European Technical Approval No. ETA
Transcription
European Technical Approval No. ETA
Service d'études sur les transports, les routes et leurs aménagements 46 avenue Aristide Briand BP 100 92 225 BAGNEUX CEDEX Tel : + 33 (0)1 46 11 31 31 Fax : + 33 (0)1 46 11 31 69 MEMBRE DE L'EOTA MEMBER OF EOTA European Technical Approval No. ETA-06/0006 (English language translation, the original version is in French language) Version of 28st July 2011 Nom commercial Trade name Détenteur de l'ATE Holder of approval Procédé de précontrainte VSL VSL Post-Tensioning System Type générique et utilisation prévue du produit de construction Procédés de précontrainte des structures par posttension (Communément appelés procédés de précontrainte) Generic type and use of construction product Post-tensioning Kits for prestressing of Structures (Commonly called Post-Tensioning Systems) Valid 31/03/2011 31/03/2016 CTT-Stronghold, SA Ribera del Congost, s/n SP – 08520 Les Franqueses del Vallès (Barcelona) VSL INTERNATIONAL Ltd. Saegestrasse, 76 CH-3098 KOENIZ from: to: Producteur du procédé Kit manufacturer Cet Agrément Technique Européen est un renouvellement de validité de This European Technical Approval extends ETA-06/0006 valide du 31/07/2006 au 30/07/2011 Le présent agrément technique européen contient This European Technical Approval contains 8+(4+59+32) pages incluant 3 annexes (0, 1, 2) faisant partie intégrante du document. 8+(4+59+32) pages including 3 annexes ( 0, 1, 2) which form an integral part of the document. ETA-06/0006 with validity from 31/07/2006 to 30/07/2011 Organisation pour l'Agrément Technique Européen European Organisation for Technical Approvals European Technical Approval No. ETA-06/0006 1 I - LEGAL BASIS AND GENERAL CONDITIONS 1- This European Technical Approval is issued by SETRA in accordance with: - Council Directive 89/106/EEC of 21 December 1988 on the approximation of laws, regulations and 1 administrative provisions of Member States relating to construction products , modified by Council 2 o 3 Directive 93/68/EEC and Regulation (EC) N 1882/2003 of the European Parliament and of the Council ; 4 - Décret n°92-647 du 8 juillet 1992 concernant l'aptitude à l'usage des produits de construction - Common Procedural Rules for Requesting, Preparing and the Granting of European Technical 5 Approvals set out in the Annex to Commission Decision 94/23/EC ; - ETAG 013, Edition June 2002, Post-Tensioning Kits for Prestressing of Structures. 2 - SETRA is authorized to check whether the provisions of this European Technical Approval are met. Checking may take place in the manufacturing plant(s). Nevertheless, the responsibility for the conformity of the products to the European Technical Approval and for their fitness for the intended use remains with the holder of the European Technical Approval. 3 - This European Technical Approval is not to be transferred to manufacturers or agents of manufacturers other than those indicated on page 0, or manufacturing plants other than those indicated on page 0 of this European Technical Approval. 4 - This European Technical Approval may be withdrawn by SETRA, in particular pursuant to information 1 by the Commission according to Article 5 of Council Directive 89/106/EEC. 5 - Reproduction of this European Technical Approval including transmission by electronic means shall be in full. However, partial reproduction can be made with the written consent of SETRA. In this case partial reproduction has to be designated as such. Texts and drawings of advertising brochures shall not contradict or misuse the European Technical Approval. 6 - The European Technical Approval is issued by the approval body in its official language(s). This (These) version(s) corresponds (correspond) fully to the version circulated in EOTA. Translations into other languages have to be designated as such. 1 2 3 4 5 Official Journal of the European Communities No L 40, 11.2.1989, p. 12 Official Journal of the European Communities No L 220, 30.8.1993, p. 1 Official Journal of the European Union No L 284, 30.10.2003, p. 1 JORF du 14 juillet 1992 Official Journal of the European Communities No L 17, 20.1.1994, p. 34 Version of 28th July 2011 European Technical Approval No. ETA-06/0006 2 II - SPECIFIC CONDITIONS CONCERNING THE EUROPEAN TECHNICAL APPROVAL 1 - Product definition and intended use 1.1 - Product definition The VSL Post-Tensioning System consists, for convenience purposes, of two systems that rely upon a set of common basic components: the VSL Multistrand System and the VSL Slab System. According to this System, cables are considered to be primarily composed of ducts, tendons (using the 0.6" 'normal' or 'super' strand, i.e. Ø 15.2 or Ø 15.7, those defined in the White Draft pr EN 10138-3: "Prestressing steels - Strands" or individually greased and sheathed monostrand complying with ETAG 013 Annex C.1), anchorages and/or couplers and other components such as protective products necessary for ensuring either a permanent level of prestressing (during the entire reference life cycle) or a temporary one (over a limited period) for civil engineering structural elements, buildings or any other type of construction. As long as EN 10138 does not exist 7-wire strands in accordance with national provisions shall be used. The VSL Multistrand System (from 1 to 55 strand cables), defined in Annex 1 and intended more for massive civil engineering parts, is used along with the strands specified above and the following components: - ducts: - metallic: corrugated steel strip sheaths, steel tubes, - made of plastic, the VSL PT-PLUS® ducting, polyethylene or polypropylene sheaths or tubes, - anchorages: - active or passive type E (1 to 55 strands), type CS (7 to 37 strands), type GC (3 to 37 strands), , type NC (55 strands) and NC-U (55 strands), - using bond type H (1 to 37 strands), - fixed couplers type K (3 to 37 strands) and movable couplers type V (3 to 37 strands); - injection products: - for rigid injection: with a cement base, in accordance with EN 447 - for flexible injection: with a grease base, with a wax base. Filling materials covered by an ETA may also be employed. The VSL Slab System (1 to 4 strands), defined in Annex 2 and primarily intended for thin construction elements for building or bridge decks, is used along with the strands specified above and either bare strands for the system with injection or individually greased and sheathed for the system without injection: - ducts for the system with injection: the circular or flat corrugated steel strip sheaths, the circular or flat VSL PT-PLUS® duct, - anchorages: - active or passive type S 6-1 (1 strand), S 6-1 PLUS (1 strand) and type S 6-4 (4 strands), - embedded dead end type SF 6-1 (1 strand) and SF 6-1 PLUS (1strand), - using bond: type H for the system with injection applied to internal bonded tendons only. - injection products for the system with injection: with a cement base, in accordance with EN 447. Filling materials covered by an ETA may also be employed. 1.2 - Intended use The VSL Post-Tensioning System has been designed to ensure the equilibrium of structures or of sections of structures submitted to the gravity effects, live load effects, climatic effects or any other type of action as well as to the imposed set of deformations. The VSL Post-Tensioning System may be used for: - new structural works, - the repair and strengthening of existing structures. Version of 28th July 2011 European Technical Approval No. ETA-06/0006 3 The VSL Post-Tensioning System may also be employed in structures made of other materials than concrete; this could entail structures made of concrete, masonry, steel, cast iron, wood or combinations of several materials. The tendons assembled as part of the VSL Post-Tensioning System may have the following basic use categories: - internal bonded tendon for concrete and composite structures, - internal unbonded tendon for concrete and composite structures, - external tendon for concrete structures with a tendon path situated outside the cross section of the structure or member but inside its envelope. (Cables for ground and rock anchors, external cables with a layout positioned beyond the structural envelope or the structural component, and stay cables are not covered by the present ETA). completed with the following optional use categories: - restressable tendon (internal or external), - exchangeable tendon (internal or external), - cryogenic applications, - internal bonded tendon with plastic duct, - encapsulated tendon, - electrically isolated tendon, - tendon for use in structural steel or composite construction as external tendon, - tendon for use in structural masonry construction as internal and/or external tendon, - tendon for use in structural timber as internal and/or external tendon. The tables presented in Chapters 1.4 and 3.4 of Annexes 1 and 2 establish the categories possible for each of the approved anchorages. 1.3 Working life The provisions, test and assessment methods in the ETAG 013 have been written based upon the assumption that the estimated design working life (nominal design value of the intended life of a structure) of the PT System is the same as the one specified in the Eurocodes relevant for the structure in which it is intended to be used provided that the PT System is subject to appropriate use and maintenance (see Chapter 7 of ETAG 013). Eurocode 1 specifies 100 years design working life for bridges and other engineering structures. These provisions are based upon the current state of the art and the available knowledge and experience. The indication given on the design working life of a product cannot be interpreted as a guarantee given by the producer (or the Approvals Body) but is regarded only as a means for choosing appropriate components and materials in relation to the expected economically reasonable design working life of structures for the works. The relevant Eurocodes would be the following: ENV 1990 "Eurocode 0": Basis of structural design ENV 1991 "Eurocode 1": Actions on structures ENV 1992 "Eurocode 2": Design of concrete structures ENV 1993 "Eurocode 3": Design of steel structures ENV 1994 "Eurocode 4": Design of composite steel and concrete structures ENV 1995 "Eurocode 5": Design of timber structures ENV 1996 "Eurocode 6": Design of masonry structures 2 - Product characteristics and verification methods 2.1 - Product characteristics The components of the VSL Post-Tensioning System comply with the drawings and conditions described in Annexes 1 and 2 of this European Technical Approval. More detailed information related to confidential specifications (e.g.: materials, processing, surface, dimensions, tolerances, manufacturing methods and control procedures) are included in the Technical Evaluation dossier concerning this European Technical Approval, which has been deposited at the Version of 28th July 2011 European Technical Approval No. ETA-06/0006 4 Approval Body. This set of information is also to be sent, whenever necessary, to the Certification Body responsible for Attestation of Conformity. Essential requirements 1 (mechanical resistance and stability) and 3 (hygiene, health and the environment) from Appendix I of the Construction Products Directive have been fulfilled. For the PT System, the other requirements need not to be complied with. Only product characteristics in relation to essential requirements 1 and 3 are to be verified. It should be pointed out that, depending on their specific nature, some prestressed structures or parts of prestressed structures may need to satisfy other requirements in respect to fire safety. 2.2 - Verification methods Assessment of the fitness for use of the PT System with essential requirement 1 related to "mechanical resistance and stability" was carried out, as stipulated in the European Technical Approval Guide focusing on post-tensioning kits for prestressing of structures (ETAG 013). The performances assessed in accordance with ETAG 013 allow to fulfill all relevant essential requirements. Such performances deal for the most part with: resistance to static loads, effective load transfer to the structure, and resistance to fatigue. A set of specific tests were carried out as stated in ETAG 013 for the following optional use categories : electrical insulation and cryogenic applications. The methods for verifying, evaluating and assessing suitability and test procedures comply with those detailed in ETAG 013. According to the kit manufacturer’s declaration, the post-tensioning kit does not contain any dangerous substances. In addition to the specific clauses relating to dangerous substances contained in this European Technical Approval, there may be other requirements applicable to the products falling within its scope (e.g. transposed European legislation and national laws, regulations and administrative provisions). In order to meet the provisions of the EU Construction Products Directive, these requirements need also to be complied with, when and where they apply. This statement has been highlighted in Chapter 5 entitled "Injection and sealing" of both Annexes 1 and 2. 3 - Evaluation, Attestation of Conformity and CE marking 3.1 - The attestation of conformity system 6 The system of attestation of conformity specified by the European Commission in mandate 98/456/EC is the system 1+, with audit testing of samples, described in Council Directive (89/106/EEC) Annex III and is detailed as follow: 3.1.1 - Tasks for the Kit Manufacturer (see Section 3.2.1): 1) Factory production control, 2) Further testing of samples taken at the factory by the manufacturer in accordance with a prescribed test plan (see Annex 0); 3.1.2 - Tasks for the Certification Body (see Section 3.2.2): 1) Initial type testing of the product, 2) Initial inspection of factory and of factory production control (FPC), 3) Continuous surveillance, assessment and approval of factory production control (FPC) 4) Audit testing of samples. 3.2 - Responsibilities 3.2.1 - Tasks for the Kit Manufacturer 3.2.1.1 - General responsibilities of the Kit Manufacturer The Kit Manufacturer shall keep available an updated list of all components manufacturers. 6 Official Journal of the European communities L201/112 of 3 July 1998 Version of 28th July 2011 European Technical Approval No. ETA-06/0006 5 This list is to be provided to the Certification Body. Another copy may also be made available to the Approval Body. The Kit Manufacturer is responsible for the production and quality of components manufactured or ordered. At least once a year, each components manufacturer has to be audited by the kit manufacturer. Each audit report shall be made available to the Certification Body. These audit reports include: - Identification of the components manufacturer - Date of audit of components manufacturer - Summary of the results and records of the FPC since last audit - Summary of the complaint records - Evaluation of the components manufacturer concerning FPC - Specific remarks as relevant - Clear and unique statement whether the requirement of the ETA are met - Name and position of signatory - Date of signature - Signature. At least once a year specimens are taken by the kit manufacturer from at least one job site. One series of single tensile element tests are performed according to Annex 0 (annex E3 of the ETAG 013) by the kit manufacturer with these specimens. One series of single tensile element tests are performed with components from only one site. The results of these test series are made available to the Certification Body. These reports include: - Identification of the job site where the components have been taken - Date of sampling - Identification of the components (e.g. anchor head, wedges, strand,…) - Place and date of testing - Summary of the results including a test report according to Annex E.3 of ETAG 013 - Specific remarks as relevant - Name and position of signatory - Date of signature - Signature. The kit manufacturer makes available for at least 10 years all records of relevant results concerning the ETA and the audit reports concerning the components manufacturers. 3.2.1.2 - Factory Production Control (FPC) 3.2.1.2.1 - General The kit manufacturer exercises permanent internal control of the production. All the elements, requirements and provisions adopted by the kit manufacturer are documented in a systematic manner in the form of written policies and procedures. This control system ensures that the PT System is in conformity with the European Technical Approval. The Factory Production Control is in accordance with the control plan of VSL named QM relating to the European Technical Approval 06/0006 issued on 31-07-2006 which is part of the technical documentation of this european technical approval. The control plan is laid down in the context of the factory production control system operated by the manufacturer and deposited at SETRA. The basic elements of the control plan comply with ETAG 013 annex E1. The results of the factory production control shall be recorded and evaluated in accordance with the provisions of the control plan. FPC and the prescribed test plan are according to Annex 0, which address the following aspects: - manufacturing - distribution and delivery to job site. FPC system complying with EN ISO 9001 : 2000 and which addresses the requirements of the ETA is recognized as satisfying the FPC requirements of the Directive. Parts of the FPC may be transferred to an independent test laboratory. Nevertheless, the kit manufacturer has the full responsibility for all results of the FPC. Version of 28th July 2011 European Technical Approval No. ETA-06/0006 6 3.2.1.2.2 - Control of the PT System components and materials The characteristics of incoming materials which comply with a harmonized European technical specification, having met the corresponding Attestation of Conformity procedure, are considered satisfactory and need, except in case of justified doubt, no further checking. All materials are to be in accordance with the requirements of the ETA and the corresponding specifications of the kit manufacturer. Where harmonized technical specifications are not available, materials according to specifications valid in the place of use may be used provided that their use is compatible with the results of approval tests. Otherwise, the specifications are given in the ETA. 3.2.1.2.3 - Inspection and testing The validity of the type and frequency of checks / testing conducted during production and on the final product has to be considered as a function of the production process. This includes verification conducted during production, on properties that cannot be inspected at a later stage and verification on the final product. These include: - Definition of the number of samples taken by the kit manufacturer - Material properties e.g. tensile strength, hardness, surface finish, chemical composition,… - Determination of the dimensions of components - Check correct assembly - Documentation of tests and test results. All tests are performed according to written procedures with suitable calibrated measuring devices. All test results are recorded in a consequent and systematic way. The prescribed test plan relative to the PT System (see Annex 0) complies with stipulations in Annex E.1 of ETAG 013, including the minimum test frequencies to perform. 3.2.1.2.4 - Control of non-conforming products Products which are considered as not conforming with the ETA are immediately marked and separated from such products which comply. The prescribed test plan addresses control of non-conforming products. 3.2.1.2.5 - Complaints ETA Technical File includes provisions to keep records of all complaints about the PT System. 3.2.2 - Tasks of the Certification Body (CB) The CB may act with its own resources or subcontract inspection tasks and testing tasks to inspection bodies and testing laboratories. 3.2.2.1 - Initial type-testing The results from tests performed during the approval procedure and then evaluated by the Approval Body may be used by the Certification Body as initial type testing as required in the ETAG 013. 3.2.2.2 - Initial assessment of factory and factory production control The Certification Body assesses both the factory capacities and the factory production control performed by the kit manufacturer in order to ensure that, in compliance with the prescribed test plan, the manufacturing resources and FPC are able to guarantee continuous and consistent manufacturing of PT System components in accordance with ETA specifications. 3.2.2.3 – Continuous surveillance The Certification Body shall perform surveillance inspections, Components Manufacturers inspections and sample extractions either in the factories or on the job sites for the purpose of conducting independent tests under its responsibility. Continuous surveillance and FPC evaluation are to proceed in accordance with the prescribed test plan and in compliance with conditions laid out under the "Continuous surveillance" heading found in the ETAG 013 guide and in Figure 8.1 in particular. The kit manufacturer shall be inspected at least once a year. Its FCP will be checked and according to Annex E.2, samples are taken for independent testing. Version of 28th July 2011 European Technical Approval No. ETA-06/0006 7 Each component manufacturer shall be inspected at least once during the period of validity of the ETA that is at least once in five years. The Certification Body shall provide SETRA, upon request, the results of certification and continuous surveillance. In cases of serious non conformities, related to important aspects of the performances of the posttensioning system, which can not be corrected within the deadlines, the certification body shall withdraw the certification of conformity and inform the SETRA without delay. 3.3 – CE-Marking CE-marking is in accordance with the Construction Products Directive and the Guidance Paper "D" named "CE marking under the construction products directive" (EC/OEAT 04/645 Document). The delivery note, associated with the components of the PT System, shall contain the CE conformity marking which consist of the CE-symbol and: 1. The name or identifying mark of the kit manufacturer 2. The last two digits of the year in which the marking was affixed 3. The number of the Certificate of Conformity 4. The ETA number 5 See information on ETA No 06/0006 6. The use category(ies) 7. The number of the Certification Body. All other information is clearly separated from the CE-marking and the accompanying information. 4- Assumptions under which the fitness for use of VSL PT System is favorably assessed 4.1 - Production This European Technical Approval document has been issued for the VSL PT System on the basis of Manufacturer Technical Dossier (MTD) submitted and verified by SETRA Any anticipated changes to the process or in the production of components that may change the MTD must be notified to SETRA, which would then decide whether change affects the ETA and, consequently, the validity of the CE-marking and whether an additional assessment with modification of this ETA would be necessary. Under all circumstances, SETRA consent is required prior to enacting the planned modifications. 4.2 - Installation The quality of a post-tensioned structure lies not only in its effective design, but also in the quality of its execution. As regards post-tensioning, it goes without saying that the appropriate use of the PT System, component quality and system installation quality serve to influence both suitability for the intended use and the design working life. Basic information has been provided in Annexes 1 and 2 of ETA document. Although such information proves essential for purposes of comprehending PT System application, it alone remains insufficient for proceeding with the installation step. For this reason, the Post-Tensioning System has been set up for installation to be performed by a PT Specialist Company. Even though this field is submitted to the national regulatory conditions of EU Member States, it should be recalled herein that the qualification of PT Specialist Companies encompasses their aptitude (specialized equipment resources and certified staff) first to design the prestressed parts of structures and then to prepare the corresponding set of components and work tasks, install the PT System (including cable tensioning using appropriate devices) and performing the injection of protective filling material. These last two tasks are to be carried out with equipment capable of meeting the requirements associated with attaining precise measurements of certain physical magnitudes. The tasks of design and installation may be extended, under some circumstances, by means of monitoring and adjustment (whenever necessary) of the installed PT System. Version of 28th July 2011 European Technical Approval No. ETA-06/0006 8 5 - Indications 5.1 - Packaging, transportation and storage Temporary protections, packaging, along with transportation and storage conditions for components of the VSL PT System have been designed to ensure availability for worksite installation without any alteration of their suitability for the particular intended use. The detailed conditions to be adopted relative to the ducts, reinforcements, anchorages and protective filling material have been set forth both in Chapter 7 of ETAG 013 and in the VSL Technical Documentation (associated with the European Technical Approval). 5.2 - Installation The entire set of equipment used for installing the PT System is submitted to periodic maintenance and repair operations, whenever necessary. Tensioning equipment measurement systems (pressure or force, displacement and/or movement) that get included in the verification of magnitudes for the actions applied to structures undergo calibration in compliance with: Chapter 7 of ETAG 013, the national provisions, and the set of practices prescribed in the VSL Technical Documentation (associated with the European Technical Approval). Version of 28th July 2011 Annex 0 of the European Technical Approval No. ETA-06/0006 1 Annex 0 ETA APPLICATION 1 - Commitments assumed by the ETA Holder Once installed, the VSL Post-Tensioning System makes a vital contribution both to the permanent equilibrium of structures and to their durability. In light of the terms inherent in this European Technical Approval (ETA), which serve to certify the fitness for use of the PT System, its service capabilities and its working life as well as to prescribe the resources utilized by the companies involved (see Appendix D of ETAG 013), it is essential for each of the prerequisite measures to be applied during the fabrication and installation steps that accompany the design step in promoting proper use of the PT System. In this aim, the ETA Holder agrees to apply and ensure application of this approval by the Kit Manufacturer, the Component Manufacturers and the PT Specialist Companies such that the installed PT System proves capable of satisfying the designated set of basic requirements (in compliance with Construction Products Directive, Chapter 1, Article 2.1). 2 - Responsibility of both the ETA Holder and Kit Manufacturer The components of the VSL Post-Tensioning System are produced in accordance with the conditions of the present European Technical Approval by the Kit Manufacturer and selected Component Manufacturers, using the production resources indicated and identified during inspections and on site audits performed by both the Approval and Certification Bodies. The Kit Manufacturer guarantees that all components of the PT System and relative individual components for which the ETA has been issued comply with the specifications given in the ETA. For the most important components, the following table summarizes the minimum procedures which have to be performed. Version of 28th July 2011 Annex 0 of the European Technical Approval No. ETA-06/0006 2 "Prescribed test plan" 1 Component 2 Item 3 Test / Check Anchorage zone components 6 bulk Check 7 Anchor plate Material Detailed 5 dimensions 3 3 Visual inspection 7 Wedges, Material Compression Treatment, fitting hardness Detailed 5 dimensions 3 Material 3 Visual inspection 7 Strand Material Diameter 3 Visual inspection 7 Constituents Cement of filling Admixtures, 7 material as additions, ... per EN 447 7 Monostrand Material 7 Plastic pipes Material 7 Plastic ducts Material full full Check Current zone components 2 Check "CE" Check National Check Certification Test 2 till "CE" Check Check full Check bulk Check Check Check 9 100% 9 9 Test Check Check Test 100% 3% = 2 elements 9 100% Test Visual inspection 7 Check Check 5 Minimum frequency 9 Test Visual inspection 7 Anchor head, Material Coupler Detailed 5 dimensions Duct 4 4 Traceability National Certification 2 till "CE" full full 5% 2 elements 9 100% 9 100% 9 0.5% = 2 elements 9 5% = 2 elements 9 100% 6 Documentation 1,6 "2.2" Yes No 2 "3.1" Yes No 2 "3.1" Yes Yes No 2 100% 100% 100 % Each coil Each coil 100% 100% "CE" No 2 "CE" No No 2 "CE" 2 "CE" 100% "CE" 100% 100% "CE" 8 "CE" 8 2 All samples are to be extracted at random and clearly identified. Details on sampling procedures including methods of recording as well as test methods have been agreed between the Approval Body and the Kit Manufacturer as part of the prescribed test plan. Preferably standardized sampling and test methods are used. Generally all results are reported in the test reports in such a way to enable direct comparison with the specification’s data in the ETA or subsidiary documentation. 1 "2.2": Test report type "2.2" according to EN 10 204 (this applies to simple steel anchor plates only). 2 "3.1": Inspection certificate type "3.1" according to EN 10 204. If the basis of "CE"-marking is not available, the prescribed test plan has to include appropriate measures, only for the time until the harmonized technical specification is available. Version of 28th July 2011 Annex 0 of the European Technical Approval No. ETA-06/0006 3 3 Visual inspections means e.g.: main dimensions, gauge testing, correct marking or labelling, appropriate performance acceptability, surface fins, kinks, smoothness, corrosion, coating, etc., as given in the prescribed test plan. 4 full: Full traceability of each component to its raw material. bulk: Traceability of each delivery of components to a defined point. 5 Detailed dimensions mean measuring of all dimensions and angles according to the specifications as given in the prescribed test plan. 6 Only if the force transfer unit is a "simple plate". Otherwise appropriate procedures have to be introduced. 7 Material checks are included for information only as these are not part of the prescribed test plan. 8 If the basis of "CE"-marking is not available, the prescribed test plan has to include appropriate measures. The certificate shall be based on specific testing on the fabrication lot from which the supply has been produced, to confirm specified properties, and shall be prepared by a department of the supplier which is independent of the production department. 9 Procedure according to VSL Final Control Specifications. Note: Generally speaking, all tests, inspections, etc. are aimed at verifying that the information contained in manufacturing drawings as well as in the ultimate set of associated specifications has actually been applied to the components. During surveillance inspections, the Certification Body has to take samples of components of the PT System or the relative individual components for which the ETA has been granted for independent testing. For the most important components, the table given below summarises the minimum procedures which are performed by the Certification Body. "Audit testing" 1 Component 2 Item Anchor head, Coupler Material according to specification Wedges, Compression fitting Single tensile element test Inclined Tube test Detailed dimensions 10 Visual inspection Material according to specification Treatment Detailed dimensions Main dimensions, surface hardness 10 Visual inspection Single tensile element test according to Annex E.3 Inclined Tube test as per Clause 11 C.4.3.3.2.1 3 Test / Check Check, test Test Check Check, test Test Test Test Check Test Test 4 Sampling Number of components per visit 1 2 2 1 5 5 1 series 1 test All samples are to be randomly selected and clearly identified. Details on sampling procedures including methods of recording as well as test methods have been agreed between the Approval Body and the Kit Manufacturer as part of the prescribed test plan. Preferably standardized sampling and test methods are used. Generally all results are reported in the test reports in such a way to enable direct comparison with the specification’s data in the ETA or subsidiary documentation. Version of 28th July 2011 Annex 0 of the European Technical Approval No. ETA-06/0006 4 10 Visual inspections means e.g. : main dimensions, gauge testing, correct marking or labelling, appropriate performance, surface, fins, kinks, smoothness, corrosion, coating, etc. 11 Applied to special grout specified within the ETAG 013 in C.4.3 and this ETA. 3 - Responsibility assigned the ETA Holder and PT Specialist Companies The respective tasks and responsibilities of the ETA Holder and PT Specialist Companies are expressed in Appendix D of ETAG 013. Installation of the VSL Post-Tensioning System is carried out in full compliance with the present European Technical Approval, all related European level documents, and all pertinent National application documents at the Country level. Version of 28th July 2011 Annex 1 TECHNICAL DATA OF THE VSL MULTISTRAND SYSTEM 2 Annex 1 of the European Technical Approval No ETA-06/0006 TABLE OF CONTENTS Title Page 1. DEFINITION OF THE SYSTEM 1.1 PRINCIPLE OF THE VSL MULTISTRAND SYSTEM 1.2 CHARACTERISTICS OF SYSTEM UNITS 1.3 ANCHORAGES 1.3.1 PRESENTATION OF THE ANCHORAGES 1.3.2 LIST OF APPROVED ANCHORAGES 1.4 CATEGORIES OF USE, POSSIBILITIES AND OPTIONS 1.4.1 USES AND OPTIONS OF THE VSL MULTISTRAND SYSTEM 1.4.2 POSSIBILITIES OF THE VSL MULTISTRAND SYSTEM 2. STRANDS AND DUCTS 2.1 STRANDS USED 2.2 DUCTING 2.2.1 TYPES AND DIMENSIONS OF USABLE DUCTS 2.2.2 METAL DUCTS 2.2.3 PLASTIC DUCTS 2.2.4 ACCESSORIES FOR INLETS, BLEED VENTS AND OUTLETS 2.2.5 CONNECTION WITH TRUMPETS 2.3 CABLE LAYOUT 2.3.1 STRAIGHT LENGTHS BEHIND THE ANCHORAGES 2.3.2 RADIUS OF CURVATURE 2.3.3 SPACING OF SUPPORTS AND TOLERANCES 2.3.4 STRAND CUT LENGTH 2.4 INSTALLATION OF DUCTS AND STRANDS 2.5 PROVISIONAL PROTECTION AND LUBRICATION 2.6 CALCULATION ELEMENTS 2.6.1 FRICTION LOSSES 2.6.2 BASIS FOR EVALUATING ELONGATIONS 2.6.3 SETTING OF ANCHORAGE WEDGES 3. ANCHORAGES 3.1 DESCRIPTION OF ANCHORAGE COMPONENTS 3.1.1 LIVE END / DEAD END ANCHORAGES 3.1.2 COUPLERS 3.1.3 PRESENTATION AND PACKING OF ANCHORAGES 3.2 ORGANIZATION OF SUPPLY QUALITY 3.3 INSTALLATION OF VARIOUS ANCHORAGES 3.3.1 TYPE "E", "CS", "GC", "NC" and "NC-U" ACTIVE END ANCHORAGES 3.3.2 TYPE "E", "CS", "GC", , "NC" and "NC-U" PASSIVE END ANCHORAGES 3.3.3 TYPE "H" BOND ANCHORAGES 3.3.4 TYPE "K" FIXED COUPLERS 3.3.5 TYPE "V" MOVABLE COUPLERS 3.4 ANCHORAGE ARRANGEMENTS 3.5 GEOMETRICAL AND MECHANICAL USE CONDITIONS 3.5.1 CLEARANCE BEHIND STRESSING ANCHORAGES 3.5.2 CONCRETE COVER AND ANCHORAGE SPACING 3.6 LOCAL ANCHORAGE ZONE REINFORCEMENT 4. STRESSING 4.1 STRESSING EQUIPMENT 4.1.1 STRESSING JACKS 4.1.2 HYDRAULIC PUMPS 4.1.3 MEASUREMENT INSTRUMENTS AND SYSTEMS 4.2 PROCESSES OF STRESSING AND CONTROL PROCEDURE Version of 28th July 2011 4 5 6 7 9 9 11 13 13 13 15 16 16 18 19 22 22 22 3 Annex 1 of the European Technical Approval No ETA-06/0006 4.2.1 FORCE MEASUREMENTS 4.2.2 ELONGATION MEASUREMENTS 5. INJECTION AND SEALING 5.1 GENERAL INFORMATION 5.2 INJECTION PRODUCTS 5.2.1 PRODUCT FOR BONDED CABLES 5.2.2 PRODUCT FOR UNBONDED CABLES 5.3 INJECTION EQUIPMENT 5.4 INJECTION AND CONTROL PROCEDURE 5.5 SEALING 6. SCHEMATIC DRAWINGS 24 24 25 25 26 27 Version of 28th July 2011 Annex 1 of the European Technical Approval No ETA-06/0006 4 CHAPTER 1 DEFINITION OF THE SYSTEM 1.1 PRINCIPLE OF THE VSL MULTISTRAND SYSTEM The cable or unit of the VSL Multistrand System is composed of a bundle of strands made of high-strength steel called a "tendon", along with the associated set of anchorages. The tendon has to be encased within a duct such as a sheath or tube, etc. The void thereby produced can potentially be filled with an injected material for the purpose of bonding with the structure and/or inhibiting corrosion. The constituting strands are those defined in the European Standard White Draft pr EN 10138-3: "Prestressing 2 steels - Strand". They refer to 7-wire strands with nominal diameters of 15.2 and 15.7 mm (fpk = 1 860 N/mm 2 or fpk = 1 770 N/mm ). As long as EN 10138 does not exist, 7-wire strands in accordance with national provisions shall be used. The VSL Multistrand system is able to accommodate bare strands and individually sheathed and greased (protected) monostrands. By varying both the strand diameter and number (and, if applicable, their specified characteristic value of maximum force), it would be possible to obtain a value for the characteristic tensile strength per cable or unit that varies between 260 and 15 345 kN. All strands of a cable are simultaneously stressed, yet each one is individually locked within a conical anchoring hole by means of wedges. The anchorage function is performed by clamping during strand moving back at the time of pressure release in the jack. The choice of post-tensioning units, as dictated by force requirements, leads for a given strand diameter and characteristic strength to a specific number of strands to be placed. In conjunction with this design element, the choice of type of anchorage associated with the cable depends on the intended function and application of the particular unit. The designation of post-tensioning units is expressed with reference to both the type and number of component strands. The VSL commercial labeling is explained below: The labeling of units 6-1… 6-55 or 6S-1… 6S-55 signifies: the first digit indicates strand diameter, 6 = 6 × 1/10" = T15.2 15.2 mm 6S = 6 × 1/10" S = T15.7 15.7 mm (S stands for super). the subsequent digits indicate the number of strands composing the unit. To provide greater detail, the designation of units begins with the names of the anchorages placed at the ends. The following designation serves as an example: Cable VSL E-E 6S-12 L = 50.000 (1) The functions and names of the anchorages will be defined hereafter. The cable features a length of 50.000 m and has been stressed at one (1) end. To cover the entire range from 1 to 55 strands, an array of basic anchorages has been developed, i.e.: 1 - 2 - 3 4 - 7 - 12 - 15 - 19 - 22 - 27 - 31 - 37 - 43 - 55, thus enabling the creation of any intermediate unit, considering that the number of strands placed may be less than the number of conical holes of the anchorage. In incompletely filled anchor heads, the present strands have to be arranged to centre the applied load to the anchor head. Version of 28th July 2011 5 Annex 1 of the European Technical Approval No ETA-06/0006 1.2 CHARACTERISTICS OF SYSTEM UNITS On the basis of the strand characteristics defined in draft Standard "pr EN 10138-3: Prestressing steels - Part 3: Strand", the values of tendon cross-sections Ap, maximum forces under anchorage upon tensioning recom2 mended by EN 1992-1-1 : Pmax = min {k1.Ap.fpk; k2.Ap.fp0.1k}, with k1 = 0.8, k2 = 0.9, fpk = 1 860 N/mm , fp0.1k = 0.88 fpk, of VSL post-tensioning units are as follows : STRAND Number of strands in the prestressing unit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 15.2 - T15.2 or 6 STRAND 2 fpk = 1 860 N/mm Fpk = 260 kN Fp0.1k = 229 kN 15.7 - T15.7 or 6S 2 fpk = 1 860 N/mm Fpk = 279 kN Fp0.1k = 246 kN Ap Ap.fpk 0.8 Ap.fpk Ap.fp0.1k 0.9 Ap.fp0.1k Ap Ap.fpk 0.8 Ap.fpk Ap.fp0.1k 0.9 Ap.fp0.1k mm² 140 280 420 560 700 840 980 1 120 1 260 1 400 1 540 1 680 1 820 1 960 2 100 2 240 2 380 2 520 2 660 2 800 2 940 3 080 3 220 3 360 3 500 3 640 3 780 3 920 4 060 4 200 4 340 4 480 4 620 4 760 4 900 5 040 5 180 5 320 5 460 5 600 5 740 5 880 6 020 6 160 6 300 6 440 6 580 6 720 6 860 7 000 7 140 7 280 7 420 7 560 7 700 kN 260.0 520.0 780.0 1 040.0 1 300.0 1 560.0 1 820.0 2 080.0 2 340.0 2 600.0 2 860.0 3 120.0 3 380.0 3 640.0 3 900.0 4 160.0 4 420.0 4 680.0 4 940.0 5 200.0 5 460.0 5 720.0 5 980.0 6 240.0 6 500.0 6 760.0 7 020.0 7 280.0 7 540.0 7 800.0 8 060.0 8 320.0 8 580.0 8 840.0 9 100.0 9 360.0 9 620.0 9 880.0 10 140.0 10 400.0 10 660.0 10 920.0 11 180.0 11 440.0 11 700.0 11 960.0 12 220.0 12 480.0 12 740.0 13 000.0 13 260.0 13 520.0 13 780.0 14 040.0 14 300.0 kN 208.0 416.0 624.0 832.0 1 040.0 1 248.0 1 456.0 1 664.0 1 872.0 2 080.0 2 288.0 2 496.0 2 704.0 2 912.0 3 120.0 3 328.0 3 536.0 3 744.0 3 952.0 4 160.0 4 368.0 4 576.0 4 784.0 4 992.0 5 200.0 5 408.0 5 616.0 5 824.0 6 032.0 6 240.0 6 448.0 6 656.0 6 864.0 7 072.0 7 280.0 7 488.0 7 696.0 7 904.0 8 112.0 8 320.0 8 528.0 8 736.0 8 944.0 9 152.0 9 360.0 9 568.0 9 776.0 9 984.0 10 192.0 10 400.0 10 608.0 10 816.0 11 024.0 11 232.0 11 440.0 kN 229.0 458.0 687.0 916.0 1 145.0 1 374.0 1 603.0 1 832.0 2 061.0 2 290.0 2 519.0 2 748.0 2 977.0 3 206.0 3 435.0 3 664.0 3 893.0 4 122.0 4 351.0 4 580.0 4 809.0 5 038.0 5 267.0 5 496.0 5 725.0 5 954.0 6 183.0 6 412.0 6 641.0 6 870.0 7 099.0 7 328.0 7 557.0 7 786.0 8 015.0 8 244.0 8 473.0 8 702.0 8 931.0 9 160.0 9 389.0 9 618.0 9 847.0 10 076.0 10 305.0 10 534.0 10 763.0 10 992.0 11 221.0 11 450.0 11 679.0 11 908.0 12 137.0 12 366.0 12 595.0 kN 206.1 412.2 618.3 824.4 1 030.5 1 236.6 1 442.7 1 648.8 1 854.9 2 061.0 2 267.1 2 473.2 2 679.3 2 885.4 3 091.5 3 297.6 3 503.7 3 709.8 3 915.9 4 122.0 4 328.1 4 534.2 4 740.3 4 946.4 5 152.5 5 358.6 5 564.7 5 770.8 5 976.9 6 183.0 6 389.1 6 595.2 6 801.3 7 007.4 7 213.5 7 419.6 7 625.7 7 831.8 8 037.9 8 244.0 8 450.1 8 656.2 8 862.3 9 068.4 9 274.5 9 480.6 9 686.7 9 892.8 10 098.9 10 305.0 10 511.1 10 717.2 10 923.3 11 129.4 11 335.5 mm² 150 300 450 600 750 900 1 050 1 200 1 350 1 500 1 650 1 800 1 950 2 100 2 250 2 400 2 550 2 700 2 850 3 000 3 150 3 300 3 450 3 600 3 750 3 900 4 050 4 200 4 350 4 500 4 650 4 800 4 950 5 100 5 250 5 400 5 550 5 700 5 850 6 000 6 150 6 300 6 450 6 600 6 750 6 900 7 050 7 200 7 350 7 500 7 650 7 800 7 950 8 100 8 250 kN 279.0 558.0 837.0 1 116.0 1 395.0 1 674.0 1 953.0 2 232.0 2 511.0 2 790.0 3 069.0 3 348.0 3 627.0 3 906.0 4 185.0 4 464.0 4 743.0 5 022.0 5 301.0 5 580.0 5 859.0 6 138.0 6 417.0 6 696.0 6 975.0 7 254.0 7 533.0 7 812.0 8 091.0 8 370.0 8 649.0 8 928.0 9 207.0 9 486.0 9 765.0 10 044.0 10 323.0 10 602.0 10 881.0 11 160.0 11 439.0 11 718.0 11 997.0 12 276.0 12 555.0 12 834.0 13 113.0 13 392.0 13 671.0 13 950.0 14 229.0 14 508.0 14 787.0 15 066.0 15 345.0 kN 223.2 446.4 669.6 892.8 1 116.0 1 339.2 1 562.4 1 785.6 2 008.8 2 232.0 2 455.2 2 678.4 2 901.6 3 124.8 3 348.0 3 571.2 3 794.4 4 017.6 4 240.8 4 464.0 4 687.2 4 910.4 5 133.6 5 356.8 5 580.0 5 803.2 6 026.4 6 249.6 6 472.8 6 696.0 6 919.2 7 142.4 7 365.6 7 588.8 7 812.0 8 035.2 8 258.4 8 481.6 8 704.8 8 928.0 9 151.2 9 374.4 9 597.6 9 820.8 10 044.0 10 267.2 10 490.4 10 713.6 10 936.8 11 160.0 11 383.2 11 606.4 11 829.6 12 052.8 12 276.0 kN 246.0 492.0 738.0 984.0 1 230.0 1 476.0 1 722.0 1 968.0 2 214.0 2 460.0 2 706.0 2 952.0 3 198.0 3 444.0 3 690.0 3 936.0 4 182.0 4 428.0 4 674.0 4 920.0 5 166.0 5 412.0 5 658.0 5 904.0 6 150.0 6 396.0 6 642.0 6 888.0 7 134.0 7 380.0 7 626.0 7 872.0 8 118.0 8 364.0 8 610.0 8 856.0 9 102.0 9 348.0 9 594.0 9 840.0 10 086.0 10 332.0 10 578.0 10 824.0 11 070.0 11 316.0 11 562.0 11 808.0 12 054.0 12 300.0 12 546.0 12 792.0 13 038.0 13 284.0 13 530.0 kN 221.4 442.8 664.2 885.6 1 107.0 1 328.4 1 549.8 1 771.2 1 992.6 2 214.0 2 435.4 2 656.8 2 878.2 3 099.6 3 321.0 3 542.4 3 763.8 3 985.2 4 206.6 4 428.0 4 649.4 4 870.8 5 092.2 5 313.6 5 535.0 5 756.4 5 977.8 6 199.2 6 420.6 6 642.0 6 863.4 7 084.8 7 306.2 7 527.6 7 749.0 7 970.4 8 191.8 8 413.2 8 634.6 8 856.0 9 077.4 9 298.8 9 520.2 9 741.6 9 963.0 10 184.4 10 405.8 10 627.2 10 848.6 11 070.0 11 291.4 11 512.8 11 734.2 11 955.6 12 177.0 Note : prestressing force applied to structure must be in accordance with national regulations. Version of 28th July 2011 Annex 1 of the European Technical Approval No ETA-06/0006 6 Temporary overstressing is permitted in accordance with the requirements of EN 1992-1-1 to a maximum force of k3.Ap.fp0.1k, with k3 = 0.95. The system can obviously be used with strands displaying a specific characteristic tensile strength of less than 2 that proposed in the table as strands with fpk = 1 770 N/mm . The provisions for tendons with strands with a 2 2 characteristic tensile strength fpk = 1 860 N/mm also apply to tendons with strands with fpk < 1 860 N/mm . The draft Standard pr EN 10138-3 sets the following criteria for the other useful characteristics of prestressing strands composing the VSL units: - Elongation at maximal force: 3.5% 2.5% - Relaxation at 0.70 fpk after 1,000 hours: - Relaxation at 0.80 fpk after 1,000 hours: 4.5% 2 6 2x10 cycles - Fatigue behavior (0.70 fpk; 190 N/mm ): - Maximum D value of deflected tensile test: 28% 2 195 000 N/mm - Modulus of elasticity Ep: Even though the modulus of elasticity of both the tendon or bundle of strands and the (single) strand are somewhat different, VSL still recommends adopting, for the cable calculations, the measured strand value that had been transmitted upon delivery of the supply of strands. Individually greased and sheathed monostrands have the same mechanical properties as listed above for bare strands. 1.3 ANCHORAGES 1.3.1 PRESENTATION OF THE ANCHORAGES The VSL Multistrand System anchorages may, depending on their function and commercial labeling, be classified as one of the following: Type "E", "CS", "GC", "NC" and "NC-U" active end anchorages These active anchorages are designed to anchor the tendons at the end through which stressing of the entire set of bundled strands will be carried out. They are composed of an anchor head (cylindrical for the "E" anchor head or a cylindrical / hexagonal-base prism for the "CS" anchor head) drilled with the same number of conically-shaped holes as strands to be anchored; the anchoring step is performed at each strand using wedges inside the conical holes to provide a strong grip. The anchor head is supported by the concrete via an "E", "CS", "GC", "NC" or "NC-U" type anchor plate connected to an "E", "CS", "GC" type trumpet housing deviating the strands to the current duct. The "NC" and "NC-U" anchor plate comprises its own deviating trumpet (ditto for smallest "GC" anchor plates). Type "E", "CS", "GC", "NC" and "NC-U" passive end anchorages These passive anchorages serve to block the tendons at the end on which no stressing force is to be exerted. The "E", "CS", "GC", "NC" and "NC-U" category only includes those anchorages that remain accessible at the time of stressing. These anchorages, which feature pre-clamped wedges and which may be controlled during stressing, are used for this purpose. Type "H" bonded anchorages These dead end anchorages rely, at least in part, on bond in order to maintain the tendon extremity fastened with respect to the concrete. In type "H" anchorages, the clean strands exhibit wires, over a given bond length, folded at their extremities to form an onion. Type "K" fixed couplers These anchorages ensure the continuity of two tendons placed in tension one after the other when two distinct phases of the construction job overlap and the first phase cable is stressed before stressing the second phase cable. Within "K" type fixed couplers, the first-phase cable is anchored on the coupler side with a type "E", "CS" or "GC" anchor (transfer) plate whose head labeled "K" contains the housing units for the coupling elements around its periphery. The second phase cable, on the coupler side, is anchored by means of compression fittings on the strands placed into the aforementioned housings. The two coupled tendons must be units of the same number of strands and the force in the second phase cable shall not be larger than the force in the first phase cable. Version of 28th July 2011 7 Annex 1 of the European Technical Approval No ETA-06/0006 The coupling is then insulated from the concrete by means of a sleeve. Type "V" movable couplers These anchorages ensure the continuity of two lengths of a tendon which are stressed simultaneously. Within "V" type mobile couplers the "movable" head labeled "K" – described here before – coupling the two lengths is mobile in its sleeve. The coupling head where the opposite strands are locked with compression fittings is equipped with retaining plates. The two coupled lengths must be units of the same number of strands. The coupling is insulated from the concrete by means of the sleeve. 1.3.2 LIST OF APPROVED ANCHORAGES The set of approved anchorages that allow creating all sorts of intermediate prestressing units have been categorized in the following table: ANCHORAGE Function CABLE Unit 1T15.2 / 1T15.7 Label 6-1/6S-1 2 2 3 3 4 4 7 7 12 12 15 15 19 19 22 22 27 27 31 31 37 37 43 43 55 55 Active end E CS GC Passive end NC NC-U E CS GC NC Bond NC-U H Coupler K V The stressing of tendons at PT system anchorages is only conducted by VSL stressing jacks, which are presented in Chapter 4. 1.4 CATEGORIES OF USE, POSSIBILITIES AND OPTIONS 1.4.1 USES AND OPTIONS OF THE VSL MULTISTRAND SYSTEM VSL Multistrand System units may be: - internal or external (to the concrete or to one another material), - with or without a bonded or unbonded permanent injection, and - applied in structures composed indiscriminately of various construction materials. These units may entail: - an adjustable force, and/or - the potential for replacement provided the absence of bonding with the structure. They can also be conceived for applications that are: - cryogenic, - encapsulated (leak-tight, waterproof), and - electrically isolated (electrical isolation implies a strong waterproofing). Uses Anchorages E CS GC NC NC-U H K V E CS GC NC NC-U H K V internal* bonded cable with metallic duct internal* bonded cable with plastic duct internal* unbonded external* bonded cable external* unbonded cable tendon for use in various material as external cable restressable tendon Version of 28th July 2011 Annex 1 of the European Technical Approval No ETA-06/0006 8 exchangeable tendon cryogenic applications encapsulated tendon (leak tight) electrically isolated tendon (*) of concrete As noted before, - absence of bonding with the structure for exchangeable cable means soft injection or double pipe at anchorage and deviator in case of rigid injection. The clearance between outside diameter of tendon duct and inside diameter of formwork pipe in structure has to be 10 mm minimum. - the VSL Multistrand System may be introduced without grouting, which for example is the case when tendons are left without protection due to their provisional use, or their location within a neutral environment. It goes without saying that all these potential uses and options presume the availability of adequate choices and combinations of all cable components as indicated in this ETA: - for strands see Chapter 2.1 "Strands used", - for ducts see Chapter 2.2 "Ducting", - for anchorages see Chapter 3.4 "Anchorage arrangements", - for injection see Chapter 5.2 "Injection products". 1.4.2 POSSIBILITIES OF THE VSL MULTISTRAND SYSTEM The VSL Multistrand System is able to take advantage of the following unique set of possibilities: - Partial stressing or stressing in stages: When prestressing needs to be applied gradually, the stressing may be performed in stages. As the first partial stressing step gets carried out, at the beginning of the second stage, the wedges are unclamped by action of the jack on the cable. Once the targeted force has been reached, pressure in the jack is relaxed and the wedges are once again clamped inside the anchor head. This procedure consists of the same steps as for tensioning of a long cable whose elongation necessitates several successive jack strokes. - Overstressing with shimming: Upon loading of the anchorage during releasing the jack pressure, due to wedges draw in, a simultaneous setting of the strands takes place causing a reduction of elongation and a drop in tension at the cable end. It is still possible however to adjust tension to the desired value by use of a jack chair ring that enables pressing the jack no longer upon the anchor head but rather via jack chair upon the bearing plate. In this case, since the stressing had been conducted under typical conditions and the wedges locked definitively, tensioning is resumed by bringing the head back to the target displacement (the wedge draw in or other value), and then shimming between the anchor head and the anchor plate with split shim (see chapter 2.6.3). - Destressing procedure: The destressing of an anchored cable by a type "E" or "CS" anchor head is possible using a special tooling assembly mounted on the tensioning jack provided that (1) the required strand overlengths have been conserved, (2) that the tendon remains unbonded to the structure. The required strand overlength exceeds the values provided in Chapter 6. From the aforementioned, two zones would appear to stand out, the free length and the anchorage zone; they will be presented in greater detail within the following chapters entitled "Strands and ducts" and "Anchorages". Version of 28th July 2011 9 Annex 1 of the European Technical Approval No ETA-06/0006 CHAPTER 2 STRANDS AND DUCTS 2.1 STRANDS USED The high-strength prestressing steel (strands) composing the tendons are labeled "Y1860S7 – No. 1.1366" and are defined in the draft Standard "pr EN 10138-3: Prestressing steels – Part 3: Strand". Alternatively, the strands labeled "Y1770S7 – No. 1.1365" may also be employed. The primary characteristics have been recalled in Section 1.2. Monostrands (individually greased and sheathed) can be used for unbonded tendons, either internal or external to concrete or other materials. They are compliant with Annex C.1 of the ETAG 013, which specifies the requirements, verification methods and acceptance criteria of both the grease and the sheathing. 2.2 DUCTING The VSL Multistrand System can use several types of duct as provided in this section. Duct type selection depends on the specific project, the final use designed for the structure and the options selected for the posttensioning units. 2.2.1 TYPES AND DIMENSIONS OF THE USABLE DUCTS Depending on the specific application, various types of ducts may be employed. From a general standpoint, the ducts used must be mechanically resistant, display continuity in shape, ensure continuity of the seal and, ultimately, continuity in electrical insulation over their entire length, as well as comply with the project's bond requirements while not causing any chemical attack to the prestressing steel. Without claiming to be exhaustive, the following table of frequently-used ducts can be cited as having demonstrated their capacities in the uses and applications associated with the given options: Metal Ducts Ducts Applications Internal with Cable, bonded in the injection concrete with unbonded injection ² External Cable, out of the concrete (or other material) with bonded injection with unbonded injection ² standard cryogenic encapsulated electricallyisolated standard + encapsulated electricallyisolated restressable and/or replaceable standard + encapsulated electricallyisolated standard + encapsulated electricallyisolated restressable and/or replaceable Corrugated metal duct Smooth metal duct Plastic Ducts Smooth plastic duct VSL PT-PLUS polyethylene, Duct polypropylene NA NR NR NR º NR NR NR NA NA º NR NA NA NR NA NA NR NR NA ¹ NR NA NA NR NA ¹ NR NA NA NR³ ¹ NR NR For the other materials such as masonry, wood, etc., refer to conditions relative to concrete and take into account the installation constraints, which may be of various types. Notes: º) This set-up features a fully-bonded cable. ¹) Smooth ducts in polyethylene or polypropylene are the most common. ²) Strands defined in chap. 2.1, i.e. bare strands with total unbonded injection of duct or (individually greased and sheathed) monostrands in rigid filling of duct. ³) Using monostrands. : Advised ~: Possible NR: not recommended NA: not allowed Version of 28th July 2011 10 Annex 1 of the European Technical Approval No ETA-06/0006 The VSL Multistrand System's post-tensioning tendon ducts, for the most part with a circular cross-section, must display an internal diameter large enough to provide for easy strands installation and adequate filling during injection of the protective filling product. With this objective, VSL recommends an internal duct diameter Øint 1.8 p , where Ap is the nominal crosssection of the strands composing the unit. This relation is suitable for the case of threading the tendons by means of pushing through strand by strand into the ducts installed prior to concreting. In the case of prefabricated cables, it is authorized to adopt a duct with a smaller diameter. Moreover, during the calculations, it is necessary to consider the distance (called eccentricity) existing between the center of the duct and the center of gravity of the strand bundle cross-section. The recommended duct dimensions, along with the corresponding eccentricity values, are given in Chapter 6. The ducts, depending on their type and capacities, may be provided on coil or in straight segments. 2.2.2 METAL DUCTS The tendons are most often (as per the "STANDARD" solution) isolated from the concrete by means of corrugated steel strip sheaths. According to Standard EN 523, they are either normal (Category 1), i.e. "normal sheaths", or (Category 2), i.e. "rigid sheaths" but bendable by hand, with their characteristics being stipulated in the standard. Connections between coils or straight segments are performed by means of screwing a connector (coupler) onto the two extremities to be connected. The sealing at the joints is done by either an adhesive ribbon or thermo-retractable sleeves. In certain applications (e.g. nuclear, offshore), the tendons are encased in smooth steel ducts. The most frequently-employed tubes, whether welded or not, are thin (in compliance with the EN standards) and machinebendable. The connections between segments are commonly performed by flaring one end and clamping the other; the seal is generated by welding, thermo-retractable sleeves or adhesive ribbon. 2.2.3 PLASTIC DUCTS S In the case of stringent requirements as regards both corrosion protection and fatigue resistance of cables, it is recommended to use the corrugated plastic duct VSL PT-PLUS . This duct may only be used inside the concrete with a grouting and generates perfect bond between the tendons and the structure. It is recommended for applications submitted to a particularly-aggressive environment or strong fatigue loads. The VSL PT-PLUS duct complies with ETAG 013. The fitting between duct segments is introduced by means of mirror welding or by connectors that provide for both the waterproofing seal and electrical isolation. This duct can be used with all anchorage types E, CS, GC, NC, NC-U, H, K and V. When used with CS-type anchorages, it allows to provide fully-encapsulated units labeled CS "PLUS" as well as electrically isolated units labeled CS "SUPER". Such applications necessitate the presence of rigid half-shells between the duct and its supports at all of the high points along cable path in order to avoid any risk of perforation during stressing of the tendon. Regarding the selection of connection options for VSL PT-PLUS duct, the prescripts in the following table have to be strictly applied. Duct Sizes (1) Øint / Øext Radius of curvature (2) [m] Prescribed Connection Type 23/25 to 100/106 3 Fpk W R (3) Mirror Welding or Connector 115/121 to 150/157 3 Fpk W R << X (3) Mirror Welding 115/121 to 150/157 R > Mirror Welding or Connector Note (1) see Schematic Drawing "Ducting" Note (2) R min see chap. 2.3.2 Note (3) Fpk expressed in MN For design considerations in accordance with EN-1992 where the relative bond properties between reinforcing steel and post-tensioning tendons are relevant it may be assumed that tendons in PT-PLUS plastic ducts have a 50% longer bond length than tendons in corrugated metal ducts. S More common ducts (sleeves or tubes) made of polyethylene or polypropylene can also be used. The connections and seals between the segments are introduced by either mirror welding or electro-weldable couplers, or other means. Plastic pipe in accordance with ETAG 013 / EN-compliant ducts are in fact required. Version of 28th July 2011 11 Annex 1 of the European Technical Approval No ETA-06/0006 With an appropriate set of fittings, they may be used for applications involving encapsulated / waterproof and electrically-isolated tendons. 2.2.4 ACCESSORIES FOR INLETS, BLEED VENTS AND OUTLETS In internal (concrete) post-tensioning applications for structures composed of prefabricated elements, duct continuity, regardless of duct type, is performed in alignment with the joints by means of a coupler fitting that encompasses a set of rings inserted at the contact element duct end. These plastic accessories serve to complete the seal. Providing permanent protection by means of grout injection presupposes the possibility of intervening anywhere along the cable path in order to adjust the filling and bleed any air, water, etc. that may be within the ducts. In this aim, accessories for re-circulation, venting and bleeding are installed on the ducts. These basically comprise shells or collars fastened onto holes in the ducts and connected to pipes with plugs opening onto an accessible face of the structure. The following options are available: Duct Corrugated steel strip sheath Smooth steel tube VSL PT-PLUS duct Plastic duct Duct connection accessory Sealed plastic shell Welded pipes Special "clipped" collar / coupler Electro-weldable collar or welded pipes Inlet, venting, bleeding or outlet accessory Plastic pipe Steel tube or plastic pipe Plastic pipe Plastic pipe Distributions of inlet, venting, bleeding and outlet points along the cable profile are selected based on a functionspecific study of both the injection pattern and procedure. 2.2.5 CONNECTION WITH TRUMPETS The strands, located within the ducts, must slightly dilate in the vicinity of the anchorages in order to pass through the corresponding holes in the anchor head. This conical deviation is done in a transition zone called a trumpet and is considered part of the anchorage element. The trumpets of a specific anchor plate are of adequate diameters, with enough length and opening at the end that allows for connection and alignment to the duct of the free length. The seal between the duct and trumpet is carried out using an adhesive strip, a thermo-retractable sleeve or a connector designed as a duct accessory (e.g. a VSL PT-PLUS coupler). 2.3 CABLE LAYOUT The cable layout patterns are not inherent to the VSL Multistrand System, but instead depend on the particular project. 2.3.1 STRAIGHT LENGTHS BEHIND THE ANCHORAGES In order for the strands not to display excessive deviation with respect to the anchor head support surface, it is recommended to lay out a rectilinear segment in the back of the anchorage. This straight length in axial alignment varies with the size of the prestressing units. The following has been specified as straight length Lmin which includes both the anchor plate and the trumpet: for Fpk < 2 MN for 2 MN W Fpk W 7 MN for Fpk > 7 MN Lmin = 0.8 m Lmin = 1.0 m Lmin = 1.5 m In the particular case of external PT, refer to chap. 2.3.2 2.3.2 RADIUS OF CURVATURE In order for the ducts and tendons to be easily installed and handled, for the friction loss values to be respected and for the actions upon deviations to be acceptable, it is recommended to limit the radius of cable curvature. Version of 28th July 2011 12 Annex 1 of the European Technical Approval No ETA-06/0006 For internal (concrete) post-tensioning, in the cases of common deviations, VSL recommends verifying that: R Z 100 Øint, where R is the radius of curvature and Øint = internal diameter of the duct. This rule is appropriate for corrugated steel strip sheaths of Category 2 (see Section 2.2.2). When using corrugated steel strip sheaths of Category 1 (Section 2.2.2), the VSL PT-PLUS duct (Section 2.2.3) and smooth steel tube, R Z 3 Fpk , where R is expressed in meters and Fpk expressed in MN. In more unique cases involving the use of smooth steel tubes, the radius of curvature may be significantly reduced: R Z 20 Øint. Under such specific conditions, local concrete strength as well as stresses in strands must be verified. If existing, national provisions may supersede previous recommendations. Tendon sections curved in a U-shape at a tight radius to form an inaccessible end of the tendon named loop anchorage (not considered to be an anchorage in the intent of ETAG 013) respect the following details: - duct in loop is either smooth or corrugated, diameter one size larger than in free length for ease of connection (one fitting into other), - radius of curvature in loop R Z max { 0.6 Fpk ; 0.6 m }, where R is expressed in meters and Fpk expressed in MN, - tendon is stressed simultaneously from both ends, tendon is subject to primarily static load (no significant fatigue load). For external (concrete) post-tensioning, in cases where a high-quality polyethylene tube and thickness adequate for external cable use as defined in Appendix C.2 of the ETAG 013, the following values should be respected. Tendon Unit [-] 6-7 6-12 6-19 6-27 6-37 6-43 6-55 Minimum Radius in deviation zone between straight lengths [m] 2.0 2.5 3.0 3.5 4.0 4.5 5.0 Minimum Radius adjacent to the trumpet in anchorage zone [m] 3.0 3.5 4.0 4.5 5.0 5.5 6.0 While corrugated metal strip sheath can be bent by hand to almost any shape in space, machine-bent smooth steel pipe can only be bent to a constant radius in one plane. The designer should take this into account when specifying the tendon profile. 2.3.3 SPACING OF THE SUPPORTS AND TOLERANCES The support heights underneath the duct are listed on the cable diagrams approximately every meter for a large radius of curvature and every fifty centimeters for a small radius of curvature, in order to allow for duct placement with the required level of precision. Depending on the type of duct and its dimensions, the fastening fittings are sufficiently robust and close enough such that the ducts and tendons will not exhibit displacements or deformations in excess of the allowed tolerances. Recommended spacing of tendon supports is 10 to 12 time duct diameter. The tolerances on cable positions in the concrete elements must respect the prescriptions stipulated in the draft standard "pr ENV 13670-1". Moreover, under all circumstances and in every direction, whenever a cable displays or potentially displays deviation in the vicinity of an edge of concrete which could lead to spalling of concrete cover, an offset with respect to the cable diagram in this direction is only tolerated provided that equilibrium reinforcing bars have been provided over this zone. Version of 28th July 2011 13 Annex 1 of the European Technical Approval No ETA-06/0006 2.3.4 STRAND CUT LENGTH Since the anchorage has been fastened with respect to the structure undergoing post-tensioning, its space consumption is limited to its specific volume. Strand length is strictly the length of the prestressed element between the anchorages increased by the over length crossing the stressing jack(s). These over length have been defined in the drawing for block out dimensions and clearance requirements in Chapter 6. 2.4 INSTALLATION OF DUCTS AND STRANDS Depending on the size and layout of the worksite, the available space on site and the schedule of works, one of the following solutions is to be adopted (for practical purposes and in order to list all installation possibilities, only the case of an internal post-tensioning of a new concrete structure has been highlighted herein): - Cables (both strands and ducts) fabricated in the plant and then delivered as needed at the worksite for installation into the passive reinforcement; - Strand bundles fabricated in a mobile workshop located adjacent to the worksite and then drawn either before or after concreting into the ducts installed in the passive reinforcement; - Tendons composed by pushing through strand by strand before or after concreting into the ducts installed in the passive reinforcement. 2.5 PROVISIONAL PROTECTION AND LUBRICATION The oiling or greasing of strands, exclusively by means of non-dangerous substances, is performed: - in the aim of providing provisional protection against corrosion from the time of leaving the plant until permanent protection has been achieved (grouting of the cable); - in the aim of lubrication since the friction loss of oiled strands in the ducts during stressing is lower. With this same objective, other products serving to reduce friction loss may be used, as long as they are recognized as non-dangerous, can be easily applied and remain inert in the presence of permanent protection (and the eventual bond to the structure),. It is necessary to point out that: "In addition to the specific clauses relating to dangerous substances contained in this European Technical Approval, there may be other requirements applicable to the products falling within its scope (e.g. transposed European legislation and national laws, regulations and administrative provisions). In order to meet the provisions of the EU Construction Products Directive, these requirements need also to be complied with, when and where they apply." 2.6 CACULATION ELEMENTS 2.6.1 FRICTION LOSSES The friction of strands in their ducts, which hinders tendon displacement during stressing, causes a tension loss by friction all along the cable path beginning at the considered live end anchorage. In examining the friction loss formula: f po (x) = f po (0) . e - µ ( + k x ) , which expresses the tension in a cable at the abscissa x as a function of the tension at the considered active anchorage (positioned at x = 0), the sum of the where µ is the friction coefficient (over the curve) between the strands and the duct, angular deviations of the cable over the distance x, and k the unintentional deviation (per unit length) affecting the cable path, it is recommended to adopt the numerical values of µ and k according to EN 1992-1-1. They can be summarized as follows: Application Internal (concrete) cable with corrugated steel strip sheath Internal (concrete) cable with smooth steel tube Internal (concrete) cable with VSL PT-PLUS duct External (concrete) cable with smooth steel tube Version of 28th July 2011 µ (rad-1) (1) 0.17 - 0.19 0.16 - 0.24 0.12 - 0.14 0.16 - 0.24 k (rad/m) (2) 0.005 - 0.010 0.005 - 0.010 0.005 - 0.010 0 14 Annex 1 of the European Technical Approval No ETA-06/0006 External (concrete) cable with plastic duct Internal (concrete) cable with individually greased and sheathed strands External (concrete) cable with individually greased and sheathed strands 0.12 - 0.14 0.05 0.05 0 0.008 0.008 The interval limit values encompass both lubricated and non-lubricated strands. The values of k are zero for cables outside the concrete. 2.6.2 BASIS FOR EVALUATING ELONGATIONS (1) (2) The calculation of elongations for stressing purposes presumes that the tension curve within the strands along the cable just before locking of the anchorage is known, i.e. fpo (x). The measurable elongation upon stressing at the back of the jack for the live end anchorage under consideration, where x = 0, may be written as follows: Elongation of tendon in the stressing jack Elongation of tendon in the prestressed element Concrete Eventual shortening of the displacement of prestressed the dead end of element the tendon where, in the second member, st - for the 1 term: L j : length of the strands in the stressing jack. fpo (x) ~ (1 + ka). fpo,o = constant where fpo,o: stress in the strands upon stressing at x = 0, ka: friction loss in the anchorage, which may be neglected for this purpose; nd - for the 2 term: La: length of the concerned tendon = length from the live end anchorage to the MIN (fpo(x)), i.e. the abscissa of the strands cross-section not moving; rd - for the 3 term: negligible in the majority of cases (except if stresses in the concrete resulting from prestressing are high); th - for the 4 term: in the case where the cable is terminated by a fixed external anchorage whose wedges were manually pre-set (common case), a draw-in g’ of these so-called wedges on the order of 3 mm must be incorporated. In simplifying and defining: fpo,m, the average stress over the concerned strands length, the following is obtained: On the worksite during stressing, elongation due to tendon slack should be eliminated from the reported value with appropriate procedures (e.g. taking into account elongations only once the tendon has been stiffened inside its duct). Note: ka : friction losses in the anchorages are expressed in Section 4.2.1 2.6.3 SETTING OF ANCHORAGE WEDGES A 6-mm draw-in of the wedges is considered; this value remains constant for all units and is applicable to all anchorages and all types of wedges. When an adjustment must be conducted, the insertion of a suitable split shim between the anchor head and its anchor plate makes it possible to compensate for the wedge draw-in up to the shim thickness. In this case, the re-tensioning force must not exceed Pmax, which is the maximum force authorized during unit stressing. If upon initial tensioning Po,o < Pmax, compensation for the wedge draw-in may thus be complete. If however upon initial tensioning Po,o = Pmax, an uncompensated wedge draw-in of 1 to 2 mm must be incorporated. The split shim is made of same material as anchor plate E and that diameter of hole is the same as specified in E or CS plate (depending of which anchor is used). Note: compression fittings are without significant setting. Version of 28th July 2011 Annex 1 of the European Technical Approval No ETA-06/0006 15 CHAPTER 3 ANCHORAGES 3.1 DESCRIPTION OF ANCHORAGE COMPONENTS VSL Multistrand System anchorages make use of a set of standard elements, to be categorized as follows: 3.1.1 LIVE END / DEAD END ANCHORAGES Live end (active) and dead end (passive) anchorages comprise: - Anchor plates and trumpets: Common anchorage plates and duct-transition trumpets exist in accordance with several models: - the "E" model composed of a simple plate made of steel according to Standard EN 10025. The E trumpet is made of steel sheet; - the "CS" model composed of a spheroidal graphite cast iron matrix according to Standard EN 1563, made composite with a very high-strength mortar. The CS trumpet is made of plastic and can be ended by an appropriate ancillary attachment for connection to the VSL PT-PLUS duct. The CS trumpet can also be associated with E anchor plate model. - the "GC" model composed of a lamellar graphite cast iron plate according to Standard EN 1561. For small units (3 to 12) the trumpet is comprised in the casting. For greater units, trumpet is made of plastic. - the “NC” model composed of a spheroidal graphite cast iron body - plate plus trumpet - according to Standard EN 1563. The “NC-U” (1) used with monostrands includes a slightly increased diameter of the transition cone compared to the one of “NC” used for bare strands. (1) u for unbonded. - Anchor heads: The basic anchor heads may be found in two models: - the "E" model, associated with plate E, GC, NC or NC-U, formed from a steel rod according to Standard EN 10083-2. - the "CS" model, associated with plate CS, formed from a steel rod, with quenching and tempering according to Standard EN 10083-1 and then machined or forged to achieve variable thickness. The conical holes are machined on transfer equipment and exhaustively controlled. - Wedges: The wedges are trimmed in alloyed steel for cementation according to Standard EN 10084, then cleaved into parts and finally treated. These elements are available as: the "W6N" or "W6S" model, with two independent parts. The wedges are specified according to two types, adapted to strand diameters, along with the 6N wedges for the 0.6" or T15.2 strands and the 6S wedges for the 0.6"S or T15.7 strands. The S (or super) wedges are differentiated from the N (normal) wedges by the presence on the plane face, which remains apparent, of a grooved trim. These wedges are all submitted to rigorous controls. Both the VSL Multistrand System and VSL Slab System (see Annex 2) wedges are identical. - Protective caps: In order to enable injecting permanent protection and ultimately contributing to protecting the anchorage, three cap models to be used with the plate are available: - the provisional cap designed to contain the injection product for the permanent protection of the zone. Following the curing period, this cap is recycled for reuse; the injection product must be a rigid grout and then the anchorage block-out must be filled with concrete; - the permanent steel cap, containing the anchor head and the protection product, which is left in place after injection; - the permanent plastic cap, containing the anchor head and protection product, which is also to be left in place after injection. This cap has been designed in particular for sealed and electrically isolated cables. Permanent caps are obviously required in all cases calling for the injection of a flexible protection product. Version of 28th July 2011 Annex 1 of the European Technical Approval No ETA-06/0006 16 Provided a few precautions have been taken against corrosion of the metallic parts, the permanent caps may be left apparent; moreover, permanent caps can also be used as temporary caps. 3.1.2 COUPLERS The couplers rely, for the second phase cable (fixed coupler) or both cable (movable coupler), upon reliable anchorage components that are supported on the installed anchor head including connection grooves. This setup consists of compression fittings, composed of a hard steel wire coil wound in a spiral and a fitting sleeve. The coil is assembled on the strand, and then the fitting sleeve is swaged on the assembled unit. 3.1.3 PRESENTATION AND PACKING OF ANCHORAGES Given that strand placement only takes place in a rather generalized manner following concreting, the delivery of anchorages on the worksite entails: (only the most common case of internal (concrete) post-tensioning of a new structure will be highlighted herein) 1. Delivery of the anchor plates along with the ducts for placement within the passive reinforcement, and fastening of the plates to the formwork. These anchorage parts are delivered tagged for identification either on pallets or in bulk. Following concreting and curing: 2. Delivery of the anchor heads and wedges along with the strands to be threaded, installation of the anchor heads, stressing and grouting of the permanent cable protection. These anchorage components are delivered tagged for identification, packaged and protected (the same applies for the strands). 3.2 ORGANIZATION OF SUPPLY QUALITY The fabrication of anchorage components of post-tensioning system and especially those designed for the VSL Multistrand System is conducted in compliance with the specifications, production and control procedures laid out in the present ETA and associated documents. The control procedures in effect for anchorage Component Manufacturers, to the same extent as those adopted by the PT Specialist Company, serve to ensure the traceability of the components all the way through to their delivery on site. It is to be recalled that the basis for evaluating these procedures and the supervision of their application have been defined in Chapter 8 and its Annex E of the ETAG 013. It should also be recalled that prior to installation, the compliance of all delivered components, by means of both identification and visual inspection of their state, must be performed by the PT Supervisor. 3.3 INSTALLATION OF VARIOUS ANCHORAGES The installation of VSL units must be assigned to a competent staff member and involve technical management personnel within the PT Specialist Company or a PT Supervisor certified by this company. Anchorage placement in accordance with model prescriptions is handled as follows (for practical purposes, only the most common case of internal (concrete) post-tensioning of a new structure has been highlighted herein): 3.3.1 TYPE "E", "CS", "GC", "NC" AND "NC-U" ACTIVE END ANCHORAGES The anchor plates and trumpets are fixed to the formwork and connected to the ducts which have been placed at the time of installation of the passive reinforcement; they are thus incorporated into the structure or structural element upon concreting. It should be noted that for the "E" plates, the possibility exists to install them on a previously-completed concrete facing by means of inserting a flexible and durable joint between the plate and concrete or installing them on a metallic surface. On the other hand, the "CS", "GC", "NC" and "NC-U" plates may only be installed into a concrete block cast around the plates. Version of 28th July 2011 Annex 1 of the European Technical Approval No ETA-06/0006 17 The arrangement of injection holes vary according to the anchorage models and structures and can either open onto the front face or may use pipes in order to open onto other faces of the structure. The anchor heads and wedges are positioned immediately before stressing, a step which serves to avoid polluting the parts. Anchorages used with monostrands (individually greased and sheathed) include sealing between anchor head and monostrands to seal the free grouted tendon length at the anchor plate surface and to confine greased protection in the anchorage zone (e.g. with neoprene disk or plastic sleeve). Initially the monostrands are slightly tensioned to remove slack. Then the free length is filled using cementitions grout to fill the interstices between individual strands and between strands and duct. To achieve this, the duct is sealed on both ends at the anchor plates using temporary formworks which maintain the correct strand pattern 2 20/25 N/mm ), the and provide a leak tight seal. Once the grout has attained sufficient strength (f cm(t) monostrands are stressed to final force. Anchorages used with both isolating plates (to be inserted between the head and plate) and isolating plastic caps, enable constituting electrically isolated tendons, such as the CS "SUPER" type units. The "E" anchorages can also be used for electrically isolated tendons when using the CS plastic trumpet and isolating plate. As for force losses in the anchorages during stressing, see Section 4.2.1: "Force Measurements". 3.3.2 TYPE "E", "CS", "GC", "NC" AND "NC-U" PASSIVE END ANCHORAGES The placement of these anchorages is performed as indicated in Section 3.3.1. Once the anchor head has been installed, before stressing at the other end, the wedges are pre-locked using a wedge tool. The anchorage then remains accessible throughout the stressing phase for observation. These anchorages also enable generating electrically isolated tendons. 3.3.3 TYPE "H" BOND ANCHORAGE The load transfer to the structure is based primarily on the bond of dilated strands within the concrete over a straight segment length and the anchorage by an onion (curvature of wires) at the strand end. Upon exiting the duct, the strands are gradually deviated towards two positioning and maintenance grids. The duct end is reinforced with a ring. The entire anchorage assembly is solidly fastened to the passive reinforcement. Following assembly of the injection tube, the sealing between duct end and strands is ensured by means of resin packing at the level of the ring. The proper working of the anchorage necessitates degreasing the strands on the bond length, along with careful concreting over this length using a concrete whose aggregate diameter does not exceed 30 mm. 3.3.4 TYPE "K" FIXED COUPLER When a structure must be built in several phases, especially when setting up the scaffolding and formwork over the entire length of the structure proves impossible, it may be wise to stress and anchor certain cables over a fraction of their length and then extend them through the use of a coupler. Once the structure has been completed, the coupler may or may not be inside the concrete. Installation of the coupler proceeds for the active part as defined in Section 3.3.1 for the "E", "CS" or "GC" type of live end anchorage, with the installed anchor head being the "K" head fitted with grooves for peripheral coupling. For the passive part of the coupling, the installation takes place prior to concreting of the zone; the strands exiting the duct are deviated through a ring towards the "K" head; they are fitted with compression fittings and placed into the designated grooves. A strapping serves to maintain them in position and a trumpet/sleeve (made of either sheet metal or plastic) isolates the coupler from the concrete, thereby making it possible to transmit the prestressing force through the joint. A vent at the apex of the trumpet/sleeve allows for accurate filling during grouting. For the use in electrically isolated tendon, in addition to specific arrangements of Section 3.3.1, the K coupler requires a load distribution plate to be installed between coupling head and isolating plate. Version of 28th July 2011 18 Annex 1 of the European Technical Approval No ETA-06/0006 3.3.5 TYPE "V" MOVABLE COUPLER When a cable must be composed of several lengths, the "K" head defined in Section 3.3.5 is used as movable coupler (of two lengths) in the sleeve. The size of the sleeve is defined to allow free movement of the coupler head during stressing. A vent at the apex of the sleeve allows for accurate filling during grouting. 3.4 ANCHORAGE ARRANGEMENTS According to categories of use, referring to Section 1.4.1, arrangements of anchorage components are described in the following table: internal bonded cable with plastic duct internal unbonded external bonded cable external unbonded cable tendon for various material (ext. cable) restressable tendon exchangeable tendon encapsulated tendon (leak tight) electrically isolated tendon Plate E E E E E E E E E E Head E E E E E E E E E CS Trumpet E E E E E E E E E CS(1) T(2) T(2) PM(3) PM(3) PM(3) PM(3) PM(4) PM(4) PM(3) PP Cap CS GC NC Cryogenic applications internal bonded cable with metal duct E Components Anchorages Uses Plate CS CS CS CS CS CS CS CS CS Head CS CS CS CS CS CS CS CS CS Trumpet CS CS CS CS CS CS CS CS CS(1) PP Cap T(2) T(2) PP(3) PP(3) PP(3) PP(4) PP(4) PP Plate GC GC GC GC GC GC GC GC GC Head E E E E E E E E E Trumpet GC GC GC GC GC GC GC GC GC Cap T(2) T(2) PM(3) PM(3) PM(3) PM(4) PM(4) PM(4) PM(3) Plate NC NC NC NC NC NC NC NC Head E E E E E E E E Cap T(2) T(2) PM(3) PM(3) PM(3) PM(4) PM(4) PM(3) tendon for various material (ext. cable) encapsulated tendon (leak tight) electrically isolated tendon H (5) (5) (5) (5) (5) (5) (5) (5) Coupler Head K K K K K K K K Trumpet Trumpet sleeve V Coupler Head Trumpet sleeve Notes: exchangeable tendon external unbonded cable K restressable tendon external bonded cable H Plate H internal bonded cable with metal duct internal bonded cable with plastic duct internal unbonded Components Anchorages …/… H (5) (5) (5) (5) (5) (5) (5) (5) M(6) M(6) M(6) M(6) M(6) M(6) M(6) P(7) V V V V V V V M(6) M(6) M(6) M(6) M(6) M(6) M(6) 1: plus isolating shim in between head or coupler and plate, 2: T (as temporary) Provisional cap, Permanent (P) cap can be used, 3: Permanent Metallic (PM) or Permanent Plastic (PP) cap, 4: Permanent Metallic (PM) or Permanent Plastic (PP) cap, special cap housing to preserve strand over-lengths should be used, 5: See E, CS or GC anchor plate and trumpet of first-phase cable, 6: Metallic (M) sleeve (cap), Plastic (P) sleeve can be used, 7: Plastic (P) sleeve (cap) Version of 28th July 2011 19 Annex 1 of the European Technical Approval No ETA-06/0006 3.5 GEOMETRICAL AND MECHANICAL USE CONDITIONS For the seating and installation of anchorages, certain construction-related conditions must be verified. 3.5.1 CLEARANCE BEHIND STRESSING ANCHORAGES In order to facilitate jack placement and simplify the stressing procedure, a free space must be allocated behind the anchorage. These dimensions are given in the drawing "Block out dimensions for anchorages, Clearance requirements" in Chapter 6. For the use of destressing equipment or overstressing equipment these dimensions must be increased. 3.5.2 CONCRETE STRENGTH, COVER AND ANCHORAGE SPACING Introducing post-tensioning forces into the structures takes the form, within the anchorage zones, of concentrated forces applied onto the plates. The high stress values encountered underneath the anchor plates necessitate certain construction-related measures. For the concrete structures: - The anchorages must be laid out at a sufficient distance from the nearest edge of the concrete (cover) and respect a spacing between anchorages (centre to centre) that will be specified below. - A local anchorage zone reinforcement must be set up in front of the plates; this local (surrounding anchorage body) zone will be defined in Section 3.6. - The concrete in the vicinity of the plates must be especially homogeneous and display, at the time of stressing, an adequate level of strength. - A general zone (surrounding local zone) must be defined by the project designer and laid out in front of the anchorage plates within the structure, thereby reducing the concentrated forces and distributing them over the concrete cross-section, in compliance with the design rules. As stated above and in considering a maximum prestressing force P(t,x) at the time of stressing (t = 0) (1) at the anchorage , thus called P(0,0) Pmax, for the normal anchor plates and P(0,0) max = Pmax, the following are defined: (1) Force in the cable, at the anchorage on the concrete side, before load transfer to anchorage b’0 b0 b0 and b’0 are the distances between the anchorage axis and the edge of the block tested. The local anchorage zone reinforcement required to prevent bursting and spalling in anchorage zones is determined in relation to a rectangular prism of concrete, known as the primary regularisation prism, located behind each anchorage. The cross section of the prism associated with each anchorage is known as the impact rectangle. The impact rectangle has the same centre and the same axes of symmetry as the anchor plate (which should have two axes of symmetry). The impact rectangle with dimensions X x X’’ has the same area as the block tested A = 4 x b0 b’0 and the same aspect ratio. Xmin,rect = 0.85 x 2 b0 ; X’ min,rect = 0.85 x 2 b’0 Xmin and X’min taking into account dimensions of local anchorage zone reinforcement are given in the tables in Chapter 6, then ) or X’ X’min [1] X Xmin ) and X x X’ = A = 4 x b0 b’0 [2] It should be noted that application of Xmin may require adaptation of the local anchorage zone reinforcement in accordance with the applicable Eurocodes and national regulations, see Chapter 3.6. Version of 28th July 2011 20 Annex 1 of the European Technical Approval No ETA-06/0006 Rules for centre distance and edge distances of anchorages: Impact rectangles associated with anchorages located in the same cross section should not overlap. In addition, they should remain inside the concrete. Taking into account the concrete cover, we obtain the distance to edge in the two directions : and Note: 10 mm is the concrete cover in the tested block (except for H anchorage block using 25 mm). For anchorage spacing, refer to equations [1] and [2] Following table gives an overview of the different anchorages and minimum concrete strengths at time of stressing for which anchorage spacing and local anchorage zone reinforcement is detailed in this ETA, Chapter 6. 2 f cm(t) [N/mm ] at time of stressing Type E CS GC NC / NC-U H 23/28 25/30 28/35 28/35 28/35 32/40 36/45 43/53 32/40 36/45 40/50 53/64 28/35 Anchorage spacing and local anchorage zone reinforcement are given in Chapter 6 (data sheets) fcm(t) given in above table is the minimum concrete strength required at the time of stressing the tendon to the maximum possible stressing force 0.8 x Ap x fpk. On site, the mean strength of concrete prisms / cubes tested shall be equal or more than the specified fcm(t) at the time when stressing is performed. It remains possible however to partially stress the tendon. In the case of tensioning to 50% of the maximum value at the anchorage for example, the strength of concrete f cm(t) may be reduced to approximately 2/3 of the values indicated above for total stressing. From a general standpoint for unique cases (e.g. when using materials other than concrete), the project designer will apply the pertinent Eurocodes with Pdesign 1.1 Fpk to design anchorage and deviation zones (contact may be made with the VSL organization, which will provide the proper advice as regards experimental work and developments). 3.6 LOCAL ANCHORAGE ZONE REINFORCEMENT As mentioned previously, a local anchorage zone reinforcement must be laid out as specified in chapter 6. In 3 accordance with ETAG013 this assumes the presence of additional general reinforcement of 50 kg/m in the structure. For the "E", "CS", "GC", "NC" and "NC-U" type anchorages, this reinforcement is split between a spiral and orthogonal reinforcement (stirrups). The spiral reinforcement defined on the drawings in Chapter 6 displays a large enough pitch of the thread to allow for adequate concreting of the zone. It is recommended to proceed with this layout as stipulated in the approval whenever both the cover and strength conditions have been minimized. As foreseen by this ETA, the local anchorage zone reinforcement specified in this ETA and confirmed in the load transfer tests, may be modified for a specific project design if required in accordance with national regulations and relevant approval of the local authority and of the ETA holder to provide equivalent performance. In the case of grouped anchorages, it is permitted to combine the reinforcement of the individual anchorages. The chosen combination must conserve the dedicated steel cross-sections in all directions. In the case of a unique arrangement in the vicinity of the plates, it is also possible to replace the spiral with a combination of bars that contain equivalent cross-sections in all directions and that are configured at the same depth with respect to the plate. Version of 28th July 2011 Annex 1 of the European Technical Approval No ETA-06/0006 21 In all cases, the local anchorage zone reinforcement must be complemented by a reinforcement in the general anchorage zone for equilibrium designed by the project designer in accordance with typical design rules. Similarly, in all cases, the contractor responsible for concreting must ensure that the density and layout of reinforcement within the anchorage zone allow for adequate and homogeneous concreting of the entire zone. Similar to every other type of anchorage, VSL type H anchorage requires a local anchorage zone reinforcement split between a spiral and orthogonal reinforcement (stirrups). This reinforcement is defined on the drawing in Chapter 6. Version of 28th July 2011 Annex 1 of the European Technical Approval No ETA-06/0006 22 CHAPTER 4 STRESSING 4.1 STRESSING EQUIPMENT The VSL equipment used for cable stressing is composed primarily of stressing jacks, hydraulic power packs (commonly called pumps) and the associated set of measurement instruments or acquisition system. 4.1.1 STRESSING JACKS Tendons are stressed by means of VSL stressing jacks. This equipment consists of double acting jacks with a central hole that enables stressing the cable in one or several stages and then, if need be, to de-stress the cable. Their primary characteristics will be defined below. In sequence starting from the anchorage, these jacks are composed of: - 1 nose (chair ring) at the front resting upon the anchor head, - 1 body or cylinder, including a piston with a central hole, resting upon the chair ring, - 1 battery composed of metallic tubes fastened to the inside of the hole that guide strands behind the jack, and - 1 pulling anchor head behind the piston, with a gripper plate for facilitating the procedure of stressing by stages. The ungripping of the jack anchorage is performed automatically. The drawing in Chapter 6 lists the VSL jacks and indicates the clearances to be introduced around the anchorages and at the ends of the post-tensioned structures in order to facilitate installation. For the purpose of implementing all the particularities and options, the VSL stressing equipment comprises a series of modular and compatible accessories; as such, a broad range of tools for these jacks is available by VSL. Included herein would be the jack chair ring, the over-stress chair ring, the de-stress chair ring, etc. 4.1.2 HYDRAULIC PUMPS The VSL pumps comprise the assembly of hydraulic components including: pumps, distributors, nozzles and safety valves. The pumps are typically driven by electric motors. The pumps themselves have been dimensioned for normal stressing speeds and contain safety measurement devices that depend on the specific application. 4.1.3 MEASUREMENT INSTRUMENTS AND SYSTEMS The VSL force and elongation measurement instruments or systems serve to control with precision the stressing operation and display the set of results obtained. 4.2 PROCESSES OF STRESSING AND CONTROL PROCEDURE Before proceeding with cable stressing, a certain number of preconditions must be met, in particular: - all pertinent safety rules and recommendations must be fully known; - the force targets along with the corresponding values of elongation; moreover, tolerances must be known by the PT Supervisor, who will have applied any eventual necessary adjustments to these values in order to account for parameters specific to the equipment and anchorages; - the procedure to be adopted in the event of a value beyond the tolerance threshold or any other unanticipated incident must be known; - the order in which the post-tensioning cables are to be stressed must be specified; Version of 28th July 2011 Annex 1 of the European Technical Approval No ETA-06/0006 23 - the stressing equipment (including measurement instruments) must comply with guidelines furnished in the present ETA; - the required strength of concrete (or other component material) of both the structure and anchorage zone undergoing stressing must be verified; - the loading and support states of the structure associated with the stressing phase must also be verified; - the over lengths of the strands for stressing must remain perfectly clean. The point should be recalled that during the stressing process, it is strictly forbidden to be positioned behind the jack or within its immediate vicinity. The same precautions must be taken for the area in the back of the deadend external anchorages. One of the VSL system's key characteristics lies in its wedge-locking process. Given that the wedges remain in constant contact with the strands during stressing, the locking operation does not require any accessory device. 4.2.1 FORCE MEASUREMENTS The measurement of force in the cable, as transformed into pressure measurement in the jack, is generally the assigned objective herein. The pressure existing in the jack chamber is indicated by the manometer installed on the pump, with the eventual possibility of exercising controls on the jack. The manometers used (Accuracy 1%), regularly recalibrated using a scale, feature a guaranteed precision of 1% of their maximum pressure, which tends to lie at 600 bars; these instruments thereby provide a precision of 6 bars over the entire manometer scale. In order to obtain the effective force onto the structure, the force resulting from the manometer reading is corrected for losses inside the jack as well as for losses due to friction of the strands in the anchorage. Losses inside the jacks are identified from intrinsic hardware data. Although they contain an independent pressure term and another closely-proportional term, submitted to the maximum pressure reached upon completion of the stressing operation, the losses inside jacks are solely expressed in proportional terms and vary from 1% to 3%. The losses in active anchorages E, CS, NC, NC-U or K, named ka, are due to friction of the strands deviated on the components and, depending on the specific anchorage, vary between 1% and 2%. For the active anchorages type GC they vary from 2 to 3%. 4.2.2 ELONGATION MEASUREMENTS The measurement of cable elongation is generally a control measurement that provides information on cable behavior during stressing. As for elongation measurements, an index is installed on the tendons. During stressing, elongations are then deduced from measurements of the displacement of this index. Since the onset of displacements combines the seating of tendons in their ducts with their actual elongation, the elongation during initial displacements is obtained by means of extrapolating the pure elongations occurring subsequently. The various pressure-elongation relations noted during the cable stressing phases are recorded on the stressing data sheets, which are to remain available. Section 2.6.2 provides a recap of the elongation evaluation basis used during the stressing operation. Version of 28th July 2011 Annex 1 of the European Technical Approval No ETA-06/0006 24 CHAPTER 5 INJECTION AND SEALING 5.1 GENERAL INFORMATION The nature and composition of injection products for the permanent protection of tendons and anchorages and for their eventual bonding to the structure are not inherent to the prestressing process; instead, they depend on the project and the structure's assigned purpose. The products involved must not be a threat to the hygiene, health and the environment. In addition to the specific clauses relating to dangerous substances contained in this European Technical Approval, there may be other requirements applicable to the products falling within its scope (e.g. transposed European legislation and national laws, regulations and administrative provisions). In order to meet the provisions of the EU Construction Products Directive, these requirements need also to be complied with, when and where they apply. 5.2 INJECTION PRODUCTS The products used for the permanent protection of post-tensioning tendons and anchorages implemented by means of injection may be categorized as follows: 5.2.1 PRODUCTS FOR BONDED CABLES When it is sought to bond the tendon to the structure, the products or grouts for bonded injection are with a hydraulic cement base: These products may pertain to common grouts defined in the standard EN 447 or special grouts that make use of performance-enhancing admixtures. In some regions of the EU, unfavorable climatic conditions or other conditions impose the application of special grouts according to ETAG 013. Completion of the tendon envelope at the end of the anchorages may be provided by means of either temporary or permanent grouting caps. The concreting of block out is only strictly necessary when using temporary grouting cap (whether recycled or not). Should the permanent grouting cap be left apparent, the metallic parts must be protected against corrosion, see Section 3.1.1. 5.2.2 PRODUCTS FOR UNBONDED CABLES When it is not sought to bond the tendon to the structure in order, for example, to be able to maintain the tendon accessible, the unbonded injection products are as follows: - with a grease base, as defined in Annex C.4.1 of the ETAG 013, - with a wax base, as defined in Annex C.4.2 of the ETAG 013. In this case, plugging the tendon envelope at the anchorages is still provided by permanent waterproof injection cap. The concreting of the block-out is not strictly necessary here, see above and Section 3.1.1. Those products for bonded or unbonded injection covered by a European Technical Approval may also be employed in accordance with the prescribed set of uses. Version of 28th July 2011 Annex 1 of the European Technical Approval No ETA-06/0006 25 5.3 INJECTION EQUIPMENT The injection equipment has been adapted to the specific products to be injected. For the cement-based grouting, the VSL injection equipment is composed for the most part of mixers and pumps integrated into a single device that enables preparing the grout and performing the injection. This equipment makes it possible to allocate with precision the grout components and to obtain a perfectlyhomogeneous mix. The pump installed in the injection equipment has been designed for continuous injection at a grout progression speed of the same order of magnitude regardless of the units used. For current grouted cable, provisional caps seal the anchorages till setting of grouting. For some applications, vacuum pumps that allow for depressurization inside the ducts have been included, thereby facilitating progression of the grouting. For the unbonded products such as grease or petroleum wax, the VSL injection equipment is composed of melting devices or heaters, stirrers and pumps. Depending on the application, these components are either integrated or separated on the worksite in accordance with implementation specifications. 5.4 INJECTION AND CONTROL PROCEDURE Before proceeding with the injection of permanent cable protection, a certain number of conditions must be fulfilled and in particular: - The injection product must comply with the terms of the present ETA and the ETAG 013; - The injection equipment must comply with indications laid out in the present ETA, - The waterproof sealing of the tendon and anchorage envelopes (ducts, fittings, rods and caps) must be verified, - The climatic conditions and temperature of the structure must satisfy use conditions of the injection product. The primary controls conducted during injection consist of verifying the adequate filling of the duct by means of rods, bleed vents and outlets laid out all along the cable path and verifying that the product discharged by the vents or outlets displays the required properties. Grouting procedures and grouting surveillance shall be carried out according to EN 446. As an initial approach, the injection product quantities per unit cable length will be derived from: [(internal duct section area - tendon section area) × (unit length)] × (1 + ), where is such that: 0.10 in order to consider worksite losses, the shape of the duct and eventual corrugations. 0.20 The various phases and parameters associated with cable injection are to be recorded on the injection data sheets, which are to remain available. 5.5 SEALING The continuity of protection against all types of aggressions must be ensured all along the cable up to and including the anchorages. The protection measures introduced for this unique zone, which is often located at the extremity of the structure and submitted to external aggressions determined during the design phase, must be effective. Refer to the section entitled "Protective Caps" in Section 3.1.1 "Active end / Passive end anchorages" and to the corresponding drawings in Chapter 6. The concreting of block-out in the anchorage zone with surface treatment and eventual reinforcing bars represents the most widespread solution. Moreover, it may be advantageously complemented by a waterproof lining that prevents against all risks of infiltration of fluids that may runoff on the face of the block-out. The permanent metallic caps (if protected by means of galvanization, paint, etc.) or plastic caps may be left apparent. Version of 28th July 2011 26 Annex 1 of the European Technical Approval No ETA-06/0006 CHAPTER 6 SCHEMATIC DRAWINGS (dimensions expressed in mm) Title Page STANDARD ANCHORAGE PARTS : Wedges, Compression fitting Anchor heads Type "E" Anchor heads Type "CS" Protective caps for anchorages 27 28 29 30 ANCHORAGES TYPE "E" Categories of use arrangements Sizes @ 43/53 Sizes @ 36/45 & 32/40 Sizes @ 23/28 & 28/35 31 32 33 34 Local anchorage zone reinforcement @ 43/53 Local anchorage zone reinforcement @ 36/45 Local anchorage zone reinforcement @ 32/40 Local anchorage zone reinforcement @ 28/35 Local anchorage zone reinforcement @ 23/28 35 36 37 38 39 ANCHORAGES TYPE "CS" Categories of use arrangements Sizes Local anchorage zone reinforcement @ 28/35 40 41 42 ANCHORAGES TYPE "GC" Categories of use arrangements Sizes Local anchorage zone reinforcement @ 40/50 Local anchorage zone reinforcement @ 36/45 Local anchorage zone reinforcement @ 32/40 Local anchorage zone reinforcement @ 28/35 Local anchorage zone reinforcement @ 25/30 43 44 45 46 47 48 49 ANCHORAGES TYPE "NC and NC-U" Categories of use arrangements Sizes Local anchorage zone reinforcement @ 53/64 50 51 52 ANCHORAGES TYPE "H" @ 28/35 Sizes and local anchorage zone reinforcement Arrangement and minimum dimensions of concrete sections 53 54 COUPLERS TYPE "K" Categories of use arrangements Sizes 55 56 COUPLERS TYPE "V" Categories of use arrangements - Sizes 57 BLOCK OUT DIMENSIONS - CLEARANCE REQUIREMENTS 58 DUCTING 59 Version of 28th July 2011 Annex 1 of the European Technical Approval No ETA-06/0006 STANDARD ANCHORAGE PARTS WEDGES Wedge W6N Wedge W6S COMPRESSION FITTINGS Fitting Insert CF6 Insert CF6N Assembly th Version of 28 July 2011 27 Annex 1 of the European Technical Approval No ETA-06/0006 28 STANDARD ANCHORAGE PARTS ANCHOR HEADS TYPE E Hole detail Hole spacing E 6-1 E 6-2 E 6-27 E 6-3 E 6-4 E 6-7 E 6-31 E 6-12 E 6-15 E 6-37 Cross section E 6-1 to E 6-55 For sizes ØD and E see ANCHORAGES TYPE E – SIZES th Version of 28 July 2011 E 6-19 E 6-43 E 6-22 E 6-55 Annex 1 of the European Technical Approval No ETA-06/0006 29 STANDARD ANCHORAGE PARTS ANCHOR HEADS TYPE CS Hole detail Hole spacing 6-7 6-12 6-19 6-22 6-27 6-31 STANDARD, PLUS, SUPER & EXTERNAL Optional for STANDARD, PLUS & EXTERNAL 6-7 to 6-37 STANDARD, PLUS & EXTERNAL SUPER For sizes ØD and E see ANCHORAGES TYPE CS – SIZES th Version of 28 July 2011 6-37 Annex 1 of the European Technical Approval No ETA-06/0006 30 STANDARD ANCHORAGE PARTS PROTECTIVE CAPS FOR ANCHORAGES Permanent steel caps for anchorage type GC, E, NC, NC-U Unit D 6-3 6-4 6-7 6-12 6-15 6-19 6-22 6-27 6-31 6-37 6-43 6-55 106 111 118 134 145 155 162 173 183 200 210 225 Unit D 6-7 6-12 6-19 6-22 6-27 6-31 6-37 112 113 114 115 140 150 160 Permanent plastic caps for anchorage type CS th Version of 28 July 2011 Annex 1 of the European Technical Approval No ETA-06/0006 ANCHORAGES TYPE E CATEGORIES OF USE ARRANGEMENTS Anchorage cast in concrete structure Anchorage placed against concrete structure Anchorage inserted in masonry structure Anchorage placed against steel structure Anchorage placed against wood structure th Version of 28 July 2011 31 Annex 1 of the European Technical Approval No ETA-06/0006 32 ANCHORAGES TYPE E @ 43/53 MPa SIZES A ØC ØD E F G ØH ØI (1) K 6-1 6-2 6-3 6-4 6-7 6-12 6-15 6-19 6-22 6-27 6-31 6-37 6-43 6-55 65 95 120 130 160 210 240 270 290 320 340 375 410 450 18 50 56 65 84 118 143 150 172 185 192 215 248 255 53 90 95 110 135 170 190 200 220 240 260 280 300 340 50 50 50 55 60 75 85 95 100 110 120 135 145 160 150 200 205 210 315 495 580 635 740 685 750 895 1020 1030 10 10 15 20 25 35 40 45 50 55 60 65 70 80 25 50 55 60 72 92 97 107 122 132 142 155 165 185 21/25 21/25 21/25 21/25 28/32 28/32 28/32 28/32 28/32 28/32 28/32 28/32 28/32 28/32 78 115 135 150 190 240 275 280 300 330 360 435 490 540 Ø5 Ø5 M12 M12 M12 M16 M16 M16 M16 M16 M16 M16 M20 M20 All dimensions in [mm] (1) J Unit J spacing of holes for fixation to formwork th Version of 28 July 2011 Annex 1 of the European Technical Approval No ETA-06/0006 33 ANCHORAGES TYPE E @ 36/45 AND 32/40MPa SIZES A ØC ØD E F G ØH ØI (1) K 6-1 6-2 6-3 6-4 6-7 6-12 6-15 6-19 6-22 6-27 6-31 6-37 6-43 6-55 70 100 125 145 175 230 265 290 320 350 370 410 450 500 18 50 56 65 84 118 143 150 172 185 192 215 248 255 53 90 95 110 135 170 190 200 220 240 260 280 300 340 50 50 50 55 60 75 85 95 100 110 120 135 145 160 150 200 205 210 315 495 580 635 740 685 750 900 1025 1040 10 10 15 20 25 35 40 45 50 55 60 70 75 90 25 50 55 60 72 92 97 107 122 132 142 155 165 185 21/25 21/25 21/25 21/25 28/32 28/32 28/32 28/32 28/32 28/32 28/32 28/32 28/32 28/32 79 122 135 150 210 265 275 280 300 330 360 435 490 540 Ø5 Ø5 M12 M12 M12 M16 M16 M16 M16 M16 M16 M16 M20 M20 All dimensions in [mm] (1) J Unit J spacing of holes for fixation to formwork th Version of 28 July 2011 Annex 1 of the European Technical Approval No ETA-06/0006 34 ANCHORAGES TYPE E @ 28/35 AND 23/28MPa SIZES A ØC ØD E F G ØH ØI (1) K 6-1 6-2 6-3 6-4 6-7 6-12 6-15 6-19 6-22 6-27 6-31 6-37 6-43 6-55 75 110 135 160 205 270 305 340 370 410 435 480 520 580 18 50 56 65 84 118 143 150 172 185 192 215 248 255 53 90 95 110 135 170 190 200 220 240 260 280 300 340 50 50 50 55 60 75 85 95 100 110 120 135 145 160 150 200 205 210 320 500 585 640 745 690 755 905 1030 1045 10 10 15 20 30 40 45 50 55 60 65 75 80 95 25 50 55 60 72 92 97 107 122 132 142 155 165 185 21/25 21/25 21/25 21/25 28/32 28/32 28/32 28/32 28/32 28/32 28/32 28/32 28/32 28/32 86 136 135 150 210 265 275 280 300 330 360 435 490 540 Ø5 Ø5 M12 M12 M12 M16 M16 M16 M16 M16 M16 M16 M20 M20 All dimensions in [mm] (1) J Unit J spacing of holes for fixation to formwork th Version of 28 July 2011 Annex 1 of the European Technical Approval No ETA-06/0006 35 ANCHORAGES TYPE E @ 43/53 MPa LOCAL ANCHORAGE ZONE REINFORCEMENT 2 Reinforcement for concrete with fcm(t) < 43/53 N/mm at time of stressing SPIRAL REINFORCEMENT Unit ØN 6-1 6-2 6-3 6-4 6-7 6-12 6-15 6-19 6-22 6-27 6-31 6-37 6-43 6-55 10 12 14 16 16 16 16 20 20 20 20 20 25 25 n (1) 5 5 5 5 6 7 7 7 8 8 9 10 9 10 ORTHOGONAL REINF. (2) P ØQ L ØR r 50 50 65 70 55 50 50 60 60 60 60 55 65 65 70 110 135 160 220 260 280 320 350 390 430 480 510 590 150 150 195 210 220 250 250 300 360 360 420 440 455 520 12 16 16 16 20 20 20 20 20 7 7 6 9 8 8 9 10 11 S T 50 50 75 50 65 65 60 60 60 295 330 370 400 445 480 530 560 640 All dimensions- in [mm] Reinforcement steel fyk < 500 N/mm² (1) (2) n Number of turns incl. first and last turn required for anchorage of spiral r Number of reinforcement layers th Version of 28 July 2011 X 95 130 155 180 240 315 350 390 420 465 500 550 585 660 Annex 1 of the European Technical Approval No ETA-06/0006 36 ANCHORAGES TYPE E @ 36/45 MPa LOCAL ANCHORAGE ZONE REINFORCEMENT 2 Reinforcement for concrete with fcm(t) < 36/45 N/mm at time of stressing SPIRAL REINFORCEMENT Unit ØN 6-1 6-2 6-3 6-4 6-7 6-12 6-15 6-19 6-22 6-27 6-31 6-37 6-43 6-55 10 12 12 12 16 16 16 16 16 16 16 20 20 20 n (1) 5 5 5 6 6 7 8 8 10 11 11 11 12 13 ORTHOGONAL REINF. (2) P ØQ L ØR r 65 55 50 45 65 50 50 50 45 45 45 50 50 50 75 115 145 170 195 270 300 345 375 425 460 505 545 625 195 165 150 180 260 250 300 300 360 405 405 450 500 550 12 12 16 16 16 16 16 16 20 20 4 5 6 7 8 10 12 10 10 12 S T 80 70 70 60 55 50 45 60 65 60 230 305 345 390 420 470 505 550 595 675 All dimensions- in [mm] Reinforcement steel fyk < 500 N/mm² (1) (2) n Number of turns incl. first and last turn required for anchorage of spiral r Number of reinforcement layers th Version of 28 July 2011 X 95 135 165 190 250 325 365 410 440 490 525 570 615 695 Annex 1 of the European Technical Approval No ETA-06/0006 37 ANCHORAGES TYPE E @ 32/40 MPa LOCAL ANCHORAGE ZONE REINFORCEMENT 2 Reinforcement for concrete with fcm(t) < 32/40 N/mm at time of stressing SPIRAL REINFORCEMENT Unit ØN 6-1 6-2 6-3 6-4 6-7 6-12 6-15 6-19 6-22 6-27 6-31 6-37 6-43 6-55 10 12 12 12 12 16 16 16 16 16 16 20 20 20 n (1) 5 5 6 6 7 7 8 8 10 11 12 11 13 14 ORTHOGONAL REINF. (2) P ØQ L ØR r 65 60 50 45 45 55 55 55 45 45 45 55 50 50 85 125 155 180 210 290 320 370 400 450 490 540 585 670 195 180 200 180 225 275 330 330 360 405 450 495 550 600 12 12 16 16 16 16 16 16 16 16 5 6 7 8 8 10 12 11 14 18 S T 65 60 60 60 60 50 45 55 45 40 245 325 365 415 445 495 535 585 630 715 All dimensions- in [mm] Reinforcement steel fyk < 500 N/mm² (1) (2) n Number of turns incl. first and last turn required for anchorage of spiral r Number of reinforcement layers th Version of 28 July 2011 X 105 145 175 200 265 345 385 435 465 515 555 605 650 735 Annex 1 of the European Technical Approval No ETA-06/0006 38 ANCHORAGES TYPE E @ 28/35 MPa LOCAL ANCHORAGE ZONE REINFORCEMENT 2 Reinforcement for concrete with fcm(t) < 28/35 N/mm at time of stressing SPIRAL REINFORCEMENT Unit ØN 6-1 6-2 6-3 6-4 6-7 6-12 6-15 6-19 6-22 6-27 6-31 6-37 6-43 6-55 10 12 12 12 12 16 16 16 16 16 16 20 20 20 n (1) 5 5 5 6 6 7 7 8 10 11 11 11 12 14 ORTHOGONAL REINF. (2) P ØQ L ØR r 65 60 55 50 50 65 65 60 50 50 50 60 55 55 90 135 165 195 225 315 345 395 430 485 525 580 630 720 195 180 165 200 200 325 325 360 400 450 450 540 550 660 12 12 16 16 16 16 16 16 16 16 5 6 6 7 7 9 10 9 11 14 S T 75 75 75 75 75 65 60 75 65 55 260 350 390 440 475 530 570 625 675 765 All dimensions in [mm] Reinforcement steel fyk < 500 N/mm² (1) (2) n Number of turns incl. first and last turn required for anchorage of spiral r Number of reinforcement layers th Version of 28 July 2011 X 110 155 185 215 280 370 410 460 495 550 590 645 695 785 Annex 1 of the European Technical Approval No ETA-06/0006 39 ANCHORAGES TYPE E @ 23/28 MPa LOCAL ANCHORAGE ZONE REINFORCEMENT 2 Reinforcement for concrete with fcm(t) < 23/28 N/mm at time of stressing SPIRAL REINFORCEMENT Unit ØN 6-1 6-2 6-3 6-4 6-7 6-12 6-15 6-19 6-22 6-27 6-31 6-37 6-43 6-55 10 12 12 12 12 16 16 16 16 16 16 20 20 20 n (1) 5 5 5 6 6 7 7 9 10 11 12 11 13 14 ORTHOGONAL REINF. (2) P ØQ L ØR r 60 60 55 50 60 65 75 60 60 55 55 65 60 60 100 150 185 220 260 345 390 450 490 545 585 645 705 805 180 180 165 200 240 325 375 420 480 495 550 585 660 720 12 12 16 16 16 16 16 16 16 16 4 7 6 6 7 8 10 9 10 15 S T 75 70 75 90 75 70 60 75 70 55 295 390 435 495 535 595 635 695 750 855 All dimensions in [mm] Reinforcement steel fyk < 500 N/mm² (1) (2) n Number of turns incl. first and last turn required for anchorage of spiral r Number of reinforcement layers th Version of 28 July 2011 X 120 170 205 240 315 410 455 515 555 615 655 715 770 875 Annex 1 of the European Technical Approval No ETA-06/0006 ANCHORAGES TYPE CS CATEGORIES OF USE ARRANGEMENTS Anchorage cast in concrete structure - STANDARD Unit - PLUS Unit (encapsulated) - SUPER Unit (Electrically Isolated Tendon) - External tendon th Version of 28 July 2011 40 Annex 1 of the European Technical Approval No ETA-06/0006 41 ANCHORAGES TYPE CS SIZES (1) Unit ØA B C ØD E F1 6-7 6-12 6-19 6-22 6-27 6-31 6-37 222 258 300 320 360 390 420 136 149 170 180 203 217 236 85 117 148 165 181 188 211 143 178 210 228 256 274 300 50 60 70 70 69 69 82 225 392 540 570 660 620 805 F2 (2) 360 530 660 740 810 740 925 G 60 80 90 100 110 122 130 All dimensions in [mm] (1) for STANDARD for PLUS or SUPER (3) J spacing of holes for fixation to formwork (2) th Version of 28 July 2011 H1 (1) 80 95 110 125 139 149 149 H2 (2) 63 81 106 106 121 136 136 ØJ (3) 188 220 260 274 310 330 357 K M12 M12 M12 M12 M16 M16 M16 Annex 1 of the European Technical Approval No ETA-06/0006 42 ANCHORAGES TYPE CS @ 28/35 MPa LOCAL ANCHORAGE ZONE REINFORCEMENT Reinforcement for concrete with fcm(t) < 28/35 N/mm² when stressing SPIRAL REINFORCEMENT (1) Unit ØN n 6-7 6-12 6-19 6-22 6-27 6-31 6-37 12 16 16 16 16 16 20 6 7 9 10 11 12 11 ORTHOGONAL REINF. (2) P ØQ L ØR r 60 65 60 60 55 55 65 260 345 450 490 545 585 645 240 325 420 480 495 550 585 10 12 16 16 16 16 16 7 9 11 11 11 12 13 S T 50 60 65 75 50 45 50 295 390 495 535 595 635 695 All dimensions in [mm] Reinforcement steel fyk < 500 N/mm². (1) (2) n Number of turns incl. first and last turn required for anchorage of spiral r Number of reinforcement layers th Version of 28 July 2011 X 315 410 515 555 615 655 715 Annex 1 of the European Technical Approval No ETA-06/0006 ANCHORAGES TYPE GC CATEGORIES OF USE ARRANGEMENTS Anchorage cast in concrete structure - STANDARD Unit - PLUS Unit - External Tendon th Version of 28 July 2011 43 Annex 1 of the European Technical Approval No ETA-06/0006 44 ANCHORAGES TYPE GC SIZES Unit 6-3 6-4 6-7 6-12 6-15 6-19 6-22 6-27 6-31 6-37 (1) (2) A 130 140 180 230 260 290 320 350 375 410 B 120 120 135 220 240 150 150 170 170 170 ØC 50 60 76 92 113 131 153 164 173 196 ØD E 95 110 135 170 190 200 220 240 260 280 50 55 60 75 85 95 100 110 120 135 F 120 (2) 120 (2) 135 (2) 220 (2) 240 450 640 620 580 770 J spacing of holes for fixation to formwork These units do not have a trumpet th (2) Version of 28 July 2011 (1) ØH J 50 60 76 92 113 112 112 127 143 142 140 154 210 264 316 354 400 430 470 524 K M12 M12 M12 M16 M16 M16 M16 M16 M16 M16 Annex 1 of the European Technical Approval No ETA-06/0006 45 ANCHORAGES TYPE GC @ 40/50 MPa LOCAL ANCHORAGE ZONE REINFORCEMENT 2 Reinforcement for concrete with fcm(t) < 40/50 N/mm at time of stressing SPIRAL REINFORCEMENT Unit ØN 6-3 6-4 6-7 6-12 6-15 6-19 6-22 6-27 6-31 6-37 12 12 16 16 20 16 20 20 20 20 n (1) 5 6 6 7 7 8 7 8 9 9 ORTHOGONAL REINF. P ØQ L ØR 50 40 60 50 60 50 60 60 60 60 135 160 220 295 330 335 370 400 435 480 150 160 240 250 300 300 300 360 420 420 12 12 16 16 20 r (2) 8 7 6 7 7 S T 50 65 85 75 80 370 400 445 480 530 All dimensions- in [mm] Reinforcement steel fyk < 500 N/mm². (1) (2) n Number of turns incl. first and last turn required for anchorage of spiral r Number of reinforcement layers th Version of 28 July 2011 X 155 180 240 315 350 390 420 465 500 550 Annex 1 of the European Technical Approval No ETA-06/0006 46 ANCHORAGES TYPE GC @ 36/45 MPa LOCAL ANCHORAGE ZONE REINFORCEMENT 2 Reinforcement for concrete with fcm(t) < 36/45 N/mm at time of stressing SPIRAL REINFORCEMENT (1) Unit ØN n 6-3 6-4 6-7 6-12 6-15 6-19 6-22 6-27 6-31 6-37 12 12 16 16 16 16 20 16 16 20 5 6 6 8 8 9 8 11 11 10 ORTHOGONAL REINF. (2) P ØQ L ØR r 55 45 65 50 50 45 60 45 45 55 145 170 230 305 315 355 385 425 460 510 165 180 260 300 300 315 360 405 405 440 10 12 12 16 16 16 6 7 6 8 10 10 S T 65 65 79 60 50 60 345 390 420 465 500 550 All dimensions in [mm] Reinforcement steel fyk < 500 N/mm². (1) (2) n Number of turns incl. first and last turn required for anchorage of spiral r Number of reinforcement layers th Version of 28 July 2011 X 165 190 250 325 365 410 440 485 520 570 Annex 1 of the European Technical Approval No ETA-06/0006 47 ANCHORAGES TYPE GC @ 32/40 MPa LOCAL ANCHORAGE ZONE REINFORCEMENT 2 Reinforcement for concrete with fcm(t) < 32/40 N/mm at time of stressing SPIRAL REINFORCEMENT (1) Unit ØN n 6-3 6-4 6-7 6-12 6-15 6-19 6-22 6-27 6-31 6-37 12 12 12 16 16 16 20 16 16 20 5 6 6 7 8 10 8 11 12 12 ORTHOGONAL REINF. (2) P ØQ L ØR r 55 45 50 55 50 45 60 45 45 50 155 180 215 295 335 375 410 455 490 540 165 180 200 275 300 360 360 405 450 500 10 10 10 12 12 16 16 16 6 5 7 7 6 8 10 8 S T 50 90 65 65 85 65 55 85 245 325 365 410 445 495 530 580 All dimensions in [mm] Reinforcement steel fyk < 500 N/mm². (1) (2) n Number of turns incl. first and last turn required for anchorage of spiral r Number of reinforcement layers th Version of 28 July 2011 X 175 200 265 345 385 430 465 515 550 600 Annex 1 of the European Technical Approval No ETA-06/0006 48 ANCHORAGES TYPE GC @ 28/35 MPa LOCAL ANCHORAGE ZONE REINFORCEMENT 2 Reinforcement for concrete with fcm(t) < 28/35 N/mm at time of stressing SPIRAL REINFORCEMENT (1) Unit ØN n 6-3 6-4 6-7 6-12 6-15 6-19 6-22 6-27 6-31 6-37 10 12 12 16 16 16 20 16 16 20 5 5 6 7 9 9 9 11 13 12 ORTHOGONAL REINF. (2) P ØQ L ØR r 50 60 50 60 50 50 60 50 45 55 140 170 230 320 365 410 445 490 530 585 150 180 200 300 350 350 420 450 495 550 8 8 10 10 8 12 10 16 16 16 4 5 6 6 9 9 7 9 10 9 S T 55 50 50 75 50 55 80 60 60 80 165 195 260 350 390 440 475 530 570 625 All dimensions in [mm] Reinforcement steel fyk < 500 N/mm². (1) (2) n Number of turns incl. first and last turn required for anchorage of spiral r Number of reinforcement layers th Version of 28 July 2011 X 185 215 280 370 410 460 495 550 590 645 Annex 1 of the European Technical Approval No ETA-06/0006 49 ANCHORAGES TYPE GC @ 25/30 MPa LOCAL ANCHORAGE ZONE REINFORCEMENT 2 Reinforcement for concrete with fcm(t) < 25/30 N/mm at time of stressing SPIRAL REINFORCEMENT (1) Unit ØN n 6-3 6-4 6-7 6-12 6-15 6-19 6-22 6-27 6-31 6-37 10 12 12 16 16 16 20 16 16 20 5 5 7 7 9 10 9 12 13 11 ORTHOGONAL REINF. (2) P ØQ L ØR r 50 60 50 60 50 50 60 50 50 60 150 180 250 345 395 445 480 530 570 630 150 180 250 300 350 400 420 500 550 540 8 8 10 10 8 12 10 16 16 16 4 5 6 5 7 7 6 9 11 10 S T 60 50 55 85 70 70 100 65 60 70 180 210 280 380 425 480 515 570 615 670 All dimensions in [mm] Reinforcement steel fyk < 500 N/mm². (1) (2) n Number of turns incl. first and last turn required for anchorage of spiral r Number of reinforcement layers th Version of 28 July 2011 X 200 230 305 400 440 495 535 590 635 690 Annex 1 of the European Technical Approval No ETA-06/0006 ANCHORAGES TYPE NC and NC-U CATEGORIES OF USE ARRANGEMENTS Anchorage cast in concrete structure - NC STANDARD Unit (bonded) - NC PLUS Unit (bonded) - NC-U STANDARD Unit (unbonded) th Version of 28 July 2011 50 Annex 1 of the European Technical Approval No ETA-06/0006 51 ANCHORAGES TYPE NC and NC-U SIZES Unit A B G ØD E ØH J NC NC-U 6-55 6-55 420 420 510 510 520 520 340 340 160 160 183 223 452 452 All dimensions in [mm] (1) (1) Type J spacing of holes for fixation to formwork th Version of 28 July 2011 K M16 M16 Annex 1 of the European Technical Approval No ETA-06/0006 52 ANCHORAGES TYPE NC and NC-U @ 53/64 MPa LOCAL ANCHORAGE ZONE REINFORCEMENT 2 Reinforcement for concrete with fcm(t) < 53/64 N/mm at time of stressing SPIRAL REINFORCEMENT (1) Unit ØN n 6-55 20 11 ORTHOGONAL REINF. (2) P ØQ L ØR r 55 580 495 18 11 S T 80 620 All dimensions in [mm] Reinforcement steel fyk < 500 N/mm². (1) (2) n Number of turns incl. first and last turn required for anchorage of spiral r Number of reinforcement layers th Version of 28 July 2011 X 650 Annex 1 of the European Technical Approval No ETA-06/0006 53 ANCHORAGES TYPE H @ 28/35 MPa SIZES AND LOCAL ANCHORAGE ZONE REINFORCEMENT Reinforcement for concrete with f cm(t) < 28/35 N/mm² when stressing Unit 6-1 6-3 6-4 6-7 6-12 6-15 6-19 6-22 6-27 6-31 6-37 A B (1) Arrangement 1 90 290 390 450 430 450 570 690 690 810 1050 - 90 90 90 90 230 230 230 230 260 260 370 - 1 3 4 4 8 9 10 12 17 14 18 - A B (1) C D D1 ØE ØF ØG ØH 155 1300 1300 1300 1300 1600 1400 1650 1600 1900 1700 2550 2000 950 950 950 1150 200 16 64 70 83 16/20 21/25 28/32 28/32 1150 230 16 114 28/32 1150 1150 1450 1250 1500 1450 1750 1550 2400 1850 300 300 16 16 130 140 28/32 28/32 350 16 146 28/32 350 16 171 28/32 400 20 171 28/32 400 20 178 28/32 Arrangement 2 210 230 390 370 470 490 530 570 690 190 210 330 370 390 470 510 510 510 4 5 12 9 16 20 20 20 24 155 155 155 155 155 165 175 Reinforcement steel fyk < 500 N/mm². (1) Number of strands with length D1 th Version of 28 July 2011 Annex 1 of the European Technical Approval No ETA-06/0006 ANCHORAGES TYPE H ARRANGEMENT AND MINIMUM DIMENSIONS OF CONCRETE SECTIONS th Version of 28 July 2011 54 Annex 1 of the European Technical Approval No ETA-06/0006 COUPLERS TYPE K CATEGORIES OF USE ARRANGEMENTS Coupler type K with anchorage type E Coupler type K with anchorage type CS Coupler type K with anchorage type GC th Version of 28 July 2011 55 Annex 1 of the European Technical Approval No ETA-06/0006 56 COUPLERS TYPE K SIZES Unit ØC ØD B F G ØH E 6-3 6-4 6-7 6-12 6-15 6-19 6-22 6-27 6-31 6-37 76 83 95 121 133 146 159 168 178 203 150 160 190 240 270 280 310 350 360 400 160 160 160 160 160 160 160 180 180 200 430 440 560 660 770 770 910 980 970 1200 200 210 310 400 510 510 610 655 625 830 62 67 77 97 102 112 122 132 142 155 118 118 128 128 128 128 128 150 150 168 All dimensions in [mm] th Version of 28 July 2011 Annex 1 of the European Technical Approval No ETA-06/0006 57 COUPLERS TYPE V CATEGORIES OF USE ARRANGEMENTS SIZES Unit C D 6-3 6-4 6-7 6-12 6-15 6-19 6-22 6-27 6-31 6-37 76 83 95 121 133 146 159 168 178 203 150 160 190 240 270 280 310 350 360 400 B F1 F2 G1 G2 H 210 220 220 220 220 220 220 240 240 260 210 220 320 420 530 530 630 690 660 870 200 210 310 410 520 520 620 670 640 850 60 60 80 80 80 80 120 110 130 130 70 70 90 90 90 90 130 130 150 150 60 65 75 95 100 110 120 130 140 153 All dimensions in [mm] s = coupler movement due to stressing th Version of 28 July 2011 E 118 118 128 128 128 128 128 150 150 168 Annex 1 of the European Technical Approval No ETA-06/0006 58 BLOCK OUT DIMENSIONS CLEARANCE REQUIREMENTS Unit Jack ZPE A B ØC D E ØF G Weight kg 6-1 ZPE-23FJ ZPE-30 135 200 140 40 300 600 90 100 116 140 1200 1350 23 28 6-2 6-3 ZPE-60 ZPE-60 170 195 140 140 60 70 650 650 140 140 180 180 1100 1100 74 74 6-4 ZPE-7A ZPE-12St2 ZPE-200 ZPE-185 220 145 80 305 150 90 650 670 950 620 200 200 210 180 280 310 315 300 1400 1300 2000 1220 115 151 308 280 6-12 ZPE-19 370 155 125 700 250 390 1500 294 6-15 ZPE-460/31 ZPE-500 460 175 150 570 1050 300 330 485 550 1500 2100 435 1064 570 1050 300 330 485 550 1500 2100 435 1064 1150 1050 860 330 330 280 510 550 500 2000 2100 1620 450 435 650 1150 1350 365 365 520 520 2600 2600 1100 1100 1200 1200 1250 950 450 450 375 360 790 790 620 650 2400 2400 2550 1760 2290 2290 1730 1170 1200 450 790 2400 2290 6-7 6-19 6-22 6-27 6-31 6-37 6-43 Notes: ZPE-460/31 ZPE-500 ZPE-500K ZPE-500 ZPE-580 ZPE-750 ZPE-750 ZPE-1000 ZPE-1000 ZPE-1250 ZPE-980 ZPE-1000 ZPE-1250 ZPE-1000 ZPE-1250 ZPE-1450 460 185 160 530 190 175 595 200 195 595 210 200 640 225 225 680 235 250 1250 375 620 2700 1730 1200 450 790 2400 2290 6-55 760 250 260 1250 375 620 2700 1730 1010 420 770 1850 1690 6-55 1000 3500 3500 ZPE-1350 760 250 260 470 840 (2) (2) (2) (1) If a deeper recess > B is required, minimum lateral clearance E applies instead of block out dimension A (2) Dimensions D, G and the weight of stressing jack type ZPE 1350 depend on jack configuration. th Version of 28 July 2011 Annex 1 of the European Technical Approval No ETA-06/0006 59 DUCTING Strand No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 (1) (2) (3) (4) Unit 6-1 6-2 6-3 6-4 6-7 6-12 6-15 6-19 6-22 6-27 6-31 6-37 6-43 6-55 Corrugated Steel Strip Sheath (1) Øint / Øext e 25/30 5 40/45 9 40/45 6 45/50 7 8 50/57 55/62 9 55/62 7 65/72 11 65/72 9 11 70/77 9 70/77 75/82 11 80/87 13 80/87 11 80/87 10 12 85/92 85/92 11 90/97 13 90/97 12 100/107 17 100/107 16 100/107 15 100/107 14 100/107 13 110/117 18 110/117 17 110/117 16 110/117 15 120/127 21 120/127 20 120/127 19 120/127 18 120/127 17 120/127 16 130/137 22 130/137 21 130/137 20 140/147 25 140/147 24 140/147 23 140/147 23 140/147 22 140/147 21 150/157 27 150/157 27 150/157 26 150/157 25 150/157 24 150/157 23 160/167 29 160/167 28 160/167 27 160/167 27 160/167 27 160/167 26 Duct VSL PT-PLUS (2) Øint / Øext e 22/25 4 58/63 58/63 58/63 76/81 76/81 76/81 76/81 76/81 100/106 100/106 100/106 100/106 100/106 100/106 100/106 100/106 100/106 100/106 115/121 115/121 115/121 115/121 115/121 130/136 130/136 130/136 130/136 130/136 130/136 130/136 130/136 130/136 130/136 150/157 150/157 150/157 150/157 150/157 150/157 150/157 150/157 150/157 150/157 150/157 150/157 150/157 150/157 150/157 150/157 150/157 150/157 13 11 9 18 16 15 13 12 25 24 23 22 20 19 18 17 16 15 22 22 21 21 20 27 27 26 25 24 23 22 22 21 20 31 30 9 29 28 27 27 27 26 25 24 23 24 23 22 22 22 21 Smooth Steel Duct (3) Øext x t 25.0 x 2.0 42.4x2.0/2.5/3.0 42.4x2.0/2.5/3.0 48.3x2.0/2.5/3.0 Plastic Duct for Bare Strand (4) Øext x t min 25 x 2.0 40 x 3.0 50 x 3.7 50 x 3.7 Plastic Duct for Sheathed Strand (4) Øext x t min 32 x 2.4 76.1 x2.0/2.5/3.0 75 x 5.6 90 x 5.4 80.0x2.0/2.5 90 x 5.4 110 x 5.3 101.6x3.0/4.0/5.0 110 x 5.3 125 x 6.0 101.6 x3.0/4.0/5.0 110 x 5.3 50 x 3.7 75 x 5.6 140 x 6.7 114.3 x3.0/4.0/5.0 125 x 6.0 114.3 x3.0/4.0/5.0 125 x 6.0 160 x 7.7 127.0 x3.0/4.0/5.0 140 x 6.7 160 x 7.7 139.7 x3.0/4.0 140 x 6.7 180 x 8.6 152.4 x3.0/4.0/5.0 160 x 7.7 200 x 9.6 168.3 x3.0/4.0 180 x 8.6 225 x 10.8 Exterior Ø of corrugations. Use next larger duct for strong deviation and long cables. The corrugated steel strip sheaths of diameters larger than 130mm follow the design of EN 523 with the same thickness. Exterior Ø of duct. According to standard EN 10255, EN 10216-1, EN 10217-1, EN 10219-2 and EN 10305-3. Recommended values. Dimensions might vary depending on project requirements. According to standard EN 12201, material PE 80. Recommended values. Dimensions might vary depending on project requirements. th Version of 28 July 2011 Annex 2 TECHNICAL DATA OF THE VSL SLAB SYSTEM 2 Annex 2 of the European Technical Approval No ETA-06/0006 TABLE OF CONTENTS Title Page 1. DEFINITION OF THE SYSTEM 1.1 PRINCIPLE OF THE VSL SLAB SYSTEM 1.2 CHARACTERISTICS OF SYSTEM UNITS 1.3 ANCHORAGES 1.3.1 PRESENTATION OF THE ANCHORAGES 1.3.2 LIST OF APPROVED ANCHORAGES 1.4 CATEGORIES OF USE, OPTIONS AND POSSIBILITIES 1.4.1 USES AND OPTIONS OF VSL SLAB SYSTEM UNITS 1.4.2 POSSIBILITIES OF THE VSL SLAB SYSTEM 2. STRANDS AND DUCTS 2.1 STRANDS USED 2.2 REQUIREMENTS OF THE UNBONDED SYSTEM 2.3 DUCTS USED FOR THE BONDED SYSTEM 2.3.1 TYPES AND DIMENSIONS OF USABLE DUCTS 2.3.2 METAL DUCTS 2.3.3 PLASTIC DUCTS 2.3.4 ACCESSORIES FOR INLETS, BLEED VENTS AND OUTLETS 2.3.5 CONNECTION WITH SLEEVES 2.4 CABLE LAYOUT 2.4.1 STRAIGHT LENGTHS BEHIND THE ANCHORAGES 2.4.2 RADIUS OF CURVATURE 2.4.3 SPACING OF THE SUPPORTS AND TOLERANCES 2.4.4 STRAND CUT LENGTH 2.5 INSTALLATION OF DUCTS AND TENDONS 2.6 PROVISIONAL PROTECTION AND LUBRICATION 2.7 CALCULATION ELEMENTS 2.7.1 FRICTION LOSSES 2.7.2 BASIS FOR EVALUATING ELONGATIONS 2.7.3 ACTIVE ANCHORAGE SETTINGS 3. ANCHORAGES 3.1 DESCRIPTION OF ANCHORAGE COMPONENTS 3.1.1 LIVE-END / DEAD-END ANCHORAGES 3.1.2 PRESENTATION AND PACKING OF ANCHORAGES 3.2 ORGANIZATION OF SUPPLY QUALITY 3.3 INSTALLATION OF VARIOUS ANCHORAGES 3.3.1 TYPE "S 6-1", "S 6-1 PLUS" AND "S 6-4" ACTIVE END ANCHORAGES 3.3.2 TYPE "S 6-1", "S 6-1 PLUS" AND "S 6-4" PASSIVE END ANCHORAGES 3.3.3 TYPE "SF 6-1" AND "SF 6-1 PLUS" EMBEDDED DEAD END ANCHORAGES 3.3.4 TYPE "H 6-(1 through 4)" BONDED ANCHORAGES 3.4 ANCHORAGE ARRANGEMENTS 3.5 GEOMETRICAL AND MECHANICAL USE CONDITIONS 3.5.1 CLEARENCE BEHIND ANCHORAGES 3.5.2 CONCRETE COVER AND ANCHORAGE SPACING 3.6 LOCAL ANCHORAGE ZONE REINFORCEMENT 4. STRESSING 4.1 STRESSING EQUIPMENT 4.1.1 STRESSING JACKS 4.1.2 HYDRAULIC PUMPS 4.1.3 INSTRUMENTS AND MEASURING SYSTEMS Version of 28th July 2011 4 5 5 6 8 8 8 10 11 11 12 13 14 14 15 15 17 18 3 Annex 2 of the European Technical Approval No ETA-06/0006 4.2 PROCESSES OF STRESSING AND CONTROL PROCEDURE 4.2.1 FORCE MEASUREMENTS 4.2.2 ELONGATION MEASUREMENTS 5. INJECTION AND SEALING 5.1 INJECTION 5.1.1 UNBONDED SYSTEM 5.1.2 BONDED SYSTEM 5.2 SEALING 19 20 21 6. SCHEMATIC DRAWINGS 22 Version of 28th July 2011 Annex 2 of the European Technical Approval No ETA-06/0006 1. 4 CHAPTER 1 SYSTEM DEFINITION DEFINITION OF THE SYSTEM 1.1 PRINCIPLE OF THE VSL SLAB SYSTEM The cable or unit of the VSL Slab System is composed of one or several strands made of high-strength steel called a "tendon", along with the associated set of anchorages. In this system, the cable may be not only the unit itself, but also the assembly of several closely spaced parallel units (in general of just one strand). This System has considered two subsystems (to be called systems in the following discussion for the sake of simplicity), i.e.: - "unbonded", using individually greased and plastic sheathed monostrands placed directly in the concrete. The unbonded protection of the tendons serves to make them independent of the structure. Only greased sheathed monostrands will be considered in the ensuing discussion, see Section 2.1; - "bonded", a grouting type of PT that uses bare strands. In this case, the strands are located within a duct that constitutes a cylindrical or flat conduit. The void thus created is then filled with grout according to EN 447 or Annex C4 of ETAG 013 for the purpose of bonding with the structure and inhibiting corrosion. The constituting strands are those defined in the European Standard White Draft pr EN 10138-3: "Prestressing 2 steels - Strand". They refer to 7-wire strands with nominal diameters of 15.2 and 15.7 mm (fpk = 1 860 N/mm 2 or fpk = 1 770 N/mm ), which are identical to those used with the VSL Multistrand system. As long as EN 10138 does not exist, 7-wire strands in accordance with national provisions shall be used. By varying both the strand diameter and number (and, if applicable, their specified characteristic value of maximum force), it would be possible to obtain a value for the characteristic tensile strength per cable or per unit that varies between 260 and 1 116 kN. Each strand, of a cable or unit, is individually stressed and becomes locked within a conical anchoring hole by means of wedges. The anchorage function is performed by clamping during strand moving back at the time of pressure release in the jack. The choice of post-tensioning units, as dictated by force requirements, leads for a given strand diameter and characteristic strength to a specific number of strands to be laid out in accordance with a recommended spacing plan. In conjunction with this design element, the choice of type of anchorage associated with the cable depends on the intended function and application of the particular unit. The system is limited to units of 1 and 4 strands since these units prove appropriate for common slabs and plates. The designation of post-tensioning units is expressed with reference to both the type and number of component strands. The VSL commercial labeling is explained below: The labeling of units 6-1… 6-4 or 6S-1… 6S-4 signifies: the first digit indicates strand diameter, 6 = 6 × 1/10" = T15.2 15.2 mm 6S = 6 × 1/10" S = T15.7 15.7 mm (S stands for super). the subsequent digits indicate the number of strands composing the unit. To provide greater detail, the designation of units begins with the names of the anchorages placed at the ends. The following designation serves as an example: Cable VSL S-S 6S-4 L = 50.000 (2) Cable VSL 4(S-S 6S-1) L = 50.000 (2) [cable composed of 4 individual but parallel and closely spaced monostrand units] The functions and names of the anchorages will be defined hereafter. The cables feature a length of 50.000 m and have been stressed at both (2) ends. The VSL Slab System contains 1 and 4 strand units. The intermediately-dimensioned cables of 2 and 3 strands are composed preferentially by means of parallel arrangement of several monostrand units. The prestressing force applied may naturally be fine-tuned to meet the required prestressing force level by adjusting the appropriate spacing between units. Version of 28th July 2011 5 Annex 2 of the European Technical Approval No ETA-06/0006 1.2 CHARACTERISTICS OF SYSTEM UNITS On the basis of the strand characteristics defined in draft Standard "pr EN 10138-3: Prestressing steels - Part 3: Strand", the values of tendon cross-sections Ap, maximum forces under anchorage upon tensioning recom2 mended by EC2 : Pmax = min {k1.Ap.fpk; k2.Ap.fp0.1k}, with k1 = 0.8, k2 = 0.9, fpk = 1 860 N/mm , fp0.1k = 0.88 fpk, of VSL post-tensioning units are as follows : STRAND STRAND 15.2 - T15.2 or 6 2 fpk = 1 860 N/mm Fpk = 260 kN Fp0.1k = 229 kN 15.7 - T15.7 or 6S 2 fpk = 1 860 N/mm Fpk = 279 kN Fp0.1k = 246 kN Number of strands in the prestressing unit Ap Ap.fpk 0.8 Ap.fpk Ap.fp0.1k 0.9 Ap.fp0.1k Ap Ap.fpk 0.8 Ap.fpk Ap.fp0.1k 0.9 Ap.fp0.1k 1 2 3 4 mm² 140 280 420 560 kN 260.0 520.0 780.0 1 040.0 kN 208.0 416.0 624.0 832.0 kN 229.0 458.0 687.0 916.0 kN 206.1 412.2 618.3 824.4 mm² 150 300 450 600 kN 279.0 558.0 837.0 1 116.0 kN 223.2 446.4 669.6 892.8 kN 246.0 492.0 738.0 984.0 kN 221.4 442.8 664.2 885.6 Note : prestressing force applied to structure must be in accordance with national regulations The system can obviously be used with strands displaying a specific characteristic tensile strength of less than 2 that proposed in the table as strands with fpk = 1 770 N/mm . The provisions for tendons with strands with a 2 2 characteristic tensile strength fpk = 1 860 N/mm also apply to tendons with strands with fpk < 1 860 N/mm . The draft Standard pr EN 10138-3 sets the following criteria for the other useful characteristics of prestressing strands composing the VSL units: - Elongation at maximal force: 3.5% 2.5% - Relaxation at 0.70 fpk after 1,000 hours: 4.5% - Relaxation at 0.80 fpk after 1,000 hours: 2 6 2x10 cycles - Fatigue behaviour (0.70 fpk; 190 N/mm ): - Maximum D value of deflected tensile test: 28% 2 195 000 N/mm - Modulus of elasticity Ep: The strands are stressed individually, the modulus of elasticity of the strand measured and communicated at the time of its supply is to be taken into account for the cable elongation calculations. Individually greased and sheathed monostrands have the same mechanical properties as listed above for bare strands. 1.3 ANCHORAGES 1.3.1 PRESENTATION OF THE ANCHORAGES The VSL Slab System anchorages are all (with the exception of the type "H" bonded anchorages) available for the two systems of unbonded or bonded tendons. Depending on their function and commercial labeling, the anchorages may be classified as follows: Type "S 6-1", "S 6-1 PLUS" and "S 6-4" active end anchorages These active anchorages have been designed to anchor tendons at the end at which the stressing will be performed strand by strand. They are composed of a single-block anchorage casing drilled with conically-shaped holes (1 or 4) in which the strands are anchored by means of locking through the use of wedges. These anchorages exist in both the unbonded and bonded systems. The continuity of protection and the waterproof sealing between the duct and the anchorage casing are provided by means of a plastic sleeve. In the case of S 6-1 PLUS, a plastic coat covers the external faces of the anchorage casing in continuity of the plastic sleeve. In the unbonded case, a cap is required to close the housing of the wedges after filling with a protective product (identical or compatible with that of the greased and sheathed single strands) by injection. The "S 6-1" and the "S 6-1 PLUS" anchorages can be used as an intermediate anchorage at a construction joint with the strand being continuous through the anchorage and over the entire tendon length to the end anchorage. The tendon is first stressed at the intermediate anchorage at the construction joint. When the entire Version of 28th July 2011 6 Annex 2 of the European Technical Approval No ETA-06/0006 slab is built, the tendon is stressed at the end anchorage and the intermediate anchorage becomes obsolete but remains in place. The remaining wedge bites on the free length are acceptable. Overlapping wedge bites on the strand and angular deviation of the strand before or behind the intermediate anchorage shall however be avoided. Type "S 6-1", "S 6-1 PLUS" and "S 6-4" passive end anchorages These passive anchorages ensure the locking of tendons at the end on which no stressing force is being exerted by means of the jack. These anchorages apply to both the unbonded and bonded systems. This category only includes those anchorages that remain accessible at the time of stressing. The type "S 6-1" or "S 6-1 PLUS" anchorages, whose wedges have been pre-locked and which may be controlled during stressing are used for the given function. The protection of these dead end anchorages is identical to that of the live end anchorages. Type "SF 6-1" and "SF 6-1 PLUS" embedded dead end anchorages These fixed anchorages are incorporated into the concrete of the structure. Only considered as embedded anchorages are those that make use of a direct transfer on the concrete in order to lock the tendon ends. In both the unbonded and bonded systems, the type SF 6-1 or SF 6-1 PLUS anchorages, which have been assembled onto the tendons prior to their installation, are used for the given function. Their wedges are locked into the anchorage bodies S 6-1 or S 6-1 PLUS and maintained using a series of washers and springs supported on the caps screwed at the end, a set-up that provides mechanical protection against any slipping movement. The SF 6-1 and SF 6-1 PLUS anchorages receive the same protection as the live end anchorages. Type "H 6- (1 through 4)" bonded anchorages These fixed anchorages rely, at least in part, on bonding in order to maintain the tendon end fastened with respect to the concrete. They are strictly the same as those of the VSL Multistrand System, which has been detailed in Annex 1. These anchorages may only be used for the bonded system. 1.3.2 LIST OF APPROVED ANCHORAGES The set of approved anchorages that allow creating all of the intermediate prestressing units have been categorized in the following table: System unbonded bonded ANCHORAGE CABLE Function Unit label 1T15.2 / 1T15.7 6-1 / 6S-1 4T15.2 / 4T15.7 6-4 / 6S-4 Unit label 1T15.2 / 1T15.7 6-1 / 6S-1 4T15.2 / 4T15.7 6-4 / 6S-4 Active end Passive end Embedded dead end S S PLUS S S PLUS S S PLUS Si Si PLUS Si Si PLUS Si Si PLUS Bonded H The stressing of tendons anchorages is only conducted by VSL stressing jacks, which are presented in Chap. 4. 1.4 CATEGORIES OF USE, OPTIONS AND POSSIBILITIES 1.4.1 USES AND OPTIONS OF VSL SLAB SYSTEM UNITS The VSL Slab System units are entirely internal to the concrete; they may be: - either unbonded, i.e. with individually greased and sheathed monostrands, unbonded to the structure, - or bonded, i.e. with "bare" strands placed inside a duct and with permanent grouting, providing bonding to the structure. These units may also be: - replaceable provided the absence of bonding with the structure, - designed to be encapsulated and perfectly waterproof, - designed to be electrically-isolated. Version of 28th July 2011 7 H 6-1 & 6-4 Si 6-4 S 6-4 SFi 6-1 PLUS SFi 6-1 Si 6-1 PLUS Si 6-1 SF 6-1 PLUS SF 6-1 S 6-1 PLUS Anchorages Uses S 6-1 Annex 2 of the European Technical Approval No ETA-06/0006 internal* bonded cable with metallic duct internal* bonded cable with plastic duct internal* unbonded external* bonded cable external* unbonded cable tendon for use in various material as external cable (1) restressable tendon exchangeable tendon (2) encapsulated tendon (leak tight) electrically isolated tendon (*) of concrete (1) the anchorage must be embedded in concrete block. (2) the designer must check feasibility regarding geometrical tendon layout. It goes without saying that the solutions and options implemented presume the availability of adequate choices and combinations of all unit or cable components, as indicated in this ETA: - for strands see Chapter 2.1 "Strands used", - for ducts see Chapters 2.2 "Requirements of the unbonded system" and 2.3 "Ducts used for bonded system", - for anchorages see Chapter 3.4 "Anchorage arrangements", - for injection see Chapter 5.1 "Injection". 1.4.2 POSSIBILITIES OF THE VSL SLAB SYSTEM The VSL Slab System is able to take advantage of the following unique set of possibilities: - Partial stressing or stressing in stages: When prestressing needs to be applied gradually, the stressing may be performed in stages. With the first partial stressing step being carried out at the beginning of the second stage, the wedges are unclamped by action of the jack on the strand. Once the targeted force has been reached, pressure in the jack is relaxed and the wedges are once again locked inside the anchorage. This procedure consists of the same steps as for stressing a long cable strand whose elongation necessitates several successive jack strokes. Since the strands have been stressed individually, the procedure may also entail the total stressing of a fraction of the strands. - Destressing procedure: The destressing of a strand(s) anchored by a type "S 6-1", "S 6-1 PLUS" or "S 6-4" anchorage is possible using a special tooling assembly mounted on the stressing jack provided that the required strand over lengths have been conserved and that the strands remain independent of the structure (unbonded). From the aforementioned, two zones appear to stand out, the free length and the anchorage zone; they will be presented in greater detail in the following chapters entitled "Strands and ducts" and "Anchorages". Version of 28th July 2011 8 Annex 2 of the European Technical Approval No ETA-06/0006 CHAPTER 2 STRANDS DUCTS 2. TENDONSAND AND DUCTS 2.1 STRANDS USED The high-strength prestressing steel (strands) composing the tendons are labeled "Y1860S7 – No. 1.1366" and are defined in the draft Standard "pr EN 10138-3: Prestressing steels – Part 3: Strand". On an occasional basis, the strands labeled "Y1770S7 – No. 1.1365" may also be employed. The primary characteristics have been recalled in Section 1.2. As regards monostrands (individually greased and sheathed) that are used in the unbonded system, they are compliant with Annex C.1 of the ETAG 013, which specifies the requirements, verification methods and acceptance criteria of both the grease and the sheathing. 2.2 REQUIREMENTS OF THE UNBONDED SYSTEM While it is obvious that the individually greased and sheathed monostrand do not necessitate any duct, the cables composed by several parallel monostrands however require assembly by means of regularly-spaced spacers ensuring their respective positions / linear lay out within the group. The connection of the monostrand sheathing with the anchorage is conducted by means of inserting the strands in a sleeve with one inlet for the "S 6-1" and "S 6-1 PLUS" anchorage or a sleeve with 4 inlets for the "S 6-4" anchorage. These connections are made of plastic and provide for a watertight seal with the sheathing. 2.3 DUCTS USED FOR THE BONDED SYSTEM The VSL Slab System can use several types of duct as provided in this section. Duct type selection depends on the specific project, the final use designed for the structure and the options selected for the post-tensioning units. Although the VSL Slab System authorizes the use of cylindrical ducts, the applications targeted with the slabs and plates increasingly rely upon the flat ducts presented below. For cylindrical ducts, for S6-1 / S6-1 Plus the interested reader is advised to consult Annex 1 of this ETA. 2.3.1 TYPES AND DIMENSIONS OF USABLE DUCTS Depending on the specific application, various types of ducts may be employed. From a general standpoint, the ducts used must be mechanically resistant, display continuity in shape, ensure continuity of the seal over their entire length and comply with the project's bond requirements, while not causing any chemical attack. Without claiming to be exhaustive, the frequently-used ducts of the following table have demonstrated their capacities in the uses and applications cited: Ducts Applications Cable inside the concrete with bonded injection Metal duct Corrugated steel strip flat sheath Plastic duct VSL PT-PLUS ~ standard encapsulated electrically isolated Note: ª) This set-up features a fully-bonded cable. : Advised ~ : Possible NA: not allowed NA ª NA ª Version of 28th July 2011 9 Annex 2 of the European Technical Approval No ETA-06/0006 The VSL Slab System's prestressing tendon ducts, with either a cylindrical cross-section or oblong, must display internal dimensions large enough to provide for easy tendon installation and adequate filling during grouting of the protective product. The small internal dimension of the oblong section is considerably less than two strand diameters in order to ensure that they remain juxtaposed side by side, in the same position all along the tendon. The most common duct sizes are listed on drawing "Ducting" of Chapter 6. 2.3.2 METAL DUCTS Tendons are most often isolated from the concrete by means of corrugated steel strip cylindrical or flat sheaths. Although not covered in Standard EN 523, these flat sheaths due to their shapes and dimensions may be qualified as normal (Category 1). Their characteristics are nearly the same as those of the cylindrical sleeve stipulated in the standard. Connections between coils or straight segments are performed by means of a coupler on the two extremities to be connected. The waterproof sealing at the joints is provided by either an adhesive ribbon or thermoretractable sleeves. 2.3.3 PLASTIC DUCTS In the case of stringent requirements as regards to both corrosion protection and fatigue resistance of cables, it is recommended to use the corrugated plastic VSL PT-PLUS flat or cylindrical duct; this material generates perfect bonding between the tendons and the structure (6-1 round / 6-4 flat see chapter 6). It is the preferred choice for tendons submitted to a particularly-aggressive environment or strong fatigue loads. The fittings between ducts segments are introduced by means of connectors that serve to generate a waterproof sealing. The VSL PT-PLUS duct complies with ETAG 013. The VSL PT-PLUS duct with its set of appropriate fittings is also employed in the case of fully-encapsulated (waterproof) and or electrically isolated cables. This application necessitates the presence of rigid half-shells between the duct and its supports at all the high points along the cable path in order to avoid any risk of perforation during stressing of the tendon. For design considerations in accordance with EN-1992 where the relative bond properties between reinforcing steel and post-tensioning tendons are relevant it may be assumed that tendons in PT-PLUS plastic ducts have a 50% longer bond length than tendons in corrugated metal ducts. 2.3.4 ACCESSORIES FOR INLETS, BLEED VENTS AND OUTLET Providing permanent protection by means of grout injection presupposes the possibility of intervening anywhere along the cable path in order to adjust the filling and bleed any air, water, etc. that may be within the ducts. In this aim, accessories for inlets, venting and outlets are installed on the ducts. These basically comprise shells or collars fastened onto holes in the ducts and then connected to pipes with plugs opening onto the slab surface or subsurface. Duct Duct connection accessory Inlet, venting, bleeding or outlet accessory Corrugated steel strip sheath Sealed plastic shell Plastic pipe VSL PT-PLUS duct Special "clipped" collar Plastic pipe The distributions of inlet, venting, bleeding and outlet points along the cable profile are selected based on a function-specific study of the cable path. 2.3.5 CONNECTION WITH SLEEVES The strands, placed within their ducts, must slightly dilate in the vicinity of the "S 6-4" anchorages in order to pass through the corresponding holes in the anchorage body. This "variable oblong"-shaped duct expansion is called a trumpet and is considered part of the anchorage element. The trumpets are fastened to the formwork of appropriate dimensions, with enough length and opening at the end to allow for connection and alignment of the duct of the current zone. Version of 28th July 2011 Annex 2 of the European Technical Approval No ETA-06/0006 10 The sealing between the ends of duct and trumpet is carried out using an adhesive strip, a thermo-retractable sleeve, or a connector designed as a duct accessory (e.g. a VSL PT-PLUS coupler). 2.4 CABLE LAYOUT The cable layout patterns are not inherent to the VSL Slab System, but instead depend on the particular project. 2.4.1 STRAIGHT LENGTHS BEHIND THE ANCHORAGES In order for the strands not to display excessive deviation with respect to the anchorage support surface, it is recommended to lay out a rectilinear segment in the back of the anchorage. In both systems (unbonded and bonded), whether the systems include an individual sleeve and a shared sleeve, their trumpet length is sufficient as straight length needed behind the anchorage. 2.4.2 RADIUS OF CURVATURE - unbonded system: The individually greased and sheathed monostrands typically laid out either isolated or flat juxtaposed must satisfy the minimum radius of curvature rmin : deviation : rmin S 2.50 m, loop anchorage: rmin S 0.60 m, the term loop anchorage indicates a zone with strong curvature over which the total deviation is nearly T radians and which is located at approximately mid-length of the cable, with simultaneous stressing at both ends. In the case of an anchorage with several strands, the strands are to be laid out such that the radial force due to deviation of one strand does not harm the adjacent strand. - bonded system: The corrugated steel strip flat sheath is bent by respecting a minimum radius of curvature rmin. With the sheath laid out flat (see drawing "Ducting" of Chapter 6), the following dimensions are respected: plane: rmin S 6.00 m, tendon curvature in one direction only elevation: rmin S 2.50 m. The VSL PT-PLUS flat duct is bent by respecting a minimum radius of curvature rmin. With the duct laid out flat, the following dimensions are respected: plane: rmin S 6.00 m, tendon curvature in one direction only elevation: rmin S 2.50 m. ® VSL PT-PLUS round duct 22/25 rminS 2.50 m 2.4.3 SPACING OF THE SUPPORTS AND TOLERANCES The support heights underneath the cables or ducts are listed on the cable diagrams approximately every meter for a large radius of curvature and every fifty centimeters for a small radius of curvature, in order to allow for cable (or duct) placement with the required level of precision. The cable (or duct) supports are laid out as stipulated in the design that also establishes the order in which the cables (or ducts) are to be installed to ensure installation without "intertwining" in the case of slabs with tendons in both directions. The fastening fittings are sufficiently robust and close enough such that the cables (or ducts) will not exhibit displacements or deformations in excess of the allowed tolerances. The tolerances on cable positions in the concrete elements must respect the prescriptions stipulated in standard "ENV 13670-1". Moreover, in every direction, whenever a cable displays or potentially displays deviation in the vicinity of an edge of concrete which could lead to spalling of the concrete cover, an offset with respect to the cable diagram in this direction is only tolerated provided that equilibrium reinforcing bars are provided over this zone. Special attention must be paid to outward pressure due to structural singularities, such as floor openings. The VSL Slab System authorizes the cable installation technique according to the so-called "free path" or "Freie Spanngliedlage" method defined here after. - In slabs with a thickness of not more than 450 mm the tendons can be placed with the method of “Freie Spanngliedlage”. Version of 28th July 2011 Annex 2 of the European Technical Approval No ETA-06/0006 11 - Tendons placed with the method of “Freie Spanngliedlage” need only a limited number of tendon supports, in general at the low and high points of the tendon profile, however, with limitations on the spacing as stated below. - The maximum spacing of tendon supports is: - 1.5 m between the tendon fixation to the top layers of reinforcement and an adjacent anchorage, - 3.0 m between the tendon fixation to the bottom layers of reinforcement and an adjacent anchorage or the tendon fixation to the top layer of reinforcement. - At the low points and high points of the tendon profile, the tendons have to be fixed to the top and bottom layers of reinforcement, respectively, on least two locations which have a distance of between 0.3 to 1.0 m. The fixation shall ensure a tight fit without damaging the tendon sheathing. The reinforcement layers have to be fixed in accordance with the relevant standards. 2.4.4 STRAND CUT LENGTH Since the anchorage has been fastened with respect to the part undergoing post-tensioning, its space consumption is limited to its specific volume. Strand length is strictly the length of the prestressed element between the anchorages increased by the over length crossing the stressing jack(s). These over length have been defined in the drawing "Clearance requirements" of Chapter 6. 2.5 INSTALLATION OF DUCTS AND STRANDS Depending on the size and layout of the worksite, the available space on site and the schedule of works, one of the following solutions is to be adopted: - unbonded system: - cables fabricated in the plant and then delivered as needed to the worksite for installation into the passive reinforcement; - cables fabricated in a mobile workshop on the worksite, all ready to be installed in the passive reinforcement. - bonded system: - cables (both tendons and ducts) fabricated in the plant and then delivered as needed on the worksite for installation into the passive reinforcement; - strand bundle fabricated in a mobile workshop located adjacent to the worksite and then drawn before concreting into the ducts installed in the passive reinforcement; - tendons composed by threading strand by strand before concreting into the ducts installed in the passive reinforcement. 2.6 PROVISIONAL PROTECTION AND LUBRIFICATION In the bonded system, the oiling or greasing of tendons, exclusively by means of non-dangerous substances, is performed: - in the aim of providing provisional protection against corrosion from the time of leaving the plant until permanent protection has been achieved (grouting of the cable); - in the aim of lubrication since the friction loss of oiled strands in the metal ducts during stressing is lower. With this same objective, other products serving to reduce friction may be used, as long as they are recognized as non-dangerous, can be easily applied and remain inert in the presence of permanent protection (and the eventual rigid bond to the structure).. It is necessary to point out that: "In addition to the specific clauses relating to dangerous substances contained in this European Technical Approval, there may be other requirements applicable to the products falling within its scope (e.g. transposed European legislation and national laws, regulations and administrative provisions). In order to meet the provisions of the EU Construction Products Directive, these requirements need also to be complied with, when and where they apply." Version of 28th July 2011 12 Annex 2 of the European Technical Approval No ETA-06/0006 2.7 CALCULATION ELEMENTS 2.7.1 FRICTION LOSSES The friction of strands in their ducts, which hinders tendon displacement during stressing, causes a tensile loss by friction all along the cable path beginning at the considered live-end anchorage. In examining the friction loss formula: f po (x) = f po (0) . e - µ ( + k x ) , which expresses the tension in a cable at the abscissa x as a function of the tension at the considered live end anchorage (positioned at x = 0), where µ is the coefficient of friction (over the curve) between the strands and the duct, the sum of the angular deviations of the cable over the distance x, and k the unintentional angular deviation (per unit length) affecting the cable path, it is recommended to adopt the numerical values of µ and k prescribed in Eurocode 2 which can be summarized as follows: Application Individually greased and sheathed monostrand Cable with corrugated steel strip sheath Cable with VSL PT-PLUS duct (1) µ (rad-1) (1) 0.05 0.17 - 0.19 0.12 - 0.14 k (rad/m) 0.008 0.005 - 0.010 0.005 - 0.010 The interval limit values encompass both lubricated and non-lubricated strands. 2.7.2 BASIS FOR EVALUATING ELONGATIONS See Section 2.6.2 of Annex 1. Due to the limited clearance inside the duct, effect of strand slack may be neglected. Note : friction losses at anchorages are expressed in Chapter 4.2.1. 2.7.3 ACTIVE ANCHORAGE SETTINGS The following wedge draw-in values will be applied herein: - 6 mm, which remains constant for all units and is applicable to all types of anchorage using the "6N" or "6S" wedges implemented without activation of the seating ram of the stressing jack (see Section 4.1.1). 5 mm, which remains constant for all units and applicable to all types of anchorage using the "6N" or "6S" wedges implemented with activation of the seating ram of the stressing jack (see Section 4.1.1). The VSL Slab System anchorages do not allow for any adjustment with shim. Version of 28th July 2011 Annex 2 of the European Technical Approval No ETA-06/0006 13 CHAPTER 3 ANCHORAGES 3.1 DESCRIPTION OF ANCHORAGE COMPONENTS VSL Slab System anchorages make use of a set of standard elements that can be categorized as follows: 3.1.1 LIVE END / DEAD END ANCHORAGES For these active/passive anchorages, the anchor head and plate are combined to form a single part, commonly called the anchorage body. The wedges used for both the VSL Slab System and VSL Multistrand System are identical (see Annex 1). These anchorages comprise: - S 6-1 anchorage The anchorage body is molded and cast in spheroidal graphite cast iron in accordance with Standard EN 1563. The conically-shaped hole is subject of a rigorous control. The plastic sleeve is screwed onto the anchorage body. In the unbonded case, the end cap is made of plastic or metal material. In the bonded case, a temporary or permanent cap provides for the waterproof seal of the envelope at the anchorage end in order to perform the grouting. - S 6-1 PLUS anchorage The anchorage body is molded and cast in spheroidal graphite cast iron in accordance with Standard EN 1563. The conically-shaped hole is subject of a rigorous control. The external plastic coating to isolate metallic anchorage body from concrete is made of polyethylene. The plastic sleeve is securely fastened to the exit of the anchorage body. In the unbonded case, the end cap is made of plastic material. In the bonded case, a temporary or permanent cap provides for the waterproof seal of the envelope at the anchorage end in order to perform the grouting. - S 6-4 anchorage The anchorage body is molded and cast in spheroidal graphite cast iron in accordance with Standard EN 1563; the four conically-shaped holes are rigorously controlled individually. The plastic sleeve of this anchorage is inserted into the concrete and accommodates in an appropriate form the simply-supported anchorage body. In the unbonded case, a permanent cap filled with grease protects the end anchorage. In the bonded case, a provisional or permanent cap provides a waterproof sealing of the envelope at the anchorage end in order to perform the grouting. 3.1.2 PRESENTATION AND PACKING OF ANCHORAGES The unbonded system: Since the installation of the monostrands and anchorage body for the S 6-1 anchorage or the trumpet for the S 6-4 anchorage is done prior to concreting, the delivery of anchorages to the worksite entails: 1. Delivery of the S 6-1, S 6-1 PLUS anchorages or the S 6-4 trumpets, along with the monostrand coils and the installation accessories for both cable manufacturing and placement in the passive reinforcement. These anchorage components are fixed to the formwork. The anchorage components are delivered already tagged, packaged and protected. After concreting and cure of the concrete, 2. Delivery of the wedges, eventually along with installation of the S 6-4 anchorage units, the stressing operation, cutting of the strand over lengths and permanent protection of the anchorages. These anchorage components are delivered identified, packaged and protected. The bonded system: Given that strand placement takes place before concreting, the delivery of anchorages on the worksite entails: Version of 28th July 2011 Annex 2 of the European Technical Approval No ETA-06/0006 14 (only the most common case of internal (concrete) post-tensioning of a new structure will be highlighted herein) 1. Delivery of the S 6-1, S 6-1 PLUS anchorages or the S 6-4 trumpets, the ducts, the accessories for placement within the passive reinforcement, along with the strands to be threaded. These anchorage parts are fastened to the formwork. The anchorage units come delivered tagged, packaged and protected. Following concreting and curing of the concrete, 2. Delivery of the wedges (eventually the S 6-4 anchorage body), the stressing operation, cutting of the excess lengths and grouting for the permanent protection of both cables and anchorages. These anchorage components are delivered identified, packaged and protected. 3.2 ORGANIZATION OF SUPPLY QUALITY The fabrication of anchorage components of the post-tensioning system and especially those designed for the VSL Slab System is conducted in compliance with the specifications, production and control procedures laid out in the present ETA document and all associated documents. The control procedures in effect for anchorage Component Manufacturers, to the same extent as those adopted by the PT Specialist Company, serve to ensure the traceability of the components all the way through to their delivery on site. It is to be recalled that the basis for evaluating these procedures and the supervision of their application have been defined in Chapter 8 and its Appendix E of the ETAG 013. It should also be recalled that prior to installation, the compliance of all delivered components, by means of both identification and visual inspection of their state, must be performed by the PT Supervisor. 3.3 INSTALLATION OF VARIOUS ANCHORAGES The implementation of VSL units must be assigned to a competent staff member and involve technical management personnel within the PT Specialist Company or a PT Supervisor certified by this company. 3.3.1 TYPE "S 6-1", "S 6-1 PLUS" AND "S 6-4" ACTIVE END ANCHORAGES The S 6-1 or S 6-1 PLUS anchorage bodies and the S 6-4 trumpets are fixed to the formwork and connected to the monostrands or ducts aligned at the time of their installation, in general during placing of the passive reinforcement, then incorporated therefore to the structure or structural element during concreting. Depending on the type of system (bonded or unbonded), sleeves or trumpets are appropriate. For detail of connections of anchorages with current ducts refer to Chapter 2.2: “Requirements of the unbonded system” and 2.3: “Duct used for the bonded system”. The S 6-4 anchorage unit is installed into the trumpet which was placed before concrete pouring. The wedges are placed immediately prior to stressing, which ensures that they are clean for use. For force losses in the anchorages during stressing, see Section 4.2.1: "Force measurements". 3.3.2 TYPE "S 6-1", "S 6-1 PLUS" AND "S 6-4" PASSIVE END ANCHORAGES The placement of these passive anchorages is performed as indicated in Section 3.3.1. Once the anchorage has been installed, before stressing at the other end, the wedges are pre-locked using a wedge tool. The anchorage then remains accessible throughout the stressing phase for observation. 3.3.3 TYPE "SF 6-1" AND "SF 6-1 PLUS" EMBEDDED DEAD END ANCHORAGES In both the bonded and unbonded systems, the fixed SF 6-1, SF 6-1 PLUS anchorages are assembled on the strands, then the wedges are pre-locked and verified and, lastly, the ducts and sleeves are connected. The anchorages assembled in this manner are then positioned and inserted into the passive reinforcement. Version of 28th July 2011 15 Annex 2 of the European Technical Approval No ETA-06/0006 3.3.4 TYPE "H 6- (1 through 4)" BONDED ANCHORAGES These fixed anchorages reserved for the bonded system are strictly identical to those of the multistrand system described in Annex 1. 3.4 ANCHORAGE ARRANGEMENTS According to categories of use, referring to Section 1.4.1, arrangements of anchorage components are described in the following table: Component internal bonded cable with metal duct internal bonded cable with plastic duct internal unbonded exchangeable tendon encapsulated tendon (leak tight) S & Si 6-1 S & Si 6-1 PLUS SF & SFi 6-1 SF & SFi 6-1 PLUS S & Si 6-4 Body S S S S S Body S PLUS S PLUS S PLUS S PLUS S PLUS Body S S S Body S PLUS S PLUS S PLUS S PLUS S PLUS H 6-1 & H 6-4 electrically isolated tendon Anchorage Use S Body S S S S Sleeve Si Si S S Cap S S S S H H S S S (1) Si S S Si SP (2) Note (1): Electrical isolation provided by plastic trumpet (anchor body), 3.5 GEOMETRICAL AND MECHANICAL USE CONDITIONS For the seating and installation of anchorages, certain construction-related conditions must be verified. 3.5.1 CLEARANCES BEHIND ANCHORAGES In order to facilitate jack placement and simplify the stressing procedure, a free space must be allocated behind the anchorage. These dimensions are given in the drawing "Clearance requirements" in Chapter 6. 3.5.2 CONCRETE STRENGTH, COVER AND ANCHORAGE SPACING Introducing post-tensioning forces into the structures takes the form, within the anchorage zones, of concentrated forces applied onto the anchorage bodies. The high stress values encountered underneath the anchorages necessitate certain construction-related measures, i.e.: - The anchorages must be laid out at a sufficient distance from the nearest edge of the concrete (cover) and respect a spacing between anchorages (centre to centre) that will be specified below. - The concrete in the vicinity of the anchorages must be especially homogeneous and display, at the time of stressing, an adequate level of strength. - A general diffusion zone must be designed and prepared in front of the anchorages within the structure, thereby reducing the concentrated forces and distributing them over the concrete cross-section, in compliance with the design rules. Version of 28th July 2011 16 Annex 2 of the European Technical Approval No ETA-06/0006 As stated above and in considering a maximum prestressing force P(t,x) at the time of stressing (t = 0)(0) at the anchorage (x = 0), thus called P(0,0) Pmax, for the normal anchor plates and P(0,0) max = Pmax, the following are defined: (0) Force in the cable, at the anchorage on the concrete side, before load transfer to anchorage. b’0 b0 b0 and b’0 are the distances between the anchorage axis and the edge of the block tested. These values are given in the tables here after. The local anchorage zone reinforcement required to prevent bursting and spalling in anchorage zones is determined in relation to a rectangular prism of concrete, known as the primary regularisation prism, located behind each anchorage. The cross section of the prism associated with each anchorage is known as the impact rectangle. The impact rectangle has the same centre and the same axes of symmetry as the anchor plate (which should have two axes of symmetry). The impact rectangle with dimensions X x X’ has the same area as the block tested A = 4 x b0 b’0 and the same aspect ratio. Xmin,rect = 0.85 x 2 b0 ; X’ min,rect = 0.85 x 2 b’0 Xmin and X’min taking into account dimensions of bursting reinforcement are given in the tables here after, then or X’ X’min X Xmin and X x X’ = A = 4 x b0 b’0 [1] [2] It should be noted that application of Xmin may require adaptation of the local anchorage zone reinforcement in accordance with the applicable Eurocodes and national regulations, see Chapter 3.6. Rules for center distance and edge distances of anchorages: Impact rectangles associated with anchorages located in the same cross section should not overlap. In addition, they should remain inside the concrete. Taking into account the concrete cover, we obtain the distance to edge in the two directions : X + cover-10 mm 2 and X' +cover – 10 mm 2 Note: 10 mm is the concrete cover in the tested block. For anchorage spacing, refer to equations [1] and [2] For f cm(t) Anchorage u | u’ mm (3) 2b0 | 2b’0 mm (4) Xmin | X’min mm 2 16/20 N/mm S 6-1 105 75 180 120 155 100 2 16/20 N/mm S 6-1 PLUS 122 94 180 140 155 120 2 16/20 N/mm S 6-4 280 115 400 220 340 185 (3) Sizes of anchor plate / anchorage body (4) Sizes of test block During cable stressing, the concrete in front of the anchorages must have reached an adequate strength level, 2 i.e. a 100% stressing of P(o,o) max = Pmax is not permitted if fcm(t) < 16/20 N/mm , regardless of the anchorage layout within the concrete element. It remains possible however to partially tension the tendon. Version of 28th July 2011 Annex 2 of the European Technical Approval No ETA-06/0006 17 (0) Force in the cable, at the anchorage on the concrete side, before load transfer to anchorage. In the case of stressing to 50% of the maximum value at the anchorage for example, the characteristic strengths fcm(t) may be reduced to approximately 2/3 of the values indicated above for total stressing. It is to be recalled that for those anchorages relying upon bonding alone, i.e. for type "H" anchorages, concrete 2 strength within the anchorage zone during stressing must be: fcm(t) 28/35 N/mm . 3.6 LOCAL ANCHORAGE ZONE REINFORCEMENT A local anchorage zone reinforcement is required due to application of the concentrated post-tensioning force. In all cases, the general anchorage zone must contain a reinforcement for equilibrium designed by the project designer in accordance with typical design rules (see examples presented in the drawings Page 29 and 30 "Reinforcement of anchorage zones" in Chapter 6). As foreseen by this ETA, the local anchorage zone reinforcement specified in this ETA and confirmed in the load transfer tests, may be modified for a specific project design if required in accordance with national regulations and relevant approval of the local authority and of the ETA holder to provide equivalent performance. The contractor responsible for concreting must ensure that the density and configuration of reinforcement within the diffusion zone allow for adequate and homogeneous concreting of the entire zone. Version of 28th July 2011 18 Annex 2 of the European Technical Approval No ETA-06/0006 CHAPTER 4 STRESSING 4.1 STRESSING EQUIPMENT The VSL equipment used for stressing is primarily composed of stressing jacks, hydraulic power packs (commonly called pumps) and the associated set of measurement instruments or systems. 4.1.1 STRESSING JACKS The strands are individually stressed by means of VSL stressing jacks, which are available according to two types: - a double acting front-gripping hollow piston jack, - a twin ram double acting jack, with solid pistons laid out on both sides of the strand. This configuration allows for stressing the intermediate anchorages. This equipment enables stressing the strand in one or several stages and then, if need be, to de-stress the strand. Their primary characteristics will be defined below. In sequence starting from the anchorage, these jacks are composed of: - 1 nose (chair ring) at the front resting upon the anchorage body, ultimately associated with a seating ram; - 1 body or cylinder, composed of one or two jacks and resting upon the chair ring, - 1 auxiliary anchorage driven by the piston(s) and laid out as close as possible to the anchorage installed in place in order to limit the over length of the strands. The ungripping of the jack anchorage is performed automatically. List of VSL jacks: Designation Type Cross section Length Weight Stroke Ram area Maximum pressure Maximum force Presence of seating ram? 2 mm mm kg mm mm² bar kN DKP 6 ZPE 23 FJ 2 // pistons 240 x 165 615 30 200 4 926 467 230 No 1 hollow piston 116 790 23 200 4 710 488 230 Yes The drawing in Chapter 6 indicates the clearances to be introduced around the anchorages at the ends of the post-tensioned structures in order to facilitate installation. 4.1.2 HYDRAULIC PUMPS The VSL pumps comprise the assembly of hydraulic components including: pumps, distributors, nozzles and safety valves. The pumps are typically driven by electric motors. The stations themselves have been dimensioned for normal stressing speeds and contain safety measurement devices that depend on the specific application. 4.1.3 INSTRUMENTS AND MEASURING SYSTEMS The VSL force and elongation measurement instruments or systems serve to control with precision the stressing operation and display the results obtained. Version of 28th July 2011 Annex 2 of the European Technical Approval No ETA-06/0006 19 4.2 PROCESSES OF STRESSING AND CONTROL PROCEDURE Before proceeding with cable stressing, a certain number of preconditions must be met, in particular: - all pertinent safety rules and recommendations must be fully known; - the force targets along with the corresponding values of elongation; moreover, tolerances must be known by the PT Supervisor, who will have applied any eventual necessary adjustments to these values in order to account for parameters specific to the equipment; - the order in which the prestressing cables are to be stressed must be specified, and the order in which the strands in the cables are to be stressed with S 6-4 anchorages must be known; - the stressing equipment (including measurement instruments) must comply with guidelines furnished in the present ETA; - the required strength of the concrete of both the structure and anchorage zone undergoing stressing must be verified; - the loading and support states of the structure associated with the stressing phase must also be verified; - the over lengths of the strands to be stressed must remain perfectly clean. It should nonetheless be recalled that during the stressing process, it is strictly forbidden to be positioned behind the jack or within its immediate vicinity. The same precautions must be taken for the area in the back of the accessible dead-end anchorages. Even though the VSL system does not require any locking accessory device, with some jacks, the wedges may be set in order to reduce the setting of anchorage wedges and its influence on the force = f (x) in the strands. 4.2.1 FORCE MEASUREMENTS The measurement of force in the cable, as transformed into pressure measurement in the jack, is generally the assigned objective herein. The pressure existing in the jack chamber is indicated by the manometer installed on the pump, with eventual control of the jack. The manometers used (Accuracy 1%), regularly recalibrated using a scale, feature a guaranteed precision of 1% of their maximum pressure, which tends to lie at 490 bars; these instruments thereby provide a precision of 5 bars over the entire manometer scale. In order to obtain the effective force on the structure, the force resulting from the manometer reading is to be corrected for losses inside the jack as well as for losses due to friction of the strands in the anchorage. Losses inside the jacks are identified from intrinsic hardware data. Although they contain an independent pressure term and another closely-proportional term, submitted to the maximum pressure reached upon completion of the stressing operation, the losses inside jacks are solely expressed in proportional terms and exhibit the following values: - DKP 6 jack: 3.5% - ZPE 23 FJ jack: 1.5% The losses in active anchorages, named ka, are due to friction of the strands deviated on the component parts and, depending on the specific anchorage, exhibit the following values: - S 6-1 and S 6-1 PLUS anchorages: 0% to 1% - S 6-4 anchorage: 0% to 1% for the two central strands, 2% for the two outside strands. 4.2.2 ELONGATION MEASUREMENTS The measurement of cable elongation is generally a control measurement that provides information on cable behavior during stressing. As for elongation measurements, an index is installed on the strands. During the stressing operation, elongations are then deduced from measurements of the displacement of this index. Since the onset of displacements combines the seating of tendons in their ducts with their actual elongation, the elongation during initial displacements is obtained by means of extrapolating the linear elastic elongations occurring subsequently. For single strand round ducts and flat ducts this effect may usually be neglected. The various pressure-elongation relations noted during cable stressing are recorded in the stressing data sheets, which are to remain available. Section 2.7.2 provides a recap of the elongation evaluation basis used during the stressing operation. Version of 28th July 2011 Annex 2 of the European Technical Approval No ETA-06/0006 20 CHAPTER 5 5.1 INJECTION INJECTION AND SEALING 5.1 INJECTION 5.1.1 UNBONDED SYSTEM The monostrand (individually greased and sheathed), protected from the factory by grease, obviously does not necessitate any special additional protection. The "S 6-1", "S 6-1 PLUS" and "S 6-4" anchorage units, after stressing and cut-off of the strands, are filled with grease (identical or compatible with that of the monostrand in compliance with the ETAG 013) by means of injection using a pump. Following filling, a cap serves to enclose the strand ends and the wedge housings. 5.1.2 BONDED SYSTEM - General information: The nature and composition of injection products for the permanent protection of tendons and anchorages and for their bonding to the structure are not inherent to the prestressing process; instead, they depend on the project and the structure's assigned purpose. The products involved must not be a threat to the hygiene, health and the environment. In addition to the specific clauses relating to dangerous substances contained in this European Technical Approval, there may be other requirements applicable to the products falling within its scope (e.g. transposed European legislation and national laws, regulations and administrative provisions) In order to meet the provisions of the EU Construction Products Directive, these requirements need also to be complied with, when and where they apply. The products used for the permanent protection of post-tensioning tendons and anchorages implemented by means of injection may be categorized as follows: Hydraulic cement-based injection grouts are the most commonly employed. These products may pertain to common grouts defined in the standard EN 447 or special grouts that make use of performance-enhancing admixtures. In some regions of the EU, unfavorable climatic conditions impose the application of special grouts according to ETAG 013. Those injection products that have already received a European Technical Approval may also be used in respect of the prescribed set of uses. Completion of the tendon envelope in the anchorage zone is provided during the time of injection by means of either temporary waterproof caps or definitively by permanent caps. - Injection equipment: The set of injection equipment has been adapted to the specific products to be injected. For the cement-based grout, the VSL injection equipment is composed for the most part of mixers and pumps integrated into a single device that enables preparing the grout and performing the injection. This equipment makes it possible to allocate with precision the grout components and to obtain a perfectly-homogeneous mix. The pump with which the equipment is fitted has been designed for continuous injection at an adapted grout progression speed. - Injection procedures: Before proceeding with the injection of a permanent cable protection, a certain number of conditions must be fulfilled and in particular: - The injection product must comply with the terms of the present ETA and the ETAG 013; - The injection equipment must comply with indications laid out in the present ETA, Version of 28th July 2011 Annex 2 of the European Technical Approval No ETA-06/0006 21 - The waterproof sealing of the tendon and anchorage envelopes (ducts, fittings, pipes and caps) must be verified, - The climatic conditions and temperature of the structure must satisfy the use conditions of the injection product. The primary controls conducted during injection consist of verifying the adequate filling of the duct by means of inlets, bleed vents and outlets laid out all along the cable path and verifying that the product discharged by the vents or outlets displays the required properties. Grouting procedures and grouting surveillance shall be carried out according to EN 446. As an initial approach, the injection product quantities per unit cable length will be derived from: [(internal duct section area - tendon section area) × (unit length)] × (1 + ), where is such that: 0.05 in order to incorporate worksite losses, the shape of the duct and eventual corrugations. 0.10 The various phases and parameters associated with cable injection are to be recorded on the injection data sheets, which are to remain available. 5.2 SEALING The continuity of protection against all types of aggressions must be ensured all along the cable up to and including the anchorages. The protection measures introduced for this unique zone, which is located at the end of the slab and frequently protected from external aggressions is most often limited in this case to the filling of the block-out with mortar or concrete. In the case of end zones exposed to aggressive environment additional protection measures may be necessary (permanent cap or waterproof lining). Version of 28th July 2011 22 Annex 2 of the European Technical Approval No ETA-06/0006 CHAPTER 6 SCHEMATIC DRAWINGS (dimensions expressed in mm) Title Page STANDARD ANCHORAGE ELEMENTS Wedges see Annex 1 ANCHORAGES Type S 6-1 and Si 6-1 anchorages Principles of both the "unbonded" and "bonded" systems Sizes 23 24 Type S 6-1 PLUS and Si 6-1 PLUS anchorages Principles of both the "unbonded" and "bonded" systems Sizes 25 26 Type S 6-4 and Si 6-4 anchorages Principles of both the "unbonded" and "bonded" systems Sizes 27 28 see Annex 1 Type H 6- (1 through 4) anchorages REINFORCEMENT OF ANCHORAGE ZONES Anchorage S 6-1 and S 6-1 PLUS Anchorage S 6-4 29 30 CLEARANCE REQUIREMENTS 31 DUCTING 32 Version of 28th July 2011 Annex 2 of the European Technical Approval No ETA-06/0006 PRINCIPLE OF UNBONDED SYSTEM – ANCHORAGE S 6-1 Note: the same anchorage body is used for SF 6-1 PRINCIPLE OF BONDED SYSTEM – ANCHORAGE Si 6-1 Note: the same anchorage body is used for SFi 6-1 Version of 28th July 2011 23 Annex 2 of the European Technical Approval No ETA-06/0006 24 ANCHORAGES TYPE S 6-1 / Si 6-1 Anchorage body and sleeve Note: anchorage S 6-1 can be used as intermediate, dead end or embedded anchorage (SF 6-1) Placing devices Version of 28th July 2011 Annex 2 of the European Technical Approval No ETA-06/0006 PRINCIPLE OF UNBONDED SYSTEM – ANCHORAGE S 6-1 PLUS Note: the same anchorage body is used for SF 6-1 PLUS PRINCIPLE OF BONDED SYSTEM – ANCHORAGE Si 6-1 PLUS Note: the same anchorage body is used for SFi 6-1 PLUS Version of 28th July 2011 25 Annex 2 of the European Technical Approval No ETA-06/0006 ANCHORAGES TYPE S 6-1 PLUS / Si 6-1 PLUS Anchorage body and sleeve Note: anchorage S 6-1 PLUS can be used as intermediate, dead end or embedded anchorage (SF 6-1 PLUS) Placing devices Version of 28th July 2011 26 Annex 2 of the European Technical Approval No ETA-06/0006 PRINCIPLE OF UNBONDED SYSTEM – ANCHORAGE S 6-4 PRINCIPLE OF BONDED SYSTEM – ANCHORAGE Si 6-4 Version of 28th July 2011 27 Annex 2 of the European Technical Approval No ETA-06/0006 ANCHORAGES TYPE S 6-4 / Si 6-4 Anchorage body and sleeve Placing devices Version of 28th July 2011 28 29 Annex 2 of the European Technical Approval No ETA-06/0006 REINFORCEMENT OF ANCHORAGE ZONES ANCHORAGE S 6-1 Example of additional reinforcement to combine with main one ANCHORAGE S 6-1 PLUS Example of additional reinforcement to combine with main one Reinforcement steel fyk Version of 28th July 2011 500 N/mm 2 Annex 2 of the European Technical Approval No ETA-06/0006 ANCHORAGE S 6-4 Example of additional reinforcement to combine with main one Version of 28th July 2011 30 Annex 2 of the European Technical Approval No ETA-06/0006 CLEARANCE REQUIREMENTS Stressing jack DKP-6 Stressing jack ZPE-23FJ Version of 28th July 2011 31 32 Annex 2 of the European Technical Approval No ETA-06/0006 DUCTING Bonded Bonded Corrugated steel strip sheath VSL PT-PLUS® Duct a int. 72 72 a int. 22 a ext. - 76 a ext. 25 A 75 86 A 31 b int. 18 21 b ext. - 25 B 21 35 Unbonded VSL PT-PLUS® Duct Version of 28th July 2011 ext. duct Min / Max 0.6’’ 18 / 20
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