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Hilti Direct FasteningBrochure
Hilti Direct Fastening – can reduce your labour time by up to 65%.
Hilti. Outperform. Outlast.
Direct Fastening Brochure
2
Welcome.
At Hilti, we are committed to working with you as partners in your field of expertise to help maximise your business. Hilti offers innovative and quality solutions to support you, along with various ways to contact us and make your life easier.
Customer Services
• AvailableMondaytoFriday8.00amto6.00pm• HighlytrainedteamofCustomerServicesAdvisors• Provideproductadvice,orders,deliverytracking
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• Hiltiwebsiteavailable365daysperyear24/7• Personalisedself-servicepurchasingwithtailoredprices• Standardnextworkingdaydeliveryisfree-of-chargeforallonlineorders
Account Managers
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Field Based Engineering
• Nationwideteamofexperiencedandqualifiedengineers• Comprehensivetechnical/engineeringadviceanddesignsupport• Technicalseminars,on-sitetestingandinstallationguidance
Telephone:0800 886 100 (GB) 1850 287 387 (IRE) Fax: 0800 886 200 (GB) 1800 654 600 (IRE)
Online: www.hilti.co.uk www.hilti.ie
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Support Engineering
• CentralEngineeringofficestaffedbyexperiencedandhighlytrainedengineers• Adviceandcalculationassistanceavailable• OnlinecomprehensiveTechnicalLibrary
Repair Centres
• ArrangeforrepairsviaHiltiCentres,CustomerServicesoronline• Pick-upanddeliveryavailable• AimtohaveHiltitoolbacktoyouwithin3-5workingdays
Outstanding service for a product lifetime.Theuniqueservicepackageforthosewhoprefertoowntheirowntools.
Hiltitoolsarebuilttolast.Butevenifadefectoccurs,Hiltiwilltakecareofit.Quicklyandprofessionally,completelyfreeofchargeforupto2yearsfromdateofpurchase.Afterthatwecontinuetoprovethequalityofourproductsbyputtingalimitonwhatarepaircancost–foraslongasyoucontinueusingyourHiltitool.Weevengiveyoualifetimemanufacturer’swarrantyagainstmanufacturingdefects.That’snotjustreassuringtoknow,it’suniqueinthisfield.
We manage your tools. Soyoucanmanageyourbusiness.
WithHiltiFleetManagement,afixedmonthlychargecoversalltool,serviceandrepaircosts.Thatgreatlysimplifiesyourfinancialplanningandtakesaloadofadministrativeworkoffyourshoulders.Therearenohiddencosts.Alltoolsinthefleetarereplacedatregularintervalswithtoolsofthelatestgeneration,thushelpingtoavoidcostlydowntimeandensuringcompliancewiththelatestsafetystandards.
Direct Fastening Brochure
NOCOSTS
MANUFACTURER’SWARRANTY
REPAIRCOST LIMIT
LIFETIMESERVICE
2Yearsup to
LifetimeLifetime
Direct Fastening Brochure
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Productivity.
Hilti Direct fastening is an innovative system that will make a large number of fixings quickly and safely with no need for power supplies or skilled labour.
• Canmakeinexcessof1000fixingsperday• Fixintoawiderangeofbasematerialsincludingsteelandconcrete• IntegrateswithHiltipositioningsystemstosavemarkingouttime• Specialistfastenersavailabletosuitdifferenttrades
ControlledtestscarriedoutbyBSRIAwhodescribethemselvesasperforming“Independent Certification and performance verification”showthatinacomparisonwiththetraditionalmethodswhenfitting200mmcircularductworkovera6metrelengthandafancoilunitthetotalinstalledcostwas36%lower.
Thesametrialalsoshowedthatthelabourcontentoftheoperationwasreducedby65%.
Thetestwascarriedoutonanactiveconstructionsiteandinvolvedaprojectteamofconstructionprofessionals.
Installed cost
Traditional Direct Fastening
100%
50%
0%
64%
Installedcost
Source:BSRIA
5
The Hilti Difference 65% savings
HiltiDirectfastening(DX)istheultimatecordlessfasteningsystemdesignedwithproductivityinmind.DXfasteningmethodscanreducelabourtimebyasmuchas65%andinstallationcostsby36%.
Contents
Welcome 2-3
Productivity 4-5
WhatisDirectFastening? 6-7
BenefitsofDirectFastening 8-9
HealthandSafety 10-11
SystemSafety 12-13
FasteningSafety 14-15
FasteningtoSteel 16-17
FasteningtoConcrete 18-21
FireData 22-23
Cartridges 24-25
ApplicationExamples1-5 26-34
Training 35-36
RiskAssessmentGuidance-DX 37
LifetimeServiceforDX 38-39
Approvals 40-41
Loaddata 42
QuickReferenceGuide 43
Labour time
Traditional Innovative DirectFastening
100%
35%
0%
35%
Installedcost
Source:BSRIA
Direct Fastening Brochure
By direct fastening we mean using a powder charge to “drive” a fixing which can be a nail, stud or specialised fastener into a solid base material.Fixingscanbemadedirectlyintothebasematerialorinothercasesthroughanothermaterialinordertofixitontothebasematerial.Basematerialcanbesteel,concreteormasonry.
DXisthenamegiventoHiltidirectfasteningproducts.
Direct Fastening for more than 50 yearsPowderActuatedfasteningwaspioneeredbyMartinHiltiduringthe1940’sandtheDXrangeasithasbecomeknownwasoneoftheearliestproductsinHilti’sindependentproductline.Developedfromanearlybasicdesign,MartinHiltiwassoenthusiasticaboutthetoolsabilitytodrivenailsintoavarietyofthesematerialsincludingconcreteandsteel,thatheboughttheoriginaldesignandpatentrights.MartinHilti’scompanyasinnovativethenastheyaretoday,settoworkimprovingandrefiningthedesignanditssafety.Introducedtothemarketin1952withfurtherrefinementsin1953theseearliermodelsweresoldunderthebrandnamePerfixuntil1954whentheHiltinamewasadoptedforitsgrowingandimprovingproductlines.
InnovationfollowedinnovationthroughtheearlyfiftiesleadingtotheintroductionoftheDX100in1957,morethanfiftyyearsago.
TheDX100,ledHilti’sexpansionintotheinternationalmarketthroughoutEuropeandintotheAmericas,ultimatelyleadingtotheformationoftheHilticorporationin1960.
Thestoryoftheinception,developmentandcontinuinginnovationofthatoriginalmachinetotheDXmachinesthatweknowtodayillustratesthephilosophythatdrivesHiltianditscommitmenttoprovidethebesttoolsforthejob.
Still in use today!Hiltiregularlyreceivescallsfromcustomersstillusingtheiroriginaltoolswhichinsomecasescouldbeupto50yearsold!Wearehappytosupplypartsandconsumablesforthesetoolswheretheyarestillavaiable.
What is Direct Fastening?
Direct Fastening Brochure
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DX 460 and X-FS formstop.
Direct Fastening Brochure
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Fastening SystemDirectfasteningsystemsaredevelopedandtestedasacompleteSystem.Thetool,magazine,fastenerprogrammeandcartridgeprogrammeforma“technicalunit”.Thismeansthatoptimalfasteningwiththissystemcanonlybeassuredifthefastenersandcartridgesspeciallymanufacturedforit,orproductsofequivalentquality,areused.ThefasteningandapplicationrecommendationsgivenbyHiltiareonlyapplicableiftheseconditionsareobserved.Selectingthecorrectcombinationoftheseelementsisessentialtoensurethathighqualityfasteningsareachievedquickly,safelyandreliably.
System SelectionThesystemselectionstartswiththeapplication,anexampleofcorrectsystemselectionisshownbelow.
Example:Fixing wood to concrete to hold formwork in place•Basematerial: Newconcrete,<6monthsold(strength<35N/mm2)•Materialtobefastened: Wood–25mmthick•Loadrequired: <0.4kNShearandTension•Environment: Shorttermexposuretoweather(i.e.during construction)
As time period is short, stainless steel is not required in this case. Concrete base material – embedment required 27+/-5mm. Material thickness to be fastened – 25mm– Fastenerlength–52mmLoadrequired<0.4kN/fasteningShearandTension– Possiblefastenerchoices(notcompletelist)are:•X-DNIP8/S12...(ispull-overaconcern?)•X-SL-DP8...(isfastremovalrequired?)•X-DNI-MX...(arerepetitivefasteningsrequired?)•X-SL-MX...(repetitiveinstallationandfastremoval)Chose X-SL-MX 54mm
DX 460-P8 tool
Magazine nails required to use •MX72FastenerGuide
X-460-P8 standard piston
Cartridge selection. To be checked on site
Step 1 – What is the Application?
Step 2 – What fastener do I require?
Step 4 – Fastener Guide
Step 3 – Tool
Step 5 – Piston
Step 6 - Cartridge / Power Setting
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Productivity Theabilitytomakedirectfixingswithouttheneedtodrillanyholesissimple,fast,safeandhighlyproductive.TheHiltiDXfasteningsystemcanbelearnedquicklybyoperatives,toofferaversatilefasteningtechnique.EveninthehardestandthickestbasedmaterialsDirectFasteningcanbeusedbutinthesecasespilotholesmayberequired.AskaboutourX-BT(steel)andDXKwik(concrete)solutions.
DXfasteningtoolsarecompletelyselfcontainedrequiringonlythenecessaryconsumables(fastenerandcartridge)forthetoolandthejobitistherefore,theultimate cordless fastening system.
Theresultisthatfixingsaremadequicklyandefficiently,reducing-projecttime,labourcontentandinstigatingoverallcostsavings.
• Noskilledlabourrequired• Higherproductivity• Lowerinstallationcosts
Benefits of Direct Fastening.
Total installed cost comparison: 100 fixings100%
50%
0%
64%
Installedcost
TraditionalInnovative DirectFastening
Forward Planning
SpecificationThebenefitsofdirectfasteningscanbemaximisedifinstallationdrawingsareproducedthatwhereverpossibleusecommonlevels,whichsimplifytheprocessofsetting-out.Thiswillenabletheeffectiveuseofmodernlasersetting-outdevices,whichcanoperateinconjunctionwithpowder-actuatedfasteningtoolstoprovideaquickmethodoflocatingfixingpoints.
FulltechnicalinformationisavailableviaHiltiTechnicalServiceson:
GB01618861144orgoonline: www.hilti.co.ukIRE1850287387orgoonline: www.hilti.ie. Hilti PR15
setting-out laser.
Direct Fastening Brochure
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Theillustrationsbelowshowsomeofthemainreasonswhycontractorsareinterestedtousepowderorgas-actuatedfastening.
5.Acompletefasteningsystemwithassured strengthisrequired.
6.Drillingisnotviablebecauseofnoise.
1.Speedisimportant. 2.Aneasy-to-use,uncomplicatedfasteningsystemisrequired.
3.Aweather-independentfasteningsystemisrequired.
4.Electricpowerisnotavailableorelectriccableswouldhinderthework.
7.Drillingwouldbetoodifficult. 8.Drillingwouldcausetoomuchdust.
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Construction Health and Safety
Inallcases,employersandself-employedpeopleareresponsibleforassessingtherisksthatmaybeinvolvedintheworktheyareplanningtocarryout.
Forexample,herearesomekeyrequirementsfromthe“VibrationDirective”
• AssesstherisktotheHealthoftheemployeesandplanforitscontrol• Providesuitableequipmentfortheiremployeestouse• Givetheiremployeesinformationandtrainingonhealthrisksandsafe use of equipment
How can Direct Fastening help?WherethereareconcernsaboutthepossibleeffectsofHandArmVibration(HAV)duetodrillingusing”electrichammerdrillsorcombihammers”.DirectFasteningisrecognisedasanAlternativeMethodtoreducethisrisk.(Source – HSE Website)http://www.hse.gov.uk/vibration/hav/campaign/construction.htm
More guidance on risk assessment is available from the HSE e.g.
1. A Guide to Risk Assessment Requirements (HSE INDG218)
2. HSE Five Steps to Risk Assessment (HSE INDG163)
Health and Safety.
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Example:
Permitted number of fastenings per dayusingHiltiDirectfasteningtechnology.
Permitted number of fastening/day
ToolType ActionValue LimitValue A(8)2.5m/s2 A(8)5m/s2
GX120 3,500 14.000
DX460(redcartridge) 1,000 4,000
SeetheHiltiProductSelectorformoredetails.www.hilti.co.uk/productselector
Therecoilvaluesitemisedinthistablearegeneratedfromlaboratorytestsandarenotaguaranteeofactualrecoilvaluesonanyspecificapplicationatthesite.
Therefore,theserecoilvaluesareanaidonly.Theemployerisresponsibleforadheringtothelegalrequirementsforworkplacehealthandsafetyandfortheevaluationoftheactualrecoilvaluesbyrespectiveon-sitemeasurements
• Valuesareaveragevaluesandarerounded• Underlyingmeasurementsareone-dimensionalandareperformedastypical applicationsunderlaboratoryconditionsaccordingtoISO8662-11.
Other Safety Benefits
•Cordless: DXtoolsarecompletelycordlessinoperation,leavingnotrailing powerleadstocausetriphazardsorproblemsfortheoperator.
• Weather:DXtoolscanbeusedwhatevertheweather.
• Ergonomics:“StandUp”toolsand“PoleTool”attachmentsareavailableto increaseworkingcomfort.
DX 860.
Trailing Cables.
Direct Fastening Brochure
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InANSI(AmericanNationalStandardsInstitute)A10.3-2006,twotypesoftoolsarerecognized:directactingandindirectacting.Thetwotypesaredefinedbythemannerinwhichtheenergyistransferredfromthehotexpandinggasestothefastener.
Direct-acting tool: Theexpandinggasesactdirectlyonthefastenerandaccelerateittoavelocityof400to500m/s
Indirect-acting tool: Theexpandinggasesactonacaptivepistonthatdrivesthefastener,whichinHiltiindirect-actingtoolsobtainsavelocityoflessthan100m/s
ANSIA10.3-2006classifiespowder-actuatedtoolsaccordingtovelocity.
All Hilti tools supplied for construction applications are low-velocity, indirect-acting tools.
System Safety.
Classofpowder- Averagetest Maximumsingleactuatedtool velocityin testvelocity m/s(FPS) m/s(FPS)
Lowvelocity <100(328) <108(354)Mediumvelocity <150(492) <160(525)Highvelocity >150(492) >160(525)
Direct Fastening Brochure
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The DX tools are safety based items with features to ensure they are safe in operation for both the operator and those around them. Each tool features a five way safety system.
1.TheHiltiPistonPrincipal,thismeansthatthepistonis“fired”ontothefixingpushingitintothebasematerial.Thereisnodirectcontactbetweenthechargeandthefixing.Atalltimes90%oftheenergyisretainedinthe piston.2. Dropfiringsafetydevicepreventsthetoolbeingfiredaccidentallyifdroppedormishandled.(AllDXtoolsmeetstatutoryregulationrequirements tobetestedto3metres).3. Contactpressuresafetydevice,meansthatthetoolrequiresaforceofat least50Newton’spressureagainstthebasematerialbeforethetoolcan befired4. Triggersafetydevicetopreventaccidentalactivation.Untilthecontactpressurehasbeentakenoffthetriggermechanismcannotbeactivated.5. Unintentionalfiringmechanism.Unlessthecorrectfiringsequenceisobservedthetoolcannotbefired.
Other Safety Benefits.
InadditiontotheDXtoolbeingsafe,theinnatesafetyfeaturesofthesystemaddtoitsoperatingsafety.Furthersafetybenefitsare:
•Dust: Operationofthetoolisvirtuallydust-free,reducingdustwhich canbeinhaled,inparticularfromoverheadapplications.•Noise: Becausetheyproducealowstructuralnoiseinconcrete,itis possiblethatworkcanbecarriedoutininhabitedbuildings.•Working at Height: Ifworkingoverheadpoletoolaccessoriesareavailable whichenableoperationfromfloorlevel,likewisethetoolhasvariantsfor workatfloorlevelwhichremovestheneedforbendingorkneelingwhen makingmultiplefixings.
1.
2.
3. 4
5.
Direct Fastening Brochure
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The necessary conditions for predictable fastening performance are:
1. Thefasteningsystemmusthavebeenengineeredandtestedforthe application.2. Thequalityofthefasteningsystemcomponentsusedmustcorrespond tothequalityofthoseoriginallytested.3. Thefasteningsmustbemadeasforeseenintheengineeringofthe systemorinthesamewayaswhenthesystemwastested.
Engineering and testingSourcesofinformationabouttheengineeringandtestingofafasteningsystemarethemanufacturer’stechnicalliterature,testreports,officialapprovals,andpublicationsintechnicaljournals.Ifan“orequal”clauseisusedinthespecification,thenapprovalofanyalternatefasteningsystemshouldbemadecontingentonprovisionofdocumentationshowingthattheproposedfasteningsystemhasbeenengineeredandtestedfortheapplication.
Production qualityTheneedforthematerialsusedonthejobsitetocorrespondtothedesignoftheproductandbeofthesamequalityasthosetestedisclear.Thisrequiresthemanufacturertohaveaproductionqualitycontrolsystem,whichisnecessaryforISO9001certification.InadditiontoISO9001(QualityManagement)Hiltialsohave14001(EnvironmentalManagement).
Manufacturing Process – Standard Hardened Steel FastenersAlmostallpowderandgas-actuatedfastenersusedintheworldaremanufacturedfromcarbonsteelwireandarethermallyhardenedtoobtainthestrengthneededfordrivingintosteelandconcrete.Zincplatedfastenersaresubjectedtoimpactbendingteststochecktheeffectivenessoftheprocess.Dependingontheirintendedapplication,somefastenersareadditionallysampledandtestedintensionandshear.
Stainless Steel FastenersIn1994,Hiltiintroducedthefirstpowder-actuatedstainlesssteelfastener.Thesefastenersaremanufacturedfromspecialstainlesssteelwirewithanultimatetensilestrengthof1850MPaandarenotthermallyhardened.Thesefastenerssufferonlyaminordecreaseinstrengthwhensubjectedtohightemperaturesasinafireandgivemuchimprovedcorrosionresistance.
Fastening Safety.
Manufacuring ProcessStandard Zinc Coated Fasteners
Cuttolengthandformhead
(Knurling)
Forgepoints
Thermalhardening
Galvanising
Baking
Assemblywithwashers
Direct Fastening Brochure
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Quality of installationTheuseoffasteningsystemsforwhichthemanufacturerprovidesapplicationguidelinesandatechnicaladvisoryservicehelpsensurethatfastenerswillbeinstalledcorrectlyandenhancesproperfastenings.
Theconceptofcontrollingthequalityoftheworkmustincludesomefeaturethatcanbemeasuredandthatfeaturemustindicatetheperformanceofthefastenings.
CorrosionThesubjectofcorrosionhasamajorinfluenceonthesuitabilityofafastenerandthereforealsoonfastenerselection.
Non-safety relevant applications,zincplatedfastenersmadeofnormalcarbonsteelcanbeusedwithoutrestriction.
Safety relevant, permanentfasteningsthefollowingtableshowsthesuitability☑underdifferentatmosphericconditions.
Checking the standoff of an X-EDNK22 roof deck fastening with a plastic template.
Pullout test of an ENP fastening with a Mark V tester and ENP adapter.
Conditionforuse Fastener Zincplated X-CR/X-BT carbonsteel stainlesssteel
Insideroomswithoutcondensation ☑ ☑andcorrosivegases
Insidewithheavycondensation ∎ ☑
Shorttermexposuretoweather ☑ ☑(i.e.duringconstruction)
Outside,coastalareaorindustrial ∎ ☑atmospherewithoutchloride
Highlycorrosivesurroundings ∎ ∎(indoorswimmingpools,highwaytunnels)
For safety relevant, permanent fastenings:UseHILTIgalvanizedDX-fastenersonlyfordryindoorapplications.Inhighercorrosiveand/orwetatmospherestheusageofHILTIX-CRfastenersisrecommended.
FastenerFastenedpart/basematerial Zincplated X-CR/X-BT carbonsteel stainlesssteel
Constructionsteel(uncoated) ☑ ☑
Galvanisedsteelsheet ☑ ☑
Aluminiumalloy ∎ ☑
Stainlesssteelsheet ∎ ☑
∎Heavycorrosionoffastener☑Negligibleornocorrosionoffastener
Direct Fastening Brochure
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Anchoring MechanismsThefollowingfourmechanismscauseaDX-/GX-fastenertoholdinsteelbasematerial.• clamping• keying• fusing(welding)• solderingThesemechanismshavebeenidentifiedandstudiedbyanalyzingpullouttestdataandbymicroscopicexaminationoffasteningcross-sections.
ClampingAsafastenerisdriven,thesteelisdisplacedradicallyandtowardsboththeentryandoppositesurfaces.Thisresultsinresidualpressureonthesurfaceofthenail,whichleadstofrictionorclamping.
KeyingThekeyingmechanismispossiblewhenthefastenerisknurled,thatis,ithasgroovesalongtheshankinwhichzincandparticlesofbasesteelaccumulateduringthedrivingprocess.Keyingisanespeciallyimportantanchoringmechanismforfastenersthatdonotpenetraterightthroughthebasematerial.
Fusing (welding)Completefusingofthefastenerwiththebasesteelisindicatedbyportionsofbasematerialclingingtotheextractedfastener.Fusingorweldingisobservedmostlyatthepointofafastenerwherethetemperatureduringdrivingcanbeexpectedtobethehighest.Forfastenersthatdonotthrough-penetrate,thisisanimportantanchoringmechanism.
Fastening to Steel.
Knurling
FastenerBasesteel
Direct Fastening Brochure
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Fusing (Soldering)Inthezonefurtherfromthepoint,thereisaprominentzinclayerseparatingthefastenerfromthebasesteel.Thiszinc,solderedtothebasesteel,alsomakesacontributiontothepulloutresistanceofthefastener.
Cyclic LoadingSidinganddeckingnailsusedinwallandroofconstructionaresubjecttocyclicloadingfromwindsuction.Cyclicloadtestingiscarriedouttodeterminecharacteristicresistanceandallowable(recommended)loads.TheapprovalrequirementsoftheEuropeanTechnicalApprovalETApreparedbyDIBt(DeutschesInstitutfürBautechnik)governthedesignrelevantnumberofloadrepetitions(5’000)andthenecessarysafetyfactors.Notesinthisregardcanbefoundonthecorrespondingproductdatasheets,e.g.X-ENP-19L15..
Mode of Failure under Cyclic LoadingAmajorfindingofcyclicloadingtestsisthatthestrengthofaDXfasteningsubjecttocyclicloadingisnotlimitedbyfailureoftheanchorage.
Effect of fasteners on structural steelDrivingpowder-orgas-actuatedfastenersintoasteelmemberdoesnotremovesteelfromthecross-section,butratherdisplacessteelwithinthecross-section.Itisthereforenotsurprisingthattestsshowthatbothdrilledholesandscrews,eitherselfdrillingorselftapping,reducethestrengthofacross-sectionmorethanapowder-actuateddrivepin.
Typical Application Guidelines – Steel
X-ENP-19L15ETA-04/0101.
Smooth or Knurled Shank Nails Correct fastener length Knurled Shank=10-14mmbasematerialpenetration +thicknessofmaterialtobefastened Smooth Shank=17-27mmbasematerialpenetration +thicknessofmaterialtobefastened Minimum steel thickness Fastenerwithshankdiameterof3.7 mm = 4 mm Fastenerwithshankdiameterof4.5 mm = 6 mm EdgeDistance= 15 mm Spacing= 20 mm
20 15
Direct Fastening Brochure
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Anchoring MechanismsThefollowingthreemechanismscauseaDX-/GX-fastenertoholdinconcretebasematerial:
• Bonding/sintering• Keying• Clamping
Thesemechanismshavebeenidentifiedandstudiedbyanalysingpullouttestdataandbymicroscopicexaminationofpulled-outfastenersandtheconcrete-fastenerinterface.
Bonding / sinteringWhendrivingafastenerintoconcrete,theconcreteiscompacted.Theintenseheatgeneratedduringdrivingcausesconcretetobesinteredontothefastener.Thestrengthofthissinteredbondisactuallygreaterthanthatoftheclampingduetoreactiveforcesoftheconcreteonthefastener.
KeyingThesinteredmaterialformsridgesonthefastenersurface.Theseridgesresultinamicro-interlockingofthefastenerandtheconcrete.
ClampingThecompressibilityofconcretelimitsthebuildupofcompressivestressaroundthedrivenfastener.Thisinturnlimitstheeffectivenessofclampingasananchoringmechanism.
Concrete failureOccasionallyconcreteconefailureisobservedwhenusingatestingdevicewithwidelyspacedsupports.Thefactthattheconcretefailedindicatesthatthefastenerbondtotheconcretewasstrongerthantheconcrete.
Fastening to Concrete.
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Factors Influencing the Resistance to PulloutFactorsthatcanaffectthepulloutstrengthoffasteningstoconcreteinclude:
• depthofpenetrationintotheconcrete• concreteconditions(compressivestrength,grainstructure,directionof concreteplacement)• distancetoconcreteedgeandfastenerspacing
Depth of penetration hET
Fastenersthataredrivendeepertypicallyhaveahigherresistancetopullout.Thisrelationisbestshownbyplacinggroupsoffastenerswithdifferentdrivingenergyandcomparingtheresultsforeachgroupwiththeothers.
Theresultofsuchatestisshowninthegraphattheright.Notethatplacingfailureswerenotconsideredincalculationoftheaverageultimateload,Nu,m
Concrete ConditionsPulloutstrengthandplacingfailureratebothincreasewithincreasingpenetrationdepth.Theoptimumdepthofpenetrationistakenasthedepthatwhichtheyieldintermsofpulloutstrengthbeginsdecreasing.It’swithinarangeof18–32mmdependingonthegradeandageoftheconcreteaswellasthestrengthofthefastener.
Typeandsizeofconcreteaggregates,typeofcementandthelocationontoporbottomsideofaconcretefloordoaffecttheplacingfailurerate,sometimessignificantly
Placingfailuresarecausedbythefastenerhittingahardaggregatelikegranitelocatedclosetotheconcretesurface.Incaseofslightfastenerbending,theremaybeconcretespallingatthesurface.However,becausepulloutstrengthisobtainedmostlyintheareaofthefastenerpoint,concretespallingdoesnotaffecttheallowableloadoftheDX-/GX-fastening.
Overheadfasteningisusuallyassociatedwithmoreplacingfailuresthanfloorfastening.Thisisduetothedirectionofconcreteplacement.Largeaggregatestendtoaccumulateatthebottomofafloorslab.Atthetop,smallaggregatesandfineswillbeinthemajority.
Note:thetechnicaldataforthefixinggivesloadcapacitiesfordifferentembedmentdepths.
Note:placingfailuresareaccountedforwithinthelimitsofthetechnicaldataforthefixing.Theseplacingfailuresarethereasonmulti-pointfixingsarerequiredinconcrete.
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Severalpossibilitiesexisttoreducethefailureratewhenpowderactuatedfastenersareusedforfasteningtoconcrete.Therearetwobasicideas.Oneistoreduceconcretetensilestressesnearthesurface.Theotheristodelaytheeffectofthesestresses.
• Pre-drilling the concrete (DX-Kwik) Bypre-drillingaverysmallhole,5mmdiameterby18or23mmdeep, thestressesarerelocatedtodeeperintheconcrete.Fastenersplaced withDX-Kwikaresurroundedbyastressbulbthatisdeepintheconcrete. Withthismethodnoplacingfailureswilloccur.DXKwikfixingshavea higherloadcapacitythanstandardDXfixingsandcanbeusedforsingle pointfastening.
• Spall stop fastener guide Aspallstopisamassivesteelfastenerguide.Itsweightandinertia counteractthestressesatthesurfaceforaveryshorttime.Thisallows aredistributionofthestressestoelsewhereintheconcrete.
Changingfromalongtoashortfastenerreducesthemagnitudeofthestressesandhenceplacingfailuresbutgivesalowerloadcapacityforsuccessfulfixings
Edge distance and fastener spacingIffastenersareplacedtooclosetotheconcreteedge,thepulloutcapacitywillbereduced.
Thetypicaledgedistanceincaseofreinforcedconcreteis80mmandincaseofnon-reinforcedconcrete,150mm.Edgedistancesandspacingguidelineshavethepurposeofhelpingtopreventconcretespallingand/orcrackingduetofastening.However,ingeneral,spallinghasonlyaninsignificantinfluenceonthepulloutstrength.
Typical Application Guidelines – Concrete
Fastening to Concrete etc.
Smooth Shank Fasteners Only Correct fastener length 22-32 mmbasematerialpenetration +thicknessofmaterialtobefastened e.g.35mmthicktimberwouldrequireanailbetween 57mmand67mmlong. Inthiscase,a62mmnailwouldbemostappropriate. EdgeDistance= 80 mm Spacing= 80 mm
80 80
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Effect of time on pullout resistance
Theeffectofageonpulloutstrengthwasinvestigatedinacomprehensivetest.ThetestresultsindicateverystronglythatrelaxationoftheconcretehasnodetrimentaleffectonthepulloutresistanceofDXfastenings.
Effect on concrete componentsFasteningsinthecompressivezoneofthestructurehavenoeffectonconcretecompressiveresistanceaslongasdetailingprovisionsonedgedistanceandspacingarefulfilled.
Forfasteningsinthetensilezonethefollowingprovisionsareprovided:
Installations into plane load bearing components like concrete walls or ceilings are generally possible without restrictions.
a. Fastenings in reinforced concrete beams: Ithastobeensuredthatthemainreinforcementsteelwillnotbehitor penetratedbytheDXfasteners.Thismeasureofprecautionismainly foundedonthereductionoftheultimatestrainofthereinforcementsteel.
Exceptionsarepossiblewhenconsultingthestructuralengineering responsiblefordesign.
b. 1. Fastenings in pre-stressed concrete members: Ithastobeensuredthatthepre-stressingreinforcementsteelorcableswill notbehitorpenetratedbytheDXfasteners.
b.2.HiltihaverecentlycompletedaseriesoftestsonPrecastconcreteslabs. Detailsofthefasteningrecommendationsareprovidedintheassociated DataSheetavailableonrequestfromHiltiTechnicalAdvisoryService: +441618861144.
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Fire Data.
Whensubjectedtohightemperaturesasinfire,thepropertiesofboththefixingandthesurroundingbasematerialaredegraded.Inordertoprovidedesignerswithapprporiateinformationforfixingswhicharetobeusedinsituationswheretheycannotbeprotectedfromthepossibilityoffire,HiltihavefiretestedloadedfixingsinsideafurnacewhichwasheatedinaccordancewiththeISO834heatingcurve.
Fire rating on fastening to concreteThisdataappliesonlytofasteningsmadeinreinforcedconcretecomponentsofagradeC20/25,whichhasatleastthesamedurationofresistancetofire.Dataisvalidforstandardsizes.
Fire Resistance
Anchor,Fastener Size Maximumload(kN)forspecified IBMBtestreportno./ durationofresistancetofire(min) TechnicalUniversityof Brunswick,Germany 30min 60min 90min 120min
DX-Kwik X-M6H 0.20 3882/5651+E
*) X-M8H 0.30
*) X-CR-M8 0.30
*) X-CR48 0.45 0.25
X-HS-M6 0.40 0.25 0.15 0.05 3027/0274-3+E X-HS-M8 0.50 0.40 0.25 0.15 3027/0274-7 X-HS-M10 0.50 0.40 0.25 0.15
*)applicationinceilingandwall.
Testedincrackedconcretedirectlyexposedtoflameswithouttakinganyinsulatingorprotectivemeasures.
Testedaccordingtotheinternationallystandardisedtemperaturecurve(ISO834).
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Fire Rating on Fastenings to Steel
Standard zinc plated, thermally hardened steel fasteners Whensubjectedtohightemperaturesasinafire,bothpowder-actuatedfastenersandstructuralsteellosestrength.
Uptoabout300OC,thestrengthlossforDXfastenersisroughlyproportionaltotheyieldstrengthlossofstructuralsteel.At600OC,DXfastenershaveabout12%oftheir20OCstrengthleftandstructuralsteelabout26%.SinceDXfastenersobtaintheirhighstrengththroughthermalhardeningprocess,thelossinstrengthatelevatedtemperaturesisproportionallygreaterthanforstructuralsteel.
Stainless Steel Fasteners (X-CR / X-CRM fasteners)
In1994,Hiltiintroducedthefirstpowder-actuatedstainlesssteelfastener.Thesefastenersaremanufacturedfromspecialstainlesssteelwirewithanultimatetensilestrengthof1850M/mm2andarenotthermallyhardened.Thesefastenerssufferonlyaminordecreaseinstrengthwhensubjectedtohightemperaturesasinafire.
At600OC,theX-CR/X-CRMmaterialhas64%ofits20OCshearstrengthleft.Bycomparison,standardfastenershaveonly12%andstructuralsteelonlyabout26%.TheexcellentfireresistanceoftheX-CR/X-CRMmaterialalonejustifiesitsuseforsomeapplications.
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Withsavingsofupto65%labourtimeusingCartridgeTooltechnology,thenewClean-Teccartridgestripwithitsinnovativenumberscaleonthebackwillhelpyouachieve:
• Greaterfasteningefficiencymakingiteveneasiertouseall10cartridgeson themagazinestrip• ReducedHazardousWastecostsasafullyusedstripcanbedisposedofwith “normal”sitewaste.• EnvironmentfriendlyastheycontainNOleadorother“heavymetals”.• Reducedtoolcleaningbyupto30%
Calibre and dimensionsThecorrespondingcalibreisclearlyprintedoneachcartridgepackage.ThefollowingcalibresareavailablefromHilti:6.8/11(cal..27short)instripsof106.8/18(cal..27long)assinglecartridgesorinstripsof10or40
Thefirstnumberindicatesthecartridgediameterandthesecondnumberindicatesthetotallengthofthecartridge,e.g.6.8/11M10greenCalibre: 6.8mm•Cartridgelength: 11mm•Magazinestripsof10cartridges: M10•Powerlevel: green•
Performance dataThedrivingpowerofthecartridgeisdeterminedtoaverygreatextentbythequantityandpropertiesofthepropellantitcontains.Cartridgepowerlevelclassificationsarelaiddownintheapplicableregulations(e.g.PATMI)andareindicatedbythecorrespondingcolourcodeofthelacquerappliedatthecrimpedtipofthecartridgeor,respectively,bythecolourofthemagazinestrip(seetable).Thecolourisalsomarkedonthepackage.
Magazine stripsThecartridgesareavailablesinglyorcollatedinmagazinestripsof10(=M10)or40(=M40).Thestripmaterialisacoloredplasticthatindicatesthepowerlevelclassification.Dependingonthecartridgecalibreandpowerlevel,themagazinestripsmayfeatureso-calledsafetylockstopreventinsertionanduseofthestripintoolsforwhichtheyarenotintended.
Cartridge positioning indexAnindexscale(adhesivefoil)ontherearofthemagazinestripindicateswhichcartridgeiscurrentlyinthecartridgechamberinthetool.Thisishelpfulwhenpartly-usedstripsarere-insertedinthetoolforfurtheruseandalsoindicates
Cartridges.
Colour PowerlevelWhite/Brown ExtralightGreen LightYellow Light-mediumBlue MediumRed HeavyBlack Extraheavy
Calibre Length
With Clean-Tec Without Clean-Tec
Clean-Tecmeanslessdirtandresiduesinthetool,lesscleaningrequiredandlongertoollifetime.
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totheuseringoodtimewhenthestripneedstobechanged.Thismakesiteasiertoensurethatallcartridgesonthestripcanbeusedup,allowingtheusertoworkmoreeconomicallyandmakingitpossibletodisposeoffully-usedcartridgestripsasnormalsitewaste.Partly-usedstrips(containingoneormoreunspentcartridges)mustbedisposedofseparatelyas“dangerouswaste”inaccordancewithnationalregulations.Morespecificinstructionscanbefoundonthepackage(EWCno.160401)andinsection2ofthesafetydatasheet.
ApprovalsHiltiqualityrequirementscorrespondatleasttotherequirementsoftheDIN7260andANSIA10.3-1995standards.Inadditiontoindividualnationalregulations,thereisalsotheC.I.P.(CommissionInternationalePermanentepourl’épreuvedesarmesafeuportative)–aninternationalcommitteewiththeaimofensuringhighsafetystandardsforuserswithregardtosystemperformanceandbehavior(powder-actuatedtoolandcorrespondingcartridge).Theappropriaterequirementsthushavetobemetortestsrepeatedandpassedatregularintervalsorwhenmodificationsaremadethataffectthesystemasawhole.IndependenttestingagencieshavebeenauthorisedbytheC.I.P.tocarryoutthesetestsand,whenthetestshavebeenpassedsuccessfully,themanufacturersoftheitemsconcernedthenhavetherighttoprinttherelevantmarkofconformityonthepackage.
Atpresent,thefollowingcountriesaremembersoftheC.I.P.:Belgium,Chile,Germany,Finland,France,GreatBritain,Italy,Yugoslavia,Austria,Russia,Spain,CzechRepublic,Hungary,UnitedArabEmirates
System approvalThepowder-actuatedtoolandcorrespondingcartridgesaretestedbyanindependenttestingagency(PTB=Physikalisch-TechnischeBundesanstaltBraunschweig)forthepurposeofsystemapproval.Confirmationofapprovalisprintedonthesmallestpackagingunit,asshowninthefollowingexamplefor6.8/18M10red:
DX750 PTBSy804HR56DX76 PTBSy813HR36DX76PTR PTBSy816HR36
Thedesignationofthetooltestedisgivenfirst(e.g.DX76),followedbythetestingagency(PTB),thesystem,i.e.thetoolandapplicableequipment(Sy813),thecartridgemanufacturer(HR),thenumberoftests(3)andthecartridgepowerlevel(6).
HandlingClean-Teccartridgesmustbekeptawayfrom•
sourcesofheatandopenflames.Clean-Teccartridgesmustnotbethrownor•
openedforciblyandmustnotbemanipulated mechanically(e.g.pinchedorsquashedwith pliers)orthroughapplicationofheat.
Clean-Teccartridgesmaybesoldorsupplied•
onlyintheoriginalpackaging.Clean-Teccartridgesaretobeusedonlyinthe•
approvedpowder-actuatedtoolsforwhichthey areintended(seePTBsystemapprovalonthe package).
Clean-Teccartridgesmaybehandledandused•
onlybyappropriatelytrainedpersonnel.Goodventilationmustbeensuredatalltimes•
whenworkinginenclosedspaces.Acartridgeshouldnotbereusedafteramisfire.•
Thecartridgestripmustalwaysberemoved•
fromthetoolattheendoftheperiodofwork.ThepointstobeobservedwhenusingHilti•
Clean-Teccartridgesaredescribedinthe materialsafetydatasheet.
StorageClean-Teccartridgesshouldalwaysbestored•
intheoriginalpackage.Directexposuretoheat ortheraysofthesunmustbeavoided.
Clean-Teccartridgesshouldbekeptdry,i.e.•
avoiddirectcontactwithwaterormoisture (e.g.rain,puddlesofwater,etc.).
ThecartridgesbelongtoStorageGroup1.4S•
Thetemperatureandairhumidityinthe•
storageroomshouldbekeptasconstantas possible.Astoragetemperatureofbetween 5°Cand25°Candarelativeairhumidityofless than65%arerecommended.Considerable fluctuationsintemperatureandhumiditymay resultinadropinperformanceorfailureofthe product.
Thecartridgesshouldbestoredinalocked•
roomorcontainertopreventaccessby unauthorisedpersons.
Cartridgesshouldnotbestoredtogetherwith•
foodstuffs.Pleasealsorefertosection7ofthematerial•
safetydatasheet.
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Construction “Kickerless Construction”.
Thetraditional‘Kicker’constructionprocesscanbesignificantlyspeededupusingquickinnovative“FormStops”fixedwithCartridgetools
Traditional process includes:Typicallyaddsaleastoneextradayperfloorwaitingforkickertobebuilt,poured,curedandstruck.
• Floorandkickerbothneedtobe‘scabbled’increasingHAVrisk• Cannotcompletemainpouronsameday.• Labourintensive: • Floor‘scabbled’(HAVrisk) • Kickerbuilt • Concretepoured • Onedaytocurebeforekickerstruck • Kickerstruckand‘repaired’ifnecessary • Kicker‘scabbled’beforeworkcanstartonnextliftofshuttering.
Application Example 1.Fastening to supports for shuttering to concrete.
Kickeroftenbuildusingoldmaterialsandconcretefromtheendofthelast‘pour’.
Repairworkisoftenrequiredtokickerbeforenextliftcanproceed.
Traditional
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Outwardpressureincreasestowardsthebottom.
X-FSFormStopbeinginstalled.
FormStoplocatesinnerfaceofformwork.
Can save up to one day per floor in time and labour
• Quickeasyinstall,nokickerrequired• Simplersettingout,afterbaseispoured• Blendsintotheconcrete(greycolour)• Noriskof‘kicker’movementorrepairsrequired• Canpourconcreteonthesameday,significant timesavingovertraditionalmethods• Noweatherrestrictions• Notrailingcablesfortriphazards• ReducedHAVriskfromscabbling• Reducedriskofhandinjury(cutting/hammering)
Estimated savings:Onedayperfloorcanbesaved~15%oflabourcostperfloor
Innovative
Total installed cost comparison:
100%
50%
0%
85%
Installedcost
TraditionalInnovative
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FixingFrameTiesandHeadRestraintsforsupportingbrickworkisacommonapplicationonmanyprojects
The ApplicationThebricktieisusuallyinaventedcavityandthereforewillbesubjecttomoistureoveritslifetime;forthatreasonStainlesssteeltiesaretypicallyused.Asthebasesteelisastructuralcarbonsteel,bi-metalliccorrosioncanoccurifcorrectinstallationprocessesarenotfollowed.
Traditional Methods• StainlessSteeltiesaretypicallyfixedusingSelfdrillscrewsorDirectFixing nails• Screwsareusuallycarbonsteelgivingariskofbi-metaliccorrosionifany contactwiththestainlesssteeltieoccurs.• Ifacarbonsteelscrewornailisused,isolationofthefastenerfromthe stainlesssteeltieshouldbeapplied(thiscanbedifficulttocoordinateand supervise• Structuralsteelofvaryingstrengthsandthicknessesmeansthatselfdrill screwswillnotalwaysworkanddrillandtapmayberequired(averyslow process)• Trainingcablescancausetriphazards,andpoorweathercancausetime delayswhenusingelectricalequipment.
Application Example 2.Fastening to steel. Example: frame ties for brickwork.
Traditional
Headrestraint.
Frametie.
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Corrosion advice• Whenanelectrochemically“lessnoble”material(i.e.carbonsteel)comesin contactwithamore“noble”material(i.e.stainlesssteel)accelerated corrosionwilloccur.Themateriallossofthenoblepartnerisreduced,the lossofsurfaceareaofthelessnoblepartnerisincreased.Prerequisitefor thisformofcorrosionisanelectricallyconductiveconnectionbetween thesetwomaterials.• Therateofcontactcorrosionalsodependsontheratioofthesurface areas.Thefastenertransferesalltheloadfromthecramptothestructural steelsolossofmaterialfromthefastenermustbeprevented.• Ifthesurfaceareaoftheless“noble”material(Carbonsteel-fixing)is smallerthanthatofthemore“noble”(Stainlesssteel-framecramp)the corrosionrateoftheless“noble”willbehigh.• Pleasenotethatzincisalsolessnoblethanstainlesssteel,sozincplated orhotdipgalvanisedcarbonsteelswillcreatethesamesituation. Forfurtherinformation,pleaseseesectiononCorrosionorcontact TechnicalAdvisoryServiceonGB01618861144IRE1850287387.
This means that:• Ifacarbonsteelfastenercomesincontactwithastainlesssteeltie, acceleratedcorrosionofthefastenerwilloccurifmoistureispresent.
TheHiltiX-QTisanallStainlessSteelFrametiecombinedwithanallStainlesssteelnail.Thismeansitcanbedirectlyfixedtothesteelworkandadditionalisolationofthefastenerisnotrequired.
Benefits of using X-QT• Highinstallationcostsavingsarepossibleduetothelabourtimesaved.• Greatlysimplifiedinstallationprocess–noadditionalisolationcomponents required.• Onesinglenailsolutionpossibleforallgradesandthicknessofstructural steel(1).• Freeonsitetrainingisprovidedtoensureoptimumperformanceand productivityisachieved
1.Note,onsitetrialswillberequiredtodeterminesuitability
Time savings of up to 66% are possible using the Hilti X-QT
HiltiX-QTQuickTie.
Significanttimesavingsarepossible.
Innovative
100%
50%
0%
InstallationTime
TraditionalInnovative
34%
Note: Thisadviceisconsistentwithanagreedamendmenttothepublication“BrickworkCladdingtoSteelFramedBuildings”jointlypublishedbyTheBrickDevelopmentAssociationandBritishSteel.
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ThefollowingisanextractfromaCaseStudyconductedbytheBuildingServicesResearch&InformationAssociation(BSRIA).
Thisexampleisbaseduponthelabourandmaterialcosttoinstall100fixingsintoaconcreteslabusingpowder-actuatedfasteningcomparedtotraditionaldrilledholesandknock-inanchors.
FullCopyoftheCaseStudyisavailableonrequestfromHilti.
Traditional Methods:• Traditionalsettingoutmethodsrequirealineandplumbobtofindthe positionofeachfixingpoint• DrillingoverheadforalargerdiameterholeforM10fixingisslowandalso causespotentialHealth&Safetyrisksof •HandArmVibration •Dustfromholefallingontooperative •Handinjuryfromsettingthefixing• Accessisrequiredfromcorrectlyerectedplatformwhichrequirestimeto erect,checkandwithadditionalcostsforhireorpurchase• Trainingcablesfrompowertoolscanalsocausetriphazards
Application Example 3.Installation of Mechanical and Electrical Services. Based on Case Study conducted by BSRIA.
Traditional
BuildingServices.
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Benefits as identified by BSRIA• Thesettingoutprocesscanbesignificantlysimplifiedandspeededupvia modernLasersettingouttools• WhencombinedwithDirectfasteningTechnologyfortheinstallation process,theoverallproductivitysavingavailableiscalculatedat36%• Thetypicalloadrangeisbetween40-90kgperfixing• Simplifiedinstallationtechnique• Installationcostreductionof36%perfixingovertraditionalmethods• Installationlabourreductionof65%perfixingovertraditionalmethods• Freeon-sitetraining/certificationbymanufacturer• Threadedrod,hangerandstructuralfixingcanbeinstalledinoneoperation• HealthandSafetyriskreducedby: •Nodrilling •Reducedhighlevelworkwhenusinginstallationextensionarm
Additional benefits include:• Almostdustfreeasnodrillingrequired• Notrainingcablestocausetriphazards• Itemstobeinstalledcanbepre-assembled
Total installed cost comparison: 100 fixings
PR25lasercombinedwithDXcartridgeToolonPoleTool.
X-HSRodHangerfixedwithPoleTool.
Theinnovativeinstallationshowsa36%costsavingovertraditionalmethods.
Innovative
Installation Traditional Innovative costs
Labour 90% 32%
Materials 10% 32%
Total 100% 64%
Traditional Innovative
100%
64%
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Background:
SAMCeiling&PartitioningareanInteriorspecialistbasedintheSouthWestofEngland.
Project:
EO2OfficeBuildingsinCardiff,athreephasesteelframebuildinginCardiffCityCentre.
Application:
Fixing120mminsulationtotheunderneathofmetaldeckingatgroundfloorlevel.Areatobecoveredapproximately3,000m2.
Challenge:
Thekeychallengewastokeepwithinthetimeallocated.TheprogrammewastightandSAMwerelookingforwaystospeeduptheprocessandmakewayforothercontractors.Naturallycostwasalsocrucial.Thetraditionalmethodwastopunchaplateanduseahammertypefixing8mm.
Theproblemwiththismethodwasdrillingaconsistentholedepthandalsothetimetakentodrillandfixtheplate.
JohnLewis-oneoftheinstallationteamsaidofthedirectfasteningsystem:
“Our method (X-IE) was 5 times quicker according to John and each phase took 5 days to complete using a two man team”.
Application Example 4.Fastening of insulation using X-IE fasteners with SAM Ceiling and Partitions Ltd.
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Approach:
SeveraldemonstrationswereconductedusingHiltiX-IEInsulationfastenersintothemetaldecking.Thetrialswerequickandeffectiveandtechnicaldataforthefixingswasprovidedtosupportthesolutionoffered.TheoperatorswereverycomfortablewiththeDX460andfeltthiswaspreferabletothealternativesavailable.
Summary:
SAMwereextremelyhappywiththeresultandwillcontinuetousethismethodforsuchapplicationsinfuture.Thefactthatthetoolisversatileandcanbeusedwiththepoletoolforfixingceilingclipswasalsoakeyfactorandwearenowlookingtomaximisethisopportunity.
MDMikeTaylorsaidoftheHiltiX-IEsystem“The Hilti X-IE fastening system has proved to be quick and reliable, it provided a very efficient and cost effect solution to the problem we faced.”
SAMhaveestimatedthatusingtheHiltiX-IEfasteningsystemmeantthatthejobwascompleted5timesfaster
Innovative
100%
50%
0%
InstallationTime
TraditionalInnovative
20%
X-IEInsulationFasteningSystem.
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LakesmereLtd.arealargeBuildingEnvelopecontractorwhoinstallroofs,walls,glazingandotherarchitecturalfeatures.TheyarealsoanapprovedcontractorfortheinstallationoftheCorus‘Kalzip’TMroofingsystems.
Project:
TheShellStanlowOilRefineryontheMerseyinCheshire.Therequirementwastoinstall1371m2ofaKalzip305AluminiumroofsystemontoStructuralsteel15-20mmthick.Thenormalsolutionwouldhavebeentofixusingselfdrillingscrewsbutitbecameapparentthatscrewfasteningwouldbeveryslowduetothethicknessesofsteelinvolved.Testsshowedthateachscrewwouldtake:
• 42secsinstallationtimetodrillandfixto15mmsteel• 16secondstofixto10mmsteel.
Decision process
DirectFastening(HiltiDX)wasconsideredasthespeed,technicalbackupandcostefficiencyhadalreadybeenprovenonotherprojects.Thiswouldallowthefixingofthe‘linersheet’tothebasestructuralsteelovercomingmuchoftheslowdrillingwork.
TheverytightHealth&SafetyregulationsonanoilrefineryalsomeantgainingapprovalatthehighestlevelandthiswasachievedviatheHiltiandKalzip’sTechnicalDepartments.
Application Example 5.Fastening to liner trays using X-ENP nails with Lakesmere Ltd. Project Manager: Graham Clelland.
Traditional
LinerTrayfixedtostructuralsteel.
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Solution
TheHiltiX-ENPfasteningsystem,whichhasbeenawardedaEuropeanTechnicalApproval(ETA-04/0101)wasalreadyanapprovedsolutionbyKalzipwhenfixingintostructuralsteel(>6mmthick).ThesystemisinstalledusingaDX76cartridgetoolandonthisprojectallowstheinstallationof:10magazinedX-ENPnailsinanaveragetimeof40seconds(i.e.4secondspernail)
Result
Theoverallresultwasthatthetimeittooktocompletetheoveralljobwas75%fasterthanusingselfdrillingscrewswhenfixingtosteel>15mmthickand50%fasterwhenfixingtosteel6-12mmthick.AsGrahamMcClellandhimselfsaid“AlthoughthematerialoutlaywasmorefortheDX,thecostsavingoverallmadeitamorecosteffectivewayofinstallingthestructurallinerdeck”
SteveJohnson,ProjectManagerforanotherLakesmereprojectalsosaidofDXthatitis
• “Farquickerinstallationoveralternativemethodsmeanscostsavings relatingtolabour”.• “Thereisnometalswarffrom‘drill-point’screwstocausedamagetothe coatingsurface/corrosion/staining”.• “Productivityisincreasedastheladscangetthesheetslaidveryquickly”.• “DXmeansasafersiteastherearenoleadsorgeneratorstoworryabout trippingoverobviouslyaconcernwhenworkingatheights”.
TimeandCostsavingbenefitsavailableusingDXinsteadofselfdrillscrews.
TheX-ENPnailhasbeenawardedaEuropeanTechnicalapprovalETA-04/0101.
Innovative
100%
50%
25%
0%
InstallationTime
6-12mm7-15mm
DX25%
DX50%
Screw
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Hilti provide certified training for all Hilti manufactured Direct Fastening tools and fittings. Hilti training equips the operator to use DX fastening techniques in most situations. Where specialist additions to the training are required these can sometimes be provided on site.
AnexampleofthecontentoftheTrainingis:
• TheDirectFasteningsystem • Operatingprinciples • Correcttoolandfasteningselection • Operationandmaintenanceoftools • Storageandcareofequipment • Awarenessofcurrentlegislation • Hands-ontestfiringofthetool
Successfultraineesarepresentedwithacertificateoftrainingthatwillformpartoftheemployer/employeetrainingrecord.HiltialsohelpyoutocomplywiththerecentConstruction,DesignandManagement(CDM)regulations.Pleaseaskforfurtherdetailsonriskassessment.
ThisisdesignedtoassistthesiteteamtoensurethatsafepracticesarefollowedatalltimeswhencarryingoutDirectFasteningoperations.
Training.
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Risk Assessment Guidance - DX.
Shouldariskassessmentberequired(CDM,HSErequirements),forataskinvolvingtheuseofHiltiDXtools(cartridgetools),weofferthefollowingguidance.Thefinalcolumnofthetableillustratesthefactthatrisksalsoexistwhenconsideringalternativefixingmethods.Clearly,anyassessmentmustconsiderallrisksinvolvedwhenthatparticulartaskisbeingcarriedout.Thereforethisisnot an exhaustive listandshouldbeusedinconjunctionwithcurrentlegislationorgoodpractice,suchastheHSEpublication“Five steps to risk assessment”.(Rev1)4/02.www.hse.gov.uk/pubns/indg163.pdf.
Risk Potential problem Measures to avoid problem Parallel risks for other fixing methods
Spalling Fragmentsentering EyeprotectiontoBSEN166codeB Swarforconcretechipsanddustdrilling. ofbase requiredforoperatorandothers material incloseproximety
eyesorhittingskin Observespacingandedgedistance recommendations.
Noise a)Hearingdamage a)EardefenderstoBSEN352 a)Applicablemostotherfixingmethods. b)Occupiedbuildings b)Cartridgetoolsmaybepreferredforworkin occupiedbuildingswhencomparedwith hammerdrilling.
Toolrecoil Injurytohand/arm Holdtoolfirmlywithbentarms Torquereactionfromdrillingmachine toabsorbrecoil. orscrewgun. Lossoffoothold Usershouldstandonafirmbase causingfall takesuitableprecautionsto preventafall.
Exhaustgases Effectsonresparitory Insignificantvolumeofharmful Dustfromdrilling,fumesfromcertain system gasesproducedinnormaluse. chemicalanchors. Formanyfixesinaconfinedspace, ensureadequateventilation.CoSHH dataavailableonrequest.
Toolmisuse Damageresultingfrom Onlytrained,certificatedpersonel Applicabletoallotherfixingmethods. irresponsibleuse shouldusethesystem.Training availablefromHilti(GB)Ltd.
Misfire Unexpectedignitionof Followmisfireprocedure None. mis-firedcartridge (ascoveredintraining).
Free-flight Fastenerinjuries Useonlylowvelocity,indirectacting None. offastener workerorbystanders tools.AllstandardHiltiDXtoolsare lowvelocity..
Fixingfailure Failureunderload Followcorrectprocedure(see Applicabletoallotherfixingmethods. instructionsandtraining).Observe Hiltitechnicaldataforthecorrect selectionandnumberoffixings. Carryoutsitetestingifdatais unavailableoriftheapplication iscritical.
ForcartridgeswecanprovideaproductdatasheetandCoSHHdata(MaterialsafetyDataSheet).Wecanalsoassistwithmethodstatementsformanyapplications.Ifyouhaveanyqueries,pleasecontactusandwewillbepleasedtoofferfurther,specificadvice.
Reduce your risk of hand-arm vibration by using
DX for lightweight fixings
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38
Lifetime Service for DX.
Total Life Cycle Management3 Steps to Total Confidence
Piston stop rings excepted.
ToolLifeCycleManagementisuniquetoHilti.Weareconfidentaboutourtoolsreliabilitythatwecanprovidetoollifecyclemanagement.Itspurposeistogiveourcustomersthebenefitofthemostreliabletoolsthatenhanceproductivity,openaccesstotechnicalandengineeringexpertisecoupledwithinnovation.
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New attractive service offering for DX tools:
Lifetime Manufacturers Warranty
2YearsNoCostcover*
* DX860-ENP,1yearNoCost.
* Only‘wearparts’excluded–Piston,StopRing/Buffer
LifetimeRepairCostLimit
Repairs-additional6months‘NoCost’cover
Lifetime maintenance and inspection package available
Maintenance/Inspectionpackageincludes: • Cleaningoftool,inspectionoftool,newpistonandstopper,shipping charges(pick-upanddelivery) • Fordetailssee“HiltiTools-makingyoumoney.”
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CE Identification mark on PAT tools.
• Feb.2010,theworld’sfirstCE-markedPATtool,aDX460MX,hasleftaHiltiplant.
• Bytheendof2010,theCEidentificationmarkwillbeadoptedtoallDXtools except the UW10 (underwater tool)
• TheCEidentificationicondeclaresthattheHiltiPowderactuatedtoolcomplies with the provisions of the Machine Directive 2006/42/EC. From now on this will co-exist with the PTB icon that declares that the tool is approved by the standards of the CIP regulation.
• CEidentificationwillreplaceCIPapprovalwithina18monthtransitionperiodinallEU-andEFTAcountries
Explaining the CE identification mark
What is new? Benefits
Tool complies with “Machinery directive” It is a tool, not a weapon
Consistent identification (similar to power tools) Simplify ISO certification
No more obligation for recurring inspection Less effort in tool maintenance(Germany, others to follow) Safety relevant instructions and data Enhance user health and safety publicationinoperator’smanual
Strict enforcement of clear-cut international guidelines High quality standard guaranteed
The Hilti Powder Actuated tool complies with the provisions of the Machine Directive 2006/42/EC.
The Hilti Powder Actuated tool has been system tested and type approved according to C.I.P. regulation.
Self certification (from 02/10) ApprovalThe CIP regulation continues to apply to C.I.P. member states outside the EU and EFTA judicial area.
3 2 6 0 0 03 2 6 0 0 0
Direct Fastening Brochure
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Approvals.The DX Fastening Systems below carry product approvals, or the product data has been derived in accordance with the standards or guidelines listed.
Technicaldata(designloads,applicationrestrictions,etc.)presentedintheseapprovals/guidelinesreflectspecificlocalconditionsandmaydifferfromdatapublishedinthisSpecifier’sguide.Iftheprojectissubjecttoaparticularapproval/guideline,thenthatdatahasprecedenceoverthedatainthisguide.Forcopiesofapprovals,pleasecontacttheHiltiTechnicalAdvisoryservice.
CSTB Centre Scientifique et Technique du Bâtiment (Building Science and Technology Centre) ENP2,ENPH2,ENP2K
DIBt Deutches Institut für Bautechnik (German Institute of Building Technology) ENP2,ENPH2,X-IE(specialversion),X-CR,X-CRM,X-HS,X-CC
DNV Det Norske Veritas (Offshore Approval, ignition test) DX450
FM Factory Mutual ENP2,ENPH2,ENP2K,ENKK
ICBO International Conference of Building Officials ENP2,ENPH2,ENP2K,ENKK,studs(notX-CRM),X-DNI,X-EDNI,ENK,EDS,DS,X-ZF
Lloyds Lloyds Register of Shipping (Offshore Approval, ignition test) DX460,DX351
ONORM Oesterreichische Norm (Austrian Standard) X-HVB
SDI Steel Deck Institute ENP2,ENPH2,ENP2K
SOCOTEC Société de Contrôle Technique (Technical Controlling Body) X-HVB,X-IE,X-HS,X-CC
SZS Schweizerische Zentralstelle für Stahbau (Swiss Steel Construction Association) X-HVB
UL Underwriters Laboratories ENP2K,ENKK,studs(notX-CRM)
TZÚS CZECHIA X-HVB
DIBt
UL®
Direct Fastening Brochure
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Load Data.
X-U P8 X-U S12
X-U P8 X-U S12
Note: when using X-U nails values are based on 27mm embedment depth.
Note: this data is a summary of the full technical data for the product which should be consulted for all safety critical applications.
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43
Quick Reference Guide.
X-U
X-C
X-CT
Hilti. Outperform. Outlast.
Hilti (Gt. Britain) Limited l1TraffordWharfRoadlTraffordParklManchesterM171BYFreephone:0800886100lFreefax:0800886200lwww.hilti.co.uk
Hilti (Fastening Systems) Limited lUnitC4lNorthCityBusinessPark lDublin11CallSave:1-850-287-387lFreefax:1-800-654-600lwww.hilti.ie
3465636June2010
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