bbr katalog

8/9/2019 BBR Katalog

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PRESTRESSINGTECHNOLOGY

www.structuralsystems.com.au


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POST-STRESSING TECHNOLOGY

www . s t r u c t u r a l s y s t em s . c om . a u

INTRODUCTION PAGE 03

POST-TENSIONING DESIGN DATA PAGE 04

MULTI-STRAND POST-TENSIONING PAGE 05

SLAB POST-TENSIONING PAGE 17

MULTI-WIRE POST-TENSIONING PAGE 28

BAR POST-TENSIONING PAGE 31

GROUND ANCHOR SYSTEMS PAGE 35

EXTERNAL PRESTRESSING PAGE 38

CABLE STAY SYSTEMS PAGE 40

INCREMENTAL LAUNCHING SYSTEMS PAGE 44

HEAVY LIFTING SYSTEMS PAGE 45

LOAD HANDLING SYSTEMS PAGE 46

Data contained herein is subject to change without notice. Use of information and details presented in this document should

be verif ied by a qualified engineer for suitability to specif ic applications.

Emirates Tower - Dubai


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3www . s t r u c t u r a l s y s t em s . c om . a u

Wandoo Concrete Gravity Structure - Western Australia

INTRODUCTION

Structural Systems is a specialist professional Engineering

and Contracting Company, which provides innovative

skills and services to the Construction and Mining

Industries both nationally and internationally. Operations

commenced as BBR Australia Pty Ltd in 1961 and

became the public company, Structural Systems Limited

in 1987.

Our innovative design, advanced construction techniques

and effective project management skills make Structural

Systems the leader in the design and installation of

prestressing systems.

The wide range of services and systems offered in

this brochure are readily available through our network

of offices and a Structural Systems representative is

available to talk directly to you regarding your project.

Eleanor Schonell Bridge - Queensland


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4

PRESTRESSING TECHNOLOGY


POST-TENSIONING DESIGN DATA STRAND PROPERTIES

STANDARD NOMINALDIAMETER

mm

STEEL AREA

mm2

MASS

kg/lm

STRANDMBL / Fm(7)

kN

MIN. PROOFLOAD

kN

STRANDRELAXATION(6)

(%)

MODULUS OFELASTICITY

MPa

AS 4672(1)12.7 super

15.2 super

15.2 EHT

100.1143.3

143.3

0.7861.125

1.125

184250

261

156.4(4)

212.5(4)

221.9(4)

2.52.5

2.5

180 to 205x103

180 to 205x103

180 to 205x103

BS 5896(2)12.9 super

15.7 super

100

150

0.785

1.180

186

265

158.1(5)

225.3(5)2.5

2.5

180 to 205x103

180 to 205x103

prEN 10138-3(3)

15.2 regular

15.7 regular

15.2 super

15.7 super

140

150

140

150

1.093

1.172

1.093

1.172

248

266

260

279

213.0(5)

229.0(5)

224.0(5)

240.0(5)

2.5

2.5

2.5

2.5

180 to 205x103

180 to 205x103

180 to 205x103

180 to 205x103

Notes: • All strands are 7 wire low relaxation steel.

WIRE PROPERTIES

STANDARD NOMINAL

DIAMETER

mm

STEEL AREA

mm2

MASS

kg/lm

WIRE

MBL(7)

kN

MIN. PROOF

LOAD

kN

STRAND

RELAXATION(6)

(%)

MODULUS OF

ELASTICITY

MPa

AS 4672(1) 7 LR 38.5 0.302 64.3 54.7(4) 2.0 195 to 205x103

BS 5896(2) 7 LR 38.5 0.302 64.3 53.4(5) 2.5 195 to 205x103

Notes: (1) Australian / New Zealand Standard AS 4672 Steel Prestressing Materials.

(2) British Standard BS 5896 High Tensile steel wire and strand for the Prestressing of Concrete.

(3) European Standard prEN 10138-3 Prestressing steels - Part 3: Strand.

(4) At 0.2% Offset. Refer AS 4672.

(5) At 0.1% Offset. Refer BS 5896 or prEN 10138-3 as applicable.

(6) Relaxation after 1000 hrs at 0.7 x Breaking Load.

(7) MBL = Minimum Breaking Load (to AS 4672 and BS 5896). Fm = Characteristic Force (to prEN 10138-3).

MAXIMUM JACKING FORCES - RECOMMENDED VALUES

SSL POST TENSIONING SYSTEM STANDARD

AS 3600 BS 8110

BBR CONA MULTI SYSTEM

BBR VT CONA CMI SYSTEM

SLAB SYSTEM

WIRE SYSTEM

BAR SYSTEM

80% MBL

80% MBL

85% MBL

80% MBL

75% MBL

80% MBL

80% MBL

80% MBL

80% MBL

75% MBL

Notes: • In some cases higher or lower jacking forces are permitted by local standards.

• MBL = Minimum Breaking Load of tendon.

PRESTRESSING LOSSES - TYPICAL DATA

SYSTEM BBR CONA MULTI BBR VT CONA CMI SLAB WIRE BAR

ANCHORAGE & JACKING LOSS (%) 2 to 4 0.9 to 1.2 2 to 5 0 to 1 0 to 1

DRAW-IN ALLOWANCE (mm) 6 6 6 2 to 3 1 to 2

D U C T

F R I C T I O N μ Round Steel Duct

Flat Steel Duct

Polyethylene Duct

Greased & Sheathed

0.15 to 0.20

0.10 to 0.15

0.20 to 0.22

0.10 to 0.15

0.15 to 0.200.20

0.10 to 0.15

0.12 to 0.16

0.10 to 0.15

0.15 to 0.20

0.10 to 0.15

0.15

T E N D O N

W O

B B L E β

( k

) r a d / m

Round Steel Duct ≤ 50mm

Round Steel Duct > 50mm

Flat Steel Duct

Greased & Sheathed

0.016 to 0.0240.008 to 0.016

0.0060.006

0.016 to 0.024

0.0160.008 to 0.012

0.008 to 0.016

0.008

Notes: • To reduce excess friction, it may be possible to flush the tendon with water or water soluble oil.

• If the duct or strand has a film or rust or the ducts are full of water, the friction values can increase significantly.


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MULTI-STRAND POST-TENSIONING


Structural Systems have two distinct systems availablefor multi-strand applications. These systems are BBR

Cona Multi, and BBR VT Cona CMI.

BBR CONA MULTI

The BBR Cona Multi has been offered for the last 40

years and is available in standardised tendon sizes

from:

• 7 strands up to 61 strands for 12.7mm and 12.9mm

strand, or

• 4 strands up to 55 strands for 15.2mm and 15.7mmstrand.

The BBR Cona Multi can be used with galvanised steel

and polyethylene ducting. The system is a bonded

system with the ducting being pressure filled with a

cementitious grout.

Standard applications use the M1 range, with the M3

range being used for cryogenic applications, and other

specialist applications. Please consult SSL for details on

which system best suits your applications.

BBR VT CONA CMI

The BBR VT Cona CMI is a revolutionary, state of the art,

bonded, post-tensioning system incorporating world’s

best practice, and is available in standard tendon sizes

from:

• 4 strands up to 61 strands for 15.2mm and 15.7mm

strand.

The system has been granted European Technical

Approval in accordance with the testing procedures

contained within ETAG013 and is CE marked.

These tests included static tests,

fatigue tests, load transfer and

cryogenic tests.

European Technical Approval provides clear independent

review, full and complete system testing to the highest

European standard, quality assurance, and independent

auditing of all systems components. Every product

is tested to the same standards and afterwards an

independent auditor ensures that what is delivered

and installed on site fully complies with that which was

tested.

On completion of the tests, the approval body evaluated

the test results, drawings, specifications and the complete

system. The package was then circulated to all member

states of the EU for ratification.

Copies of the BBR VT European Approval Documents

are available for download from www.bbrnetwork.comand www.structuralsystems.com.au.

The BBR VT Cona CMI has significant advantages over

the BBR Cona Multi as well as significant competitive

advantage over other ETAG approved systems. These

advantages include:

• Less space is required in the anchor zone which

results in less concrete, slimmer structures and less

eccentricity in the anchors.

• Significantly lower concrete strength prior to

stressing resulting in shorter construction cycles.• Less reinforcement in the anchorage zone resulting

in time and cost savings.

European Approval ETA - Testng of Anchor Head

BBR CONA MULTI - M1

BBR VT CONACMI



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6



TECHNICAL DATA OF ANCHORAGES

BBR VT CONA CMI

STRAND SIZE BBR VT CONA CMI

15.2mm / 15.7mm Anchorage Unit

Maximum No. Strands

4064

7067

120612

190619

220622

270627

310631

DIMENSIONS (mm)

Recess - Inner

Recess - Outer Recess Depth

200 x 200

250 x 250130

240 x 240

290 x 290135

295 x 295

350 x 350140

350 x 350

400 x 400160

380 x 380

420 x 430170

430 x 430

480 x 480180

430 x 430

480 x 480185

STRESSING ANCHORAGE RECESS DETAILS

STRESSING AND FIXED ANCHORAGE FIXED COUPLER FK CENTRE AND EDGE DISTANCES

BBR VT Cona CMI (M n f Strs) 4 7 12

STRand mm2 140 150 140 150 140 150

CRoSS SeCTIonal aRea mm2 560 600 980 1050 1680 1800

ChaRaCT. TenSIle STRengTh Rm

MPa 1770 1860 1770 1860 1770 1860 1770 1860 1770 1860 1770 1860

ChaRaCT. MaxIMuM FoRCe Fm

kN 992 1040 1064 1116 1736 1820 1862 1953 2976 3120 3192 3348

BBR VT Cona CMI (M n f Strs) 4 7 12

helIx and addITIonal ReInFoRCeMenT

MIn. ConCReTe STRengTh (Cyl.) fcm.0

MPa 19 23 28 31 35 19 23 28 31 35 19 23 28 31 35

helIx

ouTeR dIaMeTeR mm 180 150 150 150 230 200 200 180 180 330 280 280 260 260

BaR dIaMeTeR mm 14 12 12 12 14 14 14 14 14 14 14 14 14 14

lengTh, appRox. mm 182 181 216 216 232 232 277 277 277 332 332 332 382 282

pITCh mm 50 50 60 60 50 50 60 60 60 50 50 50 50 50

nuMBeR oF pITCheS 4 4 4 4 5 5 5 5 5 7 7 7 8 6

dISTanCe E mm 15 15 15 15 18 18 18 18 18 20 20 20 20 20

addITIonal ReInFoRCeMenT

nuMBeR oF STIRRupS 3 3 4 3 5 4 3 3 4 7 6 5 5 6

BaR dIaMeTeR mm 12 12 10 10 14 14 14 14 14 12 14 16 16 14

SpaCIng mm 60 55 40 50 55 60 65 65 60 60 55 70 65 50

dISTanCe FRoM anChoR plaTe F mm 30 30 30 30 33 33 33 33 33 35 35 35 35 35

ouTeR dIMenSIonS BxB mm 220 200 180 170 290 270 240 230 220 390 350 320 310 290

CenTRe and edge SpaCIng

MIn. CenTRe SpaCIng ac,bc mm 235 215 195 190 310 285 260 250 240 405 370 340 325 310

MIn. edge dISTanCe (pluS C) ’,b

’ mm 110 100 90 85 145 135 120 115 110 195 175 160 155 145

dIMenSIonS oF anChoRageS

anChoR dIaMeTeR D A

mm 130 170 225

anChoR lengTh L A

mm 327 454 627

CoupleR FK dIaMeTeR DFK

mm 185 205 240

CoupleR FK lengTh LFK

mm 945 1152 1435


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7

MULTI STRAND POST-TENSIONING


BBR VT CONA CMI (Max No. of Strands) 19 22 27 31

Strand mm2 140 150 140 150 140 150 140 150

CroSS SeCtional area mm2 2660 2850 3080 3300 3780 4050 4340 4650

CharaCt. tenSile Strength Rm

MPa 1770 1860 1770 1860 1770 1860 1770 1860 1770 1860 1770 1860 1770 1860 1770 1860

CharaCt. MaxiMuM ForCe Fm

kN 4712 4940 5054 5301 5456 5720 5852 6138 6696 7020 7182 7533 7688 8060 8246 8649

BBR VT CONA CMI (Max No. of Strands) 19 22 27 31

helix and additional reinForCeMent

Min. ConCrete Strength (Cyl.) fcm.0

MPa 19 23 28 31 35 19 23 28 31 35 19 23 28 31 35 19 23 28 31 35

helix

outer diaMeter mm 420 360 360 330 330 475 420 360 360 330 520 475 430 420 360 560 520 475 430 430

Bar diaMeter mm 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14

length, approx. mm 457 457 432 432 382 482 482 482 482 382 532 532 532 427 432 532 532 582 467 432

pitCh mm 50 50 50 50 50 50 50 50 50 50 50 50 50 40 50 50 50 50 40 50

nuMBer oF pitCheS 9.5 9.5 9 9 8 10 10 10 10 8 11 11 11 11 9 11 11 12 12 9

diStanCe E mm 27 27 27 27 27 31 31 31 31 31 35 35 35 35 35 35 35 35 35 35

additional reinForCeMent

nuMBer oF StirrupS 7 7 7 7 7 8 7 7 7 8 8 7 7 7 8 8 8 8 8 8

Bar diaMeter mm 16 16 16 16 16 16 20 20 20 16 20 20 20 20 20 20 20 20 20 20

SpaCing mm 65 65 65 65 65 65 75 70 65 55 80 80 75 70 60 85 75 70 65 60

diStanCe FroM anChor plate F mm 42 42 42 42 42 46 46 46 46 46 50 50 50 50 50 50 50 50 50 50

outer diMenSionS BxB mm 490 450 410 390 370 530 480 440 420 400 590 540 490 470 440 630 580 530 500 480

Centre and edge SpaCing

Min. Centre SpaCing ac

,bc

mm 510 465 425 410 390 550 500 460 440 420 610 555 505 485 460 650 595 545 520 495

Min. edge diStanCe (pluS C) ae’,b

e’ mm 245 225 205 195 185 265 240 220 210 200 295 270 245 235 220 315 290 265 250 240

diMenSionS oF anChorageS

anChor diaMeter D A

mm 280 310 360 360

anChor length L A

mm 744 946 1090 975

Coupler FK diaMeter DFK

mm 290 310 390 390

Coupler FK length LFK

mm 1600 1821 2466 2242

TECHNICAL DATA OF ANCHORAGES

Structural Systems has gained certification

from BBR as a ‘PT Specialist Company’

authorised to install the BBR VT Cona CMI

systems and all other BBR ETAG approved

post tensioning systems.

BBR VT CONA CMI

STRESSING AND FIXED ANCHORAGE FIXED COUPLER FK CENTRE AND EDGE DISTANCES


Note: Intermediate and larger sizes available on request.


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8



NO. STRANDS 4 7 12 19 22 27 31

ANCHOR HEADDiameter Ø

A (mm)

Height H A1

(mm)

100

50

130

55

160

65

200

85

225

95

255

105

255

110

COUPLER HEAD K Diameter Ø

K (mm)

Height HK (mm)

18585

20585

24090

29095

310105

390125

390130

NO. STRANDS 4 7 12 19 22 27 31

BEARING TRUMPLATEDiameter Ø

P (mm)

Height HP (mm)

130

120

170

128

225

150

280

195

310

206

360

250

360

250

NO. STRANDS 4 7 12 19 22 27 31

TRUMPET A Diameter Ø

TA (mm)

Length LTA

(mm)

72

230

88

328

127

509

153

580

170

715

191

871

191

757

TRUMPET K Diameter Ø

TK (mm)

Length LTK

(mm)

185539

203640

240730

275775

305840

3751265

3751150

SYSTEM COMPONENT DETAILS

BEARING TRUMPLATE

ANCHOR HEAD COUPLER HEAD TYPE K

TRUMPET TYPE A TRUMPET TYPE K

BEARING TRUMPLATES

ANCHOR AND COUPLER HEADS

PLASTIC TRUMPETS

BBR VT CONA CMI


9/48

MULTI STRAND POST-TENSIONING


TENDON PROPERTIES

Notes: • Table indicates maximum number of strands that can be accomodated by the tendon stressing unit.

• Larger ID ducting should be selected for tendons > 80m, or if strands are installed after concreting, or where tight or extended curvatures occur.

• Plastic sheaths conforming to ETAG013 should be used. Alternatively, corrugated polyethylene ducting may be used if permitted in the local region.

• Refer page 4 for additional design data and details.

• Maximum jacking force is usually 0.8 x MBL.

• For radii of curvature and straight portion diagram refer to BBR CONA Multi System.

STRESSING ANCHORAGE

FIXED ANCHORAGE

FIXED COUPLER FK

TENDON

UNIT

MAXIMUM

STRANDS

NO.

MAXIMUM

STEEL

DUCT ID/

OD

mm

MINIMUM

STEEL

DUCT ID/

OD

mm

MINIMUM RADII

OF CURVATURE

/ MINIMUM

STRAIGHT

PORTION

m

TENDON MIN BREAKING LOAD to prEN 10138-3

kN

15.2 regular 15.7 regular 15.2 super 15.7 super

406706

1206

1906

22062706

3106

47

12

19

2227

31

45 / 5060 / 65

80 / 85

100 / 105

105 / 110120 / 125

130 / 135

45 / 5055 / 60

70 / 75

90 / 95

95 / 100105 / 110

110 / 115

2.0 / 0.84.0 / 0.9

5.2 / 1.0

6.5 / 1.1

7.0 / 1.157.7 / 1.3

8.4 / 1.3

9921736

2976

4712

54566696

7688

10641862

3192

5054

58527182

8246

10401820

3120

4940

57207020

8060

11161953

3348

5301

61387533

8649

BBR VT CONA CMI



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10



BBR CONA MULTI

TENDON PROPERTIES

TENDON UNIT MAXIMUM METAL DUCT TENDON MBL TO AS4672 TENDON MBL TO BS5896

STRANDS ID/OD or prEN 10138-3

No. mm kN kN

Using 12.7mm strand Using 12.9mm strand

705 7 50 / 57 1288 1302

1205 12 70 / 77 2208 2232

1905 19 85 / 92 3496 3534

3105 31 105 / 112 5704 5766 4205 42 120 / 127 7728 7812

6105 61 150 / 157 11224 11346

15.2mm/15.2 EHT strand 15.7mm BS / 15.7 EN strand

406 4 50 / 57 1000 / 1044 1060 / 1116

706 7 65 / 72 1750 / 1827 1855 / 1953

1206 12 80 / 87 3000 / 3132 3180 / 3348 1906 19 100 / 107 4750 / 4959 5035 / 5301

2206 22 110 / 117 5500 / 5742 5830 / 6138

3106 31 120 / 127 7750 / 8091 8215 / 8649

4206 42 135 / 142 10500 / 10962 11130 / 11718 5506 55 150 / 157 13750 / 14355 14575 / 15345

Notes: • Table indicates maximum number of strands that can be accomodated by the tendon stressing anchorage unit.

• Duct sizes are quoted for typical situations. It may be possible to slight ly reduce duct size in some situations. Consideration should be given to the use of larger

ducts where tight or extended curvatures occur. Refer to SSL office for advice. Alternate duct sizes are generally available in 5mm ID increments

• Partial tendons are also permissible.

(i.e. a 15No. 12.7mm strand tendon would be specified as “1905-15”, supplied with a 1905 stressing anchorage and would have a MBL of 15 x 184 = 2760 kN, etc.)

• Maximum Multi-strand Jacking force is usually 0.8 x MBL.

• Refer page 5 for additional design data and details on standards.

• MBL = Minimum Breaking Load

Structural Systems has been offering the BBR Cona Multi

post-tensioning system for over 40 years. This multi-

strand system is predominantly used in civil structures

including bridges, silos, tanks and off-shore structures

and is a robust and reliable “bonded” prestressing

system.

The BBR Cona Multi system consists of up to 61 No.12.7mm/12.9mm or 91 No. 15.2mm/15.7mm strands to

form tendons which are installed inside round ducting.

The individual strands are anchored in a common

anchor head with a wedge grip system and the strands

are simultaneously stressed. Individual strand stressing

is possible in some circumstances. After stressing the

ducting is pressure filled with a cementitious grout.

The choice between the anchorage types depends on

structural requirements, availability and dimensional

constraints.

For standard applications type M1 anchorages are

generally preferred. Type M3 are used for cryogenic

applications or where it maybe necessary to use a

rectangular anchorage for clearance reasons. (It is

recommended that SSL is consulted for non-standard

plate sizes).

STRESSING ANCHORAGES (LIVE ENDS)

ANCHORAGE TYPE M1

WEDGEGRIPS

ANCHOR

HEAD ANCHORAGE CASTING

P.E. TRUMPET

DUCT

GROUT INLET


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11



ANCHORAGE TYPE M3

The type of stressing anchorage used may vary

depending on the application, size and number of

anchorages required, type of tendon sheathing, project

location and availability of components. The tables

below provide performance and dimensional data for

two typical anchorages. Several other BBR anchorage

configurations are also available and there may be some

variations in dimensions to those shown. The designer

should check with Structural Systems for full and current

technical information on the preferred anchorage type.

STRESSING ANCHORAGE TYPE M1 - ANCHORAGE CASTING WITH P.E. TRUMPET (LIVE END)

STRAND SIZE TYPE M1 ANCHORAGE DETAILS


Maximum No. Strands

705

7

1205

12

1905

19

3105

31

-

-

4205

42

6105

61


Maxiumum No. Strands

406

4

706

7

1206

12

1906

19

2206

22

3106

31

4206

42

Dimensions (mm)

A x A

BC

Inside Dia. D

Outside Dia. E

Anchor Nom. Dia. FNom. Height G

165

155100

77

55

12055

215

34585

110

77

15055

265

415100

139

92

19065

335

485116

179

112

24080

350

550125

193

117

35080

395

605145

223

137

290100

460

725175

265

157

350120

Notes: • Local zone and general zone anchorage reinforcement is normally required for all unit types and details are usually determined by the Designer to suit the specific application.

• Unless otherwise specified by the Designer, SSL Multi-strand tendons will normally be supplied with Type M1 stressing anchorages.

• Tendon grouting is achieved via 19mm poly pipe inlets at all anchorage ends and at intermediate venting points.

STRESSING ANCHORAGE TYPE M3 - FABRICATED PLATE ANCHORAGE (LIVE END)

STRAND SIZE TYPE M3 ANCHORAGE DETAILS

12.7mm / 12.9mm Anchorage Unit 705 1205 1905 3105 - 4205 6105 - Maximum No. Strands 7 12 19 31 - 42 61 -

15.2mm / 15.7mm Anchorage Unit 406 706 1206 1906 2206 3106 4206 5506 Maximum No. Strands 4 7 12 19 22 31 42 55

Dimensions A x A 175 220 270 345 375 440 600 600

(mm) B 220 435 545 785 820 910 1230 1400 C 20 30 40 55 60 70 100 120 Outside Dia. D 90 115 140 195 210 232 275 325

Outside Dia. E 55 75 90 110 115 140 160 160

Notes: • Local zone and general zone anchorage reinforcement is normally required for all unit types and details are usually determined by the Designer to suit the specific application.

• Unless otherwise specified by the Designer, multi-strand tendons will normally be supplied with Type M1 stressing anchorages.

• Tendon grouting is achieved via 19mm poly pipe inlets at all anchorages and at intermediate venting points.

ANCHORAGE TYPE M1


12/48

Notes: • Local zone and general zone anchorage reinforcement is normally required for all unit types and details are usually determined by the Designer to suit the specific application

• Swage type dead end anchorages recommended for tendon units 3105/1906 and larger

DEAD END ANCHORAGES - BULB TYPE & SWAGE TYPE

STRAND SIZE ANCHORAGE UNIT BULB TYPE ANCHORAGE (mm) SWAGE TYPE ANCHORAGE (mm)

A B C D E F

12.7mm and 12.9mm 705 175 150 600 150 150 2501205 300 250 1000 200 200 350

1905 375 300 1000 250 250 500

3105 450 425 1100 350 300 650

4205 600 450 1100 450 375 850 6105 700 550 1200 700 450 1000

15.2mm and 15.7mm 406 150 150 600 150 150 250

706 200 170 600 200 200 3501206 350 300 1000 250 250 500

1906 450 350 1000 300 300 500

2206 500 350 1000 300 300 500

3106 550 475 1100 350 350 650 4206 700 550 1200 400 350 850

5506 800 600 1200 550 475 1000

1 2




BULB TYPE DEAD END SWAGE TYPE DEAD END

Transfer beams in buildings

Note: For swage type, strand length ‘F’ shall be

debonded (using grease or similar).


13/48

1 3



COUPLING ANCHORAGE - TYPE K

STRAND SIZE TYPE K COUPLING ANCHORAGE DETAILS

12.7mm / 12.9mm Anchorage Unit 705 1205 1905 3105 - - -

Maximum No. Strands 7 12 19 31 - - -

15.2mm / 15.7mm Anchorage Unit 406 706 1206 1906 2206 3106 4206 Maximum No. Strands 4 7 12 19 22 31 42

Diameter (mm) N 168 208 258 328 328 405 460

Trumpet length (mm) P (approx) 550 650 700 900 950 1100 1200

Notes: • Unless otherwise specified by the Designer, multi-strand coupling anchorages will normally be supplied as Type K

• Refer to SSL for details and availability of larger K type coupler units

COUPLING ANCHORAGE - TYPE C STRAND SIZE TYPE C COUPLING ANCHORAGE DETAILS

12.7mm / 12.9mm Anchorage Unit 705 1205 1905 3105 - 4205 6105 - Maximum No. Strands 7 12 19 31 - 42 61 -

Dimensions (mm) Q 108 108 108 108 - 148 refer -

R 170 200 230 340 - 385 to -

S 550 650 740 1140 - 1320 SSL -

15.2mm / 15.7mm Anchorage Unit 406 706 1206 1906 2206 3106 4206 5506 Maximum No. Strands 4 7 12 19 22 31 42 55

Dimensions (mm) Q 125 125 125 125 125 145 refer refer

R 160 200 230 270 300 350 to to

S 520 630 730 860 930 1090 SSL SSL

Notes: • Unless otherwise specified by the Designer, SSL Multi-strand Coupling Anchorages will normally be supplied as Type K

• Refer to SSL for details and availability of larger C type coupler units


14/48

1 4



SPACE REQUIREMENTS FOR STRESSING JACKS

STRAND SIZE SPACE REQUIREMENTS

12.7mm / 12.9mm Tendon Unit 705 1205 1905 3105 - 4205 6105 -

15.2mm / 15.7mm Tendon Unit 406 706 1206 1906 2206 3106 4206 5506

Jack unit CC 110 CC 200 CC 300 CC 600 CC 600 CC 630 CC 1000 CC 1200

Dimensions (mm) A 710 750 810 1200 1200 1000 1130 1300 B 1400 1500 1600 2400 2400 2000 2300 2600

C 250 300 330 500 500 600 600 600

E 200 230 260 400 400 500 420 450

F 595 620 675 1100 1100 950 950 1050

Notes: • Details based on jacks having 200mm working stroke. Alternative jacks may be available and/or more suitable. Contact SSL for further details

• Check jack size and availability with your local SSL office

STRESSING ANCHORAGE RECESS DETAILS

STRAND SIZE RECESS DETAILS

12.7mm / 12.9 mm Tendon Unit 705 1205 1905 3105 - 4205 6105 -

15.2mm / 15.7mm Tendon Unit 406 706 1206 1906 2206 3106 4206 5506

Dimensions (mm) F x F 230 270 340 420 420 460 560 650

G 140 140 150 165 165 185 200 225 H x H 310 370 400 510 510 560 660 750

Notes: • Depth G achieves 50mm cover to trimmed strand ends.

• Alternative or smaller recesses may be possible depending on actual conditions and jack used. Refer to your local Structural Systems office.



15/48

1 5



TENDON CURVATURE

A straight portion L adjacent to the anchorage must be observed to limit the screw pull of the strand bundle against

the anchorage. Reduction may be allowed in certain specific instances.

TENDON ECCENTRICITYTYPE e mm

705/406 10

1205/706 11

1905/1206 14

3105/1906 15

2206 21

4205/3106 25

6105/4206 28

SHEATHING AND CORROSION PROTECTION

For conventional applications, corrugated galvanised steel ducts are used with a wall thickness of 0.3mm.

For applications requiring enhanced corrosion protection and improved fatigue resistance of the tendons, use

of corrugated plastic duct is recommended. This fully encapsulated, watertight system offers superb corrosion

protection, and the plastic duct eliminates fretting fatigue between the strand and duct. It also provides reduced duct

friction. All ducts are manufactured in a variety of standard lengths and are coupled on site. Steel ducts are available

in diameters ranging from 40mm to 160mm in approximately 5mm increments.

Notes: • “e” is indicative only and depends

on actual duct ID and number of

strands in tendon

TENDON SHEATHING AND CORROSION PROTECTION

POLYETHYLENE DUCT DETAILS

ECCENTRICITY OF TENDONS

TENDON CURVATURE LIMITATIONS

12.7mm / 12.9mm 705 1205 1905 3105 - 4205 6105 -

15.2mm / 15.7mm 406 706 1206 1906 2206 3106 4206 5506

Minimum Radius, R (m) 4 4.5 5 6 6.5 8 8 10 Minimum Straight 0.8 0.9 1.0 1.1 1.15 1.3 1.3 1.5

Portion, L (m)

Notes: • Check with SSL office for availability and lead time for standard and/or alternative polyethylene

duct sizes

TENDON TYPE

12.7mm/12.9mm 15.2mm/15.7mm

DUCT DIMENSIONS (mm)

O.D. I.D. WALL THICKNESS

705 406 61 48 2.0

1205 706 75 65 2.0

1905 1206 94 82 2.0

3105 1906 110 98 2.0

4205 3106 125 110 2.0

6105 4206 160 138 2.0

Galv. Steel Duct(refer page 6)

Polyethylene Duct(refer left)


16/48

1 6




The minimum required distance of the bearing plates

to concrete edges and to adjacent anchorage bearing

plates depends in general on:

• the post-tensioning force to be transmitted

• the concrete strength

• the bearing plate dimensions

• the reinforcing steel behind the bearing plate

• structural requirements

ao = min. distance between axis of two anchorages

bo = min. distance from concrete edge to

anchorage axis

Dsp = suggested outside diameter of reinforcing

steel spirals

f’c = nominal concrete cylinder strength

Prestressing forces can usually be applied at 80% of

nominal concrete cylinder strength.

MINIMUM DISTANCE FOR BEARING PLATES TO CONCRETE EDGES AND BETWEEN

ADJACENT ANCHORAGES

Tung Chung Bridge - Hong Kong

MINIMUM ANCHORAGE SPACING AND EDGE DISTANCES

f’c

MPa

DETAILS

mm

12.7mm & 12.9mm STRAND UNITS 15.2mm & 15.7mm STRAND TENDON UNITS

705 1205 1905 3105 4205 406 706 1206 1906 2206 3106 4205

32

ao 220 290 365 465 545 205 270 355 450 480 570 665

bo 130 155 190 235 275 120 145 180 225 240 285 335

Dsp 200 250 320 410 480 180 230 300 390 425 520 590

40

ao 205 270 340 435 505 200 255 330 420 450 535 620

bo 125 150 185 225 260 120 145 175 215 230 275 310

Dsp 190 240 310 390 460 180 230 290 370 400 490 560

50

ao 195 255 320 410 475 200 250 310 395 420 500 585

bo 120 145 180 220 250 120 145 175 210 225 265 300

Dsp 180 230 300 380 440 180 230 290 360 390 470 540

Notes: • The above details are provided as a guide only and designers should normally satisfy themselves by calculation that the adopted details are suitable for the actual application.

Mt Henry Bridge - Western Australia


17/48

1 7

SLAB POST-TENSIONING



Designers, builders, owners and end users of buildings

require more efficiencies today than ever before. The

Structural Systems Slab Post-Tensioning System offers

all the stakeholders in a building project many benefits

including:

• Reduced structural depths

• Greater clear spans

• Design flexibility

• Formwork versatility

• Reduced construction costs

• Enhanced construction speed

• Improved durability• Minimum maintenance costs

The system is comprised of high-strength steel strands

placed inside flat ducting, anchored at one end by

deforming the strand and casting it into the concrete,

then at the other end by means of a steel anchorage

casting and anchor block(s) with gripping wedges. After

the concrete has reached a suitable transfer strength,

the individual strands have a specified load applied by

calibrated jacks. The duct is filled with a water/cement

grout mixture to ensure that the system is bonded and

corrosion protection is maintained in service.

Applications for the Structural Systems Slab Post-

Tensioning System include:

• Low to high rise residential and commercial

buildings• Industrial floor slabs on grade

• Transfer floor structures

• Car parks

• Water tank bases and walls

• Transverse stressing of bridge decks

West India Quay - London

Al N uaim iah Tower s - Dubai


18/48

1 8



LIVE END ANCHORAGES


DEAD-END ANCHORAGES

BULB-TYPE SWAGE-TYPE

grout tube

grout tube bulbe d st rand ends

swaged s trand ends space r pl ate

(not always required)

swage plate

strands

duct

anchorag e cast ing

anchora ge blo ck

duct

grout tube

duct

Notes:

• Similar non-reusable recess- formers are used at angled edges

• Standard flat duct is produced from0.4mm galvanised steel sheet

STRESSING ANCHORAGE (LIVE ENDS)

BULB-TYPE DEAD-END ANCHORAGE SWAGE-TYPE DEAD-END ANCHORAGESTRAND SIZE TENDON UNIT DIMENSIONS (mm) DIMENSIONS (mm)

A B C D E F

105 75 50 600 100 75 100 12.7mm 205 135 50 600 125 75 150 and 305 230 50 600 200 75 350 12.9mm 405 270 50 600 250 75 500 505 350 50 600 300 75 500 605 400 50 750 350 75 600

106 75 50 750 125 75 100

15.2mm 206 135 50 750 150 75 250 and 306 230 50 750 225 75 450 15.7mm 406 270 50 750 300 75 600 506 350 50 750 350 75 600

STRAND SIZE TENDON UNIT No. STRANDS

ANCHORAGE

CASTINGRECESS FORMER

FLAT DUCT SIZE

mm A

mm

B

mm

C

mm

D

mm

E1

mm

E2

mm

F1

mm

F2

mm

12.7 mm

and

12.9 mm

205

305

505

605

2

3

4 or 5

6

155

150

215

270

135

150

220

265

67

75

79

79

100

100

100

100

150

180

265

265

150

180

315

315

100

100

80

80

100

100

100

100

43 x 19

43 x 19

70 x 19

90 x 19

15.2 mm

and

15.7 mm

206

406

506

2

3 or 4

5

155

215

270

135

220

265

67

79

79

100

100

100

150

265

265

150

315

315

100

80

80

100

100

100

43 x 19

70 x 19

90 x 19

grou t tu be

dead end plate

duct

Notes: • Tendon units 205, 605, and 206 are supplied with individual barrel anchorages in lieu of anchorage blocks.

• Grout tubes are 13mm ID or 19mm ID polyethylene pipe supplied to each end of tendon. Additional intermediate vents can also be supplied (designer to specify requirements).

• All sizes are nominal. Some dimensions have been rounded up for normal space, detailing and tolerance requirements.

wedge grips

grout tubeduct

anchora ge cast ing

wedge

strand

barrel


19/48

1 9



wedge grips

grout tube

anchoragecasting

coupling block

COUPLING ANCHORAGE - 505, 406 & 506

COUPLING ANCHORAGE - 405

COUPLING ANCHORAGES

COUPLING ANCHORAGES

STRAND SIZE COUPLING COUPLING ANCHORAGE DETAILSUNIT DIMENSIONS (mm)

A B C D

12.7mm / 12.9mm 405 100 220 80 220

505 100 220 110 220

15.2mm / 15.7mm 506 100 240 120 265

swaged strand ends

Note: 3 and 4-strand units are coupled using the applicable 5-strand coupler, UNO.

Grout Pump

duct


20/48

2 0



ANCHORAGE REINFORCEMENT – SLAB SYSTEM

Notes: • Reinforcement size 10dia, grade 500MPa to AS/NZS 4671 or grade 460 to BS4449.

• fcp

= min required air-cured concrete cylinder strength at anchorage at time of stressing.

• Details shown are generally satisfactory for most standard situations, however designers should satisfy themselves of the adequacy of local zone anchorage

reinforcement for specific situations.


SPIRAL TYPE

STRAND AT TENDON HIGH POINT STRAND AT TENDON LOW POINT

2X2 LIGATURE

2X1 LIGATURE SIMILAR

2X4 LIGATURE

SUGGESTED ALLOWANCES – STRAND OFFSETS FOR 19mm FLAT DUCT

STRAND SIZE A B e

12.7mm / 12.9mm 7mm 12mm 2.5mm

15.2mm / 15.7mm 8mm 11mm 1.5mm

TENDONUNIT

No. OFSTRANDS

SPIRAL TYPE LIGATURE TYPE

fcpMPa A

mm

B

mm

N

No.

C

mm

D

mm

N

No.

205

305

505

605206

406

506

2

3

4 or 5

62

3 or 4

5

90

100

100

11090

110

110

200

260

260

300200

300

300

4

4

5

74

7

7

200

200

200

200200

200

200

100

100

130

150110

130

150

2 x 1

2 x 1

2 x 2

2 x 42 x 2

2 x 2

2 x 4

17

17

22

2517

22

25


21/48

2 1


JACKING CLEARANCES

STRAND SIZE A B C D E

mm mm mm mm mm

12.7mm / 12.9mm 500 900 750 450 70

15.2mm / 15.7mm 600 900 850 450 70


JACKING CLEARANCES

DOUBLE RAM JACK SINGLE RAM JACK

INTERNAL STRESSING POCKETS

Stressing Pocket

Notes: • Internal Stressing Pockets are used where standard edge stressng is impractical, subject to design check.

• Details shown provide typical pocket spacing requirements. Actual details may vary.


22/48

2 2



Post-tensioning provides many benefits to a wide range

of suspended structures. These benefits include:

• Reduced construction cost

• Faster construction

• Water resistant properties

• Early formwork stripping

• Floor to floor height reduction

• Reduced foundation load

• Improved deflection control

• Greater column free areas

Many types of suspended slab structures typically

realise the benefits of post tensioning, such as:

• Carparks

• Apartment buildings

• Commercial office space

• Retail centres

• Vertical load transfer structures

• Hospitals

• Storage facilities

• Public buildings such as stadiums, exhibition

centres, schools and institutional facilities

Different formwork systems are compatible with post-tensioning, namely:

• Conventional plywood systems

• Permanent metal deck systems

• Ribbed slabs

• Precast systems

Structural Systems has many years of experience in the

design and installation of post-tensioned suspended

slabs and can bring measurable benefits to your

project.

SLAB POST-TENSIONING APPLICATIONS - SUSPENDED SLABS

Peppers Pier Resort - Queensland

Wollongong Links Project - NSW


23/48

2 3



It is important that the design requirements are achieved

on site. Good engineering notation can greatly assist in

achieving this, with particular attention to the following;

• The System. State that the design is based on

the Structural Systems SLAB post-tensioning system.

This ensures that a fully tested and code compliant

system will be installed.

• Concrete. Nominate the 28 day characteristic

compressive strength and shrinkage characteristics

required. Some projects may have additional

requirements.

• Concrete Strength at Transfer fcp

. This is the

minimum compressive strength that is required prior to

fully stressing the tendons. Concrete testing of site and

air cured specimens should be carried out to ensure thisstrength has been achieved prior to application of the

final stressing.

• Tendons. Clearly indicate the type and location of

anchorages and number of strands in each tendon. Check

that stressing access is possible at live ends.

• Profiling. High and low points should be nominated.

Full tendon profiles can then be determined on installation

shop drawings. Profiles are usually parabolic.

• Stressing Procedure. A two stage stressing procedure

is usually specified. Initial or 25% load is applied at 24

hours after the slab pour, and final or 100% load is applied

when the concrete transfer strength is released.

• Grout. A water/cement ratio of not more than 0.45is usually sufficient to ensure adequate grouting and

strength.

BANDED SLAB FLAT SLAB FLAT PLATE

The design of post-tensioned suspended slabs requires

sound engineering consideration in order to maximize

the benefits for all stakeholders in a project.

Structural Systems can offer design input from initial

advice to fully detailed design for construction drawings.

Typical post-tensioned floor configuration and details are:

DESIGN OF POST-TENSIONED - SUSPENDED SLABS

DEFINITIONS

Lb = Band Span

Ls = Slab Span

L = Design Span (Greater of L1 & L2)

Note: For Slab End Spans,

Add 15-20% to Slab Thickness from charts

T = Internal Slab Thickness

D = Overall Band Depth

Bw = Suggested Band Width Approx. (suit formwork)

P = Overall Drop Panel Depth (1.8xT)

TYPICAL DESIGN LOADS

LL = 5kPa, ADL = 1kPa



LL = 2.5kPa, ADL = 0.5kPa

SPECIFYING POST-TENSIONING


24/48

2 4



Structural detailing is an art that engineers develop with

experience and it is an essential part of a cost effective

and reliable structure. Below are a selection of tried and

proven details that Structural Systems recommend for a

range of situations. A key factor in achieving a successful

Post-Tensioned Structure is a sound understanding of and

a considered allowance for normal concrete shrinkage

movements.

CONSTRUCTIONStructural Systems designers have worked closely over

many years with builders and construction personnel

resulting in a well understood system that enhances theconstruction process. An appreciation of the construction

process will enable all parties involved in the on site

works to benefit from the system. The typical construction

sequence is as follows;

• Erect formwork

• Install bottom reinforcement

• Install post-tensioning

• Install top reinforcement

• Prepour inspection and pour concrete

• Strip edge forms

• Initial/ Partial stressing of tendons

• Final/ Full stressing of tendons

• Obtain engineers approval and cut

off excess tendon strand

• Grout the tendons

• Strip formwork and back prop

as required

DETAILING OF POST-TENSIONED - SUSPENDED SLABS

Cabrini Hospital - Melbourne


25/48

2 5



The post-tensioning of slabs on ground is providing

many developers and builders with a cost effective

pavement solution. Benefits realised with post tensioned

slabs on ground include:

• Large joint free slab areas

• Reduced construction costs

• Less sub base preparation and/or

excavation

• Faster construction time

• Reduced on going maintenance costs

Facilities that have adopted a post-tensioned slab on

ground system include:

• Distribution warehouses

• Freezer stores

• Container terminal facilities

• Rail freight facilities

• Aircraft hangers

• Water retaining structures

• Sporting venues• Raft slabs

DESIGN

The design of post-tensioned slabs on ground involves

the careful analysis of the loads applied to the slab,

the interaction between the slab and the ground that

supports it, restraint forces and temperature effects.

Structural Systems has refined the design process and

has achieved outstanding results on many projects.

Our design and construction expertise for preliminarydesign advice through to final design and construction

activities is available to assist builders, engineers and

developers in achieving optimum solutions for slab on

ground applications.

SLAB POST-TENSIONING APPLICATIONS - SLAB ON GROUND

Container Pavement, Port Botany - NSW

Computer modelling and Analysis


26/48

2 6



Points to consider in the design process include:

Design Loads and Load Configurations

Thermal EffectsDaily ambient temperature variations give rise to

temperature gradient stresses through the slab depth

which need to be accounted for in the design. Typical

gradients of 0.02 ºC/mm and 0.04 ºC/mm are often

used for internal and external slabs respectively causing

bottom fibre tensile stresses that are additional to the

load stresses.

Sub-grade FrictionNormal elastic and shrinkage movements give rise to

frictional restraint stresses between the slab and the

prepared subgrade. The typical design friction coefficient

for concrete laid on a plastic membrane over clean sand

bedding is around 0.5 to 0.6.

Sub-base Parameters A typical slab design will include the analysis of the

slab supported by the ground sub-base. Modelling of

the sub-base requires geotechnical data such as CBR,

and/or the modulus of sub-grade reaction.

DESIGN OF POST-TENSIONED SLAB ON GROUND

b) DESIGN WHEEL / AXLE DETAILS

a) TYPICAL DESIGN RACKING LAYOUT

DATA - Design Axle load “P”

- Wheel Spacing “W” (2 or 4 wheels etc.)

- Axle Load Repetitions

- Wheel Contact Stress

Warehouse floor construction using laser screeds Raft Foundation - The Moorings, Western Australia

Typical racking storage


27/48

2 7


Good detailing of post-tensioned slabs on ground is vital in

achieving a successful and relatively crack free slab.

The following diagrams indicate key details typically

recommended by Structural Systems:

DESIGN OF POST-TENSIONED SLAB ON GROUND

CONSTRUCTION

Structural Systems design and construction experience

is based on being the leader in the field of post-

tensioned slabs on ground. The combination of innovative

design and expedient site practices ensures that the

construction phase is a seamless operation. The main

items to consider for the construction phase are;

Pour Size A pour size of between 1500m2 and 2000m2 should

typically be considered and planned.

Pour Sequence

The sequence of slab pours and their respective stressing

requirements should be optimized to ensure the best

programme outcome.

Curing and Weather Protection

With large pours the slab is initially susceptible to

shrinkage effects hence it is important to cure and

protect the slab from extreme conditions such as heat,

high evaporation or extreme cold. The construction

of warehouse roofs prior to pouring slabs is a typical

technique adopted to provide some protection.

TYPICAL WAREHOUSE PLAN

Note: • As a guide, allow for total slab edge & M.J. movements of approximately 0.5mm per metre length of slab

(e.g for 60m long slab, each edge moves approx 15mm over the normal life of the slab),

Column blockout detail



28/48

2 8



MULTI-WIRE POST-TENSIONING

The BBR SSL Multi-Wire System is more compact

than the multi-strand system and is often preferred for

coupled cables in incrementally launched bridges, and is

ideally suited where cables are to be prefabricated and

where restressing or destressing is required.

The multi-wire tendon is composed of a bundle of 7mm

dia. wires (plain or galvanised). Each individual wire is

fixed in the anchorage with a multi-wire button head,

which is cold-formed onto the wire by means of special

machines.

• Each wire is mechanically fixed in the anchor headand reaches the full rupture load of the prestressing

steel without any slippage. Therefore the wire

bundle can sustain the maximum ultimate load.

• The prestressing force is transmitted to the concrete

under precisely known conditions without any risk

of slippage of the prestressing steel.

• Monitoring of the prestressing force and if

necessary restressing can be carried out reliably

and economically. If required, the tendon can alsobe completely destressed.

• The anchorage resists with a high degree of safety

dynamic loads and also exceptional effects such as

shock loads.

Typical applications include:

• Coupled cables in incremtally launched bridges.

• Cable stay applications.

• Restressable tendons.

• Heavy lifting and lowering cables.

• Restressable ground anchors.

Centrepoint Tower - Sydney

Narrows Bridge Duplication - Western Australia


29/48

2 9



STRESSING JACK TYPE NP 60 NP 100 NP 150 NP 200 NP 250 NP 300 GP 500 GP 800

Maximum Jacking Force kN 620 1030 1545 2060 2575 3090 5150 8000

Jack Diameter mm 160 205 250 290 315 350 560 660 Stroke mm 100 100 100 100 100 100 400 400

Weight kg 28 50 83 117 147 196 1260 2000

Clearance Requirement ‘A’ mm 1700 1700 1700 2000 2000 2000 2500 2500

PRESTRESSING JACKS

Grouting of Ducts

SSL has developed grouting methods utilising special

colloidal mixers which result in an optimal grouting of the

tendon ducts.

Prestressing Equipment

The prestressing equipment consist of a hydraulic

jack, trestle and pull-rod, which is connected to the

stressing anchorage. For tendon elongations greater

than the stroke of the jack, the pull-rod is temporarily

anchored with a lock-nut and the jack is recycled.

The prestressing force can be measured with an accuracy

of 2% by using calibrated 150mm face bourdon type

pressure gauges.

Standard Tendons

The anchoring method allows the production of post-

tensioning tendons with any number of single wires and

therefore with any given magnitude of prestressing force.

The most commonly used wire diameter is 7 millimetres.

With the following range of STANDARD TENDONS, all

prestressing requirements occurring in the construction

of bridges, buildings and other structures can be met.

For special applications, eg; nuclear vessels, tendons up

to 15,000 kN ultimate capacity are available.

STANDARD SSL - BBR WIRE TENDONS

NUMBER OF WIRES, DIA. 7mm 8 19 31 42 55 61 85 109 121 143

Minimum Breaking Load (Rm = 1670 MPa) kN 514 1222 1993 2701 3537 3922 5466 7009 7780 9195

Stressing force at 0.8 x MBL kN 412 977 1595 2160 2829 3138 4372 5607 6224 7356

Stressing force at 0.75 x MBL kN 386 916 1495 2025 2652 2942 4099 5257 5835 6896

Tendon nominal cross sectional area mm2 308 731 1194 1617 2118 2349 3273 4197 4659 5506

Weight of tendon wire kg/m 2.42 5.74 9.36 12.68 16.61 18.42 25.67 32.92 36.54 43.19 Duct I.D. mm 35 50 55 65 80 85 100 110 120 130

Notes: • Check jack size and availability with your local SSL office

Notes: • Rm = Characteristic Tensile Strength to AS 4672 and/or BS 5896


30/48

3 0




SPECIAL APPLICATION ANCHORAGES

Details of Anchorages for various special applications are also available on request .

STRESSING ANCHORAGE TYPE L

STRESSING ANCHORAGE TYPE A

FIXED ANCHORAGE TYPE S

FIXED COUPLING TYPE LK

MOVABLE COUPLING TYPE LK 1

NUMBER OF WIRES 8 12 19 31 42 55 61 85 109 121 143dia. 7mm

Anchor e mm 25 27 36 43 49 56 67 78 85 140 145

Elongation, max f mm 200 200 200 200 200 250 250 350 350 400 400Trumpet length g mm 170 185 200 280 310 335 360 390 420 450 500

Diameter h mm 37 49 59 76 87 97 105 120 135 145 160

Bearing plate i mm 140 170 200 235 270 300 330 380 430 480 500

Thickness it mm 16 20 25 30 40 45 50 60 70 80 80


Fan length k mm 460 550 660 830 880 960 1010 1060 1180 1220 1260

Anchor plate, sq l mm 120 160 200 250 280 320 350 400 450 470 520

rectangular l mm 70 90 120 140 160 180 200 240 260 280 300

w mm 200 270 340 420 500 560 600 660 760 790 900


Anchor a mm 63 74 91 108 123 135 156 180 205 240 245

Trumpet Length b mm 250 250 250 280 300 300 300 340 360 400 500

Diameter c mm 70 88 102 123 138 153 171 193 219 240 252

Bearing Plate d mm 140 170 200 245 285 315 345 400 450 500 520

Thickness dt mm 14 16 20 25 30 35 40 50 60 70 70


Trumpet length q mm 230 260 290 350 410 430 470 570 630 680 730

Diameter r mm 70 88 102 123 138 153 171 193 219 250 260


Trumpet length min s mm 600 620 670 750 810 880 950 1080 1150 1220 1260

Diameter t mm 70 88 102 123 138 153 171 193 219 250 260


31/48

3 1

BAR POST-TENSIONING


BAR POST-TENSIONING

Corrosion Protection All bars and fittings must receive protection when

installed under permanent conditions. In normal concreteconstruction the use of galvanised duct, injected with

grout, provides excellent protection. Anchorage recesses

must also be filled with cement mortar to protect

these end zones.

When bars are used in an exposed environment then

other corrosion protection systems are available for the

bar and fittings. These include:

• greased and sheathing bar

• denso wrapping

• epoxy painting

Temporary Bar Anchors Anchors used in a temporary environment may be

used without protection apart from grout required to the

bond length.

Permanent Bar AnchorsThese anchors require installation into corrugated

polyethylene sheathing or galvanised duct similar to

strand anchors to provide multiple levels of protection.

This is accomplished by the internal grout and sheathing

barrier.

Macalloy Bar Systems are ideal for the economic

application of post-tensioning forces on relatively short

tendons. Through the use of threaded connections and

anchorages they are simple to use and lend themselves to

many applications.

The robust coarse thread (CT) on the Macalloy bar

ensures rapid and reliable assembly. This is particularly

suitable for onsite use and reuse.

Typical ApplicationsBuildings

• Prestressed Beams and Columns• Precast Connections

• Temporary Bracing

Bridges

• Stay Cables and Hangers

• Precast Segments

• Strengthening (Timber & Steel Bridges)

• Tension Piles and Caissons

Wharves & Jetties

• Stressed Deck Planks

• Tie Backs

Soil and/or Rock Anchors

• Permanent and Temporary Anchors

• Uplift Anchors (Dam & Foundation)

• Tunnel Roof Bolting

• Soil Nails and Rock Bolts

• Slope Stabilisation

• Crane and Tower Bases

Specialist Engineering • Heavy Lifting

• Formwork Ties and Hangers

• Frame Ties

• Pile Testing

• Architectural Ties and Stays

Characteristic PropertiesMacalloy Bar Properties are listed in the following

tables.

Macalloy 1030 Bar Components

Bearing Plate

Nut Bar

Washer

Coupler


32/48

3 2



BAR POST-TENSIONING

RANGE OF MACALLOY 1030 BAR

GRADE CHARACTERISTIC

ULTIMATE TENSILE

STRENGTH

MPa

MINIMUM 0.1% PROOF

STRESS

MPa

MINIMUM

ELONGATION

%

APPROXIMATE

MODULUS OF

ELASTICITY

GPa

Macalloy 1030

25-50mm1030 835 6 170

Macalloy 1030

75mm1030 835 6 205

*Macalloy S1030 1030 835 10 185

MECHANICAL PROPERTIES OF MACALLOY 1030 BAR

NOMINAL DIAMETER

mm

CHARACTERISTIC BREAKING LOAD (MBL) MINIMUM 0.1% PROOF LOAD

MACALLOY 1030

kN

*MACALLOY S1030

kN

MACALLOY 1030

kN

*MACALLOY S1030

kN

20

25

26.5

3236

405075

-

506

569

8281049

129520224311

323

506

-

828-

1295--

-

410

460

670850

105016393495

262

410

-

670-

1050--

CHARACTERISTIC LOADS FOR MACALLOY 1030 BAR

* Macalloy S1030 is made from stainless steel

NOMINAL

DIAMETER

mm

NOMINAL CROSS

SECTION AREA

mm2

MASS OF BAR MAJOR DIAMETER

OF THREADS

mm

MIN. HOLE

DIAMETER IN

STEELWORK

mm

MACALLOY 1030

kg/m

*MACALLOY S1030

kg/m

2025

26.5

32

3640

50

75

315491

552

804

10181257

1963

4185

-4.09

4.58

6.63

8.3510.30

15.72

33.00

2.534.09

-

6.63

-10.30

-

-

22.028.9

30.4

36.2

40.245.3

54.8

77.2

2431

33

40

4449

59

82


33/48

3 3

BAR POST-TENSIONING

ITEM UNIT NOMINAL BAR DIAMETER - mm

†201 251 26.5 32 36 40 50 75

Bars Sectional area

Mass per metre

Metre run of bar per tonne

Characteristic failing loadPrestress at 70% characteristic

Minimum centres for anchorage

mm2

kg

m

kNkN

mm

314.2

2.466

405

314220

100

490.9

4.069

246

506354

100

551.5

4.560

219

569398

110

804.3

6.661

150

828580

125

1017.9

8.451

118

1049734

140

1256.6

10.410

96

1295907

150

1963.5

16.020

62

20221415

175

4185.4

33.200

30

43113018

250

*Flat Nuts Nut reference

Length

Width across flats (DIA for 75mm bar)

Weight

-

mm

mm

kg

FSSN20

25

42

-

FN25

33

46

-

FN26.5

37

50

0.46

FN32

41

56

0.56

FN36

46

62

0.74

FN40

51

65

0.86

FN50

71

90

2.55

FN75

100

135

7.70

*FlatWashers

Washer referenceOutside diameter

Thickness

-mm

mm

FSSW2050

5

FSW2560

5

FSW26.565

5

FSW3270

5

FSW3675

5

FSW4080

5

FSW50105

5

--

-

Couplers Coupler reference

Outside diameterLength - standard

Length - stainless

Weight

-

mmmm

mm

kg

FSSC20

35-

65

-

FC25

42.585

80

-

FC26.5

42.590

-

0.54

FC32

50115

95

0.94

FC36

57.5130

-

1.50

FC40

62.5140

120

1.78

FC50

76170

-

3.10

FC75

110230

-

9.00

End Plates Plate reference

LengthWidth

Thickness - standard

Hole diameter

Thickness - threaded

-

mmmm

mm

mm

mm

FSSP20

100100

25

26

-

FP25

100100

40

35

40

FP26.5

110110

40

36

40

FP32

125125

50

41

50

FP36

140140

50

45

50

FP40

150150

60

52

60

FP50

200175

60

61

70

FP75

300250

75

82

110

Ducts Sheathing i/d

Coupler-sheathing i/d recommended

Coupler-sheathing minimum

mm

mm

mm

41

50

45

41

59

52.5

41

59

52.5

50

66

60

50

71

65

61

75

70

71

91

90

91

125

125Grouting

flange

Flange reference

Length /o/dia

Height

-

mm

mm

-

-

-

GF25

125

40

GF25

125

40

GF32

140

40

GF36

140

40

-

-

-

-

-

-

-

-

-

Threads Pitch mm 2.5 6.0 6.0 6.0 6.0 8.0 8.0 8.0

Standard

thread

lengths

(see fig onp30)

Length - Jacking end (standard) S1

- Dead end (standard) S2

- Coupler (standard)

X1 (min) X2 (min)

X3 (min)

mm

mm

mm

mmmm

mm

250

100

40

7542

12

250

100

45

8249

12

250

100

50

9153

12

250

100

60

10557

12

250

100

65

11562

12

250

100

75

13071

16

250

100

85

16591

16

360

160

150

235116

16

MACALLOY 1030 COMPONENT PARAMETERS

* Spherical nuts and washers are available if required for rotation.† 20mm bar available in stainless steel grade only.1 Bar range available on request

Sydney Hockey Centre, Homebush - NSW



34/48

3 4



MACALLOY 1030 SUGGESTED MILD STEEL END BLOCK REINFORCEMENT

NB: Helix and links must be used together with minimum 35 MPa concrete - see figure above

Notes: • A longitudinal length of rod may be used to attach the links but it is not required as part of the reinforcement

• A more detailed explanation of the Macalloy Post Tensioning System is available in the Macalloy Design Data Handbook

• There are many permutations possible to achieve satisfactory construction details, and advice is readily available from Structural Systems

OTHER MACALLOY BAR SYSTEMS ALSO AVAILABLE

• Macalloy 460 carbon steel tendons

• Macalloy S460 stainless steel tendons

• Macalloy Guy Linking stainless steel bar tendons

• Macalloy Guy Linking stainless steel cable tendons

• Macalloy 17MHS Sheet piling ties

• Macalloy 500 Reinforcing bars

• Macalloy 500 Tie bars

• Macalloy 650 Stainless Tie bars

• Macalloy-Tensoteci Galvanised cable tendons

MACALLOY 1030 TYPICAL END BLOCK ARRANGEMENT

MACALLOY 1030 BAR END THREAD DIMENSIONS

X1 = live end

X2 = dead end

X3 = length of bar past nut or thru’ threaded plate

S1 = live end thread

S2 = dead end thread

L = length over plates

MACALLOY

DIAMETER

mm

HELIX LINKS

ROD DIAM.

mm

I/D

mm

PITCH

mm

TURNS

No.

ROD DIAM.

mm

SPACING

mm

NUMBER

25

26.532

36

4050

75

12

1212

12

1216

20

130

130165

195

220250

350

40

4040

40

4050

75

5

56

7

78

8

8

88

8

810

16

70

7080

80

80100

100

3

33

4

44

6


35/48

3 5

GROUND ANCHOR SYSTEMS



Structural Systems Ground Anchors have been utilised

world wide in conjunction with our construction

partners the BBR group of Switzerland. Ground

Anchors comprised of wires, strands or bars can be

installed into rock or soil and secured by injecting

with cement grout.

Standard Structural Systems Ground Anchors can

provide an ultimate load of between 368kN and

23,750kN depending on the configuration.

SSL BBR Anchors have been the largest and longest

installed anywhere around the world and our technicalexpertise in this field is internationally recognised.

Typical applications of Structural Systems Ground

Anchors include:

• retaining structure tie backs

• resistance of uplift forces

• slope stabilization

• underground structures

• dam stabilization

• tension foundations

• soil nailing (bar type anchors)

Transporting ground anchorsTransporting world’s longest ground anchors - Canning Dam - Western Australia

Ancho r Fab ricat ion - Cannin g Dam - Wes tern Austra lia

Ancho r ins talla tion

Ross River Dam - Queensland


36/48

3 6



GROUND ANCHOR SYSTEMSSTRAND TYPE ANCHORS


37/48

3 7



TYPICAL GROUND ANCHOR TENDON CONFIGURATIONS

Notes: • Strand tendons are based on MBL = 184kN (12.7mm strand) and MBL = 250kN (15.2mm strand) (Higher strand / anchor capacities available on request) • Details listed apply to typical applications and may vary to suit actual applications

• Macalloy Bar tendons are more commonly used for short anchor lengths

• Macalloy Bar anchor details exclude allowance for coupling of bars - refer SSL for details if required

TENDON STRAND / BAR SIZE

mm

MAXIMUMSTRANDS

PER UNIT

No.

MINIMUMBREAKING

LOAD

kN

BORE HOLE DIAMETER PERMANENT ANCHORSHEATH SIZE ID / OD BEARING PLATESIZE

TYPICAL

mm

TEMPORARY

ANCHORS

mm

PERMANENT

ANCHORS

mm

CORRUGATED

mm

SMOOTH

mm

STRAND

15.2mmor

15.7mm

2

47

12

19

2227

31

4255

6591

500

10001750

3000

4750

55006750

7750

1050013750

1625022750

76

89102

114

165

165178

178

229241

254311

102

127152

178

216

216216

216

311311

311356

50 / 65

65 / 8580 / 100

100 / 120

125 / 165

125 / 165125 / 165

125 / 165

210 / 230210 / 230

210 / 230250 / 270

55 / 63

67 / 7582 / 90

102 / 110

150 / 160

150 / 160150 / 160

150 / 160

225 / 235225 / 235

225 / 235257 / 270

200 x 200 x 32

200 x 200 x 36300 x 300 x 50

350 x 350 x 60

400 x 400 x 70

450 x 450 x 80500 x 500 x 80

500 x 500 x 90

600 x 600 x 100700 x 700 x 120

700 x 700 x 140900 x 900 x 160

91+ under development - refer SSL

STRAND

12.7mm

or

12.9mm

2

4

7

368

736

1288

76

89

102

102

127

152

50 / 65

65 / 80

80 / 100

55 / 63

67 / 75

82 / 90

200 x 200 x 32

200 x 200 x 36

250 x 250 x 40

larger sizes on request - refer SSL

MACALLOY BAR

26.5

32

4050

75

1

1

11

1

569

828

12952022

4311

76

102

102127

152

127

152

152175

203

65 / 80

80 / 100

80 / 100100 / 127

130 / 150

n/a

n/a

n/an/a

n/a

200 x 200 x 40

250 x 250 x 50

300 x 300 x 60300 x 300 x 60

400 x 400 x 90


38/48

External prestressing was first used in the late 1920’s

and has recently undergone a resurgence being

used in bridges, both for new construction as well as

strengthening of existing structures.

Features of External Prestressing

External prestressing is characterised by the following

features:

• The prestressing tendons are placed on the outside

of the physical cross section (mostly in concrete)

of the structure.

• The forces exerted by the prestressing tendons

are only transferred to the structure at the

anchorages and at deflectors.

• No bond is present between the tendon and

the structure, except at anchorage and deflector

locations.

Advantages of External Prestressing

Compared to internal bonded post-tensioning the external

prestressing has the following distinct advantages:

a) The application of external prestressing can be

combined with a broad range of construction

materials such as steel, timber, concrete,

composite structures and plastic materials. This

can considerably widen the scope of the post-

tensioning applications.

b) Due to the location and accessibility of the

tendons, monitoring and maintenance can be

readily carried out compared to internal, bonded

prestressing.

c) Due to the absence of bond, it is possible to

restress, destress and exchange any external

prestressing cable, provided that the structural

detailing allows for these actions.

d) Improves the concrete placing due to the absence

of tendons in the webs.

e) Improvement of conditions for tendon installation

which can take place independently from the

concrete works.

f) Reduction of friction losses, because the

unintentional angular changes, known as wobble,

are practically eliminated. Furthermore with

the use of a polyethylene sheathing the friction

coefficient is drastically reduced compared to

internal bonded prestressing using corrugatedmetal ducts.

g) External prestressing tendons can easily and

without major cost implication be designed to be

replaceable, de-stressable and re-stressable.

h) Generally the webs can be made thinner, resulting

in an overall lighter structure.

i) Strengthening capabilities.

As an overall result, better concrete quality can be obtained

leading to a more durable structure.

External post-tensioning - Navia, Spain

3 8



EXTERNAL

PRESTRESSING


39/48

Typical Applications for External

Prestressing

Typical applications where external tendons are feasible,

practical and economical, are:

- Repair work and strengthening of all kinds ofstructures

- Precast segmental construction

- Simple and continuous spans

- Underslung structures

- Incremental launching procedure, in particular

concentric prestressing

Basic Type

The basic SSL BAR CONA External tendon is practically

identical to the SSL Multi-Strand System for internal

applications:

- The tendon is formed from standard 15.2mm/

15.7mm diameter strands with minimum breaking

load of 250 kN or 279 kN.

- The duct is from high density polyethylene and

continuous from one anchorage to the other.

The tendon sheathing passes freely through

intermediate diaphragms and through deflectors

with a metal or HDPE sleeve providing the required

penetration.

- A standard CONA Compact anchorage assemblyconsisting of anchor head, wedges, anchorage

casting and polyethylene trumpet safely

transfers the prestressing forces to the structure

(see Fig. 1).

- Alternatively a fabricated steel bearing plate

anchorage can be used in lieu of the cast

anchorage.

- The tendon is filled with cement grout after it has

been tensioned. Depending on requirements,

the anchor heads may be protected by a cap, or

alternatively the anchorage recess is filled with non-

shrink concrete.

3 9

EXTERNAL POST-TENSIONING


Fig. 2. SSL-CONA External with anchorage casting

ANCHORAGE CASTING

NUMBER OF

STRANDS

15.2mm / 15.7mmTYPE

DIMENSIONS (mm)

A1 x A1 ØB C D E1 ØF G AD/ID ad/id

7

12

19

3142

706

1206

1906

31064206

215

265

335

395500

150

180

230

290340

52

65

80

97116

105

115

130

150155

355

425

511

650950

109

138

178

222283

75

80

90

100160

75 / 66.4

90 / 79.8

110 / 97.4

140 / 124210 / 200

90 / 79.8

110 / 97.4

140 / 114.4

180 / 147.2243 / 225

SSL CONA EXTERNAL TENDONSMain Dimensions

Fig. 1. Standard Cona Compact Anchorage Assembly


40/48

Structural Systems can provide strand (BBR HiAm

ConaTM ) stay cables, wire (DinaTM / HiAmTM ) stay cables,

and Carbon stay cables for a wide variety of structures,

drawing on both local and global expertise and resources

of the BBR Network. For suspension bridges, BBR

Technology can also be used for the main suspension

cables as well as for the hangers.

Stay cables may be plain strand / wire unsheathed for

temporary applications.

For permanent stay cable applications, galvanised,

waxed and individually sheathed strands, enclosed in

an external sheath are adopted; or wires enclosed in

a sheath and the voids filled with a flexible corrosion

protection compound.

In recent years a fatigue stress range of 200 N/mm 2

for 2x106 load cycles in combination with angular

rotations at the anchorages has been adapted and is

now specified by most codes and recommendations.

BBR Stay Cable Technology has fulfilled such fatiguetesting.

Sydney Athletics Centre - New South Waies

Eleanor Schonell Bridge - Queensland

CABLE STAY

SYSTEMS

4 0




41/48

4 1

CABLE STAY SYSTEMS


Strand Stay Cables

BBR HiAm ConaTM Parallel Strand Stay Cables Installation

is typically performed on site using the strand-by-strand

method. Each strand is tensioned immediately after

installation, using the BBR isostress tensioning method,ensuring an equal force distribution among the strands

of an individual cable. Alternatively, fully or partially

prefabricated cables can be installed and tensioned.

Strands are generally 15.7mm diameter, low relaxation

grade, minimum guaranteed ultimate tensile stress of

1770 N/mm2 or 1860 N/mm2 and subject to fatigue

testing by the manufacturer. Strands are galvanized,

waxed and individually sheathed with a continuous and

wear resistant HDPE coating, providing each strand with

an individual multilayer protection system. Alternatives

may also be available upon request. A ring nut screwedon anchor heads transfers the cable loads by contact

pressure to the supporting bearing plates, and allows

adjustment of stay force. All anchorage components are

designed for a stress range greater than 300 N/mm2 and

to withstand the ultimate breaking load of the strand

bundle with adequate safety.

Supplemental internal or alternatively external damping

devices protect the stay cable from vibrations.

Another effective countermeasure against wind and

rain-induced vibrations is the use of a helical rib on

the outside of the HDPE, architecturally coloured

co-extruded stay pipe.

Final stay cable force may also be adjusted using a

specially designed multi-strand jack acting on the entire

stay cable. Individual strands can be re-stressed at any

time during or after the installation, allowing not only

for a re-stressing but also for the selective removal,

inspection and replacement of individual strands or the

entire stay cable.

Standard Anchorage Components

TYPE FORCES STRUCTURE ANCHORAGE STAY PIPE WEIGHT

H i A m C

O N A

AXIAL CABLE FORCEBEARING PLATE / STEEL GUIDE

PIPEBBR HIAM ANCHORAGE SYSTEM

HDPE

CABLE

ULTIMATE WORKINGSHORT

TERMFATIGUE

STEEL 355 MPa YIELD STRESS

STRUCTURAL GRADE SDR32

MBL Fwl

Fext

Ffat

PLATE GUIDE PIPE Diam.

G A

H A

I A

Diam.

SCABLE

Diam. CBP

Diam. DGP

100% 45% 55% 200 MPa OD / e STRESSING FIXED OD / e

kN kN kN kN mm mm / mm mm mm mm mm mm / mm kg/m

1 06 279 126 153 30 57 70.0 / 5.0 75 390 190 1000 / 1.3

3 06 837 377 460 90 85 101.6 / 5.0 110 400 200 1500 63 / 4.0 4.7

7 06 1953 879 1074 210 133 152.4 / 4.5 165 410 210 2000 90 / 4.0 10.3

12 06 3348 1507 1841 360 170 193.7 / 5.6 210 420 220 2125 110 / 4.0 17.1

19 06 5301 2385 2916 570 210 244.5 / 6.3 260 435 235 2250 125 / 4.0 26.4

22 06 6138 2762 3376 660 225 244.5 / 6.3 275 435 235 2375 140 / 4.4 30.7

27 05 7533 3390 4143 810 248 273.0 / 6.3 305 450 250 2500 160 / 5.0 37.8

31 06 8649 3892 4757 930 264 298.5 / 7.1 325 445 245 2625 160 / 5.0 43.1

37 06 10323 4645 5678 1110 288 323.9 / 7.1 355 465 265 2750 180 / 5.7 51.6

42 06 11718 5273 6445 1260 305 323.9 / 7.1 375 465 265 2850 180 / 5.7 58.2

48 06 13392 6026 7366 1440 327 356.6 / 8.0 400 480 280 2950 200 / 6.3 66.8

55 06 15345 6905 8440 1650 349 368.0 / 8.0 425 480 280 3050 200 / 6.3 75.9

61 06 17019 7659 9360 1830 367 406.4 / 8.0 450 495 295 3150 225 / 7.1 84.8

69 06 19251 8663 10588 2070 389 406.4 / 8.0 475 500 300 3250 225 / 7.1 95.3

73 06 20367 9165 11202 2190 400 419.0 / 8.0 490 490 290 3350 250 / 7.9 1101.7

75 06 20925 9416 11509 2250 405 457.0 / 10.0 495 510 310 3450 250 / 7.9 104.3

85 06 23715 10672 13043 2550 430 457.0 / 10.0 525 515 315 3550 280 / 8.8 119.0

91 06 25389 11425 13964 2730 445 508.0 / 11.0 545 525 325 3650 280 / 8.8 126.8

97 06 27063 12178 14885 2910 458 508.0 / 11.0 560 525 325 3750 280 / 8.8 134.7

109 06 30411 13685 16726 3270 485 508.0 / 11.0 595 525 325 3850 315 / 9.9 152.4121 06 33759 15192 18567 3630 510 559.0 / 12.5 625 545 345 3950 315 / 9.9 168.1

127 06 35433 15945 19488 3810 522 559.0 / 12.5 640 555 355 4050 315 / 9.9 176.0

STRAND DIAMETER: 15.7mm TO prEN 10138-3 (REFER DESIGN DATA)

Notes: • e = nominal wall thickness


42/48

BBR HIAM STAY CABLES

4 2



CABLE STAY SYSTEMS

CABLE SIZE (WIRES PER CABLE) n Ø 7 No. 56 91 121 163 196 223 262 301 334 367 394 421

CABLE Breaking Load Fum

kn 3600 5850 7775 10475 12595 14330 16840 19345 21465 23585 25320 27055

Max. Working Load Fm

kn 1620 2635 3500 4715 5670 6450 7580 8705 9660 10615 11395 12175

Steel Weight k/m 16.9 27.5 36.6 29.2 59.2 67.4 79.2 91 100.9 111 119 127.2

Cable Weight k/m 23.8 33.2 43.8 58.0 71.2 78.4 93.8 104 118.7 128 138.3 145.5

HDPE STAY PIPE Ø pe mm 110 110 125 140.0 160 160.0 180 180 200 200 210 210

WALL THICKNESS mm 10.0 10.0 11.4 12.8 14.6 14.6 16.4 16.4 18.2 18.2 19.1 19.1

HDPE TELESCOPE PIPE Ø pe t mm 140 140 160 180.0 200 200.0 225 225 250 250 250 250

WALL THICKNESS mm 12.8 12.8 14.6 16.4 18.2 18.2 20.5 20.5 22.8 22.8 18.0 18.0

STEEL GUIDE PIPE Ø T mm 229.0 / 267.0 / 298.5 / 343.0 / 355.6 / 368.0 / 406.4 / 445.0 / 445.0 / 470.0 / 495.0 / 495.0 /

(outer/inner diameter) mm 211.4 251 282.5 311.0 330.6 352.0 378.0 405.0 416.6 435.0 455.0 470.0

BEARING PLATE B mm 365 430 480 545.0 590 625.0 675 730 755 795 830 850

THICKNESS t mm 45 55 60 70 75 75 85 95 95 100 110 105

CENTRE HOLE Ø Z mm 211 251 282 311.0 330 352.0 378 405 417 435 455 470

SOCKET Outer Diameter Ø a mm 195 235 265 295 315 335 360 385 400 420 435 450

Length Stressing Anchorage lhM mm 355 425 480 550 605 635 665 710 755 790 815 845

Length Fixed Anchorage lhF mm 320 370 415 465 505 525 540 575 605 635 650 675

LOCK NUT Ø M mm 245 290 330 365 390 420 450 480 500 520 540 560

hM mm 75 90 105 120 125 135 150 160 165 170 180 185

PROTECTION CAP Ø S mm 219 259 289 319 339 359 389 409 429 449 459 479

lSm mm 283 338 378 433 483 503 518 553 593 623 638 663lS

fmm 178 203 213 228 253 253 253 268 283 288 293 303

WEIGHT OF ANCHORAGE

(excl. Anchor Plate and Guide Pipe)

strss. k 93 157 226 314 391 465 567 668 787 898 998 1110

fi k 86 142 203 281 347 412 495 600 682 779 861 957


43/48

4 3

CABLE STAY SYSTEMS


BBR DINA STAY CABLES

CaBle Size (wireS per CaBle) Ø 7 n. 13 22 31 37 55 70 91 103 121 145 157 181 199

CaBle Bk l Fum

kn 835 1415 1990 2380 3535 4500 5850 6620 7775 9320 10090 11635 12790

M. wk l Fm

kn 375 635 895 1070 1590 2025 2635 2980 3500 4195 4540 5235 5755

S w k/m 3.9 6.6 9.4 11.2 16.6 21.1 27.5 31.1 36.6 43.8 47.4 54.7 60.1

Cb w k/m 6.4 8.8 12.4 15.8 20.7 27.6 33.2 39.0 43.8 53.1 56.4 67.2 72.0

hdpe Stay pipe Ø pe mm 63 63 75 90 90 110 110 125 125 140 140 160 160

wall thiCKneSS mm 5.8 5.8 6.9 8.2 8.2 10.0 10.0 11.4 11.4 12.8 12.8 14.6 14.6

hdpe teleSCope pipe Ø pe mm 75 75 90 110 110 140 140 160 160 180 180 200 200

wall thiCKneSS mm 4.3 4.3 5.1 6.3 6.3 12.8 12.8 14.6 14.6 16.4 16.4 18.2 18.2

Steel guide pipe Sss ac Ø Tm

mm 139.7 / 146.0 / 168.3 / 177.8 / 203.0 / 229.0 / 254.0 / 267.0 / 292.0 / 305.0 / 318.0 / 330.0 / 355.6 /

( / m) mm 125.5 136.0 155.7 165.2 190.4 211.4 238.0 245.0 267.0 285.0 298.0 310.0 327.2

F ac Ø Tf

mm 139.7 / 146.0 / 168.3 / 177.8 / 203.0 / 229.0 / 254.0 / 267.0 / 292.0 / 305.0 / 318.0 / 330.0 / 355.6 /

( / m) mm 125.5 136.0 155.7 165.2 190.4 211.4 238.0 245.0 267.0 285.0 298.0 310.0 327.2

Bearing plate Sss p Bm

mm 230 260 285 305 350 380 420 435 470 510 525 560 590

tckss tm

mm 30 35 35 40 45 50 55 60 60 65 65 70 75

C h Ø Zm

mm 125 136 155 165 190 211 238 245 267 285 298 310 327

F p Bf

mm 180 210 240 270 305 405 430 415 440 480 495 530 555

tckss tf

mm 25 35 35 45 45 70 80 60 65 75 75 80 90

C h Ø Zf

mm