DSI DYWIDAG ETA-09-0068 DYWIDAG External Strand Post-Tensioning System for 3 to 37 Strands e 01

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    DYWIDAG Post-Tensioning

    European Technical Approval

    DYWIDAG

    Post-Tensioning

    System using Strands

    DYWIDAG External StrandPost-Tensioning System

    for 3 to 37 Strands

    (140 and 150 mm2)

    ETA-09/0068

    Validity

    03 March 2009 - 03 March 2014

    European Organisation for Technical Approvals

    Europische Organisation fr Technische Zulassungen

    Organisation Europenne pour lAgrment Technique

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    Le prsent ATE contient:This ETA contains:

    45 pages incluant 25 pages dannexes (dessins)45 pages including 25 pages of annexes (drawings)

    O r g a n i s a t i o n p o u r l A g r m e n t T e c h n i q u e E u r o p e n

    E u r o p e a n O r g a n i s a t i o n f o r T e c h n i c a l A p p r o v a l s

    Stra46, avenue Aristide BriandBP 10092 225 BAGNEUX CEDEXTel: + 33 (0)1 46 11 31 31

    Fax: + 33 (0)1 46 11 31 69

    Member of EOTA

    Agrment Technique Europen ETA-09/0068

    (version originale en franais)

    European Technical Approval ETA-09/0068(original version in French language)

    Nom Commercial:

    Trade name:

    Procd de prcontrainte extrieure DYWIDAG

    DYWIDAG External Strand Post-Tensioning System

    Dtenteur de lATE:

    ETA Holder:DYWIDAG-Systems International GmbHDywidagstrasse 1

    85609 AschheimDEUTSCHLAND

    Type gnrique et utilisationprvue du produit deconstruction:

    Generic type and use

    of construction product:

    Procd de prcontrainte par post-tension DYWIDAG avec cableextrieur de 3 37 torons (140 et 150 mm)

    DYWIDAG External Strand Post-Tensioning System for 3 to 37 Strands

    (140 and 150 mm)

    Validity: from 03/03/2009to 03/03/2014

    Producteur du Procd:

    Manufacturing plant:

    DYWIDAG-Systems International GmbHDywidagstrasse 185609 AschheimDEUTSCHLAND

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    Page 2 of ETA-09/0068English translation by Stra

    A LEGAL BASIS AND GENERAL CONDITIONS

    A.1 This European Technical Approval is issued by Stra in accordance with:

    - Council Directive 89/106/EEC of 21 December 1988 on the approximation oflaws, regulations and administrative provisions of Member States relating toconstruction products1, modified by Council Directive 93/68/EEC2and Regulation(EC) No1882/2003 of the European Parliament and the Council3;

    - Dcret no 92-647 du 8 juillet 1992 4 concernant laptitude des produits deconstruction;

    - Common Procedural Rules for Requesting, Preparing and the Granting ofEuropean Technical Approvals set out in the Annex to Commission Decision94/23/EC5;

    - ETAG 013, Edition June 2002, Post-Tensioning Kits for Prestressing ofStructures.

    A.2 Stra is authorized to check whether the provisions of this European TechnicalApproval are met. Checking may take place in the manufacturing plant(s).Nevertheless, the responsibility for the conformity of the products to the EuropeanTechnical Approval and for their fitness for the intended use remains with the holderof the European Technical Approval.

    A.3 This European Technical Approval is not to be transferred to manufacturers or

    agents of manufacturers other than those indicated on page 1, or manufacturingplants other than those indicated on page 1 of this European Technical Approval.

    A.4 This European Technical Approval may be withdrawn by Stra, in particularpursuant to information by the Commission according to Article 5(1) of CouncilDirective 89/106/EEC.

    A.5 Reproduction of this European Technical Approval including transmission byelectronic means shall be in full. However, partial reproduction can be made with thewritten consent of Stra. In this case partial reproduction has to be designated assuch. Texts and drawings of advertising brochures shall not contradict or misuse the

    European Technical Approval.

    A.6 The European Technical Approval is issued by the approval body in its officiallanguage(s). This version corresponds fully to the version circulated in EOTA.Translations into other languages have to be designated as such.

    1 Official Journal of the European Communities NoL 40, 11.2.1989, p. 12

    2 Official Journal of the European Communities N

    o

    L 220, 30.8.1993, p. 13 Official Journal of the European Union NoL 284, 30.10.2003, p. 1

    4 JORF du 14 juillet 19925 Official Journal of the European Communities N

    oL 17, 20.1.1994, p. 34

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    Page 3 of ETA-09/0068English translation by Stra

    B SPECIFIC CONDITIONS OF THE EUROPEAN TECHNICAL APPROVAL

    B.1 DEFINITION OF PRODUCTS AND INTENDED USE

    B.1.1 Defin ition of Products

    This European Technical Approval applies to a kit:

    DYWIDAG External Strand Post-Tensioning System

    consisting of 3 to 37 strands.

    The DYWIDAG post-tensioning kit is designed for external prestressing.

    The prestressing tendon consists of a bundle of 7-wire strands, anchorages,deviators, sheathing and corrosion protective compounds.

    - The strandsare defined in the prEN 10138-3: Prestressing steels Strandas 0.6 normal and super strand, i.e. with 15.3 and 15.7 mm nominaldiameter, with a nominal tensile strength of 1770 or 1860 N/mm, codedY1770S7 15.3 (or 15.7) or Y1860S7 15.3 (or 15.7), respectively, referred to asthe tensile element.

    As long as EN 10138 is not implemented 7-wire strands in accordance withnational provisions shall be used.

    - Stressing(active) anchoragesand fixed(passive) anchoragesconsisting ofan anchor plate with connection tube, steel trumpet, plastic insert, gasket,retaining ring, spacer and wedge plate.

    - Sheathingsare made of plastic (polyethylene, HDPE).

    - Deviatorsare specific elements at given locations in the structure along the

    tendon. These are generally made of steel tubes (straight or prebent) placedinside the concrete structure or construction steel saddles applied to thestructure.

    - Bursting reinforcement (helix and stirrups), for the concrete confinement atanchorages to ensure local prestressing force transfer into the concretestructure.

    - The corrosion protecting compound can be a cement based grout (inaccordance with EN 447) for rigid injection or a flexible compound with a waxbase (in accordance with Annex C.4.2 of ETAG 013).

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    Page 4 of ETA-09/0068English translation by Stra

    Steel and plastic tubes, the ordinary reinforcement for bursting reinforcement,grouting products are covered by European or national provisions thus they are notdescribed in this ETA. However, they can be used for the prestressing kit.

    B.1.2 Intended use

    The DYWIDAG external strand post-tensioning system (in the following PT system)has been developed to be used for

    new structures

    repair and strengthening of existing structuresexposed to effects from gravity and live loads, climate exposures, imposed sets ofdeformations.

    This PT system is meant for concrete structures/members with a tendon pathsituated outside their cross section but inside their envelope. It may also beemployed in structures made of other materials, e.g. masonry, steel, cast iron, timberor combinations of several materials (see Annex 13). In case of use with othermaterials than concrete, dimensions and force transfer shall be designed accordingto the relevant Eurocodes or national regulations valid in place of use.

    The following optional use categories for the tendons are possible:

    restressable

    exchangeable

    encapsulated

    B.1.3 Working life

    The provisions made in this European Technical Approval are based on an assumedworking life of the PT system of 100 years. These provisions are based upon thecurrent state of the art and the available knowledge and experience. The indicationsgiven on the working life cannot be interpreted as a guarantee given by the kitmanufacturer or the Approval Body, but are to be regarded only as a means forchoosing the right products in relation to the expected economically reasonableworking life of the works.

    The relevant Eurocodes are the following:EN 1990 Eurocode 0: Basis of structural designEN 1991 Eurocode 1: Actions on structuresEN 1992 Eurocode 2: Design of concrete structuresEN 1993 Eurocode 3: Design of steel structuresEN 1994 Eurocode 4: Design of composite steel and concrete structuresEN 1995 Eurocode 5: Design of timber structuresEN 1996 Eurocode 6: Design of masonry structures

    The PT system is supposed to be subject to appropriate use and maintenance (seeChapter 7 of ETAG 013).

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    Page 5 of ETA-09/0068English translation by Stra

    B.2 Characteristics of product and methods of verification

    B.2.1 Characteris tics of product

    B.2.1.1 GeneralThe components correspond to the drawings and provisions given in this EuropeanTechnical Approval including the Annexes. The characteristic material values,dimensions and tolerances of the components not indicated in the Annexes shallcorrespond to the respective values laid down in the technical documentation of thisEuropean Technical Approval. Arrangement of the tendons, the design of theanchorage zones, the anchorage components and the diameters of the sheathingsshall correspond to the attached description and drawings; the dimensions andmaterials shall comply with the values given therein.

    The first digit of the designation of components of anchorages (6) identifies the

    nominal strand diameter in tenfold of inches (0.6/0.62), the second digit is aninternal code and the last two digits refer to the number of strands in the tendon (sizeof tendon). The components (except helix and additional reinforcement) fit fortendons with both strand strengths.

    B.2.1.2 StrandsOnly 7-wire strands shall be used in accordance with national provisions with thecharacteristics given inAnnex 16.To avoid confusions only strands with one nominal diameter shall be used on onesite. If the use of strands with Rm= 1860 MPa is intended on site, these shall only beused there.

    Only strands stranded in the same direction shall be used in a tendon.

    B.2.1.3 WedgesWedges (see Annex 2) are approved with 30-tooth or 45-tooth. The segments of

    the wedges for strands 15.3 mm are 42 mm long and the segments of the wedges

    for strands 15.7 mm are 45 mm long. The wedge dimension does not depend fromthe strands strength.

    Wedges of one supplier only may be used at one construction site.

    B.2.1.4 Wedge plates

    The conical drills of the wedge plates (see Annexes 3-5) shall be clean, stainlessand provided with a corrosion protection.

    B.2.1.5 Anchor plate with recess tubeCircular anchor plate with recess tube welded watertight to it shall be used (seeAnnexes 3-5).

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    Page 6 of ETA-09/0068English translation by Stra

    B.2.1.6 Steel trumpet with PE-insertAs a part of the steel trumpet the tension ring is welded to the steel tube with theflange. The PE-insert is fixed to the tension ring through a gasket with a retaining ringand screws (see Annex 2). A piece of plastic sheathing with relevant diameter is

    mirror welded to the PE-insert. Its length is determined in order to protrude out fromthe concrete body around the anchorage zone.

    B.2.1.7 Bursting reinforcement (helixes and stirrups)The steel grades and dimensions of the helixes and of the stirrups shall comply withthe values given in the relevantAnnexes6-11. The central position in the structuralconcrete member on site shall be ensured according to section B.4.2.3.The outer end of the helix shall be welded to the anchor plate. This is not necessaryif the final turn is welded to form a closed ring.

    B.2.1.8 Sheathings, tubes

    Sheathings made of polyethylene shall comply with EN 12201 and ETAG 013. Thedimensions of the sheathings shall comply with values given in Annex 2. Theconnections and seals between the sections of sheathing are effected either withmirror welding or electro-welding couplers.The recess tubes and steel tubes (respectively welded to anchor plate and flange,seeAnnexes3-5) are manufactured from at least 3.2 mm thick steel sheath material(seeAnnex 15).

    B.2.1.9 GroutGrout according to EN 447:1996 shall be used.

    B.2.1.10 WaxWax as defined in Annex C.4.2 of ETAG 013 or according to national regulationsvalid in place of use shall be used.

    B.2.1.11 Protective capsProtective caps serve as closing the anchorage to enable grouting/injection and itsprotection, see Annex 12. The caps are made of steel. Regularly they cover thewedge plate and are left in place after injection. Elongated caps may be used forsufficient strand over-length for later prestressing force adjustment or detensioning.

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    Page 7 of ETA-09/0068English translation by Stra

    B.2.2 Methods of verif ication

    B.2.2.1 General

    This European Technical Approval for the "DYWIDAG external strand post-tensioning

    system" is issued on the basis of agreed data, deposited at Stra, which identifies the"DYWIDAG external strand post-tensioning system" that has been assessed andjudged.

    Assessment of the fitness of the "DYWIDAG external strand post-tensioning system"for the intended use in relation to the requirements for mechanical resistance andstability in the sense of Essential Requirements 1 and for ER3 (hygiene, health andenvironment) has been made in accordance with the ETAG 013, Guideline forEuropean Technical Approval of post-tensioning kits for prestressing of structures,based on the provisions for all systems.

    The release of dangerous substances (Essential Requirement 3) is determined

    according to ETAG 013, clause 5.3.1. A declaration was made by the kitmanufacturer that the product does not contain any dangerous substances.

    In addition to the specific clauses relating to dangerous substances contained in theETA, there may be other requirements, applicable to the products falling within itsscope (e.g. transposed European legislation and national laws, regulations andadministrative provisions). In conformity with the provisions of the European directive89/106/EEC, these requirements must also be complied with wherever they apply.

    The structural members (made of normal-weight concrete) prestressed by means ofthe DYWIDAG-External Strand Post-Tensioning System used to be designed inaccordance with national regulations.

    B.2.2.2 Tendons

    The maximum prestressing and over-tensioning force to be applied on the tendon isspecified in the national standards and regulations in force in the place of use.

    The maximum force P0, maxdefined according to EN 1992-1-1 paragraph 5.10.2 (withrecommended values for k1 and k2), and according to prEN 10138, shall not exceedthe values laid down in Table1 (140 mm) or in Table2 (150 mm).

    Maximum prestressing force P0, max= min (0.8 Fpk; 0.9 Fp0.1k)

    where Fpk= Apfpkis the characteristic tensile force of tensile elements of tendons and

    Fp0.1k= Apfp0.1k the characteristic tensile yield force of tensile elements of tendon(0.1 % proof load).

    The initial prestressing force Pm0immediately after tensioning and anchoring shall notexceed the values laid down in Table1 (140 mm) or in Table2 (150 mm), see alsoAnnex 1.

    Initial prestressing force Pm0= min (0.75 Fpk; 0.85 Fp0.1k)

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    Page 8 of ETA-09/0068English translation by Stra

    Table 1: Maximum prestressing forces6for tendons with Ap= 140 mm

    TendonDesignation

    Numberof

    strands

    Crosssection

    Ap[mm]

    Prestressing forceY1770S7

    Fp0.1k= 218 kN

    Prestressing forceY1860S7

    Fp0.1k= 229 kN

    Pm0, max [kN] P0, max [kN] Pm0, max [kN] P0, max [kN]

    6803 3 420 556 589 584 618

    6804 4 560 741 785 779 824

    6805 5 700 927 981 974 1031

    6807 7 980 1297 1373 1363 1443

    6809 9 1260 1668 1766 1752 1855

    6812 12 1680 2224 2354 2336 2473

    6815 15 2100 2780 2943 2921 3092

    6819 19 26603521 3728 3699 3916

    6822 22 3080 4077 4316 4283 4534

    6827 27 3780 5003 5297 5257 5565

    6831 31 4340 5744 6082 6036 6389

    6837 37 5180 6856 7259 7204 7626

    Table 2: Maximum prestressing forces6for tendons with Ap= 150 mm

    Tendon

    Designation

    Numberof

    strands

    Crosssection

    Ap[mm]

    Prestressing forceY1770S7

    Fp0.1k= 234 kN

    Prestressing forceY1860S7

    Fp0.1k= 246 kN

    Pm0, max [kN] P0, max [kN] Pm0, max [kN] P0, max [kN]

    6803 3 450 597 632 627 664

    6804 4 600 796 842 836 886

    6805 5 750 995 1053 1046 1107

    6807 7 1050 1392 1474 1464 1550

    6809 9 1350 1790 1895 1882 1993

    6812 12 1800 2387 2527 2509 2657

    6815 15 2250 2984 3159 3137 33216819 19 2850 3779 4001 3973 4207

    6822 22 3300 4376 4633 4600 4871

    6827 27 4050 5370 5686 5646 5978

    6831 31 4650 6166 6529 6482 6863

    6837 37 5550 7359 7792 7737 8192

    6 The forces P0, maxand Pm0are given as indicative values. The actual values are to be found in nationalregulations valid on place of use. Compliance with the stabilisation and crack width criteria in the loadtransfer test was verified to a load level of 0.80 Fpk.

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    Page 9 of ETA-09/0068English translation by Stra

    The number of strands in a tendon may be reduced by leaving out strands lyingradial-symmetrically in the wedge plate. The provisions for tendons with completelyfilled wedge plates (basic types) also apply to tendons with only partly filled wedgeplates. Into the cones not filled short pieces of strands with wedges have to bepressed to assure a sufficient bending stiffness of the wedge plate. Obviously for

    such tendons wedge plates machined without the not needed conical borings can beapplied, too.

    The prestressing force is reduced per strand left out as shown in Table3.

    Table 3: Reduction of the prestressing force when leaving out one strand

    Ap Y1770S7 Y1860S7

    Pm0 [kN] P0 [kN] Pm0 [kN] P0 [kN]

    140 mm 185.3 196.2 194.7 206.1

    150 mm 198.9 210.6 209.1 221.4

    B.2.2.3 Losses of the prestressing force due to friction

    At calculation the losses of the prestressing force due to friction the friction coefficient = 0.12 0.14 shall be considered. This value is for information only. The exactfriction coefficient must be adapted to each project and also in case of restressing.

    At external tendons no wobble coefficient k (unintentional deviation) need to be taken

    into account.

    For the determination of strains and forces of prestressing steel friction losses PAinthe active anchorage zone shall be taken into account as follows:

    - For the tendon sizes from 6803 to 6805: PA= 1.0 %

    - For the tendon sizes from 6807 to 6837: PA= 0.5 %

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    Page 10 of ETA-09/0068English translation by Stra

    B.2.2.4 Radius of curvature of the tendons at deviations and geometry of deviators

    The smallest admissible radius of curvature of the tendons with sheathings asdefined in Appendix C.2 of ETAG 013 based on ENV 1992-1-5 and the requireddimensions of the bent steel deviation tubes are given in Table4 andAnnex 14.

    Table 4: Smallest radius of curvature of deviators

    Tendon Min. radiusof curvature

    Tendon Min. radiusof curvature

    6803 2.00 m 6815 2.75 m

    6804 2.00 m 6819 3.00 m

    6805 2.00 m 6822 3.25 m

    6807 2.00 m 6827 3.50 m

    6809 2.25 m 6831 3.75 m

    6812 2.50 m 6837 4.00 m

    The minimum values of radius of curvature given in Table 4 shall be respected,unless a national regulation is stricter.

    Smooth steel pipes can be bent to a constant radius in one plane. This should betaken into account at when specifying the tendon layout.

    Behind the anchor plate a straight length of the tendon (measured form the top of theanchor plate) according to Table5 is required.

    Table 5: Required straight length of the tendon in the anchorage zone (measuredfrom the top of the anchor plate)

    Tendon Straight lengthof the tendon

    Tendon Straight lengthof the tendon

    6803 0.70 m 6815 1.20 m

    6804 0.80 m 6819 1.30 m

    6805 0.85 m 6822 1.40 m

    6807 0.90 m 6827 1.50 m

    6809 1.00 m 6831 1.60 m

    6812 1.10 m 6837 1.60 m

    In case of an exchangeable tendon with cement grout no curved tendon layout is

    allowed within the concrete body around the anchorage zone.

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    Page 11 of ETA-09/0068English translation by Stra

    In case of a curved tendon layout in the anchorage zone, the smallest admissibleradius of curvature is given in Table6.

    Table 6: Smallest radius of curvature of deviators behind the anchorageTendon Min. radius

    of curvaturebehind

    anchorage

    Tendon Min. radiusof curvature

    behindanchorage

    6803 3.00 m 6815 3.75 m

    6804 3.00 m 6819 4.00 m

    6805 3.00 m 6822 4.25 m

    6807 3.00 m 6827 4.50 m

    6809 3.25 m 6831 4.75 m

    6812 3.50 m 6837 5.00 m

    The minimum values of radius of curvature given in Table 6 shall be respected,unless a national regulation is stricter.

    B.2.2.5 Concrete strength

    At the time of transmission of the full prestressing force to the concrete member the

    mean concrete strength in the anchorage zone shall be at least fcmj, cube or fcmj, cylaccording to Table7. The mean concrete strength (fcmj, cubeor fcmj, cyl) shall be verifiedby means of at least three specimens (cube with the edge length of 150 mm orcylinder with diameter of 150 mm and height of 300 mm), which shall be stored underthe same conditions as the concrete member, with the individual values of specimensnot differ more than 5 %.

    Table 7: Necessary minimum mean concrete strength fcmjof the specimens at timeof prestressing

    fcmj, cube [N/mm] fcmj, cyl[N/mm]

    25 20

    45 36

    60 50

    For partial prestressing with 30 % of the full prestressing force the actual mean valueof the concrete compressive strength to be proved is 0.5 fcmj, cube or 0.5 fcmj, cyl;intermediate values may be interpolated linearly.

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    Page 12 of ETA-09/0068English translation by Stra

    B.2.2.6 Centre and edge distances of the tendon anchorages, concrete cover

    The centre and edge distances of the tendon anchorages shall be the values given intheAnnexes 6-11 depending on the actual mean concrete strength.

    The values of the centre or edge distances of the anchorages given in the Annexesmay be reduced in one direction up to 15 %, however, not to a smaller value than theexternal diameter of the helix plus 20 mm (see Annexes6-11). The centre or edgedistances of the anchorages in the other direction shall be increased for keeping thesame concrete area in the anchorage zone. The dimensions of the additionalreinforcement shall be fitted accordingly.

    All centre and edge distances have only been specified in conjunction with loadtransfer to the structure; therefore, the concrete cover given in national standardsand provisions shall be taken into account additionally.

    The concrete cover may under no circumstance be less than 20 mm or smaller thanthe concrete cover of the reinforcement installed in the same cross section. The

    concrete cover of the anchorage should be at least 20 mm. Standards andregulations on concrete cover valid in place of use shall be considered.

    B.2.2.7 Reinforcement in the anchorage zone

    The anchorages (including reinforcement) for the transfer of the prestressing forcesto the structural concrete were verified by means of tests. The resistance to theforces occurring in the structural concrete in the anchorage zone outside the helixand the additional reinforcement shall be verified. An adequate transversereinforcement shall be provided here in particular for the occurring transverse tensileforces (not shown in the attached drawings).

    The steel grades and dimensions of the additional reinforcement (stirrups) shallfollow the values given in the Annexes6-11. From the given amount of additionalreinforcement 50 kg reinforcement steel/m concrete may be taken into account aspart of the statically required reinforcement. Existing reinforcement in acorresponding position more than the reinforcement required by design may be takeninto account for the additional reinforcement. The additional reinforcement shall be ofclosed stirrups (stirrups closed by means of bends or hooks or an equivalent method)or of orthogonal reinforcement properly anchored. The stirrups locks (bends orhooks) shall be placed staggered.

    In the anchorage zone vertically led gaps shall be provided for proper concreting.

    If required for a specific project design, the reinforcement given in the Annexes canbe modified in accordance with the respective regulations in force at the place of useas well as with relevant approval of the local authority and of the ETA holder toprovide equivalent performance. If in exceptional cases 7 due to an increasedamount of reinforcement the helix or the concrete cannot be properly placed, thehelix can be replaced by different equivalent reinforcement.

    B.2.2.8 Slip at the anchorages

    The slip at the anchorages (see section B.4.2.4) shall be taken into account in thestatic calculation and the determination of the tendon elongation.

    7 This requires the approval of the local authority for individual case according to the national regulationsand administrative provisions.

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    B.3 Evaluation and attestation of conformity and CE marking

    B.3.1 System of attestation of conformity

    According to the decision 98/456/EC of the European Commission8the system 1+ ofattestation of conformity applies.

    This system of attestation of conformity is defined as follows:

    System 1+: Certification of the conformity of the product by an approved certificationbody on the basis of:

    (a) Tasks of the kit manufacturer:

    (1) Factory production control,

    (2) Further testing of samples taken at the factory by the kit manufacturer inaccordance with a prescribed test plan.

    (b) Tasks for the approved body:

    (3) Initial type-testing of the product,

    (4) Initial inspection of factory and of factory production control,

    (5) Continuous surveillance, assessment and approval of factoryproduction control,

    (6) Audit-testing of samples taken at the kit manufacturer.

    B.3.2 ResponsibilitiesB.3.2.1 Tasks of the kit manufacturer

    B.3.2.1.1 Factory production control

    The kit manufacturer shall keep available an updated list of all componentsmanufacturers. The list is provided to the Certification Body and to the ApprovalBody.

    The kit manufacturer shall exercise permanent internal control of production. All theelements, requirements and provisions adopted by the kit manufacturer shall bedocumented in a systematic manner in the form of written policies and procedures,including records of results performed. This production control system shall insure

    that the product is in conformity with this European Technical Approval.

    The kit manufacturer may only use initial materials stated in the technicaldocumentation of this European Technical Approval.

    The factory production control shall be in accordance with the "Control Plan of 27January 2009 relating to the European Technical Approval ETA-09/0068 issued on03 March 2009" which is part of the technical documentation of this EuropeanTechnical Approval. The "Control Plan" is laid down in the context of the factoryproduction control system operated by the kit manufacturer and deposited at Stra9.

    8 Official Journal of the European Communities NoL 201/112, 3.7.1998

    9 The "control plan" is a confidential part of the European Technical Approval and only handed over tothe approved body involved in the procedure of attestation of conformity. See section 3.2.2.

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    Page 14 of ETA-09/0068English translation by Stra

    The prescribed test plan defined inAnnex 17 gives the type and frequency of checksand tests conducted during production and on the final product as part of thecontinuous internal production control.

    The results of factory production control shall be recorded and evaluated inaccordance with the provisions of the "Control Plan".

    The records shall contain at least the following information:

    - Designation of the product or the initial material and the components,

    - Kind of control or testing,

    - Date of manufacture and of testing of product or components and of initialmaterial,

    - Results of controls and tests and, where specified, comparison with therequirements,

    - Name and signature of person responsible for the factory production control.

    The records shall be kept for at least ten years and on request they shall bepresented to Stra.

    If the test results are not satisfactory, the kit manufacturer shall take immediatemeasures to eliminate defects. Construction products or components which are not incompliance with the requirements shall be handled such that they can not bemistaken for products complying with the requirements. After elimination of thedefects the relevant test shall be immediately repeated as far as is technicallypossible and necessary for verifying the deficiency elimination.

    B.3.2.1.2 Other tasks of kit manufacturer

    The kit manufacturer shall, on the basis of a contract, involve a body which isapproved for the tasks referred to in section B.3.1 in the field of Post-Tensioning Kitsfor Prestressing of Structures in order to undertake the actions laid down in sectionB.3.3. For this purpose, the "control plan" referred to in sections B.3.2.1.1and B.3.2.2shall be handed over by the kit manufacturer to the approved body involved.

    The kit manufacturer shall make a declaration of conformity, stating that theconstruction product is in conformity with the provisions of the European TechnicalApproval ETA-09/0068issued on 03 March 2009.

    At least once a year, each components manufacturer shall be audited by the kitmanufacturer.

    At least once a year specimens shall be taken from one job site and one series ofsingle tensile element tests shall be performed according to ETAG 013, Annex E3(see Annex 18). The results of these test series shall be made available to theapproved body.

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    Page 15 of ETA-09/0068English translation by Stra

    B.3.2.2 Tasks of the approved body

    B.3.2.2.1 General

    The approved body shall perform the

    - initial type-testing of the product,

    - initial inspection of factory and of factory production control,

    - continuous surveillance, assessment and approval of factory productioncontrol,

    - audit-testing of samples taken at the factory

    in accordance with the provisions laid down in the "Control Plan of 27 January 2009relating to the European Technical Approval ETA-09/0068 issued on 03 March 2009".

    The approved body shall retain the essential points of its actions referred to aboveand state the results obtained and conclusions drawn in a written report.

    The main production centre is checked at least once a year by the approved body.Each component producer is checked at least once every five years by the approvedbody.The approved certification body involved by the kit manufacturer (DYWIDAG-Systems International GmbH) shall issue an EC certificate of conformity of theproduct stating the conformity with the provisions of this European TechnicalApproval.

    In cases where the provisions of the European Technical Approval and its "ControlPlan" are no longer fulfilled the certification body shall withdraw the certificate of

    conformity and inform Stra without delay.

    B.3.2.2.2 Initial type-testing of the product

    For initial type-testing the results of the tests performed as part of the assessment forthe European Technical Approval may be used unless there are changes in theproduction line or plant. In such cases the necessary initial type-testing has to beagreed between Stra and the approved body involved.

    B.3.2.2.3 Initial inspection of factory and of factory production control

    The approved body shall ascertain that, in accordance with the "Control Plan, thefactory, in particular the staff and equipment, and the factory production control aresuitable to ensure a continuous and orderly manufacturing of the PT system with thespecifications mentioned in section B.2.1 as well as in the Annexes to the EuropeanTechnical Approval.

    B.3.2.2.4 Continuous surveillance, assessment and approval of factory productioncontrol

    The kit manufacturer shall be inspected by the approved body at least once a year.Each component manufacturer shall be inspected at least once in five years. It shall

    be verified that the system of factory production control and the specifiedmanufacturing process are maintained taking account of the prescribed test plan.

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    Page 16 of ETA-09/0068English translation by Stra

    Continuous surveillance and assessment of factory production control have to beperformed according to the prescribed test plan.

    The results of product certification and continuous surveillance shall be madeavailable on demand by the approved body to Stra.

    B.3.2.2.5 Audit-testing of samples taken at the kit manufacturer

    During surveillance inspections the approved body shall take samples at the factoryof components of the PT system or of individual components for which this TechnicalApproval has been granted, for independent testing. For the most importantcomponents Annex 17 contains the minimum procedures which have to beperformed by the approved body.

    The basic elements of the Audit testing comply with ETAG 013, Annex E2 (seeAnnex 18).

    B.3.3 CE markingCE marking is in accordance with the Construction Products Directive and theGuidance Paper D (EC/OEAT 04/645 Document).

    The CE marking shall be affixed on the delivery note. The letters "CE" shall befollowed by the identification number of the Approved Certification Body, whererelevant, and shall be accompanied by the following additional information:

    - The name or identifying mark of the kit manufacturer and of the productionplant (legal entity responsible for the manufacture),

    - the last two digits of the year in which the CE marking was affixed,

    - the number of the CE certificate of conformity for the product,

    - the number of the European Technical Approval,

    - the category(ies) of use (trade name).

    B.4 Assumptions under which the fitness of the product for the intendeduse was favourably assessed

    B.4.1 Manufacturing

    The European Technical Approval is issued for the product on the basis of agreed

    data/information, deposited with Stra, which identifies the product that has beenassessed and judged. Changes to the product or production process, which couldresult in this deposited data/information being incorrect, should be notified to Strabefore the changes are introduced. Stra will decide whether or not such changesaffect the ETA and consequently the validity of the CE marking on the basis of theETA and if so whether further assessment or alterations to the ETA shall benecessary.

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    Page 17 of ETA-09/0068English translation by Stra

    B.4.2 Installation

    B.4.2.1 General

    Assembly and installation of the tendons shall only be performed by qualified post-

    tensioning specialist companies which have the required technical skills andexperiences with this DYWIDAG PT system. The companys site manager shall havea certificate of the ETA holder certifying that he is instructed by the ETA holder andhas the required knowledge and experience with this PT system. National standardsand regulations valid on site shall be considered.

    The ETA holder is responsible to inform anyone concerned about the use of thisDYWIDAG PT system. Additional information as listed in ETAG 013, section 9.2 shallbe held available at the ETA holder and shall be distributed as needed.

    The tendons and the components shall be handled carefully.

    B.4.2.2 WeldingWelding at the anchorages is only permitted at the following points:

    a) Welding of the end of the helix to a closed ring.

    b) For ensuring the central position the helix may be attached to the anchor plateby welding.

    After mounting the tendons no more welding shall be performed at the anchoragesand in the immediate vicinity of the tendons.

    B.4.2.3 Installation of the tendon

    The central position of the helix and stirrups shall be ensured by tack-welding to theanchor plate or other appropriate mountings. The anchor plate shall be in directionperpendicular to the axis of the straight tendon in the vicinity of the anchorage.

    The tendon shall be placed straightforward behind the anchorage according toTable5.

    B.4.2.4 Wedging force, slip at anchorages, wedge securing and corrosionprotection compound

    If the calculated prestressing force is less than 0.7 Pm0, max the wedges of fixed

    anchorages shall be pre-wedged with P0, max(see section B.2.2.2).

    The draw-in of the anchorage to be taken into account for the determination of theelongations and at load transfer from the jack onto the anchorage shall be taken fromTable8.

    The wedges of all anchorages (fixed anchorages) which are no more accessibleduring tensioning shall be secured by means of wedge keeper plates and bolts.

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    Page 18 of ETA-09/0068English translation by Stra

    Table 8: Draw-in values for calculation of elongation [mm]

    Draw-in at stressing anchorage Draw-in at fixed anchorage

    Draw-in to beconsidered forcalculation of

    elongation

    Draw-in at loadtransfer fromthe jack onto

    the anchorage

    Draw-in to be consideredfor calculation of elongation

    Without pre-wedgingor power-seating 1 8 6

    With power-seating20 kN per strand atstressing anchorage

    1 4 -

    With pre-wedgingP0, maxat fixedanchorage

    - - 1

    At installation of the wedges into the conical borings of the not accessible fixedanchorages the gaps shall be filled with corrosion protection compound.

    Before pouring of concrete the wedge plates of the not accessible fixed anchoragesshall be sealed with a grout cap.

    B.4.2.5 Stressing and stressing records

    B.4.2.5.1 Stressing

    At time of stressing the minimum mean concrete strength shall comply with thevalues given in section B.2.2.5. In the vicinity of the anchor plates the concrete mustbe especially homogeneous.

    It is admissible to restress the tendons by releasing and re-using the wedges. Afterrestressing and anchoring, wedge marks on strands resulting from first stressingshall be moved to the outside by at least 15 mm.

    The minimum straight length for tensioning behind the anchorages (strandprotrusion) depends on the jack which is used on site (see Annex 20). All strands ofa tendon shall be stressed simultaneously. This can be done by centrally controlledindividual jacks or by a bundle jack.

    B.4.2.5.2 Stressing recordAll stressing operations shall be recorded for each tendon. In general, the requiredprestressing force shall be achieved. The elongation is measured and compared withthe calculated value.If during tensioning the difference between measured and calculated elongation ismore than 15 % of the calculated value then the engineer shall be informed and thecauses shall be found.

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    Page 19 of ETA-09/0068English translation by Stra

    B.4.2.5.3 Prestressing jacks and space requirements, safety-at-work

    For stressing hydraulic jacks are used. Information about the stressing equipment isshown inAnnex 20.To facilitate jack placement and stressing the tendons, clearance according toAnnex 21 shall be considered directly behind the anchorages.The safety-at-work and health protection regulations shall be complied with.

    B.4.2.6 GroutingB.4.2.6.1 Grout and grouting procedures

    Grout according section B.2.1.9 shall be used. Grouting procedures shall be carriedout in accordance with EN 446:1996. Local standards and national regulations validin place of use shall be considered.

    B.4.2.6.2 Water rinse

    Normally, sheathing shall not be rinsed with water. Local standards and nationalregulations valid in place of use shall be considered.

    B.4.2.6.3 Grouting speed

    The grouting speed shall be in the range between 3 m/min and 12 m/min.

    B.4.2.6.4 Grouted section and re-grouting

    The length of a grouted section shall not exceed 120 m for tendons with 3 to 22strands, 95 m for tendons with 23 to 27 strands and 50 m for tendons with 28 to 37

    strands. When exceeding these tendon lengths, additional grouting openings shall beprovided. Where the tendon is led via distinct high points, re-groutings shall beperformed in order to avoid voids. For re-groutings corresponding measures shall betaken into account already in design.Vents on the ducts shall be provided at both ends and at the points of the tendonwhere air or water may accumulate. In case of ducts of considerable length, vents orinlets may be required at intermediate positions. Local standards and nationalregulations valid in place of use shall be considered.

    B.4.2.6.5 Surveillance

    Surveillance according to EN 446:1996 shall be carried out.

    B.4.2.7 Wax injectionB.4.2.7.1 Wax and injection proceduresWax according section B.2.10 shall be used. Injection shall be carried out accordingto DSI special instructions. Injection equipment is normally composed of meltingdevice (heater), stirrer and pump.

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    Page 20 of ETA-09/0068English translation by Stra

    B.5 Packaging, transport and storage

    The components and the tendons shall be protected against moisture and staining.

    The tendons shall be kept away from areas where welding procedures areperformed.

    For strands the smallest diameter of curvature during transport is 1.65 m.

    The PE-tubes are delivered as straight or prebent tubes for the deviation zones andare connected on site by mirror welding or electro welding couplers.

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    CONTENT OF CONTROL PLAN

    Component Item Test/Check

    Traceability5

    Minimumfrequency

    Documentation

    Anchor plate material check bulk 100 % 2.21

    detaileddimensions

    6

    test 3 %

    2 specimens

    yes

    visualinspection

    4

    check 100 % no

    Wedge plate material check full 100 % 3.12

    detaileddimensions

    6

    test 5 %

    2 specimens

    yes

    visualinspection

    4

    check 100 % no

    Steel trumpet material check bulk 100 % 2.13

    detaileddimensions

    6

    test 3 %

    2 specimens

    yes

    visualinspection

    4

    check 100 % no

    PE-insert material check bulk 100 % 2.13

    detaileddimensions

    6

    test 3 %2 specimens

    yes

    visualinspection

    4

    check 100 % no

    Wedge material check full 100 % 3.12

    treatment,hardness

    test 0.5 %

    2 specimens

    yes

    detaileddimensions

    6

    test 5 %

    2 specimens

    yes

    visualinspection

    4

    check 100 % no

    Sheathing material check CE 100 % CE

    visualinspection

    4

    check 100 % no

    Continuation of Control Plan and footnotes see Annex 17b

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    CONTENT OF CONTROL PLAN - CONTINUED -

    Component Item Test/Check

    Traceability5

    Minimumfrequency

    Documentation

    Tensileelement strand

    material7 check full 100 % yes

    diameter test eachcoil/bundle

    no

    visualinspection

    4

    check eachcoil/bundle

    no

    Helix material check full 100 % yes

    visualinspection

    4

    check 100 % no

    Stirrups material check full 100 % yes

    visualinspection

    4

    check 100 % no

    Constituents offilling materialas per EN 447

    cement check full 100 % yes

    admixtures,additives

    check full 100 % yes

    Wax material8

    check full 100 % 2.21

    All samples shall be randomly selected and clearly identified.

    1 2.2: Testreport type 2.2, according to EN 10204

    2 3.1: Inspection certificate type 3.1, according to EN 102043 2.1: Declaration of compliance with the order type 2.1, according to EN 102044 Visual inspection means e.g.: Main dimensions, gauge testing, correct marking or

    labelling, appropriate performance, surface, fins, kinks, smoothness, corrosion, coating,etc., as given in the Inspection sheet

    5 Full: Full traceability of each component to its raw materialBulk: Traceability of each delivery of components to a defined point

    6 Detailed dimensions mean measuring of all dimensions and angles according to thespecification as given in the Inspection sheet

    7 Characteristic material properties see Annex 168 Characteristic material properties shall comply with ETAG 013, Annex C 4.2.

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    Component Item Test/Check1

    Sampling Number of

    componentsper audit

    Wedge plate material according to specification check, test 1

    detailed dimensions test

    visual inspection2 check

    Wedge material according to specification check, test 2

    treatment test 2

    detailed dimensions test 1

    main dimensions, surface hardness

    test 5

    visual inspection2 check 5

    Single tensileelement test

    ETAG 013, Annex E.3 test 1 series

    Inclined Tubetest

    ETAG 013, C.4.3.3.2.1 test 1 test

    1 All samples shall be randomly selected and clearly identified.2 Visual inspection means e.g.: main dimensions, gauge testing, correct

    marking or labelling, appropriate performance, surface, fins, kinks,smoothness, corrosion, coating, etc., as given in the Inspection sheet.

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    1 ManufactureThe setup of the DYWIDAG external strand post-tensioning tendon withdeviations can be manufactured in structure itself. At pushing of the strandsand during stressing the sheathing should be fixed against movement.In case of straight tendons partly prefabrication is possible. In this case the

    sheathing with the steel trumpet of one anchorage can be preassembled inshop or on site. If also the strands are preassembled then they must beprewedged and secured with a wedge keeper plate during transport. For theproper diameter of coil during transport must be considered.

    2 Strands usedThe strands made of high-strength prestressing steel composing the tendonsare defined in the draft European Standard prEN 10138-3: Prestressing steels Part 3: Strand or in national approvals.The primary characteristics are given in Annex16.

    3 SheathingThe sheathing is assembled from PE-tubes as characterized in Annex2. Thesheathing produced must be mechanically resistant, continuous in shape,ensure continuity of the seal, and UV-resistant, if required in the projectsspecification.The fitting between the sheathing segments is produced by means of mirrorwelding or electro-welding couplers. The sheathing can be prefabricated to itscomplete length or manufactured in the structure.The sheathing is connected to the PE-insert (or its proper extension) of theanchorage by means of mirror welding or electro-welding coupler.To compensate differences between the planned and the actual length of atendon and to compensate unexpected or not avoidable sliding of thesheathing when stressing the tendon at least one telescopic tube should beassembled along the free length near to the stressing anchorage.

    4 Inlets, bleed vents and outletsGrouting with cement grout presupposes the possibility of intervening alongthe tendon path in order to adjust the filling and bleed any air, water, etc. that

    may be within the sheathing. In this aim, accessories (electro-welding collarsor welded pipes) for reinjection, venting and bleeding are installed in properpositions on the sheathing. In case of wax injection proper accessories asinlets and for venting shall be applied at proper positions.In case of an injection or vent tube in the region of a deviator this requiredspace has to be considered when planning/dimensioning and manufacturingthe deviators, for example made of prebent steel tubes.

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    5 AnchoragesAnchorages depending on the tendon sizes are identical for both strand sizesand strand steel grades.The anchorage consists of

    - anchor plate with a steel recess tube welded watertight on it,

    - steel trumpet, consisting of a steel flange, a steel tube and a steeltension ring welded to its two opposite ends and a PE-insert fixed tothe tension ring with a retaining ring through a gasket and screws. Ifnecessary, a piece of PE-sheathing of proper length is mirror-weldedto the PE-insert in order to overhang the concrete member backsidethe anchorage and make a connection with the ordinary sheathingpossible,

    - spacer within the steel trumpet which puts the strands in order andguarantees a proper fatigue strength and improves the wedge plateplacing,

    - wedge plate,- wedges.

    The anchor plate can be concrete-encased or placed onto the structurewhereas the continuous and uniform support of the anchor plate must beguaranteed.This type of anchorage can likewise be used as stressing and accessible fixed(passive) anchorage and with a wedge keeper plate as not accessible. Thewedges of the embedded passive anchorage have to be sealed.Stressing anchorages can be restressed. In order to unload the tendon before

    grouting and to restress after grouting, shims divided into two halves shall bepositioned between flange and anchor plate. Altogether four sets of shims canbe applied at one anchorage. The cuts between the two half-shims shall bestaggered by turning 90.The bursting forces caused by the prestressing force transfer to the concretemember shall be carried by a helix made of plain steel wire or reinforcementsteel. Additional reinforcement such as straight bars or stirrups is also requiredIn any case the tendon layout in the back of the anchorage shall be straight atleast as long as mentioned in Table5. If the steel trumpet with PE-insert and

    onwelded first part of PE-sheathing is installed before concreting of thestructure then even a part of the onwelded piece of PE-sheathing can becurved, whereas the required straight part according to Table 5 and theminimum admissible radius of curvature according to Table6 shall be obeyed.The requirements of mirror-welding shall be considered. Important is that thecurved parts of the PE-sheathing must be completely and properly supportedby the concrete structure and the deviation tube in the anchorage zone inorder to minimize the bending action effects in the sheathing!

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    6 WedgesThe wedges are manufactured of alloyed steel for cementation then saw cutinto three parts and then treated. Three segments are attached by means of aretaining ring.

    7 DeviatorsNormally, deviators are made of smooth steel tubes bent in the planned form.Other deviation saddle designs like a curved concrete surface are alsopossible as long as the limits of geometry according to Table4 and Annex14are obeyed.

    8 Protective capsIn order to enable grouting/injection corrosion protective compound and forfinal protection of the anchorage a permanent metallic cap fixed onto theanchor plate shall be used. The length of the cap shall be determineddepending on, whether the tendon is restressable or not.

    9 StressingA hydraulic pump unit and a centre hole jack are used for stressing theprestressing steel. During stressing all pertinent safety rules andrecommendations must be fully known and obeyed. The force targets alongwith the corresponding values of elongation; moreover, tolerances must beknown. Furthermore, the order in which the post-tensioning tendons are to bestressed must be specified. The required/specified strength of concrete of both

    the structure and anchorage zone undergoing stressing must be verified.The strands pass through the jack and are anchored in the tension disk withclamping jaws. All strands of a tendon are stressed simultaneously. Strands ofstraight tendons can be stressed one-by-one with monojacks.The prestressing force is checked with the aid of a pressure gauge.Furthermore, the elongation of the prestressing steel serves as control of theprestressing force. Long tendons for which the jack stroke is insufficient can bestressed in stages.Stressing in load steps and resetting of the jack is easily done. After stressing,the wedges are power seated by means of a seating device within the jack. A

    wedge slip according to Table8 remains after wedge seating procedure.

    10 Grouting with cement mortarAfter stressing cement grout can be injected if specified by the designer into the void between prestressing steel and sheathing thus serving ascorrosion protection of the strands.Before grouting it shall be controlled that the stressed tendon does not kink a tthe ends of the deviations.

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    The grout is injected through the properly placed grout inlets (mostly at thedeepest points of the sheathing).The sheathing is vented at the ends of the tendon by means of venting pipesor grouting caps.Intermediate venting points at high points are necessary in case of long

    tendons.The DSI grouting equipment is composed of mixer and pump. For someapplications, vacuum pumps that allows for certain rate of depressurisationinside the sheathing, hence facilitating progression of the grouting (vacuumsupported grouting).Grouting shall be executed in accordance with EN 445, EN 446 and EN 447and national regulations, if applicable. The climatic conditions and temperatureof the structure must satisfy use conditions of the injection product.In case of restressable tendons the strands projecting ends in the cap shall becovered just after grout has been set the grout shall be removed between and

    on the projecting ends of the strands and singular tubes filled with corrosionprotecting compound shall be slid on. Before the surfaces of wedge plate andwedges shall be covered with corrosion protective tape. The ends of the tubesshall be tightened at the wedge plate with tape. The wedge plate shall becovered with tape. At the other end of the singular tubes these shall be closedwith small caps.Just after grouting the completeness of the filling grade shall be controlled withstrokes of a hammer.

    11 Injection

    Injection products with a wax base as defined in Annex C.4.2 of the ETAG 013shall be used.Before and during injection the relevant prescriptions and requirements of DSImust be obeyed.

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    Usage of jacks for tendons 68 ..

    Jack type 01 02 03 04 05 06 07 08 09 10 12 15 19 22 27 31 37

    SM 240

    HoZ 950/100

    HoZ 1,700/150

    HoZ 3,000/250

    HoZ 5,400/250

    6,800

    9,750

    Jack type 1

    Length L Diameter D Stroke Piston area Capacity 2 Weight

    [mm] [mm] [mm] [cm] [kN] [kg]

    SM 240 842 98 200 47.13 240 19

    HoZ 950/100 621 203 100 161.98 972 65

    HoZ 1,700/150 803 280 150 298.45 1,745 160

    HoZ 3,000/250 1,137 385 250 508.94 3,054 400

    HoZ 5,400/250 1,271 482 250 894.57 5,367 6006,800 1,150 560 300 1237.01 6,803 1,185

    9,750 1,170 680 300 1772.45 9,748 1,770

    1 Power seating incl.2 Without friction

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    BLOCK-OUT-DIMENSIONS [mm]

    Jack type A B C D E F G H K L 2

    SM 240 880 1 370 - 80 100 75 50 120 100 230/270

    HoZ 950/100 621 350 150 - 220 200 130 190 260 300/400

    HoZ 1,700/150 803 490 180 - 270 230 170 220 340 450/600

    HoZ 3,000/250 1,130 650 220 300 360 320 220 310 440 350/600

    HoZ 5,400/250 1,235 740 220 300 420 360 270 320 540 450/800

    6,800 1,421 1 - 80 - - 330 310 410 620 - /1,200

    9,750 1,470 1 - 120 - - 380 390 550 740 - /1,200

    1 Stroke incl.2 Nec. Strand protrusion (without/with power seating device)

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