PRESTRESSING TECHNOLOGY - Structural Systemsstructuralsystemsuk.com/downloads/PreStressing.pdf · 4. PrEStrESSinG TECHNOLOGY. . POST-TENSIONING. DESIGN DATA. STRAND PROPERTIES. STANDARD

PRESTRESSINGTECHNOLOGY

www.structuralsystems.com.au

Post-stREssING tECHNoLoGY

w w w . s t r u c t u r a l s y s t e m s . c o m . a u

INtRoduCtIoN PAGE 03

Post-tENsIoNING dEsIGN dAtA PAGE 04

MuLtI-stRANd Post-tENsIoNING PAGE 05

sLAb Post-tENsIoNING PAGE 17

MuLtI-WIRE Post-tENsIoNING PAGE 28

bAR Post-tENsIoNING PAGE 31

GRouNd ANCHoR sYstEMs PAGE 35

ExtERNAL PREstREssING PAGE 38

CAbLE stAY sYstEMs PAGE 40

INCREMENtAL LAuNCHING sYstEMs PAGE 44

HEAVY LIFtING sYstEMs PAGE 45

LoAd HANdLING sYstEMs PAGE 46

Data contained herein is subject to change without notice. Use of information and details presented in this document should be verified by a qualified engineer for suitability to specific applications.

Emirates Tower - Dubai

3w w w . s t r u c t u r a l s y s t e m s . c o m . a u

Wandoo Concrete Gravity Structure - Western Australia

introductionStructural Systems is a specialist professional Engineering and Contracting Company, which provides innovative skills and services to the Construction and Mining Industries both nationally and internationally. Operations commenced as BBR Australia Pty Ltd in 1961 and became the public company, Structural Systems Limited in 1987.

Our innovative design, advanced construction techniques and effective project management skills make Structural Systems the leader in the design and installation of prestressing systems.

The wide range of services and systems offered in this brochure are readily available through our network of offices and a Structural Systems representative is available to talk directly to you regarding your project.

Eleanor Schonell Bridge - Queensland

4

PrEStrESSinG TECHNOLOGY


POST-TENSIONING DESIGN DATASTRAND PROPERTIES

STANDARD NOMINALDIAMETER

mm

STEEL AREA

mm2

MASS

kg/lm

STRANDMBL / Fm(7)

kN

MIN. PROOF LOAD

kN

STRAND RELAXATION(6)

(%)

MODULUS OF ELASTICITY

MPa

AS 4672(1)

12.7 super15.2 super15.2 EHt

100.1143.3143.3

0.7861.1251.125

184250261

156.4(4)

212.5(4)

221.9(4)

2.52.52.5

180 to 205x103

180 to 205x103

180 to 205x103

BS 5896(2) 12.9 super15.7 super

100150

0.7851.180

186265

158.1(5)

225.3(5)

2.52.5

180 to 205x103

180 to 205x103

prEn 10138-3(3)

15.2 regular15.7 regular15.2 super15.7 super

140150140150

1.0931.1721.0931.172

248266260279

213.0(5)

229.0(5)

224.0(5)

240.0(5)

2.52.52.52.5

180 to 205x103

180 to 205x103

180 to 205x103

180 to 205x103

Notes: • All strands are 7 wire low relaxation steel.

WIRE PROPERTIESSTANDARD NOMINAL

DIAMETERmm

STEEL AREA

mm2

MASS

kg/lm

WIREMBL(7)

kN

MIN. PROOF LOAD

kN

STRAND RELAXATION(6)

(%)

MODULUS OF ELASTICITY

MPa

AS 4672(1) 7 Lr 38.5 0.302 64.3 54.7(4) 2.0 195 to 205x103

BS 5896(2) 7 Lr 38.5 0.302 64.3 53.4(5) 2.5 195 to 205x103

notes: (1) Australian / new Zealand Standard AS 4672 Steel Prestressing Materials.

(2) British Standard BS 5896 High tensile steel wire and strand for the Prestressing of concrete.

(3) European Standard prEn 10138-3 Prestressing steels - Part 3: Strand.

(4) At 0.2% offset. refer AS 4672.

(5) At 0.1% offset. refer BS 5896 or prEn 10138-3 as applicable.

(6) relaxation after 1000 hrs at 0.7 x Breaking Load.

(7) MBL = Minimum Breaking Load (to AS 4672 and BS 5896). Fm = characteristic Force (to prEn 10138-3).

MAXIMUM JACKING FORCES - RECOMMENDED VALUESSSL POST TENSIONING SYSTEM STANDARD

AS 3600 BS 8110

BBr conA MuLti SYStEM

BBr Vt conA cMi SYStEM

SLAB SYStEM

WirE SYStEMBAr SYStEM

80% MBL

80% MBL

85% MBL

80% MBL75% MBL

80% MBL

80% MBL

80% MBL

80% MBL75% MBL

Notes: • in some cases higher or lower jacking forces are permitted by local standards.

• MBL = Minimum Breaking Load of tendon.

PRESTRESSING LOSSES - TYPICAL DATASYSTEM BBR CONA MULTI BBR VT CONA CMI SLAB WIRE BAR

AncHorAGE & JAcKinG LoSS (%) 2 to 4 0.9 to 1.2 2 to 5 0 to 1 0 to 1

drAW-in ALLoWAncE (mm) 6 6 6 2 to 3 1 to 2

du

ct

Fric

tio

n μ round Steel duct

Flat Steel duct

Polyethylene ductGreased & Sheathed

0.15 to 0.20

0.10 to 0.15

0.20 to 0.22

0.10 to 0.15

0.15 to 0.200.20

0.10 to 0.15

0.12 to 0.16

0.10 to 0.15

0.15 to 0.20

0.10 to 0.150.15

tEn

do

n

Wo

BB

LE β

(k) r

ad/m

round Steel duct ≤ 50mm

round Steel duct > 50mmFlat Steel duct

Greased & Sheathed

0.016 to 0.0240.008 to 0.016

0.0060.006

0.016 to 0.024

0.0160.008 to 0.012

0.008 to 0.016

0.008

Notes: • to reduce excess friction, it may be possible to flush the tendon with water or water soluble oil.

• if the duct or strand has a film or rust or the ducts are full of water, the friction values can increase significantly.

MuLti-StrAnd POST-TENSIONING

MULTI-STRAND poST-TENSIoNINGStructural Systems have two distinct systems available for multi-strand applications. These systems are BBR Cona Multi, and BBR VT Cona CMI.

BBR CONA MULTI

The BBR Cona Multi has been offered for the last 40 years and is available in standardised tendon sizes from:

• 7strandsupto61strandsfor12.7mmand12.9mmstrand, or

• 4strandsupto55strandsfor15.2mmand15.7mmstrand.

The BBR Cona Multi can be used with galvanised steel and polyethylene ducting. The system is a bonded system with the ducting being pressure filled with a cementitious grout.

Standard applications use the M1 range, with the M3 range being used for cryogenic applications, and other specialist applications. Please consult SSL for details on which system best suits your applications.

BBR VT CONA CMI

The BBR VT Cona CMI is a revolutionary, state of the art, bonded, post-tensioning system incorporating world’s best practice, and is available in standard tendon sizes from:

• 4strandsupto61strandsfor15.2mmand15.7mmstrand.

The system has been granted European Technical Approval in accordance with the testing procedures contained within ETAG013 and is CE marked.

These tests included static tests, fatigue tests, load transfer and cryogenic tests.

European Technical Approval provides clear independent review, full and complete system testing to the highest European standard, quality assurance, and independent auditing of all systems components. Every product is tested to the same standards and afterwards an independent auditor ensures that what is delivered and installed on site fully complies with that which was tested.

On completion of the tests, the approval body evaluated the test results, drawings, specifications and the complete system. The package was then circulated to all member states of the EU for ratification.

Copies of the BBR VT European Approval Documents are available for download from www.bbrnetwork.com and www.structuralsystems.com.au.

The BBR VT Cona CMI has significant advantages over the BBR Cona Multi as well as significant competitive advantage over other ETAG approved systems. These advantages include:

• Less space is required in the anchor zone whichresults in less concrete, slimmer structures and less eccentricity in the anchors.

• Significantly lower concrete strength prior tostressing resulting in shorter construction cycles.

• Lessreinforcementintheanchoragezoneresultingin time and cost savings.

European Approval ETA - Testng of Anchor Head

BBr conA MuLti - M1

BBr Vt conA cMi


6

PoSt-StrESSinG TECHNOLOGY


TECHNICAL DATA OF ANCHORAGES

BBR VT CONA CMI

STRAND SIzE BBR VT CONA CMI

15.2mm / 15.7mmAnchorage Unit

Maximum No. Strands4064

7067

120612

190619

220622

270627

310631

DIMENSIONS (mm)Recess - InnerRecess - OuterRecess Depth

200 x 200250 x 250

130

240 x 240290 x 290

135

295 x 295350 x 350

140

350 x 350400 x 400

160

380 x 380420 x 430

170

430 x 430480 x 480

180

430 x 430480 x 480

185

STRESSING ANCHORAGE RECESS DETAILS

STRESSING AND FIXED ANCHORAGE FIXED COUPLER FK CENTRE AND EDGE DISTANCES

BBR VT Cona CMI (Max no of Strands) 4 7 12

STRand mm2 140 150 140 150 140 150

CRoSS SeCTIonal aRea mm2 560 600 980 1050 1680 1800

ChaRaCT. TenSIle STRengTh rm MPa 1770 1860 1770 1860 1770 1860 1770 1860 1770 1860 1770 1860

ChaRaCT. MaxIMuM FoRCe Fm kn 992 1040 1064 1116 1736 1820 1862 1953 2976 3120 3192 3348

BBR VT Cona CMI (Max no of Strands) 4 7 12

helIx and addITIonal ReInFoRCeMenT

MIn. ConCReTe STRengTh (Cyl.) fcm.0 MPa 19 23 28 31 35 19 23 28 31 35 19 23 28 31 35

helIx

ouTeR dIaMeTeR mm 180 150 150 150 230 200 200 180 180 330 280 280 260 260

BaR dIaMeTeR mm 14 12 12 12 14 14 14 14 14 14 14 14 14 14

lengTh, appRox. mm 182 181 216 216 232 232 277 277 277 332 332 332 382 282

pITCh mm 50 50 60 60 50 50 60 60 60 50 50 50 50 50

nuMBeR oF pITCheS 4 4 4 4 5 5 5 5 5 7 7 7 8 6

dISTanCe E mm 15 15 15 15 18 18 18 18 18 20 20 20 20 20

addITIonal ReInFoRCeMenT

nuMBeR oF STIRRupS 3 3 4 3 5 4 3 3 4 7 6 5 5 6

BaR dIaMeTeR mm 12 12 10 10 14 14 14 14 14 12 14 16 16 14

SpaCIng mm 60 55 40 50 55 60 65 65 60 60 55 70 65 50

dISTanCe FRoM anChoR plaTe F mm 30 30 30 30 33 33 33 33 33 35 35 35 35 35

ouTeR dIMenSIonS BxB mm 220 200 180 170 290 270 240 230 220 390 350 320 310 290

CenTRe and edge SpaCIng

MIn. CenTRe SpaCIng ac,bc mm 235 215 195 190 310 285 260 250 240 405 370 340 325 310

MIn. edge dISTanCe (pluS C) ae’,b

e’ mm 110 100 90 85 145 135 120 115 110 195 175 160 155 145

dIMenSIonS oF anChoRageS

anChoR dIaMeTeR dA mm 130 170 225

anChoR lengTh LA mm 327 454 627

CoupleR FK dIaMeTeR dFK mm 185 205 240

CoupleR FK lengTh LFK mm 945 1152 1435

7

MuLti StrAnd POST-TENSIONING


BBr Vt conA cMi (Max no. of Strands) 19 22 27 31

Strand mm2 140 150 140 150 140 150 140 150

CroSS SeCtional area mm2 2660 2850 3080 3300 3780 4050 4340 4650

CharaCt. tenSile Strength rm MPa 1770 1860 1770 1860 1770 1860 1770 1860 1770 1860 1770 1860 1770 1860 1770 1860

CharaCt. MaxiMuM ForCe Fm kn 4712 4940 5054 5301 5456 5720 5852 6138 6696 7020 7182 7533 7688 8060 8246 8649

BBr Vt conA cMi (Max no. of Strands) 19 22 27 31

helix and additional reinForCeMent

Min. ConCrete Strength (Cyl.) fcm.0 MPa 19 23 28 31 35 19 23 28 31 35 19 23 28 31 35 19 23 28 31 35

helix

outer diaMeter mm 420 360 360 330 330 475 420 360 360 330 520 475 430 420 360 560 520 475 430 430

Bar diaMeter mm 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14

length, approx. mm 457 457 432 432 382 482 482 482 482 382 532 532 532 427 432 532 532 582 467 432

pitCh mm 50 50 50 50 50 50 50 50 50 50 50 50 50 40 50 50 50 50 40 50

nuMBer oF pitCheS 9.5 9.5 9 9 8 10 10 10 10 8 11 11 11 11 9 11 11 12 12 9

diStanCe E mm 27 27 27 27 27 31 31 31 31 31 35 35 35 35 35 35 35 35 35 35

additional reinForCeMent

nuMBer oF StirrupS 7 7 7 7 7 8 7 7 7 8 8 7 7 7 8 8 8 8 8 8

Bar diaMeter mm 16 16 16 16 16 16 20 20 20 16 20 20 20 20 20 20 20 20 20 20

SpaCing mm 65 65 65 65 65 65 75 70 65 55 80 80 75 70 60 85 75 70 65 60

diStanCe FroM anChor plate F mm 42 42 42 42 42 46 46 46 46 46 50 50 50 50 50 50 50 50 50 50

outer diMenSionS BxB mm 490 450 410 390 370 530 480 440 420 400 590 540 490 470 440 630 580 530 500 480

Centre and edge SpaCing

Min. Centre SpaCing ac,bc mm 510 465 425 410 390 550 500 460 440 420 610 555 505 485 460 650 595 545 520 495

Min. edge diStanCe (pluS C) ae’,be’ mm 245 225 205 195 185 265 240 220 210 200 295 270 245 235 220 315 290 265 250 240

diMenSionS oF anChorageS

anChor diaMeter dA mm 280 310 360 360

anChor length LA mm 744 946 1090 975

Coupler FK diaMeter dFK mm 290 310 390 390

Coupler FK length LFK mm 1600 1821 2466 2242

TECHNICAL DATA OF ANCHORAGES

Structural Systems has gained certification from BBR as a ‘PT Specialist Company’ authorised to install the BBR VT Cona CMI systems and all other BBR ETAG approved post tensioning systems.

BBR VT CONA CMI

STRESSING AND FIXED ANCHORAGE FIXED COUPLER FK CENTRE AND EDGE DISTANCES


note: intermediate and larger sizes available on request.

8

PoSt-StrESSinG TECHNOLOGY


NO. STRANDS 4 7 12 19 22 27 31

ANCHOR HEADDiameter ØA (mm)Height HA1 (mm)

10050

13055

16065

20085

22595

255105

255110

COUPLER HEAD KDiameter ØK (mm)

Height HK (mm)18585

20585

24090

29095

310105

390125

390130

NO. STRANDS 4 7 12 19 22 27 31

BEARING TRUMPLATEDiameter ØP (mm)

Height HP (mm)130120

170128

225150

280195

310206

360250

360250

NO. STRANDS 4 7 12 19 22 27 31

TRUMPET ADiameter ØTA (mm)

Length LTA (mm)72230

88328

127509

153580

170715

191871

191757

TRUMPET KDiameter ØTK (mm)

Length LTK (mm)185539

203640

240730

275775

305840

3751265

3751150

SYStEM coMPonEnt dEtAiLS

BEARING TRUMPLATE

ANCHOR HEAD COUPLER HEAD TYPE K

TRUMPET TYPE A TRUMPET TYPE K

BEARING TRUMPLATES

ANCHOR AND COUPLER HEADS

PLASTIC TRUMPETS

BBR VT CONA CMI

MuLti StrAnd POST-TENSIONING


TENDON PROPERTIES

Notes: • table indicates maximum number of strands that can be accomodated by the tendon stressing unit. • Larger id ducting should be selected for tendons > 80m, or if strands are installed after concreting, or where tight or extended curvatures occur. • Plastic sheaths conforming to ETAG013 should be used. Alternatively, corrugated polyethylene ducting may be used if permitted in the local region. • Refer page 4 for additional design data and details. • Maximum jacking force is usually 0.8 x MBL. • For radii of curvature and straight portion diagram refer to BBR CONA Multi System.

STRESSING ANCHORAGE

FIXED ANCHORAGE

FIXED COUPLER FK

TENDON UNIT

MAXIMUM STRANDS

NO.

MAXIMUM STEEL

DUCT ID/OD

mm

MINIMUM STEEL

DUCT ID/OD

mm

MINIMUM RADII OF CURVATURE

/ MINIMUM STRAIGHT PORTION

m

TENDON MIN BREAKING LOAD to prEN 10138-3

kN

15.2 regular 15.7 regular 15.2 super 15.7 super

40670612061906220627063106

471219222731

45 / 5060 / 6580 / 85

100 / 105105 / 110120 / 125130 / 135

45 / 5055 / 6070 / 7590 / 9595 / 100105 / 110110 / 115

2.0 / 0.84.0 / 0.95.2 / 1.06.5 / 1.17.0 / 1.157.7 / 1.38.4 / 1.3

992173629764712545666967688

1064186231925054585271828246

1040182031204940572070208060

1116195333485301613875338649

BBR VT CONA CMI


10



BBR CONA MULTItEndon ProPErtiES

TENDON UNIT MAXIMUM METAL DUCT TENDON MBL TO AS4672 TENDON MBL TO BS5896 STRANDS ID/OD or prEN 10138-3

No. mm kN kN

Using 12.7mm strand Using 12.9mm strand 705 7 50 / 57 1288 1302 1205 12 70 / 77 2208 2232 1905 19 85 / 92 3496 3534 3105 31 105 / 112 5704 5766 4205 42 120 / 127 7728 7812 6105 61 150 / 157 11224 11346

15.2mm/15.2 EHT strand 15.7mm BS / 15.7 EN strand 406 4 50 / 57 1000 / 1044 1060 / 1116 706 7 65 / 72 1750 / 1827 1855 / 1953 1206 12 80 / 87 3000 / 3132 3180 / 3348 1906 19 100 / 107 4750 / 4959 5035 / 5301 2206 22 110 / 117 5500 / 5742 5830 / 6138 3106 31 120 / 127 7750 / 8091 8215 / 8649 4206 42 135 / 142 10500 / 10962 11130 / 11718 5506 55 150 / 157 13750 / 14355 14575 / 15345

Notes: • Table indicates maximum number of strands that can be accomodated by the tendon stressing anchorage unit.

• Duct sizes are quoted for typical situations. It may be possible to slightly reduce duct size in some situations. Consideration should be given to the use of larger ducts where tight or extended curvatures occur. refer to SSL office for advice. Alternate duct sizes are generally available in 5mm id increments

• Partial tendons are also permissible. (i.e. a 15no. 12.7mm strand tendon would be specified as “1905-15”, supplied with a 1905 stressing anchorage and would have a MBL of 15 x 184 = 2760 kn, etc.)

• Maximum Multi-strand Jacking force is usually 0.8 x MBL.

• Refer page 5 for additional design data and details on standards.

• MBL = Minimum Breaking Load

Structural Systems has been offering the BBR Cona Multi post-tensioning system for over 40 years. This multi-strand system is predominantly used in civil structures including bridges, silos, tanks and off-shore structures and is a robust and reliable “bonded” prestressing system.

The BBR Cona Multi system consists of up to 61 No. 12.7mm/12.9mmor91No.15.2mm/15.7mmstrandstoform tendons which are installed inside round ducting. The individual strands are anchored in a common anchor head with a wedge grip system and the strands are simultaneously stressed. Individual strand stressing is possible in some circumstances. After stressing the ducting is pressure filled with a cementitious grout.

The choice between the anchorage types depends on structural requirements, availability and dimensional constraints.

For standard applications type M1 anchorages are generally preferred. Type M3 are used for cryogenic applications or where it maybe necessary to use a rectangular anchorage for clearance reasons. (It is recommended that SSL is consulted for non-standard plate sizes).

StrESSinG AncHorAGES (LiVE EndS)

AncHorAGE tYPE M1

WEdGE GriPS

AncHor HEAd AncHorAGE cAStinG

P.E. truMPEt

duct

Grout inLEt

11



ANCHORAGE TYPE M3

The type of stressing anchorage used may vary depending on the application, size and number of anchorages required, type of tendon sheathing, project location and availability of components. The tables below provide performance and dimensional data for

two typical anchorages. Several other BBR anchorage configurations are also available and there may be some variations in dimensions to those shown. The designer should check with Structural Systems for full and current technical information on the preferred anchorage type.

STRESSING ANCHORAGE TYPE M1 - ANCHORAGE CASTING WITH P.E. TRUMPET (LIVE END)

STRAND SIzE TYPE M1 ANCHORAGE DETAILS

12.7mm / 12.9mmAnchorage unit

Maximum no. Strands7057

120512

190519

310531

--

420542

610561

15.2mm / 15.7mmAnchorage unit

Maxiumum no. Strands4064

7067

120612

190619

220622

310631

420642

dimensions (mm)

A x ABc

inside dia. doutside dia. E

Anchor nom. dia. Fnom. Height G

165155100775512055

215345851107715055

2654151001399219065

33548511617911224080

35055012519311735080

395605145223137290100

460725175265157350120

Notes: • Local zone and general zone anchorage reinforcement is normally required for all unit types and details are usually determined by the designer to suit the specific application. • unless otherwise specified by the designer, SSL Multi-strand tendons will normally be supplied with type M1 stressing anchorages. • tendon grouting is achieved via 19mm poly pipe inlets at all anchorage ends and at intermediate venting points.

STRESSING ANCHORAGE TYPE M3 - FABRICATED PLATE ANCHORAGE (LIVE END)

STRAND SIzE TYPE M3 ANCHORAGE DETAILS 12.7mm / 12.9mm Anchorage unit 705 1205 1905 3105 - 4205 6105 - Maximum no. Strands 7 12 19 31 - 42 61 -

15.2mm / 15.7mm Anchorage unit 406 706 1206 1906 2206 3106 4206 5506 Maximum no. Strands 4 7 12 19 22 31 42 55

dimensions A x A 175 220 270 345 375 440 600 600 (mm) B 220 435 545 785 820 910 1230 1400 c 20 30 40 55 60 70 100 120 outside dia. d 90 115 140 195 210 232 275 325 outside dia. E 55 75 90 110 115 140 160 160

Notes: • Local zone and general zone anchorage reinforcement is normally required for all unit types and details are usually determined by the Designer to suit the specific application. • Unless otherwise specified by the Designer, multi-strand tendons will normally be supplied with Type M1 stressing anchorages. • Tendon grouting is achieved via 19mm poly pipe inlets at all anchorages and at intermediate venting points.

ANCHORAGE TYPE M1

Notes: • Local zone and general zone anchorage reinforcement is normally required for all unit types and details are usually determined by the designer to suit the specific application

• Swage type dead end anchorages recommended for tendon units 3105/1906 and larger

dEAd End AncHorAGES - BuLB tYPE & SWAGE tYPE

STRAND SIzE ANCHORAGE UNIT BULB TYPE ANCHORAGE (mm) SWAGE TYPE ANCHORAGE (mm)

A B C D E F

12.7mm and 12.9mm 705 175 150 600 150 150 250 1205 300 250 1000 200 200 350 1905 375 300 1000 250 250 500 3105 450 425 1100 350 300 650 4205 600 450 1100 450 375 850 6105 700 550 1200 700 450 1000 15.2mm and 15.7mm 406 150 150 600 150 150 250 706 200 170 600 200 200 350 1206 350 300 1000 250 250 500 1906 450 350 1000 300 300 500 2206 500 350 1000 300 300 500 3106 550 475 1100 350 350 650 4206 700 550 1200 400 350 850 5506 800 600 1200 550 475 1000

1 2



MULTI-STRAND poST-TENSIoNING

BULB TyPE DEAD END SwAGE TyPE DEAD END

Transfer beams in buildings

note: For swage type, strand length ‘F’ shall be debonded (using grease or similar).

1 3



couPLinG AncHorAGE - tYPE K

STRAND SIzE TYPE K COUPLING ANCHORAGE DETAILS

12.7mm / 12.9mm Anchorage unit 705 1205 1905 3105 - - - Maximum no. Strands 7 12 19 31 - - -

15.2mm / 15.7mm Anchorage unit 406 706 1206 1906 2206 3106 4206 Maximum no. Strands 4 7 12 19 22 31 42

diameter (mm) n 168 208 258 328 328 405 460 trumpet length (mm) P (approx) 550 650 700 900 950 1100 1200

Notes: • Unless otherwise specified by the Designer, multi-strand coupling anchorages will normally be supplied as Type K

• Refer to SSL for details and availability of larger K type coupler units

couPLinG AncHorAGE - tYPE c

STRAND SIzE TYPE C COUPLING ANCHORAGE DETAILS

12.7mm / 12.9mm Anchorage unit 705 1205 1905 3105 - 4205 6105 - Maximum no. Strands 7 12 19 31 - 42 61 -

dimensions (mm) Q 108 108 108 108 - 148 refer - r 170 200 230 340 - 385 to - S 550 650 740 1140 - 1320 SSL -

15.2mm / 15.7mm Anchorage unit 406 706 1206 1906 2206 3106 4206 5506 Maximum no. Strands 4 7 12 19 22 31 42 55

dimensions (mm) Q 125 125 125 125 125 145 refer refer r 160 200 230 270 300 350 to to S 520 630 730 860 930 1090 SSL SSL

Notes: • Unless otherwise specified by the Designer, SSL Multi-strand Coupling Anchorages will normally be supplied as Type K

• Refer to SSL for details and availability of larger C type coupler units

1 4



SPAcE rEQuirEMEntS For StrESSinG JAcKS

STRAND SIzE SPACE REqUIREMENTS

12.7mm / 12.9mm tendon unit 705 1205 1905 3105 - 4205 6105 -

15.2mm / 15.7mm tendon unit 406 706 1206 1906 2206 3106 4206 5506

Jack unit cc 110 cc 200 cc 300 cc 600 cc 600 cc 630 cc 1000 cc 1200 dimensions (mm) A 710 750 810 1200 1200 1000 1130 1300 B 1400 1500 1600 2400 2400 2000 2300 2600 c 250 300 330 500 500 600 600 600 E 200 230 260 400 400 500 420 450 F 595 620 675 1100 1100 950 950 1050

Notes: • Details based on jacks having 200mm working stroke. Alternative jacks may be available and/or more suitable. Contact SSL for further details

• check jack size and availability with your local SSL office

StrESSinG AncHorAGE rEcESS dEtAiLS

STRAND SIzE RECESS DETAILS

12.7mm / 12.9 mm tendon unit 705 1205 1905 3105 - 4205 6105 -

15.2mm / 15.7mm tendon unit 406 706 1206 1906 2206 3106 4206 5506

dimensions (mm) F x F 230 270 340 420 420 460 560 650 G 140 140 150 165 165 185 200 225 H x H 310 370 400 510 510 560 660 750

Notes: • Depth G achieves 50mm cover to trimmed strand ends. • Alternative or smaller recesses may be possible depending on actual conditions and jack used. Refer to your local Structural Systems office.


1 5



TENDON CURVATUREA straight portion L adjacent to the anchorage must be observed to limit the screw pull of the strand bundle against the anchorage. Reduction may be allowed in certain specific instances.

TENDON ECCENTRICITY TYPE e mm

705/406 10

1205/706 11

1905/1206 14

3105/1906 15

2206 21

4205/3106 25

6105/4206 28

SHEATHING AND CORROSION PROTECTIONFor conventional applications, corrugated galvanised steel ducts are used with a wall thickness of 0.3mm. For applications requiring enhanced corrosion protection and improved fatigue resistance of the tendons, use of corrugated plastic duct is recommended. This fully encapsulated, watertight system offers superb corrosion protection, and the plastic duct eliminates fretting fatigue between the strand and duct. It also provides reduced duct friction. All ducts are manufactured in a variety of standard lengths and are coupled on site. Steel ducts are available indiametersrangingfrom40mmto160mminapproximately5mmincrements.

Notes: • “e” is indicative only and depends on actual duct id and number of strands in tendon

tEndon SHEAtHinG And corroSion ProtEction

PoLYEtHYLEnE duct dEtAiLS

EccEntricitY oF tEndonS

tEndon curVAturE LiMitAtionS

12.7mm / 12.9mm 705 1205 1905 3105 - 4205 6105 - 15.2mm / 15.7mm 406 706 1206 1906 2206 3106 4206 5506

Minimum radius, r (m) 4 4.5 5 6 6.5 8 8 10 Minimum Straight 0.8 0.9 1.0 1.1 1.15 1.3 1.3 1.5 Portion, L (m)

Notes: • Check with SSL office for availability and lead time for standard and/or alternative polyethylene duct sizes

TENDON TYPE12.7mm/12.9mm 15.2mm/15.7mm

DUCT DIMENSIONS (mm) O.D. I.D. WALL THICKNESS

705 406 61 48 2.0

1205 706 75 65 2.0

1905 1206 94 82 2.0

3105 1906 110 98 2.0

4205 3106 125 110 2.0

6105 4206 160 138 2.0

Galv. Steel duct(refer page 6)

Polyethylene duct(refer left)

1 6




The minimum required distance of the bearing plates to concrete edges and to adjacent anchorage bearing plates depends in general on: • the post-tensioning force to be transmitted • the concrete strength • the bearing plate dimensions • the reinforcing steel behind the bearing plate • structural requirements

ao = min. distance between axis of two anchoragesbo = min. distance from concrete edge to anchorage axisDsp = suggested outside diameter of reinforcing steel spiralsf’c = nominal concrete cylinder strength

Prestressing forces can usually be applied at 80% of nominal concrete cylinder strength.

MINIMUM DISTANCE FOR BEARING PLATES TO CONCRETE EDGES AND BETWEEN ADJACENT ANCHORAGES

Tung Chung Bridge - Hong Kong

MINIMUM ANCHORAGE SPACING AND EDGE DISTANCES

f’cMPa

DETAILSmm

12.7mm & 12.9mm STRAND UNITS 15.2mm & 15.7mm STRAND TENDON UNITS

705 1205 1905 3105 4205 406 706 1206 1906 2206 3106 4205

32ao 220 290 365 465 545 205 270 355 450 480 570 665bo 130 155 190 235 275 120 145 180 225 240 285 335

dsp 200 250 320 410 480 180 230 300 390 425 520 590

40ao 205 270 340 435 505 200 255 330 420 450 535 620bo 125 150 185 225 260 120 145 175 215 230 275 310

dsp 190 240 310 390 460 180 230 290 370 400 490 560

50ao 195 255 320 410 475 200 250 310 395 420 500 585bo 120 145 180 220 250 120 145 175 210 225 265 300

dsp 180 230 300 380 440 180 230 290 360 390 470 540

Notes: • the above details are provided as a guide only and designers should normally satisfy themselves by calculation that the adopted details are suitable for the actual application.

Mt Henry Bridge - Western Australia

1 7

SLAB POST-TENSIONING


SLAB poST-TENSIoNINGDesigners, builders, owners and end users of buildings require more efficiencies today than ever before. The Structural Systems Slab Post-Tensioning System offers all the stakeholders in a building project many benefits including:

• Reduced structural depths• Greater clear spans• Design flexibility• Formwork versatility• Reduced construction costs• Enhanced construction speed• Improved durability• Minimum maintenance costs

The system is comprised of high-strength steel strands placed inside flat ducting, anchored at one end by deforming the strand and casting it into the concrete,

then at the other end by means of a steel anchorage casting and anchor block(s) with gripping wedges. After the concrete has reached a suitable transfer strength, the individual strands have a specified load applied by calibratedjacks.Theductisfilledwithawater/cementgrout mixture to ensure that the system is bonded and corrosion protection is maintained in service.

Applications for the Structural Systems Slab Post-Tensioning System include:

• Low to high rise residential and commercial buildings

• Industrial floor slabs on grade• Transfer floor structures• Car parks• water tank bases and walls• Transverse stressing of bridge decks

West India Quay - London

Al Nuaimiah Towers - Dubai

1 8



LIVE END ANCHORAGES

SLAB poST-TENSIoNING

DEAD-END ANCHORAGES

BULB-TyPE SwAGE-TyPE

grout tube

grout tubebulbed strand ends

swaged strand endsspacer plate(not always required)

swage plate

strands

duct

anchorage casting

anchorage block

duct

grout tube

duct

notes:

• Similar non-reusable recess- formers are used at angled edges

• Standard flat duct is produced from 0.4mm galvanised steel sheet

StrESSinG AncHorAGE (LiVE EndS)

BULB-TYPE DEAD-END ANCHORAGE SWAGE-TYPE DEAD-END ANCHORAGE STRAND SIzE TENDON UNIT DIMENSIONS (mm) DIMENSIONS (mm) A B C D E F

105 75 50 600 100 75 100 12.7mm 205 135 50 600 125 75 150 and 305 230 50 600 200 75 350 12.9mm 405 270 50 600 250 75 500 505 350 50 600 300 75 500 605 400 50 750 350 75 600

106 75 50 750 125 75 100 15.2mm 206 135 50 750 150 75 250 and 306 230 50 750 225 75 450 15.7mm 406 270 50 750 300 75 600 506 350 50 750 350 75 600

STRAND SIzE TENDON UNIT No. STRANDS

ANCHORAGE CASTING

RECESS FORMERFLAT DUCT SIzE

mmAmm

Bmm

Cmm

Dmm

E1mm

E2mm

F1mm

F2mm

12.7 mmand

12.9 mm

205305505605

23

4 or 56

155150215270

135150220265

67757979

100100100100

150180265265

150180315315

1001008080

100100100100

43 x 1943 x 1970 x 1990 x 19

15.2 mmand

15.7 mm

206406506

23 or 4

5

155215270

135220265

677979

100100100

150265265

150315315

1008080

100100100

43 x 1970 x 1990 x 19

grout tube

dead end plate

duct

Notes: • Tendon units 205, 605, and 206 are supplied with individual barrel anchorages in lieu of anchorage blocks. • Grout tubes are 13mm id or 19mm id polyethylene pipe supplied to each end of tendon. Additional intermediate vents can also be supplied (designer to specify requirements). • All sizes are nominal. Some dimensions have been rounded up for normal space, detailing and tolerance requirements.

wedge grips

grout tube duct

anchorage casting

wedge

strand

barrel

1 9



wedge grips

grout tube

anchorage casting

coupling block

couPLinG AncHorAGE - 505, 406 & 506

couPLinG AncHorAGE - 405

COUPLING ANCHORAGES

couPLinG AncHorAGES

STRAND SIzE COUPLING COUPLING ANCHORAGE DETAILS UNIT DIMENSIONS (mm) A B C D

12.7mm / 12.9mm 405 100 220 80 220 505 100 220 110 220

15.2mm / 15.7mm 506 100 240 120 265

swaged strand ends

note: 3 and 4-strand units are coupled using the applicable 5-strand coupler, uno.

Grout Pump

duct

2 0



AncHorAGE rEinForcEMEnt – SLAB SYStEM

Notes: • Reinforcement size 10dia, grade 500MPa to AS/NZS 4671 or grade 460 to BS4449. • fcp = min required air-cured concrete cylinder strength at anchorage at time of stressing. • Details shown are generally satisfactory for most standard situations, however designers should satisfy themselves of the adequacy of local zone anchorage

reinforcement for specific situations.

SLAB poST-TENSIoNING

SPirAL tYPE

StrAnd At tEndon HiGH Point StrAnd At tEndon LoW Point

2x2 LiGAturE2x1 LiGAturE SiMiLAr

2x4 LiGAturE

SuGGEStEd ALLoWAncES – StrAnd oFFSEtS For 19mm FLAt duct STRAND SIzE A B e

12.7mm / 12.9mm 7mm 12mm 2.5mm 15.2mm / 15.7mm 8mm 11mm 1.5mm

TENDON UNIT

No. OF STRANDS

SPIRAL TYPE LIGATURE TYPEfcp

MPaAmm

Bmm

NNo.

Cmm

Dmm

NNo.

205305505605206406506

23

4 or 562

3 or 45

9010010011090110110

200260260300200300300

4457477

200200200200200200200

100100130150110130150

2 x 12 x 12 x 22 x 42 x 22 x 22 x 4

17172225172225

2 1


JAcKinG cLEArAncES STRAND SIzE A B C D E mm mm mm mm mm

12.7mm / 12.9mm 500 900 750 450 70 15.2mm / 15.7mm 600 900 850 450 70


JAcKinG cLEArAncES

douBLE rAM JAcK SinGLE rAM JAcK

intErnAL StrESSinG PocKEtS

Stressing Pocket

Notes: • Internal Stressing Pockets are used where standard edge stressng is impractical, subject to design check. • Details shown provide typical pocket spacing requirements. Actual details may vary.

2 2



Post-tensioning provides many benefits to a wide range of suspended structures. these benefits include:

• Reduced construction cost• Faster construction• Water resistant properties• Early formwork stripping• Floor to floor height reduction• Reduced foundation load• Improved deflection control• Greater column free areas

Many types of suspended slab structures typically realise the benefits of post tensioning, such as:

• Carparks• Apartment buildings• Commercial office space• Retail centres• Vertical load transfer structures• Hospitals• Storage facilities• Public buildings such as stadiums, exhibition

centres, schools and institutional facilities

different formwork systems are compatible with post-tensioning, namely:

• Conventional plywood systems• Permanent metal deck systems• Ribbed slabs• Precast systems

Structural Systems has many years of experience in the design and installation of post-tensioned suspended slabs and can bring measurable benefits to your project.

SLAB PoSt-tEnSioninG APPLicAtionS - suspended slabs

Peppers Pier Resort - Queensland

Wollongong Links Project - NSW

2 3



it is important that the design requirements are achieved on site. Good engineering notation can greatly assist in achieving this, with particular attention to the following;

• The system. State that the design is based on the Structural Systems SLAB post-tensioning system. this ensures that a fully tested and code compliant system will be installed.

• Concrete. nominate the 28 day characteristic compressive strength and shrinkage characteristics required. Some projects may have additional requirements.

• Concrete strength at Transfer fcp. this is the minimum compressive strength that is required prior to fully stressing the tendons. concrete testing of site and air cured specimens should be carried out to ensure this strength has been achieved prior to application of the final stressing.

• Tendons. clearly indicate the type and location of anchorages and number of strands in each tendon. check that stressing access is possible at live ends.

• profiling. High and low points should be nominated. Full tendon profiles can then be determined on installation shop drawings. Profiles are usually parabolic.

• stressing procedure. A two stage stressing procedure is usually specified. initial or 25% load is applied at 24 hours after the slab pour, and final or 100% load is applied when the concrete transfer strength is released.

• Grout. A water/cement ratio of not more than 0.45 is usually sufficient to ensure adequate grouting and strength.

BAndEd SLAB FLAt SLAB FLAt PLAtE

the design of post-tensioned suspended slabs requires sound engineering consideration in order to maximize the benefits for all stakeholders in a project.

Structural Systems can offer design input from initial advice to fully detailed design for construction drawings. typical post-tensioned floor configuration and details are:

dESiGn oF PoSt-tEnSionEd - suspended slabs

dEFinitionS Lb = Band SpanLs = Slab SpanL = design Span (Greater of L1 & L2)note: For Slab End Spans, Add 15-20% to Slab thickness from charts

t = internal Slab thicknessd = overall Band depthBw = Suggested Band Width Approx. (suit formwork)P = overall drop Panel depth (1.8xt)

tYPicAL dESiGn LoAdS LL = 5kPa, AdL = 1kPa LL = 4kPa, AdL = 1kPa LL = 3kPa, AdL = 1kPa LL = 2.5kPa, AdL = 0.5kPa

SPEciFYinG PoSt-tEnSioninG

2 4



Structural detailing is an art that engineers develop with experience and it is an essential part of a cost effective and reliable structure. Below are a selection of tried and proven details that Structural Systems recommend for a range of situations. A key factor in achieving a successful Post-tensioned Structure is a sound understanding of and a considered allowance for normal concrete shrinkage movements.

conStructionStructural Systems designers have worked closely over many years with builders and construction personnel resulting in a well understood system that enhances the construction process. An appreciation of the construction process will enable all parties involved in the on site works to benefit from the system. the typical construction sequence is as follows;

• Erect formwork• install bottom reinforcement• install post-tensioning• install top reinforcement• Prepour inspection and pour concrete• Strip edge forms• Initial/Partial stressing of tendons• Final/Full stressing of tendons• obtain engineers approval and cut

off excess tendon strand• Grout the tendons• Strip formwork and back prop as required

dEtAiLinG oF PoSt-tEnSionEd - suspended slabs

Cabrini Hospital - Melbourne

2 5



the post-tensioning of slabs on ground is providing many developers and builders with a cost effective pavement solution. Benefits realised with post tensioned slabs on ground include:

• Large joint free slab areas

• reduced construction costs

• Less sub base preparation and/or excavation

• Faster construction time

• reduced on going maintenance costs

Facilities that have adopted a post-tensioned slab on ground system include:

• distribution warehouses

• Freezer stores

• container terminal facilities

• rail freight facilities

• Aircraft hangers

• Water retaining structures

• Sporting venues

• raft slabs

dESiGnthe design of post-tensioned slabs on ground involves the careful analysis of the loads applied to the slab, the interaction between the slab and the ground that supports it, restraint forces and temperature effects. Structural Systems has refined the design process and has achieved outstanding results on many projects. our design and construction expertise for preliminary design advice through to final design and construction activities is available to assist builders, engineers and developers in achieving optimum solutions for slab on ground applications.

SLAB PoSt-tEnSioninG APPLicAtionS - slab on Ground

Container Pavement, Port Botany - NSW

Computer modelling and Analysis

2 6



Points to consider in the design process include:

design Loads and Load configurations

thermal Effects daily ambient temperature variations give rise to temperature gradient stresses through the slab depth which need to be accounted for in the design. typical gradients of 0.02 ºc/mm and 0.04 ºc/mm are often used for internal and external slabs respectively causing bottom fibre tensile stresses that are additional to the load stresses.

Sub-grade Frictionnormal elastic and shrinkage movements give rise to frictional restraint stresses between the slab and the prepared subgrade. the typical design friction coefficient for concrete laid on a plastic membrane over clean sand bedding is around 0.5 to 0.6.

Sub-base Parameters A typical slab design will include the analysis of the slab supported by the ground sub-base. Modelling of the sub-base requires geotechnical data such as cBr, and/or the modulus of sub-grade reaction.

dESiGn oF PoSt-tEnSionEd slab on Ground

b) dESiGn WHEEL / AxLE dEtAiLS

a) tYPicAL dESiGn rAcKinG LAYout

dAtA - design Axle load “P” - Wheel Spacing “W” (2 or 4 wheels etc.) - Axle Load repetitions - Wheel contact Stress

Warehouse floor construction using laser screeds Raft Foundation - The Moorings, Western Australia

Typical racking storage

2 7


Good detailing of post-tensioned slabs on ground is vital in achieving a successful and relatively crack free slab.

the following diagrams indicate key details typicallyrecommended by Structural Systems:

dESiGn oF PoSt-tEnSionEd slab on Ground

conStructionStructural Systems design and construction experience is based on being the leader in the field of post-tensioned slabs on ground. the combination of innovative design and expedient site practices ensures that the construction phase is a seamless operation. the main items to consider for the construction phase are;

Pour SizeA pour size of between 1500m2 and 2000m2 should typically be considered and planned.

Pour Sequence the sequence of slab pours and their respective stressing requirements should be optimized to ensure the best programme outcome.

curing and Weather ProtectionWith large pours the slab is initially susceptible to shrinkage effects hence it is important to cure and protect the slab from extreme conditions such as heat, high evaporation or extreme cold. the construction of warehouse roofs prior to pouring slabs is a typical technique adopted to provide some protection.

tYPicAL WArEHouSE PLAn

Note: • As a guide, allow for total slab edge & M.J. movements of approximately 0.5mm per metre length of slab (e.g for 60m long slab, each edge moves approx 15mm over the normal life of the slab),

Column blockout detail


2 8



MULTI-WIRE poST-TENSIoNINGThe BBR SSL Multi-wire System is more compact than the multi-strand system and is often preferred for coupled cables in incrementally launched bridges, and is ideally suited where cables are to be prefabricated and where restressing or destressing is required.

The multi-wire tendon is composed of a bundle of 7mm dia. wires (plain or galvanised). Each individual wire is fixed in the anchorage with a multi-wire button head, which is cold-formed onto the wire by means of special machines.

• Each wire is mechanically fixed in the anchor head and reaches the full rupture load of the prestressing steel without any slippage. therefore the wire bundle can sustain the maximum ultimate load.

• the prestressing force is transmitted to the concrete under precisely known conditions without any risk of slippage of the prestressing steel.

• Monitoring of the prestressing force and if necessary restressing can be carried out reliably and economically. if required, the tendon can also be completely destressed.

• the anchorage resists with a high degree of safety dynamic loads and also exceptional effects such as shock loads.

typical applications include:

• coupled cables in incremtally launched bridges.

• cable stay applications.

• restressable tendons.

• Heavy lifting and lowering cables.

• restressable ground anchors.

Centrepoint Tower - Sydney

Narrows Bridge Duplication - Western Australia

2 9

MuLti-WirE POST-TENSIONING


STRESSING JACK TYPE NP 60 NP 100 NP 150 NP 200 NP 250 NP 300 GP 500 GP 800

Maximum Jacking Force kn 620 1030 1545 2060 2575 3090 5150 8000 Jack diameter mm 160 205 250 290 315 350 560 660 Stroke mm 100 100 100 100 100 100 400 400 Weight kg 28 50 83 117 147 196 1260 2000 clearance requirement ‘A’ mm 1700 1700 1700 2000 2000 2000 2500 2500

PrEStrESSinG JAcKS

Grouting of Ducts SSL has developed grouting methods utilising special colloidal mixers which result in an optimal grouting of the tendon ducts.

Prestressing EquipmentThe prestressing equipment consist of a hydraulic jack, trestle and pull-rod, which is connected to the stressing anchorage. For tendon elongations greater than the stroke of the jack, the pull-rod is temporarily anchored with a lock-nut and the jack is recycled.

The prestressing force can be measured with an accuracy of 2% by using calibrated 150mm face bourdon typepressure gauges.

Standard TendonsThe anchoring method allows the production of post-tensioning tendons with any number of single wires and therefore with any given magnitude of prestressing force. The most commonly used wire diameter is 7 millimetres.

with the following range of STANDARD TENDONS, all prestressing requirements occurring in the construction of bridges, buildings and other structures can be met. For special applications, eg; nuclear vessels, tendons up to15,000kNultimatecapacityareavailable.

StAndArd SSL - BBr WirE tEndonS NUMBER OF WIRES, DIA. 7mm 8 19 31 42 55 61 85 109 121 143

Minimum Breaking Load (rm = 1670 MPa) kn 514 1222 1993 2701 3537 3922 5466 7009 7780 9195 Stressing force at 0.8 x MBL kn 412 977 1595 2160 2829 3138 4372 5607 6224 7356 Stressing force at 0.75 x MBL kn 386 916 1495 2025 2652 2942 4099 5257 5835 6896

tendon nominal cross sectional area mm2 308 731 1194 1617 2118 2349 3273 4197 4659 5506

Weight of tendon wire kg/m 2.42 5.74 9.36 12.68 16.61 18.42 25.67 32.92 36.54 43.19 duct i.d. mm 35 50 55 65 80 85 100 110 120 130

Notes: • Check jack size and availability with your local SSL office

Notes: • Rm = Characteristic Tensile Strength to AS 4672 and/or BS 5896

3 0



MULTI-WIRE poST-TENSIoNING

SPECIAL APPLICATION ANCHORAGESDetails of Anchorages for various special applications are also available on request .

STRESSING ANCHORAGE TYPE L

STRESSING ANCHORAGE TYPE A

FIXED ANCHORAGE TYPE S

FIXED COUPLING TYPE LK

MOVABLE COUPLING TYPE LK 1

NUMBER OF WIRES 8 12 19 31 42 55 61 85 109 121 143dia. 7mm

Anchor e mm 25 27 36 43 49 56 67 78 85 140 145

Elongation, max f mm 200 200 200 200 200 250 250 350 350 400 400

trumpet length g mm 170 185 200 280 310 335 360 390 420 450 500

diameter h mm 37 49 59 76 87 97 105 120 135 145 160

Bearing plate i mm 140 170 200 235 270 300 330 380 430 480 500

thickness it mm 16 20 25 30 40 45 50 60 70 80 80


Fan length k mm 460 550 660 830 880 960 1010 1060 1180 1220 1260

Anchor plate, sq l mm 120 160 200 250 280 320 350 400 450 470 520

rectangular l mm 70 90 120 140 160 180 200 240 260 280 300

w mm 200 270 340 420 500 560 600 660 760 790 900

NUMBER OF WIRES 8 12 19 31 42 55 61 85 109 121 143 dia. 7mm

Anchor amm 63 74 91 108 123 135 156 180 205 240 245

TrumpetLength bmm 250 250 250 280 300 300 300 340 360 400 500

Diameter cmm 70 88 102 123 138 153 171 193 219 240 252

BearingPlate dmm 140 170 200 245 285 315 345 400 450 500 520

Thickness dtmm 14 16 20 25 30 35 40 50 60 70 70


trumpet length q mm 230 260 290 350 410 430 470 570 630 680 730

diameter r mm 70 88 102 123 138 153 171 193 219 250 260


Trumpet length min smm 600 620 670 750 810 880 950 1080115012201260

Diameter tmm 70 88 102 123 138 153 171 193 219 250 260

3 1

BAr POST-TENSIONING


BAR poST-TENSIoNING

Corrosion ProtectionAll bars and fittings must receive protection when installed under permanent conditions. in normal concrete construction the use of galvanised duct, injected with grout, provides excellent protection. Anchorage recesses must also be filled with cement mortar to protect these end zones.

When bars are used in an exposed environment then other corrosion protection systems are available for the bar and fittings. these include:

• greased and sheathing bar• denso wrapping• epoxy painting

Temporary Bar AnchorsAnchors used in a temporary environment may be used without protection apart from grout required to the bond length.

Permanent Bar Anchorsthese anchors require installation into corrugated polyethylene sheathing or galvanised duct similar to strand anchors to provide multiple levels of protection. this is accomplished by the internal grout and sheathing barrier.

Macalloy Bar Systems are ideal for the economic application of post-tensioning forces on relatively short tendons. through the use of threaded connections and anchorages they are simple to use and lend themselves to many applications.

the robust coarse thread (ct) on the Macalloy bar ensures rapid and reliable assembly. this is particularly suitable for onsite use and reuse.

Typical ApplicationsBuildings

• Prestressed Beams and columns • Precast connections • temporary Bracing

Bridges • Stay cables and Hangers • Precast Segments • Strengthening (timber & Steel Bridges)

• tension Piles and caissons

Wharves & Jetties

• Stressed deck Planks • tie Backs

Soil and/or rock Anchors

• Permanent and temporary Anchors • uplift Anchors (dam & Foundation) • tunnel roof Bolting • Soil nails and rock Bolts • Slope Stabilisation • crane and tower Bases

Specialist Engineering • Heavy Lifting • Formwork ties and Hangers • Frame ties • Pile testing • Architectural ties and Stays

Characteristic PropertiesMacalloy Bar Properties are listed in the following tables.

Macalloy 1030 Bar Components

Bearing Plate

Nut Bar

WasherCoupler

3 2



BAR poST-TENSIoNINGrAnGE oF MAcALLoY 1030 BAr

GRADE CHARACTERISTIC ULTIMATE TENSILE

STRENGTHMPa

MINIMUM 0.1% PROOF STRESS

MPa

MINIMUM ELONGATION

%

APPROXIMATE MODULUS OF ELASTICITY

GPa

Macalloy 103025-50mm

1030 835 6 170

Macalloy 103075mm

1030 835 6 205

*Macalloy S1030 1030 835 10 185

MEcHAnicAL ProPErtiES oF MAcALLoY 1030 BAr

NOMINAL DIAMETER

mm

CHARACTERISTIC BREAKING LOAD (MBL) MINIMUM 0.1% PROOF LOAD

MACALLOY 1030kN

*MACALLOY S1030kN

MACALLOY 1030kN

*MACALLOY S1030kN

2025

26.53236405075

-5065698281049129520224311

323506

-828

-1295

--

-410460670850105016393495

262410

-670

-1050

--

cHArActEriStic LoAdS For MAcALLoY 1030 BAr

* Macalloy S1030 is made from stainless steel

NOMINAL DIAMETER

mm

NOMINAL CROSS SECTION AREA

mm2

MASS OF BAR MAJOR DIAMETER OF THREADS

mm

MIN. HOLE DIAMETER IN STEELWORK

mmMACALLOY 1030

kg/m*MACALLOY S1030

kg/m

2025

26.53236405075

3154915528041018125719634185

-4.094.586.638.3510.3015.7233.00

2.534.09

-6.63

-10.30

--

22.028.930.436.240.245.354.877.2

2431334044495982

3 3

BAr POST-TENSIONING

ITEM UNIT NOMINAL BAR DIAMETER - mm

†201 251 26.5 32 36 40 50 75Bars Sectional area

Mass per metreMetre run of bar per tonnecharacteristic failing loadPrestress at 70% characteristicMinimum centres for anchorage

mm2

kgmknknmm

314.22.466405314220100

490.94.069246506354100

551.54.560219569398110

804.36.661150828580125

1017.98.4511181049734140

1256.610.410

961295907150

1963.516.020

6220221415175

4185.433.200

3043113018250

*Flat nuts nut referenceLengthWidth across flats (diA for 75mm bar)Weight

-mmmmkg

FSSn202542-

Fn253346-

Fn26.53750

0.46

Fn324156

0.56

Fn364662

0.74

Fn405165

0.86

Fn507190

2.55

Fn751001357.70

*Flat Washers

Washer referenceoutside diameterthickness

-mmmm

FSSW20505

FSW25605

FSW26.5655

FSW32705

FSW36755

FSW40805

FSW501055

---

couplers coupler referenceoutside diameterLength - standardLength - stainlessWeight

-mmmmmmkg

FSSc2035-

65-

Fc2542.58580-

Fc26.542.590-

0.54

Fc325011595

0.94

Fc3657.5130

-1.50

Fc4062.51401201.78

Fc5076170

-3.10

Fc75110230

-9.00

End Plates Plate referenceLengthWidththickness - standardHole diameterthickness - threaded

-mmmmmmmmmm

FSSP201001002526-

FP25100100403540

FP26.5110110403640

FP32125125504150

FP36140140504550

FP40150150605260

FP50200175606170

FP753002507582110

ducts Sheathing i/dcoupler-sheathing i/d recommendedcoupler-sheathing minimum

mmmmmm

415045

4159

52.5

4159

52.5

506660

507165

617570

719190

91125125

Grouting flange

Flange referenceLength /o/diaHeight

-mmmm

---

GF2512540

GF2512540

GF3214040

GF3614040

---

---

---

threads Pitch mm 2.5 6.0 6.0 6.0 6.0 8.0 8.0 8.0Standard thread lengths (see fig on p30)

Length - Jacking end (standard) S1 - dead end (standard) S2 - coupler (standard) x1 (min) x2 (min) x3 (min)

mmmmmmmmmmmm

25010040754212

25010045824912

25010050915312

250100601055712

250100651156212

250100751307116

250100851659116

36016015023511616

MAcALLoY 1030 coMPonEnt PArAMEtErS

* Spherical nuts and washers are available if required for rotation.† 20mm bar available in stainless steel grade only.1 Bar range available on request

Sydney Hockey Centre, Homebush - NSW


3 4



MAcALLoY 1030 SuGGEStEd MiLd StEEL End BLocK rEinForcEMEntnB: Helix and links must be used together with minimum 35 MPa concrete - see figure above

Notes: • A longitudinal length of rod may be used to attach the links but it is not required as part of the reinforcement • A more detailed explanation of the Macalloy Post Tensioning System is available in the Macalloy Design Data Handbook • There are many permutations possible to achieve satisfactory construction details, and advice is readily available from Structural Systems

otHEr MAcALLoY BAr SYStEMS ALSo AVAiLABLE

• Macalloy 460 carbon steel tendons• Macalloy S460 stainless steel tendons• Macalloy Guy Linking stainless steel bar tendons• Macalloy Guy Linking stainless steel cable tendons• Macalloy 17MHS Sheet piling ties

• Macalloy 500 reinforcing bars• Macalloy 500 tie bars• Macalloy 650 Stainless tie bars• Macalloy-tensoteci Galvanised cable tendons

MAcALLoY 1030 tYPicAL End BLocK ArrAnGEMEnt

MAcALLoY 1030 BAr End tHrEAd diMEnSionS

x1 = live endx2 = dead endx3 = length of bar past nut or thru’ threaded plate

S1 = live end threadS2 = dead end threadL = length over plates

MACALLOY DIAMETER

mm

HELIX LINKS

ROD DIAM.mm

I/Dmm

PITCHmm

TURNSNo.

ROD DIAM.mm

SPACINGmm

NUMBER

2526.53236405075

12121212121620

130130165195220250350

40404040405075

5567788

888881016

7070808080100100

3334446

3 5

Ground AncHor SYSTEMS


GROUND ANCHOR SySTEmSStructural Systems Ground Anchors have been utilised world wide in conjunction with our construction partners the BBr group of Switzerland. Ground Anchors comprised of wires, strands or bars can be installed into rock or soil and secured by injecting with cement grout.

Standard Structural Systems Ground Anchors can provide an ultimate load of between 368kn and 23,750kn depending on the configuration.

SSL BBr Anchors have been the largest and longest installed anywhere around the world and our technical expertise in this field is internationally recognised.

typical applications of Structural Systems Ground Anchors include: • retaining structure tie backs • resistance of uplift forces • slope stabilization • underground structures • dam stabilization • tension foundations • soil nailing (bar type anchors)

Transporting ground anchorsTransporting world’s longest ground anchors - Canning Dam - Western Australia

Anchor Fabrication - Canning Dam - Western Australia

Anchor installation

Ross River Dam - Queensland

3 6



GROUND ANCHOR SySTEmSStrAnd tYPE AncHorS

3 7

Ground AncHor SYSTEMS


tYPicAL Ground AncHor tEndon conFiGurAtionS

Notes: • Strand tendons are based on MBL = 184kN (12.7mm strand) and MBL = 250kN (15.2mm strand) (Higher strand / anchor capacities available on request) • Details listed apply to typical applications and may vary to suit actual applications • Macalloy Bar tendons are more commonly used for short anchor lengths • Macalloy Bar anchor details exclude allowance for coupling of bars - refer SSL for details if required

TENDON STRAND / BAR SIzE

mm

MAXIMUM STRANDS PER UNIT

No.

MINIMUM BREAKING

LOAD

kN

BORE HOLE DIAMETER PERMANENT ANCHOR SHEATH SIzE ID / OD

BEARING PLATE SIzE

TYPICAL

mm

TEMPORARY ANCHORS

mm

PERMANENT ANCHORS

mm

CORRUGATED

mm

SMOOTH

mm

StrAnd

15.2mmor

15.7mm

247121922273142556591

500100017503000475055006750775010500137501625022750

7689102114165165178178229241254311

102127152178216216216216311311311356

50 / 6565 / 8580 / 100100 / 120125 / 165125 / 165125 / 165125 / 165210 / 230210 / 230210 / 230250 / 270

55 / 6367 / 7582 / 90

102 / 110150 / 160150 / 160150 / 160150 / 160225 / 235225 / 235225 / 235257 / 270

200 x 200 x 32200 x 200 x 36300 x 300 x 50350 x 350 x 60400 x 400 x 70450 x 450 x 80500 x 500 x 80500 x 500 x 90600 x 600 x 100700 x 700 x 120700 x 700 x 140900 x 900 x 160

91+ under development - refer SSL

StrAnd12.7mm

or12.9mm

247

3687361288

7689102

102127152

50 / 6565 / 8080 / 100

55 / 6367 / 7582 / 90

200 x 200 x 32200 x 200 x 36250 x 250 x 40

larger sizes on request - refer SSL

MAcALLoY BAr26.532405075

11111

569828129520224311

76102102127152

127152152175203

65 / 8080 / 10080 / 100100 / 127130 / 150

n/an/an/an/an/a

200 x 200 x 40250 x 250 x 50300 x 300 x 60300 x 300 x 60400 x 400 x 90

External prestressing was first used in the late 1920’sand has recently undergone a resurgence being used in bridges, both for new construction as well as strengthening of existing structures.

Features of External Prestressing

External prestressing is characterised by the following features:

• the prestressing tendons are placed on the outside of the physical cross section (mostly in concrete) of the structure.

• the forces exerted by the prestressing tendons are only transferred to the structure at the anchorages and at deflectors.

• no bond is present between the tendon and the structure, except at anchorage and deflector locations.

Advantages of External Prestressing

Compared to internal bonded post-tensioning the external prestressing has the following distinct advantages:

a) The application of external prestressing can be combined with a broad range of construction materials such as steel, timber, concrete, composite structures and plastic materials. This can considerably widen the scope of the post-tensioning applications.

b) Due to the location and accessibility of the tendons, monitoring and maintenance can be

readily carried out compared to internal, bonded prestressing.

c) Due to the absence of bond, it is possible to restress, destress and exchange any external prestressing cable, provided that the structural detailing allows for these actions.

d) Improves the concrete placing due to the absence of tendons in the webs.

e) Improvement of conditions for tendon installation which can take place independently from the concrete works.

f) Reduction of friction losses, because the unintentional angular changes, known as wobble, are practically eliminated. Furthermore with the use of a polyethylene sheathing the friction coefficient is drastically reduced compared to internal bonded prestressing using corrugated metal ducts.

g) External prestressing tendons can easily and without major cost implication be designed to be replaceable, de-stressable and re-stressable.

h) Generally the webs can be made thinner, resulting in an overall lighter structure.

i) Strengthening capabilities.

As an overall result, better concrete quality can be obtained leading to a more durable structure.

External post-tensioning - Navia, Spain

3 8



EXTERNAL pRESTRESSING

Typical Applications for ExternalPrestressing

Typical applications where external tendons are feasible, practical and economical, are:

- Repair work and strengthening of all kinds of structures

- Precast segmental construction- Simple and continuous spans- Underslung structures - Incremental launching procedure, in particular

concentric prestressing

Basic Type

The basic SSL BAR CONA External tendon is practically identical to the SSL Multi-Strand System for internal applications:

- The tendon is formed from standard 15.2mm/15.7mmdiameterstrandswithminimumbreakingloadof250kNor279kN.

- The duct is from high density polyethylene and continuous from one anchorage to the other. The tendon sheathing passes freely through intermediate diaphragms and through deflectors with a metal or HDPE sleeve providing the required penetration.

- A standard CONA Compact anchorage assembly consisting of anchor head, wedges, anchorage casting and polyethylene trumpet safely transfers the prestressing forces to the structure (see Fig. 1).

- Alternatively a fabricated steel bearing plate anchorage can be used in lieu of the cast anchorage.

- The tendon is filled with cement grout after it has been tensioned. Depending on requirements, the anchor heads may be protected by a cap, or alternatively the anchorage recess is filled with non-shrink concrete.

3 9

ExtErnAL POST-TENSIONING


Fig. 2. SSL-CONA External with anchorage casting

anCHoraGe CasTInG

NUMBER OF STRANDS

15.2mm / 15.7mmTYPE

DIMENSIONS (mm)

A1 x A1 ØB C D E1 ØF G AD/ID ad/id

712193142

7061206190631064206

215265335395500

150180230290340

52658097116

105115130150155

355425511650950

109138178222283

758090100160

75 / 66.490 / 79.8110 / 97.4140 / 124210 / 200

90 / 79.8110 / 97.4140 / 114.4180 / 147.2243 / 225

SSL conA ExtErnAL tEndonSMain dimensions

Fig. 1. Standard Cona Compact Anchorage Assembly

Structural Systems can provide strand (BBR HiAm ConaTM) stay cables, wire (DinaTM/HiAmTM) stay cables, and Carbon stay cables for a wide variety of structures, drawing on both local and global expertise and resources of the BBR Network. For suspension bridges, BBR Technology can also be used for the main suspension cables as well as for the hangers.

Staycablesmaybeplainstrand/wireunsheathedfortemporary applications.

For permanent stay cable applications, galvanised, waxed and individually sheathed strands, enclosed in an external sheath are adopted; or wires enclosed in a sheath and the voids filled with a flexible corrosion protection compound.

In recent years a fatigue stress range of 200 N/mm2 for 2x106 load cycles in combination with angular rotations at the anchorages has been adapted and is now specified by most codes and recommendations. BBR Stay Cable Technology has fulfilled such fatigue testing.

Sydney Athletics Centre - New South Waies

Eleanor Schonell Bridge - Queensland

CABLE STAY SySTEmS

4 0



4 1

cABLE StAY SYSTEMS


Strand Stay Cables

BBR HiAm ConaTM Parallel Strand Stay Cables Installation is typically performed on site using the strand-by-strand method. Each strand is tensioned immediately after installation, using the BBR isostress tensioning method, ensuring an equal force distribution among the strands of an individual cable. Alternatively, fully or partially prefabricated cables can be installed and tensioned.

Strandsaregenerally15.7mmdiameter, lowrelaxationgrade, minimum guaranteed ultimate tensile stress of 1770 N/mm2 or 1860 N/mm2 and subject to fatigue testing by the manufacturer. Strands are galvanized, waxed and individually sheathed with a continuous and wear resistant HDPE coating, providing each strand with an individual multilayer protection system. Alternatives may also be available upon request. A ring nut screwed on anchor heads transfers the cable loads by contact pressure to the supporting bearing plates, and allows adjustment of stay force. All anchorage components are designedforastressrangegreaterthan300N/mm2 and to withstand the ultimate breaking load of the strand bundle with adequate safety.

Supplemental internal or alternatively external damping devices protect the stay cable from vibrations.

Another effective countermeasure against wind and rain-induced vibrations is the use of a helical rib on the outside of the HDPE, architecturally coloured co-extruded stay pipe.

Final stay cable force may also be adjusted using a specially designed multi-strand jack acting on the entire stay cable. Individual strands can be re-stressed at any time during or after the installation, allowing not only for a re-stressing but also for the selective removal, inspection and replacement of individual strands or the entire stay cable.

Standard Anchorage Components

TYPE FORCES STRUCTURE ANCHORAGE STAY PIPE WEIGHT

HiA

m C

ON

A

AXIAL CABLE FORCEBEARING PLATE / STEEL GUIDE

PIPEBBR HIAM ANCHORAGE SYSTEM

HDPECABLE

ULTIMATE WORKINGSHORT TERM

FATIGUESTEEL 355 MPa YIELD STRESS

STRUCTURAL GRADE SDR32

MBL Fwl Fext Ffat

PLATE GUIDE PIPE Diam.GA

HA IA

Diam.S

CABLEDiam. CBP Diam. DGP

100% 45% 55% 200 MPa OD / e STRESSING FIXED OD / e

kN kN kN kN mm mm / mm mm mm mm mm mm / mm kg/m

1 06 279 126 153 30 57 70.0 / 5.0 75 390 190 1000 / 1.3

3 06 837 377 460 90 85 101.6 / 5.0 110 400 200 1500 63 / 4.0 4.7

7 06 1953 879 1074 210 133 152.4 / 4.5 165 410 210 2000 90 / 4.0 10.3

12 06 3348 1507 1841 360 170 193.7 / 5.6 210 420 220 2125 110 / 4.0 17.1

19 06 5301 2385 2916 570 210 244.5 / 6.3 260 435 235 2250 125 / 4.0 26.4

22 06 6138 2762 3376 660 225 244.5 / 6.3 275 435 235 2375 140 / 4.4 30.7

27 05 7533 3390 4143 810 248 273.0 / 6.3 305 450 250 2500 160 / 5.0 37.8

31 06 8649 3892 4757 930 264 298.5 / 7.1 325 445 245 2625 160 / 5.0 43.1

37 06 10323 4645 5678 1110 288 323.9 / 7.1 355 465 265 2750 180 / 5.7 51.6

42 06 11718 5273 6445 1260 305 323.9 / 7.1 375 465 265 2850 180 / 5.7 58.2

48 06 13392 6026 7366 1440 327 356.6 / 8.0 400 480 280 2950 200 / 6.3 66.8

55 06 15345 6905 8440 1650 349 368.0 / 8.0 425 480 280 3050 200 / 6.3 75.9

61 06 17019 7659 9360 1830 367 406.4 / 8.0 450 495 295 3150 225 / 7.1 84.8

69 06 19251 8663 10588 2070 389 406.4 / 8.0 475 500 300 3250 225 / 7.1 95.3

73 06 20367 9165 11202 2190 400 419.0 / 8.0 490 490 290 3350 250 / 7.9 1101.7

75 06 20925 9416 11509 2250 405 457.0 / 10.0 495 510 310 3450 250 / 7.9 104.3

85 06 23715 10672 13043 2550 430 457.0 / 10.0 525 515 315 3550 280 / 8.8 119.0

91 06 25389 11425 13964 2730 445 508.0 / 11.0 545 525 325 3650 280 / 8.8 126.8

97 06 27063 12178 14885 2910 458 508.0 / 11.0 560 525 325 3750 280 / 8.8 134.7

109 06 30411 13685 16726 3270 485 508.0 / 11.0 595 525 325 3850 315 / 9.9 152.4

121 06 33759 15192 18567 3630 510 559.0 / 12.5 625 545 345 3950 315 / 9.9 168.1

127 06 35433 15945 19488 3810 522 559.0 / 12.5 640 555 355 4050 315 / 9.9 176.0

StrAnd diAMEtEr: 15.7mm to prEn 10138-3 (rEFEr dESiGn dAtA)

Notes: • e = nominal wall thickness

BBr HiAM StAY cABLES

4 2



CABLE STAY SySTEmS

CABLE SIzE (WIRES PER CABLE) n Ø 7 No. 56 91 121 163 196 223 262 301 334 367 394 421

CABLE Breaking Load Funom

kn 3600 5850 7775 10475 12595 14330 16840 19345 21465 23585 25320 27055

Max. Working Load Fmax

kn 1620 2635 3500 4715 5670 6450 7580 8705 9660 10615 11395 12175

Steel Weight kg/m 16.9 27.5 36.6 29.2 59.2 67.4 79.2 91 100.9 111 119 127.2

Cable Weight kg/m 23.8 33.2 43.8 58.0 71.2 78.4 93.8 104 118.7 128 138.3 145.5

HDPE STAY PIPE Ø pe mm 110 110 125 140.0 160 160.0 180 180 200 200 210 210

WALL THICKNESS mm 10.0 10.0 11.4 12.8 14.6 14.6 16.4 16.4 18.2 18.2 19.1 19.1

HDPE TELESCOPE PIPE Ø pe t mm 140 140 160 180.0 200 200.0 225 225 250 250 250 250

WALL THICKNESS mm 12.8 12.8 14.6 16.4 18.2 18.2 20.5 20.5 22.8 22.8 18.0 18.0

STEEL GUIDE PIPE Ø T mm 229.0 / 267.0 / 298.5 / 343.0 / 355.6 / 368.0 / 406.4 / 445.0 / 445.0 / 470.0 / 495.0 / 495.0 /

(outer/inner diameter) mm 211.4 251 282.5 311.0 330.6 352.0 378.0 405.0 416.6 435.0 455.0 470.0

BEARING PLATE B mm 365 430 480 545.0 590 625.0 675 730 755 795 830 850

THICKNESS t mm 45 55 60 70 75 75 85 95 95 100 110 105

CENTRE HOLE Ø Z mm 211 251 282 311.0 330 352.0 378 405 417 435 455 470

SOCKET Outer Diameter Ø a mm 195 235 265 295 315 335 360 385 400 420 435 450

Length Stressing Anchorage lhM mm 355 425 480 550 605 635 665 710 755 790 815 845

Length Fixed Anchorage lhF mm 320 370 415 465 505 525 540 575 605 635 650 675

LOCK NUT Ø M mm 245 290 330 365 390 420 450 480 500 520 540 560

hM mm 75 90 105 120 125 135 150 160 165 170 180 185

PROTECTION CAP Ø S mm 219 259 289 319 339 359 389 409 429 449 459 479

lSm mm 283 338 378 433 483 503 518 553 593 623 638 663

lSf

mm 178 203 213 228 253 253 253 268 283 288 293 303

WEIGHT OF ANCHORAGE (excl. Anchor Plate and Guide Pipe)

stress. kg 93 157 226 314 391 465 567 668 787 898 998 1110

fixed kg 86 142 203 281 347 412 495 600 682 779 861 957

4 3

cABLE StAY SYSTEMS


BBr dinA StAY cABLES

CaBle Size (wireS per CaBle) n Ø 7 no. 13 22 31 37 55 70 91 103 121 145 157 181 199

CaBle Breaking load Funom

kn 835 1415 1990 2380 3535 4500 5850 6620 7775 9320 10090 11635 12790

Max. working load Fmax

kn 375 635 895 1070 1590 2025 2635 2980 3500 4195 4540 5235 5755

Steel weight kg/m 3.9 6.6 9.4 11.2 16.6 21.1 27.5 31.1 36.6 43.8 47.4 54.7 60.1

Cable weight kg/m 6.4 8.8 12.4 15.8 20.7 27.6 33.2 39.0 43.8 53.1 56.4 67.2 72.0

hdpe Stay pipe Ø pe mm 63 63 75 90 90 110 110 125 125 140 140 160 160

wall thiCKneSS mm 5.8 5.8 6.9 8.2 8.2 10.0 10.0 11.4 11.4 12.8 12.8 14.6 14.6

hdpe teleSCope pipe Ø pe mm 75 75 90 110 110 140 140 160 160 180 180 200 200

wall thiCKneSS mm 4.3 4.3 5.1 6.3 6.3 12.8 12.8 14.6 14.6 16.4 16.4 18.2 18.2

Steel guide pipe Stressing anchorage Ø Tm

mm 139.7 / 146.0 / 168.3 / 177.8 / 203.0 / 229.0 / 254.0 / 267.0 / 292.0 / 305.0 / 318.0 / 330.0 / 355.6 /

(inner / outer diameter) mm 125.5 136.0 155.7 165.2 190.4 211.4 238.0 245.0 267.0 285.0 298.0 310.0 327.2

Fixed anchorage Ø Tf

mm 139.7 / 146.0 / 168.3 / 177.8 / 203.0 / 229.0 / 254.0 / 267.0 / 292.0 / 305.0 / 318.0 / 330.0 / 355.6 /

(inner / outer diameter) mm 125.5 136.0 155.7 165.2 190.4 211.4 238.0 245.0 267.0 285.0 298.0 310.0 327.2

Bearing plate Stressing plate Bm

mm 230 260 285 305 350 380 420 435 470 510 525 560 590

thickness tm

mm 30 35 35 40 45 50 55 60 60 65 65 70 75

Centre hole Ø Zm

mm 125 136 155 165 190 211 238 245 267 285 298 310 327

Fixed plate Bf

mm 180 210 240 270 305 405 430 415 440 480 495 530 555

thickness tf

mm 25 35 35 45 45 70 80 60 65 75 75 80 90

Centre hole Ø Zf

mm 110 110 125 145 145 175 175 195 195 215 215 235 235

StreSSing SleeVe outer diameter Ø Zh mm 100 120 140 150 175 195 220 230 250 270 280 295 310

length lZh mm 90 105 115 130 160 190 205 225 245 255 270 290 305

length Fixed anchorage lhF mm 45 55 60 60 75 75 90 90 100 105 110 115 125

loCK nut Stressing anchorage Ø Mfmm 140 160 180 195 225 250 280 290 315 340 355 370 390

hMf

mm 30 35 40 45 55 60 70 70 75 80 85 90 95

Fixed anchorage Ø Mrmm 130 135 155 175 185 220 230 250 255 280 285 310 315

hMr

mm 30 40 45 50 55 65 70 75 80 85 90 95 100

proteCtion Cap Stressing anchorage Ø Smmm 129 149 169 179 199 219 249 259 279 299 309 319 339

lSm

mm 98 108 113 128 153 178 188 203 218 223 238 253 265

Fixed anchorage Ø Sfmm 125 130 150 170 180 215 225 245 250 275 280 305 310

lSf

mm 34 34 34 34 34 34 34 34 34 34 34 34 34

weight oF anChorage (excl. anchor plate and guide pipe)

stress. kg 15 19 26 34 48 69 86 102 125 150 169 199 230

fixed kg 11 12 16 22 24 35 40 49 52 65 69 85 90

4 4



INCREMENTAL LAUNCHING SySTEmSthe incremental Launching method combines the advantages of pre-cast segmental construction with those of segmental cast insitu methods.

Bridges are cast in segments behind an abutment under controlled conditions, as a result, high concrete quality and precise dimensions are assured. reinforcement crosses each joint in addition to the bonded pre-stressing tendons as each new segment is cast directly

against the already hardened one in front. the concentric pre-stress required during launching guarantees an excellent, relatively maintenance free performance of the bridge during its whole lifetime.

By avoiding costly and time-consuming false work and by concentrating all construction activities in the small fabrication area, considerable saving in cost and time against conventional bridge construction are achieved.

the main characteristics of the incremental launching method are:

• Production of a continuous, site cast concrete superstructure.• casting in long sections in a stationary, multiple use form behind an

abutment.• After longitudinal shifting (launching) of a completed section along the

bridge axis, the next section is cast against the previous one and stressed together.

• in this sequence the overall superstructure grows by adding new sections, step-by-step as the progressively completed girder is launched.

• temporary sliding bearings and guides at each pier facilitate the steady travel of the structure.

• A steel launching nose at the front sliding bearings, and a casting bay behind the abutment.

Some preferred requirements are:

• the girders should have a constant curvature in horizontal and vertical alignment.

• the section should be continuous over the whole bridge with preferably a constant depth.

• Span should be limited to 50-60 metres.• Span/depth ratios should be in the range of 14 to 18.

these are not exclusive but provide a guide to the standard range of applications.

Incremental Launching Girder

Mt Henry Bridge - Western Australia

Tonkin Hwy Bridge over Albany Hwy - Western Australia

4 5

HEAVY LiFtinG SYSTEMS

in many instances, it is advantageous for extremely large and heavy components to be prefabricated away from their final location. in most cases they must be lowered, jacked horizontally or lifted into their final position. When their weight or size exceeds the capacity of available cranage other heavy lifting facilities must be considered.

Structural Systems has developed specialised lifting equipment for this application. the combination of the proven BBr Buttonhead Prestress cable together with electrically operated hydraulic jacking units allows virtually unlimited loads to be moved quickly and safely over any distance. the lifting or lowering operation can be accurately controlled through the hydraulic system which allows simultaneous or individual operation of each lifting unit.

HEAVY LIFTING SySTEmS

Perth Convention Exhibition Centre - Before Roof Lift

12 outlet isoflow pump and control panel

Perth Convention Exhibition Centre - After Roof Lift

4 3w w w . s t r u c t u r a l s y s t e m s . c o m . a u

4 6



LOAD HANDLING SySTEmSConstruction procedures involving load handling systems often result in considerable savings as compared to conventional building methods using traditional scaffolds for casting concrete or installing steel structural elements in place.

The application of load handling systems requires full consideration at the structural design stage, well in advance of detailing or construction planning, as selecting or designing the necessary temporary works and choosing the related equipment must be performed as early as possible.

Structural Systems has extensive experience in the field of load handling and can provide all required services for design as well as supply and operation of equipment.

Raising roof segment - Docklands Stadium

lifting, lowering and shifting of Heavy loadsHeavy, fragile or awkward structural elements can be either fabricated on or off site, then manoeuvred into position by using jacking systems and tendons from bar, strand or wire. Examples include roof structures, bridge spans, precast concrete elements, and heavy industrial components. it is often preferred to assemble a large module adjacent to its final location then shift it into position, on the basis of safety, ease of assembly or time constraints. in some instances bridge pier headstocks are constructed parallel to traffic, then rotated to minimise traffic disruption. Some of SSL’s systems incorporate special hydraulic and monitoring systems to allow for high accuracy movement regardless of any differential loadings.

specialist Formwork & accessoccasionally access systems or working platforms may be located in areas which cannot be serviced using conventional cranage. in these instances where standard options fail, the compact yet powerful systems SSL offer allow for an effective solution to be developed. Examples of this application may be underbridge platforms, fitting of chimney liners and lift shaft installations. Additionally we have developed specialist platforms for use on high rise buildings, bridges, tanks and silo structures to permit necessary works such as post-tensioning and repair or inspection. SSL also have free spanning access walkways up to 40m. the use of our specialist hardware such as cable stays can allow formwork solutions to be developed where the formwork and false work is supported from above rather than below. this may be essential in some locations where it is not possible due to access, and cost or time.

Tendon Installation & TransportAs part of our diverse operations, we have developed systems for use on cable stay bridges or large dam projects where tendons up to 150m and weights greater than 17 tonnes need translation and fitting to the structure. A further example is the stay cables incorporated in centrepoint tower, were fabricated in Melbourne prior to shipment and installation in Sydney.

tYPicAL APPLicAtionS

Ringwood Rail Bridge Sliding Operations - Victoria


load handling systems

Flat JacksFlat jacks are used for a variety of applications where structures are required to be lifted or preloaded and installation heights are to be kept to a minimum.

Structural Systems can provide 2 types of flat jacks:

• Pan Type Contstructed of two moulded steel sections welded together

used with a top and bottom plate. These can be inflated with oil or grout and are generally used only once (see Table a).

• Safety lock nut Type Solid ram, low height hydraulic jacks with safety lock nut for

mechanical load handling, used mainly for bearing replacement work (see Table B). For heavy loads multiples of the jacks are used linked through a manifold system.

Pan Type

Safety Lock Nut Type

notes: [1] flat jack thickness may vary slightly

taBlE a - PaN tYPE

tYPE OUtsIDE DIaMEtER

mm

MaXIMUM FORcE at 10,000 PsI

kN

tHIckNEss

mm

MaXIMUM tRaVEl

mm

INstallatION GaP

mm

60T100T150T200T250T300T

138188205240300305

60010001500200030003000

110162192155150170

285050505050

125180210170165185

taBlE B - saFEtY lOck NUt tYPE

Notes: • Jacks come complete with spherical testing

tYPE D OUtsIDE DIaMEtER

mm

MaXIMUM FORcE at 13.5 MPa

kN

EFFEctIVE aREa at ZERO EXtENsION

103mm2

t tHIckNEss1

mm

E MaXIMUM tRaVEl

mm

INstallatION GaPmm

9T16T39T52T60T78T108T160T217T347T540T738T898T1364T

1201502202502703003504204806007508709201150

85155390525605780108016052170347054007385897513635

6.411.529394558801191612574005476651010

2525252525252525252525252525

2525252525252525252525252525

3838383838383838383845454550

4 7

Structural Systems operate throughout Australia, South East Asia, the Middle East and the United Kingdom.For more information on Structural Systems and the many services we provide, visit: www.structuralsystems.com.au

STRUCTURAL SYSTEMS 112 Munro Street, South Melbourne VIC 3205 Australia T. +61 3 9296 8100 F. +61 3 9646 7133

STRUCTURAL SYSTEMS 20 Hilly Street, Mortlake NSW 2137 Australia T. +61 2 8767 6200 F. +61 2 8767 6299

STRUCTURAL SYSTEMS Unit 2, 16 Maiella Street, Stapylton QLD 4207 Australia T. +61 7 3442 3500 F. +61 7 3442 3555

STRUCTURAL SYSTEMS 24 Hines Road, O’Connor WA 6163 Australia T. +61 8 9267 5400 F. +61 8 9331 4511

NASA STRUCTURAL SYSTEMS LLC Head Office Suite 302 Sara Building, Garhoud PO Box 28987 DUBAI United Arab Emirates T. +97 14 2828 595 F. +97 14 2828 386 www.bbrstructuralsystems.com

STRUCTURAL SYSTEMS 12 Collett Way Great Western Industrial Park Southall, Middlesex UB2 4SE T. +44 208 843 6500 F. +44 208 843 6509

STRUCTURAL SYSTEMS Unit 13, Block G Maynooth Business Campus, Maynooth Co. Kildare, Ireland T. +353 1628 9124 F. +353 1628 9124

STRUCTURAL DESIGN SERVICES sp.z o.o. Twarda 30 00-831 Warszawa Poland T. +48 226 979 246 +48 226 979 247 F. +48 226 979 248

VICTORIA

NEW SOUTH WALES

QUEENSLAND

WESTERN AUSTRALIA

MIDDLE EAST REGION Bahrain, Oman, Qatar,

U.A.E.

UNITED KINGDOM

IRELAND

POLAND