european technical eta 09/0169 assessment

Pembroke House,

21 Pembroke Road

Sevenoaks, Kent, TN13 1XR

Tel: 00 44 1732 450000 Website: www.ukcares.com

Member of

www.eota.eu

Technical Assessment Body issuing the ETA and designated according to Article 29 of the

Regulation (EU) No 305/2011: UK CARES

Trade name of the construction product Freyssibar

Product family to which the construction

product belongs

PAC 16 – Reinforcing and pre-stressing steel for

concrete (and ancillaries). Post tensioning kits.

Tel : (+33) 147 76 79 79

This European Technical Assessment contains 39 pages including Annexes A to Q which form

an integral part of this assessment.

This European Technical Assessment is issued

in accordance with regulation (EU) No

305/2011, on the basis of

This European Technical Assessment

replaces:

EAD160004-00-0301. Edition September 2016,

Post Tensioning Kits for Prestressing of

Structures

European Technical Assessment

ETA 09/0169

of 30/06/2018

European Technical Assessment (ETA)

ETA-09/0169 dated 30th June 2013

Manufacturing plant(s)

Manufacturer SOLETANCHE FREYSSINET 280, avenue Napoleon Bonaparte - CS 60002 92506 RUEIL MALMAISON CEDEX FRANCE

ETA 09/0169 dated 30.06.18 1 of 39

http://www.ukcares.com/

http://www.eota.eu/

Lyn

Typewritten text

Freyssinet Product Company (FPC) Zone d’Activité du Monay – Saint Eusèbe 71210 Montchanin France Tel : (+33) 385 73 69 00

Translations of this European Technical Assessment in other languages shall fully correspond to the original issued document and should be identified as such. Communication of this European Technical Assessment, including transmission by electronic means,

shall be in full. However, partial reproduction may be made, with the written consent of the issuing

Technical Assessment Body. Any partial reproduction has to be identified as such.

ETA 09/0169 dated 30.06.18 2 of 39

Contents

Clause Description Page

1 Scope of European Technical Assessment 5

1.1 Description of the Construction Product 5

1.2 Information on the intended use(s) of the Construction Product 5

1.2.1 Intended use 5

1.2.2 General Assumptions 6

1.2.3 Assumed Working Life 6

2. Essential Characteristics and relevant Assessment Methods and criteria

6

2.1 Essential Characteristics of the product 6

2.1.1 Tendons / Bars 6

2.1.2 Anchorages 6

2.1.3 Fixed Anchorages 6

2.1.4 Couplings 7

2.1.5 Tensile element 7

2.1.6 Friction in Tendons 7

2.1.7 Minimum radius of curvature 7

2.1.8 Slip at Anchorages and Couplers 7

2.1.9 Lateral Cover and Distances in Prestressed Concrete Structures 8

2.1.10 Bursting Reinforcement in Prestressed Concrete Structures 8

2.1.11 Concrete strength 8

2.1.12 Clearance behind Anchorages 8

2.1.13 Essential characteristics related to dangerous substances. 9

2.1.14 Measurement of Friction Coefficient and Load Transfer Percentage from Stressing end to the other

9

2.1.15 Adjustment of Prestressing Load 9

2.1.16 Possibility of Detensioning 9

2.1.17 Temporary or Permanent Caps 9

2.1.18 Verification Methods 9

2.2 Methods and criteria for assessing the performance of the product in relation to essential characteristics of the product

10

2.2.1 Reaction to Fire 10

2.2.2 Resistance to Fire 10

2.2.3 Content, emission and / or release of dangerous substances 10

2.2.4 Sustainable use of resources 10

2.3 Criteria for the determination of the product type(s) 11

3.0 Assessment and verification of constancy of performance 12

3.1 System (s) of assessment and verification of constancy of performance to be applied

12

3.2 Tasks of the Manufacturer 12

3.3 Tasks of the Notified body 14

3.3.1 Initial Type Testing of the product 14

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3.3.2 Initial Inspection of factory and of the factory production control 14

3.3.3 Continuous Surveillance 14

3.3.4 Audit Testing of Samples 14

3.3.5 Certification 14

3.3.6 CE Marking 14

3.3.7 Withdrawal of certification 14

4.0 Assumptions under which the fitness of the product(s) for the intended use was favourably assessed

18

5.0 Reference Documents 19

Annexes

Annex A - P Anchorage Drawings 21 - 38

Annex Q Lateral Cover and Distances in Prestressed Concrete Structures 39

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1. Scope of European Technical Assessment

1.1 Description of the construction product The Freyssinet bar prestressing system is designed for both bonded and unbonded internal and external prestressing. The Post tensioning kit is comprised of the following components: Freyssibar Post Tensioning System Anchorage Components

Tensile element Tendons are ribbed bars made of prestressing steel, hot rolled, threaded by cold deformation, with diameters: 26.5, 32, 36, 40 and 50mm, and a 1030MPa tensile strength complying with prEN 10138-4-Y-1030-H-26,5/50,0-R.

Coupling Fixed and movable couplers.

Anchorage Stressing and fixed anchorages with anchor plates, washers and nuts.

Bursting reinforcement* Additional reinforcement placed in the anchorage zone complying with EN 10080.

Ducts* Steel strip ducts complying with EN 523, Corrugated plastic ducts complying with fib bulletin 75.

Filling material* Grout complying with EN447 Grease complying with EAD160027 Wax complying with EAD160027

* Not supplied with the kit by the ETA holder

Table 1 Anchorage Components

The components of the kit have the same characteristics and geometry as the kit of ETA-09/0169

issued by CARES in October 2009

1.2 Information on the intended use(s) of the construction product 1.2.1 Intended use

The prestressing kit described in this ETA can be used for new structures, for repair and reinforcement of existing structures with following tendon types:

• Internal bonded tendon

• Internal unbonded tendon

• External tendon for structures with a tendon path situated outside the cross-section of the structure ormember but inside its envelope.

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

• bridges

• buildings

• nuclear containment structures

• offshore structures

• floating installations and platforms

• retaining walls

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1.2.2 General Assumptions

The manufacturer will provided the necessary installation instructions as detailed in section 4.0 Adherence to these instructions are essential to ensure the maintenance of performance and working life of the system.

1.2.3 Assumed working life

Measures taken in this ETA assume an intended service life of 100 years for prestressing kits. Indications mentioned on the service life of a construction product cannot be interpreted as a guarantee given neither by the manufacturer nor the approval body. They only serve as a means to select components and appropriate materials to meet the economically reasonable expected life-time of structures. Characteristics of product

2. Essential characteristics and relevant assessmentmethods and criteria

2.1 Essential characteristics of the product

2.1.1 Tendons / Bars

The thread is a special high quality and of high accuracy thread obtained by cold rolling. Nominal diameters of the ribbed bars are 26.5, 32, 36, 40 and 50mm.

The tendons consist of plain and ribbed high tensile bars complying with prEN 10138-4-Y-1030-H-R and

have the following properties:

Diameter mm 26.5 32 36 40 50

Characteristic

value of maximum force kN 568 828 1048 1294 2022

Characteristic value of

0.1% proof force kN 461 672 850 1049 1640

Table 2 Tendon properties

2.1.2 Anchorages The stressing anchorage consists of an anchor plate, a washer and a nut. For injection purposes, the bearing plate may be fitted with a grout slot and threaded holes to attach the grouting cap. The stressing anchorage can be used as a fixed anchorage. Details are given in Annex A.

2.1.3 Fixed Anchorages The fixed anchorage consists of an anchor plate with or without grout slots, a washer and a nut. The nut is tack welded onto the anchor plate at the factory

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2.1.4 Couplings The same coupler is used for mobile and fixed configurations. It connects two bars together by means of a sleeve. The fixed coupler enables the direct connection to the stressing anchorage of an already stressed tendon.

2.1.5 Tensile element

Initial prestressing and overstressing forces are specified in the respective standards and provisions valid at the place of use. The table 1 lists informative maximum values of the tendons.

Nominal bar diameter

Nominal cross sectional area

Maximum prestressing force

Maximum overstressing force (1)

d Sn 0.90 Sn Fp0.1k 0.95 Sn Fp0.1k

mm mm² kN kN

26.5 552 414 437

32 804 604 638

36 1018 765 807

40 1257 944 996

50 1964 1475 1557 The fulfilment of the stabilization criteria and requirements for crack widths in the load transfer tests were verified at 0.80 Sn Fpk ( Fp0.1k = 835 MPa; Fpk = 1030 MPa ) (1) Conditions to fulfill for overstressing as per EN 1992-1-1 - §5.10.2

Table 3 : Initial prestressing and overstressing forces according to Eurocode 2 and pr EN 10138- 4:2009

In any case, the stressing force has to satisfy regulations in the place of use.

2.1.6 Friction in Tendons

The coefficients of friction (µ) and of wobble (k), as defined in European standard EN1992-1-1 to obtain the

prestressing force with the equation P(x) = Pmax e-θ(µ+kx), vary in accordance with the type of bars.

The coefficients in the table 2 are the values provided by the above European standard.

Table 4 (Friction losses) Friction losses in the anchorages and couplers are low and need not to be taken into consideration in design and execution.

2.1.7 Minimum radius of curvature Straight bars only are used.

2.1.8 Slip at Anchorages and Couplers

Table 5 specifies the slip values to be taken into consideration in design and for determining tendon elongation.

Table 5 Slip values at anchorages

Type of bars k

(rad/m) µ

(rad-1)

Ribbed bars 0.005 k 0,01 0,65

Nominal bar diameter (mm) 26,5 - 32 - 36 40 –50

Slip at stressing anchorage (mm) 1,5 2,0

Slip at fixed anchorage (mm) 0,15

Slip at sleeve (mm) 0,30

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A smaller draw-in value is reached at the stressing anchorage by carrying out three jacking operations to the maximum load followed each time by a transfer of the force to the anchorage. Resulting draw-in values are given in the table 6. Such procedure is recommended for short bars (i.e. less than 4 meters).

Table 6 Slip values at anchorages after three jacking operations

2.1.9 Lateral Cover and Distances in Prestressed Concrete Structures

The minimum anchorage spacing and edge distance are specified in Annex Q .

2.1.10 Bursting Reinforcement in Prestressed Concrete Structures

Bursting reinforcement consists in:

• Surface reinforcement,

• Anchorage bursting reinforcement,

• General reinforcement to balance mechanically the concerned piece within the structure, thedimensions of which result from the design rules of reinforced concrete.

Anchorage bursting reinforcement as defined in annex P results from load transfer testing. If required the local zone reinforcement specified in the ETA may be modified for a specific project design in accordance with national regulations and relevant approval of the local authorities and of the ETA holder to provide equivalent performance.

2.1.11 Concrete strength Concrete according to EN 206-1 shall be used. The actual mean compressive strength of concrete measured on cylinders at time of stressing fcm,o shall be at least 30 MPa.

2.1.12 Clearance behind Anchorages

Behind each anchorage a clearance must be reserved to allow for:

• Installation of nuts,

• Placing of stressing jack,

• Sufficient protection cover of cable end after cutting-off of bar overlengths,

• Installation of temporary or permanent cap, if necessary.

Table 7 : Minimum bar overlength for stressing (mm, from the bearing plate)

For special proposes this given clearance might be reduced after consulting the ETA holder. For external fixed anchorages a minimal clearance of 200 mm allows the installation of the washer, and nut on the protruding bar.

2.1.13 Essential characteristics related to dangerous substances. The ETA holder declares that no dangerous substances are present in the components of the PT kit. 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

Nominal bar diameter (mm) 26,5 - 32 - 36 40 –50

Slip at stressing anchorage (mm) 0,5 0,7

Bar diameter 26.5 32 36 40 50

Jack directly connected to the bar 185 190 195 260 260

Jack using a traction tie rod 116 125 145 170 215

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national laws, regulations and administrative provisions). In conformity with the provisions of the European directive 89/106/EEC, these requirements must also be complied with wherever they apply.

2.1.14 Measurement of Friction Coefficient and Load Transfer Percentage from Stressing end to the other

This operation is possible whenever access to both ends is possible. 2.1.15 Adjustment of Prestressing Load

In the case of prestressing tendons injected with a flexible filling product, it is possible to adjust the prestressing load at any time during service life if tendon overlengths have been maintained. The overlengths are protected by an adequately long protection cap.

2.1.16 Possibility of Detensioning

In the case of prestressing tendons injected with a flexible filling product, it is possible to detension the tendon.

2.1.17 Temporary or Permanent Caps

Caps are available. Caps can be plastic or steel. If steel, they are protected against corrosion by hot- dip galvanising in accordance with standard EN ISO 1461, or are delivered uncoated and are painted on site.

2.1.18 Verification Methods

The assessment of the suitability of the kit for the intended use, in relation to the requirements for mechanical resistance and stability in the sense of the Essential Requirement 1 has been made in compliance with EAD 160004-00-0301.

Performances examined in conformity to the with EAD 160004-00-0301 satisfy the pertinent essential requirements. These are mainly performances related to static load, transfer on concrete and resistance to fatigue. Methods for check, evaluation and assessment of aptitude for use and test procedures conform those detailed in EAD 160004-00-0301.

2.1.19 Lubrication, Temporary protection, conditioning

Bar anchorage and couplers are delivered slightly oiled. Temporary protection of tensile elements is obtained by soluble oil. Following products may be used:

- Shell Dromus B Oil, - Caltex soluble RGBF Oil, - Mobiloil Solvag 1533 Oil,

- Rustban 310 Oil.

.

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2.2 Methods and criteria for assessing the performance of the product in relation to essential characteristics of the product

Assessment of the performance of the post-tensioning system part of this document for the intended use in the sense of basic requirement for construction work 1 (mechanical resistance and stability) and for basic requirement for construction work 3 (hygiene, health and environment) has been made in accordance with EAD 160004-00-0301.

2.2.1 Reaction to fire

Classified: Class A1( by definition as per section 2.2.35 of EAD 16004).

2.2.2 Resistance to fire

No aspect of performance relevant to this essential requirement.

2.2.3 Content, emission and/or release of dangerous substances

According to the manufacturer’s declaration the PT system does not cause harmful emissions of toxic gases, dangerous particles or radiation to the indoor environment or contamination of the outdoor environment (air, soil, water).

2.2.4 Sustainable use of natural resources

No aspect of performance relevant to this essential requirement.

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2.3 Criteria for the determination of the product-type(s)

The assessment of the fitness of the Freyssibar bar Post tensioning System for the intended use in relation to the requirements for mechanical resistance and stability has been made in compliance with Annex A of EAD 160004-00-0301. This European Technical Assessment for the post-tensioning system is issued on the basis of agreed

data, deposited at UK CARES, which identifies the post-tensioning system that has been assessed and

judged.

Table 8 – Performance of the system BWR1

Product-type: Post-Tensioning Kit Intended use: For the prestressing of structures

Basic requirements for construction work

Essential characteristic Performance

[1] Mechanical resistance and

stability

Resistance to static load

The PT system as described in the ETA meets the acceptance criteria of EAD 160004-00-0301, Clause 2.2.1

Resistance to fatigue The PT system as described in the ETA meets the acceptance criteria of EAD 160004-00-0301, Clause 2.2.2.

Load transfer to the

structure

The PT system as described in the ETA meets the acceptance criteria of EAD 160004-00-0301, Clause 2.2.3.

Table 9 – Performance of the system BWR3

Product-type: Post-Tensioning Kit Intended use: For the prestressing of structures

Basic requirement for construction work

Essential characteristic Performance

[3] Hygiene, health and

environment

Release of dangerous

substances

PT system does not cause harmful emission of toxic gases, dangerous particles or radiation to the indoor environment nor contamination of the outdoor environment (air, soil, water)

In addition to the specific clauses relating to dangerous substances contained in this European Technical Assessment, there may be other requirements applicable to the products falling within its scope (e.g. transposed European legislation and national laws, regulations and administrative provisions). In order to meet the provisions of the EU Construction Products Regulation, these requirements need also to be complied with, when and where they apply.

BWRs 2, 4, 5, 6 and 7 are not relevant according to EAD 160004.

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3 ASSESSMENT AND VERIFICATION OF CONSTANCY OF PERFORMANCE

3.1 System(s) of assessment and verification of constancy of performance to

be applied

The system of attestation of conformity specified by the European Commission in mandate 98/456/EC is system 1+, with audit testing of samples, described in Council Directive (89/106/EEC) Annex III and is detailed as follows: a) Tasks for the manufacturer (1) Factory production control (2) Further testing of samples taken at the factory by the manufacturer in accordance with a prescribed test plan.

(b) Tasks for the Approved Body: (1) Initial type testing of the product. (2) Initial inspection of factory and of factory production control (FPC). (3) Continuous surveillance, assessment and approval of factory production control (FPC). (4) Audit testing of samples.

3.2 Tasks of the manufacturer

Factory production control

According to the Commission Decision 98/456/EC the system of assessment and verification of constancy of performance to be applied to the PT system is System 1+. System 1+ is detailed in Commission Delegated Regulation (EU) № 568/2014 of 18 February 2014, Annex, 1.1., and provides for the following items. The quality plan shall specifically ensure that purchased product conforms to specified purchase requirements. The type and extent of control applied to the supplier and the purchased product shall be dependent upon the effect of the purchased product on subsequent product realization or the final product. The manufacturer shall evaluate and select suppliers based on their ability to supply product in accordance with the manufacturer’s requirements. Criteria for selection, evaluation and re-evaluation shall be established. Records of the results of evaluations and any necessary actions arising from the evaluation shall be maintained. In accordance with EN ISO9001, the manufacturer shall monitor and measure the characteristics of the product to verify that product requirements have been met. This shall be carried out at appropriate stages of the product realization process in accordance with the following test plan (Table 10). Evidence of conformity with the test plan shall be maintained and shall indicate the person(s) authorizing release of product. Product release and service delivery shall not proceed until the planned arrangements have been satisfactorily completed

All records of relevant results concerning the ETA and the audit reports concerning the components manufactures shall be made available for at least 10 years

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Table 10 Control plan for the manufacturer; corner stones

No Subject/type of control (product, raw/constituent material, component -

indicating characteristic concerned)

Test or

control

method (refer to 2.2

or 3.4)

Criteria, if any

Minimum number of samples

Minimum frequency of

control

Factory production control (FPC) [including testing of samples taken at the factory in accordance with a prescribed test plan]*

1 Bearing plate material Checking of relevant certificate 1)

100% Continuous

Bearing plate dimensions Testing 3%, min of 2 specimensper batch

Continuous

Bearing plate visual inspection Testing 100% Continuous

Bearing plate traceability Bulk

2 Nut, washer and coupling material Checking of relevant certificate 3)

2) 100% Continuous

Nut, washer and coupling treatment hardness Testing 2) 0.5%, min of 2 specimensper batch

Continuous

Nut, washer and coupling detailed dimensions Testing 2) 5%, min of 2 specimensper batch

Continuous

Nut, washer and coupling visual inspection Checking 2) 100% Continuous

Nut, washer and coupling traceability Full

3 Tensile element (bar) material Checking 2) 100% Continuous

Tensile element (bar) diameter Testing 2) 1 sample each rolled bar batch

Tensile element (bar) visual inspection Checking 2) 1 sample each rolled bar

batch

Tensile element (bar) thread form Checking 2) 1 sample Each rolled bar

batch)

Key

1) The certificate is at least a test report 2.2 according to EN 10204.

2) Conformity with the specifications of the components

3) The certificate is an inspection report 3.1 according to EN 10204

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3.3 Tasks of the notified body

3.3.1 Initial type-testing of the product The results of the tests performed as part of the initial assessment for this European Technical Approval may be used unless there are changes in the manufacturing process or plant. In such cases, the necessary initial type-testing shall be agreed between the manufacturer and the approved body involved.

3.3.2 Initial inspection of factory and of factory production control The approved body shall audit the manufacturer’s factory production control system including the prescribed test plan (Table 10) to ensure that the PT system complies with this ETA.

3.3.3 Continuous surveillance The approved body shall audit the manufacturer’s factory production control system including the prescribed test plan (Table 10) at least once a year to ensure that the PT system continues to comply with this ETA.

3.3.4 Audit testing of samples The approved body shall select component samples during surveillance audits and check for compliance with the above test plan (Table 11).

3.3.5 Certification The approved body shall issue a certificate of product conformity as evidence of compliance with this ETA.

3.3.6 CE marking The CE marking shall be affixed to the delivery note. The CE mark shall be accompanied by the following information: - Name or identifying mark of the producer and plant. - The last two digits of the year in which the marking was affixed. - The numbers of the certificates of conformity. - The ETA number. - The use categories. - The number of the approved body involved. - The product's identity (commercial name).

3.3.7 Withdrawal of certification In cases where the provisions of the European Technical Assessment and the “Freyssinet Works Factory Production Control Plan” are no longer fulfilled the notified body shall withdraw the certificate of conformity and inform the UK Certification Authority for Reinforcing Steels (CARES) without delay.

Traceability full : Full traceability of each component to its raw material. bulk : Traceability of each delivery of components to a defined point. Material: Defined according to technical specification deposited by the supplier Detailed dimension: Measuring of all the dimensions and angles according to the specification given in thetest plan Visual inspection: Main dimensions, correct marking and labelling, surface, corrosion, coating, etc.

Treatment hardness: surface hardness, core hardness and treatment depth (if applicable)

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Table 11 Control plan for the notified body; corner stones

Initial inspection of the manufacturing plant and of factory production control (for systems 1+, 1 and 2+ only)

No Subject/type of control (product, raw/constituent material, component - indicating characteristic concerned)

Test or control method

Criteria, if any


Minimum frequency of control

1 FPC documentation system: procedures and technical forms

documents check all

2 Records of the FPC documentation system records check 1 for type

3 Factory organisation: qualifications, tasks and responsibilities of the technical and management staff

documents and records (3)

check all

4 Production flow documents check all

5 Order management: offer, order and accompanying documentation

documents check 1

6 Preparation of the Register of Manufacturer and the Declaration of Performance

documents check all

7 Criteria, methods and records of materials internal controls and checks of the acceptance controls

documents and records

check 1 for type

8 Production management (frequency, number and location of samples of finished products or components, periodic tests; identification systems products and their components; certifications of materials)


check 1 for type

9 Records of tests performed by the Manufacturer

records check all

10 Inspection of production plants and warehouses

visual check all

11 Manufacturer testing lab: check of critical equipment for the purpose of experimental measurements and / or controls; assurance metrological traceability of measurement and control equipment

visual, documents and records

check all

12 Treatment of non-conforming products, criteria for declassification and segregation

visual check 1

13 Traceability of products, from raw materials to the job site and vice versa

visual and records

check 1

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Continuous surveillance, assessment and evaluation of factory production control (for systems 1+, 1 and 2+ only)



Criteria, if any



1 FPC documentation system: procedures and technical forms

documents check modificati ons only

1/year

2 Records of the FPC documentation system records check 1 for type 1/year

3 Factory organisation: qualifications, tasks and responsibilities of the technical and management staff


check modificati ons only

1/year

4 Production flow documents check modificati ons only

1/year

5 Register of Manufacturers records check all 1/year

6 Records of audits of component manufacturers

records check all 1/year

7 Declaration of Performance records check 1 1/year

8 Order management: offer, order and accompanying documentation

records check 1 1/year

9 Criteria, methods and records of materials internal controls and checks of the acceptance controls


10 Production management (frequency, number and location of samples of finished products or components, periodic tests; identification systems products and their components; certifications of materials)

records check 1 for type 1/year

11 Records of tests performed by the Manufacturer


12 Inspection of production plants and warehouses

visual check all 1/year

13 Manufacturer testing lab: check of critical equipment for the purpose of experimental measurements and / or controls; assurance metrological traceability of measurement and control equipment

visual and records

check all 1/year

14 Treatment of non-conforming products, criteria for declassification and segregation

visual and records

check 1 1/year

15 Traceability of products, from raw materials to the job site and vice versa

visual and records

check 1 1/year

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Audit-testing of samples taken before placing the product on the market (for system 1+ only)



Criteria, if any



1 Bearing plate material Checking and testing (hardness and chemical)

2) 1 1/year

Bearing plate detailed dimensions testing 2) 1 1/year

Bearing plate visual inspection checking 2) 1 1/year

2 Nut, washer and coupling material Checking and testing (mechanical and chemical)

2) 2 1/year

Nut, washer and coupling treatment hardness

Checking and testing (hardness profile)

2) 2 1/year

Nut, washer and coupling detailed dimension Testing 2) 1 1/year

Nut, washer and coupling main dimensions, surface hardness

Testing 2) 5 1/year

Nut, washer and coupling visual inspection checking 2) 5 1/year

3 Single tensile element test Annex C.7 Annex C.7 9 1/year

Key 1) If the kit comprises different types of anchor heads e.g. with different materials, different shape, different wedges, etc., then the number of samples are understood as per type. 2) Conformity with the specifications of the components 3) Requirements and points to check are the following: Technical staff: qualified staff that passed at least an internal training for the tasks

Laboratory staff for FPC with passed internal and external qualifications

Clear and reasonable system of tasking and supervising, documented; recognizable responsibilities

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4 Assumptions under which the fitness of the product(s) for the intended use was favourably assessed

4.1 Manufacturing

The Freyssinet Post-tensioning bar system shall be manufactured in accordance with this European Technical Approval and the production shall be covered by a current product conformity certificate in accordance with ETAG013.

4.2 Installation

The Freyssinet post-tensioning bar system shall be installed by an experienced specialist PT contractor in accordance with the installation instructions (Freyssinet installation manual PB1030 SPA 001) using the ETA holders specified equipment and procedures

Post-tensioning design shall comply with the recommendations given in this ETA and the anchorage shall be detailed in accordance with the bursting reinforcement requirements given in Annex P of this ETA.

Stressing shall not be undertaken until the minimum specified concrete transfer strength has been achieved.

Components supplied by third parties that are included in this ETA (and not supplied by the ETA holder) shall comply with the requirements of this European Technical Approval.

All necessary information to enable satisfactory installation shall be supplied by the ETA holder with the PT kit.

RECOMMENDATIONS FOR THE MANUFACTURER. 4.3 Recommendations on packaging, transport and storage

The ETA holder shall package the PT kit components to prevent corrosion, chemical change and mechanical damage during transportation to the end user.

The ETA holder shall give instructions for suitable storage on site to prevent corrosion, chemical change and mechanical damage.

4.4 Recommendations on use, maintenance, repair

The Freyssinet Post-tensioning bar system bar system requires no maintenance provided that it is protected from mechanical damage and corrosion. Protection may also be required against fire damage. Occasionally, there may be a requirement to reassess the tensile load in a tendon, some time after installation and stressing. Provided that access can be gained to one end, where a nut and bearing plate exist and that the thread beyond the nut is of sufficient length and not corroded, a jack can be reattached and the load in the tendon assessed

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5 Reference documents

EN 1992-1-1: 2004 Eurocode 2: Design of concrete structures

prEN 10138-4: 2000 Prestressing steels – Part 4: Bars

BS EN ISO9001:2008 Quality Management Systems. Requirements (Valid until September 2018)

BS EN ISO9001:2015 Quality Management Systems. Requirements

EN 10080: 2005 Steel for the reinforcement of concrete – Weldable reinforcing steel

EN 10025: 2004 Hot rolled products of structural steels

EN 523: 2003 Steel strip sheaths for prestressing tendons - Terminology, requirements, quality control

EN 10255:2004 Non-alloy steel tubes suitable for welding or threading,

EN 524: 1997 – Parts 1 to 6: Steel strip sheaths for prestressing tendons - Test methods

- Part 1: Determination of shape and dimensions;

- Part 2: Determination of flexural behaviour;

- Part 3: To and fro bending test;

- Part 4: Determination of lateral load resistance;

- Part 5: Determination of tensile load resistance;

- Part 6: Determination of leak tightness (Determination of water loss)

EN 445:2007 Grout for prestressing tendons, Test methods

EN 446:2007 Grout for prestressing tendons, Grouting procedures

EN 447: 2007 Grout for prestressing tendons, Specifications for common grout

EN 934-4:2009 Admixtures for concrete, mortar and grout: Admixtures for grout for prestressing

tendons – Definitions, requirements and conformity

EN ISO 1461: 2009 Hot dip galvanized coatings on fabricated iron and steel articles -- Specifications and

test methods

EN 10204:2004 Metallic products; type of inspection documents

EN 206-1:2013 + A1:2016 Concrete – Part 1: Specification, performance, production and conformity ETAG013: June 2002 – Guideline for European Technical Approval of Post Tensioning Kits for Prestressing of Structures.

ETA 09/0169 dated 30.06.18 19 of 39

ANNEXES A – P: ANCHORAGE DRAWINGS

ETA 09/0169 dated 30.06.18 20 of 39

Diagram A1.1 : with injection inlet

Diagram A1.2: without injection inlet

Nominal

diameter tube (outer diameter) Etube (thickness)

L

mm mm mm mm

26.5 42.9 2 200

32 48.5 2 200

36 50.8 2 200

40 57.2 2 250

50 76.2 2 250

FREYSSINET- PT bar tendon

Anchor plate installed before concreting

FIXED & STRESSING ANCHORAGE

Annex A1

ETA 09/0169 dated 30.06.18 21 of 39

Diagram A2.1: with injection inlet

Diagram A2.1: without injection inlet


Anchor plate installed after concreting

FIXED & STRESSING ANCHORAGE

Annex A2

ETA 09/0169 dated 30.06.18 22 of 39


Internal prestressing - Bonded tendon

Cement grout injection

EMBEDDED FIXED ANCHORAGE

Annex A3

Without cap

With cap

ETA 09/0169 dated 30.06.18 23 of 39

Nominal

diameter duct (inner diameter) Educt (thickness)

L

mm mm mm mm

26.5 45 0.45 200

32 50 0.45 200

36 55 0.45 200

40 60 0.45 250

50 75 0.50 250


Internal prestressing - Bonded tendon

Cement grout injection

STANDARD ANCHORAGES

Annex B

ETA 09/0169 dated 30.06.18 24 of 39

Nominal

diameter tube** x E tube***

steel (*)

tube** x E tube***

PE tube

mm mm mm

26.5 42.9 x 2 63 x 5.8

32 48.5 x 2 63 x 5.8

36 50.8 x 2 75 x 6.8

40 57.2 x 2 75 x 6.8

50 76.2 x 2 90 x 8.2

* for a steel ducting, tube dimensions are given assuming a butt welding of the pipe to the formwork

tube welded to the anchor plate

** outer diameter

*** thickness


Internal prestressing - Unbonded tendon

grease or wax injection

STANDARD ANCHORAGES

Annex C

ETA 09/0169 dated 30.06.18 25 of 39

Nominal


steel

mm mm

26.5 42.9 x 2

32 48.5 x 2

36 50.8 x 2

40 57.2 x 2

50 70 x 2

** outer diameter

*** thickness


External tendon with steel pipe

Cement grout or grease or wax injection

Annex D

ETA 09/0169 dated 30.06.18 26 of 39

STANDARD ANCHORAGES

Nominal


PE tube

mm mm

26.5 63 x 3.8

32 63 x 3.8

36 75 x 4.5

40 75 x 4.5

50 90 x 5.4

** outer diameter

*** thickness


External tendon with HDPE tube

cement or grease injection

STANDARD ANCHORAGES

Annex E

ETA 09/0169 dated 30.06.18 27 of 39

Nominal


PE tube

mm mm

26.5 63 x 5.8

32 63 x 5.8

36 75 x 6.8

40 75 x 6.8

50 90 x 8.2

** outer diameter

*** thickness


External tendon with HDPE tube

wax injection

STANDARD ANCHORAGES

Annex F

ETA 09/0169 dated 30.06.18 28 of 39

Diagram G1 : movable coupler

Diagram G2 : fixed coupler


Bonded tendons

MOVABLE AND FIXED COUPLEURS

Annex G

sleeve

Primary bar

Secondary bar

ETA 09/0169 dated 30.06.18 29 of 39

Diagram G.1: movable coupler

Diagram G.2: fixed coupler

Nominal

diameter D* x E**

movable coupler

D* x E **

Fixed coupler

mm mm mm

26.5 70 x 2 88.9 x 2

32 76.2 x 2 88.9 x 2

36 88.9 x 2 101.6 x 2

40 95 x 2 114.3 x 2

50 114.3 x 2 152.4 x 2

* D : outer diameter

** : thickness


Bonded tendons

CAP DIMENSIONS FOR

MOVABLE AND FIXED COUPLEURS

Annex H

ETA 09/0169 dated 30.06.18 30 of 39

Nominal

diameter W H ØA ØB PITCH

mm mm mm mm mm mm

26.5 50 37 30.8 25.9 6

32 56 41 36.5 31.6 6

36 62 46 40.7 35.8 6

40 65 55 46.2 39.5 8

50 90 71 55.9 49.25 8


Bonded, unbonded and external tendons

ANCHORAGE

NUT

Annex I

ETA 09/0169 dated 30.06.18 31 of 39

Nominal

diameter E Dext Dint

mm mm mm mm

26.5 6 65 32.5

32 6 70 38.5

36 6 75 42.5

40 6 80 48.5

50 6 105 58



ANCHORAGE

WASHER

Annex J

ETA 09/0169 dated 30.06.18 32 of 39

Nominal

diameter D L ØA ØB PITCH

mm mm mm mm mm mm

26.5 45 90 30.8 25.9 6

32 50 115 36.5 31.6 6

36 60 130 40.7 35.8 6

40 65 140 46.2 39.5 8

50 76 170 55.9 49.25 8



COUPLING DEVICE

SLEEVE

Annex K

ETA 09/0169 dated 30.06.18 33 of 39

Nominal

diameter ØA ØB PITCH

mm mm mm mm

26.5 28.8 25.2 6

32 34.5 30.8 6

36 38.6 35.0 6

40 43.4 38.6 8

50 53.2 48.2 8



BAR DIMENSIONS

Annex L

ETA 09/0169 dated 30.06.18 34 of 39

Standard manufactured dimensions

Nominal

diameter A B E D

mm mm mm mm mm

26.5 125 110 35 34

32 125 125 35 40

36 160 140 40 44

40 160 160 40 50

50 200 200 45 60

Minimum dimensions – Available on special demand

Nominal

diameter A B E D

mm mm mm mm mm

26.5 110 110 30 34

32 125 125 35 40

36 140 140 40 44

40 160 160 40 50

50 200 200 45 60



ANCHOR PLATE

Annex M

ETA 09/0169 dated 30.06.18 35 of 39

Nominal

diameter L

mm mm

26.5 80

32 85

36 100

40 100

50 130



ANCHOR PLATE WITH GROUT SLOTS

Annex N

ETA 09/0169 dated 30.06.18 36 of 39

Nominal

diameter S1 x S2 X x Y L standard

L for keeping

stressing overlength

mm mm mm mm mm

26.5 110 x 110 90 x90 95 210

32 125 x 125 95 x 95 100 220

36 140 x 140 105 x 105 120 220

40 150 x 150 110 x 110 120 220

50 185 x 185 142 x 142 150 280



PERMANENT CAP

Annex O

ETA 09/0169 dated 30.06.18 37 of 39

All reinforcement according to EN 10800:2005

fy = 500 MPa

BURSTING REINFORCEMENT

Nominal

bar

diameter

Rebar

diameter

Number

of

frames

C P Dmax Hx x Hy

(mm) (mm) (mm) (mm) mm (mm x mm)

26.5 10 5 20 40 42.9 160 x 160

32 12 4 20 50 48.5 185 x 185

36 12 5 20 50 50.8 210 x 210

40 12 6 20 60 57.2 240 x 240

50 14 6 20 60 70 310 x 310



BURSTING REINFORCEMENT

Annex P

ETA 09/0169 dated 30.06.18 38 of 39

ANNEX Q: Lateral Cover and Distances in Prestressed Concrete Structures

In what follows, it is considered that anchorages are positioned relative to two orthogonal directions x

and y.

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

B+30 (mm)

y A+30 (mm)

x . y a . b

x 0.85 a

y 0.85 b

x’ 0. 5 x + cover – 10 (mm)

y 0. 5 y + cover – 10 (mm)

The values of a and b are given in the table 5 for a concrete strengths fcm,o of 30 MPa. Table

5 : Side length of prisms

y’

y

B

A

x’ x’

y’

y

B

A

x x x’

Nominal bar diameter Fcm,o = 30 MPa

(mm) a x b (mm)

26.5 190 x 190

32 220 x 220

36 245 x 245

40 270 x 270

50 340 x 340

ETA 09/0169 dated 30.06.18 39 of 39