Appendix 2 Concrete Overlays

6
Appendix 2
11.1 Concrete overlay connection 315
11.1.1 Application range 315
11.1.2 Advantages of the method 315
11.2 Design of interface 317
11.2.1 Basic considerations 317
11.2.2 Ultimate limit state for shear transfer
at the interface 317
11.2.3 Design shear force acting longitudinally
at interface, V
Sd
322
11.2.4 Serviceability limit state 323
11.2.5 Additional rules and detailing provisions 323
11.3 Examples 326
11.3.1 Example: Double-span slab 326
11.3.2 Example: Double-span beam with new slab 329
11.4 Test results 331
11.4.1 Transfer of shear across a concrete crack 331
11.4.2 Laboratory tests by Hilti Corporate Research 331
11.4.3 Working principle of connectors 332
11.4.4 Comparison with international test results 333
11.5 Notations 334
11.6 Reference literature 335
12. Injection mortar Hit HY 150 and HAS rod
with nut or headplate 336
12.1 Terms 336
12.2 Data for the calculation 337
12.3 Minimum steel content for V
ed
338
12.4 Product Information 342
6
314
Connections for concrete overlays
11.1.1 Application range
If a new layer of concrete is applied to existing concrete with
the aim of strengthening or repairing a structure, reference is
made to a composite concrete structure. This overlay is
usually cast directly or placed as shotcrete. It functions to
augment the flexural compression or flexural tension zones,
depending on the placement. Prior to placement of the over-
lay, the surface of the old concrete member is prepared by
suitable means and pre-wetted. Shrinkage of the new con-
crete overlay can be reduced by careful selection of the con-
crete mix. Forces of constraint caused by differential shrin-
kage and, possibly, by differential temperature gradients
cannot be avoided, however. Initially, stresses in the bond in-
terface result from a combination of external loads and inter-
nal forces of constraint. It must be borne in mind that stres-
ses due to shrinkage and temperature gradients in the new
concrete typically reach their maximum at the perimeter
(peeling forces). The combination of external and internal
stresses often exceeds the capacity of the initial bond, thus
requiring the designer to allow for a de-bonded interface.
This is particularly true in the case of bridge overlays which
are subject to fatigue stresses resulting from traffic loads.
Furthermore, these stresses are dependent on time, and bond failure can take place years after overlay
placement. When this happens, the tensile forces set up must be taken up by reinforcement or connectors
positioned across the interface. Typical examples are shown schematically in Figures 1 and 2.
11.1.2 Advantages of the method
Simple and reliable application to a variety of cases
Monolithic structural component behavior assured
Shear forces are reliably transferred even if the interface is cracked
Suitable for use with the most common methods of surface roughening
Reduced requirements for anchor embedment
Repairing a bridge pavement
Removal of damaged concrete layer using high-
pressure water jetting
Anchoring of additional reinforcement using
HIT-HY 150
Installation of shear connectors using HIT-HY 150
Placement of new concrete overlay
Monolithic load-bearing behavior
Reliable transfer of shear
Stiff connection
Reduced anchor embedment
existing
concrete
new concrete
Figure 1: Strengthening a bridge deck
Case A:
new concrete overlay
Case B:
new concrete with
additional tensile reinforcement
Figure 2: Strengthening a building floor
11 Appendix 2
11.1 Concrete overlay connection
315
6
316
Strengthening the floor of an industrial building
Removal of covering and any loose overlay
Roughening of surface by shot-blasting
Installation of connectors using HIT-HY 150
according to the engineer's instructions
Inspection, if necessary, of concrete surface for
roughness and pull-away strength, and of
connectors for pull-out strength
Placement of reinforcement and overlay concrete
Reliable shear transfer; verifiable
Adequate connection stiffness
Small anchorage depth
Strengthening an industrial building foundation
Exposure of foundation
Installation of connectors using HIT-HY 150 per
design specifications (smooth surface)
Reduced labor
Reduced anchor embedment (6 diameters)
Reliable shear transfer
Ductile connection
Repairing and strengthening a pier
Roughening of concrete surface
per design specifications
A stiff connection
Repair and strengthening with shotcrete
Roughening of concrete surface
A stiff connection
Section
Connector
Plane
Beam
Tunel
Additional
reinforcement
Connector
Mesh
317
11.2 Design of interface
11.2.1 Basic considerations
Structures made of reinforced concrete or prestressed concrete which have a concrete overlay at least
40 mm thick ([2], Section 2.5.3.5.8 (109)), or at least 60 mm thick on bridge structures, may be designed
as monolithic building components if shear forces at the interface between the new and the old concre-
te are resisted in accordance with the following rules:
11.2.2 Ultimate limit state for shear transfer at the interface
11.2.2.1 Principle and set-up of the model
Actions at the interface between new and old concrete are determined from the overall forces acting on
the entire building component.
As a rule for the design, it must be assumed that the interface is de-bonded.
Reinforcement or connectors crossing the interface surface must be placed in such a way that shear
forces at the interface are transferred in the ultimate limit state.
As a result of the separation of the interface surfa-
ces, connectors are subjected to a tensile force
and simultaneously to a bending moment depen-
ding on the roughness of the interface surfaces.
If the surfaces are roughened, additional in-
terlocking effects and cohesion can take up part of
the shear force at the interface.
11.2.2.2 Design shear resistance at interface, V
Rd
(1)
Where:
(2)
V
Rd
design shear resistance at interface
V
Sd
design shear force acting at interface as per section 11.2.3
Rdj
design shear strength at interface under consideration as per Formula (3) and Diagrams 1 to 3
b
j
effective width of interface under consideration
l
j
effective length of interface under consideration
Interlock
(friction, cohesion)
Pull-out
(friction)
Dowel
(bending,
shear
force)
V
Rd
>_ V
Sd
V
Rd
=
Rdj
b
j
I
j
6
318
11.2.2.3 Design shear strength at interface,
Rdj
Formula (3) is used to calculate the design shear strength at the interface,
Rdj
[6]. When doing so, an up-
per limit is given by the design strength in the concrete struts:
(3)
Where:
Rd
basic design shear strength of concrete as per [1], Section 4.3.2.3 (the smaller value
of new or old concrete), refer also to Table 2.
k
T
cohesion factor as per Table 1
coefficient of friction as per Table 1
coefficient for effective tensile force in the connector as per Table 1
coefficient for effective dowel action as per Table 1
coefficient for effective concrete strength as per Table 1
efficiency factor as per [1], Formula (4.20); also refer to Table 2.
= A
s
/ b
j
l
j
reinforcing ratio corresponding to connectors of interface under consideration
n
_ < 0,6 f
cd
normal stress certainly acting on interface (positive compression)
f
yd
design value of yield strength of connector
f
cd
design value of cylinder compressive strength of concrete (smaller value of new or old
concrete)
R
t
mean depth of interface roughness, measured according to the sand-patch method [9]
Rdj
= k
T

Rd
+ ( f
yd
+
n
) +
f
yd
f
cd
_ < f
cd
cohesion friction dowel action concrete struts
Concrete surface treatment Mean depth of roughness Coefficients
R
t
mm k
T
f
ck
_ >20 f
ck
_ >35
High-pressure water jets / Scoring > 3.0 2.3 0.5 0.9 0.4 0.8*) 1.0*)
Sandblasting / Chipping hammer > 0.5 0 0.5 1.1 0.3 0.7
Smooth: wood or steel forms or no forms 0 0 1.5 0.2 0.5
Concrete strength class C20/25 C25/30 C30/37 C35/45 C40/50 C45/55 C50/60
f
ck
N/mm
2
20 25 30 35 40 45 50
f
cd
N/mm
2
13.3 16.7 20.0 23.3 26.7 30.0 33.3
0.60 0.58 0.55 0.53 0.50 0.50 0.50
Rd
N/mm
2
0.24 0.26 0.28 0.30 0.31 0.32 0.33
Table 1: Parameters for Formula (3) *) Intermediate values may be linearly interpolated.
Table 2:
Rd
and (as per 1]; Table 4.8).
319
Diagram 1: for surfaces roughened with high-pressure water jets or scored
(mean roughness R
t
> 3 mm, i.e. peaks > approx. 6 mm high)
0
.
4
0
.
5
0
.
6
0
.
7
0
.
8
0
.
9
1
.
0
1
.
1
1
.
2
1
.
3
1
.
4
1
.
5
1
.
6
1
.
7
1
.
8
Reinforcing ratio, % Reinforcing steel, f
yk
= 500 N/mm
2
0
.
0
0
0
.
0
2
0
.
0
4
0
.
0
6
0
.
0
8
0
.
1
0
0
.
1
2
0
.
1
4
0
.
1
6
0
.
1
8
0
.
2
0
0
.
2
2
0
.
2
4
0
.
2
6
0
.
2
8
0
.
3
0
0
.
3
2
0
.
3
4
0
.
3
6
0
.
3
8
0
.
4
0
yk
= 500 N/mm
2
6.8
6.5
6.2
5.9
5.6
5.3
5.0
4.7
4.4
4.1
3.8
3.5
3.2
2.9
2.6
2.3
2.0
1.7
1.4
2.1
2.0
1.9
1.8
1.7
1.6
1.5
1.4
1.3
1.2
1.1
1.0
0.9
0.8
0.7
0.6
0.5
R
d
j
N
/
m
m
2
R
d
j
N
/
m
m
2
6
320
Diagram 2: for sand-blasted surfaces
(mean roughness R
t
> 0.5 mm, i.e. peaks > approx. 1.0 mm high)
C5 0 / 6 0
C4 5 / 5 5
C4 0 / 5 0
C3 5 / 4 5
C3 0 / 3 7
C2 5 / 3 0
C2 0 / 2 5
C5 0 / 6 0
C4 5 / 5 5
C4 0 / 5 0
C3 5 / 4 5
C3 0 / 3 7
C2 5 / 3 0
C2 0 / 2 5
0
.
4
0
.
5
0
.
6
0
.
7
0
.
8
0
.
9
1
.
0
1
.
1
1
.
2
1
.
3
1
.
4
1
.
5
1
.
6
1
.
7
1
.
8
yk
= 500 N/mm
2
0
.
0
0
0
.
0
2
0
.
0
4
0
.
0
6
0
.
0
8
0
.
1
0
0
.
1
2
0
.
1
4
0
.
1
6
0
.
1
8
0
.
2
0
0
.
2
2
0
.
2
4
0
.
2
6
0
.
2
8
0
.
3
0
0
.
3
2
0
.
3
4
0
.
3
6
0
.
3
8
0
.
4
0
yk
= 500 N/mm
2
5.0
4.8
4.6
4.4
4.2
4.0
3.8
3.6
3.4
3.2
3.0
2.8
2.6
2.4
2.2
2.0
1.8
1.6
1.4
1.2
1.0
0.8
1.15
1.10
1.05
1.00
0.95
0.90
0.85
0.80
0.75
0.70
0.65
0.60
0.55
0.50
0.45
0.40
0.35
0.30
0.25
0.20
R
d
j
N
/
m
m
2
R
d
j
N
/
m
m
2

321
Diagram 3: for smooth cast surfaces
(wood forms, steel forms, no forms)
C5 0 / 6 0
C4 5 / 5 5
C4 0 / 5 0
C3 5 / 4 5
C3 0 / 3 7
C2 5 / 3 0
C2 0 / 2 5
C5 0 / 6 0
C4 5 / 5 5
C4 0 / 5 0
C3 5 / 4 5
C3 0 / 3 7
C2 5 / 3 0
C2 0 / 2 5
0
.
4
0
.
5
0
.
6
0
.
7
0
.
8
0
.
9
1
.
0
1
.
1
1
.
2
1
.
3
1
.
4
1
.
5
1
.
6
1
.
7
1
.
8
yk
= 500 N/mm
2
0
.
0
0
0
.
0
2
0
.
0
4
0
.
0
6
0
.
0
8
0
.
1
0
0
.
1
2
0
.
1
4
0
.
1
6
0
.
1
8
0
.
2
0
0
.
2
2
0
.
2
4
0
.
2
6
0
.
2
8
0
.
3
0
0
.
3
2
0
.
3
4
0
.
3
6
0
.
3
8
0
.
4
0
yk
= 500 N/mm
2
3.4
3.2
3.0
2.8
2.6
2.4
2.2
2.0
1.8
1.6
1.4
1.2
1.0
0.8
0.6
0.4
0.75
0.70
0.65
0.60
0.55
0.50
0.45
0.40
0.35
0.30
0.25
0.20
0.15
0.10
0.05
0.00
R
d
j
N
/
m
m
2
R
d
j
N
/
m
m
2
6
322
11.2.3 Design shear force acting longitudinally at interface, V
Sd
Normally, V
Sd
is calculated from the bending resistance of the cross-section. (Shear failure of the mem-
ber should not govern.)
11.2.3.1 Augmentation of compression zone
(4)
0,8 Reduction factor for non-rectangular stress
distribution
= 0,85 Reduction factor for sustained compression
for: x > t
new
as an approximation:
(5)
11.2.3.2 Augmentation of tension zone
(6)
If the reinforcement is staggered: allow for gradation
11.2.3.3 Shear force to be transferred at overlay perimeter
At the edges of a new concrete overlay, the design must consider a minimum tensile force F
cr
. Here,
particular attention must be paid to transferring the moment arising from F
cr
:
(7)
F
cr
tensile force effective in the overlay at the time when the cracks may first be
expected to occur, as per [1], Section 4.4.2.2
k = 0,8 for t
new
_ < 30 cmcoefficient to allow for non-uniform self-equilibrating stresses
f
ct,eff
tensile strength of overlay effective at the time when the cracks may first be
expected to occur as per [1], Section 4.4.2.2 (for general cases: f
ct,eff
= 3 N/mm
2
)
The following values may be used without further verification:
(8)
(9)
V
ed
shear force at interface derived from F
cr
N
ed
tensile force resulting from moment of F
cr
V
ed
may be distributed uniformly over the length l
e
:
a) l
e
= 3 t
new
for rough surfaces
b) l
e
= 6 t
new
for sand-blasted surfaces
c) l
e
= 9 t
new
for smooth surfaces
V
cd
= 0,8 x b
new
f
cd
+ A
se,new
f
yd
V
cd
= t
new
b
new
f
cd
+ A
se,new
f
yd
V
td
= A
se, new
f
yd
F
cr
= t
new
b k f
ct,eff
V
ed
= F
cr
N
ed
=
V
ed
c _ < 1.5 t
new
;
6
x
t
new
A
se, new Overlay
Existing concrete
V
td
t
new
A
s
Overlay
Existing concrete
V
ed
V
ed
N
ed
c
l
e
x
t
new
A
s
A
se, new neutral axis
overlay
existing concrete
V
cd
323
11.2.3.4 Regions without connectors
For low shear stresses, connectors need not be used in the field of the overlay if the load is predomi-
nantly static and if connectors are positioned around the perimeter in accordance with Section 11.2.3.3.
a) With surfaces blasted with a high-pressure water jet and scored surfaces, for
(10)
b) With clean, sand-blasted surfaces, provided that no tensile stresses set up by external forces per-
pendicular to the interface are acting (assuming a non-cracked interface), for:
(11)
11.2.4 Serviceability limit state
As an approximation for normal cases, the additional deformation of a strengthened bending element
may be determined using the monolithic cross-section and then increased as follows:
(12)
w
eff
additional deformation calculated for the reinforced section considering the flexibility of the
connectors
w
calc
additional deformation calculated for the reinforced section assuming perfect bond
factor per Table 3
s
d
displacement of connectors under the mean permanent load (F
P
~
~
0.5 F
uk
)
The displacement, s
d
, per Table 3, can be used for more accurate calculations.
Table 3: Coefficients for calculation of deformation dia. = diameter of connectors
11.2.5 Additional rules and detailing provisions
11.2.5.1 Mixed surface treatments
Variable surface treatments may only be used on the same building component if the different stiffnes-
ses of the connections are taken into account. (See also Table 3, displacement s
d
.) Note that a non-
cracked interface, i.e., rigid bond, is assumed for interfaces with small shear stresses not requiring field
connectors, as per Section 11.2.3.4.
11.2.5.2 Minimum amount of reinforcement at the interface
The following minimum amount of reinforcement passing through the interface must be provided if
connectors cannot be omitted as described in Section 11.2.3.4:
1) Slabs and other structures in which no shear reinforcement is necessary:
a) For rough interface surfaces (high-pressure water jet and scored): _ > 0.08%
b) For sand-blasted interface surfaces _ > 0.12%
c) For smooth interface surfaces: _ > 0.12%
2) Beams and other structures with shear reinforcement as per [1], Section 5.4.2.2
Sd
_ < k
T

Rd
+
n
Sd
_ <
Rd
+
n
w
eff
= w
calc
Surface treatment Mean roughness R
t
mm s
d
mm
High-pressure water jets / Scoring > 3.0 1.0 0.005 dia.
Sand-blasting / Chipping hammer > 0.5 1.1 0.015 dia.
Smooth: wood forms /steel forms/ no forms 1.2 0.030 dia.
6
324
11.2.5.3 Layout of connectors
(1) The connectors must be positioned in the load-bearing direction of the building component with
respect to the distribution of the acting shear force in such a way that both the shear force at the
interface can be taken up and de-bonding of the new concrete overlay is prevented.
(2) In sand-blasted and smooth surfaces, the connectors may be equidistantly positioned over the corre-
sponding length, l
j
, between neighboring critical sections when the load is predominantly static. Accor-
ding to [3], Section 4.1.2 (4), critical sections are points subject to maximum bending moments, support
points, points where concentrated loads are acting and points with sudden changes in cross-section.
(3) If the new concrete overlay is on the tension side of the load-bearing component, the connectors
must be distributed according to the graduation of the longitudinal reinforcement without making
any allowance for anchorage lengths.
(4) The connector spacing in the load-bearing direction may not be larger than 6 times the thickness of
the new concrete overlay, or 800 mm.
11.2.5.4 Anchorage of connectors in the old and the new concrete
(1) The connectors must be adequately embedded in the old concrete and the new overlay. The ac-
tually anchored tensile force, N
d
, may be assumed to be:
(13)
= coefficient as per Table 1.
(2) The type of application is decisive when determining the anchorage depth in the base material:
(2a) Zones with shear reinforcement or other connecting reinforcement (Figure 7):
The basic value of anchorage depth, l
b
, must be determined according to (Appendix 2). The mini-
mum anchorage depth is 10 times the diameter.
It must be borne in mind that this generally concerns an overlap of the connector and existing rein-
forcement (l
s
=
1
l
b
, see [1], Section 5.2.4).
Furthermore, the tensile force from the trussed-frame analogy as per [1], Section 4.3.2.4 must be
verified for building components with required shear reinforcement.
(2b) Zones without shear reinforcement (V
Sd
V
Rd1
) or any other connecting reinforcement (Figure 8):
The anchorage depth must be determined as per (Appendix 2). The edge distances and spacing
(c
1
, s) of adhesive anchors must be ascertained according to anchor design.
Cracks in concrete generally reduce the tensile loading capacity of adhesive anchors. If cracking is
anticipated, the anchorage depth must be increased, e.g., in the case of pure tensile reinforcement
or strengthening for bending with high shear force near beam supports or for concentrated loads.
N
d
>_ A
S
f
yd
I
s
c
1
s
I
b
Figure 7: Rebar fastening design Figure 8: Anchor design
(Appendix 1).
(Appendix 1).
325
(3) Plates, nuts or forged-on heads can be used to reduce the anchorage depth of connectors in a new
concrete overlay. If such a connector is used, the following checks must be made:
a) Concrete cone failure must be checked in accordance with [5], Section 15.1.2.4.
Sufficient reinforcement against splitting must be provided to take up splitting forces set up locally
at the top of the connectors. Calculation of the splitting forces may be based on a truss framework
model which has a line of compressive action at an angle of 45.
Normally, the connectors should extend into the upper reinforcement of the concrete overlay and
form a truss framework node there.
b) The concrete bearing pressure under the head is limited as per [5] Section 15.1.2.3, or [1],
Section 5.4.8.1.
(4) If interface surfaces are smooth, connectors must be provided with an embedment of at least
6 diameters (9 diameters recommended).
11.2.5.5 Minimum reinforcement in overlay
The procedure in [1] must be adopted to determine the minimum amount of reinforcement in the con-
crete overlay.
Beams: [1], Section 5.4.2.1.1 and 5.4.2.4
Slabs: [1], Section 5.4.3.2.1
11.2.5.6 Recommendation for overlay placement
Pre-treatment:
A primer consisting of thick cement mortar is recommended.
The old concrete should be adequately pre-wetted (24 hours earlier the first time) before applying the
cement mortar primer. At the time of placing the primer, the concrete surface should have dried to such
an extent that it has only a dull moist appearance.
The mortar used as primer should consist of water and equal parts by weight of Portland cement and
sand of particle size 0/2 mm. This mortar is then applied to the prepared concrete surface and brushed in.
Overlay:
The concrete mix for the overlay should normally be such that a low-shrinkage concrete results
(W/C 0.40). The overlay must be placed on the still fresh primer i.e. wet on wet.
Curing:
Careful follow-up is necessary to ensure good durability of the overlay. Starting immediately after place-
ment, the concrete overlay must be protected for a sufficiently long period, but at least five days,
against drying out and excessive cooling.
11.2.5.7 Recommendation for surface treatment specification
The roughness of the interface surface has a decisive influence on the shear force that can be transfer-
red. In the case of this design process, the dimension to be measured is the mean depth of roughness,
R
t
, measured according to the sand-patch method [7]. It must be borne in mind that R
t
is a mean value
and thus the difference between the peaks and valleys is about 2R
t
.
It is recommended that a mean depth of roughness, R
t
, be stipulated when specifying the interface sur-
face treatment. Prior to approving the treatment, a sample surface must be made and this then checked
on the basis of the sand-patch method.
6
326
11.3 Examples
11.3.1 Example: Double-span slab
Given:
Concrete: Overlay: 70 mm: C 30/37
Old concrete 150 mm: C 25/30
Reinforcement: S500, f
yk
= 500 N/mm
2
Span: A
se
+
= 1030 mm
2
/m
Support: A
se
= 1420 mm
2
/m
Cracking tensile force at edge (11.2.3.3):
V
ed
= 70 1 0.8 3 = 168 kN/m
Span:
Neutral axis: x
d
=
1030 0.5 1.5
= 33mm
___________________
1.15 30 0.85 0.80
V
cd
= 0.85 0.80 33 30/1.5 = 449 kN/m
Support: A
se
= 1420 mm
2
/m
V
td
= 1420 0,5/1.15 = 617 kN/m
Max. values of shear stress at interface:
cd max
=
449 2
= 0.38 N/mm
2 ______
2360
td max
=
(617 + 449) 2
= 0.58 N/mm
2 _____________
3640
a) Surface treatment: high-pressure water jet
Cohesion
Rdj
= 2.3 0.26 = 0.60 > 0.55 N/mm
2
no reinforcement required
Cracking tensile force V
ed
= 168 kN/m (Section 11.2.3.3); Strip width, l
e
= 3 70 = 210 mm
at edge:
td
=
168000
= 0.8 N/mm
2
From diagram
req
= 0.08%
1000 210
A
s
= 0.0008 210 1000 = 168 mm
2
/m selected dia. 8 s = 250 mm
Tensile force to be
transferred by anchor:
N
d
= 0.5
0.5
50.3 = 10.9 kN (Formula 13)
1.15
Anchored in old l
b
= 100 mm N
Rd
= 14.6 kN (Appendix 2, Table 10.3.5.1)
concrete:
selected: edge distance c
1
= 100 mm N
Rd,red
= 14.6
100
= 11.2 kN ([6] page 13)
130
Anchored in head dia. = 14 mm
overlay: Transferable bearing force under head ([5], Section 15.1.2.3):
N
Rd,p
=
7.5
(14
2
8
2
) 30 = 15 kN > N
Rd
= 11.2 kN OK
1.5 4
Concrete cone capacity: ([5], Section 15.1.2.4)
N
Rd,c
=
9
30
0.5
55
1.5
= 11.2 kN = N
Rd
= 11.2 kN OK
1.8
M
Rd:
Q
d:
d
: For one span
q
d
= 27,5kN/m
2
+ +
-
- -
+
+
6000 6000
-105kNm/m
-100kN/m 76,5kNm/m
65kN/m
2360 3640
2360 3640
6000
d d
0,58N/mm
2
0,55N/mm
2
0,35N/mm
2
0,38N/mm
2
(Appendix 1), Table 10.3.5.1)
327
Tensile force from resisted moment:
N
ed
=
168
= 28.0 kN/m (Formula 9)
____
6
N
Rd
=
11.2
= 44.8 > 28.0 kN/m; c
1
= 100 1.5 70 = 105 mm
OK
_____
0.25
Shear force to be anchored: V
ed
= 168 kN/m: Sirrup-type reinforcement: A
s
=
168 1.15
= 386 mm
2
/m
_________
0.5
Selected: Pins 8 dia. per connector (lap splice with mesh reinforcement
6.5 dia. s = 100 mm)
b) Surface treatment: sand-blasted
Cohesion:
Rdj
= 0.26 N/mm
2
At edge support: mean shear stress at interface
d
=
0.35 + 0.26
= 0.305 N/mm
2
2

From diagram:
req
= 0.12 % Strip width 745 mm
A
s
= 0.0012 1000 745 = 894 mm
2
/m
selected: dia. 8 s = 200/200 mm
At intermediate support: mean shear stress at interface
d
=
0.55 + 0.26
= 0.405 N/mm
2
2

From diagram:
req
A
s
= 0.0016 1000
2
= 1600 mm
2
/m
2
Cracking tensile force at edge: V
ed
= 168 kN/mm
2
Strip width l
e
= 6 70 = 420 mm

d
=
168000
= 0.4 N/mm
2
From diagram:
req
= 0.16 %
1000 420

A
s
= 0.0016 420 1000 = 672 mm
2
/m
Forces to be anchored: same as a)
Bond shear stresses at sand-blasted interface surface:
2360 3640
d
d
0,58N/mm
2
0,55N/mm
2
0,35N/mm
2
0,38N/mm
2
745
0,26N/mm
2
2015
0,26N/mm
2
6
328
Smooth
Connectors at edge
1st row 10 dia. s = 340 mm shear dowel
+ 8 dia. s = 340 headed connector
10 dia. s = 200 / 170 mm shear dowel
Edge strip width: b = 630 mm
10 dia. s = 200/250 mm shear dowel
Strip width: b
tot
= 2360 mm
Intermediate support:
10 dia. s = 200 / 170 mm shear dowel
Strip width: b 2 x 3640 mm
60
100
100
70
150
60
100
100 200 200
60
100
100
60
8 dia s = 250
mesh 6,5 dia. s = 100
pin 8 dia. s = 250
mesh 6,5 dia. s = 100
pin 8 dia.
mesh 6,5 dia. s = 100
pin 8 dia.
8 dia. s=150
8 dia. s=150
8 dia. s=340
+10 dia. s=340
10 dia. s=170
60
High-pressure water jet
Connectors only at edge
8 dia. s = 250 mm headed connector
Sand-blasted
Connectors at edge:
8 dia. s = 200 / 150 mm headed
connector
Edge support:
connector
Strip width: b
tot
= 745 mm
Intermediate support:
connector
Strip width: b 2 x 2015 mm
c) Surface without treatment (smooth)
Edge support/span: Mean shear stress at interface
d
=
0.35
= 0.175 N/mm
2
2

From diagram:
req
A
s
= 0.0015 1000
2
= 1500 mm
2
/m
2
selected dia. 10 s = 200/250 mm
At intermediate support: Mean shear stress at interface
d
=
0.55
= 0.275 N/mm
2
2

From diagram:
req
= 0.23 % half-strip width 3640 mm
A
s
= 0.0023 1000
2
= 2300 mm
2
/m
2
selected dia.10 s = 200/170 mm
Cracking tensile force at edge: V
ed
= 168 kN/mm
2
Strip width l
e
= 9 70 = 630 mm

d
=
168000
= 0.27 N/mm
2
1000 630
From diagram:
req
= 0.23 %

A
s
= 0.0023 630 1000 = 1449 mm
2
/m
selected dia. 10 s = 200/170 mm
Anchorage of dowel: I
b
= (6 times dia.) = 60 mm in new and old concrete
Forces to be anchored: Every second connector in an edge row should be a headed
connector designed as in a)
N
Rd
=
11.2
= 32.9 > N
ed
= 28.0 kN
0.34
Anchoring against de-bonding: It is recommended, that a suitable number of headed
connectors also be installed in appropriate locations to
prevent the concrete overlay from de-bonding locally.
329
11.3.2 Example: Double-span beam with new slab
1200
0,180
0,600
0,200
6000
+ +
-
- -
+ +
6000
-383kNm
-329kN
230kNm
202kN
q
d
+ g
d
= 88,5kN/m
Cross-section:
2280 3720
6000
d=650
1,53N/mm
2
1,10N/mm
2
900
e = 90 e = 300 e = 140
1,30N/mm
2
2,10N/mm
2
2,50N/mm
2
2,06N/mm
2
d=650
1,30N/mm
2
Given:
Concrete: New slab: C 30/37, Beam C 25/30
Reinforcement: Rebar S500; A
se
+
= 804 mm
2
; A
se
-
= 1340 mm
2
f
yk
= 500 N/mm
2
Span: Neutral axis x
d
=
804 0.5 1.5
= 21.4 mm
1.15 0.8 0.85 1.2 30
V
cd
= 1.20 0.8 0.85 21.4
30
= 349 kN
cd
=
349 10
3
2
= 1.53 N/mm
2
1.5 2280 200
Intermediate V
td
= 1340
0.5
= 583 kN
td
=
(349 + 583) 10
3
2
= 2.50 N/mm
2
support:
1.15 3720 200
Edge: Cracking V
ed
= 1.2 180 0.8 3 = 518 kN; l
e
0.75 b = 900 mm
ed
=
518 10
3
= 2.9 N/mm
2
tensile force:
900 200
Minimum reinforcement [1], Table 5.5:
min
= 0.26 %, s
max
= 300 mm
2 dia. 10 s = 300 mm A
s
= 523 mm
2
/m = 0.26 %
Rd
= 1.3 N/mm
2
2 dia. 10 s = 140 mm A
s
= 1121 mm
2
/m = 0.56 %
Rd
= 2.1 N/mm
2
2 dia. 10 s = 90 mm A
s
= 1743 mm
2
/m = 0.87 %
Rd
= 2.9 N/mm
2
Notes:
The anchorage length is determined by the existing stirrup-type reinforcement (lap splice).
The shear stresses at the interface are too high for smooth or sand-blasted surfaces.
High-pressure water jet: Sand-blasted: Smooth:
In this case, un-roughened
interface surfaces cannot be
used. The concrete edge at the
end face would hinder the
necessary displacement of the
connectors.
11.3.3 Example: Foundation reinforcement
Given:
Concrete: Old C 20/25; New: C 25/30
Rebar steel: S500; f
yk
= 500 N/mm
2
Reinforcement existing in foundation:
16 dia. s = 150 A
se
= 1340 mm
2
Neutral axis: x
d
=
1340 500 1.5
= 51 mm
25 0.8 0.85 1000 1.15

V
cd
= 0.8 51 0.85
25
= 579 kN/m
1.5
cd,max
=
579000 2
= 0.66 N/mm
2
1750 1000
1. End-face: Shear force on end-face
V
d
= 280 0.5 = 140 kN/m

d
=
V
d
=
140000
= 0.19 N/mm
2
d b 750 1000
a) High-pressure water jet or scored
Rdj
= 2.3 0.24 = 0.55 >
d
= 0.19 N/mm
2
no connectors required
b) Sand-blasted (special case: the interface has cracked due to the bending moment)
d
= 0.19 N/mm
2
A
s,req
= 486 mm
2
/m (Formula 3) superimposed tensile force from bending
The minimum reinforcement for flexure governs: A
se,min
> A
s,req
+ A
se,req
2. Bending
M
d
= 280 0.5
2
1
/
2
= 35 kNm/m A
se,req
= 163 mm
2
/m
1000 600
Min. reinforcement ([1], Section 4.4.2.2 (3) and Table 4.11) A
se,min
= 0.4 0.8 3 = 1285 mm
2
/m
2 280
selected: dia. 16, s = 150 mm (A
s
= 1340 mm
2
/m) anchorage length, F
d
= 201 280 = 56.3 kN : I
s
= 1.4 285 = 400 mm
3. Topside
a) High-pressure water jet or scored
Cohesion:
Rdj
= 2.3 0.24 = 0.55 >
d
= 0.38 N/mm
2
no connectors required
b) Sand-blasted
d,max
= 0.38 N/mm
2
req
= 0.16 % A
s,req
= 0.0016 1000
2
= 1600 mm
2
/m
2
selected 12 dia. s = 250 mm
Tensile force per connector N
d
= 0.5 113
0.5
= 24.6 kN anchorage length, l
b
= 150 mm
(Appendix 2, Section 10.3.5.1)
1.15
400
100
16 e = 150mm
400
16 e = 150mm
125
4 12 e = 250/250
3000 500 500
4000
700
200
900 100
500
1000 d=750
250
0,38N/mm
2
0,66N/mm
2
Fd = 1120 kN/m
p
d
= 280 kN/m
2
6 6
330
331
11.4. Test results
11.4.1 Transfer of shear across a concrete crack
Review of the literature reveals
little research into the specific
behavior of reinforced bond in-
terfaces between new and old
concrete. The majority of the
existing studies concentrate on
the transfer of shear forces
across cracks.
The effect on the shear loading
capacity of subsequent roug-
hening the surface of the old
concrete was first investigated
in 1960 in the United States.
A few years later, the so-called shear-friction theory was developed. This theory attempts to explain the
phenomena with the aid of a simple saw-tooth model. According to this, the roughness of surfaces in
the case of relative displacement always leads to a widening of the interface which sets up stresses in
steel connectors passing across the interface. They, in turn, create clamping forces across the interface
and thus also frictional forces.
In 1987, Tsoukantas and Tassios [4] presented analytical investigations into the shear resistance of
connections between precast concrete components. They cover the different contributing mechanisms
of friction and dowel action (Figure 9).
11.4.2 Laboratory tests by Hilti Corporate Research
Specific shear tests were carried out in
the laboratories of Hilti Corporate Re-
search in cooperation with the Univer-
sity of Innsbruck (Supervision: Profes-
sor Dr. techn. M. Wicke), to investigate
the interrelationships of various degre-
es of roughness and transferable shear
stresses with various degrees of rein-
forcement.
Using a unique test frame design, it was
possible to avoid secondary eccentric
moments in the specimen and to achie-
ve nearly parallel separation of the inter-
face surfaces (Figure 10). The roughe-
ned surfaces were treated with a de-
bonding agent before the new concrete
was placed.
The results clearly demonstrate that a significant increase in load-bearing capacity can be achieved by
proper roughening of the surfaces. If the surfaces are very rough, the steel connectors across the bond
interface are primarily stressed in tension, whereas, if the surfaces are smooth, the shear resistance of
the connectors (dowel action) predominates.
When interface surfaces are rough and the amount of reinforcement at the interface is small (low shear
stress), cohesion makes a major contribution to transferring the shear force.
The general design concept is presented in the thesis by Randl [6].
Figure 9: Transfer of shear across a concrete crack (shear-friction model)
Figure 10: Shear tests
Interlock
(friction, cohesion)
Pull-out
(friction)
Dowel
(bending, shear force)
6
332
11.4.3 Working principle of connectors
The test results confirm the strong
influence of roughness on shear
resistance and shear stiffness.
If the load-displacement curves
are regarded in conjunction with
the measured displacement, the
three components of cohesion,
friction and dowel action can be
isolated and determined quantita-
tively. They make different contri-
butions to the overall resistance
(Figures 11, 12 and 13), depen-
ding on surface roughness and
amount of reinforcement.
Hence, the frictional component
predominates when the surface is
blasted with a high-pressure wa-
ter jet and larger amounts of rein-
forcement are provided. But small
shear stresses can also be trans-
ferred even when no reinforce-
ment is present, due to the good
interlocking effect of the interface
surfaces. In the case of sand-bla-
sted surfaces, however, shear
stresses are transferred by a com-
bination of friction and dowel ac-
tion, but the forces that can be re-
sisted are generally far smaller
than in the case of high-pressure
water blasting.
Investigations were also conduc-
ted as to whether the post-instal-
led rebar connectors are stressed
to yield at ultimate shear transfer.
For this purpose, the strain in the
connectors at the level of the in-
terface was measured. To avoid
any disturbance of the bond, and
in order to obtain the strain due to
tensile loading only, the strain
gauges were fitted in a central
bore along the longitudinal axis of
the connectors.
These test results clearly show
that, when surfaces have the
above-mentioned degrees of
roughness, the tensile force in
the connectors has not reached
the full connector tensile yield
strength, contrary to assumpti-
Versuch Nr. 1 8 ( HDW-gest rahlt ; 2 12)
D belwir kung
0
2 0
4 0
6 0
8 0
1 0 0
1 2 0
1 4 0
1 6 0
1 8 0
2 0 0
0 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8
horizont ale Verschiebung [ mm]
S
c
h
e
r
k
r
a
f
t

[
k
N
]
Verzahnung und Reibung
Versuch Nr. 4 0 ( sandgest rahlt ; 2 12)
D belwir kung
0
2 0
4 0
6 0
8 0
1 0 0
1 2 0
1 4 0
1 6 0
1 8 0
2 0 0
0 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8
S
c
h
e
r
k
r
a
f
t

[
k
N
]
Versuch NR. 5 7 ( schalglat t ; 2 12)
D belwir kung
0
2 0
4 0
6 0
8 0
1 0 0
1 2 0
1 4 0
1 6 0
1 8 0
2 0 0
0 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8
S
c
h
e
r
k
r
a
f
t

[
k
N
]
Figure 11: Test example for water-blasted surface
Horizonal displacement [mm]
S
h
e
a
r

f
o
r
c
e

[
k
N
]
S
h
e
a
r

f
o
r
c
e

[
k
N
]
S
h
e
a
r

f
o
r
c
e

[
k
N
]
Figure 12: Test example for sand-blasted surface
Figure 13: Test example for smooth surface
friction
dowel action
dowel action
dowel action
friction and surface interlock
Test No. 18 (water-blasted; 2 dia. 12)
Test No. 40 (sand-blasted; 2 dia. 12)
Test No. 57 (formed surface; 2 dia. 12)
333
ons for other design models.
Tests carried out with connectors
of various lengths confirm this re-
sult, as they showed that redu-
ced anchorage lengths are suffi-
cient to carry the effective
connector tensile force at maxi-
mum shear transfer capacity. Ad-
ditional connector embedment
(e. g., as required for theoretical
connector tensile yield) did not
result in increased shear transfer.
The load-bearing behavior of
smooth interface surfaces with
connectors was also investiga-
ted. As displacement readings
for the horizontal and vertical di-
rections showed, there is in this
case also a separation of the in-
terface under shear loading and,
thus, owing to the lack of roughn-
ess, a loss of contact between
the shear surfaces. In this case,
the entire resistance is provided
by dowel action.
On the basis of these findings,
design approaches are develo-
ped which permit separate and
realistic analyses of the various
components of shear resistance.
As a result, a standardized level
of safety is ensured with respect
to resistance, regardless of
whether the normal stresses at
the interface are induced by an
externally applied normal force or
by internal connectors.
11.4.4 Comparison with inter-
national test results
In his thesis [6], Randl has proven
through a study of literature and
with reference to world-wide re-
search results that the determi-
ned design equations are conser-
vative. The results are shown in
Figures 14, 15 and 16.
Mat t ock, Walraven, Daschner, Hilt i
0 , 0
1 , 0
2 , 0
3 , 0
4 , 0
5 , 0
6 , 0
7 , 0
8 , 0
9 , 0
1 0 , 0
1 1 , 0
1 2 , 0
0 , 0 1 , 0 2 , 0 3 , 0 4 , 0 5 , 0 6 , 0 7 , 0 8 , 0 9 , 0 1 0 , 0 1 1 , 0 1 2 , 0
f
y
[ N/ mm ]

[
N
/
m
m
]
Figure 14: Shear tests, rough interface
0 , 0
0 , 5
1 , 0
1 , 5
2 , 0
2 , 5
3 , 0
3 , 5
4 , 0
4 , 5
5 , 0
5 , 5
0 , 0 1 , 0 2 , 0 3 , 0 4 , 0 5 , 0 6 , 0 7 , 0 8 , 0 9 , 0 1 0 , 0 1 1 , 0 1 2 , 0
f
y
[ N/ mm ]
[
N
/
m
m
]
Figure 15: Shear tests, sand-blasted interface
Daschner,Mat t ock,Paulay,Hanson, Hilt i
0 , 0
0 , 5
1 , 0
1 , 5
2 , 0
2 , 5
3 , 0
3 , 5
4 , 0
4 , 5
5 , 0
5 , 5
0 , 0 1 , 0 2 , 0 3 , 0 4 , 0 5 , 0 6 , 0 7 , 0 8 , 0 9 , 0 1 0 , 0 1 1 , 0 1 2 , 0
f
y
[ N/ mm ]
[
N
/
m
m
]
Figure 16: Shear tests, smooth interface
Mattock: rough ACI
(r = 3 mm); f
y
= 350 N/mm
2
,
f
c
= 20 45 N/mm
2
Walraven: cracked concrete;
f
y
= 450 N/mm
2
,
f
c
= 25 32 N/mm
2
Daschner: raked surface;
f
y
= 540 N/mm
2
,
f
c
= 15 N/mm
2
Hilti: water-blasted;
f
y
= 508 N/mm
2
;
f
c
= 18 N/mm
2
Hilti: water blasted;
f
y
= 508 653 N/mm
2
;
f
c
= 36 N/mm
2
Design function (charact. values):
water-blasted; f
ck
= 30 N/mm
2
,
f
yk
= 500 N/mm
2
Design function (charact. values):
water-blasted; f
ck
= 20 N/mm
2
,
f
yk
= 500 N/mm
2
Hi: sand-blasted;
f
y
= 508 N/mm
2
;
f
c
= 18 N/mm
2
;
Ib = 17dia.
Hi: sand-blasted;
f
y
= 508 653 N/mm
2
,
f
c
= 35 N/mm
2
;
I
b
> 8 dia.
Design function (charact.
values): sand-blasted;
f
ck
= 20 N/mm
2
,
f
yk
= 500 N/mm
2
values): sand-blasted;
f
ck
= 20 N/mm
2
,
f
yk
= 500 N/mm
2
Daschner: trowel;
f
y
= 450 1200 N/mm
2
,
f
cw
= 15 22 N/mm
2
Daschner: un worked surface;
f
y
= 450 1200 N/mm
2
,
f
c
= 10 17 N/mm
2
Mattock: trowel;
f
y
= 350 N/mm
2
,
f
c
= 35 N/mm
2
Paulay: trowel;
f
y
= 318 N/mm
2
,
f
c
= 24 N/mm
2
Hanson: trowel;
f
y
= 345 N/mm
2
,
f
c
= 22 29 N/mm
2
Hilti [8]: unworked surface;
f
y
= 508 653 N/mm
2
,
f
c
= 33 N/mm
2
f
y
= 508 653 N/mm
2
,
f
c
= 40 N/mm
2
f
y
= 508 653 N/mm
2
,
f
c
= 17 N/mm
2
values) [8]: smooth
f
ck
= 20 N/mm
2
,
f
yk
= 500 N/mm
2
Hilti tests
Mattlock, Walraven, Daschner, Hilti
Mattlock, Walraven, Daschner, Hilti
2
2
2
2
2
2
6
334
11.5 Notations
Lengths:
b
j
effective width of interface in the area under consideration
c
1
anchor edge distance
l
b
anchorage depth of connector in base material as per Appendix 1
l
s
splice length of reinforcement, as per [1], Section 5.2.4
l
e
length over which tensile cracking force is introduced
l
j
effective length of interface under consideration
R
t
mean depth of interface roughness, measured according to the san-patch method
s spacing of connectors or rebar
s
d
displacement of connectors under the mean of permanent load (F
p
0.5 F
uk
)
t
new
thickness of concrete overlay
w
eff
additional deformation calculated for the reinforced section considering the flexibility of the
connectors
w
calc
additional deformation calculated for the reinforced section assuming perfect bond
x distance of neutral axis from compressed edge (bending)
Areas:
A
s
cross-sectional area of interface reinforcement (connectors)
A
se
cross-sectional area of bending reinforcement
Forces:
F
cr
tensile force, effective in the overlay at the time when the cracks may first be expected to occur, as
per [1], Section 4.4.2.2
N
d
design value of tensile force in connector
N
ed
tensile force resulting from moment of F
cr
V
Rd
design shear resistance at interface
V
sd
design shear force acting at interface
V
ed
shear force at interface derived from Fcr
V
cd
design shear force acting at interface in compression zone
V
td
design shear force acting at interface in tension zone
Stresses:
f
cd
design value of cylinder compressive strength of concrete
f
yd
design value of yield strength of connector
f
ct,eff
tensile strength of overlay effective at the time when the cracks may first be
expected to occur, as per [1], Section 4.4.2.2
n
normal stress (positive compression) certainly acting at interface
Rd
basic design shear strength of concrete as per [1], Section 4.3.2.3
Tdj
design shear strength at interface under consideration
Factors and coefficients:
k Coefficient to allow for non-uniform self-equilibrating stresses
k
T
cohesion factor as per Table 1
coefficient for effective dowel action as per Table 1
coefficient for effective concrete strength as per Table 1
Increasing factor for deformation as per Table 3
coefficient of friction as per Table 1
efficiency factor as per [1], Formula (4.20); also refer to Table 2
coefficient for effective tensile force in the connector as per Table 1
= A
s
/b
j
l
j
reinforcing ratio corresponding to connectors at interface under consideration
335
11.6 Reference literature
[1] EC2; Design of concrete structures: ENV 1992-1-1:1991;
Part 1. General rules and rules for buildings
[2] EC2; Design of concrete structures: ENV 1992-1-3:12/94
Part 1-3. General rules-Precast concrete elements and structures
[3] EC4; Design of composite steel and concrete structures: ENV 1994-1-1:1992;
Part 1-1. General rules and rules for buildings
[4] Tsoukantas S. G., Tassios T.P.; Shear Resistance of Connections between
Reinforced Concrete Linear Precast Elements. ACI Journal, May-June 1989.
[5] CEB-Guide; Design of Fastenings in Concrete, Part III, January 1997
Characteristic Resistance of Fastenings with Cast-in-Place Headed Anchors.
[6] Randl, N, Untersuchungen zur Kraftbertragung zwischen Neu- und Altbeton bei unterschiedli-
chen Fugenrauhigkeiten; Dissertation in Vorbereitung, Universitt Innsbruck
(Investigation into the transfer of forces between new concrete and old concrete with different
interface surface roughnesses); thesis being prepared, University of Inssbruck, Austria.
[7] Kaufmann, N: Sandflchenverfahren (Sand-patch method), Strassenbautechnik 24, (1971,
Germany), no. 3, pages 131-135
Connection for concrete overlays
336
12. Injection mortar HIT HY 150
and HAS rod 5.8 with nut or headplate
Features :
- Base material: concrete, concrete overlays
- No splitting forces in the base material
- Easy handling, injection
- Adjustable anchor head
- plate can be used as rebar holder
Material:
Anchor rod: HAS: 5.8, ISO 898 T1, galvanised to 5 microns
Anchor plate: FeE 235, galvanised to 5 microns
Foil pack : Hilti HIT HY 150: standard size 330 ml
Hilti HIT HY 150: jumbo cartridge 1100 ml
Dispenser: MD 2000, P 5000 HY.
A4
316
Corrosion resistance
(by request)
HCR
highMo
Special Corrosion
resistance
(by request)
Close edge distance /
spacing
N
s
c
h
12.1 Terms:
a) with nut b) with plate
Note: Nut and plate have to be marked after adjusting!
h
u
anchoring depth in existing concrete h
o
height in the concrete overlay h
ef
actual anchorage depth
c
cover d
0
drill bit diameter l anchor length
m height of the nut axb lenght x width of the plate t
p
thickness of the plate
t
new
thickness of the concrete overlay
concrete
overlay
existing
concrete
c
m
h
o
h
o
h
ef
h
ef
d
0
h
u
a x b
t
p
l
d
0
c
h
u
l
existing
concrete
concrete
overlay
t
new
t
new
6
337
12.2 Data for the calculation
Calculation details (cp. also [1], page 294 to 298):
1. Bond stress t
Sd
is calculated using the available area in the connection.
2. The necessary reinforcement content can be obtained from Diagram 1, 2 and 3, the t
Rd
> t
Sd
must
be satisfied.
3. Minimum steel content is given in section 12.3.
4. Anchor rod choice should be compared to the existing geometrical conditions.
5. Calculate number of rods
s
j j
A
b l
n

= , control edge distances and spacings c
min
, resp. s
min
1)
f
yd
= f
yk
/
Ms
,
Ms
= 1.2, cp. [2], equation. (6a)]
2)
N A f
d ds yd
= k , cp. [1], section 11.2.5.4, equation (13) for rough and sandblasted surfaces
3)
Cp. [1], page 195 - 203 (Valid for rough, clean, hammer or with compressed air drilled holes)
Cp. [1]. section 11.2.5.4 (2b): Cracks in in concrete reduce the capacity of rebar. In these cases a longer embedment lenght must be
used. (e.g. for overlays or under tensile or bending loading with high shear component in the vicinity of the beam connection or of the
acting loads).
4)
N
k
f h
Rd c
Mc
ck ef ,
. .
=
1 0 5 15
; k
1
= 9.0;
Mc
= 1.8, cp. [2], section 15.1.2.4
5)
N
Rd,c
experimental (internal report A-IF-2/98)
6)
For 16 mm and 32 mm aggregate diameter in concrete: h
0,min
= 50 mm
[1] Hilti Fastening Technology Manual
[2] Design of fastenings in concrete, CEB Bulltin 233, January 1997
HAS 5.8 M8 M10 M12 M16 M20
d
0
[mm] Drill bit diameter 10 12 14 18 22
A
s
[mm] Stressed cross-sectional area of the
slot
32.8 52.3 76.2 144 225
s
w
x m [mm] nut 13 x 6.5 17 x 8 19 x 10 24 x 13 30 x16
a x b x t
p
[mm] Anchor plate 35 x 28 x
6.5
33 x 23 x
6.5
40 x 40 x 6 40x40x8 -
Material properties
f
uk
[N/mm] Nominal tensile strength 500 500 500 500 500
f
yk
[N/mm] Nominal yield strength yield strength 400 400 400 400 400
1)
f
yd
[N/mm] Design value of the 333 333 333 333 333
2)
N
d
[kN] Design value of the tensile force 5.5 8.7 12.7 24.0 37.5
3)
Embedment in the in the existing concrete (HIT-HY 150)
h
u,min
[mm] B 30/20 C 20/25 80 95 110 185 240
> B 35/25 > C 25/30 80 90 110 180 230
c
min
[mm] Min. edge distance 80 90 110 125 170
s
min
[mm] Min. spacing 120 135 165 190 255
4)
Minimum embedment in overlay concrete using a nut type head
h
o,min
[mm] B 30/20 C 20/25 45 60 75 110 150
B 35/25 C 25/30 45 55 70 105 140
B 45/35 C 30/37 45 50 65 100 130
B 50/40 C 35/45 45 50 65 95 125
> B 55/45 > C 40/50 45 50 60 95 120
c
min
[mm] Min. edge distance 55 70 90 135 185
s
min
[mm] Min. spacing 110 140 180 270 370
5)
Minimum embedment in overlay concrete using a plate type head
h
o,min
[mm] B 30/20 C 20/25
6)
40 50 60 100
> B 35/25 C 25/30
6)
35
6)
45 55 95
c
min
[mm] Min. edge distance 55 70 90 135
s
min
[mm] Min. spacing 110 140 180 270
338
Exampel: hd-high pressure water cleaning, B35/25 (C25/30)
t
neu
[mm] 60 70 80 90 100 130 150 180 200 250
V
ed
[kN] 144 168 192 216 240 312 360 432 480 600
N
ed
[kN] 24 28 32 36 40 52 60 72 80 100
l
e
[mm] 180 210 240 270 300 390 450 540 600 750
ed
[N/mm
2
] 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8
1
)A
s,erf
[mm
2
] 180 210 240 270 300 390 450 540 600 750
Nut
n
erf
HAS 5.5 M8 6.4 M8 4.6M10 3.5M12 3.9M12 2.7M16 3.1M16 2.4M20 2.7M20 3.3M20
N
Rd
kN 6.7 6.7 8.8 13.3 13.3 24.0 24.0 37.5 37.5 37.5
c
,
max
[mm] 15 25 25 20 30 25 45 40
2
)60
2
)110
h
o,min
[mm] 45 45 55 70 70 105 105 140 140 140
h
u,min
[mm] 80 80 90 110 110 180 180 230 230 230
c
min
[mm] 80 80 90 110 110 135 135 185 185 185
s
1
[mm] 180 150 210 280 250 370 320 410 370 600
s
2
[mm] - - - - - - - - - 370
Anchor plate
n
erf
HAS 5.5M8 6.4M8 4.6M10 3.5M12 3.9M12
c
,
max
[mm] 25 35 35 35 45
1
)
erf
= 0.10% (cp. diagram 1)
h
o,min
[mm]
3
)35
3
)35
3
)45 55 55
2
) head of shear connector and reinforcement
h
u,min
[mm] 80 80 90 110 110 must ensure a good load distribution.
c
min
[mm] 80 80 90 110 110
3
) concrete with max 16 mm aggregate size
s
1
[mm] 180 150 210 280 250
s
2
[mm] - - - - -
Example: sandblasted B35/25 (C25/30)
t
neu
[mm] 60 70 80 90 100 130 150 180 200 250
V
ed
[kN] 144 168 192 216 240 312 360 432 480 600
N
ed
[kN] 24 28 32 36 40 52 60 72 80 100
l
e
[mm] 360 420 480 540 600 780 900 1080 1200 1500
ed
[N/mm
2
] 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4
1
)A
s,erf
[mm
2
/m] 720 840 960 1080 1200 1740 1800 2160 2400 3000
nut
Anzahl
erf
HAS 22 M8 26 M8 18 M10 15 M12 16 M12 23 M12 24 M12 15 M16 17 M16 21 M16
N
Rd
kN 6.7 6.7 8.8 13.3 13.3 13.3 13.3 24.0 24.0 24.0
c
,
max
[mm] 15 25 25 20 30
2
)60
2
)80
2
)75
2
)95
2
)145
h
o,min
[mm] 45 45 55 70 70 70 70 105 105 105
h
u,min
[mm] 80 80 90 110 110 110 110 180 180 180
c
min
[mm] 80 80 90 110 110 110 110 135 135 135
s
1
[mm] 140 120 160 200 190 180 200 270 300 290
s
2
[mm] 2x120 2x120 2x150 2x180 2x200 3x200 4x180 3x270 4x270 5x270
Nnchor plate
n
erf
HAS 22 M8 16 M10 18 M10 15 M12 16 M12
1
)
erf
= 0.20% (cp. diagram 2)
c
,
max
[mm] 25 25 35 35 45
2
) head of shear connector and reinforcement
h
o,min
[mm]
3
)35
3
)45 45 55 55 must ensure a good load distribution.
h
u,min
[mm] 80 90 90 110 110
3
) concrete with max 16 mm aggregate size
c
min
[mm] 80 90 90 110 110
s
1
[mm] 140 180 160 200 190
s
2
[mm] 2x120 2x140 2x150 2x180 2x200
12.3 Minimum steel content for V
ed
A Anchoring of V
ed
in the overlay should contain additional safety elements, such as stirrups.
t
new
thickness of the overlay concrete
ef ctk, new cr ed
f k b t F V (vgl. [1], section. 11.2.3.3, (7))
N
V
ed
ed
6
(vgl. [1], section. 11.2.3.3, (9))
c
,max
max . possible conrete cover (cp. page 304)
l
e
length over which tensile force is introduced equation
[1], section 11.2.3.3
A
s,erf
necessary steel area of the rebar
n
erf
number of bond anchors necessary per meter
N
Rd
necessary steel area of the rebars (cp. [1] page 195)
c edge distance
s
1
rebar spacing prallel to the edge
s
2
spacing of rebar rows
t
new
l
e
c
s
2
V
ed
N
ed
c
6
339
Diagram 1: for surfaces roughened with high pressure water jets or scored
(mean roughness R
t
> 3 mm, i.e. peaks > approx. 6 mm high)
0.5
0.6
0.7
0.8
0.9
1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
0
.
0
0
0
.
0
2
0
.
0
4
0
.
0
6
0
.
0
8
0
.
1
0
0
.
1
2
0
.
1
4
0
.
1
6
0
.
1
8
0
.
2
0
0
.
2
2
0
.
2
4
0
.
2
6
0
.
2
8
0
.
3
0
0
.
3
2
0
.
3
4
0
.
3
6
0
.
3
8
0
.
4
0
Reinforcing ratio [%] HAS 5.8 fyk = 400 N/mm
2
fyd = 333 N/mm
2
R
d
j

[
N
/
m
m
2
]
B55/45 (C40/50)
B50/40 (C35/45)
B45/35 (C30/37)
B35/25 (C25/30)
B30/20 (C20/25)
1.2
1.4
1.6
1.8
2.0
2.2
2.4
2.6
2.8
3.0
3.2
3.4
3.6
3.8
4.0
4.2
4.4
4.6
4.8
5.0
5.2
0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8
2
fyd = 333 N/mm
2
R
d
j

[
N
/
m
m
2
]
B55/45 (C40/50)
B50/40 (C35/45)
B45/35 (C30/37)
B35/25 (C25/30)
B30/20 (C20/20)
recommended
reinforcement content
(minimum)
340
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
2.6
2.8
3.0
3.2
3.4
3.6
3.8
4.0
0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8
Reinforcing ratio [%] HAS 5.8 f yk = 400 N/mm
2
fyd = 333 N/mm
2
R
d
j

[
N
/
m
m
2
]
B55/45 (C40/50)
B50/40 (C35/45)
B45/35 (C30/37)
B35/25 (C25/30)
B30/20 (C20/25)
Diagram 2: for sand-blasted surfaces
(mean roughness R
t
> 0.5 mm, i.e.peaks > approx. 1.0 mm high)
0.20
0.25
0.30
0.35
0.40
0.45
0.50
0.55
0.60
0.65
0.70
0.75
0.80
0.85
0.90
0
.
0
0
0
.
0
2
0
.
0
4
0
.
0
6
0
.
0
8
0
.
1
0
0
.
1
2
0
.
1
4
0
.
1
6
0
.
1
8
0
.
2
0
0
.
2
2
0
.
2
4
0
.
2
6
0
.
2
8
0
.
3
0
0
.
3
2
0
.
3
4
0
.
3
6
0
.
3
8
0
.
4
0
2
fyd = 333 N/mm
2
R
d
j

[
N
/
m
m
2
]
B55/45 (C40/50)
B50/40 (C35/45)
B45/35 (C30/37)
B35/25 (C25/30)
B30/20 (C20/25)
Recommended
reinforcement content
(minimum)
6
341
Diagram 3: for smooth cast surfaces
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0.45
0.50
0.55
0.60
0
.
0
0
0
.
0
2
0
.
0
4
0
.
0
6
0
.
0
8
0
.
1
0
0
.
1
2
0
.
1
4
0
.
1
6
0
.
1
8
0
.
2
0
0
.
2
2
0
.
2
4
0
.
2
6
0
.
2
8
0
.
3
0
0
.
3
2
0
.
3
4
0
.
3
6
0
.
3
8
0
.
4
0
B55/45 (C40/50)
B50/40 (C35/45)
B45/35 (C30/37)
B35/25 (C25/30)
B30/20 (C20/25)
Reinforcing ratio
[%] HAS 5.8 f
yk
= 400 N/mm
2
f
yd
= 333 N/mm
2
R
d
j

[

N
/
m
m
2
]
Recommended
reinforcement
content (minimum)
0.4
0.5
0.6
0.7
0.8
0.9
1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2.0
2.1
2.2
2.3
2.4
2.5
2.6
0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8
Reinforcing ratio
[%] HAS 5.8 f
yk
= 400 N/mm
2
f
yd
= 333 N/mm
2
R
d
j

[
N
/
m
m
2
]
B55/45 (C40/50)
B50/40 (C35/45)
B45/35 (C30/37)
B35/25 (C25/30)
B30/20 (C20/25)

342
12.4 Product Information
Hilti HIT-HY 150 for concrete
Foil pack HY 150
330ml 1100ml
Setting details
Drill hole. Brush. Blow out. Inject mortar. Insert rod. Wait for curing. Pave over.
HAS rod galvanised Anchor plate galvanised
Steel, grade 5.8 Fe E 235 (St 37)

Ordering Designation Ordering Designation
HAS M8x110 HAS M16x190 SR-SMA SR-SMA-L
HAS M8x150 HAS M16x260
HAS M16x300 Ordering D. a b Tp Thread Size
HAS M10x130 HAS M16x350 mm mm mm
HAS M10x190 SR-SMA 8 35 28 6.5 M8
HAS M20x240 SR-SMA 10 33 23 6.5 M10
HAS M12x160 HAS M20x260 SR-SMA 12* 40 40 6 M12
HAS M12x220 HAS M20x300 SR-SMA 16* 40 40 8 M16
HAS M12x300 HAS M20x400 SR-SMA-L 12* 60 30 6 M12
Other lenghth and steel qualities are possible Other lenghth and steel qualities are possible
Text of tender offer
Providing and setting of injection anchors consisting of :
Injection mortar Hilti HIT-HY 150 with HAS rod, steel, grade 5.8, M ..... x length ..... mm with anchor plate
SR-SMA M .... x length ...... mm x width ...... mm x thickness ...... mm.
Drilling and cleaning of the borehole ..... mm, Tiefe .......mm according to the directions of the supplier
As well as the hight adjustment of the plate, cutting of the overlong rebars and marking .
b
Tp
a
b
6

Appendix 2 Concrete Overlays

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6

Connections for concrete overlays

Connection for concrete overlays

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