English translation prepared by DIBt Original version in German language

Transcription

1 Date: Reference: I /12 (73/13) English translation prepared by DIBt Original version in German language Approval number: Validity Z from: 14 May 2013 Applicant: Hilti Deutschland AG Hiltistraße Kaufering to: 14 May 2018 Subject of approval: Hilti Undercut Anchor HDA for fastenings in nuclear power plants and other nuclear facilities The subject of approval mentioned above is herewith generally approved in the field of construction. This allgemeine bauaufsichtliche Zulassung ('national technical approval') comprises nine pages and 20 annexes.

2 No. Z Page 2 of 9 14 May 2013 I GENERAL PROVISIONS 1 With the allgemeine bauaufsichtliche Zulassung ('national technical approval') the fitness for use and the applicability of the subject of approval according to the Landesbauordnungen ('Building Regulations of the Land') has been verified. 2 If, in the allgemeine bauaufsichtliche Zulassung ('national technical approval') requirements are made concerning the special expertise and experience of persons entrusted with the manufacture of construction products and types of construction according to the relevant regulations of the Land following section 17, sub-section 5 Musterbauordnung ('Model Building Code'), it is to 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 technical approval') does not replace the permits, approvals and certificates prescribed by law for carrying out building projects. 4 The allgemeine bauaufsichtliche Zulassung ('national technical approval') 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 technical approval') available to the user and point out that the allgemeine bauaufsichtliche Zulassung ('national technical approval') has to be available at the place of use. Upon request copies of the allgemeine bauaufsichtliche Zulassung ('national technical approval') shall be placed at the disposal of the authorities involved. 6 The allgemeine bauaufsichtliche Zulasssung ('national technical approval') may be reproduced in full only. Publication in the form of extracts 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 technical approval'). Translations of the allgemeine bauaufsichtliche Zulassung ('national technical approval') have to contain the note "Translation of the German original, not checked by Deutsches Institut für Bautechnik". 7 The allgemeine bauaufsichtliche Zulassung ('national technical approval') 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. Z /13

3 No. Z Page 3 of 9 14 May 2013 II SPECIFIC PROVISIONS 1 Subject of approval and field of application 1.1 Subject of approval The Hilti undercut anchor HDA is a self-cutting undercut anchor. It is available in the sizes M10, M12, M16 made of galvanised zinc-plated steel (HDA) and made of stainless steel (HDA-R) in the versions for pre-setting and through-fastening installation. The anchor for pre-setting (HDA-P and HDA-PR) and the anchor for through-fastening (HDA-T and HDA-TR) consist of a cone bolt with external thread, an expansion sleeve, a plastic ring, a hexagon nut with injection washer and spherical washer (filling set), a plastic cap and optional the Hilti injection mortar HIT-HY 200-A. The anchor is set by mechanical interlock and anchored by displacement control in a hole drilled with a special stop drill bit and using a special setting tool intended for this use. During setting of the anchor the undercut is made. The fixture is fastened by tightening the nut. Following the injection mortar can be pressed through the injection washer into the annular gap between the fixture and the anchor for the reduction of the displacements under shear load. The installed anchor is shown in Annexes 1 and Intended use The anchor may be used for anchorages subject to static or quasi-static loading for Requirement Categories A1, A2 and A3 according to the Leitfaden für Dübelbefestigungen in Kernkraftwerken und anderen kerntechnischen Anlagen 1 in reinforced and unreinforced normal weight concrete of strength classes C20/25 at minimum and C50/60 at maximum according to DIN EN 206-1: ); it may also be used in concrete of strength class B 25 at minimum and B 55 at maximum according to DIN 1045: The anchor may only be used when there are no requirements relating to fire resistance that have to be met by the entire structure including the anchor. It may be used in cracked and non-cracked concrete. Under accidental actions (Requirement Category A2 and A3) the anchor may be used up to a crack width w k = 1.0 mm. The anchor must not be used for fastenings in critical structure areas where the concrete could spall or large cracks could occur under extreme loads, for example, in the area of plastic hinges (critical areas) of concrete structures. The anchor made of galvanised zinc-plated steel may only be used in concrete subject to dry internal conditions. The anchor made of stainless steel (materials , und ) may be used according to the corrosion resistance class III of the Allgemeine bauaufsichtliche Zulassung "Erzeugnisse, Verbindungsmittel und Bauteile aus nichtrostenden Stählen" Nr. Z ('national technical approval Products, connecting elements and components made of stainless steel' no. Z ). If the filling of the annular gap with injection mortar is necessary for limiting the displacements under shear loads, the anchor may be used only in buildings and rooms with a maximum dose rate of 20 msv/a. The temperature in the mortar area must not exceed 72 C, short-term 120 C. 1 Deutsches Institut für Bautechnik: Leitfaden für Dübelbefestigungen in Kernkraftwerken und anderen kerntechnischen Anlagen ( Guideline for fastenings with anchors in nuclear power plants and nuclear facilities ), issued June 2010 Z /13

4 No. Z Page 4 of 9 14 May Provisions for the construction product 2.1 Properties and composition The anchor shall comply with the specifications and drawings given in the annexes. The material properties, dimensions and tolerances of the anchor not given in this allgemeine bauaufsichtliche Zulassung shall comply with the information deposited at Deutsches Institut für Bautechnik, the certification body and the external surveillance body. Material specifications of the anchor parts are given in Annex 4, Table 2. The mechanical properties of the cone bolt shall comply with the deposited specifications. The anchor is made of a non-combustible material of class A according to DIN : "Brandverhalten von Baustoffen und Bauteilen; Baustoffe - Begriffe, Anforderungen und Prüfungen" ('Fire behaviour of building materials and building components; Building material; terminology, requirements and tests'). 2.2 Packaging, storage and marking Packaging and storage The anchor shall be supplied as a complete fastening unit. The mortar foil packs and the filling set are packed separately. The foil packs shall be protected against sun radiation and shall be stored according to the manufacturer s installation instructions in dry conditions at temperatures of at least +5 C to not more than +25 C Marking The packaging, enclosed instructions or delivery note of the anchor shall be marked by the manufacturer with the conformity mark (Ü-mark) according to the Übereinstimmungszeichen- Verordnungen der Länder ('Regulations on the conformity mark of the states of the Federal Republic of Germany'). In addition, the manufacturing mark, the approval number and the complete anchor designation shall be declared. The marking may only be carried out if the requirements according to Section 2.3 "Übereinstimmungsnachweis" ('Verification of conformity') have been met. The anchor is designated by the anchor type (HDA-P KKW, HDA-PR KKW, HDA-T KKW or HDA-TR KKW), the thread size of the cone bolt, the anchorage depth and the maximum thickness of fixture. Each anchor is designated according to Annex 5. For the anchor type HDA-T (throughfastening anchor) the anchorage depth shall be marked. The injection washer in the version as cast part is embossed with the lettering "Hilti". The injection washer made of stainless steel is embossed with "A4". Each foil pack is marked with the manufacturing mark "HIT-HY 200-A", the batch number and the expiry date. The foil packs shall be marked in accordance with the Verordnung über gefährliche Arbeitsstoffe ('Regulation on hazardous materials') and provided with information about the hazard code and processing. The installation instructions supplied with the mortar shall contain the information on safety measures for dealing with hazardous materials. 2.3 Übereinstimmungsnachweis ('Verification of conformity') General Each manufacturing plant shall confirm that the anchor complies with the provisions of this allgemeine bauaufsichtliche Zulassung by means of a certificate of conformity based on the factory production control and a regular external surveillance, including initial testing of the anchor in accordance with the following provisions. Z /13

5 No. Z Page 5 of 9 14 May 2013 The manufacturer of the anchor shall organise a recognised certification body and a recognised inspection body to issue a certificate of conformity and for the external surveillance, including product testing that has to be carried out. The manufacturer shall state by marking the products with the conformity mark (Ü-mark) with reference to the intended use, that the certificate of conformity is issued. The certification body shall send a copy of the issued certificate of conformity to Deutsches Institut für Bautechnik. The required verifications for the raw material and for the supplied anchor parts shall be in accordance with the control plan which is deposited by Deutsches Institut für Bautechnik and by the external surveillance body Factory production control Each manufacturing plant shall set up and carry out a factory production control. Factory production control is a continuous surveillance of production by the manufacturer who thus ensures that the manufactured construction product is in conformity with the provisions of this allgemeine bauaufsichtliche Zulassung. Extent, type and frequency of the factory production control shall be in accordance with the control plan which is deposited by Deutsches Institut für Bautechnik and by the external surveillance body. The results of factory production control shall be recorded and evaluated. The records shall include at least the following information: - Designation of the construction product respectively the raw material and its components - Type of control or test - Date of manufacture and test of the construction product respectively of the raw material or components - Results of control and tests and, if applicable, a comparison with requirements - A signature of the person responsible for factory production control. The records shall be deposited for at least five years and presented to the recognised external surveillance body. On request, they shall be submitted to Deutsches Institut für Bautechnik and to the zuständige oberste Bauaufsichtsbehörde ('responsible building authority'). If the test results are unsatisfactory, the manufacturer shall immediately take the action necessary to eliminate the deficiency. Construction products which do not meet requirements shall be treated in such a way that confusion with conforming products is excluded. Once the deficiency has been eliminated, the original test shall be repeated immediately, provided that this is technically possible and also required to verify the elimination of the deficiency External surveillance In each production plant, external surveillance shall be carried out regularly, but at least once a year, to check the factory production control. During external surveillance, initial testing of the anchor shall be carried out and random samples taken. Sampling and testing are done on responsibility of the recognised surveillance body. Extent, type and frequency of the external surveillance shall be in accordance with the control plan which is deposited by Deutsches Institut für Bautechnik and by the external surveillance body. Z /13

6 No. Z Page 6 of 9 14 May 2013 The results of certification and external surveillance shall be deposited for at least five years. On request, they shall be submitted to Deutsches Institut für Bautechnik and the responsible building authority by the certification body respectively by the surveillance body. 3 Provisions for design 3.1 Design (concept) For the Requirement Categories A2 and A3 the "Leitfaden für Dübelbefestigungen in Kernkraftwerken und anderen kerntechnischen Anlagen" 1 shall be observed. The evaluation regarding the crack width w k = 1.0 mm consider the collective extreme cases, so that a separate verification of the expected crack width in the anchoring area is not necessary when minimal reinforcement is present. The anchorages shall be designed in accordance with engineering practice. Verifiable calculation notes and design drawings shall be prepared taking into account the loads to be anchored. The position of the anchor shall be specified in the design drawings and it is to specify whether the optional filling is planned to perform. 3.2 Design (dimensioning) The anchorages are designed under the responsibility of an engineer experienced in anchorages and concrete work in accordance with ETAG 001 "Guideline for European Technical Approval of Metal Anchors for Use in Concrete", Annex C (August 2010), Design method A. The provisions of Sections 4.2 to 4.9 of the Leitfaden (Guideline) 1 shall be considered deviating or supplementary to the Design method mentioned above. Partial safety factors and load combination factors of actions of the Requirement Category A2 and A3 are taken from DIN 25499: The characteristic anchor values for the design of the anchorage according to ETAG 001, Annex C are given in Annexes 9 to 13 (Requirement Categories A1, A2 and A3). It is to be ensured that the strength class of the concrete in which the anchor is to be placed is not lower than that of the concrete to which the characteristic loads apply. The concrete strength class shall be not lower than B25 or C20/25 and shall not exceed B55 or C50/60. For design of anchorages in normal weight concrete according to DIN 1045: , the value for f ck,cube shall be replaced by 0.97 x β WN. When determining the length of the lever arm of the shear load for anchor types HDA-T and HDA-TR, the restraint in the concrete shall be assumed at 0.5 x the bold diameter from the concrete surface. When determining the length of the lever arm of the shear load for anchor types HDA-P and HDA-PR, the restraint in the concrete shall be assumed according to Annex 12, Table 11 or Annex 13, Table 12. Furthermore, the possible displacement in the direction of the tension component shall be considered (see Annex 10, Table 9). When determining the thickness of the fixture any necessary mortar leveling layer is taken into account (see Section 4.3 and Annex 5, Table 3). The verification of the immediate local transmission of the anchor loads into the concrete member is proven. The transmission of the anchor loads to the supports of the concrete member shall be proven. Z /13

7 No. Z Page 7 of 9 14 May Provisions for installation 4.1 General The anchor shall only be used as a complete fastening unit delivered in series. Components of the anchor must not be exchanged. It may only be installed by appropriately qualified personnel under the supervision of the construction supervisor. For installation Section 5.3 of the Leitfaden (Guideline) 1 shall be considered. Before placing the anchor, the quality of the concrete member shall be checked. The concrete shall be well compacted, e.g. without significant voids. The anchor shall be installed in accordance with the design drawings according to Section 3.1. The anchor shall be installed according to the manufacturer's installation instruction (see Annexes 16 and 17) by using the appropriate specified tools (see Annexes 14 and 15). The required distances to edges, openings, steps in ceiling slabs or built-in components shall be observed, as well as the spacing to other fastenings (e.g. anchor plates with headed fasteners). 4.2 Drilling the borehole In order to reduce the risk of aborted drill holes or damage of the reinforcement, the position of the reinforcement shall be located. The position of the borehole, including the undercut, shall be determined such that the existing reinforcement is not damaged. The borehole shall be drilled perpendicular to the surface of the concrete using a hammer drill equipped with the appropriate stop drill bit for the anchor size (see Annex 14). The required borehole depth is reached when the stop on the drill bit hits the concrete in case of pre-setting anchor or it hits the fixture in case of through-fastening anchor. Inclinations from 85 to 95 relative to the existing surface are considered to be perpendicular. The nominal diameter of the drill bit and the cutting diameter of the drill bit shall comply with Annex 7. The drilling dust must be removed from the hole. Aborted drill holes shall be completely closed with high strength mortar. An aborted borehole also exists if an anchor is removed, because it is not set according to the specifications. If the aborted drill hole has a depth greater than h ef /4, the axial distance to a new borehole shall be at least twice of the borehole diameter. Pre-stressing or loading of the anchor after closing of the aborted drill hole with high-strength mortar is only allowed if the strength of the mortar is at least equal to the concrete strength. If the strength development of the mortar is not known, the anchor may be pre-stressed or loaded after 24 hours at the earliest. 4.3 Setting the anchor The surface of the concrete in the area of the steel fixture shall be such that the fixture rests fully against the concrete after anchor installation. In order to achieve a full contact surface, a mortar levelling layer with a thickness up to 3 mm may be applied. Torque moments may only be applied after the curing of the mortar. After the anchor has been set in the hole, the expansion sleeve shall be driven by using the specified hammer drill and the appropriate setting tool according to Annex 15, in this process the undercut is made. When welding fixtures subsequently on site, restraints on the anchor caused by heat input shall be avoided. Z /13

8 No. Z Page 8 of 9 14 May 2013 The fixture shall be installed by using a calibrated torque wrench. The torque moment T inst according to Annex 7 must be applied. The anchor has been properly set and may be loaded only when all conditions according to Table 4.1 are fulfilled. In all other cases, the anchor has to be removed and the borehole has to be filled with high strength mortar. Table 4.1 Installation control Characteristic Red marking Knurled marking ring Sleeve recess h s Thickness of fixture t fix Torque moment T inst Through-fastening anchor HDA-T respectively HDA-TR Pre-setting anchor HDA-P / HDA-PR The red marking on the bolt must be visible above the top edge of the expansion sleeve (see Annexes 1 and 2) The knurled marking ring on the No knurled marking expansion sleeve must not protrude over ring existing the concrete surface (see Annex 2, Figure 4) The installation tolerance for the sleeve recess h s must comply with the requirements in Annex 7 t fix maximum thickness of fixture according to Annex 5 t fix minimum thickness of fixture according to Annex 7 t fix maximum thickness of fixture according to Annex 5 The torque moment T inst according to Annex 7 must be applied An anchor may be set only once. During filling of the annular gap with injection mortar the injection mortar is pressed through the opening in the injection washer into the annular gap between the fixture and the anchor. The mortar is mixed when pressing in the static mixer of the mortar cartridges. For injection of the mortar the devices listed in the manufacturer's installation instructions are to be used. The mixer flow (mortar leaving the mixer at first) must not be used for fastenings. The first three full trigger pulls of the new foil pack (mixer flow) shall be discarded and not to use. For filling the mixer tip is pressed into the filling channel of the injection washer. There are injected so many mortar trigger pulls until the pressure resistance at the dispenser increases. After remove the mixer tip the mortar must be visible in the filling opening. During injection the installation temperature of the mortar (cartridge temperature) shall not be lower than +5 C and shall not exceed +40 C. The curing of the injection mortar depends on the temperature of the concrete / fixture. Therefore, the curing time between setting and loading of the anchor shall be observed according to Annex 3. After the installation and during the service life the nut of anchors with unfilled annular gap may be removed and tightened again by applying the torque moment according to Annex 7, Table 5. Z /13

9 No. Z Page 9 of 9 14 May Checking the installation The quality assurance measures in accordance with Section 5.4 of the Leitfaden (Guideline) 1 shall be considered. During the installation of the anchors the contractor entrusted with anchorages or the construction supervisor assigned by him or a competent representative of the construction supervisor have to be present on the job site. He has to ensure the proper installation. During installation of anchors records about the proper installation of anchors shall be kept by the construction supervisor or his competent representative. The setting and installation minutes shall contain at least the information of Annex 18 and 19. The records must be available on the job site during construction period and they shall be presented on request for inspection. These records, as well as the delivery notes, shall be deposited by the company for at least five years after completion of the construction work. When using the anchorages in nuclear power plants and nuclear facilities, consideration of additional requirements of the supervisory authorities can be required. Andreas Kummerow Head of Section Beglaubigt Wittstock Z /13

10 Pre-setting anchor HDA-P(R) KKW product and intended use Annex 1

11 Through-fastening anchor HDA-T(R) KKW product and intended use Annex 2

12 Injection mortar Hilti HIT-HY 200-A Annex 3

13 Materials Annex 4

14 Anchor dimensions Annex 5

15 Filling set Annex 6

16 Characteristic values of anchors and installation Annex 7

17 Minimum thickness of concrete member, Minimum spacing and edge distances Annex 8

18 Characteristic values of resistance to tension loads. Requirement Categories A1, A2 and A3 Annex 9

19 Displacement under tension load, Requirement Categories A1, A2 and A3 Annex 10

20 Characteristic values of resistance to shear loads HDA-P / HDA-T Requirement Categories A1, A2 and A3 Annex 11

21 Characteristic values of resistance to shear loads HDA-PR / HDA-TR Requirement Categories A1, A2 and A3 Annex 12

22 Displacement under shear loads HDA-P(R) / HDA-T(R) Requirement Categories A1, A2 and A3 Annex 13

23 Stop drill bit Annex 14

24 Setting tools and hammer drills Annex 15

25 Installation instruction I Annex 16

26 Installation instruction II Annex 17

27 Setting and installation protocol I Annex 18

28 Setting and installation protocol II Annex 19

29 Setting and installation protocol III Annex 20