Stati-CAL

structural reinforcement
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TECHNOLOGICAL INSTRUCTIONS

STRUCTURAL SUPPORT

  1. IN GENERAL
  2. This technological procedure is intended only for the in-house needs of the application companies executing the STATI-CAL system and applies for execution of structural support. It is intended for workers of companies that take part in offer, preparation and realisation work. All workers must be provably acquainted with this basic technological regulation and also with the manual of the manufacturer or importer of the specific Stati-Cal system technology.

    The Described technological procedure does not deal with performance of individual structural repairs. These are the subject of individual procedures for their performance.

    Realisation of structural support is achieved by:

    • increasing the structural carrying capacity of perimeter walls
    • increasing the structural carrying capacity of roof attics
    • increasing the structural carrying capacity of balcony panels
    • increasing the carrying capacity of other parts of the building

    The training of workers by suppliers of the Stati-Cal System technology is necessary for execution of structural support. The system can only be applied by a company that has been trained in the theory and practice of installation and may prove this fact by submitting a valid “Certification”.

    According to act no. 22/1997 Coll., it is the duty of the manufacturer or importer of the structural support to issue a declaration of consistency before introducing it onto the market. Without the existence of the declaration of consistency it is not possible to realise the given Stat-Cal System technology.

    A prepared execution project, which deals with the structural support of the building or part of the building, is necessary for realisation.

  3. MATERIALS
  4. The following materials are used for performance of the structural support:

    Stainless steel helixes, quality level AISI 304, 316 (BS)

    A summary of tensile strength:

    identification force during failure strength (N) cross section area
      declared min max  
    Stati-Cal rod diameter 6 mm
    length 1000-10 000 mm
    9.000 9.850 9.900 9,00 mm2
    Stati-Cal rod diameter 8 mm
    length 1000-10 000 mm
    9.800 10.600 10.900 10,80 mm2
    Stati-Cal rod diameter 8 mm
    length 300-1000
    9.800 10.600 10.900 10,80 mm2

    The technical parameters of Stati Cal 30 N mortar:

    Sequence number Assessed property Test procedure Measured value
    1 Tensile strength during flexion after 7 days ČSN 722450 6,18 Mpa
    2 Tensile strength during flexion after 28 days ČSN 722450 8,47 Mpa
    3 Compressive strength after 24 hours ČSN 722450 6,3 Mpa
    4 Compressive strength after 3 days ČSN 722450 20,1 Mpa
    5 Compressive strength after 7 days ČSN 722450 26,3 Mpa
    6 Compressive strength after 28 days ČSN 722450 34,9 Mpa
    7 Adhesion to base after 28 days ČSN 722451 0,81 Mpa
    8 Natural radionuclide contents Establishment ins. 10,5 ± 1,7 Bq . kg-1
    9 Adhesion to concrete after 28 days STN 73 2577:1981 0,92 Mpa
    10 Frost resistance after 15 freezing cycles STN 73 2579:1981 98,2 coefficient %

    When storing materials the instructions of the manufacturer of the Stati-Cal System apply. In general it applies that a dry store must be available at the construction site, where a temperature of at least + 5 °C will be maintained, if the manufacturer prescribes it some materials must be protected against frost. Stack packages of filler to a height of 4 items at most

  5. EQUIPMENT AND PREVENTIVE MAINTENANCE
  6. When executing structural support light to medium light scaffolding must be used according to the situation. The scaffolding structure must satisfy ČSN 73 8101. The scaffolding must be built at a distance of at least 25 cm from the final surface of the façade – while adhering to safety principles, so that there is sufficient space for due performance of the work according to the technical regulations.

    If raining the scaffolding boards must be set so that the walls are not soiled. The scaffolding anchors must be situated so that water cannot penetrate into the clamp rings.

    We recommend that special anchors with an eye for anchoring the scaffolding, fixed to wall plugs permanently fixed to the building, which can also be used later on for potential repairs to the façade, are used.

    For milling and drilling apertures, groove planes with a vacuum, vacuums with an extension and drills are used. Walling hammers, flat chisels, scrapers, flat brushes and sprayers (for moistening) are also used.

    During preparation and application of Stati-Cal 3ON mortar and the subsequent laying of stainless steel Stati-Cal ø 6 and ø 8 mm wires (rods) and Stati-Cal ø 6 and 8 mm anchors we use high-speed mixers, trowels, pallet knives, joint smoothing trowels, hammers, nails, drills, a plastic bucket, application gun + extension .

    Basic preventive maintenance consists of thoroughly cleaning the tools after completed work. The manufacturer’s instructions apply for maintenance of machinery. The foreman or building inspector is responsible for ensuring preventive maintenance.

  7. EXECUTION OF THE STRUCTURAL SUPPORT
    1. Climatic conditions
      • the temperature of the air, base and embedded materials must be at least +5 °C
      • it is recommended that work is performed during exterior temperatures of up to +35 °C
      • it is forbidden to add any additives to the structural support components (for example against freezing, etc.)
      • when executing the structural support is it necessary to prevent rain and excessive sunlight affecting the applied mortar (we recommend use of a suitable protective plastic sheeting or textile).
    2. Storing materials
      • amage to the packaging and actual materials must be prevented
      • adhere to the time limits for storage set by the manufacturer (given on the packaging, potentially in the technical conditions)
      • Stati-Cal 30N mortar should be stored in heated and dry stores (+5 °C), stack to a height of 4 packages
      • Stati-Cal rods are stored in bundles, horizontally or hung in a clean and dust-free environment without burdening
      • stainless steel Stati-Cal anchors should be stored in suitable packaging
      • all building rubble is placed on controlled dumps, or samples of historical masonry materials are stored in the warehouse of the application company
    3. The basis for application of the Stati-Cal System technology
      • scaffolding – must be built at least 25 cm from the final surface of the façade – while adhering to safety principles
      • collection of samples for a historical-building survey by a specialist worker at the sites of application
    4. Preparatory work
    5. It is always necessary to follow the instructions of the manufacturer of importer of the applied technolog

      • grooves and boreholes, must be executed according to the project documentation
      • grooves and boreholes must be thoroughly mechanically cleaned and duly moistened
      • keep milled grooves level (using lathes or other aids)
      • at sites with electrical mains, establish where the electrical mains are situated by means of a suitable instrument, so that the electrical mains are not cut
      • disassemble structural elements fixed to the surface, after the grooves are milled and the wires laid, these can be fixed back again, or mill the groove beneath the structural element!
      • the specific project documentation is always used during actual realisation
    6. Realisation of the structural support
    7. It is always necessary to follow the instructions of the manufacturer of importer of the applied technology!

      • grooves – using a milling machine or boreholes - using a drill, are created
      • the grooves must be made as horizontal as possible (using lathes) and the borehole angles must also be as horizontal as possible (using equipment for boreholes)
      • the special mortar intended for the grooves is applied to these grooves and boreholes by methods prescribed by the manufacturer or importer of the applied system
      • the level of the grooves and borehole angles is checked
      • when laying the wires into the grooves we must take care that the applied wire is situated in the middle of the mortar bed and is fixed uniformly within the groove using supporting equipment
      • if necessary we use wedges and nails, which keep the wire in the prescribed position, after the mortar dries we remove the wedges and nails.
      • if the groove length is longer than 10 m, lay the applied wires, which are only supplied in bundles of 10 m, over each other according to the technological instruction
      • use a suitable smoothing trowel to smooth the last layer of applied mortar, so that the mortar mixture is homogenous and the mortar, wire and building structure are perfectly joined. If it is necessary to fill in a join with plaster, leave the groove 10 – 25 mm without mortar and do not smooth
      • open cracks are filled by injection of suitable mortar
      • after the mortar dries, approx 24 hours, we smooth over the remainder of the groove using façade mortar and clean off.
    8. Finishing work
      • after cleaning off the grooves the overall appearance of the façade is neatened
      • before disassembling the scaffolding the elements removed from the façade are affixed again.
  8. QUALITY CONTROL
  9. When executing structural support the following is also performed:

    • inspection of the project
    • inspection of the materials and products
    • inspection of the performed work
    • final acceptance inspection
    1. Inspection of the project
    2. The project must fulfil the requirements of valid Czech technical standards. The project must be prepared by an authorised engineer in the sphere of structural engineering. The contractor ensures inspection of the project.

      Apart from the technical description the project must include solutions to:

      the structural requirements, particularly according to ČSN 73 0035, ČSN 73 0038 and related standards

    3. Inspection of materials and products
    4. Materials and products intended for embedding into the system must correspond to the specifications in the details given in the declaration of consistency and in the project.

      The following are inspected on the supplied materials:

      • the serial number on the labels of the wire and anchor bundles
      • triple packaging of the mortar – visual inspection of damage to packaging
      • documents regarding material properties
    5. Inspection of the performed work
      • inspection of the authorisation for execution of the structural support system
      • continuous records of the climatic conditions and adherence to the prescribed technologies into the building ledger
      • inspection and records of the performed work, the temperature during the performed work and the hardening of the mortar, selectively
      • maintaining the level and depth of the grooves, the angle and depth of the drilled apertures
      • inspection of the laying of wires and application of mortar
      • inspection of works whether they correspond to the given project documentation
    6. Final acceptance inspection
    7. The final acceptance inspection of the structural support is performed after the surface treatment has dried out. During the inspection the results of all the individual inspections given in article 5.1 to 5.2 of this technological procedure and the effectiveness of potential rectifying measures are evaluated.

      The user is provided with the conditions for use.

  10. SAFETY AT WORK AND PROTECTION OF HEALTH, FIRE PREVENTION
    1. Safety at work
    2. During execution it is necessary to adhere to the valid safety orders and regulations. The basic regulations are the Labour Code no. 126/1994 Coll, as amended and ČÚBP (Czech Institute for Safety at Work) decree no. 324/1990 Coll., regarding safety at work and technical equipment during construction work…It is particularly necessary to follow safety regulations during transport and handling of the equipment.

      Preparation of the construction site will be supplemented in the supplier documentation to this basic technological procedure according to the specific conditions of the given construction site:

      • sequence and parallel execution of work operations,
      • use of special machines and aids (also in connection with the manufacturer’s instructions),
      • specific types and varieties of supporting structures (platforms, scaffolding, supporting structures),
      • technical and organizational measures to ensure safety of workers, workplaces and the surroundings
      • measures to secure the workplace (potentially the building site) for the period during which no work is being performed at it,
      • measures for cases of extraordinary conditions.

      Special attention should be paid to assumption of the builder’s scaffolding before the work is commenced. The requirements for scaffolding are given in ČSN 73 8108, 73 8107, 73 8105, 73 8112, 73 8111 and 73 8110. A record must be made of assumption of the builder’s scaffolding.

      All workers must equipped with personal protective work aids /gloves, goggles, work clothing, work shoes, respirators, helmets, etc./. During application of these systems do not eat, drink or smoke and protect hands using gloves. After work wash hands and treat them with a suitable regenerative cream. If the batch liquid or mortar comes into contact with eyes, immediately rinse with a stream of clean water, boric acid and ensure medical treatment.

      Care must be taken that the workplace is kept tidy and that hygienic regulations are also followed.

      The foreman or the building supervisor of the construction work in question is responsible for adherence to safety at work and personal protective aids. The machinery may only be operated by trained and knowledgeable persons.

      The foreman and building supervisor are also responsible for all the workers being duly instructed and trained in safety at work. A training ledger is kept at the building site into which the trained workers confirm their participation at the training course with their signature.

    3. Fire prevention
    4. During execution the fire prevention regulations of the building, prepared during preparation of the building site, must be adhered to.

  11. THE ENVIRONMENT
  12. When executing the structural support there are no special requirements. Packaging must be disposed of according to the manufacturer’s instructions. A waste management program according to the statutory regulations must also be prepared and followed.

    In general the following in particular must be assessed, taken into account and ensured within the scope of preparation of the building site:

    • act no. 17/92 Coll. Environment Act
    • act no. 244/92 Coll. Assessment of Impact on the Environment Act
    • act no. 125/97 Coll. Waste Act with related decrees no. 337, 339 and 340/97 Coll.
  13. RELATED REGULATIONS
    1. ČSN standards
      • 73 8105 Wooden scaffolding
      • 73 8107 Tubular scaffolding
      • 73 8108 Shoring scaffolding
      • 73 8110 Steel pipes for shoring and builder’s scaffolding. Requirements and tests.
      • 73 8111 Builder’s and protective element scaffolding (System scaffolding). Materials, components, dimensions, burdening and safety requirements.
      • 73 8112 Mobile builder’s element scaffolding (System scaffolding). Materials, components, dimensions, burdening and safety requirements.
      • 73 8101 Scaffolding common provisions.
      • 73 0802 Fire prevention for buildings. Non-production structures.
      • 73 0804 Fire prevention for buildings. Production structures
      • 73 0818 Fire prevention for buildings. Occupation of a structure with persons.
      • 73 0831 Fire prevention for buildings. Assembly areas.
      • 73 0835 Fire prevention for buildings. Modification to structures.
      • 73 0864 Fire technical properties of material. Determining the heating power of flammable solid substances.
      • 73 0035 Burdening engineering structures.
      • 73 0038 Design and assessment of engineering structures during reconstruction.
    2. Other regulations
      • Labour Code - act 126/1994 Coll., as amended and the execution regulation by the Czech Republic government no. 108/1994.
      • ČÚBP (Czech Institute for Safety at Work) decree no. 324/1990 Coll., regarding safety at work and technical equipment during construction work.
      • Act no. 20/1996 regarding care and health of people

      Act no. 22/1997 Coll., regarding technical requirements for products and governmental order no. 178/1997 Coll., which determines the technical requirements for building products including the attachment – according to the provisions of act no. 22/1997 Coll., regarding technical requirements for products and the amendment and supplementation of some acts, as amended in act no. 71/2000 Coll., and Section 6 of governmental order no. 178/1997 Coll., as amended in governmental order no. 81/1999 of the Collection of laws of the Czech Republic.