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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

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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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• OpeninghoursMondaytoFriday8.00amto5.00pm• Demonstrationsofmachinesandsystemsavailable• Purchaseorordertoolsandconsumablesinstore

Hilti Online

• Hiltiwebsiteavailable365daysperyear24/7• Personalisedself-servicepurchasingwithtailoredprices• Standardnextworkingdaydeliveryisfree-of-chargeforallonlineorders

Account Managers

• ProfessionaladviceavailablefromHiltiinyourlocalarea• Productandsystemdemonstrationsatyourplaceofworkoron-site• CustomerServicescanputyouintouchwiththeyourlocalHiltiAccount Manager

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.


NOCOSTS

MANUFACTURER’SWARRANTY

REPAIRCOST LIMIT

LIFETIMESERVICE

2Yearsup to

LifetimeLifetime


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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

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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


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?


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DX 460 and X-FS formstop.


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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.


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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.


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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)


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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.


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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


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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


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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


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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


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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).


23

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.


24

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.


25

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.


26

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


27

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


28

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.


29

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


34%

Note: Thisadviceisconsistentwithanagreedamendmenttothepublication“BrickworkCladdingtoSteelFramedBuildings”jointlypublishedbyTheBrickDevelopmentAssociationandBritishSteel.


30

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.


31

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%


32

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.


33

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


20%

X-IEInsulationFasteningSystem.


34

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.


35

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


36

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.


37

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


38

Lifetime Service for DX.

Total Life Cycle Management3 Steps to Total Confidence

Piston stop rings excepted.

ToolLifeCycleManagementisuniquetoHilti.Weareconfidentaboutourtoolsreliabilitythatwecanprovidetoollifecyclemanagement.Itspurposeistogiveourcustomersthebenefitofthemostreliabletoolsthatenhanceproductivity,openaccesstotechnicalandengineeringexpertisecoupledwithinnovation.


39

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.”


40

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


41

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®


42

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.


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

hilti direct fastening – can reduce your labour time by up ... · pdf filehilti direct...

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