BTN 2012 / 002 – OCTOBER 2012
BRIDGE TECHNICAL NOTE
Bonded Anchors
1. Scope and Application
This technical note is intended for use by those who
are engaged in the design of bonded anchors for
bridge projects in the State of Victoria. It provides
guidance which is intended to reduce the risk of
failure of critical connections made with bonded
anchors. The contents of this technical note
supplements the requirements of AS5100 Bridge
design and is to be used in conjunction with
VicRoads Standard Specification 680 - Bonded
anchors.
2. Overview
Bonded anchors are connections comprising metallic
bolts, reinforcing bars or threaded rods together
with adhesives that may be used to connect steel,
concrete and timber components to a concrete
substrate.
Bonded anchors fall into two main categories:
Capsule anchors – comprise a metered quantity of
the adhesive (contained in either a glass capsule or
a foil pouch) which is inserted into a drill-hole, into
which the metal anchor is then inserted.
Injection systems - in which the constituent
materials of the adhesive are contained in cartridges
or in bulk and which are delivered into drill-holes by
manually-controlled injection - a single cartridge or
container being used to fill multiple anchor-holes.
Glass capsule systems are also available in which
the anchor rod is driven in with hammering action
alone (hammer-in capsules). The tension load
carrying capacity of hammer-in capsules is, in
general, inferior to other bonded anchor systems.
Metal components of the anchor may be plated or
galvanised high yield steel, or stainless steel where
a higher durability is required. Adhesives may
consist of polymer resins, cementitious materials, or
a combination. A number of different types of
adhesive are available including vinylesters, acrylic
resins, polyester resins and epoxy resins – each
having differing physical properties and applications.
2012/002
Version 1.1
Bonded anchors can provide a safe and durable
connection provided that the key factors affecting
performance are properly considered.
The performance of bonded anchors depends on:
• Suitability of the selected anchor system
(adhesive and metal components) for the
application and the ambient conditions
• Design life of the system
• Condition of the concrete substrate
• Quality of the anchor materials
• Design methodology
• Training of installation personnel
• Workmanship
• Proving tests
3. Design Considerations
Testing evidence for the prediction of design-life of
bonded anchors is generally limited to a maximum
of 50 years. For this reason, bonded anchors may be
unsuitable for use in road structures, in particular,
new structures which are required to have a design-
life of 100 years.
Bonded anchors are susceptible to creep-
displacement under sustained tensile loads and to
fatigue as a result of cyclic loading. Poor
workmanship has also contributed to an observed
variability of performance.
The performance of bonded anchors in cracked
concrete varies with the type of anchorage system.
Standard Specification 680 Bonded anchors states
the requirement to use epoxy adhesives in holes cut
with a diamond-tipped core drill.
The design of bonded anchors shall be in accordance
with the following:
3.1. Design Life
Subject to clause 3.2 Restrictions on Use, the
selected bonded anchor must have a demonstrated
design life equal to or greater than the required
design life of the structure in which the components
are being connected.
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3.2. Restrictions on Use
Bonded anchors must not be used in the following
circumstances:
• in new structures where the connection can be
achieved by the use of cast-in anchorages or
positive connections*
• in existing structures where the connection can
be achieved by the use of positive connections*
• if the required design life or the residual design
life of the structural components being
connected exceeds 50 years
• as tensile continuity connections between beams
in adjacent spans and other elements in a bridge
superstructure – for example to connect
superstructure and substructure components in
an integral bridge
• to support tensile loads in any orientation,
where failure of an anchor or anchors could
result in collapse, instability or failure of a
structure** see 3.5 Bonded anchors in Tension
• as holding-down bolts for use with cantilever or
portal sign structures and high mast light
structures
• as holding-down bolts for steel and concrete
bridge barriers and bridge barrier posts
• if the thickness of the concrete substrate into
which the anchor is being placed is less than
1.25 x required length of the anchor
• if the concrete substrate into which the anchor is
being placed is friable, shows signs of de-
lamination or any other defect other than the
permitted use in cracked concrete described in
3.3
• in concretes with strengths less than 20 MPa or
greater than 50 MPa
*Positive connections are defined as structural
connections that are achieved by clamping either
through or around the full depth of the elements
being connected. For example, a threaded rod (or
bolt) in a full-depth hole together with a backing
plate.
3.3. Permitted Uses
Subject to appropriate design considerations,
selection of adhesive and the restrictions on use
stated in this document, bonded anchors are
suitable for use in applications where they are
subjected primarily to axial compressive forces and
shear forces transverse to the anchor – for example:
• as longitudinal shear connectors in bridge-deck
overlays
• in side-mounted bridge barriers where the
tensile force arising from impact is resisted by a
cast-in bar embedded in the overlay
Bonded anchors may be used in concrete which
exhibits well-spaced flexural cracks provided that
the adhesive has a capacity for re-expansion that is
supported by manufacturer’s test data. However,
the capacity of the anchor will be substantially
reduced and must be verified by testing.
3.4. Design
Design of bonded anchors shall be in accordance
with one of the following:
• anchor theory using the Concrete Capacity (CC)
method as described in ETAG Annex C and TR
029, or ACI 318 08, Appendix D
• reinforcement theory, which shall comply with
the requirements of AS5100 Bridge design
Design loads and load factors shall be determined in
accordance with AS5100 part 2 Bridge design
The required number and size of anchors must be
determined in accordance with one of the methods
listed in clause 3.4 such that:
φRu ≥ S*
where for the load effect being considered:
φ = capacity reduction factor
Ru = ultimate strength of the connection
S* = design action effect
The type of bonded anchor and adhesive shall be
appropriate to the strength and durability required
by the design.
Consideration must be given to the probable failure
mechanism of the bonded anchor connection and
the effect of such a failure on the stability of the
structure.
Where the strength of an adhesive material in a
bonded anchor is known to diminish over time, the
reduced strength at the end of the design life of the
adhesive material shall be used for the purposes of
design.
Bonded anchors must be positioned to avoid
damage to reinforcement and pre-stressing tendons.
3.5. Bonded Anchors in Tension
** If it is not possible to use a cast-in anchorage or
to achieve a positive connection by any possible
means, bonded anchors may be used in tension,
subject to the maximum design life of 50 years and
the following conditions:
• use is subject to the written approval of the
Superintendent – refer to Standard Section 680
Bonded anchors for further detailed
requirements
• use is subject to compliance with all other parts
of this Bridge Technical Note and in particular
clause 3.2
• if a bonded anchor is required to support a
sustained tensile load, the adhesive must be one
that has been subjected to testing for creep, the
results of which enables the long-term
displacement and strength properties of the
anchor to be quantified
• the predicted creep must not affect the
serviceability and durability of the structure
• all working anchors in tensile connections must
be proof-tested in accordance with Standard
Section 680 Bonded anchors
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• the required number and size of anchors must ETAG 029: Design of Bonded Anchors, European
be determined in accordance with one of the Organisation for Technical Approvals
methods listed in clause 3.4 subject to the ETAG 020 Annex C: Design Methods for Anchorages,
application of an additional partial safety European Organisation for Technical Approvals
factor φBAT for materials Standard Specification Section 611, VicRoads
Standard Specification Sections for
such that: Bridgeworks, Victoria, Australia
φ φBAT Ru ≥ S* Standard Specification Section 680 (2012), VicRoads
Standard Specification Sections for
where for the load effect being considered: Bridgeworks, Victoria, Australia

φ = capacity reduction factor required by

the design method
φBAT = additional capacity reduction
factor for tension which has a value
of 0.5
Ru = ultimate strength of the connection
S* = design action effect

• increase in length may also be considered

subject to the maximum depth of concrete
substrate described in clause 3.2

• the final arrangement of anchors must comply

with the requirements for spacing of anchors
and minimum edge-distance required by the
design method

4. Training, Equipment, MARY DARCY

Workmanship, Installation, PRINCIPAL BRIDGE ENGINEER
VicRoads
Testing
Training, equipment, workmanship, installation and
testing must comply with Standard Specification Contact
Section 680 Bonded anchors.
For further information please contact:

References Principal Bridge Engineer

ACI 318-08 Building Code Requirements for Level 3, 60 Denmark Street
Structural Concrete and Commentary,
Kew Victoria 3101
American Concrete Institute Committee 318
AS 5100 (2004) Bridge Design, Standards Australia, Telephone: (03) 8391 7137
Sydney, Australia Facsimile: (03) 8391 7199
ATIC-Specification Section SP38 Metal Anchors for Email: mary.darcy@roads.vic.gov.au
use in concrete, Australian Technical
Infrastructure Committee Bridge Technical Notes are subject to periodic review
ETAG 001: Metal Anchors, European Organisation and may be superseded
for Technical Approvals