Ensuring best fixings practice www.the-cfa.co.uk How to test anchors on site in accordance with BS 8539:2012 Code of practice for the selection and installation of post-installed anchors in concrete and masonry. A guide for testers of fixings. 1 Introduction BS 8539 is arguably the most significant development in the use of construction fixings since the advent of European Technical Approvals (ETA)1 in 1997. It includes, for the first time in such a code, the acknowledgement of the importance of the role of the tester in ensuring that the full performance of a fixing can be realised. The CFA Guidance Note: Procedure for site testing construction fixings – 2012 is called up as a Normative reference within the code i.e. it is effectively part of the code. This “How to” guide summarises the responsibilities of people charged with the task of testing fixings on site and provides a degree of commentary on why the Code and Guidance Note are written the way they are. All stakeholders should acquire a copy of the code2. 1.1 The Code and the Guidance Note BS 8539 calls up the test regimes for anchors against the different circumstances when testing may be necessary i.e. it sets out how many tests should be carried out, to what load and how results should be treated. The Guidance Note summarises those test regimes and details the test procedures that should be used to carry them out i.e. how to set up test equipment and link it to the fixing under test, how to apply the load and monitor movement, how to record results etc. 1.2 Terminology Terminology used in the code is based largely on that used in ETA, in ETAGs (the Guidelines used to award ETA) and CEN Technical Specifications3 for anchors. This has resulted in the adoption of some terms and notation not previously used by the CFA or by some manufacturers. This is particularly significant for the testing of anchors and the reference to test loads etc. The term “load”, is used only in the general sense having been replaced by the terms “Action” and “Resistance”. Action being the load to be transferred from the fixture to the base material, and “Resistance” the capability of the anchor to resist the action. What was previously referred to as the “Applied Load” or “Unfactored load” is, in BS 8539, referred to as the “Characteristic action”. The precise meanings of the terms used in testing anchors are all detailed in the code and repeated in the CFA Guidance Note. The test load to be achieved in all tests which are NOT to be taken to failure is some multiple of the characteristic action. The factor used to determine the test load from the characteristic action will depend on the purpose of the test and is defined in the BS and repeated in the GN. For a detailed explanation of the differences between the new and old terminology see4. 1.3 Responsibilities The tester’s responsibilities, as called up in the BS, are limited to ensuring the tests are carried out to the correct procedures, that, where relevant, anchors are installed in accordance with the manufacturer’s instructions in the correct locations as required by the specifier and that results are recorded in a full and comprehensive manner and forwarded to whoever requested the tests. The tester is NOT responsible for prescribing test loads, for commenting on why anchors fail to deliver the expected performance or for calculating allowable loads from test results. CFA “How to” test anchors on site in accordance with BS 8539. (Issue 1. November 2013) 1 of 4 Ensuring best fixings practice www.the-cfa.co.uk 2 Test regimes. BS 8539 calls up test regimes for two stages of a project (determining allowable resistance when there is no manufacturer data and proof tests to validate the quality of installation) and for two statuses of anchors (those with ETA and those without). 2.1 Tests to determine allowable resistance. Tests may be required at an early stage in a project in order to confirm the suitability of an anchor in a particular base material and to determine the allowable resistance (allowable load) in that base material. Such tests are always carried out on anchors which will NOT be used on the job. These tests should not be needed for anchors with ETA for use in concrete as the necessary performance data is quoted in the ETA. For anchors with an ETA for use in masonry tests may be required if the base material of the job does not conform to that defined in the ETA (i.e. it is of the same category, e.g. solid brickwork, but is either not as large as the masonry units listed in the ETA or is not at least as strong as the masonry listed). For anchors with ETA which need these tests the BS necessarily calls up the test regimes outlined in the relevant ETAG against which the anchor was awarded its ETA. But these regimes require at least 15 tests to be carried out to failure and this number of tests may be regarded as excessive, especially with damage to the substrate possible from such tests, so an alternative approach is allowed by the BS - again testing anchors to failure but allowing more flexibility in the number of tests with a statistical approach to determining the allowable load which takes into account the number of anchors tested. For anchors without ETA again two approaches are allowed in the BS; a simplified method called “Preliminary tests” using just five tests, or a statistical approach similar to that for anchors with ETA as mentioned above. These regimes can be summarised as follows: Anchor status BS 8538 Test regime Test procedure reference CFA GN ref’ Anchor has ETA relevant to base Tests for allowable load not 3.1.2.1. material needed. Anchor has ETA but base 9.2 a) Test to relevant ETAG or 3.1.2.2. material does not conform. Test to 8538 Annex B.2.2.1. No anchor with ETA available and 9.2 b) Test to 8539 Annex B.2.3.1. 3.1.2.3. proposed anchor has no ETA. (Preliminary tests) OR Test to 8539 Annex B.2.3.2. 3.1.2.4. 2.2 Tests to check the quality of installation – Proof tests. This aspect is far more straightforward. Tests are required on a sample of anchors on all jobs except where anchors with ETA have been installed by a competent Installer5 working under supervision. The sample rate may be either 1 in 40 (in which case the proof test load is 1.5 x the characteristic action), or 1 in 20 (in which case the proof test load may be 1.25 x the characteristic action) and at least three. The latter test regime (1 in 20) matches the test regimes of the Scaffolding6 and Steeplejacking7 industries. Guidance is also given as to what action to take in the case of failures during proof testing. 2.3 Arranging for tests to be carried out. When a test is required it is important that the company asked to carry out the test has all the information they need to quote for the work and to carry out the tests. To help with the provision of this information the CFA publishes a form CFA Form 8539/04 Anchor Test Request which may be downloaded from the CFA website at www.the-cfa.co.uk section Guidance Notes and Downloads – CFA 8539 Forms. CFA “How to” test anchors on site in accordance with BS 8539. (Issue 1. November 2013) 2 of 4 Ensuring best fixings practice www.the-cfa.co.uk 3 Test equipment The following types of equipment are needed and are explained in more detail in the CFA GN. Equipment for Commentary See GN section Linking the tester with the Depends on fixing type and test objective, may be 6.2 fixing threaded coupler for projecting studs, adaptor to fit under bolt heads or nuts, clevis for eyes or ringbolts, pulling frame for bolts or nuts, special adaptors for e.g. rebar, remedial wall ties etc. Applying the load May be a test meter or hollow hydraulic ram 6.1 Showing the load Usually via a pressure gauge directly calibrated in 6.1 kN but may be by digital gauge. Supporting the test meter The distance of reaction loads from the fixing 6.3 or ram so as to direct centreline is given. Various different bridges are reaction loads away from available to meet these recommendations and load the fixing under test capacities. Monitoring movement if Generally first movement (required to be recorded in 6.4 needed all tests) may be determined by simple procedures and rarely requires detailed recording by e.g. dial gauge. If movement is to be recorded in detail the dial gauge needs to be remotely mounted (NOT on the bridge) so as to avoid being affected by the test. 4 Carrying out tests – More detailed test procedures are set out in the CFA Guidance note: Procedure for site testing construction fixings – 2012, section 4. 1 Confirm the test objective: e.g. to determine allowable load, and to which regime, or Proof Tests. 2 Confirm the required test load and number of tests. Check that the basis of the test load is the characteristic action (applied load or unfactored load). If the basis of the test load is the design action (or factored load) divide this by 1.4 to give the characteristic action from which the test load can be determined. 3 Check that the anchors to be tested are as specified, the locations are as requested (See GN section 5) and, if installed by others check, as far as possible, that anchors were installed to the manufacturer’s instructions. 4 Assemble the test rig to meet the test objective including reaction spacings. 5 Apply the test load slowly and progressively noting first movement (and recording the load) until the required test load – or failure load – is reached. 6 If monitoring movement apply the load in increments allowing both load and displacement to basically stabilise at each increment before recording displacement and load (See GN section 4.1 on the subject of load relaxation). 7 If failure has occurred note the load at which it occurred, any displacement if possible, and the mode of failure (see GN section 4.1). CFA “How to” test anchors on site in accordance with BS 8539. (Issue 1. November 2013) 3 of 4 Ensuring best fixings practice www.the-cfa.co.uk 5 Recording results – drawing conclusions and making recommendations. Results should be recorded as per the BS and CFA GN where the requirements are listed in section 8.1. Enough detail is required so as to demonstrate that the test objectives have been met and to ensure that any questions that may be asked by the person requesting the tests can be answered. Test reports should contain merely the results of tests. Unless the person carrying out tests is particularly knowledgeable and experienced in the whole subject of anchor technology no conclusions should be drawn as to why anchors may have failed or what remedial action should be taken in that event. Testing companies who feel in a position to draw conclusions or make recommendations should ensure they have appropriate levels of professional indemnity insurance. 6 Working out allowable loads Methods for calculating allowable loads are detailed in both the BS and CFA GN and will not be dealt with here. They are not the responsibility of the tester but of the engineer calling for the tests. Despite this a format for the reporting of results for this tests is provided for CFA Approved Testers which includes sections for the calculation of allowable resistance. 7 Approved Tester companies - Competent Testers The CFA offers Associate Membership to companies as “Approved Testers” as long as they satisfy the CFA qualification requirements. Membership entitles companies to training at the CFA Academy for their staff to become certified as Competent Testers. Training covers basic anchor technology as well as CFA procedures for site testing to comply with BS 8539. Method statements and report formats are provided. 1 For more information on ETAs see CFA Guidance Note: ETAs and design methods for anchors used in construction. www.the-cfa.co.uk go to section Guidance Notes and downloads. 2 For copies of British Standards relating to construction fixings, at a discount of 20%, contact the CFA via our website www.the-cfa.co.uk. 3 Design methods for anchors with ETA may be contained in CEN Technical Specifications in the series CEN TS 1992-4 Parts 1 – 5. (Otherwise they are as the relevant ETAG.) 4 CFA Guidance Note: Anchor terminology and notation 5 For competent installer training contact the CFA secretariat via the website. 6 See CFA/NASC Guidance Note TG4:11 – Anchorage systems for scaffolding. 7 See CFA/ATLAS Guidance Note: Anchorages for steeplejacking CFA “How to” test anchors on site in accordance with BS 8539. (Issue 1. November 2013) 4 of 4