Build lighter – Shape the future Leichter bauen – Zukunft formen
Reinforcement with textile concrete according to the General Building Supervisory Approval (abZ) Z-31.10-182 as on: 15. May 2018 May 15. as on:
A guide for planning architects and engineers, for executive companies and for builders
Leichter bauen – Zukunft formen Build lighter – Shape the future Leichter bauen – Zukunft formen Table of contents
1. TUDALIT® – the quality brand for textile reinforcements in concrete building
2. Textile concrete at a glance
3. Implementation of the general building approval abZ Z-31.10-182
4. Construction and process for reinforcements with textile concrete as per abZ [General Building Inspectorate Approval]
5. Strengthening of steel reinforced concrete elements under bending stress using textile reinforced concrete
6. Design software
7. Product datasheets and material samples
8. Sample text for the performance description of reinforcement work with textile concrete
09. Certified companies
10. Manufacturer, Service and Contact Person
11. Provisions and rules General building approval abZ Z-31.10-182 List of recognized inspection bodies
12. References and examples of reinforcements and crack repairs with textile concrete as on: 15. September 2020 15. as on:
The planner portfolio 0-2 Build lighter – Shape the future Leichter bauen – Zukunft formen Preface
The present general building approval number Z-31.10-182 “Process for reinforcement of steel concrete with TUDALIT (textile-reinforced concrete)” is an approval given along with the quality brand.
The present abZ is to be understood as initial development and start-up technology. Their approval is the result of several years of a one-time joint effort of the TUDALIT members.
We hope that the planner portfolio will help you in deciding on suitable projects on bending strength of reinforced concrete for the application of this new and fascinating technology. Your tips and suggestions for improvement of the planner portfolio are welcome.
Ulrich Assmann Chairman of the Management Board of TUDALIT e.V. as on: 15. September 2020 15. as on:
The planner portfolio 0-3 Build lighter – Shape the future Leichter bauen – Zukunft formen
Imprint The planner portfolio – Reinforcement with textile concrete according to abZ Z-31.10-182
TUDALIT e.V. Contact: Freiberger Str. 37 Dipl.-Ing. Kerstin Schön 01067 Dresden Tel.: +49 351 40470-410 Fax: +49 351 40470-310 www.tudalit.de | [email protected]
Editors Managing Board and office of TUDALIT e.V.
We thank Dr. Ingelore Gaitzsch for the coordinating processing of the work; Prof. Dr. Peter Offermann, employees of the Institute for Solid Construction at TU Dresden (Dipl.-Ing. Michael Frenzel, Dr.-Ing. Harald Michler, Dipl.-Ing. Egbert Müller, Dr.-Ing. Silke Scheerer), Dipl.-Ing. Ammar Al-Jamous, , Dipl.-Ing. Erich Erhard and Dr.-Ing. Silvio Weiland as well as all member companies of TUDALIT e.V. participating in the accomplishment of planner portfolio.
Design/Composition Ulrich van Stipriaan
1st version (German): 15. Nov. 2016 1st version (English): 15. Nov. 2017
as on: 15. September 2020 15. as on: Disclaimer
All the details in this document are presented to the best of our knowledge and belief. However, you cannot replace project-related planning service and absolve the user from his responsibility to examine and use relevant provisions for the application. Publishers and authors do not take responsibility for the correctness of the information.
The planner portfolio 0-4 Build lighter – Shape the future Leichter bauen – Zukunft formen 1. TUDALIT® – the quality brand for textile reinforcements in concrete building
The composite textile-reinforced concrete revolutionizes the construction work in the world and opens up new possibilities for builders and architects.
The composite textile-reinforced concrete is developed at renowned German research institutions and is available for practical applications.
Its areas of application include:
q New construction,
q Renovation,
q Reinforcement.
With the quality brand TUDALIT® products are available with the highest technical standards and a close co- operation between manufacturers and companies is guaranteed from planning up to the usage on the building site.
The association of the quality brand TUDALIT® was established in January 2009.
TUDALIT e.V. has developed and funded the basis for the first general building supervisory approval for more than four years.
Valuable experiences have been acquired through a series of projects with approvals in case-by-case basis. as on: 15. September 2020 15. as on:
Reinforcement of a hypar shell roof in Schweinfurt Photo: Ulrich van Stipriaan
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Textile concrete reinforcement Canyon Bicycles GmbH in Koblenz Photo: Frank Schladitz as on: 15. September 2020 15. as on:
Reinforcement of a department store in Prague Barrel vault tax office Zwickau after the reinforcement Photo: Frank Schladitz Photo: Enrico Lorenz
On 01.06.2014, the German Institute for Structural Engineering (DIBt) awarded a general building supervisory approval “Method for reinforcement of reinforced concrete with TUDALIT® (textile reinforced concrete).” At the same time, this approval justified the construction of a TUDALIT quality seal for textile concrete applica- tions in structural and civil engineering.
If a reinforcement measure is to be carried out as a quality-assured application by TUDALIT®, the TUDALIT association supports you as a partner.
We support you in fulfilling the following conditions laid down in the general building supervisory approval and in proving to the builder:
q Use of the TUDALIT®-Kit components defined in the general building supervisory approval Z-31.10-182
q Execution of the work by certified companies,
The planner portfolio, section 1 1-2 Build lighter – Shape the future Leichter bauen – Zukunft formen Contact person
TUDALIT e.V. Tel.: +49 351 40470-410 Dipl.-Ing. Kerstin Schön Fax: +49 351 40470-310 Freiberger Str. 37 www.tudalit.de 01067 Dresden [email protected]
LeichterBuild lighterbauen –– ShapeZukunft the formen future as on: 15. September 2020 15. as on: REINFORCEMENT WITH CARBON
✓ Improvement of bearing behaviour ✓ Repair of buildings ✓ Minimum thickness ✓ Non-corrosive and easily mouldable ✓ German Institute for Structural Engineering (DIBt) Berlin granted general building supervisory approval ✓ TUDALIT e.V. www.tudalit.de Z-31.10-182 NEW: The planner portfolio! Online at tudalit.de/planner-portfolio
TUDALIT® e. V. Freiberger Str. 37 · 01067 Dresden · Germany Tel. +49 351 40470 410 · Fax +49 351 40470 310 [email protected] · www.tudalit.de
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The planner portfolio, section 1 1-4 Build lighter – Shape the future Leichter bauen – Zukunft formen 2. Textile concrete at a glance
Textile concrete is a composite material made of special fine concrete matrices and reinforcements of lat- ticed textile layer. The base layer consists of carbon fibers or other suitable high-performance fibers such as alkali-resistant glass fibers. The maximum grain size of the mineral matrix is generally between 1 to 4 mm.
The textile carbon reinforcements do not corrode. Hence, for textile concrete with carbon reinforcement, in contrast to reinforced concrete, thick concrete covers are not required. The minimum concrete covers in the textile concrete must only ensure the bond of textile reinforcement and the concrete matrix and must be the reinforcement diameters in the millimeter range.
Textile concrete components for the strengthening reinforced concrete with TUDALIT® in accordance with abZ [General building inspectorate approval]
Fig.2.1 Carbon filaments Carbon roving Mesh scrim (textile reinforcement) as on: 15. November 2017 November 15. as on: Photos: Frank Schladitz
Contents: q Cement CEM III B 32,5 q Hard-coal fly ash q Micro silika suspension q Sand 0/1 q Superplasticizer
Fig.2.2 Fine concrete (Dry mortar)
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Fig. 2.3: 2-layer textile reinforcement made of carbon filament yarns according to abZ (12 K yarn in side load direction, 50 K yarn in main load direction Photo: Jörg Singer as on: 15. November 2017 November 15. as on:
Fig. 2.4: Example of a cylindrically curved shell with a spacer made of carbon fibers (Manufacturer V. FRAAS Solutions in Textile GmbH) Photo: Ulrich van Stipriaan
The planner portfolio, section 2 2-2 Build lighter – Shape the future Leichter bauen – Zukunft formen Composite material textile concrete Advantages of the composite material textile concrete q Textile concrete constructions are narrow, light, high-performance and material-saving. Typical thickness range of structural component lies between10 mm to 50 mm. According to the present general building inspectorate and approval, based on the number of reinforce- ment layers (up to a maximum of 4), a layer thickness of approx. 6 mm to 30 mm is required while rein- forcing steel concrete components.
q The low space requirement of the textile reinforcements makes the material ideal for the restoration and reinforcement of monument-protected structure and for geometrically restricted conditions in existing buildings.
q Another advantage of building and restoring the stand with textile concrete is the significantly lower addi- tional loads (dead load of the reinforcing layer).
q The plasticity of the textile reinforcement meshes allows creative freedom for architects and designers as well as individual restoration solutions that are suitable for the monument.
q Textile concrete has a uniform cracking pattern with a very small crack width. Hence, it is denser than normal steel concrete.
q Textile concrete is distinguished by its optical and haptic appearance.
q Textile concrete is material-efficient, resource-conserving and sustainable.
Textile concrete as reinforcement material
Textile concrete has proved its suitability for the reinforcement reinforced concrete in an extensive series of tests:
q
as on: 15. November 2017 November 15. as on: Reinforcement of the bending tension zone for boards and beams (increase of bending load bearing capacities),
q Reinforcement of shell-shaped load-bearing structures
q Reinforcement of the shear reinforcement on the web of beams and T-beams (increase of the shear force resistance),
q Wrapping of supports (increase of the normal load bearing capacity),
q Reinforcement of round and square components (increase of the torsion resistance)
The present general building inspectorate approval regulates the reinforcement of the bending tension zone for boards and beams of steel concrete under defined framework conditions.
Further application scenarios, approvals are currently required in individual cases. We support you with our many years of experience and extensive knowledge of the material behavior.
Textile concrete as restoration material
In addition to the reinforcement, textile concrete is ideal for the restoration of cracks and damaged concrete surfaces. Textile concrete is characterized by low water penetration depth. As a result, the penetration of harmful substances to the protective building structure can be prevented.
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Table 2.1: Technical comparison of the reinforcement procedures – based on application of abZ [General building inspectorate approval] 1)
Criterion Shotcrete Bonded reinforcement Textile concrete (5 stage assessment according to from ++ best assessment AbZ [Gen- to -- worst assessment) Steel FRP[fibre-reinforced plastic] eral building inspectorate Affixed Slot-applied Sheet approval] lamella laminate conditions Technical properties German institute for stand- ++ + + + + + ardization(++) / General building inspector- ate approval (+) / Approval in each individual case (O))
Load bearing capacity ++ + + + + + Reinforcement level ++ O O + O + Anchoring of old concrete ++ - - + + ++ Additional dead weight or - + ++ ++ ++ + layer thickness
Building climate control ++ + + ++ -- ++ Building material class ++ ------++ Corrosion protection of the + -- ++ ++ ++ ++ strengthening of reinforcing
Corrosion protection of ++ ------++ provided reinforcemen
Aspects of production (from ++ high to – low) as on: 15. November 2017 November 15. as on: Preparation effort O + + + + O Application effort - ++ ++ ++ ++ - Fire resistance ++ ------(++) Currently applied. Proof required.
Adaptability ++ ------+ ++
Explanations Technische Eigenschaften: q Standards are available for shotcrete, for bonded reinforcement, the DAfStB directive “Reinforcing con- crete components with glued reinforcement” is used in conjunction with an abZ [General building inspectorate approval], for textile concrete the present abZ [General building inspectorate approval] or a ZiE [Approval in each individual case] is applicable for special applications on the basis of abZ [General building inspectorate approval]
q Increase of the load bearing capacity for each reinforcement procedure
q Reinforcement grade for shotcrete without limitation, for bonded reinforcements application-specific, nor- mally factor 2, in the case of textile concrete, currently the factor greater than 3 is possible
q In case of bonded reinforcement, the composite joint is usually decisive for the introduction of forces 1) According to Jesse, F.; Curbach, M.; in Betonkalender 2010, S. 475 – 565, in consideration of granted abZ [General building inspectorate approval] and the experience gained
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into concrete, Textile concrete, on the other hand, dissipates forces over a large area into old concrete cross-sections (favorable)
q Dead weight in the case of bonded reinforcement too negligible, low in case of reinforcements with textile concrete and very high in the case of shotcrete
q Sprayed and textile concrete hardly affect building climate control and sheets act as a diffusion barrier
q Fire resistance in shotcrete corresponding to steel concrete, in the case of reinforcements with textile con- crete, fire resistance times of 90 minutes were achieved in the first tests; requirement of ZiE [Approval in each individual case] is case-dependent, for adhesive bonding, the operating temperature range is limited to 40 ° C without fire-resistant cladding
q Corrosion protection for textile concrete and fiber-reinforced plastics (CFK-Lamella / Sheets) Sprayed con- crete requires thick concrete cover
q Corrosion protection of the existing reinforcement is improved by means of injection and textile concrete, there is no influence on the stand situation for adhesive bonding
Aspects of the production/construction:
q Surface treatment with certain adhesive tensile strengths necessary, only slit production required for slot- ted lamella
q Fire protection measures for adhesive bonding are already very high in class F 30, no additional measures for shotcrete, textile concrete requires additional examinations and, if necessary, evidence dependent on the concrete application (if applicable, ZiE [Approval in each individual case])
q Customization of injection and textile concrete to existing structures very good, adhesive bonding can be glued only in a uniaxial manner, sheets can be processed according to the flux
q Qualification of the personnel makes high demands, whereby sprayed and textile concrete are similar to
as on: 15. November 2017 November 15. as on: the steel concrete
Economic comparison of the reinforcement procedures
Specific example (with table):
Framework conditions:
q Reinforcement level h ≤ 2q 500 m² reinforce ceiling surface
q Ceiling is monolithically connected with main- and substructures
q Max. span width of the ceiling panels is 1.80 m
q Crack formation in the supporting torque range is considered (Single-span beam)
q Slot-applied CFK- laminate is not possible due to insufficient concrete cove
Table 2.2: Cost of reinforcement procedures (Basis: shotcrete)1)
Cost block (share in %) CFK Shotcrete Textile Site equipment 8 11 ≤ 16* Surface preparation ≥ 17 19 19 Total expenditure on reinforcement 75 70 46 Sum ≥ 100 100 ≤ 81
* Applicable with ZiE [Approval in each individual case]-effort, otherwise low
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Results:
q Shotcrete reinforcement requires an additional reinforcement of 1.2 cm² / m (chosen Mat Q188 A, which is overlapped with steel bars every 25 cm and is anchored 8 cm deep into the mortar with reaction resin mortar); The additional dead weight can be removed over existing construction.
q With regard to the maximum limit distances, affixed CFK- laminates require 1,500 linear meters with the smallest commercial cross-section; at 200 m, major unevenness must be compensated; execution is monitored externally.
q Textile concrete reinforcement requires a layer of textile reinforcement according to abZ [General building inspectorate approval] as well as monitoring of the execution work by the PÜZ body [Testing, Surveillance and Certification body].
Textual description of the table:
q The site equipment includes the costs for the static calculations and the external monitoring.
q The pre-treatment of the subsurface is the same for textile and shotcrete, in the case of CFK-Lamella, in addition to the adhesive surfaces, damaged surfaces are also repaired or re-profiled.
q Thus the reinforcement effort for textile concrete is low, because only one layer of textile reinforcement must be carried out; a higher level of reinforcement leads to a reassessment of costs
Outlook
The development of the building materials systems (“construction kit”) for all types of reinforcement and requirement levels as required by the outdoor applications and non-static loads is carried out as intensively as in the process and production techniques for their reproducible and economical production. as on: 15. November 2017 November 15. as on:
The planner portfolio, section 2 2-6 Build lighter – Shape the future Leichter bauen – Zukunft formen 3. Implementation of the general building approval abZ Z-31.10-182
The following section of this planner portfolio gives an overview of the application of General Building In- spectorate Approval.
This information does not replace the detailed knowledge of the overall legislative framework of abZ and the generally accepted rules of technology.
The General Building Inspectorate Approval abZ Z-31.10-182 consists of a text version and the following six attachments:
q Attachment 1 In-house production control and external monitoring – coating agents and reinforcement textile
q Attachment 2 In-house production control and external monitoring – Source material of fine concrete
q Attachment 3 Checking the properties of fine concrete on the construction site
q Attachment 4 MAWO jacket air stream nozzle
q Attachment 5 Basics of dimensioning
q Attachment 6 Expected value of surface tensile strength
The subject of approval was firstly generally approved by the building inspectorate on 01.06.2014. The
as on: 15. November 2017 November 15. as on: provisions can be supplemented or amended subsequently. Please always use the approval in its most recent version! The validity period is specified on the cover page (see section 11).
Kindly also take into account the “Guideline for certification of suitability for reinforcing concrete components with textile concrete for kits with General Building Inspectorate Approval” in its most recent version.
Access to the aforementioned documents: refer to section 11.
Object of approval
Subject of approval is a kit for reinforcement of ferroconcrete components with textile concrete.
The kit consists of following components:
q Textile reinforcement TUDALIT-BZT1-TUDATEX or textile reinforcement TUDALIT-BZT2-V.FRAAS
q Fine concrete TUDALIT-TF10-PAGEL
The structure of reinforcement is as follows:
q A layer of fine concrete on the prepared concrete surface of ferroconcrete component to be reinforced,
q Incorporation of textile reinforcement,
q Next layer of fine concrete (final layer or further support layer of textile reinforcement layer),
q Maximum four layers of textile reinforcement are possible.
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Fig. 3.1: Kit components for textile reinforce- ment TUDALIT-BZT2-V.FRAAS (All photos of this series: Ammar Al-Jamous)
Fig. 3.2: Provision of a machine for executing spray works, Co. Eska as on: 15. November 2017 November 15. as on:
Fig. 3.3: “Light-weight” textile reinforcement, 25 m length / 1.25 m width
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Fig. 3.4: Spreading of textile rein- forcement up to crosscutting
Fig. 3.5: Incorporation of textile in the fine concrete layer as on: 15. November 2017 November 15. as on:
Fig. 3.6: Spraying of next fine concrete layer for preparation of applying next layer of textile reinforcement
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Fig. 3.7: Lamination of next fine concrete layer for preparation of applying next layer of textile reinforcement
Fig. 3.8 Demonstration of simultaneous work process: In the background on the left: 2 workers incorporating the rein- forcement layer. In the background to the right: Splashing of fine concrete for preparation for the next layer or the final layer of fine concrete. as on: 15. November 2017 November 15. as on:
Fig. 3.9: Final layer – unprocessed in the foreground and already smoothed in the background.
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Conditions for application
The following conditions must be fulfilled for the application of General Building Inspectorate Approval abZ Z-31.10-182:
Case of validity of General Building Inspectorate Approval q The abZ is applicable to the bending reinforcement in tension zones for dry inner components made of ferroconcrete with prepared surface under predominantly static load.
Requirements regarding the component to be reinforced q The ferroconcrete component to be reinforced must be composed of normal concrete with strength class ≤ C50/60.
q The prepared surface of ferroconcrete component in the tension zone must have a surface tensile strength with an expected value of at least 1.00 N/mm².
q In the flexural tension zone of ferroconcrete component, the diameter of the existing reinforcement must be ≤ 20 mm.
q In reinforcement areas, the concrete cover should be at least 10 mm.
Permissible cases of loading q The textile reinforcements may absorb only the tensile forces.
q Textile concrete layers may also be applied in the pressure zone; however, no forces should be allocated to these layers.
q Flexural tensile reinforcements with textile reinforcement should be applied only where no additional trav- erse force reinforcement is mathematically required.
Climatic conditions q The reinforcement measures should be carried out only on inner components. Temperature on the com- pleted reinforcements should not exceed 40°C. The relative moisture should not exceed 65% in the use
as on: 15. November 2017 November 15. as on: phase.
q The reinforcement layers must not be subject to moisture penetration, alternating moisture penetration and alternating freeze-thaw.
Requirements with regard to executing company q Reinforcement works with textile concrete should be executed only by a company with certified suitabili- ty.
Provisions for dimensioning and design
For the dimensioning, attachment 5 is applicable to General Building Inspectorate Approval. An introduction to engineering practice as well as two dimensioning examples are included in section 5 of this planner portfo- lio.
For design, section 1.2 of General Building Inspectorate Approval should be taken into account. In addition, following framework conditions must be fulfilled: The minimum concrete cover of a textile reinforcement layer for old concrete; it is 3mm between the textile reinforcement layers and the surface of reinforcement.
Requirements regarding fire protection are not included in General Building Inspectorate Approval. If there are requirements regarding fire resistance of components with textile concrete reinforcements, the requested fire resistance should be substantiated in each case.
Competence of executing company
Executing company should provide a certificate of suitability as per the „Guideline for certification of suitabili- ty for reinforcing concrete components with textile concrete”.
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During the reinforcement measure, the qualified managers of the company should be available on construc- tion site as per the “Guideline for certification of suitability for reinforcing concrete components with textile concrete”.
The reinforcement activity should be done only by the qualified personnel on the construction site as per the „Guideline for certification of suitability for reinforcing concrete components with textile concrete”.
The process of certification
Certificates of suitability for construction company is issued by a recognised inspection body.
Following inspection bodies are available:
q ÜG 010 (GÜB Berlin).
The certification of suitability contains the following:
q Proof of basic suitability of the company
The basic qualification of responsible construction personnel must be substantiated by a correspond- ing certificate. Currently, this certificate can be obtained only by the certification of education council “Processing of synthetic material in concrete construction” (SIVV certificate) in Deutschen Beton- und Bautechnik-Verein e.V. [German Concrete and Construction Engineering Association].
The company must have the necessary testing and measuring devices available as well as the required tools and mixing devices. Efficiency and measurement accuracy of devices is tested and documented regularly.
q Theoretical test
After an approximately 5-hour theoretical training, a theoretical test should be written as a half-an-hour Multiple-Choice-Test.
q
as on: 15. November 2017 November 15. as on: Practical test – Suitability tests
As a practical test, the execution of a textile concrete reinforcement is applicable when the sections of General Building Inspectorate Approval relevant to execution are adhered to in their most recent version.
In addition, all necessary tests related to construction should be conducted, assessed and documented as a proof of attained material properties of fine concrete and bond material.
The suitability tests are accepted if a flawless execution of textile concrete reinforcement and conditional results as per abZ were obtained.
Place of execution of practical training: Hentschke Bau GmbH, Bautzen
The certificate of suitability is issued for three years (is revocable) and can be extended by three years upon application. The testing authority takes a decision in this regard.
Contact persons
Dipl.-Engineer (FH) Silke Grün, Tel. +49 351 4047042-35, [email protected]
Melanie Kögler Tel. +49 351 4047042-38, [email protected]
The planner portfolio, section 3 3-6 Build lighter – Shape the future Leichter bauen – Zukunft formen 4. Construction and process for reinforcements with textile concrete as per abZ [General Building Inspectorate Approval] 4.1 Construction
The construction of reinforcement with textile carbon reinforcements is displayed below with the help of schematic diagrams. The requirements regarding the execution of reinforcement are given in detail in 4.2; a dimensioning model is given in section 5.
1
2
3 4
5 as on: 15. November 2017 November 15. as on:
1. Existing component 2. Steel reinforcement of existing component 3. Prepared old concrete surfaces 4. Fine-concrete layer 5. Textile reinforcement (max. 4 layers ) Note: Figure shows AR-glass reinforcement
Fig. 4.1 Bottom view of a 4-layered textile-concrete reinforced ferroconcrete component (main execution; here: AR glass reinforcement) Photo: IMB/TU Dresden Explanations 1 Existing component q Recording of actual status as per section 4.2 of AbZ q Requirements regarding component to be as per section 4.3 of AbZ 2 Concrete cover of steel reinforcement of existing component at least 10 mm 3 Surface preparation of old concrete as per section 4.5 of AbZ 4 Fine-concrete q General information as per section 4.4 of AbZ q Detailed information as per section 4.6 of AbZ 6 Textile reinforcement of carbon yarns q General information as per section 4.4 of AbZ q Detailed information as per section 4.6 of AbZ q End-anchorage as per section 5, point 2 available planner portfolio
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Figure 4.2 Layer structure of a one-layered and a multi-layered carbon reinforced concrete structure – Overview (up to four layers possible) Graphic: Egbert Müller
Variant 3.1 as on: 15. November 2017 November 15. as on: Overlapping of reinforcement in case of direct embedment of textile reinforcement in a new layer
Figure 4.3 Layer structure in case of overlapping of carbon reinforcement layers – one-layered and multi-layered (Shall include legends, cutting and installation plan) Graphic: Egbert Müller
Variant 3.2 Overlapping of reinforcement in case of indi- rect embedment of textile reinforcement in a new layer Figure 4.4 Layer structure in case of overlapping of carbon reinforcement layers – one-layered and multi-layered (Shall include legends, cutting and installation plan) Graphic: Egbert Müller
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The following drawings (Figures 4.5 to 4.11) show the process to strengthen a structure with carbon concrete reinforcement for the design example shown in detail, in section 5.
Figure 4.5 Plan view of a section of the structure used in the design example as on: 15. November 2017 November 15. as on:
Figure 4.6 Section A-A of proposed strengthening (see also figure 4.8)
Figure 4.7 Section B-B of proposed strengthening with detailed edge connection (see also figure 4.8)
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Figure 4.8 Installation plan of strengthening layer above beam as on: 15. November 2017 November 15. as on:
Figure 4.9 Section U-U, bottom view of ceiling slab showing installation plan for strengthening layer 1 (see also figure 4.7)
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Figure 4.10 Section U-U, bottom view of ceiling slab showing installation plan for strengthening layer 2 as on: 15. November 2017 November 15. as on:
Figure 4.11 Section U-U, bottom view of ceiling slab showing installation plan for strengthening layer 3 (due to end anchoring)
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4.2 Process
The reinforcement measure comprises the following substeps:
q Manufacturing of a reinforceable old concrete surface after the prior actual status recording of portfolio,
q Substrate preparation,
q Applying the textile reinforcement layers by spraying and lamination,
q Subsequent treatment.
During the execution, tests should be conducted as per sections 4.7.1 to 4.7.3 of abZ. After the execution, the checks specified in section 4.7.4 of abZ should be conducted.
The reinforcement measure should be monitored and documented according to section 4.8 of abZ by the executing company. Besides the monitoring by executing company, there is an external monitoring obligation (IMA Materialforschung und Anwendungstechnik GmbH, Dresden, PÜZ-Stelle [testing inspection and certi- fication body] SAC 08 for the textile reinforcement and GÜB, Berlin, PÜZ-Stelle ÜG 010) for monitoring the execution.
Assessment of the strengthening feasibility of the existing concrete structure – according to section 4.5 of abZ
In order to have the aspired success with respect to type, quality and duration for reinforcement activities with textile concrete on concrete components, the related concrete on their surface must have specific prop- erties.
q Cracks in the strengthening area, which could lead to corrosion of the steel reinforcement or provide a passage for liquids, must be treated as per “DAfStb-Richtlinie - Schutz und Instandsetzung von Betonbau- teilen” (Technical guidelines by DAfStb, in German).
q The strengthening area must not have any loose parts.
q
as on: 15. November 2017 November 15. as on: There should not be any cracks running parallel to the surface or cupped in the area near the surface.
q Likewise, there should not be any delamination.
q There should not be any foreign substances, such as abrasion residues, release agents, old coatings, efflo- rescence, oil, spalling and so on, which can affect the bond. Such things should be removed completely before the strengthening measure.
q The old concrete surface to be strengthened must be prepared for applying the first fine-grained concrete layer until aggregate with a diameter of ≥ 4 mm is visible. The average roughness of old concrete surface must be at least 1.0 mm.
q Unevenness in old concrete cross section larger than 3 mm and up to 30 mm must be re-profiled with fine-grained concrete. In case of irregularities in the old concrete cross section that are larger than 30 mm, a separate evaluation by the designer is necessary. A few concrete spalling or gravel pockets are irregulari- ties that can be excluded from this requirement.
q After the surface preparation is complete, the surface tensile strength should be demonstrated as per DIN EN 1542 (BS EN 1542:1999) with a ring groove. The expected average value of surface tensile strength must be at least ≥ 1.00 N/mm². If a higher value is recorded, a structural analysis shall be completed to check the section. At least 5 tests should be conduct- ed. If the surface tensile strength is not attained, the competent designer must be informed accordingly (where appropriate, additional tests will be necessary)
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Surface preparation – as per section 4.5 of abZ
For the application of textile reinforced concrete layer, the surface of old concrete structure must be “moist” as defined by DAfStb guideline “DAfStb-Richtlinie – Schutz und Instandsetzung von Betonbauteilen” (Tech- nical guidelines, in German) (October 2001 and 2nd Amendment December 2005), Part 2, section 2.3.5 (2). This can be attained through the following preparation regime:
q Intensively pre-wet the old concrete surface at least 24 hours before the reinforcement measure,
q Subsequently, wet every two hours during the day and cover with foil during night,
q Pre-wet the old concrete surface lastly approximately 20 minutes before applying the reinforcement.
Execution of spraying and lamination works – as per section 4.6 of abZ
The General Building Inspectorate Approval specifies detailed rules for the production of reinforcement:
q The air and component temperature must be between + 5 °C and + 30 °C during the strengthening works.
q The textile reinforcement must not have any dirt and grease during installation. They should not be trimmed or exposed to a sharp traverse compression. The handling of textile reinforcement should not exceed the mandrel diameter of 30 mm.
q The specifications of the manufacturer should be taken into account while mixing the fine-grained con- crete.
q The spray works are carried out in dense phase with the MAWO jacket air stream nozzle (for this, see attachment 4 of abZ).
q The strengthening measure begins with the application of first fine-grained concrete layers on the pre- pared old concrete structure. In this measure, the first textile reinforced concrete layer is incorporated. If the components have to be strengthened with multiple layers of textile reinforcement, then always one layer of fine-grained concrete should be laminated or sprayed first before the next application of textile
as on: 15. November 2017 November 15. as on: reinforcement layer. Then, the freshly applied textile reinforcement should again be covered with a layer of fine-grained concrete. Maximum of four layers of textile reinforcement should be applied. A sprayed or hand-laminated textile reinforced concrete layer should be at least 6mm on average. The textile layers should be in hardened state according to section 4.7.4 of abZ.
q The processing time of fine-grained concrete should not be exceeded.
q In case of interruption during the strengthening works or planned work sections/-construction joints, the last fine-grained concrete layer to be cast prior to the interruption should be roughened with a broom fin- ish before the processing time is exceeded, otherwise the surface preparation for a joint shall be complet- ed accordingly.
q During the strengthening measure, the components should not be subject to vibration or movement.
Post-treatment – as per section 4.6 of AbZ
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5 Strengthening of steel reinforced concrete elements under bending stress using textile reinforced concrete
5.1 Introduction
The use of TRC to improve bending behavior in variable situations was widely researched in the scope of the special research project 528 [1-3] and to acquire a technical construction approval [4, 5]. For other research purposes, see references [6] and [7]. A facet of this was the development of an iterative analysis and design model, whose suitability was demonstrated by simulating experimental set-ups and their corresponding struc- tural calculations [5, 8]. The current design model, including sample calculations, were published by Frenzel [9]. It allowed for a very efficient design of the reinforced cross-section by optimal use of the tension zone. Furthermore, the stress-strain states of the unreinforced component were taken consideration for a highly detailed analysis. To facilitate the use of the iterative design method, design tables and charts were developed. In the following sections, an iterative and conservative design method for determining the necessary textile reinforcement, as well as design tables and calculation examples for the strengthening of reinforced concrete elements under bending stress are presented.
5.2 Iterative design method Assumptions and definitions: q The design is carried out assuming a cracked cross section (state II). q The bond between concrete and reinforcement is assumed to be perfect.
as on: 15. May 2018 May 15. as on: q Strain distribution over the cross section is linear. q Tensile stresses will be exclusively assigned to the reinforcement. q Compression strain is defined as negative, tensile strain as positive. q Failure modes: tensile failure of the textile or steel reinforcement, compression failure of the concrete. q Characteristic design curves: q Concrete: parable-rectangle diagram according to EUROCODE 2 [10]. q Steel: Bilinear curve according to [10]. q Textile: Bilinear curve according to the Allgemeine bauaufsichtliche Zulassung (general technical ap- proval, AbZ) [11]
The required material parameters for the design of a textile concrete strengthening, for elements that are sub- jected to dry indoor conditions, and are designed to meet the ultimate limit state requirements, according to the basic load combination [10-12] are summarized in Table 1. The characteristics strength of older concrete and steel types found in existing structures, which are frequently used for reinforcement, can be inferred, for example from [13].
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Table 5.1 Material parameters
Concrete up to Compressive strength fcd 6,8…28,3 N/mm² C50/60 Compressive strain εc2 -2,0 ‰ Ultimate compressive strain εc2u -3,5 ‰
Steel B500 E modulus Es 200000 N/mm² Yield strength fyd 435 N/mm² Tensile strength ftd,cal 457 N/mm² Yield strain εy 2,17 ‰ Ultimate yield strain εsu 25,0 ‰
Textile Tension σundd,tex 307 N/mm² Textile tensile strength ftd,texK 769 N/mm² Textile yield strain εund,tex 3,0 ‰ Ultimate textile yield strain εu,tex 7, 5 ‰
® Textile cross section TUDALIT-BZT1-TUDATEX atex 1,44 cm²/m ® values per layer TUDALIT-BZT2-V.FRAAS atex 1,25 cm²/m
cross-section longitudinal section strains tensions internal forces external forces
as on: 15. May 2018 May 15. as on: Fig. 5.1 Strains, tensions, internal and external forces in the reinforced cross section
Similar than the design methodology used for steel reinforced concrete elements, the basis for the design is the equilibrium between the internal and external forces. In figure 5.1, all relevant parameters are shown,
among them As1, b, h, d = ds, d1, zs1, es1, ec2, ss1d, sc2d, ka, x, Fs1d, Fcd, zs = z, NEd, MEd, NEds1, MEds1 are known. Also, for determining the necessary textile reinforcement, the following parameters are significan:
Atex | htex | dtex area of the cross sectional area of textile reinforcement | thickness of TRC layer | effec- tive depth of textile reinforcement, measured to the center of gravity of all textile layers provided in the tensile area
ztex | ztexs1 internal lever arm of the textile reinforcement | distance between tensile force resisted by the steel and that of the textile reinforcemen
etex | std,tex | Ftd,tex strain | tension | tension force at the textile reinforcement’s center of gravity axis
ec20 | es10 | etex0 existing strains for the unreinforced state
The strain state at time t = 0, before strengthening, shall be considered, as it is especially crucial for cross- sections under high stresses, and it will affect the failure mode. For an efficient design of the textile reinforce- ment, it is desirable that the tensile strength of the textile reinforcement be reached. Detailed information to be considered for cross-sections under high stresses, as well as a sample calculation, can be found in [9]. For cross-sections under low stresses, as those assumed at service conditions, the strain level defined by
ec20 and es10 can be determined, assuming linear-elastic material laws for steel and concrete, see for example
[13] and [14], or by iterative calculations with nonlinear material theory. The fictional strain value εtex0 can be determined using equation 1. Using figure 5.1, the equilibrium of forces necessary for the design can be defined, see equations 2 and 3.
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(1)
(2)
(3)
It becomes clear that the five unknown values Ftd,tex, Fs1s, Fs2d, Fcd, zs occur in both equations. An explicit, defi- nite solution is only possible through the introduction of three additional equations. Here, the description of
the linear strain level with four independent variables εc2, εs2, εs1 and εtex becomes necessary. By definition, at
the ultimate limit state, the ultimate tensile strain of the reinforcement, either εsu, εu,tex or the ultimate concrete
strain εc2u have been reached. With this assumption as well as both of the geometric conditions, in equations 4 and 5, the strain distribution, and thus the calculation result will be defined. This approach shows that time-consuming iterations are required to determine the strain level.
(4)
(5)
Determining the required area of textile reinforcement can be done manually with the following se- quence-schema:
1. First, the textile concrete layer depth htex is determined. To calculate the effective depth, dtex, assume that
the center of gravity is located at the center of the textile reinforced concrete depth: dtex = h + 0,5 · htex
2. Determine of the strain level with the starting values εc2 and εtex = εtex0 + εtex. Here, it is for example possi-
ble to choose εc2 = εc2u = -3,5 ‰ and εtex = εu,tex = 7,5 ‰. The fictional strain in the textile, εtex0 is included in the calculation, depending on the cross-section’s service load before strengthening.
as on: 15. May 2018 May 15. as on: 3. Calculate the compression zone depth, x: (6)
4. Calculate the factors aR and ka according to Equation 7 and 8, for the parable-rectangle material law of
concrete. Such equations depend on the compression strain εc2 so that the position (distance a from the
extreme compression layer) and value of the concrete compressive force Fcd in the formulas 9 and 10 can be determined.
0 ‰ ≥ εc2 ≥ -2,0 ‰ (parable part): (7)
-2,0 ‰ ≥ εc2 ≥ -3,5 ‰ (rectangle part): (8)
(9)
(10)
5. Calculate the steel strain εs1 according to equation 4 and analogously εs2 according to equation 5.
6. Calculate the steel tension Fs1d = As1 · ss1d using equations 11 and 12 with the design valuesεy, fyd and ftd,cal;
The procedure to determine the compressive force in the compression steel, Fs2d = As2 · ss2d., is similar.
(elastic region): (11)
(plastic region, steel yielding): (12)
7. Determine the distance z, ztexs1 and zs1s2 between the resulting compressive and tensile forces:
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(13)
(14)
(15)
8. Calculate the tensile force in the textile, Ftd,tex, required to balance the loads, and keep an equilibrium of moments, see equation 3.
9. Verify equilibrium of horizontal forces by equation 2. Repeat steps 1 to 8 until the equations 1 and 2 are satisfied.
10. Calculate the textile tension std,tex with equations 16 and 17.
(region I): (16)
(region II): (17)
11. Determine the area of textile reinforcement with Atex = Ftd,tex / std,tex, the required number of layers, and the
depth of the textile concrete layer, htex. If it deviates by those values assumed in step 1, the calculation is repeated.
5.2.2 Simpified design method
The required area of textile reinforcement Atex can be estimated for a cross-section design without axial force.
The method relies on the fact that the internal lever arm zr of the resulting tensile and the compressive forces
Fr can be determined from the resulting effective depth dr with zr ~ 0.85 ... 0.95 dr = zr · dr (Figure 5.1). It holds that: as on: 15. May 2018 May 15. as on:
(18)
With the moment equilibrium defined by equation 19, it is possible to estimate the required area of textile re- inforcement using equation 20, and by transformation of the formulas. The described method is only suitable when a compression failure of the cross section can be ruled out.
(19)
(20)
5.2.3 Design tables
To simplify the use of the iterative calculation procedure and thus the determination of the required area of textile reinforcement, design tables have been made available. The mathematical basics are given in [8]. The
user calculates the moment-weight ratio μtex from the given design stress value MEd, the cross-section values
dtex, ds, b and the concrete‘s compressive strength fcd. It holds that
(21)
For every moment-weight ratio, μtex, a strain level can be found, which can be further used to define the rein-
forcement ratio, wtex, for which the equations 2 and 3 are satisfied. Taking into consideration different geome-
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tries and effects, different strain states can result in different values for μtex and wtex, as it is shown in Tables 5.2
and 5.3. As an example, see the value combination of the ratios ztexs1/dtex = 0,15 and 0.25 without regard to
the pre-strain εtex0. Underlying the values in the tables are the characteristic design curves for the reinforcing steel, class B500, according to Eurocode 2 [10]. The graphics of the table 5.2 illustrate the forces, strains and stresses on the cross-section. The required area of textile reinforcement is determined by equation 22.
(22)
As it is usual the case for steel reinforced concrete, the validity of such design tables are bound to defined specifications and values. These are:
q the type of concrete, steel- or textile and their respective characteristic design curves,
q the ratios ztexs1 / dtex- and (dtex-ds) / dtex respectively
q and the existing strain in concrete at the level of the textile reinforcement, before its installation, based on the existing linear strain distribution. This value is designated in the calculations as a fictional strain in the
textile, εtex0, for mathematical purposes only.
The application of the design tables is currently restricted to cross-sections without axial force and compres-
sion reinforcement. Comparing the values of tables A and B, it becomes clear that when the steel stress σs1d is
above the yield stress field, the relationship ztexs1 / dtex has only a very slight or even non-noticeable influence
on the reinforcement ratio wtex, and the ratio that is related to the corresponding depth of the compression
zone xtex. In contrast, larger differences can be found for the ratio that is related to the lever arm ztex and
the steel strain εs1, when the steel stresses ss1d is less than fyd. In cases where the textile is used efficiently
(εtex = εu,tex = 7,5 ‰, mtex ≤ 0,2235) and the cross-section before strengthening is only slightly stressed, both
tables can be used, as there are minimal differences when the ratio of ztexs1 / dtex lies between 0.05 and 0.30, which is relevant in practical applications. Otherwise, separate evaluations are required [9]. as on: 15. May 2018 May 15. as on:
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Table A cross-section longitudinal section strains tensions internal forces external forces as on: 15. May 2018 May 15. as on: Textile failure Textile (economical section)
Concrete failure (uneconomical section)
* Flow stretch concrete steel B500, ** a-e-line with hrizontal branch, *** a-e-line with inclined branch
Design table with dimensionless values for rectangular cross sections without compressive reinforce-
ment and without preloading (εtex0 = 0) for bending without axial forces, regular concrete ≤ C50/60, (dtex-ds)/dtex = 0.15, B500
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Table B cross-section longitudinal section strains tensions internal forces external forces as on: 15. May 2018 May 15. as on: Textile failure Textile (economical section)
Concrete failure (uneconomical section)
* Flow stretch concrete steel, ** a-e-line with hrizontal branch, *** a-e-line with inclined branch
Design table with dimensionless values for rectangular cross sections without compressive reinforce-
ment and without preloading (εtex0 = 0) for bending without axial forces, regular concrete ≤ C50/60, (dtex-ds)/dtex = 0.15, B500
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5.3 Ancorage Check
5.3.1 General information
After the area of textile reinforcement required to carry the bending moments has been determined according to section 5.2, it must be proven that the reinforcement is properly anchored to the support area, and can be assured to carry the tensile forces without suffering bond failure. Since there is, as yet, no set of design rules for textile concrete, the approach to calculating the required anchor length of the textile reinforcement is based on similar calculations for carbon fiber reinforced polymer (CFRP) lamellas and steel reinforcement in shotcrete [10], [11]
The following two conditions must be checked:
q Anchorage of the textile reinforcement due to bending
q Anchorage of existing steel reinforcement due to shear force.
Additionally, 28 days after the reinforcement is installed, it must be checked, on-site, that the tensile strength of the bond at the composite joint, between the old concrete and the textile concrete, is on average at least 1.0 N / mm² [13].
5.3.2 End-anchoring of the textile reinforcement as a result of bending
The textile reinforcement must be anchored to the concrete cross section in such a way that forces can be intro- duced into the concrete without damage. The only permitted type of anchorage is the placement of the textile reinforcement layer(s), extending up to the edge of the bearing area edge, in a straight manner, see Fig. 5.2. as on: 15. May 2018 May 15. as on: Fig. 5.2 Left: correct detail design of the anchoring of a textile concrete layer Right: incorrect detail design of the anchoring of a textile concrete layer
The anchorage check is fulfilled when the anchorage length required, b,reql , is less than or equal to the anchor-
age length provided, lb,provided, equation 23:
(23)
5.3.2.1 Determining the provided anchorage length lb,provided
The provided anchorage length 1b, provided is composed of a computational and a geometric part. This is shown in Fig. 5.3. The computational part consists of determining the position of the flexural crack closest in proxi-
mity to the support, xcrit. The geometric part is determined by the width dimension of the bearing element (a), or the height of the existing cross section, before the repair, (h).
a Width of the bearing element Flexural crack closest in proximity to the support h Height of the existing cross section
lb.provided Distance from the edge of the bearing element to the flexural crack closest to support
xcrit Distance between the flexural crack closest to support and the calculated support center
Fig. 5.3Provided anchorage length for the textile reinforced concrete layer
In theory, the first cracks occur at the position critx , as a result of bending. The position of this point must be determined using the moment function. It is defined, in a simplified manner, by the magnitude of the cracking moment at the cross section. For the determination of the cracking moment, refer to [10], 6.1.1.3.3. In this ap-
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proach, the mean value for the tensile force of the concrete is used. Conservatively, it is recommended to use the characteristic fractile value of the tensile strength of the concrete. Alternatively, the cracking moment can also be determined based on the recommendation given for the calculation of the minimum reinforcement according to [16], 5.4.1.1.
Thus, lb,provided is calculated as follows
(24)
Note:
q The calculated bearing width, a, is determined according to DIN EN 1992-1-1, 5.3.2.2.
q Instead of the cracking moment of the old concrete cross-section, that of the composite section can be calculated. However, the computational effort is substantially higher.
5.3.2.2 Determining the required anchorage length lb,rqd
According to the general technical approval [13], the required anchorage length, lb,rqd, is generally determined by:
(25)
Here, σtex represents the stress of the textile layer at the flexural crack closest to the support (at the respective section of the checking location) [11], 8.4.3. According to the general technical approval, the textile reinforce- ment may only be anchored to the non-cracked area of a section under flexural bending. Thus, the stress
σtex at the position xcrit is required. The acting moment at the flexural crack nearest to the reinforcement layer must be established, and be consistent with the cut-off profile of the flexural reinforcement, according to [12]. Once these values are known, the required anchoring length can be determined with the following simple steps.
as on: 15. May 2018 May 15. as on: In the first step, the height x of the compression zone is determined for the reinforced cross section (in this case, without compression reinforcement) by calculating the stress distribution in the strengthened steel reinforced concrete cross-sections under service loads, see [16], 4.2.1.3. The existing formula was modified to include the strengthening textile layer.
(26)
Where:
αs | αtex Ratio of the Young’s-modulus of the steel or the textile respectively to that of the concrete
As | Atex Existing cross-sectional area of the respective reinforcement
b Width of the compression zone of the cross-section being checked
ds | dtex Effective depth
Note regarding Atex: Ultimately, the amount of textile required to be able to meet the end anchoring check using existing textiles is often quite different from the calculated quantity required for the bending check. The anchoring check is often the deciding factor for the required amount of reinforcement.
Subsequently, the inner lever arms z of the steel and textile reinforcement as well as the depth of the concrete
compression area Ac (assume a linear, triangular stress distribution in the compression zone) can be deter- mined with the following equations:
(27)
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(28)
(29)
Assuming linear material laws, the following three equations can be used to determine the maximum concrete
compressive strain εc, the steel tensile strain εs, and the textile tensile strain εtex (see also Figure 5.1):
(30)
(31)
(32)
Where:
MEd Factored moment at the flexural crack closest to the support
Ec | Etex Young’s modulus of concrete and textile reinforcements
zs | ztexs1 Lever arms of the compressive force and of the textile reinforcement to the C.G. of the steel reinforcement
ds | dtex Effective depth
x Depth of the concrete compresion zone
as on: 15. May 2018 May 15. as on: Since the textile tensile strain is now known (it could also be determined using the iterative method explained
in Section 5.1), the stress σtex can be determined:
(33)
The characteristic values Atex, K (cross-sectional area of the warp thread) and Tbk, tex (calculated shear bond flow of the warp thread) can be taken from the relevant technical approval [13]. The value of the shear bond flow
Tbd, tex is calculated, according to [13], as follows:
(34)
where:
αT,b | αT∞,b | αD,b Reduction factors for the textile reinforcement and fine concrete composite as taken from [13]: with temperature effect | for creep at sustained load | for bonding of textile rein- forcement in fine concreten
Tbk,tex Characteristic strength value of the bond flow of yarn in the warp direction of the textile reinforcement [N / mm] taken from [13]
γtex,b Partial safety factor for the textile reinforcement and fine concrete composite, from [13]
Subsequently, the required anchorage length lb, rqd can be determined and compared to the existing anchorage
length 1b, as in equation (23).
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5.3.3 Anchoring of the existing steel reinforcement due to shear force
Furthermore, since the textile reinforcement cannot be anchored behind the support, it must be shown that the existing steel reinforcement of the old cross section is capable of safely carrying the tensile force caused by the additional shear force stress, in compliance with [12], section 6.2.3 (7). This tensile force results from the compression strut, based on the shear truss analogy. This proof can be carried out similarly to section 9.2.1.4 of [12].
5.4 Tensile strength of the bond at the composite joint
In the final step, it must be checked that tensile force can be transferred from the textile to the horizontal
bond and further to the concrete. In this case, the acting shear force VEd at the end support must not be great-
er than the calculated shear capacity VRd, c, tex.
(35)
The acting shear force VEd may be determined at the ultimate limit state, according to [12], 6.2.1 (8). The value
of shear capacity VRd, c, tex is calculated using equation 36, see general technical approval 6.2.6 as well as figure 5.2 [13].
(36)
Where:
VRd,c,tex Shear resistance of the bond at the composite joint
ρs1 Reinforcement ratio of the old concrete cross section
atex Distance from the end point of the textile reinforcement to the bearing line used in calcu- lations as on: 15. May 2018 May 15. as on:
VRd,ct Shear resistance of the old concrete cross section at the bearing area, calculated accord- ing to [12], section 6.2.2 (1)
Literature
[1] Bösche, A.: Möglichkeiten zur Steigerung der Biegetragfähigkeit von Beton- und Stahlbetonbauteilen durch den Einsatz textiler Bewehrungen – Ansatz für ein Bemessungsmodell. Diss., TU Dresden, 2007 – http://nbn-resolving.de/urn:nbn:de:swb:14-1197896918623-70942.
[2] Weiland, S.: Interaktion von Betonstahl und textiler Bewehrung bei der Biegeverstärkung mit textilbe- wehrtem Beton. Diss., TU Dresden, 2009 – http://nbn-resolving.de/urn:nbn:de:bsz:14-qucosa-37944.
[3] Curbach, M.; Ortlepp, R.: Sonderforschungsbereich 528 – Textile Bewehrungen zur bautechnischen Verstärkung und Instandsetzung - Abschlussbericht, TU Dresden, 2012, http://nbn-resolving.de/urn:nbn: de:bsz:14-qucosa-86425.
[4] Curbach, M.; Lorenz, E.; Schladitz, F.; Schütze, E.; Weiland, S.: Gesamtbericht der experimentellen Untersuchungen zur allgemeinen bauaufsichtlichen Zulassung für ein Verfahren zur Verstärkung von Stahlbeton mit TUDALIT (Textilbewehrter Beton) / Institut für Massivbau der TU Dresden. unveröffent lichter Bericht, dem Deutschen Institut für Bautechnik (DIBt) vorliegend, 2014.
[5] Beckmann, B.; Frenzel, M.; Lorenz, E.; Schladitz, F.; Rempel, S.: Biegetragverhalten von textilbetonver- stärkten Platten. Beton- und Stahlbetonbau Spezial 110 (2015) Supplement „Verstärken mit Textilbeton“, S. 47–53.
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[6] Schladitz, F.; Lorenz, E.; Curbach, M.: Biegetragfähigkeit von textilbetonverstärkten Stahlbetonplatten. Beton- und Stahlbetonbau 106 (2011), Heft , S. 377-384.
[7] Erhard. E.; Weiland, S.; Lorenz, E.; Schladitz, F.; Beckmann, B.; Curbach, M.: Anwendungsbeispiele für Textilbetonverstärkung. Beton- und Stahlbetonbau Spezial 110 (2015) Supplement „Verstärken mit Textil- beton“, S. 74–82.
[8] Frenzel, M.; Curbach, M.: Bemessungsmodell zur Berechnung der Tragfähigkeit von biegeverstärkten Stahlbetonplatten. In: Curbach, M.; Ortlepp, R. (Hrsg.): Textilbeton Theorie und Praxis – Tagungsband zum 6. Kolloquium zu textilbewehrten Tragwerken (CTRS6), Berlin, 2011. S. 381–399 – http://nbn-resolving.de/urn:nbn:de:bsz:14-qucosa-84550.
[9] Frenzel, M.: Bemessung textilbetonverstärkter Stahlbetonbauteile unter Biegebeanspruchung. Beton- und Stahlbetonbau Spezial 110 (2015) Supplement „Verstärken mit Textilbeton“, S. 54–68.
[10] DAfStb Heft 595: Erläuterung und Beispiele zur DAfStb-Richtlinie „Verstärken von Betonbauteilen mit geklebter Bewehrung“. Juni 2013
[11] DIN EN 18551: Spritzbeton – Nationale Anwendungsregeln zur DIN EN 14487 und Regeln für die Be- messung von Spritzbetonkonstruktionen
[12] DIN EN 1992-1-1 (EC 2): Bemessung und Konstruktion von Stahlbeton- und Spannbetontragwerken – Teil 1-1: Allgemeine Bemessungsregeln und Regeln für den Hochbau. 01/2011.
[13] Allgemeine bauaufsichtliche Zulassung Z-31.10-182: Verfahren zur Verstärkung von Stahlbeton mit TUDALIT (Textilbewehrter Beton). DIBt, Berlin, 6. Juni 2014.
[14] DIN EN 1992-1-1 (EC 2)/NA: Nationaler Anhang – National festgelegte Parameter – Eurocode 2: Bemes- sung und Konstruktion von Stahlbeton- und Spannbetontragwerken – Teil 1-1: Allgemeine Bemessungs- regeln und Regeln für den Hochbau; Deutsche Version EN 1992-1-1:2004 + AC:2010. 01/2011.
[15] Vismann, U. (Hrsg.): Wendehorst Bautechnische Zahlentafeln. 34. Auflage 2012, Vieweg+Teubner-Ver-
as on: 15. May 2018 May 15. as on: lag, Springer Fachmedien Wiesbaden GmbH, 2012.
[16] Schneider, K.-J. / Goris A.: Schneider Bautabellen für Ingenieure. 19. Auflage 2010, Werner Verlag, Wolters Kluwer Deutschland GmbH, 2010.
[17] DAfStb Heft 616: Sachstandbericht Bauen im Bestand – Teil I: Mechanische Kennwerte historischer Be- tone, Betonstähle und Spannstähle für die Nachrechnung von bestehenden Bauwerken. Januar 2016
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Beispielhafte statische Berechnung
1. Statische Berechnung einer Decke aus Stahlbeton
Statisches System und Belastung (Wohngebäude!)
[mm] 200 4800 200 4800 200
[mm] 5000 5000
hf = 20 cm Belastung: EG (Eigengewicht)
as on: 15. May 2018 May 15. as on: g , = h = 0,2 m 25 = 5,00 kN kN k 1 f Beton 3 2 = 5∗,00γ (pro 1 m Plattenstreifen∗ m !)m k,1 Ständig! kN 2 → g m
• Fußbodenaufbau
Pauschal g , = 1,5 kN k 2 m
• Veränderliche Lasten (Nutzlasten)
g = 1,5 kN 2 Kategorie A2 → k m
Seite 1 von 15
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Lastfälle:
gk,ges. = 6,5 kNm m
Nutzlasten
g = 1,5 kNm k m
2. Charakteristische Schnittgrößen:
Die Schnittgrößen werden aus den Lastfällen an den maßgebenden Stellen berechnet. as on: 15. May 2018 May 15. as on:
MF (MF1 = MF2 (aus Symmetrie)) Moment MSt (über der Stütze am Auflager B)
QBl (links neben Auflager B) Querkraft QBr (rechts neben Auflager B)
Auflager A (Amin aus Auflager C (Symmetrie)) Auflagerkraft Auflager B
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The planner portfolio, section 5 5-14 Build lighter – Shape the future Leichter bauen – Zukunft formen
aus gk
M , = 0,07 6,5 (5,0 m) = (11,37 ) kNm 2 kNm F max M = 0,125 ∗6,5 m(5,0∗ m) = ( 20,31 )m 2 kNm St Q = −Q = ∗ 0,625∗ 6,5 5,0 =−( 20,31m ) kN Bl Br A = 0,375− 6,5− 5,0 =∗ (12,∗25 ) − m kN B = 1,25 ∗6,5 ∗5,0 = (40,62 m) kN ∗ ∗ m
aus gk
M = 0,07 1,5 5,0 = + 2,62 2 kNm F M = 0,125∗ ∗1,5 5,0 = 4,m68 2 kNm St Q = − Q = ∗ 0,625∗ 1,5 − 5,0 = m 4,68 kN LF2 Bl Br A = 0−,375 1,−5 5,0 ∗= + 2,∗81 − m kN B = 1,25 ∗ 1,5 ∗ 5,0 = + 9,37 m kN ∗ ∗ m as on: 15. May 2018 May 15. as on:
M = 0,096 1,5 5,0 = + 3,6 2 kNm F ∗ ∗ m MSt = 0,063 1,5 5,0 = 2,36 2 kNm LF3 A = 0,−438 1,5∗ 5,0∗ = + 3,28− m kN B = 0,063∗ 1,5∗ 5,0 = 0,47m kN − ∗ ∗ − m
3. Bemessungsschnittgrößen
• GZT
G,ungünstig = 1,35
γQ,ungünstig = 1,5 γ
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The planner portfolio, section 5 5-15 Build lighter – Shape the future Leichter bauen – Zukunft formen
• Feldmoment
mEd,F,max = 1,35 11,35 + 1,5 3,6 =20,75 kNm ∗ ∗ m mEd,F,max = + 20,75 kNm m
• Stützmoment
mEd,St,max = 1,35 ( 20,31) + 1,5 ( 2,36)
mEd,St,max = 30,∗95− ∗ − kNm
mEd,St,min = 1−,35 ( m20,31) + 1,5 ( 4,68)
mEd,St,min = 34,∗43− ∗ − kNm − m
4. Biegebemessung
maßgebende Schnittgrößen:
mEd,F,max = + 20,75 kNm m mEd,St,min = 34,43 as on: 15. May 2018 May 15. as on: kNm − m Expositionsklasse Anforderungsklasse: XC1 (für den üblichen Hochbau)
ds = 10 mm & keine Bügelbewehrung
→
XC1 → Mindestbetonfestigkeit C16/20nom = Cmin dev
Cmin =→ max Nennmaß C min,durdes Betondeckung + Cdur, = 10 Cmm + 0 mm+ ΔC= 10 mm γ Cmin,b = dsΔ = 10 mm 10 mm
Cdev = 10 mm
ΔCnom = Cmin + Cdev = 10 mm + 10 mm = 20 mm Δ
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The planner portfolio, section 5 5-16 Build lighter – Shape the future Leichter bauen – Zukunft formen
Verlegemaß Cv,l der Längsbewehrung:
Cv,l,u = Cnom,n = 20 mm
Gewählte Baustoffe
• Beton
CK: C25/30 = 25 N 2 → σ mm cd = = 0,85 , N σcc 25mm2 → σ αcc ∗ γc ∗ 1 5 cd = 14,17 N 2 mm → σcm = 2,60 N 2 • Betonstahl→ σ : mm
yk = 500 N 2 → σ mm yd = = = 435 , N σyk 500mm2 N 2 → σ γs 1 15 mm
Querschnittswerte:
as on: 15. May 2018 May 15. as on: Druck
Zug AS1 ZS1 S du S hf hf do ZS1 Zug AS1 Druck
Feld Stütze
d = h C , = 20 cm 2 cm cm = 17,5 cm dsl 1 u f − nom n − 2 − − 2 d = h C , = 20 cm 2 cm cm = 17,5 cm dsl 1 o f − nom 0 − 2 − − 2
Berechnung des bezogenen Momentes Eds
| | = , mit M =μ M N Z MEds 2 μEds b∗d ∗σcd Eds Ed − Ed ∗ S1
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Biegebemessung für einen 1 m Plattenstreifen im Feld:
m , = m , , (weil nEd,F = 0)
Eds F Ed F max , , , = = MNm , ( , −3) , �MEds F� �20 75∗10 m � 2 MN Eds F u cd 2 μ b∗d ∗σ 1 00 m ∗ 0 175m ∗14 17m2 , = 0,0478
μEds F Tabelle für w-Verfahren:
w1=0,04919; sd=435 ; = = 0,0738 < 0,45 N ϑ 2 Z σ mm ξ d = = 0,976 d φ d , = (w d n ) 1 =0 S1 F σsd ∗1 1 ∗ u ∗ σcd ∗ Eds N d = (0,04919 0,175 m 14,17 ) , N 435 mm S1 F mm² ∗ ∗ ∗ 2
d = 2,8 s,l = 3,35 und ds,q = 1,13 , 2 2 2 cm cm cm S1 F Querbewehrungm →= gew.0,20 R335A2,8 =mit0 ,56d , mitm d > 5 mm m 2 cm ∗ m s as on: 15. May 2018 May 15. as on: Veränderte Situation: Infolge einer Umnutzung des Gebäudes ergeben sich folgende neue Einwirkungen:
q = 3,0 ; qk,2 = 1,5 ; q , = 0,21 m 25 = 5,25 , da htex 1,0 m (Annahme) kN kN kN kN 2 2 3 2 m m k 1 ∗ m m Neues Bemessungsmoment:
M , , = 0,07 (5,25 + 1,5) 5,0 1,35 + 0,096 3,0 5,0 1,5 2 2 Ed F max M , , = 26,747∗ ∗ ∗ ∗ ∗ ∗ kNm Ed F max m
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The planner portfolio, section 5 5-18 Build lighter – Shape the future Leichter bauen – Zukunft formen
5. Biegebemessung Textilbeton
ds h
dtex
htex
b
Materialkennwerte:
• Beton C25|30
= 14,2 N cd 2 Eσ = 31.000mm N 2 c = 2,0 ‰mm as on: 15. May 2018 May 15. as on: 𝜀𝜀𝜀𝜀c2 =− 3,5 ‰ 𝜀𝜀𝜀𝜀c2n − • Betonstahl B 500
E = 200.000 N s 2 = 434,8 mm bzw. 435 N N 2 2 σyd mm mm , = 456,5 bzw. 457 N N 2 2 σfd=cad2,17 ‰ mm mm
𝜀𝜀𝜀𝜀y = 2,50 ‰
𝜀𝜀𝜀𝜀su A Matte R 335
• Textil
, = 307 N 2 σundd tex mm f , = 769 N 2 td texK mm
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The planner portfolio, section 5 5-19 Build lighter – Shape the future Leichter bauen – Zukunft formen
, = 3,0 ‰
und tex 𝜀𝜀𝜀𝜀 , = 7,5 ‰
𝜀𝜀𝜀𝜀u tex
5.2 Querschnittsauslastung vor der Verstärkungsmaßnahme (realer Zustand)
• Annahme zur Belastung: G = g , + g , = 6,5 kN 2 • M = 0,07 (5,0 + 1,5) 5,0 =k 111,37k 2 m 2 kN • Bestimmung der Querschnittsaus 2 F ∗ ∗ m Wendehorst! • lastungwehrung / Dehnungsebene, reine Biegung über „Spannungsermittlung bewehrter Querschnitte im Gebrauchszustand“, siehe z.B. Scheider / Rechteckquerschnitt ohne Druckbe
A 2 b d x = 1 + 1 + b A ∝e∗ S1 ∗ ∗ ∗ �− � � ∝e∗ S1 200 3,35 cm² 2 100 cm 17,5 cm x = 31 1 + 1 + 100 cm 200 ∗ ⎛ ∗ 31 3∗,35 cm ⎞ ∗ ⎜− � 2 ⎟ � � ∗ x = 2,54 cm ⎝ ⎠ as on: 15. May 2018 May 15. as on: x 2,54 z = d = 17,5 = 16,65 cm 3 3 − M− 11,37 kN 100 cm E 16,65 cm 3,35 cm = = = E z A ∗ kN 2 S1 S 20.000 σ ∗ 𝜀𝜀𝜀𝜀S10 cm² S ∗ S1 = 1,02 ‰
S10 M 2 11,37 kN 100 cm 𝜀𝜀𝜀𝜀 2 E 100 cm 2,54 cm 16,65 cm = = = E b x Z ∗ kN∗ c ∗ c 3100 σ ∗ cm∗ εC10 c ∗ ∗ = 0,17 ‰ 2
𝜀𝜀𝜀𝜀C10
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The planner portfolio, section 5 5-20 Build lighter – Shape the future Leichter bauen – Zukunft formen
• Kontrolle über Strahlensatz:
C = - 0,17 ‰
𝜀𝜀𝜀𝜀
S10 = 1,02 ‰
𝜀𝜀𝜀𝜀 , , = | | , ‰ , ‰ x d−x 2 54 cm 14 96 cm 𝜀𝜀𝜀𝜀C10 𝜀𝜀𝜀𝜀S10 → 0 17 ≈ 1 02
→ geringtex,0 braucht ausgelasteter nicht berücksichtigt Querschnitt bei werden! der Verstärkungsmaßnahme → E as on: 15. May 2018 May 15. as on:
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The planner portfolio, section 5 5-21 Build lighter – Shape the future Leichter bauen – Zukunft formen
5.3 Bestimmung der erforderlichen Textilmenge Iteratives Berechnungsverfahren – händische Lösung
Verfahren erfolgt nach den Arbeitsschritten 1-11.
Schritt I II III
htex [cm] 1,0 1,0 1,0 1. ditex [cm] 20,5 20,5 20,5
C2 [‰] -3,5 -1,5 -1,064 2. 𝜀𝜀𝜀𝜀tex [‰] +7,5 +7,5 +7,5 3. 𝜀𝜀𝜀𝜀x [cm] 6,5 3,417 2,547
0,81 0,56 0,437
R Ka 0,42 0,36 0,35 4. α Fcd [kN] 748 -272 -158 a [cm] 2,7 1,23 0,89
5. S1 [‰] 5,9 6,18 6,24
S1d 43,9 43,9 43,9 6. 𝜀𝜀𝜀𝜀 σFS1d [kN][kN/cm²] 147 147 147 Z [cm] 14,8 16,26 16,65 7. Ztex,S1 [cm] 3,0 3,0 3,0 as on: 15. May 2018 May 15. as on: 8. Ftd,tex [kN] -2.798 -585 14,66 9. -3.399 -710 3,6 0
10. ∑bd,tex H = 76,9≈ 11. σAtex [cm²][kN/cm²] 0,14
• Bewehrung:
1 Lage TUDALIT_BZT2_V.FRAAS= 1 1,40 = 1,40 , . 2 cm • αMindesthöhetex vorh ∗der Textilbetonschicht:m 9 mm
h , = 3 3 mm = 9 mm tex min ∗
tex = 10 mm ist ausreichend genau!
→ Annahme h
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Iteratives Berechnungsverfahren – Lösung mit Bemessungstafeln
• Annahme: htex tex =20,5 cm
• S1d = 1,043,8 cm → d kN 2 Annahme: σ ≈ cm
1. Bestimmung tex:
M +des bezogenenA (d Momentesd ) μ = b d Ed σS1d ∗ S1 ∗ tex − s tex 2 μ kNm tex cd kN ∗ ∗ σ ( ) 26,74 m 100 cm + 43,8 3,35 cm 20,5 17,5 cm = cm 2kN ∗ 100 cm (20,5 cm2 ∗)² 1,42 ∗ − cm μtex = 0,052 ∗ ∗ 2
μtex 2. Nutzung der Tabelle:
d ds 20,5 17,5 = = 0,146 0,15 Tafel A d 20,5 tex − − tex= 0,052 = 0,0542 (durch≈ Interpolation→ bestimmt) as on: 15. May 2018 May 15. as on: μtex = 439→ ωtex 438 Annahme ok. N N 2 2 → σS1d mm ≈ mm → , = 769 = 76,9 N kN td tex 2 2 A→ σ = *( mm b d cm A ) 1, tex σtd tex1 ωtex ∗ ∗ tex ∗ σcd − σS1d ∗ S1 kN kN A = 0,0542 100 cm 20,5 cm 1,42 43,9 3,35 cm 76,9 kN cm cm 2 tex 2 2 A = 0,139 cm∗ � 0,14 ∗cm² ∗ ∗ − ∗ � 2 tex ≈ 3. Wahl der Bewehrung:
1 echnung zuvor!)
Lage TUDALIT_BZT2_V.FRAAS (siehe R
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The planner portfolio, section 5 5-23 Build lighter – Shape the future Leichter bauen – Zukunft formen
Vereinfachtes Bemessungsverfahren:
Annahmen:
- h = 1,0 cm d = 20,5 cm
- tex = = 43,8tex → kN - Beiwert = 0,9 2 σS1d σyd cm - , = 76r ,9 ξ kN 2 σtd tex cm M A d A = Ed r , S1 d yd s tex − ξ ∗ ∗ σ ∗ r td tex tex kn 2674ξ kNm∗ σ 0,9∗ 3,35 cm 43,8 17,5 cm A = cm kN 2 −0,9 ∗76,9 ∗20,5 cm 2 ∗ tex cm A = 0,25 cm ∗ 2 ∗ 2 tex Wahl:
1 Lage TUDALIT_BZT2_V:FRAAS (siehe Rechnung zuvor!) as on: 15. May 2018 May 15. as on: 6. Endverankerung
Situation neu:
g , = (h + h ) 2,5 = 5,25 kN kN 3 2 k 1 tex ∗ m m g , = 1,5 kN k 2 2 g = 3,0 m kN 2 k m M , , = 26,747 kNm Ed F max m
• Eds |M | Berechnung= des bezogenen= 0,062 Momentes μ b d Eds μEds 2 = 0,06424∗ ∗ σ cd → ω cm d = 3,671 , m2 S1 F
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Auflager A:
A = 0,375 1,35 g , + g , l = 17,086 kN
Ag = 0,438 ∗ 1,5 ∗g� kl1= 9,855k 2� ∗kN
Av= A + A ∗= 26∗,941k ∗ kN g v
• Bestimmung auflagernahster Biegeriss, Feld 1
P = 1,35 g , + g , + 1,5 q b
P = 13� ,613∗ �kNk 1m k 2� ∗ k� ∗
/ x M = A x P 22 x crit ∗ − ∗
• Widerstandsmoment des ungerissenen Querschnitts
( ) W = = = 6,66 10 mm 2 2 b∗h 1000 mm∗ 200 mm 6 3 M = 6 W, mit6 = 2,6 ∗ N 2 Mcr = 17σctm,31∗ kNm σctm mm
cr 2 A x 2 M 2 26,941 x 2 17,31 as on: 15. May 2018 May 15. as on: 0 = x = x + P P 13,613 13,613 2 ∗ ∗ crit ∗ cr 2 ∗ ∗ crit ∗ crit − , ∗ crit − x = [ , x , = 808 mm 3 149 → crit 0 808 → crit 1
• Versatzmaß für die Bestimmung des Momentes infolge Zugkraftdeckungslinie (EC2.9.2.1.3): = d = 0,175 m
xα1= x s+ = 0,984 m
M =1A α1P = 19,913 kNm 2 x x x − ∗ 2
• Bestimmung der Druckzonenhöhe: E = = 6,452 Es s α Ec = = 6,667 Et t α c
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Druckzonenhöhe:
A + A 2b ( A d + A d ) x = 1 + 1 + b ( A + A ) αs ∗ s αt ∗ t ∗ αs ∗ s ∗ s αt ∗ t ∗ tex 2 ∗ �− � s s t t � x = 34,4 mm α ∗ α ∗
• innerer Hebelarm Stahlbewehrung, Textilbewehrung: x Z = d = 163,56 mm 3 s s Z =− d d = 3 cm
texs1 tex − s • Druckzonenfläche Betonquerschnitt: 1 A = x b = 171,54 cm 2 2 c ∗ ∗
• Dehnung in der Betondruckzone, Stahl- und Textilbewehrung: M = = 2,103 + 10 d E A Z + x 1 E A Z −4 c x ε tex c c s t t tex
as on: 15. May 2018 May 15. as on: ∗ d ∗ � − � ∗ ∗ ∗ = 1 = 8,623 10 x s −4 εs εc ∗ �d − � ∗ = 1 = 1,046 10 x tex −3 t c ε ε ∗ � − � ∗
• Zugkraft in der Stahlbewehrung: F = E A = 57,77 kN
s s ∗ εs ∗ s • Spannung in der Textilbewehrung:
= E = 216,22 N 2 σ t t ∗ εt mm
• Verankerungslänge der Textilbewehrung: A l = = 0,709 m t Roving brd σ ∗ τlbdtex, . = x , 0,1 m = 0,709 m Bereich Wandauflagerfläche 10 cm b vorh crit 1 −
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Nachweis Verankerung der Zugkraft aus Querkraft (Bestandsbewährung):
F = A = 28,825 kN > F = 0,5 A = 13,45 kN d1 Ed s CD = 2,7∗ Z ∗ N 2 σbd 4 Amm 0,1 m F = = 45,225 kN s 8 mmbd sd ∗ ∗ σ ∗
• Schubkraftübertragung in der Fuge:
(100 ) , , , = 0,75 1 + 19,6 , d , 0 15 ∗ ρS1 νRd C tex ∗ � ∗ 0 36 � ∗ νRd C = = 1,914 10 tex As −3 S1 ρd =b100∗ds mm ∗
tex , = 2 (100 25) 1000 175 N = 5,898 10 N = 58,98 kN , , 1 0 15 3 4 Rd Ct , S1 ν �=1 5 ∗ ∗ 2 ∗ ρ25 ∗ 1000� ∗ 175 N∗ = 8,662 10 N∗ , , , 0 0525 3 4 Rd C min 1 5 ν , , = 86� ,62 N∗ √ ∗ � ∗ ∗ ∗
Rd C min ν , , ,
Rd Ct Rd C min ν , =≥ ν , , as on: 15. May 2018 May 15. as on: νRd C νRd C min (100 ) , , , = 0,75 1 + 19,6 , d , 0 15 ∗ ρS1 νRd C tex ∗ � ∗ 0 36 � ∗ νRd C , , = 254,30 kN tex
νRd C=texA (0,1 m + d ) P = 23,198 kN
νEd −, , s ∗ νEd ≤ νRd C tex
Nachweis erfüllt!
→
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BauStatik.ultimate U369.de Stahlbeton-Einfeldträger textilverstärkt Proj.Bez. Seite Projekt VI-Treffen_160428 Position 369 mb BauStatik U369.de 2016.160428 Datum 28.04.2016
Tragfähigkeit Nachweis der Biegetragfähigkeit Abs. 5.8.6(3) x Ek MEd MRd η System[m] [kNm] [kNm] Material / Querschnitt (L = 5.00 m) • Einfeldträger2.50 1 25.31 131.77 0.19 • Bauteil • nachträglich unterseitig angebrachte Biegeverstärkung - Normalbeton nach EC 2 Gesamtbelastung Gesamtbelastung auf verstärkten Querschnitt - Betonstahl nach EC 2 Querkraft Bemessung für Querkraftbeanspruchung Abs. 6.2 x Ek VEd θ VRd,max VRd,c asw,erf - Vorgabe des Betonstahlquerschnitts Belastung[m] [kN] [°] [kN] [kN] [cm2/m] • Verstärkung (L = 5.00 m) • Ermittlung4.75 2der Eigenlast -191.25 (automatisch) 45.0 191.25 52.08 29.32 - Vorgabe der Werkstoffkennlinie • Gleichlasten - automatische Ermittlung der erforderlichen Lagenanzahl Dehnungsverteilung • VorbelastungDehnungs- und Spannungsverteilung an der maßgebenden Stelle - Nachweis bei vorgegebener Lagenanzahl • ZusatzbelastungAnzahl der Textillagen 2 Stk Querschnittsfläche je Textil 1.44 cm²
Verteilung der Dehnungen über den Querschnitt x Ek z ε0 ε1 [m] [cm] [‰] [‰] 2.50 2 40.00 εc20 -0.13 εc2 -1.89 -35.00 εs10 0.46 εs1 6.53 -40.30 εt10,1 0.50 εt1,1 6.62 -40.60 εt10,2 0.50 εt1,2 6.65
Verteilung der Spannungen über den Querschnitt x Ek z σ0 σ1 [m] [cm] [N/mm2] [N/mm2] 2.50 2 40.00 σc20 -1.44 σc2 -11.30 -35.00 σs10 91.20 σs1 438.93 -40.30 σt1,1 678.71 -40.60 σt1,2 681.92
e c20 e c2
e s10 e s1 e t1,1 e t10,1 e t1,2 e t10,2
Zusammenfassung Zusammenfassung der Nachweise Einwirkungskombinationen Nachweise (GZT) Nachweise im Grenzzustand der Tragfähigkeit
• KombinationsbildungNachweis (automatisch) mit η Teilsicherheits- und Kombinationsbeiwerten [-] nachBiegung EC unverstärkter 0, DIN EN Qs. 1990:2010-12 Vorbelastung OK 0.19 Querkraft unverstärkter Qs. Vorbelastung OK 0.18 • Vorgabe von Einwirkungsmustern zur Steuerung
as on: 15. November 2017 November 15. as on: Biegung verstärkter Qs. Volllast OK derQuerkraft automatischen verstärkter Qs. KombinationsbildungVolllast OK 1.00 • manuelle Kombinationsbildung mit Vorgabe mb-Viewer Version 2016 - Copyright 2015 - mb AEC Software GmbH eigener Sicherheitsfaktoren Nachweise • Kombinationsbildung (automatisch / manuell) • Grenzzustand der Tragfähigkeit
mbfür AEC Softwaredie Nachweise GmbH Europaallee im 14 Grenzzustand 67657 Kaiserslautern der - Biegung Trag fähigkeit, der Gebrauchstauglichkeit sowie unverstärkter Querschnitt unter Vorbelastung für außergewöhnliche Bemessungs situationen verstärkter Querschnitt unter Gesamtlast • Kombinationsbildung (automatisch) - Querkraft für Orte im Norddeutschen Tiefland Nachweis ohne Verstärkung unter Gesamtlast • Lastabtrag (mit Korrekturverfolgung) Ausgabe • leicht nachvollziehbar und prüffähig dank einheitlicher Kapitel struktur (System, Belastungen, System BauStatik.ultimate ultimate Schnittgrößen, Nachweise,…) • schnelle Übersicht der geführten Nachweise Modul U369.de und Ausnutzungen in der Zusammenfassung • komplette Statikbearbeitung am Rechner Name Stahlbeton-Einfeldträger, textilverstärkt • Kurz- und Langausgabe, doppelseitiger Druck, englische Ausgabe Norm Eurocode 2 – DIN EN 1992-1-1:2011-01 • Ausgabeumfang steuerbar und durch Preis 990,- EUR eigene Texte und Grafiken erweiterbar © mb AEC Software GmbH. U369.de-4/2016
mb AEC Software GmbH · Europaallee 14 · 67657 Kaiserslautern · Tel. 0631 550999-11 · Fax -20 · [email protected] · www.mbaec.de Alle Preise zzgl. Versand kosten & MwSt. Hardlock für Einzelplatz lizenz je Arbeitsplatz erforderlich (95,- EUR). Folge lizenz-/Netzwerkbedingungen auf Anfrage. Es gelten unsere Allg. Geschäftsbedingungen. Betriebssysteme: Windows 7 (64) / Windows 8 (64) / Windows 10 (64). Änderungen & Irrtümer vorbehalten.
The planner portfolio, section 6 6-1 Build lighter – Shape the future Leichter bauen – Zukunft formen
TEXTILBETON EINFACH BERECHNEN Intuitiv, verständlich, flexibel - engidesk ist eine Software-Plattform für den PC, die Ihnen den Zugriff auf eine Vielzahl spannender Berechnungsinhalte bietet - auch für die Berechnung von Textilbeton:
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The planner portfolio, section 6 6-2 Build lighter – Shape the future Leichter bauen – Zukunft formen
PAGEL® / TUDALIT® FINE CONCRETE
PROPERTIES FIELDS OF APPLICATION T F10 • TF10 (0-1 mm) • Structural support in the tension zone of Fine concrete made from Portland cement, reinforced concrete components quartz sands 0-1 mm with continuous particle ® • Reduction of layer thicknesses of concrete size distribution, matched to the TUDALIT structures in structural engineering (production textile fabric of building components and building elements) • Soft elastic thixotropic consistency for ® • Reduction of layer thicknesses for structural TUDALIT textile fabric repair work • High-performance fine concrete as a matrix • For the reinforcement of reinforced concrete for the combination with the textile fabric components in the hand laminating method • Chloride-free and cementitious and in the MAWO-PAGEL® dense phase wet • Shrinkage-free by controlled and even spraying application method expansion Moisture class based on concrete erosion from alkali silicic acid reactions • Low modulus of elasticity in connection with Moisture WO WF WA WS high bending tensile strength class • Low w/c-value dry moist moist moist • • External • External supply Frost and road-salt resistant, waterproof and supply of of alkalis largely resistant to oil and petrol alkalis • High dynamic stress • Pumpable and easy to pour using mono- TF10 • • • • transfer pumps with variable speed gearboxes The aggregates in PAGEL®’s products comply with the requirements of alkali (ask for machine suitability) sensitivity class E1 from non-hazardous sources specified under DIN EN 12620. • Can be applied using dense phase wet Exposure class according to: spraying with MAWO nozzle DIN 1045-2 / EN 206-1 as on: 15. October 2019 15. as on: Air pressure: ͧ 5 bar PAGEL®/TUDALIT®-FINE CONCRETE 3 Air volume: ͧ 5 m /minute XO XC XD XS XF XA XM 0 1234 123 123 1234 123 123 • Complies with TF10 the requirements of TF10 • •••• ••• ••• •••• •• •• building material class A1 (non-combustible) as specified under EN 13501 and DIN 4102 Kit components: • General Type Approval DIBt approval number: Z-31.10-182 - Fine grained concrete: TF10 • Approved article: Method for the reinforcement of reinforced concrete with TUDALIT® PAGEL® /TUDALIT® - (Textile- reinforced concrete) CONCRETE • The company is certified to Coated textile reinforcement: DIN EN ISO 9001:2008 TUDALIT® -BZT1-TUDATEX or TUDALIT® -BZT2-V.FRAAS
With the trademark TUDALIT® , the production and application of textile concrete on the basis of specified quality standards for the components of
the innovative composite, the methods of their PAGEL® SPEZIAL-BETON GMBH & CO.KG is pointing to the production, the products developed from or fact that the product TF 10 PAGEL®/TUDALIT®-FINE GRAINED CONCRETE is a component of the abZ-method for the reinforcement manufactured with the composite and their of reinforced concrete with TUDALIT® (textile reinforced concrete). If a reinforcement measure shall be performed as a quality assured rein- production processes for reinforcement or repair ® forcement measure with the trademark TUDALIT , the certificates are protected. of the TUDALIT® components, the verifications of suitability of TUDALIT® as well as the die TUDALIT®-licence have to be submitted unsolicited to the client.
SPECIAL AND SEWER CONCRETE READY-FOR-USE CHANNEL CONCRETE INDUSTRIAL CONSTRUCTION GROUTS RESINS ANCHOR GROUT REHABILITATION REPAIRING MORTAR MORTAR PROTECTION FLOOR PRODUCTS
The planner portfolio, section 7 7-1 Build lighter – Shape the future Leichter bauen – Zukunft formen
PAGEL®/TUDALIT® FINE CONCRETE
TECHNICAL DATA REINFORCEMENTS: Thoroughly coat all exposed and blasted T F10 reinforcing elements with MS02 PAGEL®-CORROSION TYPE TF10 PROTECTION without leaving any gaps (observe infor- MS02 PAGEL®- Grain size mation of the technical data sheet mm 0–1 CORROSION PROTECTION). Coating mm 3–30 Amount of water max. 14 EDGE FORMWORK: Attach in such a way that it is leak pro- Consumption 3 of and robust. (dry mortar) kg/dm app. 1.9 MIXING: 3 The mortar is supplied ready for use and only needs Fresh mortar raw density kg/dm app. 2.187 to be mixed with water. Pour the specified quantity of water Processing time at +20oC min app. 60 mentioned on the packaging with exception of a small residual Slump flow 5 min cm �17 amount into a clean and suitable mixing device (e.g. compul- DIN EN 1015-3 � sory mixer). Add the dry mortar and mix for at least 3 minutes; 30 min cm 14 add the remaining water and mix for another 2 minutes until Expansion 24 h Vol. % �+ 0.1 homogeneity. 28 d Vol. % �+ 0.1 Once ready mixed, apply immediately. Compressive strength 2 � 24 h N/mm 15 MIXING WATER: Drinking water quality Prisms: 4x4x16 cm 7 d N/mm2 �40 28 d N/mm2 �65 APPLICATION: Bending strength 2 By hand: 24 h N/mm �3 ® ® TF10 PAGEL /TUDALIT FINE CONCRETE is ap- Prisms: 4x4x16 cm 2 � 7 d N/mm 6 plied onto the surface using a lamination process layer for layer, in 2 28 d N/mm �8 the simplest case by the use of a trowel or a spatula. The first lay- E-module (static) 28 d N/mm2 � 25,000 er is brush applied as a bonding bridge - with the same consisten- cy. Fine concrete matrix and textile reinforcement are All test data are guide values, proofed in our German manufacturing plants, - values from other manufacturing plants may vary. alternately applied layer by layer. The respective textile rein- * DIN EN 196-1-compliant compressive strength testing forcement layer is immediately placed and lightly pressed. The final fine concrete layer is subsequently covered with a Storage: 12 months. Cool, dry, free from frost. layer of fine concrete. The surface of the final layer of fine Unopened in its original packaging. concrete is made according to requirements. Packaging: 25-kg bag, Euro palette 1,000 kg Hazard class: Non-dangerous goods, MAWO-PAGEL-Dense phase wet spraying application observe information on packaging Hold the nozzle preferably at a right angle to the area to be Giscode: ZP1 coated. Distance about 50 cm. The first fine concrete layer is applied to support the bonding bridge effect with the full air flow rate. Rebound has to bounce off or to be removed before placing the first textile reinforcement layer. After inserting the textile reinforcement layers, the air supply must be adjusted so that the textile structures are not damaged. The respective textile reinforcement layer is immediately placed and lightly pressed. The final reinforcement insert is covered with a layer of fine concrete. The surface of the final layer of fine concrete is made according to requirements.
CAUTION: The surfaces must be protected from premature water evaporation (from wind, draughts, direct exposure to sun) immediately on completion of the work for a period of 3-5 days. as on: 15. October 2019 15. as on: Suitable finishing methods: Spray with water, cover with jute sheets, thermofoils or moisture-retaining covering sheets, 01 PAGEL® EVAPORATION PROTECTION. The technical data sheet 01 PAGEL® EVAPORATION PROTECTION 01 NPD: „No Performance Determined” must be observed when using PAGEL® EVAPORATION PROTECTION.
Limit temperatures for application (substrate, air and mortar temperature): +5 °C to +35 °C Low temperatures and cold mixing water will delay strength development, require intensive compulsory mixing and reduce APPLICATION flowability. Higher temperatures will accelerate the process.
SUBSTRATE: Clean thoroughly; remove loose and unsound material such as cement slurry and dirt etc. by blasting it with solid blasting agent, grit or high-pressure water jet blasting or similar until the underlying solid grain structure has been exposed. The substrate must have sufficient tear strength (i.m. > 1.5 N/mm2). (The mean surface roughness after the surface preparation procedure is > sr = 1 mm) Blast all rust off exposed reinforcement bars until metallically PAGEL® Spezial-Beton GmbH & Co.KG bright (Sa 2 1/2 in accordance with DIN EN ISO 12944-4). ® is a founding member of the TUDALIT Markenverband e.V. Pre-wet the concrete substrate to capillary saturation 6-24 hours (trade mark association) (www.tudalit.de) before coating.
The information provided in this leaflet, is supplied by our consulting service and is the end result of exhaustive research work and exten- sive experience. They are, however, without liability on our part, in particular with regard to third parties proprietary rights, and do not relieve the user of the responsibility for verifying that the products and processes are suitable for the intended application. The data presented was derived from tests under normal climate conditions according to DIN 50014 and mean average values and analysis. De- SPEZIAL- BETON GMBH & CO.KG viations are possible when delivery takes place. Given that recom- mendations may differ from those shown in this leaflet written con- WOLFSBANKRING 9 · 45355 ESSEN · GERMANY firmation should be sought. It is the responsibility of the purchaser � - · � - to ensure they have the latest leaflet issue and that its contents are TEL. 49 201 68504 0 FAX 49 201 68504 31 current. Our customer service staff will be glad to provide assistan- INTERNET WWW.PAGEL.COM · E-MAIL [email protected] ce at any time. We appreciate the interest you have shown in our 0606 Technical Data Sheet products. This technical data sheet supercedes previously issued QS-Formblatt 09/16 Rev. 01 information. Please find the latest leaflet issues at www.pagel.com.
The planner portfolio, section 7 7-2 Build lighter – Shape the future Leichter bauen – Zukunft formen
PAGEL VERTRIEBS- UND LAGERORGANISATION
BEZIRK TECHNISCHE BERATUNG / VERKAUF LAGER / SPEDITION
Vertriebsleitung Uwe Coen PAGEL, Versand: Wolfsbankring 9 45355 Essen Fon 0201 685040, Fax 0201 6850431 Mobil 0170 8549248 Internet www.pagel.com E-Mail [email protected] E-Mail [email protected]
Hamburg Bernd Langner Höcker Sped. Hamburg GmbH, Nartenstraße 19 21079 Hamburg Schleswig–Holstein Fon 040 70970709, Fax 040 70970719 Bremen Mobil 0170 5636297 E-Mail [email protected] Nordniedersachsen E-Mail [email protected]
Mecklenburg– Holger Barth Heinrich Gustke GmbH, Hanseatenstr. 1 18146 Rostock Vorpommern Fon 0381 6677146, Fax 0381 6677144 Sachsen–Anhalt Mobil 0170 4541852 E-Mail [email protected] Berlin E-Mail [email protected] Kaufhold Güterverkehr, Bahrendorfer Weg 20 39171 Altenweddingen Brandenburg Fon 039205 20945, Fax 039205 20946 (bei Magdeburg) Mobil 0172 3920742 KOMM Logistik, Osdorfer Ring 4 14979 Großbeeren Fon 033701 79510, Fax 033701 79150 E-Mail [email protected] Dortmund Jens Wortberg Schreiber Transporte GmbH, Hansastr. 68 30952 Ronnenberg Siegen Fon 0511 545425-66, Fax 0511 545425-67 (bei Hannover) Hannover Mobil 0171 2712608 E-Mail [email protected] Kassel E-Mail [email protected] Loewe Speditions GmbH & Co, Brückenhofstraße 79 34132 Kassel Fon 0561 408129, Fax 0561 405061 E-Mail [email protected]
Rhein–Ruhr– Holger Müller PAGEL, Versand: Wolfsbankring 9 45355 Essen Gebiet Fon 0201 685040, Fax 0201 6850431 Mobil 0171 2113255 Internet www.pagel.com E-Mail [email protected] E-Mail [email protected]
Köln PAGEL, Versand: Wolfsbankring 9 45355 Essen Aachen Fon 0201 685040, Fax 0201 6850431 Neuwied Mobil 0170 5754750 Internet www.pagel.com Bitburg E-Mail [email protected] E-Mail [email protected]
as on: 15. October 2019 15. as on: Sachsen Volker Roth Spedition Thielemann GmbH, Fritz-Bolland-Str. 7 07407 Rudolstadt Thüringen Fon 03672 82449-44, Fax 03672 82449-49 Halle/Saale Mobil 0170 3201680 E-Mail [email protected] Cottbus E-Mail [email protected] Gustav Helmrath GmbH & Co. KG, Zur Linde 9 01723 Wilsdruff Fon 035204 9510, Fax 035204 95119 OT Kesselsdorf E-Mail [email protected] (bei Dresden)
Hessen Christian Coen Kurpfalz Transport GmbH, Binnenhafenstraße 9–10 68159 Mannheim Saarland Fon 0621 1500526, Fax 0621 1500550 Rheinland–Pfalz Mobil 0170 6342792 E-Mail [email protected] Niederer GmbH, Straße des 13. Januar 191 66333 Völklingen Fon 06898 9800, Fax 06898 980290
Baden– Norwin Pollich Schäfer Spedition & Logistik, Im Neuenbühl 14 71287 Weissach Württemberg Fon 07044 93520, Fax 07044 38249 (bei Stuttgart) Mobil 0171 5586383 E-Mail [email protected] E-Mail [email protected]
Nordbayern Jan Lamshöft Gollwitzer GmbH, Duisburger Straße 130 90451 Nürnberg Nürnberg Fon 0911 963760, Fax 0911 6492803 Mobil 0171 4784637 E-Mail [email protected]
Südbayern Harald Andersohn Thomas Gemsjäger GmbH, 80993 München München Internationale Spedition Mobil 0170 4541856 Wildermuthstraße 88 E-Mail [email protected] Fon 089 14727790, Fax 089 147277929 E-Mail [email protected]
The planner portfolio, section 7 7-3 Build lighter – Shape the future Leichter bauen – Zukunft formen
Husum U. COEN
VERTRIEBSLEITUNG Kiel Fon 02 01–48 35 52 Mobil 0170 – 8 54 92 48 Rostock
Lübeck Wismar B. LANGNER
Neubrandenburg Schwerin Hamburg Emden
Lüneburg H. BARTH Vechta
Bramsche Berlin Hannover
Osnabrück Großbeeren J. WORTBERG Magdeburg
Bielefeld Altenweddingen H. MÜLLER Paderborn Cottbus Essen Dortmund Halle Leipzig Düsseldorf Kesselsdorf Kassel (Dresden) V. ROTH Köln Siegen Erfurt Aachen Rudolstadt Chemnitz
Neuwied as on: 15. October 2019 15. as on:
Koblenz Coburg Hof Frankfurt J. LAMSHÖFT C. COEN Aschaffenburg Mainz Trier Darmstadt Würzburg
Völklingen Mannheim Nürnberg
Saarbrücken Heilbronn Heidelberg Straubing Ellwangen Ingolstadt Karlsruhe Stuttgart Landshut Passau
H. ANDERSOHN N. POLLICH München Augsburg
Freiburg
Kempten
26 = Auslieferungslager
The planner portfolio, section 7 7-4 Build lighter – Shape the future Leichter bauen – Zukunft formen TUDATEX Data sheet TUDALIT—BZT1—TUDATEX Product descrigtion
TUDALIT- BZT1- TUDATEXis a textile reinforcement (a TUDALITcomponent),which serves the strengtheningof reinforced concrete according to national technical approval No. Z—31.10—182. The textile reinforcement structure is a textile grid made from carbon filament yarns (so-called Heavy Tows), which are connected mechanicallyat intersections by Ioop-forming, thin stitching threads (see image). Textileconstruction:
Thread spacing Numberof rovings per Carbon material [mm] running meter
_ _ o TohoTenax3200 tex, d"°°"°“ 127 78 w“ (° ) SGL 3300 tex, SGL 3450 tex Weft direction (90°) 14.0 — 16.0 2 62 Toho Tenax800 tex
The approved coating agent (type Lefasol VLT—1, company Lefatex) is a fiIm—forming dispersion. With a proportion of typically 15% coating agent per unit area of textile direction reinforcement, the carbon filament yarns are impregnated. Thus, the individual filaments are coated or "glued" to each Warp other, whereby inner bonding of filaments is ensured. The colour of Ioop-forming stitching threads is white for BZT1 and Weft direction red for BZT2. Dimensions‘3’(example)
Roll Sheet as on: 15. October 2019 15. as on: Width [m] 2.50 1.25 Length [m] 25.00 6.00
Properties (mean values) | 0° 90° Rated value 0° Rated value 90° Reinforcement cross-section/thread L83 0.45 140 mmz/m 28 mmz/m [mm2] Yarn tensilestrength,coated [N/mmzl 1,700 (1) 1,700 (2) — - Yarn Young's coated modtilus, 170,000 ( 1) 152,000 (z) [N/mm l
‘l’ Test accordingto ISO 3341, wrapping terminals with optical Iength Variation detection, 500 mm free clamping Iength, test speed 200 mm/min, E-modulus determination in the area of linear increase of the stress-strain-curve ‘z’ Test as described in (1), however with 200 mm free clamping Iength of coated weft threads and a test speed of 80 mm/min, to enable analogue testing of textile reinforcements with a fabric width of 1.20 m and more (3) Length and width accordingto customer's request
TUDATEXGmbH 3.3 Managing director: Prof. Dr. Chokri Cherif Bank details: l I \ A [email protected] Dresdner Bank AG Dresden l +49-351-463-3 6090 Account: o4 104 614 oo l„J | //_\L I‚ TeI.: Leichlei Damen — Zukunft formen Fax: +49-351-463—3 7372 BIC: 850 soo oo
The planner portfolio, section 7 7-5
Build lighter – Shape the future Leichter bauen – Zukunft formen
(01 mm) constructive strengthening in the tension Fine concrete from Portland cement, quartz zone of reinforced concrete components sands 01 mm with continuous grading curve, Reducing layer thicknesses of concrete adapted to thetextile fabric structures in construction engineering soft plastic thixotropic consistency for (production of components and parts) thetextile fabric Reducing layer thickness in constructive High performancefine concrete as matrix repair measures for the combination with the textile fabric for strengthening reinforced concrete chloridefree and cementbonded components in hand lamination and in MAWOPAGEL® denseflow wetspraying shrinkagefree through controlled volumization low modulus of elasticity in conjunction with a high bending tensile strength low w/cvalue frost and deicing salt resistant, watertight and widely resistant to mineral oils and fuels pumpable and easy to process with monodelivery pumps with gear unit (inquire machine suitability)
as on: 15. October 2019 15. as on: suitable for wet spray in denseflow process with MAWOnozzle Air pressure: 5 bar Air volume: 5 m3/Minute meets the conditions of building • •••• •• • ••• •••• •• •• material class A1 (noncombustible) of EN 13501 and DIN 4102 National technical approval DIBt (German Institute for Structural Engineering) approval Fine concrete: number: Z31.10182
Subject of approval: Process for strengthening reinforced concrete with(textile reinforced concrete) Coated textile reinforcements: BZT1TUDATEX or
BZT2V.FRAAS
With the brandthe production and application of textilereinforced concrete is protected on the basis of specified quality standards for the components of innovative • Alkali • Alkali supply composite material, the process of its production, points out that the product supply from from outside is a component of national the products developed and produced from or technical approval “Procedure for strengtheningoutside reinforced• heavy concrete dynamic with(textilereinforced concrete)”. If a reinforcementload measure has with the composite material, its manufacturing to be implemented as an application qualityassured by the process brand, the •proofs of • components,• the • proof of suitability and the licence must be submitted to the builder The aggregates of PAGEL®products correspond to the alkali sensitivity without being requested. class E1 from harmless occurrence according to DIN EN 12620.
The planner portfolio, section 7 7-6 Build lighter – Shape the future Leichter bauen – Zukunft formen 8. Sample text for the performance description of reinforcement work with textile concrete
Preliminary remarks
All relevant standards and rules must be observed for performing the corrective maintenance and reinforce- ment work.
Inter alia applicable standards and rules
q DIN EN 1992-1-1 2011-01 Euro Code 2 - Design and construction of reinforced concrete and pre-stressed concrete structures. Part 1-1: General design rules for building construction
q DIN EN 1992-1-1/NA National annex; Nationally Determined Parameters; Euro Code 2
q DAfStb [German committee for steel concrete] RL SIB:2001-10 Restoration guidelines 2001-10, Part 1-4: Protection and repair of components Part 1: General regulations and planning principles Part 2: Construction products and application Part 3: Requirements for operations and monitoring Part 4: Test Procedure
q DIN EN 1504 Products and systems to protect and repair concrete structures -Definitions, requirements, quality control and assessment of conformity Part 1-10
Preliminary remark – textile concrete work
The work is to be carried out in accordance with the general building supervisory approval Z-31.10-182 of the
as on: 15. November 2017 November 15. as on: DIBt (enclosed with this tender).
The laying of the textile reinforcement takes place according to the static requirement.
While laying, it must be ensured that the textile is oriented vertically and does not slip. If required, the in- sertion of corresponding fastening points must be considered. The static boundary conditions, such as the overlap lengths, etc., must be adhered to.
Quality control must be carried out in accordance with the textile concrete approval with the corresponding number of test specimens.
The planner portfolio, section 8 8-1 Build lighter – Shape the future Leichter bauen – Zukunft formen
Item Site equipment
Costs incurred q For setting up of the construction site, the supply and removal of all equipment required for carrying out the work, machinery (even construction cranes) and accommodation containers as well as their provision during the construction period. q For creating material storage places, assembly and dismantling of the accommodation, transports, produc- tion of the necessary power distribution connections, q For cleaning of the construction site and all of its subcontractors or contaminated areas and roads during and after completion of the work.
…… psch …… f. d. psch
Item Costs for the local construction management, construction supervision or building supervision of the construction project with schedule monitoring as well as supervision according to the UV and official regulations valid during the construction phase. The contractor shall ensure that a continuous monitoring of the work and compliance with the safety regula- tion is carried out by the company‘s construction supervisor or foreman.
…… psch …… f. d. psch
Item Self-monitoring for concrete repair work in accordance with the test and monitoring regulations of an approved test center such as the (GÜB) Society for Surveillance in Building Industry, registered organi- zation. q Self-monitoring in accordance with the requirements of the General Building Inspection Approval of the DIBt, approval number Z-31.10-182 q Documentation of test results
…… psch …… f. d. psch
Item External monitoring in accordance with the requirements of the General Building Inspection Approval of the DIBt q Site inspections with on-the-spot audits q
as on: 15. November 2017 November 15. as on: Implementation of lab tests q Documentation of test results Final report to client
…… psch …… f. d. psch
Item Verification of the concrete surface to be treated on hollow areas low-strength ground by tapping with a suitable tool and marking the detected hollow areas, cracks and concrete defects.
…… m2 …… f. d. m2
Item Removal of damaged concrete by means of a suitable blasting process. A surface treatment with HDW beams (depth of removal up to 2 cm, concrete reinforced) can be achieved. q The aggregate must be released d >4mm
q The average surface roughness should be 1.5 mm (deviating from the approval); Minimum value according to abZ [General building inspectorate approval] is 1.0mm.
The expected value of the average of surface tensile strength of minimum 1.0 N/mm² (or stat. requirement, see statics) is to be verified on the prepared concrete surface. Hose water and concrete removal must be collected without damage by means of appropriate collection devices. Appropriate suction and filter sys- tems must be used in such a way that a controlled, environmentally sound disposal can be carried out. The disposal measures, including the tax on landfill, must also be taken into account.
…… m2 …… f. d. m2
The planner portfolio, section 8 8-2 Build lighter – Shape the future Leichter bauen – Zukunft formen
Item Prepare the concrete surface by removing all the loose and brittle parts as well as any intrinsic and extrinsic adhesive-bond removing layers that are easily detachable. The concrete surface has to be roughened by means of suitable processes, cleaned and protected from further contamination. The accumulated material must be gathered from the scaffolding and the surrounding surfaces and removed according to official regulations.
Inclusive of tax on landfill.
Required surface tensile strength: Expected value of the mean is at least 1.0 N/mm2 required roughness depth: at least 1.0 mm
…… m2 …… f. d. m2
Item Test of the surface tensile strength of the substrate after the dry blasting. The expected value of the mean value must be at least 1.0 N / mm² (or stat. Requirement, see statics)
…… St …… f. d. St
Item Pre-dampening of the surface to be reinforced with textile concrete according to the DIBt approval Z-31.10-182 or DAfStb-directive “Protection and restoration of concrete components” Part 2, Section 2.3.5(2)
…… m2 …… f. d. m2
Item Special concrete / mortar for undercutting, prepare and apply to prepared, pre-wetted surfaces by wet spraying in accordance with DIN 18551 Special concrete: Pagel/Tudalit Fine concrete TF 10 Thickness: up to 3mm Number of layers: 1 Surface: removed
…… m2 …… f. d. m2
Item Prepare special concrete / mortar for component reinforcement and apply immediately by wet spraying
as on: 15. November 2017 November 15. as on: method in accordance with DIN 18551. 1. Layer Special concrete: Pagel/Tudalit Fine concrete TF 10 Thickness: up to 3-4 mm Number of layers: 1 Surface: spray rough
…… m2 …… f. d. m2
Item Textile reinforcement TUDALIT-BZT2-V.Fraas Vertical / horizontal installation, during installation, it is necessary to ensure that the textile is oriented vertical- ly and cannot slip. If required, appropriate fixing points must be introduced. While laying the textile reinforcement for the textile concrete, it may be necessary to re-structure the anchor- ing of the framework. The cost of this measure is to be calculated in the offer. Flat textile surface (Including the required coverage in case of horizontal and vertical shocks)
Item 1. Layer Textile reinforcement TUDALIT-BZT2-V.Fraas Deliver, imbed, press and fix the textile reinforcement into the fresh mortar according to the static specifica- tions and custom-tailored based on the selected design version. Overlapping at the impacts must be considered and adhered to in accordance with the specified horizontal and vertical impacts of the selected design variant. The quantity indicated for the item refers to the wall surface to be repaired; the total area of the textile rein- forcement including the necessary covering on the horizontal and vertical bumps is to be taken from the note „Textile reinforcement TUDALIT-BZT2-V.Fraas“
…… m2 …… f. d. m2
The planner portfolio, section 8 8-3 Build lighter – Shape the future Leichter bauen – Zukunft formen
Item Prepare special concrete / mortar for component reinforcement and apply immediately by wet spraying method in accordance with DIN 18551.
2. Lage Special concrete: Pagel/Tudalit Fine concrete TF 10 Thickness: 6 mm Number of layers: 1 Surface: spray rough
…… m2 …… f. d. m2
Item 2. Layer Textile reinforcement TUDALIT-BZT2-V.Fraas Deliver, imbed, press and fix the textile reinforcement into the fresh mortar according to the static specifica- tions and custom-tailored based on the selected design version. Overlapping at the impacts must be considered and adhered to in accordance with the specified horizontal and vertical impacts of the selected design variant The quantity indicated for the item refers to the wall surface to be repaired, the total area of the textile rein- forcement including the necessary covering on the horizontal and vertical bumps is to be taken from the note „Textile reinforcement TUDALIT-BZT2-V.Fraas“.
…… m2 …… f. d. m2
Item Provide the top layer of special concrete / mortar as an outer covering layer, process it and apply it to prepared surfaces in the wet spraying method in accordance with DIN 18551 Special concrete: Pagel/Tudalit Fine concrete TF 10 Thickness: 6 mm Number of layers: 1 Surface: Very heavily smoothed according to the specifications of the AG, the release is performed after the acceptance of a sample surface. Adhesive tensile strength: 1.5 N/mm²
…… m2 …… f. d. m2
as on: 15. November 2017 November 15. as on: Item Supply and contributions of carbon fiber fabric molded parts in the gorges, as a supplement to the textile and concrete work. Total width: …. cm
…… m2 …… f. d. m2
Item Supplement to textile concrete work for the careful formation of gorges. …… m2 …… f. d. m2
Item Supply and contributions of carbon fiber fabric molded parts in the ridges, as a supplement to the textile and concrete work. Total width: ……cm
…… m2 …… f. d. m2
Pos. Supplement to the textile concrete work for the careful formation of sharp-edged ridges including edge formwork as auxiliary formwork manufacture, supply, crop, remove and install again. EIncl. all auxiliary work, fastening material supply etc.
…… m2 …… f. d. m2
The planner portfolio, section 8 8-4 Build lighter – Shape the future Leichter bauen – Zukunft formen Certified Companies Contact personContact Dirk Dalichow 80192-0 30/ +49 Georgi Gogoladze Fabrice Kotte Fabrice 47048-0 8024/ +49 Address Potsdamer Str. 23/24 14163 14163 23/24 Potsdamer Str. Berlin 80192-0 30 +49 phone: 80211-77 fax: 30 +49 info@barg-betontech- mail: nik.de www.barg-betontechnik.de Carl-Rabe-Str. 11 Carl-Rabe-Str. 06526 Sangerhausen 3464 276769-0 +49 phone: info@deutsche-basalt-mail: faser.de www.torkret.de Industriestr. 8 Industriestr. 36275 Kirchheim 88-0 6625 +49 phone: [email protected]: www.bickhardt-bau.de Birkerfeld 30 Warngau 83627 47048-0 8024 +49 phone: 47048-20 fax: 8024 +49 mail: [email protected] www.geigergruppe.de An der Siebanlage Elserheide02979 3796-0 3564 +49 phone: as on: 15. November 2017 November 15. as on: - Rovings fibres- Cut grids reinforcement - Textile - Non-wovens - Bars Works / Services / Works Structure reinforcement with concrete textile textile concrete with Structure reinforcement lamella plastic carbon-fibreand reinforced repair crack shotcrete, repair, Concrete Construction diagnostics, renovation, facade parks parking, car underground and excavations and embankments Bridges, plants, industrial and tunnel restoration, damage water and fire facilities recreational Basalt fibre Basalt Road construction, construction repair, construction construction, repair, Road construction, landfill building, road concrete construction, dam engineering, civil special turnkey construction Bridge repair, repair, Bridge repair, parking underground protection, corrosion cathodic waterproofing, building coatings, reinforcement component - Company BARG Betontechnik und -im und Betontechnik BARG standsetzung KG & Co. GmbH DBF - Deutsche DBF Basalt Faser GmbH Bickhardt Bau AG Geiger Bauwerksanierung KG & Co. GmbH Gleisbau Sabrodt GmbH Gleisbau Logo
The planner portfolio, section 9 9-1 Build lighter – Shape the future Leichter bauen – Zukunft formen Rolf Spreemann 1887-40 720 89/ +49 Contact personContact Christian Laumer 88 440 8724/ +49 Bärbel Böttiger 48 400 34297 +49 Steffen Vogt 15 50 839 351/ +49 - - Zielstattstr. 19 Zielstattstr. 81379 München 1887-0 720 89 +49 phone: 1887-60 720 fax: 89 +49 mail: info.instandsetzung@ implenia.com www.instandsetzung.imple nia.com Address Bahnhofstr. 8 84323 Massing 88-0 8724 +49 phone: 88-500 fax: 8724 +49 [email protected] mail: www.laumer.de Fritz-Salisz-Straße 38a Fritz-Salisz-Straße 04288 Leipzig 48400 34297 +49 phone: 48399 fax: 34297 +49 mail: laumer.leipzig@laumer. de www.laumer.de Ringstr. 15 Moritzburg 01468 50-0 839 351 +49 phone: 88 50 838 fax: 351 +49 moritzburg@massenmail: berg.de www.massenberg.de - as on: 15. November 2017 November 15. as on: tion, concrete repair concrete tion, lamella plastic Carbon-fibre reinforced systems, insulation thermal balconies, Facades, protectioncathodic corrosion Shotcrete concrete, textile with Component reinforcement consultation, maintenance, planning Waterproofing/ coating injection/surfaceprotec Waterproofing/coating Works / Services / Works Execution, planning and static proofs, static component and planning Execution, reinforcement with steel lamella, and lamella plastic carbon-fibre reinforced sheets, plastic shotcreting carbon-fibre reinforced works repairs, crack anchors, stonework of Installation and planning repair concrete and stonework others to according the Instandsetzungsrichtlinien (DAfStb) Repairs] Concrete for [Guidelines the support of area in consulting Comprehensive structure) Bereich im Beratung Ganzheitliche der Tragkonstruktion Execution, planning and static proofs, static component and planning Execution, reinforcement with steel lamella, and lamella plastic carbon-fibre reinforced sheets, plastic shotcreting carbon-fibre reinforced works repairs, crack anchors, stonework of Installation and planning repair concrete and stonework others to according the Instandsetzungsrichtlinien (DAfStb) Repairs] Concrete for [Guidelines the support of area in consulting Comprehensive structure der Bereich im Beratung Ganzheitliche Tragkonstruktion Concrete repair, repair, Concrete protection,corrosion protection, corrosion cathodic painting works Implenia Instandsetzung GmbH Company Laumer Bautechnik GmbH Bautechnik Laumer Laumer Leipzig Bausanierung GmbH Massenberg GmbH Logo
The planner portfolio, section 9 9-2 Build lighter – Shape the future Leichter bauen – Zukunft formen Bernhard Schwarz 71-0 / 6288 30 +49 Dr. Christian Kulas Christian Dr. +49 7431/ 10-3118 Marco Götze Marco 030/ 772 0577-0 Torsten Welzel Dipl.-Ing. Erich Erhard 2202265 +49 171 Tel: Contact personContact Freiheit 10 Berlin 13597 628871-0 30 +49 phone: 628871-22 fax: 30 +49 mail: [email protected] www.repenn-ing.de Sigmaringer Str. 150 Str. Sigmaringer Albstadt72458 10-2670 7431 +49 phone: 10-62670 fax: 7431 +49 [email protected] mail: www.solidian.com Hochbergweg 2 Berlin 12207 0577-0 772 30 +49 phone: [email protected] mail: www.tarkus.de Chemnitztalstr. 62 09114 Chemnit 442584 371 +49 phone: z mail: [email protected] www.tdchemnitz.de Langemarckstraße 39; D-45141 Essen 2943-0 201 +49 phone: 120 2943 fax: 201 +49 [email protected] mail: www.torkret.de Address as on: 15. November 2017 November 15. as on: repair, structural maintenance, structural maintenance, repair, - Component reinforcement Component - - Construction repair maintenance - Structural buildings - Construction works existing on Repair and maintenance of engineering structures engineering of maintenance and Repair as per shotcrete DIN concrete, textile (TUDALIT process) injection SIB, as per repair RiLi 18551, with gel-injections, and KMB Waterproofing painting works floor protection, industrial corrosion of Works Act-coatings Management Water and coating Industriebodenbeschichtung und WHG-Beschichtungen Level reinforcement,Level form reinforcement, special grid, grid, plaster bar reinforcement, consultation, test laboratory dimensioning, Shotcrete, fire protection, coating, protection, coating, fire Shotcrete, concrete technique injection lamella / steel plastic Carbon-fibre reinforced systems, reinforcement art and rock building concreteTextile Concrete repair, repair, Concrete restoration / Waterproofing protective wall insulation Execution and consultation: Works / Services / Works - haltung GmbH haltung Repenning + Sohn Bauwerker + Sohn Repenning solidian GmbH TARKUS IngenieurSanierung IngenieurSanierung TARKUS GmbH TDC GmbH Gebäudeservice TORKRET GmbH TORKRET Company Logo
The planner portfolio, section 9 9-3 Build lighter – Shape the future Leichter bauen – Zukunft formen 10. Manufacturer, Service and Contact Person
q Fine concrete TF10 PAGEL Spezial-Beton GmbH & Co. KG Wolfsbankring 9 45355 Essen Tel.: +49 201 68504-28 Fax: +49 201 68504-31 E-Mail: [email protected]
q TUDALIT-BZT1-TUDATEX TUDATEX GmbH Freiberger Str. 37 01067 Dresden Contact person: Sophie Barth Tel.: +49 351 463 39300 Fax: +49 351 463 39301 E-Mail: [email protected]
q TUDALIT-BZT2-V.FRAAS WILHELM KNEITZ Solutions in Textile GmbH Holzwiesenweg 17 95028 Hof Contact person: Jasmin Weber Tel.: +49 9281 59166 – 00 Fax: +49 9281 59166 – 14 E-Mail: [email protected]
q Contact person for certification of specialist companies
as on: 15. July 2020 July 15. as on: EIPOS GmbH Freiberger Str. 37 01067 Dresden Contact person: Silke Grün Tel.: +49 351 4047042-35 Fax: +49 351 4047042-20 E-Mail [email protected]
q Contact person for licensing TUDAG/ Deutsches Zentrum Textilbeton Freiberger Str. 37 01067 Dresden Contact person: Kerstin Schön Tel.: +49 351 40470-410 Fax: +49 351 40470-310 E-Mail [email protected]
q Planning service TUDAG/ Deutsches Zentrum Textilbeton Freiberger Str. 37 01067 Dresden Tel.: +49 351 40470-410 Fax: +49 351 40470-310 E-Mail [email protected]
More useful addresses can be found in the Supplier‘s Guide of the TUDALIT e.V.! http://tudalit.de/herstellerverzeichnis-suppliers-guide/
The planner portfolio, section 10 10-1 Build lighter – Shape the future Leichter bauen – Zukunft formen as on: 15. November 2017 November 15. as on:
The planner portfolio, section 11 11-1
Build lighter Build lighter –– Shape the Shape the futurefuture Leichter bauen – Zukunft formen
Reference object
Uelzen, Germany Fire-damage restoration with carbon concrete
Key data
Realisation 04.2015 – 07.2015 Cost of construction EUR n.n. Use Sugar silo 80.1 t warehouse capacity Total/wall height 75 / 58 m Internal diameter 45.5 m
Implenia at the construction
Task Implenia Instandsetzung GmbH D-22047 Hamburg / D-81379 Munich
Services rendered
ultra-high-pressure water jetting Concrete repairs Textile-reinforced concrete work The project
In a major fire in June 2014, a silo of the sugar factory in Uelzen, just completed in Construction methods the previous year, was damaged. The timber structure of the roof and the conveyer Carbon concrete/Textile-reinforced concrete bridge collapsed and fell into the partially filled silo. Testing and structural analyses determined that the structural stability of the silo walls was not damaged. However, Project participants due to the high temperatures the concrete cover of the upper part, which at the incident was not covered by sugar, was severely damaged and showed the typical Owner as on: 15. May 2018 May 15. as on: spalling caused by the high temperature during the fire incident.
As on: 15th November 2016 Nordzucker AG, Werk The replacement of the concrete cover of the prestressed circular silo walls had to Uelzen D-29525 Uelzen provide a highly effective limitation of the crack width for the load of the sugar. Therefor 2-3 layers of carbon reinforcement where used. General planner The damaged concrete cover of 4.500m² of the silo was removed using IPRO Industrieprojekt GmbH hydrodemolition (2800 bar). Then, 14.000m² textile carbon fibre reinforcement and D-38114 Braunschweig approx. 300t fine concrete were applied up to a hight of 56m above ground level. The surface provided with a smooth finish for application of a coating. External monitoring/ZiE Dresden University of Technology Institute for solid construction D-01067 Dresden
Application of fine cement in the wet spray technique Insertion of carbon reinforcement
Challenges The reinforced-textile concrete work was carried out by specially qualified personnel after acquiring general building approval Z-31.10-182 together with an approval in an individual case (ZiE) and accompanied by an extensive test program for in-house and external monitoring for verifying the quality of execution by the Dresden University of Technology. Despite the very tight schedule, which required completion of the refurbishment in time for the sugar campaign in 2015, the work was completed ahead of schedule. .
Implenia Instandsetzung GmbH
TheThe plannerplanner portfolio, section 12 12-1 section 12 Build lighter – Shape the future Leichter bauen – Zukunft formen
TUDALIT Planermappe
Sandwichwall Eastsite VIII (Mannheim)
Owner: B.A.U. Bauträgergesellschaft mbH (www.bau-mannheim.de) Architect: Fischer Architekten GmbH (www.werkstadt.com) Precast factory: Dreßler Bau GmbH (www.dressler-bau.de) Reinforcement: solidian GmbH (www.solidian.com) Static calculation: solidian GmbH (calculation of facing shell made of textile-reinforced concrete) Expert opinion ZiE: Institut für Massivbau der RWTH Aachen (www.imb.rwth-aachen.de) Structural Inspection: Ingenieurgruppe Bauen (www.ingenieurgruppe-bauen.de) ZiE: Regierungspräsidium Tübingen, Landesstelle für Bautechnik (www.bautechnik-bw.de) Facade surface: 1.594 m² (total facade surface), 952 m² (concrete surface) Completion: 2015 The tenth building was completed in Mannheim in the year 2015, in the Eastsite office complex. The special feature of this building is the innovative wall mount, in which the facing shell has been reinforced with a AR glass reinforcement. Thereby, the thickness of the facing shell was reduced from the normal 80 mm to 100 mm (reinforced concrete construction method) to just 30 mm. In addition to saving costs for the high-value architectural concrete, the construction method especially stands out because of the economic advantages for the owners: In this building, there was approximately 30 m² of additional residential / commercial space that could be rented out. The connection between the 30 mm thick outer shell and the 220 mm thick inner shell (reinforced concrete) was established by linear thrust grid, which was also made of AR glass fibres. The advantage: as the glass fibres display a significantly low thermal conductivity as compared to conventional stainless steel joining means, thermal bridges can be minimised and thus the energy balance of the whole building can be optimised. The challenge in the project was to execute the necessary approval in the individual case (ZiE) within the schedule specified by the owner, which was achieved by the seamless cooperation of those participating. For future applications, solidian has applied for a general building approval for Sandwich as on: 15. May 2018 May 15. as on: elements made of textile-reinforced concrete at the DIBt. The procedure is still underway, the tests are completed and the approval is expected to be granted at the end of 2016.
Inner shell (Reinforced concrete) Thermal insulation Outer shell (Textile-reinforced concrete)
Thrust grid solidian GRID Q121/121-AAE-38
View of the building Eastsite VIII Wall cross-section (Image sources: solidian GmbH) Christoph Suttrop, Dreßler Bau GmbH, [email protected], +49 6027-2007 57 Dr. Christian Kulas, solidian GmbH, [email protected], +49 7431-10 3118
The planner portfolio, section 12 12-2 Build lighter – Shape the future Leichter bauen – Zukunft formen
TUDALIT Planermappe
Curtain wall Neuer Markt (Neumarkt i.d.OPf.)
Owner: NeuerMarkt Besitz- und Vermietungs GmbH (www.max-boegl.de) Architect: Design: Bögl Gierer Architekten, München (www.boegl-gierer.de) Construction documentation: Distler Architekten & Ingenieure, Neumarkt i.d.OPf. Facade manufacturer: ArchitekturBetonBögl Max Bögl Stiftung & Co.KG (www.max-boegl.de) Reinforcement: solidian GmbH (www.solidian.com) Static calculation: H+P Ingenieure GmbH (www.huping.de) Facade surface: 960 m² / 2030 m² (Textile reinforced concrete / Overall surface) Completion: 2015
An impressive facade design with a thin textile-reinforced concrete layer and massive reinforced concrete frame came into being from the combination of reinforced concrete and textile-reinforced concrete construction method, as part of the building project "Neuer Markt" in Neumarkt i. d. Upper Palatinate. The optic is strengthened by different, coloured architectural concretes. A pronounced optical depth effect of the facade could be generated because of the narrow plate thickness of 30 mm. What is also noteworthy is the enormous variety of plate sizes of up to 4 m x 4 m. As part of a cooperation between Max Bögl Bauservice GmbH & Co. KG and solidian GmbH, the large size facade panels were developed and their practicality was proven at the construction project in Neumarkt. The load-bearing capacity of the plates was ensured by the carbon reinforcement of solidian GRID Q142/142-CCE-38, which shows the currently most efficient textile reinforcement in the market with average tensile forces of approx. 360 kN/m. The concrete covers could be minimised to 15 mm, whereby a plate thickness of only 30 mm is possible with a centred arrangement of the reinforcement.
as on: 15. May 2018 May 15. as on: To avoid interrupting the high-value architectural surface by contact patches of the spacers, as part of the industrial cooperation, a corresponding spacer system was developed, which also minimised the layer tolerance of the reinforcement steel meshes.
Facade view solidian GRID Q142/142-CCE-38 Image source: Max Bögl Bauservice GmbH und Co. KG Image source: solidian GmbH
Mario Bommersbach, ArchitekturBetonBögl, [email protected], +49 9181-909 182 08 Dr. Christian Kulas, solidian GmbH, [email protected], +49 7431-10 3118
The planner portfolio, section 12 12-3 Build lighter – Shape the future Leichter bauen – Zukunft formen
TUDALIT Planermappe
Footbridge (Albstadt-Ebingen)
Owner: Stadt Albstadt (www.albstadt.de) Design: Knippes Helbig Advanced Engineering (www.knippershelbig.com) Precast factory: Max Bögl Bauservice GmbH & Co. KG (www.max-boegl.de) Reinforcement: solidian GmbH (www.solidian.com) Static calculation: Knippes Helbig Advanced Engineering (www.knippershelbig.com) Total length: 15,30 m Completion: 2015
Further expansion of the present textile-reinforced concrete bridges is represented by the footway and cycle way in Albstadt-Ebingen, because preload would be foregone and the cross-section is fully steel-free. The load-bearing effect is only ensured by a carbon reinforcement (solidian GRID Q95/95- CCE-38). Thus, bridge completed in the end of 2015 is the first bridge worldwide, which has been made exclusively out of carbon concrete. Only the railings and the four support points are made of steel. Thereby, the durability can be maximised, as there is no possibility of corrosion damage in the future. For the owners, this means that the repair costs are minimised. Because of the non-corroding carbon reinforcement, the concrete covers could be executed with 15 mm, whereby a trough wall thickness of 70 mm and a thickness of the paving slabs of 90 mm were the result. The 15.30m long bridge thus weighs about 14 tonnes, which is approximately half of a comparable conventional reinforced concrete bridge. With that, such bridge constructions are attractive for the prefabricated construction: The bridge was made by Max Bögl in Sengenthal, transported to Albstadt and mounted within two hours. as on: 15. May 2018 May 15. as on:
View Cross-section
Lateral view (Image sources: solidian GmbH)
The bridge construction was awarded with the innovation prize as a building product for the pre- fabricated component industry on the BetonTage in Neu-Ulm 2016. solidian is currently working on a general building approval for this type of bridge with a span of up to 20 m.
Dr. Christian Kulas, solidian GmbH, [email protected], +49 7431-10 3118
The planner portfolio, section 12 12-4 Build lighter – Shape the future Leichter bauen – Zukunft formen
TUDALIT Planermappe
Procedure for reduction in crack width in concrete constructions with carbon textiles inserted near the surface
Applicant: Fa. Quinting Zementol GmbH (www.quinting.com) Approval number: Z-31.10-190 Expert opinion abZ: Institut für Bauforschung der RWTH Aachen (www.ibac.rwth-aachen.de) Reinforcement: solidian GmbH (www.solidian.com) Granting of abZ: 07.08.2015
Components made of waterproof concrete (WU-concrete) should normally do not have any crack widths above 0.1 mm. In conventional construction methods, this can only be achieved nowadays by very high reinforcement quantities made of concrete steel. Quinting Zementol has developed a new type of construction method, in which a carbon reinforcement installed close to the surface, the so- called "Quinting Grid", takes over the limitation of the crack width. As part of the examinations of the Institute for building research at RWTH Aachen (ibac), it could be seen that the reinforcement solidian GRID Q85/85-CCE-21 is especially suitable for this. The carbon reinforcement used satisfies, for one, the construction principle known from the reinforced concrete, that many small bar diameters achieve a crack pattern with less crack distances and widths. Also, for usability in the WU-concrete construction, in addition to the fibre material, the watering material used is also decisive for the bond behaviour with regard to the cement and thus for the crack width: only epoxy resin watering like in the case of solidian GRID Q85/85-CCE-21 have an extremely good bond with the cement, so that there are minimum crack widths. Quinting Zementol, since August 2015, has a general building approval for a procedure, in which an additional carbon reinforcement is pushed in the fresh concrete in a reinforced concrete component. Because of the less required concrete cover of a few millimetres, a carbon reinforcement layer close to the surface is possible, which is especially effective for the crack repression. Conventional concrete
as on: 15. May 2018 May 15. as on: steel reinforcements cannot do this. Because of subsequent pushing in, it is also possible to use concrete with large grain diameters till 32 mm in combination with the carbon reinforcement.
Image source: German Institute for building technology Image source: Quinting Zementol GmbH
Burkhard Wienke, Quinting Zementol GmbH, [email protected], 02599-741 234 Dr. Christian Kulas, solidian GmbH, [email protected], +49 7431-10 3118
The planner portfolio, section 12 12-5 Build lighter – Shape the future Leichter bauen – Zukunft formen
TUDALIT Planermappe
Curtain facade SchieferErlebnis (Dormettingen)
Owner: Holcim Süddeutschland GmbH (www.holcim.de) Architect: Fahrner und Kölmel (www.fahrner-koelmel.de) Precast factory: FBW Fertigbau Wochner GmbH & Co. KG (www.wochner.de) Reinforcement: solidian GmbH (www.solidian.com) Static calculation: solidian GmbH Expert opinion ZiE: Institut für Massivbau der RWTH Aachen (www.imb.rwth-aachen.de) Structural inspection: Reck + Gass Ing.-Gesellschaft für Bauwesen mbH (www.reck-gass.de) ZiE: Regierungspräsidium Tübingen, Landesstelle für Bautechnik (www.bautechnik-bw.de) Facade surface: approx. 400 m² Completion: 2014
The park landscape "SchieferErlebnis" is a joint project of Holcim (Süddeutschland) GmbH and the community of Dormettingen. The project for harmonising the landscape and for renaturation of the former mining areas of the oil shale quarry started in 2009. The result was a landscape park, which combines interaction, conversation and experience of nature. A farm building has also been built on the property, which has been covered with facade plates made of textile-reinforced concrete. The 50mm thin plates were reinforced with a centrally arranged carbon reinforcement solidian GRID Q142/142-CCE-38. The individual facade plates of the large sized, rear- ventilated curtain facade, have a size of up to 1.20 m x 4.14 m. The plate was fastened at only four points with the facade plate anchoring system by Halfen. The load-bearing capability of the anchor was experimentally proven at the construction project; meanwhile, Halfen has a general building approval, so that the experimental examinations are not necessary any more (Z-21.8-2067). Despite the plate length of over four metres, an installation accuracy of the reinforcement of approx. one
as on: 15. May 2018 May 15. as on: millimetre was achieved. On one hand, this precision can be achieved by corresponding manufacturing methods, like the lamination process, in which the reinforcement is incorporated in the fresh concrete. On the other hand, even the most varied spacer systems by solidian can be used, which enable minimum tolerances without interrupting the high-value concrete surface.
Facade view Building corner (Image sources: solidian GmbH)
Rudi Mattes, FBW - Fertigbau Wochner GmbH & Co. KG, [email protected], +49 7427-77 155 Dr. Christian Kulas, solidian GmbH, [email protected], +49 7431-10 3118
The planner portfolio, section 12 12-6 Build lighter – Shape the future Leichter bauen – Zukunft formen
© Torkret © Torkret
Object:
Crack repairs and textile-reinforced concrete strengthening Silo 2, sugar factory at Uelzen Client: Nordzucker AG in 29525 Uelzen
Object discription: The cylindrical double chamber silo with a height of almost 50 m from the year 1962 holds about 80,000 t of sugar when full. Despite a strengthening measure in the 1990s, in retrospect, there were considerable cracks and spallings on the inside of the reinforced concrete wall. Based on an expert recommendation by Prof. Dr. Eng. E. h. Manfred Curbach, the repairs now took place as part of an approval in an individual case, granted by the building supervisory authority, by incorporating a textile-reinforced strengthening with carbon fibre non-crimp fabric. In just 6 weeks of construction time, the serviceability was re-established and the damage in the shift operation was removed. At the same time, the bending resistance of the outer shell was increased and better crack width distribution as on: 15. May 2018 May 15. as on: was ensured. After grouting the up to 1.6 mm wide crack in reinforced concrete, the damaged spots are worked upon according to the repairs guideline and finally, the outer shell of the silo is clad and strengthened with an approx. 20 mm thin, 4-layer reinforced textile-reinforced concrete layer. The smoothed surfaces were provided with a food-safe coating. Special challenges arose from the construction height, from the long wet current conveyor paths and from the procedural, constantly necessary framework anchoring. The work was academically accompanied by TU Dresden and also monitored externally.
Execution time: August 2012 – September 2012
Our services:
• Examination and documentation of the concrete surfaces for damaged spots and cracks (3500 m2) • Re-profiling of all concrete blemishes with PCC-mortar according to RILI SIB • Crack injection with EP-resin of all cracks larger than 0.3 mm (1800 m) • Underground preparation and equalisation of the surfaces with TUDALIT® fine concrete (3500 m2) • Incorporation of textile carbon-reinforcement SGL Grid 600 and lamination in fine concrete (14000 m2) • Application of a 3 mm think fine concrete cover with intensive concrete post-treatment (3500 m²) • Documentation of all works and daily production of samples with analysis
www.torkret.de 16-104-2012
The planner portfolio, section 12 12-7 Build lighter – Shape the future Leichter bauen – Zukunft formen
TUDALIT Planermappe
Footbridge (Albstadt-Lautlingen)
Owner: Town of Albstadt (www.albstadt.de) Architect: hartwig schneider architekten (www.hartwigschneider.de) Precast factory: Seb. Wochner GmbH & Co. KG (www.wochner.de) Reinforcement: Groz-Beckert / solidian GmbH (www.solidian.com) Static calculation: H+P Ingenieure GmbH (www.huping.de) Expert opinion ZiE: Institut für Massivbau der RWTH Aachen (www.imb.rwth-aachen.de) Institut für Bauforschung der RWTH Aachen (www.ibac.rwth-aachen.de) Structural inspection: Bornscheuer Drexler Eisele GmbH (www.b-d-e.de) ZiE: Regierungspräsidium Tübingen, Landesstelle für Bautechnik (www.bautechnik-bw.de) Total length: approx. 100 m max. element length: 17,20 m Completion: 2010
At almost 100 m, the so far longest textile-reinforced concrete bridge of the world was completed in Albstadt-Lautlingen in the year 2010. The total six finished parts were reinforced with alkali-resistant glass reinforcements in combination with a conventional steel pre-stressing. The combination of glass reinforcement and preload enables an extremely lean bridge construction with a construction height of only 43.5 cm. The lighting system integrated in the railing and under the steel supports underlines the lightness of the concrete top structure.
Monostrands as on: 15. May 2018 May 15. as on: shaped textile reinforcement rods level textile reinforcement
Cross-section (Image source: solidian GmbH)
A special feature is that the bridge was executed completely without surface protection system. Even if there should be unplanned crack formation and if de-icing salts were to penetrate the construction, this would not damage the bridge, because the reinforcement does not corrode. With regard to the present corrosion problem in bridge construction, it presents a promising construction method.
View (Image source: solidian GmbH)
Dr. Christian Kulas, solidian GmbH, [email protected], +49 7431-10 3118
The planner portfolio, section 12 12-8 Build lighter – Shape the future Leichter bauen – Zukunft formen
© Torkret © Torkret © Torkret
Object: Textile-reinforced concrete strengthening Canyon Bicycles GmbH in Koblenz Client: Schiefergrund CA & Co.KG, Koblenz
Object discribtion: Up to 9 cm strong deflections of the ground floor ceiling, resulting from insufficient additional reinforcement, led to stress-induced damage in walls and superstructures in the suite of offices above that and required a partial renovation of the ceiling panel in the production area of the factory building. With the lowest possible, individual net weight, the bending load-bearing capability was applied by additional textile reinforcement in the tension zone on the ceiling soffit and thus prevented as on: 15. May 2018 May 15. as on: further deformations. As there was still no general building approval for this new construction process, the approval in an individual case was applied for according to the LBauO Rhineland- Palatinate and was also granted. The necessary expert opinion on this of the Technical University of Dresden was the basis of execution. The construction sectors were scaffolded around and encased after the construction-sided franking of the necessary working space and the removal of all the hampering supply and discharge lines. The adjacent areas were protected against damage by tarpaulins, sheets and hardboards. To establish a very good bond with the old concrete, the bottom view surfaces were intensively sand blasted and the underground was roughened (Roughness depth > 1.5 mm). After that, the full-surface application of 3 layers of fine concrete in spraying procedure according to DIN 18551 was done with layer thickness of approx. 4 mm each with one textile non-crimp fabric insertion of SGL SIGRATEX® Grid 600. The last fine concrete layer was rubbed. Finally, the fine concrete surfaces were coated with an acrylate-based colour system for colour design. The results of the accompanying quality controls confirmed the material characteristic values adopted for measuring. The work was accompanied and externally monitored by the TU Dresden Aktiengesellschaft (TUDAG).
Execution time: Oktober 2010
www.torkret.de 17-110-2010
The planner portfolio, section 12 12-9 Build lighter – Shape the future Leichter bauen – Zukunft formen
Our services: • Scaffolding and encasing of the work areas • Underground pre-treatment of the concrete surfaces (approx. 40 m²) using sand blasting • Ventilation and dust exhaust during the blasting process • Re-profiling the imperfections as well as balance of existing unevenness with PCC-mortar • Textile-reinforced concrete application in 3 layers each of 4 mm on the ceiling soffit strips (approx. 40 m²)
Other picture documents:
as on: 15. May 2018 May 15. as on: © Torkret © Torkret
© Torkret
www.torkret.de 17-110-2010
The planner portfolio, section 12 12-10 Build lighter – Shape the future Leichter bauen – Zukunft formen
© Torkret © Torkret
Object: Residential and office building Prague – Strengthening of point-supported suspended ceiling Client: VN17a.s., Brno
Object discription: In case of converting a multi-storey residential and office building in central urban location of Prague, subsequently, extensive strengthening measures were indispensible. Deformations with deflections of the floor slabs of up to 15 cm had not just considerably restricted the serviceability, but also had questioned the basic load- bearing capability of the ceiling construction. The verification of the static basic conditions and the comparison with the actual construction produced a strong under dimensioning of the load reinforcement and the panel thickness in as on: 15. May 2018 May 15. as on: case of spans of up to 13 m. Diverse strengthening measures needed to be carried out subsequently. In addition to the increase in the punching shear safety by anchoring and reinforced shotcrete, the bending resistance was increased by partial grout topping, glue strips and with textile-reinforced spraying concrete. The missing stiffness with the accompanying vibration problem, the deformations that have already materialised and the necessary high degree of strengthening (MEd,strengthened / MRd, unstrengthened > 2) allowed a strengthening of the field reinforcement with glued reinforcement only in the support and the edges. A renovation with shotcrete would have significantly increased the loads and disproportionately restricted the ceiling heights. As compared to a conventional strengthening with shotcrete, the steel reinforcement is replaced by woven textile non- crimp fabric with up to 10-time high tensile strengths. As the usual corrosion protection is not available in case of carbon fibres, the otherwise usual concrete cover can be waived. This means a cross-section and with that a net weight reduction towards reinforced concrete of up to 90 per cent. In the largely flat strengthening with up to 4 layers of textile tensile reinforcement, only an additional fine concrete layer of under 2 cm was sprayed on at the ceiling soffits for additional force absorption. As compared to other strengthening procedures, the work processes thus optimised led to significant decrease in time and costs, despite the higher personal expense. The textile-reinforced concrete works were accompanied and monitored externally by the TU Dresden Aktiengesellschaft (TUDAG).
Execution time:
Total measure: November 2009 - February 2010 Textile-reinforced concrete works: February 2010
www.torkret.de 16-101a-2010
The planner portfolio, section 12 12-11 Build lighter – Shape the future Leichter bauen – Zukunft formen
Our services:
• Increase in the punching shear safety in the region of 56 reinforced concrete supports across 6 floors (1000 m2 sand blasts, 2900 St thread rods, 3600 St shear connector, 1100 to shotcrete • Strengthening the field reinforcement by textile-reinforced fine shotcrete (1100 m2 underground preparation, 3000 m2 textile carbon reinforcement, 50 to fine concrete) • Strengthening the field reinforcement by CFK-strips glued and affixed in slots, in the floor and ceiling area (3800 m) • Component strengthening by reinforced grout topping (2000 St glued thread anchor with anchor plates, 1000 m concrete steel bar DU 16 mm, 300 St adhesive anchors, 21000 kg grout topping with bonding bridge)
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© Torkret © Torkret
© Torkret © Torkret
© Torkret © Torkret
www.torkret.de 16-101a-2010
The planner portfolio, section 12 12-12
BuildBuild lighter lighter –– Shape Shape the the futurefuture Leichter bauen – Zukunft formen
Reference object
Kempten, Germany Bridge strengthening with carbon concrete
Key data
Realization 09.2009 – 10.2009 Cost of construction EUR n.n. Use Pedestrian bridge
Implenia at the construction
Task Implenia Instandsetzung GmbH D-22047 Hamburg / D-81379 Munich
Services rendered
Concrete repairs Textile-reinforced concrete work The project
The existing structure is a arched pipe bridge with a superstructure made up of Construction methods precast light weight concrete parts. The bride is used by pedestrian. Carbon concrete/Textile-reinforced concrete An updated structural analysis showed a very limited load capacity. Project participants The bridge was strengthened by construction of an carbon concrete bridge slab with two layers of carbon fibre reinforcement. The carbon concrete slab with a depth of Client 50mm serves to distribute single loads and strengthen the cantilever arms of the on: 15th November 2016 as on: 15. May 2018 May 15. as on: light weight concrete precast elements. City of Kempten As External monitoring/ZiE Dresden University of Technology Institute for solid construction D-01067 Dresden
Placement of carbon reinforcement in first layer of concrtete
Please note that the project was carried out at a time project company was part of the Bilfinger SE Group. The company was transferred to the Implenia Group in 2015. Bilfinger and Implenia are two different companies. They are not connected with each other and act independently.
Implenia Instandsetzung GmbH
TheThe planner planner portfolio, portfolio, section 12 12-13 section 12
BuildBuild lighter lighter – –Shape Shape the the futurefuture Leichter bauen – Zukunft formen
Reference object
Kempten, Germany Bridge strengthening with carbon concrete
Key data
Realization 09.2009 – 10.2009 Cost of construction EUR n.n. Use Undercrossing
Implenia at the construction
Task Implenia Instandsetzung GmbH D-22047 Hamburg / D-81379 Munich
Services rendered
ultra-high-pressure water jetting Concrete repairs The project Textile-reinforced concrete work Surface coating The structure which serves as an undercrossing for the mayor road above consists of an arche, supported by pier walls. Especially the pier walls showed severe spalling due to chloride induced corrosion. In many areas the cross section of the Construction methods reinforcement was severely damaged. Carbon concrete/Textile-reinforced concrete Damaged concrete was replaced using conventional sprayed concrete, without 15th November 2016 replacing of damaged reinforcement. On the surface an additional layer of carbon Project participants concrete was applied. This served to replace damage reinforcement and limit crack
as on: 15. May 2018 May 15. as on: width. Client As on: Minor spalling of the arch was repaired before applying a surface coat to the whole structure. City of Kempten In future the pier walls again will be painted by local graffiti artists. External monitoring/ZiE
Dresden University of Technology Institute for solid construction D-01067 Dresden
Placement of the sprayed concrete completed work of 1st phase of construction
Please note that the project was carried out at a time project company was part of the Bilfinger SE Group. The company was transferred to the Implenia Group in 2015. Bilfinger and Implenia are two different companies. They are not connected with each other and act independently.
Implenia Instandsetzung GmbH
The The planner planner portfolio, portfolio, section 12 12-14 section 12 Build lighter – Shape the future Leichter bauen – Zukunft formen
© Ulrich van Stipriaan
© Torkret © TU Dresden
Object: University of applied sciences in Schweinfurt – Strengthening the hypar shell Client: Staatliches Bauamt in 97422 Schweinfurt
Object description: The roof construction of the large auditorium of the University of Applied Sciences in Schweinfurt in the form of a hyper as on: 15. May 2018 May 15. as on: reinforced concrete hyper-shell is 38 x 39 metres. The shell thickness in the central section is only 8 cm. In the area of the projecting high points, place because of stress transgressions over the supports. TORKRET first used the innovative technology of the textile-reinforced shotcrete for strengthening worldwide. To re thoroughly roughen and pre-wet the old concrete underground at the top side by using sand blast. Then, according to DIN 18551, the fine concrete was app manner to the old concrete underground in 3-5 mm thin layers using spraying procedure. By lamination, fine concrete and three layers of textile reinforcement are applied alternatingly. The total thickness of the strengthening is just 15 mm. The last covering concrete layer was smoothed for the against fast drying out. The execution took place on the basis of an approval in an individual case. Because of the very less total coating thickness of 15 mm and because of the extremely high tensile strength of the carbon ro reduced by over 80%! Corrosion of the textile reinforcement steel meshes is excluded.
Execution time: 16.10.2006 – 10.11.2006
Our services: • Examine concrete surfaces • Repairs to damaged areas of the concrete according to Rili SIB with PCC-mortar • Strengthening the upper tensile reinforcement with 3 layer reinforced textile concrete (approx. 140 m2) • Smoothing and post-treatment of the fine concrete surfaces for the following sealing
www.torkret.de 16-92-2006
The planner portfolio, section 12 12-15 Build lighter – Shape the future Leichter bauen – Zukunft formen
Foto: Torkret
Foto: Torkret Foto: Torkret as on: 15. May 2018 May 15. as on:
Foto: Torkret Foto: Torkret
Foto: Torkret Foto: Torkret
www.torkret.de 22-45-2006
The planner portfolio, section 12 12-16 Build lighter – Shape the future Leichter bauen – Zukunft formen
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www.torkret.de 16-92-2006
The planner portfolio, section 12 12-17 Build lighter – Shape the future Leichter bauen – Zukunft formen
© Torkret
© TU Dresden © Torkret © Torkret
Object: Tax office of Zwickau – Textile-reinforced concrete renovation at the listed barrel vault Client: State-owned enterprise SIB Zwickau Object description: The mostly heritage-protected building complex of the former school of engineering in Zwickau was repaired in 2008 by extensive restructuring measures and was rebuilt. Now, the property in Lessingstraße 15 is used by the tax office of Zwickau. As part of this conversion measure, a static strengthening, made out of reinforced concrete, of the barrel-shaped roof built in 1903 was necessary above the west wing. The bending load-bearing capability of this construction could not be verified any more according to present safety standards. as on: 15. May 2018 May 15. as on: On the basis of the report by the Technical University of Dresden, an approval in an individual case (ZIE) was applied for, for strengthening with textile-reinforced concrete and was granted by the relevant county office for building technology in Leipzig. Alternatively, renovation process like strengthening by shotcrete or glued CFK-strips were not possible because of optical or geometrical reasons. By replacing a 20 mm thick interior plaster with a somewhat equally strong sprayed-on fine concrete layer with up to 7 carbon-textile layers in the region of the arched beams, the historic optics could be preserved. The bending load-bearing capability of the barrel-roof shell was also verified by 2 additional layers of textile-reinforced concrete at the top or under sides.
Execution time: Oktober - November 2008
Our services: • Underground pre-treatment of the concrete surfaces (approx. 270 m²) by means of sandblast • Re-profiling the imperfections as well as balance of existing unevenness with PCC-mortar • Force-locked sealing of existing cracks • Internal strengthening of the barrel-roof construction with 3 layers (barrel-roof shell) or with 7 layers (concrete ribs) each 3mm textile-reinforced concrete (approx. 150 m²) • Textile-reinforced concrete application in 3 layers each 3 mm on the outer side of the barrel roof (approx. 120 m²)
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www.torkret.de 22-45-2006
The planner portfolio, section 12 12-18