PREFACE Thank you for your interest in Covert Operations and USP Structural Connectors. Covert Operations Inc. has had over fifteen years of experience in supplying adhesives, anchoring, and crack injection systems to a wide range of technically demanding and high profile projects. Projects range from seismic retrofits of landmark buildings and bridges, to industrial expansions including refineries and power plants, to infrastructure including highways, runways, water and wastewater treatment plants and pump stations, to large medical and educational facilities, and down to residential and home owner applications, and every size project in between. In 2004, Covert Operations was acquired by USP Structural Connectors, an ISO 9001 Registered manufacturer of structural connectors for wood to wood, wood to concrete, and wood to masonry connections. USP is one of only two nationwide manufacturers of these product lines with eight manufacturing and warehousing locations across the United States. In turn, USP is part of Gibraltar Industries (Nasdaq: ROCK) who increased sales from $758 million in 2003 to $1 billion in 2004 (up 34%). With the backing of USP and Gibraltar, the development and sales of the adhesive and anchoring product lines will move from west coast focused operations to a nationwide and international presence. With Covert Operations new ownership, you will see some exciting changes in the near future. This includes USP branding of many of the previous Covert Operations products, updates to our literature (including an updated version of this manual), and nationwide stocking warehouses. If you require any technical assistance, you can reach us by phone at (800) 827-7229 or (562) 986-4212, or by fax at (562) 498-7426. Thank you. www.covertoperationsinc.com www.uspconnectors.com 1.0 Introduction 1.1 Table of Contents 1.0 Introduction 1.1 Table of Contents 1.2 Introduction & Company Information 2.0 CIA-Gel 7000 Epoxy Anchoring Systems 2.1 Product Details 2.2 Installation Information 2.3 Allowable Stress Load Capacities 2.4 Allowable Stress Design Examples 2.5 Mean Bond Stress Anchor Design 2.6 Bond Capacity Method 3.0 CIA-EA Epoxy Acrylate Anchoring Systems 3.1 Product Details 3.2 Installation Information 3.3 Allowable Stress Load Capacities 4.0 DUC Ductile Undercut Anchors 4.1 General Product Information 4.2 Performance Paramaters 4.3 Design Informaton 4.4 Allowable Stress Design Information 4.5 Strength Design Method - 1997 UBC 4.6 Concrete Capacity Method - 2000 IBC 5.0 Epoxy Injection for Concrete, Masonry, and Wood 5.1 Epoxy Injection Recommended Specifications 6.0 CIA-Grout 7425 - Three Component, High Strength, Flowable Epoxy Grout 6.1 General Information / Material Specificatons 6.2 Sample Product Specification 7.0 Reference Standards 8.0 Product Approvals and Listings 9.0 Product Brochures, Data Sheets, and Sales Information 1 3 31 39 53 67 77 79 97 ©2004 USP/Covert Operations 1 COTM 2004-1 1.2 Introduction & Company Information The USP Anchoring and Adhesives Technical Manual provides the latest design information for the USP/Covert Operations products and how they relate to the state of the are design methodologies including the latest ACI, IBC, IRC, and other design standards. Company History USP Structural ConnectorsTM (United Steel Products Company) has been designing, manufacturing, and marketing construction hardware for 50 years. The company's experience in marketing, engineering, and superior customer service has allowed USP to be the leader in developing new structural connectors for a changing construction industry. In February 2004, USP acquired Covert Operations, Inc. a manufacturer of adhesive and undercut anchoring and crack repair systems. Covert Operations has focused on providing high quality anchoring and epoxy products to meet the tough demands of the Western U.S. seismic engineering community for the last 15 years. The company brings extensive experience in the industrial, commercial, university, and heavy civil markets. Minneapolis Corporate Office 703 Rogers Drive Montgomery, MN 56069-1324 Phone:1-800-328-5934 Phone:1-507-364-7333 Fax:1-507-364-8762 San Francisco Office 2150 Kitty Hawk Road Livermore, CA 94551-9522 Phone:1-800-227-0470 Phone:1-925-449-4100 Fax:1-925-373-9213 Tampa Office 11910 62nd Street North Largo, FL 33773-3705 Phone:1-800-443-6442 Phone:1-727-536-7891 Fax:1-727-535-8199 USP Operations Include: ·Seven strategically placed manufacturing and warehousing locations. ·In-house quality control and testing with independent, third-party plant inspection, and test witnessing. ·On staff licensed professional engineers. ·Our National Factory Technical Sales Force is ready to help with application questions. ·Ongoing regional and national code evaluations as products are developed. USP Structural Connectors Montogomery, Livermove, Largo, and North Wilksboro achieved registration of its quality in accordance with the requirements of ISO 9001:2000 www.uspconnectors.com ©2004 USP/Covert Operations www.covertoperationsinc.com 2 COTM 2004-1 2.0 CIA-Gel 7000 Epoxy Anchoring System 2.1 Product Information 2.1.1 Product Description 2.1.2 Product Features 2.1.3 Listings/Approvals 2.1.4 Product Specifications 2.1.5 Setting Times 2.1.6 Elevated Temperature Sensitivity 2.1.7 Long Term Creep Resistance 2.1.8 Elevated Temperature Creep Resistance 2.1.9 Fire Resistive Construction 2.1.10 Sensitivity to Condition of Drilled Holes 2.1.11 Dynamic and Seismic Loading 2.1.12 Threaded Rod Materials 2.1.13 Deformed Reinforcing Bar 2.1.14 Chemical Resistance Chart 2.2 Installation Information 2.2.1 Installation 2.2.2 Hole sizes 2.3 2.4 2.5 2.6 Allowable Stress Load Capacity Information Allowable Stress Design Examples Mean Bond Stress Anchor Design Bond Capacity Method ©2004 USP/Covert Operations 3 COTM 2004-1 Section 2.1: Product Details -CIA-Gel 7000 2.1.1 Description Covert Injection Adhesive (CIA-Gel 7000) is a structural epoxy designed for anchoring into concrete as well as solid and hollow masonry construction. It is a low odor, solvent free, nonshrink, non-sag anchoring compound which may be used for a wide range of applications. The epoxy is packaged in equal volume side-by-side plastic Figure 1: CIA System cartridges. The cartridges are sealed individually with a D-plug which open easily on the jobsite and also allow partially used cartridges to be saved for later use. The epoxy components are completely mixed when dispensed through a spiral motionless mixer attached to the cartridges. The epoxy may be dispensed with either a hand-powered or air-powered injection tool. 2.1.2 Product Features Excellent Chemical Resistance Tested to ASTM E 1512 for Sesimic/Wind Loading Long Working Time, Fast Cure Times Cures and Bonds Underwater Moisture Insensitive 100% solids Meets ASTM C-881 No Odor, Solvent Free, Non shrink 2.1.3 Listings/Approvals (see section 8.0 for complete information) ICC-ES ESR-1702 City of Los Angeles: RR 25113, RR 25029 Caltrans & many other State DOT's Meets AASHTO M-235 Meets ASTM C 881 Type 1, 2, 4, & 5 - Grade 3 - Class B, C, D, E, & F 2.1.4 Product Specifications Parameter Color: Product: Viscosity (Brookfield): Shelf Life: Mixed Epoxy: Heat Deflection Temperature (ASTM D 648-82) ............................. 144°F/62°C Compressive Strength (ASTM D 695) ............................................. 18,530 psi. Tensile Strength (ASTM D 638) ...................................................... 5,500 psi. Elongation (ASTM D 229) .............................................................. 0.57% Slant Shear (ASTM C-881) ............................................................. 6000 psi. Hardness (Shore D) ........................................................................ 85 Part A Part B Mixed Gray Non-sag Epoxy Black White Epoxy Resin Amine Adduct 16,000 cps 23,500 cps 2 year minimum 2 year minimum not sensitive to UV light or heat ©2004 USP/Covert Operations 4 COTM 2004-1 2.1.5 Setting Times: Temperature (°F) (°C) Adhesives cure slower in colder substrate temperatures. The table on the right lists the recommended 40 - 50 4 -10 12 72 bolt-up and ultimate curing times. The CIA-Gel 7000 51 - 60 10 -16 8 48 epoxy is not recommended for installation in sub61 - 70 16 - 21 6 36 strates colder than 40°F/4.4°C or hotter than 125°F/ 71 - 80 21 - 27 4 24 52°C. "Bolt-up time" is the minimum time required for >80 >27 4 24 the anchors to remain undisturbed and before the anchors may be bolted-up or torqued. Anchors installed at standard embedments (9 anchor diameters) will achieve approximately 35% of their ultimate holding capacity at the "Bolt-up times". "Cure Time" is the time required for the epoxy to achieve full strength. Bolt-up Time (hrs.) Cure Time (hrs.) 2.1.6 Elevated Temperature Sensitivity The physical properties of adhesives gradually decrease with increasing temperature. This occurs because the modulus of an adhesive is not a constant and is subject to change in changing temperature environments. The heat deflection temperature (HDT) indicates the temperature range in which this modulus change is rather large. Below the heat deflection temperature, adhesive products exhibit a typically rigid behavior; above the heat deflection temperature, adhesive products exhibit typically flexible behavior. A rigid adhesive with a high heat deflection temperature can withstand sustained loads for long periods of time if the structure temperature is sufficiently distant from its HDT temperature. In most practical cases it is unlikely that the temperature of a structure exceeds the range from 100°F/37.7°C to 125°F/ 52°C. In addition to determining the HDT, temperature sensitivity tests are also performed on adhesive anchors. For these tests, epoxy anchors are installed in concrete cubes and allowed to cure. The cubes are then heated to various temperatures ranging from 68°F/20°C to 176°F/80°C. When the unit has reached the desired temperature, the anchor is tested to ultimate capacity. Figure 2 tabulates the 120 results of the tempera110 ture sensitivity tests per100 formed on the CIA-Gel 90 7000 epoxy (Ref. 9). 80 The load reduction fac70 tors noted in Fig. 2 must 60 be applied to the ten50 sion values in Table 40 Nos. IV and VI (see 30 Section 2) when the an20 chors are installed lo10 cations where the con0 70 80 90 100 110 120 130 140 150 160 170 180 190 200 crete temperature may exceed 105 °F. Temperature (°F) Relative bond strength (%) Figure 2: Relative bond strength as a function of temperature ©2004 USP/Covert Operations 5 COTM 2004-1 2.1.7 Long-Term Creep Resistance Epoxies and polyester resins, under sustained (long-term) load, creep because of their viscoelastic properties. The rate of creep is dependent on the magnitude of the load and the prevailing ambient temperature. Long-term behavior of the bond between the concrete and various chemical anchors has been studied and the results indicate that anchor displacement should be expected for long-term loads. Three CIA-Gel test anchors were installed in nominal 2 ksi concrete test cubes for long-term tests. An independent testing laboratory tested the specimens (Ref. 6) per the requirements of ASTM E 1512, Methods of Testing Bond Performance of Adhesive-Bonded Anchors, for longterm loading of chemical (adhesive) anchors. CIA-Gel 7000 anchors obtained a displacement maximum of 0.006" when subjected to a sustained load of approximately 5700 pounds (approx. 0.4Nu, where Nu = ultimate capacity) for the full test duration. The resulting load-displacement curve of the long-term tests (see Fig. 3) flattens out with increasing time. This shows that the initial rate of displacement of a CIA-Gel 7000 epoxy anchor under sustained load is greater than the final rate of displacement. The sustained load tests were performed at room temperatures (65-75°F). It is generally accepted that an adhesive anchor which maintains a 120-day load of 0.4Nu will be able to sustain adesign load of 0.25Nu indefinitely. 0.024 0.022 0.020 Average Movement (in.) 0.018 0.016 0.014 0.012 0.010 0.008 0.006 0.004 0.002 0.000 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 Elapsed Time (Days) Fig. 3: Long-term tension loading on CIA-Gel 7000 Epoxy anchors. 2.1.8 Elevated Temperature Creep Resistance Recent research has shown that short-term temperature sensitivity tests and long-term creep tests at room temperature do not provide enough data to indicate an adhesives ability to sustain design loads at higher temperatures (up to 110 °F). Therefore, additional tests were performed to obtain long-term heat sensitivity on CIA-Gel anchors exposed to a constant temperature of ©2004 USP/Covert Operations 6 COTM 2004-1 110 °F (43 °C). The long-term (40 day) heat sensitivity tests were performed on 1/2-inch diameter sections of threaded rod installed in unreinforced 2000 ...