European Technical Approval No ETA-06/0006
European Technical Approval No ETA-06/0006
European Technical Approval No ETA-06/0006
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Service d'études techniques des<br />
routes et autoroutes<br />
46 avenue Aristide Briand<br />
BP 100<br />
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Tel : + 33 (0)1 46 11 31 31<br />
Fax : + 33 (0)1 46 11 31 69<br />
MEMBRE DE L'EOTA<br />
MEMBER OF EOTA<br />
<strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> <strong>No</strong> <strong>ETA</strong>-<strong>06</strong>/00<strong>06</strong><br />
(English translation, the original version is in French)<br />
<strong>No</strong>m commercial :<br />
Trade name :<br />
Détenteur de l’ATE :<br />
<strong>ETA</strong> Holder :<br />
Type générique et utilisation prévue<br />
du produit de construction :<br />
Generic type and use of construction<br />
product :<br />
Valid from :<br />
to :<br />
Producteur du Procédé :<br />
Kit Manufacturer :<br />
Cet Agrément Technique Européen<br />
contient :<br />
This <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong><br />
contains :<br />
Procédé de précontrainte VSL<br />
VSL Post-Tensioning System<br />
VSL INTERNATIONAL Ltd.<br />
Scheibenstrasse, 70<br />
CH - 3014 BERNE<br />
Procédés de précontrainte des structures par<br />
post-tension<br />
(communément appelés procédés de précontrainte)<br />
Post-Tensioning Kits for Prestressing of Structures<br />
(commonly called Post-Tensioning Systems)<br />
31-07-20<strong>06</strong><br />
30-07-2011<br />
CTT- Stronghold, SA<br />
Ribera del Congost, s/n<br />
SP - 08520 Les Franqueses del Vallès (Barcelona)<br />
8+(4+40+28) pages incluant 3 annexes (0, 1, 2)<br />
faisant partie intégrante du document.<br />
8+(4+40+28) pages including 3 annexes (0, 1, 2)<br />
which form an integral part of the document.<br />
Organisation pour l’Agrément Technique Européen<br />
<strong>European</strong> Organization for <strong>Technical</strong> <strong>Approval</strong>s
I - LEGAL BASIS AND GENERAL CONDITIONS<br />
1- This <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> is issued by SETRA in accordance with:<br />
- Council Directive 89/1<strong>06</strong>/EEC of 21 December 1988 on the approximation of laws, regulations and<br />
administrative provisions of Member States relating to construction products 1 , modified by Council<br />
Directive 93/68/EEC 2 and Regulation (EC) N o 1882/2003 of the <strong>European</strong> Parliament and of the Council 3 ;<br />
- Décret n°92-647 du 8 juillet 1992 4 concernant l'aptitude à l'usage des produits de construction<br />
- Common Procedural Rules for Requesting, Preparing and the Granting of <strong>European</strong> <strong>Technical</strong><br />
<strong>Approval</strong>s set out in the Annex to Commission Decision 94/23/EC 5 ;<br />
- <strong>ETA</strong>G 013, Edition June 2002, Post-Tensioning Kits for Prestressing of Structures.<br />
2 - SETRA is authorized to check whether the provisions of this <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> are met.<br />
Checking may take place in the manufacturing plant(s). Nevertheless, the responsibility for the conformity<br />
of the products to the <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> and for their fitness for the intended use remains with<br />
the holder of the <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong>.<br />
3 - This <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> is not to be transferred to manufacturers or agents of<br />
manufacturers other than those indicated on page 0, or manufacturing plants other than those indicated<br />
on page 0 of this <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong>.<br />
4 - This <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> may be withdrawn by SETRA, in particular pursuant to information<br />
by the Commission according to Article 5 1 of Council Directive 89/1<strong>06</strong>/EEC.<br />
5 - Reproduction of this <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> including transmission by electronic means shall be<br />
in full. However, partial reproduction can be made with the written consent of SETRA. In this case partial<br />
reproduction has to be designated as such. Texts and drawings of advertising brochures shall not<br />
contradict or misuse the <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong>.<br />
6 - The <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> is issued by the approval body in its official language(s). This<br />
(These) version(s) corresponds (correspond) fully to the version circulated in EOTA. Translations into<br />
other languages have to be designated as such.<br />
1 o<br />
Official Journal of the <strong>European</strong> Communities N L 40, 11.2.1989, p. 12<br />
2 o<br />
Official Journal of the <strong>European</strong> Communities N L 220, 30.8.1993, p. 1<br />
3 o<br />
Official Journal of the <strong>European</strong> Union N L 284, 30.10.2003, p. 1<br />
4<br />
JORF du 14 juillet 1992<br />
5 o<br />
Official Journal of the <strong>European</strong> Communities N L 17, 20.1.1994, p. 34<br />
1
II - SPECIFIC CONDITIONS CONCERNING THE<br />
EUROPEAN TECHNICAL APPROVAL<br />
1 - Product definition and intended use<br />
1.1 - Product definition<br />
The VSL Post-Tensioning System consists, for convenience purposes, of two systems that rely upon a set<br />
of common basic components: the VSL Multistrand System and the VSL Slab System.<br />
According to this System, cables are considered to be primarily composed of ducts, tendons (using the<br />
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:<br />
"Prestressing steels - Strands" or individually greased and sheathed monostrand complying with <strong>ETA</strong>G<br />
013 Annex C.1), anchorages and/or couplers and other components such as protective products<br />
necessary for ensuring either a permanent level of prestressing (during the entire reference life cycle) or a<br />
temporary one (over a limited period) for civil engineering structural elements, buildings or any other type<br />
of construction.<br />
As long as EN 10138 does not exist 7-wire strands in accordance with national provisions shall be used.<br />
The VSL Multistrand System (from 1 to 55 strand cables), defined in Annex 1 and intended more for<br />
massive civil engineering parts, is used along with the strands specified above and the following<br />
components:<br />
- ducts:<br />
- metallic: corrugated steel strip sheaths, steel tubes,<br />
- made of plastic, the VSL PT-PLUS® ducting, polyethylene or polypropylene sheaths or tubes,<br />
- anchorages:<br />
- active or passive: type E (1 to 55 strands), type CS (7 to 37 strands),<br />
- using bond: type H (1 to 37 strands),<br />
- couplers: type K (3 to 37 strands);<br />
- injection products:<br />
- for rigid injection: with a cement base, in accordance with EN 447<br />
- for flexible injection: with a grease base, with a wax base.<br />
Filling materials covered by an <strong>ETA</strong> may also be employed.<br />
The VSL Slab System (1 to 4 strands), defined in Annex 2 and primarily intended for thin construction<br />
elements for building or bridge decks, is used along with the strands specified above and either bare<br />
strands for the system with injection or individually greased and sheathed for the system without injection:<br />
- ducts for the system with injection: the circular or flat corrugated steel strip sheaths, the circular or flat<br />
VSL PT-PLUS® duct,<br />
- anchorages:<br />
- active or passive type S 6-1 (1 strand) and type S 6-4 (4 strands),<br />
- embedded dead end type SF 6-1 (1 strand),<br />
- using bond: type H for the system with injection applied to internal bonded tendons only,<br />
- injection products for the system with injection: with a cement base, in accordance with EN 447.<br />
Filling materials covered by an <strong>ETA</strong> may also be employed.<br />
1.2 - Intended use<br />
The VSL Post-Tensioning System has been designed to ensure the equilibrium of structures or of<br />
sections of structures submitted to the gravity effects, live load effects, climatic effects or any other type<br />
of action as well as to the imposed set of deformations.<br />
The VSL Post-Tensioning System may be used for:<br />
- new structural works,<br />
- the repair and strengthening of existing structures.<br />
2
The VSL Post-Tensioning System may also be employed in structures made of other materials than<br />
concrete; this could entail structures made of concrete, masonry, steel, cast iron, wood or combinations<br />
of several materials.<br />
The tendons assembled as part of the VSL Post-Tensioning System may have the following basic use<br />
categories:<br />
- internal bonded tendon for concrete and composite structures,<br />
- internal unbonded tendon for concrete and composite structures,<br />
- external tendon for concrete structures with a tendon path situated outside the cross section of<br />
the structure or member but inside its envelope.<br />
(Cables for ground and rock anchors, external cables with a layout positioned beyond the structural<br />
envelope or the structural component, and stay cables are not covered by the present <strong>ETA</strong>).<br />
completed with the following optional use categories:<br />
- restressable tendon (internal or external),<br />
- exchangeable tendon (internal or external),<br />
- internal bonded tendon with plastic duct,<br />
- encapsulated tendon,<br />
- electrically isolated tendon,<br />
- tendon for use in structural steel or composite construction as external tendon,<br />
- tendon for use in structural masonry construction as internal and/or external tendon,<br />
- tendon for use in structural timber as internal and/or external tendon.<br />
The tables presented in Chapters 1.4 and 3.4 of Annexes 1 and 2 establish the categories possible for<br />
each of the approved anchorages.<br />
1.3 Working life<br />
The provisions, test and assessment methods in the <strong>ETA</strong>G 013 have been written based upon the<br />
assumption that the estimated design working life (nominal design value of the intended life of a<br />
structure) of the PT System is the same as the one specified in the Eurocodes relevant for the structure<br />
in which it is intended to be used provided that the PT System is subject to appropriate use and<br />
maintenance (see Chapter 7 of <strong>ETA</strong>G 013). Eurocode 1 specifies 100 years design working life for<br />
bridges and other engineering structures. These provisions are based upon the current state of the art<br />
and the available knowledge and experience.<br />
The indication given on the design working life of a product cannot be interpreted as a guarantee given<br />
by the producer (or the <strong>Approval</strong>s Body) but is regarded only as a means for choosing appropriate<br />
components and materials in relation to the expected economically reasonable design working life of<br />
structures for the works.<br />
The relevant Eurocodes would be the following:<br />
ENV 1990 "Eurocode 0": Basis of structural design<br />
ENV 1991 "Eurocode 1": Actions on structures<br />
ENV 1992 "Eurocode 2": Design of concrete structures<br />
ENV 1993 "Eurocode 3": Design of steel structures<br />
ENV 1994 "Eurocode 4": Design of composite steel and concrete structures<br />
ENV 1995 "Eurocode 5": Design of timber structures<br />
ENV 1996 "Eurocode 6": Design of masonry structures<br />
2 - Product characteristics and verification methods<br />
2.1 - Product characteristics<br />
The components of the VSL Post-Tensioning System comply with the drawings and conditions described<br />
in Annexes 1 and 2 of this <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong>.<br />
More detailed information related to confidential specifications (e.g.: materials, processing, surface,<br />
dimensions, tolerances, manufacturing methods and control procedures) are included in the <strong>Technical</strong><br />
3
Evaluation dossier concerning this <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong>, which has been deposited at the<br />
<strong>Approval</strong> Body. This set of information is also to be sent, whenever necessary, to the Certification Body<br />
responsible for Attestation of Conformity.<br />
Essential requirements 1 (mechanical resistance and stability) and 3 (hygiene, health and the<br />
environment) from Appendix I of the Construction Products Directive have been fulfilled. For the PT<br />
System, the other requirements need not to be complied with.<br />
Only product characteristics in relation to essential requirements 1 and 3 are to be verified. It should be<br />
pointed out that, depending on their specific nature, some prestressed structures or parts of prestressed<br />
structures may need to satisfy other requirements in respect to fire safety.<br />
2.2 - Verification methods<br />
Assessment of the fitness for use of the PT System with essential requirement 1 related to "mechanical<br />
resistance and stability" was carried out, as stipulated in the <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> Guide focusing<br />
on post-tensioning kits for prestressing of structures (<strong>ETA</strong>G 013).<br />
The performances assessed in accordance with <strong>ETA</strong>G 013 allow to fulfill all relevant essential<br />
requirements. Such performances deal for the most part with: resistance to static loads, effective load<br />
transfer to the structure, and resistance to fatigue.<br />
A set of specific tests were carried out as stated in <strong>ETA</strong>G 013 for the following optional use category:<br />
electrical insulation applications.<br />
The methods for verifying, evaluating and assessing suitability and test procedures comply with those<br />
detailed in <strong>ETA</strong>G 013.<br />
According to the kit manufacturer’s declaration, the post-tensioning kit does not contain any dangerous<br />
substances.<br />
In addition to the specific clauses relating to dangerous substances contained in this <strong>European</strong> <strong>Technical</strong><br />
<strong>Approval</strong>, there may be other requirements applicable to the products falling within its scope<br />
(e.g. transposed <strong>European</strong> legislation and national laws, regulations and administrative provisions). In<br />
order to meet the provisions of the EU Construction Products Directive, these requirements need also to<br />
be complied with, when and where they apply.<br />
This statement has been highlighted in Chapter 5 entitled "Injection and sealing" of both Annexes 1 and 2.<br />
3 - Evaluation, Attestation of Conformity and CE marking<br />
3.1 - The attestation of conformity system<br />
The system of attestation of conformity specified by the <strong>European</strong> Commission in mandate 98/456/EC 6 is<br />
the system 1+, with audit testing of samples, described in Council Directive (89/1<strong>06</strong>/EEC) Annex III and is<br />
detailed as follow:<br />
3.1.1 - Tasks for the Kit Manufacturer (see Section 3.2.1):<br />
1) Factory production control,<br />
2) Further testing of samples taken at the factory by the manufacturer in accordance with a prescribed<br />
test plan (see Annex 0);<br />
3.1.2 - Tasks for the Certification Body (see Section 3.2.2):<br />
1) Initial type testing of the product,<br />
2) Initial inspection of factory and of factory production control (FPC),<br />
3) Continuous surveillance, assessment and approval of factory production control (FPC)<br />
4) Audit testing of samples.<br />
3.2 - Responsibilities<br />
3.2.1 - Tasks for the Kit Manufacturer<br />
6 Official Journal of the <strong>European</strong> communities L201/112 of 3 July 1998<br />
4
3.2.1.1 - General responsibilities of the Kit Manufacturer<br />
The Kit Manufacturer shall keep available an updated list of all components manufacturers.<br />
This list is to be provided to the Certification Body. Another copy may also be made available to the<br />
<strong>Approval</strong> Body.<br />
The Kit Manufacturer is responsible for the production and quality of components manufactured or ordered.<br />
At least once a year, each components manufacturer has to be audited by the kit manufacturer. Each audit<br />
report shall be made available to the Certification Body.<br />
These audit reports include:<br />
- Identification of the components manufacturer<br />
- Date of audit of components manufacturer<br />
- Summary of the results and records of the FPC since last audit<br />
- Summary of the complaint records<br />
- Evaluation of the components manufacturer concerning PPC<br />
- Specific remarks as relevant<br />
- Clear and unique statement whether the requirement of the <strong>ETA</strong> are met<br />
- Name and position of signatory<br />
- Date of signature<br />
- Signature.<br />
At least once a year specimens are taken by the kit manufacturer from at least one job site. One series of<br />
single tensile element tests are performed according to Annex 0 (annex E3 of the <strong>ETA</strong>G 013) by the kit<br />
manufacturer with these specimens. One series of single tensile element tests are performed with<br />
components from only one site. The results of these test series are made available to the Certification Body.<br />
These reports include:<br />
- Identification of the job site where the components have been taken<br />
- Date of sampling<br />
- Identification of the components (e.g. anchor head, wedges, strand,…)<br />
- Place and date of testing<br />
- Summary of the results including a test report according to Annex E.3 of <strong>ETA</strong>G 013;<br />
- Specific remarks as relevant<br />
- Name and position of signatory<br />
- Date of signature;<br />
- Signature.<br />
The kit manufacturer makes available for at least 10 years all records of relevant results concerning the<br />
<strong>ETA</strong> and the audit reports concerning the components manufacturers.<br />
3.2.1.2 - Factory Production Control (FPC)<br />
3.2.1.2.1 - General<br />
The kit manufacturer exercises permanent internal control of the production. All the elements, requirements<br />
and provisions adopted by the kit manufacturer are documented in a systematic manner in the form of<br />
written policies and procedures. This control system ensures that the PT System is in conformity with the<br />
<strong>European</strong> <strong>Technical</strong> <strong>Approval</strong>.<br />
The Factory Production Control is in accordance with the control plan of VSL named QM relating to the<br />
<strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> <strong>06</strong>/00<strong>06</strong> issued on 31-07-20<strong>06</strong> which is part of the technical documentation<br />
of this european technical approval. The control plan is laid down in the context of the factory production<br />
control system operated by the manufacturer and deposited at SETRA.<br />
The basic elements of the control plan comply with <strong>ETA</strong>G 013 annex E1. The results of the factory<br />
production control shall be recorded and evaluated in accordance with the provisions of the control plan.<br />
FPC and the prescribed test plan are according to Annex 0, which address the following aspects:<br />
- manufacturing<br />
- distribution and delivery to job site.<br />
FPC system complying with EN ISO 9001 : 2000 and which addresses the requirements of the <strong>ETA</strong> is<br />
recognized as satisfying the FPC requirements of the Directive.<br />
5
Parts of the FPC may be transferred to an independent test laboratory. Nevertheless, the kit<br />
manufacturer has the full responsibility for all results of the FPC.<br />
3.2.1.2.2 - Control of the PT System components and materials<br />
The characteristics of incoming materials which comply with a harmonized <strong>European</strong> technical<br />
specification, having met the corresponding Attestation of Conformity procedure, are considered<br />
satisfactory and need, except in case of justified doubt, no further checking. All materials are to be in<br />
accordance with the requirements of the <strong>ETA</strong> and the corresponding specifications of the kit manufacturer.<br />
Where harmonized technical specifications are not available, materials according to specifications valid in<br />
the place of use may be used provided that their use is compatible with the results of approval tests.<br />
Otherwise, the specifications are given in the <strong>ETA</strong>.<br />
3.2.1.2.3 - Inspection and testing<br />
The validity of the type and frequency of checks / testing conducted during production and on the final<br />
product has to be considered as a function of the production process. This includes verification conducted<br />
during production, on properties that cannot be inspected at a later stage and verification on the final<br />
product. These include:<br />
- Definition of the number of samples taken by the kit manufacturer<br />
- Material properties e.g. tensile strength, hardness, surface finish, chemical composition,…<br />
- Determination of the dimensions of components<br />
- Check correct assembly<br />
- Documentation of tests and test results.<br />
All tests are performed according to written procedures with suitable calibrated measuring devices. All test<br />
results are recorded in a consequent and systematic way.<br />
The prescribed test plan relative to the PT System (see Annex 0) complies with stipulations in Annex E.1 of<br />
<strong>ETA</strong>G 013, including the minimum test frequencies to perform.<br />
3.2.1.2.4 - Control of non-conforming products<br />
Products which are considered as not conforming with the <strong>ETA</strong> are immediately marked and separated from<br />
such products which comply. The prescribed test plan addresses control of non-conforming products.<br />
3.2.1.2.5 - Complaints<br />
<strong>ETA</strong> <strong>Technical</strong> File includes provisions to keep records of all complaints about the PT System.<br />
3.2.2 - Tasks of the Certification Body (CB)<br />
The CB may act with its own resources or subcontract inspection tasks and testing tasks to inspection<br />
bodies and testing laboratories.<br />
3.2.2.1 - Initial type-testing<br />
The results from tests performed during the approval procedure and then evaluated by the <strong>Approval</strong> Body<br />
may be used by the Certification Body as initial type testing as required in the <strong>ETA</strong>G 013.<br />
3.2.2.2 - Initial assessment of factory and factory production control<br />
The Certification Body assesses both the factory capacities and the factory production control performed<br />
by the kit manufacturer in order to ensure that, in compliance with the prescribed test plan, the<br />
manufacturing resources and FPC are able to guarantee continuous and consistent manufacturing of PT<br />
System components in accordance with <strong>ETA</strong> specifications.<br />
3.2.2.3 – Continuous surveillance<br />
The Certification Body shall perform surveillance inspections, Components Manufacturers inspections and<br />
sample extractions either in the factories or on the job sites for the purpose of conducting independent<br />
tests under its responsibility. Continuous surveillance and FPC evaluation are to proceed in accordance<br />
with the prescribed test plan and in compliance with conditions laid out under the "Continuous<br />
surveillance" heading found in the <strong>ETA</strong>G 013 guide and in Figure 8.1 in particular.<br />
6
The kit manufacturer shall be inspected at least once a year. Its FCP will be checked and according to<br />
Annex E.2, samples are taken for independent testing.<br />
Each component manufacturer shall be inspected at least once during the period of validity of the <strong>ETA</strong><br />
that is at least once in five years.<br />
The Certification Body shall provide SETRA, upon request, the results of certification and continuous<br />
surveillance.<br />
In cases of serious non conformities, related to important aspects of the performances of the posttensioning<br />
system, which can not be corrected within the deadlines, the certification body shall withdraw<br />
the certification of conformity and inform the SETRA without delay.<br />
3.3 – CE-Marking<br />
CE-marking is in accordance with the Construction Products Directive and the Guidance Paper<br />
"D" named "CE marking under the construction products directive" (EC/OEAT 04/645 Document).<br />
The delivery note, associated with the components of the PT System, shall contain the CE conformity<br />
marking which consist of the CE-symbol and:<br />
1. The name or identifying mark of the kit manufacturer<br />
2. The last two digits of the year in which the marking was affixed<br />
3. The number of the Certificate of Conformity<br />
4. The <strong>ETA</strong> number<br />
5 See information on <strong>ETA</strong> <strong>No</strong> number<br />
6. The use category(ies)<br />
7. The number of the Certification Body.<br />
All other information is clearly separated from the CE-marking and the accompanying information.<br />
4 - Assumptions under which the fitness for use of VSL PT System is favorably<br />
assessed<br />
4.1 - Production<br />
This <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> document has been issued for the VSL PT System on the basis of<br />
Manufacturer <strong>Technical</strong> Dossier submitted and verified by SETRA<br />
Any anticipated changes to the process or in the production of components that may change the MTD<br />
must be notified to SETRA, which would then decide whether change affects the <strong>ETA</strong> and, consequently,<br />
the validity of the CE-marking and whether an additional assessment with modification of this <strong>ETA</strong> would<br />
be necessary. Under all circumstances, SETRA consent is required prior to enacting the planned<br />
modifications.<br />
4.2 - Installation<br />
The quality of a post-tensioned structure lies not only in its effective design, but also in the quality of its<br />
execution. As regards post-tensioning, it goes without saying that the appropriate use of the PT System,<br />
component quality and system installation quality serve to influence both suitability for the intended use<br />
and the design working life<br />
Basic information has been provided in Annexes 1 and 2 of <strong>ETA</strong> document. Although such information<br />
proves essential for purposes of comprehending PT System application, it alone remains insufficient for<br />
proceeding with the installation step. For this reason, the Post-Tensioning System has been set up for<br />
installation to be performed by a PT Specialist Company.<br />
Even though this field is submitted to the national regulatory conditions of EU Member States, it should be<br />
recalled herein that the qualification of PT Specialist Companies encompasses their aptitude (specialized<br />
equipment resources and certified staff) first to design the prestressed parts of structures and then to<br />
7
prepare the corresponding set of components and work tasks, install the PT System (including cable<br />
tensioning using appropriate devices) and performing the injection of protective filling material.<br />
These last two tasks are to be carried out with equipment capable of meeting the requirements associated<br />
with attaining precise measurements of certain physical magnitudes.<br />
The tasks of design and installation may be extended, under some circumstances, by means of<br />
monitoring and adjustment (whenever necessary) of the installed PT System.<br />
5 - Indications<br />
5.1 - Packaging, transportation and storage<br />
Temporary protections, packaging, along with transportation and storage conditions for components of the<br />
VSL PT System have been designed to ensure availability for worksite installation without any alteration of<br />
their suitability for the particular intended use.<br />
The detailed conditions to be adopted relative to the ducts, reinforcements, anchorages and protective<br />
filling material have been set forth both in Chapter 7 of <strong>ETA</strong>G 013 and in the VSL <strong>Technical</strong><br />
Documentation (associated with the <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong>).<br />
5.2 - Installation<br />
The entire set of equipment used for installing the PT System is submitted to periodic maintenance and<br />
repair operations, whenever necessary.<br />
Tensioning equipment measurement systems (pressure or force, displacement and/or movement) that get<br />
included in the verification of magnitudes for the actions applied to structures undergo calibration in<br />
compliance with: Chapter 7 of <strong>ETA</strong>G 013, the national provisions, and the set of practices prescribed in<br />
the VSL <strong>Technical</strong> Documentation (associated with the <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong>).<br />
8
Annex 0 of the <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> <strong>No</strong>. <strong>ETA</strong>-<strong>06</strong>/00<strong>06</strong> 1<br />
Annex 0<br />
<strong>ETA</strong> APPLICATION<br />
1 - Commitments assumed by the <strong>ETA</strong> Holder<br />
Once installed, the VSL Post-Tensioning System makes a vital contribution both to the permanent<br />
equilibrium of structures and to their durability.<br />
In light of the terms inherent in this <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> (<strong>ETA</strong>), which serve to certify the<br />
fitness for use of the PT System, its service capabilities and its working life as well as to prescribe the<br />
resources utilized by the companies involved (see Appendix D of <strong>ETA</strong>G 013), it is essential for each<br />
of the prerequisite measures to be applied during the fabrication and installation steps that<br />
accompany the design step in promoting proper use of the PT System.<br />
In this aim, the <strong>ETA</strong> Holder agrees to apply and ensure application of this approval by the Kit<br />
Manufacturer, the Component Manufacturers and the PT Specialist Companies such that the installed<br />
PT System proves capable of satisfying the designated set of basic requirements (in compliance with<br />
Construction Products Directive, Chapter 1, Article 2.1).<br />
2 - Responsibility of both the <strong>ETA</strong> Holder and Kit Manufacturer<br />
The components of the VSL Post-Tensioning System are produced in accordance with the conditions<br />
of the present <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> by the Kit Manufacturer and selected Component<br />
Manufacturers, using the production resources indicated and identified during inspections and on site<br />
audits performed by both the <strong>Approval</strong> and Certification Bodies.<br />
The Kit Manufacturer guarantees that all components of the PT System and relative individual<br />
components for which the <strong>ETA</strong> has been issued comply with the specifications given in the <strong>ETA</strong>. For the<br />
most important components, the following table summarizes the minimum procedures which have to be<br />
performed.
Annex 0 of the <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> <strong>No</strong>. <strong>ETA</strong>-<strong>06</strong>/00<strong>06</strong> 2<br />
"Prescribed test plan"<br />
1 2 3 4 5 6<br />
Component Item Test / Check Traceability 4 Minimum<br />
frequency<br />
Anchorage zone components<br />
Material 7<br />
Anchor plate<br />
Anchor head,<br />
Coupler<br />
Wedges,<br />
Compression<br />
fitting<br />
Detailed<br />
dimensions 5<br />
Visual inspection 3 Check<br />
Material 7<br />
Detailed<br />
dimensions 5<br />
Visual inspection 3 Check<br />
Material 7<br />
Treatment,<br />
hardness<br />
Detailed<br />
dimensions 5<br />
Visual inspection 3 Check<br />
Documen-<br />
tation<br />
Check 100% "2.2" 1,6<br />
bulk 6<br />
Test 3%<br />
≥ 2 elements<br />
Yes<br />
100% <strong>No</strong><br />
Check 100% "3.1.B" 1<br />
full<br />
Test 5%<br />
≥ 2 elements<br />
Yes<br />
100% <strong>No</strong><br />
Check 100% "3.1.B" 1<br />
full<br />
Test 0.5%<br />
≥ 2 elements<br />
Yes<br />
Test 5%<br />
≥ 2 elements<br />
Yes<br />
100% <strong>No</strong><br />
Current zone components<br />
Check "CE" 2<br />
100% "CE" 2<br />
Duct Material 7<br />
Visual inspection 3 Check 100% <strong>No</strong><br />
Strand Material 7<br />
Check 100 % "CE" 2<br />
Diameter<br />
Visual inspection<br />
Test Each coil <strong>No</strong><br />
3 National<br />
Check<br />
Certification<br />
till "CE" 2<br />
Each coil <strong>No</strong><br />
Cement 7<br />
Check full 100% "CE" 2<br />
Constituents<br />
of filling<br />
material as<br />
per EN 447<br />
Admixtures,<br />
additions, ... 7<br />
Check bulk 100% "CE" 2<br />
Monostrand Material 7<br />
Check National<br />
Certification<br />
till "CE" 2<br />
100% "CE" 8<br />
Plastic pipes Material 7<br />
Check full 100% "CE" 2<br />
Plastic ducts Material 7<br />
Check full 100% "CE" 8<br />
All samples are to be extracted at random and clearly identified.<br />
Details on sampling procedures including methods of recording as well as test methods have been<br />
agreed between the <strong>Approval</strong> Body and the Kit Manufacturer as part of the prescribed test plan.<br />
Preferably standardized sampling and test methods are used. Generally all results are reported in the<br />
test reports in such a way to enable direct comparison with the specification’s data in the <strong>ETA</strong> or<br />
subsidiary documentation.<br />
1<br />
"2.2": Test report type "2.2" according to EN 10 204 (this applies to simple steel<br />
anchor plates only).<br />
2 "3.1.B": Inspection certificate type "3.1.B" according to EN 10 204.<br />
If the basis of "CE"-marking is not available, the prescribed test plan has to include appropriate<br />
measures, only for the time until the harmonized technical specification is available.
Annex 0 of the <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> <strong>No</strong>. <strong>ETA</strong>-<strong>06</strong>/00<strong>06</strong> 3<br />
3 Visual inspections means e.g.: main dimensions, gauge testing, correct marking or<br />
labelling, appropriate performance acceptability, surface fins, kinks, smoothness, corrosion, coating,<br />
etc., as given in the prescribed test plan.<br />
4 full: Full traceability of each component to its raw material.<br />
bulk: Traceability of each delivery of components to a defined point.<br />
5 Detailed dimensions mean measuring of all dimensions and angles according to the<br />
specifications as given in the prescribed test plan.<br />
6 Only if the force transfer unit is a "simple plate". Otherwise appropriate procedures<br />
have to be introduced.<br />
7 Material checks are included for information only as these are not part of the<br />
prescribed test plan.<br />
8 If the basis of "CE"-marking is not available, the prescribed test plan has to include<br />
appropriate measures. The certificate shall be based on specific testing on the fabrication lot from which<br />
the supply has been produced, to confirm specified properties, and shall be prepared by a department<br />
of the supplier which is independent of the production department.<br />
<strong>No</strong>te: Generally speaking, all tests, inspections, etc. are aimed at verifying that the information<br />
contained in manufacturing drawings as well as in the ultimate set of associated specifications has<br />
actually been applied to the components.<br />
During surveillance inspections, the Certification Body has to take samples of components of the PT<br />
System or the relative individual components for which the <strong>ETA</strong> has been granted for independent<br />
testing. For the most important components, the table given below summarises the minimum<br />
procedures which are performed by the Certification Body.<br />
"Audit testing"<br />
1 2 3 4<br />
Component Item Test / Check Sampling Number of<br />
components per visit<br />
Anchor head, Coupler Material according to specification Check, test<br />
1<br />
Wedges,<br />
Compression fitting<br />
Single tensile<br />
element test<br />
Detailed dimensions Test<br />
Visual inspection 9 Check<br />
Material according to specification Check, test 2<br />
Treatment Test 2<br />
Detailed dimensions Test 1<br />
Main dimensions, surface hardness Test 5<br />
Visual inspection 9 Check 5<br />
Single tensile element test<br />
according to Annex E.3<br />
Test 1 series<br />
All samples are to be randomly selected and clearly identified.<br />
Details on sampling procedures including methods of recording as well as test methods have been<br />
agreed between the <strong>Approval</strong> Body and the Kit Manufacturer as part of the prescribed test plan.<br />
Preferably standardised sampling and test methods are used. Generally all results are reported in the<br />
test reports in such a way to enable direct comparison with the specification’s data in the <strong>ETA</strong> or<br />
subsidiary documentation.
Annex 0 of the <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> <strong>No</strong>. <strong>ETA</strong>-<strong>06</strong>/00<strong>06</strong> 4<br />
9 Visual inspections means e.g. : main dimensions, gauge testing, correct marking or labelling,<br />
appropriate performance, surface, fins, kinks, smoothness, corrosion, coating, etc.<br />
10 Applied to special grout covered by an <strong>ETA</strong> specified within the PT system.<br />
3 - Responsibility assigned the <strong>ETA</strong> Holder and PT Specialist Companies<br />
The respective tasks and responsibilities of the <strong>ETA</strong> Holder and PT Specialist Companies are<br />
expressed in Appendix D of <strong>ETA</strong>G 013.<br />
Installation of the VSL Post-Tensioning System is carried out in full compliance with the present<br />
<strong>European</strong> <strong>Technical</strong> <strong>Approval</strong>, all related <strong>European</strong> level documents, and all pertinent National<br />
application documents at the Country level.
Annex 1<br />
TECHNICAL DATA<br />
OF THE<br />
VSL MULTISTRAND SYSTEM
Annex 1 of the <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> <strong>No</strong> <strong>ETA</strong>-<strong>06</strong>/00<strong>06</strong> 2<br />
TABLE OF CONTENTS<br />
Title Page<br />
1. DEFINITION OF THE SYSTEM<br />
1.1 PRINCIPLE OF THE VSL MULTISTRAND SYSTEM 4<br />
1.2 CHARACTERISTICS OF SYSTEM UNITS 5<br />
1.3 ANCHORAGES 6<br />
1.3.1 PRESENTATION OF THE ANCHORAGES<br />
1.3.2 LIST OF APPROVED ANCHORAGES<br />
1.4 CATEGORIES OF USE, POSSIBILITIES AND OPTIONS 7<br />
1.4.1 USES AND OPTIONS OF THE VSL MULTISTRAND SYSTEM<br />
1.4.2 POSSIBILITIES OF THE VSL MULTISTRAND SYSTEM<br />
2. STRANDS AND DUCTS<br />
2.1 STRANDS USED 9<br />
2.2 DUCTING 9<br />
2.2.1 TYPES AND DIMENSIONS OF USABLE DUCTS<br />
2.2.2 M<strong>ETA</strong>L DUCTS<br />
2.2.3 PLASTIC DUCTS<br />
2.2.4 ACCESSORIES FOR INLETS, BLEED VENTS AND OUTLETS<br />
2.2.5 CONNECTION WITH TRUMPETS<br />
2.3 CABLE LAYOUT 11<br />
2.3.1 STRAIGHT LENGTHS BEHIND THE ANCHORAGES<br />
2.3.2 RADIUS OF CURVATURE<br />
2.3.3 SPACING OF SUPPORTS AND TOLERANCES<br />
2.3.4 STRAND CUT LENGTH<br />
2.4 INSTALLATION OF DUCTS AND STRANDS 12<br />
2.5 PROVISIONAL PROTECTION AND LUBRICATION 13<br />
2.6 CALCULATION ELEMENTS 13<br />
2.6.1 FRICTION LOSSES<br />
2.6.2 BASIS FOR EVALUATING ELONGATIONS<br />
2.6.3 SETTING OF ANCHORAGE WEDGES<br />
3. ANCHORAGES<br />
3.1 DESCRIPTION OF ANCHORAGE COMPONENTS 15<br />
3.1.1 LIVE END / DEAD END ANCHORAGES<br />
3.1.2 COUPLERS<br />
3.1.3 PRESENTATION AND PACKING OF ANCHORAGES<br />
3.2 ORGANIZATION OF SUPPLY QUALITY 16<br />
3.3 IMPLEMENTATION OF VARIOUS ANCHORAGES 16<br />
3.3.1 TYPE "E" AND "CS" LIVE END ANCHORAGES<br />
3.3.2 TYPE "E" AND "CS" DEAD END ANCHORAGES<br />
3.3.3 TYPE "H" BOND ANCHORAGES<br />
3.3.4 TYPE "K" COUPLER<br />
3.4 ANCHORAGE ARRANGEMENTS 18<br />
3.5 GEOMETRICAL AND MECHANICAL USE CONDITIONS 18<br />
3.5.1 CLEARANCE BEHIND ANCHORAGES<br />
3.5.2 CONCRETE COVER AND ANCHORAGE SPACING<br />
3.6 BURSTING REINFORCEMENT 20<br />
4. STRESSING<br />
4.1 STRESSING EQUIPMENT 21<br />
4.1.1 STRESSING JACKS<br />
4.1.2 HYDRAULIC PUMPS<br />
4.1.3 MEASUREMENT INSTRUMENTS AND SYSTEMS<br />
4.2 PROCESSES OF STRESSING AND CONTROL PROCEDURE 22<br />
4.2.1 FORCE MEASUREMENTS
Annex 1 of the <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> <strong>No</strong> <strong>ETA</strong>-<strong>06</strong>/00<strong>06</strong> 3<br />
4.2.2 ELONGATION MEASUREMENTS<br />
5. INJECTION AND SEALING<br />
5.1 GENERAL INFORMATION 23<br />
5.2 INJECTION PRODUCTS 23<br />
5.2.1 PRODUCT FOR BONDED CABLES<br />
5.2.2 PRODUCT FOR UNBONDED CABLES<br />
5.3 INJECTION EQUIPMENT 24<br />
5.4 INJECTION AND CONTROL PROCEDURE 24<br />
5.5 SEALING 24<br />
6. SCHEMATIC DRAWINGS 25
Annex 1 of the <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> <strong>No</strong> <strong>ETA</strong>-<strong>06</strong>/00<strong>06</strong> 4<br />
CHAPTER 1<br />
1. SYSTEM DEFINITION<br />
DEFINITION OF THE SYSTEM<br />
1.1 PRINCIPLE OF THE VSL MULTISTRAND SYSTEM<br />
The cable or unit of the VSL Multistrand System is composed of a bundle of strands made of high-strength steel<br />
called a "tendon", along with the associated set of anchorages.<br />
The tendon has to be encased within a duct such as a sheath or tube, etc. The void thereby produced can<br />
potentially be filled with an injected material for the purpose of bonding with the structure and/or inhibiting<br />
corrosion.<br />
The constituting strands are those defined in the <strong>European</strong> Standard White Draft pr EN 10138-3: "Prestressing<br />
steels - Strand". They refer to 7-wire strands with nominal diameters of ∅ 15.2 and 15.7 mm (fpk = 1 860 N/mm 2<br />
or fpk = 1 770 N/mm 2 ).<br />
As long as EN 10138 does not exist, 7-wire strands in accordance with national provisions shall be used.<br />
The VSL Multistrand system is able to accommodate bare strands and individually sheathed and greased<br />
(protected) monostrands.<br />
By varying both the strand diameter and number (and, if applicable, their specified characteristic value of<br />
maximum force), it would be possible to obtain a value for the characteristic tensile strength per cable or unit<br />
that varies between 260 and 15 345 kN.<br />
All strands of a cable are simultaneously stressed, yet each one is individually locked within a conical anchoring<br />
hole by means of wedges.<br />
The anchorage function is performed by clamping during strand moving back at the time of pressure release in<br />
the jack.<br />
The choice of post-tensioning units, as dictated by force requirements, leads for a given strand diameter and<br />
characteristic strength to a specific number of strands to be placed. In conjunction with this design element, the<br />
choice of type of anchorage associated with the cable depends on the intended function and application of the<br />
particular unit.<br />
The designation of post-tensioning units is expressed with reference to both the type and number of component<br />
strands. The VSL commercial labeling is explained below:<br />
The labeling of units 6-1… 6-55 or 6S-1… 6S-55 signifies:<br />
the first digit indicates strand diameter,<br />
6 = ∅ 6 × 1/10" = T15.2 ∅15.2 mm<br />
6S = ∅ 6 × 1/10" S = T15.7 ∅15.7 mm (S stands for super).<br />
the subsequent digits indicate the number of strands composing the unit.<br />
To provide greater detail, the designation of units begins with the names of the anchorages placed at the ends.<br />
The following designation serves as an example:<br />
Cable VSL E-E 6S-12 L = 50.000 (1)<br />
The functions and names of the anchorages will be defined hereafter. The cable features a length of 50.000 m<br />
and has been stressed at one (1) end.<br />
To cover the entire range from 1 to 55 strands, an array of basic anchorages has been developed, i.e.: 1 - 2 - 3 -<br />
4 - 7 - 12 - 15 - 19 - 22 - 27 - 31 - 37 - 43 - 55, thus enabling the creation of any intermediate unit, considering<br />
that the number of strands placed may be less than the number of conical holes of the anchorage.<br />
In incompletely filled anchor heads, the present strands have to be arranged to centre the applied load to the<br />
anchor head.
Annex 1 of the <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> <strong>No</strong> <strong>ETA</strong>-<strong>06</strong>/00<strong>06</strong> 5<br />
1.2 CHARACTERISTICS OF SYSTEM UNITS<br />
On the basis of the strand characteristics defined in draft Standard "pr EN 10138-3: Prestressing steels - Part 3:<br />
Strand", the values of tendon cross-sections Ap, maximum forces under anchorage upon tensioning recom-<br />
mended by EC2 : Pmax = min {k1.Ap.fpk; k2.Ap.fp0.1k}, with k1 = 0.8, k2 = 0.9, fpk = 1 860 N/mm 2 , fp0.1k = 0.88 fpk, of<br />
VSL post-tensioning units are as follows :<br />
Number of<br />
strands in the<br />
prestressing<br />
unit<br />
Ap<br />
STRAND ∅ 15.2 - T15.2 or 6<br />
fpk = 1 860 N/mm 2<br />
Fpk = 260 kN Fp0.1k = 229 kN<br />
Ap.fpk<br />
0.8<br />
Ap.fpk<br />
Ap.fp0.1k<br />
0.9<br />
Ap.fp0.1k<br />
Ap<br />
STRAND ∅ 15.7 - T15.7 or 6S<br />
fpk = 1 860 N/mm 2<br />
Fpk = 279 kN Fp0.1k = 246 kN<br />
Ap.fpk<br />
0.8<br />
Ap.fpk<br />
Ap.fp0.1k<br />
0.9<br />
Ap.fp0.1k<br />
mm² kN kN kN kN mm² kN kN kN kN<br />
1 140 260.0 208.0 229.0 2<strong>06</strong>.1 150 279.0 223.2 246.0 221.4<br />
2 280 520.0 416.0 458.0 412.2 300 558.0 446.4 492.0 442.8<br />
3 420 780.0 624.0 687.0 618.3 450 837.0 669.6 738.0 664.2<br />
4 560 1 040.0 832.0 916.0 824.4 600 1 116.0 892.8 984.0 885.6<br />
5 700 1 300.0 1 040.0 1 145.0 1 030.5 750 1 395.0 1 116.0 1 230.0 1 107.0<br />
6 840 1 560.0 1 248.0 1 374.0 1 236.6 900 1 674.0 1 339.2 1 476.0 1 328.4<br />
7 980 1 820.0 1 456.0 1 603.0 1 442.7 1 050 1 953.0 1 562.4 1 722.0 1 549.8<br />
8 1 120 2 080.0 1 664.0 1 832.0 1 648.8 1 200 2 232.0 1 785.6 1 968.0 1 771.2<br />
9 1 260 2 340.0 1 872.0 2 <strong>06</strong>1.0 1 854.9 1 350 2 511.0 2 008.8 2 214.0 1 992.6<br />
10 1 400 2 600.0 2 080.0 2 290.0 2 <strong>06</strong>1.0 1 500 2 790.0 2 232.0 2 460.0 2 214.0<br />
11 1 540 2 860.0 2 288.0 2 519.0 2 267.1 1 650 3 <strong>06</strong>9.0 2 455.2 2 7<strong>06</strong>.0 2 435.4<br />
12 1 680 3 120.0 2 496.0 2 748.0 2 473.2 1 800 3 348.0 2 678.4 2 952.0 2 656.8<br />
13 1 820 3 380.0 2 704.0 2 977.0 2 679.3 1 950 3 627.0 2 901.6 3 198.0 2 878.2<br />
14 1 960 3 640.0 2 912.0 3 2<strong>06</strong>.0 2 885.4 2 100 3 9<strong>06</strong>.0 3 124.8 3 444.0 3 099.6<br />
15 2 100 3 900.0 3 120.0 3 435.0 3 091.5 2 250 4 185.0 3 348.0 3 690.0 3 321.0<br />
16 2 240 4 160.0 3 328.0 3 664.0 3 297.6 2 400 4 464.0 3 571.2 3 936.0 3 542.4<br />
17 2 380 4 420.0 3 536.0 3 893.0 3 503.7 2 550 4 743.0 3 794.4 4 182.0 3 763.8<br />
18 2 520 4 680.0 3 744.0 4 122.0 3 709.8 2 700 5 022.0 4 017.6 4 428.0 3 985.2<br />
19 2 660 4 940.0 3 952.0 4 351.0 3 915.9 2 850 5 301.0 4 240.8 4 674.0 4 2<strong>06</strong>.6<br />
20 2 800 5 200.0 4 160.0 4 580.0 4 122.0 3 000 5 580.0 4 464.0 4 920.0 4 428.0<br />
21 2 940 5 460.0 4 368.0 4 809.0 4 328.1 3 150 5 859.0 4 687.2 5 166.0 4 649.4<br />
22 3 080 5 720.0 4 576.0 5 038.0 4 534.2 3 300 6 138.0 4 910.4 5 412.0 4 870.8<br />
23 3 220 5 980.0 4 784.0 5 267.0 4 740.3 3 450 6 417.0 5 133.6 5 658.0 5 092.2<br />
24 3 360 6 240.0 4 992.0 5 496.0 4 946.4 3 600 6 696.0 5 356.8 5 904.0 5 313.6<br />
25 3 500 6 500.0 5 200.0 5 725.0 5 152.5 3 750 6 975.0 5 580.0 6 150.0 5 535.0<br />
26 3 640 6 760.0 5 408.0 5 954.0 5 358.6 3 900 7 254.0 5 803.2 6 396.0 5 756.4<br />
27 3 780 7 020.0 5 616.0 6 183.0 5 564.7 4 050 7 533.0 6 026.4 6 642.0 5 977.8<br />
28 3 920 7 280.0 5 824.0 6 412.0 5 770.8 4 200 7 812.0 6 249.6 6 888.0 6 199.2<br />
29 4 <strong>06</strong>0 7 540.0 6 032.0 6 641.0 5 976.9 4 350 8 091.0 6 472.8 7 134.0 6 420.6<br />
30 4 200 7 800.0 6 240.0 6 870.0 6 183.0 4 500 8 370.0 6 696.0 7 380.0 6 642.0<br />
31 4 340 8 <strong>06</strong>0.0 6 448.0 7 099.0 6 389.1 4 650 8 649.0 6 919.2 7 626.0 6 863.4<br />
32 4 480 8 320.0 6 656.0 7 328.0 6 595.2 4 800 8 928.0 7 142.4 7 872.0 7 084.8<br />
33 4 620 8 580.0 6 864.0 7 557.0 6 801.3 4 950 9 207.0 7 365.6 8 118.0 7 3<strong>06</strong>.2<br />
34 4 760 8 840.0 7 072.0 7 786.0 7 007.4 5 100 9 486.0 7 588.8 8 364.0 7 527.6<br />
35 4 900 9 100.0 7 280.0 8 015.0 7 213.5 5 250 9 765.0 7 812.0 8 610.0 7 749.0<br />
36 5 040 9 360.0 7 488.0 8 244.0 7 419.6 5 400 10 044.0 8 035.2 8 856.0 7 970.4<br />
37 5 180 9 620.0 7 696.0 8 473.0 7 625.7 5 550 10 323.0 8 258.4 9 102.0 8 191.8<br />
38 5 320 9 880.0 7 904.0 8 702.0 7 831.8 5 700 10 602.0 8 481.6 9 348.0 8 413.2<br />
39 5 460 10 140.0 8 112.0 8 931.0 8 037.9 5 850 10 881.0 8 704.8 9 594.0 8 634.6<br />
40 5 600 10 400.0 8 320.0 9 160.0 8 244.0 6 000 11 160.0 8 928.0 9 840.0 8 856.0<br />
41 5 740 10 660.0 8 528.0 9 389.0 8 450.1 6 150 11 439.0 9 151.2 10 086.0 9 077.4<br />
42 5 880 10 920.0 8 736.0 9 618.0 8 656.2 6 300 11 718.0 9 374.4 10 332.0 9 298.8<br />
43 6 020 11 180.0 8 944.0 9 847.0 8 862.3 6 450 11 997.0 9 597.6 10 578.0 9 520.2<br />
44 6 160 11 440.0 9 152.0 10 076.0 9 <strong>06</strong>8.4 6 600 12 276.0 9 820.8 10 824.0 9 741.6<br />
45 6 300 11 700.0 9 360.0 10 305.0 9 274.5 6 750 12 555.0 10 044.0 11 070.0 9 963.0<br />
46 6 440 11 960.0 9 568.0 10 534.0 9 480.6 6 900 12 834.0 10 267.2 11 316.0 10 184.4<br />
47 6 580 12 220.0 9 776.0 10 763.0 9 686.7 7 050 13 113.0 10 490.4 11 562.0 10 405.8<br />
48 6 720 12 480.0 9 984.0 10 992.0 9 892.8 7 200 13 392.0 10 713.6 11 808.0 10 627.2<br />
49 6 860 12 740.0 10 192.0 11 221.0 10 098.9 7 350 13 671.0 10 936.8 12 054.0 10 848.6<br />
50 7 000 13 000.0 10 400.0 11 450.0 10 305.0 7 500 13 950.0 11 160.0 12 300.0 11 070.0<br />
51 7 140 13 260.0 10 608.0 11 679.0 10 511.1 7 650 14 229.0 11 383.2 12 546.0 11 291.4<br />
52 7 280 13 520.0 10 816.0 11 908.0 10 717.2 7 800 14 508.0 11 6<strong>06</strong>.4 12 792.0 11 512.8<br />
53 7 420 13 780.0 11 024.0 12 137.0 10 923.3 7 950 14 787.0 11 829.6 13 038.0 11 734.2<br />
54 7 560 14 040.0 11 232.0 12 366.0 11 129.4 8 100 15 <strong>06</strong>6.0 12 052.8 13 284.0 11 955.6<br />
55 7 700 14 300.0 11 440.0 12 595.0 11 335.5 8 250 15 345.0 12 276.0 13 530.0 12 177.0<br />
<strong>No</strong>te : prestressing force applied to structure must be in accordance with national regulations.
Annex 1 of the <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> <strong>No</strong> <strong>ETA</strong>-<strong>06</strong>/00<strong>06</strong> 6<br />
The system can obviously be used with strands displaying a specific characteristic tensile strength of less than<br />
that proposed in the table as strands with fpk = 1 770 N/mm 2 . The provisions for tendons with strands with a<br />
characteristic tensile strength fpk = 1 860 N/mm 2 also apply to tendons with strands with fpk < 1 860 N/mm 2 .<br />
The draft Standard pr EN 10138-3 sets the following criteria for the other useful characteristics of prestressing<br />
strands composing the VSL units:<br />
- Elongation at maximal force: ≥ 3.5%<br />
- Relaxation at 0.70 fpk after 1,000 hours: ≤ 2.5%<br />
- Relaxation at 0.80 fpk after 1,000 hours: ≤ 4.5%<br />
- Fatigue behavior (0.70 fpk; 190 N/mm 2 ): ≥ 2x10 6 cycles<br />
- Maximum D value of deflected tensile test: ≤ 28%<br />
- Modulus of elasticity Ep: 195 000 N/mm 2<br />
Even though the modulus of elasticity of both the tendon or bundle of strands and the (single) strand are<br />
somewhat different, VSL still recommends adopting, for the cable calculations, the measured strand value that<br />
had been transmitted upon delivery of the supply of strands.<br />
Individually greased and sheathed monostrands have the same mechanical properties as listed above for bare<br />
strands.<br />
1.3.1 PRESENTATION OF THE ANCHORAGES<br />
1.3 ANCHORAGES<br />
The VSL Multistrand System anchorages may, depending on their function and commercial labeling, be<br />
classified as one of the following:<br />
Type "E" and "CS" live end anchorages<br />
These active anchorages are designed to anchor the tendons at the end through which stressing of the entire<br />
set of bundled strands will be carried out.<br />
They are composed of an anchor head (cylindrical for the anchorage E or a hexagonal-base prism for the "CS"<br />
anchorage) drilled with the same number of conically-shaped holes as strands to be anchored; the anchoring<br />
step is performed at each strand using wedges to provide a strong grip.<br />
The anchor head is supported by the concrete via an "E" or "CS" type anchor plate connected to an "E" or "CS"<br />
type trumpet housing deviating the strands to the current duct.<br />
Type "E" and "CS" dead end anchorages<br />
These passive anchorages serve to block the tendons at the end on which no stressing force is to be exerted.<br />
This category only includes those anchorages that remain accessible at the time of stressing.<br />
Type "E" or "CS" anchorages, which feature pre-clamped wedges and which may be controlled during stressing,<br />
are used for this purpose.<br />
Type "H" bonded anchorages<br />
These dead end anchorages rely, at least in part, on bond in order to maintain the tendon extremity fastened<br />
with respect to the concrete.<br />
In type "H" anchorages, the clean strands exhibit wires, over a given bond length, folded at their extremities to<br />
form an onion.<br />
Type "K" couplers<br />
These anchorages ensure the continuity of two tendons placed in tension one after the other when two distinct<br />
phases of the construction job overlap.<br />
Within "K" type couplers, the first-phase cable is anchored on the coupler side with a type "E" or "CS" anchor<br />
(transfer) plate whose head labeled "K" contains the housing units for the coupling around its periphery.<br />
The second-phase cable, on the coupler side, is anchored by means of compression fittings on the strands<br />
placed into the aforementioned housings.<br />
The two coupled tendons must be units of the same number of strands and the force in the second phase cable<br />
shall not be larger than the force in the first phase cable.<br />
The coupling is then insulated from the concrete by means of a sleeve.
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1.3.2 LIST OF APPROVED ANCHORAGES<br />
The set of approved anchorages that allow creating all sorts of intermediate prestressing units have been<br />
categorized in the following table:<br />
CABLE<br />
ANCHORAGE<br />
Function Live End Dead End Bond Coupler<br />
Unit Commercial label E CS E CS H K<br />
1T15.2 / 1T15.7 6-1 / 6S-1 <br />
2 2 <br />
3 3 <br />
4 4 <br />
7 7 <br />
12 12 <br />
15 15 <br />
19 19 <br />
22 22 <br />
27 27 <br />
31 31 <br />
37 37 <br />
43 43 <br />
55 55 <br />
The stressing of tendons at PT system anchorages is only conducted by VSL stressing jacks, which are<br />
presented in Chapter 4.<br />
1.4 CATEGORIES OF USE, POSSIBILITIES AND OPTIONS<br />
1.4.1 USES AND OPTIONS OF THE VSL MULTISTRAND SYSTEM<br />
VSL Multistrand System units may be:<br />
- internal or external (to the concrete or to one another material),<br />
- with or without a bonded or unbonded permanent injection, and<br />
- applied in structures composed indiscriminately of various construction materials.<br />
These units may entail:<br />
- an adjustable force, and/or<br />
- the potential for replacement provided the absence of bonding with the structure.<br />
They can also be conceived for applications that are:<br />
- encapsulated (leak-tight, waterproof), and<br />
- electrically isolated (electrical isolation implies a strong waterproofing).<br />
Uses of units of VSL Multistrand System made of approved anchorages<br />
Uses Anchorages E CS H K<br />
internal* bonded cable with metallic duct <br />
internal* bonded cable with plastic duct <br />
internal* unbonded <br />
external* bonded cable <br />
external* unbonded cable <br />
tendon for use in various material as external cable <br />
restressable tendon <br />
exchangeable tendon <br />
encapsulated tendon (leak tight) <br />
electrically isolated tendon <br />
(*) of concrete
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As noted before,<br />
- absence of bonding with the structure for exchangeable cable means soft injection or double pipe at<br />
anchorage and deviator in case of rigid injection. The clearance between outside diameter of tendon duct and<br />
inside diameter of formwork pipe in structure has to be 10 mm minimum.<br />
- the VSL Multistrand System may be introduced without grouting, which for example is the case when<br />
tendons are left without protection due to their provisional use, or their location within a neutral environment.<br />
It goes without saying that all these potential uses and options presume the availability of adequate choices and<br />
combinations of all cable components as indicated in this <strong>ETA</strong>:<br />
- for strands see Chapter 2.1 "Strands used",<br />
- for ducts see Chapter 2.2 "Ducting",<br />
- for anchorages see Chapter 3.4 "Anchorage arrangements",<br />
- for injection see Chapter 5.2 "Injection products".<br />
1.4.2 POSSIBILITIES OF THE VSL MULTISTRAND SYSTEM<br />
The VSL Multistrand System is able to take advantage of the following unique set of possibilities:<br />
- Partial stressing or stressing in stages:<br />
When prestressing needs to be applied gradually, the stressing may be performed in stages. As the first<br />
partial stressing step gets carried out, at the beginning of the second stage, the wedges are unclamped by<br />
action of the jack on the cable. Once the targeted force has been reached, pressure in the jack is relaxed<br />
and the wedges are once again clamped inside the anchor head. This procedure consists of the same<br />
steps as for tensioning of a long cable whose elongation necessitates several successive jack strokes.<br />
- Overstressing with shimming:<br />
Upon loading of the anchorage during relaxing the jack pressure, due to wedges draw in, a simultaneous<br />
setting of the strands takes place causing a reduction of elongation and a drop in tension at the cable end.<br />
It is still possible however to adjust tension to the desired value by use of a jack chair ring that enables<br />
pressing the jack no longer upon the anchor head but rather via jack chair upon the bearing plate. In this<br />
case, since the stressing had been conducted under typical conditions and the wedges locked definitively,<br />
tensioning is resumed by bringing the head back to the target displacement (the wedge draw in or other<br />
value), and then shimming between the anchor head and the anchor plate with split shim (see chapter<br />
2.6.3) .<br />
- Destressing procedure:<br />
The destressing of an anchored cable by a type "E" or "CS" anchor head is possible using a special tooling<br />
assembly mounted on the tensioning jack provided that (1) the required strand overlengths have been<br />
conserved, (2) that the tendon remains unbonded to the structure.<br />
From the aforementioned, two zones would appear to stand out, the current zone and the anchorage zone; they<br />
will be presented in greater detail within the following chapters entitled "Strands and ducts" and "Anchorages".
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CHAPTER 2<br />
STRANDS 2. TENDONS AND DUCTS DUCTS<br />
2.1 STRANDS USED<br />
The high-strength prestressing steel (strands) composing the tendons are labeled "Y1860S7 – <strong>No</strong>. 1.1366" and<br />
are defined in the draft Standard "pr EN 10138-3: Prestressing steels – Part 3: Strand". Alternatively, the<br />
strands labeled "Y1770S7 – <strong>No</strong>. 1.1365" may also be employed.<br />
The primary characteristics have been recalled in Section 1.2.<br />
Monostrands (individually greased and sheathed) can be used for unbonded tendons, either internal or external<br />
to concrete or other materials. They are compliant with Annex C.1 of the <strong>ETA</strong>G 013, which specifies the<br />
requirements, verification methods and acceptance criteria of both the grease and the sheathing.<br />
2.2 DUCTING<br />
The VSL Multistrand System can use several types of duct as provided in this section. Duct type selection<br />
depends on the specific project, the final use designed for the structure and the options selected for the posttensioning<br />
units.<br />
2.2.1 TYPES AND DIMENSIONS OF THE USABLE DUCTS<br />
Depending on the specific application, various types of ducts may be employed. From a general standpoint, the<br />
ducts used must be mechanically resistant, display continuity in shape, ensure continuity of the seal and,<br />
ultimately, continuity in electrical insulation over their entire length, as well as comply with the project's bond<br />
requirements while not causing any chemical attack to the prestressing steel.<br />
Without claiming to be exhaustive, the following table of frequently-used ducts can be cited as having<br />
demonstrated their capacities in the uses and applications associated with the given options:<br />
Applications<br />
Ducts<br />
Corrugated metal<br />
duct<br />
Metal Ducts Plastic Ducts<br />
Smooth metal duct<br />
VSL PT-PLUS ®<br />
Duct<br />
Smooth plastic duct<br />
polyethylene,<br />
polypropylene<br />
Internal with<br />
standard ~ ~ ~<br />
Cable,<br />
in the<br />
concrete<br />
bonded<br />
injection<br />
encapsulated<br />
electricallyisolated<br />
×<br />
×<br />
<br />
×<br />
¹<br />
¹<br />
~<br />
~<br />
with<br />
unbonded<br />
injection<br />
standard +<br />
encapsulated<br />
electricallyisolated<br />
×<br />
×<br />
<br />
×<br />
×<br />
×<br />
<br />
<br />
restressable<br />
and/or<br />
replaceable<br />
× × <br />
External<br />
Cable,<br />
out of<br />
the<br />
concrete<br />
(or other<br />
material)<br />
with<br />
bonded<br />
injection<br />
with<br />
unbonded<br />
injection<br />
standard +<br />
encapsulated<br />
electricallyisolated<br />
standard +<br />
encapsulated<br />
electricallyisolated<br />
×<br />
×<br />
×<br />
×<br />
²<br />
×<br />
²<br />
×<br />
×<br />
×<br />
×<br />
×<br />
<br />
<br />
<br />
<br />
restressable<br />
and/or<br />
replaceable<br />
× ²<br />
× <br />
For the other materials such as masonry, wood, etc., refer to conditions relative to concrete and take into account the<br />
installation constraints, which may be of various types.<br />
<strong>No</strong>tes ¹: This set-up features a fully-bonded cable. ²: Smooth ducts in polyethylene or polypropylene are the most common.<br />
: Advised ~ : Possible × : Unadvised or forbidden
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The VSL Multistrand System's post-tensioning tendon ducts, for the most part with a circular cross-section, must<br />
display an internal diameter large enough to provide for easy strands installation and adequate filling during<br />
injection of the protective filling product.<br />
With this objective, VSL recommends an internal duct diameter Øi ≥ 1.8 Αp , where Ap is the nominal crosssection<br />
of the strands composing the unit. This relation is suitable for the case of threading the tendons by<br />
means of pushing through strand by strand into the ducts installed prior to concreting. In the case of<br />
prefabricated cables, it is authorized to adopt a duct with a smaller diameter. Moreover, during the calculations,<br />
it is necessary to consider the distance (called eccentricity) existing between the center of the duct and the<br />
center of gravity of the strand bundle cross-section.<br />
The recommended duct dimensions, along with the corresponding eccentricity values, are given on Page 40 in<br />
Chapter 6.<br />
The ducts, depending on their type and capacities, may be provided on coil or in straight segments.<br />
2.2.2 M<strong>ETA</strong>L DUCTS<br />
The tendons are most often (as per the "STANDARD" solution) isolated from the concrete by means of<br />
corrugated steel strip sheaths. According to Standard EN 523, they are either normal (Category 1), i.e. "normal<br />
sheaths", or (Category 2), i.e. "rigid sheaths" but bendable by hand, with their characteristics being stipulated in<br />
the standard.<br />
Connections between coils or straight segments are performed by means of screwing a connector (coupler)<br />
onto the two extremities to be connected. The sealing at the joints is done by either an adhesive ribbon or<br />
thermo-retractable sleeves.<br />
In certain applications (e.g. nuclear, offshore), the tendons are encased in smooth steel ducts. The most<br />
frequently-employed tubes, whether welded or not, are thin (in compliance with the EN standards) and machinebendable.<br />
The connections between segments are commonly performed by flaring one end and clamping the<br />
other; the seal is generated by welding, thermo-retractable sleeves or adhesive ribbon.<br />
2.2.3 PLASTIC DUCTS<br />
In the case of stringent requirements as regards both corrosion protection and fatigue resistance of cables, it is<br />
recommended to use the corrugated plastic duct VSL PT-PLUS ® . This duct may only be used inside the<br />
concrete with a grouting and generates perfect bond between the tendons and the structure. It is recommended<br />
for applications submitted to a particularly-aggressive environment or strong fatigue loads. The VSL PT-PLUS ®<br />
duct complies with <strong>ETA</strong>G 013. The fitting between duct segments is introduced by means of mirror welding or<br />
by connectors that provide for both the waterproofing seal and electrical isolation. This duct can be used with all<br />
anchorage types E, CS, K, H. When used with CS-type anchorages, it allows to provide fully-encapsulated units<br />
labeled CS "PLUS" as well as electrically isolated units labeled CS "SUPER". Such applications necessitate the<br />
presence of rigid half-shells between the duct and its supports at all of the high points along cable path in order<br />
to avoid any risk of perforation during stressing of the tendon.<br />
More common ducts (sleeves or tubes) made of polyethylene or polypropylene can also be used. The<br />
connections and seals between the coil or straight segments are introduced by either mirror welding or electroweldable<br />
couplers, or other means. Plastic pipe in accordance with <strong>ETA</strong>G 013 / EN-compliant ducts are in fact<br />
required. With an appropriate set of fittings, they may be used for applications involving encapsulated /<br />
waterproof and electrically-isolated tendons.<br />
2.2.4 ACCESSORIES FOR INLETS, BLEED VENTS AND OUTLETS<br />
In internal (concrete) post-tensioning applications for structures composed of prefabricated elements, duct<br />
continuity, regardless of duct type, is performed in alignment with the joints by means of a coupler fitting that<br />
encompasses a set of rings inserted at the contact element duct end. These plastic accessories serve to<br />
complete the seal.<br />
Providing permanent protection by means of grout injection presupposes the possibility of intervening anywhere<br />
along the cable path in order to adjust the filling and bleed any air, water, etc. that may be within the ducts. In<br />
this aim, accessories for re-circulation, venting and bleeding are installed on the ducts. These basically<br />
comprise shells or collars fastened onto holes in the ducts and connected to pipes with plugs opening onto an<br />
accessible face of the structure. The following options are available:
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Duct Duct connection accessory<br />
Inlet, venting, bleeding or outlet<br />
accessory<br />
Corrugated steel strip sheath Sealed plastic shell Plastic pipe<br />
Smooth steel tube Welded pipes Steel tube or plastic pipe<br />
VSL PT-PLUS ® duct Special "clipped" collar / coupler Plastic pipe<br />
Plastic duct Electro-weldable collar or welded pipes Plastic pipe<br />
Distributions of inlet, venting, bleeding and outlet points along the cable profile are selected based on a functionspecific<br />
study of both the injection pattern and procedure.<br />
2.2.5 CONNECTION WITH TRUMPETS<br />
The strands, located within the ducts, must slightly dilate in the vicinity of the anchorages in order to pass<br />
through the corresponding holes in the anchor head. This conical deviation is done in a transition zone called a<br />
trumpet and is considered part of the anchorage element.<br />
The trumpets of a specific anchor plate are of adequate diameters, with enough length and opening at the end<br />
that allows for connection and alignment to the duct of the current zone.<br />
The seal between the duct and trumpet is carried out using an adhesive strip, a thermo-retractable sleeve or a<br />
connector designed as a duct accessory (e.g. a VSL PT-PLUS ® coupler).<br />
2.3 CABLE LAYOUT<br />
The cable layout patterns are not inherent to the VSL Multistrand System, but instead depend on the particular<br />
project.<br />
2.3.1 STRAIGHT LENGTHS BEHIND THE ANCHORAGES<br />
In order for the strands not to display excessive deviation with respect to the anchor head support surface, it is<br />
recommended to lay out a rectilinear segment in the back of the anchorage. This straight length in axial<br />
alignment varies with the size of the prestressing units. The following has been specified as straight length Lmin<br />
which includes both the anchor plate and the trumpet:<br />
for Fpk < 2 MN Lmin = 0.8 m<br />
for 2 MN ≤ Fpk ≤ 7 MN Lmin = 1.0 m<br />
for Fpk > 7 MN Lmin = 1.5 m<br />
2.3.2 RADIUS OF CURVATURE<br />
In order for the ducts and tendons to be easily installed and handled, for the friction loss values to be respected<br />
and for the actions upon deviations to be acceptable, it is recommended to limit the radius of cable curvature.<br />
For internal (concrete) post-tensioning, in the cases of common deviations, VSL recommends verifying that:<br />
R ≥ 100 Øi, where R is the radius of curvature and Øi = inside diameter of the duct.<br />
This rule is appropriate for both corrugated steel strip sheaths of Category 2 (see Section 2.2.2) and the<br />
VSL PT-PLUS duct (see Section 2.2.3).<br />
When using corrugated steel strip sheaths of Category 1 (see Section 2.2.2) and smooth steel tube, R ≥ 3 m.<br />
In more unique cases involving the use of smooth steel tubes, the radius of curvature may be significantly<br />
reduced: R ≥ 20 Øi. Under such specific conditions, local concrete strength as well as stresses in strands<br />
verifications must be performed.<br />
Tendon sections curved in a U-shape at a tight radius to form an inaccessible end of the tendon named loop<br />
anchorage (not considered to be an anchorage in the intent of <strong>ETA</strong>G 013) respect the following details :
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- duct in loop is either smooth or corrugated, diameter one size larger than in free length for ease<br />
of connection (one fitting into other)<br />
- radius of curvature in loop R ≥ max { 0.6 Fpk<br />
; 0.6 m }, where R is expressed in meters and<br />
Fpk expressed in MN.<br />
For external (concrete) post-tensioning, in cases where a high-quality polyethylene tube and thickness adequate<br />
for external cable use as defined in Appendix C.2 of the <strong>ETA</strong>G 013, the following values (based on ENV 1992-1-<br />
5) should be respected.<br />
Tendon Unit Minimum Radius (m)<br />
6-7 2.0<br />
6-12 2.5<br />
6-19 3.0<br />
6-27 3.5<br />
6-37 4.0<br />
6-43 4.5<br />
6-55 5.0<br />
While corrugated metal strip sheath can be bent by hand to almost any shape in space, machine-bent smooth<br />
steel pipe can only be bent to a constant radius in one plane. The designer should take this into account when<br />
specifying the tendon profile.<br />
2.3.3 SPACING OF THE SUPPORTS AND TOLERANCES<br />
The support heights underneath the duct are listed on the cable diagrams approximately every meter for a large<br />
radius of curvature and every fifty centimeters for a small radius of curvature, in order to allow for duct<br />
placement with the required level of precision.<br />
Depending on the type of duct and its dimensions, the fastening fittings are sufficiently robust and close enough<br />
such that the ducts and tendons will not exhibit displacements or deformations in excess of the allowed<br />
tolerances.<br />
The tolerances on cable positions in the concrete elements must respect the prescriptions stipulated in the draft<br />
standard "pr ENV 13670-1".<br />
Moreover, under all circumstances and in every direction, whenever a cable displays or potentially displays<br />
deviation in the vicinity of an edge of concrete which could lead to spalling of concrete cover, an offset with<br />
respect to the cable diagram in this direction is only tolerated provided that equilibrium reinforcing bars have<br />
been provided over this zone.<br />
2.3.4 STRAND CUT LENGTH<br />
Since the anchorage has been fastened with respect to the structure undergoing post-tensioning, its space<br />
consumption is limited to its specific volume. Strand length is strictly the length of the prestressed element<br />
between the anchorages increased by the over length crossing the stressing jack(s).<br />
These over length have been defined in the drawing on Page 39 in Chapter 6.<br />
2.4 INSTALLATION OF DUCTS AND STRANDS<br />
Depending on the size and layout of the worksite, the available space on site and the schedule of works, one of<br />
the following solutions is to be adopted (for practical purposes and in order to list all installation possibilities,<br />
only the case of an internal post-tensioning of a new concrete structure has been highlighted herein):<br />
- Cables (both strands and ducts) fabricated in the plant and then delivered as needed at the worksite for<br />
installation into the passive reinforcement;<br />
- Strand bundles fabricated in a mobile workshop located adjacent to the worksite and then drawn either<br />
before or after concreting into the ducts installed in the passive reinforcement;<br />
- Tendons composed by pushing through strand by strand before or after concreting into the ducts installed<br />
in the passive reinforcement.
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2.5 PROVISIONAL PROTECTION AND LUBRICATION<br />
The oiling or greasing of strands, exclusively by means of non-dangerous substances, is performed:<br />
- in the aim of providing provisional protection against corrosion from the time of leaving the plant until<br />
permanent protection has been achieved (grouting of the cable);<br />
- in the aim of lubrication since the friction loss of oiled strands in the ducts during stressing is lower.<br />
With this same objective, other products serving to reduce friction loss may be used, as long as they are<br />
recognized as non-dangerous, can be easily applied and remain inert in the presence of permanent protection<br />
(and the eventual bond to the structure),.<br />
It is necessary to point out that:<br />
"In addition to the specific clauses relating to dangerous substances contained in this <strong>European</strong> <strong>Technical</strong><br />
<strong>Approval</strong>, there may be other requirements applicable to the products falling within its scope (e.g. transposed<br />
<strong>European</strong> legislation and national laws, regulations and administrative provisions). In order to meet the<br />
provisions of the EU Construction Products Directive, these requirements need also to be complied with, when<br />
and where they apply."<br />
2.6.1 FRICTION LOSSES<br />
2.6 CACULATION ELEMENTS<br />
where μ is the friction coefficient (over the curve) between the strands and the duct, θ the sum of the<br />
angular deviations of the cable over the distance x, and k the unintentional deviation (per unit length) affecting<br />
the cable path,<br />
it is recommended to adopt the numerical values of μ and k according to Eurocode 2 (EN 1992-1-1). They can<br />
be summarized as follows:<br />
Application μ (rad -1 ) k (rad/m)<br />
Internal (concrete) cable with corrugated steel strip sheath 0.17 - 0.19 0.005 - 0.010<br />
Internal (concrete) cable with smooth steel tube 0.16 - 0.24 0.005 - 0.010<br />
Internal (concrete) cable with VSL PT-PLUS duct 0.12 - 0.14 0.005 - 0.010<br />
External (concrete) cable with smooth steel tube 0.16 - 0.24 0<br />
External (concrete) cable with plastic duct 0.12 - 0.14 0<br />
Internal (concrete) cable with individually greased and sheathed strands 0.05 0.020 – 0.<strong>06</strong>0<br />
External (concrete) cable with individually greased and sheathed strands 0.05 0.020 – 0.<strong>06</strong>0<br />
The interval limit values encompass both lubricated and non-lubricated strands.<br />
The values of k are zero for cables outside the concrete.<br />
2.6.2 BASIS FOR EVALUATING ELONGATIONS<br />
The calculation of elongations for stressing purposes presumes that the tension curve within the strands along<br />
the cable just before locking of the anchorage is known, i.e. fpo (x).<br />
The measurable elongation upon stressing at the back of the jack for the live end anchorage under<br />
consideration, where x = 0, may be written as follows:
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where, in the second member,<br />
- for the 1 st term:<br />
L j : length of the strands in the stressing jack.<br />
fpo (x) ~ (1 + ka). fpo,o = constant<br />
where fpo,o: stress in the strands upon stressing at x = 0,<br />
ka: friction loss in the anchorage, which may be neglected for this purpose;<br />
- for the 2 nd term:<br />
La: length of the concerned tendon = length from the live end anchorage to the MIN (fpo(x)), i.e. the abscissa of<br />
the strands cross-section not moving;<br />
- for the 3 rd term:<br />
negligible in the majority of cases (except if stresses in the concrete resulting from prestressing are high);<br />
- for the 4 th term:<br />
in the case where the cable is terminated by a fixed external anchorage whose wedges were manually pre-set<br />
(common case), a draw-in g’ of these so-called wedges on the order of 3 mm must be incorporated.<br />
In simplifying and defining: fpo,m, the average stress over the concerned strands length, the following is<br />
obtained:<br />
On the worksite during stressing, elongation due to tendon slack should be eliminated from the reported value<br />
with appropriate procedures (e.g. taking into account elongations only once the tendon has been stiffened inside<br />
its duct).<br />
<strong>No</strong>te : ka : friction losses in the anchorages are expressed in Section 4.2.1<br />
2.6.3 SETTING OF ANCHORAGE WEDGES<br />
A 6-mm draw-in of the wedges is considered; this value remains constant for all units and is applicable to all<br />
anchorages and all types of wedges.<br />
When an adjustment must be conducted, the insertion of a suitable split shim between the anchor head and its<br />
anchor plate, makes it possible to compensate for the wedge draw-in up to the shim thickness.<br />
In this case, the re-tensioning force must not exceed Pmax, which is the maximum force authorized during unit<br />
stressing. If upon initial tensioning Po,o < Pmax, compensation for the wedge draw-in may thus be complete. If<br />
however upon initial tensioning Po,o = Pmax, an uncompensated wedge draw-in of 1 to 2 mm must be<br />
incorporated.<br />
The split shim is made of same material as anchor plate E and that diameter of hole is the same as specified in<br />
E or CS plate (depending of which anchor is used).<br />
<strong>No</strong>te : compression fittings are without significant setting.
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CHAPTER 3<br />
3. ANCHORAGES<br />
ANCHORAGES<br />
3.1 DESCRIPTION OF ANCHORAGE COMPONENTS<br />
VSL Multistrand System anchorages make use of a set of standard elements, to be categorized as follows:<br />
3.1.1 LIVE END / DEAD END ANCHORAGES<br />
Live end (active) and dead end (passive) anchorages comprise:<br />
- Anchor plates and trumpets:<br />
Common anchorage plates and duct-transition trumpets exist in accordance with two models:<br />
- the "E" model composed of a simple plate made of steel according to Standard EN 10025. The most<br />
frequently-used steel is S235JRG2 and the E trumpet is made of steel sheet;<br />
- the "CS" model composed of a cast iron matrix with spheroidal graphite in accordance with Standard<br />
EN 1563, made composite with a very high-strength mortar. The cast iron used is EN-GJS-500-7U. The<br />
CS trumpet is made of plastic and can be ended by an appropriate ancillary attachment for connection<br />
to the VSL PT-PLUS ® duct. The CS trumpet can also be associated with E anchor plate model.<br />
- Anchor heads:<br />
The basic anchor heads may be found in two models:<br />
- the "E" model, associated with plate E, formed from a steel rod, with quenching and tempering<br />
according to Standard EN 10083-2. The most frequently-used steel is C45;<br />
- the "CS" model, associated with plate CS, formed from a steel rod, with quenching and tempering<br />
according to Standard EN 10083-1 and then machined or forged to achieve variable thickness. The<br />
most frequently-used steel is 42CrMoS4.<br />
The conical holes are machined on transfer equipment and exhaustively controlled.<br />
- Wedges:<br />
The wedges are trimmed in alloyed steel for cementation according to Standard EN 10084, then cleaved into<br />
parts and then treated. The most frequently-used steel is 20NiCrMo2-2. These elements are available in two<br />
models:<br />
- the "W6N" (or "S") model, with two independent parts;<br />
- the "W6N" (or "S") 3C model, with three parts attached by means of a retaining ring.<br />
For each of the models, the wedges are specified according to two types, adapted to strand diameters, along<br />
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<br />
super) wedges are differentiated from the N (normal) wedges by the presence on the plane face, which remains<br />
apparent, of a grooved trim. These wedges are all submitted to rigorous controls.<br />
Both the VSL Multistrand System and VSL Slab System (see Annex 2) wedges are identical.<br />
- Protective caps:<br />
In order to enable injecting permanent protection and ultimately contributing to protecting the anchorage, three<br />
cap models to be used with the plate are available:<br />
- the provisional cap designed to contain the injection product for the permanent protection of the zone.<br />
Following the curing period, this cap is recycled for reuse; the injection product must be a rigid grout and<br />
then the anchorage block-out must be filled with concrete;<br />
- the permanent metallic cap, containing the anchor head and the protection product, which is left in place<br />
after injection;<br />
- the permanent plastic cap, containing the anchor head and protection product, which is also to be left in<br />
place after injection. This cap has been designed in particular for sealed and electrically isolated cables.<br />
Permanent caps are obviously required in all cases calling for the injection of a flexible protection product.<br />
Provided a few precautions have been taken against corrosion of the metallic parts, the permanent caps may be<br />
left apparent; moreover, permanent caps can also be used as temporary caps.
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3.1.2 COUPLERS<br />
The couplers rely, for the second-phase cable, upon reliable anchorage components that are supported on the<br />
installed anchor head including connection grooves.<br />
This setup consists of compression fittings, composed of a hard steel wire hoop wound in a spiral and a bushing<br />
sleeve cut into the steel to allow for quenching and tempering, as stipulated in Standard EN 10083-2. The type<br />
of steel used is C45. The hoop is assembled on the strand, and then the fitting is seamed by means of coldthreading<br />
on the assembled unit.<br />
3.1.3 PRESENTATION AND PACKING OF ANCHORAGES<br />
Given that strand placement only takes place in a rather generalized manner following concreting, the delivery<br />
of anchorages on the worksite entails:<br />
(only the most common case of internal (concrete) post-tensioning of a new structure will be highlighted herein)<br />
1. Delivery of the anchor plates along with the ducts for placement within the passive reinforcement, and<br />
fastening of the plates to the formwork. These anchorage parts are delivered tagged for identification<br />
either on pallets or in bulk.<br />
Following concreting and curing:<br />
2. Delivery of the anchor heads and wedges along with the strands to be threaded, installation of the<br />
anchor heads, stressing and grouting of the permanent cable protection. These anchorage components<br />
are delivered tagged for identification, packaged and protected (the same applies for the strands).<br />
3.2 ORGANIZATION OF SUPPLY QUALITY<br />
The fabrication of anchorage components of post-tensioning system and especially those designed for the VSL<br />
Multistrand System is conducted in compliance with the specifications, production and control procedures laid<br />
out in the present <strong>ETA</strong> and associated documents.<br />
The control procedures in effect for anchorage Component Manufacturers, to the same extent as those adopted<br />
by the PT Specialist Company, serve to ensure the traceability of the components all the way through to their<br />
delivery on site. It is to be recalled that the basis for evaluating these procedures and the supervision of their<br />
application have been defined in Chapter 8 and its Annex E of the <strong>ETA</strong>G 013.<br />
It should also be recalled that prior to installation, the compliance of all delivered components, by means of both<br />
identification and visual inspection of their state, must be performed by the PT Supervisor.<br />
3.3 IMPLEMENTATION OF VARIOUS ANCHORAGES<br />
The implementation of VSL units must be assigned to a competent staff member and involve technical<br />
management personnel within the PT Specialist Company or a PT Supervisor certified by this company.<br />
Anchorage placement in accordance with model prescriptions is handled as follows (for practical purposes, only<br />
the most common case of internal (concrete) post-tensioning of a new structure has been highlighted herein):<br />
3.3.1 TYPE "E" AND "CS" LIVE END ANCHORAGES<br />
The anchor plates and trumpets are fixed to the formwork and connected to the ducts which have been placed<br />
at the time of installation of the passive reinforcement; they are thus incorporated into the structure or structural<br />
element upon concreting.<br />
It should be noted that for the "E" plates, the possibility exists to install them on a previously-completed concrete<br />
facing by means of inserting a flexible and durable joint between the plate and concrete or installing them on a<br />
metallic surface.<br />
On the other hand, the "CS" plates may only be installed into a concrete block cast around the plates.
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The arrangement of injection holes vary according to the anchorage models and structures and can either open<br />
onto the front face or may use pipes in order to open onto other faces of the structure.<br />
The anchor heads and wedges are positioned immediately before stressing, a step which serves to avoid<br />
polluting the parts.<br />
Anchorages used with monostrands (individually greased and sheathed) include sealing between anchor head<br />
and monosheaths to close the current grouted zone and to confine greased protection in the anchorage zone<br />
(e.g. with neoprene disk or plastic sleeve).<br />
Anchorages used with both isolating rings (to be inserted between the head and plate) and isolating plastic<br />
caps, enable constituting electrically isolated tendons, such as the CS "SUPER" type units. The "E" anchorages<br />
can also be used for electrically isolated tendons when using the CS plastic trumpet.<br />
As for force losses in the anchorages during stressing, see Section 4.2.1: "Force Measurements".<br />
3.3.2 TYPE "E" AND "CS" DEAD END ANCHORAGES<br />
The placement of these anchorages is performed as indicated in Section 3.3.1. Once the anchor head has been<br />
installed, before stressing at the other end, the wedges are pre-locked using a wedge tool. The anchorage then<br />
remains accessible throughout the stressing phase for observation. These anchorages also enable generating<br />
electrically isolated tendons.<br />
3.3.3 TYPE "H" BOND ANCHORAGE<br />
The load transfer to the structure is based primarily on the bond of dilated strands within the concrete over a<br />
straight segment length and the anchorage by an onion (curvature of wires) at the strand end.<br />
Upon exiting the duct, the strands are gradually deviated towards two positioning and maintenance grids. The<br />
duct end is reinforced with a ring.<br />
The entire anchorage assembly is solidly fastened to the passive reinforcement.<br />
Following assembly of the injection tube, the sealing between duct end and strands is ensured by means of<br />
resin packing at the level of the ring.<br />
The proper working of the anchorage necessitates degreasing the strands on the bond length, along with careful<br />
concreting over this length using a concrete whose aggregate diameter does not exceed 30 mm.<br />
3.3.4 TYPE "K" COUPLER<br />
When a structure must be built in several phases, especially when setting up the scaffolding and formwork over<br />
the entire length of the structure proves impossible, it may be wise to stress and anchor certain cables over a<br />
fraction of their length and then extend them through the use of a coupler.<br />
Once the structure has been completed, the coupler may or may not be inside the concrete.<br />
Installation of the coupler proceeds for the active part as defined in Section 3.3.1 for the "E" or "CS" type of live<br />
end anchorage, with the installed anchor head being the "K" head fitted with grooves for peripheral coupling.<br />
For the passive part of the coupling, the installation takes place prior to concreting of the zone; the strands<br />
exiting the duct are deviated through a ring towards the "K" head; they are fitted with compression fittings and<br />
placed into the designated grooves. A strapping serves to maintain them in position and a trumpet/sleeve (made<br />
of either sheet metal or plastic) isolates the coupler from the concrete, thereby making it possible to transmit the<br />
prestressing force through the joint.<br />
A vent at the apex of the trumpet/sleeve allows for accurate filling during grouting.
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3.4 ANCHORAGE ARRANGEMENTS<br />
According to categories of use, referring to Section 1.4.1, arrangements of anchorage components are descri-<br />
bed in the following table :<br />
Uses Components<br />
Anchorages E CS H K<br />
Head<br />
Plate<br />
Trumpet Cap<br />
Head<br />
Plate<br />
Trumpet Cap Coupler<br />
Plate<br />
Trumpet<br />
internal bonded cable with metal duct E E T(2) CS CS T(2) H K (5) M(6)<br />
internal bonded cable with plastic duct E CS T(2) CS CS T(2) H K (5) M(6)<br />
internal unbonded E E PM(3) CS CS PP(3) K (5) M(6)<br />
external bonded cable E E PM(3) CS CS PP(3) H K (5) M(6)<br />
external unbonded cable E E PM(3) CS CS PP(3) K (5) M(6)<br />
tendon for various material (ext. cable) E E PM(3) K (5) M(6)<br />
restressable tendon E E PM(4) CS CS PP(4)<br />
exchangeable tendon E E PM(4) CS CS PP(4)<br />
encapsulated tendon (leak tight) E CS PM(3) CS CS PP K (5) M(6)<br />
electrically isolated tendon E(1) CS PP CS(1) CS PP K(1) (5) P(7)<br />
<strong>No</strong>tes : 1 : plus isolating shim in between head or coupler and plate,<br />
2 : T (as temporary) Provisional cap, Permanent (P) cap can be used,<br />
3 : Permanent Metallic (PM) or Permanent Plastic (PP) cap,<br />
4 : Permanent Metallic (PM) or Permanent Plastic (PP) cap, special cap housing to preserve strand over-lengths<br />
should be used,<br />
5 : See E or CS anchor plate and trumpet of first-phase cable,<br />
6 : Metallic (M) sleeve (cap), Plastic (P) sleeve can be used,<br />
7 : Plastic (P) sleeve (cap)<br />
3.5 GEOMETRICAL AND MECHANICAL USE CONDITIONS<br />
For the seating and installation of anchorages, certain construction-related conditions must be verified.<br />
3.5.1 CLEARANCE BEHIND ANCHORAGES<br />
In order to facilitate jack placement and simplify the stressing procedure, a free space must be allocated behind<br />
the anchorage.<br />
These dimensions are given in the drawing Page 39 "Block out dimensions for anchorages type E and type CS,<br />
Clearance requirements" in Chapter 6.<br />
3.5.2 CONCRETE COVER AND ANCHORAGE SPACING<br />
Introducing post-tensioning forces into the structures takes the form, within the anchorage zones, of<br />
concentrated forces applied onto the plates. The high stress values encountered underneath the anchor plates<br />
necessitate certain construction-related measures. For the concrete structures:<br />
- The anchorages must be laid out at a sufficient distance from the nearest edge of the concrete (cover) and<br />
respect a spacing between anchorages (centre to centre) that will be specified below.<br />
- A bursting reinforcement must be set up in front of the plates; this local (surrounding anchorage body) zone<br />
will be defined in Section 3.6.<br />
- The concrete in the vicinity of the plates must be especially homogeneous and display, at the time of<br />
stressing, an adequate level of strength.<br />
- A general (surrounding local zone) zone must be defined by the project designer and laid out in front of the<br />
anchorage plates within the structure, thereby reducing the concentrated forces and distributing them over<br />
the concrete cross-section, in compliance with the design rules.<br />
As stated above and in considering a maximum prestressing force P(t,x) at the time of stressing (t = 0) at the<br />
anchorage (x = 0), thus called P(0,0) ≤ Pmax, for the normal anchor plates and P(0,0) max = Pmax, the following are<br />
defined:<br />
Force in the cable, at the anchorage on the concrete side, before load transfer to anchorage.<br />
Sleeve<br />
(cap)
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b0 and b’0 are the distances between the anchorage axis and the edge of the block tested. These values are<br />
given in the tables here after.<br />
The reinforcement required to prevent bursting and spalling in anchorage zones is determined in relation to a<br />
rectangular prism of concrete, known as the primary regularisation prism, located behind each anchorage. The<br />
cross section of the prism associated with each anchorage is known as the impact rectangle.<br />
The impact rectangle has the same centre and the same axes of symmetry as the anchor plate (which should<br />
have two axes of symmetry).<br />
The impact rectangle with dimensions c x c’ has the same area as the block tested A = 4 x b0 b’0 and the same<br />
aspect ratio (variation of -15% is allowed in one direction).<br />
b 0<br />
b’0<br />
cmin,rect = 0.85 x 2 b0 ; c’ min,rect = 0.85 x 2 b’0<br />
cmin and c’min taking into account dimensions of bursting reinforcement are given in the tables here after, then<br />
c ≥ cmin or c’ ≥ c’min (1)<br />
and c x c’ = A = 4 x b0 b’0 (2)<br />
It should be noted that application of cmin may require adaptation of the local anchorage zone reinforcement in<br />
accordance with the applicable Eurocodes and national regulations, see Chapter 3.6.<br />
Rules for centre distance and edge distances of anchorages:<br />
Impact rectangles associated with anchorages located in the same cross section should not overlap.<br />
In addition, they should remain inside the concrete. Taking into account the concrete cover, we obtain the<br />
distance to edge in the two directions :<br />
c<br />
c '<br />
+ cov er − 10mm<br />
and + cov er − 10mm<br />
2<br />
2<br />
<strong>No</strong>te: 10 mm is the concrete cover in the tested block (except for H anchorage block using 25 mm).<br />
For anchorage spacing, refer to equations (1) and (2)<br />
Type "E" anchor plates,<br />
for f cm(t) ≥ 23/28 N/mm 2<br />
Units 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<br />
u = u’ mm (1) 75 110 135 160 205 270 300 340 370 410 435 480 520 580<br />
2b0 = 2b’0 mm (2) 115 165 205 235 310 410 455 515 550 610 655 715 775 875<br />
cmin = c’min mm<br />
100 140 175 200 265 350 385 440 470 520 555 610 665 745<br />
(1) Sizes of anchor plate<br />
(2) Sizes of test block<br />
Type "CS" anchor plates,<br />
for f cm(t) ≥ 28/35 N/mm 2<br />
Units 6-7 6-12 6-19 6-27 6-31 6-37<br />
∅ u mm (1) 222 258 300 360 390 420<br />
2b0 = 2b’0 mm(2)<br />
( ) ( ) cmin = c’min mm<br />
310 410 515 610 655 715<br />
(1) Sizes of anchor plate<br />
(2) Sizes of test block<br />
265 350 440 520 555 610<br />
Dimensions A and B (u and u’) for type “H” anchorages and minimum spacing either A + 25mm or B + 25mm,<br />
are specified on the drawing Page 36. Dimensions of concrete sections are given on Page 37 in Chapter 6.
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During cable stressing, the concrete in front of the anchor plates must have reached an adequate strength level,<br />
as previously indicated and as a complement, it would be necessary to specify:<br />
for the case of specified anchor plates on concrete,<br />
stressing to 100% of P(o,o) max = Pmax is not permitted if fcm(t) < 23/28 N/mm 2 for the "E" anchorages and<br />
28/35 N/mm 2 for "CS" anchorages, regardless of the anchorage configuration within the structure.<br />
It remains possible however to partially stress the tendon. In the case of tensioning to 50% of the maximum<br />
value at the anchorage for example, the strength of concrete f cm(t) may be reduced to approximately 2/3 of the<br />
values indicated above for total stressing.<br />
As noted above for those anchorages that rely upon bond alone, i.e. type "H" anchorages, strength of concrete<br />
within the zone during stressing must be: fcm(t) ≥ 28/35 N/mm 2 .<br />
From a general standpoint for unique cases (e.g. when using materials other than concrete), the project<br />
designer will apply the pertinent Eurocodes with Pdesign ≥ 1.1 Fpk to design anchorage and deviation zones<br />
(contact may be made with the VSL organization, which will provide the proper advice as regards experimental<br />
work and developments).<br />
3.6 BURSTING REINFORCEMENT<br />
As mentioned previously, a bursting reinforcement must be laid out in the local anchorage zone.<br />
For both the "E" and "CS" type anchorages, this reinforcement is split between a spiral and orthogonal<br />
reinforcement (stirrups). The spiral reinforcement defined on the drawings in Chapter 6 displays a large enough<br />
pitch of the thread to allow for adequate concreting of the zone.<br />
It is recommended to proceed with this layout as stipulated in the approval whenever both the cover and<br />
strength conditions have been minimized.<br />
As foreseen by this <strong>ETA</strong>, the local anchorage zone reinforcement specified in this <strong>ETA</strong> and confirmed in the<br />
load transfer tests, may be modified for a specific project design if required in accordance with national<br />
regulations and relevant approval of the local authority and of the <strong>ETA</strong> holder to provide equivalent<br />
performance.<br />
In the case of grouped anchorages, it is permitted to combine the reinforcement of the individual anchorages.<br />
The chosen combination must conserve the dedicated steel cross-sections in all directions. In the case of a<br />
unique arrangement in the vicinity of the plates, it is also possible to replace the spiral with a combination of<br />
bars that contain equivalent cross-sections in all directions and that are configured at the same depth with<br />
respect to the plate.<br />
In all cases, the bursting reinforcement must be complemented by a reinforcement in the general anchorage<br />
zone for equilibrium designed by the project designer in accordance with typical design rules.<br />
Similarly, in all cases, the contractor responsible for concreting must ensure that the density and layout of<br />
reinforcement within the anchorage zone allow for adequate and homogeneous concreting of the entire zone.<br />
Similar to every other type of anchorage, VSL type H-anchorage requires a local anchorage zone reinforcement<br />
split between a spiral and orthogonal reinforcement (stirrups). This reinforcement is defined on the drawing in<br />
Chapter 6.
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CHAPTER 4<br />
4. TRESSING<br />
STRESSING<br />
4.1 STRESSING EQUIPMENT<br />
The VSL equipment used for cable stressing is composed primarily of stressing jacks, hydraulic power packs<br />
(commonly called pumps) and the associated set of measurement instruments or acquisition system.<br />
4.1.1 STRESSING JACKS<br />
Tendons are stressed by means of VSL stressing jacks.<br />
This equipment consists of double acting jacks with a central hole that enables stressing the cable in one or<br />
several stages and then, if need be, to de-stress the cable. Their primary characteristics will be defined below.<br />
In sequence starting from the anchorage, these jacks are composed of:<br />
- 1 nose (chair ring) at the front resting upon the anchor head,<br />
- 1 body or cylinder, including a piston with a central hole, resting upon the chair ring,<br />
- 1 battery composed of metallic tubes fastened to the inside of the hole that guide strands behind the jack,<br />
and<br />
- 1 pulling anchor head behind the piston, with a gripper plate for facilitating the procedure of stressing by<br />
stages. The ungripping of the jack anchorage is performed automatically.<br />
List of VSL jacks:<br />
Designation ZPE 30 60 7A 12/St2 200 19 460/31 500 500K 750 1 000 1250<br />
Length mm 720 615 690 550 960 750 580 1 000 610 1 185 1 200 1 290<br />
Diameter mm 140 180 280 31 315 390 485 550 508 520 790 620<br />
Weight kg 28 74 115 151 305 294 435 1 <strong>06</strong>4 450 1 100 2 290 1 745<br />
Maxi force kN 320 632 1 <strong>06</strong>4 1 850 2 000 2 900 4 660 5 000 5 000 7 500 10 000 12 500<br />
Pressure bar 550 500 523 598 614 580 580 560 580 600 553 577<br />
Ram area mm² 5,832 12,640 20,360 30,940 32,570 50,030 80,400 89,460 86,200 124,700 180,950 216,800<br />
Stroke mm 250 250 160 100 300 100 100 200 100 150 200 150<br />
The drawing in Chapter 6 indicates the clearances to be introduced around the anchorages and at the ends of<br />
the post-tensioned structures in order to facilitate installation.<br />
For the purpose of implementing all the particularities and options, the VSL stressing equipment comprises a<br />
series of modular and compatible accessories; as such, a broad range of tools for these jacks is available by<br />
VSL.<br />
Included herein would be the jack chair ring, the over-stress chair ring, the de-stress chair ring, etc.<br />
4.1.2 HYDRAULIC PUMPS<br />
The VSL pumps comprise the assembly of hydraulic components including: pumps, distributors, nozzles and<br />
safety valves. The pumps are typically driven by electric motors.<br />
The pumps themselves have been dimensioned for normal stressing speeds and contain safety measurement<br />
devices that depend on the specific application.<br />
4.1.3 MEASUREMENT INSTRUMENTS AND SYSTEMS<br />
The VSL force and elongation measurement instruments or systems serve to control with precision the stressing<br />
operation and display the set of results obtained.
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4.2 PROCESSES OF STRESSING AND CONTROL PROCEDURE<br />
Before proceeding with cable stressing, a certain number of preconditions must be met, in particular:<br />
- all pertinent safety rules and recommendations must be fully known;<br />
- the force targets along with the corresponding values of elongation; moreover, tolerances must be known<br />
by the PT Supervisor, who will have applied any eventual necessary adjustments to these values in order to<br />
account for parameters specific to the equipment and anchorages;<br />
- the procedure to be adopted in the event of a value beyond the tolerance threshold or any other<br />
unanticipated incident must be known;<br />
- the order in which the post-tensioning cables are to be stressed must be specified;<br />
- the stressing equipment (including measurement instruments) must comply with guidelines furnished in the<br />
present <strong>ETA</strong>;<br />
- the required strength of concrete (or other component material) of both the structure and anchorage zone<br />
undergoing stressing must be verified;<br />
- the loading and support states of the structure associated with the stressing phase must also be verified;<br />
- the over lengths of the strands for stressing must remain perfectly clean.<br />
The point should be recalled that during the stressing process, it is strictly forbidden to be positioned behind the<br />
jack or within its immediate vicinity. The same precautions must be taken for the area in the back of the deadend<br />
external anchorages.<br />
One of the VSL system's key characteristics lies in its wedge-locking process. Given that the wedges remain in<br />
constant contact with the strands during stressing, the locking operation does not require any accessory device.<br />
4.2.1 FORCE MEASUREMENTS<br />
The measurement of force in the cable, as transformed into pressure measurement in the jack, is generally the<br />
assigned objective herein.<br />
The pressure existing in the jack chamber is indicated by the manometer installed on the pump, with the<br />
eventual possibility of exercising controls on the jack. The manometers used (Accuracy 1%), regularly<br />
recalibrated using a scale, feature a guaranteed precision of 1% of their maximum pressure, which tends to lie<br />
at 600 bars; these instruments thereby provide a precision of 6 bars over the entire manometer scale.<br />
In order to obtain the effective force onto the structure, the force resulting from the manometer reading is<br />
corrected for losses inside the jack as well as for losses due to friction of the strands in the anchorage.<br />
Losses inside the jacks are identified from intrinsic hardware data. Although they contain an independent<br />
pressure term and another closely-proportional term, submitted to the maximum pressure reached upon<br />
completion of the stressing operation, the losses inside jacks are solely expressed in proportional terms and<br />
vary from 1% to 3%.<br />
The losses in active anchorages E and CS (or K), named ka, are due to friction of the strands deviated on the<br />
components and, depending on the specific anchorage, vary between 1% and 2%.<br />
4.2.2 ELONGATION MEASUREMENTS<br />
The measurement of cable elongation is generally a control measurement that provides information on cable<br />
behavior during stressing.<br />
As for elongation measurements, an index is installed on the tendons. During stressing, elongations are then<br />
deduced from measurements of the displacement of this index. Since the onset of displacements combines the<br />
seating of tendons in their ducts with their actual elongation, the elongation during initial displacements is<br />
obtained by means of extrapolating the pure elongations occurring subsequently.<br />
The various pressure-elongation relations noted during the cable stressing phases are recorded on the<br />
stressing data sheets, which are to remain available.<br />
Section 2.6.2 provides a recap of the elongation evaluation basis used during the stressing operation.
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5. INJECTION CHAPTER AND 5 5 SEALING<br />
INJECTION AND SEALING<br />
5.1 GENERAL INFORMATION<br />
The nature and composition of injection products for the permanent protection of tendons and anchorages and<br />
for their eventual bonding to the structure are not inherent to the prestressing process; instead, they depend on<br />
the project and the structure's assigned purpose.<br />
The products involved must not be a threat to the hygiene, health and the environment.<br />
In addition to the specific clauses relating to dangerous substances contained in this <strong>European</strong> <strong>Technical</strong><br />
<strong>Approval</strong>, there may be other requirements applicable to the products falling within its scope (e.g. transposed<br />
<strong>European</strong> legislation and national laws, regulations and administrative provisions). In order to meet the<br />
provisions of the EU Construction Products Directive, these requirements need also to be complied with, when<br />
and where they apply.<br />
5.2 INJECTION PRODUCTS<br />
The products used for the permanent protection of post-tensioning tendons and anchorages implemented by<br />
means of injection may be categorized as follows:<br />
5.2.1 PRODUCTS FOR BONDED CABLES<br />
When it is sought to bond the tendon to the structure, the products or grouts for bonded injection are with a<br />
hydraulic cement base:<br />
These products may pertain to common grouts defined in the standard EN 447 or special grouts that make use<br />
of performance-enhancing admixtures. In some regions of the EU, unfavorable climatic conditions or other<br />
conditions impose the application of special grouts according to <strong>ETA</strong>G 013.<br />
Completion of the tendon envelope at the end of the anchorages may be provided by means of either temporary<br />
or permanent grouting caps.<br />
The concreting of block out is only strictly necessary when using temporary grouting cap (whether recycled or<br />
not). Should the permanent grouting cap be left apparent, the metallic parts must be protected against<br />
corrosion, see Section 3.1.1.<br />
5.2.2 PRODUCTS FOR UNBONDED CABLES<br />
When it is not sought to bond the tendon to the structure in order, for example, to be able to maintain the tendon<br />
accessible, the unbonded injection products are as follows:<br />
- with a grease base, as defined in Annex C.4.1 of the <strong>ETA</strong>G 013,<br />
- with a wax base, as defined in Annex C.4.2 of the <strong>ETA</strong>G 013.<br />
In this case, plugging the tendon envelope at the anchorages is still provided by permanent waterproof injection<br />
cap. The concreting of the block-out is not strictly necessary here, see above and Section 3.1.1.<br />
Those products for bonded or unbonded injection covered by a <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> may also be<br />
employed in accordance with the prescribed set of uses.
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5.3 INJECTION EQUIPMENT<br />
The injection equipment has been adapted to the specific products to be injected.<br />
For the cement-based grouting, the VSL injection equipment is composed for the most part of mixers and<br />
pumps integrated into a single device that enables preparing the grout and performing the injection. This<br />
equipment makes it possible to allocate with precision the grout components and to obtain a perfectlyhomogeneous<br />
mix. The pump installed in the injection equipment has been designed for continuous injection at<br />
a grout progression speed of the same order of magnitude regardless of the units used.<br />
For some applications, vacuum pumps that allow for depressurization inside the ducts have been included,<br />
thereby facilitating progression of the grouting.<br />
For the unbonded products such as grease or petroleum wax, the VSL injection equipment is composed of<br />
melting devices or heaters, stirrers and pumps. Depending on the application, these components are either<br />
integrated or separated on the worksite in accordance with implementation specifications.<br />
5.4 INJECTION AND CONTROL PROCEDURE<br />
Before proceeding with the injection of permanent cable protection, a certain number of conditions must be<br />
fulfilled and in particular:<br />
- The injection product must comply with the terms of the present <strong>ETA</strong> and the <strong>ETA</strong>G 013;<br />
- The injection equipment must comply with indications laid out in the present <strong>ETA</strong>,<br />
- The waterproof sealing of the tendon and anchorage envelopes (ducts, fittings, rods and caps) must be<br />
verified,<br />
- The climatic conditions and temperature of the structure must satisfy use conditions of the injection product.<br />
The primary controls conducted during injection consist of verifying the adequate filling of the duct by means of<br />
rods, bleed vents and outlets laid out all along the cable path and verifying that the product discharged by the<br />
vents or outlets displays the required properties.<br />
Grouting procedures and grouting surveillance shall be carried out according to EN 446.<br />
As an initial approach, the injection product quantities per unit cable length will be derived from:<br />
[(internal duct section area - tendon section area) × (unit length)] × (1 + ξ), where ξ is such that: 0.10 ≤ ξ ≤ 0.20<br />
in order to consider worksite losses, the shape of the duct and eventual corrugations.<br />
The various phases and parameters associated with cable injection are to be recorded on the injection data<br />
sheets, which are to remain available.<br />
5.5 SEALING<br />
The continuity of protection against all types of aggressions must be ensured all along the cable up to and<br />
including the anchorages.<br />
The protection measures introduced for this unique zone, which is often located at the extremity of the structure<br />
and submitted to external aggressions determined during the design phase, must be effective.<br />
Refer to the section entitled "Protective Caps" in Section 3.1.1 "Live end / Dead end anchorages" and to the<br />
corresponding drawings on Page 29 in Chapter 6.<br />
The concreting of block-out in the anchorage zone with surface treatment and eventual reinforcing bars<br />
represents the most widespread solution. Moreover, it may be advantageously complemented by a waterproof<br />
lining that prevents against all risks of infiltration of fluids that may runoff on the face of the block-out.<br />
The permanent metallic caps (if protected by means of galvanization, paint, etc.) or plastic caps may be left<br />
apparent.
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CHAPTER 6<br />
SCHEMATIC DRAWINGS<br />
(dimensions expressed in mm)<br />
Title Page<br />
STANDARD ANCHORAGE PARTS :<br />
Wedges, Compression fitting 26<br />
Anchor heads Type "E" 27<br />
Anchor heads Type "CS" 28<br />
Protective caps for anchorages Type "E" and Type "CS" 29<br />
ANCHORAGE TYPE "E"<br />
Categories of use arrangements 30<br />
Sizes 31<br />
Bursting reinforcement 32<br />
ANCHORAGE TYPE "CS"<br />
Categories of use arrangements 33<br />
Sizes 34<br />
Bursting reinforcement 35<br />
ANCHORAGE TYPE "H"<br />
Sizes and bursting reinforcement 36<br />
Arrangement and minimum dimensions of concrete sections 37<br />
COUPLER TYPE "K"<br />
Sizes 38<br />
BLOCK OUT DIMENSIONS FOR ANCHORAGES TYPE "E" AND TYPE "CS"<br />
CLEARANCE REQUIREMENTS<br />
DUCTING 40<br />
39
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STANDARD ANCHORAGE PARTS<br />
WEDGES<br />
COMPRESSION FITTING
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STANDARD ANCHORAGE PARTS<br />
ANCHOR HEADS TYPE E
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STANDARD ANCHORAGE PARTS<br />
ANCHOR HEADS TYPE CS
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STANDARD ANCHORAGE PARTS<br />
PROTECTIVE CAPS FOR ANCHORAGES TYPE E AND TYPE CS<br />
6-7<br />
6-12<br />
6-19<br />
6-27<br />
6-31<br />
6-37<br />
Unit ØA B C D<br />
6-3 78 165 30 63<br />
6-4 89 190 40 62<br />
6-7 116 230 40 63<br />
6-12 155 290 50 63<br />
6-15 185 310 40 63<br />
6-19 190 340 40 63<br />
6-27 230 370 40 63<br />
6-31 235 450 40 65<br />
6-37 260 480 40 65<br />
6-43 290 540 40 65<br />
6-55 320 600 40 65<br />
Unit ØA B C D<br />
6-3 103 160 50 110<br />
6-4 119 195 50 115<br />
6-7 153 255 60 120<br />
6-12 190 310 70 135<br />
6-15 207 320 70 145<br />
6-19 223 325 70 155<br />
6-22 244 345 70 160<br />
6-27 258 375 70 170<br />
6-31 287 405 70 180<br />
6-37 309 480 90 195<br />
6-43 346 535 90 205<br />
6-55 389 585 90 220<br />
Unit ØA ØB C(CS)<br />
209<br />
243<br />
283<br />
341 279 140<br />
370 300<br />
396<br />
170<br />
201<br />
234<br />
325<br />
112<br />
113<br />
114<br />
150<br />
160<br />
C(E)<br />
112<br />
130<br />
150<br />
180<br />
210<br />
210
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ANCHORAGE TYPE E<br />
CATEGORIES OF USE ARRANGEMENTS<br />
PRINCIPLES:
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ANCHORAGE TYPE E<br />
SIZES<br />
Units<br />
A ØB C ØD E F G ØH ØI<br />
6-1 75 18 10 53 50 80 150 25 21/25<br />
6-2 110 50 10 90 50 80 200 50 21/25<br />
6-3 135 56 15 95 50 80 205 55 21/25<br />
6-4 160 65 20 110 55 85 210 60 21/25<br />
6-7 205 84 30 135 60 90 320 72 28/32<br />
6-12 270 118 40 170 75 105 500 92 28/32<br />
6-15<br />
6-19 340 150 50 200 95 125 640 107 28/32<br />
6-22 370 172 55 220 100 130 745 122 28/32<br />
6-31 435 192 65 260 120 150 755 142 28/32<br />
6-37 480 215 75 280 135 165 905 155 28/32<br />
6-43<br />
6-55<br />
520<br />
580<br />
248<br />
255<br />
80<br />
95<br />
300<br />
340<br />
145<br />
160<br />
175<br />
190<br />
1030<br />
1045<br />
165<br />
185<br />
28/32<br />
28/32<br />
J K<br />
86<br />
136<br />
125 M10<br />
150<br />
210<br />
265<br />
280<br />
300<br />
360<br />
435<br />
Ø5<br />
Ø5<br />
M16<br />
M16<br />
M16<br />
305 143 45 190 85 115 585 97 28/32 275 M16<br />
6-27 410 185<br />
J : Fixation holes (to shuttering) spacing.<br />
M16<br />
M16<br />
60 240 110 140 690 132 28/32 330 M16<br />
M16<br />
M16<br />
490 M16<br />
540 M16
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ANCHORAGE TYPE E<br />
BURSTING REINFORCEMENT<br />
Units<br />
6-1<br />
6-2<br />
6-3<br />
6-4<br />
6-7<br />
6-12<br />
6-15<br />
6-19<br />
6-22<br />
6-31<br />
6-37<br />
6-43<br />
6-55<br />
Reinforcement for concrete with f cm(t) 23/28 N/mm² when stressing<br />
ØN<br />
8<br />
10<br />
10<br />
10<br />
12<br />
16<br />
16<br />
16<br />
16<br />
20<br />
20<br />
20<br />
SPIRAL REINFORCEMENT ORTHOGONAL REINF.<br />
n P<br />
1<br />
2<br />
2<br />
3 65<br />
4<br />
5<br />
7<br />
8<br />
10<br />
9<br />
11<br />
12<br />
70<br />
60<br />
75<br />
60<br />
70<br />
60<br />
60<br />
6-27 16 9 55 545 68<br />
16<br />
55<br />
65<br />
60<br />
60<br />
Reinforcement steel f yk500 N/mm².<br />
ØQ<br />
74<br />
124<br />
155<br />
185<br />
260<br />
345<br />
450<br />
490<br />
585<br />
645<br />
705<br />
805<br />
L<br />
ØR<br />
12<br />
12<br />
16<br />
16 10 60 635<br />
16<br />
r <br />
n : Number of turns if the last one is welded else n + 1 if the last one is opened.<br />
r : Number of reinforcement layers.<br />
M<br />
14<br />
15<br />
20<br />
25<br />
36<br />
46<br />
58<br />
63<br />
73<br />
85<br />
90<br />
105<br />
L = (Number of turns - 1) * P<br />
Reinforcements shown on this form was placed in test specimens for load transfer tests (see § 3.6).<br />
8<br />
8<br />
10<br />
10<br />
16<br />
16<br />
S<br />
T<br />
100<br />
150<br />
185<br />
220<br />
295<br />
390<br />
16 6 75 390 51<br />
16 8 75 435<br />
2<br />
3<br />
4<br />
4<br />
4<br />
7<br />
6<br />
7<br />
8<br />
9<br />
10<br />
80<br />
60<br />
55<br />
55<br />
75<br />
70<br />
90<br />
75<br />
70<br />
75<br />
70<br />
495<br />
535<br />
595<br />
695<br />
750<br />
16 15 55 855
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ANCHORAGE TYPE CS<br />
CATEGORIES OF USE ARRANGEMENTS
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ANCHORAGE TYPE CS<br />
SIZES<br />
Unit<br />
6-7<br />
6-12<br />
6-19<br />
6-27<br />
6-31<br />
ØA B C ØD E F1 ØF4 F2<br />
222 60<br />
258<br />
360 110<br />
390<br />
80<br />
300 90<br />
122<br />
136<br />
149<br />
170<br />
203<br />
217<br />
143<br />
178<br />
210<br />
256<br />
274<br />
6-37 420 130 236 300 82 805 149 925 136 211<br />
F1: CS STANDARD length.<br />
F2: CS PLUS and SUPER length.<br />
ØH : Spacing of holes for fixation to formwork.<br />
I : Thread hole.<br />
: ØF4 for F2<br />
50<br />
60<br />
70<br />
69<br />
69<br />
225 80 360<br />
392<br />
660 139 810<br />
620<br />
<br />
95 530 81 117<br />
540 110 660<br />
ØF4<br />
63<br />
1<strong>06</strong><br />
121<br />
ØF3<br />
85<br />
148<br />
181<br />
149 740 136 188<br />
G<br />
80<br />
90<br />
100<br />
100<br />
100<br />
110<br />
ØH I<br />
188 M12<br />
220<br />
260<br />
310 M16<br />
330<br />
357<br />
M12<br />
M12<br />
M16<br />
M16
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ANCHORAGE TYPE CS<br />
BURSTING REINFORCEMENT<br />
6-7<br />
6-12<br />
6-19<br />
6-27<br />
6-31<br />
12<br />
16<br />
6-37 20 9 65 645 30<br />
16 12 50 695<br />
Reinforcement steel f yk500 N/mm².<br />
SPIRAL REINFORCEMENT<br />
Unit ØN<br />
P ØQ M L ØR<br />
S T<br />
16 5 65 345 30<br />
16<br />
Reinforcement for concrete with f cm(t) 28/35 N/mm² when stressing<br />
n r <br />
4 60<br />
7 60<br />
9 55<br />
260<br />
450<br />
545<br />
16 10 55 585 30<br />
n : Number of turns if the last one is welded else n + 1 if the last one is opened.<br />
r : Number of reinforcement layers .<br />
Reinforcements shown on this form was placed in test specimens for load transfer tests (see § 3.6).<br />
50<br />
30<br />
30<br />
L = (Number of<br />
turns - 1) * P<br />
10<br />
12<br />
16<br />
16<br />
16<br />
ORTHOGONAL REINF.<br />
5<br />
8<br />
8<br />
11<br />
13<br />
50 295<br />
60<br />
50 595<br />
45<br />
390<br />
65 495<br />
635
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ANCHORAGE TYPE H<br />
SIZES AND BURSTING REINFORCEMENT<br />
Anchorage sizeH6-4 L/2 As,min= 10 cm²/m L/2<br />
6-3<br />
6-4<br />
6-7<br />
6-12<br />
6-19<br />
6-22<br />
6-31 810<br />
6-37<br />
Reinforcement for concrete with f cm(t) 28/35 N/mm² when stressing<br />
Unit A B A B C D D1 ØE ØF ØG ØH<br />
Arrangement 1 Arrangement 2<br />
6-1 90 90 1 - - - - - 950 - - - 16/20<br />
290<br />
390<br />
450<br />
430<br />
-<br />
570<br />
690<br />
1050<br />
90 3 -<br />
90<br />
230<br />
-<br />
230<br />
230<br />
260<br />
370<br />
210<br />
90 4 230<br />
-<br />
390<br />
470<br />
-<br />
-<br />
-<br />
-<br />
190<br />
210<br />
-<br />
330<br />
390<br />
- - 155 1600 1450 350<br />
-<br />
-<br />
- - 950<br />
-<br />
155<br />
155<br />
155<br />
165<br />
175<br />
-<br />
1300<br />
1300<br />
-<br />
1300<br />
1900<br />
2550<br />
950<br />
1150<br />
1150<br />
1150<br />
1750<br />
2400<br />
-<br />
-<br />
200<br />
230<br />
300<br />
400<br />
400<br />
-<br />
- 70<br />
16<br />
16<br />
16<br />
16<br />
20<br />
20<br />
64<br />
83<br />
114<br />
140<br />
146<br />
171<br />
178<br />
21/25<br />
28/32<br />
28/32<br />
28/32<br />
6-15 450 230 9 370 370 9 155 1300 1150 300 16 130 28/32<br />
10<br />
12<br />
28/32<br />
28/32<br />
6-27 690 260 17 - - - 155 1650 1500 350 16 171 28/32<br />
14<br />
18<br />
Reinforcement steel f yk500 N/mm²<br />
Number of Strand with lenght D1<br />
4<br />
8<br />
-<br />
- - - 490 470 20<br />
1400 1250<br />
- - - 530 510 20<br />
1600 1450<br />
-<br />
-<br />
-<br />
-<br />
-<br />
-<br />
570 510<br />
690<br />
510<br />
-<br />
4<br />
5<br />
-<br />
12<br />
16<br />
-<br />
20<br />
-<br />
24<br />
L<br />
1700 1550<br />
2000<br />
1850<br />
Reinforcement as per<br />
anchorage side<br />
28/32<br />
28/32
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COUPLER TYPE K<br />
SIZES<br />
Unit<br />
6-3<br />
6-7<br />
430<br />
6-4 440<br />
560<br />
6-12 660<br />
6-19<br />
160<br />
160<br />
160<br />
200<br />
210<br />
310<br />
160 400<br />
6-22 910 160 610<br />
6-31 970 180 625<br />
6-37<br />
A B C ØD ØE F ØG ØH<br />
150<br />
160<br />
190<br />
240<br />
310<br />
360<br />
62<br />
67<br />
77<br />
97 25<br />
122<br />
15<br />
15<br />
20<br />
25<br />
76<br />
83<br />
95<br />
121<br />
159<br />
28/32<br />
28/32<br />
28/32<br />
28/32<br />
6-15 770 160 510 270 102 25 133 28/32<br />
770 160 510 280 112 25 146 28/32<br />
28/32<br />
6-27 980 180 655 350 132 35 168 28/32<br />
142 35 178 28/32<br />
1200 200 830 400 155 35 203 28/32
Annex 1 of the <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> <strong>No</strong> <strong>ETA</strong>-<strong>06</strong>/00<strong>06</strong> 39<br />
BLOCK OUT DIMENSIONS FOR ANCHORAGE TYPE E AND TYPE CS<br />
CLEARANCE REQUIREMENTS<br />
Unit Jack ZPE A B ØC D E ØF G<br />
6-1 ZPE-30 135<br />
53 600 100 140 1100<br />
ZPE-23FJ 135 53 300 90 116 1200<br />
6-2 ZPE-60 170<br />
90 650 140 180 1100<br />
6-3 ZPE-60 195 95 650 140 180 1100<br />
6-4 ZPE-7A 220<br />
110 800 200 280 1350<br />
6-7 ZPE-12St2 305<br />
135 670 200 310 1300<br />
ZPE-200<br />
1100 210 315 2100<br />
6-12 ZPE-19 370<br />
170 850 250 390 1500<br />
6-19 ZPE-460/31 460<br />
200 700 300 435 1500<br />
ZPE-500<br />
1150 330 550 2000<br />
ZPE-500K<br />
700 315 508 1500<br />
6-22 ZPE-500 530<br />
220 1150 330 550 2000<br />
6-31 ZPE-750 595<br />
260 1350 365 570 2300<br />
ZPE-1000<br />
1300 450 790 2200<br />
6-37 ZPE-1000 640<br />
270 1300 450 790 2200<br />
ZPE-1250<br />
1350 375 620 2250<br />
6-43 ZPE-1000 680 250 1350 450 570 2300<br />
ZPE-1250<br />
1350 375 620 2250<br />
6-55 ZPE-1000 760<br />
255 1300 450 790 2200<br />
ZPE-1250<br />
1350 375 620 2250<br />
Unit Jack ZPE A<br />
6-7 ZPE-12St2<br />
ZPE-200<br />
360<br />
6-12 ZPE-19 420<br />
6-19 ZPE-460/31<br />
ZPE-500<br />
ZPE-500K<br />
300<br />
6-27 ZPE-750 520<br />
6-31 ZPE-750 550<br />
6-37 ZPE-1000<br />
ZPE-1250<br />
580<br />
460 if ZPE-500K is used.<br />
600 if ZPE-1250 is used.<br />
According to the end zone arrangement<br />
B<br />
According to the end<br />
zone arrangement<br />
ØC D E ØF G<br />
105 700 200 310 1300<br />
1100 210 330 2100<br />
130 850 250 390 1500<br />
150 700 300 485 1500<br />
1150 330 585 2000<br />
700 315 508 1500<br />
185 1350 365 570 2300<br />
190 1350 365 570 2300<br />
215 1300 450 790 2200<br />
1350 375 620 2250
Annex 1 of the <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> <strong>No</strong> <strong>ETA</strong>-<strong>06</strong>/00<strong>06</strong> 40<br />
DUCTING<br />
Strand<br />
<strong>No</strong><br />
Unit<br />
Corrugated steel<br />
strip sheath <br />
Duct<br />
VSL PT-PLUS <br />
Smooth steel<br />
duct <br />
Plastic duct<br />
for bare<br />
Strand <br />
Plastic duct<br />
for Sheathed<br />
Strand <br />
Øint /Øext e Øint /Øext e Øext x t Øext x t min Øext x t min<br />
1 6-1 25/30 5 23/25 4<br />
2 6-2 40/45 9<br />
3 6-3 40/45 6<br />
4 6-4 45/50 7<br />
5 6-7 50/57 8 58/63 13<br />
6<br />
55/62 9 58/63 11<br />
7<br />
55/62 7 58/63 9<br />
8 6-12 65/72 11 76/81 18<br />
9<br />
65/72 9 76/81 16<br />
10<br />
70/77 11 76/81 15<br />
11<br />
70/77 9 76/81 13<br />
12<br />
75/82 11 76/81 12<br />
13 6-15 80/87 13 100/1<strong>06</strong> 25<br />
14<br />
80/87 11 100/1<strong>06</strong> 24<br />
15<br />
80/87 10 100/1<strong>06</strong> 23<br />
16 6-19 85/92 12 100/1<strong>06</strong> 22<br />
17<br />
85/92 11 100/1<strong>06</strong> 20<br />
18<br />
90/97 13 100/1<strong>06</strong> 19<br />
19<br />
90/97 12 100/1<strong>06</strong> 18<br />
20 6-22 100/107 17 100/1<strong>06</strong> 17<br />
21<br />
100/107 16 100/1<strong>06</strong> 16<br />
22<br />
100/107 15 100/1<strong>06</strong> 15<br />
23 6-27 100/107 14 115/121 22<br />
24<br />
100/107 13 115/121 22<br />
25<br />
110/117 18 115/121 21<br />
26<br />
110/117 17 115/121 21<br />
27<br />
110/117 16 115/121 20<br />
28 6-31 110/117 15 130/136 27<br />
29 120/127 21 130/136 27<br />
30<br />
120/127 20 130/136 26<br />
31<br />
120/127 19 130/136 25<br />
32 6-37 120/127 18 130/136 24<br />
33<br />
120/127 17 130/136 23<br />
34<br />
120/127 16 130/136 22<br />
35<br />
130/137 22 130/136 22<br />
36<br />
130/137 21 130/136 21<br />
37<br />
130/137 20 130/136 20<br />
38 6-43 140/147 25 150/157 31<br />
39<br />
140/147 24 150/157 30<br />
40<br />
140/147 23 150/157 9<br />
41<br />
140/147 23 150/157 29<br />
42<br />
140/147 22 150/157 28<br />
43<br />
140/147 21 150/157 27<br />
44 6-55 150/157 27 150/157 27<br />
45<br />
150/157 27 150/157 27<br />
46<br />
150/157 26 150/157 26<br />
47<br />
150/157 25 150/157 25<br />
48<br />
150/157 24 150/157 24<br />
49<br />
150/157 23 150/157 23<br />
50<br />
160/167 29 150/157 24<br />
51<br />
160/167 28 150/157 23<br />
52<br />
160/167 27 150/157 22<br />
53<br />
160/167 27 150/157 22<br />
54 160/167 27 150/157 22<br />
55 160/167 26 150/157 21<br />
Øext. of corrugations. Use next larger duct for strong deviation and long cables.<br />
The corrugated steel strip sheaths of diameters larger than 130 mm follow the design of EN 523 with the same strip thickness.<br />
Øext. of duct.<br />
According to standard EN 10255, EN 10216-1, EN 10217-1, EN 10219-2 and EN 10305-3. Values given for information only. Design defines ducts.<br />
According to standard EN 12201, material PE 80. Values given for information only. Design defines ducts.
Annex 2<br />
TECHNICAL DATA<br />
OF THE<br />
VSL SLAB SYSTEM
Annex 2 of the <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> <strong>No</strong> <strong>ETA</strong>-<strong>06</strong>/00<strong>06</strong> 2<br />
TABLE OF CONTENTS<br />
Title Page<br />
1. DEFINITION OF THE SYSTEM<br />
1.1 PRINCIPLE OF THE VSL SLAB SYSTEM 4<br />
1.2 CHARACTERISTICS OF SYSTEM UNITS 5<br />
1.3 ANCHORAGES 5<br />
1.3.1 PRESENTATION OF THE ANCHORAGES<br />
1.3.2 LIST OF APPROVED ANCHORAGES<br />
1.4 CATEGORIES OF USE, OPTIONS AND POSSIBILITIES 6<br />
1.4.1 USES AND OPTIONS OF VSL SLAB SYSTEM UNITS<br />
1.4.2 POSSIBILITIES OF THE VSL SLAB SYSTEM<br />
2. STRANDS AND DUCTS<br />
2.1 STRANDS USED 8<br />
2.2 REQUIREMENTS OF THE UNBONDED SYSTEM 8<br />
2.3 DUCTS USED FOR THE BONDED SYSTEM 8<br />
2.3.1 TYPES AND DIMENSIONS OF USABLE DUCTS<br />
2.3.2 M<strong>ETA</strong>L DUCTS<br />
2.3.3 PLASTIC DUCTS<br />
2.3.4 ACCESSORIES FOR INLETS, BLEED VENTS AND OUTLETS<br />
2.3.5 CONNECTION WITH SLEEVES<br />
2.4 CABLE LAYOUT 10<br />
2.4.1 STRAIGHT LENGTHS BEHIND THE ANCHORAGES<br />
2.4.2 RADIUS OF CURVATURE<br />
2.4.3 SPACING OF THE SUPPORTS AND TOLERANCES<br />
2.3.4 STRAND CUT LENGTH<br />
2.5 INSTALLATION OF DUCTS AND TENDONS 11<br />
2.6 PROVISIONAL PROTECTION AND LUBRICATION 11<br />
2.7 CALCULATION ELEMENTS 12<br />
2.7.1 FRICTION LOSSES<br />
2.7.2 BASIS FOR EVALUATING ELONGATIONS<br />
2.7.3 ACTIVE ANCHORAGE SETTINGS<br />
3. ANCHORAGES<br />
3.1 DESCRIPTION OF ANCHORAGE COMPONENTS 13<br />
3.1.1 LIVE-END / DEAD-END ANCHORAGES<br />
3.1.2 PRESENTATION AND PACKING OF ANCHORAGES<br />
3.2 ORGANIZATION OF SUPPLY QUALITY 14<br />
3.3 IMPLEMENTATION OF VARIOUS ANCHORAGES 14<br />
3.3.1 TYPE "S 6-1" AND "S 6-4" LIVE-END ANCHORAGES<br />
3.3.2 TYPE "S 6-1" AND "S 6-4" DEAD-END ANCHORAGES<br />
3.3.3 TYPE "SF 6-1" EMBEDDED ANCHORAGES<br />
3.3.4 TYPE "H 6-(1 through 4)" BONDED ANCHORAGES<br />
3.4 ANCHORAGE ARRANGEMENTS 15<br />
3.5 GEOMETRICAL AND MECHANICAL USE CONDITIONS 15<br />
3.5.1 CLEARENCE BEHIND ANCHORAGES<br />
3.5.2 CONCRETE COVER AND ANCHORAGE SPACING<br />
3.6 BURSTING REINFORCEMENT 17<br />
4. STRESSING<br />
4.1 STRESSING EQUIPMENT 18<br />
4.1.1 STRESSING JACKS<br />
4.1.2 HYDRAULIC PUMPS<br />
4.1.3 INSTRUMENTS AND MEASURING SYSTEMS
Annex 2 of the <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> <strong>No</strong> <strong>ETA</strong>-<strong>06</strong>/00<strong>06</strong> 3<br />
4.2 PROCESSES OF STRESSING AND CONTROL PROCEDURE 19<br />
4.2.1 FORCE MEASUREMENTS<br />
4.2.2 ELONGATION MEASUREMENTS<br />
5. INJECTION AND SEALING<br />
5.1 INJECTION 20<br />
5.1.1 UNBONDED SYSTEM<br />
5.1.2 BONDED SYSTEM<br />
5.2 SEALING 21<br />
6. SCHEMATIC DRAWINGS 22
Annex 2 of the <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> <strong>No</strong> <strong>ETA</strong>-<strong>06</strong>/00<strong>06</strong> 4<br />
CHAPTER 1<br />
1. SYSTEM DEFINITION<br />
DEFINITION OF THE SYSTEM<br />
1.1 PRINCIPLE OF THE VSL SLAB SYSTEM<br />
The cable or unit of the VSL Slab System is composed of one or several strands made of high-strength steel<br />
called a "tendon", along with the associated set of anchorages.<br />
In this system, the cable may be not only the unit itself, but also the assembly of several juxtaposed units (in<br />
general of just one strand).<br />
This System has considered two subsystems (to be called systems in the following discussion for the sake of<br />
simplicity), i.e.:<br />
- "unbonded", using individually greased and plastic sheathed monostrands placed directly in the<br />
concrete. The unbonded protection of the tendons serves to make them independent of the structure.<br />
Only greased sheathed monostrands will be considered in the ensuing discussion, see Section 2.1;<br />
- "bonded", a grouting type of PT that uses bare strands. In this case, the strands are located within a<br />
duct that constitutes a cylindrical or flat conduit. The void thus created is then filled with grout according<br />
to EN 447 or Annex C4 of <strong>ETA</strong>G 013 for the purpose of bonding with the structure and inhibiting<br />
corrosion.<br />
The constituting strands are those defined in the <strong>European</strong> Standard White Draft pr EN 10138-3: "Prestressing<br />
steels - Strand". They refer to 7-wire strands with nominal diameters of ∅ 15.2 and 15.7 mm (fpk = 1 860 N/mm 2<br />
or fpk = 1 770 N/mm 2 ), which are identical to those used with the VSL Multistrand system.<br />
As long as EN 10138 does not exist, 7-wire strands in accordance with national provisions shall be used.<br />
By varying both the strand diameter and number (and, if applicable, their specified characteristic value of<br />
maximum force), it would be possible to obtain a value for the characteristic tensile strength per cable or per unit<br />
that varies between 260 and 1 116 kN.<br />
Each strand, of a cable or unit, is individually stressed and becomes locked within a conical anchoring hole by<br />
means of wedges.<br />
The anchorage function is performed by clamping during strand moving back at the time of pressure release in<br />
the jack.<br />
The choice of post-tensioning units, as dictated by force requirements, leads for a given strand diameter and<br />
characteristic strength to a specific number of strands to be laid out in accordance with a recommended spacing<br />
plan. In conjunction with this design element, the choice of type of anchorage associated with the cable<br />
depends on the intended function and application of the particular unit.<br />
The system is limited to units of 1 and 4 strands since these units prove appropriate for common slabs and<br />
plates.<br />
The designation of post-tensioning units is expressed with reference to both the type and number of component<br />
strands. The VSL commercial labeling is explained below:<br />
The labeling of units 6-1… 6-4 or 6S-1… 6S-4 signifies:<br />
the first digit indicates strand diameter,<br />
6 = ∅ 6 × 1/10" = T15.2 ∅15.2 mm<br />
6S = ∅ 6 × 1/10" S = T15.7 ∅15.7 mm (S stands for super).<br />
the subsequent digits indicate the number of strands composing the unit.<br />
To provide greater detail, the designation of units begins with the names of the anchorages placed at the ends.<br />
The following designation serves as an example:<br />
Cable VSL S-S 6S-4 L = 50.000 (2)<br />
Cable VSL 4(S-S 6S-1) L = 50.000 (2) [juxtaposition lying flat generally composed of 4 monostrand units]<br />
The functions and names of the anchorages will be defined hereafter. The cables feature a length of 50.000 m<br />
and have been stressed at both (2) ends.<br />
The VSL Slab System contains 1 and 4 strand units. The intermediately-dimensioned cables of 2 and 3 strands<br />
are composed preferentially by means of juxtaposing several monostrand units.<br />
The prestressing force applied may naturally be fine-tuned to meet the required prestressing force level by<br />
adjusting the appropriate spacing between units.
Annex 2 of the <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> <strong>No</strong> <strong>ETA</strong>-<strong>06</strong>/00<strong>06</strong> 5<br />
1.2 CHARACTERISTICS OF SYSTEM UNITS<br />
On the basis of the strand characteristics defined in draft Standard "pr EN 10138-3: Prestressing steels - Part 3:<br />
Strand", the values of tendon cross-sections Ap, maximum forces under anchorage upon tensioning recom-<br />
mended by EC2 : Pmax = min {k1.Ap.fpk; k2.Ap.fp0.1k}, with k1 = 0.8, k2 = 0.9, fpk = 1 860 N/mm 2 , fp0.1k = 0.88 fpk, of<br />
VSL post-tensioning units are as follows :<br />
Number of<br />
strands in the<br />
prestressing<br />
unit<br />
Ap<br />
STRAND ∅ 15.2 - T15.2 or 6<br />
fpk = 1 860 N/mm 2<br />
Fpk = 260 kN Fp0.1k = 229 kN<br />
Ap.fpk<br />
0.8<br />
Ap.fpk<br />
Ap.fp0.1k<br />
0.9<br />
Ap.fp0.1k<br />
Ap<br />
STRAND ∅ 15.7 - T15.7 or 6S<br />
fpk = 1 860 N/mm 2<br />
Fpk = 279 kN Fp0.1k = 246 kN<br />
Ap.fpk<br />
0.8<br />
Ap.fpk<br />
Ap.fp0.1k<br />
0.9<br />
Ap.fp0.1k<br />
mm² kN kN kN kN mm² kN kN kN kN<br />
1 140 260.0 208.0 229.0 2<strong>06</strong>.1 150 279.0 223.2 246.0 221.4<br />
2 280 520.0 416.0 458.0 412.2 300 558.0 446.4 492.0 442.8<br />
3 420 780.0 624.0 687.0 618.3 450 837.0 669.6 738.0 664.2<br />
4 560 1 040.0 832.0 916.0 824.4 600 1 116.0 892.8 984.0 885.6<br />
<strong>No</strong>te : prestressing force applied to structure must be in accordance with national regulations<br />
The system can obviously be used with strands displaying a specific characteristic tensile strength of less than<br />
that proposed in the table as strands with fpk = 1 770 N/mm 2 . The provisions for tendons with strands with a<br />
characteristic tensile strength fpk = 1 860 N/mm 2 also apply to tendons with strands with fpk < 1 860 N/mm 2 .<br />
The draft Standard pr EN 10138-3 sets the following criteria for the other useful characteristics of prestressing<br />
strands composing the VSL units:<br />
- Elongation at maximal force: ≥ 3.5%<br />
- Relaxation at 0.70 fpk after 1,000 hours: ≤ 2.5%<br />
- Relaxation at 0.80 fpk after 1,000 hours: ≤ 4.5%<br />
- Fatigue behaviour (0.70 fpk; 190 N/mm 2 ): ≥ 2x10 6 cycles<br />
- Maximum D value of deflected tensile test: ≤ 28%<br />
- Modulus of elasticity Ep: 195 000 N/mm 2<br />
The strands are stressed individually, the modulus of elasticity of the strand measured and communicated at the<br />
time of its supply is to be taken into account for the cable elongation calculations.<br />
Individually greased and sheathed monostrands have the same mechanical properties as listed above for bare<br />
strands.<br />
1.3.1 PRESENTATION OF THE ANCHORAGES<br />
1.3 ANCHORAGES<br />
The VSL Slab System anchorages are all (with the exception of the type "H" bonded anchorages) available for<br />
the two systems of unbonded or bonded tendons. Depending on their function and commercial labeling, the<br />
anchorages may be classified as follows:<br />
Type "S 6-1" and "S 6-4" live end anchorages<br />
These active anchorages have been designed to anchor tendons at the end at which the stressing will be<br />
performed strand by strand.<br />
They are composed of a single-block anchorage casing drilled with conically-shaped holes (1 or 4) in which the<br />
strands are anchored by means of locking through the use of wedges. These anchorages exist in both the<br />
unbonded and bonded systems.<br />
The continuity of protection and the waterproof sealing between the duct and the anchorage casing are provided<br />
by means of a plastic sleeve.<br />
In the unbonded case, a cap is required to close the housing of the wedges after filling with a protective product<br />
(identical or compatible with that of the greased and sheathed single strands) by injection.<br />
The "S 6-1" anchorage can be used as an intermediate anchorage at a construction joint with the strand being<br />
continuous through the anchorage and over the entire tendon length to the end anchorage. The tendon is first<br />
stressed at the intermediate anchorage at the construction joint. When the entire slab is built, the tendon is<br />
stressed at the end anchorage and the intermediate anchorage becomes obsolete but remains in place.
Annex 2 of the <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> <strong>No</strong> <strong>ETA</strong>-<strong>06</strong>/00<strong>06</strong> 6<br />
Type "S 6-1" and "S 6-4" dead end anchorages<br />
These passive anchorages ensure the locking of tendons at the end on which no stressing force is being<br />
exerted by means of the jack. These anchorages apply to both the unbonded and bonded systems.<br />
This category only includes those anchorages that remain accessible at the time of stressing.<br />
The type "S" anchorages, whose wedges have been pre-locked and which may be controlled during stressing<br />
are used for the given function.<br />
The protection of these dead end anchorages is identical to that of the live end anchorages.<br />
Type "SF 6-1" embedded dead end anchorages<br />
These fixed anchorages are incorporated into the concrete of the structure. Only considered as embedded<br />
anchorages are those that make use of a direct transfer on the concrete in order to lock the tendon ends.<br />
In both the unbonded and bonded systems, the type SF 6-1 anchorages, which have been assembled onto the<br />
tendons prior to their installation, are used for the given function. Their wedges are locked into the anchorage<br />
body S 6-1 and maintained using a series of washers and springs supported on the caps screwed at the end, a<br />
set-up that provides mechanical protection against any slipping movement. The SF 6-1 anchorages receive the<br />
same protection as the S 6-1 anchorages.<br />
Type "H 6- (1 through 4)" bonded anchorages<br />
These fixed anchorages rely, at least in part, on bonding in order to maintain the tendon end fastened with<br />
respect to the concrete. They are strictly the same as those of the VSL Multistrand System, which has been<br />
detailed in Annex 1.<br />
These anchorages may only be used for the bonded system.<br />
1.3.2 LIST OF APPROVED ANCHORAGES<br />
The set of approved anchorages that allow creating all of the intermediate prestressing units have been<br />
categorized in the following table:<br />
System<br />
unbonded<br />
bonded<br />
ANCHORAGES<br />
Functions Live end Dead end Embedded<br />
Dead end Bonded<br />
Unit Commercial label S S SF<br />
1T15 / 1T16 6-1 / 6S-1 <br />
4 6-4 / 6S-4 <br />
CABLES<br />
Unit Commercial label Si Si SFi H<br />
1T15 / 1T16 6-1 / 6S-1 <br />
4 6-4 / 6S-4 <br />
The stressing of tendons anchorages is only conducted by VSL stressing jacks, which are presented in Chap. 4.<br />
1.4 CATEGORIES OF USE, OPTIONS AND POSSIBILITIES<br />
1.4.1 USES AND OPTIONS OF VSL SLAB SYSTEM UNITS<br />
The VSL Slab System units are entirely internal to the concrete; they may be:<br />
- either unbonded, i.e. with individually greased and sheathed monostrands, unbonded to the structure,<br />
- or bonded, i.e. with "bare" strands placed inside a duct and with permanent grouting, providing bonding<br />
to the structure.<br />
These units may also be:<br />
- replaceable provided the absence of bonding with the structure,<br />
- designed to be encapsulated and perfectly waterproof,<br />
- designed to be electrically-isolated.
Annex 2 of the <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> <strong>No</strong> <strong>ETA</strong>-<strong>06</strong>/00<strong>06</strong> 7<br />
Anchorages S SF Si SFi S Si H<br />
Uses<br />
6-1 6-1 6-1 6-1 6-4 6-4 6-1:6-4<br />
internal* bonded cable with metallic<br />
duct<br />
<br />
internal* bonded cable with plastic duct <br />
internal* unbonded<br />
external* bonded cable<br />
external* unbonded cable<br />
<br />
tendon for use in various material as<br />
external cable (1)<br />
<br />
restressable tendon <br />
exchangeable tendon (2) <br />
encapsulated tendon (leak tight) <br />
electrically isolated tendon<br />
(*) of concrete<br />
<br />
It goes without saying that the solutions and options implemented presume the availability of adequate choices<br />
and combinations of all unit or cable components, as indicated in this <strong>ETA</strong>:<br />
- for strands see Chapter 2.1 "Strands used",<br />
- for ducts see Chapters 2.2 "Requirements of the unbonded system" and 2.3 "Ducts used for bonded<br />
system",<br />
- for anchorages see Chapter 3.4 "Anchorage arrangements",<br />
- for injection see Chapter 5.1 "Injection".<br />
(1) the anchorage must be embedded in concrete block.<br />
(2) the designer must check feasibility regarding geometrical tendon layout.<br />
1.4.2 POSSIBILITIES OF THE VSL SLAB SYSTEM<br />
The VSL Slab System is able to take advantage of the following unique set of possibilities:<br />
- Partial stressing or stressing in stages:<br />
When prestressing needs to be applied gradually, the stressing may be performed in stages. With the first<br />
partial stressing step being carried out at the beginning of the second stage, the wedges are unclamped by<br />
action of the jack on the strand. Once the targeted force has been reached, pressure in the jack is relaxed<br />
and the wedges are once again locked inside the anchorage. This procedure consists of the same steps as<br />
for stressing a long cable strand whose elongation necessitates several successive jack strokes.<br />
Since the strands have been stressed individually, the procedure may also entail the total stressing of a<br />
fraction of the strands.<br />
- Destressing procedure:<br />
The destressing of a strand(s) anchored by a type "S 6-1" or "S 6-4" anchorage is possible using a special<br />
tooling assembly mounted on the stressing jack provided that the required strand over lengths have been<br />
conserved and that the strands remain independent of the structure (unbonded).<br />
From the aforementioned, two zones appear to stand out, the current zone and the anchorage zone; they will be<br />
presented in greater detail in the following chapters entitled "Strands and ducts" and "Anchorages".
Annex 2 of the <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> <strong>No</strong> <strong>ETA</strong>-<strong>06</strong>/00<strong>06</strong> 8<br />
CHAPTER 2<br />
STRANDS AND DUCTS<br />
2. TENDONS AND DUCTS<br />
2.1 STRANDS USED<br />
The high-strength prestressing steel (strands) composing the tendons are labeled "Y1860S7 – <strong>No</strong>. 1.1366" and<br />
are defined in the draft Standard "pr EN 10138-3: Prestressing steels – Part 3: Strand". On an occasional basis,<br />
the strands labeled "Y1770S7 – <strong>No</strong>. 1.1365" may also be employed.<br />
The primary characteristics have been recalled in Section 1.2.<br />
As regards monostrands (individually greased and sheathed) that are used in the unbonded system, they are<br />
compliant with Annex C.1 of the <strong>ETA</strong>G 013, which specifies the requirements, verification methods and<br />
acceptance criteria of both the grease and the sheathing.<br />
2.2 REQUIREMENTS OF THE UNBONDED SYSTEM<br />
While it is obvious that the individually greased and sheathed monostrand do not necessitate any duct, the<br />
cables composed by juxtaposing side by side several monostrands however require assembly by means of<br />
regularly-spaced spacers ensuring their respective positions / linear lay out within the group.<br />
The connection of the monostrand sheathing with the anchorage is conducted by means of inserting the strands<br />
in a sleeve with one inlet for the "S 6-1" anchorage or a sleeve with 4 inlets for the "S 6-4" anchorage. These<br />
connections are made of plastic and provide for a watertight seal with the sheathing.<br />
2.3 DUCTS USED FOR THE BONDED SYSTEM<br />
The VSL Slab System can use several types of duct as provided in this section. Duct type selection depends on<br />
the specific project, the final use designed for the structure and the options selected for the post-tensioning<br />
units.<br />
Although the VSL Slab System authorizes the use of cylindrical ducts, the applications targeted with the slabs<br />
and plates increasingly rely upon the flat ducts presented below. For cylindrical ducts, the interested reader is<br />
advised to consult Annex 1 of this <strong>ETA</strong>.<br />
2.3.1 TYPES AND DIMENSIONS OF USABLE DUCTS<br />
Depending on the specific application, various types of ducts may be employed. From a general standpoint, the<br />
ducts used must be mechanically resistant, display continuity in shape, ensure continuity of the seal over their<br />
entire length and comply with the project's bond requirements, while not causing any chemical attack.<br />
Without claiming to be exhaustive, the frequently-used ducts of the following table have demonstrated their<br />
capacities in the uses and applications cited:<br />
Ducts<br />
Metal duct Plastic duct<br />
Applications Corrugated steel strip flat sheath VSL PT-PLUS ® flat duct<br />
Cable with standard ~<br />
inside the<br />
concrete<br />
bonded<br />
injection<br />
encapsulated<br />
electrically<br />
isolated<br />
×<br />
×<br />
ª<br />
ª<br />
<strong>No</strong>te ª: This set-up features a fully-bonded cable.<br />
: Advised ~ : Possible × : Unadvised or forbidden
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The VSL Slab System's prestressing tendon ducts, with either a cylindrical cross-section or oblong, must display<br />
internal dimensions large enough to provide for easy tendon installation and adequate filling during grouting of<br />
the protective product.<br />
The small internal dimension of the oblong section is considerably less than two strand diameters in order to<br />
ensure that they remain juxtaposed side by side, in the same position all along the tendon.<br />
The most common duct sizes are listed on drawing "Ducting" of Chapter 6.<br />
2.3.2 M<strong>ETA</strong>L DUCTS<br />
Tendons are most often isolated from the concrete by means of corrugated steel strip cylindrical or flat sheaths.<br />
Although not covered in Standard EN 523, these flat sheaths due to their shapes and dimensions may be<br />
qualified as normal (Category 1). Their characteristics are nearly the same as those of the cylindrical sleeve<br />
stipulated in the standard.<br />
Connections between coils or straight segments are performed by means of a coupler on the two extremities to<br />
be connected. The waterproof sealing at the joints is provided by either an adhesive ribbon or thermoretractable<br />
sleeves.<br />
2.3.3 PLASTIC DUCTS<br />
In the case of stringent requirements as regards to both corrosion protection and fatigue resistance of cables, it<br />
is recommended to use the corrugated plastic VSL PT-PLUS ® flat (or cylindrical) duct; this material generates<br />
perfect bonding between the tendons and the structure. It is the preferred choice for tendons submitted to a<br />
particularly-aggressive environment or strong fatigue loads. The fittings between ducts segments are introduced<br />
by means of connectors that serve to generate a waterproof sealing. The VSL PT-PLUS ® duct complies with<br />
<strong>ETA</strong>G 013.<br />
The VSL PT-PLUS ® duct with its set of appropriate fittings is also employed in the case of fully-encapsulated<br />
(waterproof) and or electrically isolated cables. This application necessitates the presence of rigid half-shells<br />
between the duct and its supports at all the high points along the cable path in order to avoid any risk of<br />
perforation during stressing of the tendon.<br />
2.3.4 ACCESSORIES FOR INLETS, BLEED VENTS AND OUTLET<br />
Providing permanent protection by means of grout injection presupposes the possibility of intervening anywhere<br />
along the cable path in order to adjust the filling and bleed any air, water, etc. that may be within the ducts. In<br />
this aim, accessories for inlets, venting and outlets are installed on the ducts. These basically comprise shells or<br />
collars fastened onto holes in the ducts and then connected to pipes with plugs opening onto the slab surface or<br />
subsurface.<br />
Duct Duct connection accessory Inlet, venting, bleeding or outlet<br />
accessory<br />
Corrugated steel strip sheath Sealed plastic shell Plastic pipe<br />
VSL PT-PLUS ® duct Special "clipped" collar Plastic pipe<br />
The distributions of inlet, venting, bleeding and outlet points along the cable profile are selected based on a<br />
function-specific study of the cable path.<br />
2.3.5 CONNECTION WITH SLEEVES<br />
The strands, placed within their ducts, must slightly dilate in the vicinity of the "S 6-4" anchorages in order to<br />
pass through the corresponding holes in the anchorage body. This "variable oblong"-shaped duct expansion is<br />
called a trumpet and is considered part of the anchorage element.<br />
The trumpets are fastened to the formwork of appropriate dimensions, with enough length and opening at the<br />
end to allow for connection and alignment of the duct of the current zone.<br />
The sealing between the ends of duct and trumpet is carried out using an adhesive strip, a thermo-retractable<br />
sleeve, or a connector designed as a duct accessory (e.g. a VSL PT-PLUS ® coupler).
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2.4 CABLE LAYOUT<br />
The cable layout patterns are not inherent to the VSL Slab System, but instead depend on the particular project.<br />
2.4.1 STRAIGHT LENGTHS BEHIND THE ANCHORAGES<br />
In order for the strands not to display excessive deviation with respect to the anchorage support surface, it is<br />
recommended to lay out a rectilinear segment in the back of the anchorage. In both systems (unbonded and<br />
bonded), whether the systems include an individual sleeve and a shared sleeve, their trumpet length is sufficient<br />
as straight length needed behind the anchorage.<br />
2.4.2 RADIUS OF CURVATURE<br />
- unbonded system:<br />
The individually greased and sheathed monostrands typically laid out either isolated or flat juxtaposed must<br />
satisfy the minimum radius of curvature rmin :<br />
deviation : rmin ≥ 2.50 m,<br />
loop anchorage: rmin ≥ 0.60 m, the term loop anchorage indicates a zone with strong curvature<br />
over which the total deviation is nearly π radians and which is located at approximately mid-length of the<br />
cable, with simultaneous stressing at both ends.<br />
In the case of an anchorage with several strands, the strands are to be laid out such that the radial force due to<br />
deviation of one strand does not harm the adjacent strand.<br />
- bonded system:<br />
The corrugated steel strip flat sheath is bent by respecting a minimum radius of curvature rmin. With the sheath<br />
laid out flat (see drawing "Ducting" of Chapter 6), the following dimensions are respected:<br />
plane: rmin ≥ 6.00 m,<br />
elevation: rmin ≥ 2.50 m.<br />
The VSL PT-PLUS ® flat duct is bent by respecting a minimum radius of curvature rmin. With the duct laid out flat,<br />
the following dimensions are respected:<br />
plane: rmin ≥ 6.00 m,<br />
elevation: rmin ≥ 2.50 m.<br />
2.4.3 SPACING OF THE SUPPORTS AND TOLERANCES<br />
The support heights underneath the cables or ducts are listed on the cable diagrams approximately every meter<br />
for a large radius of curvature and every fifty centimeters for a small radius of curvature, in order to allow for<br />
cable (or duct) placement with the required level of precision.<br />
The cable (or duct) supports are laid out as stipulated in the design that also establishes the order in which the<br />
cables (or ducts) are to be installed to ensure installation without "intertwining" in the case of slabs with tendons<br />
in both directions.<br />
The fastening fittings are sufficiently robust and close enough such that the cables (or ducts) will not exhibit<br />
displacements or deformations in excess of the allowed tolerances.<br />
The tolerances on cable positions in the concrete elements must respect the prescriptions stipulated in draft<br />
standard "pr ENV 13670-1".<br />
Moreover, in every direction, whenever a cable displays or potentially displays deviation in the vicinity of an<br />
edge of concrete which could lead to spalling of the concrete cover, an offset with respect to the cable diagram<br />
in this direction is only tolerated provided that equilibrium reinforcing bars are provided over this zone. Special<br />
attention must be paid to outward pressure due to structural singularities, such as floor openings.<br />
The VSL Slab System authorizes the cable installation technique according to the so-called "free path" or "freie<br />
Spanngliedlage" method defined here after.<br />
- In slabs with a thickness of not more than 450 mm the tendons can be placed with the method of “Freie<br />
Spanngliedlage”.<br />
- Tendons placed with the method of “Freie Spanngliedlage” need only a limited number of tendon supports, in<br />
general at the low and high points of the tendon profile, however, with limitations on the spacing as stated<br />
below.<br />
- The maximum spacing of tendon supports is:
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- 1.5 m between the tendon fixation to the top layers of reinforcement and an adjacent anchorage,<br />
- 3.0 m between the tendon fixation to the bottom layers of reinforcement and an adjacent anchorage or<br />
the tendon fixation to the top layer of reinforcement.<br />
- At the low points and high points of the tendon profile, the tendons have to be fixed to the top and bottom<br />
layers of reinforcement, respectively, on least two locations which have a distance of between 0.3 to 1.0 m. The<br />
fixation shall ensure a tight fit without damaging the tendon sheathing. The reinforcement layers have to be fixed<br />
in accordance with the relevant standards.<br />
2.4.4 STRAND CUT LENGTH<br />
Since the anchorage has been fastened with respect to the part undergoing post-tensioning, its space<br />
consumption is limited to its specific volume. Strand length is strictly the length of the prestressed element<br />
between the anchorages increased by the over length crossing the stressing jack(s).<br />
These over length have been defined in the drawing "Clearance requirements" of Chapter 6.<br />
2.5 INSTALLATION OF DUCTS AND STRANDS<br />
Depending on the size and layout of the worksite, the available space on site and the schedule of works, one of<br />
the following solutions is to be adopted:<br />
- unbonded system:<br />
- cables fabricated in the plant and then delivered as needed to the worksite for installation into the<br />
passive reinforcement;<br />
- cables fabricated in a mobile workshop on the worksite, all ready to be installed in the passive<br />
reinforcement.<br />
- bonded system:<br />
- cables (both tendons and ducts) fabricated in the plant and then delivered as needed on the<br />
worksite for installation into the passive reinforcement;<br />
- strand bundle fabricated in a mobile workshop located adjacent to the worksite and then drawn<br />
before concreting into the ducts installed in the passive reinforcement;<br />
- tendons composed by threading strand by strand before concreting into the ducts installed in the<br />
passive reinforcement.<br />
<strong>No</strong>te: If round ducts are used, threading of strand may also be done after concreting.<br />
2.6 PROVISIONAL PROTECTION AND LUBRIFICATION<br />
In the bonded system, the oiling or greasing of tendons, exclusively by means of non-dangerous substances, is<br />
performed:<br />
- in the aim of providing provisional protection against corrosion from the time of leaving the plant until<br />
permanent protection has been achieved (grouting of the cable);<br />
- in the aim of lubrication since the friction loss of oiled strands in the metal ducts during stressing is lower.<br />
With this same objective, other products serving to reduce friction may be used, as long as they are recognized<br />
as non-dangerous, can be easily applied and remain inert in the presence of permanent protection (and the<br />
eventual rigid bond to the structure)..<br />
It is necessary to point out that:<br />
"In addition to the specific clauses relating to dangerous substances contained in this <strong>European</strong> <strong>Technical</strong><br />
<strong>Approval</strong>, there may be other requirements applicable to the products falling within its scope (e.g. transposed<br />
<strong>European</strong> legislation and national laws, regulations and administrative provisions). In order to meet the<br />
provisions of the EU Construction Products Directive, these requirements need also to be complied with, when<br />
and where they apply."
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2.7.1 FRICTION LOSSES<br />
2.7 CALCULATION ELEMENTS<br />
The friction of strands in their ducts, which hinders tendon displacement during stressing, causes a tensile loss<br />
by friction all along the cable path beginning at the considered live-end anchorage.<br />
In examining the friction loss formula: f po (x) = f po (0) . e<br />
- μ ( θ + k x ) , which expresses the tension in a<br />
cable at the abscissa x as a function of the tension at the considered live end anchorage (positioned at x = 0),<br />
where μ is the coefficient of friction (over the curve) between the strands and the duct, θ the sum of the<br />
angular deviations of the cable over the distance x, and k the unintentional angular deviation (per unit length)<br />
affecting the cable path,<br />
it is recommended to adopt the numerical values of μ and k prescribed in Eurocode 2 which can be summarized<br />
as follows:<br />
Application μ (rad -1 ) k (rad/m)<br />
Individually greased and sheathed monostrand 0.05 0.020 - 0.<strong>06</strong>0<br />
Cable with corrugated steel strip sheath 0.17 - 0.19 0.005 - 0.010<br />
Cable with VSL PT-PLUS ® duct 0.12 - 0.14 0.005 - 0.010<br />
The interval limit values encompass both lubricated and non-lubricated strands.<br />
2.7.2 BASIS FOR EVALUATING ELONGATIONS<br />
See Section 2.6.2 of Annex 1.<br />
On the worksite during stressing, whether the unbonded or bonded system is being employed, elongation only<br />
gets evaluated once the strand has been stiffened inside its duct.<br />
<strong>No</strong>te : friction losses at anchorages are expressed in Chapter 4.2.1.<br />
2.7.3 ACTIVE ANCHORAGE SETTINGS<br />
The following wedge draw-in values will be applied herein:<br />
- 6 mm, which remains constant for all units and is applicable to all types of anchorage using the<br />
"6N" or "6S" wedges implemented without activation of the seating ram of the stressing jack (see<br />
Section 4.1.1).<br />
- 5 mm, which remains constant for all units and applicable to all types of anchorage using the "6N"<br />
or "6S" wedges implemented with activation of the seating ram of the stressing jack (see<br />
Section 4.1.1).<br />
The VSL Slab System anchorages do not allow for any adjustment with shim.
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3. CHAPTER ANCHORAGES 3<br />
3.1 DESCRIPTION OF ANCHORAGE COMPONENTS<br />
VSL Slab System anchorages make use of a set of standard elements that can be categorized as follows:<br />
3.1.1 LIVE END / DEAD END ANCHORAGES<br />
ANCHORAGES<br />
For these active/passive anchorages, the anchor head and plate are combined to form a single part, commonly<br />
called the anchorage body.<br />
These anchorages comprise:<br />
- S 6-1 anchorage<br />
The anchorage body is molded and cast in cast iron with spheroidal graphite in accordance with Standard<br />
EN 1563; the conically-shaped hole, subject of a rigorous control, is drilled into this body. The cast iron used<br />
herein is EN-GJS-500-7.<br />
The plastic sleeve is screwed onto the anchorage body.<br />
In the unbonded case, the end cap is made of plastic material.<br />
In the bonded case, a temporary or permanent cap provides for the waterproof seal of the envelope at the<br />
anchorage end in order to perform the grouting.<br />
- S 6-4 anchorage<br />
The anchorage body is molded and cast in cast iron with spheroidal graphite in accordance with Standard<br />
EN 1563; the four conically-shaped holes are drilled into this casing and rigorously controlled individually. The<br />
cast iron used herein is EN-GJS-500-7.<br />
The plastic sleeve of this anchorage is inserted into the concrete and accommodates in an appropriate form the<br />
simply-supported anchorage body.<br />
In the unbonded case, a permanent cap filled with grease protects the end anchorage.<br />
In the bonded case, a provisional or permanent cap provides a waterproof sealing of the envelope at the<br />
anchorage end in order to perform the grouting.<br />
- Wedges<br />
The wedges used for both the VSL Slab System and VSL Multistrand System are identical (see Annex 1).<br />
3.1.2 PRESENTATION AND PACKING OF ANCHORAGES<br />
The unbonded system:<br />
Since the installation of the monostrands and anchorage body for the S 6-1 anchorage or the trumpet for the<br />
S 6-4 anchorage is done prior to concreting, the delivery of anchorages to the worksite entails:<br />
1. Delivery of the S 6-1 anchorages or the S 6-4 trumpets, along with the monostrand coils and the<br />
installation accessories for both cable manufacturing and placement in the passive reinforcement.<br />
These anchorage components are fixed to the formwork. The anchorage components are delivered<br />
already tagged, packaged and protected.<br />
After concreting and cure of the concrete,<br />
2. Delivery of the wedges, eventually along with installation of the S 6-4 anchorage units, the stressing<br />
operation, cutting of the strand over lengths and permanent protection of the anchorages. These<br />
anchorage components are delivered identified, packaged and protected.<br />
The bonded system:<br />
Given that strand placement takes place before concreting, the delivery of anchorages on the worksite entails:<br />
(only the most common case of internal (concrete) post-tensioning of a new structure will be highlighted herein)<br />
1. Delivery of the S 6-1 anchorages or the S 6-4 trumpets, the ducts, the accessories for placement within<br />
the passive reinforcement, along with the strands to be threaded. These anchorage parts are fastened<br />
to the formwork. The anchorage units come delivered tagged, packaged and protected.
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Following concreting and curing of the concrete,<br />
2. Delivery of the wedges (eventually the S 6-4 anchorage body), the stressing operation, cutting of the<br />
excess lengths and grouting for the permanent protection of both cables and anchorages. These<br />
anchorage components are delivered identified, packaged and protected.<br />
3.2 ORGANIZATION OF SUPPLY QUALITY<br />
The fabrication of anchorage components of the post-tensioning system and especially those designed for the<br />
VSL Slab System is conducted in compliance with the specifications, production and control procedures laid out<br />
in the present <strong>ETA</strong> document and all associated documents.<br />
The control procedures in effect for anchorage Component Manufacturers, to the same extent as those adopted<br />
by the PT Specialist Company, serve to ensure the traceability of the components all the way through to their<br />
delivery on site. It is to be recalled that the basis for evaluating these procedures and the supervision of their<br />
application have been defined in Chapter 8 and its Appendix E of the <strong>ETA</strong>G 013.<br />
It should also be recalled that prior to installation, the compliance of all delivered components, by means of both<br />
identification and visual inspection of their state, must be performed by the PT Supervisor.<br />
3.3 IMPLEMENTATION OF VARIOUS ANCHORAGES<br />
The implementation of VSL units must be assigned to a competent staff member and involve technical<br />
management personnel within the PT Specialist Company or a PT Supervisor certified by this company.<br />
3.3.1 TYPE "S 6-1" AND "S 6-4" LIVE END ANCHORAGES<br />
The S 6-1 anchorage bodies and the S 6-4 trumpets are fixed to the formwork and connected to the<br />
monostrands or ducts aligned at the time of their installation, in general during placing of the passive<br />
reinforcement, then incorporated therefore to the structure or structural element during concreting.<br />
Depending on the type of system (bonded or unbonded), sleeves or trumpets are appropriate.<br />
For detail of connections of anchorages with current ducts refer to Chapter 2.2: “Requirements of the unbonded<br />
system” and 2.3: “Duct used for the bonded system”.<br />
The S 6-1 anchorage, used like an intermediate anchorage, is strictly installed as a live end anchorage with the<br />
tendon that crosses it coiled up and stored beyond. After stressing of the first-phase length during installation of<br />
the second-phase tendon and duct, a sleeve is laid out in order to link the anchorage and this duct.<br />
The S 6-4 anchorage unit is installed into the trumpet which was placed before concrete pouring. The wedges<br />
are placed immediately prior to stressing, which ensures that they are clean for use.<br />
For force losses in the anchorages during stressing, see Section 4.2.1: "Force measurements".<br />
3.3.2 TYPE "S 6-1" AND "S 6-4" DEAD END ANCHORAGES<br />
The placement of these passive anchorages is performed as indicated in Section 3.3.1. Once the anchorage<br />
has been installed, before stressing at the other end, the wedges are pre-locked using a wedge tool. The<br />
anchorage then remains accessible throughout the stressing phase for observation.<br />
3.3.3 TYPE "SF 6-1" EMBEDDED ANCHORAGES<br />
In both the bonded and unbonded systems, the fixed SF6-1 anchorages are assembled on the strands, then<br />
the wedges are pre-locked and verified and, lastly, the ducts and sleeves are connected. The anchorages<br />
assembled in this manner are then positioned and inserted into the passive reinforcement.
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3.3.4 TYPE "H 6- (1 through 4)" BONDED ANCHORAGES<br />
These fixed anchorages reserved for the bonded system are strictly identical to those of the multistrand system<br />
described in Annex 1.<br />
3.4 ANCHORAGE ARRANGEMENTS<br />
According to categories of use, referring to Section 1.4.1, arrangements of anchorage components are descri-<br />
bed in the following table :<br />
Anchorages<br />
Components<br />
Uses<br />
S and Si 6-1<br />
Anchorage<br />
Unit<br />
SF and SFi<br />
6-1<br />
Anchorage<br />
Unit<br />
Anchor<br />
Body<br />
S and Si 6-4<br />
Sleeve Cap<br />
internal bonded cable with<br />
metal duct<br />
S S S Si S<br />
internal bonded<br />
plastic duct<br />
cable with<br />
S S S Si S<br />
internal unbonded S S S S S<br />
exchangeable tendon S S S S<br />
encapsulated tendon (leak tight) S S S S Si S<br />
electrically isolated tendon S (1) S Si S P (2)<br />
<strong>No</strong>tes : 1 : Electrical isolation provided by plastic trumpet (anchor body),<br />
2 : Plastic cap,<br />
3.5 GEOMETRICAL AND MECHANICAL USE CONDITIONS<br />
For the seating and installation of anchorages, certain construction-related conditions must be verified.<br />
3.5.1 CLEARANCES BEHIND ANCHORAGES<br />
In order to facilitate jack placement and simplify the stressing procedure, a free space must be allocated behind<br />
the anchorage.<br />
These dimensions are given in the drawing Page 29 "Clearance requirements" in Chapter 6.<br />
3.5.2 CONCRETE COVER AND ANCHORAGE SPACING<br />
Introducing post-tensioning forces into the structures takes the form, within the anchorage zones, of<br />
concentrated forces applied onto the anchorage bodies. The high stress values encountered underneath the<br />
anchorages necessitate certain construction-related measures, i.e.:<br />
- The anchorages must be laid out at a sufficient distance from the nearest edge of the concrete (cover) and<br />
respect a spacing between anchorages (centre to centre) that will be specified below.<br />
- The concrete in the vicinity of the anchorages must be especially homogeneous and display, at the time of<br />
stressing, an adequate level of strength.<br />
- A general diffusion zone must be designed and prepared in front of the anchorages within the structure,<br />
thereby reducing the concentrated forces and distributing them over the concrete cross-section, in<br />
compliance with the design rules.<br />
As stated above and in considering a maximum prestressing force P(t,x) at the time of stressing (t = 0) at the<br />
anchorage (x = 0), thus called P(0,0) ≤ Pmax, for the normal anchor plates and P(0,0) max = Pmax, the following are<br />
defined:<br />
Force in the cable, at the anchorage on the concrete side, before load transfer to anchorage.
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b0 and b’0 are the distances between the anchorage axis and the edge of the block tested. These values are<br />
given in the tables here after.<br />
The reinforcement required to prevent bursting and spalling in anchorage zones is determined in relation to a<br />
rectangular prism of concrete, known as the primary regularisation prism, located behind each anchorage. The<br />
cross section of the prism associated with each anchorage is known as the impact rectangle.<br />
The impact rectangle has the same centre and the same axes of symmetry as the anchor plate (which should<br />
have two axes of symmetry).<br />
The impact rectangle with dimensions c x c’ has the same area as the block tested A = 4 x b0 b’0 and the same<br />
aspect ratio (variation of -15% is allowed in one direction).<br />
cmin,rect = 0.85 x 2 b0 ; c’ min,rect = 0.85 x 2 b’0<br />
cmin and c’min taking into account dimensions of bursting reinforcement are given in the tables here after, then<br />
c ≥ cmin or c’ ≥ c’min (1)<br />
and c x c’ = A = 4 x b0 b’0 (2)<br />
Rules for center distance and edge distances of anchorages:<br />
Impact rectangles associated with anchorages located in the same cross section should not overlap.<br />
In addition, they should remain inside the concrete. Taking into account the concrete cover, we obtain the<br />
distance to edge in the two directions :<br />
c<br />
c '<br />
+ cov er − 10mm<br />
and<br />
+ cov er − 10mm<br />
2<br />
2<br />
<strong>No</strong>te: 10 mm is the concrete cover in the tested block.<br />
For anchorage spacing, refer to equations (1) and (2)<br />
For f cm(t) ≥ 16/20 N/mm 2<br />
Anchorage S 6-1 S 6-4<br />
u | u’ mm (1) 105 75 280 115<br />
2b0 | 2b’0 mm (2) 180 120 400 220<br />
cmin | c’min mm<br />
155 100 340 185<br />
(1) Sizes of anchor plate / anchorage body<br />
(2) Sizes of test block<br />
During cable stressing, the concrete in front of the anchorages must have reached an adequate strength level,<br />
i.e. a 100% stressing of P(o,o) max = Pmax is not permitted if fcm(t) < 16/20 N/mm 2 , regardless of the anchorage<br />
layout within the concrete element.<br />
It remains possible however to partially tension the tendon.<br />
In the case of stressing to 50% of the maximum value at the anchorage for example, the characteristic<br />
strengths fcm(t) may be reduced to approximately 2/3 of the values indicated above for total stressing.<br />
It is to be recalled that for those anchorages relying upon bonding alone, i.e. for type "H" anchorages, concrete<br />
strength within the anchorage zone during stressing must be: fcm(t) ≥ 28/35 N/mm 2 .<br />
b 0<br />
b’0
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3.6 BURSTING REINFORCEMENT<br />
A bursting reinforcement is required in the local anchorage zone due to application of the concentrated posttensioning<br />
force.<br />
In all cases, the general anchorage zone must contain a reinforcement for equilibrium designed by the project<br />
designer in accordance with typical design rules (see examples presented in the drawing Page 27<br />
"Reinforcement of anchorage zones" in Chapter 6).<br />
As foreseen by this <strong>ETA</strong>, the local zone reinforcement specified in this <strong>ETA</strong> and confirmed in the load transfer<br />
tests, may be modified for a specific project design if required in accordance with national regulations and<br />
relevant approval of the local authority and of the <strong>ETA</strong> holder to provide equivalent performance.<br />
The contractor responsible for concreting must ensure that the density and configuration of reinforcement within<br />
the diffusion zone allow for adequate and homogeneous concreting of the entire zone.
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CHAPTER 4<br />
4. STRESSING<br />
4.1 STRESSING EQUIPMENT<br />
The VSL equipment used for stressing is primarily composed of stressing jacks, hydraulic power packs<br />
(commonly called pumps) and the associated set of measurement instruments or systems.<br />
4.1.1 STRESSING JACKS<br />
The strands are individually stressed by means of VSL stressing jacks, which are available according to two<br />
types:<br />
- a double acting front-gripping hollow piston jack,<br />
- a twin ram double acting jack, with solid pistons laid out on both sides of the strand. This configuration allows<br />
for stressing the intermediate anchorages.<br />
This equipment enables stressing the strand in one or several stages and then, if need be, to de-stress the<br />
strand. Their primary characteristics will be defined below.<br />
In sequence starting from the anchorage, these jacks are composed of:<br />
- 1 nose (chair ring) at the front resting upon the anchorage body, ultimately associated with a seating ram;<br />
- 1 body or cylinder, composed of one or two jacks and resting upon the chair ring,<br />
- 1 auxiliary anchorage driven by the piston(s) and laid out as close as possible to the anchorage installed in<br />
place in order to limit the over length of the strands. The ungripping of the jack anchorage is performed<br />
automatically.<br />
List of VSL jacks:<br />
Designation DKP 6 ZPE 23 FJ<br />
Type 2 // pistons 1 hollow piston<br />
Cross section mm 2<br />
240 x 165 ∅ 116<br />
Length mm 615 790<br />
Weight kg 30 23<br />
Stroke mm 200 200<br />
Ram area mm² 4 926 4 710<br />
Maximum pressure bar 467 488<br />
Maximum force kN 230 230<br />
Presence of seating ram ? <strong>No</strong> Yes<br />
The drawing on Page 28 indicates the clearances to be introduced around the anchorages at the ends of the<br />
post-tensioned structures in order to facilitate installation.<br />
4.1.2 HYDRAULIC PUMPS<br />
The VSL pumps comprise the assembly of hydraulic components including: pumps, distributors, nozzles and<br />
safety valves. The pumps are typically driven by electric motors.<br />
The stations themselves have been dimensioned for normal stressing speeds and contain safety measurement<br />
devices that depend on the specific application.<br />
4.1.3 INSTRUMENTS AND MEASURING SYSTEMS<br />
STRESSING<br />
The VSL force and elongation measurement instruments or systems serve to control with precision the stressing<br />
operation and display the results obtained.
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4.2 PROCESSES OF STRESSING AND CONTROL PROCEDURE<br />
Before proceeding with cable stressing, a certain number of preconditions must be met, in particular:<br />
- all pertinent safety rules and recommendations must be fully known;<br />
- the force targets along with the corresponding values of elongation; moreover, tolerances must be known by<br />
the PT Supervisor, who will have applied any eventual necessary adjustments to these values in order to<br />
account for parameters specific to the equipment;<br />
- the order in which the prestressing cables are to be stressed must be specified, and the order in which the<br />
strands in the cables are to be stressed with S 6-4 anchorages must be known;<br />
- the stressing equipment (including measurement instruments) must comply with guidelines furnished in the<br />
present <strong>ETA</strong>;<br />
- the required strength of the concrete of both the structure and anchorage zone undergoing stressing must be<br />
verified;<br />
- the loading and support states of the structure associated with the stressing phase must also be verified;<br />
- the over lengths of the strands to be stressed must remain perfectly clean.<br />
It should nonetheless be recalled that during the stressing process, it is strictly forbidden to be positioned behind<br />
the jack or within its immediate vicinity. The same precautions must be taken for the area in the back of the<br />
accessible dead-end anchorages.<br />
Even though the VSL system does not require any locking accessory device, with some jacks, the wedges may<br />
be set in order to reduce the setting of anchorage wedges and its influence on the force (abscissa function) in<br />
the strands.<br />
4.2.1 FORCE MEASUREMENTS<br />
The measurement of force in the cable, as transformed into pressure measurement in the jack, is generally the<br />
assigned objective herein.<br />
The pressure existing in the jack chamber is indicated by the manometer installed on the pump, with eventual<br />
control of the jack. The manometers used (Accuracy 1%), regularly recalibrated using a scale, feature a<br />
guaranteed precision of 1% of their maximum pressure, which tends to lie at 490 bars; these instruments<br />
thereby provide a precision of 5 bars over the entire manometer scale.<br />
In order to obtain the effective force on the structure, the force resulting from the manometer reading is to be<br />
corrected for losses inside the jack as well as for losses due to friction of the strands in the anchorage.<br />
Losses inside the jacks are identified from intrinsic hardware data. Although they contain an independent<br />
pressure term and another closely-proportional term, submitted to the maximum pressure reached upon<br />
completion of the stressing operation, the losses inside jacks are solely expressed in proportional terms and<br />
exhibit the following values:<br />
- DKP 6 jack: 3.5%<br />
- ZPE 23 FJ jack: 1.5%<br />
The losses in active anchorages, named ka, are due to friction of the strands deviated on the component parts<br />
and, depending on the specific anchorage, exhibit the following values:<br />
- S 6-1 anchorage: 0% to 1%<br />
- S 6-4 anchorage: 0% to 1% for the two central strands, 2% for the two outside strands.<br />
4.2.2 ELONGATION MEASUREMENTS<br />
The measurement of cable elongation is generally a control measurement that provides information on cable<br />
behavior during stressing.<br />
As for elongation measurements, an index is installed on the strands. During the stressing operation,<br />
elongations are then deduced from measurements of the displacement of this index. Since the onset of<br />
displacements combines the seating of tendons in their ducts with their actual elongation, the elongation during<br />
initial displacements is obtained by means of extrapolating the pure elongations occurring subsequently.<br />
The various pressure-elongation relations noted during cable stressing are recorded in the stressing data<br />
sheets, which are to remain available.<br />
Section 2.7.2 provides a recap of the elongation evaluation basis used during the stressing operation.
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5.1.1 UNBONDED SYSTEM<br />
CHAPTER 5<br />
5.<br />
5.1 INJECTION<br />
The monostrand (individually greased and sheathed), protected from the factory by grease, obviously does not<br />
necessitate any special additional protection.<br />
The S 6-1 and S 6-4 anchorage units, after stressing and cut-off of the strands, are filled with grease (identical<br />
or compatible with that of the monostrand in compliance with the <strong>ETA</strong>G 013) by means of injection using a<br />
pump. Following filling, a cap serves to enclose the strand ends and the wedge housings.<br />
5.1.2 BONDED SYSTEM<br />
INJECTION AND SEALING<br />
- General information:<br />
The nature and composition of injection products for the permanent protection of tendons and anchorages and<br />
for their bonding to the structure are not inherent to the prestressing process; instead, they depend on the<br />
project and the structure's assigned purpose.<br />
The products involved must not be a threat to the hygiene, health and the environment.<br />
In addition to the specific clauses relating to dangerous substances contained in this <strong>European</strong> <strong>Technical</strong><br />
<strong>Approval</strong>, there may be other requirements applicable to the products falling within its scope (e.g. transposed<br />
<strong>European</strong> legislation and national laws, regulations and administrative provisions) In order to meet the<br />
provisions of the EU Construction Products Directive, these requirements need also to be complied with, when<br />
and where they apply.<br />
The products used for the permanent protection of post-tensioning tendons and anchorages implemented by<br />
means of injection may be categorized as follows:<br />
Hydraulic cement-based injection grouts are the most commonly employed. These products may pertain<br />
to common grouts defined in the standard EN 447 or special grouts that make use of performance-enhancing<br />
admixtures. In some regions of the EU, unfavorable climatic conditions impose the application of special grouts<br />
according to <strong>ETA</strong>G 013.<br />
Those injection products that have already received a <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> may also be used in<br />
respect of the prescribed set of uses.<br />
Completion of the tendon envelope in the anchorage zone is provided during the time of injection by means of<br />
either temporary waterproof caps or definitively by permanent caps.<br />
- Injection equipment:<br />
The set of injection equipment has been adapted to the specific products to be injected.<br />
For the cement-based grout, the VSL injection equipment is composed for the most part of mixers and pumps<br />
integrated into a single device that enables preparing the grout and performing the injection. This equipment<br />
makes it possible to allocate with precision the grout components and to obtain a perfectly-homogeneous mix.<br />
The pump with which the equipment is fitted has been designed for continuous injection at an adapted grout<br />
progression speed.<br />
- Injection procedures:<br />
Before proceeding with the injection of a permanent cable protection, a certain number of conditions must be<br />
fulfilled and in particular:<br />
- The injection product must comply with the terms of the present <strong>ETA</strong> and the <strong>ETA</strong>G 013;<br />
- The injection equipment must comply with indications laid out in the present <strong>ETA</strong>,
Annex 2 of the <strong>European</strong> <strong>Technical</strong> <strong>Approval</strong> <strong>No</strong> <strong>ETA</strong>-<strong>06</strong>/00<strong>06</strong> 21<br />
- The waterproof sealing of the tendon and anchorage envelopes (ducts, fittings, pipes and caps) must be<br />
verified,<br />
- The climatic conditions and temperature of the structure must satisfy the use conditions of the injection<br />
product.<br />
The primary controls conducted during injection consist of verifying the adequate filling of the duct by means of<br />
inlets, bleed vents and outlets laid out all along the cable path and verifying that the product discharged by the<br />
vents or outlets displays the required properties.<br />
Grouting procedures and grouting surveillance shall be carried out according to EN 446.<br />
As an initial approach, the injection product quantities per unit cable length will be derived from:<br />
[(internal duct section area - tendon section area) × (unit length)] × (1 + ξ), where ξ is such that: 0.05 ≤ ξ ≤ 0.10<br />
in order to incorporate worksite losses, the shape of the duct and eventual corrugations.<br />
The various phases and parameters associated with cable injection are to be recorded on the injection data<br />
sheets, which are to remain available.<br />
5.2 SEALING<br />
The continuity of protection against all types of aggressions must be ensured all along the cable up to and<br />
including the anchorages.<br />
The protection measures introduced for this unique zone, which is located at the end of the slab and frequently<br />
protected from external aggressions is most often limited in this case to the filling of the block-out with mortar or<br />
concrete. In the case of end zones exposed to aggressive environment additional protection measures may be<br />
necessary (permanent cap or waterproof lining).
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CHAPTER 6<br />
SCHEMATIC DRAWINGS<br />
(dimensions expressed in mm)<br />
Title Page<br />
STANDARD ANCHORAGE ELEMENTS<br />
Wedges see Annex 1<br />
ANCHORAGES<br />
Type S 6-1 anchorages<br />
Principles of both the "unbonded" and "bonded" systems 23<br />
Sizes 24<br />
Type S 6-4 anchorages<br />
Principles of both the "unbonded" and "bonded" systems 25<br />
Sizes 26<br />
Type H 6- (1 through 4) anchorages see Annex 1<br />
REINFORCEMENT OF ANCHORAGE ZONES 27<br />
CLEARANCE REQUIREMENTS 28<br />
DUCTING 28