European Technical Approval Post-Tensioning Systems

Transcription

1 European Technical Approval Post-Tensioning Systems DYWIDAG External and Internal Unbonded Strand Post- Tensioning System for 3 to 37 Strands (140 and 150 m 2 ) ETA-13/0979 European Organisation for Technical Approvals Europäische Organisation für Technische Zulassungen Organisation Européenne pour l Agrément Technique Validity 27 June June 2018

2 Service d'études sur les transports, les routes et leurs aménagements 110 rue de Paris Sourdun Tel : + 33 (0) Fax : + 33 (0) MEMBRE DE L'EOTA MEMBER OF EOTA European Technical Approval ETA-13/0979 (English language translation, the original version is in French language) Nom commercial : Trade name : Détenteur de l'ate : Holder of approval : Type générique et utilisation prévue du produit de construction : Generic type and use of construction product : Procédé de précontrainte extérieur DYWIDAG DYWIDAG External and Internal unbonded Strand Post-Tensioning System DYWIDAG-Systems International GmbH Destouchesstrasse München DEUTSCHTLAND Procédé de précontrainte par post-tension DYWIDAG avec câble extérieur et intérieur non adhérent de 3 à 37 torons (140 et 150 m 2 ). DYWIDAG External and Internal unbonded Strand Post-Tensioning System for 3 to 37 Strands (140 and 150 m 2 ). Valid from: to: Producteur du procédé : Kit manufacturer : Le présent agrément technique européen contient : This European Technical Approval contains : DYWIDAG-Systems International GmbH Max-Planck-Ring Langenfeld DEUTSCHLAND 50 pages comprenant 27 pages de dessins faisant partie intégrante du document. 50 pages including 27 pages of drawings which form an integral part of the document. Organisation pour l'agrément Technique Européen European Organisation for Technical Approvals

3 European Technical Approval n 13/0979 Page 2 of 50 Version of the 27 th June 2013

4 European Technical Approval n 13/0979 Page 3 of 50 CONTENTS A LEGAL BASES AND GENERAL CONDITIONS...4 B SPECIFIC CONDITIONS OF THE EUROPEAN TECHNICAL APPROVAL...5 B.1 DEFINITION OF PRODUCTS AND INTENDED USE...5 B.1.1 Definition of Products...5 B.1.2 Intended use...6 B.1.3 Working life...6 B.2 CHARACTERISTICS OF PRODUCT AND METHODS OF VERIFICATION...7 B.2.1 Characteristics of product...7 B.2.2 Methods of verification...9 B.3 EVALUATION AND ATTESTATION OF CONFORMITY AND CE MARKING16 B.3.1 Attestation of System Conformity...16 B.3.2 Responsibilities...16 B.3.3 CE Marking...19 B.4 ASSUMPTIONS UNDER WHICH THE FITNESS OF THE PRODUCT FOR THE INTENDED USE WAS FAVOURABLY ASSESSED...20 B.4.1 Manufacturing...20 B.4.2 Installation...20 B.5 PACKAGING, TRANSPORT, AND STORAGE...23 Version of the 27 th June 2013

5 European Technical Approval n 13/0979 Page 4 of 50 A LEGAL BASES AND GENERAL CONDITIONS A.1 This European Technical Approval is issued by Sétra in accordance with: Council Directive 89/106/EEC of 21 December 1988 on the approximation of laws, regulations and administrative provisions of Member States relating to construction products 1, modified by Council Directive 93/68/EEC 2 and Regulation (EC) N 1882/2003 of the European Parliament and of the Council 3 ; décret n du 8 juillet concernant l'aptitude à l'usage des produits de construction ; Common Procedural Rules for Requesting, Preparing and the Granting of European Technical Approvals set out in the Annex to Commission Decision 94/23/EC 5 ; ETAG 013, Edition June 2002, Post-Tensioning Kits for Prestressing of Structures. A.2 Sétra is authorised to check whether the provisions of this European Technical Approval are met. Checking may take place in the manufacturing plant(s). Nevertheless, the responsibility for the conformity of the products to the European Technical Approval and for their fitness for the intended use remains with the holder of the European Technical Approval. A.3 This European Technical Approval is not to be transferred to manufacturers or agents of manufacturers other than those indicated on page 1, or manufacturing plants other than those indicated on page 1 of this European Technical Approval. A.4 This European Technical Approval may be withdrawn by Sétra, in particular pursuant to information by the Commission according to Article 5(1) of Council Directive 89/106/EEC. A.5 Reproduction of this European Technical Approval including transmission by electronic means shall be in full. However, partial reproduction can be made with the written consent of Sétra. In this case partial reproduction has to be designated as such. Texts and drawings of advertising brochures shall not contradict or misuse the European Technical Approval. A.6 The European Technical Approval is issued by the approval body in its official language. This version corresponds fully to the version circulated in EOTA. Translations into other languages have to be designated as such. 1 Official Journal of the European Communities N L 40, , p Official Journal of the European Communities N L 220, , p. 1 3 Official Journal of the European Union N L 284, , p. 1 4 Official Journal of the French Republic of the 14 th July Official Journal of the European Communities N L 17, , p. 34 Version of the 27 th June 2013

6 European Technical Approval n 13/0979 Page 5 of 50 B SPECIFIC CONDITIONS OF THE EUROPEAN TECHNICAL APPROVAL B.1 DEFINITION OF PRODUCTS AND INTENDED USE B.1.1 Definition of Products This European Technical Approval applies to a kit: DYWIDAG External Strand Post-Tensioning System consisting of 3 to 37 strands. The DYWIDAG post-tensioning kit is designed for internal unbonded and external prestressing. The prestressing tendon consists of a bundle of 7-wire strands, anchorages, deviators, sheathing and corrosion protective compounds. - The strands are defined in the pren : Prestressing steels Strand as 0.6 normal and super strand, i.e. with Ø 15.3 and Ø 15.7 mm nominal diameter, with a nominal tensile strength of 1770 or 1860 N/mm², coded Y1770S (or 15.7) or Y1860S (or 15.7), respectively, referred to as the tensile element. - As long as EN is not implemented 7-wire strands in accordance with national provisions shall be used. - Stressing (active) anchorages and fixed (passive) anchorages consisting of an anchor plate with connection tube, steel trumpet, plastic insert and wedge plate, or consisting of a cast iron anchor body with a HDPE-trumpet and a wedge plate. - Sheathings are made of plastic (polyethylene, HDPE). - Deviators are specific elements at given locations in the structure along the tendon. These are generally made of steel tubes (straight or prebent) placed inside the concrete structure or construction steel saddles applied to the structure. - Bursting reinforcement (helix and stirrups), for the concrete confinement at anchorages to ensure local prestressing force transfer into the concrete structure. - The corrosion protecting compound can be a flexible compound with a wax base (in accordance with Annex C.4.2 of ETAG 013) for external and internal unbonded use, or a cement based grout (in accordance with EN 447) for rigid injection for external use only. Steel and plastic tubes, the ordinary reinforcement for bursting reinforcement, grouting products are covered by European or national provisions thus they are not described in this ETA. However, they can be used for the prestressing kit. Version of the 27 th June 2013

7 European Technical Approval n 13/0979 Page 6 of 50 B.1.2 Intended use The DYWIDAG internal unbonded and external strand post-tensioning system (in the following PT system) has been developed to be used for: new structures repairing and strengthening existing structures exposed to effects from gravity and live loads, climate exposures, imposed sets of deformations. If used for external prestressing this PT system is meant for concrete structures/members with a tendon path situated outside their cross section but inside their envelope. It may also be employed in structures made of other materials, e.g. masonry, steel, cast iron, timber or combinations of several materials (see Annex 15). In case of use with other materials than concrete, dimensions and force transfer shall be designed according to the relevant Eurocodes or national regulations valid in place of use. The following optional use categories for the tendons are possible: restressable exchangeable encapsulated B.1.3 Working life The provisions made in this European Technical Approval are based on an assumed working life of the PT system of 100 years. These provisions are based upon the current state of the art and the available knowledge and experience. The indications given on the working life cannot be interpreted as a guarantee given by the kit manufacturer or the Approval Body, but are to be regarded only as a means for choosing the right products in relation to the expected economically reasonable working life of the works. The relevant Eurocodes are the following: EN 1990 Eurocode 0 : Basis of structural design EN 1991 Eurocode 1 : Actions on structures EN 1992 Eurocode 2 : Design of concrete structures EN 1993 Eurocode 3 : Design of steel structures EN 1994 Eurocode 4 : Design of composite steel and concrete structures EN 1995 Eurocode 5 : Design of timber structures EN 1996 Eurocode 6 : Design of masonry structures The PT system is supposed to be subject to appropriate use and maintenance (see Chapter 7 of ETAG 013). Version of the 27 th June 2013

8 European Technical Approval n 13/0979 Page 7 of 50 B.2 CHARACTERISTICS OF PRODUCT AND METHODS OF VERIFICATION B.2.1 Characteristics of product B General The components correspond to the drawings and provisions given in this European Technical Approval including the Annexes. The characteristic material values, dimensions and tolerances of the components not indicated in the Annexes shall correspond to the respective values laid down in the technical documentation of this European Technical Approval. Arrangement of the tendons, the design of the anchorage zones, the anchorage components and the diameters of the sheathings shall correspond to the attached description and drawings; the dimensions and materials shall comply with the values given therein. The first digit of the designation of components of anchorages (6) identifies the nominal strand diameter in tenfold of inches (0.60 /0.62 ), the second digit is an internal code and the last two digits refer to the number of strands in the tendon (size of tendon). The components (except helix and additional reinforcement) fit for tendons with both strand strengths. B Strands Only 7-wire strands shall be used in accordance with national provisions with the characteristics given in Annex 18. To avoid confusions only strands with one nominal diameter shall be used on one site. If the use of strands with R m = 1860 MPa is intended on site, these shall only be used there. Only strands stranded in the same direction shall be used in a tendon. B Wedges Wedges (see Annex 2) are approved with 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 dimension does not depend on the strands strength. Wedges of one supplier only may be used at one construction site. B Wedge plates The conical drills of the wedge plates (see Annex 2) shall be clean, stainless and provided with a corrosion protection. B Anchor plate with recess tube Circular anchor plate with recess tube welded watertight to it shall be used (see Annexes 3-5). B Steel trumpet with PE-insert As a part of the steel trumpet the tension ring is welded to the steel tube with the flange. The PE-insert is fixed to the tension ring through a gasket with a retaining ring and screws (see Annex 2). A piece of plastic sheathing with relevant diameter is mirror welded to the PE-insert. Its length is determined in order to protrude out from the concrete body around the anchorage zone. Version of the 27 th June 2013

9 European Technical Approval n 13/0979 Page 8 of 50 B Cast-iron anchor bodies For 5 to 37 strands multi-plane cast-iron anchor bodies shall be used (see Annexes 9 and 10). B Bursting reinforcement (helixes and stirrups) The steel grades and dimensions of the helixes and of the stirrups shall comply with the values given in the relevant Annexes 6-8 and The central position in the structural concrete member on site shall be ensured according to section B The outer end of the helix shall be welded to the anchor plate or the anchor body MA. This is not necessary if the final turn is welded to form a closed ring. B Sheathings, tubes and trumpets Sheathings made of polyethylene shall comply with EN and ETAG 013. The dimensions of the sheathings shall comply with values given in Annex 2. The connections and seals between the sections of sheathing are effected either with mirror welding or electro-welding couplers. The recess tubes and steel tubes (respectively welded to anchor plate and flange, see Annexes 3-5) are manufactured from at least 3.2 mm thick steel sheath material (see Annex 17). The trumpets at the stressing and fixed anchorages (see Annexes 9 and 10) are manufactured from 3.0 mm thick PE material (see Annex 17). The connections and seals between a section of sheathing and a trumpet are effected with mirror welding. B Grout Grout according to EN 447:1996 shall be used. B Wax Wax as defined in Annex C.4.2 of ETAG 013 or according to national regulations valid in place of use shall be used. B Protective caps Protective caps serve as closing the anchorage to enable grouting/injection and its protection. The caps are made of steel. Regularly they cover the wedge plate and are left in place after injection. Elongated caps may be used for sufficient strand over-length for later prestressing force adjustment or detensioning. Version of the 27 th June 2013

10 European Technical Approval n 13/0979 Page 9 of 50 B.2.2 Methods of verification B General This European Technical Approval for the "DYWIDAG external strand post-tensioning system" is issued on the basis of agreed data, deposited at Sétra, which identifies the "DYWIDAG external strand post-tensioning system" that has been assessed and judged. Assessment of the fitness of the "DYWIDAG external strand post-tensioning system" for the intended use in relation to the requirements for mechanical resistance and stability in the sense of Essential Requirements 1 and for Essential Requirement 3 (hygiene, health and environment) has been made in accordance with the ETAG 013, Guideline for European Technical Approval of post-tensioning kits for prestressing of structures, based on the provisions for all systems. The release of dangerous substances (Essential Requirement 3) is determined according to ETAG 013, clause A declaration was made by the kit manufacturer that the product does not contain any dangerous substances. In addition to the specific clauses relating to dangerous substances contained in the ETA, there may be other requirements, applicable to the products falling within its scope (e.g. transposed European legislation and national laws, regulations and administrative provisions). In conformity with the provisions of the European directive 89/106/EEC, these requirements must also be complied with wherever they apply. The structural members (made of normal-weight concrete) prestressed by means of the DYWIDAG-External Strand Post-Tensioning System used to be designed in accordance with national regulations. B Tendons The maximum prestressing and over-tensioning force to be applied on the tendon is specified in the national standards and regulations in force in the place of use. The maximum force P 0, max defined according to EN paragraph (with recommended values for k1 and k2), and according to pren 10138, shall not exceed the values laid down in Table 1 (140 mm²) or in Table 2 (150 mm²). Maximum prestressing force P 0, max = min (0.8 F pk ; 0.9 F p0.1k ) where F pk = A p f pk is the characteristic tensile force of tensile elements of tendons and F p0.1k = A p f p0.1k the characteristic tensile yield force of tensile elements of tendon (0.1 % proof load). The initial prestressing force P m0 immediately after tensioning and anchoring shall not exceed the values laid down in Table1 (140 mm²) or in Table2 (150 mm²), see also Annex 1. Initial prestressing force P m0 = min (0.75 F pk ; 0.85 F p0.1k ) Version of the 27 th June 2013

11 European Technical Approval n 13/0979 Page 10 of 50 Tendon Designation Table 1: Maximum prestressing forces 6 for tendons with A p = 140 mm² Number of strands Cross section A p [mm²] Prestressing force Y1770S7 F p0.1k = 218 kn Prestressing force Y1860S7 F p0.1k = 229 kn P m0, max [kn] P 0, max [kn] P m0, max [kn] P 0, max [kn] Tendon Designation Table 2: Maximum prestressing forces 6 for tendons with A p = 150 mm² Number of strands Cross section A p [mm²] Prestressing force Y1770S7 F p0.1k = 234 kn Prestressing force Y1860S7 F p0.1k = 246 kn P m0, max [kn] P 0, max [kn] P m0, max [kn] P 0, max [kn] The forces P 0, max and P m0 are given as indicative values. The actual values are to be found in national regulations valid on place of use. Compliance with the stabilisation and crack width criteria in the load transfer test was verified to a load level of 0.80 F pk. Version of the 27 th June 2013

12 European Technical Approval n 13/0979 Page 11 of 50 Tendon Designation Number of strands Cross section A p [mm²] Prestressing force Y1770S7 F p0.1k = 234 kn Prestressing force Y1860S7 F p0.1k = 246 kn P m0, max [kn] P 0, max [kn] P m0, max [kn] P 0, max [kn] The number of strands in a tendon may be reduced by leaving out strands lying radialsymmetrically in the wedge plate. The provisions for tendons with completely filled wedge plates (basic types) also apply to tendons with only partly filled wedge plates. Into the cones not filled short pieces of strands with wedges have to be pressed to assure a sufficient bending stiffness of the wedge plate. Obviously for such tendons wedge plates machined without the not needed conical borings can be applied, too. The prestressing force is reduced per strand left out as shown in Table 3. Table 3: Reduction of the prestressing force when leaving out one strand A p Y1770S7 Y1860S7 IP m0 [kn] IP 0 [kn] IP m0 [kn] IP 0 [kn] 140 mm² mm² B Losses of the prestressing force due to friction At calculation of the losses of the prestressing force due to friction the friction coefficient U = shall be considered. This value is for information only. The exact friction coefficient must be adapted to each project and also in case of restressing. For internal unbonded tendons the wobble coefficient k = rad/m (unintentional deviation) shall be considered. At external tendons no wobble coefficient k need to be taken into account. For the determination of strains and forces of prestressing steel friction losses VP UA in the active anchorage zone shall be taken into account as follows: - For the tendon sizes from 6803 to 6805: P UA = 1.0 % - For the tendon sizes from 6807 to 6837: P UA = 0.5 % Version of the 27 th June 2013

13 European Technical Approval n 13/0979 Page 12 of 50 B Radius of curvature of the tendons at deviations and geometry of deviators The smallest admissible radius of curvature of the tendons with sheathings as defined in Appendix C.2 of ETAG 013 based on ENV and the required dimensions of the bent steel deviation tubes are given in Table 4 and Annex 16. Tendon Table 4: Smallest radius of curvature of deviators Min. radius of curvature Tendon m m m m m m m m m m m m Min. radius of curvature The minimum values of radius of curvature given in Table 4 shall be respected, unless a national regulation is stricter. Smooth steel pipes can be bent to a constant radius in one plane. This should be taken into account at when specifying the tendon layout. By using anchor bodies type MA a straight length of the tendon behind the anchorage (measured from the top of the anchor body) according to Table 5 is required. Table 5: Required straight length of the tendon in the anchorage zone by using anchor bodies (measured from the top of the anchor body) Tendon Straight length of the tendon Tendon m m m m m m m m m m Straight length of the tendon Version of the 27 th June 2013

14 European Technical Approval n 13/0979 Page 13 of 50 By using anchor plates a straight length of the tendon behind the anchorage (measured from the top of the anchor plate) according to Table 6 is required. Table 6: Required straight length of the tendon in the anchorage zone by using anchor plates (measured from the top of the anchor plate) Tendon Straight length of the tendon Tendon m m m m m m m m m m m m Straight length of the tendon In case of an external exchangeable tendon with cement grout no curved tendon layout is allowed within the concrete body around the anchorage zone. In case of a curved tendon layout in the anchorage zone of an external tendon with wax, the smallest admissible radius of curvature is given in Table 7. Table 7: Smallest radius of curvature of deviators behind the anchorage Tendon Min. radius of curvature behind anchorage Tendon m m m m m m m m m m m m Min. radius of curvature behind anchorage The minimum values of radius of curvature given in Table 7 shall be respected, unless a national regulation is stricter. B Concrete strength At the time of transmission of the full prestressing force to the concrete member the mean concrete strength in the anchorage zone shall be at least f cmj, cube or f cmj, cyl according to Table 8. The mean concrete strength (f cmj, cube or f cmj, cyl ) shall be verified by means of at least three specimens (cube with the edge length of 150 mm or cylinder with diameter of 150 mm and height of 300 mm), which shall be stored under the same conditions as the concrete member, with the individual values of specimens not differ more than 5 %. Version of the 27 th June 2013

15 European Technical Approval n 13/0979 Page 14 of 50 Table 8: Necessary minimum mean concrete strength f cmj of the specimens at time of prestressing Plate anchorage MA with helix MA without helix f cmj, cube [N/mm²] f cmj, cyl [N/mm²] For partial prestressing with 30 % of the full prestressing force the actual mean value of the concrete compressive strength to be proved is 0.5 f cmj, cube or 0.5 f cmj, cyl ; intermediate values may be interpolated linearly. B Centre and edge distances of the tendon anchorages, concrete cover The centre and edge distances of the tendon anchorages shall be the values given in the Annexes 6-8 and depending on the actual mean concrete strength. These are valid for both strand sizes (Ø)15,7 mm and (Ø)15,3 mm. The values of the centre or edge distances of the anchorages given in the Annexes may be reduced in one direction up to 15 %, however, in the other direction these values shall be increased for keeping the same concrete area in the anchorage zone. By reducing these values, a minimal centre and edge distance has to be considered: - MA-Anchorages without helix (see Annexes 13 and 14): External dimension of the stirrup reinforcement plus 20 mm. - Plate and MA-Anchorages with helix (see Annexes 6-8 and 11-12): External diameter of the helix plus 20 mm. The dimensions of the additional reinforcement shall be fitted accordingly. All centre and edge distances have only been specified in conjunction with load transfer to the structure; therefore, the concrete cover given in national standards and provisions shall be taken into account additionally. The concrete cover may under no circumstance be less than 20 mm or smaller than the concrete cover of the reinforcement installed in the same cross section. The concrete cover of the anchorage should be at least 20 mm. Standards and regulations on concrete cover valid in place of use shall be considered. B Reinforcement in the anchorage zone The anchorages (including reinforcement) for the transfer of the prestressing forces to the structural concrete were verified by means of tests. The resistance to the forces occurring in the Version of the 27 th June 2013

16 European Technical Approval n 13/0979 Page 15 of 50 structural concrete in the anchorage zone outside the helix and the additional reinforcement shall be verified. An adequate transverse reinforcement shall be provided here in particular for the occurring transverse tensile forces (not shown in the attached drawings). The steel grades and dimensions of the additional reinforcement (stirrups) shall follow the values given in the Annexes 6-8 and Existing reinforcement in a corresponding position more than the reinforcement required by design may be taken into account for the additional reinforcement. The additional reinforcement shall be of closed stirrups (stirrups closed by means of bends or hooks or an equivalent method) or of orthogonal reinforcement properly anchored. The stirrups locks (bends or hooks) shall be placed staggered. In the anchorage zone vertically led gaps shall be provided for proper concreting. If required for a specific project design, the reinforcement given in the Annexes can be modified in accordance with the respective regulations in force at the place of use as well as with relevant approval of the local authority and of the ETA holder to provide equivalent performance. If in exceptional cases 7 due to an increased amount of reinforcement the helix or the concrete cannot be properly placed, the helix can be replaced by different equivalent reinforcement. B Slip at the anchorages The slip at the anchorages (see section B.4.2.4) shall be taken into account in the static calculation and the determination of the tendon elongation. B Resistance to fatigue With the fatigue tests carried out in accordance with ETAG 013, the stress range of 80 MPa of the anchorages at maximum load of 0.65 f pk at 2x10 6 load cycles was demonstrated. 7 This requires the approval of the local authority for individual case according to the national regulations and administrative provisions. Version of the 27 th June 2013

17 European Technical Approval n 13/0979 Page 16 of 50 B.3 EVALUATION AND ATTESTATION OF CONFORMITY AND CE MARKING B.3.1 Attestation of System Conformity According to the decision 98/456/EC of the European Commission 8 the system 1+ of attestation of conformity applies and is defined as follows: System 1+: Certification of the conformity of the product by an approved certification body on the basis of: (a) Tasks of the kit manufacturer: (1) Factory production control, (2) Further testing of samples taken at the factory by the kit manufacturer in accordance with a prescribed test plan. (b) Tasks for the approved body (certification body): (3) Initial type-testing of the product, (4) Initial inspection of factory and of factory production control, (5) Continuous surveillance, assessment and approval of factory production control, (6) Audit-testing of samples taken at the kit manufacturer. (see ETAG013, section 8.1 (b)). Note: Approved bodies are also referred to as notified bodies. B.3.2 Responsibilities B Tasks of the kit manufacturer B Factory production control The kit manufacturer shall keep available an updated list of all components manufacturers. The list is provided to the Certification Body and to the Approval Body. The kit manufacturer shall exercise permanent internal control of production. All the elements, requirements and provisions adopted by the kit manufacturer shall be documented in a systematic manner in the form of written policies and procedures, including records of results performed. This production control system shall insure that the product is in conformity with this European Technical Approval. The kit manufacturer may only use initial materials stated in the technical documentation of this European Technical Approval. The factory production control shall be in accordance with the "Control Plan of 27 June 2013 relating to the European Technical Approval ETA-13/0979 issued on 27 June 2013" which is part of the technical documentation of this European Technical Approval. The "Control Plan" is 8 Official Journal of the European Communities N o L 201/112, Version of the 27 th June 2013

18 European Technical Approval n 13/0979 Page 17 of 50 laid down in the context of the factory production control system operated by the kit manufacturer and deposited at Sétra 9. The prescribed test plan defined in Annex 19 gives the type and frequency of checks and tests conducted during production and on the final product as part of the continuous internal production control. The results of factory production control shall be recorded and evaluated in accordance with the provisions of the "Control Plan". The records shall contain at least the following information: - Designation of the product or the initial material and the components, - Kind of control or testing, - Date of manufacture and of testing of product or components and of initial material, - Results of controls and tests and, where specified, comparison with the requirements, - Name and signature of person responsible for the factory production control. The records shall be kept for at least ten years and on request they shall be presented to Sétra. If the test results are not satisfactory, the kit manufacturer shall take immediate measures to eliminate defects. Construction products or components which are not in compliance with the requirements shall be handled such that they cannot be mistaken for products complying with the requirements. After elimination of the defects the relevant test shall be immediately repeated as far as is technically possible and necessary for verifying the deficiency elimination. B Other tasks of kit manufacturer The kit manufacturer shall, on the basis of a contract, involve a body which is approved for the tasks referred to in section B.3.1 in the field of Post-Tensioning Kits for Prestressing of Structures in order to undertake the actions laid down in section B.3.3. For this purpose, the "control plan" referred to in sections B and B shall be handed over by the kit manufacturer to the approved body involved. The kit manufacturer shall make a declaration of conformity, stating that the construction product is in conformity with the provisions of the European Technical Approval ETA-13/0979 issued on 27 June At least once a year, each components manufacturer shall be audited by the kit manufacturer. The result of the audit shall be made available for at least 10 years to the certifying body. At least once a year specimens shall be taken from one job site and one series of single tensile element tests shall be performed according to ETAG 013, Annex E3 (see Annex 20). The results of these test series shall be made available to the approved body. 9 The "control plan" is a confidential part of the European Technical Approval and only handed over to the approved body involved in the procedure of attestation of conformity. See section Version of the 27 th June 2013

19 European Technical Approval n 13/0979 Page 18 of 50 B Tasks of the approved body B General The approved body shall perform the - initial type-testing of the product, - initial inspection of factory and of factory production control, - continuous surveillance, assessment and approval of factory production control, - audit-testing of samples taken at the factory in accordance with the provisions laid down in the "Control Plan of 26 June 2013 relating to the European Technical Approval ETA-13/0979 issued on 27 June 2013". The approved body shall retain the essential points of its actions referred to above and state the results obtained and conclusions drawn in a written report. The main production centre is checked at least once a year by the approved body. Each component producer is checked at least once every five years by the approved body. The approved certification body involved by the kit manufacturer (DYWIDAG-Systems International GmbH) shall issue an EC certificate of conformity of the product stating the conformity with the provisions of this European Technical Approval. In cases where the provisions of the European Technical Approval and its "Control Plan" are no longer fulfilled the certification body shall withdraw the certificate of conformity and inform Sétra without delay. B The approved Initial type-testing of the product For initial type-testing the results of the tests performed as part of the assessment for the European Technical Approval may be used unless there are changes in the production line or plant. In such cases the necessary initial type-testing has to be agreed between Sétra and the approved body involved. B The approved Initial inspection of factory and of factory production control The approved body shall ascertain that, in accordance with the "Control Plan, the factory, in particular the staff and equipment, and the factory production control are suitable to ensure a continuous and orderly manufacturing of the PT system with the specifications mentioned in section B.2.1 as well as in the Annexes to the European Technical Approval. B Continuous surveillance, assessment and approval of factory production control The kit manufacturer shall be inspected by the approved body at least once a year. Each component manufacturer shall be inspected at least once in five years. It shall be verified that the system of factory production control and the specified manufacturing process are maintained taking account of the prescribed test plan. Continuous surveillance and assessment of factory production control have to be performed according to the prescribed test plan. Version of the 27 th June 2013

20 European Technical Approval n 13/0979 Page 19 of 50 The results of product certification and continuous surveillance shall be made available on demand by the approved body to Sétra. B Audit-testing of samples taken at the kit manufacturer During surveillance inspections the approved body shall take samples at the factory of components of the PT system or of individual components for which this Technical Approval has been granted, for independent testing. For the most important components Annex 19 contains the minimum procedures which have to be performed by the approved body. The basic elements of the Audit testing comply with ETAG 013, Annex E2 (see Annex 20). B.3.3 CE Marking The CE marking must comply with the European Council Directive 89/106/CEE, and to the EC guideline D related to the marking. The delivery bill accompanying the PT kit components shall bear the conformity CE marking symbol and the following mentions: 1. Name and address of kit manufacturer, 2. Last two digits of the year during which the marking has been made, 3. Number of conformity certificate, 4. Number of ETA, 5. See information on ETA, 6. Number of Certification body, 7. Product Identification (commercial denomination) and use category(ies). All other information must be clearly distinct from the CE marking and the related mentions. Version of the 27 th June 2013

21 European Technical Approval n 13/0979 Page 20 of 50 B.4 ASSUMPTIONS UNDER WHICH THE FITNESS OF THE PRODUCT FOR THE INTENDED USE WAS FAVOURABLY ASSESSED B.4.1 Manufacturing The European Technical Approval is issued for the product on the basis of agreed data/information, deposited with Sétra, which identifies the product that has been assessed and judged. Changes to the product or production process, which could result in this deposited data/information being incorrect, should be notified to Sétra before the changes are introduced. Sétra will decide whether or not such changes affect the ETA and consequently the validity of the CE marking on the basis of the ETA and if so whether further assessment or alterations to the ETA shall be necessary. B.4.2 Installation B General Assembly and installation of the tendons shall only be performed by qualified post-tensioning specialist companies which have the required technical skills and experiences with this DYWIDAG PT system. The company s site manager shall have a certificate of the ETA holder certifying that he is instructed by the ETA holder and has the required knowledge and experience with this PT system. National standards and regulations valid on site shall be considered. The ETA holder is responsible to inform anyone concerned about the use of this DYWIDAG PT system. Additional information as listed in ETAG 013, section 9.2 shall be held available at the ETA holder and shall be distributed as needed. The tendons and the components shall be handled carefully. B Welding Welding at the anchorages is only permitted at the following points: a) Welding of the end of the helix to a closed ring. b) For ensuring the central position the helix may be attached to the anchor plate or to the anchor body by welding. After mounting the tendons no more welding shall be performed at the anchorages and in the immediate vicinity of the tendons. B Installation of the tendon The central position of the helix and stirrups shall be ensured by tack-welding to the anchor plate or the anchor body or other appropriate mountings. The anchor plate or the anchor body, respectively, shall be in direction perpendicular to the axis of the straight tendon in the vicinity of the anchorage. The tendon shall be placed straightforward behind the anchorage according to Table 5 and Table 6. Version of the 27 th June 2013

22 European Technical Approval n 13/0979 Page 21 of 50 B Wedging force, slip at anchorages, wedge securing and corrosion protection compound The draw-in of the anchorage to be taken into account for the determination of the elongations and at load transfer from the jack onto the anchorage shall be taken from Table 9. The wedges of all anchorages (fixed anchorages) which are no more accessible during tensioning shall be secured by means of wedge keeper plates and bolts.if the calculated prestressing force in these anchorages is less than 0.7 P m0, max the wedges shall be pre-wedged with P 0, max (see section B.2.2.2). Table 9: Draw-in values for calculation of elongation [mm] Draw-in at stressing anchorage Draw-in at fixed anchorage Draw-in to be considered for calculation of elongation Draw-in at load transfer from the jack onto the anchorage Draw-in to be considered for calculation of elongation Without pre-wedging or power-seating With power-seating 20 kn per strand at stressing anchorage With pre-wedging P 0, max at fixed anchorage At installation of the wedges into the conical borings of the not accessible fixed anchorages the gaps shall be filled with corrosion protection compound. Before pouring of concrete the wedge plates of the not accessible fixed anchorages shall be sealed with a grout cap. B Stressing and stressing records B Stressing At time of stressing the minimum mean concrete strength shall comply with the values given in section B In the vicinity of the anchorages the concrete must be especially homogeneous. It is admissible to restress the tendons by releasing and re-using the wedges. After restressing and anchoring, wedge marks on strands resulting from first stressing shall be moved to the outside by at least 15 mm. The minimum straight length for tensioning behind the anchorages (strand protrusion) depends on the jack which is used on site (see Annex 22). All strands of a tendon shall be stressed simultaneously. This can be done by centrally controlled individual jacks or by a bundle jack. Version of the 27 th June 2013

23 European Technical Approval n 13/0979 Page 22 of 50 B Stressing record All stressing operations shall be recorded for each tendon. In general, the required prestressing force shall be achieved. The elongation is measured and compared with the calculated value. If during tensioning the difference between measured and calculated elongation is more than 15 % of the calculated value then the engineer shall be informed and the causes shall be found. B Prestressing jacks and space requirements, safety-at-work For stressing hydraulic jacks are used. Information about the stressing equipment is shown in Annex 22. To facilitate jack placement and stressing the tendons, clearance according to Annex 23 shall be considered directly behind the anchorages. The safety-at-work and health protection regulations shall be complied with. B Grouting B Grout and grouting procedures Grout according section B shall be used. Grouting procedures shall be carried out in accordance with EN 446:1996. Local standards and national regulations valid in place of use shall be considered. B Water rinse Normally, sheathing shall not be rinsed with water. Local standards and national regulations valid in place of use shall be considered. B Grouting speed The grouting speed shall be in the range between 3 m/min and 12 m/min. B Grouted section and re-grouting The maximum length of a grouted section depends on the capacity of the grouting apparatus and shall be determined before the grouting procedure. When exceeding these tendon lengths, additional grouting openings shall be provided. Where the tendon is led via distinct high points, re-groutings shall be performed in order to avoid voids. For re-groutings corresponding measures shall be taken into account already in design. Vents on the ducts shall be provided at both ends and at the points of the tendon where air or water may accumulate. In case of ducts of considerable length, vents or inlets may be required at intermediate positions. Local standards and national regulations valid in place of use shall be considered. B Surveillance Surveillance according to EN 446:1996 shall be carried out. Version of the 27 th June 2013

24 European Technical Approval n 13/0979 Page 23 of 50 B Wax injection B Wax and injection procedures Wax according section B.2.11 shall be used. Injection shall be carried out according to DSI special instructions. Injection equipment is normally composed of melting device (heater), stirrer and pump. B.5 PACKAGING, TRANSPORT, AND STORAGE The components and the tendons shall be protected against moisture and staining. The tendons shall be kept away from areas where welding procedures are performed. For strands the smallest diameter of curvature during transport is 1.65 m. The PE-tubes are delivered as straight or prebent tubes for the deviation zones and are connected on site by mirror welding or electro welding couplers. Version of the 27 th June 2013

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26 th Page 25 of ETA-13/0979, version of the 27 June 2013 English translation by Sétra Wedge: Strand 140 mm² (0,6") 7.5 Strand 150 mm² (0.62") 7.5 Wedge tooth geometries (for both wedge sizes) Ø29 Sheathing - Plate anchorage: PE-Insert PE-Tube Grout tube Telescopic tube Steel tube Flange Steel trumpet Mirror welding Electro welding coupler PE-Tube Sheathing - Multiplane anchorage MA: PE-Tube Grout tube Telescopic tube PE-Trumpet Mirror welding Electro welding coupler PE-Tube Pitch circles: Wedge plate Cone (for both wedge sizes) Spacer c Wedge keeper plate 6 7 f ** f * f Ø29 Øp Ø17.5 Dimensions in mm Tendon size No. of strands Spacer Wedge keeper plate Pitch circles c Øp Duct (min. values): Outer diameter f f * f ** PE80, PN6 (cement gr. injection): min. wall thickness PE100, PN10 (wax or cement gr. inj.): min. wall thickness DYWIDAG-Systems International GmbH DYWIDAG - PT external strand tendon Details: Wedge, Cone, Sheathing Annex 2 of European Technical Approval ETA-13/0979

27 th Page 26 of ETA-13/0979, version of the 27 June 2013 English translation by Sétra m Anchor plate Wedge plate ( f acc. to Annex 2 ) c e e* f Ød* Øa Øb Ød ør Dimensions in mm Tendon size No. of strands Cone pattern and position Minimum actual concrete strength at stressing fcm,0,cube N/mm² Anchor plate Type 2353/2354/2355 Ø a Ø b Wedge plate Ø d Type 1350 for 6803, 6804 Ø d * Type 1362 for 6805, 6807 e c e * Trumpet Length m Recess tube Ø r DYWIDAG-Systems International GmbH DYWIDAG - PT external strand tendon Plate anchorage Dimensions of components for Annex 3 of European Technical Approval ETA-13/0979

28 th Page 27 of ETA-13/0979, version of the 27 June 2013 English translation by Sétra m Anchor plate c Wedge plate ( f, f * acc. to Annex 2 ) e e* f * f Øa Øb Ød Ød* ør Dimensions in mm Tendon size No. of strands Cone pattern and position Minimum actual concrete strength at stressing fcm,0,cube N/mm² Anchor plate Type 2353/2354/2355 Ø a Ø b c Wedge plate Ø d Type 1362 Ø d * e e * Trumpet Length m Recess tube Ø r DYWIDAG-Systems International GmbH DYWIDAG - PT external strand tendon Plate anchorage Dimensions of components for Annex 4 of European Technical Approval ETA-13/0979

29 th Page 28 of ETA-13/0979, version of the 27 June 2013 English translation by Sétra m Anchor plate c Wedge plate ( f, f *, f ** acc. to Annex 2 ) e e* f ** f * f Øa Øb Ød Ød* ør Dimensions in mm Tendon size No. of strands Cone pattern and position Minimum actual concrete strength at stressing fcm,0,cube N/mm² Anchor plate Type 2353/2354/2355 Ø a Ø b c Wedge plate Ø d Type 1362 Ø d * e e * Trumpet Length m Recess tube Ø r DYWIDAG-Systems International GmbH DYWIDAG - PT external strand tendon Plate anchorage Dimensions of components for Annex 5 of European Technical Approval ETA-13/0979

30 th Page 29 of ETA-13/0979, version of the 27 June 2013 English translation by Sétra z i i i i i i i Additional reinforcement n x ds y da l * i * Helix, n * x ds da x Dimensions in mm For z the concrete cover has to be considered! Tendon size Strand 150mm², fpk=1860n/mm² (Fpk=279.0kN) and 150mm², fpk=1770n/mm² (Fpk=265.5kN) No. of strands Minimum actual concrete strength at stressing fcm,0,cube N/mm² Centre distance A Edge distance R 0.5 x Centre distance + Concrete cover - 10mm Additional reinforcement (Material see Annex 18) No. Ø n d s z i x / y Helix (Material see Annex 18) Turns Ø Ø n * d s d a i * min l * DYWIDAG-Systems International GmbH DYWIDAG - PT external strand tendon Plate anchorage Centre and edge distances of tendon sizes for strand Y1860S and 15.7 and for strand Y1770S and 15.7 Annex 6 of European Technical Approval ETA-13/0979

31 th Page 30 of ETA-13/0979, version of the 27 June 2013 English translation by Sétra z i i i i i i i Additional reinforcement n x ds y da l * i * Helix, n * x ds da x Dimensions in mm For z the concrete cover has to be considered! Tendon size Strand 150mm², fpk=1860n/mm² (Fpk=279.0kN) and 150mm², fpk=1770n/mm² (Fpk=265.5kN) No. of strands Minimum actual concrete strength at stressing fcm,0,cube N/mm² Centre distance A Edge distance R 0.5 x Centre distance + Concrete cover - 10mm Additional reinforcement (Material see Annex 18) No. Ø n d s z i x / y Helix (Material see Annex 18) Turns Ø Ø n * d s d a i * min l * DYWIDAG-Systems International GmbH DYWIDAG - PT external strand tendon Plate anchorage Centre and edge distances of tendon sizes for strand Y1860S and 15.7 and for strand Y1770S and 15.7 Annex 7 of European Technical Approval ETA-13/0979

32 th Page 31 of ETA-13/0979, version of the 27 June 2013 English translation by Sétra z i i i i i i i Additional reinforcement n x ds y da l * i * Helix, n * x ds da x Dimensions in mm For z the concrete cover has to be considered! Tendon size Strand 150mm², fpk=1860n/mm² (Fpk=279.0kN) and 150mm², fpk=1770n/mm² (Fpk=265.5kN) No. of strands Minimum actual concrete strength at stressing fcm,0,cube N/mm² Centre distance A Edge distance R x Centre distance + Concrete cover - 10mm Additional reinforcement (Material see Annex 18) No. Ø n d s z i x / y Helix (Material see Annex 18) Turns Ø Ø n * d s d a i * min l * DYWIDAG-Systems International GmbH DYWIDAG - PT external strand tendon Plate anchorage Centre and edge distances of tendon sizes for strand Y1860S and 15.7 and for strand Y1770S and 15.7 Annex 8 of European Technical Approval ETA-13/0979

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39 th Page 38 of ETA-13/0979, version of the 27 June 2013 English translation by Sétra External application Plate anchorage Multiplane anchorage MA Internal application Plate anchorage Multiplane anchorage MA DYWIDAG-Systems International GmbH DYWIDAG - PT external strand tendon External and internal applications Annex 15 of European Technical Approval ETA-13/0979

40 th Page 39 of ETA-13/0979, version of the 27 June 2013 English translation by Sétra Expansion tube d o e t PE - tube Ø duct R Deviation tube α = Designed deviation angle β = Deviation angle in reserve β 3 at each end in all directions required, R Rmin min duct o * ** ** * ** DYWIDAG-Systems International GmbH DYWIDAG - PT external strand tendon Deviator - Geometrical requirements for circular steel tubes Annex 16 of European Technical Approval ETA-13/0979

41 th Page 40 of ETA-13/0979, version of the 27 June 2013 English translation by Sétra Designation Material Standard Wedge Case hardened steel * EN : 2008 EN : 2006 Wedge plate Quenched and tempered steel * EN : 2006 EN : 2006 Anchor plate Structural steel * EN : 2004 Multiplane anchor body Type MA Cast ductile iron * EN 1563: 1997 ASTM A536: 1999 Steel tube for anchor plate Structural steel * EN : 2002 EN : 2002 Spacer Polyethylene (PE) EN ISO : 1999 Flange Structural steel * EN : 2004 Steel tube for steel trumpet Structural steel * EN : 2002 EN : 2002 Tension ring Structural steel * EN : 2004 PE - Insert Polyethylene (PE) EN ISO : 1999 Retaining ring Structural steel * EN : 2004 Helix S 235 JR Reinf. steel Re 500 MPa EN : 2004 EN 10080: 2005 ** Additional reinforcement Re 500 MPa EN 10080: 2005 PE - Tube Polyethylene (PE) EN : 2003 PE - Trumpet Polyethylene (PE) EN ISO : 1999 * Exact material properties and definitions deposited at Sétra. ** As long as EN does not exist harmonized, national standards shall be considered. DYWIDAG-Systems International GmbH DYWIDAG - PT external strand tendon Materials and standard references Annex 17 of European Technical Approval ETA-13/0979

42 th Page 41 of ETA-13/0979, version of the 27 June 2013 English translation by Sétra DIMENSIONS AND PROPERTIES OF 7-WIRE STRANDS Designation Symbol Unit Value Tensile strength R /F m pk MPa 1770 or 1860 Strand Nominal diameter D mm A p Nominal cross section mm² Nominal mass M g/m Surface configuration plain Force of Single Strand at 0.1 % Y 1770 F p0.1k kn Y 1860 F p0.1k kn Modulus of elasticity E MPa 195,000 Individual wires External wire diameter d mm 5.0 ± ± 0.04 Core wire diameter d' mm 1.02 to 1.04 d As long as EN does not exist 7 - wire strands in accordance with national provisions and with the characteristics given in the table above shall be used. DYWIDAG-Systems International GmbH DYWIDAG - PT external strand tendon 7 - wire strands Annex 18 of European Technical Approval ETA-13/0979

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