insert plate armourmate™ - · pdf fileinsert plate armourmate™ joint edge...

Insert Plate ArmourMate™ Joint Edge Protection

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Joint Edge ProtectionI N D U S T R I A L S L A B O N G R O U N D

Accommodates larger concrete shrinkage gaps

Facilities thermal movement

Prevents spalling on construction joints

Extends the life-cycle of the floor and the asset

Insert Plate ArmourMate™


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Product Description

Insert Plate ArmourMate™ systems are designed to provide the total joint system solution by incorporating three systems in the one solution, being the Insert Plate ArmourMate™ steel angles and plate as the armour edging, the Square Dowel and Flanged Dowel Box as the load transfer system and the galvanised separation plate as the sacrificial formwork that takes place of the traditional wooden formboard.

Insert Plate ArmourMate™ is made to customer specification and is designed to be used in situations where larger shrinkage and thermal movement is expected. It allows for future expansion with each replacement plate used in the joint. The plate over the gap provides a smooth ride for traffic travelling over the joint, minimising wheel damage and impacts.

Insert Plate ArmourMate™ replacement plates are available to customer specification. The standard 65 mm plates are designed to open up to 15 mm, if more movement is required or the gap at the top of the concrete needs to be reduced replacement plates can be ordered to suit.

Range Options

• Full Joint Systems specifications

• Black or hot-dip galvanized steel to AS/NZS 4680

• Multiple dowel options

• Infill lengths available on request

• Made to custom configurations

• Removable cover plate

Concreter Benefits

• Full system configuration eliminates formboards.

• Staking system eliminates Hot Work (on-site welding).

• Twist and lock stake system provides fine height and level adjustment.

• Provides a straight edge and screed rail.

Asset Protection Benefits • Reduces concrete spalling

damage at the joints.

• Provides a safer operating environment for tenant employees.

• Extends the life-cycle of the asset by protecting the floor.

• Reduces floor maintenance and downtime costs over the lifecycle of the facility.

• Increased tenant satisfaction and return on investment.

Engineering Benefits • Provides a bridge across

the construction joint.

• Provides the ability to resize and retrofit the coverplate.

• Facilitates movement while maintaining cover over joint gap.

• Transfers load across the joint and into the slab panel.

• Accuracy of dowel placement ensures the most effective load transfer performance.

Features1. A drop in cover plate that can be re-sized and retrofitted to bridge

large joint gaps

2. Used with high capacity Grade 300 square dowels and Flanged Dowel Boxes.

3. Shear Studs tested at 34 kN breaking strain, shears at shank.

4. The cover plate covers the joint gap between slabs preventing debris from filling joint gap.

5. Patented twist and lock stake bracket system for an easy setup.

6. Galvanised formwork plate on all systems.

Advantages• Incorporates the joint cover, edge protection, load transfer device

and formwork in a single system.• Provides slab edge protection to prevent concrete spalling.• The cover plate remains supported either side of the gap once the

joint has opened up.• Smooth wheel transition over large gap openings.

Insert Plate ArmourMate™ provides slab edge protection to prevent concrete spalling.

Benefits


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COMPONENT DIMENSION (mm) MATERIAL TYPE MATERIAL

STANDARDSSTEEL GRADE EQUIVALENT

YIELD STRESS (MPa)

TENSILE STRENGTH

(MPa)

STANDARDS COMPLIANCE

Angles 50 x 50 x 6 Hot RolledSteel AS/NZS 3679.1 ≥ Grade 300 340 500 AS/NZS 3679.1

Flat 20 x 10 Hot RolledSteel AS/NZS 3679.1 ≥ Grade 300 365 520 AS/NZS 3679.1

Insert Plate 65 x 10 Hot RolledSteel AS/NZS 3679.1 ≥ Grade 300 345 510 AS/NZS 3679.1

Shear Stud 100 x 10 Cold Drawn DIN 1.040 C22 1010 415 520 AS1443

Formwork 1.95 Galv. G2 Z275 AS1365 ≥ Grade 300 340 370 AS1397

Square Dowel 20 x 20 x400 Mild Steel Bar AS/NZS 3679.1 ≥ Grade 300 360 510 AS/NZS 3679.1

Flanged Dowel Box 0.77 Galv. G2 Z275 AS1365 ≥ Grade 300 310 360 AS1397:2011

OVERALL LENGTH ±2 mm OVERALL HEIGHT ±1 mm

Material Technical Data

Manufacturing Tolerances

Joint Section - After Sab Shrinkage

Joint Section - At Install

Field and Product SupportWe pride ourselves on our ability to provide on-site product and installation support. Our field sales and support teams are available to advise and work side by side with the industry when on site clarification or problem solving is required.

Initial movement 15 mm max. due to slab shrinkage * Removable sliding cover plate

Cover plate covers joint gap eliminating the need for fillers

Armoured edge

* Initial cover plate (65 mm) allows for a maximum of 15 mm joint opening. Additional opening can be accommodated by replacing the initial cover plate with a wider custom cover plate giving an additional 15 mm of opening.


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Installation Process (Initial Setup)

• TheArmourMate™lengthareflushontheends.Theyneedtobejoinedtogetherwiththesuppliedjoinerplateandfixingbolts.

• Ensurea5mmgapisleftbetweeneachlength.Thisallowsforthelateralmovementofthejoint.Repeattheprocessforeachsectionuntilthedesiredlengthisachieved.

• Installtheanyrequiredconcretereinforcing.Pourtheconcreteinsuringtovibratealongthejointatregularintervals.

• ThetopoftheArmourMate™railscanbeusedtoscreedalong.

• Afterthefirstpourhassetremoveanyadditionalstaking.Placethedowelsthroughtheseparationplateslotsintothesleevesinthefirstpourbeforepouringthesecondpour.Dowelsshouldbeplacedwithin36hoursofthefirstpour.

• Adjusttheheightofthejointuntilitislevelandattherequiredslabdepth.Turnthestakes90degreesusingtheshiftertolockthejointinplace.

Step 1.INSTALLATION

Step 2.INSTALLATION

Step 3.INSTALLATION

Step 6.INSTALLATION

Step 5.INSTALLATION

InstallationStep 4.INSTALLATION

• InstalltheseparatelysuppliedFlangedDowelBoxesusingtheself-tappingscrewsattheprovideddowelcut-outs,ensuringtheflangeisfacingtowardsthetopofthejoint.

• Checksub-gradeforlevelnessandgrade.SetastringlinealongthejointpathandpositionthefirstlengthofArmourMate™.

• Ensurethesleevesgoonthesideoffirstconcretepourwilloccur.Insertstakes(sixperlength)throughthestakebracketsattachedtotheArmourMate™separationplate.

• Hammerthestakesintothegrounduntiltheyare50mmbelowthetopofthejoint.Additionalstakingandbracingmayberequiredtokeepsectionssteadyduringtheconcretepour.

TOOLS REQUIRED: Danley™ Stakes (Six Per Length) | Hammer Small Shifter | Spirit Level | String Line | Extra Bracing And Stakes As Required (Customer To Supply) | Cordless Drill 3.5 mm X 20 mm Self-Tapping Screws | Drill Bit


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5 mm min.

Movement Gap - Plan Detail

Please Note: Duringinstallationa5mmmin.gapmustbeprovidedbetweenlengthstoallowforanythermalmovementofthejoint.

Correct Mesh Placement - The following points are recommended when placing mesh at the joint

Mesh Reinforced Slab Design - Typical Install

Slab h

eight

½ Sl

ab he

ight

(±5%

)

Reinforcing mesh supported by bar chairs (⅓ the slab cover)

Mesh to be spaced a minimum of 50 mm from the joint (either side)

1. Mesh should be located externally of stud position

2. The mesh should be supported by bar chairs to rest

approximately ⅓ of the slab height.

3. The mesh should never rest on the dowel or the dowel cover.

4. The mesh edge should be located approximately 50 mm from the formwork plate (on either side).

5. Continuous mesh wire should be broken at the edge of the sheet to prevent cracking. Failing to do so may induce a crack in-line with the edge of the mesh.

6. Dowel sleeves should always be located on the stake bracket side of the joint.

Joint Placement For Mesh Reinforced Slabs

Thermal Movement Gap Detail


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Max. 75-100 mm from soff saw-cut (both sides)

Max. 75-100 mm from cut infill ends

Soff saw cut Weld loose stud to rail on-site

Cut infill end

Insert Plate ArmourMate™ Typical Stud Placement (Plan View)

IMPORTANT - Replacing anchors on-site cut lengths

If Danley™ ArmourMate™ rails are cut to length on-site, and the remaining anchors on the rails are in excess of 100 mm from the cut, it is the responsibility of the contractor to secure an anchor or anchors onto the rail to be cast into the concrete, before pouring concrete. The replacement anchor or anchors may be removed from the off-cut, or a device similar to the anchor on the off-cut may be used; and should be tack welded to the rail within 75 mm of the cut end.

Similarly, it is the responsibility of the contractor, when setting out the ArmourMate™ rails prior to pouring concrete, to examine the location of any saw-cut contraction joint that may pass through the ArmourMate™ rails, and add additional anchors within 75 mm each side of the proposed saw-cut on each side of the rail. Both these actions will ensure that the ends of the Danley™ ArmourMate™ rails are anchored appropriately when the concrete is poured.

Typical Companion ProductFlanged Dowel Boxes

Flanged Dowel Boxes are multi-directional metal sleeves with high capacity square dowels. They are attached to metal or wooden formwork with integral nailing flanges and location marks. They allow for both contraction and expansion at the joint, as well as having a large lateral movement capacity. They are designed for construction joints in both ground and elevated slabs and are available in a number of different standard sizes.

Second pour First pour

Square dowel inserted into Flanged Dowel Box after first pour

Compressible foam in sleeve allows for expansion capacity

½ dowel length


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Insert Plate Installation Steps (Replacement Plate)Insert Plate ArmourMate™ Replacement Plates are made to customer specification. The standard 65 mm plates are designed to open up to 15 mm, if more movement is required or the gap at the top of the concrete needs to be reduced replacement plates can be ordered to suit. It is the responsibility of the customer to conduct on site measuring to determine the plate lengths, widths and hole locations.

Length to be specified by customer

Bolt centres

W

Width to be specified by customer

Common Widths75 mm, 90 mm, 100 mm and 110 mm

Insert Plate ArmourMate™ Dimension Details (Replacement Plates)

Replacement Insert Plate Installation Process

• Theexistingjointopeningsneedtobemeasuredtocalculaterequiredreplacementplateswidths.Anyinfillsneedtobemeasuredforrequiredlengthandboltcentresaswell.ThisshouldberecordedandsubmittedtoDanley™forquotingandmanufacturing.

• Oncetheplateshavebeenreceivedtheoldinsertplatescanberemovedbyundoingthescrewsandstarwasherswiththe5mmHexKeydrillbitanddrill.Pleasekeepthescrewsforreuse.

• Ensurethatthechannelisfreeofanydebrisorconcretebyscrapingwithascrewdriverandplacethenewwidthplatewheretheprevioushadbeenmakingsuretoaligntheholesintheplatewiththeholesinthecastinangles.

• Thescrewscanbereinsertedintheholesandfastenedwiththedrill.• Oldinsertplatescanbediscardedorkeptforspareparts.

TOOLS REQUIRED: Tape Measure | 5 mm Hex Key Drill Bit Or Allen Key | Cordless Drill | Flat Head Screw Driver

Step 1.INSTALLATION

Step 2.INSTALLATION

Step 4.INSTALLATION

InstallationStep 3.INSTALLATION


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Durability Testing

Our in-house test rig is on the job consistently running cycle testing for durability of our Insert Plate ArmourMate™.

JOINT STOCKED POUR THROUGH

EXPANSION JOINTS

POST TENSIONING

DIAMOND™ DOWEL

FLANGED DOWEL BOX INFILLS INTERSECTIONS

Hyper ArmourMate™ (Full Joint) ✓ ✓ ✓ ✓ ✓ ✓ ✓

Hyper ArmourMate™ (Top Rail) ✓ ✓ ✓ ✓ ✓ ✓ ✓

Plate 60 ArmourMate™ ✓ ✓ ✓ ✓ ✓

Insert Plate ArmourMate™ ✓ ✓ ✓ ✓ ✓

APPLICATION HYPER PLATE 60 INSERT PLATE

Small, hard wheeled traffic (pallet jacks) ✓ ✓ ✓

Cushioned wheel traffic (forklifts & trucks) ✓ ✓ ✓

Heavy loads ✓ ✓ ✓

Warehouse internal slabs ✓ ✓ ✓

External slabs, pavements & carparks ✓ ✓ ✓

Large slab shrinkage & movement at joint (PT) ✓ ✓

High FF & FL floors ✓


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RAAF Base Warehouses

Danley™ Products Used

• Insert Plate ArmourMate™• Diamond™ Dowel• Plate Dowel Cradle™

Project Information

The Insert Plate ArmourMate™ technology was used within an RAAF (Royal Australian Air Force's Base) development project located 8 km southwest of Ipswich. Insert Plate ArmourMate™ was predominantly used as the Armour Edging, for its effective ability to remove and replace the cover plate.

Specifier SKM

Location Amberley, QLD

Client Leightons Contracting

Installer QR Concrete

Installation Date March 2014

Case Study

Site Photos


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Insert Plate ArmourMate™ (Full Formwork Systems) - Dimension Details

3000 mm overall length

Dowel centres as specified

Slab h

eight

Dowel type/size

Section At Joint - When Poured

Slab h

eight

½ Sl

ab he

ight

Specified roadbase (10 mm typ.)

x x x x x x x

Specification

How to write a (custom) specification

Product specification for custom Insert Plate ArmourMate™ consists of a standard full joint system.

In order for Danley™ to help with your project requirements please have the following information available for when you contact your sales representative.

REQUIRED INFORMATION FOR QUOTATION

Slab HeightJoint Finish (Blk/Galv.)

Roadbase (10 mm Typical) Dowel SizeDowel Type Stand or StakesDowel Centres


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Local ManufactureWe pride ourselves in being a local manufacturer of Edge Protection Systems in Australia with all systems being fabricated and assembled at our QLD manufacturing facility in Morningside, Brisbane. Maintaining local manufacture and growth in Australia generates local employment and ensures we are able react quickly to providing non-standard design solution for tough applications.

Square Dowel Cradles™ positioned at the soffcut joint lines.

Typical 30 x 30 meter slab panel.

Construction Joints

Contraction Joints

ArmourMate™ or loose dowels (Flanged Dowel Box) positioned around the perimeter of each concrete pour.

Danley Insert Plate Armourmate™ Panel Layout

1. Flanged Dowel Box

Flanged Dowel Boxes are multi-directional metal sleeves with high capacity square dowels. They are able to be attached to metal or wooden formwork with ease there integral nailing flanges and location marks. They allow for both contraction and expansion at the joint, as well as having a large lateral movement capacity. They are ideal for construction joints in both ground and elevated slabs and are available in a number of different standard sizes.

2. Square Dowel Cradle

Square Dowel Cradles are designed to provide a total contraction joint system solution by incorporating two systems in the one solution. The square dowels act as the load transfer system with the dowel sleeves to provide lateral and longitudinal movement capabilities and reduces the risk of restraint. The wire cage acts as a chair and spacer to ensure the dowels are aligned and maintained at the correct height and spacing during the pouring of the slab.

3. Crack-A-Joint™

As an option to saw cutting, place Crack-A-Joint™ into the wet concrete along the joint line (above the centre of the Dowel Cradle), to induce a crack for the full depth of the concrete. The Crack -A-Joint™ is available in standard 3 m lengths formed from galvanised sheet steel to a height of 25 mm. It can be supplied as a plain joint or with a permanent Rip-A-Strip™ capping in three different colour options (Black, Grey or Sandstone).

4. Ground Crack Inducer

An inverted V-shaped PVC extrusion, 3 m long and available in 25 mm and 50 mm heights. It is positioned on the sub-grade before the Dowel Cradles are placed. It produces a weakening in the slab that initiates a crack from the bottom up. Ground Crack Inducer is optional and should only be used when Crack-A-Joint™ is used, or when saw cuts are to made in the slab on the same day as the slab is poured.

5. Cradle Hold Down Hook

A small optional wire hook that allows you to anchor the base of your Cradles into the site sub-base. It prevents the Dowel Cradles from moving during the pour process. They hook over the bottom wire of the Cradles securing them to the ground.

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Disclaimer: The information contained in this publication is intended to give a fair description of the products and their capabilities.Noresponsibilityorliabilitybythemanufacturerswillbeacceptedformisuse,misreadingordeviationfromtherecommendedguidelinesoftheseproducts.Asnewtechnologyisintroduced,orindustrystandardsarealtered,ITWCSreservestherighttoaltertheinformationwithoutnotice.www.itwcsanz.com | [email protected]

Rev2-June2015Other related ITW Construction Systems brands

Companion Products

www.danley.com.au | [email protected] DANLEY (1300 326 539)

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