Cast-in Channels 9-1.

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1 Cast-in Channels 9-1

2 Contents Typical Channel Applications 9-3 Typical Cast-in Channel Anchor Variations 9-4 Cast-in Channel - Cold Rolled 9-5 Cast-in Channel - Hot Rolled 9-7 T-Bolts 9-8 Longitudinal Resistance 9-10 Toothed Channel Type CHT 9-11 CFS Flexi Channels Type F 9-12 CFS Captive Fixing Nuts 9-13 CFS UNI Channel 41/21 Cast-In Insert 9-14 Sled Channels for Metal Deck Floors 9-15 Met Stop for Fixing to the Edge of Metal Deck Floors 9-16 CFS Plain Back Channels 9-18 Special Channel Fabrications 9-19 Channels - Material, Standards 9-20 CAST-IN CHANNELS

3 Typical Channel Applications Curtain Wall Curtain Wall: Bracket to Top of Slab Curtain Wall: Bracket to Side of Slab Masonry Support System: Fixing brick and stone support angles Structural Steel: Curtain Wall Bracket Steel to Structural Steel with Plain Backet Channel Fixing of Mechanical Services Pipe Support Bracket to Underside of Slab Lift guide rails Fixing elevator guide rails and door surrounds 9-3

4 Typical Cast-in Channel Anchor Variations CFS high quality inserts are designed to provide flexible fixing points for concrete structures. Channels are ideal for use near the edges of concrete where drilling is not possible. They are ideal for use in post-tensioned structures. T -bolts can be placed in the channels easily and moved to the desired position. Subsequent removal of components is very simple. CFS-S stud anchor standard CFS-W welded wave anchor CFS channels can be supplied with either of the above anchor configurations. The load capacity is identical. Standard anchor centres on long lengths of channel are 250 mm. Other centres can be supplied on request. Special anchor types can be provided to suit specific site requirements. T-Bolts T head bolts or locking plates are simply inserted anywhere along the channel and turned through 90 to block into position. Filler All channels intended for casting in contain CFS quick to remove filler. CAST-IN CHANNELS Cold Rolled or Hot Rolled In most circumstances, cold rolled sections provide the appropriate solution. Where vibration is an issue or in safetycritical applications, hot rolled channels should be considered. If in doubt, seek advice. 9-4

5 Cast-in Channel - Cold Rolled Channel Anchor PEC-TA 28/15 Cold rolled Bolt anchor PEC-TA 38/17 Cold rolled Bolt anchor PEC-TA 40/25 Cold rolled Bolt anchor PEC-TA 49/30 Cold rolled Bolt anchor PEC-TA 54/33 Cold rolled Bolt anchor PEC-TA 72/49 Cold rolled Welded I anchor min 15 min 15 min 15 min min α α β α α β α β β Material Hot-dip. galvan. x x x x x x Stainless steel A4 x x x x x x Stainless steel A2 On Demand On Demand On Demand On Demand On Demand On Demand Bolt 28/15 38/17 40/22 50/30 50/30 72/48 h ef,min /b ch /h ch 45/28/15 76/38/17 79/40/25 94/50/30 155/53.5/33 179/72/49 h ef,min - Effective anchoring depth min. b ch - Width of channel h ch - Height of channel Anchor centres (mm) F F F F F F F F F F 2F 2F 2F 2F 2F mm 150mm (recommended 150mm 150mm (recommended minimum) minimum) minimum) F r F r F r F F rrr F r F F r r F r r F r r F r r F r r F r r F r r F r F rr F r Standard Short piece cast-in channels Standard channel lengths (mm) Other short lengths are available to order, please consult CFS. Cold Rolled C-Channel 9-5

6 Cast-in Channel - Cold Rolled Dimensioning and design calculations The design of the products with a European Technical Approval is based on the standard CEN/TS We provide PEC Rail software to allow you to optimize product selection, which is available on our website The design loads for the CFS-PEC-TA Cast in channel are provided in this brochure. Please contact our technical office for assistance if necessary Load capacities for cold rolled channels Capacities per bolt where the T-bolts are spaced no closer than the anchors on the back of the channel CFS-PEC- TA 28/15 CFS-PEC- TA 38/17 CFS-PEC- TA 40/25 CFS-PEC- TA 49/30 CFS-PEC- TA 54/33 CFS-PEC- TA72/49 Tension Capacity C25/30 where c Tension Only Max Shear Capacity C30/37 where c Shear Only Min Shear Capacity C30/37 where c Shear Only Slab thickness (if thinner, consult software) Anchor Spacing 5min mm kn mm kn mm kn mm mm mm max CAST-IN CHANNELS This table may be used in simple cases. The values are for tension only, shear only, or compare resultant forces of a tension and shear components with the shear capacities. In cases where there is a longitudinal force along the length of the channel, please see our nibbed bolt and toothed channel products. These values are ultimate capacities and should be compared with the factored design loads. PEC Rail software is available on our website that would be useful for complex cases, with tensile and shear forces together, with close edge distances, different slab thickness or different concrete strength. CFS will provide technical assistance for any problems you have, so if in doubt, ask for help. 9-6

7 Cast-in Channel - Hot Rolled Channel PEC-TA 40/22 PEC-TA 50/30 PEC-TA 52/34 Anchor Hot rolled Hot rolled Hot rolled Welded I anchor Welded I anchor Welded I anchor Hot Rolled C-Channel Material Hot-dip. galvan. x x x Stainless steel A2 On Demand On Demand On Demand Bolt to suitv 40/22 50/30 50/30 h ef,min /b ch /h ch 79/40/22 94/50/30 155/52/34 h ef,min - Effective anchoring depth min. b ch - Width of channel h ch - Height of channel Capacities per bolt where the T-bolts are spaced no closer than the anchors on the back of the channel Tension Capacity C25/30 Shear Capacity C30/37 Shear Capacity C30/37 Slab thickness Anchor Spacing where c Tension Only where c Shear Only where c Shear Only (if thinner, consult software) 5min 5max mm kn mm kn mm kn mm mm mm PEC-TA 40/ PEC-TA 50/ PEC-TA 52/ This table may be used in simple cases. The values are for tension only, shear only, or compare resultant forces of a tension and shear components with the shear capacities. These values are ultimate capacities and should be compared with the factored design loads. For more complicated design cases, please consult with CFS who will prepare a calculation for situation. 9-7

8 T-Bolts CFS T-bolts are drop forged specifically designed to be used with the appropriate channel section. All mild steel T-bolts are supplied electroplated finish as standard grade 4.6. They are also available grade 4.6 hot dip spun galvanised to BS-1971 to provide a minimum of 43 microns thickness. Stainless steel T-bolts are A2 grade 50. Grade A4 and class 70 are also available to order. Please note that when deciding the correct channel and T -bolt combination the load capacity of both channel and T -bolt need to be taken into consideration. Size Range for Channels Type T Bolt 28/15 T Bolt 38/17 T Bolt 40/22 T Bolt 50/30 T Bolt 72/48 All bolts are delivered in one box with nuts and washers. Nuts and washers are packed in separate plastic bags. Electro zinc plated* x x x x x Stainless steel A4 x x x x x Grade 4.6 as standard x x x x x 8.8 on request x x x x x Diameter M8-M12 M10-M16 M10-M16 M12-M20 M20-M30 Length (mm) *Hot-dip galvanised available on request. CAST-IN CHANNELS SWL and Technical Characteristics Grade 4.6 Grade 8.8 Bolt size Torque Nm Max. Load kn* Bending Max. Load kn* Torque Moment Nm Tension Shear knm Tension Shear Bending Moment knm M M M M M M M M M * Please also check channel capacities for the conditions present. 9-8

9 DETERMINING REQUIRED BOLT LENGTH Profile Type f (mm) Bolt m+s+u (mm) CFS-PEC-TA 28/15 Cold 2.3 M6 8.8 CFS-PEC-TA 38/17 Cold 3 M CFS-PEC-TA 40/25 Cold 6 M CFS-PEC-TA 49/30 Cold 7.5 M CFS-PEC-TA 54/33 Cold 8 M CFS-PEC-TA 72/49 Cold 10 M CFS-PEC-TA 40/22 Hot 6 M CFS-PEC-TA 50/30 Hot 8 M CFS-PEC-TA 52/34 Hot 11.5 M30 40 Cold = Cold rolled Hot = Hot rolled l = Required bolt length f = Height of the profile lip m = Height of the nut s = Thickness of the washer l k = Clamping thickness u = Length of bolt protruding Once you have determined the minimum required bolt length for your application, please consult with CFS to establish the suitable stock length. We carry a wide range of lengths in stock. 9-9

10 Longitudinal Resistance Where forces exist along the length of the channel, there are two alternative solutions, ribbed T-Bolts alongside our hot-rolled channels, or toothed channels. If in doubt, please send your conditions to CFS for advice. Nibbed T-Bolts These bolts must be used with hot rolled channels, hot dipped galvanized. All bolts grade 8.8 Channel Nibbed T-Bolt Toque Nm CFS-PEC-TA 40/22 HSZ M CFS-PEC-TA 50/30 HSZ M CFS-PEC-TA 50/30 HSZ M CFS-PEC-TA 52/34 HSZ M A steel-to-steel contact is required between channel and attachment. A calibrated torque wrench must be used. Longitudinal Design Capacity kn CAST-IN CHANNELS 9-10

11 Toothed Channel Type CHT Bolt diameter Channel profile (CHT) Allowable loads in reinforced concrete (kn) Long length Short channel or single bolt with bolt pair 3-anchor or single bolt 3-anchor Longitudinal loads Long length Bolt pair or single bolt 2-anchor* 3-anchor* Minimum spacing in reinforced concrete (mm) Channel spacing Normal pair Parallel edge End edge C1 C2 C3 C1 C2 C C1 C2 C3 T-bolts Grade 8.8 M16 38/23 41/22 M12 38/23 41/22 Stainless steel bolts M16 41/ M12 41/ Notes: *Subject to check on resultant load. Pull-out, transverse shear or resultant loads. Allowable loads quoted are after application of a Safety Factor of approximately 2.5 on test in reinforced concrete. For extreme bolt positions and minimum cut edge distances, please consult CFS Ltd. Two bolts on the same channel taking longitudinal loads can be as little as 50mm apart, please consult CFS Ltd

12 CFS Flexi Channels Type F CFS Flexi Channels are ideally suited for the quick, reliable and cost efficient fixing of different construction elements to metal deck floors. The insert can be adjusted in height to suit the varying floor profiles and fabricated ski assemblies are simple to fit to the base of the adjustable feet. CFS Cast-In 49/30 with Flexible Anchor Product Description Hot dipped galvanized or stainless steel Length [mm] Number of Anchors Min. Total Height [mm] Max. Total [mm] CFS - TA/F - 40/25, 49/ or (2) / 350 (3) CFS - TA/F - 40/25, 49/30, 54/ or (2) / 350 (3) CFS - TA/F - 40/25, 49/30, 54/ or (2) / 350 (3) Other lengths / profile types or materials are available on request For min. total height = 60mm the loads FRd have to be reduced by factor 0.92 N V N N V V Total min and max height CAST-IN CHANNELS 200m 350m Section Tension [kn] SWL [NRD] Shear [kn] SWL [N] Resultant [kn] SWL [R] Min. Edge Distance [mm] T-Bolts SWL 40/ mm (9.3kN) 16mm (17.3kN) 49/ mm (17.3kN) 20mm (27.0kN) 54/ mm (17.3kN) 20mm (27.0kN) All load values in accordance with design criteria CEN /TS Loads based on minimum C35 concrete strength For 350mm channels minimum bolt centres = 150mm For minimum height flexi anchors reduce the load by (x 0.92) 9-12

13 CFS Captive Fixing Nuts The Economic Fix to Channel Inserts The main benefits are: Channels are supplied ready for casting in complete with the channel nuts. Very quick to install no down time looking for seperate T-Bolts. Very economical particularly for larger diameters and longer projections. Captive Nut Data for Cast-In Channel Inserts Captive Nut Indicative Load Capacities 40/25 Channel c/w M12 Captive Nut 8kN Tensile: 10kN Shear 49/30 Channel c/w M16 Captive Nut 12.5kN Tensile: 15kN Shear 54/33 Channel c/w M20 Captive Nut 25kN Tensile: 25kN Shear 40/25 Channel c/w M12 Captive Nut 49/30 Channel c/w M16 Captive Nut 54/33 Channel c/w M20 Captive Nut 9-13

14 CFS UNI Channel 41/21 Cast-In Insert Size: 41 x 21 x 2.5mm Concrete inserts are available in standard lengths of 3 metres which are supplied complete with polystyrene infill and End Caps in place. Non-standard lengths can be supplied in increments of 200mm. Dedicated lengths to suit your requirements can also be produced. Finish pre-galvanised or hot dip galvanised. If site installation requires the concrete insert to be cut and end caps must be reinserted at each end mm mm 100mm CAST-IN CHANNELS 7mm Diameter Fixing Hole 21mm Recommended loadings UNI Channel 41/21 Point load (250mm centres) Continuous Load (per 1000mm) Concrete Strength 35 N/mm Safe working load 5.5 kn 22 kn 41mm 9-14

15 Sled Channels for Metal Deck Floors CFS ski channels are designed to to be used in the top surface of metal deck floors. Ski channel assemblies allow channel inserts to be easily positioned so that they are flush with the surface of the concrete and maintain a correct edge distance from the decking edge trim. Ski channel assemblies are fabricated to suit your particular project requirements. We manufacture to suit your slab depth and decking type and edge condition details. CFS will be pleased to advise of the most economical assembly for you. Channel with support foot for metal deck flooring Ski allowable load data (for typical example when used to fix curtain walling) Min. edge Resultant Loads (R) Reinforcement Channel distance e Single point Bolt pair* requirements 38/ mm 16 kn 12 kn Standard mesh 40/ mm 18 kn 16 kn and 49/ mm 10 kn 20 kn 10 mm dia. bar Notes: Quoted loads assume unit cast into lightweight con- 450 mm long crete minimum 130 mm thick, 25 N/mm 2 strength and are with after the application of a safety factor of approximately 3:1. 4 No. * Loads quoted assume the component is fixed to sled 10 mm dia. assembly using two bolts minimum 100 mm apart. Bobs(300/80) 9-15

16 Met Stop for Fixing to the Edge of Metal Deck Floors CFS Met stop provides the complete solution for fixing to metal deck floors. Comprising a cast-in channel contained within a metal edge trim. to order Min 50 to order CFS Met stop is manufactured to suit your particular project conditions. Met-stop edge trim is produced from pre-galvanized sheet with either hot-dip galvanized or stainless steel channel inserts. CAST-IN CHANNELS Typical installation showing Met stop shot fired or tek-screwed down to the steel frame. Restraint straps are provided to give additional restraint to the upper edge. Fix restraint straps, tying vertical leg backto the metal decking 9-16

17 MET STOP LOAD DATA AND REINFORCEMENT REQUIREMENTS Met stop load data and reinforcement requirements Loading data for lightweight concrete of minimum 25 N/mm 2 strength reinforced as detailed on previous page. Loading data for lightweight concrete of minimum 25 N/mm 2 strength reinforced as detailed on previous page. 250 mm mc ed Extreme bolt Allowable Maximum position (ed), resultant Met stop cantilever (c)* (assuming mc)* load (F) 28/15 MTS 40 mm 25 mm 3.5 kn 38/17 MTS 50 mm 30 mm 6.0 kn 40/25 MTS 75 mm 45 mm 8.0 kn Quoted loads are after the application of a safety factor of 3:1. * Preferred cantilever = 25 mm. F Reinforcement requirements to achieve full loading in lightweight concrete, strength 25 N/mm 2. Reinforcement requirements to achieve full loading in lightweight concrete, strength 25 N/mm 2. to order to order min. min to order to order standart mesh standart mesh Standard mesh plus 10 Standard mm diameter mesh longitudinal bar plus with 10 mm diameter longitudinal bar 10 mm diameter bobs (300/80) with at mm mm diameter centres bobs for long (300/80) lengths 150 at 300 mm mm centres centres for short for long lengths lengths 150 mm centres for short lengths CFS Met stop can be provided to suit your site requirements at short notice. We manufacture to suit your site dimensions. CFS Met-stop can be provided to suit your site requirements at short notice. We manufacture to suit your site dimensions

18 CFS Plain Back Channels Plain back channels are useful in non-concrete applications for example, welded to steel stations. Max.point load Bending load capacity at span L (single span element) F flex [kn] 2x F flex [kn] q flex [kn/m] Corresponding Bolt Fz [kn] L max [cm] L [m] L [m] L [m] Type Thread M 28/ / / / / / / / / / / / / / CAST-IN CHANNELS 52/ / / / All load bearing are calculated as elastic-plastic values according to DIN 18800; these are approximate values and can be used for EC3. Partial safey coefficient gamma f =1.4, deflection =max l/150. Calculate the design values as F R,d =1.4xF For other sizes, please consult CFS

19 Special Channel Fabrications Welded in pairs to aid setting out SKI Channel for the Metal Deck Floor Radiussed Fabricated corner piece 9-19

20 Channels - Material, Standards Channel Hot Rolled, Cold Rolled T-Bolt Grade 4.6, Grade 8.8 Mild Steel Material S235JR (RSt 37-2) Material No , DIN EN Hot Dip Galvanized Stainless Steel Material S235JR (RSt 37-2) Material No , DIN EN hot dip galvanised - DIN EN ISO 1461, zinc coating 50 µm HCR Material No / DIN EN A4 Material No / / DIN EN Hot Dip Galvanized DIN EN ISO 10684, DIN EN ISO DIN EN ISO 4034 zinc coating 40 µm Stainless Steel DIN 50961, DIN EN 1403, DIN EN ISO 4042 DIN EN ISO zinc coating 12 µm Grade A2-50, A2-70 Grade A4-50, A4-70 HCR Material No , HCR50 DIN EN DIN EN A4 Material No / / DIN EN ISO DIN EN CAST-IN CHANNELS 9-20

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