic type and use of construction product Validità da/a Validity from/to Indirizzo stabilimento di produzione Manufacturing plant ECOSISM ECOSISM S.r.l. Via Rivella, 22 I Battaglia Terme (PD) - Italy Sistema non portante di casseratura a rimanere in pannelli i di EPS Non load-bearing permanent shuttering kits based on EPS panels / Via Rivella, 22 I Battaglia Terme (PD) - Italy Questo Benestare Tecnico Europeo contiene: This European Technical Approval contains: 15 pagine, inclusi 6 allegati 15 pages, including 6 annexes European Organisation for Technical Approvals Organisation pour l Agrément Technique Européen

2 I LEGAL BASIS AND GENERAL CONDITIONS 1. This European Technical Approval is issued by Istituto per le Tecnologie della Costruzione - Consiglio Nazionale delle Ricerche (called ITC-CNR in the following text) in accordance with: - Council Directive 89/106/EEC of 21 December 1988 on the approximation of laws, regulations and administrative provisions of Member States relating to Construction Products 1, modified by the Council Directive 93/68/EEC of 22 July and by Regulation EC n. 1882/2003 of the European Parliament and of the Council 3 ; - DPR 246 of 21/04/93 4 and DPR 499 of 10/12/97 5, concerning the implementation of Council Directive 89/106/EEC; - Common Procedural Rules for Requesting, Preparing and Granting of European Technical Approvals set out in the Annex of Commission Decision 94/23/EC 6 ; - Guideline for European Technical Approval of Non-load-bearing permanent shuttering systems based on hollow blocks or panels of insulating materials and sometimes concrete ETA Guideline 009 Edition June ITC-CNR is authorised to check whether the provisions of this European Technical Approval are met. Checking may take place in the manufacturing plant. Nevertheless, the responsibility for the conformity of the products to this European Technical Approval and for their fitness for the intended use remains with the Holder of the European Technical Approval. 3 This European Technical Approval is not to be transferred to manufacturers or agents of manufacturers other than those indicated on cover page, or manufacturing plants other than those as laid down in the context of this European Technical Approval. 4. This European Technical Approval may be withdrawn by ITC-CNR, according to Article 5 (1) of Council Directive 89/106/EEC. 5. Reproduction of this European Technical Approval including transmission by electronic means shall be in full. However, partial reproduction can be made with the written consent of ITC- CNR. In this case partial reproduction has to be designated as such. Texts and drawings of advertising brochures shall not contradict or misuse the European Technical Approval. 6. The European Technical Approval (ETA) is issued by the Approval Body in its official language. This version fully corresponds to the version used by EOTA for circulation. Translations into other languages have to be designated as such. 1 Official Journal of the European Communities N L 40, , p.12 2 Official Journal of the European Communities N L 220, , p.1 3 Official Journal of the European Union N 1 L 220, , p.1 4 Gazzetta Ufficiale della Repubblica Italiana n. 170 of Gazzetta Ufficiale della Repubblica Italiana n. 21 of 10/12/ Official Journal of the European Communities N L 17, , p.34 ETA 11/0281 Page 1 of 15

3 II SPECIFIC CONDITIONS OF THE EUROPEAN TECHNICAL APPROVAL 1 DEFINITION OF PRODUCT, INTENDED USE AND ASSUMED WORKING LIFE The system ECOSISM is a non load-bearing shuttering kit based on preassembled expanded polystyrene (EPS) panels of one storey height applicable as formwork for plain and reinforced concrete walls cast in-situ. The concrete infill structural pattern is of continuous type according to the definition given in 2.2 of ETAG 009 Edition The expanded polystyrene (EPS) elements are mechanically inserted into a 3D wire-rod reinforcement cage. The reinforcement cage consists of horizontal and vertical electrically welded steel rods of Ø2 mm (see Annex 1). The panels are 100 to 1200 mm wide (steps of 100 mm, the last step can be adjusted to 1 cm), 150 to mm high (steps of 150 mm, the last step can be adjusted to 5 cm). The thickness of the outer shuttering panels ranges from 40 to 200 mm while that of the inner shuttering panels ranges from 40 to 100 mm (see Annex 2). The concrete layer of the wall can be produced in the thickness range from 95 to 340 mm. The total thickness of the shuttering can vary from 200 to 530 mm according to the dimensions of the wire spacers and/or the EPS elements (see Annex 3). The vertical edges of each EPS panel are flat. Prior to pouring concrete, adjacent units are wired together, vertically plumbed and propped on one side (see Annex 4). The props are kept in place until the concrete has reached the initial design strength. Renderings, coatings and plasters are not part of this ETA. No special elements are used for making joints, window and door openings, which are obtained by inserting (or not) EPS elements into the 3D steel cage (see Annexes 5 and 6). Finally, after concrete has cured, the metal wire rods inside the openings, doors and windows, shall be removed. ETA Holder s design and installation instructions are deposited with ITC-CNR. Use categories according to Eurocode 1 are: A, B, C, D and E. For the intended use it is essential to protect the formwork against effects of the weather. The ETA Holder declares an assumed average working life of at least 50 years. The indication on the working life cannot be interpreted as a guarantee given by the producer, but has to be regarded only as a means for choosing the right products in relation to the expected economically reasonable working life of the works. 1.1 Intended use Ecosism kit is a non load-bearing permanent shuttering system intended to be used only for the construction of internal and external walls (according to types definition given in 2.2 of ETAG 009 Edition 2002) above or below ground. The walls could be load-bearing or non load-bearing, including those which are subject to fire regulation. The load-bearing concrete walls obtained with the kit are not covered by this ETA and they are subject to the applicable national regulation, under the direct responsibility of the designer. 2. CHARACTERISTICS OF PRODUCT AND METHODS OF VERIFICATION 2.1 General This ETA is issued for ECOSISM on the basis of admitted information/data, deposited with ITC-CNR, which identify the kit that was assessed and judged. Changes to the production process of the components or to the components of the kit which could result in deposited information/data being incorrect, shall be notified to ITC-CNR before they are introduced and ITC-CNR will assess whether or not such changes affect the ETA and, if so, whether further assessment and/or alteration to the ETA shall be necessary 7. 7 The ETA Holder may change, under his own responsibility, some of the suppliers of a component, but only provided that the characteristics and the performances of the new components and the final performances of the system do not change at all. These changes must be fully recorded within the Factory Production Control documents in order to grant full traceability. ETA 11/0281 Page 2 of 15

4 The characteristics of the components and of the system not mentioned in this ETA nor in the Annexes shall correspond to the respective values laid down in the Technical Documentation of this ETA, checked by ITC-CNR. The insulating materials used in the system are CE marked according to the products standard (EN 13163) and they are delivered in the form of boards and have to be cut to the size of the inserts to make the shuttering panels. The requirements are reported in the Table Methods of verification The identification tests and the assessment of fitness for use of ECOSISM were carried out in compliance with ETAG 009 Edition June ER 1: MECHANICAL RESISTANCE AND STABILITY Type of structural pattern According to the definition given in 2.2 of ETAG 009 Edition 2002, the type of structural pattern is continuous. Efficiency of filling The efficiency of filling has been determined by erection of trial structures. According to the experience of the ETA Holder, the concrete properties shall fulfil the following requirements: - concrete according to UNI EN 206-1: the slump class of fresh concrete S4 - the flow class of fresh concrete according to of ETAG 009 Edition concrete shall be compacted by means of a shaking device - the aggregate sizes shall be according to EN maximum 20 mm - strength developing according to UNI EN 206-1:2001, Table 12 - the maximum height of filling shall not be greater than 1,00 m and the next filling with concrete shall be made after 1 hours at least. The requirements according to ETAG 009 Edition 2002, chapter are met satisfactorily. Possibility of steel reinforcement The geometry of the 3D cage is compatible with correct installation and provide appropriate covering (additional spacer wire welded 15mm from EPS) of the reinforcement, as resulted from drawings examination and from practice tests (see Annex 1). The requirements according to ETAG 009 Edition 2002, chapter are met satisfactorily ER 2: SAFETY IN CASE OF FIRE Reaction to fire The reaction to fire of the ECOSISM shuttering kit materials (EPS and steel) was classified in accordance with of ETAG 009 Edition 2002, with reference to the EN standard. Steel: Class A1 (decision 96/603/EC and following amendment) EPS: Class E (supplier attestation of conformity) Fire resistance According to Annex C, Table 1, depending on the thickness of the concrete core, the walls meet the criteria listed in the column Continuous type load bearing wall, when exposed to the fire on only one side. The preconditions for the use of the mentioned table are: - The design of the building has to take into consideration the secondary effects of fire. Especially constraints, introduced by thermal strain, should be sufficiently low and appropriate building joints should be foreseen. The rules, valid in the place of use, apply. Structural requirements on work in normal conditions, valid in the place of use, may require ETA 11/0281 Page 3 of 15

5 larger dimensions. Concrete cover for the reinforcement has to be observed according to the rules valid in the place of use. - A normal weight concrete as defined in EN 206-1:2006 or EN :2005 Eurocode2. -The strength of concrete shall be between C16/20 and C50/60 according to EN 206-1: The walls shall be plastered/rendered on both sides. The mortar for plastering/rendering or for sealing shall be based on inorganic aggregates, gypsum, cement or lime or on suitable combinations of these three binders. Fire resistance REI (minutes) Minimum thickness of the concrete core (mm) Tab.1: Fire resistance depending on the thickness of the concrete core With the minimum thickness of the continuous concrete core of 95 mm, the fire resistance class of load-bearing walls according to ETAG 009, Annex C, Table 1, is No Performance Determined respectively EI 60 for non load-bearing walls. NOTE: The classification of the walls constructed with the shuttering system regarding to fire resistance are valid for walls without openings (for windows or doors for example ER 3: HYGIENE, HEALTH AND ENVIRONMENT Content and/or release of dangerous substances The manufacturer has presented a written declaration in which he states that the shuttering kit does not contain any dangerous substances as listed in EU database. In addition to the specific clauses relating to dangerous substances contained in this European Technical Approval, there may be other requirements applicable to the products falling within its scope (e.g. transposed European legislation and national laws, regulations and administrative provisions). In order to meet the provisions of the EU Construction Products Directive, these requirements need also to be complied with, when and where they apply. Water vapour permeability The tabulated design value of water vapour diffusion resistance coefficient of expanded polystyrene, in accordance with the European standard EN ISO 10456:2008 "Building materials and products - Hygrothermal properties - Tabulated design values and procedures for determining declared and design thermal values" is 60. The values for the water vapour diffusion resistance of concrete depending on density and type and of the different inserts of insulating material are tabulated in EN ISO Water absorption The requirements according to ETAG 009 Edition 2002, chapter are met satisfactorily. Watertightness Not relevant ER4: SAFETY IN USE Bond strength and resistance to impact load Not relevant. ETA 11/0281 Page 4 of 15

6 Resistance to filling pressure The main property related to the resistance to concrete pressure is the tensile strength of the 3D steel cage. The other parameter to consider to prevent EPS elements from bursting is the compressive resistance of EPS. Both parameters were evaluated, by calculation and testing, and they are considered satisfactory. Furthermore, the resistance to filling pressure has been determined by observation of lower sections of the shuttering leaves, in the 3 m-high trial structure, and it proved to be satisfactory. Considering that the ETA Holder specifications envisage a 1,00 m filling height and that the next cast shall be made not before 1 hour, the requirements according to ETAG 009 Edition 2002, chapter are met satisfactorily. Safety against personal injury by contact Delivered on site, the shuttering kit has sharp points. As there is a certain risk of limited personal injuries, handling on site shall be done with gloves and protective glasses. The requirements according to ETAG 009 Edition 2002, chapter are met satisfactorily ER5: PROTECTION AGAINST NOISE Airborne sound insulation The No Performance Determined option was adopted, as envisaged in ETAG 009 Edition 2002 table ER 6: ENERGY ECONOMY AND HEAT RETENTION Thermal resistance The EPS is delivered with the CE Mark in accordance with the products standards, in the form of boards; they have to be cut to the size of the insert and have to meet at least the following requirements: Material Standard Requirements EPS EPS EN T1 L1- W1-S1-P3-DS(N)5-BS200-CS(10) 70 Only on demand EPS EN T1 L1- W1-S1-P3-DS(N)5- EN BS200-CS(10)150 EPS graphite EPS EN T2 L2- W2-S2-P4-DS(N)2-BS115-CS(10) 70- R100-WL(T)2 Tab.2: insulating materials requirements An example of the thermal resistance RD of the wall obtained with Ecosism shuttering system type10+5nes37 has been calculated according to EN ISO 6946:2008 Thermal characteristics: Mortar finishing (1 cm) Mortar rendering (1 cm) EPS (10 cm) Concrete core (20 cm) EPS (5 cm) Mortar rendering (1 cm) Mortar finishing (1 cm) λ= W/mK λ= W/mK λ= W/mK λ= W/mK λ= W/mK λ= W/mK λ= W/mK Thermal Resistance RD = 4,9151 m 2 K/W Thermal Transmittance U= 0,2035 W/m 2 K ETA 11/0281 Page 5 of 15

7 Thermal Inertia The values for the heat capacity of the concrete and expanded polystyrene are tabulated in the standard EN ISO 10456:2008. An example of the inertia effect in a wall obtained with Ecosism shuttering system type10+5nes37 has been calculated according to EN ISO 13786:2008 Summer time shift = 10 h and 34 Winter time shift= 10 h and ASPECTS OF DURABILITY AND SERVICEABILITY Physical agents The requirements according to ETAG 009 Edition 2002 chapter are met satisfactorily. Chemical agents The requirement according to ETAG 009 Edition 2002 chapter is met satisfactorily. Finishes are not part of the ETA. Biological agents The ETA Holder demonstrated that, if the walls are protected by standard finishes in relation with the conditions of use of the building, the EPS elements are sufficiently protected against fungi, bacteria, algae and insects. The requirements according to ETAG 009 Edition 2002 chapter are met satisfactorily RESISTANCE TO NORMAL USE DAMAGES Normal use impacts As the finishes of the walls are not part of the ETA, determination of this property was not possible. No Performance Determined. Incorporation of the ducts The voids for horizontal passing ducts are made on site; the diameter of the voids shall coincide with the diameter of the ducts; the ducts must be installed in the voids before filling in with concrete. Detailed instructions are given in the installation guide of the manufacturer. The requirements according to ETAG 009 Edition 2002 chapter are met satisfactorily. Fixing of objects Although finishes are not included in this ETA, as resulted from eccentric vertical loads tests (ISO DIS ) it is possible to fix the objects (up to 100 kg mass with 4 plastic fixing devices Ø 12 mm and 70 mm long) in the finishes of the shuttering leaves (coating based on 3 cm-thick cement-lime mortar); for other cases the fixing devices should be inserted in the concrete. The requirements according to ETAG 009 Edition 2002 chapter are met satisfactorily. 3. EVALUATION OF CONFORMITY AND CE MARKING 3.1 Attestation of conformity system According to the Decision on the procedure of attestation of conformity 98/279/EC of 5 December 1997 amended by the Decision 2001/596/EC of the European Commission the system 2+ of attestation of conformity applies. ETA 11/0281 Page 6 of 15

8 Considering the Euroclass for the reaction to fire of components and that no stage in production process has been identified that corresponds to an improvement of the reaction to fire classification, the system of Attestation of Conformity specified by the European Commission is System 2+ described in the Council Directive 89/106/EEC Annex III, 2 (i), First possibility and described as follows: Declaration of Conformity of the product by the manufacturer on the basis of: a) Tasks of the manufacturers: 1. Initial type testing of the product 2. Factory Production Control, including testing of samples taken at the factory in accordance with a control plan 8. b) Tasks of the Notified Body: 3. Certification of Factory Production Control on the basis of: - Initial inspection of the factory and of factory production control; - Continuous surveillance, assessment and approval of Factory Production Control. 3.2 Responsibilities Tasks of the manufacturer Initial Type testing (system 2+) For Initial Type Testing, the results of the test performed as part of the assessment for this European Technical Approval shall be used unless there are changes in the production line or plant. In such cases, the necessary new initial type testing has to be agreed between ITC-CNR and the Notified Body involved. These tests could be taken over by the Manufacturer for Declaration of Conformity Factory production control The ETA Holder has a Factory Production Control system in his plant and exercises permanent internal control of production, including testing samples in accordance with his control plan. For the components of ECOSISM which the ETA Holder does not manufacture by himself, he makes sure that a proper Factory Production Control carried out by the other manufacturers guarantees the components compliance with the European Technical Approval. To this end: - he relies on national certification bodies, and - has specified through contracts with his suppliers the awaited characteristics, the needed controls and the frequencies, and - he carries out by himself controls on these components. The control plan and the provisions taken by the ETA Holder for components not produced by himself have been agreed with the Approval Body and deposited with ITC-CNR where they are only made available to the Notified Body involved in the Conformity attestation procedure. This control plan will be given to the Notified Body chosen by the ETA Holder to perform the foreseen tasks on attestation of conformity. The manufacturer only uses raw materials supplied with the relevant inspection documents as laid down in the control plan. The incoming raw materials are subjected to verifications by the manufacturer before acceptance. All the elements, requirements and provisions adopted by the manufacturer are documented in a systematic manner in the form of written processes and procedures. This 8 The control plan has been deposited with ITC-CNR and is only made available to the Notified Bodies involved in the conformity attestation procedure. ETA 11/0281 Page 7 of 15

9 production control system ensures that ECOSISM and its components are in conformity with this European Technical Approval. The results of Factory Production Control are recorded and evaluated. The records include, among the others, the following information: - designation of the product, raw materials and components; - type of control or testing; - date of the product s manufacture and date of testing of the product or raw materials and components; - results of controls and testing and, if appropriate, comparison with requirements; - signature of the person responsible for Factory Production Control. The records shall be submitted to the inspection body during the continuous surveillance. On request, they shall be submitted to ITC-CNR. Details of the extent, nature and frequency of testing and controls to be performed within the Factory Production Control shall correspond to the control plan which is part of the technical documentation of this European Technical Approval Tasks of the Notified Bodies Initial inspection of factory and Factory Production Control The Notified Body shall ascertain that, in accordance with the control plan, the factory (in particular the employees and the equipment) and the Factory Production Control are suitable to ensure continuous and orderly manufacturing of the components according to the specifications mentioned in clause 2 of this ETA Continuous surveillance, assessment and approval of factory production control The Notified Body shall visit the factory at least once a year for surveillance. It has to be verified that the system of Factory Production Control and the specified manufacturing process are maintained taking into account the deposited control plan. Continuous surveillance and assessment of Factory Production Control have to be performed in accordance with the control plan. During each visit, the Notified Body shall use an ad-hoc checklist and shall examine, among the others: - the control registers of raw materials, products in the course of manufacture and finished products, - the document attesting the respect of the control frequencies, - the conformity of the products subjected to this ETA. In cases where the provisions of the European Technical Approval and the control plan are no longer fulfilled, the conformity certificate shall be withdrawn CE Marking The CE Marking shall be affixed on the packaging or on accompanying commercial documents (DDT). The symbol «CE» shall be accompanied by the following information: - identification number of the Notified Body, - name or identifying mark of the ETA Holder and name of his manufacturing plant, - legal address of the ETA Holder, - the last two digits of the year in which the CE-marking was affixed, - number of the EC Certificate of conformity, - number of this European Technical Approval, - ECOSISM, - ETAG 009 Edition June 2002 ETA 11/0281 Page 8 of 15

10 4. ASSUMPTIONS UNDER WHICH THE FITNESS OF THE PRODUCT FOR THE INTENDED USE WAS FAVOURABLY ASSESSED 4.1 Manufacturing The ECOSISM blocks shall correspond, as far as their composition and manufacturing process are concerned, to the products subjected to the approval tests. The manufacturing process scheme is deposited with ITC-CNR. 4.2 Installation General It is the responsibility of the ETA Holder to guarantee that the information about design and installation of the system ECOSISM is actually communicated to all those concerned. The above information can be given using reproductions of the respective parts of this European Technical Approval. Furthermore, all the data concerning the execution shall be clearly indicated on the packaging and/or on the enclosed instruction sheets using one or several illustrations. In any case, it is appropriate to comply with national regulations and particularly those concerning fire. 5 RECOMMENDATIONS 5.1 Packaging, transport and storage The blocks are tied up by means of plastic bands. The manufacturer takes measures to avoid damage during storage and transport. 5.2 Maintenance and repair of the product As finishes are not included in this ETA, no maintenance works are foreseen. Repairs of localized damage due to accidents shall be effected rapidly. The original version is signed by Mr. Roberto Vinci (ITC Director) ETA 11/0281 Page 9 of 15

11 Annex 1 of European Technical Approval 11/0281: ECOSISM 3D wire-rod reinforcement cage EPS elements inserted ECOSISM 3D view of the system with concrete infill ECOSISM Annex 1 ECOSISM shuttering system of European Technical Approval 11/0281: Shuttering system ECOSISM ETA 11/0281 Page 10 of 15

12 Annex 2 of European Technical Approval 11/0281: ECOSISM 15 cm a b c d e f g Cross section of 3D cage (see Annex 3) steps of 15 cm up to steps of 10 cm up to 120 Module steps ECOSISM cage steps ECOSISM Annex 2 of European Technical Approval 11/0281: Shuttering system ECOSISM ETA 11/0281 Page 11 of 15

13 Annex 3 of European Technical Approval 11/0281: ECOSISM CODE Thickness for external rendering Thickness for external insulation material Distance between the wires in 3D cage (mm) The column title is referred to the function Thickness to cover the steel reinforcement Thickness for concrete infill Thickness to cover the steel reinforcement Thickness for internal insulation material Thickness for internal rendering Thickness of shuttering (mm) (a) (b) (c) (d) (e) (f) (g) 4+4NES NES NES NES NES NES NES NES NES NES NES NES NES NES NES NES NES NES NES NES NES NES NES NES NES NES NES NES NES NES NES NES ECOSISM Annex 3 ECOSISM Range production of European Technical Approval 11/0281: Shuttering system ECOSISM ETA 11/0281 Page 12 of 15

14 Annex 4 of European Technical Approval 11/0281: ECOSISM , ECOSISM Annex 4 ECOSISM patented props system of European Technical Approval 11/0281: Shuttering system ECOSISM ETA 11/0281 Page 13 of 15

15 Annex 5 of European Technical Approval 11/0281: ECOSISM General view of shuttering and prop alignment system Non permanent EPS inserts EPS inserts to make the openings (doors and windows) ECOSISM Annex 5 ECOSISM Bracing of windows and doors of European Technical Approval 11/0281: Shuttering system ECOSISM ETA 11/0281 Page 14 of 15

16 Annex 6 of European Technical Approval 11/0281: ECOSISM Example of window-wall connections T connection L connection Vertical reinforcement connected with foundation Example of intermediate floor wall connection ECOSISM Annex 6 ECOSISM construction details of European Technical Approval 11/0281: Shuttering system ECOSISM ETA 11/0281 Page 15 of 15