Post Tension Ing Cables ETA 06 0226

A/S Skandinavisk Spændbeton, Ny Vestergaardsvej 11, 3500 Værløse, +45 44 35 08 11, [email protected]

Post-tensioning Cables

Freyssinet ETA-06/0226

Skandinavisk Spændbeton comments

Version 0.1

September 23th 2009

A/S Skandinavisk Spændbeton, Ny Vestergaardsvej 11, 3500 Værløse, +45 44 35 08 11, [email protected]

Skandinavisk Spændbeton has the following corrections to

ETA-06/0226:

C1. J.2.2 Lateral Cover and Distances

It is written: “In what follows … with the smaller dimension of the trumplate aligned along axis x.”

The correct formulation: “In what follows … with the smaller dimension of the trumplate aligned along axis y.”

C2. J.3.1.1 Cross-laid Wave-form Bars / Stirrups

On the drawing there is a distance b0 – the right distance is y’

C3. J.3.2.1 Anchorage A 1F13 and A 1F15

On the drawing there is an error, the “face” drawing is rotated 900 C4. J.2.2. Lateral Cover and Distances

In table 15 there is something wrong with the distance “a” for 3/4 F13, we recommend that the distance for 3/4 F15 is used instead.

FREYSSINET PRESTRESSING SYSTEM – EUROPEAN TECHNICAL APPROVAL

English translation 2006.12.15 page 1/50

Service d'études techniques des routes et

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MEMBRE DE L'EOTA

MEMBER OF EOTA

Agrément Technique Européen No. ETA-06/0226 (version originale en français)

European Technical Approval No. ETA-06/0226 (Original Version in French Language)

Nom commercial Trade name:

��

Détenteur de l'ATE Holder of approval:

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

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

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

Valid from: to:

25.01.2007 24.01.2012

Producteur du procédé: Kit manufacturer

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

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

90 pages comprenant 40 pages d’annexes (dessins) faisant partie intégrante du document.

90 pages including 40 pages of annexes which form an integral part of the document

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

Skandinavisk Spændbeton

Ny Vestergårdsvej 11, 3500 Værløse, Danmark



CONTENTS

A LEGAL BASES AND GENERAL CONDITIONS................................................................................... 5

B – SPECIFIC CONDITIONS OF THE EUROPEAN TECHNICAL APPROVAL............................. 6

B.1 DEFINITION OF PRODUCTS AND INTENDED USE .................................................................................... 6B.2 CHARACTERISTICS OF PRODUCTS AND VERIFICATION METHODS ....................................................... 12B.3 EVALUATION AND ATTESTATION OF CONFORMITY AND CE MARKING .............................................. 13B.4 ASSUMPTIONS UNDER WHICH THE FITNESS OF THE PRODUCTS FOR THE INTENDED USE WAS ASSESSED

15B.5 INDICATIONS TO THE MANUFACTURER ............................................................................................... 16

C – PRESCRIBED TEST PLAN .............................................................................................................. 17

D – BASIC ELEMENTS OF AUDIT TESTING..................................................................................... 19

E – PRESTRESSING UNITS AND USE CATEGORIES...................................................................... 20

E.1 UNITS CODING .................................................................................................................................... 20E.2 USE CATEGORIES................................................................................................................................ 20E.3 PARTICULARITIES OF THE KIT............................................................................................................. 24E.4 FORCES OF PRESTRESSING TENDONS .................................................................................................. 25

F – ANCHORAGES .................................................................................................................................. 26

F.1 DESCRIPTION OF ANCHORAGE COMPONENTS ..................................................................................... 27F.2 RECOMMENDATIONS FOR USE OF ANCHORAGES ................................................................................ 29

G – TENSILE ELEMENTS AND DUCTS............................................................................................... 31

G.1 TENSILE ELEMENTS ............................................................................................................................ 31G.2 DUCTS ................................................................................................................................................ 32G.3 CABLE LAY-OUT ................................................................................................................................ 36

H – TENSIONING...................................................................................................................................... 38

H.1 TENSIONING EQUIPMENT .................................................................................................................... 38H.2 PARTICULAR RECOMMENDATIONS ..................................................................................................... 38H.3 RECOMMENDATIONS FOR TENSIONING AND CONTROL ....................................................................... 38

I – PROTECTION OF TENDONS.......................................................................................................... 39

I.1 LUBRICATION AND TEMPORARY PROTECTION......................................................................................... 39I.2 FILLING MATERIALS USED ...................................................................................................................... 39I.3 INJECTION EQUIPMENT ............................................................................................................................ 39

J – MECHANICAL AND GEOMETRICAL CONDITIONS OF USE................................................ 40

J.1 FRICTION LOSSES AND ELONGATIONS ..................................................................................................... 40J.2 GEOMETRICAL CONDITIONS OF USE ........................................................................................................ 41J.3 BURSTING REINFORCEMENT.................................................................................................................... 44

K – DRAWINGS......................................................................................................................................... 50





LIST OF DRAWINGS

1. C15 anchoring wedge 2. C13 anchoring wedge 3. T15D swage 4. T15DC swage 5. T13D swage 6. P 15 strand connector 7. P 13 strand connector 8. A nC15 anchorage – bare strand – duct 9. A nC15 anchorage – bare strand – steel pipe 10. A nC15 anchorage – monostrand – duct 11. A nC15 anchorage – monostrand – steel pipe 12. A nC15 anchorage – monostrand – plastic pipe 13. A nC15 anchorage – monostrand – no duct 14. AD nC15 anchorage – bare strand – injected with cement grout 15. AD nC15 anchorage – bare strand – injected with wax or grease 16. A nC15 EI electrically isolated anchorage 17. CI nC15 fixed coupler 18. CM nC15 movable coupler 19. NB nC15 anchorage 20. A 1F15 – A 1F13 – NB 1F15 – NB 1F13 single anchorage – bonded prestressing 21. A nF13 – A nF15 anchorage – bare strand – bonded prestressing 22. CI nF13 – CI nF15 fixed coupler – bare strand – bonded prestressing 23. A 1F15 – A 1F13 – NB 1F15 – NB 1F13 single anchorage – unbonded prestressing 24. A nF13 – A nF15 anchorage – monostrand – unbonded prestressing 25. A 1X13 – A 1X15 anchorage – monostrand 26. A 2X13 – A 2X15 anchorage – monostrand 27. Liaseal� seal system for match-cast segments 28. Identification drawings for C-series anchorage blocks 29. Permanent cachetage of nC15 anchorages 30. Temporary or permanent cachetage of nC15 anchorages 31. Sealing-in of restressable nC15 anchorages 32. External prestressing with monostrands – injection closure 33. External prestressing allowing load monitoring, restressing and replacement without damage

to duct 34. Space requirement for CCxxx jacks 35. Space requirement for CxxxF jacks 36. Space requirement for KxxxC jacks (with hydraulic lock-off) 37. Space requirement for KxxxC jacks (without hydraulic lock-off) 38. Space requirement for K500F jack 39. Space requirement for VPxxxC jacks 40. Space requirement for 55C15 equitension jack 41. Load-monitoring jack for threaded 55C15 anchorage 42. Space requirement for single strand jacks – type C 43. Space requirement for jacks – A 1F13 - 1F15 anchorage 44. Space requirement for jacks – A nF13 – A nF15 anchorage 45. Adapter for 1X13 – 1X15 anchorage 46. Adapter for 2X13 – 2X15 anchorage





LIST OF TABLES

Table 1 Low-Capacity Anchorages

Table 2 High-Capacity Anchorages

Table 3 Anchrorage Models for Basic and Optional Categories of Use

Table 3bis Selection of Kit Elements Depending on Basic and Optional Categories of Use

Table 4 Concrete Structures – Use Categories

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

Table 6 Maximum Force at Stressing Anchorage for a Single Strand

Table 7 Thickness of Steel Strip Sheaths

Table 8 Dimensions of Smooth HDPE Tubes

Table 9 Minimum Curvature Radius for Internal Prestressing

Table 10 Minimum Curvature Radius for External Prestressing

Table 11 Friction Loss in Anchorages

Table 12 Friction and Wobble Coefficient

Table 13 Wedge Pull-In at Stressing Anchorages

Table 14 Minimum Edge Distances for C-Model Anchorages

Table 15 Minimum Edge Distances for Model F Anchorages

Table 16 FeE 235 Bursting Steel for fcm,o = 24 MPa



Table 19 Helical Bursting Steel with FeE 235 for fcm,o = 24 MPa







A LEGAL BASES AND GENERAL CONDITIONS

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

��Council Directive 89/106/EEC of 21 December 1988 on the approximation of laws, regulations and administrative provisions of Member States relating to construction products1, modified by Council Directive 93/68/EEC2 and Regulation (EC) No 1882/2003 of the European Parliament and of the Council3;

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

��Common Procedural Rules for Requesting, Preparing and the Granting of European Technical Approvals set out in the Annex to Commission Decision 94/23/EC5;

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

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

A.3 This European Technical Approval is not to be transferred to manufacturers or agents of manufacturers other than those indicated on page 1, or manufacturing plants other than those indicated on page 1 of this European Technical Approval.

A.4 This European Technical Approval may be withdrawn by SETRA, in particular pursuant to information by the Commission according to Article 5(1) of Council Directive 89/106/EEC.

A.5 Reproduction of this European Technical Approval including transmission by electronic means shall be in full. However, partial reproduction can be made with the written consent of SETRA. In this case partial reproduction has to be designated as such. Texts and drawings of advertising brochures shall not contradict or misuse the European Technical Approval.

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

1 Official Journal of the European Communities No L 40, 11.2.1989, p. 12

2Official Journal of the European Communities No L 220, 30.8.1993, p. 1

3Official Journal of the European Union No L 284, 30.10.2003, p. 1

4 JORF du 14 juillet 1992 5

Official Journal of the European Communities No L 17, 20.1.1994, p. 34





B – SPECIFIC CONDITIONS OF THE EUROPEAN TECHNICAL APPROVAL

B.1 DEFINITION OF PRODUCTS AND INTENDED USE

B.1.1 Definition of Products

The Freyssinet prestressing kit is a post-tensioning kit designed for both internal and external prestressing. A prestressing cable consists of a bundle of 7-wire strands in accordance with section G.1 and is referred to as the ‘tensile element’. When fitted with its anchorages, the prestressing tendon is referred to as the ‘prestressing unit’.

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

In the case of unbonded internal prestressing, however, monostrands (strands with individual protection by grease or wax and plastic sheath) may be used without any duct, the strands being placed in the structure according to the design requirement.

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

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

The prestressing tensile elements consist of: • 12,5 mm or 12,9 mm nominal diameter strands, with a nominal tensile strength of

1770 MPa or 1860 MPa, coded respectively Y1770 (or Y1860) S7 12,5 (or 12,9) in prEN 10138-3 and designated T13, T13S or simply T13 in the present document,

• 15,3 mm or 15,7 mm nominal diameter strands, with a nominal tensile strength 1770 MPa or 1860 MPa, coded respectively Y1770 (or Y1860) S7 15,3 (or 15,7) in prEN 10138-3 and designated T15, T15S or simply T15 in the present document.

Freyssinet stressing anchorages anchor each strand individually by means of a conical wedge inserted in a conical hole of anchorage block. The diameter of the internal thread of the Freyssinet anchor wedge depends on the strand nominal diameter, T13 or T15 (drawings 1 and 2).

B.1.1.1 Stressing anchorages

Anchorages are said to be the stressing type (and are coded ‘A’ for ‘active’) when they are the anchorages at the end of tensile elements where the tensioning operation takes place. A stressing anchorage consists of an anchorage head, i.e. a steel block or a casting with holes to receive anchorage wedges. The anchorage head bears on a load spreading plate, except for models F and X where the load spreading plate is part of the anchorage block. This load spreading plate is:

• either a casting known as a ‘trumplate’, which is cast into the concrete of the structure, • or a bearing plate of dimensions to suit the load-bearing capacity of the structure

(when not in concrete).





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

Structural anchorages model C

Prestressing anchorages model C are generally used for civil engineering prestressed structures. They consist of a circular steel anchor head bearing on a cast-iron trumplate with one or several intermediate spreading rings. They cover a range between 3 and 55 strands T13 or T15 (drawings 8 to 16).

Slab anchorages model F

Prestressing anchorages model F are generally used for prestressing thin elements (e.g. concrete floor slabs and walls) and consist of a one-piece casting which combines the anchorage block and the trumplate. It is available for prestressing units with 1, 3 or 4 strands T13 or T15 (drawings 20 to 24).

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 25),

• 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 26).

B.1.1.2 External passive anchorages

When anchorages are said ‘external passive’ they will not allow fitting of a tensioning jack but are nevertheless accessible during the tensioning operation. This kind of anchorage is made out of stressing anchorages in which the wedges have been pre-blocked, without protruding tendon length for tensioning. They can be inspected during tensioning. The Freyssinet denomination for these types is identical to that of stressing anchorages.

Anchorages are said embedded or internally fixed when incorporated in concrete of structure. These NB designated anchorages use swages to ensure fixing of strand ends (drawings 3 to 5) on a model C anchor head fitted with cylindrical holes and seated on a tromplate. They can be used for units ranging from 1 to 55 strands T13 or T15 (drawing 19).

B.1.1.3 Fixed Couplers

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

Coupler CI

It consists of individual type P strand connectors (see paragraph B.1.1.4 below) connecting each strand of the primary tendon to its counterpart in the secondary tendon (drawing 17). It is used for prestressing units with 1 to 37 strands T13 or T15.

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





B.1.1.4 Movable couplers CM

Movable couplers CM connect two tensile elements which are tensioned simultaneously in a single operation. Strands are connected together with a type P individual strand connector; strand connector positions are offset in the case of multistrand units. The connector consists of a cast-iron body to receive two anchorage wedges and serves to connect two sections of a tensile element. Two models are available:

• strand connector P 13 is used with T13 and T13S strands (drawing 7), • strand connector P 15 is used with T15 and T15S strands (drawing 6).

Movable couplers are used for prestressing units with 1 to 37 strands T13 or T15 (drawing 18).

The length of the coupler resevation is obtained by the formula L = M + U, where U is the connector displacement including provision for stressing tolerance according to national regulations and M is a fixed dimension depending on the tendon type including necessary installation tolerance given in the table of relevant drawings.

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

TypeNumber of strands T13 or T15 Anchorage

model 1 2 3 4

A F x x x X x x

AD X x x NB F x CI F x x x

CM F x x x

Table 1. Low-Capacity Anchorages

For definition of symbols, see §E.1 below

Number of strands T13 or T15 Type

Anchorage

model 3 4 7 9 12 13 19 22 25 25C 27 31 37 55

A 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 NB C 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

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

Table 2. High-Capacity Anchorages

B.1.1.6 Other Components

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

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





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

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

- Tubes or specific elements for deviation of external cables at given locations in the structure. These deviators are generally made out of steel plain pipes. The specific elements may include reservations inside the concrete reinforcement or construction steel saddles to obtain the cable deviator.

- Bursting steel reinforcement, for the concrete confinement at anchorages and deviators, to complete the general structural reinforcement and ensure prestressing force transfer.

- Specific accessories to facilitate cable placing and stressing, tendon grouting, de-tensioning and replacement of tendon, such as vents, duct drainage, tendon supports, temporary and permanent protection caps of anchorages and couplers, coupling elements between duct sections and for duct connection to anchorages.

Following components are covered by national or European provisions: - prestressing steels, - steel corrugated sheath, - steel or plastic pipes or tubes, - grouting products, - bursting reinforcing steel.

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

B.1.2 Intended Use

The prestressing kit described in this ETA can be used for new structures, for repair and reinforcement of existing structures with following basic categories of use:

• Internal bonded tendon for concrete and composite system • Internal unbonded tendon for concrete and composite system • External tendon for concrete structures with a tendon path situated outside the cross-

section of the structure but inside its envelope.

The prestressing kit described in this ETA offers additionally optional categories of use for which standard tendon characteristics are improved. These options are as follows:

1. restressable tendon (external or internal), 2. exchangeable tendon (external or internal), 3. tendon for cryogenic applications, 4. internal bonded tendon with plastic ducts, 5. encapsulated tendon, 6. electrically isolated tendon, 7. tendon for use in structural steel or composite construction as external tendon, 8. tendon for use in structural masonry construction as internal or external tendon, 9. tendon for use in structural timber construction as internal or external tendon.





PT-anchorage zones have to be designed to resist 1,1 Fpk according to the relevant Eurocode in case of use with other materials than concrete.

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

• bridges (superstructures, piers, abutments, foundations), • buildings (floors, foundations, core walls, walls, columns, shear walls, lateral load

resisting frames, foundations), • reservoirs (walls, slabs, roofs), • silos (walls), • nuclear containment structures, • offshore structures (all parts), • floating installations and platforms (all parts), • retaining walls, • dams, • tunnels (longitudinal and transverse/hoop tendons),• large diameter pipes, • roads and airports.

Categories of Use

Mo

del C

Fix

ed C

ou

plers

CI

Mo

va

ble

Co

up

lers CM

Mo

del F

Mo

del X

Mo

del N

B

Bonded Internal Tendon for Concrete and Composite Structures 3 to 55 1 to 37 3 to 37 1 to 4 1 to 2 1 to 55

Unbonded Internal Tendon for Concrete and Composite Structures 3 to 55 1 to 37 3 to 37 1 to 4 1 to 2

External Tendon for Concrete and Composite Structures 3 to 37 1 to 37 1 to 2

Options (a) Restressable Tendon 3 to 55 1 to 4 1 to 2 (b) Replaceable Tendon 3 to 55 1 to 4 1 to 2 (c) Tendon for Cryogenic Applications 3 to 55

(d) Bonded Internal with Plastic Duct 3 to 37 1 to 37 3 to 37 1 to 4 1 to 2

(e) Encapsulated Tendon 3 to 37 1 to 37 3 to 37 1 to 4 1 to 2 (f) Electrically Isolated Tendon 3 to 37 3 to 37 3 to 37 (g) External Cable for Steel or Composite Structures 3 to 37 1 to 2

(h) Internal/External Tendon for Masonry Structures 3 to 37 1 to 4 1 to 2

(i) Internal/External Tendon for Timber Structures 3 to 37 1 to 2

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





Structures Options

Pre-

stressing

Type

Concrete

Steel

Masonry

Tim

ber

Restressable

Exchangeable

Cryogenic

Encapsulated

Electrical

Isolated

Anchorage &

Coupler Type Model Duct Tensile Element Injection

Anchor

Protection

Sealing

Typical

Drawings

[3]

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

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

Bonded x x x Isolated C, F Plastic [1] Bare Strand Cement Grout Cachetage/Cap 16, 20, 21 x Standard C Steel Bare Strand Grease/Wax Cachetage/Cap 9 x x Standard C Plastic Bare Strand Grease/Wax Cachetage/Cap 9 x x x Standard C Steel Bare Strand Grease/Wax Extended Cap 9 x x x x Standard C Plastic Bare Strand Grease/Wax Extended Cap 9 x x x Standard C Steel Monostrand Cement Grout Extended Cap 10, 11 x x x x Standard C Plastic Monostrand Cement Grout Extended Cap 10, 12 x Standard F Steel Monostrand Cement Grout Cachetage/Cap 23, 24 x x Standard F Plastic Monostrand Cement Grout Cachetage/Cap 23, 24 x x x Standard C, F no duct Monostrand no injection Cachetage/Cap 13, 24 x x x x x Standard C, F no duct Monostrand no injection Extended Cap 13, 24 x x x Isolated C, F no duct Monostrand no injection Cachetage/Cap 13

Internal

Un-

bonded

x x x x x Isolated C, F no duct Monostrand no injection Extended Cap 13, 16, rare x x x x Standard C Steel [2] Bare Strand Cement Grout Cachetage/Cap 9, rare x x x x Standard C Steel [2] Bare Strand Grease/Wax Cap 15 x x x x x x Standard C Steel [2] Bare Strand Grease/Wax Extended Cap 15 x x x x x Standard C Plastic[2] Bare Strand Cement Grout Cachetage/Cap 14 x x x x x x x Standard C Plastic[2] Bare Strand Cement Grout Extended Cap 14 x x x x x Standard C Plastic[2] Bare Strand Grease/Wax Cap 15 x x x x x x x Standard C Plastic[2] Bare Strand Grease/Wax Extended Cap 15 x x x x x x Isolated C Plastic[2] Bare Strand Grease/Wax Cap 15 x x x x x Standard C Plastic[2] Monostrand Cement Grout Cachetage/Cap 12, 14 x x x x x Standard C Plastic[2] Monostrand Cement Grout Cachetage/Cap 12, 14 x x x Standard X Plastic[2] Monostrand Cement Grout Cap 12, 25, 26 x x x x x x x Standard C Plastic[2] Monostrand Cement Grout Extended Cap 12 x x x x x x Isolated C Plastic[2] Monostrand Cement Grout Cap 12

External

x x x x x Standard C, F no duct Monostrand no injection Cap 13, 23, 24

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




English translation 2006.12.08 12/50

NotesStandard Anchorage as per typical drawings, Isolated Anchorage: interposition of isolating liner and seal inside trumplate and at contact to anchor block Cachetage: see drwg 29, Cap: see drwg 30, Extended Cap: see drwg 31 Duct out of Steel or Plastic: Corrugated or Smooth, unless otherwise marked. [1] Corrugated duct only

[2] Smooth duct only [3] References given to drawings are not exhaustive [4] e.g. see drwgs 8, 9, 17, 18, 19, 20, 21, 22, 27, 29 [5] e.g. see drwgs 8, 17, 18, 19, 20, 21, 22, 23, 27

B.1.3 Working Life

The provisions made in this ETA are based on an assumed intended working life of the PT System of 100 years. The indications given on the working life can not be interpreted as a guarantee given by the producer or the approval body, but are to be regarded only as a means for choosing the right products in relation to the expected economically reasonable working life of the structures.

B.2 CHARACTERISTICS OF PRODUCTS AND VERIFICATION METHODS

B.2.1 Characteristics of Products

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

B.2.2 Verification Methods

The assessment of the aptitude of the kit for its intended use, in relation to the requirements for mechanical resistance and stability in the sense of the Essential Requirement 1 has been made in compliance with the Guideline for European Technical Approval (ETAG 013) of “Post-Tensioning Kits for Prestressing of Structures”. Performances examined in conformity to the ETAG 013 satisfy the pertinent essential requirements. These are mainly performances related to static load, transfer on concrete and resistance to fatigue. Methods for check, evaluation and assessment of aptitude for use and test procedures according to those detailled in ETAG 013.

Assessment of experience gathered and specific tests were realised in conformity to ETAG 013 for optional use categories listed in paragraph B.1.2.

B.2.3 Emission of Dangerous Substances

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





In addition to the specific clauses relating to dangerous substances contained in the ETA, there may be other requirements, applicable to the products falling within its scope (e.g. transposed European legislation and national laws, regulations and administrative provisions). In conformity with the provisions of the European directive 89/106/EEC, these requirements must also be complied with wherever they apply.

B.3 EVALUATION AND ATTESTATION OF CONFORMITY AND CE MARKING

B.3.1 Attestation of Conformity System

According to the decision 98/456/EC of the European Commission6 the system 1+ of attestation of conformity applies and is defined as follows :

Tasks of the Manufacturer

1. Factory production control, 2. further testing of samples taken at the factory by the manufacturer in accordance with a prescribed test plan.

Tasks of the Approved Body (Certification Body)

3. Initial type testing of the product, 4. initial inspection of factory and of factory production control, 5. continuous surveillance, assessment and approval of factory production control, 6. audit testing of samples (see ETAG013, section 8.1 (b)).

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

B.3.2 Responsabilities

B.3.2.1 Tasks of the Manufacturer

The manufacturer of the kit has the full responsability of the production and quality of components whether produced by himself or by sub-manufacturers.

The type and frequency of checks and tests conducted during production and on the final product as part of the continuous internal production control are described in the prescribed test plan, Chapter C of this ETA.

All the tests are conducted according to written procedures, by means of adequate calibrated measuring devices. Results are recorded logically and systematically.

If test results do not comply, the produced lot is inspected in detail. It may be rejected, completely or partially. Defectuous parts may be retreated in order to eliminate defects and checks and tests are then repeated.

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

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





Each main component has a prescribed inspection plan, established by Freyssinet and applied by its manufacturers. Production control methods are defined in the Freyssinet Quality Assurance Plan PAQ ATE PRE.

B.3.2.2 Tasks of the Certification Body

Methods of surveillance for production control are defined in the Quality Assurance Plan established and updated by Freyssinet, in conformity with paragraph 8.2.2 of ETAG.

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

The Certification Body checks inspection results, control tests as well as results of production control results and establishes the conformity to the ETA.

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

• corrective intervention, following the notification of the Certification Body, • control strengthening and higher test frequence, • setting-up of modifications.

During continuous surveillance auditing, the Certification Body takes samples to test in independent laboratories. Samples are taken according to the requirements of the table attached in the chapter D of this ETA.

During the certificate validity the ETA holder supplies once a year to the Certification Body anchorages and strands necessary for a test series according to Annex E of ETAG 013 and sends them to the laboratory designated by the Certification Body. These well-identified parts and reinforcement are from the same construction site. If possible construction sites are chosen in such a way that the tensile steel manufacturer will be different from year to year.

B.3.2.3 CE Marking

The CE marking must comply with the European Council Directive 89/106/CEE, and to the EC guideline "D" related to the marking. The delivery bill accompagnying the PT kit components shall bear the conformity CE marking symbol and the following mentions:

1. Name and address of kit manufacturer, 2. Last two digits of the year during which the marking has been made, 3. Number of conformity certificate, 4. Number of ETA, 5. See information on ETA,

6. Number of Certification body, 7. Product Identification (commercial denomination) and use category(ies).

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





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

INTENDED USE WAS ASSESSED

The ETA is issued under the following assumptions:

B.4.1 Manufacture of Product

The ETA is issued for the Freyssinet post-tensioning kit on basis of information and documents submitted by Freyssinet to Sétra, with identification of product tested and assessed. Any modification of characteristics of product or factory production process which might modify the conformity of the kit shall be notified to the Sétra prior to its application. The Sétra will decide if this modification affects the ETA and if a more detailled assessment or amendment of ETA are required.

A Quality Assurance Plan related to the prestressing kit ETA is established and regularly updated by Freyssinet ; it is made available to the Sétra. A list of sub-contractors and component suppliers is part of this Quality Assurance Plan.

Freyssinet is committed to impose the requirements of the present ETA and ETAG 013 upon the producer of his prestressing kit, as well as upon his subcontractors and suppliers.

B.4.2 Installation Design and Execution

B.4.2.1 Design of Structures

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

The designer of the structure is assumed to respect specifications set by applicable standards, e.g. Eurocodes or equivalent applicable national standards, and to adapt his design in accordance with the construction methods foreseen and the instructions of the ETA holder.

The arrangement of anchorages shall respect the specifications of chapter J as to edge and axis distances and bursting steel.

B.4.2.2 Stressing equipment

Stressing jacks shall be calibrated in conformity with Freyssinet procedures, national regulations of Member States and the provisions of ETAG 013 §7.3.

B.4.3 Components not detailed in the ETA

Following components, not detailed in the present ETA, conform European standards or equivalent applicable national standards or regulations:

• Prestressing steel : prEN 10138 • Monostrands : ETAG 013 Annex C1, XP A 35 037 • Steel corrugated sheaths : EN 523 • Steel pipes: prEN 10255, ISO 4200, EN 10216-1, EN 10217-1 • Smooth plastic pipes: prEN 12201 • Cement grout: EN 445, EN 447 • Bursting steel: prEN 10080, EN 10025





B.5 INDICATIONS TO THE MANUFACTURER

B.5.1 Packaging, transport and storage

It is recommended to apply a temporary protection to prestressing steels and steel components of the kit to prevent corrosion during transport from production factory to the site.

Transport and handling of prestressing steel and steel components of the kit shall be done in such a manner as to avoid any mechanical, chemical or physical damage.

Prestressing steels and steel components shall be stored free from humidity. Plastic components and ducts shall be protected from UV radiation.

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

B.5.2 Recommendations for safety

The specialist company shall establish a Unique Document in conformity with the Guidance Directive 89/391/CEE dated 1989.06.12, identifying and analysing recurring risks bound to installation of prestressing. The technician in charge of the prestressing works shall modify this Unique Document to account for the particular and not recurring risks of his working site.

During stressing, standing behind or immediatly close to a jack is strictly forbidden, as well as behind a passive anchorage while stressing at the other end. Wherever necessary, safety rails shall be installed and passing zones for personnel shall be kept free.

B.5.3 Use, maintenance and repair

Durability of prestressed structures requires an adequate periodic inspection. Since any disorder in the structure may result in damage of PT tendons, a specialist company should repair as soon as possible according to adequate procedures.





C – PRESCRIBED TEST PLAN

The following table summarises the test procedures necessary to ensure that all kit components meet the ETA specifications. Sétra has adapted Table E.1 of ETAG 013 according to the importance of the components for the performance of the Freyssinet PT-system.

1 2 3 4 5 6

Component Item Test/ Check

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 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


continued next page





1 2 3 4 5 6

Component Item Test/ Check

Traceability4

Minimum frequency

Documentation

Duct material 7 check CE2 100 % yes


Tensile element material 6 check full 100 % yes

diameter test each coil no

visual inspection3 check each coil no

Constituents of filling cement 7 check full 100 % yes

material as per EN 447 admixtures, additions, …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 to a defined point. 5 detailed dimensions mean measuring of all dimensions and angles according to the specification as given in

the prescribed test plan 6 conformity to applicable national provisions in absence of relevant EN. 7 material checks are included for information only as these are not part of the prescribed test plan.





D – BASIC ELEMENTS OF AUDIT TESTING

Component Item Test/Check Sampling – No. of

components per visit

Trumplate Material according to specification

Test / Check 1

for anchorages C Detailed dimensions Test Main dimensions1 Check Machined anchor block Material according to

specification Test / Check 1

Detailed dimensions Test Main dimensions1 Check Cast iron anchor parts Material according to


for anchorages F, X, Detailed dimensions Test or strand connector P Main dimensions1 Check Wedge, swage Material according to


Heat treatment (if applicable)

Test 2

Detailed dimensions Check 1 Main dimensions

Surface hardness Test 5

Visual Inspection1 Check 5 Single tensile element test

Single tensile element test according to Annex E.3

Test 1 series

All samples taken at random and clearly identified.

1 visual inspection relates to main dimensions, calibration tests, correctness of marking or tag, adequate performing, surface aspect, absence of burrs or faults, absence of cavities, corrosion, coating, etc.





E – PRESTRESSING UNITS AND USE CATEGORIES

E.1 UNITS CODING

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

the first letters ‘TY’ indicate the anchorage type (function): • A: active* internal-prestressing anchorage (*stressing anchorage) • AD: active* replaceable external-prestressing anchorage (*stressing anchorage) • NB: embedded anchorage with trumplate • CI: coupler with individual connectors P • CM: movable coupler with individual connectors P

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

letters ‘M’ indicate the model of the stressing anchorage (component): • C: structural prestressing • F: slab prestressing (one-piece anchorage) • 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 anticorrosion protection: • PE: with plastic sheath (generally polyethylene) • GI: with sliding individually greased/waxed and sheathed strand (monostrand) • EI: with electrical isolation • W: with flexible corrosion-inhibiting product injected (generally wax).

E.2 USE CATEGORIES

E.2.1 Bonded Internal Prestressing for Concrete Structures

Internal prestressing units bonded to the concrete consist of bare strands in a thin-wall corrugated duct made of steel (see G.2.1), plastic (see G.2.2) or smooth steel pipes (see G.2.3) and injected with a cement grout in accordance with EN 447 or Annex C4 of ETAG013.

E.2.2 Unbonded Internal Prestressing for Concrete Structures

Unbonded internal prestressing tendons consist of one of the following types: W units: tensile elements housed in a steel or plastic duct injected with a soft filling material,





GI units: tensile elements made of monostrands. Outside the anchorage zones, monostrands are either placed in a round or flat duct injected with cement grout prior to tensioning or installed directly in the structure, in accordance with design requirements. Unbonded internal prestressing tendons allow re-stressing and the steel part of tensile elements is replaceable.

‘A n C 15 W’ anchorages can be used to make electrically isolated prestressing tendons if the measures described in paragraph E.2.4 have been taken.

E.2.3 External Prestressing for Concrete Structures

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

• Standard type: with double tube where the tendon passes through the concrete of the structure, to ensure the independence of the tensile element and its duct from the structure and to enable extraction. The duct is injected with cement grout.

• Type W: with a duct injected with a flexible corrosion-inhibiting product enabling the tensile element to be extracted.

• Type GI: with monostrands housed in a general duct injected or not with cement grout before tensioning.

‘AD n C 15’ anchorages can be used to make electrically isolated prestressing tendons if the measures described in paragraph E.2.4 have been taken.

E.2.3.1 Standard Tendons

Tensile elements are housed in a continuous HDPE plain tube. At anchorages the trumplates are fitted with a plastic trumpet welded to the tube. A watertight gasket between the two parts allows dismantling.

Where tendons pass through concrete a double casing is realised by means of a second tube used as a concrete formwork which ensures the independence of the HDPE tube from the concrete.

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

E.2.3.2 GI Tendons

Tensile elements consist of monostrands grouped together in a plastic duct, injected or not with cement grout prior to tensioning. The anchorage head is protected by a permanent cap filled either with a soft corrosion protection material fully compatible with that of monostrands or injected with cement grout.

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

E.2.3.3 W Tendons

Tensile elements are housed in a continuous HDPE plain tube. At the anchorages, the trumplates are fitted with a plastic trumpet welded to the tube. A watertight gasket between the two parts allows dismantling. Double tubing is not necessary to ensure dismantling.





After tensioning, the tendon is injected with a soft corrosion protection material, such as a microcristaline petroleum wax. The anchorage head is protected by a permanent cap which allows the injection of the tendon.

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

E.2.3.4 Non-Replaceable External Prestressing Tendons

In this exceptional case, external prestressing tendons consist of anchorages identical to those used for bonded internal prestressing tendons. Thin-wall corrugated ducts are prohibited in all exposed sections of tendon. Steel tubes may be used for sections embedded in concrete.

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

E.2.4 Common Application Options

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

Freyssinet prestressing anchorages can be used to make prestressing tendons with a watertight casing when used with a watertight plastic duct, a permanent cap to cover the anchorage head and watertight connections between each section of the casing.

Model C anchorages can be used to make electrically isolated prestressing tendons. These tendons consist then of strands housed in an electrically isolating plastic casing comprising in particular:

• a plastic trumpet fitted inside the trumplate, • a bearing plate made out of an electrically isolating composite material placed under

the anchor block, • a plastic cap.





Applications Types Models Corrosion

Protection

with steel duct -

with plastic duct

A NB - C

CI

C - F C

C - F PE

Bonded Internal Prestressing

electrically isolated with plastic duct

A - CI - CM C EI

with monostrands A

NB

C - F - X C - F GI

injection with soft protection material

A C W Unbonded Internal Prestressing

injection with soft protection material and electrical isolation

A C WEI

injection with cement grout

C -

with monostrands C - X GI

injection with soft protection material

C W

External Prestressing

electrically isolated

AD

C EI

Table 4. Concrete Structures – Use Categories

E.2.5 External Prestressing for Steel Structures and Composite Structures

Model C anchorages are used in the case of steel structures, without the standard load-spreading component (trumplate) which is replaced by a bearing plate of a size in accordance with the strength of the steel of the structure (see EN 1993 and EN 1994).

E.2.6 Prestressing for Masonry Structures

Model C anchorages are used in the case of masonry structures, without the standard load-spreading component (trumplate) which is replaced by a bearing plate of a size in accordance with the strength of the masonry of the structure (see EN 1996).

E.2.7 Prestressing for Timber Structures

Model C anchorages are used in the case of timber structures, without the standard load-spreading component (trumplate) which is replaced by a bearing plate of a size in accordance with the strength of the timber of the structure (see EN 1995). ‘1 F’ anchorages can be used for timber structures if adequately embedded by means of epoxy resin.





E.3 PARTICULARITIES OF THE KIT

E.3.1 Possibility of individual tensioning strand by strand

In the case of stressing anchorages for units comprising monostrands, the strands may be tensioned either collectively with a multistrand jack, or individually with a monostrand jack, proceeding in several loading stages, if cement grouted before tensioning.

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

end to the other

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

E.3.3 Adjustment of prestressing load

In the case of prestressing tendons with monostrands (type GI) or injected with a flexible filling product (type W), it is possible to adjust the prestressing load at any time during service life if tendon overlengths have been maintained. The overlengths are protected by an adequately long protection cap.

E.3.4 Possibility of monitoring prestressing load

When an ‘A n C15(or C13)’ or ‘AD n C15(or C13)’ anchorage uses a threaded block, the load in the tensile element can be monitored with a special ring jack installed between the anchor block threaded ring and the anchorage trumplate.

E.3.5 Possibility of detensioning

A non-grouted tendon can be detensioned with a monostrand jack and a detensioning stool 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 wedges with a blow torch, one by one. Special precautions must be taken at the other end to contain any strand expulsion within special protective systems.

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

Once detensioning has been performed as described in paragraph E.3.5, and on condition that both ends can be easily accessed, a tendon can be replaced without demolishing.

In the case of tendons with type CI couplers, this operation is possible only for the primary part of the tendon, before concreting of the secondary part.

When the prestressing tendon consists of monostrands, each strand can be replaced by a strand of the same sectional area if the alignment of the tensile element is straight or slightly deviated, and by a strand of smaller sectional area in other cases. When a new strand is threaded in, a protective product of the same quality as that of the strand replaced must be introduced into the individual sheath left in place.





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

without damage to the duct

An unbonded prestressing tendon is fitted with a model C 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 33).

E.3.8 Temporary or permanent caps

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

E.3.9 Equitension

In the case of a prestressing unit with model C anchorages, when it is to be ensured that the initial length of each strand is the same prior to tensioning, a pre-tensioning operation can be carried out with the equitension jack. It has as many tensioning chambers as there are strands to be tensioned, and takes up any slack in the strands individually.

E.4 FORCES OF PRESTRESSING TENDONS

Maximum forces beneath the anchorage during tensioning, F0, must be taken from standards or regulations in place of use. Values shown in the following table, comply French regulations which are identical to the values recommended by Eurocode2.

The number of strands in a tendon may be decreased either by reducing the number of drilled holes in the anchor block (special order to factory) or by leaving out strands in the anchorages or couplers. In both cases the strands are placed in the best possible symmetrical manner. The provisions for tendons with completely filled anchorages and couplers also apply to partially filled ones.





Tensile Strength (N/mm²)

1770 1770 1860 1860 1860 1860

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

1 196 211 137 148 206 221

2 392 421 274 295 412 443

3 589 632 410 443 618 664

4 785 842 547 590 824 886

5 981 1053 684 738 1031 1107

6 1177 1264 821 886 1237 1328

7 1373 1474 958 1033 1443 1550

9 1766 1895 1231 1328 1855 1993

12 2354 2527 1642 1771 2473 2657

13 2551 2738 1778 1919 2679 2878

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

Nu

mb

er o

f S

tran

ds

55 10791 11583 7524 8118 11336 12177

Table 5. Maximum Force with Stressing Limit Fo = min{0,8 Fpk,0,9 Fp0,1%} acc. Eurocode 2 and prEN 10138-3:2006 (only informative)

F – ANCHORAGES

Freyssinet active anchorages are based on the wedge principle and use the Freyssinet C-wedge. Each wedge is anchored in a conical hole of the anchor head, which is either a steel block for anchorage models C, or a cast iron part for strand couplers and for anchorage models F and X. Depending on situations, the anchorage block seats on a cast iron load spreading part, called trumplate, or on a steel plate for structures other than concrete ones, the dimensions of which depend of the strength of the structure.





F.1 DESCRIPTION OF ANCHORAGE COMPONENTS

Main dimensions are given on the drawings in Annex K.

F.1.1 Anchorage Wedge

The Freyssinet anchor wedge is a conical one-use wedge, consisting of three matching wedges held together by a circlip. Two models of wedges are available: - the C13 wedge used with T13 and T13S strands, - the C15 wedge used with T15 and T15S strands.

Its internal diametre is adapted to the strand diameter class: either T15/T15S (C15 wedge), or T13/T13S (C13 wedge).

Anchorage wedges are precision machined from hot-rolled or cold-drawn rods of cement steel defined by reference to standard EN 10084 and are case hardened. The steel grade is 16MnCr5.

F.1.2 Anchorage Swage

Internal fixed anchorages are made with anchor swages made by swaging a tubular section enclosing a spiral spring onto each strand using a special Freyssinet jack. There are two standard versions and a compact version:

- T13D swage is used with T13 and T13S strands - T15D swage is used with T15 and T15S strands - T15DC compact swage is used with T15 and T15S strands.

Swages are turned from hot-rolled bars of tempered and quenched structural alloy steel defined in reference to standard EN 10083-1. The used grades are 34CrMo4 and 36CrNiMo4.

F.1.3 Steel Anchor Blocks

F.1.3.1 Model C Anchor Blocks

Model C anchorage heads are circular steel blocks with conical holes cut out of hot-rolled bars. These anchorage blocks have a strength class 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 stress on the electrical isolation plate .

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

Note 3: when an external thread is necessary for monitoring prestressing load, the anchor block shall have a larger diameter in order to cut the thread outside the original anchor block size.





F.1.4 Castings for Anchorages

F.1.4.1 Model F 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.

F.1.4.2 Individual strand connectors type P

The body of the type P strand connector is made of bainitic spheroidal graphite cast iron defined by reference to standard EN 1564. The grade is EN-GJS-1000-5.

F.1.4.3 Load Spreading Parts or Trumplates

The trumplates of type ‘NB n C15 (or C13)’, ‘CI n C15 (or C13)’ and ‘C n C15 (or C13)’ anchorages are identical to those of type ‘A n C15’ anchorages. Trumplates of type ‘AD n C15 (or C13)’ differ from those of type ‘A n C15 (or C13)’ anchorages only in their internal shape which allows for placement of a plastic trumpet and a seal.

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 above size 13C15;

grade is EN-GJS-500-7.

F.1.4.4 Model C Anchorage Caps

Anchorage caps are generally castings of: - grey cast iron defined in reference to standard EN 1561; the most commonly used grade is

EN-GJL-250; or - spheroidal graphite cast iron defined in reference to standard EN 1563; the most

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

F.1.5 Conditioning and Temporary 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 C15 wedges are colour-coded differently to those of type C13 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 and X anchorages and the trumplates of

model C anchorages may be zinc coated to a thickness of at least 70 �m by the hot-dip process in accordance with standard EN ISO 1461, except for the wedge housings;

- the cast-iron anchorage component of the model X anchorage may be coated with polyamide, except for the wedge housings.





F.1.6 Characteristics of Plastic Parts

F.1.6.1 Plastic Trumpets

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

F.1.6.2 Electrical Isolation Plates

Electrically isolated anchorages are fitted with an electrical isolation plate between the anchorage block and the trumplate. The plate is generally a glass-reinforced thermosetting resin.

F.1.6.3 Plastic Caps

Plastics caps are made from polyolefin.

F.2 RECOMMENDATIONS FOR USE OF ANCHORAGES

Regulations valid at place of use shall be considered.

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

Tightness at connection between anchorage and duct if realised either by adhesive tape or heat-shrink sleeves. For F anchorage models used with monostrands the sealing between anchorage and monostrands is realised by means of a mastic plug.

F.2.1 Stressing Anchorages

Size of anchorage reservation and clearance for placing the stressing jack should be checked at the design stage (see drawings 34 to 44).

F.2.2 Model X Anchorages

Loop tendons are stressed simultaneously at both ends by means of single-strand jacks (see drawings 45 and 46).

F.2.3 Anchorages for External Prestressing

Exchangeable external prestressing tendons injected with cement grout are realised by means of a double duct at deviation or anchoring points :• A minimum gap of 10mm between the two ducts is required. • External shuttering tube, generally out of steel, • Tendon duct, continuous between anchorages (see drawing 14)





F.2.4 Embedded Fixed Anchorages Model NB

Model «NB n C 15» anchorages consist of an anchor block with cylindrical holes and swages. Type T13D swage is used for T13 and T13S strands, and type T15DC for T15 and T15S strands. Swages are realised before concreting and maintained in position with a locking template.

F.2.5 Fixed Couplers

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

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

The secondary cable is connected to the primary cable by means of type P strand connectors. 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 and eliminates possible effort transfer through the cap during tensioning of the coupled secondary tendon. • at the other end the cap is formed as a trumpet to allow its connection to the second phase cable duct.

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

Each strand of the primary cable is connected to the corresponding srand of the secondary cable by means of a type P strand connector. The complet assembly is covered with a cap ensuring the same functions as the one for fixed couplers. This cap must allow for the elongation of first phase cable and the resulting displacement of strand connectors. In practice, the cap length is therefore adapted to each case.

F.2.7 Case of Monostrands

When directly embedded in the concrete structure, without overall duct, monostrands are fixed on supports arranged within the general steel reinforcement. In case of large cable units exceeding 6 monostrands, monostrands should be arranged in groups of 3, the distance between each of them being sufficient to allow a correct concreting (see drawing 13).

When monostrands are placed in a general duct (see drawings 10 to 12), the duct is injected with cement grout and tensioning is done after the grout has reached a 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 32). After removal of the stuffing box, ends of strands are freed from their sheath to receive the anchor block, to be stressed and injected by grease under pressure.





F.2.8 Electrically Isolated Tendons

The envelope of electrically isolated tendons consists of plastic ducts with thermo-shrink PE connections. In particular multi-strand fixed couplers type «CI n C 15 EI» and movable couplers type «CM n C 15 EI» are isolated in a PE or PP cap. An isolating plate is inserted between the trumplate and the anchor block before stressing.

G – TENSILE ELEMENTS AND DUCTS

G.1 TENSILE ELEMENTS

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

G.1.1 Standard Designation of Strands

Tensile elements consist of: • Either strands with nominal diametre 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 diametre 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.

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 1820 or 1860) – A + (Z or ZA) + G + P. The G attribute means protection with grease and P means sliding, i.e. the strand is free to slide in its individual sheath, even embedded in concrete, allowing for its stressing without any bond to the concrete of the structure.

G.1.2 Maximum Force in Strand

The maximum stressing force F0 at anchorage indicated in the following table for a single strand has been calculated in accordance with Eurocode 2. It must be adapted to the applicable national regulations.





Tm D S Fpk M Fp0.1% Fo To

MPa mm mm² kN kg/m kN kN N/mm²

1770 12.5 93 165 0.726 145 130.5 1416

1770 12.9 100 177 0.781 156 140.4 1416

1770 15.3 140 248 1.093 218 196.2 1416

1770 15.7 150 266 1.172 234 210.6 1416

1860 12.5 93 173 0.726 152 136.8 1488

1860 12.9 100 186 0.781 164 147.6 1488

1860 15.3 140 260 1.093 229 206.1 1488

1860 15.7 150 279 1.172 246 221.4 1488

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

Fp0.1% characteristic value of load at 0,1% elasticity limit Fo Indicative maximum force at stressing anchorage: Fo = Min { 0,8 Fpk ; 0,9 Fp0.1%} m Nominal mass per metre S Nominal area To Tensile stress under Fo

Tm Tensile stress at break

Table 6. Maximum Force at Stressing Anchorage for a Single Strand acc. to Eurocode 2 and prEN 10138-3:2006 (only informative)

G.2 DUCTS

The Freyssinet prestressing kit for post-tensioning may be used with different types of duct depending the project and the use categories of tendons.

The typical internal diametre of ducts is defined on the drawings in Annex K for each anchorage model, which may be increased if required by the project specifications or the national regulations. In the case of prefabricated cables threaded in one operation, the duct internal diametre may be increased in sections with large deviation curvature to facilitate threading.

G.2.1 Steel Strip Sheaths

Steel strip sheaths are either circular or oval, generally corrugated to ensure a mechanical bond with the concrete. The overall external dimensions of steel strip sheaths are about 6 mm larger than the internal dimensions because of corrugation. This must be taken into account in the design.





G.2.1.1 Circular Steel Strip Sheaths

Sheaths are purchased according to prEN 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.

Diametre

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

100 100-130

130-160

Category

1 0,25 0,25 0,30 0,30 0,35 0,35 0,40 0,40 0,40 min.

thickness

of sheath

(mm) Category

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

Table 7. Thickness of Steel Strip Sheaths

Sheath sections are connected together with helical sleeves screwed onto the ends of the sheaths. The watertightness at connections is obtained by adhesive tape or heat-shrink sleeves.

G.2.1.2 Oval Steel Strip Sheaths

Model F tendons are generally used together with oval or so-called ‘flat’ sheaths. These are oblong sheaths with a stiffening corrugation. Lengths of duct are connected by use of sleeves of the same shape. The watertightness at connections is obtained by adhesive tape or heat-shrink sleeves.

G.2.1.3 Option: Galvanisation

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

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

On request, crimped sheaths may be made out of soap-lined phosphated steel strip in order to reduce the friction coefficient between strands and duct during tensioning.

G.2.2 Corrugated Plastic Ducts

Plastics ducts may be of high-density polyethylene (HDPE) or polypropylene (PP). They conform Appendix C.3 of ETAG 013 and meet the requirements of fib technical bulletin ‘Corrugated plastic ducts for internal bonded post-tensioning’.

The ducts may be circular or flat, but are always corrugated to ensure a bond with the concrete. The overall outer dimensions of a corrugated plastic duct are about 13 mm larger than its internal dimensions because of corrugation. This must be taken into account in the design.

Plastics ducts are sensitive to wear induced by movement of the strands in the duct during tensioning. Duct thickness is selected in accordance with the severity of the tendon alignment (total length and radii of curvature).

Special precautions must be taken if the temperature of the surrounding concrete is likely to exceed 60°C during setting or if the external pressure is likely to exceed 0,5 bar.





G.2.2.1 Plyduct��

The Plyduct� sheath is circular, made out of a polyethylene or polypropylene strip. It is 2,5 mm thick for duct diameters up to 95 mm and 3,0 mm thick for larger diameters. Sheath sections are connected by a sleeve of the same design as the basic sheath screwed onto the sections to be joined together. Watertightness at connections is obtained by heat-shrink sleeves coated on the inside with a hot-melt resin which are shrunk onto the sheath with a hot-air blower. The dimensions of the heat-shrink sleeves are chosen so as to have a residual thickness of at least 1,5 mm after shrinking.

G.2.2.2 Flat Ducts

Model F tendons can be used with flat plastic sheaths of high-density polyethylene (HDPE) or polypropylene (PP). Duct sections are connected by a sleeve of the same design as the basic sheath placed onto the sections to be joined together. Watertightness at connections is obtained by heat-shrink sleeves coated on the inside with a hot-melt resin which are shrunk onto the sheath with a hot-air blower. The dimensions of the heat-shrink sleeves are chosen so as to have a residual thickness of at least 1,5 mm after shrinking.

G.2.3 Smooth Steel Pipes

The steel pipes used as prestressing ducts are generally chosen in compliance with one of the following standards: EN 10305-3 (welded cold-sized tubes), EN 10216-1 (seamless tubes), EN 10217-1 (welded steel tubes) or prEN 10219 (fine-grain steel pipe).

Pipes can be zinc-coated by hot-dip galvanising in accordance with standard EN ISO 1461, if allowed by the applicable national regulations.

G.2.4 Smooth Plastic Pipes

G.2.4.1 Pipes for External Prestressing

Pipes for external prestressing are made of high-density polyethylene (HDPE) and purchased in reference to standards EN 12201-1 and 2, without consideration of properties affecting water quality.

The polyethylene used is PE80 or PE100. Nominal pressure class (table 2 of standard EN 12201-2) is chosen as follows:

• Class PN4.0 at least, for injection prior to tensioning of monostrands, • Class PN6.3 at least, for injection at ambient temperature, • Class PN10 at least, for injection at temperatures exceeding 60°C (wax injection).





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

EN 12201-2 PE 80 PE 100

Series Low pressure Pressure Pressure

PN** 6.3 10 10 SDR 21 13.6 17

Nominal external

diameter Thickness Thickness Thickness

(mm) (mm) (mm) (mm) 50 3.7* 3.7 63 4.7* 4.7 75 5.5* 5.5 90 6.6* 6.6

110 5.3 8.1 125 6.0 9.2 140 6.7 10.3 160 7.7 11.8 180 8.6 10.7 200 9.6

SDR: ratio of external diameter to nominal wall thickness * these pipes have not standardised dimensions ** PN values are based on a global service factor C = 1.25

Table 8. Dimensions of Smooth HDPE Tubes

Ducts for external prestressing are delivered in straight lengths. The most common lengths are 6 and 12 m. Lengths of pipe are connected by mirror welding or by means of polyethylene sleeves electro-welded.

G.2.4.2 Indented Pipes for Hoop Tendon Anchorages

Hoop prestressing tendons are used with continuous polyethylene or polypropylene pipes, generally extruded and supplied on reels. These pipes are smooth or indented for centering the strand in its duct.

G.2.5 Liaseal�� Duct Connector

The Liaseal� duct connector is a polyolefin component providing a sealed connection between lengths of duct that is used in the construction of precast concrete segments for bridge construction (drawing 27). Used in conjunction with the Plyduct� duct, the Liaseal�

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





G.3 CABLE LAY-OUT

G.3.1 Alignment at Anchorage

Close to anchorages the duct must guide the tensile element so that its strands bear against the deviation zone of the trumplate and enter the holes in the anchorage head at the correct angle: in practice the cable lay-out must be straight on a length of at least 6 times the duct internal diametre, between the trumplate end and the start of the curved section.

G.3.2 Curvature Radii

G.3.2.1 Internal Prestressing

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

Stand Type Duct Type Minimum Curvature

Radius

steel 100 x internal diametre 2, 3

Flat duct Plastic 100 x internal diametre 3

Steel 100 x internal diametre Circular duct Plastic 100 x internal diametre

Bare Strand

Tube Steel 3,0 m 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

Monostrand

Single strand Dead anchorage

(180° hoop) 0,6 m

1 according to ENV 1992-1-5:1994 2 concrete stability against splitting to be checked and simultaneous stressing at both ends 3 flat duct dimension in the considered direction

Table 9. Minimum Curvature Radius for Internal Prestressing

In the case of bonded prestressing, the minimum radius of steel tubes can be reduced down to 20 times the internal diameter, assuming that: - the resulting radius is not less than 1,1 m for T13 strands and 1,3 m for T15 strands, - the tensile stress does not exceed 70% of strand guaranteed tensile strength where the

radius is less than 3,0 m, - the sum of angular deviations along the cable is less than 3π/2 radians, - the sharply curved zone is considered as a dead anchorage if the angular deviation exceeds

π/2 radians.





G.3.2.2 Removable External Prestressing

In the absence of more restrictive national specifications, the minimum curvature radius in deviators, normally made out of curved steel pipes, is defined as follows:

Tendon Minimum Curvature

Radius at Anchorages

Minimum Curvature

Radius in Deviators

7C15 3,0 m 2,0 m

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

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

27C15 4,5 m 3,5 m

37C15 5,0 m* 4,0 m

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

Table 10. Minimum Curvature Radius for External Prestressing

G.3.3 Support Distances and Tolerances

The maximum distance between duct supports is 1,0 m for straight sections or with high curvature radius and 0,5 m for sections with small radius. In the case of smooth steel pipes, at least one support at each elementary length shall be placed but the distance shall not exceed 3 m.

Any axial thrust along the pipe must be balanced by appropriate arrangements at the bottom of the formwork. 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 draft standard ENV 13670-1. Special attention must be given to tendon breakout induced by deviated cables near an outside surface: the local positioning tolerance will have to be determined in accordance with the lay-out of the passive reinforcement.





H – TENSIONING

H.1 TENSIONING EQUIPMENT

Freyssinet equipment is covered by an EC declaration of conformity for new or rental equipment. Clearance for jacks at tensioning end must be made available in accordance with drawings 34 to 46. This clearance must remain available during service life of the structure if force adjustment, load monitoring or replacement of tendon has been foreseen.

H.2 PARTICULAR RECOMMENDATIONS

H.2.1 Tendons with Couplers

Tensioning of secondary cables shall be such as to avoid the force at coupler end to exceed that of the primary cables after blocking.

H.3 RECOMMENDATIONS FOR TENSIONING AND CONTROL

H.3.1 General Method for Tensioning

Tensioning is done in accordance with the Freyssinet procedures, the specifications of ETAG 013, CWA 14646, ENV 13670-1 and applicable national regulations.

H.3.2 Measurements of Stressing Forces

Force readings must take into account calibration of tensioning equipment and losses due to friction in anchorages as given in the following table:

Bare Strands Monostrands

Anchorage Model Min. Max. Min. Max.

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

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

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

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

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

* tensioning using jack with curved front adaptor-fitting

Table 11. Friction Loss in Anchorages





I – PROTECTION OF TENDONS

I.1 LUBRICATION AND TEMPORARY PROTECTION

Temporary protection of tensile elements is obtained by factory-applied soluble oil. If storage of strands on site is longer or if tendon injection cannot be done in due time after tensioning (delay exceeding four weeks), this temporary protection must be regularly renewed, in conformity with applicable specifications. This lubrication may also be used to reduce friction coefficient of cable inside duct.

I.2 FILLING MATERIALS USED

I.2.1 Cement Grout

Cement grout is a stable, uniform mix of Portland cement, additives and water obtained by a mechanical mixing process. It is screened and kept agitated in a storage tank until injected into the duct.

Freyssinet prestressing tendons can be injected with: • either a common grout complying with the requirements of European standards

EN 447 (requirements for common grout) and EN 445 (test methods). The grout setting can be retarded to provide a longer groutability,

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

I.2.2 Wax

The wax for injecting prestressing tendons shall be a petroleum wax meeting the requirements of paragraph C.4.2 of ETAG 013.

I.2.3 Grease

The grease for Freyssinet prestressing tendons shall be a mineral-oil-based grease meeting the requirements of paragraph C.4.1 of ETAG 013.

I.3 INJECTION EQUIPMENT

Mixers, wax melting units, and pumps supplied by Freyssinet for injecting tendons are all subject to an EC declaration of conformity with the applicable regulations governing new or rented equipment.





J – MECHANICAL AND GEOMETRICAL CONDITIONS OF USE

J.1 FRICTION LOSSES AND ELONGATIONS

J.1.1 Friction in Tendons

The coefficients of friction (µ) and of wobble (k), as defined in European standard pr EN1992-1-1 to obtain the prestressing force with the equation P(x) = Pmax e

-µ(θ+kx), vary in accordance with uses (internal or external prestressing, standard strands or monostrands), the type and stiffness of ducts (steel or HDPE strip sheath or pipe), surface treatments, lubrication of the strands, whether with soluble oil or grease.

The acceptable variation of the coefficient of friction is usually ±25%. The coefficient of friction can rise significantly in deviation zones with a curvature radius less than 6 metres. The coefficients in the following table are for information only (and must be adapted to each project).

Friction Coefficient µ µ µ µ(rad

-1) Use Duct Type

Lubricated

Strand

Unlubricated

Strand

Wobble factor k

(rad/m)

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

LFC 3 Corrugated steel sheath

0,10 0,12 0,007 1

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

Internal Prestressing

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

HDPE pipe 0,10 0,12 0 External Prestressing

Steel pipe 0,16 0,24 0

Single Monostrands 0,05 2 0,007 2

Unbonded Internal

Prestressing Group of Pre-Grouted

Monostrands 0,05 0,012

1 as per standard EN 1992-1-1: 2004 2 as per standard ENV 1992-1-5: 1994 3 Freyssinet phosphated duct

Table 12 Friction and Wobble Coefficient





J.1.2 Parameters for Evaluation of Elongation during Stressing

J.1.2.1 Pull-In at Wedge Blocking

At end of stressing the jack is released and the wedges are pulled-in into the anchorage block to anchor the strands. Freyssinet jacks can allow a hydraulic blocking to reduce the pull-in amount.

The elongation loss with or without hydraulic blocking shall be accounted for in tensioning calculations by using the values given in the following table.

Stressing Jack with hydraulic blocking without hydraulic blocking

Strand diametre T13 T15 T13 T15

min 4 4 6 6

mean 5 6 7 8

Pull-in at

stressing

anchorage

mm max 6 8 8 9

Table 13 Wedge Pull-In at Stressing Anchorages

J.1.2.2 Pull-In at Passive Anchorages

The pull-in value at passive anchorage creates a translation of the cable and increases the elongation at stressing end. This value must be deduced from the measured elongation at each stressing step.

The mean pull-in values at passive end are: • T13 strand: 5 mm, • T15 strand: 6 mm.

J.1.2.3 Pull-in within Type P Coupling Units

The mean pull-in values within strand connectors are as follows: • T13 strand: 10 mm, • T15 strand: 12 mm.

J.2 GEOMETRICAL CONDITIONS OF USE

J.2.1 Clearance behind Anchorages

Behind each anchorage a clearance must be reserved to allow for: • Installation of wedges, • Placing of stressing jack, • Sufficient protection cover of cable end after cutting-off of strand overlengths, • Installation of temporary or permanent cap, if necessary.





In the case of an active anchorage the necessary clearance for jack placing and actioning is described in the drawings given in Part K thereafter.

For external passive anchorages a minimal clearance of 500 mm allows the installation of wedges on protruding strands.

J.2.2 Lateral Cover and Distances

Anchorages must have a sufficient edge distance and be separated from each other by a minimum centre distance. These distances are derived from reference dimensions a and b of the test specimens.

In what follows, it is considered that anchorages are positioned relative to two orthogonal directions x and y, with the smaller dimension of the trumplate aligned along axis x.

Notations: • A, B: plane dimensions of the trumplate (A � B), • a, b: side lengths of test specimen (a � b), • x, y: minimum centre distance between two anchorages in the structure in x- and y-

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

x- and y-directions, • fcm,o: mean compressive strength measured on cylinder required before tensioning.

Dimensions x and y shall satisfy the following conditions: x ≥ A + 30 (mm) y ≥ B + 30 (mm) x . y ≥ a . b x ≥ 0,85 a y ≥ 0,85 b x’ ≥ 0,5 x + concrete cover – 10 (mm) y’ ≥ 0,5 y + concrete cover – 10 (mm)

y y y’

x’

x

x’

x

y’y’

A

BB

A





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

a = b (mm)

fcm,o (MPa)

Unité 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

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

55 C15 1070 750 690

Table 14 Minimum Edge Distances for C-Model Anchorages

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

1 F 13/15 22 190 140

3/4 F 13 22 500 160

3/4 F 15 22 390 190

Table 15 Minimum Edge Distances for Model F Anchorages

If the project calls for a value fcm,o other than any of those in the two 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 and 15 (e.g. 24 MPa for model C anchorages).

For partial tensioning or for a tension of less than Min{0.8 Fpk; 0.9Fp0.1%}, the required value for fcm,o can be determined by interpolation considering that at 50% of the total force, the required concrete strength can be reduced to 2/3 of the values given in the two tables above





and at 30% of the total force, the required concrete strength can be reduced to 1/2 of the values given in the same tables.

J.3 BURSTING REINFORCEMENT

In anchorage zone prestressing tendons impose to the structure concentrated forces requiring a specific arrangement of reinforcement. In case of concrete structures, bursting reinforcement consists in:

• Surface reinforcement, • Anchorage bursting reinforcement, • General reinforcement to equilibrate mechanically the concerned piece within the

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

Anchorage bursting reinforcement as defined thereunder results from load transfer testing. If required the local zone reinforcement specified in the ETA may be modified for a specific project design in accordance with national regulations and relevant approval of the local authorities and of the ETA holder to provide equivalent performance.

J.3.1 C-Model Anchorages

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

The diagrams below define the general layout of bursting reinforcement when cross-laid wave-form bars are used. Each layer has two cross-laid bent bars. For practical reasons, each bent bar can be replaced by two stirrups of at least equivalent resisting section (see diagram below).

General reinforcement not shown General reinforcement not shown

CCC0 C0C





��

wfb (wave-form bursting steel)

��

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.

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

AnchorNumber

of Layers

Comm

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 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 20 130 250 630 175 20 4 31C15 4 210 150 wfb 20 130 255 670 180 20 4 37C15 4 250 225 wfb 20 130 270 740 130 25 5 55C15 5 290 200 wfb 25 160 340 1050 200 20 6 * wfb – wave-form bar

Table 16 Bursting Steel for fcm,o = 24 MPa






AnchorNumber

of Layers

Comm

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



AnchorNumber

of Layers

Comm

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






J.3.1.2 Helical reinforcement

The diagram below defines the general layout of bursting reinforcement when a circular helical device is used. This arrangement is preferable with isolated anchorages or anchorages on several rows.

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 19 C 15 60 16 8 40 470 180 20 4 22 C 15 70 16 8 40 510 130 16 6 25 C 15 80 20 7 40 550 175 20 5 27 C 15 80 20 7 40 570 175 20 4 31 C 15 80 20 7 40 600 180 20 5 37 C 15 90 20 7 40 660 130 25 5 55 C 15 100 25 9 40 930 200 20 6

Table 19 Helical Bursting Steel for fcm,o = 24 MPa

C0






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 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 55 C 15 100 25 10 40 650 250 20 3



Anchor Pitch

(mm)

Diameter d

(mm)

Number Co (mm)

External Diameter D

(mm)

Pitch

(mm)

Diameter d (mm)

Number

3 C 15 50 8 5 40 150 150 8 2 4 C 15 60 10 5 40 160 150 8 2 7 C 15 60 12 6 40 200 160 10 3 9 C 15 70 14 6 40 250 200 12 2

12 C 15 50 14 7 40 260 200 12 2 13 C 15 70 14 7 40 290 135 12 3 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 55 C 15 100 25 9 40 600 180 16 3


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





J.3.2 Model F Anchorages

J.3.2.1 Anchorage A 1F13 and A 1F15

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

J.3.2.2 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 3F13A 4F13

∅10





J.3.2.3 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

K – DRAWINGS

46 drawings distributed in 40 pages follow.

bar types

A 3F15A 4F15

see bar types below



















































































Documents

Post Tension Ing Cables ETA 06 0226