Geotechnical Systems - DSI Deutschland · PDF fileGeotechnical Systems SUSPA Compact Rock and...

Validity18 March 2010 - 17 March 2017

Approval NumberZ-20.1-64

Geotechnical Systems

SUSPA Compact Rockand Soil Anchors

Approval office for construction products and construction. Testing office for structural engineering

A joint public-law institution of the federal government and the federal states

Member of the EOTA, the UEAtc and the WFTAO

regarding the extension of the validity period of the technical approval dated 18th

of March 2010

Date: Reference:

09.03.2015 I 64-1.34.11-22/14

Approval number: Z-20.1-64

Valid from: 9. March 2015 until: 17. March 2017

Applicant: DYWIDAG-Systems International GmbH Destouchesstraße 68 80796 München

Object of Approval: SUSPA Compact Rock and Soil Anchors This notification extends the validation of the technical approval Nr. Z-20.1-64 from the 18th of Match 2010, changed and expanded by the notification from the 9th of April 2014. This notification is comprised of one page. It is only valid in conjunction with the above mentioned technical approval and thus can only be used together with this technical approval.

Notification

Important Notice The approval in hand is the translation of a document originally prepared in German language which has not been verified and officially authorized by the “Deutsches Institut für Bautechnik“ (German Institute for Civil Engineering). In case of doubt in respect to wording and/or interpretation of this approval, the original German version of this document shall prevail exclusively. Therefore, no liability is assumed for translation errors or inaccuracies.

D E U T S C H E S I N S T I T U T F Ü R B A U T E C H N I K German Institute for Civil Engineering

Statutory Body

Approval office for construction products and construction Testing office for structural engineering Member of the EOTA, the UEAtc and the WFTAO Phone: +49 30 78730 - 0 Fax: +49 30 78730 - 320 E-Mail: [email protected] Date: March 18th 2010 Reference No.: I 63-1.34.11-6/09

APPROVAL CERTIFICATE

Approval Number: Z-20.1-64

Valid until: 17 March 2015

Applicant: DYWIDAG-Systems International GmbH Destouchesstraße 68, 80796 München

Object of Approval: SUSPA Compact Rock and Soil Anchors

The above-mentioned subject of the approval is herewith granted a general construction supervisory authority approval and supersedes the general construction supervisory authority approval No. Z-20.1-64 of 18 March 1999. This general construction supervisory authority approval consists of 18 pages and nine appendices.

I DIBt I Kolonnenstraße 30 L I D – 10829 Berlin I Phone:+49 30 78730 – 0 I Fax:+49 30 78730 – 320 I E-Mail: [email protected] I www.dibt.de

Important Notice The approval in hand is the translation of a document originally prepared in German language which has not been verified and officially authorized by the “Deutsches Institut für Bautechnik“ (German Institute for Civil Engineering). In case of doubt in respect to wording and/or interpretation of this approval, the original German version of this document shall prevail exclusively. Therefore, no liability is assumed for translation errors or inaccuracies.

DIBT Approval Certificate Page 2 of 14 I march 18th 2010 Z-20.1-64

I. GENERAL REGULATIONS

1 This general construction supervisory authority approval verifies the suitability (fitness for the intended purpose) of the subject of the approval in keeping with the state construction ordinances.

2 If in the general building approval requirements for special expertise and experience with

the manufacture of construction products and persons in charge according to § 17 section 5 model building code corresponding state regulations are made, please note that this expertise and experience, even with equivalent qualifications from other Member States of the European Union may be assigned. This applies for under the Agreement on the European Economic Area (EEA) or other bilateral agreements submitted by an equivalent proof.

3 The general construction supervisory authority approval does not replace any permissions,

agreements and certifications required by law for a construction project to be carried out. 4 The general construction supervisory authority approval is granted without prejudicing the

rights of third parties, especially private protection rights. 5 Notwithstanding any further regulations in the "Special Provisions" section, the

manufacturer and distributor of the object of approval shall provide the user with copies of the general construction supervisory authority approval; furthermore, they shall inform the user that the general construction supervisory authority approval must be available at the place of use. Copies of the general construction supervisory authority approval must be made available to involved authorities on request.

6 The general construction supervisory authority approval may only be copied completely.

The publication of extracts is subject to approval by the DIBt. Texts and drawings of advertising material may not contradict the general construction supervisory authority approval. Translations of the general construction supervisory authority approval must contain the note 'Translation of the German original which has not been checked by the DIBt".

7 The general construction supervisory authority approval is granted, but is revocable. The

provisions in the general construction supervisory authority approval can be subsequently supplemented or changed, especially if the latest technical findings give reason for this.


II. SPECIAL REGULATIONS

1 Subject of approval and applications

1.1 General

Subject of the following general construction supervisory authority approval are "SUSPA Compact Anchors" manufactured by SUSPA-DSI GmbH with steel tendons consisting of 2 to 12 strands of steel quality St 1570/1770, nominal diameter 15.3 mm (0.6"; nominal cross-section 140 mm²) or 15.7 mm (0.62"; nominal cross-section 150 mm²). Unless otherwise stated below, the requirements of DIN 41251 and DIN 10542 must be observed with regard to construction and testing.

1.2 applications

Depending on the type of design, the grouted anchors may be used either as permanent anchors with steel tendons consisting of 2 to 12 strands or as temporary anchors with steel tendons consisting of 11 to 12 strands. The tendon free length of anchors with more than 4 strands must be at least 5 m and their bond length at least 4 m. Their application is limited to such cases where the entire fixed anchor length of the anchor is located either in non-cohesive or cohesive soil or rock (cf. DIN 10542). Deviating cases may only be carried out subject to the permission of a geotechnical engineering expert. DIN 41251, Section 5.1, applies with regard to subsoil requirements.

2 Regulations covering the construction product

2.1 Features and constituents

2.1.1 General

The grouted anchor may be manufactured in the types listed hereinafter: - Types 6-2 to 6-12 with 2 to 12 strands as permanent rock anchors. - Types 6-2 to 6-12 with 2 to 10 strands as permanent anchors in cohesive and non-

cohesive soil. - Types 6-11 to 6-12 with 11 to 12 strands as temporary rock anchors. The permanent anchor may be manufactured in the following types: a) Type G with smooth plastic sheathing in the area of lfS and corrugated plastic

sheathing in the area of lv as shown in Appendix 1. 1 DIN 4125:1990-11 Anchors, anchor short-term and permanent anchor; design, implementation and

testing

2 DIN 1054:2005-01 Subsoil - Verification of the safety Geotechnical Engineering

DIN 1054 Ber. 1:2005-04 corrections to DIN 1054:2005-01




DIN 1054/A1:2009-07 Subsoil - Verification of the safety of earthworks and foundation engineering;

Amendment A1


b) Type R with continued full-length corrugated plastic sheathing for lfs + lv as illustrated in Appendix 2.

c) Type T with two concentric corrugated plastic sheathings in the area of lv as shown in Appendix 3.

2.1.2 Steel tendon

Only strands of steel quality St 1570/1770, nominal diameter 15.3 mm (0.6"; nominal cross-section 140 mm²) or nominal diameter 15.7 mm (0.62"; nominal cross-section 150 mm²), consisting of seven cold-drawn, smooth individual wires, which have been granted general construction supervisory authority approval, may be used as steel tendon material, whereas strands granted general construction supervisory authority approval and coated with a corrosion-protection system are to be used for permanent anchors. The corrosion protection system consisting of an anti-corrosion compound and PE sheathing is to be applied at the factory where the prestressing steel is produced. Alternatively, prestressing strands may be used which are to be provided with PE sheathings in the area of the tendon free length at applicant's factory, with the cavity between strand and sheathing being completely injected with the Nontribos MP-2 anti-corrosion compound (see Section 2.2.1.2). During installation and transportation of the anchors, the following minimum bending radii R must be observed: min R = 0.90 m (Permanent anchors consisting of 1 to 9 strands and temporary anchors consisting of 11 to 12 strands). min R = 1.00 m (Permanent anchors consisting of 10 to 12 strands).

2.1.3 Anchor head

The anchor head is to be designed in compliance with Appendix 4 or 5 (permanent anchor) or Appendix 8 (temporary anchor). Assembly of the anchor head on the construction site must be carried out in accordance with the description filed with the DIBt. The strands of the steel tendon are to be anchored with wedges in the anchor bushing. Only strands of the same nominal diameter may be used within one steel tendon. As regards form and material quality, anchor bushings and wedges must comply with those stipulated in the general construction supervisory authority approvals for "SUSPA Strand Post-Tensioning System 140 mm²", approval No. Z-13.1-21, or "SUSPA Strand Post-Tensioning System 150 mm²", approval No. Z-13.1-82, except that the anchor bushings have permanent anchors in an external thread for tensioning and for verifying the anchoring force. The specifications set forth in Appendix 6 apply to the outer diameter of anchor bushings with an external thread. To avoid confusion, only wedges granted general construction supervisory authority approval may be used on the construction site. For the transfer of load from the anchor bushing to the structure to be anchored bearing plates as specified in Appendix 6 (permanent anchor) or Appendix 9 (temporary anchor) must be used. If not cast in concrete completely, the bearing plate of permanent anchors is to be provided with a corrosion protection system in accordance with DIN EN ISO 12 944-53. Coating examples pursuant to DIN EN ISO 12944-53Fehler! Textmarke nicht definiert. are the following corrosion protection systems with the figures: a) Without a metallic coating: A5I.02, A5I.05, A5I.06, A5M.02, and A5M.04. These

systems are applied to the prepared steel with Surface preparation Sa 2 ½ according to DIN EN ISO 12944-44.

3 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

4 DIN EN ISO 12944-4:1998-07 Paints and varnishes - Corrosion protection of steel structures by protective paint

systems - Part 4: Types of surface and surface preparation (ISO 12944-4:1998); German version EN ISO 12944-4:1998


b) With metallic coating (galvanized): A7.11, A7.12 (both systems not for corrosivity C5-I and C5-M), A7.13

c) With metallic coating (thermally sprayed metal): A8.01 (not for corrosivity C5-I and C5-M), A8.03.

The exposed surfaces of the anchor trumpet and the steel protection cap of permanent anchors must also be provided with one of the above corrosion protection systems. Corrosion protection for those parts may be omitted, if they have a wall thickness of ≥ 6.0 mm or will be cast in concrete. If the steel protection cap consists of stainless steel with the material numbers 1.4301, 1.4541 or 1.4571 (see also Appendix 5) in accordance with the general construction supervisory authority approval for "Structural and Connection Elements made of Stainless Steel", approval No. Z-30.3-6, it need not be provided with a corrosion protection system. As regards corrosion, the steels specified in approval No. Z-30.3-6 are assigned either to resistance class II (material numbers 1.4301 and 1.4541) or III (material number 1.4571). The specifications on exposure to corrosion and typical applications set forth therein must be observed. The tendon must be anchored perpendicular to its axis in each direction. To ensure that the anchor head is positioned rectangular to the steel tendon, angular deviations must be compensated (e.g. wedge plates, mortar bed or similar). When anchored, the wedges are embedded 6 mm in the anchor head; the effect of that embedment has to be taken into account as slip when elongation is determined. For tendon free lengths of ≤ 5 m slip has to be compensated in that the anchor bushing is lifted off the bearing plate after the wedges have been embedded and, subsequently, washers with an overall height of 6 mm are to be placed between the anchor head and bearing plate. After stressing, the wedges used in temporary anchors must be covered with a wedge locking plate. The anchor bushings have an external thread to restress and check the anchor load of permanent anchors. Anchor bushings without an external thread may be used for temporary anchors.

2.1.3.1 Air-side anchorage via rock

The design values of rock pressures for anchorage via rock must be identified by an expert (cf. annotation 12 on page 12), taking into consideration a possible structural fault in the immediate vicinity of the borehole. Any necessary adapters are to be designed pursuant to the relevant standards, taking into account the permissible rock pressures.

2.1.3.2 Air-side anchorage via steel and reinforced concrete structures

DIN 4125 applies to the design of structural elements to be anchored. The support on steel structures must be carried out in compliance with Appendix 6 (permanent anchor) or Appendix 9 (temporary anchor). Adequate load capacity and corrosion protection of the steel transition structure must be demonstrated or identified respectively for each individual case. (The steel transition structure is not subject of the present general construction supervisory authority approval.) If the bearing plate does not have the dimensions given in Appendix 6 (permanent anchor) or Appendix 9 (temporary anchor), their load capacity must be demonstrated as well. If anchorage is carried out via a reinforced concrete element in accordance with Type 1 of Appendix 6 (permanent anchor) or Appendix 9 (temporary anchor), the general construction supervisory authority approvals for the "SUSPA Strand Post-Tensioning System 140 mm²" (approval No. Z-13.1-21) and the "SUSPA Strand Post-Tensioning System 150 mm²" (approval No. Z-13.1-82) may be applied. The additional reinforcement indicated therein must be taken into account. If the dimensions of the bearing plates and the aperture specified for Type 2 in Appendix 6 (permanent anchor) or Appendix 9 (temporary anchor) are observed, the load capacity of the bearing plates must not be demonstrated. The transfer of loads in the structure (e.g. splitting forces) must be verified on a case-to-case basis.

DIBT Approval Certificate Page 6 of 14 I march 18th 2010 Z-20.1-64 2.1.4 Plastic pipes

For the sheathing of the tendon free length (permanent and temporary anchors) and the bond length (permanent anchors only) respectively, only plastic pipes may be used which consist of PVC-U as specified by DIN EN ISO 1163-15, polyethylene with a moulding compound pursuant to DIN EN ISO –1872-16 – PE, E, 45 T 022 - or polypropylene with a moulding compound as required by DIN EN ISO 1873-17 - PP - B, EAGC, 10-16-003 or DIN EN ISO 1873-1 - PP - H, E, 06-35-012/022. Only pipes without trapped bubbles and with uniform pigmentation may be used. If required, individual segments of PVC-U sheathings are to be screwed together and glued with PVC glue. Unspliced pipes are to be used as PE or PP sheathings. Care must be taken to ensure that only straight pipes are used.

2.2 Manufacture, storage, transport and marking

2.2.1 Corrosion protection and manufacture of prefabricated anchors for installation and grouting

2.2.1.1 General

Corrosion protection and manufacture must be carried out at the shop in accordance with the work instructions filed with the DIBt. The effectiveness of corrosion protection depends on the integrity of the corrosion protection components. Therefore, special care must be taken during transport and installation of the readily assembled anchor so that sheathings will not be damaged as a result of improper handling. Prior to its installation, the prestressing steel is to be treated in accordance with the provisions set forth in the general construction supervisory authority approval applicable for such prestressing steel.

2.2.1.2 Permanent anchor

The strand bundle is encased by a plastic pipe in the area of the tendon free length. The individual strand is to be provided either with a PE sheathing or an individual PE sheathing and some plastic anti-corrosion compound (cf. Appendices 1 to 5). Alternatively, the following methods may be used:

- Only prestressing strands granted general construction supervision authority approval having a corrosion protection system applied at the prefabricating plant of the prestressing steel consisting of an anti-corrosion compound and PE coating pursuant to section 2.1.2 may be used.

- In the area of the tendon free length the strands are to be provided with a PE duct dia. 19.2 x 1.25 mm (for dia. 15.3 mm strands/0.6") or dia. 19.7 x 1.25 mm (for dia. 15.7 mm strands/0.62") made of polyethylene with a moulding compound as required by DIN EN ISO 1672-1 – PE, E, 45 – T022, with the cavity between the strand and duct being completely injected with the Nontribos MP-2 anti-corrosion compound. The amount of anti-corrosion compound applied referring to a length of 1 m should on average be at least 42 m/g and may not fall short of 25 g/m (see Section 2.3.2.10).

When using prestressing strands granted general construction supervision authority approval having a corrosion protection system, the PE sheathing of the strands extruded in

5 DIN EN ISO 1163-1:1999-10 Plastics - Plasticizer-free polyvinyl chloride (PVC-U) molding and extrusion materials -

Part 1: Designation system and basis for specifications (ISO 1163-1:1995) - German

version EN ISO 1163-1:1999

6 DIN EN ISO 1872-1:1999-10 Plastics - Polyethylene (PE) molding and extrusion materials - Part 1: Designation

system and basis for specifications (ISO 1872-1:1993) - German version EN ISO

1872 1:1999

7 DIN EN ISO 1873-1:1995-12 Plastics - Polypropylene (PP) molding and extrusion materials - Part 1: Designation

system and basis for specifications (ISO 1873-1:1995) - German version EN ISO 1873 1:1995


the steel mill is to be removed in the area of the planned bond length; the anti-corrosive agent is be washed off with water having a temperature of approx. 90 °C and a pressure of 70 to 80 bar. The strands are to be centred within a continuous PVC cord with a shore hardness of D ≥ 40 throughout the length of the bonding area. The minimum diameter of the PVC cord is 6 mm, inclination 25 cm. The strands are to be bundled by means of steel straps. The strands must be inserted into a corrugated plastic sheathing within the designated bond length for anchors type G and over the whole anchor length for anchors type R; the sheathing must have a uniform wall thickness of ≥ 1 mm. The diameters of the sheathings depend on the number of strands in the tendon (see Appendices 1 and 2). The sheathing is to be closed with a PE end cap having a wall thickness of ≥ 1 mm to the soil or rock side, with the PE end cap being connected to the sheathing via a shrink sleeve. The overlap on the sheathing must be at least 85 mm. As regards anchors type G, the strand bundle in the area of the free tendon length lfS is to be inserted into a smooth plastic sheathing with a minimum wall thickness of ≥ 3 mm. The diameters of the sheathings depend on the number of strands in the tendon (see Appendix 4). With respect to anchors type G, a steel coupler is to be positioned at the transition point from the bond length to the tendon free length to connect the corrugated and smooth sheathings; both sheathings are to be pushed onto the steel coupler to one third of the steel coupler length (see Appendix 1). The transitions of both sheathings on the steel coupler are to be sealed off with a common seamless shrink sleeve made of polimerised polyethylene that is at least 300 mm long. The polyethylene shrink sleeves must be shrunk on with hot air, infrared radiation or the soft yellow flame of a propane gas burner; their wall thickness in shrunk condition must be ≥ 1.5 mm. The adhesive compound sealing within the shrink sleeves must be hot-melt-type adhesive. The cavity in the area of the bond length between the corrugated plastic sheathing and the steel tendon is to be injected with cement grout in accordance with DIN EN 4478 either at the shop or in the borehole. In addition, DIN EN 4459 and DIN EN 44610 must be observed. If grouted at the shop, the anchors in the area of the bond length must be stored in an inclined manner for such purpose and grouted with cement mortar from the bottom end cap in upward direction. As regards anchors of the R type (Appendix 2), grouting is to take place until grout exits the ventilation opening located on the corrugated pipe. Such ventilation opening is to be arranged so that the ends of the PE sheathings of the monostrands are in about 300 mm depth of the bond length. As regards anchors of type T (Appendix 3), a second concentric corrugated sheathing is placed above the corrugated sheathing in the area of the bond length. The requirements for the external corrugated sheathing regarding the material to be used are consistent with the requirements for the internal corrugated sheathing. The cavity within the inner corrugated sheathing is to be shop grouted in the area of the bond length from bottom to top via an end cap on an inclined plane with cement grout in accordance with DIN EN 4478. In addition, DIN EN 4459 and DIN EN 44610 must be observed. Subsequently, the end cap of the external corrugated sheathing will be assembled and the annular space between the two corrugated sheathings grouted with cement mortar. The grout level is controlled during grouting of the inner anchor space via a borehole in the internal corrugated sheathing and during grouting of the annular space via a borehole in the external corrugated sheathing. Both boreholes will be closed with a heat shrink sleeve after injection of the cement grout.

8 DIN EN 447:1996-07 Grout for prestressing tendons - Specification for common grout - German version EN

447:1996 9 DIN EN 445:1996-07 Grout for prestressing tendons - Test methods - German version EN 445:1996 10 DIN EN 446:1996-07 Grout for prestressing tendons - Grouting procedures; German version EN 446: 1996


If grouted in the borehole, an inner grouting pipe is to be built in already at the shop. For anchors of the G type to be installed upwardly inclined also an inner ventilation pipe and a cement grout or bitumen plug are to be built into the steel coupler at the shop (see Appendix 1). In both cases, the cement grout is to be injected with a grouting speed of no more than 5 m/min. Inner grouting in the borehole is not envisaged for upwardly inclined anchors of the R type.

2.2.1.3 Temporary anchors

The tendon is to be bundled by means of steel straps within the bond length. Spacers according to Appendix 7 are to be arranged to ensure a cement grout cover of ≥ 20 mm. In the area of the tendon free length the tendon is to be inserted into a smooth plastic sheathing. The plastic sheathing is to be sealed with a sealing plug made of bitumen, cement grout or 2C-polyurethane (no foam) against the rock side.

2.2.2 Storage

The smooth and corrugated plastic sheathings of readily assembled anchors may not rest on sharp-edged bearing surfaces. If anchors are piled up, they must lie on top of each other in a parallel manner. If supported in intervals by square timbers or adequate spacers, the weight of the anchors on top in the area of the plastic sheathings may only be transferred via the timbers or spacers. The readily assembled anchors may not be stored on the ground.

2.2.3 Transport

In no case may the anchors be thrown or dropped. They must be carried (e.g. by hand or on shoulders or by means of carrying straps) so that in particular the plastic sheathings will not be damaged. The anchors may also be transported wound up in coils and inserted into the borehole from the coil, with the rigid, shop cement grouted bond length of the permanent anchor tangentially protruding from the coil.

2.2.4 Marking

The delivery note for the preassembled anchor structure must be marked with the conformity mark ("Ü-Zeichen") by the manufacturer in accordance with the Conformity Mark Ordinances of the German Laender. The marking may only be carried out, if the requirements according to clause 2.3 have been met. Among other things, the delivery note must indicate for which grouted anchors the components (e.g. bearing plate subject to the intermediate structure selected) are determined and in which shop they have been manufactured. The delivery note must clearly indicate to which type of grouted anchor the components are assigned.

2.3 Evidence of conformity

2.3.1 General

Each manufacturing plant must confirm that the anchor components and the prefabricated anchors for installation and grouting comply with the provisions in this general construction supervisory authority approval by means of a certificate of conformity based on the plant’s own quality control and regular external surveillance, including initial testing, in accordance with the following provisions. The manufacturer of the anchor components and of the prefabricated anchors must commission a recognised certification authority and a recognised external surveillance authority to issue the certificate of conformity and carry out external surveillance, including product testing, respectively. The certification agency must send a copy of the issued certificate of conformity to the DIBt for information. In addition, a copy of the initial test report must be forwarded to the DIBt for information.

2.3.2 In-house manufacturing control

DIBT Approval Certificate Page 9 of 14 I march 18th 2010 Z-20.1-64 2.3.2.1 General

Each manufacturing plant must set up and also carry out its own quality control. In-house manufacturing control is understood to be the continual monitoring of production by the manufacturer who thus ensures that the construction products manufactured by him meet the requirements of this general construction supervisory authority approval. The results of the internal quality control must be recorded and evaluated. The recordings must contain at least the following information:

- Description of the building product or the basic material respectively and its components,

- nature of the control or inspection, - date of manufacture and date of inspection of the building product or of the basic

material respectively or its components, - results of the controls and inspections and, if applicable, comparison with the

requirements, - a signature from the person responsible for in-house quality controls.

The records must be filed for at least five years and presented to the external agency assigned with surveillance. On request, they must be submitted to the DIBt and the highest construction supervisory authority responsible. If the inspection results are unsatisfactory, the manufacturer must immediately take the action necessary for elimination of the problem. Construction products which do not meet requirements must be treated in such a manner that they cannot be mixed with conforming products. Once the problem has been eliminated, the original inspection must be repeated immediately, provided that this is technically possible and also required, to verify elimination of the problem. In-house quality control must include at least the following measures:

2.3.2.2 Strands

Only strands may be used for which an evidence of conformity has been produced pursuant to the provisions of the relevant general construction supervisory authority approvals.

2.3.2.3 Wedges

Only wedges may be used for air-side anchorage for which an evidence of conformity has been produced pursuant to the provisions of the general construction supervisory authority approval No. Z-13.1-21 or Z-13.1-82. The stipulations for the receiving inspection set in the approval certificates must be observed.

2.3.2.4 Anchor heads without outside thread

Only anchor bushings may be used for air-side anchorage for which an evidence of conformity has been produced pursuant to the provisions of the general construction supervisory authority approval No. Z-13.1-21 or Z-13.1-82. The stipulations for the receiving inspection set in the approval certificates must be observed.

2.3.2.5 Anchor heads with outside thread

The provisions of the general construction supervisory authority approval No. Z-13.1-21 or Z-13.1-82 apply to the anchor bushings with the following exceptions. Each anchor head must be verified with regard to its nominal diameter and thread depth for compliance with the specifications in the deposited shop drawings of the German Institute for Building Technology by means of a yes/no check. No recording required thereof.

2.3.2.6 Plastic pipes

Composition of the moulding compound is to be attested by certificate of compliance "2.1" as per DIN EN 1020411. The wall thicknesses and diameters of the plastic pipes are to be

11 DIN EN 10204:2005-01 Metallic products Types of inspection; German version EN 10204:2004


measured. As regards corrugated plastic pipes, one corrugated plastic pipe must be taken per batch (100 pipes) to measure the wall thicknesses at one internal and one external corrugation each and on the flank as well as the diameters of the pipes. The decision whether a batch is accepted or rejected is to be made in accordance with Section 2.3.2.11.

2.3.2.7 Shrink sleeves

The material characteristics of the shrink sleeves and of the bonding agent is to be attested by certificate of compliance "2.1" in accordance with DIN EN 1020411. The thicknesses of the heat shrink sleeves are to be measured in shrunk condition. For this purpose, one sleeve must each be shrunk onto corresponding pipe sections parallel to the manufacture of an anchor type.

2.3.2.8 Lip seals, roll rings and washers

From each lip seal batch delivered, the diameters of 1% but at least 5 pieces are to be checked with regard to their functioning (e.g. by means of a gauge) at the shop. At least 5% of the anchor trumpets must be examined at the shop with regard to whether the lip seal is immovably seated in the anchor trumpet and tightly connected to the designated plastic pipe. From each roll ring batch delivered, the diameters of 1% but at least 5 pieces are to be checked with regard to their functioning (e.g. by means of a gauge) at the shop. At least 5% of the anchor trumpets must be examined at the shop with regard to whether the roll rings are tightly connected to the designated plastic pipe. From each washer batch delivered, 1% but at least 5 pieces are to be checked with regard to their dimensions at the shop. The decision whether a batch is accepted or rejected is to be made in accordance with Section 2.3.2.14.

2.3.2.9 Bearing plates

If a bearing plate in accordance with Appendix 6 (permanent anchor) or Appendix 9 (temporary anchor) is used or statically evidenced in an individual case, compliance with the material characteristics is to be attested by certificate of compliance "2.2" pursuant to DIN EN 1020411. In addition, each bearing plate must be verified with regard to its dimensions and gross faults by means of a yes/no check (no recording required thereof).

2.3.2.10 Encasing individual strands with anti-corrosion compound and PE sheathings

On every workday, but at least on every 20th anchor, a sample is to be taken to determine the volume of the anti-corrosion compound injected, relating to a length of 1 m. Such volume must amount to at least 25 g/m. In doing so, it also must be checked whether anti-corrosion compound has penetrated into the clear spacing of the strand and whether the overall surface of all individual wires of the strand is coated with anti-corrosion compound. PE sheathings are to be monitored in accordance with Section 2.3.2.3.

2.3.2.11 Structure of the strand in the bond length

It must be checked by means of an attribute check (yes/no check) that the bond length of each strand is free of anti-corrosion compound (statistical evaluation not necessary).

2.3.2.12 Anti-corrosion coating

Compliance with the layer thickness requirements for the anti-corrosion coating of the bearing plate, anchor trumpet and steel protection cap must be verified on 5% of each production batch at the shop.

2.3.2.13 Assembly and corrosion protection

Cement grout is to be tested pursuant to DIN EN 4459.


The necessary working steps including the corrosion protection measures to be carried out at the shop pursuant to Section 2.2.1 must be verified by visual inspection for each anchor (statistical evaluation not necessary).

2.3.2.14 Test plan

If each individually measured value equals or exceeds the minimum value stipulated, the batch is to be accepted. If not, further samples may be taken. The same measurements as those on the first sample must be carried out on such samples. The measuring results are to be summarised with the previous measurements. The mean average value x and the standard deviation s must be obtained from all values. If the resulting test value (numerical value) z = x -1.64 s equals or exceeds the minimum value stipulated, the batch is to be accepted, otherwise rejected.

2.3.3 External surveillance

The in-house quality control at each manufacturing plant is to be monitored by external surveillance on a regular basis, but at least twice a year. An initial inspection is to be carried out as part of the external surveillance. Also samples for sampling tests are to be taken and testing tools inspected. In each case, samplings and tests are incumbent on the respective recognised surveillance authority. The results of the certification and of the external surveillance must be kept for at least five years. On request, they must be presented to the DIBt and to the highest construction supervisory authority responsible by the certification agency or the surveillance agency.

3 Regulations covering design and dimensions

3.1 General

Unless stated otherwise below, DIN 10542 applies to the design and calculation of structures using Pressure-grouted anchors.

3.2 Further verifications

3.2.1 Permissible prestressing forces

There is evidence required that the permissible prestressing forces Pm0,max according to section 3.2 of the general construction supervisory authority approval No. Z-13.1-21 or section 3.2 of the general construction supervisory authority approval No. Z-13.1-82 are not exceeded.

3.2.2 Change of load in the steel tendon due to frequently repetitive live loads

When determining the anchor load, evidence must be provided that the change of load (characteristic value) in the steel tendon due to frequently repetitive live loads (including wind) is not larger than 20% of the characteristic stress Ek. The fatigue tests that were performed on the anchor bushings according to the general construction supervisory authority approval No. Z-13.1-21 and No. Z-13.1-82 as part of the approval process, detected in the upper voltage of 0,65 fpk an oscillating width of 80 N/mm2 (prestressing steel) of load cycles of 2x106. Evidence will be required that the amplitude on the air side of the anchor bushing is not over the value of 0,7 times. Numbers of load cycles over 2x106 are not proven with the general construction supervisory authority approval No. Z-13.1-21 and No. Z-13.1-82.


Anchor bushings with outside thread must not be subject to not predominantly static loads. A certificate is only required if the pulsating load is not covered by the prestressing operation.

3.3 Rock anchors

The overall safety of the anchored rock mass is subject of the rock mechanical stability evidences; the anchor forces required for stability must be determined by an expert12.

4 Regulations covering installation

4.1 General

Assembly and installation of pressure-grouted anchors may only be carried out under responsible technical leadership of the applicant. Work must be carried out in accordance with the work instructions and deposited with the DIBt. Applicant must keep a list of structures secured with permanent anchors in compliance with this general construction supervisory authority approval, which indicates the structure anchored and the number of anchors installed.

4.2 Drilling the boreholes

4.2.1 Borehole diameter

The borehole diameter must be chosen so that the anchor including spacers can be inserted without any problems. The minimum borehole diameters are indicated in Appendices 1 to 3 (permanent anchor) or Appendix 7 (temporary anchor).

4.2.2 Drilling boreholes in the ground

In general, borehole drillings are to be cased. Boreholes may be drilled uncased or partly cased in cohesive soils, if it is demonstrated within the scope of a suitability test that there is solid ground on the total length of the uncased part of the drilling, that the drill rods used are sufficiently rigid to assure straight drilling and that the borehole can be properly cleaned.

4.2.3 Drilling boreholes in rock

The drilling method is to be chosen subject to the specific rock properties. It must be verified that in the area of the free anchor length perpendicular to the borehole axis

- no joint movements will be anticipated, if the annular space between the borehole wall and sheathing is grouted with cement mortar (e.g. when the fixed anchor length has not been limited as per Section 4.4.4), and

- the expected joint movements will be smaller than the difference between the sheathing and borehole diameter, if the annular space between the borehole wall and sheathing is not grouted with cement mortar (e.g. when the fixed anchor length has been limited as per Section 4.4.4).

It is recommended to check the free passage of the boreholes by means of a gauge.

4.3 Insertion into the borehole

Spacers are to be positioned in the area of the bond length as stipulated by Appendices 1 to 3 or Appendix 7. Positioning spacers may be omitted in non-cohesive soils, if the wall thickness of the starting tube or the material thickness at the nipple passages is ≥ 10 mm.

12 Earthwork and foundation engineering experts must be consulted to determine the static and constructive requirements and

working loads.


If in case of a cased borehole, the projecting end of the drill outfit has an edged internal thread or a sharp-edged pipe end, the anchors prepared in accordance with Section 2.2.1 may only be inserted into the borehole, when an edge-free inserting trumpet or a pipe nipple fully covering the internal thread of the casing has been placed onto the projecting end of the drill outfit. Care must be taken that the corrosion protection is not damaged when inserting the anchor. Having injected the borehole with cement grout in accordance with section 4.4.2 and placed the grout cap, grouting may be necessary - at least up to the transition point from bond length lv to tendon free length lfs - while pulling out the casings gradually.

4.4 Manufacturing the grouted anchor

4.4.1 Composition of the cement grout

The basic materials for the cement grout are cements with particular properties in accordance with DIN 1164-1013 and cements by DIN EN 197-114 - taking account of this exposure class in accordance with DIN EN 206-115 in connection with DIN 1045-216 (Tables 1, F.3.1 F.3.2) -, water according to DIN EN 100817 and any additional funds in accordance with DIN EN 934-218 in connection with DIN V 1899819 taking into account of DIN V 20000-10020 with general approval and aggregate for concrete (concrete aggregates) according to DIN EN 1262021 in combination with DIN V 20000-10322. The water/cement value must range between 0.35 and 0.7 and should be chosen as low as possible. The cement grout must be mixed mechanically, and may not segregate and lump before its injection. When cement grout gets into direct contact with prestressing strands, cement grout as per DIN EN 4478 and, in addition, in compliance with DIN EN 4459 and DIN EN 44610 is to be used. This applies, for example, for temporary anchors, or, in case the cavity between the

13 DIN 1164-10:2004-08 Cements with special properties - Part 10: Composition, specifications and proof of

conformity of common cements with special properties

14 DIN 1164-10 cor1:2005-01 Corrigenda to DIN 1164-10:2004-08

DIN EN 197-1:2004-08 Cement - Part 1: Composition, specifications and conformity criteria for common

cements; German version EN 197-1:2000 + A1: 2004

15 DIN EN 197-1 cor1:2004-11 Corrigenda to DIN EN 197-1:2004-08 DIN EN 206-1:2001-07 Concrete - Part 1: Specification, performance, production and conformity

DIN EN 206-1/A1:2004-10 Concrete - Part 1: Specification, performance, production and conformity; German

version EN 206-1/A1: 2004

DIN EN 206-1/A2:2005-09 Concrete - Part 1: Specification, performance, production and conformity; German

version EN 206-1:2000 / A2: 2005

16 DIN 1045-2:2008-08 Structures made of concrete, reinforced concrete and prestressed concrete Part 2:

Concrete, Specification, performance, production and conformity - Application rules

for DIN EN 206 1

17 DIN EN 1008:2002-10 Mixing water for concrete - Specification for sampling, testing and assessing the suitability of water, including water accumulating in the concrete industry, as mixing

water for concrete; German version EN 1008:2002

18 DIN EN 934-2:2002-02 Admixtures for concrete, mortar and grout - Part 2: Concrete admixtures -

Definitions, requirements, conformity, marking and labeling

DIN EN 934-2/A1:2005-06 Admixtures for concrete, mortar and grout - Part 2: Concrete admixtures -

Definitions, requirements, conformity, marking and labeling; German version EN 934-

2:2001 / A1: 2004

DIN EN 934-2/A2:2006-03 Admixtures for concrete, mortar and grout - Part 2: Concrete admixtures -

Definitions, requirements, conformity, marking and labeling; German version EN 934-2:2001 / A2: 2005

19 DIN V 18998:2002-11 Assessment of the corrosion behavior of additives according to the standards of DIN

EN 934

DIN V 18998/A1:2003-05 Assessment of the corrosion behavior of additives according to the standards of DIN

EN 934; Amendment A1

20 DIN V 20000-100:2002-11 Application of building products in structures - Part 100: Concrete admixtures

according to DIN EN 934-2:2002-02

21 DIN EN 12620: 2003-04 Aggregates for concrete; German version EN 12620:2002

DIN EN 12620 cor1:2004-12 Corrigenda to DIN EN 12620:2003-04

22 DIN V 20000-103:2004-04 Application of building products in structures - Part 103: aggregates according to DIN EN 12620:2003-04


steel tendon and corrugated plastic pipe is grouted, after insertion of the anchor into the borehole.

4.4.2 Making the grout body

4.4.2.1 General, making the grout body in the ground

The grout body must be produced in accordance with DIN 41251, Section 7.3.3. As regards downwardly inclined anchors, cement grouting of the borehole may be carried out before the anchor is inserted. If the borehole is grouted after insertion of the anchor construction into the borehole, the grouting pipe mounted on the outside of the anchor is used for such purpose, whereas ventilation for upwardly inclined anchors is conducted via an external ventilation pipe. Cement grouting must always be carried out from the deepest point, whereas ventilation must be carried out at the highest point of the grout body at all times. The grouting operation may not be stopped until cement grout will emerge through the vent tube without any bubbles. In case of downwardly inclined anchors, the vent tube may be omitted, if the borehole is injected from the bottom until cement grout will escape at the top. In case of upwardly inclined anchors, the packer mounted outside of the sheathing must be activated first prior to grouting. In case of a cased borehole, grouting may be carried out after injection of the casing with cement grout, with the pipes being drawn slowly while maintaining the necessary grouting pressure. Also in case of a cased borehole, grouting may be carried out under hydrostatic pressure, with the pipes being drawn slowly.

4.4.2.2 Making the grout body in rock

The rock must be so compact that perfect making of the grout body will be ensured. This must be verified by special examinations (e.g. visual borehole inspection, gauge measurement of the grout level, geohydraulic test) to the extent required. In each individual case, the mortar formula, grouting pressure and grouting operation must be determined by the field engineer in consultation with the expert (cf. foot note 12 on page 11) in compliance with the results of the rock explorations, water injection tests and the findings after the boreholes have been drilled. The designated grouting method must be examined within the scope of a suitability test. The quantity of cement grout required for one anchor, its composition and the grouting pressure must be measured and recorded. It is recommended to use the form provided in Appendix A of DIN 41251.

4.4.3 Grouting the cavity within sheathings

Grouting must always be carried out from the deepest point, whereas ventilation must be carried out from the highest point of the cavity at all times. The inner grouting pipe is to be injected with cement grout until bubble-free cement grout will escape at the mouth of the borehole (downwardly inclined anchors) or through the inner ventilation pipe (upwardly inclined anchors). The grouting speed may not exceed 5 m/min. If, in case of an upwardly inclined anchor, grouting of the cavity is anticipated in the area between the steel tendon and smooth plastic sheathing, a short cement grout spout must be injected first. After its hardening, the remaining part of such cavity must be grouted by means of the inner grouting and the inner ventilation pipes. With respect to permanent anchors with shop grouted, corrugated sheathing in the bond length, the cavity in the area between the bond length and anchor head must still be grouted for downwardly inclined anchors. In case of upwardly inclined anchors, grouting of that cavity may be omitted. In respect of permanent anchors where the cavity within the corrugated sheathing has not already been injected with cement grout at the shop (see Section 2.2.1.2), grouting may be carried out after insertion of the anchor into the borehole in the course of making the grout body. Such possibility is mainly used, when limited space conditions require a ductile anchor. In case of downwardly inclined anchors, the entire area between the end cap and anchor head is to be grouted. In case of ascending anchors, sheathings are to be grouted


by means of an inner grouting pipe and in addition by means of an inner ventilation pipe. In case of upwardly inclined anchors, grouting of the cavity in the area between the steel tendon and smooth plastic sheathing may be omitted. Cement grout in accordance with DIN EN 4478 is to be used both for inner grouting and the making of the grout body for such type of anchor manufacture. In addition, DIN EN 4459 and DIN EN 44610 must be observed.

4.4.4 Limitation of the load transfer length

In general, the load transfer length is to be limited by the methods listed hereinafter: a) by flushing out excess cement grout (e.g. with water or bentonite suspension) by

means of a flushing hose tightly mounted on the sheathing. The flushing hose must be arranged so that the first lateral exit openings are positioned 50 cm above the designated grout body length Iv. Verification of that value must be confirmed in the record. The flushing pressure applied must amount to about 4 bar.

b) by flushing out excess cement grout by means of a flushing lance. The flushing lance, which is closed at the bottom and provided with side openings, must be inserted up to approx. 1.0 m above the designated grout body length lv. The flushing pressure applied must amount to about 4 bar.

c) by blocking the load transfer length by means of a packer. Suitability of the packer is to be demonstrated within the scope of a suitability test.

Methods a) and b) are to be applied for downwardly inclined grouted anchors in soil and may also be used for downwardly inclined ground anchors in rock. Method c) is to be applied for upwardly inclined grouted anchors, but may also be used for downwardly inclined anchors. Limitation of the fixed anchor length can be neglected, if the conditions comply with DIN 41251, section 7.5.

4.4.5 Post-grouting

Post-grouting operations using cement suspension may be carried out in accordance with DIN 41251, Section 7.4. Subsequently, the free anchor length is to be flushed free, e.g. with water or bentonite suspension.

4.5 Protective measures against corrosion on site

4.5.1 General

The individual steps for the assembly of the anchor head on the construction site including corrosion protection measures must be carried out in accordance with the work instructions filed with the DIBt. The following corrosion protection measures are to be carried out on the anchor head on the construction site.

4.5.2 Permanent anchors

The area between the bearing plate and the upper end of the smooth plastic sheathing (anchor type G) or of the corrugated plastic sheathing (anchor types R and T) must be protected by means of a steel tube (anchor trumpet) welded to the bearing plate. For this purpose, the transition to the smooth plastic sheathing must be sealed by means of a lip seal in the case of anchors type G (see Appendix 4) and the transition to the corrugated plastic pipe by means of two roll rings in the case of anchors types R and T (see Appendix 5). The cavity between the steel tendon and the bearing plate/steel tube is to be injected with Nontribos MP-2 or vaseline "Cox GX". If the smooth or corrugated plastic sheathing has been injected with cement grout and Nontribos MP-2 has been used as the anti-corrosion compound, then the cement grout surface inside the plastic sheathing is to be sealed with Icosit 277 beforehand. After the anchor has been stressed, the anchor bushing and the excess protruding prestressing steel are to be protected by means of an inner PE protection cap that will be screwed onto the anchor head and whose cavity is also to be injected with vaseline "Cox


GX". The inner protection cap is to be sealed against the bearing plate by means of a sealing consisting of a Denso Bandage. An outer steel protection cap including an underlying washer made of Perbunan is to be screwed onto the bearing plate as an additional protection measure. If the anchor head is set in concrete, such outer protection cap may be omitted. If anchors must be restressed, care must be taken that corrosion protection is properly executed after restressing again, e.g. through injection of vaseline "Cox GX".

4.5.3 Temporary anchors

The area between the bearing plate and the upper end of the smooth plastic sheathing is to be protected by means of a steel tube (anchor trumpet) welded to the bearing plate, with the transition to the smooth plastic sheathing being sealed by means of a lip seal (see Appendix 8). After the anchor has been stressed, the anchor bushing and the excess protruding prestressing steel are to be protected by means of a PE protection cap that will be pushed onto the anchor bushing.

4.6 Stressing operation

After sufficient hardening of the grout body, the anchors may be stressed. To do so, a hollow piston jack is pushed onto the excess protruding strand. That jack is seated on the anchor bushing of the anchor head. A 6 mm wedge slip occurring at the anchor head when transferring the stressing force from the jack to the wedges must be taken into account (see Section 2.1.3). After the anchor has been defined and the stressing jack dismantled, the strands are to be severed about 30 mm outside of the anchor bushing. The wedges of temporary anchors are covered by means of a wedge locking plate screwed to the anchor bushing. Supplementary corrosion protection measures are described in Section 4.5 hereof.

4.7 Suitability and acceptance tests, supervision of the installation

Suitability and acceptance tests are to be carried out on every construction site in compliance with DIN 41251. Suitability tests for permanent anchors are to be supervised by a surveillance agency for monitoring the installation of grouted anchors, which is stated in the list of inspection, surveillance and certification agencies according to the German state construction ordinances, part V, as amended from time to time23. The surveillance agency employed, within the scope of monitoring activities related to suitability and acceptance tests, must supervise at least randomly the assembly of permanent anchors on the construction site, especially the corrosion protection measures to be carried out on site, e.g. the complete grouting of the anchor head area with anti-corrosion compound. If the annular space between the steel tendon and the corrugated plastic sheathing is only injected with cement grout in the borehole (see Sections 2.2.1.2 and 4.4.3), the basic functioning is to be controlled by the surveillance agency. In addition, proper execution is to be monitored by random checks. This has to be mentioned in the test report. The surveillance agency must report to the competent building supervision authority, when facilities and personnel on site do not warrant proper installation. The beginning of such work is to be reported to the building supervision authority in charge.

23 last: List of testing, inspection and certification bodies to the state building codes - as of May 2009 - DIBt - Communications,

German Institute for Building Technology 40 (2009), Special Issue No. 37

DIBT Approval Certificate Page 17 of 14 I march 18th 2010 Z-20.1-64 5 Provisions for usage, maintenance and service

5.1 Restressing, verifying the anchor force

The anchors may be restressed. To do so, a jack will be used that is supported by the bearing plate via a stressing chair. The anchor bushing is lifted off the bearing plate via a tensioning sleeve screwed onto its thread without loosening the wedges by means of the stressing jack. After the restressing distance has been reached, supporting shells (half shells) are inserted from the height of the restressing distance between the anchor bushing and the bearing plate, so that the restressing force is transferred from the anchor bushing to the bearing plate via the supporting shells. The anchor force of a stressed anchor may be verified either by the stressing device described for restressing operations or by means of a special testing jack that is directly screwed onto the thread of the anchor bushing. In doing so, such anchor force is measured that occurs in the moment when the anchor bushing is lifted off the bearing plate (lift-off test). Restressing of the anchor including loosening of the wedges is only permissible as a variant, if the wedge positions of the wedges resulting from a previous stressing operation are shifted by at least 15 mm outwards after restressing and anchoring. However, such restressing is only possible, if the strands are sufficiently protruding from the anchor bushing. That variant is especially used for temporary anchors where the anchor bushing normally has no external thread.

5.2 Verification

DIN 41251, Section 13, applies. If required, verification should be assumed by the surveillance agency which has already conducted the suitability tests.

Henning Certified by: W. Faller Deutsches Institut für Bautechnik

A U S T R I A

A R G E N T I N A

A U S T R A L I A

B E L G I U M

B O S N I A A N D H E R Z E G O V I N A

B R A Z I L

C A N A D A

C H I L E

C O L O M B I A

C O S T A R I C A

C R O A T I A

C Z E C H R E P U B L I C

D E N M A R K

E G Y P T

E S T O N I A

F I N L A N D

F R A N C E

G E R M A N Y

G R E E C E

G U A T E M A L A

H O N D U R A S

H O N G K O N G

I N D O N E S I A

I T A L Y

J A P A N

K O R E A

L E B A N O N

L U X E M B O U R G

M A L A Y S I A

M E X I C O

N E T H E R L A N D S

N O R W A Y

O M A N

P A N A M A

P A R A G U A Y

P E R U

P O L A N D

P O R T U G A L

Q A T A R

S A U D I A R A B I A

S I N G A P O R E

S O U T H A F R I C A

S P A I N

S W E D E N

S W I T Z E R L A N D

T A I W A N

T H A I L A N D

T U R K E Y

U N I T E D A R A B E M I R A T E S

U N I T E D K I N G D O M

U R U G U A Y

U S A

V E N E Z U E L A

w w w . d y w i d a g - s y s t e m s . d e

DYWIDAG-Systems International GmbHGermanenstrasse 886343 Koenigsbrunn, GermanyPhone +49-8231-96 07 0Fax +49-8231-96 07 40E-mail [email protected]

DYWIDAG-Systems International GmbHMax-Planck-Ring 140764 Langenfeld, GermanyPhone +49-2173-79 02 0Fax +49-2173-79 02 20E-mail [email protected]

DYWIDAG-Systems International GmbHSchuetzenstrasse 2014641 Nauen, GermanyPhone +49-3321-44 18 0Fax +49-3321-44 18 18E-mail [email protected]

0461

4-1/

06.1

5-w

eb c

a

Geotechnical Systems - DSI Deutschland · PDF fileGeotechnical Systems SUSPA Compact Rock and...

Documents

Transcript of Geotechnical Systems - DSI Deutschland · PDF fileGeotechnical Systems SUSPA Compact Rock and...