PHILIPP Power Box System

PHILIPP Power Box System

Installation Instruction

PHILIPP GmbHLilienthalstrasse 7-963741 AschaffenburgTel . +49 (0) 6021 / 40 27-0Fax +49 (0) 6021 / 40 27-440

Institut fürWerkstoffe im Bauwesen

Technische UniversitätDarmstadt

Z – 21.8-1840

VB3-

V-00

2-en

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/18

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2 © 2018 PHILIPP GmbH, 63741 Aschaffenburg • Technical changes and errors reserved • August 2018

Transport and mounting systems for prefabricated building

Technical department Ourstaffwillbepleasedtosupportyourplanningphasewithsuggestionsforthe

installationanduseofourtransportandmountingsystemsforprecastconcreteconstruction.

Special designs Customizedtoyourparticularneeds.

Practical tests on site Weensurethatourconceptsaretailoredpreciselytoyourrequirements.

Inspection reports Fordocumentationpurposesandyoursafety.

On-site service Ourengineerswillbepleasedto instructyour techniciansandproductionper-

sonnelatyourplant,toadviseontheinstallationofprecastconcretepartsandtoassistyouintheoptimisationofyourproductionprocesses.

High safety level when using our products Closecooperationwithfederalmaterialstestinginstitutes(MTIs),andofficialap-

provalsfortheuseofourproductsandsolutionswhenevernecessary.

Software solutions The latestdesignsoftware,animatedvideosandCADlibrariescanalwaysbe

foundunderwww.philipp-gruppe.de.

Engineering contact Phone: +49(0)6021/4027-318

Fax: +49(0)6021/4027-340 E-mail: [email protected]

Sales contact Phone: +49(0)6021/4027-300

Fax: +49(0)6021/4027-340 E-mail: [email protected]

3© 2018 PHILIPP GmbH, 63741 Aschaffenburg • Technical changes and errors reserved • August 2018

PHILIPPGROUP

Systemcomponents............................................................. Page 4

Application............................................................................. Page 5

Designandconstruction........................................................ Page 6

Reinforcement....................................................................... Page 7

Designexample.................................................................... Page 8

Installation............................................................................. Page 9

Preparationformounting....................................................... Page 9

Mountingandgrouting.......................................................... Page 10

PHILIPPGroutingmortar...................................................... Page 11

Software/CAD..................................................................... Page 13

Generalnotes........................................................................ Page 14

Content

VRd,║

VRd,┴

VRd,║

VRd,┴



The Power Box System is optimally harmonised and consists of: ThegalvanisedPowerBoxincludingahigh-capacity,flexiblesteelwireropeandaplasticcover High-strength,free-flowinggroutingmortar(Picture3)

System components and dimensionsThePowerBoxSystemisusedfortheconnectionofprecastconcreteunitswhereatransferofhighloadsandaproofforitisrequired.Itisabletotransfershearforcesparallelandright-angledtothewallsafelyintotheconcreteunit(seepage3).Itssimpleinstallationbymeansofatimberboardensuresapractice-orientedapplication.

Table 1: Dimensions of the Power BoxRef.-No. Dimensions PU Weight

SL [mm]

B [mm]

H [mm]

L [mm]

L1 [mm] [pcs.] [kg/PU]

54PB120 120 80 25 220 190 100 42.0

Picture1

L

B

H

SL

L1

Advantages at a glance Flexibleconnectingelements Nocomplicated“rebend”required Highbearingcapacity Shearforcesright-angledandparalleltothejointtransferable SimpledesignduetoshearforcespecificationperPowerBox Cost-optimizedduetostackabletransportpackaging OptimalutilizationbecauseofvariablenumberofPowerBoxperjoint Boxcoverrecyclable Stableboxcoveralsosuitableforhotbonding Weatherproofboxcover Germanapproval

Picture2 Picture3

L

System components


PHILIPPGROUP

Range of applications and examplesThePowerBoxSystemcanbeusedforalmostallconnec-tionsofreinforcedprecastconcretewallelements.Primar-ily, it transfersstaticshear loadsparallelandright-angledtothewall.

Geometry of precast unitThe reinforced concrete elementsmust have aminimumthicknessof14cm.Ifshearforcesright-angledtothejointhavetobetransferredthewallthicknessmustbeincreasedto18cm.Ingeneral,amaximumjointheightof3.5misal-lowed.

Application

Tensileforcesinthejoint(alongthewall)havetobeexclud-edortakenbyappropriatestaticorconstructivemeasures.

Higherjointsarepossibleifthesubsequentgrout-ingofthejointismadestep-by-stepinsectionsof3.5mwithagroutinghose.

Picture6

Picture7

Picture5

Picture4

30

90min.140

StirrupØ8/250anchoringlengthacc.toEC2

B500AØ10

20 20

20

B500AØ12≥50

B500AØ12

B500AØ12

Picture8

20

B500AØ12

80

25 40



ThereinforcedprecastconcreteunitstobeconnectedmustcorrespondtoEC2.Furthermore,theprecastunitshavetobemadeofnormalweightconcretewithastrengthclassofatleastC30/37accordingtoEN206.Thestructuralen-gineerisresponsibletodesigntheelementsandtoprovethe joint connection according to the German approval (Z-21.8-1840).Valuesforthedesignshearresistanceparallel tothewall(VRd,II)aswellasright-angledtothewall(vRd,┴)areasfol-lows:

Reduction factor = 1/3 + 0.025 × (40 – VEd,II) vRd,┴ = Reduction factor × tabular value

Table 2: Design shear resistance parallel and right-angled to the joint (wall level)Wallthickness

hDesignshearresistance

C30/37 C35/45 C40/50 C45/55VRd,II vRd,┴ VRd,II vRd,┴ VRd,II vRd,┴ VRd,II vRd,┴

[cm] [kN/Box] [kN/m] [kN/Box] [kN/m] [kN/Box] [kN/m] [kN/Box] [kN/m]14

40.0

6.2

40.0

7.1

40.0

7.6

40.0

8.116 8.9 10.1 10.9 11.6

18 11.9 13.5 14.5 15.420 15.0 17.1 18.4 19.622 18.4 21.0 22.5 24.024 22.0 25.0 26.9 28.6

DesignshearresistancevRd,┴forwallthicknesses<18cmonlypossibleifjointresp.elementlength>100cm.

Thepercentageoftheshearforceright-angledtothejointisgivenindiagram1orcalculatedasfollows:

WithVEd,II ≤ 13 kN/Box it is possible to take vRd,┴ given in table 2 with 100 %forthedesign!WithVEd,II > 13 kN/Box, vRd,┴must bemultipliedwith thefollowingreductionfactor:

Diagram1:Interactionofshearforces right-angledandparalleltothejoint

25% 50% 75% 100%0%

0

5

10

15

20

25

30

35

40

Design and construction

Ifthereareshearforcesright-angledtothejoint,atensileforcemustbeconsidered,whichisoneandahalftimesofthetransferredshearforce.Thistensileforcecanbetrans-ferredviaappropriatereinforcemente.g.arrangedasaringbeamor other constructivemeasures (e.g. fixed column,frictionforces).Ifbothshearforcesoccuraninteractionisnecessary,thentheshearforceright-angledtothejoint(vRd,┴)canonlybeconsideredpartly.Forthis,vRd,┴mustbemultipliedwithadesignfactor.Diagram1showstheinteractionbetweentheshearforcesparallelandright-angledtothejoint.

Fire protectionInaddition to theactualapproval the joint construction isalsocertifiedbytheUniversityofKaiserslautern,Germany,for thefire protection class F180 (with aminimumwallthicknessof15cm)onthebasisofEC2andEC3.

AconstructionwiththePowerBoxdoesnottransferfireorsmokebeforethe180thminute.Alsoinadmissibletemper-atureincreasesabovetheinitialtemperatureatthebegin-ningdonotoccursothatthestructuralstabilityisguaran-teed.

V Rd,II[kN

/Pow

erBox]

vRd,┴[%valuefromtable2]


PHILIPPGROUP

BymeansofatimberboardthePowerBoxisinstalled.Theminimum distance between the Power Boxes of 120mmand to the edge of 150mmmust not be exceeded (Pic-ture 9). In the range of thePowerBoxes the precast el-

This requirement is fulfillede.g.byamesh reinforcementtypeQ257A(equivalent2.57cm²/m).

Theendanchorageoftheconnectingloopsmustbealignedright-angledtothePowerBoxintheprecastelement.Foraverticalinstallationinthemouldthealignmentofthewireloopsintheprecastunitshouldbeensuredbytyingthosetothereinforcement.

ementsmustbeprovidedwithaminimum reinforcement.ThisreinforcementshallbestirrupsØ8foreachwireloopandlongitudinalreinforcement2Ø10(Picture9,alternative-lyPicture10).

Reinforcement

Abendingof theendanchoragebythereinforce-mentisnotallowed.

Alternatively, the stirrups can be replaced by acomparablemeshreinforcement(Picture10).

Picture9 Picture10

220

min.150

220 max.3750

170

170

Picture11

ReinforcingbarØ10

StirrupØ8

Doublebendedmeshreinf.Q257A

Longitudinalreinf.Ø10

170

min.120

220

min.120

min.150

220

min.150

220 max.3750

min.120

220

min.120

min.150



Example wall supportInthisexamplethesupportreactionsofapanelaretransferredviathePowerBoxSystem.Notonlythedeadweightofthepanelbutalsotheweightofthebeamandtheceilingboardsaswellasvariableloadsaretakenintoconsideration.

Actions to the joint: Weightofthepanel:2.5m×4.0m×0.18m×25kN/m3=45kN Weightofceilingboardsandbeam:120kN Significantvariableforce:30kN Buildingheight≤10m,windzone1,innerland,accordingtoEC1

Herewith the final design value is calculated (shear force parallel to the joint): VEd,II=(1.35×(45kN+120kN)+1.5×30kN)/2=133.9kNforeachjointvEd,II=133.9kN/2.5m=53.6kN/mforeachjoint

Shear force right-angled to the joint caused by wind:vEd,┴=1.5×(0.8kN/m2×0.5×2.5m×4.0m)/2=3kN/mforeachjointChosenconcretestrength:C30/37ChosennumberofPowerBoxpairs:n=4

As a result the resistance forces (right-angled and parallel) are:Shearforceparallel:vRd,II=40kN×4boxes/2.5m=64kN/m(forcesforeachbox:VEd,II/4=133.9kN/4=33.5kN/box)Shearforceright-angled:vRd,┴=11.9kN/m(valuefromtable2)Ifbothforcesoccuratthesametimeaninteraction(Diagram1)mustbeconsidered:Reductionfactor=1/3+0.025×(40kN–33.5kN)=0.50

The reduced shear force right-angled to the joint can be set to 50 %: red.vRd,┴=0.50×11.9kN/m=5.95kN/m≥3.0kN/m=vEd,┴Thiscalculationshowsthatnotonlythedeadweightofthepanelbutalsoe.g.highforcesofbeamconstructionsandwindloadsatthesametimecanbetransferredbythePowerBoxSystem.

Design example

Picture12

Picture12a

Picture12b

vRd, ┴

vRd,II

vRd,┴

vRd,II

2.5 m

4.0 m0.18 m


PHILIPPGROUP

Production of precast concrete elementsThePowerBoxSystemworksontheprinciple of a lapped joint. Thereforeit isnecessarythat theoppositecon-necting loops are arranged on thesameheight(Picture22).AfixationofthePowerBoxSystemispossiblebynailingaswellashotclu-ingtothemould(Picture13andPic-ture14).

Installation

Preparing for mountingBefore grouting the cover of the boxhastoberemoved(Picture15).Then, the connecting loops are ex-pandedperpendicularly to thePowerBox(Picture16).

Picture13 Picture14

Picture15 Picture16



Mounting and groutingIf thePowerBoxesare installedcor-rectly the loops overlap horizontallywithnominal90mmasshowninpic-ture 17. Ideally, in vertical directionthereisnodistancebetweentheloopsfrombothsides(Picture19).Nevertheless, the approval for thePowerBoxSystemalreadyconsidershorizontalandverticaltolerances.Themaximumtolerancesforallcasesareshowninpicture20to22.PriorsealingthejointareinforcingbarØ12mmshallbepositionedalongtheentire length of the joint through theoverlapping loops. Make sure whenusing an expanding waterstop tapethat it does not affect the groutingcrosssectionorreducestherequiredconcretecoverforthePowerBoxSys-tem.Theappropriateinstallationshouldbeinspectedvisually.After this, the jointissealedonbothsidesandfilledwithgroutingmortar.Theuseofagroutinghosewithahoppereasesthisprocesssignificantly. It is recommended tofillthejointinsectionsinordertoreducethepressureofthegroutingmortar.Thegroutingmortarshouldbemixed,filled in and compacted according tothe processing instructions given onpage11.

Mounting

20

B500AØ1290

B500AØ12

10

100B500AØ12

40

70B500AØ12

B500AØ12

max.20

Picture17 Picture18

≥50

Picture21 Picture22

Picture19 Picture20


PHILIPPGROUP

PHILIPP Grouting mortar

Grouting with PHILIPP Grouting mortarThegroutingmortarisajointmortarfortheapprovedPowerBoxSystem.It isaready-to-usedrymixtureonacementbaseforgroutingofprecastconcreteunits.Furthermore,itis shrinkage-free,hasahighearlyandfinal strengthandgoodflowability.

Pre-treatmentThesurfacemustbecleanofoils,greasesetc.andcementslurry at the surface shall be removed.Each timea sealformworkshouldbeused.Inordertoimprovetheadhesionthejointsurfaceshallbepre-wettedthoroughly.

PropertiesThegroutingmortarisfreeofchlorides.Ithasagoodad-hesiontosteelandconcreteandshowsnosignsofsegre-gation.Furthermore ithasagoodpumpabilityand resist-ancetofrostdeicingsalt.Thegroutingmortarisproducedinconsistentlyhighqualityandiseasytoprocess.Duetoitsflowableconsistencythemortarisself-levellingandfillsoutallaccessibleventinghollowspaces.

Mixing and groutingApproximately2/3ofthemixingwaterisputintothemixerfirst,thenthegroutingmortarisstirredincompletely.After-wardstheremainingwaterisusedtoadjusttheconsisten-cy.Themixingtimeis4-6minutesdependingonthetypeofmixing.Finally,thejointissealedatbothsides(ifthishasnotbeendonebefore)beforeitisfilledwithgroutingmortar.Here,theuseofagroutinghosewithahoppereasestheprocessconsiderably.Toreducetheconcretingpressureitis recommended to fill in thegroutingmortar in sections.(MakesurewhenusinganexpandingwaterstoptapethatitdoesnotaffectthegroutingcrosssectionorreducestherequiredconcretecoverforthePowerBoxSystem).

Processing temperatureDIN1045-2andDINEN206mustbetakenintoconsider-ationwhenworkingwiththegroutingmortar.Thesestand-ardssetaprocessingtemperaturetoaminimumof+5°C.

Post-treatmentItshouldbepreventedthatthemortardriesuptofastforatleast threedaysafter thegrouting.Appropriatemeasuresarecoveringwithplasticsheets,applicationofwettissuesorwatering.

Duringgrouting,makesurethataircandisappear.Acarefulvibratingcanavoidtrappedair.Thepro-cessingtimeisapproximately60minutesat20°C.

Picture25

Picture23

3.0litres4-6minutes

Picture24



Software / CAD

Calculation toolIn order to design connections youcanfindacalculationtoolonourweb-site (www.philipp-gruppe.de) - a freesoftwarewithoutanyregistration.

ALLPLAN of company NemetschekCustomers using the powerful CADsystem ALLPLAN from Nemetschekcan use the PHILIPP 3D part libraryalready implemented. This CAD li-brarymakes theconstructionof con-nectionswiththePHILIPPPowerBoxSystemmucheasier.IntheCADlibraryforALLPLANitselfthe products are logically structuredandclassified.

Theuserisabletochoosetheneededitemquicklyandaddit to his plan.Theproductsareoffered in sevendifferentviews,as3Dmodelandsymbol.

3D mounting partsTime-savingduringtheplanningprocessandsupportfortheBuildingInformationModelling(BIM)methodarebecomingmoreandmoreimportant.ThisisthereasonwhytheuniversalPHILIPPCADlibraryhelpstoworkefficientonthesemat-ters.

More than1200PHILIPPproductsareavailableas3DmodelUniversalCADlibrarywithmanyexportformatssuitableforallCADsystems(e.g.IFC,DWG)FreeofferforallpeopleinvolvedinprecastbuildingTime-saving in the design process because of ready-mademodelsandviewsSimplystructuredcatalogueMore product details are provided (e.g. weight, dimen-sions,materialanddocumentations)


PHILIPPGROUP

General notes

Table 3: Site check list

Step What Comment

1 Openbox Removecover

2 Inspectionofthebox Payattentiontocleansurfaces,ifnecessarycleanagain

3 Expandtheconnectingloops Payattentiontothe90°positionoftheloops

4 Alignconcreteunits Payattentiontoadmissibletolerances

5 Installjointreinforcement Alongtheentirelengthofthejoint

6 Pre-wettingofgroutingjoints Improvementofadhesion

7 Sealbothsidesofthejoint Useformwork,timberboardsorexpandingwaterstoptape

8 Jointgrouting Payattentiontotheinstructionsregardingambienttemperature,compacting,pro-cessingtime,etc.

9 Demoulding Afterhardeningofthemortar

10 Post-treatmentofthejoint Protectfromrapiddrying

Please consider also the German approval of thePHILIPP Power Box, the datasheet for the PHILIPP Grouting mortar and the fireprotectionexpert report.Youcanfind thesebrochuresonwww.philipp-group.deorareavailableonrequest.

PHILIPP Verbindungstechnik

Gutachterliche Stellungnahme

Brandschutz

VB3-

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7/18

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PHILIPP - P&T Grouting mortar

Technical Data Sheet

for the Power Duo and Power Box System


Bauaufsichtliche Zulassung

Z - 21.8 - 1840

VB3-

VZ-0

02-d

e-D

E - 0

5/17

Table 4: Mortar consumption per 1 m joint with 2 boxes/m [kg/m]

Wallthick-ness

PHILIPP - P&T Grouting mortar Jointwidth[cm]

[cm] 1.0 2.0 3.0 4.014 19.0 21.7 24.4 27.115 19.2 22.1 25.0 27.916 19.4 22.5 25.6 28.617 19.6 22.9 26.1 29.418 19.8 23.2 26.7 30.219 20.0 23.6 27.3 30.920 20.2 24.0 27.9 31.721 20.4 24.4 28.4 32.522 20.6 24.8 29.0 33.223 20.7 25.2 29.6 34.024 20.9 25.6 30.2 34.825 21.1 25.9 30.7 35.626 21.3 26.3 31.3 36.327 21.5 26.7 31.9 37.128 21.7 27.1 32.5 37.929 21.9 27.5 33.1 38.630 22.1 27.9 33.6 39.4

Givenconsumptiondataareonlyguidevalues.

JointwidthWallthicknessMortarkg/m

Table 5: Packing unit (PHILIPP - P&T)Mortar PU FinishedvolumeType [kg] [l]

Groutingmortar 25 13.0

P&T Technische Mörtel GmbH & Co. KG Phone:+49(0)2131/5669-0 Fax: +49(0)2131/5669-22

PHILIPP GmbHLilienthalstrasse 7-9D-63741 AschaffenburgPhone: + 49 (0) 6021 / 40 27-0Fax: + 49 (0) 6021 / 40 [email protected]

PHILIPP GmbHRoßlauer Strasse 70D-06869 Coswig/AnhaltPhone: + 49 (0) 34903 / 6 94-0Fax: + 49 (0) 34903 / 6 [email protected]

PHILIPP GmbHSperberweg 37D-41468 NeussPhone: + 49 (0) 2131 / 3 59 18-0Fax: + 49 (0) 2131 / 3 59 [email protected]

PHILIPP Vertriebs GmbHLeogangerstraße 21A-5760 Saalfelden / SalzburgPhone + 43 (0) 6582 / 7 04 01Fax + 43 (0) 6582 / 7 04 01 [email protected]

For more information visit our website: www.philipp-gruppe.de

Sustainable solutions

PHILIPP ACON Hydraulic GmbHHinterdemgrünenJäger3D-38836DardesheimPhone:+49(0)39422/9568-0Fax:+49(0)39422/[email protected]

Ourcustomerstrustustodeliver.Wedoeverythinginourpowertorewardtheirfaithandwestarteachdayintendingtodobetterthanthelast.Weprovidestrengthandstabilityinanever-changingworld.

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PHILIPP Power Box System

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