National technical approval Coupler Z-1.5-100 12.02.2015 english Mechanical connection of B500B reinforcing steel bars with screw couplers Nominal diameter: 12 to 32 mm Tested by: DIBt, Berlin Max Frank GmbH & Co. KG Mitterweg 1 94339 Leiblfing Germany Phone +49 9427 189-0 Fax +49 9427 1588 info@maxfrank.com www.maxfrank.com
Date: Reference: 12 Feb. 2015 I 24-1.1.5-16/14 Approval number: Validity Z-1.5-100 from: 12 February 2015 Applicant: Max Frank GmbH & Co KG Mitterweg 1 94339 Leiblfing to: 31 March 2019 Subject of approval: Mechanical connection of B500B reinforcing steel bars with screw couplers Nominal diameter: 12 to 32 mm "System Couplerbox" rebar connection The subject of approval named above is herewith granted an allgemeine bauaufsichtliche Zulassung ('national. This allgemeine bauaufsichtliche Zulassung ('national contains eight pages and four annexes. This allgemeine bauaufsichtliche Zulassung ('national replaces the allgemeine bauaufsichtliche Zulassung ('national no. Z-1.5-100 of 2 April 2014. The subject of approval was granted the first allgemeine bauaufsichtliche Zulassung ('national on 9 July 1990.
Page 2 of 8 12 February 2015 I GENERAL PROVISIONS 1 With the allgemeine bauaufsichtliche Zulassung ('national the fitness for use and the applicability of the subject of approval in accordance with the Landesbauordnungen ('Building Regulations of the Land') have been verified. 2 If in the allgemeine bauaufsichtliche Zulassung ('national requirements are made concerning the special expertise and experience of persons entrusted with the manufacture of construction products and types of construction in accordance with the relevant regulations of the Land following section 17, sub-section 5, of the Musterbauordnung ('Model Building Code'), it shall be noted that this expertise and experience can also be proven by equivalent verifications from other Member States of the European Union. If necessary, this also applies to verifications presented within the framework of the Agreement on the European Economic Area (EEA) or other bilateral agreements. 3 The allgemeine bauaufsichtliche Zulassung ('national does not replace the permits, approvals and certificates prescribed by law for carrying out building projects. 4 The allgemeine bauaufsichtliche Zulassung ('national will be granted without prejudice to the rights of third parties, in particular private property rights. 5 Notwithstanding further regulations in the 'Specific Provisions', manufacturers and distributors of the subject of approval shall make copies of the allgemeine bauaufsichtliche Zulassung ('national available to the user and point out that the allgemeine bauaufsichtliche Zulassung ('national shall be available at the place of use. Upon request copies of the allgemeine bauaufsichtliche Zulassung ('national shall be placed at the disposal of the authorities involved. 6 The allgemeine bauaufsichtliche Zulassung ('national may be reproduced in full only. Partial publication requires the consent of Deutsches Institut für Bautechnik. Texts and drawings of advertising brochures may not be in contradiction to the allgemeine bauaufsichtliche Zulassung ('national. In the event of a discrepancy between the German version of the national technical approval and its English translation, the German version shall prevail. 7 The allgemeine bauaufsichtliche Zulassung ('national is granted until revoked. The provisions of the allgemeine bauaufsichtliche Zulassung ('national technical approval') can subsequently be supplemented and amended, in particular if this is required by new technical findings.
Page 3 of 8 12 February 2015 II SPECIFIC PROVISIONS 1 Subject of approval and field of application 1.1 Subject of approval 1.1.1 General The subject of approval is the mechanical connection of B500B reinforcing steel bars of nominal diameters of 12 to 32 mm with screw couplers, referred to below as the "System Couplerbox" rebar connection. The bar ends to be connected are provided with threads. The coupling bar has a coupler screwed on one end, secured against twisting with a compression stroke. Bars without couplers are connection bars. The thread of the connection bar is completely screwed into the coupler of the coupling bar and twisted in the coupling thread to a specified torque to reduce the slip. 1.1.2 Standard coupler Standard couplers are used if the connection bar can be shifted lengthwise and turned freely. 1.1.3 Position coupler Position couplers are used if the connection bar cannot be rotated and/or cannot be shifted. 1.1.4 Reduction coupler Reduction couplers serve to connect reinforcing steel bars to various diameters. The diameter differences correspond to those of the neighbouring bars in the standardised diameter series in accordance with DIN 488-2:2009-08. 1.1.5 Steel construction coupler Steel construction couplers are used for connecting reinforcing steel bars with a steel structure via a steel screw with metric thread. 1.2 Field of application The "System Couplerbox" rebar connection is a screwed butt joint in accordance with DIN 1045-1:2008-08, section 12.8 or DIN EN 1992-1-1 and DIN EN 1992-1-1/NA, section 8.7. It is primarily used for force transmission in construction joints. The connection bar is screwed into the coupler of the coupling bar which is already embedded in concrete. 2 Provisions for the construction product 2.1 Properties and composition 2.1.1 Couplers The materials used for the connection parts and the geometrical dimensions of the couplers and threaded bars are given in Annexes 1, 2 and 4. The workshop drawings, including the tolerance information for the geometrical dimensions and information on the manufacturing parameters of the coupling bars, are included in a deposited data sheet. 2.1.2 Reinforcing steel bars The requirements with regard to the properties set out in DIN 488-1, Table 2 shall be fulfilled for the B500B reinforcing steel bars of nominal diameters of 12 to 32 mm.
Page 4 of 8 12 February 2015 2.2 Manufacture, packaging, transport, storage and marking 2.2.1 Manufacture 2.2.1.1 Couplers The raw material is bar steel of quality C35 or C45 with a circular cross section from which the coupler is cut to length, provided with a core hole and a cut inner thread. 2.2.1.2 Bar thread The ends of the reinforcing steel bars to be connected are peeled to a specified length. A metric thread is rolled onto the cylindrically peeled lateral surface cold. 2.2.1.3 Coupling bar During the manufacturing process, the coupler is screwed onto the threaded bar end to half its length and secured in place with a specified, diameter-dependent compression stroke. The geometry of the deformation of the coupler caused by the compression stroke and further information on its execution are included in a deposited data sheet. 2.2.2 Packaging, transport and storage The threads of the coupling and connection bars shall be packed, transported and stored in such a way that they are protected against corrosion, mechanical damage and contamination until they are installed at the construction site. 2.2.3 Marking The couplers shall bear markings on the positions indicated in the annexes in such a way that the manufacturing plant can be deduced from them. If the manufacturing plant is indicated in encrypted form, a list with the complete information and its relationship to the key shall be deposited with Deutsches Institut für Bautechnik and the external surveillance body. The delivery note shall be marked by the manufacturer with the conformity mark ('Ü mark') in accordance with the conformity marking regulations of the Laender. If the connection parts are produced by a subcontractor, the monitoring report for these products shall be presented to the manufacturer for the marking. This mark may only be applied if all requirements of the attestation of conformity given in section 2.3 are met. 2.3 Attestation of conformity 2.3.1 General The attestation of conformity of the "System Couplerbox" rebar connection with the provisions of this allgemeine bauaufsichtliche Zulassung ('national shall be issued for every manufacturer and every subcontractor in the form of a certificate of conformity based on factory production control and regular external surveillance, including initial type-testing of the "System Couplerbox" rebar connection, in accordance with the following provisions. To issue the certificate of conformity and for external surveillance, including the associated product testing to be carried out in the process, the applicant for the "System Couplerbox" rebar connection shall use an appropriately recognised certification body and an appropriately recognised inspection body. The declaration that a certificate of conformity has been granted shall be given by the manufacturer by marking the construction products with the mark of conformity ('Ü mark') stating the intended use. The certification body shall send a copy of the certificate of conformity issued by it to Deutsches Institut für Bautechnik.
Page 5 of 8 12 February 2015 2.3.2 Factory production control A factory production control system shall be set up and performed on the premises of each manufacturer and each subcontractor. Factory production control is understood to be continuous surveillance of production by the manufacturer/subcontractor to ensure that the construction products manufactured satisfy the provisions of this allgemeine bauaufsichtliche Zulassung ('national. If a manufacturer uses semi-finished products manufactured not in its factory but by subcontractors, an appropriate incoming inspection shall be performed. The factory production control shall include at least the measures specified in the May 2007 version of "Grundsätze für Zulassungs- und Überwachungsprüfungen von mechanischen Betonstahlverbindungen" ("Principles of Approval and Monitoring Tests of Mechanical Couplers"). The geometry of the coupling and connection bars shall be inspected with a yes/no test (statistical analysis not necessary). Load-bearing capacity shall be tested in a tensile test for each 1000 "System Couplerbox" rebar connections produced. The test is passed if the assessment criteria of the May 2007 version of "Grundsätze für Zulassungs- und Überwachungsprüfungen von mechanischen Betonstahlverbindungen" ("Principles of Approval and Monitoring Tests of Mechanical Couplers"), sections 2.7.2 and 2.9.2 are met. The results of the factory production control shall be recorded and evaluated by each manufacturer and each subcontractor. The records shall at least include the following information: - Designation of the construction product or the raw material and the components, - Type of inspection or test, - Date of manufacture and testing of the construction product or the raw material or the components, - Results of the inspections and tests, as well as comparison to requirements if applicable, - Signature of the person responsible for factory production control. The records shall be kept for at least five years and submitted to the inspection body used for external surveillance. They shall be submitted to Deutsches Institut für Bautechnik and the competent supreme building supervisory authority upon request. If the test result is unsatisfactory, the manufacturer shall immediately take the necessary measures to resolve the defect. Construction products which do not meet the requirements shall be handled in such a manner that they cannot be confused with compliant products. After the defect has been remedied the relevant test shall be repeated immediately, where technically practicable and necessary for demonstration that the defect has been eliminated. 2.3.3 External surveillance The factory production control shall be checked regularly by external surveillance in accordance with the principles given in section 2.3.2 for each manufacturer and each subcontractor, at least twice a year. Samples for random testing shall be taken as part of external surveillance. If semi-finished products are used in the manufacturing, the incoming goods inspection from the factory production control shall be documented and evaluated by the external surveillance body. The analysis of the tensile tests in accordance with section 2.3.2 performed as part of the factory production control shall be checked. The results of certification and external surveillance shall be kept for at least five years. The certification body or inspection body shall present them to Deutsches Institut für Bautechnik and the competent supreme building supervisory authority upon request.
Page 6 of 8 12 February 2015 3 Provisions for design and structural analysis 3.1 General For design and structural analysis DIN 1045-1 or DIN EN 1992-1-1 shall apply, unless otherwise specified in the following. Mixing the two Technical Building Regulations is not permitted. DIN EN 1992-1-1 shall always apply in connection with DIN EN 1992-1-1/NA. All bars in a cross section may be butt-joined (full butt joint). The position of the System Couplerbox rebar connection and its dimensions shall be marked in the reinforcement drawings, and the preconditions following from the installation specifications shall be fulfilled. 3.2 Ultimate limit states 3.2.1 Design for static and quasi-static loading The System Couplerbox rebar connection can be loaded up to 100% like a non-butt-joined bar in the event of static or quasi-static tensile and compressive loading. Position couplers (see Annex 2) shall be executed with a high lock nut (see Annex 2, nut height m 2 ) in the event of compressive and alternating stress. They may be executed with either a high or low lock nut (see Annex 2, nut height m 2 or m 1 ). 3.2.2 Fatigue The fatigue verification shall be performed in accordance with DIN 1045-1, section 10.8 or DIN EN 1992-1-1 and DIN EN 1992-1-1/NA, section 6.8. The following values shall be assumed as the characteristic value for the resistance stress range σ Rsk, depending on the type of execution: Type of execution Standard coupler Nominal diameter Characteristic value for the resistance stress range σ Rsk [N/mm²] at N=2 10 6 load cycles Reduction coupler 12 to 32 75 with k 1 =k 2 =5 Steel construction coupler Position coupler 12 to 32 65 with k 1 =k 2 =5 3.2.3 Connection of reinforced concrete components to steel components The concrete steel bar of a reinforced concrete component is connected to a steel component with a steel construction screw connection (see Annex 4). Only axial forces may be transmitted. Steel components and steel construction screw connections shall be protected against corrosion in accordance with DIN EN ISO 12944-5. Hot-dip galvanised coating is not permissible. The requirements of DASt Guideline 006 shall be met for welding over corrosion prevention coating systems. 3.3 Centre and edge distances The same values as for non-butt-joined bars in accordance with DIN 1045-1, section 6.3 and section 12.2 or DIN EN 1992-1-1 and DIN EN 1992-1-1/NA, section 4.4.1 and 8.2 apply to
Page 7 of 8 12 February 2015 the concrete covering over the outer edge of a coupler and to the clearance of the coupling outer edges. The distances necessary for installation remain unaffected by this. 3.4 Bending For bent (pre-bent) bars, the planned bending shall not begin until a distance of 5 d from the coupling end (d = nominal diameter of the bent bar). If coupling bars are bent in the manufacturing plant with a special device, the distance to the coupling end may be reduced to 2 d. 4 Provisions for execution 4.1 General The System Couplerbox rebar connection shall only be installed by trained staff in accordance with the manufacturer's written work instructions. These installation instructions are part of the delivery notes. Only coupling and connection bars that are marked in accordance with section 2.2.3 shall be used. The threads of coupling and connection bars shall be free of rust and contamination. The coaxial position of the coupling and connection bars shall be secured with brackets in such a way that no bending moment arises in the threads. The connection bar shall be screwed in completely hand-tight. The torque necessary for the respective diameter in accordance with the annexes shall then be applied with a torque wrench. Only torque tools whose functionality and precision have been tested in accordance with DIN EN ISO 6789 shall be used for securing the screwed coupling connection. 4.2 Monitoring the manufacture of the coupling connections at the construction site The dimensions of the threads on the bar ends shall be inspected by random sampling with gauges (statistical analysis not necessary). The torque wrenches shall be inspected before and during use to ensure compliance with the requirements of section 4.1 The installation of the specified, load-type-dependent lock nut (high or low; see section 3.2.1) shall be verified. The building supervisory authority is also entitled to draw samples from the finished reinforcement if there is a suspicion of non-compliant production. 4.3 Notification of the building supervisory authority The authority supervising the construction or the persons whom it has assigned to supervise the construction shall be notified in advance of the installation of the System Couplerbox rebar connection.
Page 8 of 8 12 February 2015 The following standards and references are referred to in the allgemeine bauaufsichtliche Zulassung ('national : - DIN 488-1:2009-08 Reinforcing steels Part 1: Grades, properties, marking - DIN 488-2:2009-08 Reinforcing steels Reinforcing steel bars. - DIN 1045-1:2008-08 Concrete, reinforced and prestressed concrete structures Part 1: Design and construction - DIN EN 1992 1 1:2011-01 Eurocode 2: Design of concrete structures Part 1-1: General rules and rules for buildings; German version EN 1992-1-1:2004+AC:2010 and DIN EN 1992-1-1/NA:2013-04 National Annex - Nationally determined parameters - Eurocode 2: Design of concrete structures Part 1-1: General rules and rules for buildings - DIN EN 10083-2:2006-10 Steels for quenching and tempering Part 2: Technical delivery conditions for non alloy steels; German version EN 10083-2:2006 - DIN EN ISO 6789:2003-10 Assembly tools for screws and nuts -- Hand torque tools Requirements and method for design conformance testing, quality conformance testing and recalibration procedure (ISO 6789:2003) - DIN EN ISO 12944-5:2008-01 Paints and varnishes Corrosion protection of steel structures by protective paint systems Part 5: Protective paint systems (ISO 12944-5:2007); German version EN ISO 12944-5:2007 - DASt Guidelines 006:2008 Welding over shop primers in steel construction - The data sheet is deposited with Deutsches Institut für Bautechnik and the body consulted regarding the external surveillance. Andreas Kummerow Beglaubigt Head of Section
Allgemeine bauaufsichtliche Zulassung ('national of 12 Februar 2015 Standard coupler Coupling bar Threaded bar Installation with torque wrench Item no. Nominal bar diameter Ø Coupler 1 Coupling length L Coupling external Ø Peel length L 1 Coupling and threaded bar 2 Thread length L 2 External thread diameter d CA 12 43 22 33.5 22.0 M13x1.75 60 CA 14 47 22 36.0 24.0 M15x2.0 100 CA 16 47 32 36.0 24.0 M17x2.0 100 CA 20 55 32 36.5 28.0 M21x2.5 200 CA 25 64 40 41.0 32.5 M26x3.0 250 CA 28 69 45 41.0 35.0 M29x3.0 280 Torque M [Nm] CA 32 80 50 51.0 41.0 M33x3.5 450 Dimensions for standard coupler; torque specifications 1 Coupler material in accordance with EN 10083-2, material number: 1.0501/1.0503, steel grade C35/C45 2 Reinforcing steel bars in accordance with DIN 488-1: B500B Mechanical connection of B500B reinforcing steel bars with screw couplers, nominal diameter: 12 to 32 mm Standard coupler Annex 1
Allgemeine bauaufsichtliche Zulassung ('national of 12 Februar 2015 Position coupler 1 st Concreting section 2 nd Concreting section Threaded bar for positioning connection, Threaded bar with loosely screwed on nut secured lock nut and position coupler Individual components 1 st Concreting section, threaded bar for Torque for Minimum screw-in depth positioning connection, nut secured installation threaded bar 2 nd CS Item number Nominal Peel length Thread length Positioning Positioning min. screw-in dimension Torque connection connection depth d L3 L4 C12GEPOS1BA 12 M13 x 1.75 40 35 C14GEPOS1BA 14 M15 x 2 43 38 C16GEPOS1BA 16 M17 x 2 50 45 C20GEPOS1BA 20 M21 x 2.5 56 51 C25GEPOS1BA 25 M26 x 3 61 56 C28GEPOS1BA 28 M29 x 3 65 60 C32GEPOS1BA 32 M33 x 3.5 75 70 Ø M [Nm] 12 60.0 14 100.0 16 100.0 20 200.0 25 250.0 28 280.0 32 450.0 Ø E 12 22.0 14 24.0 16 24.0 20 28.0 25 32.5 28 35.0 32 41.0 2 nd Concreting section, threaded bar with loosely screwed on lock nut and position coupler Nominal dimension Length Ø Position coupler item no. d L D Item no. of the lock nut (for tensile load) Nut height m 1 Item no. of the lock nut (for compressive and alternating load) Nut height m 2 Wrench size s Threaded bar 2nd CS item number Peel length L5 CMGRPOS12 M13 x 1.75 60 22 CKMM13 8 CSKMGRE12 11 22 C12GEPOS2BA 72 67 CMGRPOS14 M15 x 2 60 22 CKMM15 10 CSKMGRE14 13 27 C14GEPOS2BA 72 67 CMGRPOS16 M17 x 2 66 32 CKMM17 12 CSKMGRE16 15 27 C16GEPOS2BA 85 80 CMGRPOS20 M21 x 2.5 74 32 CKMM21 12 CSKMGRE20 19 32 C20GEPOS2BA 95 90 CMGRPOS25 M26 x 3 80 40 CKMM26 15 CSKMGRE25 23 41 C25GEPOS2BA 103 98 CMGRPOS28 M29 x 3 80 45 CKMM29 15 CSKMGRE28 25 46 C28GEPOS2BA 105 100 CMGRPOS32 M33 x 3.5 100 50 CKMM33 15 CSKMGRE32 28 50 C32GEPOS2BA 121 116 Thread length L6 Mechanical connection of B500B reinforcing steel bars with screw couplers, nominal diameter: 12 to 32 mm Bewehrungsanschluss "System Couplerbox" Position coupler Annex 2
Allgemeine bauaufsichtliche Zulassung ('national of 12 Februar 2015 Application principle of position coupler Step 1 Position the threaded bar with the coupler welded on. Perform the concreting of the first concreting section. Step 2 Place positioning coupling bar flush against the threaded bar embedded in concrete in the first concreting section. Screw the position coupler onto the thread of the threaded bar till the stop. When screwing the position coupler on, observe the minimum screw-in depth of the thread on the position coupler. The coupler must not be turned over the colour marking. Secure the position coupler on the back side with the lock nut. Step 3 Tighten the position coupler, which has been screwed on up to the stop, to the necessary torque with a torque wrench. Also retighten the lock nut located on the back and secure it to the necessary torque. Positioning connection Torque Ø M [Nm] 12 60.0 14 100.0 16 100.0 20 200.0 25 250.0 28 280.0 32 450.0 Mechanical connection of B500B reinforcing steel bars with screw couplers, nominal diameter: 12 to 32 mm Application principle of position coupler Annex 3
Allgemeine bauaufsichtliche Zulassung ('national of 12 Februar 2015 Reduction coupler Manufacturer marking Item number Nominal Nominal Length Diameter Torque dimension dimension L D d g d k M g /M k [Nm] CMGRED1412 47 22 M15x2 M13x1.75 100/60 CMGRED1614 47 32 M17x2 M15x2 100/100 CMGRED2016 55 32 M21x2.5 M17x2 200/100 CMGRED2520 64 40 M26x3 M21x2.5 250/200 CMGRED2825 69 45 M29x3 M26x3 280/250 CMGRED3228 80 50 M33x3.5 M29x3 450/280 Steel construction coupler Manufacturer marking Item number Length Nominal dimension Nominal dimension Coupler - external diameter Nominal dimension Nominal dimension Torque L L m L c D d c d m M [Nm] CMGRSTA1312 43 21 22 22 M13x1.75 M12 60 CMGRSTA1516 47 23 24 22 M15x2 M16 100 CMGRSTA1716 47 23 24 32 M17x2 M16 100 CMGRSTA2120 55 27 28 32 M21x2.5 M20 200 CMGRSTA2624 64 32 32 40 M26x3 M24 250 CMGRSTA2930 69 34 35 45 M29x3 M27 280 CMGRSTA3330 81 40 41 50 M33x3.5 M30 450 Mechanical connection of B500B reinforcing steel bars with screw couplers, nominal diameter: 12 to 32 mm Reduction and steel construction coupler Annex 4