TECHNICALAPPROVAL
5012
CARES Technical Approval Report TA1-B 5012
Assessment of the LENTON® FORM SAVER Coupler Product, and Quality System for Production
LENTON® FORM SAVER Coupler
Issue 4
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Product
1 Product Summary
1
LENTON® FORM SAVER mechanical couplers for reinforcing steel
The products are for the mechanical connection of deformed high yield carbon steel bars for the reinforcement of concrete complying with the tensile properties of BS4449 Grade B500B and B500C as defined in Table 1.
Provided by:
ERICO Europe, B.V.Jules Verneweg 75,5015 BG,Tilburg,The Netherlands
1.1 Scope of Application
LENTON® FORM SAVER couplers have been evaluated for use as follows:
•BS8110andEC2forstaticuseintensiononly.
1.2 Design Considerations BS8110Clause3.12.8.9states“Connectionstransferring stress may be lapped, welded or joined with mechanical devices. They should be placed, if possible, away from points of high stress and should preferably bestaggered”.BS8110Clause3.12.8.16.2statesthata mechanical coupler satisfying the specified slip and tensile strength criteria is the only acceptable form of a full strength butt joint.
The specified cover for fire resistance and durability should be provided to the coupler sleeve. All couplers have been designed with controlled mechanical properties to be compatible with reinforcing bars to BS4449 Grade B500B and B500C.
Eurocode2,Clause8.7Lapsandmechanicalcouplers8.7.1General(1)P“Forcesaretransmittedfromonebarto another by: • lappingofbars,withorwithoutbendsorhooks;•welding;•mechanicaldevicesassuringloadtransferintension-
compression or in compression only.”
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TECHNICALAPPROVAL
5012
CARES Technical Approval Report TA1-B 5012
1.3 Conclusion
It is the opinion of UK CARES that LENTON® FORM SAVER couplers are satisfactory for use within the stated limits when applied and used in accordance with the manufacturer’s instructions and the requirements of this certificate.
B. BowsherExecutive Director
August2014
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2 Technical Specification
3
2.1 General
LENTON® FORM SAVER mechanical couplers are for joining deformed grade B500B and B500C steel reinforcing bars complying with the tensile properties of BS4449.
2.2 LENTON® FORM SAVER
LENTON® FORM SAVER couplers enable the splicing of rebar in staged construction while protecting formworkfromdamage.AllLENTON®FORMSAVERcouplersaresuppliedpre-assembled(frictionwelded)tothereinforcingbarandwithaplasticplug.
Size Part Art Length ‘ A ‘ ‘ B ‘ ‘ D ‘ Weight Reinforcing Reinforcing mm No No mm Kg bar grade bar grade ‘ X ‘ ‘ Y ‘ tension only tension only
10 SA10/400** 152631 400 17* 48 18 0.31 B500B -
10 SA10/550 152632 550 17* 48 18 0.41 B500B -
10 SA10/700 152633 700 17* 48 18 0.50 B500B -
10 SA10/1000 152634 1000 17* 48 18 0.68 B500B -
12 SA12/400 152635 400 17* 50 19 0.41 B500B B500C
12 SA12/600** 152636 600 17* 50 19 0.59 B500B B500C
12 SA12/800 152637 800 17* 50 19 0.77 B500B B500C
12 SA12/1200 152638 1200 17* 50 19 1.12 B500B B500C
16 SA16/400 152644 400 22* 56 24 0.75 B500B B500C
16 SA16/800** 152646 800 22* 56 24 1.39 B500B B500C
16 SA16/1050 152647 1050 22* 56 24 1.78 B500B B500C
16 SA16/1450 152648 1450 22* 56 24 2.41 B500B B500C
20 SA20/550 152654 550 27* 73 35 1.62 B500B B500C
20 SA20/850** 152655 850 27* 73 35 2.36 B500B B500C
20 SA20/1250 152656 1250 27* 73 35 3.35 B500B B500C
20 SA20/1800 152657 1800 27* 73 35 4.71 B500B B500C
LENTON® FORM SAVER Coupler
Format product description: SA X/Y
SA = LENTON® FORM SAVER attached on barX = rebar diameterY = total length of LENTON® FORM SAVER
B
D
Y
A X
*UseHexagonmaterial(measuredacrosstheflats)**standardlaplengthaccordingtoBS8110
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CARES Technical Approval Report TA1-B-5012
4
TECHNICALAPPROVAL
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CARES Technical Approval Report TA1-B 5012
3 Product Performance and Characteristics
Full destructive tests have been carried out to demonstrate compliance withperformancerequirementsdefinedinCARESAppendixTA1-BincludingtheperformancerequirementsofBS8110andEC2whenusedwith reinforcing bars to BS4449 Grade B500B and B500C:
TA1-B
• Permanentdeformationislessthan0.10mmat0.65fy in tension.• Tensilestrengthisgreaterthan540N/mm2 for B500B reinforcement
and 575 N/mm2 for B500C reinforcement.
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5
4 Installation
Figure 1
Figure 2
The bars to be threaded must be cut square and threaded, using LENTON® equipment and suitably trained and experienced operatives in accordance with LENTON® operating instructions. These operators will have a LENTON® Training Certificate.
It is recommended that the joints be tightened to the correct torque mentioned in the installation manual, using the appropriate LENTON® torque wrench.
Nail HFF plate toformwork
NailCFFPplatetoformwork
Nail HFF plate twist coupler
onto HFF
Twist coupler ontoCFFP
Remove HFF plug and install 2ndbar
RemoveCFFPplug and install 2ndbar
Pourconcrete
Pourconcrete
Remove formwork
Remove formwork
HFF Hexagonal Form FixerNailingform-fixingplateforpositioningofhexagonalLENTON®FORMSAVERcouplerstoformwork
CFFP Plastic Formfixing PlateNailingplasticform-fixingplateforpositioningLENTON®FORMSAVERcouplerstoformwork
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CARES Technical Approval Report TA1-B-5012
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TECHNICALAPPROVAL
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CARES Technical Approval Report TA1-B 5012
6 Product Testing and Evaluation
7 Quality Assurance
LENTON® FORM SAVER mechanical couplers have been tested tosatisfytherequirementsofBS8110andEC2whenusedwithreinforcing bars to BS4449 Grade B500B and B500C. The testing comprised the following elements:
TA1-B• TensileStrengthgreaterthan540MPaforgrade B500Breinforcementor575MPaforgradeB500C.
• Permanentdeformationoflessthan0.10mmat0.65fy
The products are subject to a programme of periodic testing to ensure that they remain within the performance limits of this technical approval.
LENTON® FORM SAVER mechanical couplers are produced at an approvedfacilityunderaCARESapprovedISO9001:2008qualitymanagement system. The quality assurance scheme monitors the production of the couplers and ensures that materials and geometry remain within the limits of this technical approval.
5 Safety Considerations
Caremustbetakeninhandlingandinstallingcouplers.Weightofthepackingunitsisbasedon25Kgperunit.Itisadvisabletowearprotective gloves during handling the containers, threaded bars and installing the couplers.
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8 Building Regulations
8.1 The Building Regulations (England and Wales)
Structure, Approved Document A
The LENTON®FORMSAVERcouplers,whenusedinEC2baseddesignsusingthedatacontainedwithinthistechnicalapproval,satisfytherelevantrequirementsofTheBuildingRegulations(EnglandandWales),ApprovedDocumentA.
Materials and Workmanship, Approved Document
This technical approval gives assurance that the LENTON® FORM SAVER couplers comply with the materialrequirementsofEC2.
8.2 The Building Regulations (Northern Ireland)
Materials and Workmanship
This technical approval gives assurance that the LENTON® FORM SAVER couplers comply with the materialrequirementsofEC2byvirtueofregulation23, Deemed to satisfy provisions regarding the fitness of materials and workmanship.
8.3 The Building Standards (Scotland)
Fitness of Materials
This technical approval gives assurance that the LENTON® FORM SAVER couplers comply with the materialrequirementsofEC2byvirtueofClause 0.8.
Structure
The LENTON®FORMSAVERcouplers,whenusedinEC2baseddesignsusingthedatacontainedwithin this technical approval, satisfy the requirements of The Building Standards (Scotland) clause 1.
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8
TECHNICALAPPROVAL
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CARES Technical Approval Report TA1-B 5012
9 References
•BS4449:2005,Steelforthereinforcementofconcrete-Weldablereinforcingsteel-Bar,coilanddecoiledproduct-Specification.
•BS8110:Part1:1997(Revised2005):StructuralUseofConcrete,CodeofPracticeforDesignandConstruction.
•BSENISO9001:2008Qualitymanagementsystems-Requirements.
•QualityandOperationsSchedulefortheTechnicalApproval ofCouplersforReinforcingSteelForBS8110andEN1992-1-1Applications for Static Loading in Tension or Tension and Compression.
•BSEN1992-1-1:2004Eurocode2Designofconcretestructures-General rules for buildings.
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10 Conditions
1. The quality of the materials and method of manufacture have been examined by CARES and found to be satisfactory. This technical approval will remain valid providing that:
a. The product design and specification are unchanged. b. The materials and method of manufacture are unchanged. c. The manufacturer complies with CARES regulations for technical approvals. d.ThemanufacturerholdsavalidCARESCertificateofProductAssessment. e. The product is installed and used as described in this report.
2. CARESmakenorepresentationastothepresenceorabsenceofpatentrightssubsistingintheproductand/orthelegalrightofERICOtomarkettheproduct.
3. Anyreferencestostandards,codesorlegislationarethosewhichareinforceatthedateofthiscertificate.
4. Any recommendations relating to the safe use of this product are the minimum standards required when the product is used. These requirements do not purport to satisfy the requirements of the HealthandSafetyatWorkact1974oranyotherrelevantsafetylegislation.
5. CARES does not accept any responsibility for any loss or injury arising as a direct or indirect result of the use of this product.
6. ThisTechnicalApprovalReportshouldbereadinconjunctionwithCARESCertificateofProductAssessmentNo5012.Confirmationthatthistechnicalapprovaliscurrentcanbeobtainedfrom UK CARES.
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002TECHNICALAPPROVALUK CARES
Pembroke House21 Pembroke RoadSevenoaksKent TN13 1XR
Phone: +44(0)1732 450000Fax: +44(0)1732 455917E-mail: [email protected]: www.ukcares.com
Independent Product Assessments for the Construction Industry
Copyright UK CARES © 7.8.
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