General Technical Approval

Transcription

1 General Technical Approval German approval body for construction products and types of construction Construction Testing Authority Authority of the German Länder Governments for a uniform fulfilment of technical tasks in the field of public law Member of EOTA, UEAtc and WFTAO Date: Reference No.: I /14 Approval No.: Period of Validity: Z from: 16. Februar 2015 Holder: FATZER AG Drahtseilwerk Salmsacherstrasse Romanshorn Switzerland to: 16. Februar 2020 Subject of Approval: Rope Tension Components with HYEND Sockets This translation of the German original has not been verified by DIBt and is for information only. The legally binding version is the German version. The subject as named above is hereby approved for use in the construction industry. This general technical approval includes eight pages and eight appendices. This construction product was approved for the first time on March 21st DIBt Kolonnenstrasse 30 B D Berlin Tel.: Fax: dibt@dibt.de

2 No. Z Page 2 of 8 February 16 th 2015 I GENERAL REMARKS 1 With the general technical approval, the usability or applicability of the subject of the approval is proven under the regulations of the federal state building regulations. 2 In the case of requirements to 17 Abs. 5 Musterbauordnung according to federal state regulations in this general technical approval regarding competencies and experiences of personnel in the context of the production of the construction products and construction methods, it needs to be considered that these competencies and experiences can also be proven by equivalent regulations and documentations from other members of the European Union. This may also apply for submitted equivalent proof in the context of the agreement on the European Economic Area (EEA) or other bilateral agreements. 3 The general technical approval does not replace other approvals and certificates that are legally required for construction projects. 4 The general technical approval is granted notwithstanding the rights of third parties, in particular rights protecting private property. 5 Manufacturers and distributors of the object of the approval must, notwithstanding addon regulations in the "Special Determinations", provide users with copies of the general technical approval and must notify them that the general technical approval must be available at the user site. Copies of the general technical approval must be made available to the participating authorities upon request. 6 The general technical approval may only be copied in its entirety. Publication of extracts requires the consent of the German Institute for Building and Civil Engineering Technology. Text and graphics from printed marketing materials may not contradict the general technical approval. Translation of the general technical approval must contain the notice "This translation of the German original has not been verified by the Deutsches Institut für Bautechnik. 7 The general technical approval, having been granted, may be revoked. The determinations of the general technical approval may subsequently be supplemented and updated, especially as required by new technical findings.

3 No. Z Page 3 of 8 February 16 th 2015 II SPECIAL REMARKS 1 Subject of Approval and intended Applications The subject of approval are prefabricated high tensile rope tension components composed of spiral strand ropes with sockets (see Appendix 1). This general technical approval covers the manufacture, the design and the use of prefabricated high tensile rope tension components under static and quasi static loads in respect to DIN EN 1990: that do not require fatigue design to DIN EN The design rules from DIN EN including its corresponding application standards and from the general technical approval No. Z apply as long as this general technical approval does not overrule them. 2 Requirements for the construction products 2.1 Properties and Compositions Dimensions and Tolerances Spiral strand ropes The technical delivery conditions of DIN EN , DIN EN and DIN EN as well as the content of DIN EN , DIN EN , DIN EN and DIN EN , of section 1 and in the annexes Sockets The content of the annexes applies. 1 DIN EN 1990: Eurocode: Basis of Structural Design 2 DIN EN : Eurocode 3: Design of steel structures - Part 1-9: Fatigue in conjunction with DIN EN /NA: DIN EN : Eurocode 3: Design of steel structures - Part 1-11: Design of structures with tension components in conjunction with DIN EN /NA: Z :2014 General Technical Approval - Products, connectors and components made from stainless steel 5 DIN EN : Steel wire and wire products - Steel wire for ropes - Part 1: General requirements 6 DIN EN : Steel wire and wire products - Steel wire for ropes - Part 2: Cold drawn non alloy steel wire for ropes for general applications 7 DIN EN : Steel wire and wire products - Steel wire for ropes - Part 4: Stainless steel wire 8 DIN EN : Steel wire ropes - Safety - Part 1: General requirements 9 DIN EN : Steel wire ropes - Safety - Part 2: Definitions, designation and classification 10 DIN EN : Steel wire ropes - Safety - Part 4: Stranded ropes for general lifting applications 11 DIN EN : Steel wire ropes - Safety - Part 10: Spiral ropes for general structural applications

4 No. Z Page 4 of 8 February 16 th 2015 The sockets in the annexes shall have metric ISO threads to DIN 13-1, 10, 20 and The specifications in the series of the DIN standards named before apply to the thread tolerances in conjunction with the information documented at the Deutsches Institut für Bautechnik Material properties Spiral strand ropes The technical delivery specification of the standards mentioned in section the provisions in section 1 and in the annexes apply Sockets for spiral strand rope made from unalloyed steel The threaded studs shall be made from structural steel S355 with the material number to DIN EN The open and closed sockets shall be made from fine grain structural steel S460N with the material number to DIN EN Alternatively the open and closed sockets can be made from unalloyed cast steel G42CrMo4+QT1 with the material number to DIN EN The pins of the open sockets shall be made from steel for quenching and tempering 34CrNiMo6+QT with the material number to DIN EN The internal and external quality of the open and closed sockets made from unalloyed cast steel shall comply with the quality levels SM2, LM2 and AM2 to DIN EN and with quality level 2 to DIN EN Additionally the rules in the annexes apply Sockets for spiral strand rope made from stainless steel The open and closed sockets as well as the threaded studs shall be made from stainless steel X2CrNiMoN with material number in the tensile grade S460 to general technical approval No. Z The open and closed sockets can also be made from stainless unalloyed cast steel GX2CrNiMoN with material number in tensile grade S460 to DIN EN The pins of the open sockets shall be made from stainless steel X2CrNiMoN with material number in tensile grade S460 to the general technical approval No. Z DIN 13-1: ISO general purpose metric screw threads - Part 1: Nominal sizes for coarse pitch threads; Nominal diameter from 1 mm to 68 mm DIN 13-10: ISO general purpose metric screw threads - Part 11: Nominal sizes for 8 mm fine pitch threads; Nominal diameter from 130 mm to 1000 mm DIN 13-20: ISO general purpose metric screw threads - Part 20: Limits of sizes for coarse pitch threads with the prefered tolerance classes; nominal sizes from 1 mm to 68 mm DIN 13-23: ISO general purpose metric screw threads - Part 23: Limits of sizes for fine pitch threads with the prefered tolerance classes; Nominal diameter from 53 mm to 110 mm 13 DIN EN : Hot rolled products of structural steels - Part 2: Technical delivery conditions for non-alloy structural steels 14 DIN EN : Hot rolled products of structural steels - Part 3: Technical delivery conditions for normalized/normalized rolled weldable fine grain structural steels 15 DIN EN 10293: Steel castings - Steel castings for general engineering uses 16 DIN EN : Steels for quenching and tempering - Part 3: Technical delivery conditions for alloy steels 17 DIN EN 1369: Founding - Magnetic particle testing 18 DIN EN : Founding - Ultrasonic examination - Part 1: Steel castings for general purposes 19 DIN EN 10283: Corrosion resistant steel castings

5 No. Z Page 5 of 8 February 16 th 2015 The maximum permissible indication for the internal quality of the open and closed sockets made from stainless cast steel is defined according to table A.1 of DIN EN via the comparison pictures series from ASTM-E with the following criteria: - Cavities / blowholes Figure 2 for thickness up to 25mm - Cavities / blowholes Figure 3 for thickness greater than 25mm - Gas pockets Figure 4 - Inclusions, cracks, chaplets and chills not allowed Imperfections in the outer quality of the open and closed sockets made from stainless cast steel shall not be worse than quality level 6 to table 2 and quality level 5 to table 3 of DIN EN Additionally the rules in the annexes apply Corrosion resistance class of the rope tension components made from stainless steel The rules in annex 2, table 1 apply. 2.2 Manufacturing and labeling Manufacturing of the rope tension components The detailed manufacturing procedure of the rope tension components is documented at the Deutsches Institut für Bautechnik Labeling The manufacturer shall display the Ü-Sign on the packaging of the rope tension components according to the federal state's compliance marking regulations (Übereinstimmungszeichen-Verordnung der Länder). The label may only be applied if the requirments of section 2.3 have been met. The label shall also show the manufacturing location, the year of manufacture, the name of the construction product, the rope diameter, the nominal thread diameter and the material of the individual parts. The tension components shall be marked in a way that prevents mix-ups. 2.3 Proof of Conformity General The conformity of the rope tension components with the rules in this general technical approval must be ensured for each manufacturing location with a certificate of conformity based on the manufacturer s in-house quality control and regular third party monitoring including an initial inspection of the rope tension components as provided by the following requirements. The manufacturer of the rope tension components nominates an approved certification body as well as an approved third party for the granting of the certificate of conformity and for the required product testing. The manufacturer demonstrates the issuing of the certificate of conformity by labeling the construction products with the Ü-Sign and the designated use. The certification body provides a copy of the certificate of conformity to the Deutsches Institut für Bautechnik. 20 DIN EN 12681: Founding - Radiographic examination 21 ASTM-E (Reapproved 2013) Standard Reference Radiographs of Investment Steel Castings for Aerospace Applications 22 DIN EN : Founding - Liquid penetrant testing - Part 2: Investment castings

6 No. Z Page 6 of 8 February 16 th Manufacturer s in-house quality control An manufacturer s in-house quality control shall be set up and implemented in every manufacturing location. The manufacturer s in-house quality control is the continuous monitoring of the production processes by the manufacturer which ensures that his products fulfill the requirements of this general technical approval. The manufacturer s in-house quality control shall include the following measures as a minimum: - Spiral strand ropes The measurements required in section shall be checked for every batch. The material properties required in section shall be proven by a 3.1 certificate to DIN EN Conformity between the information in the 3.1 certificate with the information in section 2.1 shall be verified. - Open sockets, closed sockets and threaded studs The measurements, tolerances and material properties required in section 2.1 shall be verified for each size of component and for each manufacturing batch. All cast steel parts shall be visually checked for external defects. The internal and external quality of unalloyed cast steel parts described in section shall be checked by non-destructive methods on the basis of DIN EN /NA 24, Annex NA.B for each size of component per manufacturing batch. The internal quality of stainless cast steel parts described in section shall be checked on the basis of DIN EN ISO , DIN EN ISO and DIN EN for each size of component per manufacturing batch. The external quality of stainless cast steel parts described in section shall be checked on the basis of surface crack testing by liquid penetrant testing to DIN EN ISO and DIN EN for each size of component per manufacturing batch. In case that the non-destructive methods lead to ambiguous results regarding the internal quality, destructive methods shall be used for clarification. The material properties required in section as well as the internal and external quality of the open and closed sockets made of unalloyed cast steel and made of stainless cast steel shall be proven by a 3.1 certificate to DIN EN Conformity between the information in the 3.1 certificate with the information in section 2.1 shall be verified. - Checking of k e-values (see annex 2) on prefabricated rope tension components The k e-values given in Annex 2, table 2, shall be checked for each wire rope batch by a tensile test with the end anchorages designated for this batch. 23 DIN EN 10204: Metallic products Types of inspection documents 24 DIN EN /NA: National Annex - Nationally determined parameters - Eurocode 3: Design of steel structures - Part 1-8: Design of joints 25 DIN EN ISO 5579: Non-destructive testing - Radiographic testing of metallic materials using film and X- or gamma rays - Basic rules 26 DIN EN ISO : Non-destructive testing - Image quality of radiographs - Part 1: Determination of the image quality value using wire-type image quality indicators 27 DIN EN ISO : Non-destructive testing Pentetrant testing Part 1: General principles

7 No. Z Page 7 of 8 February 16 th 2015 The results of the manufacturer s in-house quality control must be recorded and evaluated. The records must include at least the following information: - Designation construction product or of the material and the components, - Type of check or test, - Date of manufacture and of test of the construction product or of the material or components, - Result of the checks and tests and comparison with the requirements - Signature of the person responsible for the manufacturer s in-house quality control. The records shall be retained for at least five years and submitted to the third party authority. They must be submitted to the Deutsches Institut für Bautechnik and to the highest construction authority on demand. In case of insufficient test results, the manufacturer must undertake without delay the necessary measures to remedy the deficiencies. Building products that do not meet the requirements must be handled in such manner that it is impossible to mistake them for those that do comply. Once the deficiencies have been resolved - insofar as technically possible and as necessary to prove that the deficiency has been solved - the appropriate test must be repeated without delay Third party control In every manufacturing location the manufacturer s in-house quality control shall be accompanied by a regular (but minimum twice a year) third party monitoring. The first third party inspection is an initial inspection of the construction products and random test samples shall be taken to test the requirements of the rope tension components of section 2.1. The checks and tests carried out within the initial inspection must conform to section The scope of sampling and testing is at the discretion of the third party. The statistic evaluation of the values measured during the third party inspection shall demonstrate that the requirements are fulfilled. The results of the certification and of the third party inspection shall be kept for at least five years. They must be submitted to the Deutsches Institut für Bautechnik and to the highest construction authority on demand. 3 Rules for design and dimensioning 3.1 General The design calculations for the rope tension components shall be done to DIN EN The proof of design for the rope tension components is given when the design loads of the rope tension components do not exceed the design resistance to section 3.2. For the stainless steel rope tension components the coefficient of thermal expansion α T, the creep factor ε K, and the nominal modulus E Q shall be taken from annex 2. The creep factor ε K shall be taken into account when dimensioning the stainless steel rope tension components if the characteristic values of the design loads exceed 40% of the minimum breaking load to DIN EN , section 6.2 (4). 3.2 Design resistance of the rope tension components The design resistance of the rope tension components shall be calculated to DIN EN , section 6.2 (2) in connection with section 6.2 (4).

8 No. Z Page 8 of 8 February 16 th 2015 The minimum values for R m from annex 2, table 1 can be used as characteristic values f u,k for the calculation of the design resistance of the rope tension components made from stainless steel. The partial safety factor γ R of 1.1 shall be used. The ks- and ke-values that are required for the calculation of the design resistance shall be taken from annex 2, table 2. The ks-value corresponds to the reduction factor for spinning k to DIN EN The design resistance is valid for the rope including the sockets as described in the annexes if - the minimum thread engagement of the sockets corresponds to the annexes 3.1 to the thickness of the connecting plates correspond to the values given in the annexes 3.1 and Rules for installation The manufacturer shall issue instructions for the installation of the prefabricated rope tension components to the contractor. Before installation, the condition of all components of the rope tension components shall be checked for their integrity. Damaged parts shall not be used. The person responsible for the installation shall make a note stating that all threaded sockets have their associated parts and stating that the minimum thread engagement has been applied. The firm carrying out the construction work shall confirm that the connection parts and the installation of the prefabricated tension components comply with the regulations given in this general technical approval. Andreas Schult Referatsleiter

9 No. Z Page 9 of 8 February 16 th 2015 HYEND Open Socket HYEND Closed Socket HYEND Threaded Stud Rope Tension Components with HYEND sockets System overview Annex 1

10 No. Z Page 10 of 8 February 16 th 2015 Table 1: Stainless steels: Types of steel, corrosion resistance classes and mechanical properties Parts, component Type of steel, Material number Yield strength Ultimate tensile strength Corrosion resistance class 3) Coefficient of thermal expansion αt [K -1 ] Rp 0.2 [N/mm 2 ] Rm [N/mm 2 ] Wires for spiral strand 1) II 16 x HYEND open and ) / closed sockets (S460) III 13 x Pins for HYEND open and (S460) closed sockets III 13 x HYEND ) III 13 x 10 threaded stud (S460) ) see technical delivery specification to DIN EN 10264: ) and 3) see general technical approval Z Table 2: Termination factor k e, spinning factor k s and modulus E Q Rope constructions Spiral strand rope 1x19 1 x 37 1x61 1x91 Termination factor ke for swaged HYEND sockets 4) Spinning factor ks 4) for ropes made from unalloyed steel Spinning factor ks 4) for ropes made from stainless steel Modulus EQ for spiral strand rope made from stainless steel [N/mm 2 ] 5) 0.13 x ) The values for k e and k s are valid for ropes made from unalloyed steel and for ropes made from stainless steel which are covered in this general technical approval 5) The values in DIN EN : are valid for the modulus of spiral strand rope made from unalloyed steel. Table 3: Creep strain ε K for spiral strand rope made from stainless steel Temperature [ C] Coefficient of creep εk [%] x x x 10-2 Rope Tension Components with HYEND sockets Table 1: Stainless steels: Types of steel, corrosion resistance classes and mechanical properties Table 2: Termination factor ke, spinning factor ks and modulus EQ Table 3: Creep strain εk for spiral strand rope made from stainless steel Annex 2

11 No. Z Page 11 of 8 February 16 th 2015 Rope Short thread stud S 355 øs ødv max ødv Lv Thrd. ø M Open socket S 460N Adjustment Pins 34CrNiMo6 +QT LG C ød H O N J L V øb Connecting plate S M M M M M M M M M M M M M M M72x M72x All dimensions in [mm], Ø Dv, Ø Dv max = swaged diameter, Lv = swaged length min a min c ødi Tg Rope Tension Components with HYEND sockets HYEND Open Socket made from unalloyed steel Annex 3.1

12 No. Z Page 12 of 8 February 16 th 2015 Rope Short thread stud / S 460 øs ødv Max ødv Lv Thrd. ø M Open socket / S 460 LG C ød H O N J L Adjustment Pins / S 460 V øb min a Connecting plate S M M M M M M M M M M M M M M M M All dimensions in [mm], Ø Dv, Ø Dv max = swaged diameter, Lv = swaged length min c ødi Tg Rope Tension Components with HYEND sockets HYEND Open Socket made from stainless steel Annex 3.2

13 No. Z Page 13 of 8 February 16 th 2015 Rope øs ødv max ødv Short thread stud S 355 Lv Thread ø M Closed socket S 460N LG C ød BT O N J L V M M M M M M M M M M M M M M M72x M72x All dimensions in [mm], Ø Dv, Ø Dv max = swaged diameter, Lv = swaged length Adjustment Rope Tension Components with HYEND sockets HYEND Closed Socket made from unalloyed steel Annex 4.1

14 No. Z Page 14 of 8 February 16 th 2015 Rope Short thread stud / S 460 øs ødv max ødv Lv Thread ø M Closed socket / S 460 LG C ød BT O N J L V M M M M M M M M M M M M M M M M All dimensions in [mm], Ø Dv, Ø Dv max = swaged diameter, Lv = swaged length Adjustment Rope Tension Components with HYEND sockets HYEND Closed Socket made from stainless steel Annex 4.2

15 No. Z Page 15 of 8 February 16 th 2015 Rope Threaded stud S 355 øs ødv max ødv LG ~Lv Length of thread engagement M M M M M M M M M M M M M M M M All dimensions in [mm], Ø Dv, Ø Dv max = swaged diameter, Lv = swaged length Thread øm SW min Rope Tension Components with HYEND sockets HYEND Threaded Stud made from unalloyed steel Annex 5.1

16 No. Z Page 16 of 8 February 16 th 2015 Rope Swaged fitting / S460 Thread øs ødv max ødv LG ~Lv Length of thread engagement M M M M M M M M M M M M M M M M All dimensions in [mm], Ø Dv, Ø Dv max = swaged diameter, Lv = swaged length Thread øm SW min Rope Tension Components with HYEND sockets HYEND Threaded Stud made from stainless steel Annex 5.2