halfen hlb loop box z-hlb-t100...

HALFEN HLB LOOP BOX

CONCRETE

Z-HLB-T100 13-E

Translation of the General Certificate of Approval

Approval Office:

German Institute for Construction Engineering

(Deutsches Institut für Bautechnik DIBt) Kolonnenstrasse 30, D-10829 Berlin

Date: 24. July 2008

Approval Number: Z-21.8-1871

Duration of validity: 31. July 2013

Applicant:

HALFEN GmbH

Liebigstrasse 14, 40764 Langenfeld

Approval Object: HALFEN Loop Box HLB T 100/250-System

The above-mentioned object of approval is hereby generally approved by the building authorities. This general building authority approval comprises seven pages and six appendices. Note: This is a translation of the original German version not certified by the German Institute for Construction Engineering.

Translation of the DIBt approval No.

Z-21.8-1871 page 2 of 7 |

Note: This is a translation of the original German version not certified by the German Institute for Construction Engineering DIBt.

I. GENERAL PROVISIONS

1 In the sense of the regional building law the applicability or respectively the practicability of the object of approval is verified by the general building authority approval.

2 The general building authority approval does not replace the legally prescribed authorisations, agreements and certifications.

3 The general building authority approval is granted notwithstanding the rights of any third party, in particular private property rights.

4 The manufacturer and distributor of the object of approval have to provide copies of the general building authority approval to the users or operators of the object of approval irrespective of any further rules in the “particular provisions” and draw attention to the fact that the general building authority approval must be present at the site of application. If demanded copies of the general building authority approval are to be provided for the authorities concerned.

5 The general building authority approval may only be duplicated in its complete form. Publication of extracts requires the approval of the German Institute for Construction Engineering. Texts and diagrams of brochures may not be in conflict with the general building authority approval. Translations of the general building authority approval must contain the reference “A translation of the original German version not certified by the German Institute for Construction Engineering”.

6 The general building authority approval is revocable granted. The provisions of the general building authority approval can be subsequently supplemented and changed, particularly if new technical findings demand this.


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II. PARTICULAR PROVISIONS

1 Object of approval and scope of application

1.1 Approval Object

The HALFEN Loop Box HLB T 100/250-System consists of the HALFEN connection boxes type HLB M 20/250 and type HLB M 100/250 (subsequently called connection boxes) and the HALFEN joint mortar HLB MIX (subsequently called joint mortar). The connection boxes consist of a storage box constructed of rolled galvanised sheet metal, in which cable loops made out of high-strength steel wire cable with a diameter of 6 mm are arranged in a distance of 249 mm. The connection boxes are set in pre-fabricated reinforced concrete walls and function as stay-in-place formwork in combination with the surrounding concrete.

The connection boxes are illustrated in Appendix 1 in the embedded state.

1.2 Range of application

The HALFEN Loop Box HLB T 100/250-System may only be utilised for assembly or connection of pre-fabricated reinforced concrete walls, in which exclusively shear forces are transferred parallel and/or perpendicular to the joint as a predominantly static loading. Regular tensile loads in the joints (in the element plane) are to be excluded or to be transferred by suitable methods.

If requirements are set concerning duration of fire resistance in the whole construction, the regulations are in force according to DIN 4102-4:1994-03 in connection with DIN 4102-22:2004-11.

The pre-fabricated reinforced concrete elements must comply with DIN 1045-1:2001-07 “Structures of concrete, reinforced concrete and pre-stressed concrete – Part 1: Design and Construction” and be fabricated of normal concrete with a strength class of at least C30/37 according to DIN 1045-2:2001-07 “Structures of concrete, reinforced concrete and pre-stressed concrete – Part 2: Concrete – specification, properties, fabrication and conformity.”

2 Building product regulations

2.1 Properties and Composition

2.1.1 Connection box

The connection box must comply with the drawings and specifications in the appendices.

The material properties, dimensions and tolerances of the connection box which are not declared in this general building authority approval must comply with the specifications deposited with the German Institute for Construction Engineering, with the certification authority and the third-party inspectors.

2.1.2 Joint mortar

The joint mortar must comply with the DAfStb instructions “Manufacture and usage of cement-bound grouting concrete and casting mortar” (Edition June 2006) and with the specifications deposited with the German Institute for Construction Engineering.

The compression strength of the joint mortar must correspond at least to the early strength class A after ageing for 24 hours when tested according to the DAfStb instructions “Manufacture and usage of cement-bound grouting concrete and casting mortar” (Edition June 2006).


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2.2 Packaging, warehousing and identification


Packaging, enclosed labels or delivery note for the connection box must be designated by the manufacturer with the conformity symbol (Ü-symbol) according to the conformity symbol directives of the federal states. Additionally the manufacturer's symbol, the approval number and the complete designation of the connection box must be supplied. The identification may only take place after the prerequisites given in Section 2.3 have been fulfilled.

Additionally each connection box is to be labelled with the manufacturer’s symbol and the designation “HLB M 20/250” and “HLB M 100/250” respectively.

2.2.2 Joint mortar

Packaging, enclosed labels or delivery note for the joint mortar must be carried out according to the regulations of the DAfStb instructions “Manufacture and usage of cement-bound grouting concrete and casting mortar” Edition June 2006).

2.3 Certificate of conformity


2.3.1.1 General The endorsement of conformity of the connection boxes with the regulations of this general building authority approval must take place for each production plant with a certificate of conformity on the basis of an in-house production check and a regular third-party inspection including an initial inspection of the connection boxes according to the requirements of the following regulations.

For the issuing of the certificate of conformity and the third-party inspection including the product inspections which have to be carried out, the respective manufacturer has to call in a recognised certification authority and an inspection authority recognised for this purpose.

The German Institute for Construction Engineering is to be given a copy of the certificate of conformity issued by the certification authority for information.

2.3.1.2 In-house production inspection An in-house production inspection is to be set up and implemented in each production plant. In-house production inspection means a continuous monitoring of production undertaken by the manufacturer, with which the latter ensures that the building products manufactured by him fulfil the regulations of this general building authority approval.

The inspection plan deposited with the German Institute for Construction Engineering and the third-party inspectorate is definitive for the range, type and frequency of the in-house production inspection.

The findings and results of the in-house production inspections are to be recorded and evaluated. The records must contain at least the following particulars:

− identification of the building product or resp. the raw material and the components

− Type of inspection or testing

− Date of manufacture and the testing of the building products or resp. the raw material or components

− Findings and results of the inspections and tests and as far as applicable a comparison with the requirements.

− Signature of the person responsible for the in-house production inspection.

The records are to be kept for at least five years and are to be presented to the inspection authority called in for external monitoring. If requested, they are to be presented to the


Z-21.8-1871 page 5 of 7 |


German Institute for Construction Engineering and to the appropriate highest construction supervisory board.

In the case of inadequate test results, the manufacturer must immediately take the necessary measures to remedy the fault. Building products which do not meet the requirements are to be managed so that there can be no confusion with conforming products. After eliminating the fault, the required test is to be repeated without delay as far as technically possible and to verify that the fault has been eliminated.

2.3.1.3 External monitoring (third-party inspection)

In every production plant the in-house production inspection is to be regularly monitored by third-party inspectors (external monitoring).

Within the scope of external monitoring an initial test is to be carried out and samples are to be taken for random sampling tests. The recognised inspection authority is in each case responsible for sampling and tests.

The inspection plan deposited with the German Institute for Construction Engineering and the third-party inspectorate is definitive for the range, type and frequency of the external monitoring.

The findings and results of the certification and external monitoring are to be kept for at least five years. If requested, they are to be presented from the certification authority or from the third-party inspectorate respectively to the German Institute for Construction Engineering and to the appropriate highest construction supervisory board.

2.3.2 Joint mortar

The certification of conformity for the joint mortar must be carried out according to the regulations of the DAfStb instructions "Manufacture and usage of cement-bound grouting concrete and casting mortar" (Edition June 2006).

3 Regulations for layout and design

3.1 Layout

3.1.1 Pre-fabricated reinforced concrete element

The pre-fabricated reinforced concrete elements are to be designed in compliance with DIN 1045-1:2001-07 if nothing else is defined in the following.

Normal concrete with a strength class of at least C30/37 according to DIN 1045-2:2001-07 is to be used for the pre-fabricated reinforced concrete elements.

The pre-fabricated reinforced concrete elements must have a minimum wall thickness of 14 cm.

As a rule a maximum of three connection boxes may be arranged one above the other. The maximum joint height must not exceed 3.54 m. Higher joints are only permissible if the later grouting of the joints is carried out in sections of 3.54 m at maximum with a grouting hose.

In the region of the connection boxes, in order to ensure the transfer of the induced loop strengths, a minimum reinforcement of the surrounds of the pre-fabricated elements is to be provided with stirrups Ø8/25 and longitudinal bars 2Ø10 appropriate to the details of the appendices. The stirrups can be replaced with comparable mesh reinforcement (e.g. Q257 A).

The minimal edge distance of the cable loops should be according to the specifications in the appendices.

3.1.2 Pre-fabricated reinforced concrete element connection

The connection of the pre-fabricated reinforced concrete elements may transfer exclusively shear forces parallel and perpendicular to the joint as a predominantly static


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loading. Tensile loads in the joints (in the element plane) are to be excluded or to be transferred by suitable methods.

Any imposed deformation of the pre-fabricated reinforced concrete element – connection due to temperature changes or free weathering must be excluded. This can be deviated from, if for the respective application evidence can be given for the limitation of the crack width according to Section 3.2.4.

The pre-fabricated reinforced concrete element– connection is to be designed appropriate to the specifications of the appendices. The connections are to be planned so that the declared set value in the appendices for the overlapping of the cable loops is adhered to.

3.2 Design

3.2.1. General

The analyses of the load bearing capacity of the pre-fabricated reinforced concrete elements and their connections is to be done in each individual case.

The pre-fabricated reinforced concrete elements are to be designed in accordance with DIN 1045-1:2001-07. The following design values are only valid for pre-fabricated reinforced concrete elements with a concrete strength class of at least C30/37 according to DIN 1045-2:2001-07.

The connection of the pre-fabricated reinforced concrete elements with connection boxes can transfer shear forces parallel and perpendicular to the joint as a predominantly static loading.

3.2.2 Shear force load bearing capacity parallel to the joint

For the shear force load bearing capacity parallel to the joint for the joint reinforced with the connection boxes, the design value VRd,II may be set according to Appendix 5, table 1 for the ultimate limit state.

For the simultaneous action of shear forces perpendicular to the joint the design value VRd,II is to be reduced with the interaction relationship according to Appendix 5, diagram 1.

3.2.3 Shear force load bearing capacity perpendicular to the joint

For the shear force load bearing capacity perpendicular to the joint for the joint reinforced with the connection boxes, the design values VRd,I may be set according to Appendix 5, table 2 for the ultimate limit state, depending on the thickness of the building component and the concrete strength class.

To include the expansion forces arising in the joint, an exterior tensional force has to be taken into consideration according to DAfStb booklet 525, which is at least 1.5 times the shear force to be transferred over the joint. This tensile force can be transferred by an appropriately arranged reinforcement (e.g. a ring anchor) or through other constructional measures (clamped supports, frictional forces through contiguously upright wall elements, or similar).

For the simultaneous action of shear forces parallel to the joint the design values VRd,I are to be reduced with the interaction relationship according to Appendix 5, diagram 1.

3.2.4 Limitation of the crack width

If imposed deformations of the pre-fabricated reinforced concrete element – connection by reason of temperature changes or free weathering cannot be excluded, it must be proved that in the region of the pre-fabricated reinforced concrete element – connection the crack width due to this loading is limited to wk ≤ 0.3 mm.

Due to

When verifying the crack width limitation, no additional crack width is to be taken into consideration due to shear force loading parallel to the joint.


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4 Regulations for construction

4.1 Manufacture of pre-fabricated reinforced concrete elements

The connection boxes are to be inserted according to the installation instructions of the manufacturer and the appendices.

The connection boxes are to be inserted according to the manufacturer’s symbol with the arrow pointing upwards.

The end anchors of the cable loops are to be aligned at an angle of 90° to the storage box in the pre-fabricated element. For vertical installation of the connection boxes in the formwork, the assembly stability of the end anchors of the cable ends in the pre-fabricated element is to be ensured by fixing to the reinforcement with wire.

In order to limit deformation by shrinkage, the pre-fabricated elements should be appropriately warehoused prior to dispatch.

4.2 Manufacture of the pre-fabricated reinforced concrete element connection

The pre-fabricated reinforced concrete element connection with connection boxes is to be manufactured according to the installation instructions of the manufacturer and the details of the appendices.

The cable loops are folded into the storage box during manufacturing of the pre-fabricated elements and the storage box is blocked off against penetration of concrete with a metal profile (lengthwise) and adhesive tape (frontal). For assembly of the hardened pre-fabricated elements the seal is opened and removed and the loops are folded out at an angle of 90° to the storage box.

If the cable loops are correctly aligned these overlap horizontally with the nominal measure declared in the appendices and lie above each other in the vertical plane with no displacement. Horizontal or vertical displacements of the cable loops are only permissible up to the maximum tolerances declared in the appendices.

The joint mortar is to be mixed according to the manufacturer’s operating instruction and to be carefully filled in.

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HALFEN is represented in more than 45 countries worldwide. Please contact us: www.halfen.com

CoNtACt HALFEN WoRLDWIDE

The Quality Management System of Halfen GmbH is certified for the locations in Germany, Switzerland and Poland according to DIN EN ISo 9001:2000, Certificate No. QS-281 HH.

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