English translation authorized by DIBt Original version in German language

Transcription

1 Date: Reference: 29/09/2014 I /13 English translation authorized by DIBt Original version in German language Approval number: Validity Z from: 29 September 2014 Applicant: Lindapter International Lindsay House Brackenbeck Road Bradford, West Yorkshire BD7 2NF GREAT BRITAIN to: 29 September 2019 Subject of approval: Connections in steel structures with LINDAPTER Girder Clamps The subject of approval mentioned above is herewith generally approved in the field of construction. This allgemeine bauaufsichtliche Zulassung comprises ten pages and six Annexes. This allgemeine bauaufsichtliche Zulassung replaces the allgemeine bauaufsichtliche Zulassung Z of 15 August 2007 extended by notification, dated 28 June An allgemeine bauaufsichtliche Zulassung (national technical approval) was granted for this construction product for the first time on 28 May 1984.

2 Page 2 of September 2014 I GENERAL PROVISIONS 1 With the allgemeine bauaufsichtliche Zulassung the fitness for use and the applicability of the subject of approval according to the Landesbauordnungen ('Building Regulations of the Land') has been verified. 2 If, in the allgemeine bauaufsichtliche Zulassung requirements are made concerning the special expertise and experience of persons entrusted with the manufacture of construction products and types of construction according to the relevant regulations of the Land following section 17, sub-section 5 Musterbauordnung ('Model Building Code'), it is to be noted that this expertise and experience can also be proven by equivalent verifications from other Member States of the European Union. If necessary, this also applies to verifications presented within the framework of the Agreement on the European Economic Area (EEA) or other bilateral agreements. 3 The allgemeine bauaufsichtliche Zulassung does not replace the permits, approvals and certificates prescribed by law for carrying out building projects. 4 The allgemeine bauaufsichtliche Zulassung will be granted without prejudice to the rights of third parties, in particular private property rights. 5 Notwithstanding further regulations in the "Specific Provisions" manufacturers and distributors of the subject of approval shall make copies of the allgemeine bauaufsichtliche Zulassung available to the user and point out that the allgemeine bauaufsichtliche Zulassung has to be available at the place of use. Upon request copies of the allgemeine bauaufsichtliche Zulassung shall be placed at the disposal of the authorities involved. 6 The allgemeine bauaufsichtliche Zulassung may be reproduced in full only. Publication in the form of extracts requires the consent of Deutsches Institut für Bautechnik. Texts and drawings of advertising brochures may not be in contradiction to the allgemeine bauaufsichtliche Zulassung. 7 The allgemeine bauaufsichtliche Zulassung is granted until revoked. The provisions of the allgemeine bauaufsichtliche Zulassung ('national technical approval') can subsequently be supplemented and amended in particular, if this is required by new technical findings.

3 Page 3 of September 2014 II SPECIFIC PROVISIONS 1 Subject of approval and field of application The subject of approval are girder clamp connections, used for load-bearing connections of crossing girders of different shapes and dimensions (samples of girder clamp connections of crossing girders see Annex 1). The connection of girders on top of each others is possible if the width of flanges is identical. An intermediate plate in carbon steel expanded over the girder flanges with four holes in the corners is situated between the girders. Bolting assemblies are installed through these holes with a girder clamps under the bolt head and a girder clamp in malleable cast under the nut, pressing the girder flanges on the intermediate plate. The bolting assemblies are preloaded by a specified torque moment. Packings and tips may be used for compensating different flange thicknesses. Girder clamp connections are foreseen for temporary as well as for permanent structures. This allgemeine bauaufsichtliche Zulassung specifies the girder clamp connections for static and dynamic loading. 2 Characteristics of the construction product 2.1 Characteristics and composition Dimensions The basic dimensions of the girder clamps made of white and black malleable cast as well as of the related intermediate plates shall be taken from the Annexes 2 and 3. The basic dimensions of the packings are given in Annex 4. Further information with regard to the specific dimensions are deposited at Deutsches Institut für Bautechnik. The dimensions of the bolts, nuts and washers follow from the details in the Annexes and from the provisions in the clauses and Materials Girder clamps The girder clamps are made of malleable cast EN-GJMB or EN-GJMW according to DIN EN 1562: The internal and surface soundness of the castings shall be quality level SM2, LM2 and AM2 according to DIN EN 1369: as well as quality level 2 in dependence on DIN EN : Packings and tips The type CW packings are made of carbon steel strength class S235 or higher according to DIN EN : The type P1 and P2 packings and the type T tips are made of malleable cast according to EN-GJMB or EN-GJMW according to DIN EN 1562: or made of carbon steel strength class S235 or higher according to DIN EN : The internal and surface soundness of the castings shall be quality level SM2, LM2 and AM2 according to DIN EN 1369: as well as quality level 2 based on DIN EN :

4 Page 4 of September Intermediate plates The intermediate plates shall be made of carbon steel strength class S235 or higher according to DIN EN : Bolts, nuts and washers Only bolting assemblies according to DIN EN : , consisting of hexagon bolts of strength class 8.8, hexagon nuts of strength class 8 and round washers shall be used. Bolts, nuts and washers (components of assemblies) may be used as well as far as the dimensions and the mechanical properties are in compliance with the provisions in DIN EN : Corrosion protection 2.2 Marking DIN EN : applies for the corrosion protection of the girder clamp connections The package of the girder clamps, packings and tips shall be marked by the manufacturer with the conformity mark Ü (Ü-mark) according to the Übereinstimmungszeichen- Verordnungen der Länder ('Regulations on the conformity mark of the states of the Federal Republic of Germany'). The marking may only be applied if the requirements according to Section 2.3 have been met. Every package shall have additional information about the factory, the description of the construction product and the material. 2.3 Verification of conformity General Proof of conformity of the girder clamps, packings and tips with the provisions of this allgemeine bauaufsichtliche Zulassung ( national technical approval ), shall be delivered by means of a certificate of conformity issued for each manufacturing plant and based on factory production control and continuous surveillance including initial-type testing of the girder clamps, packings and tips in accordance with the following provisions. The manufacturer of the girder clamps, packings and tips shall involve an accredited certification body and an accredited monitoring body for the issuing of the certificate of conformity and for the external monitoring, including the related product inspections. The declaration that a certificate of conformity has been granted shall be given by the manufacturer by marking the construction products with the mark of conformity (Ü-Zeichen) ('Ü mark') stating the intended use. The certification body shall submit, for information, a copy of the relevant certificate of conformity to the Deutsches Institut für Bautechnik Factory production control Every manufacturing plant shall have a factory production control system and exercise factory production control. Factory production control means the permanent control of production exercised by the manufacturer by which the latter ensures that the construction products produced by him are in conformity with this allgemeine bauaufsichtliche Zulassung ( national technical approval ). The factory production control shall contain at least the following measures. The dimensions of the girder clamps, packings and tips shall be checked regularly in the manufacturing plant (compare also clause 2.1.1).

5 Page 5 of September 2014 The proof of conformity of the mechanical material properties of the malleable castings with the provisions in clause and shall be done by tests according to DIN EN 1562: , clause 9. Therefore, specific test specimen shall be casted with every cast. All malleable cast parts shall be visually checked for surface discontinuities. The internal and surface soundness of the malleable castings, stipulated in clause and , shall be verified by non-destructive testing for every production lot. If the non-destructive testing does not give clear results for the internal soundness, the internal soundness shall be checked by destructive testing. The proof of conformity of the mechanical material properties as well as the internal and surface soundness of the malleable castings with the provisions in clause and shall be verified by inspection certificate 3.1 according to DIN EN 10204: in each case. The results of factory production control shall be recorded and evaluated. The records shall include at least the following information: - designation of the construction product or the initial materials and the components - type of control, - date of manufacture and date of testing of the construction product or the initial materials and the components, - results of control and comparison with requirements deposited at DIBt, - signature of the person responsible for factory production control. The records shall be kept for at least five years and shall be presented to the inspection body involved in surveillance. On request, they shall be presented to the Deutsches Institut für Bautechnik and to the relevant supreme building authority. In case of unsatisfactory test results the manufacturer shall immediately take the measures necessary to rectifying the fault. Construction products not meeting the requirements shall be handled in a way that confusion with the products in compliance with the specifications will be excluded. As soon as the fault has been rectified as far as technically possible and required for evidence that the fault has been rectified the corresponding test shall be repeated immediately Surveillance Factory production control exercised in every manufacturing plant shall be continuously verified by surveillance, but at least once a year. In the framework of surveillance, an initial-type testing shall be performed and also tests in accordance with clause shall be performed at random. Sampling and testing are in the responsibility of the approved body. The surveillance shall show that the requirements are fulfilled in each case. The results of the certification and surveillance shall be kept for at least five years. On request, it shall be presented by the certification body or inspection body to the Deutsches Institut für Bautechnik and to the relevant supreme building authority.

6 Page 6 of September Provisions for design and calculation 3.1 Design The standard case of the girder clamp connection is two rectangular crossing H beams (see Annex 1). Beside the described standard case, cases adjacent to the standard case with the same mechanical effect are permitted. Primarily, these are connections of H beams with multi section girders. Samples for this are given in Annex 5. For the use of such variations of the standard case it shall be ensured that the mechanical effect by an adequate connection of the single parts of the multi section girder is equivalent to that of the H beam. The connection of inclined crossing girders with a deviation of 10 from the right angel is also allowed. 3.2 Calculation General The verification concept given in DIN EN 1990: in conjunction with the National Annex applies. Connections in steel structures with Lindapter girder clamps shall be calculated in accordance with the applicable part of DIN EN 1993 unless otherwise specified in the following Loading in direction of bolt axis (tension) Predominant static loading The characteristic values of tension resistance N R,k of one connection with 4 bolts are given in Table 1. Table 1 Characteristic values of resistance Nominal size Characteristic values for tension resistance of one connection (4 bolts) N R,k [kn] Characteristic values for shear resistance of one connection (4 bolts) V R,k [kn] M M M M M The partial safety factor for calculation of the design values to be used is: γ M = Fatigue loading For the verification of the fatigue resistance DIN EN : applies in conjunction with the National Annex. Deviating from DIN EN : the detail category given in Table 2 of this allgemeine bauaufsichtliche Zulassung ( national technical approval ) applies.

7 Page 7 of September 2014 The maximum values of resistance are the values for static loading. For direct stress without load reversal (κ = 0) and with load reversal (κ = -1.0), depending on the number of cycles to achieve according to Annex 6 of this allgemeine bauaufsichtliche Zulassung ( national technical approval ), values are given for safe loads as design values of resistance for the partial safety factors γ Ff = 1.0 and γ Mf = 1.0. Table 2 Detail category Constructional detail Description Requirements 63 Connection with Lindapter girder clamps (with 4 bolts) and stress in direction of bolt axis. Bolting assemblies of the nominal sizes M12, M16, M20 and M24 according to clause and the appropriate connection components according to the clauses to of this allgemeine bauaufsichtliche Zulassung ( national technical approval ) shall be used. has to be calculated using the tensile stress area of one bolt for one girder clamp connection. The bolts shall be preloaded according to clause 4.3 in connection with Table 3 of this allgemeine bauaufsichtliche Zulassung ( national technical approval ) The preload shall be checked at frequent intervals according to clause 5 of this allgemeine bauaufsichtliche Zulassung ( national technical approval ). For preloaded bolts, a reduction of the stress range is not allowed Loading rectangular to bolt axis (slip resistance) Only a predominant loading is allowed unless repeating loads are short-time only (e. g. at crane runway girders as a consequence of run-up and braking of cranes, from inert forces from engines or from skew of cranes). The characteristic values of shear resistance V R,k of one connection with four bolts is given in Table Loading by bending moments Possible bending moments which have to be transfered by Lindapter girder clamp connections shall be considered and calculated as tensile stress using the following formula: 3 M N = b with M - bending moment N - equivalent tensile stress for girder clamp connection (4 bolts) b - width of flange of torsion loaded girder Combined loading In the case of combined loading (tensile stress, shear stress in direction of girder axis and rectangular to girder axis, bending) the verification may be carried out separated for every kind of loading. A tensile load N, resulting from bending, shall therefore be added to the direct tensile load.

8 Page 8 of September Local bending of girder flanges The impact of additional bending moments in the girder flanges due to loads rectangular to the flanges resulting from the girder clamp connections shall be verified. Therefore, ¼ of the acting load on the girder clamp connection shall be assumed for each of the four girder clamps. The flange edges may be supposed as location for load transmission. The calculation methods proposed in [1] und [2] 1 may be used for the calculation of the local bending stress in the girder flanges. 4 Provisions for execution 4.1 General DIN EN : and DIN EN : apply for the execution of the structural parts to be connected and the intermediate plates unless otherwise stated in the following. The execution applies to the cases of application described in clause 3.1. The contact faces of the structural components to be connected with the intermediate plates shall be flat and parallel to each other. For the transfer of different high loads bolts of the nominal sizes M10, M12, M16, M20 and M24 together with the appropriate girder clamps may be used. All bolts in one connection shall always have the same nominal size. 4.2 Structural design The girder clamps with three selectable tail heights (short, medium, long) in conjunction with three different thick special type CW, P 1 and P 2 packings (see Annex 4) can be adapted to the current flange thickness of the girders. The adaption shall be carried out this way that the contact point between girder flange and girder clamp nose is in the area of the nose base and not at the nose tip. The tail height and the thickness of the packing underneath are selected correctly if the tail is just in contact with the intermediate plate or the packing before preloading. A small gap of maximum 1.0 mm for M10 to M16 and respectively 1.5 mm for M20 to M24 is allowed. For the connection of parallel-flange girders type T tips may be arranged between girder clamp nose and girder flange to get a flat horizontal contact area instead of a serrated and inclined contact area. The required clamping length of the assemblies results from the sum of the clamp heights C of both clamps according to Annex 2 or Annex 3, the thickness of the intermediate plate, the flange thicknesses of the girders to be connected, the thickness of maybe used packings according to Annex 4 and the thickness of the washer. The used bolt length shall guaranty an excess of at least one thread pitch over the nut. After turning the nut at least one thread pitch shall remain between the nut and the thread free shank of bolts with shank 1 [1] P. Sahmel Zur Berechnung der durch Laufkatzen hervorgerufenen Biegebeanspruchung in Trägerflanschen Fördern und Heben 19 (1969) Nr. 14, S [2] British Standard B.S. 2853: 1957 Amendment No. 3, published 3rd August, 1967 The design and testing of overhead runway beams

9 Page 9 of September Provisions for installation The structural components mentioned in clause 2.1 shall only be installed if the conformity mark Ü (Ü-mark) according to clause 2.2 or CE marking (bolting assemblies, intermediate plates) is on the package, on the enclosed leaflet or on the delivery note. The installation of the girder clamp connections shall only be carried out according to this allgemeine bauaufsichtliche Zulassung ( national technical approval ) and to the instruction of the manufacturer. The manufacturer hands over the assembly instruction with details to the positioning of the single components to each other and the installation process. Connections according to clause 1 shall only be executed by companies with the necessary experience unless the instruction of the assembly personnel is arranged by specialists experienced in this field. The minimum thickness of the intermediate plates according to Table 3 and the dimensions according to Annex 2 or Annex 3 shall be met. The nominal sizes are M10, M12, M16, M20 and M24. In each connection (4 bolts) only one nominal size is allowed. Type B girder clamps may be used under the bolt head as well. In this case the bolt head shall be held during the tightening. The nuts shall be tightened with the torque moment according to Table 3. Table 3 Torque moment for the bolts and minimum thickness of the intermediate plates Nominal size Torque moment for bolts grade 8.8 as delivered (not lubricated 1) ) [Nm] Minimum thickness of intermediate plates M M M M M ) If lubricated bolts are used the torque moment shall be reduced in such a way that the preload is the same as for not lubricated bolts. The torque moment shall be checked at random after 24 h if the girder clamp connections are used for coated structures. If applicable, different coating systems shall be taken into account. If the torque moment is less than given in Table 3 all connections of structures with the same coating system shall be checked and if necessary re-tightened. This shall be repeated until no loss of torque moments occurs any longer. Installed girder clamps shall be accessible that the torque moment of the nuts can be checked for control. Installed girder clamp connections shall be accessible in such a way that the torque moment of the nut can be checked during monitoring. Every component of the girder clamp connection shall be checked for damages before installation. Damaged components shall be excluded from use. In particular the bolts shall be free from deformations, damages of the thread and corrosion. The contact surfaces of a connection shall be free from oil, grease or other kind of pollutions if this could lead to reduced friction.

10 Page 10 of September 2014 Bolts and girder clamps already dynamic loaded shall not be reused. The executing company shall confirm the correct execution of the girder clamp connection in accordance with this allgemeine bauaufsichtliche Zulassung ( national technical approval ). 5 Provisions for use, service and maintenance The person, responsible for the condition of the structure executed with Lindapter girder clamps (or a delegate) shall check the connections at random latest after two years. In the course of this,the connections shall be checked for corrosion and cracks in bolts and girder clamps. The torque moments of the bolts shall be also checked at random as well as for maybe displacements/distortions of the connections. If shear stress acts predominantly in one direction and a displacement is not excluded by design it shall be checked regularly that unallowable transverse displacement does not occur. Corrosion damages shall be repaired (see clause 2.1.3). Damaged components shall be replaced immediately. If Lindapter girder clamp connections are dynamic loaded the preload of the bolts shall be checked at random within the first half year after installation but not immediately after initial start-up. If necessary the connections shall be re-tightened. If re-tightening is necessary for more than 10% of the checked bolted connections all connections shall be checked and retightened if necessary. This shall be repeated after about one year after initial start-up. The respective test result shall be documented. It shall also be documented if and which repairing measures were required. The document shall be deposited for at least 5 years. The period between the checks may be extended if the test results tolerate this. The company executing the girder clamp connections shall inform the responsible person for the structure in written form about these obligations. A copy of this writing shall be added to the record for the structure. Andreas Schult Head of section Beglaubigt ( confirmed ) Ulbrich

11 ( national technical approval ) of 29 September 2014 Composition of a Lindapter girder clamp connection 1 Hexagon nut 1) 2 Washer 1) 3 Type B girder clamp 4 Packing 5 Intermediate plate 6 Type A girder clamp 7 Hexagon bolt 1) 1) acc. clause of this national technical approval Type A girder clamp suitable for bolt head side Type B girder clamp suitable for nut side, may also be used under bolt head Connections in steel structures with LINDAPTER Girder Clamps Composition of a Lindapter girder clamp connection Type A and B girder clamp Annex 1

12 ( national technical approval ) of 29 September 2014 Hexagon bolts Dimensions of Lindapter type A girder clamp (in white malleable cast) Nominal size d Width between flats Y X Tail N short medium long C Width of clamps M M M M Hexagon bolts Dimensions of Lindapter type B girder clamp (in white malleable cast) Nominal size d Width between flats Y X Tail N short medium long C Width of clamps M M M M L 1 = Length of plate (b x d) L 2 = Width of plate (b x d) 1M = Hole clearance (b 1 + d) 2M = Hole clearance (b 2 + d) b 1, b 2 = Width of flanges d = Hole diameter Dimensions of intermediate plate Connections in steel structures with LINDAPTER Girder Clamps Dimensions of type A and B clamps (in white malleable cast) and of intermediate plate Annex 2

13 ( national technical approval ) of 29 September 2014 Hexagon bolts Dimensions of Lindapter type A girder clamp (in black malleable cast) Nominal size d Width between flats Y X Tail N short medium long C Width of clamps M M M M Hexagon bolts Dimensions of Lindapter type B girder clamp (in black malleable cast) Nominal size d Width between flats Y X Tail N short medium long C Width of clamps M M M M L 1 = Length of plate (b x d) L 2 = Width of plate (b x d) 1M = Hole clearance (b 1 + d) 2M = Hole clearance (b 2 + d) b 1, b 2 = Width of flange d = Hole diameter Dimensions of intermediate plate Connections in steel structures with LINDAPTER Girder Clamps Dimensions of type A and B clamps (in black malleable cast) and of intermediate plate Annex 3

14 ( national technical approval ) of 29 September 2014 Bolt diameter Dimension type CW packing d s Y X s Width M M M M M Bolt diameter Dimension type P1 packing d s Y X s Width M M M M M Bolt diameter Dimension type P2 packing d s Y X s Width M M M M M Bolt diameter d s Y s Width M M M M Dimension type T tip (not available for bolt diameter M10) Connections in steel structures with LINDAPTER Girder Clamps Dimensions packings Dimension tip Annex 4

15 ( national technical approval ) of 29 September 2014 Connections in steel structures with LINDAPTER Girder Clamps Samples for application of Lindapter girder clamps for connections in structures Annex 5

16 ( national technical approval ) of 29 September 2014 κ Partial safety factors: γ Ff = 1.0 and γ Mf = 1.0 Admissible maximum forces F zul,κ = 0 for tension (κ = 0) Numbers of cycles from from M12 [kn] M16 [kn] M20 [kn] M24 [kn] ) ) ) ) greater than κ Partial safety factors: γ Ff = 1.0 and γ Mf = 1.0 Admissible maximum forces F zul,κ = -1.0 for alternating loads (κ = -1.0) Numbers of cycles from to M12 [kn] M16 [kn] M20 [kn] M24 [kn] ) ) ) ) greater than ) Design value of tensile force N R,d for predominantly static loading Connections in steel structures with LINDAPTER Girder Clamps Admissible maximum forces for fatigue loading Annex 6