ETA Freyssinet En

5/28/2018 ETA Freyssinet En

1/90

FREYSSINET PRESTRESSING SYSTEM EUROPEAN TECHNICAL APPROVAL

English translation 2006.12.15 page 1/50

Service d'tudes techniques des routes et

autoroutes

46 avenue Aristide BriandBP 10092 225 BAGNEUX CEDEX

Tel : + 33 (0)1 46 11 31 31Fax : + 33 (0)1 46 11 31 69

MEMBRE DE L'EOTA

MEMBER OF EOTA

Agrment Technique Europen No. ETA-06/0226

(version originale en franais)European Technical Approval No. ETA-06/0226

(Original Version in French Language)

Nom commercialTrade name:

Dtenteur de l'ATEHolder of approval:

FREYSSINET1 bis, rue du Petit ClamartF-78140 VELIZY

Type gnrique etutilisation prvue du

produit de constructionGeneric type and use ofconstruction product:

Kit de prcontrainte de structures par posttensionPost-tensioning kit for prestressing of structures

Valid from:to:

25.01.200724.01.2012

Producteur du procd:

Kit manufacturer

PPC

Z.A. du Monay-Saint EusbeF-71210 SAINT EUSBE

Le prsent agrmenttechnique europencontient :This European TechnicalApproval contains:

90 pages comprenant 40 pages dannexes (dessins) faisant partie intgrante dudocument.

90 pages including 40 pages of annexes which form an integral part of thedocument

Organisation pour l'Agrment Technique Europen

European Organisation for Technical Approvals


2/90



CONTENTS

A LEGAL BASES AND GENERAL CONDITIONS................................................................................... 5

B SPECIFIC CONDITIONS OF THE EUROPEAN TECHNICAL APPROVAL............................. 6

B.1 DEFINITION OF PRODUCTS AND INTENDED USE ............................................................ ........................ 6B.2 CHARACTERISTICS OF PRODUCTS AND VERIFICATION METHODS ..................................................... .. 12B.3 EVALUATION AND ATTESTATION OF CONFORMITY AND CE MARKING .............................................. 13B.4 ASSUMPTIONS UNDER WHICH THE FITNESS OF THE PRODUCTS FOR THE INTENDED USE WAS ASSESSED 15B.5 INDICATIONS TO THE MANUFACTURER..................................................... .......................................... 16

C PRESCRIBED TEST PLAN .............................................................................................................. 17

D BASIC ELEMENTS OF AUDIT TESTING..................................................................................... 19

E PRESTRESSING UNITS AND USE CATEGORIES...................................................................... 20

E.1 UNITS CODING ............................................................ ............................................................ ............ 20

E.2 USE CATEGORIES........................................................ ............................................................ ............ 20E.3 PARTICULARITIES OF THE KIT......................................................... .................................................... 24E.4 FORCES OF PRESTRESSING TENDONS ........................................................ .......................................... 25

F ANCHORAGES .................................................................................................................................. 26

F.1 DESCRIPTION OF ANCHORAGE COMPONENTS ..................................................... ................................ 27F.2 R ECOMMENDATIONS FOR USE OF ANCHORAGES .......................................................... ...................... 29

G TENSILE ELEMENTS AND DUCTS............................................................................................... 31

G.1 TENSILE ELEMENTS .................................................... ............................................................ ............ 31G.2 DUCTS .................................................... ............................................................ ................................ 32G.3 CABLE LAY-OUT ........................................................ ............................................................ ............ 36

H TENSIONING...................................................................................................................................... 38

H.1 TENSIONING EQUIPMENT ...................................................... ............................................................ .. 38H.2 PARTICULAR RECOMMENDATIONS ........................................................... .......................................... 38H.3 R ECOMMENDATIONS FOR TENSIONING AND CONTROL ........................................................... ............ 38

I PROTECTION OF TENDONS.......................................................................................................... 39

I.1 LUBRICATION AND TEMPORARY PROTECTION......................................................... ................................ 39I.2 FILLING MATERIALS USED ........................................................ ............................................................ .. 39I.3 INJECTION EQUIPMENT .................................................... ............................................................ ............ 39

J MECHANICAL AND GEOMETRICAL CONDITIONS OF USE................................................ 40

J.1 FRICTION LOSSES AND ELONGATIONS ........................................................... .......................................... 40

J.2 GEOMETRICAL CONDITIONS OF USE .................................................... .................................................... 41J.3 BURSTING REINFORCEMENT...................................................... ............................................................ .. 44

K DRAWINGS......................................................................................................................................... 50


3/90



LIST OF DRAWINGS

1. C15 anchoring wedge2. C13 anchoring wedge3. T15D swage

4. T15DC swage5. T13D swage6. P 15 strand connector7. P 13 strand connector8. A nC15 anchorage bare strand duct9. A nC15 anchorage bare strand steel pipe10. A nC15 anchorage monostrand duct11. A nC15 anchorage monostrand steel pipe12. A nC15 anchorage monostrand plastic pipe13. A nC15 anchorage monostrand no duct14. AD nC15 anchorage bare strand injected with cement grout15. AD nC15 anchorage bare strand injected with wax or grease16. A nC15 EI electrically isolated anchorage17. CI nC15 fixed coupler18. CM nC15 movable coupler19. NB nC15 anchorage20. A 1F15 A 1F13 NB 1F15 NB 1F13 single anchorage bonded prestressing21. A nF13 A nF15 anchorage bare strand bonded prestressing22. CI nF13 CI nF15 fixed coupler bare strand bonded prestressing23. A 1F15 A 1F13 NB 1F15 NB 1F13 single anchorage unbonded prestressing24. A nF13 A nF15 anchorage monostrand unbonded prestressing25. A 1X13 A 1X15 anchorage monostrand26. A 2X13 A 2X15 anchorage monostrand

27. Liaseal

seal system for match-cast segments28. Identification drawings for C-series anchorage blocks29. Permanent cachetage of nC15 anchorages30. Temporary or permanent cachetage of nC15 anchorages31. Sealing-in of restressable nC15 anchorages32. External prestressing with monostrands injection closure33. External prestressing allowing load monitoring, restressing and replacement without damage

to duct34. Space requirement for CCxxx jacks35. Space requirement for CxxxF jacks36. Space requirement for KxxxC jacks (with hydraulic lock-off)37. Space requirement for KxxxC jacks (without hydraulic lock-off)

38. Space requirement for K500F jack39. Space requirement for VPxxxC jacks40. Space requirement for 55C15 equitension jack41. Load-monitoring jack for threaded 55C15 anchorage42. Space requirement for single strand jacks type C43. Space requirement for jacks A 1F13 - 1F15 anchorage44. Space requirement for jacks A nF13 A nF15 anchorage45. Adapter for 1X13 1X15 anchorage46. Adapter for 2X13 2X15 anchorage


4/90



LIST OF TABLES

Table 1 Low-Capacity Anchorages

Table 2 High-Capacity Anchorages

Table 3 Anchrorage Models for Basic and Optional Categories of Use

Table 3bis Selection of Kit Elements Depending on Basic and Optional Categories of Use

Table 4 Concrete Structures Use Categories

Table 5 Maximum Force with Stressing Limit Fo= min{0,8 Fpk,0,9 Fp0,1%}

Table 6 Maximum Force at Stressing Anchorage for a Single Strand

Table 7 Thickness of Steel Strip Sheaths

Table 8 Dimensions of Smooth HDPE Tubes

Table 9 Minimum Curvature Radius for Internal Prestressing

Table 10 Minimum Curvature Radius for External Prestressing

Table 11 Friction Loss in Anchorages

Table 12 Friction and Wobble Coefficient

Table 13 Wedge Pull-In at Stressing Anchorages

Table 14 Minimum Edge Distances for C-Model Anchorages

Table 15 Minimum Edge Distances for Model F Anchorages

Table 16 FeE 235 Bursting Steel for fcm,o= 24 MPa



Table 19 Helical Bursting Steel with FeE 235 for fcm,o= 24 MPaTable 20 Helical Bursting Steel with FeE 235 for fcm,o= 44 MPa

Table 21 Helical Bursting Steel with FeE 235 for fcm,o= 60 MPa


5/90



A LEGAL BASES AND GENERAL CONDITIONS

A.1 This European Technical Approval is issued by SETRA in accordance with:

Council Directive 89/106/EEC of 21 December 1988 on the approximation of

laws, regulations and administrative provisions of Member States relating toconstruction products1, modified by Council Directive 93/68/EEC2 andRegulation (EC) No1882/2003 of the European Parliament and of the Council3;

dcret n92-647 du 8 juillet 19924concernant l'aptitude l'usage des produits deconstruction

Common Procedural Rules for Requesting, Preparing and the Granting ofEuropean Technical Approvals set out in the Annex to Commission Decision94/23/EC5;

ETAG 013, Edition June 2002, Post-Tensioning Kits for Prestressing ofStructures.

A.2 SETRA is authorised to check whether the provisions of this European TechnicalApproval are met. Checking may take place in the manufacturing plant(s). Nevertheless, theresponsibility for the conformity of the products to the European Technical Approval and fortheir fitness for the intended use remains with the holder of the European Technical Approval.

A.3 This European Technical Approval is not to be transferred to manufacturers or agentsof manufacturers other than those indicated on page 1, or manufacturing plants other thanthose indicated on page 1 of this European Technical Approval.

A.4 This European Technical Approval may be withdrawn by SETRA, in particularpursuant to information by the Commission according to Article 5(1) of Council Directive89/106/EEC.

A.5 Reproduction of this European Technical Approval including transmission byelectronic means shall be in full. However, partial reproduction can be made with the writtenconsent of SETRA. In this case partial reproduction has to be designated as such. Texts anddrawings of advertising brochures shall not contradict or misuse the European TechnicalApproval.

A.6 The European Technical Approval is issued by the approval body in its officiallanguage. This version corresponds fully to the version circulated in EOTA. Translations intoother languages have to be designated as such.

1Official Journal of the European Communities NoL 40, 11.2.1989, p. 12

2Official Journal of the European Communities NoL 220, 30.8.1993, p. 1

3 Official Journal of the European Union NoL 284, 30.10.2003, p. 14JORF du 14 juillet 19925

Official Journal of the European Communities NoL 17, 20.1.1994, p. 34


6/90



B SPECIFIC CONDITIONS OF THE EUROPEAN TECHNICAL APPROVAL

B.1 DEFINITION OF PRODUCTS AND INTENDED USE

B.1.1 Definition of Products

The Freyssinet prestressing kit is a post-tensioning kit designed for both internal and externalprestressing. A prestressing cable consists of a bundle of 7-wire strands in accordance withsection G.1 and is referred to as the tensile element. When fitted with its anchorages, the

prestressing tendon is referred to as the prestressing unit.

The tensile element is housed in a duct in accordance with section G.2.

In the case of unbonded internal prestressing, however, monostrands (strands with individualprotection by grease or wax and plastic sheath) may be used without any duct, the strandsbeing placed in the structure according to the design requirement.

The set of anchorages available allows using prestressing units up to 55 strands.

Prestressing strands can be made in accordance with European and national provisions.

The prestressing tensile elements consist of: 12,5 mm or 12,9 mm nominal diameter strands, with a nominal tensile strength of

1770 MPa or 1860 MPa, coded respectively Y1770 (or Y1860) S7 12,5 (or 12,9) inprEN 10138-3 and designated T13, T13S or simply T13 in the present document,

15,3 mm or 15,7 mm nominal diameter strands, with a nominal tensile strength1770 MPa or 1860 MPa, coded respectively Y1770 (or Y1860) S7 15,3 (or 15,7) in

prEN 10138-3 and designated T15, T15S or simply T15 in the present document.

Freyssinet stressing anchorages anchor each strand individually by means of a conical wedgeinserted in a conical hole of anchorage block. The diameter of the internal thread of theFreyssinet anchor wedge depends on the strand nominal diameter, T13 or T15 (drawings 1and 2).

B.1.1.1 Stressing anchorages

Anchorages are said to be the stressing type (and are coded A for active) when they are theanchorages at the end of tensile elements where the tensioning operation takes place. Astressing anchorage consists of an anchorage head, i.e. a steel block or a casting with holes toreceive anchorage wedges. The anchorage head bears on a load spreading plate, except formodels F and X where the load spreading plate is part of the anchorage block. This loadspreading plate is:

either a casting known as a trumplate, which is cast into the concrete of the structure, or a bearing plate of dimensions to suit the load-bearing capacity of the structure

(when not in concrete).


7/90



Different active anchorage models are available, to meet specific construction needs.

Structural anchorages model C

Prestressing anchorages model C are generally used for civil engineering prestressedstructures. They consist of a circular steel anchor head bearing on a cast-iron trumplate withone or several intermediate spreading rings. They cover a range between 3 and 55 strands T13or T15 (drawings 8 to 16).

Slab anchorages model F

Prestressing anchorages model F are generally used for prestressing thin elements (e.g.concrete floor slabs and walls) and consist of a one-piece casting which combines theanchorage block and the trumplate. It is available for prestressing units with 1, 3 or 4 strandsT13 or T15 (drawings 20 to 24).

Hoop anchorages model X

The Freyssinet hoop anchorage consists of a casting bearing against the circular structurewhich serves as anchorage to the two ends of one or two hoops:

The 1 X anchorage is used to make one prestressing hoop, with radius of up to 27,5 m(drawing 25),

The 2 X anchorage is used to anchor two hoops, each wrapped once or twice aroundthe structure, with radius of up to 5,5 m (drawing 26).

B.1.1.2 External passive anchorages

When anchorages are said external passive they will not allow fitting of a tensioning jackbut are nevertheless accessible during the tensioning operation. This kind of anchorage ismade out of stressing anchorages in which the wedges have been pre-blocked, without

protruding tendon length for tensioning. They can be inspected during tensioning. TheFreyssinet denomination for these types is identical to that of stressing anchorages.

Anchorages are said embedded or internally fixed when incorporated in concrete of structure.These NB designated anchorages use swages to ensure fixing of strand ends (drawings 3 to 5)on a model C anchor head fitted with cylindrical holes and seated on a tromplate. They can beused for units ranging from 1 to 55 strands T13 or T15 (drawing 19).

B.1.1.3 Fixed CouplersCouplers connect two tensile elements that are tensioned one after the other in two separateconcreting phases

Coupler CI

It consists of individual type P strand connectors (see paragraph B.1.1.4 below) connectingeach strand of the primary tendon to its counterpart in the secondary tendon (drawing 17). It isused for prestressing units with 1 to 37 strands T13 or T15.

The reinforcement in the deviation zone has to be calculated by the designer.


8/90



B.1.1.4 Movable couplers CM

Movable couplers CM connect two tensile elements which are tensioned simultaneously in asingle operation. Strands are connected together with a type P individual strand connector;strand connector positions are offset in the case of multistrand units.The connector consists of a cast-iron body to receive two anchorage wedges and serves toconnect two sections of a tensile element. Two models are available:

strand connector P 13 is used with T13 and T13S strands (drawing 7), strand connector P 15 is used with T15 and T15S strands (drawing 6).

Movable couplers are used for prestressing units with 1 to 37 strands T13 or T15(drawing 18).

The length of the coupler resevation is obtained by the formula L = M + U, where U is theconnector displacement including provision for stressing tolerance according to nationalregulations and M is a fixed dimension depending on the tendon type including necessary

installation tolerance given in the table of relevant drawings.

B.1.1.5 Tables : anchorage models and ETA-covered units

TypeNumber of strands T13 or T15Anchorage

model1 2 3 4

A F x x xX x x

AD X x xNB F xCI F x x x

CM F x x x

Table 1. Low-Capacity Anchorages

For definition of symbols, see E.1 below

Number of strands T13 or T15Type

Anchorage

model 3 4 7 9 12 13 19 22 25 25C 27 31 37 55

A x x x x x x x x x x x x x xAD x x x x x x x x x x x x xNB C x x x x x x x x x x x x x xCI x x x x x x x x x x x x x

CM x x x x x x x x x x x x x

Table 2. High-Capacity Anchorages

B.1.1.6 Other Components

Prestressing units of Freyssinet kit require different components, some of them beingcommon to several models.

- Ducts, used to isolate, guide and protect tensile elements (see section G.2).


9/90



- Connecting accessories may be improved by plastic adhesives, heat-shrink sleeves ormastic.

- Injection materials for anchorages and ducts, such as cement grout, grease and wax.

- Tubes or specific elements for deviation of external cables at given locations in thestructure. These deviators are generally made out of steel plain pipes. The specificelements may include reservations inside the concrete reinforcement or construction steelsaddles to obtain the cable deviator.

- Bursting steel reinforcement, for the concrete confinement at anchorages and deviators, tocomplete the general structural reinforcement and ensure prestressing force transfer.

- Specific accessories to facilitate cable placing and stressing, tendon grouting, de-tensioning and replacement of tendon, such as vents, duct drainage, tendon supports,

temporary and permanent protection caps of anchorages and couplers, coupling elementsbetween duct sections and for duct connection to anchorages.

Following components are covered by national or European provisions:- prestressing steels,- steel corrugated sheath,- steel or plastic pipes or tubes,- grouting products,- bursting reinforcing steel.

For this reason, these components are not described in this ETA. However, they can be usedfor the prestressing kit.

B.1.2 Intended Use

The prestressing kit described in this ETA can be used for new structures, for repair andreinforcement of existing structures with following basic categories of use:

Internal bonded tendon for concrete and composite system Internal unbonded tendon for concrete and composite system External tendon for concrete structures with a tendon path situated outside the cross-

section of the structure but inside its envelope.

The prestressing kit described in this ETA offers additionally optional categories of use forwhich standard tendon characteristics are improved. These options are as follows:1. restressable tendon (external or internal),2. exchangeable tendon (external or internal),3. tendon for cryogenic applications,4. internal bonded tendon with plastic ducts,5. encapsulated tendon,6. electrically isolated tendon,7. tendon for use in structural steel or composite construction as external tendon,8. tendon for use in structural masonry construction as internal or external tendon,9. tendon for use in structural timber construction as internal or external tendon.


10/90



PT-anchorage zones have to be designed to resist 1,1 Fpk according to the relevant Eurocodein case of use with other materials than concrete.

The prestressing kit described in this ETA can be used in any type of structure and is usedmore frequently in:

bridges (superstructures, piers, abutments, foundations), buildings (floors, foundations, core walls, walls, columns, shear walls, lateral load

resisting frames, foundations), reservoirs (walls, slabs, roofs), silos (walls), nuclear containment structures, offshore structures (all parts), floating installations and platforms (all parts), retaining walls, dams,

tunnels (longitudinal and transverse/hoop tendons), large diameter pipes, roads and airports.

Categories of Use

ModelC

FixedCoupler

s

CI

Movable

CouplersCM

ModelF

ModelX

ModelNB

Bonded Internal Tendon for Concreteand Composite Structures 3 to 55 1 to 37 3 to 37 1 to 4 1 to 2 1 to 55

Unbonded Internal Tendon forConcrete and Composite Structures 3 to 55 1 to 37 3 to 37 1 to 4 1 to 2

External Tendon for Concrete andComposite Structures 3 to 37 1 to 37 1 to 2

Options

(a) Restressable Tendon 3 to 55 1 to 4 1 to 2(b) Replaceable Tendon 3 to 55 1 to 4 1 to 2(c) Tendon for Cryogenic

Applications

3 to 55

(d) Bonded Internal with PlasticDuct

3 to 37 1 to 37 3 to 37 1 to 4 1 to 2

(e)Encapsulated Tendon 3 to 37 1 to 37 3 to 37 1 to 4 1 to 2(f) Electrically Isolated Tendon 3 to 37 3 to 37 3 to 37(g) External Cable for Steel orComposite Structures 3 to 37 1 to 2

(h) Internal/External Tendon forMasonry Structures 3 to 37 1 to 4 1 to 2

(i) Internal/External Tendon forTimber Structures 3 to 37 1 to 2

Table 3. Anchorage Models for Basic and Optional Categories of Use


11/90


12/90


English translation 2006.12.08 12/50

NotesStandard Anchorage as per typical drawings, Isolated Anchorage: interposition of isolatingliner and seal inside trumplate and at contact to anchor block

Cachetage: see drwg 29, Cap: see drwg 30, Extended Cap: see drwg 31Duct out of Steel or Plastic: Corrugated or Smooth, unless otherwise marked.[1]Corrugated duct only[2]Smooth duct only[3]References given to drawings are not exhaustive[4]e.g. see drwgs 8, 9, 17, 18, 19, 20, 21, 22, 27, 29[5]e.g. see drwgs 8, 17, 18, 19, 20, 21, 22, 23, 27

B.1.3 Working Life

The provisions made in this ETA are based on an assumed intended working life of the PTSystem of 100 years. The indications given on the working life can not be interpreted as aguarantee given by the producer or the approval body, but are to be regarded only as a meansfor choosing the right products in relation to the expected economically reasonable workinglife of the structures.

B.2 CHARACTERISTICS OF PRODUCTS AND VERIFICATION METHODS

B.2.1 Characteristics of Products

Chapters E to K of this ETA, including drawings attached to it, detail the characteristics ofproducts.

B.2.2 Verification Methods

The assessment of the aptitude of the kit for its intended use, in relation to the requirementsfor mechanical resistance and stability in the sense of the Essential Requirement 1 has beenmade in compliance with the Guideline for European Technical Approval (ETAG 013) ofPost-Tensioning Kits for Prestressing of Structures. Performances examined in conformityto the ETAG 013 satisfy the pertinent essential requirements. These are mainly performancesrelated to static load, transfer on concrete and resistance to fatigue. Methods for check,

evaluation and assessment of aptitude for use and test procedures according to those detailledin ETAG 013.

Assessment of experience gathered and specific tests were realised in conformity toETAG 013 for optional use categories listed in paragraph B.1.2.

B.2.3 Emission of Dangerous Substances

According to the manufacturer declaration the post-tensioning kit does not contain anydangerous substances.


13/90



In addition to the specific clauses relating to dangerous substances contained in the ETA,there may be other requirements, applicable to the products falling within its scope (e.g.transposed European legislation and national laws, regulations and administrative provisions).In conformity with the provisions of the European directive 89/106/EEC, these requirementsmust also be complied with wherever they apply.

B.3 EVALUATION AND ATTESTATION OF CONFORMITY AND CE MARKING

B.3.1 Attestation of Conformity System

According to the decision 98/456/EC of the European Commission6 the system 1+ ofattestation of conformity applies and is defined as follows :

Tasks of the Manufacturer1. Factory production control,2. further testing of samples taken at the factory by the manufacturer in accordance with a

prescribed test plan.

Tasks of the Approved Body (Certification Body)

3. Initial type testing of the product,4. initial inspection of factory and of factory production control,5. continuous surveillance, assessment and approval of factory production control,6. audit testing of samples (see ETAG013, section 8.1 (b)).

Note: Approved bodies are also referred to as notified bodies.

B.3.2 Responsabilities

B.3.2.1 Tasks of the Manufacturer

The manufacturer of the kit has the full responsability of the production and quality ofcomponents whether produced by himself or by sub-manufacturers.

The type and frequency of checks and tests conducted during production and on the finalproduct as part of the continuous internal production control are described in the prescribedtest plan, Chapter C of this ETA.

All the tests are conducted according to written procedures, by means of adequate calibratedmeasuring devices. Results are recorded logically and systematically.

If test results do not comply, the produced lot is inspected in detail. It may be rejected,completely or partially. Defectuous parts may be retreated in order to eliminate defects andchecks and tests are then repeated.

Products non complying with the ETA are marked and separated from complying products.

6Official Journal of the European communities L201/112 of 3 July 1998


14/90



Each main component has a prescribed inspection plan, established by Freyssinet and appliedby its manufacturers. Production control methods are defined in the Freyssinet QualityAssurance Plan PAQ ATE PRE.

B.3.2.2 Tasks of the Certification Body

Methods of surveillance for production control are defined in the Quality Assurance Planestablished and updated by Freyssinet, in conformity with paragraph 8.2.2 of ETAG.

The main production centre is checked at least once a year by the Certification Body. Eachcomponent producer is checked at least once every five years by the Certification Body.

The Certification Body checks inspection results, control tests as well as results of productioncontrol results and establishes the conformity to the ETA.

Corrective measures are taken by the Manufacturer when defects have been met. These

measures are: corrective intervention, following the notification of the Certification Body, control strengthening and higher test frequence, setting-up of modifications.

During continuous surveillance auditing, the Certification Body takes samples to test inindependent laboratories. Samples are taken according to the requirements of the tableattached in the chapter D of this ETA.

During the certificate validity the ETA holder supplies once a year to the Certification Bodyanchorages and strands necessary for a test series according to Annex E of ETAG 013 and

sends them to the laboratory designated by the Certification Body. These well-identified partsand reinforcement are from the same construction site. If possible construction sites arechosen in such a way that the tensile steel manufacturer will be different from year to year.

B.3.2.3 CE Marking

The CE marking must comply with the European Council Directive 89/106/CEE, and to theEC guideline "D" related to the marking. The delivery bill accompagnying the PT kitcomponents shall bear the conformity CE marking symbol and the following mentions:

1. Name and address of kit manufacturer,

2. Last two digits of the year during which the marking has been made,3. Number of conformity certificate,4. Number of ETA,5. See information on ETA,6. Number of Certification body,7. Product Identification (commercial denomination) and use category(ies).

All other information must be clearly distinct from the CE marking and the related mentions.


15/90



B.4 ASSUMPTIONS UNDER WHICH THE FITNESS OF THE PRODUCTS FOR THE

INTENDED USE WAS ASSESSED

The ETA is issued under the following assumptions:

B.4.1 Manufacture of Product

The ETA is issued for the Freyssinet post-tensioning kit on basis of information anddocuments submitted by Freyssinet to Stra, with identification of product tested andassessed. Any modification of characteristics of product or factory production process whichmight modify the conformity of the kit shall be notified to the Stra prior to its application.The Stra will decide if this modification affects the ETA and if a more detailled assessmentor amendment of ETA are required.

A Quality Assurance Plan related to the prestressing kit ETA is established and regularlyupdated by Freyssinet ; it is made available to the Stra. A list of sub-contractors and

component suppliers is part of this Quality Assurance Plan.

Freyssinet is committed to impose the requirements of the present ETA and ETAG 013 uponthe producer of his prestressing kit, as well as upon his subcontractors and suppliers.

B.4.2 Installation Design and Execution

B.4.2.1 Design of Structures

The Freyssinet prestressing kit is fit for use in structures designed properly.

The designer of the structure is assumed to respect specifications set by applicable standards,e.g. Eurocodes or equivalent applicable national standards, and to adapt his design inaccordance with the construction methods foreseen and the instructions of the ETA holder.

The arrangement of anchorages shall respect the specifications of chapter J as to edge and axisdistances and bursting steel.

B.4.2.2 Stressing equipment

Stressing jacks shall be calibrated in conformity with Freyssinet procedures, national

regulations of Member States and the provisions of ETAG 013 7.3.

B.4.3 Components not detailed in the ETA

Following components, not detailed in the present ETA, conform European standards orequivalent applicable national standards or regulations:

Prestressing steel : prEN 10138 Monostrands : ETAG 013 Annex C1, XP A 35 037 Steel corrugated sheaths : EN 523 Steel pipes: prEN 10255, ISO 4200, EN 10216-1, EN 10217-1 Smooth plastic pipes: prEN 12201 Cement grout: EN 445, EN 447 Bursting steel: prEN 10080, EN 10025


16/90



B.5 INDICATIONS TO THE MANUFACTURER

B.5.1 Packaging, transport and storage

It is recommended to apply a temporary protection to prestressing steels and steel components

of the kit to prevent corrosion during transport from production factory to the site.

Transport and handling of prestressing steel and steel components of the kit shall be done insuch a manner as to avoid any mechanical, chemical or physical damage.

Prestressing steels and steel components shall be stored free from humidity. Plasticcomponents and ducts shall be protected from UV radiation.

Prestressing steels and steel components shall be protected or kept away from welding areas.

B.5.2 Recommendations for safety

The specialist company shall establish a Unique Document in conformity with the GuidanceDirective 89/391/CEE dated 1989.06.12, identifying and analysing recurring risks bound toinstallation of prestressing. The technician in charge of the prestressing works shall modifythis Unique Document to account for the particular and not recurring risks of his working site.

During stressing, standing behind or immediatly close to a jack is strictly forbidden, as well asbehind a passive anchorage while stressing at the other end. Wherever necessary, safety railsshall be installed and passing zones for personnel shall be kept free.

B.5.3 Use, maintenance and repair

Durability of prestressed structures requires an adequate periodic inspection. Since anydisorder in the structure may result in damage of PT tendons, a specialist company shouldrepair as soon as possible according to adequate procedures.


17/90



C PRESCRIBED TEST PLAN

The following table summarises the test procedures necessary to ensure that all kitcomponents meet the ETA specifications. Stra has adapted Table E.1 of ETAG 013according to the importance of the components for the performance of the Freyssinet PT-system.

1 2 3 4 5 6

Component Item Test/Check

Traceability4

Minimumfrequency

Documentation

Bearing plate material 7 check bulk 6 100 % "2.2" 1, 6

detailed

dimensions5test 3 %

2 specimen

yes

visual inspection3 check 100 % no

Trumplate material 7 check full 100 % "3.1"2

detaileddimensions5

test 3 %2 specimen

yes


Anchor head/block material 7 check full 100 % "3.1" 2

detaileddimensions5

test 5 %2 specimen

yes

visual inspection3 check 100 % noCast iron anchor parts material 7 check full 100 % "3.1" 2

for anchorages andcouplers

detaileddimensions5

test 5 %2 specimen

yes


Wedge material 7 check full 100 % "3.1" 2

treatment, hardness test 0,5 %2 specimen

yes

detailed

dimensions5

test 5 %

2 specimen

yes


Swage material 7 check full 100 % "3.1" 2

detaileddimensions5

test 5 %2 specimen

yes


continued next page


18/90



1 2 3 4 5 6

Component Item Test/Check

Traceability4

Minimumfrequency

Documentation

Duct material 7 check CE2 100 % yes


Tensile element material 6 check full 100 % yes

diameter test each coil no

visual inspection3 check each coil no

Constituents of filling cement 7 check full 100 % yes

material as per EN 447 admixtures,additions, 7

check bulk 100 % yes

Monostrand, Annex C.1 material

6

check full 100 % "3.1"

2

Plastic pipe, Annex C.2 material 7 check full 100 % "3.1" 2

Plastic duct, Annex C.3 material 7 check full 100 % "3.1" 2

Special grout, Annex C.4.3 material 7 check full 100 % "3.1" 2

Liasealcoupler material 7 check full 100 % "2.2" 1

detaileddimensions5

test 3 %2 specimen

yes


1 "2.2" : Test report type "2.2" according to EN 102042 "3.1" : Inspection certificate type "3.1" according to EN 102043 Visual inspections means e.g.: main dimensions, gauge testing, correct marking or labelling, appropriate

performance, surface, fins, kinks, smoothness, corrosion, coating, etc., as given in the prescribed test plan4 full : full traceability of each component to its raw material.

bulk : traceability of each delivery of components to a defined point.5 detailed dimensions mean measuring of all dimensions and angles according to the specification as given in

the prescribed test plan6 conformity to applicable national provisions in absence of relevant EN.7 material checks are included for information only as these are not part of the prescribed test plan.


19/90



D BASIC ELEMENTS OF AUDIT TESTING

Component Item Test/Check Sampling No. ofcomponents per visit

Trumplate Material according tospecification

Test / Check 1

for anchorages C Detailed dimensions TestMain dimensions1 Check

Machined anchor block Material according tospecification

Test / Check 1

Detailed dimensions TestMain dimensions1 Check

Cast iron anchor parts Material according to

specification

Test / Check 1

for anchorages F, X, Detailed dimensions Testor strand connector P Main dimensions1 CheckWedge, swage Material according to

specificationTest / Check 3

Heat treatment(if applicable)

Test 2

Detailed dimensions Check 1Main dimensionsSurface hardness

Test 5

Visual Inspection1 Check 5

Single tensile elementtest

Single tensile element testaccording to Annex E.3

Test 1 series

All samples taken at random and clearly identified.

1 visual inspection relates to main dimensions, calibration tests, correctness of marking or tag,adequate performing, surface aspect, absence of burrs or faults, absence of cavities, corrosion,coating, etc.


20/90



E PRESTRESSING UNITS AND USE CATEGORIES

E.1 UNITS CODING

Prestressing anchorages are coded as follows: TY n M d PR where:

the first letters TY indicate the anchorage type (function): A: active* internal-prestressing anchorage (*stressing anchorage) AD: active* replaceable external-prestressing anchorage (*stressing anchorage) NB: embedded anchorage with trumplate CI: coupler with individual connectors P CM: movable coupler with individual connectors P

letter n indicates the number of strands in a tensile element;

letters M indicate the model of the stressing anchorage (component): C: structural prestressing F: slab prestressing (one-piece anchorage) X: hoop anchorage

number d indicates the strand diameter category: 13: T13 and T13S strands 15: T15 and T15S strands

letters PR indicate the level of anticorrosion protection: PE: with plastic sheath (generally polyethylene) GI: with sliding individually greased/waxed and sheathed strand (monostrand) EI: with electrical isolation W: with flexible corrosion-inhibiting product injected (generally wax).

E.2 USE CATEGORIES

E.2.1 Bonded Internal Prestressing for Concrete Structures

Internal prestressing units bonded to the concrete consist of bare strands in a thin-wallcorrugated duct made of steel (see G.2.1), plastic (see G.2.2) or smooth steel pipes (see G.2.3)and injected with a cement grout in accordance with EN 447 or Annex C4 of ETAG013.

E.2.2 Unbonded Internal Prestressing for Concrete Structures

Unbonded internal prestressing tendons consist of one of the following types:W units: tensile elements housed in a steel or plastic duct injected with a soft filling

material,


21/90



GI units: tensile elements made of monostrands. Outside the anchorage zones,monostrands are either placed in a round or flat duct injected with cement grout prior totensioning or installed directly in the structure, in accordance with design requirements.Unbonded internal prestressing tendons allow re-stressing and the steel part of tensileelements is replaceable.

A n C 15 W anchorages can be used to make electrically isolated prestressing tendons if themeasures described in paragraph E.2.4 have been taken.

E.2.3 External Prestressing for Concrete Structures

Other than in exceptional circumstances, external prestressing tendons are replaceable and re-stressable, and are one of the following types:

Standard type: with double tube where the tendon passes through the concrete of thestructure, to ensure the independence of the tensile element and its duct from the

structure and to enable extraction. The duct is injected with cement grout. Type W: with a duct injected with a flexible corrosion-inhibiting product enabling the

tensile element to be extracted. Type GI: with monostrands housed in a general duct injected or not with cement grout

before tensioning.

AD n C 15 anchorages can be used to make electrically isolated prestressing tendons if themeasures described in paragraph E.2.4 have been taken.

E.2.3.1 Standard Tendons

Tensile elements are housed in a continuous HDPE plain tube. At anchorages the trumplatesare fitted with a plastic trumpet welded to the tube. A watertight gasket between the two partsallows dismantling.

Where tendons pass through concrete a double casing is realised by means of a second tubeused as a concrete formwork which ensures the independence of the HDPE tube from theconcrete.

The corresponding anchorages are coded AD n C 15.

E.2.3.2 GI Tendons

Tensile elements consist of monostrands grouped together in a plastic duct, injected or notwith cement grout prior to tensioning. The anchorage head is protected by a permanent capfilled either with a soft corrosion protection material fully compatible with that ofmonostrands or injected with cement grout.

The corresponding anchorages are coded AD n C 15 GI.

E.2.3.3 W Tendons

Tensile elements are housed in a continuous HDPE plain tube. At the anchorages, thetrumplates are fitted with a plastic trumpet welded to the tube. A watertight gasket between

the two parts allows dismantling. Double tubing is not necessary to ensure dismantling.


22/90



After tensioning, the tendon is injected with a soft corrosion protection material, such as amicrocristaline petroleum wax. The anchorage head is protected by a permanent cap whichallows the injection of the tendon.

The corresponding anchorages are coded AD n C 15 W.

E.2.3.4 Non-Replaceable External Prestressing Tendons

In this exceptional case, external prestressing tendons consist of anchorages identical to thoseused for bonded internal prestressing tendons. Thin-wall corrugated ducts are prohibited in allexposed sections of tendon. Steel tubes may be used for sections embedded in concrete.

The corresponding anchorages are coded A n C 15.

E.2.4 Common Application Options

Model C internal prestressing anchorages can be used to make prestressing tendons forcryogenic applications.

Freyssinet prestressing anchorages can be used to make prestressing tendons with a watertightcasing when used with a watertight plastic duct, a permanent cap to cover the anchorage headand watertight connections between each section of the casing.

Model C anchorages can be used to make electrically isolated prestressing tendons. Thesetendons consist then of strands housed in an electrically isolating plastic casing comprising in

particular: a plastic trumpet fitted inside the trumplate,

a bearing plate made out of an electrically isolating composite material placed underthe anchor block, a plastic cap.


23/90



Applications Types ModelsCorrosion

Protection

with steel duct -

with plastic duct

ANB - C

CI

C - FC

C - F PE

Bonded

InternalPrestressing

electrically isolated withplastic duct

A - CI - CM C EI

with monostrandsA

NB

C - F - XC - F GI

injection with softprotection material

A C WUnbondedInternalPrestressing


and electrical isolation

A C WEI

injection with cementgrout

C -

with monostrands C - X GI


C W

ExternalPrestressing

electrically isolated

AD

C EI

Table 4. Concrete Structures Use Categories

E.2.5 External Prestressing for Steel Structures and Composite Structures

Model C anchorages are used in the case of steel structures, without the standard load-spreading component (trumplate) which is replaced by a bearing plate of a size in accordancewith the strength of the steel of the structure (see EN 1993 and EN 1994).

E.2.6 Prestressing for Masonry Structures

Model C anchorages are used in the case of masonry structures, without the standard load-spreading component (trumplate) which is replaced by a bearing plate of a size in accordance

with the strength of the masonry of the structure (see EN 1996).

E.2.7 Prestressing for Timber Structures

Model C anchorages are used in the case of timber structures, without the standard load-spreading component (trumplate) which is replaced by a bearing plate of a size in accordancewith the strength of the timber of the structure (see EN 1995).1 F anchorages can be used for timber structures if adequately embedded by means of epoxyresin.


24/90



E.3 PARTICULARITIES OF THE KIT

E.3.1 Possibility of individual tensioning strand by strand

In the case of stressing anchorages for units comprising monostrands, the strands may betensioned either collectively with a multistrand jack, or individually with a monostrand jack,

proceeding in several loading stages, if cement grouted before tensioning.

E.3.2 Measurement of friction coefficient and load transfer percentage from stressing

end to the other

This operation is possible whenever tensioning from both ends is possible.

E.3.3 Adjustment of prestressing load

In the case of prestressing tendons with monostrands (type GI) or injected with a flexiblefilling product (type W), it is possible to adjust the prestressing load at any time duringservice life if tendon overlengths have been maintained. The overlengths are protected by anadequately long protection cap.

E.3.4 Possibility of monitoring prestressing load

When an A n C15(or C13) or AD n C15(or C13) anchorage uses a threaded block, the loadin the tensile element can be monitored with a special ring jack installed between the anchor

block threaded ring and the anchorage trumplate.

E.3.5 Possibility of detensioning

A non-grouted tendon can be detensioned with a monostrand jack and a detensioning stool ifthe strand overlengths have not been cut off.

If the strands have been cut off, the tendon can only be detensioned by heating the wedgeswith a blow torch, one by one. Special precautions must be taken at the other end to containany strand expulsion within special protective systems.

E.3.6 Possibility of re-threading a new tendon after detensioning

Once detensioning has been performed as described in paragraph E.3.5, and on condition thatboth ends can be easily accessed, a tendon can be replaced without demolishing.

In the case of tendons with type CI couplers, this operation is possible only for the primarypart of the tendon, before concreting of the secondary part.

When the prestressing tendon consists of monostrands, each strand can be replaced by astrand of the same sectional area if the alignment of the tensile element is straight or slightlydeviated, and by a strand of smaller sectional area in other cases. When a new strand isthreaded in, a protective product of the same quality as that of the strand replaced must beintroduced into the individual sheath left in place.


25/90



E.3.7 Prestressing tendon allowing for load monitoring, retensioning, and replacement

without damage to the duct

An unbonded prestressing tendon is fitted with a model C anchorage with standard wedgesextended by a clamping length mounted on a common retaining plate (drawing 1). The entire

tendon is retensioned after pulling on the overlength and inserting a special bearing ringadapted to the jack. Detensioning is made possible by the wedge-retaining plate whichprevents wedge assemblies being pulled back into the anchorage when the tendon isdetensioned. Strand overlengths are retained (jack gripping length plus any elongation) andare protected by a special long cap injected with flexible filling material (drawing 33).

E.3.8 Temporary or permanent caps

Caps can be fitted to anchorage types A, AD and NB.

E.3.9 Equitension

In the case of a prestressing unit with model C anchorages, when it is to be ensured that theinitial length of each strand is the same prior to tensioning, a pre-tensioning operation can becarried out with the equitension jack. It has as many tensioning chambers as there are strandsto be tensioned, and takes up any slack in the strands individually.

E.4 FORCES OF PRESTRESSING TENDONS

Maximum forces beneath the anchorage during tensioning, F0, must be taken from standardsor regulations in place of use. Values shown in the following table, comply French regulationswhich are identical to the values recommended by Eurocode2.

The number of strands in a tendon may be decreased either by reducing the number of drilledholes in the anchor block (special order to factory) or by leaving out strands in the anchoragesor couplers. In both cases the strands are placed in the best possible symmetrical manner. The

provisions for tendons with completely filled anchorages and couplers also apply to partiallyfilled ones.


26/90



Tensile Strength(N/mm)

1770 1770 1860 1860 1860 1860

Diametre (mm) 15,3 15,7 12,5 12,9 15,3 15,7

1 196 211 137 148 206 2212 392 421 274 295 412 443

3 589 632 410 443 618 664

4 785 842 547 590 824 886

5 981 1053 684 738 1031 1107

6 1177 1264 821 886 1237 1328

7 1373 1474 958 1033 1443 1550

9 1766 1895 1231 1328 1855 1993

12 2354 2527 1642 1771 2473 2657

13 2551 2738 1778 1919 2679 2878

19 3728 4001 2599 2804 3916 4207

22 4316 4633 3010 3247 4534 4871

25 4905 5265 3420 3690 5153 5535

27 5297 5686 3694 3985 5565 5978

31 6082 6529 4241 4576 6389 6863

37 7259 7792 5062 5461 7626 8192

NumberofStrand

s

55 10791 11583 7524 8118 11336 12177

Table 5. Maximum Force with Stressing Limit Fo= min{0,8 Fpk,0,9 Fp0,1%} acc. Eurocode 2 andprEN 10138-3:2006 (only informative)

F ANCHORAGES

Freyssinet active anchorages are based on the wedge principle and use the Freyssinet C-wedge. Each wedge is anchored in a conical hole of the anchor head, which is either a steel

block for anchorage models C, or a cast iron part for strand couplers and for anchoragemodels F and X. Depending on situations, the anchorage block seats on a cast iron load

spreading part, called trumplate, or on a steel plate for structures other than concrete ones, thedimensions of which depend of the strength of the structure.


27/90



F.1 DESCRIPTION OF ANCHORAGE COMPONENTS

Main dimensions are given on the drawings in Annex K.

F.1.1 Anchorage Wedge

The Freyssinet anchor wedge is a conical one-use wedge, consisting of three matchingwedges held together by a circlip. Two models of wedges are available:- the C13 wedge used with T13 and T13S strands,- the C15 wedge used with T15 and T15S strands.

Its internal diametre is adapted to the strand diameter class: either T15/T15S (C15 wedge), orT13/T13S (C13 wedge).

Anchorage wedges are precision machined from hot-rolled or cold-drawn rods of cement steel

defined by reference to standard EN 10084 and are case hardened. The steel grade is16MnCr5.

F.1.2 Anchorage Swage

Internal fixed anchorages are made with anchor swages made by swaging a tubular sectionenclosing a spiral spring onto each strand using a special Freyssinet jack. There are twostandard versions and a compact version:

- T13D swage is used with T13 and T13S strands- T15D swage is used with T15 and T15S strands

- T15DC compact swage is used with T15 and T15S strands.

Swages are turned from hot-rolled bars of tempered and quenched structural alloy steeldefined in reference to standard EN 10083-1. The used grades are 34CrMo4 and 36CrNiMo4.

F.1.3 Steel Anchor Blocks

F.1.3.1 Model C Anchor Blocks

Model C anchorage heads are circular steel blocks with conical holes cut out of hot-rolledbars. These anchorage blocks have a strength class determined by the nominal ultimate tensilestrength 650 MPa.

It is made from a non-alloy quenched and tempered structural steel, defined by reference tostandard EN 10083-1 (C45).

Note 1: electrically isolated anchorages may be made with blocks of larger dimensions thanthe standard blocks in order to reduce compressive stress on the electrical isolation plate .

Note 2: blocks for type NB embedded anchorages are made with cylindrical holes.

Note 3: when an external thread is necessary for monitoring prestressing load, the anchor

block shall have a larger diameter in order to cut the thread outside the original anchor blocksize.


28/90



F.1.4 Castings for Anchorages

F.1.4.1 Model F and X Anchorages

The bodies of model F and X anchorages are made of spheroidal graphite cast iron defined byreference to standard EN 1563. The grade is EN-GJS-500-7.

F.1.4.2 Individual strand connectors type P

The body of the type P strand connector is made of bainitic spheroidal graphite cast irondefined by reference to standard EN 1564. The grade is EN-GJS-1000-5.

F.1.4.3 Load Spreading Parts or Trumplates

The trumplates of type NB n C15 (or C13), CI n C15 (or C13) and C n C15 (or C13)anchorages are identical to those of type A n C15 anchorages. Trumplates of type

AD n C15 (or C13) differ from those of type A n C15 (or C13) anchorages only in theirinternal shape which allows for placement of a plastic trumpet and a seal.

Trumplates are castings of:- grey cast iron defined in reference to standard EN 1561, for C Models up to size 13C15;

the grade is EN-GJL-250; or- spheroidal graphite cast iron defined in reference to standard EN 1563 above size 13C15;

grade is EN-GJS-500-7.

F.1.4.4 Model C Anchorage Caps

Anchorage caps are generally castings of:- grey cast iron defined in reference to standard EN 1561; the most commonly used grade isEN-GJL-250; or

- spheroidal graphite cast iron defined in reference to standard EN 1563; the mostcommonly used grade is EN-GJS-400-15.

F.1.5 Conditioning and Temporary Corrosion Protection

Except for anchorage wedges, all uncoated components are packaged in sealed containers, arerust-free and slightly oiled.

Anchorage wedges are packaged in white buckets. They are suitably protected againstoxidation. The buckets containing type C15 wedges are colour-coded differently to those oftype C13 wedges.

Optionally, the following reinforced corrosion protection is available:- the anchor blocks of model C anchorages may be corrosion protected by bichromate and

zinc treatment in accordance with standard EN 12329, except for the wedge housings;- the cast-iron anchorage components of model F and X anchorages and the trumplates of

model C anchorages may be zinc coated to a thickness of at least 70 m by the hot-dipprocess in accordance with standard EN ISO 1461, except for the wedge housings;

- the cast-iron anchorage component of the model X anchorage may be coated with

polyamide, except for the wedge housings.


29/90



F.1.6 Characteristics of Plastic Parts

F.1.6.1 Plastic Trumpets

Type AD n C15 (or C13) external-prestressing anchorages are fitted with polyethylene (PE)trumplates.

F.1.6.2 Electrical Isolation Plates

Electrically isolated anchorages are fitted with an electrical isolation plate between theanchorage block and the trumplate. The plate is generally a glass-reinforced thermosettingresin.

F.1.6.3 Plastic Caps

Plastics caps are made from polyolefin.

F.2 RECOMMENDATIONS FOR USE OF ANCHORAGES

Regulations valid at place of use shall be considered.

Bursting steel is fixed to general reinforcing bars at locations given in this ETA.

Tightness at connection between anchorage and duct if realised either by adhesive tape orheat-shrink sleeves. For F anchorage models used with monostrands the sealing betweenanchorage and monostrands is realised by means of a mastic plug.

F.2.1 Stressing Anchorages

Size of anchorage reservation and clearance for placing the stressing jack should be checkedat the design stage (see drawings 34 to 44).

F.2.2 Model X Anchorages

Loop tendons are stressed simultaneously at both ends by means of single-strand jacks (seedrawings 45 and 46).

F.2.3 Anchorages for External Prestressing

Exchangeable external prestressing tendons injected with cement grout are realised by meansof a double duct at deviation or anchoring points : A minimum gap of 10mm between the two ducts is required. External shuttering tube, generally out of steel, Tendon duct, continuous between anchorages (see drawing 14)


30/90



F.2.4 Embedded Fixed Anchorages Model NB

Model NB n C 15 anchorages consist of an anchor block with cylindrical holes and swages.Type T13D swage is used for T13 and T13S strands, and type T15DC for T15 and T15Sstrands.

Swages are realised before concreting and maintained in position with a locking template.F.2.5 Fixed Couplers

The prestressing force of the secondary tendon at the coupler shall not exceed that of theprimary cable.

F.2.5.1 Multi-Strand Couplers Model CI with Type P Strand connectors

The secondary cable is connected to the primary cable by means of type P strand connectors.The complete assembly is covered with an overall cap : at one end the cap is fixed to the primary trumplate. A flexible seal provideswatertightness during concreting and grouting and eliminates possible effort transfer throughthe cap during tensioning of the coupled secondary tendon. at the other end the cap is formed as a trumpet to allow its connection to the second phasecable duct.

F.2.6 Movable Couplers Model CM with Type P Strand connectors

Each strand of the primary cable is connected to the corresponding srand of the secondarycable by means of a type P strand connector. The complet assembly is covered with a capensuring the same functions as the one for fixed couplers. This cap must allow for theelongation of first phase cable and the resulting displacement of strand connectors. In

practice, the cap length is therefore adapted to each case.

F.2.7 Case of Monostrands

When directly embedded in the concrete structure, without overall duct, monostrands arefixed on supports arranged within the general steel reinforcement. In case of large cable unitsexceeding 6 monostrands, monostrands should be arranged in groups of 3, the distance

between each of them being sufficient to allow a correct concreting (see drawing 13).

When monostrands are placed in a general duct (see drawings 10 to 12), the duct is injectedwith cement grout and tensioning is done after the grout has reached a strength of 10 MPa.

When multi-strand anchorages are used, the precise arrangement of strands in the anchor zoneduring concreting or injection of duct is secured by the use of a temporary stuffing box(drawing 32). After removal of the stuffing box, ends of strands are freed from their sheath toreceive the anchor block, to be stressed and injected by grease under pressure.


31/90



F.2.8 Electrically Isolated Tendons

The envelope of electrically isolated tendons consists of plastic ducts with thermo-shrink PEconnections. In particular multi-strand fixed couplers type CI n C 15 EI and movable

couplers type CM n C 15 EI are isolated in a PE or PP cap. An isolating plate is insertedbetween the trumplate and the anchor block before stressing.

G TENSILE ELEMENTS AND DUCTS

G.1 TENSILE ELEMENTS

In absence of European standards on prestressing steel, strands complying with nationalprovisions and with characteristics given in G.1.1 and table 6 shall be used.

G.1.1 Standard Designation of Strands

Tensile elements consist of: Either strands with nominal diametre 12,5 mm or 12,9 mm, tensile strength 1770 MPa

or 1860 MPa, designated respectively Y1770 (or Y1860) S7 12,5 (or 12,9) in theEuropean standard prEN 10138-3, and hereafter named T13 or T13S or more simply

T13, or strands with nominal diametre 15,3 mm or 15,7 mm, tensile strength 1770 MPa or1860 MPa, designated respectively Y1770 (or Y1860) S7 15,3 (or 15,7) in theEuropean standard prEN 10138-3, and hereafter named T15 or T15S or more simplyT15.

These strands may also be ordered according to national standards applicable in the countryconcerned, e.g in France to XPA 35-045-3 standard for bare strands.

Monostrands are covered in France by the XP A 35-037 standard, and designated by S 12,5(or 12,9 or 15,3 or 15,7) 1770 (or 1820 or 1860) A + (Z or ZA) + G + P. The G attribute

means protection with grease and P means sliding, i.e. the strand is free to slide in itsindividual sheath, even embedded in concrete, allowing for its stressing without any bond tothe concrete of the structure.

G.1.2 Maximum Force in Strand

The maximum stressing force F0 at anchorage indicated in the following table for a singlestrand has been calculated in accordance with Eurocode 2. It must be adapted to theapplicable national regulations.


32/90



Tm D S Fpk M Fp0.1% Fo To

MPa mm mm kN kg/m kN kN N/mm

1770 12.5 93 165 0.726 145 130.5 1416

1770 12.9 100 177 0.781 156 140.4 1416

1770 15.3 140 248 1.093 218 196.2 1416

1770 15.7 150 266 1.172 234 210.6 1416

1860 12.5 93 173 0.726 152 136.8 1488

1860 12.9 100 186 0.781 164 147.6 1488

1860 15.3 140 260 1.093 229 206.1 1488

1860 15.7 150 279 1.172 246 221.4 1488

D Nominal diametreFpk Characteristic value of maximum load (equal to fpk.Apin Eurocode 2 or Fmin prEN)

Fp0.1% characteristic value of load at 0,1% elasticity limitFo Indicative maximum force at stressing anchorage: Fo= Min { 0,8 Fpk; 0,9 Fp0.1%}m Nominal mass per metreS Nominal areaTo Tensile stress under FoTm Tensile stress at break

Table 6. Maximum Force at Stressing Anchorage for a Single Strand acc. to Eurocode 2 andprEN 10138-3:2006 (only informative)

G.2 DUCTS

The Freyssinet prestressing kit for post-tensioning may be used with different types of ductdepending the project and the use categories of tendons.

The typical internal diametre of ducts is defined on the drawings in Annex K for eachanchorage model, which may be increased if required by the project specifications or thenational regulations. In the case of prefabricated cables threaded in one operation, the ductinternal diametre may be increased in sections with large deviation curvature to facilitatethreading.

G.2.1 Steel Strip Sheaths

Steel strip sheaths are either circular or oval, generally corrugated to ensure a mechanicalbond with the concrete. The overall external dimensions of steel strip sheaths are about 6 mmlarger than the internal dimensions because of corrugation. This must be taken into account inthe design.


33/90



G.2.1.1 Circular Steel Strip Sheaths

Sheaths are purchased according to prEN 523 standard. There are two categories of sheath:normal or reelable category 1 sheath and rigid category 2 sheath. Rigid sheath reducesthe wobble effect and is stronger, but is less easy to shape (curve) by hand.

Diametre

(mm)25-35 35-45 45-55 55-65 65-75 75-85 85-

100100-130

130-160

Category

10,25 0,25 0,30 0,30 0,35 0,35 0,40 0,40 0,40min.

thickness

of sheath

(mm)Category

20,40 0,45 0,45 0,50 0,50 0,60 0,60 0,60

Table 7. Thickness of Steel Strip Sheaths

Sheath sections are connected together with helical sleeves screwed onto the ends of the

sheaths. The watertightness at connections is obtained by adhesive tape or heat-shrink sleeves.G.2.1.2 Oval Steel Strip Sheaths

Model F tendons are generally used together with oval or so-called flat sheaths. These areoblong sheaths with a stiffening corrugation. Lengths of duct are connected by use of sleevesof the same shape. The watertightness at connections is obtained by adhesive tape or heat-shrink sleeves.

G.2.1.3 Option: Galvanisation

On request and if allowed by the applicable national regulations, the sheaths may be hot-dip

galvanised or zinc-plated.G.2.1.4 Option: Factory-applied LFC Lubrication (Low Friction Coefficient)

On request, crimped sheaths may be made out of soap-lined phosphated steel strip in order toreduce the friction coefficient between strands and duct during tensioning.

G.2.2 Corrugated Plastic Ducts

Plastics ducts may be of high-density polyethylene (HDPE) or polypropylene (PP). Theyconform Appendix C.3 of ETAG 013 and meet the requirements of fib technical bulletinCorrugated plastic ducts for internal bonded post-tensioning.

The ducts may be circular or flat, but are always corrugated to ensure a bond with theconcrete. The overall outer dimensions of a corrugated plastic duct are about 13 mm largerthan its internal dimensions because of corrugation. This must be taken into account in thedesign.

Plastics ducts are sensitive to wear induced by movement of the strands in the duct duringtensioning. Duct thickness is selected in accordance with the severity of the tendon alignment(total length and radii of curvature).

Special precautions must be taken if the temperature of the surrounding concrete is likely toexceed 60C during setting or if the external pressure is likely to exceed 0,5 bar.


34/90



G.2.2.1 Plyduct

The Plyduct sheath is circular, made out of a polyethylene or polypropylene strip. It is2,5 mm thick for duct diameters up to 95 mm and 3,0 mm thick for larger diameters. Sheathsections are connected by a sleeve of the same design as the basic sheath screwed onto thesections to be joined together. Watertightness at connections is obtained by heat-shrinksleeves coated on the inside with a hot-melt resin which are shrunk onto the sheath with a hot-air blower. The dimensions of the heat-shrink sleeves are chosen so as to have a residualthickness of at least 1,5 mm after shrinking.

G.2.2.2 Flat Ducts

Model F tendons can be used with flat plastic sheaths of high-density polyethylene (HDPE) orpolypropylene (PP). Duct sections are connected by a sleeve of the same design as the basicsheath placed onto the sections to be joined together. Watertightness at connections isobtained by heat-shrink sleeves coated on the inside with a hot-melt resin which are shrunkonto the sheath with a hot-air blower. The dimensions of the heat-shrink sleeves are chosen so

as to have a residual thickness of at least 1,5 mm after shrinking.

G.2.3 Smooth Steel Pipes

The steel pipes used as prestressing ducts are generally chosen in compliance with one of thefollowing standards: EN 10305-3 (welded cold-sized tubes), EN 10216-1 (seamless tubes),EN 10217-1 (welded steel tubes) or prEN 10219 (fine-grain steel pipe).

Pipes can be zinc-coated by hot-dip galvanising in accordance with standard EN ISO 1461, ifallowed by the applicable national regulations.

G.2.4 Smooth Plastic Pipes

G.2.4.1 Pipes for External Prestressing

Pipes for external prestressing are made of high-density polyethylene (HDPE) and purchasedin reference to standards EN 12201-1 and 2, without consideration of properties affectingwater quality.

The polyethylene used is PE80 or PE100. Nominal pressure class (table 2 of standardEN 12201-2) is chosen as follows:

Class PN4.0 at least, for injection prior to tensioning of monostrands, Class PN6.3 at least, for injection at ambient temperature, Class PN10 at least, for injection at temperatures exceeding 60C (wax injection).


35/90



For guidance, pipes may be chosen from the following table:

EN 12201-2 PE 80 PE 100

Series Low pressure Pressure Pressure

PN** 6.3 10 10SDR 21 13.6 17Nominal external

diameterThickness Thickness Thickness

(mm) (mm) (mm) (mm)50 3.7* 3.763 4.7* 4.775 5.5* 5.590 6.6* 6.6110 5.3 8.1125 6.0 9.2140 6.7 10.3160 7.7 11.8180 8.6 10.7200 9.6

SDR: ratio of external diameter to nominal wall thickness* these pipes have not standardised dimensions** PN values are based on a global service factor C = 1.25

Table 8. Dimensions of Smooth HDPE Tubes

Ducts for external prestressing are delivered in straight lengths. The most common lengths are6 and 12 m. Lengths of pipe are connected by mirror welding or by means of polyethylenesleeves electro-welded.

G.2.4.2 Indented Pipes for Hoop Tendon Anchorages

Hoop prestressing tendons are used with continuous polyethylene or polypropylene pipes,generally extruded and supplied on reels. These pipes are smooth or indented for centering thestrand in its duct.

G.2.5 LiasealDuct Connector

The Liaseal

duct connector is a polyolefin component providing a sealed connectionbetween lengths of duct that is used in the construction of precast concrete segments forbridge construction (drawing 27). Used in conjunction with the Plyductduct, the Liaseal

connector makes a continuous, leakfree plastic duct crossing the match-cast joints betweensegments.


36/90



G.3 CABLE LAY-OUT

G.3.1 Alignment at Anchorage

Close to anchorages the duct must guide the tensile element so that its strands bear against thedeviation zone of the trumplate and enter the holes in the anchorage head at the correct angle:in practice the cable lay-out must be straight on a length of at least 6 times the duct internaldiametre, between the trumplate end and the start of the curved section.

G.3.2 Curvature Radii

G.3.2.1 Internal Prestressing

In the absence of more restrictive national specifications, the minimum curvature radius isdefined as follows:

Stand Type Duct TypeMinimum Curvature

Radius

steel 100 x internal diametre 2, 3Flat ductPlastic 100 x internal diametre 3

Steel 100 x internal diametreCircular ductPlastic 100 x internal diametre

Bare Strand

Tube Steel 3,0 mStrands directly

incorporated in concrete

(in group of three strandsmaximum) or placed in aduct injected with cementgrout before tensioning

Deviation 1,7 m for T13

1

2,5 m for T15 1

Deviation 2,5 m

Monostrand

Single strandDead anchorage

(180 hoop)0,6 m

1according to ENV 1992-1-5:19942concrete stability against splitting to be checked and simultaneous stressing at both ends3flat duct dimension in the considered direction

Table 9. Minimum Curvature Radius for Internal Prestressing

In the case of bonded prestressing, the minimum radius of steel tubes can be reduced down to20 times the internal diameter, assuming that:- the resulting radius is not less than 1,1 m for T13 strands and 1,3 m for T15 strands,- the tensile stress does not exceed 70% of strand guaranteed tensile strength where the

radius is less than 3,0 m,- the sum of angular deviations along the cable is less than 3/2 radians,- the sharply curved zone is considered as a dead anchorage if the angular deviation exceeds

/2 radians.


37/90



G.3.2.2 Removable External Prestressing

In the absence of more restrictive national specifications, the minimum curvature radius indeviators, normally made out of curved steel pipes, is defined as follows:

TendonMinimum Curvature

Radius at Anchorages

Minimum Curvature

Radius in Deviators

7C15 3,0 m 2,0 m

12C15 3,5 m* 2,5 m*

19C15 4,0 m* 3,0 m*

27C15 4,5 m 3,5 m

37C15 5,0 m* 4,0 m

* : according to ENV 1992-1-5:1994

Table 10. Minimum Curvature Radius for External PrestressingG.3.3 Support Distances and Tolerances

The maximum distance between duct supports is 1,0 m for straight sections or with highcurvature radius and 0,5 m for sections with small radius. In the case of smooth steel pipes, atleast one support at each elementary length shall be placed but the distance shall not exceed3 m.

Any axial thrust along the pipe must be balanced by appropriate arrangements at the bottomof the formwork. Similarly, the spacing of supports and the attachment of the duct must take

account of the buoyancy effect in fresh concrete.Flat ducts are more sensitive to accidental crushing before tendon threading than circularducts. For this reason the tendons should be threaded into the duct before concreting. If it isnot possible to thread the tendons before concreting, measures must be taken to protect theduct from crushing, or the ducts must be threaded with temporary dummy strands whichwill be removed before the real tendons are threaded.

When ducts cross over each other in layers, contact between ducts should be avoided, and itmay be advisable to strengthen the area of intersection with a half-sleeve in order to preventany risk of communication between ducts during cement grouting.

In the case of corrugated plastic sheaths, a plastic half-shell must be placed between the ductand its support in all areas where tendon is deviated.

For monostrands directly incorporated in concrete, sheath punching at support must bechecked.

The tolerance on the position of tendons in concrete parts must meet the requirements of draftstandard ENV 13670-1. Special attention must be given to tendon breakout induced bydeviated cables near an outside surface: the local positioning tolerance will have to bedetermined in accordance with the lay-out of the passive reinforcement.


38/90



H TENSIONING

H.1 TENSIONING EQUIPMENT

Freyssinet equipment is covered by an EC declaration of conformity for new or rentalequipment.Clearance for jacks at tensioning end must be made available in accordance with drawings 34to 46. This clearance must remain available during service life of the structure if forceadjustment, load monitoring or replacement of tendon has been foreseen.

H.2 PARTICULAR RECOMMENDATIONS

H.2.1 Tendons with Couplers

Tensioning of secondary cables shall be such as to avoid the force at coupler end to exceedthat of the primary cables after blocking.

H.3 RECOMMENDATIONS FOR TENSIONING AND CONTROL

H.3.1 General Method for Tensioning

Tensioning is done in accordance with the Freyssinet procedures, the specifications ofETAG 013, CWA 14646, ENV 13670-1 and applicable national regulations.

H.3.2 Measurements of Stressing Forces

Force readings must take into account calibration of tensioning equipment and losses due tofriction in anchorages as given in the following table:

Bare Strands Monostrands

Anchorage Model Min. Max. Min. Max.

3 to 13 C 15 2 % 3 % 1 % 2 %

19 to 55 C 15 and 25 CC 15 2,5 % 3,5 % 1 % 2 %

1 F 13/15 1 % 2 % 0 % 1 %

3 to 4 F 13/15 1 % 2 % 1 % 2 %

1 to 2 X 15 1 % 2 % 0 % 1 %

* tensioning using jack with curved front adaptor-fitting

Table 11. Friction Loss in Anchorages


39/90



I PROTECTION OF TENDONS

I.1 LUBRICATION AND TEMPORARY PROTECTION

Temporary protection of tensile elements is obtained by factory-applied soluble oil.If storage of strands on site is longer or if tendon injection cannot be done in due time aftertensioning (delay exceeding four weeks), this temporary protection must be regularlyrenewed, in conformity with applicable specifications. This lubrication may also be used toreduce friction coefficient of cable inside duct.

I.2 FILLING MATERIALS USED

I.2.1 Cement Grout

Cement grout is a stable, uniform mix of Portland cement, additives and water obtained by amechanical mixing process. It is screened and kept agitated in a storage tank until injectedinto the duct.

Freyssinet prestressing tendons can be injected with: either a common grout complying with the requirements of European standards

EN 447 (requirements for common grout) and EN 445 (test methods). The groutsetting can be retarded to provide a longer groutability,

or a special grout, as per the requirements of paragraph C.4.3 of ETAG 013.

I.2.2 Wax

The wax for injecting prestressing tendons shall be a petroleum wax meeting the requirementsof paragraph C.4.2 of ETAG 013.

I.2.3 Grease

The grease for Freyssinet prestressing tendons shall be a mineral-oil-based grease meeting therequirements of paragraph C.4.1 of ETAG 013.

I.3 INJECTION EQUIPMENT

Mixers, wax melting units, and pumps supplied by Freyssinet for injecting tendons are allsubject to an EC declaration of conformity with the applicable regulations governing new orrented equipment.


40/90



J MECHANICAL AND GEOMETRICAL CONDITIONS OF USE

J.1 FRICTION LOSSES AND ELONGATIONS

J.1.1 Friction in Tendons

The coefficients of friction () and of wobble (k), as defined in European standardpr EN1992-1-1 to obtain the prestressing force with the equation P(x) = Pmaxe

-(+kx), vary inaccordance with uses (internal or external prestressing, standard strands or monostrands), thetype and stiffness of ducts (steel or HDPE strip sheath or pipe), surface treatments, lubricationof the strands, whether with soluble oil or grease.

The acceptable variation of the coefficient of friction is usually 25%. The coefficient of

friction can rise significantly in deviation zones with a curvature radius less than 6 metres.The coefficients in the following table are for information only (and must be adapted to eachproject).

Friction Coefficient(rad

-1)Use Duct Type

Lubricated

Strand

Unlubricated

Strand

Wobble factor k

(rad/m)

Corrugated steel sheath 0,17 0,191 0,0071

LFC3Corrugated steel

sheath 0,10 0,12 0,0071

Corrugated plastic sheath 0,10 0,12 0,0071Internal

Prestressing

Steel pipe 0,16 0,24 0,0071

HDPE pipe 0,10 0,12 0ExternalPrestressing

Steel pipe 0,16 0,24 0

Single Monostrands 0,052 0,0072Unbonded

InternalPrestressing

Group of Pre-GroutedMonostrands

0,05 0,012

1 as per standard EN 1992-1-1: 2004

2 as per standard ENV 1992-1-5: 1994

3 Freyssinet phosphated duct

Table 12 Friction and Wobble Coefficient


41/90



J.1.2 Parameters for Evaluation of Elongation during Stressing

J.1.2.1 Pull-In at Wedge Blocking

At end of stressing the jack is released and the wedges are pulled-in into the anchorage blockto anchor the strands. Freyssinet jacks can allow a hydraulic blocking to reduce the pull-in

amount.

The elongation loss with or without hydraulic blocking shall be accounted for in tensioningcalculations by using the values given in the following table.

Stressing Jack with hydraulic blocking without hydraulic blocking

Strand diametre T13 T15 T13 T15

min 4 4 6 6

mean 5 6 7 8Pull-in atstressing

anchorage

mmmax 6 8 8 9

Table 13 Wedge Pull-In at Stressing Anchorages

J.1.2.2 Pull-In at Passive Anchorages

The pull-in value at passive anchorage creates a translation of the cable and increases theelongation at stressing end. This value must be deduced from the measured elongation at each

stressing step.The mean pull-in values at passive end are:

T13 strand: 5 mm, T15 strand: 6 mm.

J.1.2.3 Pull-in within Type P Coupling Units

The mean pull-in values within strand connectors are as follows: T13 strand: 10 mm, T15 strand: 12 mm.

J.2 GEOMETRICAL CONDITIONS OF USE

J.2.1 Clearance behind Anchorages

Behind each anchorage a clearance must be reserved to allow for: Installation of wedges, Placing of stressing jack, Sufficient protection cover of cable end after cutting-off of strand overlengths, Installation of temporary or permanent cap, if necessary.


42/90



In the case of an active anchorage the necessary clearance for jack placing and actioning isdescribed in the drawings given in Part K thereafter.

For external passive anchorages a minimal clearance of 500 mm allows the installation ofwedges on protruding strands.

J.2.2 Lateral Cover and Distances

Anchorages must have a sufficient edge distance and be separated from each other by aminimum centre distance. These distances are derived from reference dimensions a and b ofthe test specimens.

In what follows, it is considered that anchorages are positioned relative to two orthogonaldirections x and y, with the smaller dimension of the trumplate aligned along axis x.

Notations: A, B: plane dimensions of the trumplate (A B), a, b: side lengths of test specimen (a b), x, y: minimum centre distance between two anchorages in the structure in x- and y-

directions, x, y: minimum edge distance between anchorages and the closest external surface in

x- and y-directions, fcm,o: mean compressive strength measured on cylinder required before tensioning.

Dimensions x and y shall satisfy the following conditions:x A + 30 (mm)y B + 30 (mm)x . y a . bx 0,85 ay 0,85 bx 0,5 x + concrete cover 10 (mm)y 0,5 y + concrete cover 10 (mm)

y y y

x

x

x

x

yy

A

BB

A


43/90



The values of a and b are given in the table below for three different concrete strengths fcm,o.

a = b (mm)

fcm,o(MPa)Unit 24 44 60

3 C15 220 200 180

4 C15 250 220 200

7 C15 330 260 240

9 C15 380 300 280

12 C15 430 320 300

13 C15 450 340 310

19 C15 530 400 380

22 C15 590 430 410

25 C15 630 460 440

27 C15 650 480 470

31 C15 690 520 500

37 C15 750 580 540

55 C15 1070 750 690

Table 14 Minimum Edge Distances for C-Model Anch

ETA Freyssinet En

Documents

Transcript of ETA Freyssinet En