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CARES Technical Approval Report TA1-B 5006

Assessment of Halfen HBM Mechanical Couplers and the Quality System for Production

Product

Halfen HBM mechanical couplers for reinforcing steel

Produced by:
HALFEN Ltd Humphrys Road Woodside Estate Dunstable England LU5 4TP Tel: Fax: Email: Web: +44 (0)1582 470300 +44 (0)1582 470304 info@halfen.co.uk www.halfen.co.uk

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Product Summary 1.1 Scope of Application

HALFEN HBM mechanical couplers, in the size range 12mm-40mm, have been evaluated for use as follows: a) Static tension applications in reinforced concrete structures designed to BS8110: Part 1: 1997: Structural use of concrete, Code of practice for design and construction, in accordance with CARES Appendix TA1-B Issue 3.

HALFEN HBM mechanical couplers are used for the mechanical connection of deformed high-yield carbon steel bars for the reinforcement of concrete complying with the requirements of BS4449:2005.

1.2 Design Considerations

BS 8110 Clause 3.12.8.9 Laps and Joints states Connections transferring 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 be staggered. However, BS 8110 Clause 3.12.8.16.2 Bars in tension states The only acceptable form of fullstrength butt joint for a bar in tension comprises a mechanical coupler satisfying specified permanent elongation and tensile strength criteria. The specified cover for fire resistance and durability should be provided to the coupler sleeve.

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1.3 Conclusion
It is the opinion of UK CARES that HALFEN HBM mechanical couplers are satisfactory for use within the limits stated in paragraph 1.1 when applied and used in accordance with the manufacturers instructions and the requirements of this certificate.

B. Bowsher Executive Director November 2007

Technical Specification
The threaded collar is manufactured from cold drawn, seamless precision steel tube dimensioned to LN2391 and using material grade S355J2G3-1.0569. Thread dimensions comply with BS3643-2-1981 tolerance class 7H. The 12-32 male connector bar as dimensioned in TABLE 2 on page 4 consists of a reinforcing bar with a male threaded end that is compatible with the same sized female socket bar. The threaded part of the male bar is enlarged by hot forging prior to roll threading to retain the full cross sectional area of the bar. Thread dimensions comply with BS3643-2-1981 tolerance class 8g. The 40mm male connector bar shown in TABLE 2 consists of a 40mm female socket bar with an M48 hot rolled threaded stud screwed and locked in to the socket part to form a male connector bar. All the manufacturing processes comply to ISO 9001:2000 and bars are cropped and bent according to BS8666:2005.

2.1 General
The HBM mechanical coupler system is for joining reinforcment bars to provide reinforcement continuity at concrete joints. The system is suitable for static applications in accordance with BS8110 Part 1:1997 The system uses reinforcement sizes 12mm to 40mm that complies with DIN488-1 and BS4449 Grade 500B with a nominal yield stress of 500 N/mm2. The 12-32 mm couplers (see FIGURE 1) comprise a female socket bar (1) and a male connector bar (2). The 40mm coupler comprises a female socket bar (3) and a male connector bar (4) that consists of threaded stud screwed and locked in to a female socket bar. The 12-40mm female socket bar consists of an internally threaded collar, factory swaged by machine on to the reinforcement bars. The swaged collar dimensions are shown in TABLE 1 on page 4.

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FIGURE 1
1 2

12/16/20/25/32mm coupler

40mm coupler

2.2 Dimensions and Loads

TABLE 1 Female socket bars
L

b a l

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Bar dia. thread dia. 12 16 20 25 32 40 M16 M20 M24 M30 M42 M43

stock length L 500 650 800 1000 1300 2455

max length L 6000 6000 6000 6000 2000 2455

thread depth a 16 20 24 30 42 48

socket width b 21 26 32 40 54 67

socket length l 47 57 74 95 110 180

Yield kN 56 100 157 245 400 628

TABLE 2 Male connector bars

L

Bar dia. 12 16 20 25 32

thread dia. M16 M20 M24 M30 M42

stock length L >800 >1440 >1800 >2260 >2300

max length L 2000 2200 2200 2260 2300

min/max torque N/m 30-60 60-80 80-100 100-125 140-160

Yield kN 56 100 157 245 400

Bar dia. 40

thread dia. M48

stock length L 2456

max length L 2455

min/max torque N/m 360-400

Yield kN 628

3 Product Performance and Characteristics

Full destructive tests have been carried out to demonstrate compliance with performance requirements defined in CARES Appendix TA1-B Issue 3 including the performance requirements of BS8110 when used with reinforcing bars to BS4449 Grade B500B: Permanent deformation is less than 0.1mm at 276 N/mm2 in tension. Tensile strength is greater than 497 N/mm2.

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4 Installation
Halfen HBM mechanical couplers are fixed to the concrete formwork by two methods: using a washer at the formwork face. Ensure the assembly is fully secure prior to the concrete pour. Tie the bar to the main reinforcement for added security. Once the concrete has reached the required strength, remove the bolts prior to stripping the formwork. The correct size male connector bar must then be screwed fully into the female socket bar to the torque recommended in Table 2 on page 4.

4.1 To fix into position by bolt

Drill a hole of suitable diameter in the formwork in the required position. Place the female socket bar at the hole and screw the correct size bolt into the coupler from the opposite side of the formwork

4.2 To fix into position using plastic nailing plates

Nail the correct size nailing plate to the wooden formwork in the required position. Screw the female socket bar onto the nailing plate and ensure

it is fully secure prior to the concrete pour. Tie the bar to the main reinforcement for added security. Once the concrete has reached the required strength remove the formwork to expose the nailing plate. The nailing plate is removed by unscrewing.

5 Safety Considerations
Halfen HBM female socket bars and male connector bars can be supplied in lengths up to 6m and will be delivered in bundles or on pallets weighing up to 1 tonne, which should be lifted using appropriate equipment. Care should be taken when breaking the bundles open to avoid injury from moving bars. Suitable gloves should be worn when handling the bars.

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6 Product Testing and Evaluation

HALFEN HBM mechanical couplers have been tested to satisfy the requirements of BS8110 when used with reinforcing bars to BS4449 Grade B500B. The testing comprised the following elements: BS8110 Tensile Strength Permanent Deformation

Testing has been undertaken in accordance with the CARES Appendix detailed in Section 9, References. The products are subject to a programme of periodic testing to ensure that they remain within the performance limits of this technical approval.

Photos show Halfen routine batch-testing at its Dunstable works

7 Quality Assurance
HALFEN HBM mechanical couplers are produced under an ISO9001: 2000 quality management system certified by CARES. The quality management system monitors the production of the couplers and ensures that materials and geometry remain within the limits of this technical approval.

8 Building Regulations 8.1 The Building Regulations (England and Wales) Structure, Approved Document A
HALFEN HBM mechanical couplers, when used in BS8110 based designs using the data contained within this technical approval, satisfy the relevant requirements of The Building Regulations (England and Wales), Approved Document A. This technical approval gives assurance that HALFEN HBM mechanical couplers comply with the material requirements of BS8110 by virtue of regulation B3, Deemed to satisfy provisions regarding the fitness of materials and workmanship.

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8.3 The Building Standards (Scotland) Regulations Part B, Fitness of Materials

Materials and Workmanship, Approved Document, to support regulation 7

This technical approval gives assurance that HALFEN HBM mechanical couplers comply with the material requirements of BS8110.

This technical approval gives assurance that HALFEN HBM mechanical couplers comply with the material requirements of BS8110 by virtue of Clause B2.1

Part C, Structure
HALFEN HBM mechanical couplers, when used in BS8110 based designs using the data contained within this technical approval, satisfy the requirements of The Building Standards (Scotland) Regulations 1990, Part C, C2.1 clause b. construction,ii.

8.2 The Building Regulations (Northern Ireland) Part B, Materials and Workmanship

9 References
BS 4449:2005 Specification for carbon steel bars for the reinforcement of concrete. BS 8110:Part 1:1997 Structural use of concrete, Code of practice for design and construction. ISO10012-1:1992 Quality assurance requirements for measuring equipment. BS 8666:2005 Specification for scheduling, dimensioning, bending and cutting of steel reinforcement for concrete. BS EN ISO 9001:2000 Quality Systems. Model for quality assurance in production, installation and servicing. CARES Appendix TA1-B Issue 3, Quality and Operations Schedule for the Technical Approval of Couplers for Reinforcing Steel For BS8110 Applications for Static Tension or Static Compression.

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 provided that: a b c d e The product design and specification is unchanged. The materials and method of manufacture are unchanged. The manufacturer complies with CARES regulations for technical approvals. The manufacturer holds a valid CARES Certificate of Product Assessment. The product is installed and used as described in this report.

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2 CARES make no representation as to the presence or absence of patent rights subsisting in the product and/or the legal right of HALFEN to market the product. 3 Any references to standards, codes or legislation are those which are in force at the date of this certificate. 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 Health and Safety at Work act 1974 or any other relevant safety legislation. 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 This Technical Approval Report should be read in conjunction with CARES Certificate of Product Assessment No 5006. Confirmation that this technical approval is current can be obtained from UK CARES.

Typical Applications
Halfen HBM mechanical couplers can be supplied to suit most application conditions. Some popular examples are illustrated here. Please consult Halfen Ltd for technical application advice.

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UK CARES Pembroke House, 21 Pembroke Road, Sevenoaks, Kent TN13 1XR Phone: +44(0)1732 450000 Fax: +44(0)1732 455917 E-mail: general@ukcares.com www.ukcares.com Independent Product Assessments for the Construction Industry Copyright UK CARES