DSI-DYWIDAG Prestressing Systems Using Bars EMEA

8/10/2019 DSI-DYWIDAG Prestressing Systems Using Bars EMEA

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ETA Approvals ...........................................................................................................4

System description .................................................................................................... 5

Prestressing Bars / Technical Data ............................................................................6

System overview ........................................................................................................7

Overview of anchorages ............................................................................................8

Applications ...............................................................................................................9

Overview of bonded bar tendons .............................................................................10

Overview of unbonded and external bar tendons .....................................................11

Geometrical characteristics of accessories ............................................................. 12

Installation ...............................................................................................................13

Stressing and grouting ............................................................................................. 14

Equipment for stressing and grouting ......................................................................15

Contents


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Construction products with an Euro-pean Technical Approval (ETA) meetall essential demands given in theConstruction Products Directive (CPDThe ETA holder is authorized to applyCE-marking (Conformit Europennon his product. The CE-marking certi-es the conformity with the technicalspecication and is the basis for thefree movement of goods within the EUmember states. DSI is proud to haveEuropean Technical Approvals for itsPT-systems with bars, bonded strandsand unbonded strands.

ETA Approvals

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DYWIDAG Prestressing Systemsare world renowned for reliability andperformance, most suitable for allapplications in post-tensioned andprestressed constructions. Theyembrace the whole spectrum from bridgeconstruction, buildings, to civilapplications, above and underground.

The rst ever structure built with a pro-totype DYWIDAG Post-TensioningSystem using bars was the arch-bridge

Alsleben (Germany) in 1927. From thattime on DYWIDAG has continuouslyimproved its systems to keep up with thegrowing demand of modern constructiontechnology. In addition to the traditionalpost-tensioning system using bars, thatis mainly geared towards geotechnicalapplications, building rehabilitation andstrengthening, DSI offers a completeproduct line in strand prestressing (bon-ded, unbonded and external) as well asstay-cables being able to fully serve thepost-tensioning construction. DYWIDAGPrestressing Systems have always com-bined highest safety and reliability stan-dards with most economical efciency intheir research and development. Depen-dable corrosion protection methods of theDYWIDAG Prestressing Systems contri-bute to the longevity of modern construc-tion. High fatigue resistance is achievedwith optimized material selection andcautious detailing of all the componentsespecially in their system assembly.

The post-tensioning system for theprestressing of structures with bars (inter-nal bonded, unbonded and external ten-dons) is regulated in European Technical

Approval ETA-05/0123. This ETA can bedownloaded at: http://www.dywidag-systems.com/emea/downloads/dsi-approvals/european-approvals.html

System Description

Ground anchors of up to 47 mm areprovided for geotechnical applications.

Additionally, DSI USA providesDYWIDAG Prestressing Systems with65 and 75 mm threadbars.

Internal bar tendons are mainly used inconcrete, composite and masonrystructures. Internal unbonded andexternal bar tendons are used for con-crete, composite, steel, timber andmasonry structures. Typical applicationsare transversal prestressing, strengthe-ning of bridges, rehabilitations, connec-tion elements for steel structures andmachines and temporary applications.

Uhlavu Bridge, Pilsen, Czech Republic

Typical Coupling, Uhlavu Bridge, Pilsen, Czech Republic

Advantages and Characteristics

n Easy system handlingn Robust designn Flexible transport length due to couplersn Also applicable for (very) short tendons due to little slipn Used in new structures and for strengthening of existing structuresn Suitable as longitudinal or transversal tendonsn Usable as shear reinforcement

n Usable as straight or curved tendonsn Can be used as hangers for concrete or steel arch bridgesn Usable for the temporary or permanent connection of precast

concrete elementsn Many combination of any structural material are possible

(such as steel with concrete)n Preassembled unbonded or external tendons with permanent corrosion

protection are available


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Prestressing Bars and Technical Data

GeneralThe prestressing bars are hot-rolled, tem-pered from the rolling heat, stretched andannealed, with a circular cross section.

The bars are of prestressing steelY 1050 H according to prEN 10138-4.

The threadbars and plain bars areavailable in mill length up 18 m andmay be cut to specied lengths beforeshipment to the jobsite.

Threadbars

Threadbars are available in diameters17.5, 26.5, 32, 36, 40 and 47 mm.

The threadbars feature continuoushot-rolled ribs providing a right-handedthread along the entire length.

The threadbar can be cut anywhere andis threadable without further preparation.

The threadbars are specied bynominal diameter and WR, e.g. 26 WR

Plain bars

Plain bars are available in diameters32 and 36 mm.

Both ends of a plain bar cut to the lengthspecied in the project are provided withspecial cold-rolled threads.

The thread lengths are manufactured inthe shop according to the specicationsof the project.

The plain bars are specied bynominal diameter and WS, e.g. 32 WS.

THREADBAR Plain bar

Designation 18 WR 26 WR 32 WR 36 WR 40 WR 47 WR 32 WS 36 WS

Nominal diameter d s [mm] 17.5 26.5 32 36 40 47 32 36

Cross section area S n [mm] 241 552 804 1,018 1,257 1,735 804 1,018

Nominal mass per metre 1 M [kg/m] 1.96 4.48 6.53 8.27 10.20 14.10 6.31 7.99

Pitch c [mm] 8 13 16 18 20 21 3 3

Characteristic breakingload Fm [kN] 255 580 845 1,070 1,320 1,820 845 1,070

Max. initial stressing force 2P m0,max = S n x 0,8 x f p,k [kN] 204 464 676 856 1,056 1,457 676 856

Max. overstressing force 3 P 0,max = S n x 0,95 x f p0,1k

[kN] 219 499 722 912 1,131 1,566 722 912

1The nominal mass per metre includes 3.5% not load bearing portion of ribs. 2The given values are maximum values according to Eurocode 2, i.e. min (k1xfpk, k2x fp0.1k ) applies. The fulllment of the stabilization criteria and the requiremencracks width in the load transfer tests were veried at 0.8 x Fpk.

Fpk = Sn x fpk Fp0.1k = Sn x fp0.1k 3Overstressing is permitted if the force in the prestressing jack can be measured to an accurary of 5% of the nal value of the prestressing force.

Technical data


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Available tendons Anchor

plate 18 WR 26 WR 32 WR 36 WR 40 WR 47 WR 32 WS 36 WS

Bonded bar tendonwith QR-plate anchoragewith additional reinforcement

2074

Bonded bar tendonwith small solid rectangular plate anchoragewith additional reinforcement

2076

Bonded bar tendonwith QR-plate anchoragewithout additional reinforcement

2074

Bonded bar tendonwith small solid rectangular plate anchoragewithout additional reinforcement

2076

Bonded bar tendonwith small solid square plate anchoragewithout additional reinforcement

2011

Bonded bar tendonwith solid rectangular plate anchoragewith additional reinforcement

2012

Unbonded and external bar tendonwith solid square plate anchoragewithout additional reinforcement

2011

Unbonded and external bar tendonwith solid rectangular plate anchoragewith additional reinforcement

2012

System Overview

4 Hex nuts 2002 are not included in ETA-05/0123.


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Stressing anchorage, bondedThe bar is xed with the domed

anchor nut and the retaining nut to theanchorage plate and this latter will bexed to the scaffolding. The retaining

nut provides the connection to the duct.Grouting is performed through the grout

cap, the domed anchor nut with the threegrout slots and the retaining nut.

Fixed anchorage, bondedThe xed anchorage is mostlycompletely embedded in the con-crete. The domed anchor nut is tackwelded perpendicularly onto the anchorplate. The duct sleeve B ends direct-ly at the anchor plate the duct will beinjected respectively vented there. Axed anchorage can be designed as astressing anchorage; the requiredbar-over length for the stressing can bedispensed.

Stressing anchorage, unbonded Against water intrusion in the

anchorage region a connection tube iswelded to the anchor plate for bridging of

a gap behind the anchor plate.Different corrosion protection systems

are available.

Fixed anchorage, unbondedThe xed anchorage is mostlycompletely embedded in the concrete.The domed anchor nut is tack weldedperpendicularly onto the anchor plate.The prestressing bar will be providedwith the respective corrosion protection.The xed anchorage can be carried outas an unbonded stressing anchorage,too.

domed anchor nutprestressing bar WR/W

hex nuttoroidal ring

grout cap sealing ring anchor plate

retaining nut

anchor plate

anchor plate with connection tube

domed anchor nut

duct sleeve B

prestressing bar WR/WS

domed anchor nuttube

heatshrinking sleeveprestressing bar WR/WS

domed anchor nut

anchor plate

prestressing bar WR/WS

tube heatshrinking sleeve

Overview of Anchorages


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Prestressing bar tendons can be usedat new structures and for strengtheningof existing structures, as longitudinalor transversal tendons, as shearreinforcement, straight or curved,as hangers at concrete or steel archbridges, for temporary or permanent

connections of precast concreteelements, xations of concrete toconcrete, new concrete to old concrete,steel to concrete, concrete to masonryor any combination of members made ofany structural material.

Applications

Grand-Mre Generating Station, Canada

Church of Our Lady, Germany


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Bonded bar tendons are embedded inconcrete. The corrosion protection of theprestressing steel and the bond with thestructural concrete is provided by groutinjected in the ducts.

A bonded tendon is intendedto be used for concrete, compositeand masonry structures.

Overview Bonded Bar Tendons

Bonded bar tendon, design QR-plate,square and rectangular solid plates


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Overview Unbonded and External Bar Tendons

Unbonded and external bar tendonsare installed either inside or outsidethe cross section of the structure. Forcorrosion protection various systemsare available, all of which do not bondwith the structure. The tendons may be

restressed at any time and dependingon the tendon type, they can also beremoved or exchanged.

Internal unbonded and external tendonsare intended to be used for concrete,

composite, steel, timber and masonrystructures.

The corrosions protection of unbondedand external tendons depends on anenvironmental conditions and service time.

Bar tendons with free tendon duct,permanent corrosion protection executedduring grouting before stressing,design square and rectangular solid plates

Bar tendons with free tendon duct,permanent corrosion protection executedby heatshrinking sleeve, design square andrectangular solid plate


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Tendon with free tendon duct Tendon without free tendon duct

Corrosionprotection for

Temporarycorrosionprotection 3 years

Permanent corrosion protection Permanent corrosion protection

ThreadbarPlain bar coating

grouting withcement grout

before stressing(installation)

grouting withcement grout after

stressing

heatshrinkingsleeve or corrosion

protection tape

corrosionprotectioncompound

heatshrinking sleeveor corrosion

protection tape

corrosioprotectiocompoun

coating acc. toEN ISO 12944-5with protection

tube (PE)

cement grout withprotection tube

(PE or steel)

cement grout withprotection tube

(PE or steel)


protection tapewith protection

tube (PE or steel)

protection tube(PE), void groutwith corrosion

protectioncompound


protection tapewith protection

tube (PE or steel)

corrosioprotection tawith protect

tube (PE

Anchorage,range of

connectiontube

corrosionprotection

compound ortape

sealing ringplus corrosion

protectioncompound tape

sealing ringplus grout

sealing ring orheatshrinking

sleeveplus corrosion

protectioncompound or tape



protectioncompound



protectioncompound or tape

sealing ringheatshrink

sleeveplus corrosi

protectiocompoun

Anchorage,range of

anchor nut

corrosionprotection

compound ortape

corrosionprotection

compound or tapeor grout

corrosionprotection

compound or tapeor grout

corrosionprotection

compound or tape

corrosionprotectioncompound

corrosionprotection

compound or tape

corrosioprotectiocompoun

cap, PE or steel cap, PE or steel cap, PE or steel

Coupler heatshrinkingsleeve

tubes (PE or steel) with transition pieces, sealed with heatshrinking sleeve or tape,lled with corrosion protection compound or tape or grout

tube with transition pieces, lled witcorrosion protection compound

Overview of Corrosion Protection Systems


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Geometrical Characteristics of Accessories

Overview of Tensioning Jacks for Prestressing Tendons

THREADBAR Plain bar

Bar designation 18 WR 26 WR 32 WR 36 WR 40 WR 47 WR 32 WS 36 WS

Domed Anchor Nut 2099length [mm] 55 75 90 100 115 135 46 60

width across at [mm] 36 50 60 65 70 80 55 65

Hex nut 4 2002length [mm] 60 80 90 110 120 140 55 80

width across at [mm] 41 46 55 60 70 80 55 60

Coupler (Standard) 3003length [mm] 100 170 200 210 245 270 110 160

outside diameter [mm] 36 50 60 68 70 83 60 68

Square Solid Plate 2011

width [mm] 110 150 180 200 220 260 180 200

length [mm] 110 150 180 200 220 260 180 200

thickness [mm] 25 35 40 45 45 50 40 45

Rectangular Solid Plate(Unbonded and Bonded) 2012

width [mm] 100 130 140 150 160 200 140 150

length [mm] 130 150 180 220 250 280 180 220

thickness [mm] 30 35 40 50 60 60 40 50

Rectangular Solid Plate(Bonded) 2076

width [mm] 80 120 140 160 180 210 140 160

length [mm] 90 130 165 180 195 235 165 180

thickness [mm] 25 30 35 40 45 55 35 40

QR-Plate 2074

width [mm] - 120 140 160 180 - - 160

length [mm] - 130 165 180 195 - - 180

thickness [mm] - 30 35 40 45 - - 40

Corrugated Duct 4061internal diameter [mm] 25 38 44 51 55 65 44 51

outside diameter [mm] 30 43 49 56 60 70 49 56

Minimum Bar Protrusion at stressing anchorage [mm] 60 75 90 100 115 135 46 60

THREADBAR Plain bar

Bar designation 18 WR 26 WR 32 WR 36 WR 40 WR 47 WR 32 WS 36 WS

60 Mp x x x 1 x1

110 Mp x x x x x x

200 Mp x1 stressing force limited to 625 kN max.

4 Hex nuts 2002 are not included in ETA-05/0123.


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ValueFormwork

Grout Tube

Pocket Former

Duct Duct Sleeve A Duct

Anchor PlateHex Nut

Stressing End

Domed Anchor Nut

Retaining Nut

Installation

DYWIDAG-Systems Internationaloffers a full line of special installationaccessories to facilitate eld assemblyand installation. Installation shall becarried out by properly trainedand experienced personnel.Tendons can be delivered to the jobsiteprefabricated when desired(e.g. unbonded bar tendon), too.

In the area of anchorage adequatespace shall be accomplished througha pocket former assembled at theformwork before concreting in order tput on the jack and for the grout cap.

Jeju Port Extension, South Korea

Woodrow Wilson Bridge, Washington, D.C., USA


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Stressing and Grouting

The small, light and conveniently operatedDYWIDAG-Systems International jacksfacilitate the stressing operation. Heavylifting aids are generally not necessary.

Stressing notesStraight tendons are generally stressedfrom one end only. In order to reducefriction losses (especially in drapedtendons) it is recommended to stressfrom both sides.

The prestressing load can be adjustedup and down at any given time untilthe tendon is fully grouted by simplyreinstalling the jack. This allows partiallystressing. Several controls during andafter the stressing operation check theeffective stressing load:

n bar protrusion at the anchoragebefore and after stressing to evaluatethe effective elongation

n counter control for elongation duringstressing operation

n gauge control for hydraulic pressure

To comply with exceptional highdemands on accuracy for example onvery short tendons special accessoriescan be applied to minimize the inuenceof alignment tolerances.

GroutingThe durability of bonded post-tensionedconstruction depends to a great degreeon the success of the grouting operation.The hardened cement grout providesbond between concrete and tensileelements as well as primary long termcorrosion protection (alkaline medium)for the prestressing steel.

DYWIDAG-Systems International hasdeveloped a grouting operation thatis based on highly plasticized groutwith thixotropic properties, and utilizesdurable grouting equipment. Advancedmethods such as pressure grouting,post-grouting and vacuum grouting areall results of many years of development.

Grouting is always done from a low-pointof the tendon. This can be one of theanchorages with a grout cap with groutinlet or along the tendon utilizing anintermediate grout saddle. All groutingcomponents are threaded for easy, fastand proper connection.

The jack is pushed over a pull rod couplerthat is threaded onto the bar protrusionbehind the domed anchor nut. The jack isthen xed with a pulling nut.

The tension load is hydraulically transfer-red. The domed anchor nut is tightenedby an internal wrench. The bar 47 WR hasa specially equipped stressing jack.


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E

A B

L

D

E

L

A B

D

C

F

Equipment for Stressing and Grouting

Tensioning jacks

Dimensions (for Block-Out design)

Tensioning jacks L E stroke piston area Ak capacity max. piston weight A B C D F pressure [mm] [mm] [mm] [cm] [kN] [bar] [kg] [mm] [mm] [mm] [mm] [mm]60 Mp Series 04 401 190 50 132.5 625 50 36 225 176 3) 3) 30060 Mp Series 05 456 190 100 132.5 625 50 44 225 231 3) 3) 300

110 Mp Series 01 494 267 50 235.6 1,100 50 46 275 2194)

4)

375110 Mp Series 03 594 267 150 235.6 1,100 50 54 275 319 4) 4) 375200 Mp 865 315 150 361.3 2,000 60 172 350 515 - 270 -

C D for type of bar [mm] [mm]3) 105 106 18 WR, 26 WR, 32 WS 135 114 32 WR4) 122 106 26 WR 125 110 32 WS 125 120 32 WR, 36 WR/WS 134 134 40 WR

Hydraulic pumps

Hydraulic pumps Tensioning jacks 60 Mp 110 Mp 200 Mp77-193 A n nR 3.0 V n nR 6.4 n n n

Pump type max. operating oil ow rate usable weight dimensions pressure oil capacity with oil 1 L x W x H [bar] [l/min] [l] [kg] [mm]77-193 A 600 3.0 10 63 420x380x480R 3.0 V 600 3.0 13 98 600x390x750R 6.4 600 6.4 70 310 1,400x700x1,100

1) Hydraulic pumps will be supplied without oil.

Grouting equipment (mixing and pumping)

Grouting max. injection capacity weight dimensionsequipment pressure L x W x H [bar] [l/h] [kg] [mm]MP 2000-5 15 420 300 2,000x950x1,600

Pump Type R 6.4Pump Type 77-193 A

Mixer MP 2000-5

Tensioning jack 110 Mp/60 Mp Tensioning jack HOZ 200 Mp


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A U S T R I A A R G E N T I N A A U S T R A L I A

B E L G I U MB O S N I A A N D H E R Z E G O V I N A

B R A Z I LC A N A D A

C H I L EC O L O M B I A

C O S TA R I C A C R O AT I A

C Z E C H R E P U B L I CD E N M A R K

E G Y P TE S T O N I A F I N L A N DF R A N C E

G E R M A N YG R E E C E

G U AT E M A L A H O N D U R A S

H O N G K O N GI N D O N E S I A

I TA LYJ A PA NK O R E A

L E B A N O NL U X E M B O U R G

M A L AY S I A M E X I C O

N E T H E R L A N D SN O RWAY

O M A NPA N A M A

PA R A G U AYP E R U

P O L A N DP O RT U G A L

Q ATA RS A U D I A R A B I A

S I N G A P O R ES O U T H A F R I C A

S PA I NS W E D E N

S W I T Z E R L A N DTA I WA N

T H A I L A N DT U R K E Y

U N I T E D A R A B E M I R AT E SU N I T E D K I N G D O M

U R U G U AYU S A

V E N E Z U E L A

www.dywidag-systems.com

Please note:This brochure serves basic informationpurposes only. Technical data and informationprovided herein shall be considerednon-binding and may be subject to changewithout notice. We do not assume any liabilityfor losses or damages attributed to the useof this technical data and any improperuse of our products. Should you requirefurther information on particular products,please do not hesitate to contact us.

AustriaDYWIDAG-SystemsInternational GmbH Alfred-Wagner-Strasse 14061 Pasching/Linz, AustriaPhone +43-7229-61 04 90Fax +43-7229-61 04 980E-mail [email protected]

FranceDSI-ArtonRue de la CrazZ.I. des Chartinires01120 DagneuxFrancePhone +33-4-78 79 27 82Fax +33-4-78 79 01 56E-mail [email protected]

Germany DYWIDAG-SystemsInternational GmbHSchuetzenstrasse 2014641 Nauen, GermanyPhone +49 3321 44 18 0Fax +49 3321 44 18 18E-mail [email protected]

DYWIDAG-SystemsInternational GmbHMax-Planck-Ring 140764 Langenfeld, GermanyPhone +49 2173 79 02 0Fax +49 2173 79 02 20E-mail [email protected]

DYWIDAG-SystemsInternational GmbHGermanenstrasse 886343 Koenigsbrunn, GermanyPhone +49 8231 96 07 0Fax +49 8231 96 07 10E-mail [email protected]

DYWIDAG-SystemsInternational GmbHSiemensstrasse 885716 Unterschleissheim, GermanyPhone +49-89-30 90 50-100Fax +49-89-30 90 50-120E-mail [email protected]

Italy DYWIT S.P.A.Viale Europa 72 Strada A 7/920090 Cusago (MI), ItalyPhone +39-02-901 65 71Fax +39-02-901 65 73 01E-mail [email protected]

NetherlandsDYWIDAG-SystemsInternational B.VVeilingweg 25301 KM Zaltbommel, NetherlandsPhone +31-418-57 89 22Fax +31-418-51 30 12E-mail [email protected]

PolandDYWIDAG-SYSTEMSINTERNATIONAL Sp. z o.o.ul. Przywidzka 4/6880-174 Gdansk, PolandPhone +48-58-300 13 53Fax +48-58-300 13 54E-mail [email protected]

PortugalDYWIDAG SISTEMASCONSTRUCTIVOS, SA Rua D. Manuel I, n.24 A Quinta da Parreirinha2695-003 Bobadela (Loures), PortugalPhone +351-21-89 22 890Fax +351-21-89 22 899E-mail [email protected]

SpainDYWIDAG SISTEMASCONSTRUCTIVOS, S.A. Avd/de la Industria, 4Pol. Ind. la Cantuena28947 Fuenlabrada (Madrid), SpainPhone +34-91-642 20 72Fax +34-91-642 27 10E-mail [email protected]

United KingdomDYWIDAG-SystemsInternational Ltd.Northeld RoadSoutham, WarwickshireCV47 0FG, Great BritainPhone +44-1926-81 39 80Fax +44-1926-81 38 17E-mail [email protected]

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DSI-DYWIDAG Prestressing Systems Using Bars EMEA