methods Bautechnisches Prüfamt General building approval

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General building approval Approval number: Z-21.8-1995 Applicant: DeWalt Black & Decker Straße 40 65510 Idstein DIBt | Kolonnenstraße 30 B| D-10829 Berlin | Tel.: +49 30 78730-0 | Fax: +49 30 78730-320 | E-Mail: [email protected] | www.dibt.de The subject of approval stated above is hereby granted a general building approval. This general building approval encompasses seven pages and eight annexes. This general building approval replaces general building approval No. Z-21.8-1995, dated June 4th 2013. This subject has rst received a general building approval on June 4th 2013. Subject of approval: Post-installed rebar connection using the DeWalt AC100-PRO Injection System Approving authority for construction products and building methods Bautechnisches Prüfamt A public institution sustained by both the federal government and the provincial governments of the FRG Member of the EOTA, the UEAtc and the WFTAO Date: File number: 09/13/2013 I 26.1-1.21.8-91/13 Period of validity from: September 13th 2013 to: June 4th 2018 English language translation, the original version is in German language

Transcript of methods Bautechnisches Prüfamt General building approval

Page 1: methods Bautechnisches Prüfamt General building approval

General building approval

Approval number:Z-21.8-1995

Applicant:DeWaltBlack & Decker Straße 4065510 Idstein

DIBt | Kolonnenstraße 30 B| D-10829 Berlin | Tel.: +49 30 78730-0 | Fax: +49 30 78730-320 | E-Mail: [email protected] | www.dibt.de

The subject of approval stated above is hereby granted a general building approval.This general building approval encompasses seven pages and eight annexes.This general building approval replaces general building approval No.Z-21.8-1995, dated June 4th 2013. This subject has fi rst received a general building approval on June 4th 2013.

Subject of approval:Post-installed rebar connection using the DeWalt AC100-PRO Injection System

Approving authority for construction products and building methodsBautechnisches PrüfamtA public institution sustained by both the federal government and the provincial governments of the FRGMember of the EOTA, the UEAtc and the WFTAO

Date: File number:

09/13/2013 I 26.1-1.21.8-91/13

Period of validityfrom: September 13th 2013to: June 4th 2018

English language translation, the original version is in German language

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Z74444.13 1.21.8-91/13

General building approvalNo. Z-21.8-1995 Page 2 of 7 I September 13th 2013

I GENERAL PROVISIONS

1 The general building approval certifi es the usability or applicability of the subject of approval in the sense of the State Building Regulations (Landesbauordnungen).

2 If the general building approval requires special expertise and experience of the persons involved with the production of construction products and building methods in accordance with the respective state regulations listed in § 17, paragraph 5 of the „Musterbauordnung“, it has to be ensured that this special expertise and experience can be verifi ed by equivalent certifi cates issued by other member states of the European Union. This might possibly also apply to equivalent certifi cates issued within the framework of the Agreement on the European Economic Area (EEA) or other bilateral agreements.

3 The general building approval does not replace the approvals, permits and certifi cates necessary for the execution of construction projects.

4 The general building approval is issued without prejudice to the rights of third parties, especially private property rights.

5 Producers and distributors of the approval subject have to make copies of the general building approval available to the user of the approval subject and to inform him about the requirement to have the general building approval present at the application site, all this notwithstanding further regulations stated in the „Special Provisions“. Upon request, the involved authorities have to be provided with copies of the general building approval.

6 The general building approval may only be copied or reproduced in full. The publication of extracts requires the approval of the German Institute of Construction Engineering (Deutsches Institut für Bautechnik). Texts and drawings of promotional material may not contradict the general building approval. Translations of the general building approval have to contain a reference stating that it is a „Translation from the German source not approved by the Deutsche Institut für Bautechnik“.

7 The general building approval is revocable. The provisions of the general building approval may be subsequently complemented and changed, especially if new technical knowledge requires this.

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General building approvalNo. Z-21.8-1995 Page 3 of 7 I September 13th 2013

II SPECIAL PROVISIONS

1 Subject of approval and application area

1.1 Subject of approval The application of the post-installed rebar connection using the DeWalt AC100-PRO

Injection System in accordance with European technical approval ETA-13/0316.

1.2 Application area The rebar connection may be used in normal concrete of a minimum strength class

of C12/15 and a maximum of C50/60 in accordance with DIN EN 206-1:2001-7 ; it may also be used in concrete from a minimum of B 15 to a maximum of B 55 in accordance with DIN 1045:1988-07.

The rebar connection may be used in non-carbonated concrete with a permissible chloride content of 0.40 % (CL 0.40) with regard to the concrete content in accordance with DIN EN 206-1.

Rebar connections with B500 B reinforcing bars may only be used for static and quasi-static loads.

They may be used for anchorings with fi re resistance requirements. Only rebar connections that would also be possible with straight reinforcing bars encased

in concrete may be implemented, such as in the following applications (see annex 1): - Overlapping joint with a reinforcement already existing in the component (images

1 and 2), - Anchoring of the reinforcement at a slab or beam support (for example in accordance

with image 3: End bearing on a plate that was calculated as pin ended as well as an appropriate general reinforcement for restraint forces),

- Anchoring of reinforcement of building components stressed primarily in compression (image 4),

- Anchoring of reinforcement to cover the envelope line of tensile force in the bending member (image 5).

The post-installed rebar connections may be used in the temperature range of -40 °C to +80°C (max short term temperature +80°C and max long term temperature +50 °C).

This approval covers anchoring in bore holes made by hammer drilling or pneumatic drilling.

The post-installed rebar connection may be installed in dry or wet concrete, however, it must not be installed in holes fl ooded with water.

2 Provisions concerning the construction product

2.1 Properties and composition The DeWalt AC100-PRO Injection System and the used reinforcing steel have to comply

with the provisions of ETA-13/0316.

2.2 Packaging, storage and labelling Packaging, storage and labelling of the DeWalt AC100-PRO Injection System have

to comply with ETA-13/0316.

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3 Provisions concerning design and dimensioning

3.1 General Rebar connections must be designed in keeping with good engineering practice.

Considering the loads to be anchored, verifi able design calculations and design drawings must be produced.

The dimensioning of the rebar connection with B500 B reinforcing steel shall be based on DIN 1045-1:2008-08 and section 3.2 of this general building approval or on DIN EN 1992-1-1:2011-01 with DIN EN 1992-1-1/NA:2011-01 and in accordance with ETA-13/0316, section 4.1.

Section 3.3 has to be observed for components subject to fi re protection requirements. In addition, the type, arrangement and fastening of possibly required fi re protection clothes in accordance with section 3.3 has to be indicated.

3.2 Dimensioning in accordance with DIN 1045-1:2008-083.2.1 General The actual position of the reinforcement in the existing component shall be determined

on the basis of the construction documentation and taken into account during the design phase.

The dimensioning of the post-installed rebar connections according to annex 1 and the determination of the internal cutting forces to be transferred in the construction joint depend on DIN 1045-1:2008-08. When ascertaining the tensile force in the rebar, the statically effective height of the bonded-in reinforcement shall be taken into account.

The immediate local force transfer to the concrete has been verifi ed. The transferring of the loads to be anchored in the component has to be verifi ed/proven.

3.2.2 Determination of the basic anchorage length The basic anchorage length b is do be determined in accordance with

DIN 1045-1:2008-08, section 12.6.2: b =(ds / 4) • (fyd / fbd) with: ds = diameter of the rebar fyd = design value of the reinforcing steel‘s yield strength fbd = design value of bond strength according to ETA-13/0316 in

consideration of the coeffi cient related to the quality of bond conditions3.2.3. Determination of the required anchorage length The required anchorage length b,net is do be determined in accordance with DIN

1045-1:2008-08, section 12.6.2: b,net = αa • b • (As,erf / As,vorh) ≥ b,min

with: b = in accordance with 3.2.2 αa = coeffi cient for considering the effectiveness of the anchoring methods

in accordance with DIN 1045-1:2008-08, table 26 As,erf = cross-sectional area of the reinforcement required for calculation As,vorh = available cross-sectional area of the reinforcement b,min = minimum anchorage length in accordance with DIN 1045-1:2008-08

and ETA-13/0316 = max {0.3 • αa • b; 10ds; 100 mm} under tension = max {0.6 • b; 10ds; 100 mm} under pressure The maximum permissible embedment depth is stated in ETA-13/0316.

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General building approvalNo. Z-21.8-1995 Page 5 of 7 I September 13th 2013

3.2.4 Overlap length The required overlap length s should be determined in accordance with DIN

1045-1:2008-08, section 12.8.2: s = α1 • b,net ≥ s,min

with: b,net = in accordance with 3.2.3 α1 = coeffi cient for the overlap length in accordance with DIN

1045-1:2008-08, table 27 s,min = minimum overlap length in accordance with DIN 1045-1:2008-08

and ETA-13/0316 = max {0.3 • αa • α1 • b 15ds; 200 mm} If the clear distance between overlapping bars exceeds 4 ds, the overlap length shall be

increased by the difference between the existing clear bar distance and 4 ds.3.2.5 Embedment depth for overlap joints The maximum permissible embedment depth is stated in ETA-13/0316. Overlap joints for rebars: When calculating the effective embedment depth of overlap joints, the concrete cover on

the front side of the existing bar has to be taken into account: v ≥ s + c with: s = required overlap length in accordance with section 3.2.4 c = concrete cover on the front side of the existing bar3.2.6 Concrete cover The required concrete cover for the bonded-in rebars in accordance with ETA-13/0316

has to be observed. Furthermore, the minimum concrete cover according to DIN 1045-1:2008-08, section 6.3,

table 4 has to be observed.3.2.7 Transverse reinforcement The requirements of transverse reinforcement in the area of the post-installed rebar

connection shall comply with DIN 1045-1:2008-08, Section 12.8.3.3.2.8 Connection joint The transfer of transverse forces between new and existing concrete shall be designed

according to DIN 1045-1:2008-08. The concrete joints must be roughened to at least such an extent that the aggregates protrude.

In case of a carbonated surface of the existing concrete structure, the carbonated layer shall be removed in the area of the post-installed rebar connection with a diameter of ds + 6 cm mm prior to the installation of the new rebar.

The depth of the concrete to be removed shall correspond to at least the minimum concrete cover for the respective environmental conditions in accordance with DIN 1045-1:2008-08.

The foregoing may be neglected if building components are new and not carbonated and if building components are in dry conditions.

3.3 Fire protection In case of fi re protection requirements, it has to be certifi ed that the design value derived

from the impacts is smaller than that of the resistance. The design values of the resistance against tensile load NRd,fi for rebar connections with

reinforcing steel, which are arranged perpendicular to the fi re-exposed surfaces of plates and walls, are specifi ed in annexes 2 and 3.

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The design values of the bond stress fbd,fi for rebar connections, which are arranged perpendicular to the fi re-exposed surfaces of plates and walls, are specifi ed in annex 4 depending on the concrete cover of the bonded-in reinforcement.

For rebar connections in parallel to the fi re-exposed surface, the required embedment depth has to be determined in accordance with the information specifi ed in annex 4. The computational anchoring or overlap length may only amount to a maximum of 80 ds. The maximum embedment depth according ETA-13/0316 is to be observed. For concrete covers over 50 mm, a protective reinforcement in accordance with DIN 4102-4:1994-03, section 3.1.5.2 has to be arranged, if necessary.

The design values for the fi re exposure in case of two or three-sided fi re exposure are not governed by this general building approval.

The fi re protection requirements may also be satisfi ed by plaster coverings in accordance with DIN 4102-4:1994-03 or other coverings if their suitability is confi rmed by an offi cial certifi cate or a general building approval (for example mineral fi bre board of building material class A with a melting point ≥ 1000 ° C and a gross density ≥ 150 kg / m 3 as well as calcium silicate or vermiculite plates). 2 cm of concrete cover may be replaced by 1 cm of covering thickness for the coverings listed above. The fastening of the covers also has to satisfy the fi re protection requirements and this has to be certifi ed separately.

4 Provisions concerning execution

4.1 General The company entrusted with the execution of the rebar connection has to have at its

disposal - a qualifi ed executive or supervisor, - a responsible site manager, - specialist construction personnel that is specially trained for the execution of the rebar

connection and - the required equipment in accordance with annexes 6 to 8 „Operational requirements for the execution of rebar

connections with post-installed rebars“ and also be able to present a valid verifi cation or certifi cate of suitability regarding these aspects.

The training of the specialist construction personnel is handled by the applicant under supervision of a body determined by the Deutsche Institut für Bautechnik.

If this body has determined that the training has been successfully carried out, it shall provide the specialist construction personnel with a certifi cate stating the capability of establishing rebar connections using the DeWalt AC100-PRO Injection System.

If this body has determined that the operational requirements for the execution of rebar connections with post-installed rebars stated in annexes 6 to 8 are satisfi ed, the body will then issue a certifi cate of suitability in this regard as well. The certifi cate of suitability is issued for three years and is revocable. At request, the certifi cate‘s period of validity can be renewed for another three years. Prior to any renewal or extension, the inspecting body or authority has to be presented evidence that the requirements concerning the execution of rebar connections with post-installed rebars are still being met. The responsible supervisor or manager of the company has to indicate any changes to the responsible specialist personnel to the inspecting body or authority.

The rebar connection must be made in accordance with the design drawings and the instructions of the applicant. Only equipment intended for this purpose may be used for the drilling and cleaning of holes as well as the injection of the mortar.

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For every rebar connection, an installation protocol in accordance with the requirements of annex 5 has to be prepared.

4.2 Inspection of the anchoring base Prior to drilling the borehole, the concrete strength class of the anchoring base has to be

determined. The concrete strength class may not be below the strength class stated in section 3.1 of the design drawings and may not exceed C50/60 or B 55.

If the locations of the existing rebars is not apparent, they have to be determined using a suitable rebar detection device based on the construction documentation and be marked on the component for the overlap joints.

When preparing the bonded-in rebars, the component temperature may not be below -10 °C and not exceed +40 °C.

4.3 Execution The anchorings (borehole making, borehole cleaning, preparation of the rebar, injection

of the bonding mortar and setting of the rebar) shall be established in accordance with ETA-13/0316.

4.4 Inspection of the execution The inspection of the execution is based on annex 5, table 3. When executing the rebar

connections, a construction supervisor of the entrusted company or his competent representative has to be present at the site. He is responsible for the proper execution of the operations and has to document the inspection (installation protocol). The records or documentations have to be present on the construction site for the duration of the construction operations and have to be presented to the person responsible for the site inspection upon request. Similar to the delivery notes, they have to be stored by the company for at least 5 years after completion of the work.

Andreas Kummerow Certifi ed Head of Section

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Image 1: Overlap joint for rebar connections of plates and beams

Roughen joint in accordance with section 3,2.8 of this approval

Image 2: Overlap joint of a support or wall under bending stress to a foundation

Roughen joint in accordance with section 3,2.8 of this approval

Image 3: End anchorage of plates or beams

Roughen joint in accordance with section 3,2.8 of this approval

Image 4: Rebar connections of components mainly subject to pressure

Image 5: Anchoring of reinforcement to cover the envelope line of tensile force

Envelope line of tensile force

Envelope Med/Z + Ned

Components of the connection:• Normal concrete C12/15 - C50/60 in accordance with

DIN EN 206-1:2001-07• Normal concrete B15 - B55 in accordance with

DIN 1045:1988-07• Reinforcing steel B500 B, ds = 8 mm - 25 mm,

in accordance with DIN 488 or the general building approval

• DeWalt AC100-PRO injection mortar in accordance with ETA-13/0316

Notes concerning images 1 to 5:No lateral force reinforcement is portrayed on the images. The lateral force reinforcement required in accordance with DIN 1045-1 has to be present. The lateral force transmission between old and new concrete according to DIN 1045-1 has to be certifi ed.

Rebar connection using the DeWalt AC100-PRO Injection SystemAnnex 1

Application examples for bonded-in rebars

General building approvalNo. Z-21.8-1995, dated September 13th 2013

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Table 1a: Design values of the resistance against tensile load NRd,fi for verifi cation in accordance with section 3.3 concerning classifi cation of the fi re resistance classes, rebar connection perpendicular to the fi re-exposed surfaces of plates and walls

Bar diameter Maximum tensile force

Embedment depth

Fire resistance class

F 30 F 60 F 90 F 120 F 180

ds max NRd,fi v NRd,fi

[mm] [kN] [mm] [kN] [kN] [kN] [kN] [kN]

8 16.2

80 1.64 0.44 0.12 0.00 0.00150 13.04 5.55 2.79 1.64 0.49170 16.20 9.17 5.37 3.03 0.96210 16.20 12.61 9.21 3.08230 16.20 12.82 5.41250 16.20 9.03

290 16.20

10 25.3

100 4.99 1.34 0.50 0.21 0.00150 16.30 6.93 3.49 2.05 0.62190 25.30 15.98 11.24 7.01 2.29235 25.30 21.42 17.16 7.89255 25.30 21.69 16.94275 25.30 16.94315 25.30

12 36.4

120 11.42 3.25 1.45 0.75 0.16180 27.71 16.46 10.77 6.20 2.02215 36.40 26.96 20.27 15.17 5.31255 36.40 32.49 26.02 14.90275 36.40 31.45 20.33295 36.40 25.76335 36.40

14 49.6

140 19.66 7.13 3.50 2.02 0.58200 38.66 25.54 18.90 12.94 4.14235 49.60 36.62 29.98 24.03 11.05280 49.60 44.23 38.28 25.30305 49.60 46.19 33.21320 49.60 37.96355 49.05

Note: Intermediate steps may be interpolated linearly. Extrapolation is not permitted.

Verifi cation/proof: NSd,fi ≤ NRd,fi

Rebar connection using the DeWalt AC100-PRO Injection SystemAnnex 2Fire protection verifi cation in accordance with section 3.3

Rebar connection ds = 8 to14 mm, perpendicular to the wall exposed to fi re

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Table 1b: Design values of the resistance against tensile load NRd,fi for verifi cation in accordance with section 3.3 concerning classifi cation of the fi re resistance classes, rebar connection perpendicular to the fi re-exposed surfaces of plates and walls

Bar diameter Maximum tensile force

Embedment depth

Fire resistance class

F 30 F 60 F 90 F 120 F 180

ds max NRd,fi v NRd,fi

[mm] [kN] [mm] [kN] [kN] [kN] [kN] [kN]

16 64.8

160 29.70 14.71 7.79 4.47 1.39240 58.66 43.67 36.08 29.27 14.44260 64.80 50.90 43.31 36.51 21.67300 64.80 57.79 50.98 36.15320 64.80 58.22 43.39340 64.80 50.63380 64.80

20 101.2

200 55.23 36.49 27.00 18.49 5.92250 77.84 59.11 49.62 41.11 22.57305 101.20 83.99 74.50 65.99 47.45345 101.20 92.60 84.09 65.54365 101.20 93.13 74.59385 101.20 83.64425 101.20

25 158.1

250 97.31 73.88 62.02 51.39 28.21300 125.58 102.16 90.30 79.66 56.48360 158.10 136.09 124.23 113.59 90.41400 158.10 146.85 136.21 113.03420 158.10 147.52 124.34440 158.10 135.65480 158.10

Note: Intermediate steps may be interpolated linearly. Extrapolation is not permitted.

Verifi cation/proof: NSd,fi ≤ NRd,fi

Rebar connection using the DeWalt AC100-PRO Injection SystemAnnex 3Fire protection verifi cation in accordance with section 3.3

Rebar connection ds = 16 to 25 mm, perpendicular to the wall exposed to fi re

General building approvalNo. Z-21.8-1995, dated September 13th 2013

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General building approvalNo. Z-21.8-1995, dated September 13th 2013

Table 2: Design value of the bond stress fbd,fi subject to the existing concrete cover for classifi cation of fi re resistance classes, rebar connection in parallel to the surfaces of plates and walls exposed to fi re

Fire resistance classConcrete cover of the

bonded-in reinforcement cF 30 F 60 F 90 F 120 F 180Characteristic bond stress fbd,fi

[N/mm2] [N/mm2] [N/min2] [N/mm2] [N/mm2] [mm]0.27 0.00 0.00 0.00 0.00 300.34 0.00 0.00 0.00 0.00 350.44 0.00 0.00 0.00 0.00 400.55 0.00 0.00 0.00 0.00 450.71 0.26 0.00 0.00 0.00 500.86 0.31 0.00 0.00 0.00 551.07 0.38 0.00 0.00 0.00 601.41 0.46 0.00 0.00 0.00 651.96 0.56 0.26 0.00 0.00 702.30 0.69 0.31 0.00 0.00 75

0.85 0.36 0.00 0.00 800.97 0.42 0.25 0.00 851.12 0.50 0.31 0.00 901.31 0.60 0.35 0.00 951.57 0.73 0.41 0.00 1001.79 0.85 0.49 0.00 1052.07 1.00 0.61 0.25 1102.30 1.19 0.71 0.28 115

1.45 0.85 0.32 1201.66 0.99 0.37 1251.92 1.16 0.44 1302.17 1.38 0.48 1352.30 1.67 0.52 140

1.84 0.59 1452.03 0.67 1502.23 0.75 1552.30 0.85 160

0.99 1651.16 1701.38 1751.67 1801.84 1852.03 1902.01 1952.22 2002.30 205

Rebar connection using the DeWalt AC100-PRO Injection SystemAnnex 4Fire protection

Rebar connection in parallel to the fi re-exposed surface

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NSd,fi Design value of the tensile force subject to fi re exposure selected overlap length. This value has to correspond to

(v-c1) s at the least, but may not be higher than 80 ds

s Overlap length of the joint in accordance with 3.2.4ds Nominal diameter of the rebarfbd,fi Design value of the tensile force subject to fi re exposure

It has to be verifi ed/certifi ed that the design value of the tensile force subject to fi re exposure NSd,fi can be transferred in the rebar connection with the selected length v:NSd,fi ≤ (v -c1) • π • ds • fbd,fi with s ≤ (v -c1) ≤ 80 • ds

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Table 3: Inspection of the execution

No. Subject of the inspection Type of inspection Requirements Frequency, point in time

Concrete subsurface1 Concrete

Concrete strength

Visual inspection

from construction documentation

Suitability for the intended work

as specifi ed by the structural engineer

Prior to commencing the work

every component, prior to commencing work operations

2 existing reinforcement Inspection of the locations and distances

No reinforcement strikes during drilling operations, mark existing reinforcements on the component surface

every component, prior to commencing work operations

Raw materials3 DeWalt AC100- PRO

mortar cartridgePackaging label

Visual inspection

Storage conditions

Expiration date has not passed

No noticeable changesInstallation instructions of the manufacturer

Every delivery

Ongoing

During storage and removal4 Processing equipment Functional inspection Proper operation During commissioning

and on a daily basis5 Work plan Instructions for preparation

and processingCompliance with the work instructions

Prior to commencing the work

Processing6 Weather effects Temperature

Protection of the borehole from water ingress

Compliance with the work instructions

No water in the borehole

3 times each working day

Prior to fi lling the borehole

7 Borehole drilling Covering, edge distances Compliance with the work instructions

Every borehole

8 Borehole cleaning Visual inspection and blowout inspection

Dust free; clean borehole surface

Every borehole prior to fi lling

9 Rebars Condition, marking, movement inside the borehole

Only fl ash rust, embedment depth marked, movable

Every bar prior to fi lling the borehole

10 Work safety Personal protective equipment

Wear suitable protective clothing, gloves and protective goggles/face protection

When working with injection mortar

11 Filling Fill marking on the mixer extension void-free

In accordance with ETA-13/0316, annex 8, no springback of the bar, no mortar spraying

Every bar while embedding

12 Anchored rebar connections

Embedment depth

Filling

Embedment marker on the borehole mouthMortar visibly exits from the borehole mouth

Every bar after embedment

Rebar connection using the DeWalt AC100-PRO Injection SystemAnnex 5

Inspection of the execution

General building approvalNo. Z-21.8-1995, dated September 13th 2013

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