VicRoads Section 680: The Specification Engineers Reference for Anchor Testing

The gap in Australian standards

Australia does not have an Australian Standard for the site testing of post-installed anchors. AS 5216:2021, which superseded AS 5216:2018 and the earlier SA TS 101:2015, covers anchor design using the Concrete Capacity Design method, but it does not mandate or specify field testing procedures.

AEFAC TN05 (Volumes 1-4) provides the most comprehensive Australian guidance on site testing, but these are explicitly published as Technical Notes, industry guidelines, not standards. The AEFAC website states their guidance documents "are intended to become codes of practice in Australia," which confirms they are not yet codes of practice.

BS 8539:2012+A1:2021 is a British Standard, a code of practice for the selection and installation of post-installed anchors, but it has no formal regulatory status in Australia.

In this gap, VicRoads Standard Specification Section 680 has become the most referenced Australian document for specifying anchor testing on projects. But it is important to understand what Section 680 actually is.

What VicRoads Section 680 is, and is not

Section 680 is a project specification issued by the Victorian Department of Transport. It is mandatory on VicRoads transport infrastructure projects, bridges, tunnels, and structural roadway components. It has been in use since at least 2016, with significant revisions in 2018 and most recently September 2022.

It is not an Australian Standard published by Standards Australia. It does not have the regulatory status of AS 5216 or AS 3600. Engineers reference it because it provides clear, quantified requirements that other documents leave to engineering judgement, but adopting its requirements on non-VicRoads projects is a choice, not a code obligation.

Key requirements worth understanding

Proof load derivation

VicRoads specifies the proof load as 1.5 times the maximum serviceability design load certified by the design engineer. For bonded anchors in cracked concrete, the multiplier increases to 2.0 times the serviceability load.

Sampling rates (Table 680.091)

VicRoads provides explicit sampling rates based on lot size:

• 1 to 50 anchors: 100% tested
• 51 to 150 anchors: 50% tested
• 151 to 300 anchors: 25% tested
• 301 to 500 anchors: 20% tested
• 501 to 1,000 anchors: 15% tested
• Over 1,000 anchors: 10% tested

These rates apply to anchors subject to tensile loads, combined tension-shear loads, or fatigue loads. For all other bonded anchors, a minimum of 5% is required regardless of lot size.

Lot definition

A lot must be a discrete group where the base material, anchor type, installation method, and installer are all the same. Where any of these conditions change, a separate lot is required.

Hold period and load decay

The proof load must be held for a minimum of 30 seconds. The load must not drop by more than 10% of the peak value during the hold period.

Equipment accuracy

Measuring equipment must be capable of measuring applied force to an accuracy of plus or minus 2%. Where displacement measurement is required, equipment must comply with AS 1391 and measure elongation to an accuracy of plus or minus 0.02 mm.

How it compares to AEFAC TN05 guidelines

VicRoads requirements are generally more conservative than AEFAC TN05 Volume 2. AEFAC specifies a minimum sample of 3 specimens or 2.5% of the fastener population (whichever is greater), with escalation to 5% if a failure is detected, and 100% if multiple failures occur.

VicRoads specifies percentage-based sampling that starts at 100% for small lots, significantly more conservative for small installations.

Neither document is an Australian Standard. In practice, engineers use VicRoads as an upper-bound reference and AEFAC as a lower-bound reference, applying a risk-based approach that considers installation risk, consequence of failure, and system redundancy.

The practical reality

Until Australia develops a unified standard for anchor site testing, which AEFAC has indicated is a goal, engineers must assemble their testing specifications from multiple sources:

• AS 5216:2021: for anchor design theory and failure modes
• AEFAC TN05: (guidelines) for site testing methodology and displacement monitoring profiles
• BS 8539: (British code of practice) for proof load derivation and statistical ultimate testing methods
• VicRoads Section 680: (project specification) for sampling rates, lot definitions, and equipment accuracy

None of these alone constitutes a complete Australian framework for anchor testing. Understanding what each document is, standard, guideline, code of practice, or project specification, helps engineers apply them correctly.

References

• AS 5216:2021, Design of post-installed and cast-in fastenings in concrete (Australian Standard)
• AEFAC TN05 Volumes 1-4, Guidelines for Site Testing of Anchors (Technical Notes / Industry Guidelines)
• BS 8539:2012+A1:2021, Code of Practice for the Selection and Installation of Post-Installed Anchors (British Standard)
• VicRoads Standard Specification Section 680, Bonded Anchors, September 2022 (Project Specification)