TECHNICAL DESIGN AND INSTALLATION GUIDE THE COMPLETE ENGINEERED SOLUTION FOR TEMPORARY MOVEMENT JOINTS

Transcription

1 TECHNICAL DESIGN AND INSTALLATION GUIDE THE COMPLETE ENGINEERED SOLUTION FOR TEMPORARY MOVEMENT JOINTS

2 LOW COST, ECONOMICAL, TECHNICAL AND PRACTICAL SOLUTION. FULLY SEALED SYSTEM. FULLY GROUTED SYSTEM FOR PERMANENT LOCKING. REDUCED SITE INSTALL TIME. VERTICAL SHEAR CAPACITY WITHOUT CORBELS. ELIMINATES JOINT SEALING FOR PURPOSES OF GROUTING, CORBELS AND DRILLING EDGE FORM FOR DOWEL. AN INNOVATIVE ADVANCEMENT FROM ALL CURRENT MARKET OPTIONS. 2

3 SureLok TM is a revolutionary engineered solution to temporary movement joints (TMJ). SureLok TM has been specifically designed to eliminate issues that current TMJ market options present. SureLok TM is the result of years of experience, investment, research, development and testing. It has been developed for the post-tensioning, construction and mining industries with a patent pending in Australia and Internationally. SureLok TM is revolutionary as it offers a range of safety, cost, design and performance benefits. It is a worldclass leader in the industry as it is the first of its kind to provide temporary movement while at the same time remain sealed as it achieves its shear capacity. Temporary Movement Joints (TMJ) are the most complex joint as they require temporary free movement in two horizontal directions prior to being locked tight for permanent stability and integrity of a structure. The solution required a combination of specialist areas of engineering outside of the standard field of structural engineering, using hydraulic engineering to design a movable pressure seal as well as unfamiliar materials such as rubber and plastics to deliver affordability. The solution SureLok engineers an intelligent void with a pressure sealed system bridging the joint whilst allowing horizontal movement before being locked together with a typical cement grout mixture used for post-tensioned tendons. The intelligent void ensures the dowel contains cover for durability and fire within the sleeve across the joint without having to rely on the joint itself being sealed or grouted. During the 3 years of development there were 12 prototype phases tested against the rigorous design and site criteria. In addition, the product has also been tested at the University of Technology Sydney (UTS). SRG are extremely pleased and proud to have finally resolved the past long standing issues of temporary movement joint performance, whilst utilising materials such as plastics, rubber and mild steel to ensure the product is financially feasible and available to all. You can now have peace of mind knowing that SureLok TM is the tested and proven solution to temporary movement joints and is the answer to your TMJ needs and requirements. The team at SRG has now developed two separate ranges of the SureLok TM system, the first is for slab to slab connections, the second is for slab to wall connections. SURELOK SLAB TO SLAB The SureLok TM slab to slab range encompasses two SureLok TM products. The SureLok TM 160S and the SureLok TM 200S. The SureLok TM 160S was launched in 2014 as a TMJ product for slab to slab connections starting at a minimum slab depth of 160mm. In 2016, SRG launched the SureLok TM 200S which is designed for slab depths of a minimum of 200mm and has been engineered to significantly improve the vertical displacement between slabs. SURELOK SLAB TO WALL The SureLok TM slab to wall range encompasses three SureLok TM products. The SureLok TM 160W, the SureLok TM 160W+ and the SureLok TM BRS (Basement Retention System). All three products are designed to provide a temporary movement joint between a wall and slab and eliminate the requirement for pour strips. The SureLok TM 160W is used on applications where the anchor can be fixed inside the wall cavity and positioned and secured by local reinforcement or is set into a precast wall. The SureLok TM 160W+ is used in applications where the anchor is attached to the inside of the shutter by way of the void former. The Surelok TM BRS is used for basement applications where the walls are formed using shotcrete. SAFETY, QUALITY, ENVIRONMENT Safety, Quality and the Environment are paramount to SRG. Being a customer focused organisation with an intense desire to be the best in our field, SRG operates and complies with the requirements of the following Quality Management, Environmental Management and Occupational Health & Safety Management Systems. Occupational Health & Safety Management System AS/NZS 4801:2001 OHSAS Quality Management System ISO 9001:2008 Environmental Management System AS/NZS ISO 14001:2004 CIA Awards for Excellence in Concrete Whilst other similar products exist in the market place, the judges commended SureLok for its Reliability, Simplicity and most importantly for its Economy. 3

4 APPLICATIONS NO MORE POUR STRIPS NO MORE CORBELS NO MORE UNRELIABILITY NO MORE MESS SURELOK TM SLAB TO SLAB SURELOK TM SLAB TO WALL SURELOK TM SLAB TO SLAB The SureLok TM slab to slab range encompasses two SureLok TM products. The SureLok TM 160S and the SureLok TM 200S. The SureLok TM 160S was launched in 2014 as a TMJ product for slab to slab connections starting at a minimum slab depth of 160mm. In 2016, SRG launched the SureLok TM 200S which is designed for slab depths of a minimum of 200mm and has been engineered to significantly improve the vertical displacement between slabs. Slab to slab SureLok TM 160S SureLok TM 200S Slab to slab connection No pour strips No corbels Most economical TMJ Simple installation Reduced construction time Improved job site safety Slab thickness 160mm+ Slab thickness 200mm to 260mm+ Propping can be removed prior to grouting SURELOK TM SLAB TO WALL The SureLok TM slab to wall range encompasses three SureLok TM products. The SureLok TM 160W, the SureLok TM 160W+ and the SureLok TM BRS (Basement Retention System). All three products are designed to provide a temporary movement joint between a wall and slab and eliminate the requirement for pour strips. The SureLok TM 160W is used on applications where the anchor can be fixed inside the wall cavity and positioned and secured by local reinforcement or is set into a precast wall. The SureLok TM 160W+ is used in applications where the anchor is attached to the inside of the shutter by way of the void former. The Surelok TM BRS is used for basement applications where the walls are formed using shotcrete. Slab to wall SureLok TM BRS SureLok TM 160W SureLok TM 160W+ Slab to wall connection No pour strips No corbels Most economical TMJ Simple installation Reduced construction time Improved job site safety Suitable for existing wall structures 04

5 COMPONENTS SLAB TO SLAB COMPONENTS SURELOK TM 160S Grout tube N24 Dowel Bar mm long Main sleeve - female Male connector SURELOK TM 200S Grout tube N20/N32 Dowel Bar mm long once assembled Main sleeve - female Male connector SLAB TO WALL COMPONENTS SURELOK TM BRS, 160W, 160W+ Anchor foot with void former Grout tube Male connector N24 Dowel Bar - 500mm long (threaded) Main sleeve - female 5

6 PERFORMANCE PERFORMANCE SURELOK TM 160S, BRS, 160W, 160W+ GROUTED SHEAR ONLY (NO TENSION) SLAB THICKNESS (mm) ULTIMATE - VERTICAL DESIGN RESISTANCE (kn) FOR VARYING JOINT WIDTHS 5mm 10mm 15mm 20mm 25mm 30mm VERTICAL DISPLACEMENT (mm) SERVICE - VERTICAL DESIGN RESISTANCE (kn) FOR VARYING JOINT WIDTHS 5mm 10mm 15mm 20mm 25mm 30mm 2mm mm GROUTED COMBINATION SHEAR & TENSION SLAB THICKNESS (mm) ULTIMATE TENSION (kn) ULTIMATE - VERTICAL DESIGN RESISTANCE (kn) FOR VARYING JOINT WIDTHS 5mm 10mm 15mm 20mm 25mm 30mm VERTICAL DISPLACEMENT (mm) SERVICE - VERTICAL DESIGN RESISTANCE (kn) FOR VARYING JOINT WIDTHS 5mm 10mm 15mm 20mm 25mm 30mm 2mm mm GROUTED TENSION ONLY SLAB THICKNESS (mm) ULTIMATE TENSION (kn) SERVICE TENSION (kn) Note: 1. All grouted capacities based on 32Mpa concrete and 40Mpa grout 2. FOS of 1.7 used for the above shear capacities 3. SureLok cover to N24 dowel bar is 20mm (with 40Mpa grout) 4. Requires additional reinforcement for punching shear PERFORMANCE SURELOK 200S CAPACITY TABLE SLAB THICKNESS ULTIMATE TENSION ULTIMATE - VERTICAL DESIGN RESISTANCE (kn) FOR VARYING JOINT WIDTHS (mm) (kn) 5mm 10mm 15mm 20mm 25mm 30mm 35mm 40mm ENGINEERING QUALIFICATION Engineers to satisfy themselves for earthquake load path Under fire circumstances, the structure needs to be assessed for horizontal actions without contribution from SureLok TM capacity in tension across the joint Slab to Slab - Provide fire seal and or grouting of joint to provide fire adequacy, integrity and insulation Slab to Wall - Joint to be grout filled for fire adequacy, integrity, insulation and durability INSTALLATION QUALIFICATION Care must be taken to install the product as per installation instructions ensuring no damage to the product during the installation phase including concreting. Any product damage can result in product failure. GENERAL QUALIFICATION Engineers to satisfy themselves that SureLok TM is fit for purpose in the context of all design, installation and service risks and parameters. 6

7 DIMENSIONS AND SPACINGS EDGE DISTANCE AND SPACING SURELOK TM 160S, 200S, BRS, 160W, 160W+ To utilise the full capacity of each unit, the following minimum spacing rules apply. h Min. 0.75h Min. 1.5h DIMENSIONS SURELOK TM 160S, BRS, 160W, 160W DIMENSIONS SURELOK TM 200S

8 REINFORCEMENT Each SureLok TM unit requires local reinforcement to ensure adequate performance capacity is achieved. Reinforcement must be detailed in accordance with relevant codes and the details shown below. Lacer bars can form part of the main edge reinforcement. REINFORCEMENT SLAB TO SLAB SURELOK TM 160S Lacer Bars 100mm 2 N12 U-Bars 2 N12 U-Bars Notes: <240 Slab Depth - 2 N12 U-Bars (2 N as per image above) REINFORCEMENT SLAB TO SLAB SURELOK TM 200S 4 N12 U-Bars Notes: >=240 Slab Depth - 4 N12 U-Bars (2 N N 12-50) 4 N12 U-Bars REINFORCEMENT SLAB TO WALL SURELOK TM BRS, 160W, 160W+ 2 N12 U-Bars Notes: Slab to Wall requires minimum wall reinforcement at 200 centres horizontal and vertical 8

9 INSTALLATION SLAB TO SLAB POUR 2 POUR 1 INSTALLATION SLAB TO SLAB SURELOKTM 160S 1. Screw sleeve to formwork (using supplied screws ONLY) and chair ends or attach to reinforcement. 2. Fix the local reinforcement, as specified by engineer. 1. Pull off protective sticker 2. Install SureLokTM connector using Selleys Armour Flex as per sealing guide provided 3a. Connect grout tubes (option 1) and pour concrete. 3b. Connect grout tubes (option 2) and pour concrete. MAX 2 units together. MAX 2 units together. 3. Install N24 dowel bar and reinforcement. Seal SureLokTM connector to dowel bar with duct tape 4. Concrete POUR 2. Grout joint and SureLokTM at specified time 3a. Connect grout tubes (option 1) and pour concrete. 3b. Connect grout tubes (option 2) and pour concrete. MAX 4 units together. MAX 4 units together. 3. Insert dowel bar firmly and fix the local reinforcement around the dowel. 4. Pour concrete. Grout joint and SureLokTM sleeves as specified by engineer. Remove grout tubes. POUR 2 POUR 1 INSTALLATION SLAB TO SLAB SURELOKTM 200S 1. Screw sleeve to formwork (using supplied screws ONLY) and chair ends or attach to reinforcement. 2. Fix the local reinforcement, as specified by engineer. 1. Remove formwork and remove circular protective sticker ONLY. 2. Attach male locking piece connector to sleeve by rotating clockwise by hand until locked. Notes: 1. Grout tubes can link or connect maximum 2 units together for grouting SureLokTM 160S or a maximum of 4 units together for grouting SureLokTM 200S. Always asses the risk of connecting multiple units together. 2. Grouting must be carried out under low pressure. 3. Each SureLokTM unit must utilise the 2 grout ports, one port as an inlet and the other as an outlet so as grout flows from one end of the unit to the other. Grout can flow in any direction along the SureLokTM unit. 4. Grout mix must achieve 40Mpa to ensure the full tension capacity is achieved. 9

10 INSTALLATION SLAB TO WALL INSTALLATION SLAB TO WALL SURELOK TM 160W and BRS* POUR 2 POUR 1 * Image above for pour 1 shows connection for SureLok TM 160W only 1. After POUR 1 formwork removed and if application allows, use void tool to imprint shape into concrete. Remove rubber stopper. 2. Apply a sealant to the washer on the threaded side of the N24 dowel bar, before fitting the male connector piece. 1. Fix SureLok TM shear reinforcement, to achieve full shear capacity as specified by engineer. 2. Position anchor castings and secure to reinforcement with wire, ensuring anchor is fully flush against outside wall edge of formwork. 3. Apply ArmourFlex around the lip of the male connector piece, before screwing in the fitted N24 dowel bar into the anchor. 4. Slide main sleeve over dowel bar ensuring full engagement onto male connector piece, then chair ends. 5. Fix SureLok TM shear reinforcement, to achieve full shear capacity as specified by engineer. 6. Connect grout tubes in series and pour concrete. MAX 2 units together. 7. Grout joint and SureLok TM sleeves as specified by engineer. Remove grout tubes. Notes: 1. Grout tubes can link or connect maximum 2 units together for grouting. Always assess the risk of connecting multiple units together. 2. Grouting must be carried out under low pressure. 3. Each SureLok TM unit must utilise the 2 grout ports, one port as an inlet and the other as an outlet so as grout flows from one end of the unit to the other. Grout can flow in any direction along the SureLok TM unit. 4. Grout mix must achieve 40Mpa to ensure the full tension capacity is achieved. 10

11 INSTALLATION SLAB TO WALL INSTALLATION SLAB TO WALL SURELOK TM 160W+ POUR 2 POUR 1 1. After POUR 1 formwork removed, unscrew and discard void former. 2. Apply a sealant to the washer on the threaded side of the N24 Plus 20 dowel bar, before fitting the male connector piece. 1. Fix Surelok TM shear reinforcement, to achieve full shear capacity as specified by engineer. 2. Assemble and position 2-part void former, then fasten to inside wall form using supplied screws ONLY. 3. Screw anchor foot onto fastened void former ensuring full thread depth engaged, then grease void former to allow easy release out of concrete wall. Pour concrete. 3. Apply ArmourFlex around the lip of the male connector piece, before screwing in the fitted N24 Plus 20 dowel bar into the anchor. 4. Slide main sleeve over dowel bar ensuring full engagement onto male connector piece, then chair ends. 5. Fix SureLok TM shear reinforcement, to achieve full shear capacity as specified by engineer. 6. Connect grout tubes in series and pour concrete. MAX 2 units together. 7. Grout joint and SureLok TM sleeves as specified by engineer. Remove grout tubes. Notes: 1. Grout tubes can link or connect maximum 2 units together for grouting. Always assess the risk of connecting multiple units together. 2. Grouting must be carried out under low pressure. 3. Each SureLok TM unit must utilise the 2 grout ports, one port as an inlet and the other as an outlet so as grout flows from one end of the unit to the other. Grout can flow in any direction along the SureLok TM unit. 4. Grout mix must achieve 40Mpa to ensure the full tension capacity is achieved. 11

12 CONTACT The information and details contained in this brochure are indicative and intended for marketing purposes only. They should not be relied upon as being complete and accurate. Prospective purchasers should make and rely on their own enquiries and a competent, experienced and qualified professional should always be consulted prior to using the product. SRG Limited, its employees, agents and other representatives do not accept any responsibility or liability for any direct, indirect, consequential or other loss or damage suffered by any person arising out of or in connection with any reliance on the enclosed information. SRG reserves the right to amend or modify any information contained herein at any time and without notice. Any subsequent sale will be based on our terms and conditions. Issue 2017/11 GET TO KNOW US AT SRGLIMITED.COM.AU AUSTRALIA / AFRICA / MIDDLE EAST / ASIA PACIFIC / HONG KONG CALL