AEFAC TN05: A Practical Guide for Australian Anchor Testing Practitioners

AEFAC TN05 sits at the centre of how post-installed anchors are proof tested and ultimate load tested across Australian construction and height safety projects. Published by the Anchors, Fasteners and Fixings Advisory Council, it provides the methodological framework that AS 5532:2025 and AS/NZS 1891.4:2025 reference but do not fully detail. If you are specifying, conducting, or reviewing anchor testing in Australia, TN05 is the document you need to understand at a working level, not just cite in a test report.

The document is structured across four volumes, each addressing a distinct phase or aspect of the testing process. Volume 1 covers planning and test design. Volume 2 addresses equipment and calibration. Volume 3 sets out field testing procedures. Volume 4 deals with reporting and data interpretation. Together they form a coherent framework that takes a practitioner from first principles through to a defensible, standards-compliant test record. This article works through each volume in practical terms, with reference to how the guidance applies to common site conditions, substrate types, and anchor configurations encountered in Australian practice.

Understanding how to apply TN05 on site requires more than reading it sequentially. The four volumes are interdependent. Decisions made in the planning phase directly constrain what equipment is acceptable and what displacement tolerances apply during testing. A practitioner who skips Volume 1 and goes straight to Volume 3 procedures will often find they have conducted a test that cannot be fully reported under Volume 4 requirements.

Volume 1: Test Planning and Design Principles

Volume 1 establishes the theoretical and practical basis for anchor testing. It defines the difference between proof load testing and ultimate load testing, a distinction that matters enormously in practice because the two test types have different objectives, different load protocols, and different consequences for the anchors being tested.

Proof load testing verifies that an installed anchor can sustain a specified load without exceeding allowable displacement thresholds. The anchor remains in service after testing. Ultimate load testing, by contrast, loads the anchor to failure or to a defined termination criterion, and the anchor is destroyed in the process. Both test types are legitimate and are used in different contexts: proof testing is the standard approach for compliance verification on height safety systems under AS/NZS 1891.4:2025, while ultimate testing is used for design validation, substrate characterisation, and investigation of anchor performance margins.

Volume 1 also addresses test design considerations including:

• Sample size selection: : The number of anchors to be tested must be statistically defensible. TN05 provides guidance on minimum sample rates relative to installed populations, which differs from the flat percentage requirements some practitioners assume apply universally.
• Anchor selection criteria: : Which anchors within a population get tested is not arbitrary. Volume 1 explains how to identify representative specimens, including anchors in areas of suspected substrate variability.
• Load direction: : Tension, shear, and combined loading configurations all require different test setups. Volume 1 requires the practitioner to confirm the load direction matches the governing design action for the anchor being tested.
• Substrate investigation: : Before testing begins, Volume 1 requires that the substrate be characterised. For reinforced concrete, this includes compressive strength data, cover measurements, and identification of reinforcing that may affect reaction frame placement. For masonry and hollowcore planks, substrate variability must be accounted for in test design.

The planning volume also addresses the concept of reference displacement measurement. TN05 requires that displacement be measured relative to a stable datum independent of the test rig, not from the hydraulic ram itself. This is a common failure point in field practice: rigs that measure stroke rather than actual anchor head displacement produce data that cannot be interpreted correctly under Volume 4 criteria.

Volume 2: Equipment, Calibration, and Measurement Systems

Volume 2 is where TN05 becomes prescriptive about what constitutes acceptable test equipment. It specifies calibration requirements for hydraulic load cells, jack systems, and displacement transducers. For practitioners operating commercially, the calibration requirements in TN05 are not optional: test data produced by out-of-calibration equipment cannot be reported as TN05-compliant.

Hydraulic Load Application Systems

TN05 requires that hydraulic jacks used for anchor testing are rated for the loads being applied with adequate margin. For fall arrest anchor testing under AS 5532:2025, proof loads of 6 kN per person plus the system load are typical for personal fall arrest anchors, while the standard requires testing at specific multiples of the working load limit. Many anchors are rated at 12 kN, 15 kN, or 21 kN depending on configuration and substrate, and the jack system must be capable of applying these loads with documented accuracy.

Calibration certificates must be current and traceable to national measurement standards. NATA accreditation for the calibration laboratory is the accepted standard in Australian practice. TN05 specifies calibration intervals, and Volume 2 is explicit that field damage, overloading events, or significant temperature exposure can invalidate a calibration certificate before its nominal expiry date.

Displacement Measurement

The displacement measurement system is often where field practice diverges from TN05 requirements. The document requires:

• Transducer type: : Linear voltage displacement transducers (LVDTs) or dial gauges of specified resolution are acceptable. Spring-return dial gauges with inadequate resolution are not.
• Datum independence: : The displacement transducer must be referenced to a stable datum frame that bears on the substrate independently of the test rig and reaction frame. A bracket clamped to the test rig itself does not satisfy this requirement.
• Resolution and accuracy: : Volume 2 specifies minimum resolution requirements. For proof load testing where displacement limits of 1 mm or less may apply, a dial gauge reading to 0.01 mm is required.
• Data recording: : Where electronic data acquisition is used, Volume 2 addresses sampling rates and data integrity requirements.

Reaction Frame Design

TN05 addresses reaction frame geometry in Volume 2, specifically the minimum distance between the anchor under test and the reaction frame bearing points. This is critical because a reaction frame bearing too close to the anchor influences the failure cone geometry and artificially inflates the apparent anchor capacity. The required clear distance depends on the anchor embedment depth and substrate type, and TN05 provides the calculation basis rather than a single prescriptive value.

Volume 3: Field Testing Procedures

Volume 3 is the operational core of TN05 for site practitioners. It sets out the step-by-step procedures for conducting proof load tests and ultimate load tests, including load application rates, hold periods, and termination criteria.

Proof Load Test Procedure

The standard proof load test procedure in Volume 3 involves a defined load ramp, a hold period at proof load, and measurement of displacement at load and after load removal. The key procedural elements are:

• Pre-load cycle: : A seating load is applied and released before the test proper begins. This removes slack from the test assembly and establishes a reliable zero datum. TN05 specifies the magnitude of the seating load as a percentage of the proof load.
• Load ramp rate: : Load must be applied at a controlled rate. Volume 3 specifies maximum ramp rates to prevent dynamic load effects that would artificially influence displacement readings. In hydraulic systems without flow control, this is a common source of non-compliance.
• Hold period: : Once proof load is reached, it must be maintained for a specified minimum period. TN05 specifies this hold period explicitly, and the displacement reading taken at the end of the hold period is the governing measurement for pass/fail assessment.
• Residual displacement: : After load removal, a residual displacement reading is taken. TN05 provides acceptance criteria for both peak displacement under load and residual displacement after unloading. An anchor that shows acceptable displacement under load but excessive residual displacement has partially failed and must be assessed accordingly.
• Failure during testing: : Volume 3 defines what constitutes test failure, including sudden displacement events, audible substrate distress, and displacement exceeding defined limits before proof load is reached.

Ultimate Load Test Procedure

Ultimate testing follows a different protocol. The objective is to characterise anchor behaviour across the full load range from zero to failure. Volume 3 requires:

• Staged loading: : Load is applied in increments with displacement recorded at each stage. This produces the load-displacement curve that forms the primary data product of ultimate testing.
• Failure identification: : TN05 defines failure as the load at which anchor displacement becomes non-self-limiting under constant applied load. This is a more precise definition than simple peak load, and it requires continuous monitoring rather than point-in-time readings.
• Termination criteria: : Where full failure cannot be achieved safely (for example, in a congested substrate where concrete breakout would endanger personnel), TN05 provides alternative termination criteria based on displacement rate.
• Post-test inspection: : After ultimate testing, Volume 3 requires inspection and documentation of the failure mode. The failure mode, whether anchor pullout, concrete cone breakout, splitting, or steel fracture, is reported alongside the failure load because it determines the applicability of the result to the broader anchor population.

Site Safety During Testing

Volume 3 includes requirements for exclusion zones during testing, particularly for ultimate load tests where substrate failure can be sudden and energetic. In practice, concrete cone breakout events release stored elastic energy rapidly. The exclusion zone requirements in TN05 should be reflected in the Safe Work Method Statement for any testing programme.

Volume 4: Reporting and Data Interpretation

Volume 4 is where field data becomes a compliant test record. It specifies what must be included in a test report and how results are to be interpreted against acceptance criteria.

Mandatory Report Content

A TN05-compliant test report must include:

• Project and substrate identification: : Location, element description, concrete strength data or masonry classification, and substrate condition observations.
• Anchor identification: : Manufacturer, product name, diameter, embedment depth, installation method, and installation date if known. For M12 or M16 through-bolts, sleeve anchors, or chemical capsules, the specific product and embedment must be stated.
• Equipment records: : Identification of all load application and measurement equipment with current calibration certificate references.
• Raw test data: : Load and displacement readings at each recorded interval, not just peak values. Volume 4 is explicit that summary-only reporting is not acceptable.
• Load-displacement plots: : For ultimate tests, graphical presentation of the full load-displacement curve is required. For proof tests, tabular data with the plot is best practice even where not strictly required.
• Failure mode description: : For ultimate tests, a written description and photograph of the failure mode.
• Acceptance assessment: : A clear statement of whether each tested anchor passed or failed the specified acceptance criteria, with reference to the criterion applied.
• Practitioner qualification: : The report must identify the testing practitioner and their basis of competence. TN05 addresses practitioner qualification requirements in Volume 1, but they appear in reporting requirements because the report is the auditable record.

Interpreting Displacement Data

Volume 4 provides the framework for interpreting displacement data, and this is where many practitioners encounter difficulty. The relationship between displacement under load and residual displacement after unloading reflects the ratio of elastic to plastic deformation in the anchor-substrate system. An anchor showing predominantly elastic displacement, with small residual after unloading, has behaved as expected. An anchor showing large residual displacement relative to peak displacement has experienced plastic deformation in the anchor, grout annulus, or surrounding substrate.

TN05 does not provide single absolute displacement limits that apply to all anchors and substrates. Instead, Volume 4 requires the practitioner to assess displacement against the acceptance criteria specified for the test, which may come from the anchor manufacturer's technical data, from AS/NZS 1891.4:2025 for fall arrest anchors, or from a project-specific engineering specification. This is an important point for practitioners: TN05 provides the interpretive framework, but the acceptance limits must be sourced from the appropriate standard or specification for the application.

Statistical Treatment of Results

Where a population of anchors has been tested, Volume 4 addresses how individual results are combined to make inferences about the wider population. This matters for large testing programmes where not every anchor is tested. The statistical approach TN05 adopts is conservative: a single failure in a test sample has implications for the entire untested population, and Volume 4 provides guidance on how to respond, including expanded testing, engineering assessment, or remediation.

Applying TN05 Across Common Australian Substrates

TN05 was developed with the full range of Australian construction substrates in mind. The guidance applies across reinforced concrete of varying strength classes, precast panels, structural steel, masonry, and hollowcore planks, but the application differs by substrate.

In reinforced concrete, the primary variables are compressive strength and cover. TN05 requires that cover to reinforcing steel be measured before placing the reaction frame, because bearing close to a bar changes the failure mode. In older buildings where concrete strength is unknown, TN05 supports the use of carbonation-corrected Schmidt hammer data or core sample results to establish a working strength estimate.

In masonry, substrate variability is higher and failure modes are less predictable. TN05 requires larger test samples in masonry to achieve the same statistical confidence as in homogeneous concrete. It also distinguishes between testing anchors in the masonry unit itself and anchors that may span a mortar joint, because these have materially different load-displacement characteristics.

In hollowcore planks, the geometry constrains both anchor type and test rig placement. Through-bolt anchors are generally required, and the reaction frame must be positioned to avoid bearing on the flange edge. TN05 provides guidance on reaction geometry for thin-section precast elements.

In structural steel, anchor testing is less common but arises in fall arrest systems attached to steel purlins or structural members. TN05 addresses testing in steel substrates, including the requirement to verify that the test load does not induce yield in the parent member.

Practitioner Qualifications and Competency

TN05 is explicit that anchor testing must be conducted by competent practitioners. Volume 1 defines competency in terms of demonstrated knowledge of anchor mechanics, substrate behaviour, and test equipment operation, as well as familiarity with the relevant standards. This matters under WHS Regulations because the PCBU has an obligation to ensure that testing activities are conducted by persons with the skills and knowledge to do so safely and accurately.

In practice, this means that a height safety installer who purchases a hydraulic test kit and conducts proof load tests without understanding TN05 is not conducting TN05-compliant testing, regardless of whether they apply the correct load value. The competency requirement is substantive, not administrative.

For organisations commissioning anchor testing, the practical implication is to ask testing providers for evidence of TN05 familiarity alongside calibration certificates. A test report that references TN05 without the practitioner demonstrating working knowledge of all four volumes should be treated with caution.

Why TN05 Matters for Compliance and Liability

AS 5532:2025 and AS/NZS 1891.4:2025 reference proof load testing as the verification mechanism for installed anchor systems, but they do not fully prescribe the test methodology. TN05 fills that gap. A test conducted and reported in accordance with TN05 is defensible under audit, provides a clear chain of evidence from substrate characterisation through to acceptance assessment, and creates a record that a subsequent practitioner or engineer can interpret without ambiguity.

For building owners, strata committees, and facilities managers, TN05 compliance is the standard against which a testing contractor's work should be assessed. Requesting a TN05-compliant report is not a bureaucratic requirement; it is the way to confirm that the testing actually demonstrates what it claims to demonstrate.

AEFAC TN05 is available through the Anchors, Fasteners and Fixings Advisory Council. Any organisation conducting or commissioning post-installed anchor testing in Australia should hold a current copy and understand how its four volumes interact. If you need guidance on applying TN05 to a specific project, or need to commission testing that will produce a fully compliant test record, contact the team at [Anchor Testing Australia](/services/anchor-testing).