Text_cnot 2012_0491_d.docx

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Additional Technical Terms of Contract – Hydraulic Engineering (German designation: ZTV-W) for Concrete and Reinforced Concrete Hydraulic Structures (Performance Category 215) 2012 Edition EU Notification No. …./…/D dated ….. 2012

TABLE OF CONTENTS

Page

Preliminary Comments General

3 3

Part 1: Dimensioning and construction 3 Materials (cf. DIN EN 1992-1-1, 3) 4 Durability and cover to reinforcement (cf. DIN EN 1992-1-1, 4) 6 Ultimate Limit States (ULS) (cf. DIN EN 1992-1-1, 6) 7 Serviceability Limit States (SLS) (cf. DIN EN 1992-1-1, 7) 8 Detailing of reinforcement – General (cf. DIN EN 1992-1-1, 8) 9 Detailing of members and particular rules (cf. DIN EN 1992-1-1, 9)

5 5 5 5 5 5 5

Part 2: Concrete 1 Scope (cf. DIN EN 206-1, 1) 4 Classification (cf. DIN EN 206-1, 4) 5 Concrete requirements (cf. DIN EN 206-1, 5) 6 Specification of concrete (cf. DIN EN 206-1, 6) 7 Delivery of fresh concrete (cf. DIN EN 206-1, 7) 8 Conformity control and conformity criteria (cf. DIN EN 206-1, 8) 9 Production control (cf. DIN EN 206-1, 9) Cf. Appendix A (normative), Initial Test (cf. A.1, General)

7 7 7 9 13 14 16 16 16

Part 3 3 4 5 6 8 10

17 17 17 17 18 19 22

Building work Definitions (cf. DIN EN 13670, 3) Execution management (cf. DIN EN 13670, 4) Falsework and formwork (cf. DIN EN 13670, 5) Reinforcement (cf. DIN 13670, 6) Concrete work (cf. DIN EN 13670, 8) Geometrical tolerances (cf. DIN EN 13670, 10)

Re DIN 1045-3, Appendix NB: Tests for the definitive fresh and hardened concrete characteristics Re DIN 1045-3, Appendix NC: Monitoring the installation of concrete in monitoring categories 2 and 3 by the building company

23

Summary of regulations cited

25

Appendix 1: Appendix 2:

26 28

Suitability tests Concreting concept and concreting plan

24

Note: The obligations arising from Directive 98/34/EC of the European Parliament and of the Council of 22 June 1998 laying down a procedure for the provision of information in the field of technical standards and regulations (OJ L 204, p.37), most recently amended by Directive 98/48/EC of the European Parliament and of the Council of 20 July 1998 (OJ L 217, p.18), have been met.

ZTV-W LB 215 Edition 2012

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Published by the Federal Ministry of Transport, Building and Urban Development Waterways and Shipping Directorate-General

All rights reserved. Prepared by the working group ‘New standard specifications in hydraulic engineering’ with the participation of               

the Federal Ministry of Transport, Building and Urban Development and its subordinate departments the Ministry of Industry, Labour and Transport of Lower Saxony the Ministry of Rural Areas, Agriculture, Nutrition and Tourism of the State of Schleswig-Holstein the Senator for Ports, Supraregional Transport and Foreign Trade, Bremen the Economic Authority of the Free Hanseatic City of Hamburg Niedersachsen-Ports GmbH & Co. KG, Oldenburg Bundesverband Öffentlicher Binnenhäfen e. V. (Federal Association of Public Inland Ports) RMD Wasserstraßen GmbH Emschergenossenschaft/Lippeverband (Water Management Association for the rivers Emscher and Lippe) Linksniederrheinische Entwässerungsgenossenschaft (Left Lower Rhine Drainage Association) Ruhrverband (Ruhr Federation) Wasserverband Eifel-Rur (Eifel-Rur Water Association) Wupperverband (Wupper Association) Österreichisch-Bayerischen Kraftwerke AG Lech-Elektrizitätswerke AG

Reference: Central Waterways Engineering Library (VZB) of the Federal Waterways Engineering and Research Institute PO Box 210253, 76152 Karlsruhe Phone: +49 (0)721 9726-0 Fax: +49 (0)721 9726-5320 E-Mail: [email protected] Download from the Internet at http://vzb.baw.de/digitale_bib/stlk-w_ztv-w.php

ZTV-W LB 215 Edition 2012

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Preliminary Comments The Additional Technical Terms of Contract – Hydraulic Engineering (ZTV-W) – for Concrete and Reinforced Concrete Hydraulic Structures (Performance Category (LB) 215), referred to as ZTV-W LB 215, shall apply in combination with the basic standards: DIN EN 1990 and DIN EN 1990/NA and concrete standards: DIN EN 1992-1-1 and DIN EN 1992-1-1/NA DIN EN 206-1 and DIN 1045-2 DIN EN 13670 and DIN 1045-3 and hydraulic engineering standard: DIN 19702

(hereinafter: DIN EN 1990) (hereinafter: DIN EN 1992-1-1) (hereinafter: DIN EN 206-1) (hereinafter: DIN EN 13670)

DIN EN 1992-1-1

DIN EN 206-1

Design of concrete structures

Concrete – Specification, performance, production and conformity

DIN EN 13670 Execution of concrete structures

DIN EN 1992-1-1/NA

DIN 1045-2

DIN 1045-3

National Annex to DIN EN 1992-1-1

National Annex to DIN EN 206-1

National Annex to DIN EN 13670

DIN 19702 Solid structures in hydraulic engineering – Bearing capacity, serviceability and durability

Concrete works

Basis of structural design

Part C: DIN 18331

DIN EN 1990 + DIN EN 1990/NA

German construction contract procedures (VOB),

in the following order: ZTV-W LB 215 before DIN 18331 before the hydraulic engineering standard before concrete standards before basic standards. The structure of ZTV-W is analogous to the corresponding parts and sections of the concrete standards (cf. Figure 1). The numbering and section figures in the various parts of ZTV-W LB 215 correspond to sections in the relevant parts of the concrete standards. Additionally, the regulations in ZTV-W LB 215 are numbered in ascending order independently of the standards.

ZTV-WLB 215 Part 1

Part 2

Part 3

Dimensioning and construction

Concrete

Execution of structures

Fig. 1: Overview of standards relevant to ZTV-W LB 215

Products which are lawfully manufactured and/or placed on the market in another Member State of the European Union or in Turkey, or products which are lawfully manufactured in an EFTA Member State that is a contracting party of the Agreement on the European Economic Area (EEA) as the case may be, which do not conform to these technical specifications shall be treated as equivalent, as well as the tests and inspections conducted in the country of manufacture, if the required level of protection regarding safety, health and serviceability is reached. General 1) ZTV-W LB 215 shall apply to the construction of solid hydraulic structures, e.g. locks, weirs, barrages, water scoops, culverts, outlets, port structures, bank reinforcements, including their secondary systems, unless otherwise agreed. They do not apply to road and railway bridges and tunnels (see ZTV-ING). (2) The regulations in ZTV-W LB 215 are generally aimed at a 100-year service life of the structure. A durability assessment shall be carried out on components with exposure classes XS2 and XS3 and a service life of more than 50 years.

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(3) The regulations of ZTV-W LB 215 are also aimed at the required impermeability to water for the use of these structures of components with surfaces that are in constant or temporary in contact with water. The standard specifications contain stricter requirements areas in contact with water around special category spaces (e.g. engineering rooms). (4) DAfStb-1 shall apply to massive components (smallest component dimension ≥ 0.8 m). For components with a smallest dimension of < 0.8 m, DAfStb-1 shall apply if forces and residual stresses must be given special consideration (e.g. component with surface-area constraints). (5) BAW-MZ shall apply to second stage concrete, as regards to materials, planning and execution. DIN 18197 and the DIN 7865 series shall apply to waterstops, as regards to planning, materials and execution. BAW-Brief 3/2008 shall apply to expansion joints, as regards to planning and design. (6) The requirements of ZTV-W LB 215 shall apply mutatis mutandis to precast elements with hydraulic requirements, unless otherwise stipulated in the specifications. (7) The terms “approval” or “approve” are used to express existing cooperation rights within the meaning of Section 4(1) Point 2 Clause 1 of the VOB/B in combination with Sections 311, 241(2) of the BGB (German Civil Code).

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Part 1: Design and Construction 3

Materials (cf. DIN EN 1992-1-1, 3)

3.2

Ductility characteristics (cf. DIN EN 1992-1-1, 3.2.4) (8) Only highly ductile reinforcing steel of grade B500B in accordance with DIN 488-1 shall be used. The ductility of the reinforcing steels shall also be given on the reinforcement drawings.

4

Durability and cover to reinforcement (cf. DIN EN 1992-1-1, 4)

4.4

Concrete cover (cf. DIN EN 1992-1-1, 4.4.1) (9) The minimum concrete cover cmin is 50 mm, the allowance in design for deviation cdev is 10 mm, see also (161). The minimum concrete cover cmin of reinforcement parallel to the construction joint is 30 mm. Parts 2 and 3 of ZTV-W LB 215 contain additional provisions to ensure durability. Ensuring sufficient resistance to wear from hydroabrasion by increasing the concrete cover (sacrificial concrete) is not permitted.

6

Ultimate Limit States (ULS) (cf. DIN EN 1992-1-1, 6)

6.2

Shear transfer in joints (cf. DIN EN 1992-1-1, 6.2.5) (10) Regarding shear transfer at the interface between concretes cast at different times (“construction joints”), the roughness and surface quality of a joint can be assumed to be categorised as “rough” for formwork-lined joints and “corrugated” for non-formwork-lined joints, if the respective construction joint preparation is performed in accordance with Part 3 of ZTV-W LB 215.

7

Serviceability Limit States (SLS) (cf. DIN EN 1992-1-1, 7)

7.3

Crack control, general considerations (cf. DIN EN 1992-1-1, 7.3.1) (11) The gap and pore water pressure may be ignored when determining the crack width. (12) Special measures for components in exposure class XS3 can be found in the specifications. Minimum reinforcement areas for limiting crack width (cf. DIN EN 1992-1-1, 7.3.2) (13) Stresses from early forces (draining heat of hydration) for massive components should be determined in accordance with BAW-MFZ.

7.4

Limitation of deformations (cf. DIN EN 1992-1-1, 7.4) (14) If deformation of the structure or of individual components is to be limited according to the specifications, e.g. joint gaps within concrete components or between the concrete component and the steel hydraulic component, checks shall be carried out for all relevant directions.

8

Detailing of reinforcement – General (cf. DIN EN 1992-1-1, 8)

8.4

Anchorage of longitudinal reinforcement (cf. DIN EN 1992-1-1, 8.4.4) (15) For plane load-bearing structures of solid hydraulic structures, the design anchorage length coefficients α2, α3, α4, α5 may assumed to be 1.0.

9

Detailing of members and particular rules (cf. DIN EN 1992-1-1, 9)

9.1

General (cf. DIN EN 1992-1-1, 9.1) (16) For the subgrade areas of lock chamber walls and heads, quays and similar components, the following rules apply: –

–

If the subgrade concrete and the wall concrete below it is installed in layers of 0.3 m to 0.5 m (‘fresh-onfresh’execution), the calculated reinforcement for the vertical edge areas shall also be installed on the subgrade surface. The adiabatic temperature development of the concrete shall be taken into account for the design. In a simplified approach, the adiabatic temperature development for the concrete with the highest volume in the particular concreting section may be used. When installing subgrade concrete on the cured concrete of the concrete section underneath (‘fresh-on-firm’ execution), the layer thickness of the subgrade concrete shall be a minimum of 0.2 m. Layer thickness of more than 0.4 m should be avoided with regard to stresses from forces.

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(17) In the zoned building method, the minimum thickness of the edge layer subject to hydro-abrasive wear shall be 0.3 m.

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Part 2: Concrete 1

Scope (cf. DIN EN 206-1, 1) (18) The use of high-strength concrete and self-compacting concrete is only permissible if approved of in the specifications.

4

Classification (cf. DIN EN 206-1, 4)

4.1

Exposure classes in relation to environmental conditions (cf. DIN EN 206-1, 4.1) (19) The client shall specify the exposure classes in the specifications. In addition to what is stated in DIN EN 206-1, Table 1, the hydraulic engineering specific examples listed in Table 2.1 can be assigned to the exposure classes.

Table 2.1 – Exposure classes

Class designation

Hydraulic engineering specific examples1) for the allocation of exposure classes (for information)

Description of environment

1 No risk of corrosion or attack X0

For concrete without reinforcement or embedded metal: in environments where the concrete is not attacked.

Unreinforced core concrete with zoned building method

2 Reinforcement corrosion, triggered by carbonisation XC1

dry or permanently wet

Floors of lock chambers, economising basins or weirs, lock chamber walls below bottom water, hydraulic filling and emptying systems

XC2

wet, rarely dry

Lock chamber walls in the area between bottom water and headwater (mutatis mutandis for economising basin walls)

XC3

moderate humidity

Surfaces not open to the weather (outside air, protected against precipitation)

XC4

cyclic wet and dry

Freeboard of lock chamber or economising basin walls, weir columns above low water, outside surfaces open to the weather, quays

3 Reinforcement corrosion caused by chloride, except for seawater XD1

moderate humidity

XD2

wet, rarely dry

XD3

cyclic wet and dry

Weir columns in the spray mist areas of road bridges

Platforms of locks, traffic areas (e.g. port areas), steps on weir columns

4 Reinforcement corrosion caused by chloride from seawater XS1

Exposed to airborne salt but not in External components near the coast direct contact with seawater

XS2

Permanently submerged

Barrier floors, walls and foundation piles below lowest known low-tide level

XS3

tidal, splash and spray zones

Foundation piles, quays, moles and walls above lowest known low-tide level

5 Frost with and without de-icing agents/seawater XF1

moderate water saturation with Freeboard of economising basin walls, weir columns fresh water, without de-icing agents above high water

XF2

moderate water saturation with seawater and/or de-icing agents

ZTV-W LB 215 Edition 2012

Vertical components in spray water area and components in direct spray mist areas of seawater

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Class designation

Hydraulic engineering specific examples1) for the allocation of exposure classes (for information)

Description of environment

Lock chamber walls in the area between bottom water1.0 m and headwater+1.0 m (applies mutatis mutandis to economising basin walls), inlet and outlet areas of culverts between low water and high water, weir columns between low water and high water

XF3

high water saturation with fresh water without de-icing agents

XF4

Vertical surfaces of seawater components such as foundation piles, quays and moles in fluctuating water high water saturation with seawater level areas, horizontal surfaces affected by seawater, and/or de-icing agents platforms of locks, traffic areas (e.g. port areas), steps on weir columns

6 Concrete corrosion through chemical attack XA1

slightly aggressive chemical environment

XA2

moderately aggressive chemical environment and marine structures

XA3

Highly aggressive chemical environment

Concrete components which are in contact with seawater (underwater and fluctuating water level areas, spray water areas)

7 Concrete corrosion through wear stress

XM1

moderate wear stress 2)

Surfaces subject to stress from friction with ships (e.g. lock chamber walls above bottom water-1.0 m), components for energy conversion with wear from small-grain bed-load transport (e.g. due to construction measures such as bed-load catch basin), ice drift

XM2

severe wear stress

Weir backs and components for energy conversion (stilling basins, chute blocks) with wear from largegrain bed-load transport

XM3

very severe wear stress

Components in mountain streams or bed-load deflection tunnels

8 Concrete corrosion due to alkali silica reaction

WO

WF

WA

WS 1)

2)

Generally: Only for non-massive components (smallest component dimension ≤ 0.80 m). Internal components of hydraulic structures that are not continuously exposed to a relative air humidity of more than 80 % (e.g. interior spaces of steering stations). Generally: Always for massive components (smallest dimension > 0.80 m) regardless of humidity exposure. Concrete components of hydraulic structures exposed Concrete that in use is frequently to weather or subject to temporary or permanent water wet or wet over extended periods exposure in inland waterways (e.g. entire height of lock of time. chamber walls). Inner components of hydraulic structures subject to a relative air humidity of 80 % or more. Concrete components of hydraulic structures which Concrete, which, in addition to come into contact with seawater (underwater and class WF wear, is exposed to alkali fluctuating water level areas, spray water areas). frequently or for extended periods Concrete components of hydraulic structures with deof time. icing salt exposure (e.g. subgrade areas of lock chamber walls). Concrete that is subject to high Not relevant to hydraulic engineering. dynamic wear and direct alkali charge. Concrete which after normal curing is not moist for an extended time and, after drying out, remains mostly dry during use.

These examples apply to the predominant stress factors during service life. Past experience suggests that different ambient conditions during construction or use (e.g. drainage) do not cause damage. Lock chamber floors and filling systems not subject to bed-load transport wear are normally not subject to concrete corrosion due to hydroabrasion.

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5

Concrete requirements (cf. DIN EN 206-1, 5)

5.1

Basic requirements for raw materials (cf. DIN EN 206-1, 5.1) General (cf. DIN EN 206-1, 5.1.1) (20) All certifications to be provided as regards the suitability of raw materials for the production of concrete (results of standard investigations, results of initial tests, etc.) shall be submitted to the client, unless otherwise approved in the specifications, no later than 2 weeks before the start of the concrete suitability tests in accordance with Part 2, Chapter 6.1 of ZTV-W LB 215. (21) The contractor shall immediately submit to the client results of the monitoring of raw materials by the recognised monitoring authorities, and in the case of aggregates, the contractor shall also immediately submit the results of the factory’s own production tests. Cement (cf. DIN EN 206-1, 5.1.2) (22) The following cements in accordance with DIN EN 197-1, DIN EN 197-4 and DIN 1164-10 may be used: – – – – – –

CEM I CEM II/A-S, CEM II/B-S CEM II/A-T, CEM II/B-T CEM II / A-LL CEM II/A-M (S-LL), CEM II/A-M (S-T), CEM II/B-M (S-T), CEM II/A-M (T-LL) CEM III/A, CEM III/B

For massive components, only normal cements with low development of heat of hydration (LH cements in accordance with DIN EN 197-1) may be used. Aggregates (cf. DIN EN 206-1, 5.1.3) (23) Only aggregates in accordance with standard DIN EN 206-1 in combination with DIN EN 12620 and DIN EN 13055-1, the conformity of which has been verified according to certification of conformity system ‘2+’, are allowed. The use of recycled aggregates is not permitted. (24) The use of industrially manufactured aggregates is not permitted. (25) The harmlessness of fine particles of fine aggregates shall be verified according to DIN EN 12620, Appendix D, letter a), b) or c). (26) Unless otherwise stipulated in the specifications, frost/thaw resistance or frost/de-icing salt resistance of the aggregates according to DIN EN 206-1, Appendix U, may not be more than 6 months old at any time during the execution of the building works. Mixing water (cf. DIN EN 206-1, 5.1.4) (27) Mixing water shall meet the requirements of DIN EN 1008. The use of mixing water other than drinking water, well water or residual water from reprocessing plants in concrete manufacture is not permitted. Admixtures (cf. DIN EN 206-1, 5.1.5) (28) The following admixtures may be used: – – – –

concrete plasticisers (CP) fluxing agents (FA) air-entraining agents (AA) retarding agents (RA)

The use of other admixtures is not permitted. Additives (cf. DIN EN 206-1, 5.1.6) (29) Fly ash shall be in accordance with DIN EN 450. (30) The fly ash shall be covered by the same product certificate (origin) for the duration of the building period. Any change in fly ash shall be agreed on with the client. The substitute fly ash must be named at the start of the building work. New suitability tests shall be carried out before the fly ash is changed.

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5.2

Basic requirements for composition of concrete (cf. DIN EN 206-1, 5.2) Use of aggregates, General (cf. DIN EN 206-1, 5.2.3.1) (31) The grading curve shall be constant and should be between the limit grading curves A and B. As a rule, an aggregate with D = 32 mm or more shall be used for massive building components. (32) If aggregates larger than 8 mm are used, at least three separate grain groups should be added. (33) For the use of aggregates in concrete, the following requirements shall apply in addition to the requirements of DIN EN 206-1, Appendix U: – – – – –

The proportion of lightweight organic pollutants in fine aggregates my not exceed 0.25 % of weight component and 0.05 % of weight for coarse aggregates. The grain shape of coarse aggregates shall comply at least with Category SI40 for broken grains. The resistance of broken rock aggregate to fragmentation shall comply at least with Category LA50 or Category SZ32. The granular composition of coarse aggregate must be closely graded. Grain mixtures may not be used.

Naturally composed aggregate (cf. DIN EN 206-1, 5.2.3.2) (34) Naturally composed (not processed) aggregate according to DIN 12620 may not be used. Resistance to alkali silica reaction (cf. DIN EN 206-1, 5.2.3.4) (35) For the evaluation and use of aggregates containing harmful quantities of alkali-solvent silica or where this possibility cannot be reliably excluded, and for the measures that may need to be taken in the case of concrete, in addition to DAfStb-2, the Alkali Guideline issued by the Federal Ministry for Transport, Building and Urban Development shall be followed. Use of additives (cf. DIN EN 206-1, 5.2.5) (36) The use of silica dust is not permitted. Principle of equivalent concrete efficiency (cf. DIN EN 206-1, 5.2.5.3) (37) The application of the principle of equivalent concrete efficiency is only permitted if agreed upon in the specifications. Use of admixtures (cf. DIN EN 206-1, 5.2.6) (38) Within one concrete, only one concrete admixture from one action group may be used. The simultaneous use of admixtures made by different manufacturers within one concrete is not permitted. The total quantity of admixtures may not exceed the maximum dosage recommended by the admixture manufacturer or 50 g/kg of cement in the concrete. (39) Fluxing agents from the polycarboxylate and polycarboxylate ether active substance groups may only be used with the same concrete raw materials with which the suitability test was carried out, and only in the concrete temperature ranges which formed the basis for the suitability test (c.f. Chapter 6.1 of ZTV-W LB 215). (40) Concrete admixtures with the active substance groups saccharose and hydroxycarboxylic acids may not be used. This also applies to mixed products containing these groups of active substances. (41) Concrete in consistency classes F4 is to be made with plasticising admixtures, and the consistency of the starting concrete shall be F2. (42) The consistency shall be achieved with concrete plasticisers. Subsequent dosing by addition of fluxing agent on site is permitted. If fluxing agent is added on site to achieve consistency, only a single subsequent dosing will be permitted. If fluxing agents are added later, the concrete must not be so hardened that its value falls below the actual consistency measured at the point before the first dosage. Tests should therefore be carried out on site, before subsequent dosing, to determine the spread dimension. Subsequent dosing must be carried out using suitable dosing devices. (43) Delay times over 12 hours must be agreed on with the client.

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Concrete temperature (cf. DIN EN 206-1, 5.2.8) (44) For components with the smallest dimension < 0.8, the fresh concrete temperature T concrete at the point of handover shall be adjusted to the permissible fresh concrete temperature at the place of installation (max. +30 °C). For subgrade areas, the fresh concrete temperature at the point of handover shall be adjusted as not to exceed the permissible fresh concrete temperature at the place of installation (max. +25° C). (45) Unless stipulated otherwise in the specifications, concrete for massive components (smallest dimension ≥ 0.8 m) should be planned and manufactured in such a way that the following requirements are met: – –

– –

The fresh concrete temperature at the point of handover shall be adjusted to the permissible fresh concrete temperature at the place of installation (max. +25° C). The quasi-adiabatic temperature increase Tadiab,7d in the concrete may not exceed the limit values given in Table 2.2, column 3 of ZTV-W LB 215. The total of the fresh concrete temperature Tconcrete and the quasiadiabatic temperature increase Tqadiab,7d in the concrete may not exceed the limit values given in Table 2.2, column 4 of ZTV-W LB 215. The quasi-adiabatic temperature increase Tqadiab,7d shall be determined on a large concrete block as part of suitability testing in accordance with 6.1 of ZTV-W LB 215 or according to the provisions of the specifications (see Appendix 1, Chapter 2). The heat of hydration of the cement batch used in the suitability test shall be determined in accordance with DIN EN 196-8. The concrete compressive strength fcm,cube,28d (mean from a test series of 3 cubes) may not exceed the limit values given in Table 2.2, column 5.

(46) For massive components with exposure classes other than those mentioned in Table 2.2 of ZTV-W LB 215, the respective limit values are specified in the specifications. Table 2.2: Concrete requirements for massive components (smallest dimension ≥ 0.80 m) 1 Concrete with exposure classes XC1 / XC2

XC1 / XC2 + XA1

XC1 / XC2 + XA2 (+XS2)

XC 1...4 + XF3 (+ XM1)

XC 1...4 + XF4 + XS3 + XA2 (+ XM1) 1) 2)

5.3

2

3

fcm,cube,28d 2)

K

4 maximum component temperature C

Example (for information)

Tqadiab,7d 1)

--Lock floor

 28 (33)

 53

 41

Lock floor in environment with a slight chemical corrosive effect

 31 (36)

 56

 43

 36 (41)

 61

 46

 36 (41)

 61

 46

 40 (45)

 65

 49

Lock floor in environment with a moderate chemical corrosive effect and marine structures Lock chamber wall between bottom water and headwater Vertical surfaces in fluctuating water level areas of seawater

5

N/mm²

For fresh concrete temperatures ≤ 15 C, the values in parentheses may be used. See 5.5 of DIN EN 206-1 regarding the admittance of a time period for testing the strength category that deviates from 28 days. Even if the time for testing the strength category deviates from 28 days, proof of compliance with fcm,cube,28d must be provided.

Requirements as a function of exposure classes (cf. DIN EN 206-1, 5.3) Limiting values for concrete composition (cf. DIN EN 206-1, 5.3.2) (47) Concretes for hydraulic structures must not exceed a w/c value of 0.65. (48) Concretes for hydraulic structures shall have a high resistance to water penetration according to DIN EN 206-1, 5.5.3. (49) For exposure category XF3, only aggregates in category F1 according to DIN EN 12620 may be used. Concretes in exposure class XF3 shall have a minimum air content in accordance with DIN EN 206-1, Table F.2.2, Footnote f, or DAfStb-1, Table F.2.2, Footnote f.

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(50) Unless otherwise approved in the specifications, for exposure classes XF3 and XF4, frost tests shall be carried out on the hardened concrete as part of suitability testing. The BAW-MFB is authoritative for carrying out the test and for the associated acceptance criteria. (51) Only the following binding agents may be used for concretes of exposure classes XD2, XS2, XD3 and XS3: – – –

CEM I and CEM II cements according to (22), in combination with fly ash as a concrete additive, where the minimum fly ash content must be 20 % by mass of (c+f). CEM III/A with fly ash as a concrete additive, where the minimum fly ash content must be 10 M% of (c+f). CEM III/B.

(52) Unless otherwise stipulated in the specifications, components categorized in exposure class XM2 due to hydroabrasion shall meet the following requirements: – – – –

Round grain with a minimum quartzite content of 70% is used as aggregate. The largest grain of the aggregate does not exceed 16 mm. Only variant w/c ≤ 0.45 in accordance with DIN EN 206-1, Table F.2.2, or DAfStb-1, Table F.2.2, is permitted. The minimum cement content is 270 kg/m³.

(53) Only cement from the same cement factory may be used for each concrete. The name of the supplier factory shall be given to the client prior to suitability testing. (54) The use of several cement types in one concrete is not permitted. (55) In massive components with primary exposure XF3 in combination with XC2 or XC4 and where applicable XM1 (e.g. lock chamber walls in inland waterways), for concrete for which frost resistance is ensured by adding air-entraining agents, and for which CEM I, CEM II-A, CEM II/B-S or CEM III/A cements are used, the following may be specified in deviation from DAfStb-1: – –

Minimum compressive strength class C20/25 (test age 56 days), unless higher strengths are required for static reasons or due to different exposure classes; Minimum cement content in accordance with DAfStb-1, Table F.2.2, line 3, may be specified as 270 kg/m³.

This rule may also be applied for the area between headwater level and bottom edge of platform concrete. (56) For concrete for subgrade areas of lock chamber walls and heads and similar components with exposure classes XC4, XD3 and XF4 (where applicable in combination with XM1), for which rating in exposure classes XD3 and XF4 is based primarily on the use of de-icing agents to ensure traffic safety for pedestrians and infrequent vehicle traffic, the following rules apply: – – – – – – 5.4

The maximum permissible w/c value is 0.50 (taking into consideration the fly ash share). The minimum cement content is 300 kg/m³, however, under conditions in accordance with DIN EN 206-1 and taking into consideration the fly ash share, the cement content may be reduced to 270 kg/m³. To reduce contraction, the total water content in fresh concrete shall be limited to 160 dm³/m³ if largest grain = 32 mm, and 165 dm³/m³ if largest grain = 16 mm. The minimum compressive strength class is C25/30 (test age 28 days or 56 days), unless higher strengths are required due to static reasons or different exposure classes. Frost resistance testing in accordance with (50) shall be carried out for exposure class XF4. The rules in (51) need not be applied.

Requirements for fresh concrete (cf. DIN EN 206-1, 5.4) Consistency (cf. DIN EN 206-1, 5.4.1) (57) Determining the consistency of the concrete by the degree of settlement and settlement time (Vebe) is not permitted. (58) The consistency shall be specified through the target value. The permissible deviation from the target value is +/- 30 mm. (59) With the exception of concretes for surface finish and second stage concrete, concretes with a maximum target value for the spread dimension of 490 mm may be used.

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Cement content and water-cement ratio (cf. DIN EN 206-1, 5.4.2) (60) Unless otherwise approved in the specifications, in order to determine the water-cement ratio in the fresh concrete by testing, – –

the effective water content should be determined using kiln-drying according to DBV-1, Chapter 3, and the cement and additive content should be taken from the information on actual levels in the delivery ticket.

In concretes for massive components (smallest dimension ≥ 0.8 m), the cement content specified in the suitability test must not be exceeded by more than 10 kg/m³. Air content (cf. DIN EN 206-1, 5.4.3) (61) If plasticising admixtures (CP, FA) and air-entraining agents (AA) are used at the same time, the specified minimum air content (DIN EN 206-1, Table F.2.2) should be increased by 1 vol. %. 5.5

Requirements for hardened concrete (cf. DIN EN 206-1, 5.5) General (cf. DIN EN 206-1, 5.5) (62) Compressive strength testing shall be carried out on a 28-day-old specimen. For concretes to which DAfStb-1 can apply, the test may be carried out on a 56-day-old specimen. A test age over 56 days is only permitted if approved in the specifications. Unless otherwise approved in the specifications, all other tests for hardened concrete characteristics (e.g. water penetration resistance, frost resistance (for XF3) and frost/deicing salt resistance (for XF4)) may, in deviation from the 28 days, be carried out at the same time as the compressive strength class test. Compressive strength (cf. DIN EN 206-1, 5.5.1.2). (63) Compressive strength testing may only be carried out using the cube or cylinder test. Water penetration resistance (cf. DIN EN 206-1, 5.5.3) (64) Water penetration resistance shall be determined on the basis of water penetration depth according to DIN EN 12390-8 and may not exceed 30 mm in the case of concrete for hydraulic structures.

6

Specification of concrete (cf. DIN EN 206-1, 6)

6.1

General (cf. DIN EN 206-1, 6.1) (65) Before the building work, the contractor shall prove, through suitability tests taking into consideration siteand structure-specific conditions (see Appendix 1), that the concrete can be reliably installed with the foreseen raw materials and the proposed consistency under the conditions on the site in question and that the required characteristics can be reliably achieved. (66) When the suitability tests are carried out, all influences relevant for the concrete (background climatic conditions, manufacture, transport, conveyance, installation, subsequent treatment, etc.) shall be taken into consideration. At the start of concrete installation, the suitability test must not date back more than 12 months. For all concretes, only the same raw materials (type, manufacturer, place of extraction) may be used as those used in the suitability test. (67) If concrete for concreting originates from several supplier factories, the entire suitability test shall be carried out with concrete from one of the factories. For the remaining supplier factories, at least one initial test in accordance with DIN EN 206-1 shall be carried out using the respective production equipment. The different travel times shall be taken into consideration in particular for future deliveries. (68) No later than 2 weeks before the start of suitability testing, the contractor shall supply to and coordinate with the client the following information: – –

– – –

Concept for the production of the concrete (site-mixed concrete or ready-mixed concrete) In the case of ready-mixed concrete, information on the location of the ready-mixed concrete mixing plant(s) including replacement mixing plant(s) and the distance and travel time between the mixing plant(s) and the site Information on the type, characteristics, origin and availability of the concrete raw materials Concrete formulations Planned building work

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(69) The suitability testing of concrete shall include at least the following standard tests: – – – – – –

visual evaluation of the fresh concrete characteristics (water discharge, cohesiveness, flow behaviour, sedimentation behaviour, etc.) fresh concrete temperature consistency of the fresh concrete compressive strength (incl. strength development r according to DIN EN 206-1, 7.2 and Table 12) gap tensile strength water penetration resistance

(70) Additional tests are necessary for the following concretes and exposure classes: – – – – –

for delayed concrete: setting behaviour For AA concrete: air content in fresh concrete at the place of installation For massive components: quasi-adiabatic temperature increase, static modulus of elasticity For XF3: frost resistance in accordance with BAW-MFB For XF4: frost/de-icing salt resistance in accordance with BAW-MFB

(71) When carrying out suitability tests, Appendix 1 should be consulted. For concretes that are manufactured using an air-entraining agent, – –

The compression strength class compliance check shall be carried out using the maximum permissible air content in fresh concrete at the place of installation during execution; The frost resistance check in accordance with Appendix 1, 3.4, shall be carried out on concrete with an air content corresponding to minimum air content according to DIN EN 206-1, Table F.2.2 and (61).

(72) The client shall be informed in good time of the start of the suitability testing to allow the client to participate in contractor’s suitability testing. (73) The results of the suitability tests shall be made available to the client in good time before the first installation of the concrete in question so that the client has sufficient time (unless otherwise stipulated in the specifications, at least the same time as for the execution of the suitability tests plus 3 weeks) to carry out monitoring tests to verify the suitability testing. The contractor shall provide the necessary raw materials for the monitoring tests at the client’s test location in accordance with what is stated in the specifications. (74) The contractor is obliged to carry out new suitability tests if the raw materials for the concrete (type, manufacturer, place of extraction) or the conditions on site are to be changed. 6.2

Specification for designed concrete (cf. DIN EN 206-1, 6.2) (75) To maintain the fresh concrete characteristics at the place of installation, possible changes in the fresh concrete consistency and air content due to conveyance at the site from handover to place of installation shall be taken into consideration. The contractor shall specify the target values of consistency and air content at handover for the manufacturer and document them. Additional requirements (cf. DIN EN 206-1, 6.2.3) (76) Surface finish concrete, see also (157) – (159), shall meet the following requirements: – –

6.3

The deviation of the w/c value from the target value must be limited to max. 0.02. The deviation of the spread dimension from the target value shall be limited to max. 20 mm.

Specification for designed concrete by composition (cf. DIN EN 206-1, 6.3) General (cf. DIN EN 206-1, 6.3.1) (77) Concrete by composition is only permitted if approved of in the specifications.

6.4

Specification of standard concrete (cf. (cf. DIN EN 206-1, 6.4) (78) Standard concrete is not permitted.

7

Delivery of fresh concrete (cf. DIN EN 206-1, 7)

7.2

Information from the manufacturer of the concrete to the user (cf. DIN EN 206-1, 7.2) (79) The strength ratio fcm,2/fcm,x (x = 28, 56, 91) for designating the curing period shall be determined on the basis of the corresponding strength values from the suitability testing.

7.3

Delivery ticket for ready-mixed concrete (cf. DIN EN 206-1, 7.3)

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(80) The delivery ticket for ready-mixed concrete shall contain the information listed in Table 2.3 of ZTV-W LB 215, be unencoded and, if required, automatically printed out. The delivery ticket shall contain a breakdown of target weight according to suitability testing and actual weight indicating the differences. The assumed surface moistness of the different grain fractions shall be clearly itemized. Delivery tickets must be handed over to the client. Table 2.3: Additional delivery ticket information for ready-mixed concrete according to ZTV-W LB 215

Seq. No

Pre-printed or entry by hand

2

X

3

Date and time of loading

X

4

Registration number of delivery vehicle

X

5

Name of purchaser

X

6

Designation and location of site

X

7

Details or references to the agreement, e.g. number in list directory, type key, order number

X

8

Building supervisory compliance marking, quoting DIN EN 2061

X

9

Name or ID of certification office

X

10

Time of arrival of the concrete on site

X

11

Time of start of unloading

X

12

Time of end of unloading

13

Concrete strength category

X

14

Exposure category (categories)

X

15

Strength development Type of use of concrete (unreinforced concrete, reinforced concrete, prestressed concrete) Target value of consistency

X

Origin, type and strength class of cement Origin, action group (type designation) and name of admixtures plus origin and type of additives Special characteristics, e.g. longer processing time

X

X

23

Nominal value of the largest grain in the aggregate Gross density category with lightweight concrete or gross density target value with heavy concrete Total actual quantity of aggregate per grain fraction

24

Total actual quantity of cement

X

25

Total actual quantity of additive

X

26

Total actual quantity of water (mixing water and own moisture)

X

27

Total actual quantity per admixture

X

28

Concrete delivery volume of vehicle in [m³]

X

16 17 18 19 20 21 22

7.4

Automatic printout

Name, address and telephone number of the ready-mixed concrete plant Delivery ticket number

1

1)

Information on the delivery ticket

X

X

X X

X

X1)

X

X X

X1)

If fluxing agent is added on site. The time of addition of the fluxing agent and the estimated residual quantity in the mixer drum before the addition must be indicated.

Delivery information for site-mixed concrete (cf. DIN EN 206-1, 7.4) (81) The information required for ready-mixed concrete according to 7.3 of DIN EN 206-1 is also required for site-mixed concrete and shall be given to the client.

7.5

Consistency at delivery (cf. DIN EN 206-1, 7.5) (82) Consistency on delivery may only achieve the specified value through use of fluxing agents. (83) The later addition of water is not allowed, even under special circumstances.

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8

Conformity check and conformity criteria (cf. DIN EN 206-1, 8)

8.1

General (cf. DIN EN 206-1, 8.1) (84) The tests on fresh and hardened concrete to be carried out by the contractor at handover are regulated in Part 3 of ZTV-W LB 215 (Chapters 4.3, 8.1 and 8.3 as well as additions to DIN 1045-3, Appendix A).

8.2

Conformity check for designed concrete (cf. DIN EN 206-1, 8.2) (85) The principle of concrete families under the conditions listed in DIN of the Draft 206-1, 8.2.1.1, may not be applied. Conformity criteria for characteristics other than strength (cf. DIN EN 206-1, 8.2.3.2, Tables 17 and 18) (86) In deviation from DIN EN 206-1, Table 17, the upper limit for deviations from the target value is +10 kg/m³.

8.4

Actions in case of non-conformity of the product (cf. DIN EN 206-1, 8.4) (87) If non-conformity is confirmed by the determination tests, the contractor shall notify the client immediately.

9

Production control (cf. DIN EN 206-1, 9)

9.5

Concrete composition and initial testing (cf. DIN EN 206-1, 9.5) (88) In the case of a new concrete composition, a suitability test according to Chapter 6.1 of ZTV-W LB 215 or an initial test may not be waived, even if long-term experience is available for a similar concrete or a similar concrete family. (89) Variations in the content of cement and additives for controlling the fresh and hardened concrete characteristics of a concrete must be limited to a range of -5 kg/m³ to +10 kg/m³ in each case.

9.9

Production control procedures (cf. DIN EN 206-1, 9.9) (90) The measures set out in DIN EN 206-1, Tables 22 to 24, may not be changed. (91) Examination of the water for components which are harmful to concrete according to DIN EN 206-1, Table 22, line 14, column “Minimum Frequency”, must be carried out in parallel with the building work at least semiannually.

Cf. Appendix A (normative), Initial Test (cf. A.1, General) (92) Initial testing may not be waived due to the availability of existing test results or long-term experience.

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Part 3 Building Work 3

Definitions (cf. DIN EN 13670, 3) (93) The place of installation is the part of the construction area where the concrete to be assessed will be installed.

4

Execution management (cf. DIN EN 13670, 4)

4.2

Documentation (cf. DIN EN 13670, 4.2) Construction documentation (cf. DIN EN 13670, 4.2.1) (94) For concrete cover, the provisions of Part 1, Chapter 4, of ZTV-W LB 215 shall apply. The type, number and layout of spacers and supports shall be shown on the reinforcement drawings. The layout of the expansion joints in the form of a waterstop system plan shall be submitted to the client as construction documentation for approval.

4.3

Quality management (cf. DIN EN 13670, 4.3) Execution classes (cf. DIN EN 13670, 4.3.1) (95) Concrete for hydraulic structures should be classified at least in execution class 2 according to DIN 13670, Table NA.1. Inspection of materials and products (cf. DIN EN 13670, 4.3.2) (96) For each shipment of materials and components, the contractor shall check the delivery ticket or packing slip for conformity with the information on the construction documentation. Insufficiently marked materials and components may not be installed. Inspection of the execution (cf. DIN EN 13670, 4.3.3) (97) The requirements given in Appendix 2 shall be taken into consideration. (98) Each concreting section will require prior approval from the client. Before this, the formwork, reinforcement, connection surfaces and installed components shall be checked by the contractor. The inspection by the contractor shall be recorded in a log. The log shall be submitted to the client.

4.4

Action in the event of non-conformity (cf. DIN EN 13670, 4.4) (99) ZTV-W LB 219 shall apply to repair measures. The measures to be taken shall be agreed on with the client in advance.

5

Falsework and formwork (cf. DIN EN 13670, 5)

5.1

Basic requirements (cf. DIN EN 13670, 5.1) (100) When testing formwork in accordance with DIN 19702, the largest calculated deflection of the formwork and the supporting structure may not exceed 5 mm in total, taking into account planned cambers.

5.2

Materials (cf. DIN EN 13670, 5.2) Release agents (cf. DIN EN 13670, 5.2.2) (101) Release agents for areas in contact with water and soil must be quickly biodegradable in accordance with RAL-UZ 64. To avoid mould and mildew formation, quickly biodegradable release agents are not permitted for interior spaces that are dry during use.

5.4

Design and installation of formwork (cf. DIN EN 13670, 5.4) General (102) The formwork concept (this includes formwork times, anchorage, anchor cone seals, release agents) shall be agreed on with the client before the start of the formwork works. (103) New, untreated wooden formwork shall be treated with cement sludge before first use and then cleaned. (104) Before the start of and during concreting, formwork and anchors shall be checked by the contractor to ensure that they are functioning properly.

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(105) Formwork anchors which leave continuous cavities may not be used where there is water pressure. Anchoring holes must be completely closed in such a way that the required component characteristics are also provided in these areas. The colour and surface structure of the filler should be matched to those of the component wherever concrete surfaces remain visible. Remaining anchor parts must end at least 50 mm below the surface of the concrete. The intended execution must be agreed on with the client. (106) The required position of the formwork must be recorded by the contractor on the basis of contractor’s own measurements. The correct position shall be confirmed by the contractor. (107) The formwork shall be absorbent or mildly absorbent in accordance with DBV-2; non-absorbent formwork is only permitted if approved in the specifications. (108) The vertical edge area of horizontal construction joints requiring formwork shall be tipped with a strip (e.g. a roof lath) so that the construction joint is closed, overlapping outward the next time concreting is carried out. (109) Formwork material shall be kept moist and be thoroughly wetted at least one day before concrete works. Here, concreting sections that are already finished and the concrete still to be installed must not be contaminated with water discoloured by rust. (110) Formwork boards shall be clean-edged, undamaged and, for level surfaces, at least 8 cm wide and comply at least with sorting category S 10. Unplaned boards must be at least 24 mm thick, and planed ones must be at least 22 mm thick. (111) The offsetting of the joints between formwork elements and between the first concrete surface and the second concrete surface may not exceed 5 mm. The height of the ridges left in the concrete surface may not exceed 5 mm. (112) Water-draining formwork tracks must not be treated with release agents. When installing the concrete, soiling of the formwork track above the concreting level should be avoided. Formwork tracks may only be used once to guarantee their drainage capacity. The evenness of the concrete surface shall be guaranteed. If internal vibrating units are used, a minimum distance of 10 cm from the formwork skin should be maintained. (113) Unless otherwise approved in the specifications, formwork surfaces in contact with water and air shall meet the requirements of surface finish concrete 2 in accordance with DBV-2. The concrete surface shall be executed closed and with few pores. With regard to porosity requirements, pores or holes 30 mm in diameter and/or 10 mm in depth are not permitted. (111) and (162) apply to offset and straightness requirements. (114) Fine mortar leaks shall be removed. 5.6

Inserts in formwork (cf. DIN EN 13670, 5.6) (115) Measures for the sufficient sealing of the formwork and to prevent any damage to the corrosion protection should be taken at the edges of the inserts. (116) If installed components are installed by third parties before concreting, the contractor shall be responsible for maintaining the correct position during installation of the formwork and concreting. The contractor must check that these inserts are properly fixed before concreting. (117) To avoid rust stripes on the concrete surfaces, untreated steel components shall be protected with suitable means until conservation is carried out. (118) An offset of > 3 mm between the concrete surface and the installed component is not permitted.

6

Reinforcement (cf. DIN 13670, 6)

6.1

General (cf. DIN EN 13670, 6.1) (119) The origin and grade of the reinforcing steel shall be verified by the contractor through delivery tickets 4 weeks prior to installation. (120) Prior to performing steps that will withdraw parts of the work from testing and assessment, the client shall be notified ahead of time in writing, and given the opportunity to request assessment of the status together with the contractor pursuant to Section 4 (10) VOB/B. At the same time, a building inspection pursuant to public law will be performed by the client.

6.2

Materials (cf. DIN EN 13670, 6.2) (121) Unless otherwise approved in the specifications, 4 spacers per square metre shall be installed.

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(122) Spacers between adjoining areas (e.g. formwork, concrete sublayer, foundation pit linings) shall be made from cement-bound mortar or concrete. Their characteristics shall be at least the same as those of the surrounding concrete. (123) S-hooks may only be used in combination with spacer brackets. (124) The reinforcement shall be supported by suitable devices which must be dimensioned for the necessary working processes. The secure position of the reinforcement shall be demonstrated by static calculations. (125) Installation openings for the concrete shall be provided in horizontal reinforcements with dense reinforcement layers. These openings (minimum 20 cm x 20 cm) shall be planned and marked in the execution plans and the location. 6.4

Welding (cf. DIN EN 13670, 6.4) (126) The welding of reinforcing steel is only permitted in justified exceptional cases and requires the client’s approval. In this case, tests according to DIN EN ISO 17660 shall be carried out.

8

Concrete work (cf. DIN EN 13670, 8)

8.2

Concrete specification and pre-concreting operations (cf. DIN EN 13670, 8.2) (127) Unless otherwise approved in the specifications, the client shall be provided with a concreting concept for approval at least 4 weeks before the first concrete installation and be provided with a concreting plan for approval at least 3 working days before each concreting. The concreting concept and concreting plan must contain at least the information according to Appendix 2. (128) Fresh concrete at the place of installation and hardened concrete in the building component shall possess the characteristics which are specified in the specifications and the suitability tests. (129) For components with the smallest dimension < 0.8 m, the fresh concrete temperature at the point of handover may not exceed 30 C, and max. 25 °C for subgrade concretes. (130) The following applies to massive components: – –

Fresh concrete with a temperature > 25 C at the place of installation may not be installed. For the first 168 hours (7 days) after the installation of the concrete, the maximum temperature increase in the component may not exceed the limit values given in Table 2.2, column 3 of ZTV-W LB 215, and the maximum building component temperature may not exceed the limit values given in Table 2.2, column 4 of ZTV-W LB 215, or any corresponding regulations in the specifications for components in other exposure classes.

Construction joints (131) The layout of the construction joints (including all sealing elements) shall be presented in plans and, together with the execution drawings, submitted to the client for approval. The execution of the construction joints (curing, preparation, type and number of sealing elements, joints in sealing elements, cleaning options, accessibility) shall be presented in detail in the concreting concept and the construction plans. The use of surface retarding agents in construction joints is not permitted. (132) Construction joints should run horizontally or vertically. In water level fluctuation areas (in the case of locks in the area of the top and bottom water level), they should be avoided. (133) To achieve sufficient bonding, the coarse granular structure of the concrete should be exposed in the joint surfaces. Roughness and surface quality of –

–

Construction joints without formwork shall, in the entire construction joint area including the subsequent concrete cover immediately before concrete installation, meet the requirements of the “corrugated” category according to DIN EN 1992-1-1, 6.2.5. For surfaces to be classed as “corrugated” using the Kaufmann method of measurement, they should have a mean profile height Rt ≥ 3.0 mm or a maximum profile height of Rp ≥ 2.2 mm or a minimum 6 mm aggregate exposure when using aggregate with dg ≥ 16 mm. Construction joints with formwork shall, in the entire construction joint area including the subsequent concrete cover immediately before concrete installation, meet the requirements of the “rough” category according to DIN EN 1992-1-1, 6.2.5. When using the Kaufmann method of measurement, surfaces to be classed as “rough” should have a mean height of the profile Rt ≥ 1.5 mm or a maximum profile height Rp ≥ 1.1 mm or a 3 mm minimum exposure of the aggregate, respectively.

(134) Immediately after concreting, the surface of the construction joints shall be cured in accordance with Chapter 8.5 of ZTV-W LB 215.

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(135) If expanded metal is used, it shall be completely removed from the construction joint prior to installing the concrete of the next concreting section. After that, the construction joint shall be treated to meet the requirements according to (133) for construction joints without formwork. (136) For wall or column type components (thickness < 0.8 m) or very strongly reinforced building components, a joint mixture with largest grain ≤ 16 mm shall be provided. The joint mixture should meet the same requirements as the remaining concrete in the relevant concreting section. (137) To ensure the water impermeability of construction joints in first stage concrete, additional sealing elements according to (133) shall be provided. Two internal sealing levels shall be provided in construction methods with expansion joints; in monolithic construction, a central sealing level shall be provided. (138) Joint plates shall be arranged in horizontal construction joints, and joint plates or elastomer waterstops with steel tabs in accordance with DIN 7865-1 shall be arranged in vertical construction joints. Half of the width of the sealing element shall be cast in concrete on both sides of the construction joint. Construction joint waterstops and plates shall be connected at the crossover points with each other and, if necessary, with expansion joint waterstops and at butt joints these shall be connected in a way that is watertight. Butt joints of elastomer waterstop shall be connected by vulcanisation only. Overlaps in the butt joint area of joint plates shall be sealed with a watertight edge. Joint plates shall be made of sheet metal with a min. 2 mm thickness. The minimum width of the joint plates shall be 300 mm. (139) In construction joints, as an additional safety measure for the concrete edge zone, an injection hose shall be inserted approx. 6 cm after the last reinforcement layer. The junction boxes shall be stored outside of the aforementioned areas. ZTV-ING applies for the filling agent and injection with injection hoses. Unless stipulated otherwise in the specifications, the injection shall be carried out under cement suspension. Acrylate gels as fillers are not permitted. The injection time shall be approved by the client. (140) On components bordering on interior spaces with special requirements for water impermeability (e.g. technology rooms), additional injection hoses shall be placed as potential secondary sealing in construction joints for later injections. The junction boxes shall be stored outside of construction joints in locations that will be accessible later on. ZTV-ING applies for injection with injection hoses. The injection time shall be agreed upon with the client ahead of time. Expansion joints (141) In construction with expansion joints, two sealing levels with internal expansion joint waterstops shall be provided in one expansion joint. The free ends of expansion joint waterstops shall be routed to run underneath the respective subgrade. Samples of expansion joint waterstops, possibly including the connection, test certificates (acceptance test certificate A in accordance with DIN 7865-2 with tests according to Table 1, 6.2 to 6.8, object-specifically 6.9 to 6.12, where applicable) and information on the material composition shall be submitted to the client for approval 6 weeks prior to installation. For each waterstop type used, 0.4 m of extra length shall be provided for the monitoring test. Samples for the monitoring test shall be taken in the presence of the client and documented by the contractor. DIN 18197 applies to the connection of waterstops. Site documentation in accordance with DIN 18197, Appendix B, qualification tests in accordance with DIN 18197, Appendix C and test reports in accordance with DIN 18197, Appendix E, shall be submitted to the client. 8.3

Delivery, reception and site transport of concrete (cf. DIN EN 13670, 8.3) (142) The contractor shall ensure that the proposed concreting is still carried out in the event mixing plants fail. Substitute mixing plants shall keep and use the same concrete raw materials as the proposed mixing plants. (143) If concrete pumps are used, it must be possible to use a replacement pump of the same capacity within 30 minutes in the event of a concrete pump failure. (144) Mobile mixers or vehicles with stirring equipment shall be completely unloaded after no more than 90 minutes, and vehicles without mixers or stirring equipment for the transport of concrete of a stiff consistency shall be completely unloaded no more than 45 minutes after the first addition of water to the cement.

8.4

Placing and compacting (cf. DIN EN 13670, 8.4) (145) The concrete shall be installed in horizontal layers of equal thickness fresh-on-fresh; the thickness of the individual layers should generally not exceed 0.5 m. (146) External shakers are only permitted for simultaneous use with internal shakers. (147) During the concreting works, a representative of the contractor with proven extended training in concrete technology (so-called ‘E Certificate’) shall be present on site and supervise the concrete installation. (148) Horizontal or slightly inclined surfaces of building components should be levelled off, as far as possible, with vibrating beams.

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(149) Before the surface treatment, the concrete should always be re-compacted. (150) If subgrade concrete according to (56) is installed “fresh-in-fresh” according to (16), suitable measures shall be taken to ensure that the subgrade concrete of the top 0.2 mm does not mix with the concrete below the subgrade concrete. 8.5

Curing and protection (cf. DIN EN 13670, 8.5) (151) Other curing methods than the ones according to DIN EN 13670, 8.5, are only permitted if approved in the specifications. (152) The use of curing agents shall be agreed on with the client. The suitability of the curing agents and their compatibility with the subsoil (separating agent) shall be demonstrated. On vertical surfaces, curing agents must be applied in two cycles (layers). Curing agents are not permitted in construction joints and interior spaces. (153) Determining the curing duration in accordance with DIN EN 13670, 8.5, is not permitted. Table 3.1 should be applied to determine the curing duration: Table 3.1: Minimum duration for the curing of concrete Strength development of the concrete r = fcm,2/fcm,x (x = 28, 56, 91) d) r  0.50 (fast)

r  0.30 (medium)

r  0.15 (slow)

Minimum total curing duration in days 4

10

c)

r < 0.15 (very slow)

a), b), e)

14

21

Of which minimum duration of curing in the formwork for concrete surfaces with formwork 2 a) b)

c)

d) e)

5

7

b)

10

For more than 5 h processing time, the curing duration should be extended accordingly. With temperatures below 5 °C, the curing duration shall be extended by the time during which the temperature was below 5 °C. The strength development of the concrete is described by the ratio of the mean values for compressive strengths fcm,2/fcm,x (x = 28, 56, 91), which was determined in the suitability test. Interim values for the curing duration may be used. For concrete surfaces which are exposed to wear in accordance with exposure classes XM2 and XM3, the minimum total curing duration should be doubled. The maximum value for the minimum duration is 30 days.

(154) For formwork-lined concrete surfaces which are exposed solely to exposure classes XC1 or XC2, and which are covered with earth after completion of the building component, no further curing is necessary after the minimum period of curing in the formwork as seen in Table 3.1. (155) For subgrade concrete according to (56), assuming that complete freezing of the concrete can be precluded, thermal insulation of the component surfaces is not permitted in the ‘fresh-on-firm’ execution variant according to (16). The subgrade surface must be protected against evaporation in both variants according to (16) immediately upon completion of concreting. To reduce heating due to sun radiation, the subgrade surface shall be covered with light-coloured or reflective foil. 8.6

Post-concreting operations (cf. DIN EN 13670, 8.6) (156) The hardened surface shall have a surface tensile strength of at least 1.5 N/mm².

8.8

Surface finish (cf. DIN EN 13670, 8.8) (157) If stricter requirements than those in 5.4 of ZTV-W LB 215 are approved of in the specifications, DBV-2 shall apply. However, the minimum requirements in (158) and (159) shall apply. (158) The contractor and the client shall agree on a formwork sample plan in good time. The layout and formation of the formwork, formwork anchors and cone closures (e.g. direction of formwork boards, joints, joint seals, formwork flaps and openings) as well as all other anchorage points (e.g. for climbing scaffold) shall be shown in a schematic.

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(159) The formwork shall meet the following requirements: – – – – –

Formwork joints shall be leak-tight, and any leakage of cement paste is to be prevented. The formwork skin shall be such that the formwork looks neat and tidy. Repairs to the formwork skin that change the appearance of the concrete surface are not allowed. In the case of board formwork, a leak-tight tongue and groove structure, e.g. under-jointed wedge tongue and groove work, shall be provided. Formwork with formwork skins from different manufacturers may not be used together within a building component.

10

Geometrical tolerances (cf. DIN EN 13670, 10)

10.1

General (cf. DIN EN 13670, 10.1) (160) Deviation limits of inserts are specified in the specifications.

4.6

Sections (cf. DIN EN 13670, 10.6) (161) The concrete cover on the finished component may exceed the nominal value c nom by no more than 20 mm.

4.7

Surfaces and edge straightness (cf. DIN EN 13670, 10.7) (162) Unless otherwise approved in the specifications, the following straightness tolerance requirements shall apply: – – –

The straightness of the top side of lock and weir floors shall be in accordance with DIN 18202, Table 3, line 1. The straightness of traffic areas (lock subgrade, operating rooms, quay) shall be in accordance with DIN 18202, Table 3, line 3. The straightness of vertical surfaces and undersides of ceilings shall be in accordance with DIN 18202, Table 3, line 6.

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Re DIN 1045-3, Appendix NB: Tests for the definitive fresh and hardened concrete characteristics NB.1

General (cf. DIN 1045-3, NB.1) (163) The principle of concrete families under the conditions listed in DIN 1045-3, Appendix NB, NB.1 (4) may not be applied. (164) In addition to DIN 1045-3, Table NB.1, the following minimum frequencies shall apply to monitoring categories 2 and 3 upon handover of the concrete from the ready-mixed concrete manufacturer to the contractor for each supplier plant: – –

–

The consistency of the first five vehicles and every fifth vehicle afterwards shall be inspected. The w/c value of the first two vehicles and every tenth vehicle afterwards shall be inspected, as well as where there is doubt as to the w/c value. The effective water content shall be determined according to DBV1, Chapter 3. The cement and additive content should be taken from the information on actual levels in the delivery ticket. The air-entraining pot shall be used to determine the fresh concrete particle density. If the core moisture of the aggregate is to be taken into account (water absorption in accordance with DIN EN 1097-6), its size shall be tested as part of suitability testing and a valid test certificate from the aggregate supplier shall be provided. In the case of concrete with requirements for minimum air content, the consistency and air content of the concrete in every vehicle shall be tested.

(165) The following tests shall be performed at the place of installation, documented and made available to the client: –

–

–

–

In the case of concrete with requirements for minimum air content, to verify processing characteristics and the stability of the air pores, the consistency and air content of the fresh concrete shall also be tested directly at the place of installation. For this, at each concreting section, the concrete in the first 10 delivery vehicles and then that in every 10th vehicle shall be inspected. For the testing of the gap tensile strength, unless otherwise approved in the specifications, for monitoring categories 2 and 3, at least 2 samples each for max. 300 m³ or 3 concreting days should be taken, whichever yields the greater number of samples. As far as the sampling process is concerned, DIN 1045-3, Appendix NB.2, line (2), should be noted. To test the water penetration depth (testing only at w/c > 0.55), unless otherwise approved in the specifications, with monitoring categories 2 and 3, at least 1 sample each for max. 300 m³ or 3 concreting days should be taken, whichever yields the greater number of samples. As far as the sampling process is concerned, Appendix NB.2, line (2), should be noted. In the case of concrete with requirements for frost/de-icing salt resistance XF4, the test according to BAWMFB shall be carried out at least once during building work, unless otherwise approved in the specifications. The samples should be taken directly at the place of installation.

(166) Regarding the fresh concrete characteristics at the point of handover, the client shall specify allowances in design for deviation that take into consideration any change in the fresh concrete characteristics between handover and place of installation. (167) If the results of above tests are insufficient, the concrete in this delivery must be rejected or may not be installed. (168) A function check of the technical equipment according to DIN 1045-3, Table NB.1, line 9, shall be carried out every fifth concreting day and shall be documented. (169) In the case of site-mixed concrete which is transported with ready-mixed concrete vehicles, the rules for ready-mixed concrete shall apply correspondingly. For ready-mixed concrete and site-mixed concrete which is transported in other ways, rules which ensure a comparable level of quality must be laid down and submitted to the client for approval. NB.2

Testing the compressive strength of concrete according to its properties if ready-mixed concrete is used (cf. DIN 1045-3, NB.2) (170) Concretes with the same raw materials, same w/c value but different largest grain are not considered to be one and the same concrete. (cf. DIN 1045-3, NB.2 (6)) (171) If a test according to DIN 1045-3, NB.2, (6), cannot be carried out, the client shall be notified immediately. (172) The use of non-destructive test methods (e.g. rebound hammer) is not permitted.

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Re

DIN 1045-3, Appendix NC: Monitoring the installation of concrete in monitoring categories 2 and 3 by the building company (173) After completion of the concreting work for the concreting section in question, or upon special request, the client shall promptly be given a summary and evaluation, including statistics, of the tests that have been carried out.

NC.2

Documentation (cf. DIN 1045-3, NC.2) (174) All documents (e.g. concreting log, summary of results) shall be kept separately for each concrete.

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Summary of regulations cited BAW-MFZ

BAW-MFB BAW-MZ BMVBS-AKR

DAfStb-1 DAfStb-2 DBV-1 DBV-2 DIN EN 196-8, DIN EN 197-1 DIN EN 197-4 DIN EN 206-1 DIN EN 450 DIN 488-1 DIN EN 934-2 DIN EN 1008

DIN 1045-2 DIN 1045-3 DIN 1048 DIN EN 1097-6 DIN 1164-10 DIN EN 1990 DIN EN 1992-1-1 DIN 7865-1 DIN 7865-2 DIN 7865-3 DIN EN 12390-8 DIN EN 12620 DIN EN 13055-1 DIN EN 13670 DIN EN ISO 17660 DIN 18197 DIN 18202 DIN 18331 DIN 19702 RAL-UZ 64 ZTV-ING ZTV-W LB 219

ZTV-W LB 215 Edition 2012

BAW Code of Practice “Limitation of Crack Widths resulting from Thermal Restraint Due to Hydration Heat in Solid Structural Elements” (MFZ), Federal Waterways Engineering and Research Institute, Karlsruhe BAW Code of Practice "Frost Resistance Testing of Concrete" (MFB), Federal Waterways Engineering and Research Institute, Karlsruhe BAW Code of Practice “Second stage concrete”, Federal Waterways Engineering and Research Institute, Karlsruhe Decree by the Federal Ministry for Transport, Building and Urban Development, Dept. WS on: DAfStb-2, DAfStb Guideline “Measures to prevent harmful alkali reactions in concrete (Alkali Guideline)” in its latest version, last: WS 13/5257.6/2, Bonn, 08.12.2010 Guideline “Massive concrete components“ Guideline “Measures to prevent harmful alkali reactions in concrete” DBV Code of Practice “Special methods for testing fresh concrete” DBV Code of Practice “Surface finish concrete” Methods of testing cement – Part 8: Heat of hydration – Solution method Cement – Part 1: Composition, requirements and conformity criteria of common cements Cement – Part 4: Composition, specifications and conformity criteria for low early strength blast furnace cements Concrete – Part 1: Specification, performance, production and conformity Fly ash for concrete Reinforcing steels: Grades, properties, marking Admixtures for concrete, mortar and grout – Part 2: Concrete admixtures; Definitions, requirements, conformity, marking and labelling Mixing water for concrete -Specification for sampling, testing and assessing the suitability of water, including water recovered from processes in the concrete industry, as mixing water for concrete Plain, reinforced and prestressed concrete structures – Part 2: Concrete – Specification, properties, production and conformity – Application rules for DIN EN 206-1 Concrete, reinforced and prestressed concrete structures – Part 3: Execution of structures – Application rules for DIN EN 13670 Testing concrete; testing of hardened concrete Tests for mechanical and physical properties of aggregates – Part 6: Determination of particle density and water absorption Special cement – Part 10: Composition, requirements and conformity evaluation for special common cement Basis of structural design, including National Annex Design of concrete structures, Part 1-1, General rules and rules for buildings, including National Annex Elastomeric-Waterstops for sealant of joints in concrete – Part 1: Shapes and dimensions Elastomeric-Waterstops for sealant of joints in concrete – Part 2: Material specifications and testing Elastomer waterstops for sealing joints in concrete – Part 3: Range of applications Testing hardened concrete – Part 8: Depth of penetration of water under pressure Aggregates for concrete; German version of EN 12620 Lightweight aggregates – Part 1: Lightweight aggregates for concrete, mortar and grout German version of EN 13055-1 Execution of concrete structures Welding – Welding of reinforcing steel Sealing of joints in concrete with waterstops Tolerances in building construction – Buildings German construction contract procedures (VOB) – Part C: General technical specifications in construction contracts (ATV) – Concrete works Solid structures in hydraulic engineering – Bearing capacity, serviceability and durability Basic principles for awarding the environmental marking RAL-UZ 64, an environmental marking for rapidly biodegradable lubricants and forming oils, RAL e.V., St. Augustin Additional technical terms of contract and guidelines for civil engineering works Additional technical terms of contract – Hydraulic Engineering for the Protection and Repair of Concrete Components of Hydraulic Structures, LB 219

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Appendix 1:

Suitability tests

Explanatory note: Suitability testing by the contractor includes tests similar to initial tests according to DIN EN 206-1 and additional tests specified in ZTV-W 215.

1

Fresh concrete testing

1.1

General Testing compatibility if several admixtures are used should take into account the climatic conditions on site and the concrete temperature. The stability of the air pores in concrete with artificially incorporated air pores should be demonstrated up to the place of installation (at the end of the pump hose in the case of concrete pumps). As part of suitability testing, for concrete of consistency class  F4, tests shall be carried out on fresh concrete before the addition of admixtures (starting concrete) and, where for the formula so provided for, after the addition of one or more admixtures.

2

Quasi-adiabatic temperature increase

2.1

Determination using large concrete blocks For each concrete, a large-format concrete block (approx. 2.0 m x 2.0 m x 2.0 m) shall be made according to specifications (Fig. 1). The block shall be provided on all sides with thermal insulation (d  360 mm; thermal conductance class 040 or less, sufficient compressive strength). Through-ties are not permitted. The fresh concrete temperature at installation must not fall below 15 C; the ambient air temperature during the test (duration: 168 h) must not fall below 5 C. Two temperature sensors (5 cm apart) should be positioned at the centre of the block. In each case, two further temperature sensors should be positioned on an imaginary line between the centre of the block and the middle of a side surface or the middle of the top side, at a distance of 5 cm and 50 cm from the surface (see Figure). The temperature sensors to be used are resistance detectors with a permissible variation of +/- 1 K. The measuring chain (temperature sensor, data logger, power supply) shall have an accuracy of ± 1 K for temperature recording. The documentation of the measuring chain (data sheets, data logger configuration, data processing) shall be enclosed with the measuring report. The change in temperature in the concrete block and the temperature of the ambient air shall be measured continuously over a period of at least 168 hours (7 days). It must be possible to determine the fresh concrete temperature T concrete and the temperature rise Tadiab,7d (temperature change detected by temperature sensors over 168 hours in the block centre) from the records.

• Temperature sensor Figure 1: Concrete block showing location of temperature sensor 2.2

Determination by calculation/measurement Unless otherwise approved in the specifications, the quasi-adiabatic temperature increase of the concrete shall be determined after 7 days: a)

by measurement using an adiabatic concrete calorimeter. The measurement shall be conducted over a period of at least 168 hours (7 days). The progress of the temperature shall be recorded continuously. The evolution in temperature must be continuously recorded. It must be possible to determine the fresh

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concrete temperature Tconcrete and the temperature rise Tq,adiab,7d (temperature change within 168 hours) from the records. The name of the institute to be entrusted with carrying out the calorimeter tests shall be submitted to the client for approval. b)

by calculation, taking into consideration the actual heat of hydration development of the cement determined in accordance with DIN EN 196-8.

3

Hardened concrete tests

3.1

Compressive and gap tensile strength The compressive strength and the gap tensile strength should be determined at the age of 2, 7 and 28 days, and for the verification of the compressive strength class at a higher age, additionally at this age. For this, for each test objective and test date, 3 test samples should be prepared, stored and tested according to DIN EN 12390. The gap tensile strength shall be carried out on cubic test samples in accordance with DIN EN 12390-6, Appendix A.

3.2

Resistance to water penetration The water penetration resistance (e  30 mm) shall be determined on the basis of the water penetration depth at the age of 28 days. For compressive strength testing at a higher age, the water penetration depth may be determined at that age in deviation from the aforementioned.

3.3

Static modulus of elasticity The static modulus of elasticity should be determined according to DIN 1048 1 at the age of 2, 7 and 28 days, and for the verification of the compressive strength class at a higher age, additionally at this age on three test specimens each.

3.4

Frost resistance Frost resistance testing is governed by BAW-MFB.

3.5

Frost/de-icing salt resistance Frost/de-icing salt resistance testing is governed by BAW-MFB.

1

DIN 1048 applies until a European test standard for e-modulus testing is available. After that, the European test

standard shall apply. ZTV-W LB 215 Edition 2012

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Appendix 2:

Concreting concept and concreting plan

1 Concreting concept The following additional records and information are necessary and shall be handed to the client in the form of an overall concept 4 weeks prior to installation of the concrete. a) List of concretes sorted by building component/use – fresh and hardened concrete characteristics, – exposure class. b) Concrete manufacture – – – –

supply and storage of raw materials (capacities, cement types/fly ash, mixing water, admixtures), ready-mixed concrete plants (distance and required transport time), distances both between mixing plants and site and between substitute mixing plants and site, obstacles on the transport or substitute route, e.g. rail-type railway crossings, long hilly distances, travel through towns, diversions, ferries.

c) List of building components sorted by component type (diaphragm wall, floor, walls, etc.) – requirements according to static loading and building sequence (when will which characteristics be needed, 2/7/28/56 day values, pressure, water impermeability, other), – installation quantities, installation times (capacity calculations, m³ concrete per hour, number of plants, vehicles, concrete pumps, staff, etc.), – concrete installation, compaction (consistency requirements, type of installation and compaction, concreting sections, reinforcement density), – requirements for concrete surfaces, type of formwork, use of prefabricated elements or partly prefabricated elements – requirements for construction joints. d) Testing of raw materials The results of the testing of all raw materials by the testing monitoring centres, and with aggregates, additionally the results of the factory’s own production tests, shall be forwarded continuously to the client. e) Construction joints – – – –

curing of construction joints, preparation of construction joints (accessibility, methods, point in time, distance from water and erosion material, protection against recontamination, etc.), sealing elements (type, number, installation location, securing of position during construction, butt joint execution, etc.), cleaning prior to concreting (accessibility, methods, openings/pump sumps for removing water, waste, erosion material, etc.).

2 Concreting plan The concreting plan shall contain at least the following information: a) Timetable – –

duration of concreting work, interruptions.

b) Building component plan – – – – –

requirements according to static loading and building sequence (when will which characteristic be needed, 2/7/28/56 day values, pressure, WU, consistency, other), installation quantities, installation times (capacity calculations, m³ concrete per hour, number of plants, vehicles, concrete pumps, staff, etc.), concrete installation, compaction (consistency requirements, type of installation and compaction, concreting sections, reinforcement content, 0-32 or 0-16), requirements for concrete surfaces, type of formwork, use of prefabricated elements or partly prefabricated elements manufacture of construction joints.

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c) Concrete sorted by building components/use/installation sequence – requirements (strength, water impermeability, frost resistance, temperature, monitoring category), – fresh concrete characteristics, other characteristics. d) Consideration of the effects of the weather – – – –

measures to maintain the fresh concrete temperature (+5°C to +25°C, cooling, heating), concreting at low temperatures/frost (aggregates, concreting on frozen components, thin components, monitoring component temperature), influence of weather conditions on concrete technology (consistency, hardening, air pore space), sufficient processing capability (addition of retarding agents).

e) Personnel plan (per layer of concrete) – – – – – – –

concrete installation/concrete production, supplying the concrete, conveyance of the concrete, curing of the concrete, internal monitoring – concrete testing, proof of special capability for monitoring category 2, documentation of concreting. The personnel deployment plan should list the proposed personnel by name and show the various qualifications f) Concrete manufacture –

list of supplier plants.

g) Concrete installation – –

specification of installation quantities, installation times, installation layers work instructions for installation and compaction, conveyance and curing.

h) Conveyance of the concrete –

pump plan – standby equipment – position adaptors.

i)

Monitoring the concrete manufacture

– – –

type and scope of fresh concrete tests, type and scope of quality control tests, hardening tests (e.g. at low temperatures).

j)

Development of heat, measurement monitoring

–

monitoring temperature differences, measurement programme, defining measurement points.

k) Curing plan – – – –

type of curing (formwork, mats, liquid curing agents), curing duration (depending on concrete formula, weather, etc.), timing of curing measures, timing of work on construction joints.

l)

Measures in the event of problems

–

failure of machinery and equipment during concrete production, supply and conveyance (mixer unit, vehicles, concrete pump, compaction equipment, etc.).

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