Keybox Reinforcement Continuity Systems - Ancon · PDF fileAncon Keybox Reinforcement...

Keybox ReinforcementContinuity Systemsfor the Construction Industry

CI/SfB Et6

May 2014

2 Tel: 1300 304 320 www.ancon.com.au

Ancon designs and manufactures high integrity steel products for

the construction industry. Through continuous programmes of

new product development, inward investment and employee

advancement, the company is committed to maintaining the

highest level of customer service within a dynamic and

challenging industry.

The use of reinforcement continuity systems isa widely accepted means of providingcontinuity of reinforcement across constructionjoints in concrete. The Keybox systemcomprises a galvanised steel casing whichhouses pre-bent bars. The unit is cast into theface of a concrete wall and the bars arestraightened, ready for lapping when required.

Reinforcement Continuity Systems 4

Standard Range Configurations 5

Standard Range Specifications 6

Special Requirements (Coupler Boxes) 7

Installation 8

On-site Cutting 9

Enquiry/Order Form 10

Applications 11

Other Ancon Products 11

Masonry Support Systems

Windposts and Lintels

Wall Ties and Restraint Fixings

Channel and Bolt Fixings

Tension and Compression Systems

Stainless Steel Fabrications

Flooring and Formed Sections

Shear Load Connectors

Stainless Steel Reinforcement

Reinforcing Bar Couplers

Reinforcement ContinuitySystems

Punching Shear Reinforcement

Precast Concrete Accessories

3

Reinforcement Continuity Systems

Ancon Keybox ReinforcementContinuity SystemsThe Keybox Reinforcement Continuity Systemis a quick and easy to install method ofmaintaining continuity of reinforcement atconstruction joints in concrete. It consists of a galvanised steel casing with a dimpledsurface to provide an effective concrete bond.Pre-bent bars are housed within the casingand are enclosed by a protective cover. Each end of the unit is sealed with apolystyrene block in order to prevent theingress of concrete.

The complete unit is nailed to the formwork.Alternatively it can be wired back to the mainreinforcement cage. The concrete is then cast.After striking the formwork, the cover isremoved and the bars are straightened, readyfor lapping onto the main reinforcement, usinga Keybox re-bending tool.

The steel casing remains embedded in the walland is filled with concrete when the nextsection is poured, the dimpled surfaceproviding an efficient key.

QualityKeybox Reinforcement Continuity Systems are manufactured using ACRSapproved bar which meets the requirements of AS/NZS 4671: 2001. The grade ofreinforcing bar used is Grade 500N, minimumyield 500MPa, minimum uniform elongationAgt 5%. The bars are bent in accordance withAS/NZS 4671: 2001.

Use of the Keybox system offers manybenefits over conventional joint construction,including the simplification of formwork designand removal of the need to drill shuttering. This contributes to the acceleration of theconstruction process. As the bars remainenclosed within the casing until required, theyare protected and the risk of injury fromprojecting bars is minimised. Easy to use, thesystem requires no on site training in order tocarry out installation.

The Keybox system is potentially suitable foruse in any construction joint in concrete, butthe most commonly found applicationsinclude:

• Floor slabs

• Walls

• Stairwells

• Corbels

• Diaphragm walls

• Jumpforms

• Brick support ledges


KB 220 U

1000mm

130

250

85

36

130

150

190

36

Unit will be supplied as a double box, joinedtogether, when stirrup width exceeds 220mm

130

180

220

36

130

100

120

130

120

150

36

150mm*Centres

200mm*Centres1000/1200mm

KB 120 UKB 85 L

KB 190 U

KB 150 U

*Other centres are available

This brochure contains an enquiry/order formon page 10. An order form can also bedownloaded from www.ancon.com.au

Standard Range Configurations

36

5


Standard Range SpecificationsThe following table gives details of the Keyboxstandard range. Many customers requirepurpose made units to suit their particularapplication. In order to meet this requirementAncon will manufacture according to yourspecific bar arrangement. The most commonshapes are shown on page 10. For furtherdetails please contact Ancon Building Products.

Code Slab Size Box Box Rebar Centres Bar Wall Bar Bar Width/ Leg Bars/mm Width Length Dia mm Shape Thickness Embedment Cog Length Length Box

mm (w) mm mm mm mm (h) mm (b) mm (I)

KB85L7 - 1000 90 - 140 85 1000 12 150 L >=180 130 250 450 7

KB85L8 - 1200 90 - 140 85 1200 12 150 L >=180 130 250 450 8

KB85L5 - 1000 90 - 140 85 1000 12 200 L >=180 130 250 450 5

KB85L6 - 1200 90 - 140 85 1200 12 200 L >=180 130 250 450 6

KB120U7 - 1000 140 - 160 120 1000 12 150 U >=180 130 100 450 7

KB120U8 - 1200 140 - 160 120 1200 12 150 U >=180 130 100 450 8

KB120U5 - 1000 140 - 160 120 1000 12 200 U >=180 130 100 450 5

KB120U6 - 1200 140 - 160 120 1200 12 200 U >=180 130 100 450 6

KB150U7 - 1000 160 - 190 150 1000 12 150 U >=180 130 120 450 7

KB150U8 - 1200 160 - 190 150 1200 12 150 U >=180 130 120 450 8

KB150U5 - 1000 160 - 190 150 1000 12 200 U >=180 130 120 450 5

KB150U6 - 1200 160 - 190 150 1200 12 200 U >=180 130 120 450 6

KB190U7 - 1000 190 - 220 190 1000 12 150 U >=180 130 150 450 7

KB190U8 - 1200 190 - 220 190 1200 12 150 U >=180 130 150 450 8

KB190U5 - 1000 190 - 220 190 1000 12 200 U >=180 130 150 450 5

KB190U6 - 1200 190 - 220 190 1200 12 200 U >=180 130 150 450 6

KB220U7 - 1000 220 - 300 220 1000 12 150 U >=180 130 180 450 7

KB220U8 - 1200 220 - 300 220 1200 12 150 U >=180 130 180 450 8

KB220U5 - 1000 220 - 300 220 1000 12 200 U >=180 130 180 450 5

KB220U6 - 1200 220 - 300 220 1200 12 200 U >=180 130 180 450 6

Notes: Dimensions shown in the above table are nominal. Heights and lengths may vary by one bar diameter. Maximum box length is determined by practicality and weight.

Suggested slab sizes are based on a minimum top and bottom cover of 20mm.

h l

b

w

h

b

d

U Type Box Dimensions

Bar Type

U U-bars to fit within the specifiedcasing to give two rows to lap onto

L L-bars placed approximately 15mmfrom top edge of casing (unless notedotherwise)

LL L-bars to fit within the specified casingto give two rows to lap onto

A Straight bars placed approximately15mm from top edge of casing(unless noted otherwise) - typicallyused for penetrations

AA Straight bars to fit within casing togive two rows to lap onto - typicallyused for penetrations

Standard casing lengths are 1000mm and1200mm, specials can be made ifnecessary.

Bar embedment (E) is 130mm as standardfrom front of casing, larger or smallerdepths can be made if necessary.

Casing widths can vary by joining smaller casings to form larger sizes (150 + 190 = 340mm).The thinner the casing width the more difficult it is to fit more bars e.g.10 bars will not fit in a120mm casing.

Keybox IdentificationThe description of a Keybox is generally of the form:

KB 150 U 7 -1000 (E230)

Keybox

Casing Width85, 120, 150,

190, 220

Type of barU, L, LL,

A, AA

Length ofcasing

Quantity ofbars in the

casing

Depth of bar ifnot 130mm


KSN AnchorsIf reinforcing bar congestion in the wall is aproblem when installing the coupler box,Ancon offers an alternative anchor system.The KSN anchor system works in exactly thesame way as a coupler box but instead ofL-bars cast into the wall this box uses headedanchors conforming to the requirements ofAS 3600: 2009. A threaded continuation bar isused in the same way as above.

This product has undergone extensive testingand tabulated performance data can be foundin the Ancon KSN Anchor brochure.

Other Reinforcement Continuity SystemsCoupler BoxesWhere the connecting bar is larger than12mm, continuity of reinforcement can beprovided by the installation of an AnconCoupler Box. These boxes combine standardKeybox casings with the BT mechanicalsplicing system.

The BT mechanical splice is a full strengthconnection and is one of the smallest couplersystems in the Ancon range. More informationcan be found in the Ancon Reinforcing BarCouplers brochure.

7

When connecting beams or thick slabs to corewalls, couplers are attached to the dimpledcasing and cast into the wall with an approvedembedment length of bar. This is typically anL-bar, designed to be tied onto the vertical wallsteel but any shape or size of bar can be usedas long as the bending detail conforms to AS/NZS 4671: 2001.

When the steel cover is stripped, the threadedcontinuation bars are screwed into thecouplers leaving a lap length of bar for futureconnection. These boxes can be made inshort lengths to simplify onsite handling.

Ancon Coupler Boxes are manufactured to suitthe requirements of specific projects.


Nail the Keybox through the casing to theformwork or alternatively securely tie theprojecting anchorage reinforcing bars back tothe main reinforcement. In both cases theKeybox box should be securely fixed to avoiddisplacement during concreting. The casingshould be tight against the formwork. Pourconcrete.

Strike the formwork to reveal the steel cover.

Straighten the bars using a Keybox re-bendingtool. The bars should be straightened onlyonce. To avoid damage to adjacent concrete,it is prudent to allow a concrete curing periodof seven days. See ‘Bar Straightening’ formore information.

Once the bars are straightened and alignedthey are ready for lapping.

Installation Bar StraighteningThe bars must be straightened using theappropriate sized Ancon Keybox re-bendingtool. This is a steel tube designed to fit overthe bar, the internal diameter being slightlylarger than the maximum dimension of the ribson the bar. One end of the tube has a sectioncut away; this provides support to the outsideof the bend during straightening of the bar andlimits the point contact of the tube on the bar.

Use of the tool allows the re-bending processto be carried out in a smooth continuousaction (avoiding jerky action), the tube beingmoved along the bar and around the bend asit is straightened.

To enable the re-bending tool to be fitted ontothe bar, the bar should be pulled the minimumdistance from the Keybox steel casing.The re-bending tool should then be slid alongthe bar to the start of the bend radius.

The bar straightening process should besmooth and progressive with the tube allowedto move along the bend towards the metalcasing as it is straightened. The tool shouldcontact the Keybox steel casing at thecompletion of the straightening process.

The tube is then removed and the straightenedbar checked for alignment and cover with theadjoining reinforcement.

Keybox reinforcing bars should not bestraightened when the temperature of the steelis below 5°C. Where straightening is necessarybelow 5°C, indirect warming of the steel to atemperature not exceeding 100°C is permitted.

Scaffold tubes or similar must not be used tostraighten bar. Inappropriate tools will result inexcessive kinks in the region of the bar bendand result in undesirable work hardening whichmay damage the bar and affect the strength.Bending the bar in excess of therecommendations will also result in workhardening of the rebar and should therefore beavoided.

1 4

52

3

Remove the steel cover to expose thepre-bent bars.


Identify the location of the intended cut.

On-Site Cutting1

Slide the protective cover from the box and remove the bars which pass over the cut location.

2

Cut through the steel casing using a disc cutter.

3

Replace the bars to face the opposite direction to their original position. Cut the cover to the samelengths as the steel casing and replace to protect the bars. The ends of the boxes must besealed, using polystyrene blocks, to prevent the ingress of concrete.

Note: Protective gloves should be worn when removing covers, straightening bars,cutting boxes and during general handling of Keybox.

4

9

Item Qty Box Bar Dia Stirrup Stirrup Box Embedment Pullout Leg Stirrup CogWidth (1) 10, 12 Spacing (2) Type Length (3) Depth Length Width (4) Length

h l c b(mm) (mm) (mm) (see above) (mm) (mm) (mm) (mm) (mm)

Re-bending Tool


Enquiry/Order Form

Please photocopy this page and use it to detail your enquiry/order.

Type LL Double AngleType LJ Double AngleType L Angle

Type A Straight BarType U U Bar Type AU U Bar Type AA Double Straight Bar

(1) Standard box widths 85, 120, 150, 190, 220mm.

(2) Variable stirrup spacing available. Standard spacing 150, 200mm.

(3) Standard lengths are 1000mm and 1200mm. Other sizes are available on request.

(4) Standard stirrup widths 100, 120, 150, 180mm.Note: Bars must be straightened using a Keybox re-bending tool. Do not straighten bars more than once.

If you would like help in creating a schedule of keyboxes and a programme for delivery for your project, please contact your local Ancon office.

Date � Order � Enquiry

Company

Address

Town Post Code

Contact

Tel Fax

Delivery Date

Delivery Address

Town Post Code

Contact

Tel Fax

Project

h l h l

h

b c

c c c

cb

l h

b

b

l

h l h l

h

b

l


Other Ancon Products

BT Parallel Threaded CouplersBT parallel threaded couplers provide a costeffective coupler system best suited to largescale, high coupler volume projects. The barends are enlarged by cold forging and aparallel thread is cut on to the ends to suit thethreaded coupler. Installation requires the useof a pipe or chain wrench.

MBT Mechanically Bolted CouplersMBT couplers offer a convenient means ofjoining bars without the need for bar endpreparation to suit BT couplers. The bars aresupported within the coupler on two serratedsaddles and are locked in place by a series ofspecial lockshear bolts. Bar rotation is notrequired.

Shear Load ConnectorsAncon DSD and ESD Shear Load Connectorsare used to transfer shear across expansionand contraction joints in concrete. They aremore effective at transferring load and allowingmovement to take place than standard dowels,and can be used to eliminate double columnsat structural movement joints in buildings.A ‘Lockable’ dowel is also available fortemporary movement joints in post-tensionedconcrete frames.

Punching Shear ReinforcementAncon Shearfix is used within a slab to provideadditional reinforcement from punching sheararound columns. The system consists ofdouble-headed steel studs welded to flat railsand is designed to suit the load conditions andslab depth at each column using freecalculation software from Ancon.

Channel and Bolt FixingsAncon offers a wide range of channels andbolts in order to fix stainless steel masonrysupport, restraints and windposts to structuralframes. Cast-in channels and expansion boltsare used for fixing to the edges of concretefloors and beams. A range of stainless steelset screws and self-drill self-tap screws aredesigned to fix to steel frames.

Special FabricationsAncon is an ASSDA accredited specialistfabricator and has a wealth of experience inworking with a variety of material grades. Highintegrity steel components are supplied to awide range of industries including CivilEngineering, Building, Infrastructure, WaterTreatment, Nuclear and Mining.

Beaumonde Apartments, Sydney, NSW

Condor Apartments, Docklands, VIC

ESP Apartments, Zetland, NSW

Eureka Tower, Melbourne, VIC

11

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Applications

Masonry Support Systems

Windposts and Lintels

Wall Ties and Restraint Fixings

Channel and Bolt Fixings

Tension and Compression Systems

Stainless Steel Fabrications

Flooring and Formed Sections

Shear Load Connectors

Stainless Steel Reinforcement

Reinforcing Bar Couplers


Punching Shear Reinforcement

Precast Concrete Accessories

© Ancon Building Products 2013

The construction applications and details provided in this literatureare indicative only. In every case, project working details should beentrusted to appropriately qualified and experienced persons.

Whilst every care has been exercised in the preparation of thisdocument to ensure that any advice, recommendations orinformation is accurate, no liability or responsibility of any kind isaccepted in respect of Ancon Building Products.

With a policy of continuous product development Ancon BuildingProducts reserves the right to modify product design andspecification without due notice.

These products are available from:

Ancon Building Products7-9 Second AvenueSunshineMelbourneVIC 3020Tel: 1300 304 320Fax: +61 (0) 3 9311 1777

Ancon Building Products18 Tennant StreetWelshpoolPerthWA 6106Tel: 1300 304 320Fax: +61 (0) 8 9361 1262

Ancon Building Products2/19 Nuttall DriveHillsboroughChristchurch 8022Tel: +64 (0) 3 376 5205Fax: +64 (0) 3 376 5206Email: [email protected]: www.ancon.co.nz

Ancon Building Products98 Kurrajong AvenueMount DruittSydneyNSW 2770Tel: 1300 304 320Fax: +61 (0) 2 9675 3390

Ancon Building Products4/15 Terrace PlaceMurarrieBrisbaneQLD 4172Tel: 1300 304 320Fax: +61 (0) 7 3395 6693

Email: [email protected]: www.ancon.com.auInternational Enquiries: +61 (0) 2 8808 1111

Overseas Offices:

Ancon Building ProductsSheffieldUnited Kingdomwww.ancon.co.uk

Ancon Building Products GesmbHViennaAustriawww.ancon.at

Ancon (Schweiz) AGRied bei KerzersSwitzerlandwww.ancon.ch

Ancon GmbHNurembergGermanywww.anconbp.de

Ancon (Middle East) FZEDubaiUnited Arab Emirateswww.ancon.ae

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