PRESTRESSING TECHNOLOGYwww.structuralsystems.com.au Post-STRESSING TECHNOLOGY Introduction Post-Tensioning Design data Multi-Strand Post-TensioninG Slab Post-Tensioning Multi-Wire Post-Tensioning Bar Post-Tensioning Emirates Tower - Dubai PAGE 03 PAGE 04 PAGE 05 PAGE 17 PAGE 28 PAGE 31 PAGE 35 PAGE 38 PAGE 40 Ground Anchor SYSTEMS External PRESTRESSING Cable Stay SYstemS INCREMENTAL LAUNCHING SYSTEMS PAGE 44 HEAVY LIFTING SYSTEMS LOAD HANDLING SYSTEMS PAGE 45 PAGE 46 www.structuralsystems.com.au Data contained herein is subject to change without notice. Use of information and details presented in this document should be verified by a qualified engineer for suitability to specific applications. introduction Structural Systems is a specialist professional Engineering and Contracting Company, which provides innovative skills and services to the Construction and Mining Industries both nationally and internationally. Operations commenced as BBR Australia Pty Ltd in 1961 and became the public company, Structural Systems Limited in 1987. Our innovative design, advanced construction techniques and effective project management skills make Structural Systems the leader in the design and installation of prestressing systems. The wide range of services and systems offered in this brochure are readily available through our network of offices and a Structural Systems representative is available to talk directly to you regarding your project. Wandoo Concrete Gravity Structure - Western Australia Eleanor Schonell Bridge - Queensland www.structuralsystems.com.au 3 PRESTRESSING TECHNOLOGY POST-TENSIONING DESIGN DATA STRAND PROPERTIES STANDARD NOMINAL DIAMETER mm 12.7 super 15.2 super 15.2 EHT 12.9 super 15.7 super 15.2 regular 15.7 regular 15.2 super 15.7 super STEEL AREA mm 2 MASS kg/lm 0.786 1.125 1.125 0.785 1.180 1.093 1.172 1.093 1.172 STRAND MBL / Fm kN 184 250 261 186 265 248 266 260 279 (7) MIN. PROOF LOAD kN 156.4 212.5 221.9 158.1 225.3 (4) (4) (4) STRAND RELAXATION (%) 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 (6) MODULUS OF ELASTICITY MPa 180 to 205x10 180 to 205x10 180 to 205x10 3 3 3 AS 4672 (1) 100.1 143.3 143.3 100 150 140 150 140 150 BS 5896 (5) (5) (2) 180 to 205x10 180 to 205x10 180 180 180 180 to to to to 3 3 prEN 10138-3 (3) 213.0 229.0 224.0 240.0 (5) (5) (5) (5) 205x10 205x10 205x10 205x10 3 3 3 3 Notes: • All strands are 7 wire low relaxation steel. WIRE PROPERTIES STANDARD NOMINAL DIAMETER mm 7 LR 7 LR STEEL AREA mm 2 MASS kg/lm 0.302 0.302 WIRE MBL kN 64.3 64.3 (7) MIN. PROOF LOAD kN 54.7 53.4 (4) STRAND RELAXATION (%) 2.0 2.5 (6) MODULUS OF ELASTICITY MPa 195 to 205x10 3 AS 4672 Notes: (1) (2) (3) (4) (5) (6) (7) (1) 38.5 38.5 BS 5896 (2) (5) 195 to 205x10 3 Australian / New Zealand Standard AS 4672 Steel Prestressing Materials. British Standard BS 5896 High Tensile steel wire and strand for the Prestressing of Concrete. European Standard prEN 10138-3 Prestressing steels - Part 3: Strand. At 0.2% Offset. Refer AS 4672. At 0.1% Offset. Refer BS 5896 or prEN 10138-3 as applicable. Relaxation after 1000 hrs at 0.7 x Breaking Load. MBL = Minimum Breaking Load (to AS 4672 and BS 5896). Fm = Characteristic Force (to prEN 10138-3). MAXIMUM JACKING FORCES - RECOMMENDED VALUES SSL POST TENSIONING SYSTEM AS 3600 BBR CONA MULTI SYSTEM BBR VT CONA CMI SYSTEM SLAB SYSTEM WIRE SYSTEM BAR SYSTEM Notes: STANDARD BS 8110 80% 80% 80% 80% 75% MBL MBL MBL MBL MBL 80% 80% 85% 80% 75% MBL MBL MBL MBL MBL • In some cases higher or lower jacking forces are permitted by local standards. • MBL = Minimum Breaking Load of tendon. PRESTRESSING LOSSES - TYPICAL DATA SYSTEM ANCHORAGE & JACKING LOSS (%) DRAW-IN ALLOWANCE (mm) DUCT FRICTION μ Round Steel Duct Flat Steel Duct Polyethylene Duct Greased & Sheathed Round Steel Duct ≤ 50mm Round Steel Duct > 50mm Flat Steel Duct Greased & Sheathed BBR CONA MULTI 2 to 4 6 0.15 to 0.20 0.10 to 0.15 BBR VT CONA CMI 0.9 to 1.2 6 0.20 to 0.22 0.10 to 0.15 SLAB 2 to 5 6 0.15 to 0.20 0.20 0.10 to 0.15 WIRE 0 to 1 2 to 3 0.12 to 0.16 0.10 to 0.15 BAR 0 to 1 1 to 2 0.15 to 0.20 0.10 to 0.15 0.15 0.008 to 0.016 0.008 TENDON WOBBLE β (k) rad/m 0.016 to 0.024 0.008 to 0.016 0.006 0.006 0.016 to 0.024 0.016 0.008 to 0.012 Notes: • To reduce excess friction, it may be possible to flush the tendon with water or water soluble oil. • If the duct or strand has a film or rust or the ducts are full of water, the friction values can increase significantly. 4 www.structuralsystems.com.au BBR CONA MULTI The BBR Cona Multi has been offered for the last 40 years and is available in standardised tendon sizes from: • 7 strands up to 61 strands for 12. Standard applications use the M1 range.com. load transfer and cryogenic tests. On completion of the tests. the approval body evaluated the test results. These systems are BBR Cona Multi. specifications and the complete system. state of the art. or • 4 strands up to 55 strands for 15.au. Every product is tested to the same standards and afterwards an independent auditor ensures that what is delivered and installed on site fully complies with that which was tested.7mm and 12.com and www. Please consult SSL for details on which system best suits your applications. and other specialist applications. and is available in standard tendon sizes from: • 4 strands up to 61 strands for 15. full and complete system testing to the highest European standard.au 5 BBR VT CONA CMI The BBR VT Cona CMI is a revolutionary. • Less reinforcement in the anchorage zone resulting in time and cost savings. The package was then circulated to all member states of the EU for ratification.MULTI-STRAND POST-TENSIONING multi-strand post-tensioning Structural Systems have two distinct systems available for multi-strand applications.com.M1 The BBR Cona Multi can be used with galvanised steel and polyethylene ducting. European Approval ETA .bbrnetwork. The system is a bonded system with the ducting being pressure filled with a cementitious grout.structuralsystems.9mm strand. BBR VT CONA CMI The system has been granted European Technical Approval in accordance with the testing procedures contained within ETAG013 and is CE marked. European Technical Approval provides clear independent review. These advantages include: • Less space is required in the anchor zone which results in less concrete.2mm and 15.structuralsystems. • Significantly lower concrete strength prior to stressing resulting in shorter construction cycles. drawings. These tests included static tests. quality assurance. and independent auditing of all systems components.2mm and 15.Testng of Anchor Head BBR CONA MULTI . bonded. slimmer structures and less eccentricity in the anchors. with the M3 range being used for cryogenic applications.7mm strand. . Copies of the BBR VT European Approval Documents are available for download from www. and BBR VT Cona CMI. post-tensioning system incorporating world’s best practice. www. fatigue tests.7mm strand. The BBR VT Cona CMI has significant advantages over the BBR Cona Multi as well as significant competitive advantage over other ETAG approved systems. Post-STRESSING TECHNOLOGY BBR VT CONA CMI TECHNICAL DATA OF ANCHORAGES BBR VT Cona CMI (Max No of Strands) Strand Cross Sectional Area Charact. approx.structuralsystems. Maximum Force BBR VT Cona CMI (Max No of Strands) Helix and Additional Reinforcement Min.be’ mm mm 235 110 215 100 195 90 190 85 310 145 285 135 260 120 250 115 240 110 405 195 370 175 340 160 325 155 310 145 F BxB mm mm mm mm 3 12 60 30 220 3 12 55 30 200 4 10 40 30 180 3 10 50 30 170 5 14 55 33 290 4 14 60 33 270 3 14 65 33 240 3 14 65 33 230 4 14 60 33 220 7 12 60 35 390 6 14 55 35 350 5 16 70 35 320 5 16 65 35 310 6 14 50 35 290 E mm mm mm mm mm 180 14 182 50 4 15 150 12 181 50 4 15 150 12 216 60 4 15 150 12 216 60 4 15 230 14 232 50 5 18 200 14 232 50 5 18 200 14 277 60 5 18 180 14 277 60 5 18 180 14 277 60 5 18 330 14 332 50 7 20 280 14 332 50 7 20 280 14 332 50 7 20 260 14 382 50 8 20 260 14 282 50 6 20 fcm.0 MPa 19 23 28 31 35 19 23 28 31 35 19 23 28 31 35 Rm Fm mm2 mm2 MPa kN 140 560 1770 992 4 150 600 1860 1770 1860 1040 1064 1116 4 140 980 1770 1736 7 150 1050 1860 1770 1860 1820 1862 1953 7 140 1680 1770 2976 12 150 1800 1860 1770 1860 3120 3192 3348 12 STRESSING AND FIXED ANCHORAGE FIXED COUPLER FK CENTRE AND EDGE DISTANCES STRESSING ANCHORAGE RECESS DETAILS Strand Size 15.au . Strands Recess .Outer Recess Depth 406 4 200 x 200 250 x 250 130 706 7 240 x 240 290 x 290 135 BBR VT Cona CMI 1206 12 295 x 295 350 x 350 140 1906 19 350 x 350 400 x 400 160 2206 22 380 x 380 420 x 430 170 2706 27 430 x 430 480 x 480 180 3106 31 430 x 430 480 x 480 185 6 www. Concrete Strength (cyl. Edge Distance (plus c) Dimensions of Anchorages Anchor Diameter Anchor Length Coupler FK Diameter Coupler FK Length DA LA DFK LFK mm mm mm mm 130 327 185 945 170 454 205 1152 225 627 240 1435 ac.) Helix Outer Diameter Bar Diameter Length.bc ae’.2mm / 15.com.7mm DIMENSIONS (mm) Anchorage Unit Maximum No. Pitch Number of Pitches Distance Additional Reinforcement Number of STIRRUPS Bar Diameter Spacing Distance from Anchor Plate Outer Dimensions Centre and Edge Spacing Min. Tensile Strength Charact.Inner Recess . Centre Spacing Min. Centre Spacing Min.com. Maximum Force Rm Fm mm2 mm2 MPa kN 140 2660 1770 4712 19 150 2850 1860 1770 1860 4940 5054 5301 19 140 3080 1770 5456 22 150 3300 1860 1770 1860 5720 5852 6138 22 140 3780 1770 6696 27 150 4050 1860 1770 1860 7020 7182 7533 27 140 4340 1770 7688 31 150 4650 1860 1770 1860 8060 8246 8649 31 BBR VT Cona CMI (Max No. Tensile Strength Charact.MULTI STRAND POST-TENSIONING BBR VT CONA CMI TECHNICAL DATA OF ANCHORAGES BBR VT Cona CMI (Max No. Pitch Number of Pitches Distance Additional Reinforcement Number of STIRRUPS Bar Diameter Spacing Distance from Anchor Plate Outer Dimensions Centre and Edge Spacing Min. of Strands) Helix and Additional Reinforcement Min.au 7 5 .5 27 360 14 432 50 9 27 330 14 432 50 9 27 330 14 382 50 8 27 475 14 482 50 10 31 420 14 482 50 10 31 360 14 482 50 10 31 360 14 482 50 10 31 330 14 382 50 8 31 520 14 532 50 11 35 475 14 532 50 11 35 430 14 532 50 11 35 420 14 427 40 11 35 360 14 432 50 9 35 560 14 532 50 11 35 520 14 532 50 11 35 475 14 582 50 12 35 430 14 467 40 12 35 430 14 432 50 9 35 E mm 27 7 mm mm F BxB mm mm 16 65 42 490 7 16 65 42 450 7 16 65 42 410 7 16 65 42 390 7 16 65 42 370 8 16 65 46 530 7 20 75 46 480 7 20 70 46 440 7 20 65 46 420 8 16 55 46 400 8 20 80 50 590 7 20 80 50 540 7 20 75 50 490 7 20 70 50 470 8 20 60 50 440 8 20 85 50 630 8 20 75 50 580 8 20 70 50 530 8 20 65 50 500 8 20 60 50 480 mm mm 510 245 465 225 425 205 410 195 390 185 550 265 500 240 460 220 440 210 420 200 610 295 555 270 505 245 485 235 460 220 650 315 595 290 545 265 520 250 495 240 280 744 290 1600 310 946 310 1821 360 1090 390 2466 360 975 390 2242 Note: Intermediate and larger sizes available on request. STRESSING AND FIXED ANCHORAGE FIXED COUPLER FK CENTRE AND EDGE DISTANCES Structural Systems has gained certification from BBR as a ‘PT Specialist Company’ authorised to install the BBR VT Cona CMI systems and all other BBR ETAG approved post tensioning systems. Edge Distance (plus c) Dimensions of Anchorages Anchor Diameter Anchor Length Coupler FK Diameter Coupler FK Length DA LA DFK LFK mm mm mm mm ac.structuralsystems.5 360 14 457 50 9. of Strands) Strand Cross Sectional Area Charact.be’ fcm.bc ae’.) Helix Outer Diameter Bar Diameter Length. www. Concrete Strength (cyl.0 MPa 19 23 28 31 35 19 23 28 31 35 19 23 28 31 35 19 23 28 31 35 mm mm mm mm 420 14 457 50 9. approx. Strands Anchor Head Coupler Head K Diameter ØA (mm) Height HA1 (mm) Diameter ØK (mm) Height HK (mm) 4 100 50 185 85 7 130 55 205 85 12 160 65 240 90 19 200 85 290 95 22 225 95 310 105 27 255 105 390 125 31 255 110 390 130 ANCHOR HEAD COUPLER HEAD TYPE K PLASTIC TRUMPETS No.com.structuralsystems.au . Strands Trumpet A Trumpet K Diameter ØTA (mm) Length LTA (mm) Diameter ØTK (mm) Length LTK (mm) 4 72 230 185 539 7 88 328 203 640 12 127 509 240 730 19 153 580 275 775 22 170 715 305 840 27 191 871 375 1265 31 191 757 375 1150 TRUMPET TYPE A TRUMPET TYPE K 8 www.Post-STRESSING TECHNOLOGY BBR VT CONA CMI SYSTEM COMPONENT DETAILS BEARING TRUMPLATES No. Strands Bearing TRUMPLATE Diameter ØP (mm) Height HP (mm) 4 130 120 7 170 128 12 225 150 19 280 195 22 310 206 27 360 250 31 360 250 BEARING TRUMPLATE ANCHOR AND COUPLER HEADS No. 7 super 1116 1953 3348 5301 6138 7533 8649 4 7 12 19 22 27 31 45 60 80 100 105 120 130 / / / / / / / 50 65 85 105 110 125 135 • Table indicates maximum number of strands that can be accomodated by the tendon stressing unit.8 x MBL.1 7. • Maximum jacking force is usually 0.com.3 TENDON MIN BREAKING LOAD to prEN 10138-3 kN 15. • Larger ID ducting should be selected for tendons > 80m.2 super 1040 1820 3120 4940 5720 7020 8060 15.2 regular 992 1736 2976 4712 5456 6696 7688 15.15 7.7 / 1. • Refer page 4 for additional design data and details. or if strands are installed after concreting.4 / 1.8 4.au 9 . or where tight or extended curvatures occur.0 / 0.MULTI STRAND POST-TENSIONING BBR VT CONA CMI TENDON PROPERTIES TENDON UNIT MAXIMUM MAXIMUM MINIMUM STRANDS STEEL STEEL NO.9 5. STRESSING ANCHORAGE FIXED ANCHORAGE FIXED COUPLER FK www.2 / 1. • For radii of curvature and straight portion diagram refer to BBR CONA Multi System.structuralsystems.0 6. DUCT ID/ DUCT ID/ OD OD mm 406 706 1206 1906 2206 2706 3106 Notes: mm 45 / 50 55 / 60 70 / 75 90 / 95 95 / 100 105 / 110 110 / 115 MINIMUM RADII OF CURVATURE / MINIMUM STRAIGHT PORTION m 2.7 regular 1064 1862 3192 5054 5852 7182 8246 15. corrugated polyethylene ducting may be used if permitted in the local region. Alternatively.0 / 1.0 / 0. • Plastic sheaths conforming to ETAG013 should be used.5 / 1.3 8. 12. It may be possible to slightly reduce duct size in some situations. • Duct sizes are quoted for typical situations. For standard applications type M1 anchorages are generally preferred. 12.) • Maximum Multi-strand Jacking force is usually 0. • MBL = Minimum Breaking Load stressing Anchorages (Live Ends) Structural Systems has been offering the BBR Cona Multi post-tensioning system for over 40 years. 15. (i.e. Alternate duct sizes are generally available in 5mm ID increments • Partial tendons are also permissible. The choice between the anchorage types depends on structural requirements.9mm or 91 No. • Refer page 5 for additional design data and details on standards. Consideration should be given to the use of larger ducts where tight or extended curvatures occur. silos. After stressing the ducting is pressure filled with a cementitious grout. availability and dimensional constraints.8 x MBL.e.com.PRESTRESSING TECHNOLOGY BBR CONA MULTI Tendon Properties Tendon Unit Maximum Strands No.7mm strand tendon would be specified as “1905-15”. Refer to SSL office for advice. Type M3 are used for cryogenic applications or where it maybe necessary to use a rectangular anchorage for clearance reasons. Individual strand stressing is possible in some circumstances.9mm strand 1302 2232 3534 5766 7812 11346 15. trumpet anchor head anchorAGE casting duct anchorage Type M1 10 www. The BBR Cona Multi system consists of up to 61 No. Metal Duct Tendon MBL to AS4672 ID/OD mm kN Using 12. (It is recommended that SSL is consulted for non-standard plate sizes). This multistrand system is predominantly used in civil structures including bridges.au .7 EN strand 1060 / 1116 1855 / 1953 3180 / 3348 5035 / 5301 5830 / 6138 8215 / 8649 11130 / 11718 14575 / 15345 705 7 50 / 57 1205 12 70 / 77 1905 19 85 / 92 3105 31 105 / 112 4205 42 120 / 127 6105 61 150 / 157 406 4 50 / 57 706 7 65 / 72 1206 12 80 / 87 1906 19 100 / 107 2206 22 110 / 117 3106 31 120 / 127 4206 42 135 / 142 5506 55 150 / 157 Notes: • Table indicates maximum number of strands that can be accomodated by the tendon stressing anchorage unit.2 EHT strand 1000 / 1044 1750 / 1827 3000 / 3132 4750 / 4959 5500 / 5742 7750 / 8091 10500 / 10962 13750 / 14355 Tendon MBL to BS5896 or prEN 10138-3 kN Using 12. etc.2mm/15.structuralsystems.7mm strands to form tendons which are installed inside round ducting.7mm BS / 15. grout inlet wedge grips p. tanks and off-shore structures and is a robust and reliable “bonded” prestressing system.2mm/15. supplied with a 1905 stressing anchorage and would have a MBL of 15 x 184 = 2760 kN. The individual strands are anchored in a common anchor head with a wedge grip system and the strands are simultaneously stressed.7mm/12. a 15No.7mm strand 1288 2208 3496 5704 7728 11224 15. • Tendon grouting is achieved via 19mm poly pipe inlets at all anchorages and at intermediate venting points. Strands 7 12 19 31 15.7mm Anchorage Unit Maximum No.com.7mm / 12. size and number of anchorages required. multi-strand tendons will normally be supplied with Type M1 stressing anchorages.9mm 15. SSL Multi-strand tendons will normally be supplied with Type M1 stressing anchorages. project location and availability of components. • Unless otherwise specified by the Designer.au 11 . • Unless otherwise specified by the Designer. F Nom.7mm Anchorage Unit Maximum No. D Outside Dia.9mm Anchorage Unit 705 1205 1905 3105 Maximum No. The tables below provide performance and dimensional data for two typical anchorages. D Outside Dia. Dia. Strands Anchorage Unit Maxiumum No. Height G 705 7 406 4 165 155 100 77 55 120 55 TYPE M1 ANCHORAGE DETAILS 1205 12 706 7 215 345 85 110 77 150 55 1905 19 1206 12 265 415 100 139 92 190 65 3105 31 1906 19 335 485 116 179 112 240 80 2206 22 350 550 125 193 117 350 80 4205 42 3106 31 395 605 145 223 137 290 100 6105 61 4206 42 460 725 175 265 157 350 120 Dimensions (mm) Notes: • Local zone and general zone anchorage reinforcement is normally required for all unit types and details are usually determined by the Designer to suit the specific application. • Tendon grouting is achieved via 19mm poly pipe inlets at all anchorage ends and at intermediate venting points.2mm / 15.Fabricated Plate Anchorage (LIVe END) Strand size Type M3 Anchorage details 12. The designer should check with Structural Systems for full and current technical information on the preferred anchorage type.2mm / 15. E Anchor Nom.structuralsystems. Strands AxA B C Inside Dia. TRUMPET (LIVE END) STRAND SIZE 12.7mm / 12.E. Several other BBR anchorage configurations are also available and there may be some variations in dimensions to those shown. E Notes: • Local zone and general zone anchorage reinforcement is normally required for all unit types and details are usually determined by the Designer to suit the specific application. Anchorage type m1 Stressing Anchorage Type M3 . Strands 406 4 175 220 20 90 55 706 7 220 435 30 115 75 1206 12 270 545 40 140 90 1906 19 345 785 55 195 110 - - 2206 22 375 820 60 210 115 4205 42 3106 31 440 910 70 232 140 6105 61 4206 42 600 1230 100 275 160 5506 55 600 1400 120 325 160 Dimensions A x A (mm) B C Outside Dia.ANCHORAGE CASTING WITH P. STRESSING ANCHORAGE TYPE M1 .MULTI-STRAND post-tensioninG The type of stressing anchorage used may vary depending on the application. Anchorage type m3 www. type of tendon sheathing. strand length ‘F’ shall be debonded (using grease or similar).7mm 406 150 150 706 200 170 1206 350 300 1906 450 350 2206 500 350 3106 550 475 4206 700 550 5506 800 600 Notes: • Swage type dead end anchorages recommended for tendon units 3105/1906 and larger • Local zone and general zone anchorage reinforcement is normally required for all unit types and details are usually determined by the Designer to suit the specific application bulb type dead end swage type dead end Note: For swage type.com.au .7mm and 12.9mm 705 175 150 1205 300 250 1905 375 300 3105 450 425 4205 600 450 6105 700 550 15.PRESTRESSING TECHNOLOGY multi-strand post-tensioning Dead End AnchorageS .Bulb Type & Swage Type Strand Size Anchorage Unit Bulb Type Anchorage (mm) A B C 600 1000 1000 1100 1100 1200 600 600 1000 1000 1000 1100 1200 1200 swage Type Anchorage (mm) D E F 150 200 250 350 450 700 150 200 250 300 300 350 400 550 150 200 250 300 375 450 150 200 250 300 300 350 350 475 250 350 500 650 850 1000 250 350 500 500 500 650 850 1000 12.2mm and 15.structuralsystems. Transfer beams in buildings 12 www. SSL Multi-strand Coupling Anchorages will normally be supplied as Type K • Refer to SSL for details and availability of larger C type coupler units www.9mm 15.7mm / 12.au 13 . Strands Type K Coupling Anchorage details 705 7 406 4 168 550 1205 12 706 7 208 650 1905 19 1206 12 258 700 3105 31 1906 19 328 900 - - 2206 22 328 950 - - 3106 31 405 1100 4206 42 460 1200 Diameter (mm) N Trumpet length (mm) P (approx) Notes: • Unless otherwise specified by the Designer.Type K Strand size 12.7mm / 12.Type C Strand size 12.9mm Anchorage Unit Maximum No.MULTI-STRAND post-tensioning Coupling Anchorage . Strands Dimensions (mm) Q R S 15.2mm / 15. Strands Anchorage Unit Maximum No.com.7mm Anchorage Unit Maximum No. multi-strand coupling anchorages will normally be supplied as Type K • Refer to SSL for details and availability of larger K type coupler units Coupling Anchorage . Strands Dimensions (mm) Q R S Notes: Type C Coupling Anchorage details 705 7 108 170 550 406 4 125 160 520 1205 12 108 200 650 706 7 125 200 630 1905 19 108 230 740 1206 12 125 230 730 3105 31 108 340 1140 1906 19 125 270 860 - - - - - 2206 22 125 300 930 4205 42 148 385 1320 3106 31 145 350 1090 6105 61 refer to SSL 4206 42 refer to SSL 5506 55 refer to SSL • Unless otherwise specified by the Designer.structuralsystems.2mm / 15.7mm Anchorage Unit Maximum No. au .7mm / 12.PRESTRESSING TECHNOLOGY multi-strand post-tensioning Stressing Anchorage Recess details Strand size 12.structuralsystems. Contact SSL for further details • Check jack size and availability with your local SSL office 14 www.7mm Tendon Unit Dimensions (mm) F x F G H x H 705 406 230 140 310 1205 706 270 140 370 Recess details 1905 1206 340 150 400 3105 1906 420 165 510 - 2206 420 165 510 4205 3106 460 185 560 6105 4206 560 200 660 5506 650 225 750 Notes: • Depth G achieves 50mm cover to trimmed strand ends. Space Requirements for Stressing Jacks Strand size 12. Refer to your local Structural Systems office.9mm Tendon Unit 15.com.7mm / 12. • Alternative or smaller recesses may be possible depending on actual conditions and jack used.2mm / 15. Alternative jacks may be available and/or more suitable.2mm / 15.9 mm Tendon Unit 15.7mm Tendon Unit 705 406 Space Requirements 1205 706 1905 1206 3105 1906 - 2206 4205 3106 6105 4206 5506 Jack unit CC 110 CC 200 CC 300 CC 600 CC 600 CC 630 CC 1000 CC 1200 Dimensions (mm) A 710 750 810 1200 1200 1000 1130 1300 B 1400 1500 1600 2400 2400 2000 2300 2600 C 250 300 330 500 500 600 600 600 E 200 230 260 400 400 500 420 450 F 595 620 675 1100 1100 950 950 1050 Notes: • Details based on jacks having 200mm working stroke. 7mm O. watertight system offers superb corrosion protection.0 2.15 4205 3106 8 1. Steel Duct (refer page 6) 705 1205 1905 3105 4205 6105 406 706 1206 1906 3106 4206 61 75 94 110 125 160 48 65 82 98 110 138 2.0 2.D.0 2.com.0 2. L (m) Sheathing and Corrosion Protection For conventional applications.8 1205 706 4. WALL THICKNESS Galv.3mm. and the plastic duct eliminates fretting fatigue between the strand and duct. It also provides reduced duct friction. For applications requiring enhanced corrosion protection and improved fatigue resistance of the tendons.5 1.5 Minimum Radius.0 2.3 5506 10 1.0 3105 1906 6 1. Reduction may be allowed in certain specific instances.7mm 705 406 4 0.2mm/15.1 - 2206 6. R (m) Minimum Straight Portion.3 6105 4206 8 1.9 1905 1206 5 1. DUCT DIMENSIONS (mm) I.structuralsystems.5 0.D.7mm/12. All ducts are manufactured in a variety of standard lengths and are coupled on site.MULTI-STRAND post-tensioning Tendon Curvature A straight portion L adjacent to the anchorage must be observed to limit the screw pull of the strand bundle against the anchorage.2mm / 15. corrugated galvanised steel ducts are used with a wall thickness of 0.9mm 15.0 Polyethylene Duct (refer left) Notes: • Check with SSL office for availability and lead time for standard and/or alternative polyethylene duct sizes Eccentricity of Tendons TENDON eCcentricity TYPE e mm 705/406 10 11 14 15 21 25 28 1205/706 1905/1206 3105/1906 2206 4205/3106 6105/4206 Notes: • “e” is indicative only and depends on actual duct ID and number of strands in tendon www. Tendon Curvature Limitations 12. This fully encapsulated.au 15 . Tendon Sheathing and Corrosion Protection Polyethylene Duct Details TENDON TYPE 12.9mm 15. use of corrugated plastic duct is recommended.7mm / 12. Steel ducts are available in diameters ranging from 40mm to 160mm in approximately 5mm increments. com.Western Australia 16 www.7mm STRAND TENDON UNITS 406 205 120 180 200 120 180 200 120 180 706 270 145 230 255 145 230 250 145 230 1206 355 180 300 330 175 290 310 175 290 1906 450 225 390 420 215 370 395 210 360 2206 480 240 425 450 230 400 420 225 390 3106 570 285 520 535 275 490 500 265 470 4205 665 335 590 620 310 560 585 300 540 40 50 Notes: • The above details are provided as a guide only and designers should normally satisfy themselves by calculation that the adopted details are suitable for the actual application.structuralsystems.au . distance from concrete edge to anchorage axis = suggested outside diameter of reinforcing steel spirals = nominal concrete cylinder strength Prestressing forces can usually be applied at 80% of nominal concrete cylinder strength. Tung Chung Bridge . distance between axis of two anchorages = min. MINIMUM ANCHORAGE SPACING AND EDGE DISTANCES f’c MPa 32 DETAILS mm ao bo Dsp ao bo Dsp ao bo Dsp 12.2mm & 15.7mm & 12.9mm STRAND UNITS 705 220 130 200 205 125 190 195 120 180 1205 290 155 250 270 150 240 255 145 230 1905 365 190 320 340 185 310 320 180 300 3105 465 235 410 435 225 390 410 220 380 4205 545 275 480 505 260 460 475 250 440 15.Hong Kong Mt Henry Bridge .PRESTRESSING TECHNOLOGY multi-strand post-tensioning Minimum Distance for Bearing Plates to concrete Edges and between Adjacent Anchorages The minimum required distance of the bearing plates to concrete edges and to adjacent anchorage bearing plates depends in general on: • the post-tensioning force to be transmitted • the concrete strength • the bearing plate dimensions • the reinforcing steel behind the bearing plate • structural requirements ao bo Dsp f’c = min. com.Dubai West India Quay . Al Nuaimiah Towers . owners and end users of buildings require more efficiencies today than ever before. the individual strands have a specified load applied by calibrated jacks. After the concrete has reached a suitable transfer strength. Applications for the Structural Systems Slab PostTensioning System include: • Low to high rise residential and commercial buildings • Industrial floor slabs on grade • Transfer floor structures • Car parks • Water tank bases and walls • Transverse stressing of bridge decks The system is comprised of high-strength steel strands placed inside flat ducting.structuralsystems. anchored at one end by deforming the strand and casting it into the concrete.London www.au 17 .slab POST-TENSIONING slab post-tensioning Designers. The Structural Systems Slab Post-Tensioning System offers all the stakeholders in a building project many benefits including: • • • • • • • • Reduced structural depths Greater clear spans Design flexibility Formwork versatility Reduced construction costs Enhanced construction speed Improved durability Minimum maintenance costs then at the other end by means of a steel anchorage casting and anchor block(s) with gripping wedges. builders. The duct is filled with a water/cement grout mixture to ensure that the system is bonded and corrosion protection is maintained in service. 2mm and 15.2 mm and 15.7mm and 12.au . 605. and 206 are supplied with individual barrel anchorages in lieu of anchorage blocks. Additional intermediate vents can also be supplied (designer to specify requirements).9 mm 15.9mm 15. detailing and tolerance requirements.PRESTRESSING TECHNOLOGY slab post-tensioning live end anchorages grout tube duct grout tube anchorage block strand duct wedge grips anchorage casting wedge strands barrel anchorage casting Notes: • Similar non-reusable recessformers are used at angled edges •S tandard flat duct is produced from 0.7 mm Notes: 205 305 505 605 206 406 506 2 3 4 or 5 6 2 3 or 4 5 43 x 19 70 x 19 90 x 19 • Tendon units 205. Dead-End Anchorages bulbed strand ends grout tube duct dead end plate swage plate duct grout tube grout tube duct spacer plate (not always required) swaged strand ends bulb-type Strand size tendon UNIT 12. • All sizes are nominal. Some dimensions have been rounded up for normal space.7mm 105 205 305 405 505 605 106 206 306 406 506 swage-type Bulb-Type Dead-End Anchorage Swage-type dead-end anchorage DIMENSIONS (mm) dimensions (mm) A B C d E F 75 135 230 270 350 400 75 135 230 270 350 50 50 50 50 50 50 50 50 50 50 50 600 600 600 600 600 750 750 750 750 750 750 100 125 200 250 300 350 125 150 225 300 350 75 75 75 75 75 75 75 75 75 75 75 100 150 350 500 500 600 100 250 450 600 600 18 www. STRANDS ANCHORAGE CASTING A mm 155 150 215 270 155 215 270 RECESS FORMER D mm 100 100 100 100 100 100 100 B mm 135 150 220 265 135 220 265 C mm 67 75 79 79 67 79 79 E1 mm 150 180 265 265 150 265 265 E2 mm 150 180 315 315 150 315 315 F1 mm 100 100 80 80 100 80 80 F2 mm 100 100 100 100 100 100 100 FLAT DUCT SIZE mm 43 43 70 90 x x x x 19 19 19 19 12. • Grout tubes are 13mm ID or 19mm ID polyethylene pipe supplied to each end of tendon.4mm galvanised steel sheet Stressing Anchorage (Live Ends) STRAND SIZE TENDON UNIT No.structuralsystems.com.7 mm and 12. www.405 Grout Pump Coupling Anchorages Strand Size Coupling Unit 12.com. uno.slab POST-TENSIONING coupling anchorages Coupling Anchorage .9mm 15.structuralsystems.505.7mm 405 505 506 A 100 100 100 Coupling Anchorage Details Dimensions (mm) B C 220 220 240 80 110 120 D 220 220 265 Note: 3 and 4-strand units are coupled using the applicable 5-strand coupler. 406 & 506 duct grout tube swaged strand ends anchorage casting coupling block wedge grips Coupling Anchorage .2mm / 15.7mm / 12.au 19 . grade 500MPa to AS/NZS 4671 or grade 460 to BS4449.9mm 15.7mm / 12.5mm 1. 2 2 2 2 2 2 2 x x x x x x x 1 1 2 4 2 2 4 fcp MPa 17 17 22 25 17 22 25 • Reinforcement size 10dia.com.structuralsystems. OF STRANDS 2 3 4 or 5 6 2 3 or 4 5 SPIRAL TYPE A mm 90 100 100 110 90 110 110 B mm 200 260 260 300 200 300 300 N No.2mm / 15.5mm strand at tendon high point 20 www. • Details shown are generally satisfactory for most standard situations. however designers should satisfy themselves of the adequacy of local zone anchorage reinforcement for specific situations. Spiral Type 2x2 ligature 2x1 ligature similar 2x4 ligature suggested allowances – strand offsets for 19mm flat duct Strand Size 12.au strand at tendon low point .PRESTRESSING TECHNOLOGY slab post-tensioning Anchorage Reinforcement – slab system TENDON UNIT 205 305 505 605 206 406 506 Notes: No.7mm A 7mm 8mm B 12mm 11mm e 2. • fcp = min required air-cured concrete cylinder strength at anchorage at time of stressing. 4 4 5 7 4 7 7 C mm 200 200 200 200 200 200 200 LIGATURE TYPE D mm 100 100 130 150 110 130 150 N No. com.2mm / 15.slab POST-TENSIONING Jacking Clearances double ram jack single ram jack Jacking Clearances Strand Size 12.9mm 15. Actual details may vary. Stressing Pocket www. • Details shown provide typical pocket spacing requirements.7mm A mm 500 600 B mm 900 900 C mm 750 850 D mm 450 450 E mm 70 70 internal stressing pockets Notes: • Internal Stressing Pockets are used where standard edge stressng is impractical. subject to design check.7mm / 12.structuralsystems.au 21 . schools and institutional facilities Different formwork systems are compatible with posttensioning.au .structuralsystems.com. These benefits include: • • • • • • • • Reduced construction cost Faster construction Water resistant properties Early formwork stripping Floor to floor height reduction Reduced foundation load Improved deflection control Greater column free areas Wollongong Links Project .Queensland 22 www.suspended slabs Post-tensioning provides many benefits to a wide range of suspended structures.NSW Many types of suspended slab structures typically realise the benefits of post tensioning. exhibition centres. Peppers Pier Resort .PRESTRESSING TECHNOLOGY SLAb post-tensioning applications . namely: • • • • Conventional plywood systems Permanent metal deck systems Ribbed slabs Precast systems Structural Systems has many years of experience in the design and installation of post-tensioned suspended slabs and can bring measurable benefits to your project. such as: • • • • • • • • Carparks Apartment buildings Commercial office space Retail centres Vertical load transfer structures Hospitals Storage facilities Public buildings such as stadiums. 45 is usually sufficient to ensure adequate grouting and strength. High and low points should be nominated. • Stressing Procedure. • Grout. Structural Systems can offer design input from initial advice to fully detailed design for construction drawings. (suit formwork) P = Overall Drop Panel Depth (1. • Profiling. Concrete testing of site and air cured specimens should be carried out to ensure this strength has been achieved prior to application of the final stressing. Typical post-tensioned floor configuration and details are: banded slab flat slab flat plate DEFINITIONS Lb = Band Span Ls = Slab Span L = Design Span (Greater of L1 & L2) Note: For Slab End Spans.5kPa. Clearly indicate the type and location of anchorages and number of strands in each tendon. Nominate the 28 day characteristic compressive strength and shrinkage characteristics required. • Concrete.5kPa Specifying Post-Tensioning It is important that the design requirements are achieved on site.structuralsystems.suspended slabs The design of post-tensioned suspended slabs requires sound engineering consideration in order to maximize the benefits for all stakeholders in a project. A water/cement ratio of not more than 0. Full tendon profiles can then be determined on installation shop drawings. This ensures that a fully tested and code compliant system will be installed. • Concrete Strength at Transfer fcp. • The System. Add 15-20% to Slab Thickness from charts T = Internal Slab Thickness D = Overall Band Depth Bw = Suggested Band Width Approx. Check that stressing access is possible at live ends.au 23 . Some projects may have additional requirements.slab POST-TENSIONING Design of post-tensioned . A two stage stressing procedure is usually specified. Profiles are usually parabolic.8xT) TYPICAL DESIGN LOADS LL = 5kPa. • Tendons. ADL = 1kPa LL = 4kPa. State that the design is based on the Structural Systems SLAB post-tensioning system. ADL = 1kPa LL = 3kPa. Good engineering notation can greatly assist in achieving this. www.com. ADL = 0. and final or 100% load is applied when the concrete transfer strength is released. ADL = 1kPa LL = 2. Initial or 25% load is applied at 24 hours after the slab pour. with particular attention to the following. This is the minimum compressive strength that is required prior to fully stressing the tendons. au . Erect formwork Install bottom reinforcement Install post-tensioning Install top reinforcement Prepour inspection and pour concrete Strip edge forms Initial/Partial stressing of tendons Final/Full stressing of tendons Obtain engineers approval and cut off excess tendon strand • Grout the tendons • Strip formwork and back prop as required • • • • • • • • • Cabrini Hospital . Below are a selection of tried and proven details that Structural Systems recommend for a range of situations.Melbourne 24 www. An appreciation of the construction process will enable all parties involved in the on site works to benefit from the system.suspended slabs Structural detailing is an art that engineers develop with experience and it is an essential part of a cost effective and reliable structure.structuralsystems. The typical construction sequence is as follows. Construction Structural Systems designers have worked closely over many years with builders and construction personnel resulting in a well understood system that enhances the construction process.com. A key factor in achieving a successful Post-Tensioned Structure is a sound understanding of and a considered allowance for normal concrete shrinkage movements.PRESTRESSING TECHNOLOGY Detailing of post-tensioned . Computer modelling and Analysis www. engineers and developers in achieving optimum solutions for slab on ground applications. Port Botany .NSW Design The design of post-tensioned slabs on ground involves the careful analysis of the loads applied to the slab. the interaction between the slab and the ground that supports it.slab on ground The post-tensioning of slabs on ground is providing many developers and builders with a cost effective pavement solution.slab post-tenSioning Slab post-tensionING applications . Our design and construction expertise for preliminary design advice through to final design and construction activities is available to assist builders. Structural Systems has refined the design process and has achieved outstanding results on many projects.com.au 25 .structuralsystems. Benefits realised with post tensioned slabs on ground include: • Large joint free slab areas • Reduced construction costs • Less sub base preparation and/or excavation • Faster construction time • Reduced on going maintenance costs Facilities that have adopted a post-tensioned slab on ground system include: • Distribution warehouses • Freezer stores • Container terminal facilities • Rail freight facilities • Aircraft hangers • Water retaining structures • Sporting venues • Raft slabs Container Pavement. restraint forces and temperature effects. Western Australia 26 www. Warehouse floor construction using laser screeds Raft Foundation .structuralsystems. Typical gradients of 0.Design Axle load “P” .The Moorings.Axle Load Repetitions .5 to 0. Modelling of the sub-base requires geotechnical data such as CBR.com. Normal elastic and shrinkage movements give rise to frictional restraint stresses between the slab and the prepared subgrade.PRESTRESSING TECHNOLOGY DEsign of post-tensioned slab on ground Points to consider in the design process include: Design Loads and Load Configurations a) typical design racking layout DATA .6.04 ºC/mm are often used for internal and external slabs respectively causing bottom fibre tensile stresses that are additional to the load stresses.Wheel Contact Stress Typical racking storage Sub-grade Friction b) design wheel / axle details Thermal Effects Daily ambient temperature variations give rise to temperature gradient stresses through the slab depth which need to be accounted for in the design. Sub-base Parameters A typical slab design will include the analysis of the slab supported by the ground sub-base.) .02 ºC/mm and 0. The typical design friction coefficient for concrete laid on a plastic membrane over clean sand bedding is around 0.Wheel Spacing “W” (2 or 4 wheels etc.au . and/or the modulus of sub-grade reaction. 5mm per metre length of slab (e. Curing and Weather Protection With large pours the slab is initially susceptible to shrinkage effects hence it is important to cure and protect the slab from extreme conditions such as heat.Slab post-tenSioning DEsign of post-tensioned slab on ground Good detailing of post-tensioned slabs on ground is vital in achieving a successful and relatively crack free slab. The construction of warehouse roofs prior to pouring slabs is a typical technique adopted to provide some protection. The main items to consider for the construction phase are. each edge moves approx 15mm over the normal life of the slab).g for 60m long slab.com. .J. high evaporation or extreme cold. movements of approximately 0. The following diagrams indicate key details typically recommended by Structural Systems: Column blockout detail typical warehouse plan Note: • As a guide.au 27 Pour Size A pour size of between 1500m2 and 2000m2 should typically be considered and planned. The combination of innovative design and expedient site practices ensures that the construction phase is a seamless operation. www. Construction Structural Systems design and construction experience is based on being the leader in the field of posttensioned slabs on ground. allow for total slab edge & M.structuralsystems. Pour Sequence The sequence of slab pours and their respective stressing requirements should be optimized to ensure the best programme outcome. which is cold-formed onto the wire by means of special machines. Narrows Bridge Duplication . wires (plain or galvanised).PreSTRESSING TECHNOLOGY multi-wire post-tensioning The BBR SSL Multi-Wire System is more compact than the multi-strand system and is often preferred for coupled cables in incrementally launched bridges. Centrepoint Tower . and is ideally suited where cables are to be prefabricated and where restressing or destressing is required. • Restressable ground anchors. Therefore the wire bundle can sustain the maximum ultimate load. • The anchorage resists with a high degree of safety dynamic loads and also exceptional effects such as shock loads. • Restressable tendons. The multi-wire tendon is composed of a bundle of 7mm dia.au . • Monitoring of the prestressing force and if necessary restressing can be carried out reliably and economically. Each individual wire is fixed in the anchorage with a multi-wire button head.Sydney Typical applications include: • Coupled cables in incremtally launched bridges.Western Australia 28 www. • The prestressing force is transmitted to the concrete under precisely known conditions without any risk of slippage of the prestressing steel. • Heavy lifting and lowering cables. If required.structuralsystems. • Cable stay applications.com. • Each wire is mechanically fixed in the anchor head and reaches the full rupture load of the prestressing steel without any slippage. the tendon can also be completely destressed. buildings and other structures can be met. which is connected to the stressing anchorage.75 x MBL kN Tendon nominal cross sectional area Weight of tendon wire Duct I. The prestressing force can be measured with an accuracy of 2% by using calibrated 150mm face bourdon type pressure gauges. nuclear vessels.42 65 80 85 32. eg. all prestressing requirements occurring in the construction of bridges.67 100 109 7009 5607 5257 4197 121 7780 6224 5835 4659 143 9195 7356 6896 5506 43. For special applications. dia.8 x MBL kN Stressing force at 0.com.54 110 120 • Rm = Characteristic Tensile Strength to AS 4672 and/or BS 5896 Grouting of Ducts SSL has developed grouting methods utilising special colloidal mixers which result in an optimal grouting of the tendon ducts.92 36.42 35 19 1222 977 916 731 5.000 kN ultimate capacity are available.MULTI-wire POST-TENSIONING Standard Tendons The anchoring method allows the production of posttensioning tendons with any number of single wires and therefore with any given magnitude of prestressing force. trestle and pull-rod.structuralsystems.19 130 mm2 kg/m mm 12.36 55 42 2701 2160 2025 1617 55 3537 2829 2652 2118 61 3922 3138 2942 2349 85 5466 4372 4099 3273 25. The most commonly used wire diameter is 7 millimetres.61 18.68 16. Prestressing Jacks Stressing Jack Type Maximum Jacking Force Jack Diameter Stroke Weight Clearance Requirement ‘A’ Notes: NP 60 620 160 100 28 1700 NP 100 1030 205 100 50 1700 NP 150 1545 250 100 83 1700 NP 200 2060 290 100 117 2000 NP 250 2575 315 100 147 2000 NP 300 3090 350 100 196 2000 GP 500 5150 560 400 1260 2500 GP 800 8000 660 400 2000 2500 kN mm mm kg mm • Check jack size and availability with your local SSL office www.BBR Wire Tendons Number of wires. Prestressing Equipment The prestressing equipment consist of a hydraulic jack. the pull-rod is temporarily anchored with a lock-nut and the jack is recycled. For tendon elongations greater than the stroke of the jack. With the following range of STANDARD TENDONS. Standard SSL . 7mm Minimum Breaking Load (Rm = 1670 MPa) kN Stressing force at 0.74 50 31 1993 1595 1495 1194 9. Notes: 8 514 412 386 308 2.D.au 29 . tendons up to 15. 7mm Fan length rectangular 19 31 85 109 121 143 k mm 460 550 660 830 880 960 1010 1060 1180 1220 1260 l mm 70 90 120 140 160 180 200 240 260 280 300 Anchor plate.PRESTRESSING TECHNOLOGY multi-wire post-tensioning Stressing Anchorage Type L Number of wires dia. 7mm Anchor 8 12 27 19 36 31 43 42 49 55 56 61 67 85 109 121 143 78 85 140 145 e mm 25 Elongation. 7mm Anchor Diameter Thickness 8 12 74 19 31 42 55 61 85 109 121 143 a mm 63 c mm 70 dt mm 14 91 108 123 135 156 180 205 240 245 Trumpet Length b mm 250 250 250 280 300 300 300 340 360 400 500 88 102 123 138 153 171 193 219 240 252 16 20 25 30 35 40 50 60 70 70 Bearing Plate d mm 140 170 200 245 285 315 345 400 450 500 520 Stressing Anchorage Type A Number of wires dia. sq l mm 120 160 200 250 280 320 350 400 450 470 520 w mm 200 270 340 420 500 560 600 660 760 790 900 Fixed Coupling Type LK Number of wires dia.au .com. 7mm Diameter 8 12 19 31 42 55 61 85 109 121 143 Trumpet length q mm 230 260 290 350 410 430 470 570 630 680 730 r mm 70 88 102 123 138 153 171 193 219 250 260 Movable Coupling Type LK 1 Number of wires dia.structuralsystems. 30 www. max f mm 200 200 200 200 200 250 250 350 350 400 400 Trumpet length g mm 170 185 200 280 310 335 360 390 420 450 500 Diameter Bearing plate Thickness h mm 37 it mm 16 8 49 20 12 59 25 76 30 87 40 42 97 105 120 135 145 160 45 55 50 61 60 70 80 80 i mm 140 170 200 235 270 300 330 380 430 480 500 Fixed Anchorage Type S Number of wires dia. 7mm Diameter 8 12 19 31 42 55 61 85 109 121 143 Trumpet length min s mm 600 620 670 750 810 880 950 1080 1150 1220 1260 t mm 70 88 102 123 138 153 171 193 219 250 260 Special Application Anchorages Details of Anchorages for various special applications are also available on request . The robust coarse thread (CT) on the Macalloy bar ensures rapid and reliable assembly. Permanent Bar Anchors These anchors require installation into corrugated polyethylene sheathing or galvanised duct similar to strand anchors to provide multiple levels of protection.structuralsystems.com. Bearing Plate Nut Bar Characteristic Properties Macalloy Bar Properties are listed in the following tables. When bars are used in an exposed environment then other corrosion protection systems are available for the bar and fittings. Anchorage recesses must also be filled with cement mortar to protect these end zones. Washer Coupler Macalloy 1030 Bar Components www. Through the use of threaded connections and anchorages they are simple to use and lend themselves to many applications.au 31 . This is accomplished by the internal grout and sheathing barrier.bar POST-TENSIONING bar post-tensioning Macalloy Bar Systems are ideal for the economic application of post-tensioning forces on relatively short tendons. These include: • greased and sheathing bar • denso wrapping • epoxy painting Temporary Bar Anchors Anchors used in a temporary environment may be used without protection apart from grout required to the bond length. provides excellent protection. Typical Applications Buildings • Prestressed Beams and Columns • Precast Connections • Temporary Bracing Bridges • Stay Cables and Hangers • Precast Segments • Strengthening (Timber & Steel Bridges) • Tension Piles and Caissons Wharves & Jetties • Stressed Deck Planks • Tie Backs Soil and/or Rock Anchors • Permanent and Temporary Anchors • Uplift Anchors (Dam & Foundation) • Tunnel Roof Bolting • Soil Nails and Rock Bolts • Slope Stabilisation • Crane and Tower Bases Specialist Engineering • Heavy Lifting • Formwork Ties and Hangers • Frame Ties • Pile Testing • Architectural Ties and Stays Corrosion Protection All bars and fittings must receive protection when installed under permanent conditions. injected with grout. This is particularly suitable for onsite use and reuse. In normal concrete construction the use of galvanised duct. 5 32 36 40 50 75 NOMINAL CROSS SECTION AREA mm2 315 491 552 804 1018 1257 1963 4185 MASS OF BAR MACALLOY 1030 kg/m 4.0 28.63 10.30 MAJOR DIAMETER OF THREADS mm 22.09 6.35 10.72 33.PRESTRESSING TECHNOLOGY BAR post-tensioning RANGE OF MACALLOY 1030 BAR NOMINAL DIAMETER mm 20 25 26.4 36.2 MIN.2 45.structuralsystems.1% PROOF STRESS MPa 835 835 835 MINIMUM ELONGATION % 6 6 10 APPROXIMATE MODULUS OF ELASTICITY GPa 170 205 185 Macalloy 1030 25-50mm Macalloy 1030 75mm *Macalloy S1030 CHARACTERISTIC LOADS FOR MACALLOY 1030 BAR NOMINAL DIAMETER mm 20 25 26.8 77.5 32 36 40 50 75 * Macalloy S1030 is made from stainless steel CHARACTERISTIC BREAKING LOAD (MBL) MACALLOY 1030 kN 506 569 828 1049 1295 2022 4311 *MACALLOY S1030 kN 323 506 828 1295 - MINIMUM 0.9 30.au .00 *MACALLOY S1030 kg/m 2.30 15.58 6. HOLE DIAMETER IN STEELWORK mm 24 31 33 40 44 49 59 82 MECHANICAL PROPERTIES OF MACALLOY 1030 BAR GRADE CHARACTERISTIC ULTIMATE TENSILE STRENGTH MPa 1030 1030 1030 MINIMUM 0.com.2 40.53 4.09 4.63 8.3 54.1% PROOF LOAD MACALLOY 1030 kN 410 460 670 850 1050 1639 3495 *MACALLOY S1030 kN 262 410 670 1050 - 32 www. 0 250 100 60 105 57 12 FC36 57.standard Length .94 FP32 125 125 50 41 50 50 66 60 GF32 140 40 6. † 1 20mm bar available in stainless steel grade only.5 250 100 40 75 42 12 FC25 42.50 FP36 140 140 50 45 50 50 71 65 GF36 140 40 6.com.0 250 100 50 91 53 12 FC32 50 115 95 0.200 118 96 62 30 1049 1295 2022 4311 734 907 1415 3018 140 150 175 250 FN36 46 62 0.451 10.74 FN40 51 65 0.bar POST-TENSIONING MACALLOY 1030 COMPONENT PARAMETERS ITEM Bars Sectional area Mass per metre Metre run of bar per tonne Characteristic failing load Prestress at 70% characteristic Minimum centres for anchorage Nut reference Length Width across flats (DIA for 75mm bar) Weight Washer reference Outside diameter Thickness Coupler reference Outside diameter Length .00 FP75 300 250 75 82 110 91 125 125 8.5 140 120 1.mm 251 490.10 FP50 200 175 60 61 70 71 91 90 8.0 250 100 65 115 62 12 FC40 62.Dead end (standard) S2 .661 150 828 580 125 FN32 41 56 0.5 85 80 FP25 100 100 40 35 40 41 59 52.6 1963.4 8.threaded Ducts Sheathing i/d Coupler-sheathing i/d recommended Coupler-sheathing minimum Flange reference Length /o/dia Height Pitch Length .069 246 506 354 100 FN25 33 46 26.410 16.020 33.Coupler (standard) X1 (min) X2 (min) X3 (min) Grouting flange Threads Standard thread lengths (see fig on p30) * Spherical nuts and washers are available if required for rotation.5 110 110 40 36 40 41 59 52.54 FP26.stainless Weight UNIT mm2 kg m kN kN mm mm mm kg mm mm mm mm mm kg mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm †201 314.78 FP40 150 150 60 52 60 61 75 70 8.5 GF25 125 40 6.5 130 1.NSW www.46 32 804.0 250 100 85 165 91 16 End Plates Plate reference Length Width Thickness .5 4185.0 360 160 150 235 116 16 *Flat Nuts FSSN20 25 42 - *Flat Washers Couplers FSSW20 FSW25 FSW26.9 4.5 90 0.560 219 569 398 110 FN26. Homebush .70 FC75 110 230 9. Bar range available on request Sydney Hockey Centre.Jacking end (standard) S1 .56 36 40 50 75 1017.86 FN50 71 90 2.466 405 314 220 100 NOMINAL BAR DIAMETER .structuralsystems.5 4.55 FN75 100 135 7.9 1256.standard Hole diameter Thickness .0 250 100 45 82 49 12 FC26.5 GF25 125 40 6.3 6.5 551.au 33 .5 42.5 37 50 0.5 FSW32 FSW36 FSW40 FSW50 50 60 65 70 75 80 105 5 5 5 5 5 5 5 FSSC20 35 65 FSSP20 100 100 25 26 41 50 45 2.2 2.0 250 100 75 130 71 16 FC50 76 170 3. mm 12 12 12 12 12 16 20 I/D mm 130 130 165 195 220 250 350 PITCH mm 40 40 40 40 40 50 75 TURNS No.PRESTRESSING TECHNOLOGY MACALLOY 1030 BAR END THREAD DIMENSIONS X1 = live end X2 = dead end X3 = length of bar past nut or thru’ threaded plate S1 = live end thread S2 = dead end thread L = length over plates MACALLOY 1030 TYPICAL END BLOCK ARRANGEMENT MACALLOY 1030 SUGGESTED MILD STEEL END BLOCK REINFORCEMENT NB: Helix and links must be used together with minimum 35 MPa concrete . and advice is readily available from Structural Systems OTHER MACALLOY BAR SYSTEMS ALSO AVAILABLE • • • • • Macalloy Macalloy Macalloy Macalloy Macalloy 460 carbon steel tendons S460 stainless steel tendons Guy Linking stainless steel bar tendons Guy Linking stainless steel cable tendons 17MHS Sheet piling ties • • • • Macalloy 500 Reinforcing bars Macalloy 500 Tie bars Macalloy 650 Stainless Tie bars Macalloy-Tensoteci Galvanised cable tendons 34 www.5 32 36 40 50 75 Notes: HELIX ROD DIAM.com. 5 5 6 7 7 8 8 ROD DIAM.structuralsystems.see figure above MACALLOY DIAMETER mm 25 26.au . mm 8 8 8 8 8 10 16 LINKS SPACING mm 70 70 80 80 80 100 100 NUMBER 3 3 3 4 4 4 6 • A longitudinal length of rod may be used to attach the links but it is not required as part of the reinforcement • A more detailed explanation of the Macalloy Post Tensioning System is available in the Macalloy Design Data Handbook • There are many permutations possible to achieve satisfactory construction details. Western Australia www.ground anchor systemS ground anchor SystemS Structural Systems Ground Anchors have been utilised world wide in conjunction with our construction partners the BBR group of Switzerland.Canning Dam . Typical applications of Structural Systems Ground Anchors include: • retaining structure tie backs • resistance of uplift forces • slope stabilization • underground structures • dam stabilization • tension foundations • soil nailing (bar type anchors) Transporting world’s longest ground anchors . Standard Structural Systems Ground Anchors can provide an ultimate load of between 368kN and 23. strands or bars can be installed into rock or soil and secured by injecting with cement grout.au 35 .Western Australia Transporting ground anchors Ross River Dam .Queensland Anchor installation Anchor Fabrication .750kN depending on the configuration. Ground Anchors comprised of wires.structuralsystems.com.Canning Dam . SSL BBR Anchors have been the largest and longest installed anywhere around the world and our technical expertise in this field is internationally recognised. com.structuralsystems.PRESTRESSING TECHNOLOGY ground anchor SystemS STRAND TYPE ANCHORS 36 www.au . 7mm or 12.2mm or 15. STRAND 2 4 7 12 19 22 27 31 42 55 65 91 91+ STRAND 12.9mm MACALLOY BAR 26.refer SSL 55 / 63 67 / 75 82 / 90 2 4 7 larger sizes on request .7mm under development .2mm strand) (Higher strand / anchor capacities available on request) • Details listed apply to typical applications and may vary to suit actual applications • Macalloy Bar tendons are more commonly used for short anchor lengths • Macalloy Bar anchor details exclude allowance for coupling of bars .refer SSL for details if required www.ground anchor systemS TYPICAL GROUND ANCHOR TENDON CONFIGURATIONS TENDON STRAND MAXIMUM / BAR SIZE STRANDS PER UNIT mm No.au 37 .5 32 40 50 75 Notes: MINIMUM BREAKING LOAD kN 500 1000 1750 3000 4750 5500 6750 7750 10500 13750 16250 22750 368 736 1288 BORE HOLE DIAMETER PERMANENT ANCHOR SHEATH SIZE ID / OD SMOOTH mm 55 67 82 102 150 150 150 150 225 225 225 257 / / / / / / / / / / / / 63 75 90 110 160 160 160 160 235 235 235 270 TEMPORARY PERMANENT CORRUGATED ANCHORS ANCHORS mm mm mm 76 89 102 114 165 165 178 178 229 241 254 311 76 89 102 102 127 152 178 216 216 216 216 311 311 311 356 102 127 152 50 / 65 65 / 85 80 / 100 100 / 120 125 / 165 125 / 165 125 / 165 125 / 165 210 / 230 210 / 230 210 / 230 250 / 270 50 / 65 65 / 80 80 / 100 BEARING PLATE SIZE TYPICAL mm 200 x 200 x 32 200 x 200 x 36 300 x 300 x 50 350 x 350 x 60 400 x 400 x 70 450 x 450 x 80 500 x 500 x 80 500 x 500 x 90 600 x 600 x 100 700 x 700 x 120 700 x 700 x 140 900 x 900 x 160 200 x 200 x 32 200 x 200 x 36 250 x 250 x 40 15.7mm strand) and MBL = 250kN (15.refer SSL 1 1 1 1 1 569 828 1295 2022 4311 76 102 102 127 152 127 152 152 175 203 65 / 80 80 / 100 80 / 100 100 / 127 130 / 150 n/a n/a n/a n/a n/a 200 250 300 300 400 x x x x x 200 250 300 300 400 x x x x x 40 50 60 60 90 • Strand tendons are based on MBL = 184kN (12.structuralsystems.com. b) Due to the location and accessibility of the tendons. g) External prestressing tendons can easily and without major cost implication be designed to be replaceable. readily carried out compared to internal. better concrete quality can be obtained leading to a more durable structure. because the unintentional angular changes.com. concrete. d) Improves the concrete placing due to the absence of tendons in the webs. de-stressable and re-stressable. bonded prestressing. resulting in an overall lighter structure. monitoring and maintenance can be 38 www. both for new construction as well as strengthening of existing structures. except at anchorage and deflector locations. e) Improvement of conditions for tendon installation which can take place independently from the concrete works. As an overall result. Advantages of External Prestressing Compared to internal bonded post-tensioning the external prestressing has the following distinct advantages: a) The application of external prestressing can be combined with a broad range of construction materials such as steel. External post-tensioning . composite structures and plastic materials.structuralsystems. • No bond is present between the tendon and the structure. f) Reduction of friction losses. it is possible to restress. timber.au . • The forces exerted by the prestressing tendons are only transferred to the structure at the anchorages and at deflectors.Navia. are practically eliminated.PRESTRESSING TECHNOLOGY external pREStReSSING External prestressing was first used in the late 1920’s and has recently undergone a resurgence being used in bridges. provided that the structural detailing allows for these actions. known as wobble. c) Due to the absence of bond. This can considerably widen the scope of the posttensioning applications. Furthermore with the use of a polyethylene sheathing the friction coefficient is drastically reduced compared to internal bonded prestressing using corrugated metal ducts. h) Generally the webs can be made thinner. Spain Features of External Prestressing External prestressing is characterised by the following features: • The prestressing tendons are placed on the outside of the physical cross section (mostly in concrete) of the structure. destress and exchange any external prestressing cable. i) Strengthening capabilities. 1. Standard Cona Compact Anchorage Assembly Fig.7mm 7 12 19 31 42 DIMENSIONS (mm) TYPE 706 1206 1906 3106 4206 A1 x A1 215 265 335 395 500 ØB C 52 65 80 97 116 D 105 115 130 150 155 E1 355 425 511 650 950 ØF G 75 80 90 100 160 AD/ID 75 / 66.au 39 .4 90 / 79. practical and economical. ANCHORAGE CASTING Fig. Underslung structures . in particular concentric prestressing - Alternatively a fabricated steel bearing plate anchorage can be used in lieu of the cast anchorage.2mm / 15. 2. Repair work and strengthening of all kinds of structures . are: . anchorage casting and polyethylene trumpet safely transfers the prestressing forces to the structure (see Fig.8 110 / 97.7mm diameter strands with minimum breaking load of 250 kN or 279 kN.Simple and continuous spans .com. Incremental launching procedure. - A standard CONA Compact anchorage assembly consisting of anchor head. The tendon sheathing passes freely through intermediate diaphragms and through deflectors with a metal or HDPE sleeve providing the required penetration. Precast segmental construction . - The duct is from high density polyethylene and continuous from one anchorage to the other. wedges. the anchor heads may be protected by a cap. - The tendon is filled with cement grout after it has been tensioned.4 180 / 147. Depending on requirements.4 140 / 124 210 / 200 ad/id 90 / 79.8 110 / 97. SSL-CONA External with anchorage casting SSL CONA EXTERNAL TENDONS Main Dimensions NUMBER OF STRANDS 15.2 243 / 225 150 180 230 290 340 109 138 178 222 283 www.2mm/ 15.4 140 / 114.external POST-TENSIONING Typical Applications for External Prestressing Typical applications where external tendons are feasible.structuralsystems. or alternatively the anchorage recess is filled with nonshrink concrete. Basic Type The basic SSL BAR CONA External tendon is practically identical to the SSL Multi-Strand System for internal applications: - The tendon is formed from standard 15. 1). com. waxed and individually sheathed strands. wire (DinaTM / HiAmTM) stay cables. and Carbon stay cables for a wide variety of structures. drawing on both local and global expertise and resources of the BBR Network. BBR Stay Cable Technology has fulfilled such fatigue testing.Queensland 40 www. For suspension bridges. galvanised.New South Waies Eleanor Schonell Bridge . BBR Technology can also be used for the main suspension cables as well as for the hangers. In recent years a fatigue stress range of 200 N/mm2 for 2x106 load cycles in combination with angular rotations at the anchorages has been adapted and is now specified by most codes and recommendations. For permanent stay cable applications.au . Sydney Athletics Centre . Stay cables may be plain strand / wire unsheathed for temporary applications. or wires enclosed in a sheath and the voids filled with a flexible corrosion protection compound.PreSTRESSING TECHNOLOGY cable stay systemS Structural Systems can provide strand (BBR HiAm ConaTM) stay cables. enclosed in an external sheath are adopted.structuralsystems. DGP OD / e mm / mm 70.1 51. waxed and individually sheathed with a continuous and wear resistant HDPE coating.3 200 / 6.0 279 837 1953 3348 5301 6138 7533 8649 10323 11718 13392 15345 17019 19251 20367 20925 23715 25389 27063 30411 33759 35433 • e = nominal wall thickness www.8 43.0 180 / 5.0 / 10. low relaxation grade.0 140 / 4.4 30.0 406.7 200 / 6.0 / 10. Standard Anchorage Components Supplemental internal or alternatively external damping devices protect the stay cable from vibrations.7 180 / 5.7mm to prEN 10138-3 (refer design DATA) Type Forces Axial Cable Force HiAm CONA Ultimate Working MBL 100% kN 1 06 3 06 7 06 12 06 19 06 22 06 27 05 31 06 37 06 42 06 48 06 55 06 61 06 69 06 73 06 75 06 85 06 91 06 97 06 109 06 121 06 127 06 Notes: Structure Bearing Plate / Steel Guide Pipe Steel 355 MPa yield stress structural grade Plate Diam.0 / 8.5 / 7. Final stay cable force may also be adjusted using a specially designed multi-strand jack acting on the entire stay cable.0 152. providing each strand with an individual multilayer protection system. All anchorage components are designed for a stress range greater than 300 N/mm2 and to withstand the ultimate breaking load of the strand bundle with adequate safety.5 / 6. A ring nut screwed on anchor heads transfers the cable loads by contact pressure to the supporting bearing plates.2 66.0 419.0 101.3 298.9 / 7.0 / 11.0 110 / 4.3 273.4 160 / 5.1 250 / 7. and allows adjustment of stay force.4 168.3 225 / 7.9 250 / 7.0 160 / 5.7mm diameter.1 176.4 / 8.4 / 8. inspection and replacement of individual strands or the entire stay cable.0 125 / 4.6 244.3 4.0 406. CBP mm 57 85 133 170 210 225 248 264 288 305 327 349 367 389 400 405 430 445 458 485 510 522 Guide Pipe Diam.7 37. GA mm 390 400 410 420 435 435 450 445 465 465 480 480 495 500 490 510 515 525 525 525 545 555 HA Stressing Fixed mm 190 200 210 220 235 235 250 245 265 265 280 280 295 300 290 310 315 325 325 325 345 355 mm 1000 1500 2000 2125 2250 2375 2500 2625 2750 2850 2950 3050 3150 3250 3350 3450 3550 3650 3750 3850 3950 4050 IA Diam. Alternatively.0 / 12. ensuring an equal force distribution among the strands of an individual cable.6 / 8.0 90 / 4.0 368.8 75.0 / 12. Strands are galvanized. using the BBR isostress tensioning method. allowing not only for a re-stressing but also for the selective removal. architecturally coloured co-extruded stay pipe.8 95.3 1101.8 134. minimum guaranteed ultimate tensile stress of 1770 N/mm2 or 1860 N/mm2 and subject to fatigue testing by the manufacturer.structuralsystems.9 315 / 9.0 457.5 193. Each strand is tensioned immediately after installation.0 508.3 244.0 559.7 104.com. STRAND DIAMETER: 15.0 126.1 26. Alternatives may also be available upon request.1 323. S OD / e mm / mm / 63 / 4.9 / 7.9 280 / 8.0 508.5 mm 75 110 165 210 260 275 305 325 355 375 400 425 450 475 490 495 525 545 560 595 625 640 Anchorage Stay Pipe Weight HDPE Short Fatigue Term Fext 55% kN 153 460 1074 1841 2916 3376 4143 4757 5678 6445 7366 8440 9360 10588 11202 11509 13043 13964 14885 16726 18567 19488 Ffat 200 MPa kN 30 90 210 360 570 660 810 930 1110 1260 1440 1650 1830 2070 2190 2250 2550 2730 2910 3270 3630 3810 BBR HiAm Anchorage System SDR32 Diam. fully or partially prefabricated cables can be installed and tensioned.3 17.1 225 / 7.8 280 / 8.0 / 6.9 84.0 508.9 315 / 9.7 10.5 559.9 Cable Fwl 45% kN 126 377 879 1507 2385 2762 3390 3892 4645 5273 6026 6905 7659 8663 9165 9416 10672 11425 12178 13685 15192 15945 Cable kg/m 1.1 323.0 / 5.0 / 11.6 58.cable stay systemS Strand Stay Cables BBR HiAm ConaTM Parallel Strand Stay Cables Installation is typically performed on site using the strand-by-strand method.0 / 8. Strands are generally 15.7 152.8 280 / 8.7 / 5.6 / 5.au 41 . Individual strands can be re-stressed at any time during or after the installation. Another effective countermeasure against wind and rain-induced vibrations is the use of a helical rib on the outside of the HDPE.1 356.8 315 / 9.3 119.0 / 11.4 / 4.5 / 6.0 457. 5 33.5 mm 229.structuralsystems.6 200 18. Working Load Steel Weight Cable Weight HDPE Stay Pipe Wall Thickness HDPE Telescope Pipe Wall Thickness Steel Guide Pipe (outer/inner diameter) Bearing Plate ThicknesS Centre Hole Socket Outer Diameter Length Stressing Anchorage Length Fixed Anchorage Lock Nut Protection Cap B t ØZ ØA ØT Ø PE t Ø PE n Ø 7 No.0 / 267.0 18.0 16.9 23.4 225 20.0 / 365 45 211 195 355 320 245 75 219 283 178 93 86 430 55 251 235 425 370 290 90 259 338 203 157 142 480 60 282 265 480 415 330 105 289 378 213 226 203 545.4 160.0 335 635 525 420 135 359 503 253 465 412 675 85 378 360 665 540 450 150 389 518 253 567 495 730 95 405 385 710 575 480 160 409 553 268 668 600 755 95 417 400 755 605 500 165 429 593 283 787 682 795 100 435 420 790 635 520 170 449 623 288 898 779 830 110 455 435 815 650 540 180 459 638 293 998 861 850 105 470 450 845 675 560 185 479 663 303 1110 957 LHM LHF ØM HM ØS LSm LSf Weight of Anchorage (excl.0 7580 79.6 43.8 110 10.2 250 22.0 138.8 125 11.5 4715 29.6 200.8 416.0 140 12.0 14.2 352.0 127.0 / 298.0 5670 59.6 282. FUnom Fmax kN kN kg/m kg/m mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm kg kg 56 3600 1620 16.0 70 311.0 / 495.0 12.2 110 10.0 / 406.2 71.8 180.1 250 18.4 78.0 / 355.PRESTRESSING TECHNOLOGY cable stay systemS BBR HIAM Stay Cables Cable Size (wires per cable) Cable Breaking Load Max.0 8705 91 104 180 16.0 75 352.0 9660 10615 11395 12175 100.5 405.2 160 14.6 6450 67.0 / 495.8 251 121 163 196 223 262 301 334 367 394 421 7775 10475 12595 14330 16840 19345 21465 23585 25320 27055 3500 36.5 / 343. Anchor Plate and Guide Pipe) stress.0 140 12.0 / 445.2 93.4 160 14.8 211.8 435.6 / 368. fixed 42 www.0 455.2 330.2 58.1 250 18.0 295 550 465 365 120 319 433 228 314 281 590 75 330 315 605 505 390 125 339 483 253 391 347 625.com.0 119 210 19.4 / 445.8 180 16.6 111 128 200 18.0 470.5 378.0 140.7 200 18.2 210 19.0 / 470.au .4 91 5850 2635 27.3 145.4 225 20.9 118.2 250 22.4 311. 3 139.6 8.0 / 190.3 177.0 140 12.0 254.6 / 327.7 168.0 146.4 318.0 / 310.0 157 10090 4540 47.2 177.6 267.0 / 211.0 / 211.2 110 6. Working Load Steel Weight Cable Weight HDPE Stay Pipe Wall Thickness HDPE Telescope Pipe Wall Thickness Steel Guide Pipe Stressing Anchorage (inner / outer diameter) Fixed Anchorage (inner / outer diameter) Bearing Plate Stressing Plate Thickness Centre Hole Fixed Plate Thickness Centre Hole STRESSING SLEEVE Outer Diameter Length Length Fixed Anchorage Lock Nut Stressing Anchorage Bm tm Ø Zm Bf tf Ø Zf Ø ZH LZH LHF Ø Mf HMf Fixed Anchorage Ø Mr HMr PROTECTION CAP Stressing Anchorage Ø Sm LSm Fixed Anchorage Ø Sf LSf Weight of Anchorage (excl.0 / 310.6 200 18.4 70 4500 2025 21.8 125 11.8 75 4.0 31 1990 895 9.3 203.2 230 30 125 180 25 110 100 90 45 140 30 130 30 129 98 125 34 15 11 260 35 136 210 35 110 120 105 55 160 35 135 40 149 108 130 34 19 12 285 35 155 240 35 125 140 115 60 180 40 155 45 169 113 150 34 26 16 305 40 165 270 45 145 150 130 60 195 45 175 50 179 128 170 34 34 22 350 45 190 305 45 145 175 160 75 225 55 185 55 199 153 180 34 48 24 380 50 211 405 70 175 195 190 75 250 60 220 65 219 178 215 34 69 35 420 55 238 430 80 175 220 205 90 280 70 230 70 249 188 225 34 86 40 435 60 245 415 60 195 230 225 90 290 70 250 75 259 203 245 34 102 49 470 60 267 440 65 195 250 245 100 315 75 255 80 279 218 250 34 125 52 510 65 285 480 75 215 270 255 105 340 80 280 85 299 223 275 34 150 65 525 65 298 495 75 215 280 270 110 355 85 285 90 309 238 280 34 169 69 560 70 310 530 80 235 295 290 115 370 90 310 95 319 253 305 34 199 85 590 75 327 555 90 235 310 305 125 390 95 315 100 339 265 310 34 230 90 www.3 / 155.0 125 11.8 229.8 180 16.7 / 125.8 / 165.8 / 165.7 37 2380 1070 11.4 160 14.4 91 5850 2635 27.8 75 4.4 160 14.7 90 8.0 / 298.com.0 140 12.8 63 5.0 103 6620 2980 31.cable stay systemS BBR Dina STAY CABLES Cable Size (wires per cable) Cable Breaking Load Max.8 180 16.0 305.0 121 7775 3500 36.2 110 10.6 20.0 / 267.0 / 245.structuralsystems.0 / 267.9 6.6 200 18.0 145 9320 4195 43.5 33.0 318.4 229.2 355.4 63 5.4 305.0 292.6 292.6 / 327.9 90 5.7 67.0 / 238.0 / 285.2 110 6.0 / 285.1 72.0 160 14. kN kN kg/m kg/m mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm kg kg 13 835 375 3.0 267.4 75 6.2 160 14.2 355.1 27.7 / 125.2 330.0 / 190.au 43 .8 53.8 254.0 / 245. Anchor Plate and Guide Pipe) stress.1 39.8 90 8.0 330.2 55 3535 1590 16.4 12.4 140 12.6 43.0 / 136.6 110 10.5 139.3 146.1 140 12.0 / 136.0 199 12790 5755 60.5 22 1415 635 6.4 56.0 181 11635 5235 54.1 168.3 / 155.0 / 238.0 / 298. fixed Ø Tf Ø Tm Ø PE Ø PE nØ7 FUnom Fmax No.4 203.2 15. considerable saving in cost and time against conventional bridge construction are achieved. Mt Henry Bridge . Tonkin Hwy Bridge over Albany Hwy .com. Some preferred requirements are: • The girders should have a constant curvature in horizontal and vertical alignment. site cast concrete superstructure.Western Australia These are not exclusive but provide a guide to the standard range of applications. • After longitudinal shifting (launching) of a completed section along the bridge axis. • A steel launching nose at the front sliding bearings. multiple use form behind an abutment. relatively maintenance free performance of the bridge during its whole lifetime.structuralsystems.PRESTRESSING TECHNOLOGY INCREMENTAL LAUNCHING systemS The Incremental Launching method combines the advantages of pre-cast segmental construction with those of segmental cast insitu methods. • Casting in long sections in a stationary. • Span should be limited to 50-60 metres. • The section should be continuous over the whole bridge with preferably a constant depth. and a casting bay behind the abutment. Reinforcement crosses each joint in addition to the bonded prestressing tendons as each new segment is cast directly Incremental Launching Girder against the already hardened one in front. The concentric pre-stress required during launching guarantees an excellent. step-by-step as the progressively completed girder is launched.au .Western Australia 44 www. The main characteristics of the incremental launching method are: • Production of a continuous. • Temporary sliding bearings and guides at each pier facilitate the steady travel of the structure. By avoiding costly and time-consuming false work and by concentrating all construction activities in the small fabrication area. Bridges are cast in segments behind an abutment under controlled conditions. the next section is cast against the previous one and stressed together. • Span/depth ratios should be in the range of 14 to 18. as a result. • In this sequence the overall superstructure grows by adding new sections. high concrete quality and precise dimensions are assured. The lifting or lowering operation can be accurately controlled through the hydraulic system which allows simultaneous or individual operation of each lifting unit. Perth Convention Exhibition Centre .HEAVY LIFTING SYSTEMS HEAVY LIFTING SystemS In many instances. Structural Systems has developed specialised lifting equipment for this application. When their weight or size exceeds the capacity of available cranage other heavy lifting facilities must be considered. In most cases they must be lowered.au 43 5 .com.structuralsystems. The combination of the proven BBR Buttonhead Prestress Cable together with electrically operated hydraulic jacking units allows virtually unlimited loads to be moved quickly and safely over any distance.Before Roof Lift 12 outlet isoflow pump and control panel Perth Convention Exhibition Centre . jacked horizontally or lifted into their final position.After Roof Lift www. it is advantageous for extremely large and heavy components to be prefabricated away from their final location. well in advance of detailing or construction planning.au . In some instances bridge pier headstocks are constructed parallel to traffic. fitting of chimney liners and lift shaft installations. then manoeuvred into position by using jacking systems and tendons from bar. and cost or time. Structural Systems has extensive experience in the field of load handling and can provide all required services for design as well as supply and operation of equipment. Tendon Installation & Transport As part of our diverse operations. The application of load handling systems requires full consideration at the structural design stage. tanks and silo structures to permit necessary works such as post-tensioning and repair or inspection. on the basis of safety. ease of assembly or time constraints.Docklands Stadium Typical Applications Lifting. bridge spans. Some of SSL’s systems incorporate special hydraulic and monitoring systems to allow for high accuracy movement regardless of any differential loadings.com. Raising roof segment . bridges.Victoria 46 www. then rotated to minimise traffic disruption. strand or wire. In these instances where standard options fail. Lowering and Shifting of Heavy Loads Heavy. precast concrete elements. This may be essential in some locations where it is not possible due to access. Ringwood Rail Bridge Sliding Operations . SSL also have free spanning access walkways up to 40m. were fabricated in Melbourne prior to shipment and installation in Sydney. Examples of this application may be underbridge platforms. Additionally we have developed specialist platforms for use on high rise buildings. as selecting or designing the necessary temporary works and choosing the related equipment must be performed as early as possible. fragile or awkward structural elements can be either fabricated on or off site. and heavy industrial components. A further example is the stay cables incorporated in Centrepoint tower. the compact yet powerful systems SSL offer allow for an effective solution to be developed.preSTRESSING TECHNOLOGY load handling systemS Construction procedures involving load handling systems often result in considerable savings as compared to conventional building methods using traditional scaffolds for casting concrete or installing steel structural elements in place. The use of our specialist hardware such as cable stays can allow formwork solutions to be developed where the formwork and false work is supported from above rather than below. Examples include roof structures. we have developed systems for use on cable stay bridges or large dam projects where tendons up to 150m and weights greater than 17 tonnes need translation and fitting to the structure. It is often preferred to assemble a large module adjacent to its final location then shift it into position.structuralsystems. Specialist Formwork & Access Occasionally access systems or working platforms may be located in areas which cannot be serviced using conventional cranage. Structural Systems can provide 2 types of flat jacks: • Pan Type Contstructed of two moulded steel sections welded together used with a top and bottom plate.com.load handling systemS Flat Jacks Flat jacks are used for a variety of applications where structures are required to be lifted or preloaded and installation heights are to be kept to a minimum.5 MPa kN 85 155 390 525 605 780 1080 1605 2170 3470 5400 7385 8975 13635 EFFECTIVE AREA AT ZERO EXTENSION 103mm2 6.SAFETY LOCK NUT TYPE TYPE OUTSIDE DIAMETER mm 60T 100T 150T 200T 250T 300T Notes: MAXIMUM FORCE AT 10.PAN TYPE TYPE D OUTSIDE DIAMETER mm 120 150 220 250 270 300 350 420 480 600 750 870 920 1150 MAXIMUM FORCE AT 13.5 29 39 45 58 80 119 161 257 400 547 665 1010 T THICKNESS1 mm 25 25 25 25 25 25 25 25 25 25 25 25 25 25 E MAXIMUM TRAVEL mm 25 25 25 25 25 25 25 25 25 25 25 25 25 25 INSTALLATION GAP mm 38 38 38 38 38 38 38 38 38 38 45 45 45 50 9T 16T 39T 52T 60T 78T 108T 160T 217T 347T 540T 738T 898T 1364T Notes: [1] flat jack thickness may vary slightly TABLE B . Safety Lock Nut Type Pan Type TABLE A .4 11. low height hydraulic jacks with safety lock nut for mechanical load handling.au 47 .000 PSI kN 600 1000 1500 2000 3000 3000 THICKNESS mm 110 162 192 155 150 170 MAXIMUM TRAVEL mm 28 50 50 50 50 50 INSTALLATION GAP mm 125 180 210 170 165 185 138 188 205 240 300 305 • Jacks come complete with spherical testing www. These can be inflated with oil or grout and are generally used only once (see Table A). • Safety Lock Nut Type Solid ram. For heavy loads multiples of the jacks are used linked through a manifold system. used mainly for bearing replacement work (see Table B).structuralsystems. +61 2 8767 6200 F. +61 8 9267 5400 F. +61 3 9646 7133 STRUCTURAL SYSTEMS 20 Hilly Street.com. +48 226 979 248 NEW SOUTH WALES QUEENSLAND WESTERN AUSTRALIA MIDDLE EAST REGION Bahrain. Stapylton QLD 4207 Australia T. +353 1628 9124 F. Maynooth Co. Twarda 30 00-831 Warszawa Poland T. +48 226 979 246 +48 226 979 247 F. Mortlake NSW 2137 Australia T.o. Oman.A. Middlesex UB2 4SE T. +61 7 3442 3555 STRUCTURAL SYSTEMS 24 Hines Road. U. Garhoud PO Box 28987 DUBAI United Arab Emirates T. For more information on Structural Systems and the many services we provide. visit: www. O’Connor WA 6163 Australia T. South Melbourne VIC 3205 Australia T. 16 Maiella Street. South East Asia. +44 208 843 6500 F.com STRUCTURAL SYSTEMS 12 Collett Way Great Western Industrial Park Southall.au . +61 7 3442 3500 F. Ireland T.bbrstructuralsystems. +61 8 9331 4511 NASA STRUCTURAL SYSTEMS LLC Head Office Suite 302 Sara Building. Qatar.structuralsystems. +61 3 9296 8100 F. the Middle East and the United Kingdom.z o. UNITED KINGDOM IRELAND POLAND Structural Systems operate throughout Australia. +44 208 843 6509 STRUCTURAL SYSTEMS Unit 13. +61 2 8767 6299 STRUCTURAL SYSTEMS Unit 2. +353 1628 9124 STRUCTURAL DESIGN SERVICES sp. +97 14 2828 386 www.E.VICTORIA STRUCTURAL SYSTEMS 112 Munro Street. Block G Maynooth Business Campus. +97 14 2828 595 F. Kildare.