Freyssinet Australia Pty Ltd - European Technical ETA 06 ......The Freyssinet prestressing kit is a post-tensioning kit designed for both internal and external prestressing. A prestressing

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www.eota.eu

Cerema ITM 110 rue de Paris 77 171 Sourdun FRANCE

Mail: [email protected] Tel: +33 160 523 131 Web: www.cerema.fr

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European Technical Assessment

ETA 06/0226 of 09/03/2018

Technical Assessment Body issuing the ETA: Cerema

Trade name of the construction product

Système Freyssinet

Freyssinet system

Product family to which the construction product belongs

16 - Post-tensioning kit for prestressing of structures

Manufacturer SOLETANCHE FREYSSINET 280 avenue Napoléon Bonaparte F-92500 Rueil-Malmaison

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

This European Technical Assessment contains

110 pages including 53 pages of Annexes which form an integral part of this assessment.

This European Technical Assessment is issued in accordance with Regulation (EU) No 305/2011, on the basis of

ETAG 013, Edition June 2002, Post-Tensioning Kits for Prestressing of Structures used as European Assessment Document

This ETA replaces

ETA 06/0226, issued on 28/06/2013

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INDEX

1. Technical description of the product ..................................................................................7

1.1 Definition and designation of the product .............................................................................. 7

1.1.1 Definition of the product ............................................................................................................................... 7

1.1.2 Designation of the product ............................................................................................................................ 7

1.2 Components .......................................................................................................................... 8

1.2.1 Strands ....................................................................................................................................................... 8

1.2.1.1 Standard Designation of Strands ............................................................................................................ 8

1.2.1.2 Maximum Force in Strand ...................................................................................................................... 8

1.2.2 Stressing anchorages...................................................................................................................................... 9

1.2.2.1 Structural anchorages model C............................................................................................................... 9

1.2.2.2 Slab anchorages model F ........................................................................................................................ 9

1.2.2.3 Slab anchorages model B ...................................................................................................................... 10

1.2.2.4 Hoop anchorages model X .................................................................................................................... 10

1.2.3 Passive anchorages ...................................................................................................................................... 10

1.2.4 Fixed Couplers CI .......................................................................................................................................... 10

1.2.4.1 Monostrand fixed coupler .................................................................................................................... 10

1.2.4.2 Multistrand fixed couplers .................................................................................................................... 10

1.2.5 Movable couplers CM .............................................................................................................................. 11

1.2.6 Tables: anchorage models and ETA-covered units .................................................................................. 11

1.2.7 Anchorage wedge .................................................................................................................................... 12

1.2.8 Anchorage swage ..................................................................................................................................... 12

1.2.9 Steel anchor blocks: model C Anchor Blocks and multistrand steel coupler ............................................... 12

1.2.10 Castings for anchorage ............................................................................................................................... 12

1.2.10.1 Model F, B and X anchorages ............................................................................................................. 12

1.2.10.2 Individual strand connectors type P ................................................................................................... 13

1.2.10.3 Load Spreading Parts or Trumplate .................................................................................................... 13

1.2.10.4 Model C anchorage caps ..................................................................................................................... 13

1.2.11 Characteristics of Plastic Parts ................................................................................................................... 13

1.2.11.1 Plastic Trumpets ................................................................................................................................. 13

1.2.11.2 Electrical Isolation Plates .................................................................................................................... 13

1.2.11.3 Plastic Caps ......................................................................................................................................... 13

1.2.12 Ducts .......................................................................................................................................................... 13

1.2.12.1 Steel Strip Sheaths .............................................................................................................................. 14

1.2.12.2 Corrugated Plastic Ducts..................................................................................................................... 14

1.2.12.3 Smooth Steel Pipes ............................................................................................................................. 15

1.2.12.4 Smooth Plastic Pipes ........................................................................................................................... 15

1.2.12.5 Liaseal Duct Connector ..................................................................................................................... 16

1.2.13 Other Components..................................................................................................................................... 16

1.3 Design ................................................................................................................................. 17

1.3.1 Maximum force ............................................................................................................................................ 17

1.3.2 Frictions losses ............................................................................................................................................. 18

1.3.2.1 Friction losses and elongations ............................................................................................................. 18

1.3.2.2 Geometrical Conditions of Use ............................................................................................................. 20

1.3.3 Radius of curvature ...................................................................................................................................... 23

1.3.4 Support distance and tolerances ................................................................................................................. 25

1.3.5 Alignment at anchorage ............................................................................................................................... 25

1.3.6 Protection of tendons .................................................................................................................................. 25

1.3.6.1 lubrification and temporary protection ................................................................................................ 25

1.3.6.2 Filling materials used ............................................................................................................................ 26

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1.3.6.3 Injection equipment ............................................................................................................................. 26

1.3.7 Bursting reinforcements .............................................................................................................................. 26

1.3.7.1 C-Model Anchorages ............................................................................................................................ 26

1.3.7.2 Model F Anchorages ............................................................................................................................. 33

1.3.7.3 Model B anchorages ............................................................................................................................. 36

2. Specification of the intended uses in accordance with ETAG 013 .......................................... 37

2.1 Intended use............................................................................................................................. 37

2.2 Additional uses ......................................................................................................................... 38

2.3 Particularities of the kit ............................................................................................................. 43

2.3.1 Possibility of individual tensioning strand by strand ................................................................................... 43

2.3.2 Measurement of friction coefficient and load transfer percentage from stressing end to the other ......... 43

2.3.3 Adjustment of prestressing load .................................................................................................................. 43

2.3.4 Possibility of monitoring prestressing load .................................................................................................. 43

2.3.5 Possibility of detensioning ........................................................................................................................... 43

2.3.6 Possibility of re-threading a new tendon after detensioning ...................................................................... 43

2.3.7 Prestressing tendon allowing for load monitoring, retensioning, and replacement without damage to

the duct ................................................................................................................................................................. 44

2.3.8 Temporary or permanent caps .................................................................................................................... 44

2.3.9 Equitension .................................................................................................................................................. 44

2.4 Working life .............................................................................................................................. 44

2.4.1 Packaging, transport and storage ................................................................................................................ 44

2.4.2 Recommendations for safety ....................................................................................................................... 44

2.4.3 Use, maintenance and repair ....................................................................................................................... 44

2.4.4 Conditioning and corrosion protection ........................................................................................................ 45

3. Performance of the product and references to the methods used for its assessment: ........... 46

4. Assessment and verification of constancy of performance (AVCP) system applied, with

reference to its legal base....................................................................................................... 48

5. Technical details necessary for the implementation of the AVCP system, as provided for in

the applicable EAD: ................................................................................................................ 48

5.1 Tasks for the manufacturer ....................................................................................................... 48

5.1.1. Factory production control ......................................................................................................................... 48

5.1.2. Other tasks .................................................................................................................................................. 49

5.2 Tasks of the Notified Body ........................................................................................................ 49

5.2.1. General ........................................................................................................................................................ 49

5.2.2. Determination of the product-type on the basis of type testing (including sampling), type calculation,

tabulated values or descriptive documentation of the product ........................................................................... 50

5.2.3. Initial inspection of factory and of factory production control ................................................................... 50

5.2.4. Surveillance, assessment and approval of factory production control ....................................................... 50

5.2.5. Audit testing of samples taken at the manufacturer .................................................................................. 50

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List of Tables

Table 1. Maximum Force at Stressing Anchorage for a Single Strand acc. to Eurocode 2 and prEN 10138-3:2006 (only informative)

Table 2. Low-Capacity Anchorages (For definition of symbols, see 1.1.2.)

Table 3. High-Capacity Anchorages

Table 4 Thickness of Steel Strip Sheaths

Table 5. Dimensions of Smooth HDPE Tubes

Table 6. Maximum Force with Stressing Limit Fo = min{0,8 Fpk,0,9 Fp0,1%} acc. Eurocode 2 and prEN 10138-3:2006 (only informative)

Table 7. Friction and Wobble Coefficient

Table 8. Wedge Pull-In at Stressing Anchorages

Table 9. Minimum Edge Distances for C-Model Anchorages

Table 10. Minimum Edge Distances for Model F Anchorages

Table 11. Minimum Edge Distances for B Anchorages

Table 12. Minimum Curvature Radius for Internal Prestressing

Table 13. Minimum Curvature Radius for External Prestressing

Table 14 Bursting Steel for fcm,o = 24 Mpa

Table 15 Bursting Steel for fcm,o = 44 Mpa

Table 16. Bursting Steel for fcm,o = 60 Mpa

Table 17. Helical Bursting Steel for fcm,o = 24 MPa



Table 20 Bursting steel for Model B anchorage

Table 21. Concrete Structures – Use Categories

Table 22. Anchorage Models for Basic and Optional Categories of Use

Table 22 bis. Choice of Kit Elements for Basic and Optional Categories of Use

Table 23 – Performance of the system BWR1. Anchorage details and optional applications are detailed in Table 22

Table 24 – Performance of the system BWR3

Table 25. AVCP system

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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 single anchorage – unbonded prestressing 28. A nF13 – A nF15 anchorage – monostrand – unbonded prestressing 29. A nB13 & nB15 anchorage – bare strand – sheath – cast iron block 30. A nB13 & nB15 anchorage – bare strand – corrugated sheath – cast steel block 31. A nB15 anchorage – monostrand – sheath – cast iron block 32. A nB15 anchorage – monostrand – sheath – cast steel block 33. A nB15 anchorage – monostrand – no duct – cast iron block 34. A nB15 anchorage – monostrand – no duct – cast steel block 35. A 1X13 – A 1X15 anchorage – monostrand - cast steel block 36. A 2X13 – A 2X15 anchorage – monostrand 37. Liaseal seal system for match-cast segments 38. Identification drawings for C-series anchorage blocks 39. Identification drawings for coupler blocks CU nC15 40. Permanent cachetage of nC15 anchorages 41. Temporary or permanent cachetage of nC15 anchorages 42. Sealing-in of restressable nC15 anchorages 43. External prestressing with monostrands – grouting stuffing box 44. External prestressing allowing load monitoring, restressing and replacement without

damage to duct 45. Clearance requirement for CCxxx jacks 46. Clearance requirement for CxxxF jacks 47. Clearance requirement for KxxxC jacks (with hydraulic lock-off) 48. Clearance requirement for KxxxC jacks (without hydraulic lock-off) 49. Clearance requirement for K500F jack 50. Clearance requirement for VPxxxC jacks 51. Clearance requirement for 55C15 equitension jack clearance 52. Load-monitoring jack for threaded 55C15 anchorage 53. Clearance requirement for monostrand jacks – type C 54. Clearance requirement for jacks – A 1F13 - 1F15 anchorage

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55. Clearance requirement for jacks – A nF13 – A nF15 anchorage 56. Clearance requirement for SC2 and U24 jacks – AnB13 A nB15 anchorage 57. Clearance requirement for M25 jacks – A nB13 – A nB15 anchorage 58. Clearance requirement for titan 25 and IHS 25T jacks – A nB13 A nB15 anchorage 59. Adapter for 1X13 – 1X15 anchorage 60. Adapter for 2X13 – 2X15 anchorage 61. Grouting vents possibility 62. C15 Anchorages with load cell

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Translations of this European Technical Assessment in other languages shall fully correspond to the original issued document and shou ld be identified as such.

Communication of this European Technical Assessment , including transmission by electronic means, shall be in full. However, partia l reproduction may be made, with the written consent of the issuing Technical Assessment Body. Any partial reproduction has to be identified as such.

1. Technical description of the product

1.1 Definition and designation of the product

1.1.1 Definition of the product 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 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 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).

1.1.2 Designation of the product Each type of anchorage is defined as per the following example, where the three parameters shown below give full information about the product:

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

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- 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).

1.2 Components

1.2.1 Strands In absence of European standards on prestressing steel, strands complying with national provisions and with characteristics given in 1.1 and table 6 shall be used.

1.2.1.1 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.

1.2.1.2 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.

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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 1. Maximum Force at Stressing Anchorage for a Single Strand acc. to Eurocode 2 and prEN 10138-3:2006 (only informative)

1.2.2 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.

1.2.2.1 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).

1.2.2.2 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

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block and the trumplate. It is available for prestressing units with 1, 3 or 4 strands T13 or T15 (drawings 24 to 28).

1.2.2.3 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 either cast-iron or cast-steel anchorage block with cast-iron trumplate. The model B cover a range between 3 and 5 strands T15 and T13 (see drawings 29 to 34).

1.2.2.4 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 35),

• 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 36).

1.2.3 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 type of anchorages are designated by “NB” and 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).

1.2.4 Fixed Couplers CI Couplers connect two tensile elements that are tensioned one after the other in two separate concreting phases

1.2.4.1 Monostrand fixed coupler

It consists of individual type P strand connectors (see paragraph 1.2.5 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.

1.2.4.2 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.

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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.

1.2.5 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.

1.2.6 Tables: anchorage models and ETA-covered unit s

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 2. Low-Capacity Anchorages (For definition of symbols, see 1.1.2.)

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 C 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 3. High-Capacity Anchorages

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1.2.7 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 (T15 wedges), 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.

1.2.8 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.

1.2.9 Steel anchor blocks: model C Anchor Blocks an d multistrand steel coupler 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.

1.2.10 Castings for anchorage

1.2.10.1 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 EN 1563 standard or cast-steel (G24Mn6) defined by reference to EN10293 standard.

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1.2.10.2 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.

1.2.10.3 Load Spreading Parts or Trumplate

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)’.

For specific applications, such as electrically isolated tendons or instrumented tendon (with dynamometers), the trumplate “A n C15” or “AD n C 15” can be machined in order to ensure a flat contact surface (drawing 62).

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.

1.2.10.4 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.

1.2.11 Characteristics of Plastic Parts

1.2.11.1 Plastic Trumpets

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

1.2.11.2 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.

1.2.11.3 Plastic Caps

Plastics caps are made from plastic materials (as polyethylene or polyamide or polypropylene).

1.2.12 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

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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.

1.2.12.1 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.

• 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

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

of sheath (mm)

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

Table 4 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.

• 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.

• Option: Galvanisation

On request and if allowed by the applicable national regulations, the sheaths may be hot-dip galvanised or electro zinc-plated.

• 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.

1.2.12.2 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.

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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.

• 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.

• 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.

1.2.12.3 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.

1.2.12.4 Smooth Plastic Pipes

• 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:

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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 3.0 63 4.7* 4.7 3.8 75 5.5* 5.5 4.5 90 6.6* 6.6 5.4 110 5.3 8.1 6.6 125 6.0 9.2 7.4 140 6.7 10.3 8.3 160 7.7 11.8 9.5 180 8.6 13.8 10.7 200 9.6 14.7 11.9

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 5. 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.

• 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.

1.2.12.5 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 37). Used in conjunction with the Plyduct duct, the Liaseal connector makes a continuous, leakfree plastic duct crossing the match-cast joints between segments.

1.2.13 Other Components Prestressing units of Freyssinet kit require different components, some of them being common to several models.

- 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.

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- 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.

The 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

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

1.3 Design

1.3.1 Maximum force 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 with 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.

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Tensile Strength (N/mm²)

1770 1770 1860 1860 1860 1860

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

Num

ber

of S

tran

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

Number 9 1766 1895 1231 1328 1855 1993

of 12 2354 2527 1642 1771 2473 2657

Strands 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 6. Maximum Force with Stressing Limit Fo = min{0,8 Fpk,0,9 Fp0,1%} acc. Eurocode 2 and prEN 10138-3:2006 (only informative)

1.3.2 Frictions losses

1.3.2.1 Friction losses and elongations

• 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

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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

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

Internal Prestressing

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

Single Monostrands embedded in the concrete 0,05 2 0,007 2

Prestressing Group of Pre-Grouted Monostrands (external or

internal prestressing)

0,05 0,012

Table 7. Friction and Wobble Coefficient

• Parameters for Evaluation of Elongation during Stressing

o 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.

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Stressing Jack with hydraulic blocking without hydraulic

blocking

Strand diameter T13 T15 T13 T15

min 4 4 6 6

Pull -in at stressing anchorage

mm mean 5 6 7 8

max 6 9 8 10

Table 8. Wedge Pull-In at Stressing Anchorages

o 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.

o 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.

1.3.2.2 Geometrical Conditions of Use

• 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.

• 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.

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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)

The values of a and b are given in the table below for three different concrete compressive strengths fcm,o.

y y y’

x’

x

x’

x

y’ y’

A

B B

A

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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 9. 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 10. Minimum Edge Distances for Model F Anchorages

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Strand type f cm,o (MPa)

fcm,o on

cube (MPa)

unit a (mm) b (mm)

Minimum slab

thickness (mm)

3B13 300 175 150

B13 - T13/T13S 20 22 4B13 350 200 170

5B13 400 200 170

3B15 350 200 170

B15 - T15 22 24 4B15 400 200 170

5B15 450 220 190

3B15 350 200 170

B15 - T15S 23.5 22.5 4B15 400 200 170

5B15 450 220 190

Table 11. 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.

1.3.3 Radius of curvature In the absence of more restrictive national specifications, the minimum curvature radius is defined as follows:

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Strand type Duct Type Minimum Curvature Radius

Flat duct Steel 100 x internal diameter 2

Plastic 100 x internal diameter 2

Bare strand 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

Deviation 2,5 m

Single strand Dead anchorage (180° hoop)

0,6 m

1 according to ENV 1992-1-5:1994

2 flat duct dimension in the considered direction

Table 12. Minimum Curvature Radius for Internal Prestressing

In the case of bonded prestressing, to determine the minimum radius of steel tubes two possibilities may be considered:

Case 1 - The radius can be reduced down to 20 times the internal diameter, assuming that:

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

o the tensile stress does not exceed 70% of strand guaranteed tensile strength where the radius is less than 3,0 m,

o the sum of angular deviations along the cable is less than 3π/2 radians, o the sharply curved zone is considered as a dead anchorage if the angular

deviation exceeds π/2 radians. Case 2 – Tendon sections curved in a U-shape at a tight radius to form an inaccessible end of the tendon named loop anchorage respect the following details:

o duct in loop is either smooth or corrugated, diameter one size larger than in free length for ease of connection (one fitting into other),

o radius of curvature in loop R ≥ max { 0.6 Fpk ; 0.6 m }, where R is expressed in meters and Fpk expressed in MN,

o tendon is stressed simultaneously from both ends, o tendon is subject to primarily static load (no significant fatigue load).

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:

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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

Table 13. Minimum Curvature Radius for External Prestressing

1.3.4 Support distance 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.

1.3.5 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.

1.3.6 Protection of tendons

1.3.6.1 Lubrification and temporary protection

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

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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 as applying soluble oil or blowing dry air into the tendon. This lubrication may also be used to reduce friction coefficient of cable inside duct.

1.3.6.2 Filling materials used

• 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:

o 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,

o or a special grout, as per the requirements of EAD 15-16-0027-03.01.

• Wax

The wax for injecting prestressing tendons shall be a petroleum wax meeting the requirements of EAD 15-16-0027-03.01.

• Grease

The grease for Freyssinet prestressing tendons shall be a mineral-oil-based grease meeting the requirements of EAD 15-16-0027-03.01.

1.3.6.3 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.

1.3.7 Bursting reinforcements 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.

1.3.7.1 C-Model Anchorages

• Cross-laid Wave-form Bars / Stirrups

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or (see

tables)

wfb (wave-form bursting steel)

equivalent 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

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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


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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


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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

Table 16. Bursting Steel for fcm,o = 60 MPa

• 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

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

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


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

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


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

reinforcement (Stirrups)

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.

1.3.7.2 Model F Anchorages

• Anchorage A 1F13 and A 1F15

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

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• Anchorage A n F13


type q’ty φ 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

∅10

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• Anchorage A n F15


type q’ty φ 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

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1.3.7.3 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 20. Bursting steel for Model B anchorage

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2. Specification of the intended uses in accordanc e with ETAG 013

2.1 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 prestressing units bonded to the concrete consist of bare strands in a thin-wall corrugated duct made of steel, plastic smooth steel pipes and injected with a cement grout in accordance with EN 447 or Annex C4 of ETAG013.

• Internal unbonded tendon for concrete and composite 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 1.3.1 have been taken.

• External tendon for concrete structures with a tendon path situated outside the cross-section of the structure but inside its envelope.

Other than in exceptional circumstances, external prestressing tendons are replaceable and re-stressable, and are one of the following types:

- Standard type: The duct is injected with cement grout. 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’.

- Type W: 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’.

- Type GI: 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’.

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‘AD n C 15’ anchorages can be used to make electrically isolated prestressing tendons if the measures described in paragraph 1.3.1 have been taken. In exceptional case, non-replaceable external prestressing tendons can be used. 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’.

2.2 Additional uses 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 (internal or external),

4. internal bonded tendon with plastic ducts,

5. encapsulated tendon,

6. electrically isolated tendon: 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: o a plastic trumpet fitted inside the trumplate, o a bearing plate made out of an electrically isolating composite material placed

under the anchor block, o a plastic cap.

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

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

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

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Applications Types Models Corrosion Protection

with steel duct A C-F-B

-

Bonded Internal

Prestressing

with plastic duct NB

CI

CM

C

C-F

B

PE

electrically isolated with plastic duct

A - CI - CM C EI

with monostrands

A

NB

C - F – X - B

C - F

GI

Unbonded Internal

Prestressing

injection with soft protection material

A C - B W

injection with soft protection material

and electrical isolation

A C

WEI

injection with cement grout C

-

External with monostrands AD C - X GI

Prestressing injection with soft protection material

C W

electrically isolated

C EI

Table 21. Concrete Structures – Use Categories

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.

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Categories of Use

Fixed C

ouplers

CI

Movable

Couplers C

M

Model F

Model C

Model B

Model X

Model N

B

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 1 to 55 1 to 2

(h) Internal/External Tendon for Masonry Structures

1 1 to 55 1 to 2

(i) Internal/External Tendon for Timber Structures

1 1 to 55 1 to 2

Table 22. Anchorage Models for Basic and Optional Categories of Use

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Structures Options

Anchorage &

Coupler Type

Model

Duct

Tensile Element

Injection

Anchor Protection

Sealing

Typical Drawings

[3]

Pre stressing

type

Concrete

Steel

Masonry

Tim

ber

Restressable

Exchangeable

Cryogenic

Encapsulated

Electrically

Isolated

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

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

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

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

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

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

Bounded 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

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

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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

External 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 22 bis. 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 drawing 40, Cap: see drawing 41, Extended Cap: see drawing 42. 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 drawings 11, 12, 20, 22, 23, 24, 25, 26, 37, 40 [5] e.g. see drawings 11, 20, 22, 23, 24, 25, 26, 27, 37

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2.3 Particularities of the kit

2.3.1 Possibility of individual tensioning strand b y 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.

2.3.2 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.

2.3.3 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.

2.3.4 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 (unbounded) can be monitored with a special ring jack installed between the anchor block threaded ring and the anchorage trumplate.

Monitoring can also be performed thanks to a dynamometer located between the anchorage block (n C15 or C13) and the trumplate where the contact surface is previously machined to allow a correct bearing area.

2.3.5 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.

2.3.6 Possibility of re-threading a new tendon afte r detensioning Once detensioning has been performed as described in previous paragraph 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.

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2.3.7 Prestressing tendon allowing for load monitor ing, 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 42).

2.3.8 Temporary or permanent caps Caps can be fitted to anchorage types A, AD and NB.

2.3.9 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.

2.4 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 technical assessment 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.

2.4.1 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.

2.4.2 Recommendations for safety 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.

2.4.3 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.

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2.4.4 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.

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3. Performance of the product and references to the methods used for its assessment: This European Technical Assessment for the post-tensioning system part of this document is issued on the basis of agreed data, deposited at Cerema, which identifies the post-tensioning system that has been assessed and judged.

Assessment of the performance of the post-tensioning system part of this document for the intended use in the sense of basic requirement for construction work 1 (mechanical resistance and stability) and for basic requirement for construction work 3 (hygiene, health and environment) has been made in accordance with the ETAG 013, European Technical Approvals Guideline of post-tensioning kits for prestressing of structures used as EAD, based on the provisions for all systems.

Product type : Post-tensioning Kit

Intended use : for prestressing of structures

Basic requirement for construction work

Essential characteristics Performance

Resistance to static load Satisfaction of acceptance criteria given in paragraph 6.1.1-I of ETAG013

1 Mechanical resistance and stability

Resistance to fatigue Satisfaction of acceptance criteria given in paragraph 6.1.2-I of ETAG013

Load transfer to the structure Satisfaction of acceptance criteria given in paragraph 6.1.3-I of ETAG013

Practicability / reliability of installation

Satisfaction of acceptance criteria given in paragraph 6.1.6-I of ETAG 013

Restressable tendon (external or internal)

Satisfaction of acceptance criteria given in paragraph 6.1.part II (a) of ETAG 013

Exangeable tendon (external or internal)

Satisfaction of acceptance criteria given in paragraph 6.1.part II (b) of ETAG 013

Tendon for cryogenic applications (internal or external)

Satisfaction of acceptance criteria given in paragraph 6.1.part II (c) of ETAG 013

Internal bonded tendon with plastic duct

Satisfaction of acceptance criteria given in paragraph 6.1.part II (d) of ETAG 013

Encapsulated tendon Satisfaction of acceptance criteria given in paragraph 6.1.part II (e) of ETAG 013

Electrically isolated tendon Satisfaction of acceptance criteria given in paragraph 6.1.part II (f) of ETAG 013

Tendon for use in structural steel or composite construction as external tendon

Satisfaction of acceptance criteria given in paragraph 6.1.part II (g) of ETAG 013

Tendon for use in structural masonry construction as internal

Satisfaction of acceptance criteria given in paragraph 6.1.part II (h) of ETAG 013

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or external tendon

Tendon for use in structural timber construction as internal or external tendon

Satisfaction of acceptance criteria given in paragraph 6.1.part II (i) of ETAG 013

Table 23 – Performance of the system BWR1. Anchorage details and optional applications are detailled in Table 22

Product type : Post-tensioning Kit Intended use : for prestressing of structures Basic requirement for construction work

Essential characteristics Performance

3 Hygiene, health and environment

Release of dangerous substances

PT system does not cause harmful emission of toxic gases, dangerous particles or radiation to the indoor environment nor contamination of the outdoor environment (air, soil, water)

Table 24. Performance of the system BWR3

BWRs 2, 4, 5, 6 and 7 are not relevant according to ETAG 013.

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4. Assessment and verification of constancy of perf ormance (AVCP) system applied, with reference to its legal base In accordance with the decision 98/456/EC of the European Commission1, the system 1+ of assessment and verification of constancy of performances (see Annex V to Regulation (EU) No 305/2011), given in the following table applies:

Product(s) Intended use(s) Level(s) or class(es) System(s)

Post-tensioning kit For structures prestressing

- 1+

Table 25. AVCP system

This AVCP system is defined as follows: System 1+: Declaration of the performance of the essential characteristics of the construction product by the manufacturer on the basis of the following items:

(a) 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;

(b) Tasks for the notified body (3) Determination of the product-type on the basis of type testing (including

sampling), type calculation, tabulated values or descriptive documentation 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 taken at the factory.

5. Technical details necessary for the implementati on of the AVCP system, as provided for in the applicable EAD:

5.1 Tasks for the manufacturer

5.1.1. Factory production control The manufacturer shall exercise permanent internal control of production. All the elements, requirements and provisions adopted by the manufacturer shall be documented in a systematic manner in the form of written policies and procedures, including records of results performed. This production control system shall insure that the product is in conformity with this European Technical Assessment.

The manufacturer may only use initial material stated in the technical documentation of this European Technical Assessment.

The factory production control shall be in accordance with the "Freyssinet Control Plan" relating to this European technical assessment which is part of the technical documentation of this

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European technical Assessment. The "Control Plan" is laid down in the context of the factory production control system operated by the manufacturer and deposited at CeremaITM.

The prescribed test plan defined in Annex from 42 to 43 gives the type and frequency of checks and tests conducted during production and on the final product as part of the continuous internal production control.

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

The records contain at least the following information:

- designation of the product or basic materials and the components;

- type of control or testing;

- date of manufacture and of testing of product or components and of basic materials or components;

- results of controls and tests and, where relevant, comparison with the requirements;

- signature of person responsible for the factory production control.

If the test results are unsatisfactory, the manufacturer shall immediately implement measures to eliminate defects. Construction products or components which are not in compliance with the requirements shall be handled such that they cannot be mistaken for products complying with the requirements. After elimination of the defects the relevant tests shall be immediately repeated as far as is technically possible and necessary for verifying the deficiency elimination.

5.1.2. Other tasks The manufacturer shall, on the basis of a contract, involve a body which is approved for the tasks referred to in section 5.2 in the field of Freyssinet post-tensioning system in order to undertake the actions laid down in section 5.2. For this purpose, the "control plan" referred to in sections 5.1.1 shall be handed over by the manufacturer to the Notified Body or bodies involved.

The manufacturer shall make a declaration of performance, stating that the construction product is in conformity with the provisions of this European Technical Assessment.

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

5.2 Tasks of the Notified Body

5.2.1. General The Notified Body (bodies) shall perform the:

- Determination of the product-type on the basis of type testing (including sampling),

- initial inspection of factory and of factory production control,

- continuous surveillance, assessment and approval of factory production control,

- audit-testing of samples taken at the factory

in accordance with the provisions laid down in the "Control Plan" relating to this European Technical Assessment.

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

The main production centre is checked at least once a year by the Notified Body. Each component producer is checked at least once every five years by the Notified Body.

The Notified Body involved by the manufacturer shall issue a certificate of constancy of performance of the product stating the conformity with the provisions of this European Technical Assessment.

In cases where the provisions of the European Technical Assessment and its “Control Plan” are no longer fulfilled the Notified Body shall withdraw the certificate of constancy of performance and inform CeremaITM without delay.

5.2.2. Determination of the product-type on the bas is of type testing (including sampling), type calculation, tabulated values or de scriptive documentation of the product For initial type testing the results of the tests performed as part of the assessment of the European Technical Assessment may be used unless there are changes in production procedure or factory plant. In such cases, the necessary initial type testing shall be agreed between CeremaITM and the Notified Body involved.

5.2.3. Initial inspection of factory and of factory production control The Notified Body shall ascertain that, in accordance with the prescribed test plan, the manufacturing plant, in particular personnel and equipment, and the factory production control are suitable to ensure a continuous orderly manufacturing of the PT system according to the specifications given in the Annexes of this European Technical Assessment.

5.2.4. Surveillance, assessment and approval of fac tory production control The manufacturer shall be inspected at least once a year. Each component manufacturer shall be inspected at least once in five years. It shall be verified that the system of factory production control and the specified manufacturing process are maintained taking into account the prescribed test plan.

5.2.5. Audit testing of samples taken at the manufa cturer During surveillance inspection, the Notified Body shall take samples at the factory of components of the PT system or of individual components for which this European Technical Assessment has been granted, for independent testing.

For the most important components Annex 44, complying with ETAG 013, Annex E.2, summarises the minimum procedures.

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Issued in Sourdun on 12/03/2018

By

Barthélémy PETIT

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ANNEX 1 – Prescribed Test Plan

The following table summarises the test procedures necessary to ensure that all kit components meet the ETA specifications. Cerema 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

Traceability4

Minimum frequency

Documentation

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



yes


Anchor head/block for coupler

material 7 check full 100 % "3.1" 2



yes


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

for anchorages and couplers



yes


Wedge material 7 check full 100 % "3.1" 2

treatment, hardness

test 0,5 %

≥ 2 specimen

yes



yes


Swage material 7 check full 100 % "3.1" 2



yes


1 2 3 4 5 6

Component Item Test/ Check

Traceability4

Minimum frequency

Documentation

Duct material 7 check CE2 100 % yes

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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



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.

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ANNEX 2 – Basic elements for 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.

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ANNEX 3 – 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.

Stressing Anchorages

Size of anchorage reservation and clearance for placing the stressing jack should be checked at the design stage (see drawings 45 to 58).

Model X Anchorages

Loop tendons are stressed simultaneously at both ends by means of single-strand jacks (see drawings 59 and 61).

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)

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.

• Fixed Couplers

The prestressing force of the secondary tendon at the coupler shall not exceed that of the primary cable. The following applies to 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.

• 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

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first phase cable and the resulting displacement of strand connectors. In practice, the cap length is therefore adapted to each case.

• 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 43). 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).

• 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.

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ANNEX 4 – Tensionning

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 45 to 60. 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.

Particular Recommendations

• 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.

Recommendations for Tensioning and Control

• 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.

• 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 1. Friction Loss in Anchorages

Documents

Freyssinet Australia Pty Ltd - European Technical ETA 06 ......The Freyssinet prestressing kit is a post-tensioning kit designed for both internal and external prestressing. A prestressing