European Technical Assessment Post-Tensioning Systems

Transcription

1 European Techncal Post-Tensonng Systems DYWIDAG External and Internal Unbonded Strand Post-Tensonng System European Organsaton for Techncal Approvals Europäsche Organsaton für Technsche Zulassungen Organsaton Européenne pour l Agrément Technque 30 May 1

2 Member of Cerema ITM 110 rue de Pars Sourdun FRANCE Mal: Tel: web: European Techncal General Part ETA 13/0979 of 30/05/1 Techncal Body ssung the ETA: Cerema Trade name of the constructon product DYWIDAG external and nternal unbonded strand post-tensonng system Product famly to whch the constructon product belongs Manufacturer - Post-tensonng kt for prestressng of structures DYWIDAG Systems Destouchesstrasse Munch Germany Manufacturng plant Ths European Techncal contans Ths European Techncal s ssued n accordance wth Regulaton (EU) No 305/11, on the bass of Ths ETA replaces DYWIDAG Systems Max Planck Rng, Langenfeld Germany 4.pages ncludng 24 Annexes whch form an ntegral part of ths assessment. EAD Edton September, Post-Tensonng Kts for Prestressng of Structures ETA 13/0979, ssued on 27/06/13

3 Index 1. TECHNICAL DESCRIPTION OF THE PRODUCT Defnton of the product Components and desgn Range and desgnaton of anchorages Strands Wedges Wedge plates Anchor plates Cast-ron anchor bodes Steel trumpet wth PE-nsert (for external tendon) Helx and addtonal renforcement Sheathngs, tubes and trumpets Grout Wax and grease Protectve caps Desgn General Concrete strength Weldng Frcton losses Radus of curvature of the tendons at devatons and geometry of devators Centre and edge dstances of the tendon anchorages, concrete cover Renforcement n the anchorage zone Support of ducts Resstance to fatgue at anchorages Installaton Installaton of the tendon Wedgng force, slp at anchorages, wedge securng and corroson protecton compound Stressng and stressng records Stressng Restressng Stressng record Prestressng jacks and space requrements, safety-at-work Stressng forces Groutng Wax and grease njecton 15 2 SPECIFICATIONS OF THE INTENDED USE IN ACCORDANCE WITH THE APPLICABLE EUROPEAN ASSESSMENT DOCUMENT 2.1 Intended use 2.2 Workng lfe 3 PERFORMANCE OF THE PRODUCT AND METHODS USED FOR ITS ASSESSMENT 17 2

4 4 ASSESSMENT AND VERIFICATION OF CONSTANCY OF PERFORMANCE SYSTEM APPLIED, WITH REFERENCE TO ITS LEGAL BASE 1 5. TECHNICAL DETAILS NECESSARY FOR THE IMPLEMENTATION OF THE AVCP SYSTEM, AS PROVIDED FOR IN THE APPLICABLE EAD Tasks for the manufacturer Factory producton control Other tasks Tasks of the Notfed Body General Determnaton of the product-type on the bass of type testng (ncludng samplng), type calculaton, tabulated values or descrptve documentaton of the product Intal nspecton of factory and of factory producton control Survellance, assessment and approval of factory producton control Audt testng of samples taken at the manufacturer 21 3

5 1. Techncal descrpton of the product 1.1 Defnton of the product Ths European Techncal apples to: DYWIDAG external and nternal unbonded strand post-tensonng system. Consstng of 3 to strands. The prestressng tendon conssts of a bundle of 7-wre strands, anchorages, devators, sheathng/duct and corroson protectve compounds. Strands: - 7-wre prestressng steel strand wth dameter and tensle strengths as gven n Table 1, accordng to the pren : Prestressng steels Strand. As long as EN 1013 s not mplemented, 7-wre strands n accordance wth natonal provsons shall be used. Table 1: Dmensons and propertes of 7-wre strands Nomnal dameter Desgnaton accordng to pren Nomnal tensle strength mm nch - N/mm Y1770S Y1S Y1770S Y1S7 1 Anchorages: - Stressng (actve) and fxed (passve) anchor: o Multplane anchorage MA for tendons wth 5 to strands: - Anchor body MA - Wedge plate MA - PE Trumpet o Plate anchorage for tendons wth 3 to strands: - Anchor Plate, - Wedge Plate, - Steel trumpet wth PE nsert - PE-nsert Devators: - For external PT-systems, devators are specfc elements at gven locatons n the structure along the tendon. These are generally made of steel tubes (straght or prebent) placed nsde the concrete structure or constructon steel saddles appled to the structure Devators shall be desgned accordng to ths ETA, unless a natonal regulaton n the place of use s strcter. 4

6 Renforcements: - Helx and addtonal renforcement (strrups) n the anchorage zone for the concrete confnement at anchorages to ensure local prestressng force transfer nto the concrete structure. Sheaths and ducts: - Sheaths and plastc ducts. Sheathngs for external and nternal unbonded tendons are made of plastc (polyethylene, HDPE). Corroson protecton:- Permanent corroson protecton for tensle elements, and anchorages can be a cement based grout (n accordance wth EN 447 or EAD ) for rgd njecton or for flexble njecton grease or wax based compound (n accordance wth EAD ). Plastc tubes, ducts, the ordnary renforcement for burstng renforcement and groutng products are covered by European or natonal provsons thus they are not descrbed n ths ETA. However, they can be used for the prestressng kts. 1.2 Components and desgn The components correspond to the drawngs and provsons gven n ths European Techncal ncludng the Annexes. The characterstc materal values, dmensons and tolerances of the components not ndcated n the Annexes shall correspond to the respectve values lad down n the techncal documentaton of ths European Techncal. Arrangement of the tendons, the desgn of the anchorage zones, the anchorage components and the dameters of the sheathngs shall correspond to the attached descrpton and drawngs; the dmensons and materals shall comply wth the values gven theren Range and desgnaton of anchorages The frst dgt of the desgnaton of components of anchorages (6) dentfes the nomnal strand dameter n tenfold of nches (0. /0.62 ), the second dgt s an nternal code and the last two dgts refer to the number of strands n the tendon (sze of tendon). The components (except helx and addtonal renforcement) ft for tendons wth both strand strengths Strands 7-wre prestressng steel strands wth a nomnal dameter of 15.3 mm or 15.7 mm and tensle strengths of N/mm² or 1 N/mm² shall be used, n accordance wth natonal provsons wth the characterstcs gven n Annex 19. To avod confusons only strands wth one nomnal dameter and tensle strength shall be used at one ste. Only strands stranded n the same drecton shall be used n a tendon Wedges Wedges, see Annex 2 are approved wth 30 -tooth or 45 -tooth. The segments of the wedges for strands 15.3 mm are 42 mm long and the segments of the wedges for strands 15.7 mm are 45 mm long. The wedge dmenson does not depend on the strands strength. Wedges of one suppler only may be used at one constructon ste. 5

7 1.2.4 Wedge plates The concal drlls of the wedge plates, see Annex 2 shall be clean, stanless and provded wth a corroson protecton Anchor plates The 3 to strands anchor plates (see Annexes 3, 4 and 5) are made of plan steel and are used together wth wedge plates as stressng of fxed anchors. In case of external prestressng, a crcular anchor plate wth recess tube welded watertght to t shall be used, see Annexes 1 and 3 to 5. In case of nternal prestressng an anchor plate wth steel trumpet and tenson rng, welded watertght to each other shall be used, see Annexes 1 and 3 to Cast-ron anchor bodes The 3 to strands anchor bodes MA (see Annexes 9 and 10) are made of cast ron and are used together wth wedge plates as stressng or fxed anchor, for external and nternal prestressng. They are crcular n shape and provde several load transfer planes for load transfer to concrete and feature a centrc crcular hole for passng through the tendon Steel trumpet wth PE-nsert (for external tendon) Steel trumpets are applcable for both nternal and external prestressng. As a part of the steel trumpet the tenson rng s welded to the steel tube wth the flange. The PEnsert s fxed to the tenson rng through a gasket wth a retanng rng and screws, see Annex 1. A pece of plastc sheathng wth relevant dameter s mrror welded to the PE-nsert. Its length s determned n order to protrude out from the concrete body around the anchorage zone Helx and addtonal renforcement The steel grades and dmensons of the helxes and addtonal renforcement shall be n conformty wth the specfcatons gven n the Annexes 6 to, and Annexes 11 to 15 and the techncal documentaton of the ETA. The central poston n the structural concrete member on ste shall be ensured accordng to secton Helxes for anchorages wth anchor bodes MA can be made of plan round steel wre or rbbed renforcng steel. The end turn of the helx shall be welded the anchor plate or the anchor body MA or to a closed rng. Weldng of the helx end turn may be omtted f the helx s extended by 1.5 addtonal turns Sheathngs, tubes and trumpets Sheathngs made of polyethylene shall comply wth EN 121 and Annex D of EAD The dmensons of the sheathngs shall comply wth values gven n Annex 2. The connectons and seals between the sectons of sheathng are effected ether wth mrror weldng or electro-weldng couplers. The recess tubes and steel tubes (respectvely welded to anchor plate and flange, see Annexes 3 to 5 are manufactured from at least 3.2 mm thck steel sheath materal (see Annex 1). 6

8 The trumpets at the stressng and fxed anchorages (see Annexes 9 and 10) are manufactured from 3.0 mm thck PE materal (see Annex 1). The connectons and seals between a secton of sheathng and a trumpet are effected wth mrror weldng Grout Grout accordng to EN 447 shall be used Wax and grease Wax and grease as defned n EAD or accordng to natonal regulatons vald n place of use shall be used Protectve caps Caps serve as closng the anchorage to enable groutng/njecton and ts protecton. The caps are made of steel. Regularly they cover the wedge plate and are left n place after njecton. Elongated caps may be used for suffcent strand over-length for later prestressng force adjustment or detensonng (f applcable). 1.3 Desgn General Desgn of the structure shall permt correct nstallaton, stressng and groutng of the tendon and the desgn and renforcement of the anchorage zone shall permt a correct placng of renforcement and compactng of the concrete. Tendons arranged one on top of each other should be separated by an approprately thck concrete layer, as n case of tendon curvatures there s a rsk of the nner ducts to be crushed by the outer tendons, as a result of devaton forces resultng from the prestressed tendons. The ntal prestressng force appled to the stressng anchor wll decrease especally as a result of frcton along the tendon and of the elastc shortenng of the structure and n the course of tme because of relaxaton of the prestressng steel, and creep and shrnkage of the concrete. The stressng nstructons prepared by the ETA holder shall be consulted Concrete strength Concrete accordng to EN 6-1 shall be used. At the tme of transmsson of the full prestressng force to the concrete member the mean concrete strength n the anchorage zone shall be at least f cm,0,cube or f cm,0,cyl accordng to Table 3. The mean concrete strength (f cm,0,cube or f cm,0,cyl) shall be verfed by means of at least three specmens (cube wth the edge length of 1 mm or cylnder wth dameter of 1 mm and heght of 300 mm), whch shall be stored under the same condtons as the concrete member, wth the ndvdual values of specmens not dffer more than 5 %. For partal prestressng wth 30 % of the full prestressng force the actual mean value of the concrete compressve strength to be proved s 0.5 f cm,0,cube or 0.5 f cm,0,cyl; ntermedate values may be nterpolated lnearly accordng to Eurocode 2. 7

9 Table 3: Requred mnmum mean concrete strength fcm,0 of the specmens at tme of prestressng f cm,0,cube [N/mm²] f cm,0,cyl [N/mm²] Plate Anchorage MA wth helx MA wthout helx Weldng Weldng at the anchorages s only permtted at the followng ponts: a) Weldng the end turn of the helx to a closed rng. b) Weldng the helx end rng turn to the anchor body MA or ts connecton tube or by means of spacers braced aganst the tendon to secure the centrc poston of the helx. Durng weldng t shall be ensured that there s no contact between duct and prestressng steel strand. After mountng the tendons no more weldng shall be performed at the anchorages and n the mmedate vcnty of the tendons Frcton losses At calculaton the losses of the prestressng force due to the frcton coeffcent µ = shall be consdered. Ths value s for nformaton only. The exact frcton coeffcent must be adapted to each project and also n case of restressng. For nternal unbonded tendons the wobble coeffcent k = rad/m (unntentonal devaton) shall be consdered. At external tendons no wobble coeffcent k need to be taken nto account. For the determnaton of strans and forces of prestressng steel frcton losses n the actve anchorage zone, ΔP µa n the actve anchorage zone shall be taken nto account as follows : - For tendons szes from 3 to 5 : ΔP µa = 1.0 %, - For tendons szes from 7 to 6 : ΔP µa = 0.5 % Radus of curvature of the tendons at devatons and geometry of devators The smallest admssble radus of curvature of the tendons as defned n the Table 2 of EAD clause and the requred dmensons of the bent steel devaton tubes are gven n Table 4 (also see Annex 17). All values that dffer from the Table 2 of the Table 2 of EAD were calculated by lnear extrapolaton.

10 Table 4: Smallest radus of curvature PE-Tube Tendon Mn. radus of curvature (m) Tendon Mn. radus of curvature (m) Tendon Mn. radus of curvature (m) The mnmum values of radus of curvature gven n Table 4 shall be respected, unless a natonal regulaton s strcter. A straght length of the tendon behnd the anchorage accordng to Tables 5 and 6 s requred. Behnd the anchor plate a straght length of the tendon (measured from the top of the anchor plate) accordng to Table 5 s requred. Table 5: Requred straght length of the tendon n the anchorage zone by usng anchor plates (measured from the top of the anchor plate) Tendon Straght length of the tendon (m) Tendon Straght length of the tendon (m) Tendon Straght length of the tendon (m) By usng anchor bodes type MA, a straght length of the tendon behnd the anchorage (measured from the top of the anchor body) accordng to Table 6 s requred. Table 6: Requred straght length of the tendon n the anchorage zone by usng anchor bodes (measured from the top of the anchor body) Tendon Straght length of the tendon (m) Tendon Straght length of the tendon (m) In case of an external exchangeable tendon wth cement grout, no curved tendon layout s allowed wthn the concrete body around the anchorage zone. In case of a curved tendon layout n the anchorage zone of an external tendon wth wax, the smallest admssble radus of curvature s gven Table 7. Tables 5, 6 and 7 gve conservatve values. 9

11 Tendon Table 7: Mnmum radus of curvature n the anchorage area Mn. radus of curvature n the anchorage area (m) Tendon Mn. radus of curvature n the anchorage area (m) Tendon Mn. radus of curvature n the anchorage area (m) The mnmum values of radus of curvature gven n Table 7 shall be respected unless a natonal regulaton s strcter Centre and edge dstances of the tendon anchorages, concrete cover The centre and edge dstances of the tendon anchorages shall be the values gven n the Annexes 6 to and Annexes 11 to 15 dependng on the actual mean concrete strength at tme of stressng, f cm,0 (Annexes 6 to and 11 to 15). These are vald for both strand szes ()15,7 mm and ()15,3 mm. The values of the centre or edge dstances of the anchorages gven n the Annexes may be reduced n one drecton up to 15 %, however, n the other drecton these values shall be ncreased for keepng the same concrete area n the anchorage zone. By reducng these values, a mnmal centre and edge dstance has to be consdered: - MA-Anchorages wthout helx (see Annexes and 15): External dmenson of the strrup renforcement plus mm. - Plate and MA-Anchorages wth helx (see Annexes 6 to and Annexes 11 and 12): External dameter of the helx plus mm. The dmensons of the addtonal renforcement shall be ftted accordngly. All centre and edge dstances have only been specfed n conjuncton wth load transfer to the structure; therefore, the concrete cover gven n natonal standards and provsons shall be taken nto account addtonally. The concrete cover may under no crcumstance be less than mm or smaller than the concrete cover of the renforcement nstalled n the same cross secton. The concrete cover of the anchorage should be at least mm. Standards and regulatons on concrete cover vald n place of use shall be consdered Renforcement n the anchorage zone The anchorages (ncludng renforcement) for the transfer of the prestressng forces to the structural concrete were verfed by means of tests. The resstance to the forces occurrng n the structural concrete n the anchorage zone outsde the helx and the addtonal renforcement shall be verfed. An adequate transverse renforcement shall be provded here n partcular for the occurrng transverse tensle forces (not shown n the attached drawngs). The steel grades and dmensons of the addtonal renforcement (strrups) shall follow the values gven n the Annexes 6 to and Annexes 11 to 15. From the gven amount of addtonal renforcement kg renforcement steel/m³ concrete may be taken nto account as part of the 10

12 structurally requred renforcement. Exstng renforcement n a correspondng poston more than the renforcement requred by desgn may be taken nto account for the addtonal renforcement. The addtonal renforcement shall be of closed strrups (strrups closed by means of bends or hooks or an equvalent method) or of orthogonal renforcement properly anchored. The strrups locks (bends or hooks) shall be placed staggered. In the anchorage zone, vertcally led gaps shall be provded for proper concretng. If requred for a specfc project desgn, the renforcement gven n the Annexes can be modfed n accordance wth the respectve regulatons n force at the place of use as well as wth relevant approval of the local authorty and of the ETA holder to provde equvalent performance. If n exceptonal cases due to an ncreased amount of renforcement the helx or the concrete cannot be properly placed, the helx can be replaced by dfferent equvalent renforcement Support of ducts Tendons shall be nstalled wth hgh accuracy. Ths s acheved by nstallng duct supports exactly levelled wth regard to ther planned poston. The supports shall be secured n ther poston and the ducts fxed thereto. Dstance between duct supports shall not exceed 1.m. In sectons wth maxmum tendon curvature, the dstance between the duct supports s reduced and shall be of 0. to 1. m. If the strands are nstalled after concretng (duct type II), attenton shall be pad that the duct wll not dsplace. For ths purpose, the duct shall be addtonally fxed between the supports e.g. to the renforcement of the structure. If tendons are nstalled n several layers, only the lowest layer can be rgdly connected wth the duct support. All other tendon layers shall be fxed on subsequently placed supports. For corrugated plastc ducts, spacng of supports should be 0. to 1.0 m for szes rangng from to 5 mm, and from 0. or 0.75 as stated above, to 1.4 m for the szes rangng from 100 to 130 mm Resstance to fatgue at anchorages Wth the fatgue tests carred out n accordance wth EAD , the stress range of 0 MPa of the anchorages at the maxmum load of 0.65 f pk at 2x10 6 load cycles was demonstrated. 1.4 Installaton Installaton of the tendon The central poston of the helx and strrups shall be ensured by tack-weldng to the anchor plate or other approprate mountngs. The anchor plate or the anchor body respectvely, shall be n drecton perpendcular to the axs of the straght tendon n the vcnty of the anchorage. The tendon shall be placed straghtforward behnd the anchorage accordng to Tables 5 and 6. Durng nstallaton, careful handlng of the tendon shall be ensured. Pror to placng the concrete, the person responsble shall perform a fnal check on the nstalled tendons Wedgng force, slp at anchorages, wedge securng and corroson protecton compound If the calculated prestressng force s less than 0.7 P m0,max the wedges of non accesble fxed anchorages shall be pre-wedged wth P 0,max (see secton ). 11

13 The draw-n at the anchorage to be taken nto account for the determnaton of the elongatons and at load transfer from the jack onto the anchorage shall be taken from Table. The wedges of all anchorages (fxed anchorages) whch are no more accessble durng tensonng shall be secured by means of wedge keeper plates and bolts. Table : Draw-n values for calculaton of elongaton [mm] Wthout prewedgng or power-seatng Wth power-seatng kn perstrand at stressng anchorage Wth pre-wedgng P0,max at fxed anchorage Draw-n at stressng anchorage (mm) Draw-n to be consdered for calculaton of elongaton Draw-n at load transfer from the jack onto the anchorage Draw-n at fxed anchorage (mm) Draw-n to be consdered for calculaton of elongaton At nstallaton of the wedges nto the concal borngs of the not accessble fxed anchorages the gaps shall be flled wth corroson protecton compound. Before pourng of concrete the wedge plates of the not accessble fxed anchorages shall be sealed wth a grout cap Stressng and stressng records Stressng At tme of stressng the mnmum mean concrete strength shall comply wth the values gven n secton Near the anchorages the concrete must be especally homogeneous. The mnmum straght length for tensonng behnd the anchorages (strand protruson) depends on the jack whch s used on ste (see Annex 23). All strands of a tendon shall be stressed smultaneously. Ths can be done by centrally controlled ndvdual jacks or by a bundle jack. The prestressng forces are appled n accordance wth a prescrbed stressng plan. Such schedule ncludes tme and sequence of the varous prestressng levels and the elongatons calculated for the tendons, the requred mean cube or cylnder compressve strength of the concrete as well as tme and knd of shutterng lowerng and removal. Any possble sprng back forces of the falsework shall be taken nto account Restressng Restressng of tendons n combnaton wth release and reuse of wedges s permtted. After restressng the wedges shall bte nto at least 15 mm of vrgn strand surface and no wedge marks shall reman of the tendon between the anchorages Stressng record All stressng operatons shall be recorded for each tendon. In general, the requred prestressng force shall be acheved. The elongaton s measured and compared wth the calculated value. 12

14 Prestressng jacks and space requrements, safety-at-work For stressng hydraulc jacks are used. Informaton about the stressng equpment s shown n Annex 23. To facltate jack placement and stressng the tendons, clearance accordng to Annex 23 shall be consdered drectly behnd the anchorages. The safety-at-work and health protecton regulatons shall be compled wth Stressng forces The maxmum prestressng and over-tensonng force to be appled on the tendon s specfed n the natonal standards and regulatons n force n the place of use. Table 9: Maxmum prestressng forces 1 for tendons wth Ap = 1 mm² Tendon Desgnaton Number of strands Cross secton Ap [mm²] Prestressng force Y1770S7 Fp0.1k = 21 kn Prestressng force Y1S7 Fp0.1k = 229 kn Pm0, max [kn] P0, max [kn] Pm0, max [kn] P0, max [kn] The maxmum force P 0,max defned accordng to EN paragraph (wth recommended values for k 1 and k 2), and accordng to pren 1013, shall not exceed the values lad down n Table 1 (1 mm²) or n Table 2 (1 mm²). Maxmum prestressng force P 0,max = mn (0. F pk ; 0.9 F p0.1k) where F pk = A p f pk s the characterstc tensle force of tensle elements of tendons and F p0.1k = A p f p0.1k the characterstc tensle yeld force of tensle elements of tendon (0.1 % proof load). The ntal prestressng force P m0 mmedately after tensonng and anchorng shall not exceed the values lad down n Table 9 (1 mm²) or n Table 10 (1 mm²), see also Annex 1. Intal prestressng force P m0 = mn (0.75 F pk ; 0.5 F p0.1k) 1 The forces P0, max and Pm0 are gven as ndcatve values. The actual values are to be found n natonal regulatons vald on place of use. Complance wth the stablsaton and crack wdth crtera n the load transfer test was verfed to a load level of 0.0 Fpk. 13

15 Table 10: Maxmum prestressng forces 2 for tendons wth Ap = 1 mm² Tendon Desgnaton Number of strands Cross secton Ap [mm²] Prestressng force Y1770S7 Fp0.1k = 234 kn Prestressng force Y1S7 Fp0.1k = 246 kn Pm0, max [kn] P0, max [kn] Pm0, max [kn] P0, max [kn] The number of strands n a tendon may be reduced by leavng out strands lyng radalsymmetrcally n the wedge plate. The provsons for tendons wth completely flled wedge plates (basc types) also apply to tendons wth only partly flled wedge plates. Into the not flled cones short peces of strands wth wedges have to be pressed to assure a suffcent bendng stffness of the wedge plate. For such tendons wedge plates machned wthout the not requred concal borngs can be appled, too. The prestressng force s reduced per strand left out as shown n Table 11. Table 11: Reducton of the prestressng force per strand Ap [mm²] Y1770S7 Y1S7 ΔPm0 [kn] ΔP0 [kn] ΔPm0 [kn] ΔP0 [kn] Groutng Grout and groutng procedures Grout accordng tp secton shall be used. Groutng procedures shall be carred out n accordance wth EN 446. Local standards and natonal regulatons vald n place of use shall be consdered. 2 The forces P0, max and Pm0 are gven as ndcatve values. The actual values are to be found n natonal regulatons vald on place of use. Complance wth the stablsaton and crack wdth crtera n the load transfer test was verfed to a load level of 0.0 Fpk.

16 Water rnse Normally, sheathng shall not be rnsed wth water. Local standards and natonal regulatons vald n place of use shall be consdered. Groutng speed The groutng speed shall be n the range between 3 m/mn and 12 m/mn. Grouted secton and re-groutng After completon of the prestressng operaton and acceptance of the stressng records, the tendons are grouted as soon as possble. If the tendons reman ungrouted for a longer tme, approprate corroson protecton measures shall be mplemented after acceptance of the ETA holder. The maxmum length of a grouted secton depends on the capacty of the groutng equpment and shall be determned before the groutng procedure. When exceedng these tendon lengths, addtonal groutng openngs shall be provded. Where the tendon s led va dstnct hgh ponts, re-groutngs shall be performed n order to avod vods. For re-groutngs, approprate measures shall be taken nto account already n desgn. Vents on the ducts shall be provded at both ends and at the ponts of the tendon where ar or water may accumulate. In case of ducts of consderable length, vents or nlets may be requred at ntermedate postons. Local standards and natonal regulatons vald n place of use shall be consdered. If plastc ducts are used, the relevant notes n the techncal documentaton of the plastc duct system shall be observed. Survellance Survellance accordng to EN 446 shall be carred out Wax and grease njecton Wax and grease accordng secton shall be used. Injecton shall be carred out accordng to DSI specal nstructons. Injecton equpment s normally composed of meltng devce (heater), strrer and pump. 15

17 2 Specfcatons of the ntended use n accordance wth the applcable European Document 2.1 Intended use DYWIDAG External and nternal strand, unbonded post tensonng system The DYWIDAG external and nternal unbonded strand post-tensonng systems (n the followng PT systems) have been developed to be used for : - New structures, - Repar and strengthenng of exstng structures exposed to effects from gravty and lve loads, clmate exposures, mposed sets of deformatons. These PT systems are meant for concrete structures/members wth a tendon path stuated : - Outsde ther cross secton but nsde ther envelope (external tendon), - Insde ther cross secton (nternal unbonded tendon). They may also be employed n structures made of other materals, e.g. masonry, steel, cast ron, tmber or combnaton of several materals. In case of use wth other materals than concrete, dmensons and prestressng force transfer shall be desgned accordng to the relevant Eurocodes or natonal regulatons vald n place of use. The followng optonal use categores for the external and unbonded nternal (wax njected) tendons are possble: - restressable tendon ; - exchangeable tendon ; - encapsulated tendon. 2.2 Workng lfe The provsons made n ths European Techncal are based on an assumed workng lfe of the PT system of 100 years. These provsons are based upon the current state of the art and the avalable knowledge and experence. The ndcatons gven on the workng lfe cannot be nterpreted as a guarantee gven by the kt manufacturer or the Body, but are to be regarded only as a means for choosng the rght products n relaton to the expected economcally reasonable workng lfe of the works. The relevant Eurocodes are the followng: EN 1990 Eurocode 0 : Bass of structural desgn EN 1991 Eurocode 1 : Actons on structures EN 1992 Eurocode 2 : Desgn of concrete structures EN 1993 Eurocode 3 : Desgn of steel structures EN 1994 Eurocode 4 : Desgn of composte steel and concrete structures EN 1995 Eurocode 5 : Desgn of tmber structures EN 1996 Eurocode 6 : Desgn of masonry structures The PT system s supposed to be subject to approprate use and mantenance (see of EAD ).

18 3 Performance of the product and methods used for ts assessment Ths European Techncal for the post-tensonng systems part of ths document s ssued on the bass of agreed data, deposted at Cerema, whch dentfes the post-tensonng systems that have been assessed and judged. of the performance of the post-tensonng system part of ths document for the ntended use n the sense of basc requrement for constructon work 1 (mechancal resstance and stablty) has been made n accordance wth the EAD Post-Tensonng Kts for Prestressng of Structures based on the provsons for all systems. Table 12: Essental characterstcs and performances of the product N Essental characterstc Product performance Basc requrement for constructon work 1 : Mechancal resstance and stablty 1 Resstance to statc load 95% of Actual Ultmate Tensle Strength AUTS (acceptance crtera gven n paragraph of EAD ) 2 Resstance to fatgue No fatgue falure n anchorage and not more than 5% loss on cross secton after 2 mllon cycles (acceptance crtera gven n paragraph of EAD ) 3 Load transfer to the structure Stablzaton of crack wdth under cyclc load and ultmate resstance 110% characterstc load (acceptance crtera gven n paragraph EAD ) 4 Frcton coeffcent See Clause Devaton/deflecton (lmts) for external and nternal unbonded tendon Mnmum rad of external and nternal unbonded tendon (acceptance crtera n paragraph of EAD ) 6 of assembly Installaton of strands, duct fllng (acceptance crtera gven n paragraph of EAD ) 7 Corroson protecton Not relevant accordng to EAD Basc requrement for constructon work 2: Safety n case of fre - Not relevant. No characterstc assessed -- Basc requrement for constructon work 3: Hygene, health and the envronment - Not relevant. No characterstc assessed -- Basc requrement for constructon work 4: Safety and accessblty n use - Not relevant. No characterstc assessed -- Basc requrement for constructon work 5: Protecton aganst nose - Not relevant. No characterstc assessed -- Basc requrement for constructon work 6: Energy economy and heat retenton - Not relevant. No characterstc assessed -- Basc requrement for constructon work 7: Sustanable use of natural ressources - Not relevant. No characterstc assessed -- 17

19 4 and verfcaton of constancy of performance system appled, wth reference to ts legal base In accordance wth the decson 9/456/EC2 of the European Commsson, the system 1+ of assessment and verfcaton of constancy of performances (see Annex V to Regulaton (EU) No 305/11), gven n the followng table apples: Table 13: AVCP system of the product Product(s) Intended use(s) Level(s) or class(es) System(s) Post-tensonng Kts For the prestressng of structures - 1+ Ths AVCP system s defned as follows: System 1+: Declaraton of the performance of the essental characterstcs of the constructon product by the manufacturer on the bass of the followng tems: (a) Tasks of the manufacturer (1) Factory producton control; (2) Further testng of samples taken at the factory by the manufacturer n accordance wth a prescrbed test plan; (b) Tasks for the notfed body (3) Determnaton of the product-type on the bass of type testng (ncludng samplng), type calculaton, tabulated values or descrptve documentaton of the product; (4) Intal nspecton of factory and of factory producton control; (5) Contnuous survellance, assessment and approval of factory producton control; (6) Audt testng of samples taken at the factory. 1

20 5. Techncal detals necessary for the mplementaton of the AVCP system, as provded for n the applcable EAD 5.1 Tasks for the manufacturer Factory producton control The manufacturer shall exercse permanent nternal control of producton. All the elements, requrements and provsons adopted by the manufacturer shall be documented n a systematc manner n the form of wrtten polces and procedures, ncludng records of results performed. Ths producton control system shall nsure that the product s n conformty wth ths European Techncal. The manufacturer may only use ntal materal stated n the techncal documentaton of ths European Techncal. The factory producton control shall be n accordance wth the "Dywdag Control Plan" relatng to ths European techncal assessment whch s part of the techncal documentaton of ths European techncal. The "Control Plan" s lad down n the context of the factory producton control system operated by the manufacturer and deposted at CeremaITM. The prescrbed test plan defned n Annexes.a and.b gves the type and frequency of checks and tests conducted durng producton and on the fnal product as part of the contnuous nternal producton control. The results of factory producton control shall be recorded and evaluated n accordance wth the provsons of the "Control Plan". The records contan at least the followng nformaton: - desgnaton of the product or basc materals and the components; - type of control or testng; - date of manufacture and of testng of product or components and of basc materals or components; - results of controls and tests and, where relevant, comparson wth the requrements; - sgnature of person responsble for the factory producton control. If the test results are unsatsfactory, the manufacturer shall mmedately mplement measures to elmnate defects. Constructon products or components whch are not n complance wth the requrements shall be handled such that they cannot be mstaken for products complyng wth the requrements. After elmnaton of the defects the relevant tests shall be mmedately repeated as far as s techncally possble and necessary for verfyng the defcency elmnaton Other tasks The manufacturer shall, on the bass of a contract, nvolve a body whch s approved for the tasks referred to n secton 5.2 n the feld of Dywdag post-tensonng system n order to undertake the actons lad down n secton 5.2. For ths purpose, the "control plan" referred to n sectons shall be handed over by the manufacturer to the Notfed Body or bodes nvolved. The manufacturer shall make a declaraton of performance, statng that the constructon product s n conformty wth the provsons of ths European Techncal. 19

21 At least once a year, each components manufacturer shall be audted by the manufacturer. 5.2 Tasks of the Notfed Body General The Notfed Body (bodes) shall perform the: - Determnaton of the product-type on the bass of type testng (ncludng samplng), - ntal nspecton of factory and of factory producton control, - contnuous survellance, assessment and approval of factory producton control, - audt-testng of samples taken at the factory n accordance wth the provsons lad down n the "Control Plan" relatng to ths European Techncal. The approved body (bodes) shall retan the essental ponts of ts actons referred to above and state the results obtaned and conclusons drawn n a wrtten report. The man producton centre s checked at least once a year by the Notfed Body. Each component producer s checked at least once every fve years by the Notfed Body. The Notfed Body nvolved by the manufacturer shall ssue a certfcate of constancy of performance of the product statng the conformty wth the provsons of ths European Techncal. In cases where the provsons of the European Techncal and ts Control Plan are no longer fulflled the Notfed Body shall wthdraw the certfcate of constancy of performance and nform CeremaITM wthout delay Determnaton of the product-type on the bass of type testng (ncludng samplng), type calculaton, tabulated values or descrptve documentaton of the product For ntal type testng the results of the tests performed as part of the assessment of the European Techncal may be used unless there are changes n producton procedure or factory plant. In such cases, the necessary ntal type testng shall be agreed between CeremaITM and the Notfed Body nvolved Intal nspecton of factory and of factory producton control The Notfed Body shall ascertan that, n accordance wth the prescrbed test plan, the manufacturng plant, n partcular personnel and equpment, and the factory producton control are sutable to ensure a contnuous orderly manufacturng of the PT system accordng to the specfcatons gven n the Annexes of ths European Techncal Survellance, assessment and approval of factory producton control The manufacturer shall be nspected at least once a year. Each component manufacturer shall be nspected at least once n fve years. It shall be verfed that the system of factory producton control and the specfed manufacturng process are mantaned takng nto account the prescrbed test plan.

22 Audt testng of samples taken at the manufacturer Durng survellance nspecton, the Notfed Body shall take samples at the factory of components of the PT system or of ndvdual components for whch ths European Techncal has been granted, for ndependent testng. For the most mportant components Annex 21 summarses the mnmum procedures. 21

23 Page 22 of, verson of the 30 th May 1 Desgnaton Fgure Tendon Sze Intal prestressng force Y17S Pm0, max [kn] Strand 1 mm² Strand 1 mm² Plate anchorage 3-6 Annex 3-, Multplane anchorage MA 5-6 Annex 9-, Sheathng - Plate anchorage: PE-Insert PE-Tube Grout tube Telescopc tube Steel tube Flange Steel trumpet Mrror weldng Electro weldng coupler PE-Tube Sheathng - Multplane anchorage MA: PE-Tube Grout tube Telescopc tube PE-Trumpet Mrror weldng Electro weldng coupler PE-Tube Anchorage range Components - Sheathng Annex 1 Techncal

24 Page 23 of, verson of the 30 th May 1 Wedge: Strand 1 mm² (0,6") 7.5 Strand 1 mm² (0.62") 7.5 Wedge tooth geometres (for both wedge szes) Ptch crcles: Wedge plate Spacer Wedge keeper plate c 6 f ** f * f Cone (for both wedge szes) p c p Dmensons n mm Tendon sze No. of strands Spacer Wedge keeper plate Ptch crcles c p Duct (mn. values): Outer dameter f f * f ** f *** 622 PE0, PN6 (cement gr. njecton): mn. wall thckness PE100, PN10 (wax or cement gr. nj.): mn. wall thckness Detals: Wedge, Cone, Hole pattern, Duct dmensons Annex 2 Techncal

25 Page 24 of, verson of the 30 th May 1 m Anchor plate Wedge plate ( f acc. to Annex 2 ) c e e* f d* a b d ør Dmensons n mm Tendon sze No. of strands Cone pattern and poston Mnmum actual concrete strength at stressng fcm,0,cube [N/mm²] Anchor plate Type 2353/2354/23 a b Wedge plate d Type 13 for 3, 4 d * Type 1362 for 5, 7 e c e * Trumpet Length mm Recess tube r Plate Anchorage Dmensons of components for 3-9 Annex 3 Techncal

26 Page 25 of, verson of the 30 th May 1 m Anchor plate c Wedge plate ( f, f * acc. to Annex 2 ) e e* f * f a b d d* ør Dmensons n mm Tendon sze No. of strands Cone pattern and poston Mnmum actual concrete strength at stressng fcm,0,cube [N/mm²] Anchor plate Type 2353/2354/23 Wedge plate a b c d Type 1362 d * e e * Trumpet Length mm Recess tube r Plate Anchorage Dmensons of components for Annex 4 Techncal

27 Page 26 of, verson of the 30 th May 1 m Anchor plate c Wedge plate ( f, f *, f ** acc. to Annex 2 ) e e* f ** f * f a b d d* ør Dmensons n mm Tendon sze No. of strands Cone pattern and poston Mnmum actual concrete strength at stressng fcm,0,cube [N/mm²] Anchor plate a Type 2353/2354/23 b c Wedge plate d Type 1362 d * e e * Trumpet Length mm Recess tube r Plate Anchorage Dmensons of components for Annex 5 Techncal

28 Page 27 of, verson of the 30 th May 1 z Addtonal renforcement n x ds ] y ] da l * * Helx, n * x ds ]da ] x Dmensons n mm Tendon sze Strand No. of strands For z the concrete cover has to be consdered! mm², fpk=1n/mm² (Fpk=279.0kN) and 1mm², fpk=1770n/mm² (Fpk=265.5kN) Mnmum actual concrete strength at stressng fcm,0,cube [N/mm²] Centre dstance A Edge dstance R x Centre dstance + Concrete cover - 10mm Addtonal renforcement (Materal see Annex 1) No. n d s z x / y Helx (Materal see Annex 1) Turns n * d s d a * mn l * Plate Anchorage Centre and edge dstances of tendon szes 3-9 for strand Y1S and 15.7 and for strand Y1770S and 15.7 Annex 6 Techncal

29 Page 2 of, verson of the 30 th May 1 z Addtonal renforcement n x ds ] y ] da l * * Helx, n * x ds ]da ] x Dmensons n mm Tendon sze Strand No. of strands Mnmum actual concrete strength at stressng fcm,0,cube [N/mm²] Centre dstance A Edge dstance R For z the concrete cover has to be consdered! 1mm², fpk=1n/mm² (Fpk=279.0kN) and 1mm², fpk=1770n/mm² (Fpk=265.5kN) x Centre dstance + Concrete cover - 10mm 5 0 Addtonal renforcement (Materal see Annex 1) No. n d s z x / y Helx (Materal see Annex 1) Turns n * d s d a * mn l * Plate Anchorage Centre and edge dstances of tendon szes for strand Y1S and 15.7 and for strand Y1770S and 15.7 Annex 7 Techncal

30 Page 29 of, verson of the 30 th May 1 z Addtonal renforcement n x ds ] y ] da l * * Helx, n * x ds ]da ] x Dmensons n mm Tendon sze Strand No. of strands For z the concrete cover has to be consdered! mm², fpk=1n/mm² (Fpk=279.0kN) and 1mm², fpk=1770n/mm² (Fpk=265.5kN) Mnmum actual concrete strength at stressng fcm,0,cube [N/mm²] Centre dstance A Edge dstance R x Centre dstance + Concrete cover - 10mm Addtonal renforcement (Materal see Annex 1) No. n d s z x / y Helx (Materal see Annex 1) Turns n * d s d a * mn l * Plate Anchorage Centre and edge dstances of tendon szes for strand Y1S and 15.7 and for strand Y1770S and 15.7 Annex Techncal

31 Page 30 of, verson of the 30 th May 1 j m Anchor body MA j s Wedge plate MA ( f, f* acc. to Annex 2 ) f* e f e* a b b* d d* Dmensons n mm Tendon sze No. of strands Cone pattern and poston Anchor body MA Type 2311 a b b* j s Wedge plate Type 1362 d d* e e* Trumpet Length mm Multplane anchorage MA Dmensons of components for Annex 9 Techncal

32 Page 31 of, verson of the 30 th May 1 j m Anchor body MA j s Wedge plate MA ( f, f* acc. to Annex 2 ) f* e f e* a b b* d d* Dmensons n mm Tendon sze No. of strands Cone pattern and poston Anchor body MA Type 2311 a b b* j s Wedge plate Type 1362 d d* e e* Trumpet Length mm Multplane anchorage MA Dmensons of components for Annex 10 Techncal

33 Page 32 of, verson of the 30 th May 1 z Addtonal renforcement, n x ds ] y ] d l* * Helx, n* x ds ] d ] x Dmensons n mm Tendon sze Strand 1mm², fpk=1n/mm² (Fpk=279kN) and 1mm², fpk=1770n/mm² (Fpk =265,5kN) No. of strands Mnmum actual concrete strength at stressng fcm,0,cube[ N/mm²] Center dstance A Edge dstance R 0,5 x Center dstance + Concrete cover - 10 mm Addtonal renforcement (Materal see Annex 1) No. n d s z x/y Helx (Materal see Annex 1) Turns n* d s d a * mn l* 4, , Multplane anchorage MA wth Helx Centre and edge dstances of tendon szes for strand Y1S and 15.7 and for strand Y1770S and 15.7 Annex 11 Techncal

34 Page 33 of, verson of the 30 th May 1 z Addtonal renforcement, n x ds ] y ] d l* * Helx, n* x ds ] d ] x Dmensons n mm Tendon sze Strand 1mm², fpk=1n/mm² (Fpk=279kN) and 1mm², fpk=1770n/mm² (Fpk =265,5kN) No. of strands Mnmum actual concrete strength at stressng fcm,0,cube [ N/mm²] Center dstance A Edge dstance R 0,5 x Center dstance + Concrete cover - 10 mm Addtonal renforcement (Materal see Annex 1) No. n d s z x/y Helx (Materal see Annex 1) Turns n* d s d a * mn l*, , , , Multplane anchorage MA wth Helx Centre and edge dstances of tendon szes for strand Y1S and 15.7 and for strand Y1770S and 15.7 Annex 12 Techncal

35 Page 34 of, verson of the 30 th May 1 z Addtonal renforcement, n x ds ] y ] d l* * Helx, n* x ds ] d ] x Dmensons n mm Tendon sze Strand No. of strands Mnmum actual concrete strength at stressng fcm,0,cube [ N/mm²] Center dstance A Edge dstance R 1mm², fpk=1n/mm² (Fpk=279kN) and 1mm², fpk=1770n/mm² (Fpk =265,5kN) ,5 x Center dstance + Concrete cover - 10 mm Addtonal renforcement (Materal see Annex 1) No. n d s z x/y Helx (Materal see Annex 1) Turns n* d s d a * mn l* Multplane anchorage MA wth Helx Centre and edge dstances of tendon szes for strand Y1S and 15.7 and for strand Y1770S and 15.7 Annex 13 Techncal

36 Page 35 of, verson of the 30 th May 1 z Addtonal renforcement, n x ds ] y ] x Dmensons n mm Tendon sze Strand 1mm², fpk=1n/mm² (Fpk=279kN) and 1mm², fpk=1770n/mm² (Fpk =265,5kN) No. of strands Mnmum actual concrete strength at stressng fcm,0,cube[ N/mm²] Center dstance A Edge dstance R 0,5 x Center dstance + Concrete cover - 10 mm Addtonal renforcement (Materal see Annex 1) No. n d s z 1 x/y The dstances x/y must be strctly adhered to. Multplane anchorage MA wthout Helx Centre and edge dstances of tendon szes for strand Y1S and 15.7 and for strand Y1770S and 15.7 Annex Techncal

37 Page 36 of, verson of the 30 th May 1 z Addtonal renforcement, n x ds ] y ] x Dmensons n mm Tendon sze Strand 1mm², fpk=1n/mm² (Fpk=279kN) and 1mm², fpk=1770n/mm² (Fpk =265,5kN) No. of strands Mnmum actual concrete strength at stressng fcm,0,cube[ N/mm²] Center dstance A Edge dstance R ,5 x Center dstance + Concrete cover - 10 mm Addtonal renforcement (Materal see Annex 1) No. n d s z x/y The dstances x/y must be strctly adhered to. Multplane anchorage MA wthout Helx Centre and edge dstances of tendon szes for strand Y1S and 15.7 and for strand Y1770S and 15.7 Annex 15 Techncal

38 Page 37 of, verson of the 30 th May 1 External applcaton Plate anchorage Multplane anchorage MA Internal applcaton Plate anchotage Multplane anchorage MA External and nternal applcatons Annex Techncal

39 t Page 3 of, verson of the 30 th May 1 Expanson tube d o e PE - tube duct R Devaton tube α = Desgned devaton angle β = Devaton angle n reserve β ³ 3 at each end n all drectons requred, R ³ Rmn Tendon sze * R mn ø * d duct o * * * t e * the mnmum values of radus of curvature shall be respected, unless a natonal regulaton s strcter ** mnmum values Devator - Geometrcal requrements for crcular steel tubes Annex 17 Techncal

40 Page 39 of, verson of the 30 th May 1 Desgnaton Materal Standard Wedge Case hardened steel * EN : 0 EN : 06 Wedge plate Quenched and tempered steel * EN : 06 EN : 06 Anchor plate Structural steel * EN : 04 Multplane anchor body Type MA Cast ductle ron * EN 1563: 11 ASTM A536: 1999 Steel tube for anchor plate Structural steel * EN 102-1: 13 EN : 02 Spacer Polyethylene (PE) EN ISO 172-1: 1999 Flange Structural steel * EN : 04 Steel tube for steel trumpet Structural steel * EN 102-1: 13 EN : 02 Tenson rng Structural steel * EN : 04 PE - Insert Polyethylene (PE) EN ISO 172-1: 1999 Retanng rng Structural steel * EN : 04 Helx S 235 JR Renf. steel Re ] 0 MPa EN : 04 EN 1000: 05 ** Addtonal renforcement Re ] 0 MPa EN 1000: 05 ** PE - Tube Polyethylene (PE) EN 121-2: 11 PE - Trumpet Polyethylene (PE) EN ISO 172-1: 1999 * Exact materal propertes and defntons deposted at CEREMA. ** As long as EN 1000 does not exst harmonzed, natonal standards shall be consdered. Materals and standard references Annex 1 Techncal

41 Page of, verson of the 30 th May 1 DIMENSIONS AND PROPERTIES OF 7-WIRE STRANDS Desgnaton Symbol Unt Value Tensle strength R /F m pk MPa 1770 or 1 Strand Nomnal dameter D mm A p Nomnal cross secton mm² 1 1 Nomnal mass M g/m Surface confguraton plan Force of Sngle Strand at 0.1 % Y 1770 F p0.1k kn Y 1 F p0.1k kn Modulus of elastcty E MPa 195,000 Indvdual wres External wre dameter d mm 5.0 ± ± 0.04 Core wre dameter d' mm 1.02 to 1.04 d As long as EN 1013 does not exst 7 - wre strands n accordance wth natonal provsons and wth the characterstcs gven n the table above shall be used. 7 - wre strands 3-6 Annex 19 Techncal

42 Page 41 of, verson of the 30 th May 1 Control Plan 3-6 Annex a Techncal

43 Page 42 of, verson of the 30 th May 1 Control Plan contnued 3-6 Annex b Techncal

44 Page 43 of, verson of the 30 th May 1 Audt Testng 3-6 Annex 21 Techncal

45 Page 44 of, verson of the 30 th May 1 Descrpton of the DYWIDAG External Strand Post-Tensonng System Annex 22a Techncal

46 Page 45 of, verson of the 30 th May 1 Descrpton of the DYWIDAG External Strand Post-Tensonng System Annex 22b Techncal

47 Page 46 of, verson of the 30 th May 1 Descrpton of the DYWIDAG External Strand Post-Tensonng System Annex 22c Techncal

48 Page 47 of, verson of the 30 th May 1 Descrpton of the DYWIDAG External Strand Post-Tensonng System Annex 22d Techncal

49 Page 4 of, verson of the 30 th May 1 Jack Types - Techncal Data Annex 23 Techncal