European Technical Approval ETA-11/0345

Transcription

1 ETA-Danmark A/S Kollegievej 6 DK-2920 Charlottenlund Tel Fax Internet Authorised and notified according to Article 10 of the 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 MEMBER OF EOTA European ETA-11/0345 Trade name: Holder of approval: BOSSONG BCR EPOXY 21 for rebar connections BOSSONG SPA Via Enrico Fermi 51 IT Grassobbio (Bg) Tel Fax Internet Generic type and use of construction product: Valid from: to: Manufacturing plant: Post-installed rebar connections of the sizes 8 to 32 mm with BOSSONG BCR EPOXY 21 injection mortar BOSSONG SPA Via Enrico Fermi 51 IT Grassobbio (Bg) This European Technical Approval contains: 25 pages including 16 annexes which form an integral part of the document

2 Page 2 of 25 pages no. ETA-11/0345 I LEGAL BASIS AND GENERAL CONDITIONS 1 This European is issued by ETA-Danmark A/S 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, as amended by Council Directive 93/68/EEC of 22 July Bekendtgørelse 559 af (afløser bekendtgørelse 480 af ) om ikrafttræden af EF direktiv af 21. december 1988 om indbyrdes tilnærmelse af medlemsstaternes love og administrative bestemmelser om byggevarer. 4 This European may be withdrawn by ETA-Danmark A/S pursuant to Article 5(1) of Council Directive89/106/EEC. 5 Reproduction of this European Technical Approval including transmission by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 ETA-Danmark A/S. 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 This European is issued by ETA-Danmark A/S in English. This version corresponds fully to the version circulated within EOTA. Translations into other languages have to be designated as such. - Common Procedural Rules for Requesting, Preparing and the Granting s set out in the Annex to Commission Decision 94/23/EC 3. - ETAG Guideline for European Technical Approval of metal anchors for use in concrete Part 5: Bonded anchors 2 ETA-Danmark A/S is authorized to check whether the provisions of this European are met. Checking may take place in the manufacturing plant. Nevertheless, the responsibility for the conformity of the products to the European and for their fitness for the intended use remains with the holder of the European. 3 This European is not to be transferred to manufacturers or agents of manufacturers other than those indicated on page 1, or manufacturing plants other than those indicated on page 1 of this European Technical Approval. 1 Official Journal of the European Communities N o L40, 11 Feb 1989, p Official Journal of the European Communities N o L220, 30 Aug 1993, p 1. 3 Official Journal of the European Communities N o L 17, 20 Jan 1994, p 34.

3 Page 3 of 25 pages no. ETA-11/0345 II SPECIAL CONDITIONS OF THE EUROPEAN TECHNICAL APPROVAL 1 Definition of product and intended use The subject of this approval are the post-installed connections, by anchoring or overlap connection joint consisting of steel reinforcing bars (rebars) in existing structures made of normal weight concrete, using injection mortar BOSSONG BCR EPOXY 21 in accordance with the regulations for reinforced concrete construction. The design of the post-installed rebar connections shall be done in accordance with EN (Eurocode 2). Reinforcing bars with diameters from 8 to 32 mm and BOSSONG BCR EPOXY 21 injection mortar according to Annex 5 are used for the postinstalled rebar connections covered by this ETA. The steel element is placed into a drilled hole previously injected with a mortar and is anchored by the bond between embedded element, injection mortar and concrete. Intended use The post-installed rebar connections may be used in normal weight concrete of a minimum grade C12/15 and maximum grade C50/60 according to EN They may be used in non-carbonated concrete with the allowable chloride content of 0,40 % (Cl 0,40) related to the cement content according to EN The rebar connections may be used for predominantly static loads. - anchoring of reinforcement to cover the line of acting tensile force (Figure 5, Annex 2). The post-installed rebar connections may be installed in dry or wet concrete and it must not be installed in flooded holes. The post-installed rebar connections may be used overhead. The post-installed rebar connections may be used in the temperature range -40 C to +80 C (max. short term temperature +80 C and max. long term temperature +50 C). This ETA covers anchoring in bore holes made with hammer drilling and diamond drilling technique (wet and dry cutting system). Assumed working life The provisions made in this European Technical Approval are based on an assumed intended working life of the anchor of 50 years. The indications given on the working life cannot be interpreted as a guarantee given by the producer or the Approval Body, but are to be regarded only as a means for choosing the right products in relation to the expected economically reasonable working life of the works. Fatigue, dynamic or seismic loading of post-installed rebar connections are not covered by this ETA. The fire resistance of the post-installed rebar connections is not covered by this ETA. The rebar connections may only be carried out in the manner, which is also possible with reinforcing bars, e.g. those in the following applications: - an overlapping joint with existing reinforcement in a building component (Figures 1 and 2, Annex 2), - anchoring of the reinforcement at a slab or beam support (Figure 3, Annex 2; end support of a slab, designed as simply supported, as well as appropriate reinforcement for restraint forces), - anchoring of reinforcement of building components stressed primarily in compression (Figure 4, Annex 2),

4 Page 4 of 25 pages no. ETA-11/ Characteristics of product and assessment 2.1 Characteristics of product The post-installed rebar connections correspond to the drawings and provisions given in Annexes 1 to 14. The characteristic material values, dimensions and tolerances not indicated in Annexes shall correspond to the respective values laid down in the technical documentation 4 of this European. Each mortar cartridge is marked with the identifying mark of the producer and with the trade name. The rebars are either delivered with the mortar cartridges or commercial standard rebars purchased separately. The BOSSONG BCR Epoxy injection mortar is delivered in mortar cartridges in a size of 265 ml, 400 ml and 900 ml in accordance with Annex Methods of verification The assessment of fitness of the anchor for the intended use in relation to the requirements for mechanical resistance and stability and safety in use in the sense of the Essential Requirements 1 and 4 has been made in accordance with the «Guideline for European Technical Approval of Metal Anchors for use in Concrete», Part 1 «Anchors in general» and Part 5 «Bonded anchors», and EOTA Technical Report 023 Assessment of postinstalled rebar connections 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).!n order to meet the provisions of the Construction Products Directive, these requirements need also to be complied with, when and where they apply. 4 The technical documentation of this European Technical Approval is deposited at ETA-Danmark and, as far as relevant for the tasks of the approved bodies involved in the attestation of conformity procedure, is handed over to the approved bodies

5 Page 5 of 25 pages no. ETA-11/ Attestation of Conformity and CE marking 3.1 Attestation of Conformity system The system of attestation of conformity 2 (i) (referred to as system 1) according to Council Directive 89/106/EEC Annex III laid down by the European Commission provides: a) tasks for the manufacturer: 1. factory production control, 2. further testing of samples taken at the factory by the manufacturer in accordance with a prescribed test plan. b) tasks for the notified body: 3. initial type-testing of the product, 4. initial inspection of factory and of factory production control, 5. continuous surveillance, assessment and approval of factory production control. 3.2 Responsibilities Tasks of the manufacturer Factory production control The manufacturer has a factory production control system in the plant and exercises permanent internal control of production. All the elements, requirements and provisions adopted by the manufacturer are documented in a systematic manner in the form of written policies and procedures. This production control system ensures that the product is in conformity with the European. The manufacturer shall only use raw materials supplied with the relevant inspection documents as laid down in the control plan 5. The incoming raw materials shall be subject to controls and tests by the manufacturer before acceptance. Check of incoming materials shall include control of the inspection documents presented by suppliers. The frequency of controls and tests conducted during production and on the assembled anchor is laid down in the control plan taking account of the automated manufacturing process of the anchor. 5 The control plan has been deposited at ETA-Danmark and is only made available to the approved bodies involved in the conformity attestation procedure. The results of factory production control are recorded and evaluated. The records include at least the following information: - designation of the product, basic material and components; type of control or testing; - date of manufacture of the product and date of testing of the product or basic material and components; - result of control and testing and, if appropriate, comparison with requirements; - signature of person responsible for factory production control. The records shall be presented to the inspection body during the continuous surveillance. On request, they shall be presented to ETA-Danmark Details of the extent, nature and frequency of testing and controls to be performed within the factory production control shall correspond to the prescribed test plan which is part of the technical documentation of this European Tasks of notified bodies Initial type testing of the product For initial type testing the results of the tests performed as part of the assessment for the European shall be used unless there are changes in the production line or plant. In such cases the necessary initial type testing has to be agreed between ETA-Danmark and the notified body Initial inspection of factory and of factory production control The approved body shall ascertain that, in accordance with the control plan, the factory and the factory production control are suitable to ensure continuous and orderly manufacturing of the anchor according to the specifications mentioned in 2.1 as well as to the Annexes to the European Continuous surveillance The approved body shall visit the factory at least once a year for regular inspection. It has to be verified that the system of factory production control and the specified automated manufacturing process are maintained taking account of the control plan. Continuous surveillance and assessment of factory production control have to be performed according to the prescribed test plan.

6 Page 6 of 25 pages no. ETA-11/0345 The results of product certification and continuous surveillance shall be made available on demand by the certification body or inspection body, respectively, to ETA-Danmark. In cases where the provisions of the European and the control plan are no longer fulfilled the conformity certificate shall be withdrawn. 3.3 CE marking The CE marking shall be affixed on each packaging of injection mortar cartridge. The symbol «CE» shall be accompanied by the following information: - identification number of the certification body; - name or identifying mark of the - producer and manufacturing plant; - the last two digits of the year in which the CEmarking was affixed; - number of the EC certificate of conformity; - Number of ETA Guideline - number of the European ;

7 Page 7 of 25 pages no. ETA-11/ Assumptions under which the fitness of the product for the intended use was favourably assessed 4.1 Manufacturing The products are manufactured in accordance with the provisions of the European using the automated manufacturing process as identified during inspection of the plant by ETA-Danmark and the approved body and laid down in the technical documentation. 4.2 Drafting Rebar connections must be designed in keeping with good engineering practice. Considering the loads to be anchored, design calculations and design drawings must be produced in a way they can be checked. At least the following items must be given in the design drawings: - grade of concrete strength, - diameter, drilling technique, concrete cover, spacing and embedment depth of the rebar, - kind of preparation of the joint between building component being connected including the thickness of concrete layer that has to be removed. 4.3 Rebar connections design General The actual position of the reinforcement in the existing structure shall be determined on the basis of the construction documentation and taken into account when designing. The design of the post-installed rebar connections according to Annex 2 and determination of the internal section forces to be transferred in the construction joint shall be verified in accordance with EN The minimum clear spacing between two post-installed rebars shall be: a = 40 mm 4 Ø (according to Annex 4) Determination of basic anchorage depth The required basic anchorage length l b,rqd shall be determined in accordance with EN , clause 8.4.3: where: l b,rqd = (Ø / 4) (σ sd / f bd ) Ø = diameter of the rebar σ sd = calculated design stress of the rebar fbd = design value of bond strength according to Annex 3, Table 2 and table 3 in consideration of the coefficient related to the quality of bond conditions and of the coefficient related to the rebar diameter Determination of the design anchorage length The required design anchorage length l bd shall be determined in accordance with EN , clause 8.4.4: l bd = α 1 α 2 α 3 α 4 α 5 l b,rqd l b,min where: α 1, α 2, α 3, α 4, α 5 determined acc. to EN , Table 8.2: α 1 = 1,0 for straight rebars α 2 = 0,7 α2 1,0 calculated acc. to EN , Table 8.2 α 3 = 1,0 because no transverse reinforcement α 4 = 1,0 because no transverse reinforcement α 5 = 0,7 α5 1,0 influence of transverse pressure acc. to EN , Table 8.2 with: l b,rqd = according to clause l b,min = minimum anchorage length acc. to EN , equations 8.6 and 8.7 modified with TR 023, 4.2 l b,min = 1,5 max {0,3 l b,rqd ; 10 Ø; 100 mm} under tension l b,min = 1,5 max {0,6 l b,rqd ; 10 Ø; 100 mm} under compression The maximum anchorage depth is given in Annex 3, Table Overlap joints The required design anchorage length l0 shall be determined in accordance with EN , clause 8.7.3: l 0 = α 1 α 2 α 3 α 5 α 6 l b,rqd l 0,min where: α 1, α 2, α 3, α 5, α 6 determined acc. to EN , Tables 8.2 and 8.3 with: α 1 = 1,0 for straight rebars α 2 = 0,7 α2 1,0 calculated acc. to EN , Table 8.2 α 3 = 1,0 because no transverse reinforcement α 5 = 0,7 α 5 1,0 influence of transverse pressure

8 Page 8 of 25 pages no. ETA-11/0345 α 6 = with: acc. to EN , Table 8.2 1,0 α 6 1,5 influence of percentage of lapped bars relative to the total cross-section area acc. to EN , Table The foregoing may be neglected if building components are new and not carbonated and if building components are in dry conditions. l b,rqd = according to clause l 0,min = minimum lap length acc. to EN , equation 8.11 modified with TR 023, 4.2 l 0,min = 1,5 max {0,3 α6 l b,rqd ; 15 Ø; 200 mm} The maximum anchorage depth is given in Annex 3, Table Embedment depth for overlap joints For the calculation of the effective embedment depth of overlap joints (see annex 4) the concrete cover at endface of bonded-in rebar c 1 shall be considered: l v l 0 + c 1 where: l 0 = required lap length acc. to clause and EN c 1 = concrete cover at end-face of bonded-in rebar If the clear distance between overlapping rebars is greater than 4 Ø the overlap length shall be enlarged by the difference between the clear distance and 4 Ø Concrete cover The concrete cover required for bonded-in rebars is shown in Annex 4. Furthermore the minimum concrete cover given in EN , clause shall be observed Transverse reinforcement The requirements of transverse reinforcement in the area of the post-installed rebar connection shall comply with EN , clause Connection joint The transfer of shear forces between new concrete and existing structure shall be designed according to EN The joints for concreting shall be roughened to at least such an extent that aggregate protrude. In the case of 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 Ø + 60 mm prior to the installation of the new rebar. The depth of concrete to be removed shall correspond to at least the minimum concrete cover for the respective environmental conditions in accordance with EN Installation The fitness for use of the post-installed rebar can only be assumed if the anchor is installed as follows: - installation of the post-installed rebars shall be carried out by appropriately qualified personnel and under the supervision of the person responsible for technical matters on the site; - use of the injection system only as supplied by the manufacturer without exchanging the components of an anchor; - installation in accordance with the manufacturer's specifications and drawings prepared for that purpose and using the tools indicated in the technical documentation of this ETA; - checks before rebar installation to ensure that the strength class of the concrete in which the anchor is to be placed is in the range given and is not lower than that of the concrete to which the characteristic loads apply; - check of concrete being well compacted, e.g. without significant voids; - check the position of existing rebars - keeping the anchorage depth as specified in the design drawings - keeping of the edge distance and spacing as specified in the design drawings, - positioning of the drill holes without damaging the reinforcement, - in case of aborted drill hole: the drill hole shall be filled with mortar, - The drilling and cleaning of the hole and the installation shall be performed only with the equipment as specified by the manufacturer given in annexes 3 to 14. It shall be ensured that this equipment is available on site and is used - component installation temperature shall be at least +5 C, - during installation and curing of the injection mortar the temperature of the concrete must not fall below 0 C, and no more than +30 C, observing the curing time given in Annex Responsibility of the manufacturer It is the manufacturer's responsibility to ensure that the information on the specific conditions according to 1 and 2 including Annexes referred to in and is given to those who are concerned. This information

9 Page 9 of 25 pages no. ETA-11/0345 may be made by reproduction of the respective parts of the European. In addition all installation data shall be shown clearly on the package and/or on an enclosed instruction sheet, preferably using illustration(s). The minimum data required are: - drill bit diameter, - diameter of rebar, - admissible service temperature range, - curing time of the bonding material depending on the installation temperature, - information on the installation procedure, including cleaning of the hole, preferably by means of an illustration, - reference to any special installation equipment needed, - identification of the manufacturing batch. All data shall be presented in a clear and explicit form. 5 Recommendations on packaging, transport and storage The mortar cartridges shall be protected against sun radiation and shall be stored according to the manufacturer's instructions in dry conditions at temperatures of at least +5 C to not more than +30 C. Mortar cartridges with expired shelf life must no longer be used. Thomas Bruun Manager, ETA-Danmark

10 Page 10 of 25 pages no. ETA-11/0345 The post-installed rebar connection consists of injection mortar BCR EPOXY 21 and an embedded straight deformed reinforcing bar with properties of class B and C according to Annex C of EC2. Covered are post-installed rebar connections in non-carbonated concrete C12/15 to C50/60 (EN 206-1) on the assumption only that the design of post-installed rebar connections is done in accordance to EN The BCR EPOXY 21 adhesive can be used in exposure class (EN 206-1) from X0 to XA. Use category: Installation in dry or wet concrete, it must not be installed in flooded holes. Overhead installation is allowable. Use category 2: post-installed rebar connections in concrete Cl 0,40 (EN 206-1). Temperature range: -40 C to +80 C (max. short term temperature +80 C and max. long term temperature +50 C). BOSSONG BCR EPOXY 21 for post-installed rebar connection Product description and intended use Annex 1

11 Page 11 of 25 pages no. ETA-11/0345 BOSSONG BCR EPOXY 21 for post-installed rebar connection Annex 2 Example of use for rebar

12 Page 12 of 25 pages no. ETA-11/0345 Table 1: Drill bit diameter and setting depth 1) Rebar diameter [mm] Ø8 Ø10 Ø12 Ø14 Ø16 Ø20 Ø25 Ø28 Ø32 HD 2) DD 3) HD 2) DD 3) HD 2) DD 3) Nominal drill hole d 0 [mm] Min anchorage depth l b,min [mm] Min overlap joint depth l 0, min [mm] HD 2) Max anchorage depth DD 3) l v, max [mm] ) According to EN modified with TR023: l b,min (8.6) and l 0,min (8.11) with maximum yield stress for rebar BSt 500S, γ M = 1,15, α 6 = 1,0, concrete C20/25 with f bd = 2,30 N/mm 2 and good bond condition. 2) HD: hammer drilling method. 3) DD: diamond drilling method (dry and wet cutting system). Table 2: Design values of the ultimate bond resistance f bd according to EN for hammer drilling method 4) Rebar diameter [mm] Ultimate bond resistance f bd [N/mm 2 ] for Hammer Drilling (HD) C12/15 C16/20 20/25 C25/30 C30/37 C35/45 C40/50 C45/55 C50/60 Ø8 to Ø28 1,60 2,00 2,30 2,70 3,00 3,40 3,70 4,00 4,30 Ø32 1,60 2,00 2,30 2,70 3,00 3,40 3,70 4,00 4,00 Table 3: Design values of the ultimate bond resistance f bd according to EN for diamond drilling method (dry and wet cutting system) 4) Rebar diameter [mm] Ultimate bond resistance f bd [N/mm 2 ] for Diamond Drilling (DD) C12/15 C16/20 20/25 C25/30 C30/37 C35/45 C40/50 C45/55 C50/60 Ø8 to Ø25 1,60 2,00 2,30 2,70 3,00 3,40 3,70 4,00 4,30 Ø28 1,60 2,00 2,30 2,70 3,00 3,40 3,70 3,70 3,70 Ø32 1,60 2,00 2,30 2,70 3,00 3,00 3,00 3,00 3,00 4) The values given in Table 2 and 3 are valid for good bond condition as described on EN For all other conditions multiply the value by 0.7. BOSSONG BCR EPOXY 21 for post-installed rebar connection Annex 3 Setting depths and design values

13 Page 13 of 25 pages no. ETA-11/0345 Figure 6: General design rules of construction for bonded-in rebars The following applies to Figure 6: *If the clear distance between overlapping rebars is greater than 4Ø the overlap length shall be enlarged by the difference between the clear distance and 4Ø. The provision of sufficient transverse reinforcement according to section of this approval must be verified. For the calculation of the effective embedment depth of overlap joints the concrete cover at end-face of bonded-in rebar c 1 shall be considered: l v l 0 + c 1 where: l 0 = required lap length acc. to clause and EN c 1 = concrete cover at end-face of bonded-in rebar c = concrete cover of bonded-in bar c min = the minimum concrete cover is equal to: - c min = ,06 l v 2 Ø [mm] for hammer drilling method (HD) and for diamond drilling technique (DD, dry and wet cutting system Note: the minimum concrete cover according EC2 must be observed a = minimum clear spacing between two post-installed rebars: - a = 40 mm 4 Ø Ø = diameter of bonded-in bar lv = effective embedment depth d0 = nominal drill bit diameter, see table 1, Annex 3 BOSSONG BCR EPOXY 21 for post-installed rebar connection Spacing and edge distances: general rules Annex 4

14 Page 14 of 25 pages no. ETA-11/0345 Table 4: Rebar according to EN , Annex C, Tables C.1 and C.2 Product form Bars and de-coiled rods Class B C Characteristic yield strength f yk or f 0,2k [N/mm 2 ] 400 to 600 Minimum value of k = (f t / f y ) k 1,08 Characteristic strain at minimum force, ε uk [%] 5,0 7,5 Bendability Maximum deviation from nominal mass (individual bar), [%] Bond: Minimum relative rib area, f R,min Rib height h: The rib height h should be: 0,05 Ø h 0,07 Ø Ø = nominal bar diameter Table 5: Injection mortar Nominal bar size [mm] 8 > 8 Nominal bar size [mm] 8 to 12 > 12 1,15 < 1,35 Bend / Rebend test ± 6.0 ± 4.5 0,040 0,056 Product BOSSONG BCR EPOXY 21 two components injection mortar Composition Additive: quartz Bonding agent: epoxy resin Table 6: Minimum curing time 5) Concrete temperature Processing time Minimum curing time 7) 0 C 6) 3 h 20 min 54 h 5 C 6) 2 h 30 min 41 h 10 C 1 h 40 min 28 h 15 C 1 h 10 min 22 h 20 C 50 min 16 h 25 C 30 min 14 h 30 C 20 min 12 h 5) The minimum time from the end of the mixing to the time when the anchor may be torque or loaded (whichever is longer). 6) Minimum resin temperature recommended, for injection between 5 C and 0 C, equal to 10 C. 7) Minimum curing time for dry and wet conditions. 8) Maximum resin temperature for maximum anchorage length equal to 24 C. BOSSONG BCR EPOXY 21 Annex 5 Materials and curing time

15 Page 15 of 25 pages no. ETA-11/0345 BOSSONG BCR EPOXY 21 Annex 6 Cartridge types and sizes

16 Page 16 of 25 pages no. ETA-11/0345 Manual blower pump: nominal dimensions Mixer extension (from 380 mm to 1000 mm) with nominal diameter equal to 8 mm For the hole with depth grater 1000 mm up to 2500 mm it is possible use the special mixer extension (see Annex 9) for blower operation. BOSSONG BCR EPOXY 21 Annex 7 Cleaning tools (1)

17 Page 17 of 25 pages no. ETA-11/0345 Standard brush Table 7: Standard brush diameter Rebar diameter - Ø Ø8 Ø10 Ø12 Ø14 d 0 Nominal drill hole [mm] d b Brush diameter [mm] Special brush Table 8: Special brush diameter (mechanical brush) Rebar diameter - Ø Ø8 Ø10 Ø12 Ø14 Ø16 Ø20 Ø25 Ø28 Ø32 d 0 Nominal drill hole [mm] d b Brush diameter [mm] BOSSONG BCR EPOXY 21 Annex 8 Cleaning tools (2)

18 Page 18 of 25 pages no. ETA-11/0345 Use the mixer extension (assembled on the standard mixer) for the injection up to 300 mm if necessary. Use this system for special conditions: Insert the special mixer extension in the inner diameter of the injection plug up to reach the top of the plug BOSSONG BCR EPOXY 21 Annex 9 Tools for injection (1)

19 Page 19 of 25 pages no. ETA-11/0345 Resin injection pump details Pump example Size cartridge Type 900 ml Pneumatic 400 ml Pneumatic 400 ml Manual (up to 300 mm anchorage depth) 265 ml Manual (up to 300 mm anchorage depth) BOSSONG BCR EPOXY 21 Tools for injection (2) Annex 10

20 Page 20 of 25 pages no. ETA-11/ Drill the hole with the correct diameter and depth using a rotary percussive machine. Check the perpendicularity of the hole during the drilling operation. 2 4x 4x 4x Blower Manual Standard Blower Manual Pump Brush Pump if necessary use a mixer extension for the blower operation (see Annex 7) Clean the hole from drilling dust: the hole shall be cleaned by at least 4 blowing operations, by at least 4 brushing operations followed again by at least 4 blowing operations; before brushing clean the brush and check (see Annex 8, standard brush) if the brush diameter is sufficient. For the blower tools see Annex 7. 3 Unscrew the front cup, screw on the mixer and insert the cartridge in the gun if necessary use a mixer extension for the injection (see Annex 9) ATTENTION: Use the rods dry and free oil and other contaminants Before starting to use the cartridge, eject a first part of the product, being sure that the two components are completely mixed. The complete mixing is reached only after that the product, obtained by mixing the two component, comes out from the mixer with an uniform color. Fill the drilled hole uniformly starting from the drilled hole bottom, in order to avoid entrapment of the air; remove the mixer slowly bit by bit during pressing-out; filling the drill hole with a quantity of the injection mortar corresponding to 2/3 of the drill hole depth. Insert immediately the rebar, marked according to the proper anchorage depth, slowly and with a slight twisting motion, removing excess of injection mortar around the rebar. Observe the processing time according Annex 5. Wait the curing time according Annex 5. BOSSONG BCR EPOXY 21 Installation procedure up to 300 mm depth (hammer drilling) Annex 11

21 Page 21 of 25 pages no. ETA-11/ Drill the hole with the correct diameter and depth using a rotary percussive machine. Check the perpendicularity of the hole during the drilling operation x 5 seconds 4x 4 x 5 seconds ATTENTION: compressed air free oil Clean the hole from drilling dust: the hole shall be cleaned by at least 4 blowing operations (5 seconds for single operation) with compressed air, by at least 4 brushing operations with special brush followed again by at least 4 blowing operations (5 seconds for single operation) with compressed air. Before brushing clean the brush and check (see Annex 8, special brush) if the brush diameter is sufficient. For the blower tools see Annex 7. Unscrew the front cup of the 400 ml or 900 ml size cartridges, screw on the mixer and insert the cartridge in the proper pneumatic-pump ATTENTION: Use the rebar dry and free oil and other contaminants Before starting to use the cartridge, eject a first part of the product, being sure that the two components are completely mixed. The complete mixing is reached only after that the product, obtained by mixing the two component, comes out from the mixer with an uniform color. Before starting the injection, assemble the system according to Annex 9. After that, fill the drilled hole uniformly from the drilled hole bottom, in order to avoid entrapment of the air; remove the special mixer extension with injection plug slowly bit by bit during pressingout; filling the drill hole with a quantity of the injection mortar corresponding to 2/3 of the drill hole depth. Procedure for overhead installation are detailed in Annex 14. Insert immediately the rebar, marked according to the proper anchorage depth, slowly and with a slight twisting motion, removing excess of injection mortar around the rebar. Observe the processing time according Annex 5. Wait the curing time according Annex 5. BOSSONG BCR EPOXY 21 Installation procedure up to max anchorage depth (hammer drilling) Annex 12

22 Page 22 of 25 pages no. ETA-11/ Drill the hole with the correct diameter and depth using a core drill machine. Check the perpendicularity of the hole during the drilling operation. Remove completely the core from the hole. After operation 1, if the diamond drilling machine used has a dry cutting system to proceed with the installation procedure according to the point 2. Instead if it is used a wet cutting system before of the point 2 the following operation must be done: - flush hole 2 times by inserting a water hose to the back of the hole until water runs clear; - brush 2 times with the proper special brush. Before brushing clean the brush and check (see Annex 8, special brush) if the brush diameter is sufficient; - flush again 2 times until water runs clear; - remove all standing water completely (using for example vacuum system or compressed air free oil). 2 4 x 5 seconds 6x 4 x 5 seconds ATTENTION: compressed air free oil Clean the hole from drilling dust: the hole shall be cleaned by at least 4 blowing operations (5 seconds for single operation) with compressed air, by at least 4 brushing operations with special brush followed again by at least 4 blowing operations (5 seconds for single operation) with compressed air. Before brushing clean the brush and check (see Annex 8, special brush) if the brush diameter is sufficient. For the blower tools see the Annex 7. After the operation above, to follow the operations from 3 to 6 on the previous Annex 12 and 11 in function of the depth of the hole. BOSSONG BCR EPOXY 21 Installation procedure with diamond drilling (wet and dry) for all depths Annex 13

23 Page 23 of 25 pages no. ETA-11/0345 BOSSONG BCR EPOXY 21 Overhead installation procedure Annex 14

24 Page 24 of 25 pages no. ETA-11/0345 BOSSONG BCR EPOXY 21 for post-installed rebar connection Annex 15 Design Values for anchoring connection

25 Page 25 of 25 pages no. ETA-11/0345 BOSSONG BCR EPOXY 21 for post-installed rebar connection Annex 16 Design Values for overlap joint connection