General building approval

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1 General building approval Approval body for construction products and building methods Bautechnisches Prüfamt A public institution sustained by both the federal government and the provincial governments of the FRG Member of the EOTA, the UEAtc and the WFTAO Date: File number: 04/29/2013 I /13 English language translation, the original version is in German language Approval number: Z Applicant: DeWalt Black & Decker Straße Idstein Period of validity from: 04/29/2013 to: 04/29/2018 Subject of approval: Rebar connection using the DeWalt PURE150-PRO Injection System The subject of approval stated above is hereby granted a general constructive approval. This general building approval encompasses seven pages and eight annexes. DIBt Kolonnenstraße 30 B D Berlin Tel.: Fax: dibt@dibt.de

2 No. Z Page 2 of 7 I April 29th 2013 I GENERAL PROVISIONS 1 The general building approval certifi es the usability or applicability of the subject of approval in the sense of the State Building Regulations (Landesbauordnungen). 2 If the general building approval requires special expertise and experience of the persons involved with the production of construction products and building methods in accordance with the respective state regulations listed in 17, paragraph 5 of the Musterbauordnung, it has to be ensured that this special expertise and experience is verifi ed by equivalent certifi cates issued by other member states of the European Union. This might possibly also apply to equivalent certifi cates issued within the framework of the Agreement on the European Economic Area (EEA) or other bilateral agreements. 3 The general building approval does not replace the approvals, permits and certifi cates necessary for the execution of construction projects. 4 The general building approval is issued without prejudice to the rights of third parties, especially private property rights. 5 Producers and distributors of the approval subject have to make copies of the general building approval available to the user of the approval subject and to inform him about the requirement to have the general building approval present at the application site, all this notwithstanding further regulations stated in the Special Provisions. Upon request, the involved authorities have to be provided with copies of the general building approval. 6 The general building approval may only be copied or reproduced in full. The publication of extracts requires the approval of the German Institute of Construction Engineering (Deutsches Institut für Bautechnik). Texts and drawings of promotional material may not contradict the general building approval. Translations of the general building approval have to contain a reference stating that it is a Translation from the German source not approved by the Deutsche Institut für Bautechnik. 7 The general building approval is revocable. The provisions of the general building approval may be subsequently complemented and changed, especially if new technical knowledge requires this. Z /13

3 No. Z Page 3 of 7 I April 29th 2013 II SPECIAL PROVISIONS 1 Subject of approval and application area 1.1 Subject of approval The application of the post-installed rebar connection using the DeWalt PURE150-PRO Injection System in accordance with European technical approval ETA-13/ Application area The rebar connection may be used in normal concrete of a minimum strength class of C12/15 and a maximum of C50/60 in accordance with DIN EN 206-1: ; it may also be used in concrete from a minimum of B 15 to a maximum of B 55 in accordance with DIN 1045: The rebar connection may be used in non-carbonated concrete with a permissible chloride content of 0.40 % (CL 0.40) with regard to the concrete content in accordance with DIN EN Rebar connections with B500 B reinforcing bars may only be used for static loads. They may be used for anchorings with fi re resistance requirements. Only rebar connections that would also be possible with straight reinforcing bars encased in concrete may be implemented, such as in the following applications (see annex 1): - Overlapping joint with a reinforcement already existing in the component (images 1 and 2), - Anchoring of the reinforcement on the support of plates or beams (for example in accordance with image 3: End bearing on a plate that was calculated as pin ended as well as an appropriate general reinforcement for restraint forces), - Anchoring of reinforcement of building components stressed primarily in compression (image 4), - Anchoring of reinforcement to cover the envelope line of tensile force in the bending member (image 5). The post-installed rebar connections may be used in the temperature range of -40 C to +80 C (max short term temperature +80 C and max long term temperature +50 C). This approval covers anchoring in bore holes made by hammer drilling or pneumatic drilling. The post-installed rebar connection may be installed in dry or wet concrete, however, it must not be installed in holes fl ooded with water. 2 Provisions concerning the construction product 2.1 Properties and composition The DeWalt PURE150-PRO Injection System and the used reinforcing steel have to comply with the provisions of ETA-13/ Packaging, storage and labelling Packaging, storage and labelling of the DeWalt PURE150-PRO Injection System have to comply with ETA-13/0049. Z /13

4 No. Z Page 4 of 7 I April 29th Provisions concerning design and dimensioning 3.1 General Rebar connections must be designed in keeping with good engineering practice. Considering the loads to be anchored, verifi able design calculations and design drawings must be produced. The dimensioning of the rebar connection with B500 B reinforcing steel shall be based on DIN : and section 3.2 of this general building approval or on DIN EN : with DIN EN /NA: and in accordance with ETA-13/0049, section 4.1. Section 3.3 has to be observed for components subject to fi re protection requirements. In addition, the type, arrangement and fastening of possibly required fi re protection clothes in accordance with section 3.3 has to be indicated. 3.2 Dimensioning in accordance with DIN : General The actual position of the reinforcement in the existing component shall be determined on the basis of the construction documentation and taken into account during the design phase. The dimensioning of the post-installed rebar connections according to annex 1 and the determination of the internal cutting forces to be transferred in the construction joint depend on DIN : When ascertaining the tensile force in the rebar, the statically effective height of the bonded-in reinforcement shall be taken into account. The verifi cation of the immediate local force transfer to the concrete has been provided. The transferring of the loads to be anchored in the component has to be verifi ed Determination of the basic anchorage length The basic anchorage length b is do be determined in accordance with DIN : , section : b = (d s /4) (f yd /f bd ) with: d s = diameter of the rebar f yd = design value of the reinforcing steel yield strength f bd = design value of bond strength according to ETA-13/0049 in consideration of the coeffi cient related to the quality of bond conditions Determination of the required anchorage length The required anchorage length b,net is do be determined in accordance with DIN : , section : b,net = α a b (A s,erf /A s,vorh ) b,min with: b = in accordance with section α a = coeffi cient for considering the effectiveness of the anchoring methods in accordance with DIN : , table 26 A s,erf = cross-sectional area of the reinforcement required for calculation A s, vorh = available cross-sectional area of the reinforcement b,min = minimum anchorage length in accordance with DIN : and ETA713/0049 = max {0.3 α a b ; 10d s ; 100 mm} under tension = max {0.6 b ; 10d s ; 100 mm} under pressure The maximum permissible embedment depth is stated in ETA-13/0049. Z /13

5 No. Z Page 5 of 7 I April 29th Overlap joint length The required overlap length s is do be determined in accordance with DIN : , section : s = α 1 b,net s,min with: b,net = in accordance with α 1 = coeffi cient for the overlap length in accordance with DIN : , table 27 s,min = minimum overlap length in accordance with DIN : and ETA-13/0049 = max {0.3 α a α 1 b ; 15d s ; 200 mm} If the clear distance between overlapping bars exceeds 4 d s, the overlap length shall be increased by the difference between the existing clear bar distance and 4 d s Embedment depth for overlap joints The maximum permissible embedment depth is stated in ETA-13/0049 and in annex 9, table 6. Overlap joints for rebars: When calculating the effective embedment depth of overlap joints, the concrete cover on the front side of the existing bar has to be taken into account: v s + c with: s = required overlap length in accordance with section c = concrete cover on the front side of the existing bar Concrete cover The required concrete cover for the bonded-in rebars in accordance with ETA-13/0049 has to be observed. Furthermore, the minimum concrete cover according to DIN : , section 6.3, table 4 has to be observed Transverse reinforcement The requirements of transverse reinforcement in the area of the post-installed rebar connection shall comply with DIN : , Section Connection joint The transfer of transverse forces between new and existing concrete shall be designed according to DIN : The concrete joints must be roughened to at least such an extent that the aggregates protrude. In case of a carbonated surface of the existing concrete structure, the carbonated layer shall be removed in the area of the post-installed rebar connection with a diameter of d s + 6 cm prior to the installation of the new rebar. The depth of the concrete to be removed shall correspond to at least the minimum concrete cover for the respective environmental conditions in accordance with DIN : The foregoing may be neglected if building components are new and not carbonated and if building components are in dry conditions. 3.3 Fire protection In case of fi re protection requirements, it has to be certifi ed that the design value derived from the impacts is smaller than that of the resistance. The design values of the resistance against tensile load N Rd, fi for rebar connections with reinforcing steel, which are arranged perpendicular to the fi re-exposed surfaces of plates and walls, are specifi ed in annexes 2 and 3. Z /13

6 No. Z Page 6 of 7 I April 29th 2013 The design values of the bond stress f bd, fi for rebar connections, which are arranged perpendicular to the fi re-exposed surfaces of plates and walls, are specifi ed in annex 5 depending on the concrete cover of the bonded-in reinforcement. For rebar connections in parallel to the fi re-exposed surface, the required embedment depth in accordance with the information specifi ed in annex 4 has to be determined. The computational anchoring or overlap length may only amount to a maximum of 80 d s. The maximum embedment depth according ETA-13/0049 is to be observed. For concrete covers over 50 mm, a protective reinforcement in accordance with DIN : , section has to be arranged, if necessary. The design values for the fi re exposure in case of two or three-sided fi re exposure are not governed by this general building approval. The fi re protection requirements may also be satisfi ed by plaster coverings in accordance with DIN : or other coverings if their suitability is confi rmed by an offi cial certifi cate or a general building approval (for example mineral fi bre board of building material class A with a melting point 1000 C and a gross density 150 kg / m 3 as well as calcium silicate or vermiculite plates). 2 cm of concrete cover may be replaced by 1 cm of covering thickness for the coverings listed above. The fastening of the covers also has to satisfy the fi re protection requirements and this has to be certifi ed separately. 4 Provisions concerning execution 4.1 General The company entrusted with the execution of the rebar connection has to have at its disposal - a qualifi ed executive or supervisor, - a responsible site manager, - specialist construction personnel that is specially trained for the execution of the rebar connection and - the required equipment in accordance with annexes 6 to 8 Operational requirements for the execution of rebar connections with post-installed rebars and also be able to present a valid verifi cation or certifi cate of suitability regarding these aspects. The training of the specialist construction personnel is handled by the applicant under supervision of a body determined by the Deutsche Institut für Bautechnik. If this body has determined that the training has been successfully carried out, it shall provide the specialist construction personnel with a certifi cate stating the capability of establishing rebar connections using the DeWalt PURE150-PRO Injection System. If this body has determined that the operational requirements for the execution of rebar connections with post-installed rebars stated in annexes 6 to 8 are satisfi ed, the body will then issue a certifi cate of suitability in this regard as well. The certifi cate of suitability is issued for three years and is revocable. At request, the certifi cate s period of validity can be renewed for another three years. Prior to any renewal or extension, the inspecting body or authority has to be presented evidence that the requirements concerning the execution of rebar connections with post-installed rebars are still being met. The responsible supervisor or manager of the company has to indicate any changes to the responsible specialist personnel to the inspecting body or authority. The rebar connection must be made in accordance with the design drawings and the instructions of the applicant. Only equipment intended for this purpose may be used for the drilling and cleaning of holes as well as the injection of the mortar. Z /13

7 No. Z Page 7 of 7 I April 29th 2013 For every rebar connection, an installation protocol in accordance with the requirements of annex 8 has to be prepared. 4.2 Inspection of the anchoring base Prior to drilling the borehole, the concrete strength class of the anchoring base has to be determined. The concrete strength class may not be below the strength class stated in section 3.1 of the design drawings and may not exceed C50/60 or B 55. If the locations of the existing rebars is not apparent, they have to be determined using a suitable rebar detection device based on the construction documentation and be marked on the component for the overlap joints. When preparing the bonded-in rebars, the component temperature may not be below +5 C and not exceed +40 C. 4.3 Execution The anchorings (borehole making, borehole cleaning, preparation of the rebar, injection of the bonding mortar and setting of the rebar) shall be established in accordance with ETA-13/ Inspection of the execution The inspection of the execution is based on annex 5, table 3. When executing the rebar connections, a construction supervisor of the entrusted company or his competent representative has to be present at the site. He is responsible for the proper execution of the operations and has to document the inspection (installation protocol). The records or documentations have to be present on the construction site for the duration of the construction operations and have to be presented to the person responsible for the site inspection upon request. Similar to the delivery notes, they have to be stored by the company for at least 5 years after completion of the work. Andreas Kummerow Head of Section Certifi ed Z /13

8 No. Z , dated April 29th 2013 Image 1: Overlap joint for rebar connections of plates and beams Image 2: Overlap joint of a support or wall under bending stress to a foundation Roughen joint in accordance with section 3,2.8 of this approval Roughen joint in accordance with section 3,2.8 of this approval Image 3: End anchorage of plates or beams Image 4: Rebar connections of components mainly subject to pressure Roughen joint in accordance with section 3,2.8 of this approval Image 5: Anchoring of reinforcement to cover the tensile forces Envelope line of tensile force Envelope M ed /Z + N ed Components of the connection: Normal concrete C12/15 - C50/60 in accordance with DIN EN 206-1: Normal concrete B15 - B55 in accordance with DIN 1045: Reinforcing steel B500 B, d s = 8 mm - 25 mm, in accordance with DIN 488 or the general building approval DeWalt PURE150-PRO injection mortar in accordance with ETA-13/0049 Notes concerning images 1 to 5: No lateral force reinforcement is portrayed on the images. The lateral force reinforcement required in accordance with DIN has to be present. The lateral force transmission between old and new concrete according to DIN has to be certifi ed. Rebar connection using the DeWalt PURE150-PRO Injection System Application examples for bonded-in rebars Annex 1 Z /13

9 No. Z , dated April 29th 2013 Table 1a: Design values of the tensile load N Rd,fi 1) for verifi cation in accordance with section 3.3 concerning classifi cation of the fi re resistance classes, rebar connection perpendicular to the fi re-exposed surfaces of plates and walls Bar diameter Maximum tensile force Embedment depth Fire resistance class F 30 F 60 F 90 F 120 F 180 d s max N Rd,fi v N Rd,fi [mm] [kn] [mm] [kn] [kn] [kn] [kn] [kn] Note: Intermediate steps may be interpolated linearly. Extrapolation is not permitted. In addition, the embedment depth has to be dimensioned in accordance with section Verifi cation/proof: N Sd,fi N Rd,fi 1) Partial safety factor of the impact γ F,fi = 1,0 Partial safety factor of the resistance γ M,fi = 1.0 Rebar connection using the DeWalt PURE150-PRO Injection System Fire protection verifi cation in accordance with section 3.3 Rebar connection d s = 8 to 16 mm, perpendicular to the wall exposed to fi re Annex 2 Z /13

10 No. Z , dated April 29th 2013 Table 1b: Design values of the tensile load N Rd,fi 1) for verifi cation in accordance with section 3.3 concerning classifi cation of the fi re resistance classes, rebar connection perpendicular to the fi re-exposed surfaces of plates and walls Bar diameter Maximum tensile force Embedment depth Fire resistance class F 30 F 60 F 90 F 120 F 180 d s max N Rd,fi v N Rd,fi [mm] [kn] [mm] [kn] [kn] [kn] [kn] [kn] Note: Intermediate steps may be interpolated linearly. Extrapolation is not permitted, in addition, the embedment depth has to be dimensioned in accordance with section Verifi cation/proof: N Sd,fi N Rd, fi 1) Partial safety factor of the impact γ F,fi = 1.0 Partial safety factor of the resistance γ M,fi = 1.0 Rebar connection using the DeWalt PURE150-PRO Injection System Fire protection verifi cation in accordance with section 3.3 Rebar connection d s = 20 to 25 mm, perpendicular to the wall exposed to fi re Annex 3 Z /13

11 No. Z , dated April 29th 2013 Table 2: Design value of the bond stress f bd,fi 1) subject to the existing concrete cover for classifi cation of fi re resistance classes, rebar connection in parallel to the surfaces of plates and walls exposed to fi re F 30 F 60 Fire resistance class Concrete cover of the F 90 F 120 F 180 F 240 bonded-in reinforcement c Maximum bond stress f bd,fi [N/mm2] [N/mm2] [N/mm2] [N/mm2] [N/mm2] [N/mm2] [mm] Defi nitions: N Rdfi Design value of the tensile force under fi re exposure ( v - c 1 ) Selected overlap length. This value must at least correspond to s but may only amount to 80 d s at a maximum s Overlap length of the joint in accordance with Nominal diameter of the rebar d s f bd,fi Design value of the bond stress under fi re exposure It has to be proven that the design value of the tensile force under fi re exposure N Rd,fi can be transferred in the rebar connection with the selected length v ; N Rd,fi = ( v - c 1 ) π d s f bd,fi with s ( v - c 1 ) 80 d s 1) Partial safety factor of the impact γ F,fi = 1.0 ; Partial safety factor of the resistance γ M,fi = 1.0 Rebar connection using the DeWalt PURE150-PRO Injection System Fire protection Rebar connection in parallel to the fi re-exposed surface Annex 4 Z /13

12 No. Z , dated April 29th 2013 Table 3: Inspection of the execution No. Subject of the inspection Type of inspection Requirements Frequency, point in time Concrete subsurface 1 Concrete Visual inspection Concrete strength from construction documentation Suitability for the intended work operations in accordance with the specifi cations of the structural engineer Prior to commencing the work every component, prior to commencing work operations 2 existing reinforcement Inspection of the locations and distances No reinforcement strikes during drilling operations Mark existing reinforcement on the component surface every component, prior to commencing work operations Raw materials 3 DeWalt PURE150-PRO mortar cartridge Packaging label Visual inspection Storage conditions Expiration date has not passed No noticeable changes, installation instructions of the manufacturer Every delivery Ongoing During storage and removal 4 Processing equipment Functional inspection Proper operation During commissioning and on a daily basis 5 Work plan Instructions for preparation and processing Compliance with the work instructions Prior to commencing the work Processing 6 Weather effects Temperature Protection of the borehole Compliance with the work instructions, no water in the borehole 3 times each working day Prior to fi lling the borehole from water ingress 7 Borehole drilling Covering, edge distances Compliance with the work instructions Every borehole 8 Borehole cleaning Visual inspection Dust free; clean borehole Every borehole prior and blowout inspection surface to fi lling 9 Rebars Condition Marking Movement in the borehole 10 Work safety Personal protective equipment 11 Filling Fill marking on the mixer extension void-free 12 Anchored rebar connections Embedment depth Filling Rebar connection using the DeWalt PURE150-PRO Injection System Only fl ash rust, embedment depth marked, movable Wear suitable protective clothing, gloves and protective goggles/face protection In accordance with ETA-13/0049, annex 8, no springback of the bar, no mortar spraying Embedment marking on the borehole and mortar visibly exits from the borehole mouth Every bar prior to fi lling the borehole When working with injection mortar Every bar while setting Every bar after embedment Inspection of the execution Annex 5 Z /13