European Technical Approval ETA-06/0226 - Freyssinet...The Freyssinet prestressing kit is a post-tensioning kit designed for both internal and external prestressing. A prestressing

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MEMBER OF EOTA

European Technical Approval ETA-06/0226 (English language translation, the original version is in French language)

Version of 28th June 2013 Nom commercial Trade name:

Système Freyssinet Freyssinet system

Détenteur de l'ATE Holder of approval:

SOLETANCHE FREYSSINET 1 bis, rue du Petit Clamart F-78140 VELIZY

Type générique et utilisation prévue du produit de construction Generic type and use of construction product:

Kit de précontrainte de structures par post-tension Post-tensioning kit for prestressing of structures

Valid from: to:

28/06/2013 28/06/2018

Producteur du procédé: Kit manufacturer

FPC Z.A. du Monay-Saint Eusèbe F-71210 SAINT EUSÈBE

Cet Agrément Technique Européen réunie 3 agréments : This European Technical Approval is a merger of 3 approvals :

ETA-06/0226 version of 12th Mars 2012 with validity from 19/01/2012 to 19/01/2017 ETA-11/0172 version of 7th July 2011 with validity from 07/07/2011 to 07/07/2016 ETA-10/0326 version of 11th October 2010 with validity from 11/10/2010 to 11/10/2015

Le présent agrément technique européen contient : This European Technical Approval contains:

104 pages comprenant 48 pages d’annexes (dessins) faisant partie intégrante du document. 104 pages including 48 pages of annexes which form an integral part of the document

Organisation pour l'Agrément Technique Européen European Organisation for Technical Approvals

European Technical Approval n° 06/0226 Page 2 of 56 _________________________________________________________________________________

Version of 28th June 2013

CONTENTS

A LEGAL BASES AND GENERAL CONDITIONS ................................................................................... 6

B SPECIFIC CONDITIONS OF THE EUROPEAN TECHNICAL APPROVAL ................................... 7

B.1 DEFINITION OF PRODUCTS AND INTENDED USE ......................................................................................... 7 B.2 CHARACTERISTICS OF PRODUCTS AND VERIFICATION METHODS ............................................................ 14 B.3 EVALUATION AND ATTESTATION OF CONFORMITY AND CE MARKING ................................................... 15 B.4 ASSUMPTIONS UNDER WHICH THE FITNESS OF THE PRODUCTS FOR THE INTENDED USE WAS ASSESSED . 17 B.5 INDICATIONS TO THE MANUFACTURER .................................................................................................... 18

C – PRESCRIBED TEST PLAN .............................................................................................................. 19

D – BASIC ELEMENTS OF AUDIT TESTING ..................................................................................... 21

E – PRESTRESSING UNITS AND USE CATEGORIES ...................................................................... 22

E.1 UNITS CODING ......................................................................................................................................... 22 E.2 USE CATEGORIES ..................................................................................................................................... 22 E.3 PARTICULARITIES OF THE KIT .................................................................................................................. 26 E.4 FORCES OF PRESTRESSING TENDONS ....................................................................................................... 27

F – ANCHORAGES .................................................................................................................................. 29

F.1 DESCRIPTION OF ANCHORAGE COMPONENTS .......................................................................................... 29 F.2 RECOMMENDATIONS FOR USE OF ANCHORAGES ..................................................................................... 32

G – TENSILE ELEMENTS AND DUCTS ............................................................................................... 34

G.1 TENSILE ELEMENTS ................................................................................................................................. 34 G.2 DUCTS ..................................................................................................................................................... 35 G.3 CABLE LAY-OUT ..................................................................................................................................... 39

H – TENSIONING...................................................................................................................................... 41

H.1 TENSIONING EQUIPMENT ......................................................................................................................... 41 H.2 PARTICULAR RECOMMENDATIONS .......................................................................................................... 41 H.3 RECOMMENDATIONS FOR TENSIONING AND CONTROL ............................................................................ 41

I – PROTECTION OF TENDONS.......................................................................................................... 42

I.1 LUBRICATION AND TEMPORARY PROTECTION ......................................................................................... 42 I.2 FILLING MATERIALS USED ...................................................................................................................... 42 I.3 INJECTION EQUIPMENT ............................................................................................................................ 42

J – MECHANICAL AND GEOMETRICAL CONDITIONS OF USE ................................................ 43

J.1 FRICTION LOSSES AND ELONGATIONS ..................................................................................................... 43 J.2 GEOMETRICAL CONDITIONS OF USE ........................................................................................................ 44 J.3 BURSTING REINFORCEMENT .................................................................................................................... 47

K – DRAWINGS ......................................................................................................................................... 56



LIST OF DRAWINGS

1. T15 anchoring wedge

2. T13 anchoring wedge

3. B13 wedge

4. T15D swage

5. T15DC swage

6. T13D swage

7. P 15 strand connector

8. P 13 strand connector

11. A nC15 anchorage – bare strand – duct

12. A nC15 anchorage – bare strand – steel pipe

13. A nC15 anchorage – monostrand – duct

14. A nC15 anchorage – monostrand – steel pipe

15. A - AD nC15 anchorage – monostrand – polyethylene pipe

16. A nC15 anchorage – monostrand – no duct

17. AD nC15 anchorage – bare strand – injected with cement grout

18. AD nC15 anchorage – bare strand – injected with wax or grease

19. A nC15 EI electrically isolated anchorage

20. CI nC15 fixed coupler

21. CU nC15 fixed coupler

22. CM nC15 movable coupler

23. NB nC15 anchorage

24. A 1F15 – A 1F13 – NB 1F15 – NB 1F13 flat anchorage – bonded prestressing

25. A nF13 – A nF15 anchorage – bare strand – bonded prestressing

26. CI nF13 – CI nF15 fixed coupler – bare strand – bonded prestressing

27. A 1F15 – A 1F13 – NB 1F15 – NB 1F13 anchorage – unbonded prestressing

28. A nF13 – A nF15 anchorage – monostrand – unbonded prestressing

29. A nB13 & nB15 anchorage – bare strand – sheath

30. A nB15 anchorage – monostrand – sheath

31. A nB15 anchorage – monostrand – no duct

32. A 1X13 – A 1X15 anchorage – monostrand

33. A 2X13 – A 2X15 anchorage – monostrand

34. Liaseal seal system for match-cast segments

35. Identification drawings for C-series anchorage blocks

36. Identification drawings for coupler blocks CU nC15

37. Permanent recess of nC15 anchorages

38. Temporary or permanent recess of nC15 anchorages

39. Sealing-in of restressable nC15 anchorages

40. External prestressing with monostrands – grouting stuffing box

41. External prestressing allowing load monitoring, restressing and replacement without damage to duct

42. Clearance requirement for CCxxx jacks

43. Clearance requirement for CxxxF jacks

44. Clearance requirement for KxxxC jacks (with hydraulic lock-off)

45. Clearance requirement for KxxxC jacks (without hydraulic lock-off)

46. Clearance requirement for K500F jack

47. Clearance requirement for VPxxxC jacks

48. 55C15 equitension jack clearance

49. Load-monitoring jack for threaded 55C15 anchorage

50. Clearance requirement for monostrand jacks – type C

51. Clearance requirement for jacks – A 1F13 - 1F15 anchorage

52. Clearance requirement for jacks – A nF13 – A nF15 anchorage

53. Clearance requirement for SC2 and U24 jacks – AnB13 A nB15 anchorage

54. Clearance requirement for titan 25 and IHS 25T jacks – A nB13 A nB15 anchorage



55. Clearance requirement for jack 1X13 – 1X15 anchorage

56. Clearance requirement for jack 2X13 – 2X15 anchorage

57. Grouting vents possibilities



LIST OF TABLES

Table 1 Low-Capacity Anchorages

Table 2 High-Capacity Anchorages

Table 3 Anchorage Models for Basic and Optional Categories of Use

Table 3bis Choice of Kit Elements for Basic and Optional Categories of Use

Table 4 Concrete Structures – Use Categories

Table 5 Maximum Force with Stressing Limit Fo = min{0,8 Fpk,0,9 Fp0,1%}

Table 6 Maximum Force at Stressing Anchorage for a Single Strand

acc. to Eurocode 2 prEN 10138-3:2006 (only informative)

Table 7 Thickness of Steel Strip Sheaths

Table 8 Dimensions of Smooth HDPE Tubes

Table 9 Minimum Curvature Radius for Internal Prestressing

Table 10 Minimum Curvature Radius for External Prestressing

Table 11 Friction Loss in Anchorages

Table 12 Friction and Wobble Coefficients

Table 13 Wedge Pull-In at Stressing Anchorages

Table 14 Minimum Edge Distances for C-Model Anchorages

Table 15 Minimum Edge Distances for Model F Anchorages

Table 16 Minimum Edge Distances for Model B Anchorages

Table 17 FeE 235 Bursting Steel for fcm,o = 24 MPa



Table 20 Helical Bursting Steel with FeE 235 for fcm,o = 24 MPa



Table 23 Bursting steel for Model B anchorages



A LEGAL BASES AND GENERAL CONDITIONS

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

Council Directive 89/106/EEC of 21 December 1988 on the approximation of

laws, regulations and administrative provisions of Member States relating to

construction products1, modified by Council Directive 93/68/EEC2 and

Regulation (EC) No 1882/2003 of the European Parliament and of the Council3;

décret n°92-647 du 8 juillet 19924 concernant l'aptitude à l'usage des produits de

construction

Common Procedural Rules for Requesting, Preparing and the Granting of

European Technical Approvals set out in the Annex to Commission Decision

94/23/EC5;

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

Structures.

A.2 Sétra is authorised to check whether the provisions of this European Technical

Approval are met. Checking may take place in the manufacturing plant(s). Nevertheless, the

responsibility for the conformity of the products to the European Technical Approval and for

their fitness for the intended use remains with the holder of 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 manufacturing plants other than

those indicated on page 1 of this European Technical Approval.

A.4 This European Technical Approval may be withdrawn by Sétra, in particular pursuant

to information by the Commission according to Article 5(1) of Council Directive

89/106/EEC.

A.5 Reproduction of this European Technical Approval including transmission by

electronic means shall be in full. However, partial reproduction can be made with the written

consent of Sétra. In this case partial reproduction has to be designated as such. 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 official

language. 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 No L 40, 11.2.1989, p. 12 2 Official Journal of the European Communities No L 220, 30.8.1993, p. 1 3 Official Journal of the European Union No L 284, 30.10.2003, p. 1 4 JORF du 14 juillet 1992 5 Official Journal of the European Communities No L 17, 20.1.1994, p. 34



B SPECIFIC CONDITIONS OF THE EUROPEAN TECHNICAL APPROVAL

This European Technical Approval is a merger of three documents :

ETA-06/0226 version of 12th March 2012 with validity from 19/01/2012 to 19/01/2017

ETA-11/0172 version of 7th July 2011 with validity from 07/07/2011 to 07/07/2016

ETA-10/0326 version of 11th October 2010 with validity from 11/10/2010 to 11/10/2015

Holder of the three European Technical Approvals is :

SOLETANCHE FREYSSINET

1bis, rue du petit Clamart

F-78140 VELIZY

The present document contains all the technical data and content of the three above

mentioned documents : It replaces last version of ETA-06/0226,

It cancels and supersedes ETA-11/0172 and ETA-10/0326.

B.1 DEFINITION OF PRODUCTS AND INTENDED USE

B.1.1 Definition of Products

The Freyssinet prestressing kit is a post-tensioning kit designed for both internal and external

prestressing. A prestressing cable consists of a bundle of 7-wire strands in accordance with

section G.1 and is referred to as the ‘tensile element’. When fitted with its anchorages, the

prestressing tendon is referred to as the ‘prestressing unit’.

The tensile element is housed in a duct in accordance with section G.2.

In the case of unbonded internal prestressing, however, monostrands (strands with individual

protection by grease or wax and plastic sheath) may be used without any duct, the strands

being placed in the structure according to the design requirement.

The set of anchorages available allows using prestressing units up to 55 strands.

Prestressing strands can be made in accordance with European and national provisions.

The prestressing tensile elements consist of:

12,5 mm or 12,9 mm nominal diameter strands, with a nominal tensile strength of

1770 MPa or 1860 MPa, coded respectively Y1770 (or Y1860) S7 12,5 (or 12,9) in

prEN 10138-3 and designated T13, T13S or simply T13 in the present document,

15,3 mm or 15,7 mm nominal diameter strands, with a nominal tensile strength

1770 MPa or 1860 MPa, coded respectively Y1770 (or Y1860) S7 15,3 (or 15,7) in

prEN 10138-3 and designated T15, T15S or simply T15 in the present document.

Freyssinet stressing anchorages anchor each strand individually by means of a conical wedge

inserted in a conical hole of anchorage block. The diameter of the internal thread of the

Freyssinet anchor wedge depends on the strand nominal diameter, T13 or T15 (drawings 1, 2

and 3).



B.1.1.1 Stressing anchorages

Anchorages are said to be the stressing type (and are coded ‘A’ for ‘active’) when they are the

anchorages at the end of tensile elements where the tensioning operation takes place. A

stressing anchorage consists of an anchorage head, i.e. a steel block or a casting with holes to

receive anchorage wedges. The anchorage head bears on a load spreading plate, except for

models F and X where the load spreading plate is part of the anchorage block. This load

spreading plate is:

either a casting known as a ‘trumplate’, which is cast into the concrete of the structure,

or a bearing plate of dimensions to suit the load-bearing capacity of the structure.

Different active anchorage models are available, to meet specific construction needs.

Structural anchorages model C

Prestressing anchorages model C are generally used for civil engineering prestressed

structures. They consist of a circular steel anchor head bearing on a cast-iron trumplate with

one or several intermediate spreading rings. They cover a range between 3 and 55 strands T13

or T15 (drawings 11 to 19).

Slab anchorages model F

Prestressing anchorages model F are generally used for prestressing thin elements (e.g.

concrete floor slabs and walls) and consist of a one-piece casting which combines the

anchorage block and the trumplate. It is available for prestressing units with 1, 3 or 4 strands

T13 or T15 (drawings 24 to 28).

Slab anchorages model B

Prestressing anchorages of the Freyssinet B system are generally used in prestressed thin

elements of the concrete structures. They are composed of cast-iron anchorage block and

trumplate. The model B cover a range between 3 and 5 strands T15 and T13 (see drawings 29

to 31).

Hoop anchorages model X

The Freyssinet hoop anchorage consists of a casting bearing against the circular structure

which serves as anchorage to the two ends of one or two hoops:

The 1 X anchorage is used to make one prestressing hoop, with radius of up to 27,5 m

(drawing 32),

The 2 X anchorage is used to anchor two hoops, each wrapped once or twice around

the structure, with radius of up to 5,5 m (drawing 33).

B.1.1.2 Passive anchorages

When anchorages are said ‘external passive’ they will not allow fitting of a tensioning jack

but are nevertheless accessible during the tensioning operation. This kind of anchorage is

made out of stressing anchorages in which the wedges have been pre-blocked, without

protruding tendon length for tensioning. They can be inspected during tensioning. The

Freyssinet denomination for these types is identical to that of stressing anchorages.



Anchorages are said embedded or internally fixed when incorporated in concrete of structure.

These NB designated anchorages use swages to ensure fixing of strand ends (drawings 4 to 6)

on a model C anchor head fitted with cylindrical holes and seated on a trumplate. They can be

used for units ranging from 3 to 55 strands T13 or T15 (drawing 23).

B.1.1.3 Fixed Couplers CI

Couplers connect two tensile elements that are tensioned one after the other in two separate

concreting phases

Monostrand fixed coupler

It consists of individual type P strand connectors (see paragraph B.1.1.4 below) connecting

each strand of the primary tendon to its counterpart in the secondary tendon (drawing 20). It is

used with all active stressing anchorages for prestressing units with 1 to 37 strands T13 or

T15.

The reinforcement in the deviation zone has to be calculated by the project designer.

Multistrand fixed couplers

Multistrand fixed couplers (drawing 21) connect two tensile elements that are tensioned one

after the other in two separate concreting phases.

They are made of machined steel with two series of conical holes bored, each series counting

at least as many holes as there are strands in the prestressing tendon.

Units with 3, 4, 7, 9, 12, 13, 15, 19, 22, 25, 27, 31 and 37 conical holes are available in the

range.

The holes of the first series are positioned in the central part of the coupler, according the

same pattern as for the C anchorages of the basic kit.

The holes of the second series are bored on the opposite side of the coupler, according a

circular pattern. For unit 31 and 37, these holes are positioned on two concentric circles.

B.1.1.4 Movable couplers CM

Movable couplers CM connect two tensile elements which are tensioned simultaneously in a

single operation. Strands are connected together with a type P individual strand connector;

strand connector positions are offset in the case of multistrand units.

The connector consists of a cast-iron body to receive two anchorage wedges and serves to

connect two sections of a tensile element. Two models are available:

strand connector P 13 is used with T13 and T13S strands (drawing 8),

strand connector P 15 is used with T15 and T15S strands (drawing 7).

Movable couplers are used for prestressing units with 1 to 37 strands T13 or T15

(drawing 22).

The length of the coupler reservation is obtained by the formula L = M + U, where U is the

connector displacement including provision for stressing tolerance according to national

regulations and M is a fixed dimension depending on the tendon type including necessary

installation tolerance given in the table of relevant drawings.



B.1.1.5 Tables : anchorage models and ETA-covered units

Type Anchorage

model

Number of strands T13 or T15

1 2 3 4 5

A F x x x

B x x x

AD X x x

NB F x

CI F x x x

CM F x x x

B x x x

Table 1. Low-Capacity Anchorages

For definition of symbols, see §E.1 below

Type Anchorage

model

Number of strands T13 or T15

1 3 4 7 9 12 13 15 19 22 25 25C 27 31 37 42 48 55

A

C

x x x x x x x x x x x x x x x x x x

AD x x x x x x x x x x x x x x x x x x

NB x x x x x x x x x x x x x x x x x x

CI x x x x x x x x x x x x x x x

CM x x x x x x x x x x x x x x x

Table 2. High-Capacity Anchorages

B.1.1.6 Other Components

Prestressing units of Freyssinet kit require different components, some of them being

common to several models.

- Ducts, used to isolate, guide and protect tensile elements (see section G.2). They can

consist of steel or plastic corrugated sheath or steel or plastic tubes or pipes.

- Connecting accessories may be improved by plastic adhesives, heat-shrink sleeves or

mastic.

- Injection materials for anchorages and ducts, such as cement grout, grease and wax.

- Tubes or specific elements for deviation of external cables at given locations in the

structure. These deviators are generally made out of steel plain pipes. The specific

elements may include reservations inside the concrete reinforcement or construction steel

saddles to obtain the cable deviator.

- Bursting steel reinforcement, for the concrete confinement at anchorages and deviators, to

complete the general concrete structural reinforcement and ensure prestressing force

transfer.

- Specific accessories to facilitate cable placing and stressing, tendon grouting, de-

tensioning and replacement of tendon, such as vents, duct drainage, tendon supports,



temporary and permanent protection caps of anchorages and couplers, coupling elements

between duct sections and for duct connection to anchorages.

Following components are covered by national or European provisions:

- prestressing steels,

- steel corrugated sheath,

- steel or plastic pipes or tubes,

- grouting products,

- bursting reinforcing steel.

For this reason, these components are not described in this ETA. However, they can be used

for the prestressing kit.

B.1.2 Intended Use

The prestressing kit described in this ETA can be used for new structures, for repair and

reinforcement of existing structures with following basic categories of use:

Internal bonded tendon for concrete and composite structures

Internal unbonded tendon for concrete and composite structures

External tendon for concrete structures with a tendon path situated outside the cross-

section of the structure but inside its envelope.

The prestressing kit described in this ETA offers additionally optional categories of use for

which standard tendon characteristics are improved. These options are as follows:

1. restressable tendon (external or internal),

2. exchangeable tendon (external or internal),

3. tendon for cryogenic applications,

4. internal bonded tendon with plastic ducts,

5. encapsulated tendon,

6. electrically isolated tendon,

7. tendon for use in structural steel or composite construction as external tendon,

8. tendon for use in structural masonry construction as internal or external tendon,

9. tendon for use in structural timber construction as internal or external tendon.

PT-anchorage zones have to be designed to resist 1,1 Fpk according to the relevant Eurocode

in case of use with other materials than concrete.



The prestressing kit described in this ETA can be used in any type of structure and is used

more frequently in:

bridges (superstructures, piers, abutments, foundations),

buildings (floors, foundations, core walls, walls, columns, shear walls, lateral load

resisting frames, foundations),

reservoirs (walls, slabs, roofs),

silos (walls),

nuclear containment structures,

offshore structures (all parts),

floating installations and platforms (all parts),

retaining walls,

dams,

tunnels (longitudinal and transverse/hoop tendons),

large diameter pipes,

roads and airports.

Categories of Use

Fix

ed

Cou

plers

CI

Movab

le

Cou

plers C

M

Mod

el F

Mod

el C

Mod

el B

Mod

el X

Mod

el NB

Bonded Internal Tendon for

Concrete and Composite Structures 1 to 37 1 to 37 1 to 4 1 to 55 3 to 5 1 to 2 1 to 55

Unbonded Internal Tendon for

Concrete and Composite Structures 1 to 37 1 to 37 1 to 4 1 to 55 3 to 5 1 to 2

External Tendon for

Concrete and Composite Structures 1 to 37 1 to 55 1 to 2

Options (a) Restressable Tendon 1 to 4 1 to 55 3 to 5 1 to 2 (b) Replaceable Tendon 1 to 4 1 to 55 3 to 5 1 to 2 (c) Tendon for Cryogenic Applications 1 to 55 (d) Bonded Internal with Plastic Duct 1 to 37 1 to 37 1 to 4 1 to 55 3 to 5 1 to 2 (e) Encapsulated Tendon 1 to 37 1 to 37 1 to 4 1 to 55 1 to 2 (f) Electrically Isolated Tendon 3 to 37 3 to 37 3 to 55 (g) External Cable for Steel or

Composite Structures 1 to 55 1 to 2

(h) Internal/External Tendon for

Masonry Structures 1 to 4 1 to 55 1 to 2

(i) Internal/External Tendon for

Timber Structures 1 to 55 1 to 2

Table 3. Anchorage Models for Basic and Optional Categories of Use



Pre-

stressing

Type

Structures Options

Anchorage &

Coupler Type

Model

Duct

Tensile Element

Injection

Anchor

Protection

Sealing

Typical Drawings

[3]

Co

ncrete

Steel

Maso

nry

Tim

ber

Restressab

le

Ex

chan

geab

le

Cry

og

enic

En

capsu

lated

Electrically

Isolated

Internal

Bonded

x x x Standard C, F, NB, B Steel Bare Strand Cement Grout Cachetage/Cap refer to [4]

x x x x Standard C, F, NB, B Plastic [1] Bare Strand Cement Grout Cachetage/Cap refer to [5]

x x x Isolated C, B Plastic [1] Bare Strand Cement Grout Cachetage/Cap 19, 24, 25, 29

Internal

Un-

bonded

x Standard C Steel Bare Strand Grease/Wax Cachetage/Cap 12

x x Standard C Plastic Bare Strand Grease/Wax Cachetage/Cap 12

x x x Standard C Steel Bare Strand Grease/Wax Extended Cap 12

x x x x Standard C Plastic Bare Strand Grease/Wax Extended Cap 12

x x x Standard C Steel Monostrand Cement Grout Extended Cap 13, 14

x x x x Standard C Plastic Monostrand Cement Grout Extended Cap 13, 15

x Standard F, B Steel Monostrand Cement Grout Cachetage/Cap 27, 28

x x Standard F, B Plastic Monostrand Cement Grout Cachetage/Cap 27, 28

x x x Standard C, F, B no duct Monostrand No injection Cachetage/Cap 16, 28

x x x x x Standard C, F, B no duct Monostrand No injection Extended Cap 16, 28

x x x Isolated C, F, B no duct Monostrand No injection Cachetage/Cap 16

x x x x x Isolated C, F, B no duct Monostrand No injection Extended Cap 16, 19, rare

External

x x x x Standard C Steel [2] Bare Strand Cement Grout Cachetage/Cap 12, rare

x x x x Standard C Steel [2] Bare Strand Grease/Wax Cap 18

x x x x x x Standard C Steel [2] Bare Strand Grease/Wax Extended Cap 18

x x x x x Standard C Plastic[2] Bare Strand Cement Grout Cachetage/Cap 17

x x x x x x x Standard C Plastic[2] Bare Strand Cement Grout Extended Cap 17

x x x x x Standard C Plastic[2] Bare Strand Grease/Wax Cap 18

x x x x x x x Standard C Plastic[2] Bare Strand Grease/Wax Extended Cap 18

x x x x x x Isolated C Plastic[2] Bare Strand Grease/Wax Cap 18

x x x x x Standard C Plastic[2] Monostrand Cement Grout Cachetage/Cap 15, 17

x x x x x Standard C Plastic[2] Monostrand Cement Grout Cachetage/Cap 15, 17

x x x Standard X Plastic[2] Monostrand Cement Grout Cap 15, 31, 32

x x x x x x x Standard C Plastic[2] Monostrand Cement Grout Extended Cap 15

x x x x x x Isolated C Plastic[2] Monostrand Cement Grout Cap 15

x x x x x Standard C, F, B no duct Monostrand No injection Cap 16, 27, 28

Table 3bis. Choice of Kit Elements for Basic and Optional Categories of Use



Notes

Standard Anchorage as per typical drawings, Isolated Anchorage: interposition of isolating

liner and seal inside trumplate and at contact to anchor block

Cachetage: see drwg 37, Cap: see drwg 38, Extended Cap: see drwg 39

Duct out of Steel or Plastic: Corrugated or Smooth, unless otherwise marked.

[1] Corrugated duct only [2] Smooth duct only

[3] References given to drawings are not exhaustive [4] e.g. see drwgs 11, 12, 20, 22, 23, 24, 25, 26, 34, 37

[5] e.g. see drwgs 11, 20, 22, 23, 24, 25, 26, 27, 34

B.1.3 Working Life

The provisions made in this ETA are based on an assumed intended working life of the PT

System of 100 years. The indications given on the working life can not be interpreted as a

guarantee given by the producer or the approval body, but are to be regarded only as a means

for choosing the right products in relation to the expected economically reasonable working

life of the structures.

B.2 CHARACTERISTICS OF PRODUCTS AND VERIFICATION METHODS

B.2.1 Characteristics of Products

Chapters E to K of this ETA, including drawings attached to it, detail the characteristics of

products.

B.2.2 Verification Methods

The assessment of the aptitude of the kit for its intended use, in relation to the requirements

for mechanical resistance and stability in the sense of the Essential Requirement 1 has been

made in compliance with the Guideline for European Technical Approval (ETAG 013) of

“Post-Tensioning Kits for Prestressing of Structures”. Performances examined in conformity

to the ETAG 013 satisfy the pertinent essential requirements. These are mainly performances

related to static load, transfer on concrete and resistance to fatigue. Methods for check,

evaluation and assessment of aptitude for use and test procedures according to those detailled

in ETAG 013.

Assessment of experience gathered and specific tests were realised in conformity to

ETAG 013 for optional use categories listed in paragraph B.1.2.

B.2.3 Emission of Dangerous Substances

According to the manufacturer declaration the post-tensioning kit does not contain any

dangerous substances.

In addition to the specific clauses relating to dangerous substances contained in the ETA,

there may be other requirements, applicable to the products falling within its scope (e.g.

transposed European legislation and national laws, regulations and administrative provisions).



In conformity with the provisions of the European directive 89/106/EEC, these requirements

must also be complied with wherever they apply.

B.3 EVALUATION AND ATTESTATION OF CONFORMITY AND CE MARKING

B.3.1 Attestation of Conformity System

According to the decision 98/456/EC of the European Commission6 the system 1+ of

attestation 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 certification body

on the basis of :

Tasks of the Manufacturer

1. Factory production control,

2. further testing of samples taken at the factory by the manufacturer in accordance with a

prescribed test plan.

Tasks of the Approved Body (Certification 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 factory production control,

6. audit testing of samples (see ETAG013, section 8.1 (b)).

Note: Approved bodies are also referred to as “notified bodies”.

B.3.2 Responsabilities

B.3.2.1 Tasks of the Manufacturer

The manufacturer of the kit has the full responsability of the production and quality of

components whether produced by himself or by sub-manufacturers.

The type and frequency of checks and tests conducted during production and on the final

product as part of the continuous internal production control are described in the prescribed

test plan, Chapter C of this ETA.

All the tests are conducted according to written procedures, by means of adequate calibrated

measuring devices. Results are recorded logically and systematically.

If test results do not comply, the produced lot is inspected in detail. It may be rejected,

completely or partially. Defectuous parts may be retreated in order to eliminate defects and

checks and tests are then repeated.

Products non complying with the ETA are marked and separated from complying products.

6 Official Journal of the European communities L201/112 of 3 July 1998



Each main component has a prescribed inspection plan, established by Freyssinet and applied

by its manufacturers. Production control methods are defined in the Freyssinet Quality

Assurance Plan PAQ ATE PRE.

At least once a year, each component producer is audited by the kit manufacturer. The results

of the audit shall be made available to the certifying body.

B.3.2.2 Tasks of the Certification Body

Methods of surveillance for production control are defined in the Quality Assurance Plan

established and updated by Freyssinet, in conformity with paragraph 8.2.2 of ETAG 013.

The main production centre is checked at least once a year by the Certification Body. Each

component producer is checked at least once every five years by the Certification Body.

The Certification Body checks inspection results, control tests as well as results of production

control results and establishes the conformity to the ETA.

Corrective measures are taken by the Manufacturer when defects have been met. These

measures are:

corrective intervention, following the notification of the Certification Body,

control strengthening and higher test frequency,

setting-up of modifications.

During continuous surveillance auditing, the Certification Body takes samples to test in

independent laboratories. Samples are taken according to the requirements of the table

attached in the chapter D of this ETA.

During the certificate validity the ETA holder supplies once a year to the Certification Body

anchorages and strands necessary for a test series according to Annex E of ETAG 013 and

sends them to the laboratory designated by the Certification Body.

These well-identified parts and tensile elements are from the same construction site. If

possible, construction sites are chosen in such a way that the tensile element manufacturer

will be different from year to year.

B.3.2.3 CE Marking

The CE marking must comply with the European Council Directive 89/106/CEE, and to the

EC guideline "D" related to the marking. The delivery bill accompagnying the PT kit

components shall bear the conformity CE marking symbol and the following mentions :

1. Name and address of kit manufacturer,

2. Last two digits of the year during which the marking has been made,

3. Number of conformity certificate,

4. Number of ETA,

5. See information on ETA, 6. Number of Certification body,

7. Product Identification (commercial denomination) and use category(ies).

All other information must be clearly distinct from the CE marking and the related mentions.



B.4 ASSUMPTIONS UNDER WHICH THE FITNESS OF THE PRODUCTS FOR THE

INTENDED USE WAS ASSESSED

The ETA is issued under the following assumptions:

B.4.1 Manufacture of Product

The ETA is issued for the Freyssinet post-tensioning kit on basis of information and

documents submitted by Freyssinet to Sétra, with identification of product tested and

assessed. Any modification of characteristics of product or factory production process which

might modify the conformity of the kit shall be notified to the Sétra prior to its application.

The Sétra will decide if this modification affects the ETA and if a more detailled assessment

or amendment of ETA is required.

A Quality Assurance Plan related to the prestressing kit ETA is established and regularly

updated by Freyssinet ; it is made available to the Sétra. A list of sub-contractors and

component suppliers is part of this Quality Assurance Plan.

Freyssinet is committed to impose the requirements of the present ETA and ETAG 013 upon

the producer of his prestressing kit, as well as upon his subcontractors and suppliers.

B.4.2 Installation Design and Execution

B.4.2.1 Design of Structures

The Freyssinet prestressing kit is fit for use in structures designed properly.

The designer of the structure is assumed to respect specifications set by applicable standards,

e.g. Eurocodes or equivalent applicable national standards, and to adapt his design in

accordance with the construction methods foreseen and the instructions of the ETA holder.

The arrangement of anchorages shall respect the specifications of chapter J as to edge cover,

axis distances and bursting steel.

B.4.2.2 Stressing equipment

Stressing jacks shall be calibrated in conformity with Freyssinet procedures, national

regulations of Member States and the provisions of ETAG 013 §7.3.

B.4.3 Components not detailed in the ETA

Following components, not detailed in the present ETA, conform to European standards or

equivalent applicable national standards or regulations:

Prestressing steel : prEN 10138

Monostrands : ETAG 013 Annex C1, XP A 35 037

Steel corrugated sheaths : EN 523

Steel pipes: prEN 10255, ISO 4200, EN 10216-1, EN 10217-1

Smooth plastic pipes: prEN 12201

Cement grout: EN 445, EN 447

Bursting steel: prEN 10080, EN 10025



B.5 INDICATIONS TO THE MANUFACTURER

B.5.1 Packaging, transport and storage

It is recommended to apply a temporary protection to prestressing steels and steel components

of the kit to prevent corrosion during transport from production factory to the site.

Transport and handling of prestressing steel and steel components of the kit shall be done in

such a manner as to avoid any mechanical, chemical or physical damage.

Prestressing steels and steel components shall be stored free from humidity. Plastic

components and ducts shall be protected from UV radiation.

Prestressing steels shall be protected or kept away from welding areas.

B.5.2 Recommendations for safety

The specialist company shall establish a Unique Document in conformity with the Guidance

Directive 89/391/CEE dated 1989.06.12, identifying and analysing recurring risks bound to

installation of prestressing.

The technician in charge of the prestressing works shall modify this Unique Document to

account for the particular and not recurring risks of his working site.

During stressing, standing behind or immediatly close to a jack is strictly forbidden, as well as

behind a passive anchorage while stressing at the other end. Wherever necessary, safety rails

shall be installed and passing zones for personnel shall be kept free.

B.5.3 Use, maintenance and repair

Durability of prestressed structures requires an adequate periodic inspection.

Since any disorder in the structure may result in damage of PT tendons, a specialist company

should repair as soon as possible according to adequate procedures.



C – PRESCRIBED TEST PLAN

The following table summarises the test procedures necessary to ensure that all kit

components meet the ETA specifications. Sétra has adapted Table E.1 of ETAG 013

according to the importance of the components for the performance of the Freyssinet PT-

system.

1 2 3 4 5 6

Component Item Test/

Check Traceability

4

Minimum

frequency

Documen

tation

Bearing plate material 7 check bulk 6 100 % "2.2" 1, 6

detailed

dimensions5

test 3 %

2 specimen

yes

visual inspection3 check 100 % no

Trumplate material 7 check full 100 % "3.1"2

detailed

dimensions5

test 3 %

2 specimen

yes


Anchor head/block for

coupler

material 7 check full 100 % "3.1" 2

detailed

dimensions5

test 5 %

2 specimen

yes


Cast iron anchor parts material 7 check full 100 % "3.1" 2

for anchorages and

couplers

detailed

dimensions5

test 5 %

2 specimen

yes


Wedge material 7 check full 100 % "3.1" 2

treatment, hardness test 0,5 %

2 specimen

yes

detailed

dimensions5

test 5 %

2 specimen

yes


Swage material 7 check full 100 % "3.1" 2

detailed

dimensions5

test 5 %

2 specimen

yes


continued next page



1 2 3 4 5 6

Component Item Test/

Check Traceability

4

Minimum

frequency

Documen

tation

Duct material 7 check CE2 100 % yes


Tensile element material 6 check full 100 % yes

diameter test each coil no

visual inspection3 check each coil no

Constituents of filling cement 7 check full 100 % yes

material as per EN 447 admixtures,

additives, …7

check bulk 100 % yes

Monostrand, Annex C.1 material 6 check full 100 % "3.1" 2

Plastic pipe, Annex C.2 material 7 check full 100 % "3.1" 2

Plastic duct, Annex C.3 material 7 check full 100 % "3.1" 2

Special grout, Annex C.4.3 material 7 check full 100 % "3.1" 2

Liaseal® coupler material 7 check full 100 % "2.2" 1

detailed

dimensions5

test 3 %

2 specimen

yes


1 "2.2" : Test report type "2.2" according to EN 10204

2 "3.1" : Inspection certificate type "3.1" according to EN 10204

3 Visual inspections means e.g.: main dimensions, gauge testing, correct marking or labelling, appropriate

performance, surface, fins, kinks, smoothness, corrosion, coating, etc., as given in the prescribed test plan

4 full : full traceability of each component to its raw material.

bulk : traceability of each delivery of components from a defined point.

5 detailed dimensions mean measuring of all dimensions and angles according to the specification as given in

the prescribed test plan

6 conformity to applicable national provisions in absence of relevant EN.

7 material checks are included for information only as these are not part of the prescribed test plan.



D – BASIC ELEMENTS OF AUDIT TESTING

Component Item Test/Check Sampling – No. of

components per visit

Trumplate Material according to

specification

Test or Check 1

for anchorages C or B Detailed dimensions Test

Main dimensions1 Check

Machined anchor block /

block for coupler

Material according to

specification

Test or Check 1

Detailed dimensions Test

Main dimensions1 Check

Cast iron anchor parts Material according to

specification

Test or Check 1

for anchorages F, X, B Detailed dimensions Test

or strand connector P Main dimensions1 Check

Wedge, swage Material according to

specification

Test or Check 3

Heat treatment

(if applicable)

Test 2

Detailed dimensions Check 1

Main dimensions

Surface hardness

Test 5

Visual Inspection1 Check 5

Single tensile element

test

Single tensile element test

according to Annex E.3

Test 1 series

All samples taken at random and clearly identified.

1 visual inspection relates to main dimensions, calibration tests, correctness of marking or tag,

adequate performing, surface aspect, absence of burrs or faults, absence of cavities, corrosion,

coating, etc.



E – PRESTRESSING UNITS AND USE CATEGORIES

E.1 UNITS CODING

Prestressing anchorages are coded as follows: TY n M d PR where:

the first letters ‘TY’ indicate the anchorage type (function):

A: active* internal-prestressing anchorage (*stressing anchorage)

AD: active* replaceable external-prestressing anchorage (*stressing anchorage)

NB: embedded anchorage with trumplate

CI: coupler with individual connectors P or multistrand couplers CU

CM: movable coupler with individual connectors P

letter ‘n’ indicates the number of strands in a tensile element;

letters ‘M’ indicate the model of the stressing anchorage (component):

C: structural prestressing

F: slab prestressing (one-piece anchorage)

B: slab prestressing (two-pieces anchorage)

X: hoop anchorage

number ‘d’ indicates the strand diameter category:

13: T13 and T13S strands

15: T15 and T15S strands

letters ‘PR’ indicate the level of corrosion protection:

PE: with plastic sheath (generally polyethylene)

GI: with sliding individually greased/waxed and sheathed strand (monostrand)

EI: with electrical isolation

W: with flexible corrosion-inhibiting product injected (generally wax).

E.2 USE CATEGORIES

E.2.1 Bonded Internal Prestressing for Concrete Structures

Internal prestressing units bonded to the concrete consist of bare strands in a thin-wall

corrugated duct made of steel (see G.2.1), plastic (see G.2.2) or smooth steel pipes (see G.2.3)

and injected with a cement grout in accordance with EN 447 or Annex C4 of ETAG013.

E.2.2 Unbonded Internal Prestressing for Concrete Structures

Unbonded internal prestressing tendons consist of one of the following types:

W units: tensile elements housed in a steel or plastic duct injected with a soft filling

material,



GI units: tensile elements made of monostrands. Outside the anchorage zones,

monostrands are either placed in a round or flat duct injected with cement grout prior to

tensioning or installed directly in the structure, in accordance with design requirements.

Unbonded internal prestressing tendons allow re-stressing and the steel part of tensile

elements is replaceable.

‘A n C 15 W’ anchorages can be used to make electrically isolated prestressing tendons if the

measures described in paragraph E.2.4 have been taken.

E.2.3 External Prestressing for Concrete Structures

Other than in exceptional circumstances, external prestressing tendons are replaceable and re-

stressable, and are one of the following types:

Standard type: with double tube where the tendon passes through the concrete of the

structure, to ensure the independence of the tensile element and its duct from the

structure and to enable extraction. The duct is injected with cement grout.

Type W: with a duct injected with a flexible corrosion-inhibiting product enabling the

tensile element to be extracted.

Type GI: with monostrands housed in a general duct injected or not with cement grout

before tensioning.

‘AD n C 15’ anchorages can be used to make electrically isolated prestressing tendons if the

measures described in paragraph E.2.4 have been taken.

E.2.3.1 Standard Tendons

Tensile elements are housed in a continuous HDPE plain tube. At anchorages the trumplates

are fitted with a plastic trumpet welded to the tube. A watertight gasket between the two parts

allows dismantling.

Where tendons pass through concrete a double casing is realised by means of a second tube

used as a concrete formwork which ensures the independence of the HDPE tube from the

concrete.

The corresponding anchorages are coded ‘AD n C 15’.

E.2.3.2 GI Tendons

Tensile elements consist of monostrands grouped together in a plastic duct, injected with

cement grout prior to tensioning. The anchorage head is protected by a permanent cap filled

either with a soft corrosion protection material fully compatible with that of monostrands or

injected with cement grout.

The corresponding anchorages are coded ‘AD n C 15 GI’.

E.2.3.3 W Tendons

Tensile elements are housed in a continuous HDPE plain tube. At the anchorages, the

trumplates are fitted with a plastic trumpet welded to the tube. A watertight gasket between

the two parts allows dismantling. Double tubing is not necessary to ensure dismantling.



After tensioning, the tendon is injected with a soft corrosion protection material, such as a

microcristaline petroleum wax. The anchorage head is protected by a permanent cap which

allows the injection of the tendon.

The corresponding anchorages are coded ‘AD n C 15 W’.

E.2.3.4 Non-Replaceable External Prestressing Tendons

In this exceptional case, external prestressing tendons consist of anchorages identical to those

used for bonded internal prestressing tendons. Thin-wall corrugated ducts are prohibited in all

exposed sections of tendon. Steel tubes may be used for sections embedded in concrete.

The corresponding anchorages are coded ‘A n C 15’.

E.2.4 Common Application Options

Model C internal prestressing anchorages can be used to make prestressing tendons for

cryogenic applications.

Freyssinet prestressing anchorages can be used to make prestressing tendons with a watertight

casing when used with a watertight plastic duct, a permanent cap to cover the anchorage head

and watertight connections between each section of the casing.

Model C anchorages can be used to make electrically isolated prestressing tendons. These

tendons consist then of strands threaded in an electrically isolating plastic casing comprising

in particular:

a plastic trumpet fitted inside the trumplate,

a bearing plate made out of an electrically isolating composite material placed under

the anchor block,

a plastic cap.



Applications Types Models Corrosion

Protection

Bonded

Internal

Prestressing

with steel duct A

NB

CI

CM

C – F - B

C

C - F

B

-

with plastic duct PE

electrically isolated with

plastic duct A - CI - CM C EI

Unbonded

Internal

Prestressing

with monostrands A

NB

C - F – X - B

C - F

GI

injection with soft

protection material A C - B W

injection with soft

protection material

and electrical isolation

A

C

WEI

External

Prestressing

injection with cement

grout

AD

C -

with monostrands C - X GI

injection with soft

protection material C W

electrically isolated C EI

Table 4. Concrete Structures – Use Categories

E.2.5 External Prestressing for Steel Structures and Composite Structures

Model F (single strand unit) and C anchorages are used in the case of steel structures, without

the standard load-spreading component (trumplate) which is replaced by a bearing plate of a

size in accordance with the strength of the steel of the structure (see EN 1993 and EN 1994).

E.2.6 Prestressing for Masonry Structures

Model F (one strand only) and C anchorages are used in the case of masonry structures,

without the standard load-spreading component (trumplate) which is replaced by a bearing

plate of a size in accordance with the strength of the masonry of the structure (see EN 1996).

E.2.7 Prestressing for Timber Structures

Model F (one strand only) and C anchorages are used in the case of timber structures, without

the standard load-spreading component (trumplate) which is replaced by a bearing plate of a

size in accordance with the strength of the timber of the structure (see EN 1995).

‘1 F’ anchorages can be used for timber structures if adequately embedded by means of epoxy

resin.



E.3 PARTICULARITIES OF THE KIT

E.3.1 Possibility of individual tensioning strand by strand

In the case of stressing anchorages for units comprising monostrands, the strands may be

tensioned either collectively with a multistrand jack, or individually with a monostrand jack,

proceeding in several loading stages, if cement grouted before tensioning.

E.3.2 Measurement of friction coefficient and load transfer percentage from stressing

end to the other

This operation is possible whenever tensioning from both ends is possible.

E.3.3 Adjustment of prestressing load

In the case of prestressing tendons with monostrands (type GI) or injected with a flexible

filling product (type W), it is possible to adjust the prestressing load at any time during

service life if tendon overlengths have been maintained. The overlengths are protected by an

adequately long protection cap.

E.3.4 Possibility of monitoring prestressing load

When an ‘A n C15 (or C13)’ or ‘AD n C15 (or C13)’ anchorage uses a threaded block, the

load in the tensile element can be monitored with a special ring jack installed between the

anchor block threaded ring and the anchorage trumplate.

E.3.5 Possibility of detensioning

A non-grouted tendon can be detensioned with a monostrand jack and a detensioning tool if

the strand overlengths have not been cut off.

If the strands have been cut off, the tendon can only be detensioned by heating the strands at

wedges location with a blow torch, one by one. Special precautions must be taken at the other

end to contain any strand expulsion within special protective systems.

E.3.6 Possibility of re-threading a new tendon after detensioning

Once detensioning has been performed as described in paragraph E.3.5, and on condition that

both ends can be easily accessed, a tendon can be replaced without concrete demolishing.

In the case of tendons with type CI couplers, this operation is possible only for the primary

part of the tendon, before concreting of the secondary part.

When the prestressing tendon consists of monostrands, each strand can be replaced by a

strand of the same sectional area if the alignment of the tensile element is straight or slightly

deviated, and by a strand of smaller sectional area in other cases. When a new strand is

threaded in, a protective product of the same quality as that of the strand replaced must be

introduced into the individual sheath left in place.



E.3.7 Prestressing tendon allowing for load monitoring, retensioning, and replacement

without damage to the duct

An unbonded prestressing tendon is fitted with a model C or B anchorage with standard

wedges extended by a clamping length mounted on a common retaining plate (drawing 1).

The entire tendon is retensioned after pulling on the overlength and inserting a special bearing

ring adapted to the jack. Detensioning is made possible by the wedge-retaining plate which

prevents wedge assemblies being pulled back into the anchorage when the tendon is

detensioned. Strand overlengths are retained (jack gripping length plus any elongation) and

are protected by a special long cap injected with flexible filling material (drawing 39).

E.3.8 Temporary or permanent caps

Caps can be fitted to anchorage types A, AD and NB.

E.3.9 Equitension

In the case of a prestressing unit with model C anchorages, when it is to be ensured that the

initial length of each strand is the same prior to tensioning, a pre-tensioning operation can be

carried out with the equitension jack. It has as many tensioning chambers as there are strands

to be tensioned, and takes up any slack in the strands individually.

E.4 FORCES OF PRESTRESSING TENDONS

Maximum forces beneath the anchorage during tensioning, F0, must be taken from standards

or regulations in place of use.

Values shown in the following table, comply French regulations which are identical to the

values recommended by Eurocode2.

The number of strands in a tendon may be decreased either by reducing the number of drilled

holes in the anchor block (special order to factory) or by leaving out strands in the anchorages

or couplers. In both cases the strands are placed in the best possible symmetrical manner. The

provisions for tendons with completely filled anchorages and couplers also apply to partially

filled ones.



Tensile Strength

(N/mm²) 1770 1770 1860 1860 1860 1860

Diameter (mm) 15,3 15,7 12,5 12,9 15,3 15,7 N

um

ber

of

Str

an

ds

1 196 211 137 148 206 221

2 392 421 274 295 412 443

3 589 632 410 443 618 664

4 785 842 547 590 824 886

5 981 1053 684 738 1031 1107

6 1177 1264 821 886 1237 1328

7 1373 1474 958 1033 1443 1550

9 1766 1895 1231 1328 1855 1993

12 2354 2527 1642 1771 2473 2657

13 2551 2738 1778 1919 2679 2878

15 2943 3159 2051 2214 3091 3320

19 3728 4001 2599 2804 3916 4207

22 4316 4633 3010 3247 4534 4871

25 4905 5265 3420 3690 5153 5535

27 5297 5686 3694 3985 5565 5978

31 6082 6529 4241 4576 6389 6863

37 7259 7792 5062 5461 7626 8192

42 7416 7862 5107 5510 7684 8265

48 8475 8985 5836 6297 8793 9446

55 10791 11583 7524 8118 11336 12177

Table 5. Maximum Force with Stressing Limit Fo = min{0,8 Fpk,0,9 Fp0,1%} acc. Eurocode 2 and

prEN 10138-3:2006 (only informative)



F – ANCHORAGES

Freyssinet active anchorages are based on the wedge principle and use the Freyssinet T and B

wedges T15, T13 or B13 when relevant. Each wedge is anchored in a conical hole of the

anchor head, which is either a steel block for anchorage models C, or a cast iron part for

strand connectors and for anchorage models F, B and X. Depending on situations, the

anchorage block seats on a cast iron load spreading part, called trumplate, or on a steel plate

for structures other than concrete ones, the dimensions of which depend of the strength of the

structure.

F.1 DESCRIPTION OF ANCHORAGE COMPONENTS

Main dimensions are given on the drawings in Annex K.

F.1.1 Anchorage Wedge

The Freyssinet anchor wedge is a conical one-use wedge, consisting of three matching

wedges held together by a circlip. Three models of wedges are available:

- the T13 wedge used with T13 and T13S strands for C, F and X anchorages (drawing 2),

- the B13 wedge used with T13 and T13S strand for B anchorage (drawing 3),

- the T15 wedge used with T15 and T15S strands for B, C, F and X anchorages (drawing

1),

Its internal diameter is adapted to the strand diameter: either T15/T15S (T15wedges), or

T13/T13S (T13 and B13 wedges).

Anchorage wedges are precision machined from hot-rolled or cold-drawn rods of cement steel

defined by reference to standard EN 10084 and are case hardened. The steel grade

is 16MnCr5.

F.1.2 Anchorage Swage

Internal fixed anchorages are made with anchor swages made by swaging a tubular section

enclosing a spiral spring onto each strand using a specific Freyssinet jack. There are two

standard versions and a compact version:

- T13D swage is used with T13 and T13S strands

- T15D swage is used with T15 and T15S strands

- T15DC compact swage is used with T15 and T15S strands.

Swages are turned from hot-rolled bars of tempered and quenched structural alloy steel

defined in reference to standard EN 10083-1. The used grades are 34CrMo4 and 36CrNiMo4.



F.1.3 Steel Anchor Blocks

F.1.3.1 Model C Anchor Blocks and multistrand steel couplers

Model C anchorage heads and multistrand steel couplers are circular steel blocks cut out of

hot-rolled bars with machined conical holes cut out of hot-rolled bars. These anchorage

blocks have a strength grade determined by the nominal ultimate tensile strength 650 MPa.

It is made from a non-alloy quenched and tempered structural steel, defined by reference to

standard EN 10083-1 (C45).

Note 1: electrically isolated anchorages may be made with blocks of larger dimensions than

the standard blocks in order to reduce compressive strength on the electrical isolation plate .

Note 2: blocks for type ‘NB’ embedded anchorages are made with cylindrical holes.

Note 3: when an external thread is necessary for monitoring prestressing load, the anchor

block shall have a larger diameter in order to cut the thread outside the original anchor block

size.

F.1.4 Castings for Anchorages

F.1.4.1 Model F, B and X Anchorages

The bodies of model F and X anchorages are made of spheroidal graphite cast iron defined by

reference to standard EN 1563. The grade is EN-GJS-500-7.

Model B anchorage heads are spheroidal graphite cast iron ( GJS 800-4) defined by reference

to standard EN 1563.

F.1.4.2 Individual strand connectors type P

The body of the type P strand connector is made of bainitic spheroidal graphite cast iron

defined by reference to standard EN 1564. The grade is EN-GJS-1000-5.

F.1.4.3 Load Spreading Parts or Trumplates

The trumplates of type ‘NB n C15 (or C13)’, ‘CI n C15 (or C13)’ and ‘C n C15 (or C13)’

anchorages are identical to those of type ‘A n C15’ anchorages. Trumplates of type

‘AD n C15 (or C13)’ differ from those of type ‘A n C15 (or C13)’ anchorages only in their

internal shape which allows for placement of a plastic trumpet and a seal. These trumplates

can be used either for type ‘AD n C15 (or C13)’ or ‘A n C15 (or C13)’

Trumplates are castings of:

- grey cast iron defined in reference to standard EN 1561, for C Models up to size 13C15;

the grade is EN-GJL-250; or

- spheroidal graphite cast iron defined in reference to standard EN 1563, for C Models

above size 13C15 and B models ; grade is EN-GJS-500-7. For fatigue purposes, plastic

sleeves are installed into the B model trumplates.



F.1.4.4 Model C Anchorage Caps

Anchorage caps are generally castings of:

- grey cast iron defined in reference to standard EN 1561; the most commonly used grade is

EN-GJL-250; or

- spheroidal graphite cast iron defined in reference to standard EN 1563; the most

commonly used grade is EN-GJS-400-15.

F.1.5 Conditioning and Corrosion Protection

Except for anchorage wedges, all uncoated components are packaged in sealed containers, are

rust-free and slightly oiled.

Anchorage wedges are packaged in white buckets. They are suitably protected against

oxidation. The buckets containing type T15 wedges are colour-coded differently to those of

type T13 and B13 wedges.

Optionally, the following reinforced corrosion protection is available:

- the anchor blocks of model C anchorages may be corrosion protected by bichromate and

zinc treatment in accordance with standard EN 12329, except for the wedge housings;

- the cast-iron anchorage components of model F, B and X anchorages and the trumplates of

model C anchorages may be zinc coated to a thickness of at least 70 μm by the hot-dip

process in accordance with standard EN ISO 1461, except for the wedge housings;

- the cast-iron anchorage component of the model X anchorage may be coated with

polyamide, except for the wedge housings.

F.1.6 Characteristics of Plastic Parts

F.1.6.1 Plastic Trumpets

Type ‘AD n C15 (or C13)’ external-prestressing anchorages are fitted with polyethylene (PE)

trumpets.

F.1.6.2 Electrical Isolation Plates

Electrically isolated anchorages are fitted with an electrical isolation plate between the

anchorage block and the trumplate. The plate is generally a glass-reinforced thermosetting

resin.

F.1.6.3 Plastic Caps

Plastics caps are made from polyolefin.



F.2 RECOMMENDATIONS FOR USE OF ANCHORAGES

Regulations valid at place of use shall be considered.

Bursting steel is fixed to general reinforcing bars at locations given in this ETA.

Tightness at connection between anchorage and duct is realised either by adhesive tape or

heat-shrink sleeves. For F and B anchorage models used with monostrands the sealing

between anchorage and monostrands is realised by means of a mastic plug.

F.2.1 Stressing Anchorages

Size of anchorage reservation and clearance for placing the stressing jack should be checked

at the design stage (see drawings 42 to 54).

F.2.2 Model X Anchorages

Loop tendons are stressed simultaneously at both ends by means of single-strand jacks

(see drawings 55 and 56).

F.2.3 Anchorages for External Prestressing

Exchangeable external prestressing tendons injected with cement grout is realised by means

of a double duct at deviation or anchoring points :

A minimum gap of 10 mm between the two ducts is required.

External shuttering tube, generally out of steel,

Tendon duct, continuous between anchorages (see drawing 17)

F.2.4 Embedded Fixed Anchorages Model NB

Model «NB n C 15» anchorages consist of an anchor block with cylindrical holes and swages.

Type T13D swage is used for T13 and T13S strands, and type T15DC for T15 and T15S

strands.

Swages are realised before concreting and maintained in position with a locking template.

F.2.5 Fixed Couplers

The prestressing force of the secondary tendon at the coupler shall not exceed that of the

primary cable.

F.2.5.1 Multi-Strand Model CI with Type P Strand connectors and Multi-Strand Model

CU steel couplers

The secondary cable is connected to the primary cable by means of type P strand connectors

or CU multistrand steel coupler. The complete assembly is covered with an overall cap :

at one end the cap is fixed to the primary trumplate. A flexible seal provides

watertightness during concreting and grouting.

at the other end the cap is formed as a trumpet to allow its connection to the second phase

cable duct.



F.2.6 Movable Couplers Model CM with Type P Strand connectors

Each strand of the primary cable is connected to the corresponding strand of the secondary

cable by means of a type P strand connector. The complet assembly is covered with a cap

ensuring watertightness during concreting and grouting; and eliminating possible effort

transfer through the cap during tensioning of the coupled secondary tendon. This cap must

allow for the elongation of first phase cable and the resulting displacement of strand

connectors. In practice, the cap length is therefore adapted to each case.

F.2.7 Case of Monostrands

When directly embedded in the concrete structure, without overall duct, monostrands are

fixed on supports arranged within the general steel reinforcement. In case of large cable units

exceeding 6 monostrands, monostrands should be arranged in groups of 3, the distance

between each of them being sufficient to allow a correct concreting (see drawing 16).

When monostrands are placed in a general duct (see drawings 13 to 15), the duct is injected

with cement grout and tensioning is done after the grout has reached a compressive strength

of 10 MPa.

When multi-strand anchorages are used, the precise arrangement of strands in the anchor zone

during concreting or injection of duct is secured by the use of a temporary stuffing box

(drawing 40). After removal of the stuffing box, sheath ends of strands are removed in order

to install the anchorage block, stress the tendon and inject the anchorage area with soft

product (wax or grease).

F.2.8 Electrically Isolated Tendons

The envelope of electrically isolated tendons consists of plastic ducts with thermo-shrink PE

connections. In particular multi-strand fixed couplers type «CI n C 15 EI» and movable

couplers type «CM n C 15 EI» are isolated in a PE or PP cap. An isolating plate is inserted

between the trumplate and the anchor block before stressing.



G – TENSILE ELEMENTS AND DUCTS

G.1 TENSILE ELEMENTS

In absence of European standards on prestressing steel, strands complying with national

provisions and with characteristics given in G.1.1 and table 6 shall be used.

G.1.1 Standard Designation of Strands

Tensile elements consist of:

Either strands with nominal diameter 12,5 mm or 12,9 mm, tensile strength 1770 MPa

or 1860 MPa, designated respectively Y1770 (or Y1860) S7 12,5 (or 12,9) in the

European standard prEN 10138-3, and hereafter named T13 or T13S or more simply

T13,

or strands with nominal diameter 15,3 mm or 15,7 mm, tensile strength 1770 MPa or

1860 MPa, designated respectively Y1770 (or Y1860) S7 15,3 (or 15,7) in the

European standard prEN 10138-3, and hereafter named T15 or T15S or more simply

T15.

These strands may also be ordered according to national standards applicable in the country

concerned, e.g in France to XPA 35-045-3 standard for bare strands (as long as the EN 10138

standard is provisional).

Monostrands are covered in France by the XP A 35-037 standard, and designated by S 12,5

(or 12,9 or 15,3 or 15,7) 1770 (or 1860) – A + (Z or ZA) + G + P. The G attribute means

protection with grease and P means sliding, i.e. the strand is free to slide in its individual

sheath, even embedded in concrete, allowing for its stressing without any bond to the concrete

of the structure.

G.1.2 Maximum Force in Strand

The maximum stressing force F0 at anchorage indicated in the following table for a single

strand has been calculated in accordance with Eurocode 2. It must be adapted to the

applicable national regulations.



Tm D S Fpk M Fp0.1% Fo To

MPa mm mm² kN kg/m kN kN N/mm²

1770 12.5 93 165 0.726 145 130.5 1416

1770 12.9 100 177 0.781 156 140.4 1416

1770 15.3 140 248 1.093 218 196.2 1416

1770 15.7 150 266 1.172 234 210.6 1416

1860 12.5 93 173 0.726 152 136.8 1488

1860 12.9 100 186 0.781 164 147.6 1488

1860 15.3 140 260 1.093 229 206.1 1488

1860 15.7 150 279 1.172 246 221.4 1488

D Nominal diameter

Fpk Characteristic value of maximum load (equal to fpk.Ap in Eurocode 2 or Fm in prEN)

Fp0.1% Characteristic value of load at 0,1% elasticity limit

Fo Indicative maximum force at stressing anchorage: Fo = Min { 0,8 Fpk ; 0,9 Fp0.1%}

m Nominal mass per metre

S Nominal area

To Tensile stress under Fo

Tm Tensile stress at break

Table 6. Maximum Force at Stressing Anchorage for a Single Strand acc. to Eurocode 2 and

prEN 10138-3:2006 (only informative)

G.2 DUCTS

The Freyssinet prestressing kit for post-tensioning may be used with different types of duct

depending of the project and the use categories of tendons.

The typical internal diameter of ducts is defined on the drawings in Annex K for each

anchorage model, which may be increased if required by the project specifications or the

national regulations. In the case of prefabricated cables threaded in one operation, the duct

internal diameter may be increased in sections with large deviation curvature to facilitate

threading.

G.2.1 Steel Strip Sheaths

Steel strip sheaths are either circular or oval, generally corrugated to ensure a mechanical

bond with the concrete. The overall external dimensions of steel strip sheaths are about 6 mm

larger than the internal dimensions because of corrugation. This must be taken into account in

the design.

Steel strip sheaths are made from cold formed (if corrugated) steel strip wound helically and

welded along the edges or locked together by crimping.



G.2.1.1 Circular Steel Strip Sheaths

Sheaths are purchased according to EN 523 standard. There are two categories of sheath:

‘normal’ or ‘reelable’ category 1 sheath and ‘rigid’ category 2 sheath. Rigid sheath reduces

the wobble effect and is stronger, but is less easy to shape (curve) by hand.

Diameter

(mm) 25-35 35-45 45-55 55-65 65-75 75-85 85-

100

100-

130

130-

160

min.

thickness

of sheath

(mm)

Category

1 0,25 0,25 0,30 0,30 0,35 0,35 0,40 0,40 0,40

Category

2 0,40 0,45 0,45 0,50 0,50 0,60 0,60 0,60

Table 7. Thickness of Steel Strip Sheaths

Sheath sections are connected together with helical sleeves screwed onto the ends of the

sheaths. The watertightness at connections is obtained by adhesive tape or heat-shrink sleeves.

G.2.1.2 Oval Steel Strip Sheaths

Model F and B tendons are generally used together with oval or so-called ‘flat’ sheaths. These

are oblong sheaths with a stiffening corrugation. Lengths of sheaths are connected by use of

sleeves of the same shape. The watertightness at connections is obtained by adhesive tape or

heat-shrink sleeves.

G.2.1.3 Option: Galvanisation

On request and if allowed by the applicable national regulations, the sheaths may be hot-dip

galvanised or electro zinc-plated.

G.2.1.4 Option: Factory-applied LFC Lubrication (‘Low Friction Coefficient’)

On request, crimped sheaths may be made out of soap-lined phosphated steel strip in order to

reduce the friction coefficient between strands and duct during tensioning.

G.2.2 Corrugated Plastic Ducts

Plastics ducts may be of high-density polyethylene (HDPE) or polypropylene (PP). They

comply with Appendix C.3 of ETAG 013 and meet the requirements of fib technical bulletin

‘Corrugated plastic ducts for internal bonded post-tensioning’.

The ducts may be circular or flat, but are always corrugated to ensure a bond with the

concrete. The overall outer dimensions of a corrugated plastic duct are about 13 mm larger

than its internal dimensions because of corrugation. This must be taken into account in the

design.

Plastics ducts are sensitive to wear induced by movement of the strands in the duct during

tensioning. Duct thickness is selected in accordance with the severity of the tendon alignment

(total length and radii of curvature).

Special precautions must be taken if the temperature of the surrounding concrete is likely to

exceed 60°C during setting or if the external pressure is likely to exceed 0,5 bar (e.g.

depending on the application and the concrete height).



Duct sections are connected by a sleeve of the same design as the basic sheath placed onto the

sections to be joined together. Watertightness at connections is obtained by adhesive tape or

by heat shrink sleeves coated on the inside with a hot-melt resin which are shrunk onto the

sheath with a hot-air blower. The dimensions of the heat-shrink sleeves are chosen so as to

have a residual thickness of at least 1,5 mm after shrinking.

G.2.2.1 Plyduct

The Plyduct sheath is circular, made out of a polyethylene or polypropylene strip. It is

2,5 mm thick for duct diameters up to 95 mm and 3,0 mm thick for larger diameters. Sheath

sections are connected by a sleeve of the same design as the basic sheath screwed onto the

sections to be joined together. Watertightness at connections is obtained by heat-shrink

sleeves coated on the inside with a hot-melt resin which are shrunk onto the sheath with a hot-

air blower. The dimensions of the heat-shrink sleeves are chosen so as to have a residual

thickness of at least 1,5 mm after shrinking.

G.2.2.2 Flat Ducts

Model F and B tendons can be used with flat plastic sheaths of high-density polyethylene

(HDPE) or polypropylene (PP). Duct sections are connected by a sleeve of the same design as

the basic sheath placed onto the sections to be joined together. Watertightness at connections

is obtained by heat-shrink sleeves coated on the inside with a hot-melt resin which are shrunk

onto the sheath with a hot-air blower. The dimensions of the heat-shrink sleeves are chosen so

as to have a residual thickness of at least 1,5 mm after shrinking.

G.2.3 Smooth Steel Pipes

The steel pipes used as prestressing ducts are generally chosen in compliance with one of the

following standards: EN 10305-3 (welded cold-sized tubes), EN 10216-1 (seamless tubes),

EN 10217-1 (welded steel tubes) or prEN 10219 (fine-grain steel pipe).

Pipes can be zinc-coated by hot-dip galvanising in accordance with standard EN ISO 1461, if

allowed by the applicable national regulations.

G.2.4 Smooth Plastic Pipes

G.2.4.1 Pipes for External Prestressing

Pipes for external prestressing are made of high-density polyethylene (HDPE) and purchased

in reference to standards EN 12201-1 and 2, without consideration of properties affecting

water quality.

The polyethylene used is PE80 or PE100. Nominal pressure class (table 2 of standard

EN 12201-2) is chosen as follows:

Class PN4.0 at least, for injection prior to tensioning of monostrands,

Class PN6.3 at least, for injection at ambient temperature,

Class PN10 at least, for injection at temperatures exceeding 60°C (wax injection).



For guidance, pipes may be chosen from the following table:

EN 12201-2 PE 80 PE 100

Series Low pressure Pressure Pressure

PN** 6.3 10 10

SDR 21 13.6 17

Nominal external

diameter Thickness Thickness Thickness

(mm) (mm) (mm) (mm)

50 3.7* 3.7

63 4.7* 4.7

75 5.5* 5.5

90 6.6* 6.6

110 5.3 8.1

125 6.0 9.2

140 6.7 10.3

160 7.7 11.8

180 8.6 10.7

200 9.6

SDR: ratio of external diameter to nominal wall thickness

* these pipes have not standardised dimensions

** PN values are based on a global service factor C = 1.25

Table 8. Dimensions of Smooth HDPE Tubes

Ducts for external prestressing are delivered in straight lengths. The most common lengths are

6 and 12 m. Lengths of pipe are connected by mirror welding or by means of polyethylene

sleeves electro-welded.

G.2.4.2 Pipes for Hoop Tendon Anchorages

Hoop prestressing tendons are used with continuous polyethylene or polypropylene pipes,

generally extruded and supplied on reels. These pipes are smooth or indented for centering the

strand in its duct.

G.2.5 Liaseal Duct Connector

The Liaseal duct connector is a polyolefin component providing a sealed connection

between lengths of duct that is used in the construction of precast concrete segments for

bridge construction (drawing 34). Used in conjunction with the Plyduct duct, the Liaseal

connector makes a continuous, leakfree plastic duct crossing the match-cast joints between

segments.



G.3 CABLE LAY-OUT

G.3.1 Alignment at Anchorage

Close to anchorages the duct must guide the tensile element so that its strands bear against the

deviation zone of the trumplate and enter the holes in the anchorage head at the correct angle:

in practice the cable lay-out must be straight on a length of at least 6 times the duct internal

diameter between the trumplate end and the start of the curved section.

G.3.2 Curvature Radii

G.3.2.1 Internal Prestressing

In the absence of more restrictive national specifications, the minimum curvature radius is

defined as follows:

Strand Type Duct Type Minimum Curvature

Radius

Bare Strand

Flat duct Steel 100 x internal diameter 2

Plastic 100 x internal diameter 2

Circular duct Steel 100 x internal diameter

Plastic 100 x internal diameter

Tube Steel 3,0 m

Monostrand

Strands directly

incorporated in concrete

(in group of three strands

maximum) or placed in a

duct injected with cement

grout before tensioning

Deviation

1,7 m for T13 1

2,5 m for T15 1

Single strand

Deviation 2,5 m

Dead anchorage

(180° hoop) 0,6 m

1 according to ENV 1992-1-5:1994 2 flat duct dimension in the considered direction

Table 9. Minimum Curvature Radius for Internal Prestressing

In the case of bonded prestressing, the minimum radius of steel tubes can be reduced down to

20 times the internal diameter, assuming that:

- the resulting radius is not less than 1,1 m for T13 strands and 1,3 m for T15 strands,

- the tensile stress does not exceed 70% of strand guaranteed tensile strength where the

radius is less than 3,0 m,

- the sum of angular deviations along the cable is less than 3/2 radians,

- the sharply curved zone is considered as a dead anchorage if the angular deviation exceeds

/2 radians.



G.3.2.2 Removable External Prestressing

In the absence of more restrictive national specifications, the minimum curvature radius in

deviators, normally made out of curved steel pipes, is defined as follows:

Tendon Minimum Curvature

Radius at Anchorages

Minimum Curvature

Radius in Deviators

7C15 3,0 m 2,0 m

12C15 3,5 m* 2,5 m*

19C15 4,0 m* 3,0 m*

27C15 4,5 m 3,5 m

37C15 5,0 m* 4,0 m

* : according to ENV 1992-1-5:1994

Table 10. Minimum Curvature Radius for External Prestressing

G.3.3 Support Distances and Tolerances

The maximum distance between duct supports is 1,0 m for straight sections or with high

curvature radius and 0,5 m for sections with small radius. In the case of smooth steel pipes, at

least one support at each elementary length shall be placed but the distance shall not exceed

3 m.

Any bulging along the duct must be balanced by appropriate reinforcement arrangement.

Similarly, the spacing of supports and the attachment of the duct must take account of the

buoyancy effect in fresh concrete.

Flat ducts are more sensitive to accidental crushing before tendon threading than circular

ducts. For this reason the tendons should be threaded into the duct before concreting. If it is

not possible to thread the tendons before concreting, measures must be taken to protect the

duct from crushing, or the ducts must be threaded with temporary “dummy” strands which

will be removed before the real tendons are threaded.

When ducts cross over each other in layers, contact between ducts should be avoided, and it

may be advisable to strengthen the area of intersection with a half-sleeve in order to prevent

any risk of communication between ducts during cement grouting.

In the case of corrugated plastic sheaths, a plastic half-shell must be placed between the duct

and its support in all areas where tendon is deviated.

For monostrands directly incorporated in concrete, sheath punching at support must be

checked.

The tolerance on the position of tendons in concrete parts must meet the requirements of ENV

13670-1 standard. Special attention must be given to tendon breakout induced by deviated

cables near an outside surface: the local positioning tolerance will have to be determined in

accordance with the lay-out of the passive reinforcement.



H – TENSIONING

H.1 TENSIONING EQUIPMENT

Freyssinet equipment is covered by an EC declaration of conformity for new or rental

equipment.

Clearance for jacks at tensioning end must be made available in accordance with drawings 42

to 56. This clearance must remain available during service life of the structure if force

adjustment, load monitoring or replacement of tendon has been foreseen.

For multistrand steel couplers, these clearance lengths given should be increased by 100 mm.

H.2 PARTICULAR RECOMMENDATIONS

H.2.1 Tendons with Couplers

Tensioning of secondary cables shall be such as to avoid the force at coupler end to exceed

that of the primary cables.

H.3 RECOMMENDATIONS FOR TENSIONING AND CONTROL

H.3.1 General Method for Tensioning

Tensioning is done in accordance with the Freyssinet procedures, the specifications of

ETAG 013, CWA 14646, ENV 13670-1 and applicable national regulations.

H.3.2 Measurements of Stressing Forces

Force readings must take into account calibration of tensioning equipment and losses due to

friction in anchorages as given in the following table:

Bare Strands Monostrands

Anchorage Model Min. Max. Min. Max.

3 to 13 C 15 2 % 3 % 1 % 2 %

19 to 55 C 15 and 25 CC 15 2,5 % 3,5 % 1 % 2 %

1 F 13/15 1 % 2 % 0 % 1 %

3 to 4 F 13/15 1 % 2 % 1 % 2 %

3 to 5 B 13/15 2 % 3 % 1 % 2 %

1 to 2 X 15 1 % 2 % 0 % 1 %

Table 11. Friction Loss in Anchorages



I – PROTECTION OF TENDONS

I.1 LUBRICATION AND TEMPORARY PROTECTION

Temporary protection of tensile elements is obtained by factory-applied soluble oil.

If storage of strands on site is longer or if tendon injection cannot be done in due time after

tensioning (delay exceeding four weeks), this temporary protection must be regularly

renewed, in conformity with applicable specifications. This lubrication may also be used to

reduce friction coefficient of cable inside duct.

I.2 FILLING MATERIALS USED

I.2.1 Cement Grout

Cement grout is a stable, uniform mix of Portland cement, additives and water obtained by a

mechanical mixing process. It is screened and kept agitated in a storage tank until injected

into the duct.

Freyssinet prestressing tendons can be injected with:

either a common grout complying with the requirements of European standards

EN 447 (requirements for common grout) and EN 445 (test methods). The grout

setting can be retarded to provide a longer groutability,

or a special grout, as per the requirements of paragraph C.4.3 of ETAG 013.

I.2.2 Wax

The wax for injecting prestressing tendons shall be a petroleum wax meeting the requirements

of paragraph C.4.2 of ETAG 013.

I.2.3 Grease

The grease for Freyssinet prestressing tendons shall be a mineral-oil-based grease meeting the

requirements of paragraph C.4.1 of ETAG 013.

I.3 INJECTION EQUIPMENT

Mixers, wax melting units, and pumps supplied by Freyssinet for injecting tendons are all

subject to an EC declaration of conformity with the applicable regulations governing new or

rented equipment.



J – MECHANICAL AND GEOMETRICAL CONDITIONS OF USE

J.1 FRICTION LOSSES AND ELONGATIONS

J.1.1 Friction in Tendons

The coefficients of friction (μ) and of wobble (k), as defined in European standard EN1992-1-

1 to obtain the prestressing force with the equation , vary in accordance with uses

(internal or external prestressing, standard strands or monostrands), the type and stiffness of

ducts (steel or HDPE strip sheath or pipe), surface treatments, lubrication of the strands,

whether with soluble oil or grease.

The acceptable variation of the coefficient of friction is usually 25%. The coefficient of

friction can rise significantly in deviation zones with a curvature radius less than 6 metres.

The coefficients in the following table are for information only (and must be adapted to each

project).

Use

Duct Type

Friction Coefficient

(rad-1) Wobble factor k

(rad/m) Lubricated

Strand Unlubricated

Strand

Internal

Prestressing

Corrugated steel sheath 0,17 0,19 1 0,007 1

LFC 3 Corrugated steel

sheath 0,10 0,12 0,007 1

Corrugated plastic sheath 0,10 0,12 0,007 1

Steel pipe 0,16 0,24 0,007 1

External

Prestressing

HDPE pipe 0,10 0,12 0

Steel pipe 0,16 0,24 0

Unbonded

Internal

Prestressing

Single Monostrands 0,05 2 0,007 2

Group of Pre-Grouted

Monostrands 0,05 0,012

1 as per standard EN 1992-1-1: 2004

2 as per standard ENV 1992-1-5: 1994

3 Freyssinet phosphated duct

Table 12 Friction and Wobble Coefficient



J.1.2 Parameters for Evaluation of Elongation during Stressing

J.1.2.1 Pull-In at Wedge Blocking

At end of stressing the jack is released and the wedges are pulled-in into the anchorage block

to anchor the strands. Freyssinet jacks can allow a hydraulic lock-off to reduce the wedge

pull-in .

The elongation loss with or without hydraulic lock-off shall be accounted for in tensioning

calculations by using the values given in the following table.

Stressing Jack with hydraulic blocking without hydraulic blocking

Strand diameter T13 T15 T13 T15

Pull-in at

stressing

anchorage

mm

min 4 4 6 6

mean 5 6 7 8

max 6 8 8 9

Table 13 Wedge Pull-In at Stressing Anchorages

J.1.2.2 Pull-In at Passive Anchorages

The pull-in value at passive anchorage creates a translation of the cable and increases the

elongation at stressing end. This value must be deduced from the measured elongation at each

stressing step.

The mean pull-in values at passive end are:

T13 strand: 5 mm,

T15 strand: 6 mm.

J.1.2.3 Pull-in within Type P Coupling Units

The mean pull-in values within P strand connectors are as follows:

T13 strand: 10 mm,

T15 strand: 12 mm.

J.2 GEOMETRICAL CONDITIONS OF USE

J.2.1 Clearance behind Anchorages

Behind each anchorage a clearance must be reserved to allow for:

Installation of wedges,

Placing of stressing jack,

Sufficient protection cover of cable end after cutting-off of strand overlengths,

Installation of temporary or permanent cap, if necessary.



In the case of an active anchorage the necessary clearance for jack placing and actioning is

described in the drawings given in Part K thereafter.

For external passive anchorages a minimal clearance of 500 mm allows the installation of

wedges on protruding strands.

For CU couplers clearance lengths should be taken from the C anchorage blocks increased by

100 mm.

J.2.2 Lateral Cover and Distances

Anchorages must have a sufficient edge distance and be separated from each other by a

minimum centre distance. These distances are derived from reference dimensions a and b of

the test specimens.

In what follows, it is considered that anchorages are positioned relative to two orthogonal

directions x and y, with the smaller dimension of the trumplate aligned along axis y.

Notations:

A, B: plane dimensions of the trumplate (A ≥ B),

a, b: side lengths of test specimen (a ≥ b),

x, y: minimum centre distance between two anchorages in the structure in x- and y-

directions,

x’, y’: minimum edge distance between anchorages and the closest external surface in

x- and y-directions,

fcm,o: mean compressive strength measured on cylinder required before tensioning.

Dimensions x and y shall satisfy the following conditions:

x A + 30 (mm)

y B + 30 (mm)

x . y a . b

x 0,85 a

y 0,85 b

x’ 0,5 x + concrete cover – 10 (mm)

y’ 0,5 y + concrete cover – 10 (mm)

y y y’

x’

x

x’

x

y’ y’

A

B B

A



The values of a and b are given in the table below for three different concrete compressive

strengths fcm,o.

a = b (mm)

fcm,o (MPa)

Unit 24 44 60

3 C15 220 200 180

4 C15 250 220 200

7 C15 330 260 240

9 C15 380 300 280

12 C15 430 320 300

13 C15 450 340 310

15C15 480 360 340

19 C15 530 400 380

22 C15 590 430 410

25 C15 630 460 440

27 C15 650 480 470

31 C15 690 520 500

37 C15 750 580 540

42C15 800 620 580

48C15 860 660 620

55 C15 1070 750 690

Table 14 Minimum Edge Distances for C-Model Anchorages

fcm,o (MPa) a (mm) b (mm)

1 F 13/15 22 190 140

3/4 F 13 22 500 160

3/4 F 15 22 390 190

Table 15 Minimum Edge Distances for Model F Anchorages



Strand type

fcm,o (MPa) fcm,o on

cube

(MPa)

unit a (mm) b (mm) Minimum

slab

thickness

(mm)

B13 - T13/T13S 20 22

3B13 300 175 150

4B13 350 200 170

5B13 400 200 170

B15 - T15 22 24

3B15 350 200 170

4B15 400 200 170

5B15 450 220 190

B 15 - T15S 23,5 25,5

3B15 350 200 170

4B15 400 200 170

5B15 450 220 190

Table 16 Minimum Edge Distances for B Anchorages

If the project calls for a value fcm,o other than any of those in the three tables directly above,

the appropriate values of x and y can be determined by interpolation. However, full tension

cannot be exerted when fcm,o is less than the lowest value indicated in tables 14, 15 and 16

(e.g. 24 MPa for model C anchorages).

For partial tensioning or for a tension of less than Min{0.8 Fpk; 0.9Fp0.1%}, the required value

for fcm,o can be determined by interpolation considering that at 50% of the total force, the

required concrete strength can be reduced to 2/3 of the values given in the two tables above

and at 30% of the total force, the required concrete strength can be reduced to 1/2 of the

values given in the same tables.

J.3 BURSTING REINFORCEMENT

In anchorage zone prestressing tendons impose to the structure concentrated forces requiring a

specific arrangement of reinforcement. In case of concrete structures, bursting reinforcement

consists in:

Surface reinforcement,

Anchorage bursting reinforcement,

General reinforcement to equilibrate mechanically the concerned piece within the

structure, the dimensions of which result from the design rules of reinforced concrete.

Anchorage bursting reinforcement as defined thereunder results from load transfer testing.

If required the local zone reinforcement specified in the ETA may be modified for a specific

project design in accordance with national regulations and relevant approval of the local

authorities and of the ETA holder to provide equivalent performance.



or (see

tables)

wfb (wave-form bursting steel)

equivalent stirrups

J.3.1 C-Model Anchorages

J.3.1.1 Cross-laid Wave-form Bars / Stirrups

The diagrams below define the general layout of bursting reinforcement when cross-laid

wave-form bars are used. Each layer has two cross-laid bent bars. For practical reasons, each

bent bar can be replaced by two stirrups of at least equivalent resisting section (see diagram

below).

In the case of several rows of anchorages, as a rule W = L = Lo. In the case of a single row of

anchorages, W is reduced and L is increased, but the minimum value of E shown in the

following table is retained.

General reinforcement not shown General reinforcement not shown

C C C0 C0 C



Wave form bars (wfb) or Stirrups (FeE 235) (B500) Complementary

reinforcement (Stirrups)

Anchor Number

of Layers Co

(mm)

C

(mm) Type

Steel

diameter

d

(mm)

Mandrel

diameter

D

(mm)

min Centre

distance

E

(mm)

Overall

Length

L

(mm)

Pitch

(mm)

Diameter

d

(mm)

Number

3C15 3 100 75 wfb 8 31 90 200 110 8 3

4C15 3 100 75 wfb 8 46 90 230 115 12 3

7C15 3 120 90 wfb 12 74 130 310 120 12 4

9C15 3 120 110 wfb 12 74 140 360 125 14 4

12C15 3 120 120 wfb 14 83 160 410 140 16 4

13C15 3 140 125 wfb 14 88 170 430 130 16 4

15C15 3 150 125 wfb 16 117 180 460 150 16 4

19C15 3 160 125 wfb 16 117 200 520 180 20 4

22C15 3 170 140 wfb 20 118 215 570 130 16 6

25C15 3 200 160 wfb 20 135 220 610 175 20 5

27C15 3 175 170 wfb 20 130 250 630 130 20 6

31C15 4 210 150 wfb 20 130 255 670 140 20 6

37C15 4 250 225 wfb 20 130 270 740 130 25 5

42C15 4 260 230 wfb 20 130 290 780 140 20 6

48C15 4 270 240 wfb 25 160 310 840 200 20 6

55C15 5 290 200 wfb 25 160 340 1050 200 20 6

Table 17 Bursting Steel for fcm,o = 24 MPa



Anchor Number

of Layers Co

(mm)

C

(mm) Type

Steel

diameter

d

(mm)

Mandrel

diameter

D

(mm)

min Centre

distance

E

(mm)

Overall

Length

L

(mm)

Pitch

(mm)

Diameter

d

(mm)

Number

3C15 3 100 75 wfb 8 26 90 190 150 8 2

4C15 3 100 75 wfb 8 31 90 200 250 8 3

7C15 3 120 90 wfb 12 39 130 240 140 10 4

9C15 3 120 110 wfb 12 39 140 290 150 14 3

12C15 3 120 120 stirrups 14 84 160 300 240 14 3

13C15 3 140 125 stirrups 14 84 170 330 120 14 4

15C15 3 150 125 stirrups 16 96 180 350 150 14 3

19C15 3 160 125 stirrups 16 96 200 380 200 16 3

22C15 3 170 140 stirrups 20 120 215 410 160 14 4

25C15 3 200 160 stirrups 20 120 220 440 165 16 3

27C15 3 175 170 stirrups 20 120 250 460 165 16 3

31C15 3 210 190 stirrups 20 120 255 500 210 20 3

37C15 4 250 225 stirrups 20 120 270 600 210 20 4

42C15 4 260 235 stirrups 20 120 290 610 210 20 4

48C15 4 270 245 stirrups 25 150 310 650 200 20 4

55C15 4 290 255 stirrups 25 150 340 730 200 20 4






Anchor Number

of Layers Co

(mm)

C

(mm) Type

Steel

diameter

d

(mm)

Mandrel

diameter

D

(mm)

min Centre

distance

E

(mm)

Overall

Length

L

(mm)

Pitch

(mm)

Diameter

d

(mm)

Number

3C15 2 100 75 wbf 8 26 90 190 150 8 2

4C15 2 100 75 wbf 10 31 90 200 150 8 2

7C15 3 120 90 stirrups 12 39 130 240 180 10 2

9C15 3 120 110 stirrups 12 39 140 290 150 12 3

12C15 3 120 120 stirrups 14 84 160 300 150 12 3

13C15 3 140 125 stirrups 14 84 170 330 135 14 3

15C15 3 150 125 stirrups 16 84 180 330 150 14 3

19C15 3 160 125 stirrups 20 120 200 380 250 10 4

22C15 3 170 140 stirrups 20 120 215 410 240 10 3

25C15 3 200 160 stirrups 20 120 220 440 220 12 3

27C15 3 175 170 stirrups 20 120 250 460 220 14 3

31C15 3 210 190 stirrups 20 120 255 500 220 16 3

37C15 4 250 225 stirrups 20 120 270 550 180 16 3

42C15 4 260 235 stirrups 20 120 290 570 190 16 4

48C15 4 270 245 stirrups 25 150 310 610 200 16 3

55C15 4 290 255 stirrups 25 150 340 670 200 16 4


J.3.1.2 Helical reinforcement

The diagram below defines the general layout of bursting reinforcement when a circular

helical device is used. This arrangement is preferable with isolated anchorages or anchorages

on several rows.

C0



Type Helical bursting steel (FeE 235) (B500) Complementary


Anchor Pitch

(mm)

Diameter

d

(mm)

Number Co

(mm)

External

Diameter

D

(mm)

Pitch

(mm)

Diameter

d

(mm)

Number

3 C 15 50 8 5 40 160 110 8 3

4 C 15 60 10 5 40 190 115 10 3

7 C 15 60 14 6 40 270 120 10 4

9 C 15 70 14 6 40 320 125 12 4

12 C 15 70 14 7 40 370 140 16 4

13 C 15 70 14 7 40 390 130 16 4

15 C 15 70 14 7 40 420 150 16 4

19 C 15 60 16 8 40 470 180 20 4

22 C 15 70 16 8 40 510 130 20 5

25 C 15 80 20 7 40 550 150 20 5

27 C 15 80 20 7 40 570 160 20 5

31 C 15 80 20 7 40 600 140 20 6

37 C 15 90 20 7 40 660 130 25 5

42 C 15 90 20 7 40 740 140 25 5

48 C 15 90 25 8 40 800 140 20 6

55 C 15 100 25 9 40 930 200 20 6

Table 20 Helical Bursting Steel for fcm,o = 24 MPa



Anchor Pitch

(mm)

Diameter

d

(mm)

Number Co

(mm)

External

Diameter

D

(mm)

Pitch

(mm)

Diameter

d

(mm)

Number

3 C 15 50 8 5 40 150 150 8 2

4 C 15 60 10 5 40 160 250 8 3

7 C 15 60 12 6 40 200 140 10 4

9 C 15 70 14 6 40 250 150 12 3

12 C 15 50 14 7 40 260 240 14 3

13 C 15 70 14 7 40 290 120 14 4

15 C 15 70 14 7 40 310 200 16 3

19 C 15 60 16 8 40 320 200 16 3

22 C 15 70 16 8 40 350 160 14 4

25 C 15 80 20 7 40 380 165 16 3

27 C 15 80 20 7 40 400 165 16 3

31 C 15 80 20 8 40 420 210 16 3

37 C 15 90 20 9 40 520 210 20 4

42 C 15 90 20 8 40 570 140 25 4

48 C 15 90 25 9 40 610 140 20 4

55 C 15 100 25 10 40 650 250 20 3






Anchor Pitch

(mm)

Diameter

d

(mm)

Number Co

(mm)

External

Diameter

D

(mm)

Pitch

(mm)

Diameter

d

(mm)

Number

3 C 15 50 8 5 40 150 150 8 2

4 C 15 60 10 5 40 160 150 8 2

7 C 15 60 12 6 40 200 160 10 3

9 C 15 70 14 6 40 250 200 12 2

12 C 15 50 14 7 40 260 200 12 2

13 C 15 70 14 7 40 290 135 12 3

15 C 15 70 14 7 40 300 150 12 4

19 C 15 60 16 8 40 320 250 10 4

22 C 15 70 16 8 40 360 240 12 3

25 C 15 80 20 7 40 390 220 10 3

27 C 15 80 20 7 40 400 220 12 3

31 C 15 80 20 8 40 420 220 14 3

37 C 15 90 20 9 40 470 180 16 3

42C15 90 20 8 40 510 140 20 4

48C15 90 20 9 40 580 140 20 4

55 C 15 100 25 9 40 600 180 16 3


Note : the number of turns must be increased by one and a half if the last turn is open.

J.3.2 Model F Anchorages

J.3.2.1 Anchorage A 1F13 and A 1F15

Bursting reinforcement, steel quality FeE 235 for fcm,o 22 MPa

10



J.3.2.2 Anchorage A n F13


type q’ty L1 L2 L3 h

1 12 8 320

2 3 8 320 20 160 140

3 3 8 320 20 160 140

see bar types below

A 3F13

A 4F13



J.3.2.3 Anchorage A n F15


type q’ty L1 L2 L3 h

2 2 8 350 60 160 160

3 2 8 350 60 160 160

4 4 12 350 160 160

Note: 2 bars type 1 may be replaced by 1 bar type 4

bar types

A 3F15

A 4F15

see bar types below



J.3.3 Model B anchorages

1 (B500 steel) 2 (B500 steel)

Unit Pitch d N A B Co e C D

3B13 60 8 4 120 200 45 8 120 120

4B13 60 10 6 140 240 45 8 140 160

5B13 60 10 6 140 260 45 8 140 190

3B15 60 10 6 140 240 45 8 140 160

4B15 60 10 6 140 280 45 8 140 190

5B15 60 12 6 140 320 45 10 140 240

Table 23 Bursting steel for Model B anchorage



K – DRAWINGS

57 drawings distributed in 48 pages hereafter.

The drawing 57 is an example of grouting vents possibility.

Documents

European Technical Approval ETA-06/0226 - Freyssinet...The Freyssinet prestressing kit is a post-tensioning kit designed for both internal and external prestressing. A prestressing