ICS 91.100.

30

ROMANIAN STANDARD
METALIC STENCILS FOR CONCRETE, REINFORCED CONCRETE AND PRESTRESSED CONCRETE PREFABRICATED UNITS Quality technical requirements MOULES MTALLIQUES POUR LEMENTS PRFABRIQUES EN BTON, BTON ARM ET BTON PRCONTRAINT Conditions techniques de qualit TIPARE METALICE PENTRU ELEMENTE PREFABRICATE DE BETON, BETON ARMAT I BETON PRECOMPRIMAT Condiii tehnice de calitate

STAS 7721-90
Classification index G 46 Supersedes: STAS 7721-76 Previous editions: 1967,1976

Validation date: 1990-08-01

1 GENERAL

1.1

Scope

1.1.1 This standard establishes the technical quality requirements of the metallic stencils for casting of concrete, reinforced concrete and prestressed concrete prefabricated units. 1.1.2 For combined stencils, made of metal and other materials (concrete, glass fiber reinforced polyesters etc.), the provisions of this standard apply only to the metallic parts. 1.1.3 The metallic stencils are made of the component units with the accuracy classes of the geometric characteristics which are different depending to the corresponding accuracy relevant to the prefabricated units to which manufacturing are intended. 1.1.4 The accuracy classes of the metallic stencils, depending on their execution type, for various geometrical characteristic of the forming gauge of the prefabricated units, are in conformity with table 1.

ASOCIAIA DE STANDARDIZARE DIN ROMNIA (ASRO),

Adresa potal: str. Mendeleev 21-25, 70168, Bucureti 1, Direcia General: Tel.: +40 1 211.32.96; Fax: +40 1 210.08.33, Direcia Standardizare: Tel. : +40 1 310.43.08; +40 1 310.43.09, Fax: +40 1 315.58.70, Direcia Publicaii: Serv. Vnzri/Abonamente: Tel: +40 1 212.77.25, +40 1 212.79.20, +40 1 212.77.23, +40 1 312.94.88 ; Fax : +40 1 210.25.14, +40 1 212.76.20

ASRO

Entire or partial multiplication or use of this standard in any kind of publications and by any means (electronically, mechanically, photocopy, micromedia etc.) is strictly forbidden without a prior written consent of ASRO

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Shape limit deviations T dimensions tolerances Stencils execution types Basic dimensions, in mm Edges rectilinearly AFR Surfaces planeity AFP

Limit deviations to the reciprocal position of the edges API gradient APL parallelism (perpendicularity) 3001 9000

900
By casting and metal cutting (planing, milling, facing etc.) on fix stencils By casting and metal cutting on mobile units stencils Out of profiles, metal sheets and strips assembled through welding and metal cutting on fix stencils Out of profiles, metal sheets and strips assembled through welding and metal cutting on mobile units stencils Out of profiles, metal sheets and strips assembled through welding without metal cutting on fix stencils Out of profiles, metal sheets and strips assembled through welding without metal cutting on mobile units stencils Out of profiles, metal sheets and strips assembled through bolting or row of rivets without metal cutting

901 3000

3001 9000

Reference length (partial or Reference maximum Reference length, in mm total), in mm length, in mm 3001 901 901 901 3001 3001 >9000 900 >9000 900 >9000 3000 >9000 900 9000 3000 9000 3000 9000 3000 Stencil accuracy class for various geometrical characteristics, in conformity with the tables from 3 to 8 CP 5 CP 4 CP 4 CP 4 CP 4 CP 3 CP 3 CP 3 CP 3 CP 3 CP 3 CP 3 CP 3 CP 3

>9000

CP 5

CP 5

CP 5

CP 3

CP 3

CP 5

CP 5

CP 6

CP 6

CP 4

CP 4

CP 5

CP 5

CP 4

CP 5

CP 5

CP 4

CP 4

CP 5

CP 5

CP 3

CP 3

CP 4

CP 4

CP 6

CP 6

CP 6

CP 7

CP 5

CP 5

CP 5

CP 6

CP 5

CP 5

CP 5

CP 5

CP 5

CP 6

CP 6

CP 4

CP 4

CP 5

CP 5

CP 6

CP 6

CP 7

CP 7

CP 5

CP 5

CP 6

CP 6

CP 5

CP 6

CP 6

CP 6

CP 6

CP 6

CP 6

CP 5

CP 5

CP 5

CP 5

CP 6

CP 6

CP 7

CP 7

CP 6

CP 6

CP 6

CP 7

CP 6

CP 6

CP 6

CP 6

CP 6

CP 7

CP 7

CP 5

CP 5

CP 6

CP 6

CP 7

CP 7

CP 7

CP 7

CP 6

CP 6

CP 7

CP 7

CP 6

CP 6

CP 6

CP 6

CP 7

CP 7

CP 7

CP 5

CP 6

CP 6

CP 6

CP 7

CP 8

CP 8

CP 8

CP 7

CP 7

CP 7

CP 7

CP 6

CP 6

CP 6

CP 7

CP 7

CP 7

CP 7

CP 6

CP 6

CP 6

CP 6

NOTE The accuracy classes (CP) are in conformity with STAS 8600-79.

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STAS 7721-90

1.2

General indications

The execution project of the metallic stencils shall include execution drawings and written documents. That shall mainly provide for: - the corresponding resistance and functioning requirements of the prefabricated element for which it is intended (as for example the reversed arrow for the pre stressed concrete elements, striping gradients etc.); - technical details necessary to the manufacturing of the metallic stencils including the devices meant to assure the correct placement of the included elements (metallic plates and profiles for assembling, steel-concrete reinforcements traversing the sides etc.); - stipulations regarding the handling, storage, transport and installation of the metallic stencils; - the quality of the materials composing the metallic stencils; - the technical requirements concerning the quality of the metallic stencils including the necessary endowments; - the special technical requirements for providing protection or sustainability; - the periodic mandatory checks of the abidance by the technical requirements of the metallic stencils during exploitation; - special rules for work protection and the safety measures generated by the specific of the metallic stencil, if case, besides the current work protection rules provided for by the valid legislation;

1.3

Reference standards
STAS 7384 85 Geometric deviations and tolerances. Terminology STAS 8600 79 Civil, industrial and agricultural and zoo-technical buildings. Tolerances and assemblies in constructions. Tolerance systems. STAS 6657/1- 89 Concrete, reinforced concrete and pre stresses concrete prefabricated units. General technical quality requirements STAS 6657/3 89 Concrete, reinforced concrete and pre stresses concrete prefabricated units. Proceedings and devices for checking of geometric characteristics.

2 QUALITY TECHNICAL REQUIREMENTS 2.1 Materials

The materials used currently for the manufacturing of the metallic stencils are in accordance with table 2. Table 2 Material Rolled common carbon steel Construction steel pipes Carbon steel casted in pieces Silvery pig iron Structural steel Rivets, bolts, nuts etc. STAS 500/1,2 80 STAS 530 87; STAS 404 87 STAS 600 82 STAS 568 82 STAS 438/1 80 In conformity with the execution design Standard

NOTE The use of other materials than those provided for in Table 2 is allowed with the approval of the stencil designer.

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2.2

Tolerances and deviations from the geometrical characteristics

2.2.1 The tolerances and deviations from the geometrical characteristics of the metallic stencils (the shaping gauge resulted from the assembling and affixing of components) shall correspond to an accuracy class immediately superior to those provided for the prefabricated units STAS 6657/1 89. 2.2.2 For the dimensions of the shaping gauge of the metallic stencils, the dimensional tolerances are those in table 3. Table 3 Basic dimensions, in mm Accuracy class CPD 5 6 7 8 9 100 2 3 4 6 10 101300 3 4 6 10 16 301900 4 6 10 16 24 9013000 5 8 12 20 32 3001900 0 6 10 16 24 40 >9000 8 12 20 32 50

Tolerance (T), in mm

NOTE The basic dimensions refer to the execution dimensions of the shaping gauge. 2.2.3 For the shape of the shaping gauge of the metallic stencils: a) The limit deviations from the rectilinearly of the edges AFR are those in table 4. Table 4 Accuracy class CPR 4 5 6 7 Reference length, in mm 3001900 90011800 301900 9013000 0 0 Limit deviation (AFR), in mm 2 3 4 6 3 4 6 10 3 5 8 12 4 6 10 16

300 1 2 3 4

>18000 5 8 12 20

b) The limit deviations from the planeity of the surfaces AFP are those in table 5. Table 5 Accuracy class CPP 3 4 5 6 300 0.5 1 2 3 Maximum length of the reference surface, in mm 301900 9013000 30019000 Limit deviation (AFP), in mm 1 2 3 4 2 3 4 6 2 3 5 8 >9000 3 4 6 10

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STAS 7721-90

2.2.4

For the reciprocal position of the profiles or of the edges of the shaping gauge of metallic stencils: a) The limit deviations from the parallelism of the edges APL are those in table 6. Table 6 300 Distance between the edges that are checked, in mm 301900 9013000 Reference length, in mm 3001 301 301 901 901 3001 >9000 300 900 900 3000 3000 9000 9000 Limit deviations (APL), in mm 2 3 4 5 3 4 5 6 4 5 6 8 5 6 8 10 2 3 4 5 3 4 5 6 4 5 6 8 5 6 8 10 > 3000 301 >9000 300 900

Precis ion class CPL

300

301 900

901 3000

3001 9000

>9000 300

901 3000

3001 9000

>9000

3 4 5 6

0.5 1 2 3

1 2 3 4

2 3 4 5

3 4 5 6

4 5 6 8

1 2 3 4

7 8 10 12

2 3 5 6

4 5 6 8

5 6 8 10

7 8 10 12

9 10 12 16

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b) The limit deviations to the inclination (perpendicularity) of the edgesAP1 are those presented in table 7. Table 7 Accuracy class CP1 3 4 5 6 300 0.5 1 2 3 Reference length, in mm 301900 9013000 Limit deviation (API), in mm 1 2 2 3 3 4 4 6 >3000 3 4 6 10

2.2.5 The values of the maximum dislevelments of the local deformations (depths, swellings) are those presented in table 8. Table 8 Accuracy class Local deformations, maximum depth, mm 5 1 6 2 7 3 8 3 9 3

2.3
2.3.1

Execution
Metallic stencils are executed only upon a design and in conformity with the provisions in the design.

2.3.2 Metallic stencils shall be endowed, depending on the situation, with the devices necessary for their functioning (compacting, thermal insulation and thermal treatment devices). 2.3.3 Metallic stencils with dismantle or mobile units shall be manufactured so as they do not allow leaking of the cement milk. 2.3.4 Metallic stencils are protected against corrosion by dying and greasing in conformity with the provisions in the design.

3 RULES FOR QUALITY VERIFICATION

3.1 3.2 The quality verification of the metallic stencils upon delivery is made piece by piece. Verification consists of: - verification of the quality of materials; - verification of the quality of welding and processing operations; - verification of abiding by the tolerances and limit deviations of the geometrical characteristics of the shaping gauge; - verification of the maximum dislevelment of the local deformation; - strength verification of the devices for closing and fixing of the mobile units of the metallic stencil; - verification of the devices and details intended to the correct placement of the elements included in concrete; - verification of the metallic stencils endowing with the auxiliary devices provided for in the design (e.g.: those for concrete compacting), their placement and correct functioning (e.g.: pressure test of the heating installation for the thermal treatments); - verification of dying and greasing quality; - verification of metallic stencils functioning.

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STAS 7721-90

3.3 If the user is asking for, the high complexity metallic stencils are verified on the head series stencil that includes a complete manufacturing cycle of the respective prefabricated unit. 3.3.4 If the metallic stencils do not correspond to a single verification, this is rejected. The metallic stencil can be reconditioned and presented again for verification.

4 VERIFICATION METHODS
4.1 Verification of materials and welding is done upon the quality certification. If there is a doubt, the metallic stencils manufacturing enterprise executes, in specialized laboratories, before using the respective materials, the tests necessary for these materials quality determination. 4.2 Verification of the tolerances and limit deviations of the geometrical characteristics of the shaping gauges is executed, usually, by using the methods and devices indicated in STAS 6657/3-89. In the case of the geometric characteristics for which the provisions in STAS 6657/3-89 cannot be applied, the proceedings and verifications devices providing for a measuring accuracy of at least 1/6 compared to the accuracy of the characteristic being tested, is applied. The verification is made both on the component units as well as on the assembled metallic stencils. 4.3 The verification of the maximum dislevelment of the local deformations related to meter or to square meter is done in conformity with STAS 6657/3-89. 4.4 Verification of the auxiliary devices placing is done in conformity with STAS 6657/3-89.

4.5 Verification of the metallic stencils and auxiliary devices functioning is done in conformity with the technical requirements provided for through the design for their exploitation or by casting a prefabricated element on the head series stencil. 4.6 Verification of metallic stencils dying or greasing is done visually, in conformity with the technical requirements provided for through the design.

5 MARKING, HANDLING, STORAGE, TRANSPORT AND DOCUMENTS

5.1 The marking of the metallic stencils is done with figures and letters or through writing plates, comprising the following data: 5.2 factory mark or name (the initials) of the manufacturing enterprise; the symbol of the stencil (established by the design); the no. of the stencil on the technological line; the mass of the stencil, assembled; STAS 7721 90.

The handling of the metallic stencils is done in conformity with the specifications in the design.

5.3 The storage of the metallic stencils, both before delivery and in keeping at the user is done in piles of overlapped stencils on a 2 m maximum high. Elastic separators are placed between the horizontal rows of the pile near the lifting handles, in the same vertical plan. The first row of metallic stencils is placed on elements meant to assure a free space of minimum 100 mm up to the level of the platform. The storage platforms shall be flat and with slopes allowing the easy draining of water. 5.4 The transport is made by placing the metallic stencils in the transportation means, with the longitudinal axis towards the transport direction and the stencils piles are assured against sliding or overturning. Propping of the metallic stencils is done on elastic props anchored to the transportation mean.

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5.5 Each delivery batch shall be accompanied by a document of quality certification, drawn up as per the legal valid legislation.

6 GUARANTIES

The guaranty period for metallic stencils is of 12 months.

____________

Project manager: MRI DIMC Research and Design Institute for Material Construction Industry Eng. tefan Maniiu Final redaction: Romanian Standardization Association Eng. Parschiva Mavromatis

Collaborators: Central Research, Design and Directing in Construction Institute, Construction Research Institute and Construction Economy Designing Institute Design - Bucharest