REINFORCEMENT STEEL CONTINUITY SYSTEMS HEAVY DUTY ANCHOR … Steel... · CONTENTS Reinforcement...

11REINFORCEMENT STEEL CONTINUITY SYSTEMS

HEAVY DUTY ANCHOR

CONTENTS

Reinforcement Steel Continuity System 11-03

Rebar Couplers 11-04

Threaded Rebar Coupler Variations 11-05

Threaded Female Rebar Coupler 11-06

TSE Friction welded Male Bar Coupler 11-07

Friction Welding 11-08

RS Heavy Duty Anchor 11-09

Stud Anchor System BA A4 11-10

Reinforcement Steel Continuity Systems 11-12

Anchor Systems for Civil and Structural Engineering Works 11-13

European Quality Assurance 11-14

REINFORCEMENT STEEL CONTINUITY SYSTEMS

HEAVY DUTY ANCHOR

www.cfsfixings.com 0311

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REINFORCEMENT STEEL CONTINUITY SYSTEM

• Suitable for reinforcement steel diameter 12mm – 40mm.

• System allows to use full diameter (cross section) of the bar.

• The strength of the connection is equivalent to the reinforcement steel (bar-break) strength.

• Suitable for dynamic loads.

• Slip below 0.1 mm at 70% of the yield strength.

• Reduces welding on site.

• It ensures safe construction as reinforcement steel does not require any special preparation.

• Use of steel with a nominal yield strength of ≥500N/mm2 and a tensile strength of ≥550N/mm2.

• The shape, height and type of steel reinforcement has no influence on the connection.

• Every diameter and length of reinforcement steel system, straight or bent, can be fitted with a coupler and easily connected.

• Lock nuts are not required.

• Better concrete cover is generated.

• No special tools or training are required to assemble or tighten the coupling.

• Crane time can be reduced to a minimum.

• Sustainable anti-corrosion option available (see the section Heavy Duty Anchor).

Tested and approved according to International and European standards and regulations.

The CFS full strength reinforcement continuity system is based on male threaded starter bars joined to female threaded reinforcement steel couplers. Reinforcement steel bars with a nominal yield strength of 500N/mm2 and ultimate tensile strength of ≥550N/mm2 are capable of withstanding dynamic loads.

Shear wall Column Column Beam Future Extension Beam-Column


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REBAR COUPLERS

Consists of two elements, male and female bar couplers. The female bar is a threaded socket crimped to a steel reinforcing bar (designation for M 16, for example: O 12-M 16). The male bar is a threaded stud welded to a steel reinforcing bar.

ApprovalCFS rebar couplers have been tested and certified by KIWA, certificate No. K 45993 for static loads (cat1) and K56447 for dynamic loads (cat2).

Material properties Reinforcing steel - FeB 500 HWL/B500BThreaded socket - E 355 - DIN EN 10305

AccessoriesNailing plates, magnetic plates, seal caps.

During the installation of the socket (female part) it is vital to make sure that the female socket bar is lapped along side existing reinforcement.

The male bar should be fully screwed in to the female bar (tighten with a torque M [Nm] = 5 x ds [mm], see Tab. 2).

Any bend in the reinforcing bar, should comply with the bending radius specified in the respective national standard for reinforced concrete. To avoid damage, roller diameter less than dbr = 5 x ds must be used. The minimum clearance to the weld seam and the threaded socket must be as given as Tabs. 1 and 2.

Dimensions (mm)

Reinforcing steel Ø D1 L1 Lbmin /lbx

12 M16 27 100/140

16 M20 33 125/180

20 M24 38 140/210

25 M30 43 190/275

32 M42 65 210/325

40 M48 52 230/370

Dimensions (mm) NM

Reinforcing steel Ø D1 L1 Lbmin /lbx Torque

12 M16 30 85/130 60

16 M20 40 112/170 80

20 M24 46 137/210 100

25 M30 50 160/250 125

32 M42 70 210/325 160

40 M48 57 230/370 400

Dimensions (mm)

Reinforcing steel Ø D1 Bending roller Ø

12 M16 60

16 M20 80

20 M24 100

25 M30 125

32 M42 160

40 M48 200

Tab

./F

ig. 1

: Dim

ensi

ons

of

Fem

ale

bar

Ta

b./

Fig

. 2: D

imen

sio

ns o

f M

ale

bar

Ta

b./

Fig

. 3: B

end

ing

ro

ller

ft Ø

THREADED REBAR COUPLER VARIATIONS

PSTS Double Ended Rebar Coupler female end one side and male end other side.

Please specify overall length, required bar diameter and thread size.

PSAD Double Ended Rebar Coupler female end in both sides.

Rebar coupler with an internal metric thread at both ends.


TSAD Double Ended Rebar Coupler Male end in both sides.

Assembled from a threaded bar with locked couplers with an internal metric thread on each end. Used for applications where tolerance on the length is less than 3mm.


PSAG – Bent Rebar Coupler.

The assembly of the PSAG rebar coupler is identical to that of the PSA rebar coupler. The lengths (L2 and L3) of the reinforcement steel can be made to order and bent as required.

To order, please specify leg length L2, L3 and D, bar diameter and thread size. For bending radius please refer to Tab./Fig. 3: Bending roller Ø

A

L

Ø M

Ø d

AL1

Ø D ØM

AL1

Ø dØ D Ø DØ M

AL1

Ø DØ MØ dØ D

A

LL1

Ø DØ M

Ø d

AL1

Ø DØ M

Ø d

L

A

Ø M

A

Ø M

AL1

L3

R=2.5× Ø d

Ø DØ M

Ø d

L2

L

Ø d Ø D Ø M

L2 b

L

Ø a

AL1

Ø dØ D Ø DØ M

AL1

Ø DØ MØ dØ D

A

LL1

Ø DØ M

Ø d

AL1

Ø DØ M

Ø d

L

A

Ø M

A

Ø M

AL1

L3

R=2.5× Ø d

Ø DØ M

Ø d

L2

L

Ø d Ø D Ø M

L2 b

L

Ø a

AL1

Ø dØ D Ø DØ M

AL1

Ø DØ MØ dØ D

A

LL1

Ø DØ M

Ø d

AL1

Ø DØ M

Ø d

L

A

Ø M

A

Ø M

AL1

L3

R=2.5× Ø d

Ø DØ M

Ø d

L2

L

Ø d Ø D Ø M

L2 b

L

Ø a


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TSE FRICTION WELDED MALE BAR COUPLER

For use with PSA coupler.

Part No Diam d min

Length L min

Thread*Reinforcement Steel Tensile Capacity (kN)

Rated Section (mm2)

M Length A mm

CFS-TSE-12-375 12 375 16 MIN 22 56.5 113

CFS-TSE-12-575 12 575 16 MIN 22 56.5 113

CFS-TSE-12-775 12 775 16 MIN 22 56.5 113

CFS-TSE-12-1000 12 1000 16 MIN 22 56.5 113

CFS-TSE-12-1500 12 1500 16 MIN 22 56.5 113

CFS-TSE-16-520 16 520 20 MIN 28 100.5 201

CFS-TSE-16-770 16 770 20 MIN 28 100.5 201

CFS-TSE-16-1020 16 1020 20 MIN 28 100.5 201

CFS-TSE-16-1410 16 1410 20 MIN 28 100.5 201

CFS-TSE-16-1500 16 1500 20 MIN 28 100.5 201

CFS-TSE-20-465 20 465 24 MIN 35 157 314

CFS-TSE-20-665 20 665 24 MIN 35 157 314

CFS-TSE-20-965 20 965 24 MIN 35 157 314

CFS-TSE-20-1250 20 1250 24 MIN 35 157 314

CFS-TSE-20-1500 20 1500 24 MIN 35 157 314

CFS-TSE-20-1800 20 1800 24 MIN 35 157 314

CFS-TSE-20-2000 20 2000 24 MIN 35 157 314

CFS-TSE-25-600 25 600 30 MIN 43 245.5 491

CFS-TSE-25-1000 25 1000 30 MIN 43 245.5 491

CFS-TSE-25-1500 25 1500 30 MIN 43 245.5 491

CFS-TSE-25-2260 25 2260 30 MIN 43 245.5 491

CFS-TSE-32-1400 32 1400 42 MIN 45 401.9 803.8

CFS-TSE-32-2000 32 2000 42 MIN 45 401.9 803.8

CFS-TSE-32-2300 32 2300 42 MIN 45 401.9 803.8

CFS-TSE-40-1600 40 2000 48 MIN 56 625 1250

CFS-TSE-40-3400 40 2600 48 MIN 56 625 1250

* When cast into concrete, concrete failure must be concidered

Ø M

A

Ø d

L

A

Ø M

L1 L1 L2

L

PSA THREADED FEMALE REBAR COUPLER

Part No Diam d min

Length L min

Thread Coupling*Reinforcement Steel Tensile Capacity (kN)

Rated Section (mm2)

M Length A mm

Diam D mm L1 mm

CFS-PSA-12-400 12 400 16 25 22 62 56.5 113

CFS-PSA-12-600 12 600 16 25 22 62 56.5 113

CFS-PSA-12-800 12 800 16 25 22 62 56.5 113

CFS-PSA-12-1000 12 1000 16 25 22 62 56.5 113

CFS-PSA-12-1500 12 1500 16 25 22 62 56.5 113

CFS-PSA-16-550 16 550 20 36 27 86 100.5 201

CFS-PSA-16-800 16 800 20 36 27 86 100.5 201

CFS-PSA-16-1020 16 1020 20 36 27 86 100.5 201

CFS-PSA-16-1440 16 1440 20 36 27 86 100.5 201

CFS-PSA-16-1500 16 1500 20 36 27 86 100.5 201

CFS-PSA-20-500 20 5000 24 40 34 99 157 314

CFS-PSA-20-700 20 700 24 40 34 99 157 314

CFS-PSA-20-1000 20 1000 24 40 34 99 157 314

CFS-PSA-20-1280 20 1280 24 40 34 99 157 314

CFS-PSA-20-1500 20 1500 24 40 34 99 157 314

CFS-PSA-20-1800 20 1800 24 40 34 99 157 314

CFS-PSA-20-2000 20 2000 24 40 34 99 157 314

CFS-PSA-25-600 25 600 30 50 41 117 245.5 491

CFS-PSA-25-1000 25 1000 30 50 41 117 245.5 491

CFS-PSA-25-1500 25 1500 30 50 41 117 245.5 491

CFS-PSA-25-2260 25 2260 30 50 41 117 245.5 491

CFS-PSA-32-1400 32 1400 42 65 55 153 401.9 803.8

CFS-PSA-32-2000 32 2000 42 65 55 153 401.9 803.8

CFS-PSA-32-2300 32 2300 42 65 55 153 401.9 803.8

CFS-PSA-40-1600 40 1600 48 72 65 172 625 1250

CFS-PSA-40-3400 40 3400 48 72 65 172 625 1250

* When cast into concrete, concrete failure must be concidered

Ø DØ M

Ø d

LL1

A

A

LL1

Ø DØ M

Ø d


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FRICTION WELDING

A simple, efficient and more effective method of connecting reinforcement, which overcomes the disadvantages of the traditional method.

Commonly used in industrial applications, friction welding is the process of generating heat through mechanical friction between a moving work piece and a stationary component. Our approach is to distinguish between the friction phase and the forging phase. During the friction phase a rotating work piece is pressed against a fixed one, then once both have been heated to a sufficient temperature the forging phase begins whereby the rotating work piece is stopped and a force is applied to continue pressing the two pieces together.

Advantages

• Friction welding method offers very fast joining times.

• It is suitable for many types of assembly.

• Recommended over other methods for both metallurgical and commercial reasons.

• Ability to securely join dissimilar metals.

• Cost-effective solution for connections between stainless steel and other types of steel.

• A friction-welded joint is a butt-type, full-contact welded joint that achieves a fusion between the two materials at the joint interface with no gaps. Hardly any electrochemical reaction is possible at the joint, which eliminates the risk of galvanic corrosion. in turn providing cost benefits over time by eliminating the need for expensive repair work.

• The heating of the two materials is uniform over the entire contact face, ensuring the same strength properties can be assumed throughout the plane of the joint.

Dealing with Fatigue Loads

Following extensive testing and countless years of practical experience, particularly in transport infrastructure projects, it has been proven that friction welding is the ideal method for dealing with Fatigue stresses. For further proof, fatigue tests with 2.5, 5 and 10 million load cycles were carried out. In the subsequent tensile tests it was always the ribbed reinforcing bar that failed.

Friction welding benefit has been specified in the framework development planning of Deutsche Bahn AG and confirmed as a production method for the Federal Ministry.

A characteristic feature of the friction welded anchor is the combination of a stainless steel threaded socket (or stainless steel bolt) with anchorage bar from reinforcing steel where two components are welded together.

Friction welded socket (or stainless steel bolt) can be used in the areas near the concrete surface where reinforcement part requires high corrosion-resistance. Friction welded stainless steel part allows to use budget reinforcing steel in the deeper areas of the concrete. The Friction Welding is an economical and high-tech quality production process, which allows connecting various workpieces.

The benefit for corrosion resistance is that the socket is solid Stainless Steel material preventing a corrosion path to the carbon reinforcing steel below.

Pressure - Rotation - Diagram

Compression phaseFriction phase

RotationPressure

Stainless steel socket anchor system HA A4

• M16, M20, M22, M24, M27, M30 and M36 threaded sockets in stainless steel, group A4, grades 1.4401, 1.4404, 1.4571 – for attaching items to concrete.

• Friction-welded to B500B steel reinforcing bar, d = 14 to 32 mm – for anchorages.

• In system complete with threaded bars, nuts, washers and elastomeric washers.

German National Approval - Z-30.6-70

CFS Friction Welded (RS) Heavy Duty Threaded Socket System. Static Loads

Socket Anchor System A4. Fatigue Loads

CFS Friction Welded Heavy Duty Threaded Socket HA

Socket

dmm

M16 M16 M20 M20 M22 M24 M27 M27 M30 M36

Reinforcement bar/ threaded rod 14 16 16 20 20 25 25 28 28 32

Outer diameter DH 22 27 27 32 36 40 40 45 50

Steel failure of the threaded rod A4-50

Axial Capacity NRD,s kN 30 46.8 57.8 64.4 87.6 107.1 156

Steel failure of threaded rod A4-70

Axial Capacity NRD,s kN 57.7 64.5 106 141.4 171 220.7 236.3

Socket

d mmM16 M16 M20 M20 M22 M24 M27 M27 M30 M36


2* 10^6 Load Cycle

Axial Capacity NRD,s kN 7.8 11.2 18.4 24.6 29.7 38.4 39.3

5* 10^6 Load Cycle

Axial Capacity NRD,s kN 5.7 8.3 13.6 18.1 21.9 28.3 28.9

RS (FRICTION WELDED) HEAVY DUTY ANCHOR - FOR STATIC AND FATIGUE LOADS

Please contact CFS for calculation

Friction welded socket RS

Reinforcing steel bar B500B


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Installation

For casting in during concreting – immediate bond with concrete – all types.

For grouting in afterwards with an approved injection grout for later reinforcement connections – single bars with straight ends only, for stud anchors with weld bead removed.

Application

Corrosion resistance class (CRC) III according to national stainless steel approval or to EC 3. Wet interior conditions, outdoors, industrial

Load-carrying behaviour

Tensile and compressive forces in anchors are also possible without grouting bed under the base plate.

For fatigue-relevant loads: only tensile forces in anchors and grout bed under the base plate for carrying compressive forces are allowed.

Very high loads can be achieved near the edges and in tension anchor groups.

Socket Projection into grout bed

Excessive projection of socket from structural concrete + shear force and bending moment due to out-of-true position of anchor -> socket overloaded.

Projection must be limited. Allowed only for the socket anchor with fatigue loads and maximum out-of-true position as shown in the diagram.

Corrosion protection, concrete cover

Concrete cover to weld seam in axial direction >= 60 mm, or 50 mm concrete cover to avoid discolouration darker than straw yellow.

Concrete cover to weld seam in all other directions with corrosion loads >= 50 mm.

Or concrete cover >= cnom to EC 2.

>=50mm>=60mm

• M16, M20, M24, M27, M30, M36, M42 and M56 threaded studs in stainless steel, group A4, grades 1.4401, 1.4404, 1.4571 – for attaching items to concrete.

• Friction-welded to B500B steel reinforcing bar, d = 14 to 40 mm – for anchorages.

• Also available with weld bead removed.

• In system complete with nuts, washers and elastomeric washers.

Types

• Single bars

• Anchor cradles and cages

• Straight or bent ends

Stainless Steel Stud Anchor System. Fatigue Loads

Socket

d mm

M16 M20 M24 M27 M30 M30 M36 M36 M42 M56


Steel grade A4-70 A4-50

2* 10^6 Load Cycle

Axial Capacity NRD,s kN 10.7 14 21.8 34.2 34.2 42.9 55.9 55.9 80.3 80.3

5* 10^6 Load Cycle

Axial Capacity NRD,s kN 9.3 12.2 19.1 29.8 29.8 37.4 48.8 48.8 70.1 70.1

CFS Friction Welded (RS) Stud Anchor System. Static Loads

CFS Friction Welded Stud anchor HA A4 -70 A4 -50

Bolt

d mmM16 M20 M24 M27 M30 M30 M36 M36 M42 M56


Axial Capacity NRD,s kN 60.5 79 123.4 187.8 192.9 229.5 315.9 156 213.8 387.5

STUD ANCHOR SYSTEM BA A4 STAINLESS STEEL

Stainless Steel Socket

Conventional Steel Socket

3 Thread sizes

3 Thread sizes



Friction welded (RS) Male Stud anchor

Reinforcing steel bar B500B


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ANCHOR SYSTEMS FOR CIVIL AND STRUCTURAL ENGINEERING WORKS Friction welded connections between stainless steel and reinforcing bars

Many years of practical experience with fricition welded connections in transport - infrastructure projects under static and dynamic loads

REINFORCEMENT STEEL CONTINUITY SYSTEM

Please contact CFS in order to use CFS socket and stud anchor system connections with reinforcement bars

Stainless steel bar couplers are produced with the female half manufactured from solid stainless steel bar friction welded to conventional reinforcement. The main benefit of this process is enhanced corrosion resistance compared to pressed on couplers and excellent dynamic load performance.

SPECIAL APPLICATION - GERMAN RAILWAY FATIGUE LOADS5.000.000 load cycles. Pressure in front of the train and vacuum in the back – high speed 300 km/h

Friction welded RS stainless steel socket

Pressed reinforcing conventional steel threaded socket

Please note that working stress for stainless steel is X

Please note that working stress for conventional steel is usually greater Steel columns installed to support noise barriers.

Stainless Steel Friction Welded RS Stud Anchor System in Cages for steel beam fixing.

Stainless Steel Friction Welded RS Stud Anchor cage fixing for the steel beam.

Stainless Steel Friction Welded RS Socket Anchor System Cage detail with pressed tube for welding and distance bar.


EUROPEAN QUALITY ASSURANCE

Product Certification

• Sample testing

• University and test authority based accreditation traceability

• Accreditation for various applications on construction projects or your production plant

• CE marking and declaration of conformity for all products.

Approved Welding Techniques

• Certified to DIN/EN 1090 – 2nd part fulfilment class EXC4

• Welding of dynamically structural components to class CC3 (friction welding, head bolt welding, MAG-welding)

• Rebarsteel, Carbonsteel, Stainless steel.

German Quality Assurance

• Products and material remain within the limits of their technical approval ensured by ISO 9001 quality management

• Local testing facility up to 1000kN mobile testing equipment up to 300kN

• Continuous in-house quality assurance and furthermore supervision by SLM Magdeburg, MPA Dortmund & KIWA.

REINFORCEMENT STEEL CONTINUITY SYSTEMS HEAVY DUTY ANCHOR … Steel... · CONTENTS Reinforcement...

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Transcript of REINFORCEMENT STEEL CONTINUITY SYSTEMS HEAVY DUTY ANCHOR … Steel... · CONTENTS Reinforcement...