Download pdf - Dywidag DSI Bonded PT System

DYWIDAG-SYSTEMS INTERNATIONAL

6803 . 6861 . 5915 . 6837 . 5909 . 6801 . 6819 . 6802 . 6815 . 6827 . 5920 . 6809 . 5937 . 6812 . 5932 . 6802 . 6804 . 6801 . 6819 . 6815 . 5909 . 6901 . 5908 . 5915 . 6812 . 6804 . 6837 . 5909 . 6801 . 6819 . 6802 . 6815 . 6803 . 6861 . 5915 . 6837 . 68

6803 . 6861 . 5915 . 6837 . 5909 . 6801 . 6819 . 6802 . 6815 . 6827 . 5920 . 6809 . 5937 .

. 6815 . 6827 . 5920 . 6809 . 5937 . 6912 . 5932 . 6802 . 6904 . 6803 . 6861 . 5915 . 6837 . 5909 . 6801 . 6919 . 6802 . 6815 . 6827 . 5920 . 6809 . 5937 . 6812 . 5932 . 6802 . 6904 .

DYWIDAG Bonded Post-Tensioning Systems

6803 . 6861 . 5915 .

32G 26D 32E 36C 36E 32D

DYWIDAGPost-Tensioning Systems

DYWIDAG Post-TensioningSystems are world renownedfor reliability and performance,most suitable for all applica-tions in post-tensioned con-struction. They embrace thewhole spectrum from bridgeconstruction, buildings, tocivil applications, above andunderground.

The first ever structure builtwith a prototype DYWIDAGPost-Tensioning System usingBars was the arch-bridgeAlsleben (Germany) in 1927.From that time on DYWIDAGhas continuously improved itssystems to keep up with thegrowing demand of modernconstruction technology. Inaddition to the traditionalpost-tensioning system usingbars, that is mainly gearedtowards geotechnical applica-tions, building rehabilitationand strengthening, DSI offersa complete product line instrand post-tensioning (bonded,unbonded and external) aswell as stay-cables being ableto fully serve the post-tensioning construction.DYWIDAG Post-TensioningSystems have always combi-ned highest safety and reliabi-lity standards with most eco-nomical efficiency in their re-search and development.Dependable corrosion protec-

tion methods of the DYWIDAG Post-TensioningSystems contribute to thelongevity of modern construc-tion. High fatigue resistance isachieved with optimizedmaterial selection and cau-tious detailing of all the com-ponents especially in theirsystem assembly.

We look back on many yearsof valuable experience in thefield of post-tensioning whichleads to our extremely versa-tile product range that offerseconomical solutions forpractically any problem. Thisincludes our highly developed,most sophisticated equipmentwhich is easy to operate in allphases beginning with assem-bly, installation, stressing andfinally grouting.

DYWIDAG Post-TensioningSystems are being developedand maintained by DYWIDAG-SYSTEMS INTERNATIONALand are serviced and distribu-ted by a worldwide networkof subsidiaries owned by theDyckerhoff and Widmann AG(DYWIDAG). Our systems comply with theinternational specificationsand recommendations (ASTM,AASHTO, BS, Eurocode, DIN,Austrian Code, SIA, FIP, EOTA, etc.). The American

construction market demandeda product range that is descri-bed in separate brochures.The quality of the DSI productsand services is in full compli-ance with ISO 9001.

DSI scope:

- consulting- design and shop-drawing

engineering- manufacturing and supply- installation or training and

/or supervision of installation - inspection and maintenance

22

1 Water Tanks, Florida, USA

2 The Museum of Men, Spain

3 Krungthep Bridge Project, Thailand

4 Silver Legacy Hotel, Las Vegas, USA

1

2

3

3

Contents

DYWIDAG Post-Tensioning Systems using Strands page 4

Standard Strands 4Corrugated Sheathing 5PE/PP Sheathing 6Anchorages 7Installation 11Stressing 12Grouting 13Multiplane Anchorage MA 14Plate Anchorage SD 15Plate Anchorage SDR 16Mono Anchorage EV 17Bond Head Anchorage ZF/ZR 18Loop Anchorage HV 19Flat Anchorage FA 20Coupler M/ME (Floating Anchorage Block) 21Coupler R 22Coupler P 23Coupler D 24Equipment Overview 25Calculation of Elongation 29

DYWIDAG Post-Tensioning Systems using Bars page 30

DYWIDAG Standard Bars 31Anchorages for Bar Tendons 32QR Plate Anchorage 33Solid Plate Anchorage, Rectangular 34Solid Plate Anchorage, Square 35Splices and Corrugated Sheathing 36Installation and Stressing 37Stressing 38Grouting 39Equipment Overview 40Calculation of Elongation 42

4

subject to modification, January 2001

Post-Tensioning Systemsusing Strands

4

Strands are usually packaged in so-called coils that can weigh

up to 3.5 tons.

S

S C

V

V

VV V

VSV

V

PGD PGD

construction joint

S = stressing

= post-grouting P

C = coupling

G = grouting

V = vent

= drainingD

subject to modification, January 2001subject to modification,

Strands are made from 7 indi-vidual cold-drawn wires, 6helically wound outer wiresand one center wire (kingwire). The mechanical pro-perties of the strand as wellas corrosion protection pro-perties are most important toDSI. Strands can be suppliedeither bare, galvanized orepoxy-coated without anyloss in strength including thewedge anchorage. For amaximum in corrosion protec-tion we offer electrically isola-ted systems using polyethyle-ne (PE) or polypropylene (PP)sheathings. See also page 6.

Standard Strands

Technical Data

In addition to standard strands, DSI offers a variety of special strands such as DYFORM with a guaranteed ultimate capacity of 309 kN. The technical data for these products is available upon request.

1) yield measured at 1% effective elongation2) yield measured at 0.1% residual elongation3) applicable for relaxation class 2 according to Eurocode prEN 10138/BS 5896: or low relaxation complying with ASTM A 416, respectively.

~195,000

max. 2.5

type 13 mm (0.5") 15 mm (0.6")code/specification ASTM A 416 prEN 10138 ASTM A 416 prEN 10138 ASTM A 416 prEN 10138

Grade 270 BS 5896 Super Grade 250 BS 5896 Super Grade 270 BS 5896 Superyield strength fp0.1k [N/mm2] 1,6701) 1,5802) 1,5501) 1,5002) 1,6701) 1,5802)

ultimate strength fpk [N/mm2] 1,860 1,860 1,725 1,770 1,860 1,860nom. diameter [mm2] 12.70 12.90 15.24 15.70 15.24 15.70cross-sectional area [mm2] 98.71 100.00 139.35 150.00 140.00 150.00weight [kg/m] 0.775 0.785 1.094 1.180 1.102 1.18ultimate load [kN] 183.7 186.0 240.2 265.0 260.7 279.0modulus of elasticity [N/mm2]relaxation3) after1,000 h at 0.7 x [%]ultimate load fpk

5

Corrugated Sheathing

Dimensions of Corrugated Sheathing (Standard Size)

1) according to German approval

tendon type tendon type

min. support wobble coefficient

0.5" 0.6"

center distances angle of frictiondistances1) up to1) ß1) µ1)

mm m º/m -5901 6801 36 1.8 0.8 0.155902 6802 72 1.8 0.5 0.175903 6803 90 1.8 0.3 0.185904 6804 99 1.8 0.3 0.195905 6805 108 1.8 0.3 0.205907 6806 117 1.8 0.3 0.195909 6807 117 1.8 0.3 0.195912 6809 117 1.8 0.3 0.195915 6812 144 1.8 0.3 0.195920 6815 162 1.8 0.3 0.195927 6819 171 1.8 0.3 0.205932 6822 180 1.8 0.3 0.205937 6827 198 1.8 0.3 0.205955 6837 235 1.8 0.3 0.20

- 6861 306 1.8 0.3 0.20

Metal ducts represent themost economical means tocreate a void for tensile elements.These thin-walled (0.25 - 0.35mm), ribbed sheet metal ductsprovide a fair secondary cor-rosion protection with excel-lent bond behavior betweentendon and concrete. Primarycorrosion protection is provi-ded by the alkalinity of groutand concrete.

tendon type tendon type sheathing

0.5" 0.6"I.D. O.D.mm mm

5901 6801 20 255902 6802 40 455903 6803 50 555904 6804 55 605905 6805 60 655907 6806 65 705909 6807 65 705912 6809 75 805915 6812 80 855920 6815 90 955927 6819 95 1005932 6822 100 1055937 6827 110 1185955 6837 130 138

- 6861 170 178

The tendon type number (e.g. 5901, 6801) is composed as follows: the first digit(5 or 6) identifies the nominal strand diameter in tenth of inches, i.e. 0.5" or 0.6"/0.62", the last two digits (..01) reference the number of used strands (= 1 strand).The second digit is an internal code. As regards the 0.6" tendon types, the acces-sories fit both Grade 250 (GUTS 1770 N/mm2) and Grade 270 (GUTS 1860 N/mm2)strands.


O.D.

I.D.

6

Thick-walled polyethylene/polypropylene (PE/PP) plasticducts provide long-termsecondary corrosion protec-tion especially in aggressiveenvironments such as wastewater treatment plants, acidtanks or silos. Plastic ductsare an integral part in theelectrically isolated tendons.

The minute friction coeffi-cients for strands inside PEsheathing enhance the fatiguelife of tendons. Plastic ductselectrically isolate the tendonfrom the structure and thusprovide a tool to inspect theintegrity of the corrosion pro-tection system.

DYWIDAG-SYSTEMSINTERNATIONAL offers ductsin lengths between 4 and 6m.

type tendon type tendon type

diameter wall thickness

0.5" 0.6" I.D. O.D. tmm mm mm

5905 - 5909 6805 - 6807 59 73 2,00

round duct5912 - 5915 6809 - 6812 76 91 2.505919 - 5927 6815 - 6819 100 116 3.005932 - 5937 6822 - 6827 130 147 3.50

type tendon type tendon type a x b A x B wall thickness

0.5" 0.6"t

mm mm mmflat duct 5905 6804 72/21 86/35 2.00

PE/PP Sheathing


7

Multiplane Anchorage MA

Plate Anchorage SD/SDR

Mono Anchorage EV

The two-part multiplane an-chorage is primarily used forlongitudinal tendons in beamsand bridges. The wedge plate with theconical anchor body andusually three load transferplanes introduces the pre-stressing force continuouslyinto the member with minimalfront area.The separation of anchorbody and wedge plate makesit possible to insert the strandafter casting the concrete.The wedge plate self-centerson the anchor body providingconsistent assembly andinstallation as well as trouble-free stressing.

The single unit plate anchor-age is designed for platestructures as well as trans-verse tendons in bridges.Small edge and center dis-tances allow for an economi-cal anchorage layout in con-densed situations. The PlateAnchorage SDR has an en-larged plate that is designedto work with lower strengthconcrete (C20/25 accordingto EC2).

Single unit anchorage usedfor one strand in slabs andsimilar structures.

✔ ✔ ✔ ✔

stressing dead end anchoragecoupling

ultimate load

anchorage[kN]

accessible not accessible from to

1,302 17,019

✔ ✔ ✔

stressing dead end anchorage couplingultimate load

anchorage[kN]


265 279

✔ ✔ ✔

stressing dead end anchoragecoupling

ultimate load

anchorage[kN]


744 2,511

pocket former for each anchorage system on request




✔


SD SDR

88

Bond Head AnchorageZF/ZR

Loop Anchorage HV

Flat Anchorage FA

Primarily used with prefabri-cated tendons, it is also pos-sible to fabricate this anchor-age on site. The strand wiresare plastically deformed toensure a safe load transfer upto ultimate capacity in thearea of the bond head provenin static as well as in dynamicapplications. Depending onthe boundary conditions eithertwo-dimensional or a three-dimensional bond head an-chorage pattern is available.

Often used in large plate-shapedstructures, walls in off-shorestructures or LNG tanks withgenerally static loadings. The180º loop should be positio-ned in the center of the ten-don to allow for non-slippageduring two-end stressing.

The Flat Anchorage of max.4-0.62" or 5-0.52" strands inone plane to deviate into oneoval duct is designed to beinstalled in thin members suchas transverse post-tensioningof the top slab of box-girderbridges and prestressed flatslabs.

✔


anchorage[kN]


279 5,301

✔ ✔ ✔


anchorage[kN]


744 1,116

✔


anchorage[kN]


372 5,301





ZF ZR

9

Coupler M/ME (Floating Anchorage Block)

Coupler R

Coupler P

Cylindrical structures (watertanks, digestor tanks, largepipes or dome shells) thatrequire circumferential post-tensioning are the principalapplications for the non-fixedcoupler M/ME. The tendonanchorage consists of ananchorage block with wedgeholes on both sides to acceptbare or greased and sheathedstrands. The strands actuallyoverlap in the block and usethe belt-buckle principle. Thering-tendon is very compactand requires a very smallpocket only.

Coupler R is designed to cou-ple on to already installed andstressed tendons. The coup-ler consists of a multiplaneanchor body and a couplerwedge plate where the strandsare overlapped. The conti-nuing strands can be installedeasily and independently.

Coupler P consists of a multi-plane anchorage body, thestandard wedge plate and acoupler ring that acceptsthe continuing strands withswaged anchorages insteadof wedges. For similar appli-cations both coupler R and Pcan be installed alternatively.

fixed floatingultimate load

coupler coupler[kN]

from to

1,395 7,533✔


coupler coupler[kN]

from to

1,395 7,533✔

✔


anchorage[kN]


265 3,348



M ME

✔

1010

Overview

To lengthen unstressed ten-dons, e.g. in segmental bridgeconstruction, coupler D is put to use. The splice chuck consists of two spring- loadedwedges that connect twostrands individually.

Coupler D

Tendon Type 68 ..

Anchorage Type 68...

01 02 03 04 05 06 07 08 09 10 12 15 19 22 27 37 61

Multiplane Anchorage MA ● ● ● ● ● ● ● ● ● ●

Plate Anchorage SD ● ● ● ● ● ● ●

Plate Anchorage SDR ● ● ●

Mono Anchorage EV ●

Bond Head Anchorage ZF/ZR ● ● ● ● ● ● ● ● ●

Loop Anchorage HV ● ● ● ● ● ● ● ● ● ●

Flat Anchorage FA ● ●

Coupler M and ME (Floating Anchorage) ● ● ● ● ● ● ●

Coupler R ● ● ● ● ● ● ● ●

Coupler P ● ● ● ● ● ●

Coupler D ● ● ● ● ● ● ● ● ● ●

Tendon Type 59 ..

Anchorage Type 59...

01 02 03 04 05 06 07 08 09 12 15 19 20 22 27 32 37 55

Multiplane Anchorage MA ● ● ● ● ● ● ● ● ●

Plate Anchorage SD ● ● ● ● ● ●

Plate Anchorage SDR ● ● ●

Bond Head Anchorage ZF/ZR ● ● ● ● ● ● ● ● ●

Loop Anchorage HV ● ● ● ● ● ● ● ● ●

Flat Anchorage FA ● ●

Coupler R ● ● ● ● ● ● ●

Coupler P ● ● ● ● ● ●

Coupler D ● ● ● ● ● ● ● ● ● ●


coupler coupler[kN]

from to

558 7,533✔


11

Installation

Method 1 : Pushing

Method 2 : Pulling

Method 3 : Pre-Assembled Tendons

11

DYWIDAG-SYSTEMS INTERNATIONAL has develo-ped three different methodsto insert strands into ducts. The selection of the insertionmethod depends on theboundary conditions of thestructure and the job site.

To push strands into the ducton the job site is very econo-mical and can be done eitherbefore or after casting theconcrete. The pushing equip-ment can be installed remote-ly and connected flexibly tothe insertion point. DSI strandpushers provide relativelyhigh speed of up to 8 m/sand require minimal operatingpersonnel of only two men.These advantages make thismethod the preferred stan-dard for strand installation.

To install strands while pullingthem into the duct can bevery efficient in special struc-tures, for example where theloop anchorage is used. In normal cases the wholebundle of strands is pulledthrough winching with a steel cable.

The prefabrication of tendonseither in the shop or in thefield can also be very econo-mical, especially with shortertendons and short shippingdistances. Special uncoilersor hydraulic winches arenecessary to properly installthe tendons in the structure.

crane

tendon(strands)

reel

tendon(strands)

pulling rope

winch

DSI pulling head

coil pushing device

strand

tube


12

5904 6804 6801 5920

5920

919 . 6803 . 6861 .

Stressing

DYWIDAG has developed aseries of jacks and rams andhydraulic pumps in order toreach the target stressingload. The necessary versatilityis provided by changing devi-ces that make one unit adap-table for many different ten-don sizes. DYWIDAG Equip-ment is designed to cover awide spectrum of applicationswith jack capacities rangingfrom 250 kN up to 15,000 kN.

DYWIDAG Rams are highlysophisticated, but still conve-nient to operate. They employinner tube bundles with auto-matic gripping devices thatguide the strand safely throughthe inside of the ram. This fea-ture allows the stressing ope-ration to be controlled withthe highest degree of reliabili-ty as well as minimal wedgeseating losses by benefitingfrom the power seating option.Power seating is a way ofhydraulically pressing in thewedges with a predefinedload individually and simulta-neously rather than relyingsimply on friction seating.DYWIDAG Rams also make it possible to overstress andrelease the tendon to com-pensate for friction losses andmaximize the stress level overthe tendon length.

Every ram has a pressure reliefvalve for safety reasons thatactivates to limit hydraulicpressure should the hydraulicpump malfunction.To further verify the stressingoperation an additional gaugeport is provided directly onthe ram.

Stressed tendons can be de-stressed with special wedgesand a special ram configuration.Hydraulic pumps can beequipped with a convenientremote control device.Further information concerningthe equipment is provided onpage 25 and following.

hydraulic pump with a remotecontrol

measurement of piston stroke

jack HoZ 3000

Grouting

13

The durability of post-tensionedconstruction depends mainlyon the success of the grou-ting operation.The hardened cement groutprovides a bond betweenconcrete and tendon as wellas primary long-term corrosi-on protection for the prestres-sing steel.

DYWIDAG has developed agrouting operation that is based on thixotropic andhighly plasticized grout, andutilizes durable groutingequipment. Advanced me-thods such as pressure grou-ting, post-grouting and vacuumgrouting are all results of manyyears of development.

Grouting is always done froma low-point of the tendon.This can be one of the an-chorages where a grout capwith grout hose is the port forthe grout or along the tendonutilizing an intermediate groutsaddle. All grouting compo-nents are threaded for easy,fast and positive connection(see page 26 and following).

6819 5909 5907 6801 6802 6804 5905 5908

6819 5909 5907 6801 6802 6804

5915 . 6837 . 5909 . 6801

draining operation

mixing and grouting unit

vacuum grouting

1414

Multiplane Anchorage MA

Details of the Anchorage Zone

Technical Data

1) rectangular shape 2) additional surface reinforcement in area G required

alternative reinforcement on request

Max. prestressing load 75% of ultimate load (GUTS) (short-term overstressing to 80% is permissible)

The values for the anchorage arebased on FIP Code for concretestrengths of 25 N/mm2 (cube) or 21 N/mm2 (cylinder) (after 28 days)

Possible to apply to other codesystems or concrete strengths.(e.g. ASTM, BS, DIN and concretestrengths of 35 N/mm2, 45 N/mm2 )

Ø 15.7mm, ultimate load 279 kNtype distances of the additional reinforcement0.6" anchorages helix

GUTS center edge1860 distances distances

E F n e

N/mm2 mm mm mm mm mm6805 240 140 210 240 5 146807 280 160 250 335 6 146809 340 190 310 365 6 166812 380 210 350 350 7 166815 420 230 390 440 8 166819 480 260 450 350 6 206822 520 280 490 430 7 206827 580 310 550 480 8 206837 680 360 650 910 10 2068611) 880 460 850 855 10 25

1) rectangular shape 2) additional surface reinforcement in area G required


Ø 12.9/15.7 mm, ultimate load 186/265 kNtype type distances of the additional reinforcement0.5" 0.6" anchorages helix

GUTS GUTS center edge1860 1770 distances distances

E F n e

N/mm2 N/mm2 mm mm mm mm mm5907 6805 220 130 190 220 5 125909 6807 260 150 200 290 5 145912 6809 310 175 240 330 6 145915 6812 350 195 280 300 6 145919 6815 390 215 320 340 6 165927 6819 440 240 360 390 7 165932 6822 470 255 380 420 7 165937 6827 530 285 430 480 7 16

- 6837 620 340 540 550 7 20- 68611) 800 420 680 705 8 25

type ultimate load type ultimate load0.5" Ø 12.9 mm 0.6" Ø 15.7 mm

A B C1 C2 DGUTS (186kN per strand) GUTS (279kN per strand)

1860 1860N/mm2 kN N/mm2 kN mm mm mm mm mm5907 1,302 6805 1,395 117 150 36 90 1905909 1,674 6807 1,953 130 170 40 100 2005912 2,232 6809 2,511 140 180 43 125 3005915 2,790 6812 3,348 160 220 44 180 3505919 3,534 6815 4,185 180 250 51 200 4005927 5,022 6819 5,301 200 280 55 220 4505932 5,952 6822 6,138 220 300 66 220 5505937 6,882 6827 7,533 240 315 75 240 6005955 10,230 6837 10,323 270 390 90 350 600

- - 6861 17,019 340 490 143 405 800

15

Plate Anchorage SD

Technical Data

type ultimate load type ultimate load0.5" Ø 12.9 mm 0.6" Ø 15.7 mm A B C D

GUTS (186 kN per strand) GUTS (279 kN per strand)

1860 1860N/mm2 kN N/mm2 kN mm mm mm mm5904 744 6803 837 125 140 41 3005905 930 6804 1,116 135 160 41 3005907 1,302 6805 1,395 150 180 40 3505908 1,488 6806 1,674 165 205 44 3505909 1,674 6807 1,953 170 215 44 400

- - 6808 2,232 180 230 48 4005912 2,232 6809 2,511 190 245 48 400




Ø 12.9/15.7 mm, ultimate load 186/265 kNtype type distances of the additional reinforcement0.5" 0.6" anchorages helix long. bars


E F n e G n g

N/mm2 N/mm2 mm mm mm mm mm mm mm5904 6803 190/320 115/180 140 200 3 10 229 4 125905 6804 200/360 120/200 150 200 3 10 289 5 125907 6805 210/390 125/205 160 200 3 10 296 5 125908 6806 230/430 135/235 175 250 4 10 296 6 125909 6807 240/460 140/250 190 250 4 10 296 6 12

- 6808 300/460 170/250 240 250 4 10 242 5 145912 6809 320/480 180/260 260 250 4 12 242 5 14


Ø 15.7 mm, ultimate load 279 kNtype distances of the additional reinforcement0.6" anchorages helix long. bars


E F n e G n g

N/mm2 mm mm mm mm mm mm mm6803 200/320 120/180 140 250 4 10 229 4 126804 215/360 130/200 150 250 4 10 289 5 126805 230/390 135/205 160 250 4 10 290 5 126806 245/430 145/235 175 250 4 12 246 5 146807 260/460 150/250 190 250 4 12 246 5 146808 320/460 180/250 240 300 5 14 242 5 166809 340/480 190/260 260 300 5 14 242 5 16


type ultimate load type ultimate load0.5" Ø 12.9 mm 0.6" Ø 15.7 mm

A B C DGUTS (186kN per strand) GUTS (279kN per strand)

1860 1860N/mm2 kN N/mm2 kN mm mm mm mm5902 372 6802 558 130 180 50 3505903 - 6803 837 130 180 50 3505904 744 6804 1,116 140 200 52 350

1616

Plate Anchorage SDR

Technical Data


Ø 12.9/15.7 mm, ultimate load 186/265 kN type distances of the add. type distances of the additional reinforcement0.5“ anchorages reinforce. 0.6" anchorages helix stirrupsGUTS center edge GUTS center edge1860 distances distances 1770 distances distances

E F n e a x b G n g

N/mm2 N/mm2 mm mm mm mm mm mm mm mm5902 6802 160/240 100/140 170 200 4 8 140/220 235 4 105903 on request 6803 180/260 110/150 170 200 4 10 160/240 265 5 105904 6804 200/280 120/160 170 200 4 12 180/260 273 6 12





Ø 15.7 mm, ultimate load 279 kNtype distances of the additional reinforcement0.6“ anchorages helix stirrups


E F n e a x b G n g

N/mm2 mm mm mm mm mm mm mm mm6802 160/240 100/140 170 200 4 10 140/220 235 4 126803 180/260 110/150 170 200 4 12 160/240 265 5 126804 200/280 120/160 170 200 4 14 180/260 273 6 14

17

Mono Anchorage EV




Technical Data

type ultimate load0.6" Ø 15.7 mm

A B C D

GUTS1860N/mm2 (279 kN per strand) mm mm mm mm6801 279 55 130 38 140

Details of the Anchorage ZoneInstallation with min. Reinforcement1)

Ø 15.7 mm, ultimate load 265 kN Ø 15.7 mm, ultimate load 279 kNtype center edge type center edge0.6" distances distances 0.6" distances distances

GUTS GUTS1770 1860

N/mm2 mm mm N/mm2 mm mm6801 140/240 90/140 6801 160/240 100/140

1) surface reinforcement required


Installation with min. Distances

Ø 15.7 mm, ultimate load 265 kNtype distances of the additional reinforcement0.6" anchorages


a x b e n g

N/mm2 mm mm mm mm mm6801 100/190 70/115 80/110 8 2 8

stirrup long. bars

stirrup long. bars

Ø 15.7 mm, ultimate load 279 kNtype distances of the additional reinforcement0.6" anchorages


a x b e n g

N/mm2 mm mm mm mm mm6801 120/200 80/120 100/120 10 2 10


Bond Head AnchorageZF/ZR

1818

ZF

ZR

ZR




position ..05 ..07 ..09 ..12 ..15 ..19

type ZR

position ..01 ..03 ..04

type ZF


type0.6"


N/mm2 mm mm mm mm - mm6801 170/170 105/105 - - - -6803 220/400 110/200 - - - -6804 240/480 110/180 - - - -6805 280/280 160/160 200 300 5 106807 280/330 160/185 200 300 5 126809 380/280 210/160 200 300 5 126812 380/330 210/185 200 300 5 146815 380/380 210/210 200 300 5 166819 380/480 210/260 200 350 6 16

distances of theanchorages

Ø 15.7 mm, ultimate load 279 kNadditional reinforcement

helix

E F n e

type type0.5" 0.6"

GUTS GUTS center edgeE F n e

1860 1770 distances distancesN/mm2 N/mm2 mm mm mm mm - mm5901 6801 170/170 105/105 - - - -5903 6803 220/400 110/200 - - - -5904 6804 240/480 120/240 - - - -5905 6805 280/280 160/160 200 300 5 105907 6807 280/330 160/185 200 300 5 105909 6809 380/280 210/160 200 300 5 105912 6812 380/330 210/185 200 300 5 125915 6815 380/380 210/210 200 300 5 145920 6819 380/480 210/260 200 350 6 14

Ø12.9/15.7 mm, ultimate load 186/265 kNdistances of the

anchoragesadditional reinforcement

helix

type ultimate load type ultimate load0.5" Ø 12.9 mm 0.6" Ø 15.7 mm A B CGUTS GUTS1860 (186 kN per strand) 1860 (279 kN per strand)

N/mm2 kN N/mm2 kN mm mm mm5901 186 6801 279 140 140 10005903 558 6803 837 130 240 10005904 744 6804 1,116 150 300 10005905 930 6805 1,395 280 280 10005907 1,302 6807 1,953 330 280 10005909 1,674 6809 2,511 280 300 10005912 2,232 6812 3,348 330 300 10005915 2,790 6815 4,185 380 300 10005920 3,720 6819 5,301 480 300 1000

Technical Data

1) additional surface reinforcement in area G required 1) additional surface reinforcement in area G required

• = long

• = short


19

Loop Anchorage HV

Additional Reinforcement




Caution: radius depends on duct (cor-rugated or smooth metal duct)! Ductsneed to be pre-bent. Tendons need to be stressed simultaneouosly atboth ends.

type ultimate load type ultimate load0.5" Ø 12.9 mm 0.6" Ø 15.7 mm A B


1860 1860N/mm2 kN N/mm2 kN mm mm5902 372 6803 837 50 405903 558 6804 1,116 55 455904 744 6805 1,395 60 505905 930 6806 1,674 65 555906 1,116 6807 1,953 75 605907 1,302 6809 2,511 85 755909 1,674 6812 3,348 95 805912 2,232 6815 4,185 110 905915 2,790 6819 5,301 120 95

Technical Data

Ø 12.9/15.7 mm, ultimate load 186/265 kNtype type0.5" 0.6"

R As

GUTS GUTS1860 1770

N/mm2 N/mm2 mm cm2

5902 6803 800 8.95903 6804 800 11.95904 6805 800 14.85905 6806 800 17.85906 6807 800 20.75907 6809 1,000 24.95909 6812 1,000 33.25912 6815 1,500 41.45915 6819 1,500 54.1


Ø 15.7 mm, ultimate load 279 kNtype 0.6"

R As

GUTS1860

N/mm2 mm cm2

6803 1,000 8.36804 1,000 11.16805 1,000 13.86806 1,000 16.66807 1,000 19.36809 1,250 24.96812 1,250 33.26815 1,750 41.46819 2,000 54.1

Z ≥ 3 · (ØA + 5 mm) Z = 4 · (ØA + 5 mm)

Case 1 Case 2 Case 3

Z ≥ 4 · (ØA + 5 mm)

Flat Anchorge FA

2020

type ultimate load type ultimate load0.5" Ø 12.9 mm 0.6" Ø 15.7 mm A B C D DA DB


1860 1860N/mm2 kN N/mm2 kN mm mm mm mm mm mm5904 744 6803 837 100 255 57 115 23 755905 930 6804 1,116 100 330 57 220 23 75

Technical Data

type type0.5" 0.6"


a x b n g

N/mm2 N/mm2 mm mm mm mm5904 6803 305 190 160/280 4 105905 6804 380 230 180/360 4 12


distances of the anchorages

additional reinforcementstirrups

Ø 12.9/15.7 mm, ultimate load 186/265 kNtype0.6"


a x b n g

N/mm2 mm mm mm mm6803 320 200 160/280 4 106804 400 250 180/360 4 12

distances of the anchorages

additional reinforcementstirrups

Ø 15.7 mm, ultimate load 279 kN





Coupler M/ME (Floating Anchorage Block)

21

Case 1:If LR ≤ L2-1/2 ∆Ithen L = s + 1/2 ∆I + 285 mm + L2

Case 2:If LR > L2-1/2 ∆Ithen L = s + 285 mm + L2

s = 0.2 x 1/2 ∆I � 120 mm


Coupler M

Coupler ME


type ultimate load ultimate load0.6" Ø 15.7 mm Ø 15.7 mm A B C D AD BD E

(265 kN per strand) (279 kN per strand)

kN kN mm mm mm mm mm mm mm6801 265 279 98 55 200 20 - - -6802 530 558 90 105 120 45 60 70 2006804 1,060 1,116 130 160 120 55 60 130 6506806 1,590 1,674 130 160 120 65 70 130 6506808 2,120 2,232 130 210 120 75 70 170 1,0506810 2,650 2,790 168 210 120 80 70 170 1,1506812 3,180 3,348 168 210 120 80 70 170 1,150

Technical Data


Ø 15,7 mm, ultimate load265/279 kN

type X Y Z

0.6"mm mm mm

6801 1) 180 606802 130 155 506804 180 195 706806 180 195 706808 230 195 706810 230 235 906812 230 235 90

Block-Out Dimensions

type L2 LR0.6"mm mm

6801 - -6802 550 5506804 700 6006806 700 6006808 1,350 6006810 1,500 8006812 1,500 800

Coupler R

2222

Technical Data

type ultimate load0.5" Ø 12.9 mm A B C D

GUTS (186 kN per strand)

1860N/mm2 kN mm mm mm mm5909 1,953 226 140 105 3005912 2,511 226 150 105 3505915 3,348 248 165 105 4505919 4,185 266 190 110 4505927 5,301 320 250 120 5805932 6,138 340 300 125 6205937 7,533 380 300 135 650



1860N/mm2 kN mm mm mm mm6805 1,395 207 140 110 3306807 1,953 207 140 110 3306809 2,511 226 150 105 3506812 3,348 248 165 105 4506815 4,185 266 190 110 4506819 5,301 289 205 120 5806822 6,138 340 275 125 6206827 7,533 380 300 135 650

type type center distances length of space 0.5" 0.6" of anchorages for installation

GUTS GUTS1860 1860

N/mm2 N/mm2 mm mm- 6805 320 2,000

5909 6807 320 2,0005912 6809 350 2,0005915 6812 370 2,0005919 6815 400 2,0005927 6819 430 2,0005932 6822 460 2,0005937 6827 500 2,000

Ø 12.9/15.7 mm, ultimate load 186/279 kN

Details of the Coupler Zone


Coupler P

23


Ø 12.9/15.7 mm, ultimate load 186/279 kNtype type center distances length of space0.5" 0.6" of anchorages for installation

GUTS GUTS1860 1770

N/mm2 N/mm2 mm mm- 6805 300 2,000

5912 6809 360 2,0005915 6812 380 2,0005920 6815 420 2,0005927 6819 450 2,0005932 - 480 2,0005937 6827 500 2,000



1860N/mm2 kN mm mm mm mm5912 2,232 236 205 135 5705915 2,790 264 225 145 7555920 3,534 294 250 150 7555927 5,022 308 265 155 8805932 5,952 339 290 170 8305937 6,882 365 320 180 905

Technical Data



1860N/mm2 kN mm mm mm mm6805 1,395 176 165 132 5106809 2,511 236 205 136 5706812 3,348 260 225 145 7556815 4,185 290 250 150 7556819 5,301 305 265 155 8806827 7,533 365 320 170 905


1050 L+sB B

D

150

A = 2B+1200+ L+ss = 0,2 · L ≥120

C

dimensions in mm

Coupler D

2424

Ø 12.9/15.7 mm, ultimate load 186/279 kNtype type center distances center distances0.5" 0.6" coupler to coupler duct to coupler

GUTS GUTS1860 1860

N/mm2 N/mm2 mm mm5903 6803 180 1355904 6804 200 1505905 6805 210 1605907 6807 225 1705909 6809 250 1905912 6812 290 2155915 6815 325 2405919 6819 360 2655922 6822 400 2905927 6827 430 315


type ultimate load type ultimate load0.5" Ø 12.9 mm 0.6" Ø 15.7 mm B C DGUTS (186 kN per strand) GUTS (279 kN per strand)

1860 1860N/mm2 kN N/mm2 kN mm mm mm5903 558 6803 837 150 100 505904 744 6804 1,116 200 110 555905 930 6805 1,395 250 120 605907 1,302 6807 1,953 250 125 655909 1,674 6809 2,511 300 140 755912 2,232 6812 3,348 350 160 805915 2,790 6815 4,185 350 180 905919 3,534 6819 5,301 400 200 955922 4,092 6822 6,138 400 220 1005927 5,022 6827 7,533 400 240 110

Technical Data

200 mm

Ø 46 mm


Equipment Overview

25

L

D

01 02 03 04 05 06 07 08 09 12 15 20 22 27 32 37 55 01● ●

● ● ● ●

● ● ● ●

● ●

● ● ●

● ●

●

02 03 04 05 06 07 08 09 10 12 15 19 22 27 37 61

● ● ●

● ● ●

● ● ● ●

● ●

● ●

●

●

59.. 68..jack typeSM 200 HoZ 950/100HoZ 1,700/150HoZ 3,000/250HoZ 4,000/2506,8009,75015,000

Technical Data

jack type1) length L diameter D stroke piston area capacity2) weightmm mm mm cm2 kN kg

SM 200 842 98 200 47.13 198 19HoZ 950/100 621 203 100 161.98 972 65HoZ 1,700/150 803 280 150 298.45 1,745 160HoZ 3,000/250 1,137 385 250 508.94 3,054 400HoZ 4,000/250 1,271 482 250 894.57 4,204 6006,800 1,150 560 300 1237.01 6,803 1,1859,750 1,170 680 300 1772.45 9,748 1,77015,000 1,640 980 500 2695.29 15,000 5,500

1) wedging incl.2) without friction

Tensa SM 200 HoZ 950/1,700 HoZ 3,000/4,000 15,000Tensa SM 200

Jacks


2626

G

K

A

B

C

FE

H

D

Equipment Overview

Block-Out Dimensions

jack type A B C D E F G H K L2)

SM 200 8801) 370 - 80 100 75 50 120 100 200/ -HoZ 950/100 621 350 150 - 220 200 130 190 260 300/400HoZ 1,700/150 803 490 180 - 270 230 170 220 340 450/600HoZ 3,000/250 1,130 650 220 300 360 320 220 310 440 350/600HoZ 4,000/250 1,235 740 220 300 - 360 270 320 540 450/8006,800 1,4211) - 80 - - 330 310 410 620 - /1,2009,750 1,4701) - 120 - - 380 390 550 740 - /1,20015,000 2,200 - - - - - 540 - 1,240 - /1,600

1) stroke incl.2) nec. strand protrusion (with/without power seating device)


27

L

HWidth W

Hydraulic Pumps

77 - 159 A R 6.4 R 11.2 - 11.2/210

Equipment Overview

Technical Data

pumps1) operation capacity eff.weight

dimensionspressure V min oil amount L x W x H

MPa l/min I kg mm77-159 A 70 3.0 10.0 60 420/380/48077-193 A 70 3.0 10.0 63 420/380/480R 3.0 70 3.0 13.0 98 600/390/750R 6.4 60 6.4 70.0 310 1,400/700/1,100R 11.2-11.2/210 55 11.2/22.4 170.0 720 2,000/800/1,300ZP 57/58 16/22 53/80 175.0 610 1,260/620/1,330

SM HoZ HoZ HoZ HoZ6,800 9,750 15,000

pumps jacks1)

200 950 1,700 3,000 4,000/25077 - 159 A ● ●

77 - 193 A ● ● ●

R 3 ● ● ●

R 6.4 ● ● ● ●

R 11.2-11.2 ● ● ●

R 11.2-11.2/210 ● ● ● ●

ZP 57/28 for all pushing devices

1) for pistons without power seating

1) hydraulic pumps will be delivered without oil


2828

ESG 8 - 1

Equipment Overview

Pushing Equipment

tensile or pushing dimensions hydraulictype compression speed weight L x W x H pumps

forcekN m/s kg mm -

ESG 8 - 1 3.9 6.1 140 1,400/350/510 ZP 57/28

Grouting Equipment(mixing and pumping)

grouting equipment max dimensionsinjection capacitiy weight L x W x Hpressure

MPa l/h kg mmMP 2,000 - 5 1.5 420 60 2,000/950/1,600MP 4,000 - 2 1.5 1,500 63 2,040/1,040/1,750P 13 EMRT 8.0 3,000 98 2,150/1,750/1,500

MP 2,000 - 5 MP 4,000 - 2


Ie = ��In · Ep · Ap

P0 · µ · �1

�

29

Calculation of Elongation

Px,0 = prestressing force of the tendon at any point distance x [kN]

Px,0 = P0 · e

P0 = prestressing force at the stressing end [kN]

�x = ∑ angle of deflection between the stressing end and at any point distance x [rad]

� = [�� ]µ = coefficient of friction (see p.5)

ß = wobble angle (see p.5)

Pe = prestressing force at the stressing end after wedge draw-in [kN]

Ap = area of prestressing strands

1

2

3

Po

Po

Pe

l c

l e

�Itot = �Ip + �Ic + �Isl + �Ie

accessiblenot accessible

slip �lsl [mm] stressing dead end bond head coupler coupler coupleranchorage anchorage anchorage R D M

1 4 - - - 3- 3 *) 3 6 -

values are based on prestressing force acc. to German Code*) see German approval

aH2 + aV

2 + ß·| � 180

-µ·�X

�

��

Calculation of Strand Tendon Elongation

The total elongation �Itot which the tendon has to achieve during stressing should be calculated as:

The stressing records are part of the structural design and serve as a basis for the stressing operation.

Besides the prestressing data, they contain the sequence of stressing and directions for procedures directly

connected with the stressing operation, such as lowering of the formwork and releasing of bearings.

�Ip = elongation of the strand tendon [mm]

lp = length of tendon [m]

�Ic = elastic deformation of the concrete (shortening must be treated as a positive value) [mm]

�cm = average stress in the concrete cross section at the center of gravity of all tendons due to prestressing force [MN/m2]

lc = length of the concrete member [m]

�cmEc

�Ic = · lc

�Ie = elongation of the prestressing steel in the jack and seating device (if applicable) [mm]

Calculation of Prestressing Force Pe [kN] at Stressing End and Influence Length le [m]

due to wedge draw-in �In [mm] at stressing end during lock-off of tensioning jack

�1 = average angle of deflection along the influence length l e of tendon behind the stressing end [rad/m]

�Isl = sum of anchor plate impressions and wedge slip

according to the anchorage type applied [mm]

Pe = P0 · (1 - 2 · le· µ · �1)

�

�

at the coupler M

draw-in slip �In [mm] tendon type jack typestandard case special case

6801 - 6807 2* 4**6809 - 6827 2* 4**6802 - 6812 8 -

values are based on prestressing force acc. to German Code*) with wedge seating **) without wedge seating

at the stressing anchorage

modulus of elasticity [N/mm2]

required cube strength of the concrete at

stressing acc. to DIN 4227, Part 1

1

Ap · Ep�Ip = · ∫Px,0·dx

concrete class B 25 B 35 B 45 B 55Ec 30,000 34,000 37,000 39,000

strand Ep = 195,000 [N/mm2]

partial prestressing 12 16 20 24full prestressing 24 32 40 48

lp

0


3030

DYWIDAG Post-TensioningSystems using Bars

Gschnitztal Bridge, Austria

BMW Building, Germany

1030 1080/1230 835/1030

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2G 26D 32E 36C 36E

31

DYWIDAG Standard Bars

DYWIDAG Bar Post-Tensioninghas been successfully usedfor more than 40 years inpost-tensioned construction.It has evolved over time andhas been optimized to enhanceits performance and increaseits competitiveness.

All accessories of the DYWIDAG Post-TensioningSystem using Bars are threadedproviding a fast, simple andpositive assembly. The thread-ability of the anchor nut alsooffers the advantage of adjus-ting the prestress force in thetendon at any given timebefore the tendon is grouted.

DYWIDAG High -Strength Bars are available in lengths up to 30m.

DYWIDAG SMOOTH BAR

The DYWIDAG Smooth Barhas threaded ends with a rol-led on thread. The threads aremanufactured in the shop tothe specifications of thecustomer. The rolled thread ofthe smooth bar results in acharacteristic low seating lossand high fatigue resistance.This is the reason why thesmooth bar is best used forvery short tendons.

DYWIDAG THREADBAR®

DYWIDAG THREADBARS®

are hot rolled in the steel milland come with thread-likedeformed ribs over the entirelength of the bar. The bar canbe cut anywhere and isinstantly threadable withoutfurther preparation.

Technical Data1

bar type SMOOTH BAR THREADBAR®

steel grade fp0.1k/fpk N/mm2 835/1,030 1,080/1,230 835/1,030 1,080/1,230diameter mm 32 36 26.5 32.0 36.0 26.5 32.0 36.0diameter/type 32G 36C 26E 32E 36E 26D 32D 36Dnom. cross-sectional area mm2 804 1,018 551 804 1,018 551 804 1,018weight kg/m 6.31 7.99 4.48 6.53 8.27 4.48 6.53 8.27pitch mm 3.0 3.0 13.0 16.0 18.0 13.0 16.0 18.0yield load fp0.1k A kN 671 1,099 460 671 850 595 868 1,099ultimate load fpk A kN 828 1,252 568 828 1,049 678 989 1,252fatigue stress rangesteel: (0.55 fpk/0.9fp0.1k)

N/mm2 290/230 290/230 240/210 240/210

fatigue stress rangenut/coupler: 0.6 fpk

N/mm2 98 98 98 78 78 78 78 78

bendingelastic bending min. R

m 19.50 12.10 16.20 19.50 21.90 8.90 10.75 12.10

cold bending min. R m 4.80 5.40 5.30 6.40 7.20 5.30 6.40 7.201) The values are based on the GermanCode (DIN). Possible to apply to othercode systems or concrete strengths.(e.g. ASTM, BS and concrete strengthsof 25 N/mm2, 35 N/mm2, 45 N/mm2 )


..

3232

Anchorages for Bar Tendons


steel grade fp0.1k/fpk 835/1,030 1,080/1,230 835/1,030 1,080/1,230diameter 32.0 36.0 26.5 32.0 36.0 26.5 32.0 36.0diameter/type 32G 36C 26E 32E 36E 26D 32D 36DQR plate anchorage ● ● ● ● ●

solid plate anchorage, rectangular ● ● ● ● ● ● ● ●

solid plate anchorage, squared ● ● ● ●

Bar Anchorages consist ofone anchor body that trans-fers the load into the concreteand bears against the anchornut. The anchor nut canaccommodate a small angularmis-alignment due to con-struction tolerances.

DYWIDAG-SYSTEMSINTERNATIONAL offers otheranchor types in addition tothe standard configurationsdescribed on the followingpages. For special applicati-ons please contact one ofour offices.

stressing anchorage dead end anchorage

sheathing

grout vent


33

QR Plate Anchorage

Technical Data


steel grade fp0.1k /fpk N/mm2 835/1,030 1,080/1,230 835/1,030 1,080/1,230nom. diameter mm 32.0 36.0 26.5 32.0 36.0 26.5 32.0 36.0diameter/type - 32G 36C 26E 32E 36E 26D 32D 36D

A mm - 160 - - 140 120 140 160B mm - 180 - - 165 130 165 180C mm - 75 - - 107 90 107 115

width across flats A/F mm - 65 - - 60 50 60 65

1) dimensions for QR plate stressing anchorage without additional reinforcement only



steel grade fp0.1k/fpk N/mm2 835/1,030 1,080/1,230 835/1,030 1,080/1,230nom. diameter mm 32.0 36.0 26.5 32.0 36.0 26.5 32.0 36.0diameter/type - 32G 36C 26E 32E 36E 26D 32D 36Dconcrete strength

Ycenter distances - 280 - - - 200 250 280

class B 25 edge distances - 160 - - - 120 145 160

Xcenter distances - 320 - - - 220 280 320edge distances - 180 - - - 130 160 180

concrete strengthY

center distances - 2601) (380) - - (340) 190 230 2601)(380)class B 35 edge distances - 1501) (190) - - (170) 115 135 1501)(190)

Xcenter distances - 2901) (440) - - (400) 210 260 2901)(440)edge distances - 1651) (220) - - (200) 125 150 1651)(220)

concrete strengthY

center distances - 230 - - - 170 210 230class B45 edge distances - 135 - - - 105 125 135

Xcenter distances - 260 - - - 190 230 260edge distances - 150 - - - 115 135 150

The values are based on the German Code (DIN). Possible to apply to other code systems or concrete strengths (e.g. ASTM, BS etc.)


3434

The Solid Plate Anchorage issuitable for regular and light-weight concrete. In addition,the anchor plate can be castin or dry placed after the concrete has hardened. TheSolid Plate Anchorage isalmost universal in use andvery versatile, and frequentlyused in rehabilitation andstrengthening applications.

Solid Plate Anchorage, Rectangular

Technical Data


steel grade fp0.1k/fpk N/mm2 835/1,030 1,080/1,230 835/1,030 1,080/1,230nom. diameter mm 32.0 36.0 26.5 32.0 36.0 26.5 32.0 36.0diameter/type - 32G 36C 26E 32E 36E 26D 32D 36D

A mm 120 150 120 120 150 150 150 150B mm 220 290 150 220 240 180 240 290C mm 82 100 86 111 127 100 127 140

width across flats A/F mm 55 65 46 55 60 50 60 65




steel grade fp0.1k /fpk 835/1030 1,080/1,230 835/1,030 1,080/1,230nom. diameter 32.0 36.0 26.5 32.0 36.0 26.5 32.0 36.0diameter/type 32G 36C 26E 32E 36E 26D 32D 36Dconcrete strength

Ycenter distances - 160 - - 160 160 160 160

class B 25 edge distances - 100 - - 100 100 100 100

Xcenter distances - 550 - - 440 280 440 550edge distances - 300 - - 240 160 240 300

concrete strengthY

center distances - 160 - - 160 160 160 160class B 35 edge distances - 100 - - 100 100 100 100

Xcenter distances - 440 - - 360 230 360 440edge distances - 240 - - 200 140 200 240

concrete strengthY

center distances 130 160 130 130 160 160 160 160class B45 edge distances 85 100 85 85 100 100 100 100

Xcenter distances 300 330 200 300 280 180 280 330edge distances 170 190 120 170 160 110 160 190

N/mm2

mm-


35

Solid Plate Anchorage,Square

Technical Data


steel grade fp0.1k/fpk N/mm2 835/1,030 1,080/1,230 835/1,030 1,080/1,230nom. diameter mm 32.0 36.0 26.5 32.0 36.0 26.5 32.0 36.0diameter/type - 32G 36C 26E 32E 36E 26D 32D 36D

A mm 160 - - 160 180 - 180 -C mm 72 - - 100 117 - 117 -

width across flats A/F mm 55 - - 55 60 - 60 -


steel grade fp0.1k/fpk 835/1,030 1,080/1,230 835/1,030 1,080/1,230nom. diameter 32.0 36.0 26.5 32.0 36.0 26.5 32.0 36.0diameter/type 32G 36C 26E 32E 36E 26D 32D 36Dconcrete strength center distances 240 - - 240 - - - -class B 25 edge distances 140 - - 140 - - - -concrete strength center distances 220 - - 220 - - - -class B 35 edge distances 130 - - 130 - - - -concrete strength center distances 200 - - 200 230 - 230 -class B 45 edge distances 120 - - 120 135 - 135 -


N/mm2

mm-



3636

Splices

Corrugated Sheathing

DYWIDAG Splices are used to extend bars to any desirablelength. The DYWIDAG BarPost-Tensioning System uses3 different connection varia-tions for fixed and movablecouplers:

Thin-walled flexible metalducts are used to create thevoid for prestressing elements.The ducts are threadable alongtheir entire length to enableeasy and fast installation onthe job site.

A larger metal duct is placedin the areas where DYWIDAGBar Couplers are used. Thesecoupler ducts allow for move-ment of the coupler duringstressing.

A full line of grouting acces-sories services the DYWIDAGPost-Tensioning System usingBars.

to join bars in the free lengthand at anchorages

to bridge gaps of bar enddistances, for example in free cantilever and precast segmental construction

to couple bar tendons of different sizes or types

1. Standard Coupler 2. Compensation Coupler 3. Transition Coupler


steel grade fp0.1k/fpk N/mm2 835/1,030 1,080/1,230 835/1,030 1,080/1,230nom. diameter mm 32 36 26.5 32.0 36.0 26.5 32.0 36.0type/diameter - 32G 36C 26E 32E 36E 26D 32D 36Dinternal diameter I.D. mm 44 51 38 44 51 38 44 51external diameter O.D. mm 49 57 43 49 57 43 49 57

Dimensions of Corrugated Sheathing (Standard Size)

Technical Data


steel grade fp0.1k/fpk N/mm2 835/1,030 1,080/1,230 835/1,030 1,080/1,230nom. diameter mm 32 36 26.5 32.0 36.0 26.5 32.0 36.0type/diameter - 32G 36C 26E 32E 36E 26D 32D 36Dmin. center distances mm 79 92 68 79 92 68 79 92support distances m 0.5 - 2.5 0.5 - 2.5wobble factor ß º/m 0.3 0.3friction factor µ - 0.25 0.5



37

Pocket Former

Stressing

DYWIDAG-SYSTEMSINTERNATIONAL offers a fullline of special installationaccessories to facilitate fieldassembly and installation.Inexperienced workers areeasily trained in the assemblydue to all threaded compo-nents. On the other hand,tendons can be delivered tothe job site prefabricatedwhen desired.

The pocket former was deve-loped as a principal accessoryto provide just enough spacein a block-out to position theram onto the anchorage.

The small, light and convenientlyoperated DYWIDAG BarJacks facilitate the stressingoperation. Heavy lifting aidsare generally not necessary.The jack is pushed over a pullrod coupler that is threadedonto the bar protrusionbehind the anchor nut. Thejack is then fixed with a pul-ling nut. The tension load ishydraulically transferred. Theanchor nut is tightened by aninternal wrench.

Installation

3838

articulated jack nose

bar protrusion

Stressing

Stressing Notes

Straight tendons are generallystressed from one end only. Inorder to reduce friction losses(especially in draped tendons)it is recommended to stressfrom both sides.

The prestressing load can beadjusted up and down at anygiven time until the tendon isfully grouted by simply reinstalling the jack. This alsomakes it possible to partiallystress tendons. Several controls during andafter the stressing operationcheck the effective stressingload:

- bar protrusion at the anchorage before and after stressing to evaluate the effective elongation

- counter control for elonga-tion during stressing opera-tion

- gauge control for hydraulic pressure

- to comply with exceptionalhigh demands on accuracy

- for example on very short tendons special accessoriescan be introduced to minimizeseating losses.

Technical data about theDYWIDAG-Jacks are availableon page 40.

39

Grouting

Temporary Corrosion Protection

mixing and pumping unit

unprotected bar (top); protected bar with Rust Ban (bottom)

Rust Ban

A special emulsified oil (RustBan) provides an optimal tem-porary corrosion protection.The bar can be coated beforeshipping or as it arrives onthe job site before it is inser-ted into the duct. There aremeans to even apply the oilafter the bar is installed in thesheathing. Please inquireabout other corrosion protec-tion systems to suit specialrequirements.

Protection against Dirt andWater

Special accessories havebeen developed to properlyseal accessible anchoragesagainst the environment. This is used for tendons thatremain ungrouted over a longperiod of time or on winterjob sites to avoid ice develop-ment in the tendon.

The durability of post-tensionedconstruction depends to agreat degree on the successof the grouting operation.The hardened cement groutprovides a bond betweenconcrete and tensile ele-ments as well as primarylongterm corrosion protec-tion (alkaline medium) for the prestressing steel.

DYWIDAG has developed agrouting operation that isbased on thixotropic, highlyplasticized grout, and utilizesdurable grouting equipment.Advanced methods such aspressure grouting, post-grou-ting and vacuum grouting areall results of many years ofdevelopment.

Grouting is always done froma low-point of the tendon.This can be one of theanchorages where a grout capwith grout hose is the port for the grout or along the ten-don utilizing an intermediategrout saddle. All groutingcomponents are threaded foreasy, fast and positiveconnection.

Technical data on the groutingequipment is available onpage 28.

Grout Cap

The grout cap is threaded onthe anchorage forcing thegrout through grout channelsin the anchor nut (slottedanchor nut) into the tendon.

4040

DYWIDAG Bar Jacks

jack 60 Mp Series 04 jack 110 Mp Series 03

Equipment Overview

Jack Dimensions (for Pocket Design)


steel grade 835/1,030 1,080/1,230 835/1,030 1,080/1,230nom. diameter 32 36 26.5 32.0 36.0 26.5 32.0 36.0diameter/type 32G 36C 26E 32E 36E 26D 32D 36D60 Mp ● ● ● ✖ ● ✖

110 Mp ❍ ● ❍ ● ● ●

jack typeslength L O.D. stroke piston area capacity weight

mm mm mm cm2 kN MPa kg60 Mp Series 04 401 190 50 132.5 625 50 3660 Mp Series 05 456 190 100 132.5 625 50 44

110 Mp Series 01 494 267 50 235.6 1100 50 46110 Mp Series 03 594 267 150 235.6 1100 50 54

jack typesA B C1) D1) E

mm mm mm mm mm60 Mp Series 04 225 176 106 106 30060 Mp Series 05 225 231 106 106 300

110 Mp Series 01 275 219 125 120 375110 Mp Series 03 275 319 125 120 375

✖ use 60 Mp if only stressed 55% to ultimate load

❍ can be stressed with 110 Mp on certain exceptions

1) C and D are estimated values, exact measures depend on the bar diameter andstrength

Technical Data


41

hand pump ZPH 1/5 hydraulic pump R 3.0

hydraulic pump operatingcapacity

eff. oilweight

dimensionstype pressure amount L x W x H

MPa l/min l kg mm x mm x mmZPH 1/5 70 10/1.6 4.5 15 650/220/21077-159 A 60 3.01) 10.0 50 420/450/380R 3.0 70 3.0 13.0 84 600/750/390R 6.4 60 6.4 70.0 185 850/980/450

1) cm3/stroke

Equipment Overview

Hydraulic Pumps

Necessary Bar Protrusion

Grouting Equipment

see page 28


steel grade fp0.1k/fpk 835/1,030 1,080/1,230 835/1,030 1,080/1,230diameter/type 32G 36C 26E 32E 36E 26D 32D 36Dnec. bar protrusion 45 60 55 60 90 70 80 100

N/mm2

mm


4242


�Itot = �Ip + �Ic + �Isl

Calculation of Bar Tendon Elongation

The total elongation �Itot [mm] which the bar has to achieve during stressing should be calculated as:

The stressing records are part of the structural design and serve as a basis for the stressingoperation. Besides the prestressing data, they contain the sequence of stressing and direc-tions for procedures directly connected with the stressing operation, such as lowering of theformwork and releasing of bearings.

�Ip = elongation of the bar tendon [mm]

or in many cases it is accurate enough

P0,l + P0,0

2 · Ap · Ep�Ip = · lp

Ip = length of tendon [m]

Px,0 = P0 · ePx,0 = prestressing force of the tendon at any point distance x [kN] P0,0 = prestressing force at the stressing end [kN]P0,l = prestressing force at the dead end�x = ∑ angle of deflection between the stressing end and at any point distance x [rad]� = [�� ]µ = coefficient of friction (see page 36)ß = wobble angle (see page 36)Pe = prestressing force at the stressing end after anchor nut drawn- in [kN]Ap = area of prestressing bar (see page 31)Ep = modulus of elasticity of prestressing bar ≈ 195.000 [N/mm2]

aH2 + aV

2 + ß·| � 180

-µ·�X

�

��

�Ic = elastic deformation of the concrete (shortening must be treated as a positive value) [mm]

�cm = average stress in the concrete cross section at the center of gravity of all tendons due to prestressing force [MN/m2]

lc = length of the concrete member [m]

Ec = modulus of elasticity of concrete (see page 29)

�cmEc

�Ic = · lc

�lsl [mm] = For allowable stresses of 0.55 fpk the technicaldetails are given in the Certificate of Approval for DYWIDAGPost-Tensioning Systems, for higher stresses the valuesincrease in proportion.

�Isl = sum of slip in the thread of the anchorages and couplers [mm]

1Ap · Ep

�Ip = · ∫Px,0·dx0

IpP

P0,0

P0, l

xlp

P

P0

xlp

Pe

le


43


Calculation of ExistingElongation

In order to control the exist-ing elongation the bar protru-sions at the stressing endbefore and after stressing willbe measured. The resultingelongation lu is the differenceof these aforementionedvalues. The lu value must fair-ly well coincide with the cal-culated elongation.

lu = existing elongationlub = bar protrusion measured before stressinglua = bar protrusion measured after stressing

Calculation of GaugePressure

The gauge pressure corre-sponding to the total elonga-tion ltot should be increasedwith the value of the pressurelosses due to the internal fric-tion in the jack.

P0

Akp = 1,000 · � pr p = required gauge pressure [1 MPa = 10 bar]

P0 = Ap · �p = required prestressing force [kN]Ap = cross-sectional area of bar tendon [mm2]�p = steel stress at the stressing end [N/mm2]

Ak = effective piston area of the jack [mm2]pr = friction loss in the jack. The positive sign applies

for stressing, negative one for unstressing [Mp]

tendon type SMOOTH BAR pr [MPa] THREADBAR® pr [MPa]

steel grade fp0.1k/fpk 835/1,030 1,080/1,230 835/1,030 1,080/1,230plate anchorage 0.05 0.10 0.10 0.15coupler 0.10 0.10 0.10 0.15

lu = lub - lua

Calculation of Prestressing Force Pe [kN] at Stressing End and Influence Length le [m]

due to anchor nut drawn-in �In [mm] at stressing end during lock-off tensioning jack

�1 = average angle of deflection along the influence length le of tendon behind the stressing end [rad/m]

�In · Ep · ApP0 · µ · �1

Ie = ��

�

�

Pe = P0 · (1 - 2 · le· µ · �1)

�


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www.dywidag-systems.com

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Asia/Pacific HQ

DSI Group HQ

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Europe HQ

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