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REBAR FOR ENGINEERS

Part 1

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Foreword
Together with its companion e-learning module this document intends to give field
engineers a solid background on the Hilti HIT Rebar System. This part 1 introduces
the product system and the theory for rebar design according to approvals.
It is suggested to carefully read the document before tackling the e-learning module
which is very interactive and does not provide background information.
You will need to spend 4 – 5 hours on this document and the e-learning module

Contents:

1. Concrete Design and Reinforcement 3

1.1 Flow of Forces inside a Concrete Structure 3
1.1.1 B- and D-regions 3
1.1.2 Parallel Chord Truss Analogy (B-regions) 4
1.1.3 strut and tie models for D-regions 5
1.2 Anchorage of reinforcement 7
1.2.1 Development Length 7
1.2.2 Overlap Splices 7
1.2.3 Design of Development and Overlap Length with Eurocode 2 8

2. Post-Installed Reinforcement Approvals 9

2.1 High Quality Installation 10
2.1.1 Drilling 10
2.1.2 Hole cleaning 10
2.1.3 Injection and bar installation 11
2.2 High Quality Product 12
2.2.1 Assessment criteria 12
2.2.2 Types of adhesives 12
2.3 Design of Connections “like cast-in” 13
2.3.1 Application Range 13
2.3.2 Approvals with or without exceptions 14
2.3.3 Special provisions 15

3. Communication to Designers 15

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1. Concrete Design and Reinforcement

1.1 Flow of Forces inside a Concrete Structure

“Reinforcing adequately is an ART. Its practice requires a clear view of the flow of forces
inside a structure and of the interaction between steel and concrete.”
(F. Leonhardt, Vorlesungen über Massivbau, 1978)

1.1.1 B- and D-regions

In selecting the appropriate design approach for structural concrete, it is useful to classify
portions of the structure as either B- (Beam or Bernoulli) Regions or D- (Disturbed or
Discontinuity) Regions. B-Regions are parts of a structure in which Bernoulli's hypothesis of
straight-line strain profiles applies. D-Regions, on the other hand, are parts of a structure with
a complex variation in strain. D-Regions include portions near abrupt changes in geometry
(geometrical discontinuities) or concentrated forces (statical discontinuities). Based on St.
Venant's principle, the extent of a D-Region spans about one section depth of the region on
either side of the discontinuity.

Figure 1 shows an example of the division between B-Regions and D-Regions in building
and bridge structures, respectively. In the figures, the unshaded area with a notation B
indicates B-Region, and the shaded area with a notation D is used to indicate D-Region. The
notations h1, h2, h3, ... are used to denote the depth of structural members. The notations b1
and b2 denote the flange width of structural members.

Figure 1: Example of D-Regions in a Common Building Structure

Most design practices for B-Regions are based on a model for behavior. As examples,
design for flexure is based on conventional beam theory while the design for shear is based
on the well-known parallel chord truss analogy. By contrast, the most familiar types of D-
Regions, such as deep beams, corbels, beam-column joints, and pile caps, are currently still
designed by empirical approaches or by using common detailing practices. For most other
types of D-Regions, code provisions provide little guidance to designers. The Strut-and-Tie

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Method (STM) is a methodology for the design of all types of D-Regions in structural
concrete.

1.1.2 Parallel Chord Truss Analogy (B-regions)

Compression
C
M
d
h

z
Tension (cracks)
Steel area As
Fs

Figure 2: Forces inside concrete under pure bending

A concrete beam or slab will bend under loading which leads to cracks, see fig. 2. A
compressive force will be concentrated close to one surface while reinforcement will take the
tensile force on the other side. In pure bending, the inner forces of a concrete slab or beam
are

M
C  Fs 
z

where C is the concrete force in the compression chord and Fs the tension in the reinforcing
steel. z is called “inner lever arm”. Depending on the moment M, the steel area As and the
concrete quality z varies between 0.8d and 0.95d. d is called the effective depth; it is the
distance form the outermost compression fibre to the centre of the reinforcing steel area. In
some cases, e.g. for pre-design purposes, the simplified formula z=0.9d is assumed.

Normally, reinforced concrete sections are not loaded by pure bending, but there will also be
shear and possibly torsion. The idea of the strut-and-tie method came from the truss analogy
method introduced independently by Ritter and Mörsch in the early 1900s for shear design of
B-Regions. This method employs the so-called truss model as its design basis. The model
was used to idealize the flow of force in a cracked concrete beam.

Figure 3: truss model according to Ritter and Mörsch

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The internal forces are calculated by the equilibrium condition in every node of the truss. The
simple truss of figure 3 was generalized since. The main evolution is that the truss angle t
can be selected within certain limits, roughly between 30° and 60°. Many modern concrete
design codes show a figure similar to the following:

Figure 4: truss model in modern codes

The equilibrium equations in horizontal and vertical directions result in these internal forces
and stresses:

My N x Vz  cot 
Fs   
z 2 2
M y N x Vz  cot 
C  
z 2 2
Fcw Vz 1
 cw   
bw  z  cos bw  z sin   cos
Vz  s w
Fsw 
z  cot 

Note that the first equation implies that the tensile force in the rebars is the tension out of the
moment increased by a contribution due to the shear load.

1.1.3 strut and tie models for D-regions

In the strut and tie modelling (STM), the complex flow of internal forces in the D-Region
under consideration is idealized as a truss carrying the imposed loading through the region to
its supports. This truss is called strut-and-tie model and is a statically admissible stress
field in lower-bound (static) solutions. Like a real truss, a strut-and-tie model consists of
struts and ties interconnected at nodes (also referred to as nodal zones or nodal regions). A
selection of strut-and-tie models for a few typical 2-D D-Regions is illustrated in Figure 5. As
shown in the figure, struts are usually symbolized using broken lines, and ties are usually
denoted using solid lines.

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Figure 5: Examples of Strut-and-Tie Models for Common Structural Concrete Members

Source: http://dankuchma.com/stm/STM/

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1.2 Anchorage of reinforcement

a) Reinforcement that is not anchored is no reinforcement.

b) Bars need to be anchored from where they are not needed any more.

1.2.1 Development Length

In the node of the strut and tie model to the left the concrete
compression force, the support force and the steel tensile force are
in equilibrium. It assumes that the reinforcing bar can provide its
tensile force on the right side of the node while there is no steel
stress at all on the left side of the node. Physically this is not
possible. The strut and tie model is an idealization of the real flow of
forces. If we remain within this idealization, the steel stress has to
Figure 6: simple support
be developed on the left side of the node. The development of steel
stress is operated by bond between steel and concrete. To give the bar the possibility to
develop stress, it needs to be extended on the left side of the node; this extension is called
development length or anchorage length. In the above figure the space on the left of the
node is not sufficient to develop enough steel stress by bond. Therefore, either the concrete
section needs to be extended over the support or the development length needs to be
reduced by appropriate means. Typical solutions are hooks, heads, welded transverse
reinforcement or external anchorage.

1.2.2 Overlap Splices

If the equilibrium of a node cannot be

established (without using the tensile
capacity of concrete), then the tensile force
of a bar which is ending must be transmitted
to other reinforcement bars. A typical
example is starter bars for columns or walls.
For practical reasons, foundations are often
built with rebars sticking out far less than the
final column height. The column
Figure 7: overlap splices reinforcement is later spliced to the starter
bars sticking out. Once there is bending on the columns, the tension load will be transferred
from the column reinforcement to the starter bars through the overlap splice.

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1.2.3 Design of Development and Overlap Length with Eurocode 2

The following is a summary of sections 8.4 and 8.7 of Eurocode 2 (2004) as far as they
concern the design of post-installed reinforcement, i.e. the parts concerning bond between
steel and concrete. For adequate anchorage and splicing, a number of detailing rules need to
be considered as well.
The bond strength fbd [N/mm2] to be considered is calculated as
f bd  0.315 1  2  f ck2 / 3
fck is the characteristic cylinder strength of the concrete (it is the first number of the
standard concrete designation, e.g. for C25/35, fck=25N/mm2).
1 is a coefficient related to the quality of the bond condition and the position of the
bar during concrete pouring. 1=1.0 stands for good bond conditions and 1=0.7 is
taken for all other cases. In figure 9, the white areas denote good bond conditions,
the marked ones show “poor” bond conditions.

300mm

250mm

h > 250mm h > 600mm

Figure 8: good and poor bond conditions

2 is related to the rebar diameter: 2 = (132-)/100 ≤ 1.0 where  is the nominal

rebar diameter [mm]

The basic anchorage length b,rqd [mm] is calculated as

 b , rqd  ( / 4)  ( sd / f bd )

sd [N/mm2] is the design stress of the bar at the position from where the anchorage is
measured.
The design anchorage length is calculated from b,rqd taking into account the influence of five
parameters and it should not be less than a minimum anchorage length:
 bd  1   2   3   4   5   b ,rqd   b , min

For bars in compression (usually considered only in highly loaded columns), all -factors
except 4 are taken as 1.0. For bars in tension (and 4 also in compression) the factors are
defined as follows:
1 considers the shape of the bar: for straight bar ends 1=1.0, for other shapes in
certain conditions 1=0.7.
2 takes into account the concrete cover: 2=1-0.15(cd-)/ ≥ 0.7 where cd is the
smallest concrete cover or half of the clear distance between bars, whichever is
smaller.
3 =1-K ≥ 0.7 is for the effect of transverse reinforcement where
 =(Ast-Ast,min)/As

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Ast = cross-sectional area of the minimum transverse reinforcement along the

design anchorage length bd
Ast,min=0.25As for beams and Ast,min=0 for slabs
As = area of a single anchored bar with maximum bar diameter
K:

4 =0.7 if there is transverse reinforcement welded to the reinforcement to be

anchored, otherwise 4=1.0
5 considers transverse pressure: 5=1-0.04p ≥ 0.7 where p is the transverse
pressure along the anchorage length.
The cumulating of the influences is limited by 1·2·3·4·5 ≥ 0.7
The minimum anchorage length is
b,min = max(0.3b,rqd; 10; 100mm) for bars under tension
b,min = max(0.6b,rqd; 10; 100mm) for bars under compression

The design overlap length is also calculated from b,rqd:

 0  1   2   3   5   6   b , rqd   0, min

For bars in compression (usually considered only in highly loaded columns), all -factors
except 6 are the same as for anchorage, see above. For bars in tension (and 4 also in
compression) the factors are defined as follows:
6 =1.5 if all bars are spliced in the same area, i.e. the splices are not staggered,
which is usually the case with post-installed splices.
If the clear distance between lapped bars, e, exceeds four times the bar diameter  or 50mm,
then the overlap length shall be increased by a length equal to e-4 or e-50mm.
The minimum overlap length is
0,min = max(0.3·6·b,rqd; 15; 200mm)

2. Post-Installed Reinforcement Approvals

There are European Technical Approvals for post-installed rebar connections. Systems
getting such approvals have to be assessed according to the EOTA technical guideline
TR023 (available under www.eota.eu). Requirements for a positive assessment are an
installation system providing high installation quality for deep holes and an adhesive fulfilling
the test requirements of the guideline TR023. Obtaining the approval is basically the proof
that the post-installed rebars work at least as well as cast-in rebars (with respect to bond
strength and displacement); consequently, the design of the rebar anchorage is performed
according to structural concrete design codes, in the case of Europe this is Eurocode 2.

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2.1 High Quality Installation

2.1.1 Drilling

Injection anchor systems are used to fix reinforcement bars into concrete. Fast cure products
are generally used with rebar diameters up to 25mm and moderate hole depths of up to
about 1.5m, depending on the ambient temperature. Slow cure systems can be used with
larger bar diameters and deep holes: The deepest rebar fixing so far was 12m to our
knowledge. As rebar embedment lengths are usually much longer than with standard anchor
applications, there are a number of additional system components helping to provide high
quality of installation:
Drilling aid: Rebars are usually situated close to the concrete surface. If a long drill hole is not
parallel o the surface, the inner lever arm of the structure will decrease along the hole if the
deviation is away from the surface and even worse, the hole may penetrate the concrete
surface or result in insufficient cover if the deviation is towards the surface. According to the
rebar approvals, the deviations to be taken into account are 0.08 times the hole length (4.6°)
for compressed air drilling, 0.06 times the hole length (3.4°) with hammer drilling and 0.02
times the hole length (1.1°) if a drilling aid is used (optical help or drilling rig, see fig. 9).

Figure 9: drilling aids

Depending on the required minimum concrete cover in every section of the post-installed
rebar, the minimum “edge distance” at the start of the drilled hole is then:

cmin = 50 + 0,08 lv ≥ 2ds (mm) for compressed air drilled holes

cmin = 30 + 0,06 lv ≥ 2ds (mm) for hammer drilled holes

cmin = 30 + 0,02 lv ≥ 2ds (mm) if a drilling aid is used

2.1.2 Hole cleaning

The holes should be blown out using compressed, oil free air. If holes are deeper than
250mm, extension tubes and air nozzles directing the air to the hole walls should be used

Holes deeper than 250mm should be brushed by machine brushing using steel brushes and
brush extensions:

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Screw the round steel brush HIT-RB to the end of the brush extension(s) HIT-RBS, so that
the overall length of the brush is sufficient to reach the base of the borehole. Attach the other
end of the extension to the TE-C/TE-Y chuck.
The rebar approvals (ETA’s) give detailed information on the cleaning procedure for each
product.
The following figure underlines the importance of adequate hole cleaning: If the drill hole is
cleaned according to instruction, the post-installed bar (blue line) shows higher stiffness and
higher resistance than the equivalent cast-in bar. With substandard cleaning (red line),
however, stiffness and resistance are clearly below those of the cast-in bar.

Post-installed, adequately cleaned hole HIT-HY 150

Cast-in d s = 20mm

Post-installed, concrete humid,

tension [kN]

cleaning not adequate

30cm

d 0 = 25mm

displacement [mm]

2.1.3 Injection and bar installation

It is important that air bubbles are avoided during the injection of the adhesive: when the bar
is installed later, the air will be compressed and may eject part of the adhesive from the hole
when the pressure exceeds the resistance of the liquid adhesive, thus endangering the
installer. Moreover, the presence of air may prevent proper curing of the adhesive.
In order to reach the bottom of the drilled holes, mixer extensions shall be used. The holes
should be filled with HIT to about 2/3. Marking the extension tubes at 1/3 of the hole length
from the tip will help to dispense the correct amount of adhesive. Piston plugs ensure filling
of the holes without air bubbles.
Hilti provides different dispensers and cartridges: 330ml, 500ml and 1400ml. With rebar
applications often large volumes need to be dispensed. The ideal setup is then the Volume
Injection tool P 8000 with 1400ml cartridges.

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After injecting the HIT, the rebars should be inserted into the hole with a slight rotating
movement. When rebars are installed overhead, dripping cups OHC can be used to prevent
excess HIT from falling downward in an uncontrolled manner.

2.2 High Quality Product

2.2.1 Assessment criteria

EOTA TR023 specifies a number of tests in order to qualify products for post-installed rebar
applications. For information, these are the performance areas checked by the tests:
1. bond strength in different strengths of concrete
2. substandard hole cleaning
3. Wet concrete
4. Sustained load and temperature influence
5. Freeze-thaw conditions
6. Installation directions
7. Maximum embedment depth
8. Avoidance of air bubbles during injection
9. Durability (corrosion, chemical attack)

2.2.2 Types of adhesives

Hilti provides two basic types of rebar adhesives: Fast curing adhesives of HIT-HY 150-MAX
type can be considered as "general mortars" for the fixing of bars up to 25mm diameter.
Their name is also their main advantage: work can continue soon after installation of the

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bars. With slow curing adhesives an extended curing time of up to 12 hours needs to be
respected before they can be loaded; details are given in the respective product information.
But they are excellent problem solvers, especially for high temperatures and large bar
diameters.
Ø 40

use HIT-RE 500

Ø 25
Rebar Size in mm

use HIT-HY 150

or HIT-RE 500

Ø 08
-5 / 23 10 / 50 20 / 68 30 / 85 40 / 105
Base Material Temperature in °C / °F

2.3 Design of Connections “like cast-in”

2.3.1 Application Range

The principle that rebars are anchored “where they are not needed any more” (anchorage) or
where the force is taken over by an other bar (splice) together with the fact that only straight
rebars can be post-installed leads to the following range of applications as shown by the
figures taken from EOTA TR023:

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All other applications lead to tensile stress in the concrete. Therefore, the principle “works
like cast-in” would not be true any more. Such cases must be considered with specific
models exceeding the approval based approach to post-installed rebar connections.

2.3.2 Approvals with or without exceptions

If an adhesive fulfils all assessment criteria of EOTA TR023, rebar connections carried out
with this adhesive can be designed with the bond strength and minimum anchorage lengths
according to Eurocode 2 as outlined in section 1.2.3 of this document.
Adhesives which do not fully comply with all assessment criteria can still obtain an “approval
with exceptions”.
- If the bond strength obtained in tests does not fulfil the specified requirements, then
bond strengths lower than those given by Eurocode 2 shall be applied. These values
are given in the respective ETA.
- If it cannot be shown that the bond strength of rebars post-installed with a selected
product and cast-in rebars in cracked concrete (w=0.3mm) is similar, then the
minimum anchorage length b,min and the minimum overlap length 0,min (see sect.
1.2.3) shall be increased by a factor 1.5.

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2.3.3 Special provisions

In order to avoid crossing of holes, the minimum clear spacing between two post-installed
bars should be 4≥ 40mm.

3. Communication to Designers

If you wish to know the mind of a man, listen to his words. (Chinese proverb)

Some input on how to prepare discussions on post-installed rebar with designers:

- When you are in a design office to show anchor design, as a Hilti Field Engineer you
will usually be much more competent than your audience. With post-installed rebar
this is different: the designers will probably more experienced in the field of rebar
connections.

- Don’t teach designers how to design reinforcement; they know very well how to do
this. Their main concern is that post-installed reinforcement is possibly different from
what they know. Thus your main tasks are to confirm that basically post-installed
reinforcement really works like cast in, but then also to be able to show the
differences.
- Reinforcement design is different in every code and there are even differences in
approach from office to office since much of it is experience based. As a Hilti Field
Engineer you cannot know every detail of practice. Thus it is important to listen to the
designer and first find out his concerns.
- Competition sometimes argues that their adhesive is so strong that embedding seven
to ten times the bar diameter will result in yielding of the rebar steel; and they even
prove it with on-site tests. This may be a way to approach contractors, but designers
usually do not feel comfortable with such an approach. Their experience says that
rebar anchorages must be much longer. You can clarify the discussion by stating that
o Hilti adhesives have the same ultimate bond strength. But normally rebars are
set close to the concrete cover and thus splitting of the concrete cover
controls. Yielding of bar would only be achieved with very large concrete
cover.
o Moreover test statistics show that scatter in concrete related failures (such as
splitting or pullout) is much higher than scatter in steel strength. Thus, for
design purposes, the concrete related strength has to be considered with
much higher safety factors than steel strength.
o Thus it becomes clear that the short embedment is only applicable in anchor
design accepting brittle concrete related failures, but not in rebar design
supposing ductile behaviour of the construction.

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4. List of Symbols

C compression force in concrete

Fs tensile force in reinforcement
M moment acting on section
N normal force acting on section
V shear force acting on section
d effective depth of member
z inner lever arm of section
cw compressive stress in concrete strut
sd tensile stress in rebar
Fsw tensile force in shear (web) reinforcement
fbd bond strength
fck is the characteristic cylinder strength of the concrete
1 factor for influence of bar position on bond strength.
2 factor for influence of rebar diameter on bond strength
b,rqd The basic anchorage length [mm]
sd [N/mm2] is the design stress of the bar at the position from where the anchorage is
measured.
1 considers the shape of the bar: for straight bar ends 1=1.0, for other shapes in
certain conditions 1=0.7.
2 takes into account the concrete cover: 2=1-0.15(cd-)/ ≥ 0.7 where cd is the
smallest concrete cover or half of the clear distance between bars, whichever is smaller.
3 is for the effect of transverse reinforcement where

4 factor for welded transverse reinforcement 5 considers transverse pressure
b,min = max(0.3b,rqd; 10; 100mm) for bars under tension
b,min = max(0.6b,rqd; 10; 100mm) for bars under compression
b,min = max
 0  1   2   3   5   6   b , rqd   0, min

6 lap splice factor

bd design anchorage length
0 design overlap length
inst installation length or drill hole length
cmin minimum concrete cover

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