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BBR VT CONA CMF BT

Internal Post-tensioning System with Flat Anchorages

European Technical Approval ETA 12/0076

0432 ETA-12/0076 BBR VT CONA CMF Internal Post-tensioning System with Flat Anchorages and 02, 03 and 04 Strands BBR VT International Ltd Bahnstrasse 23, 8603 Schwerzenbach (Switzerland) www.bbrnetwork.com 0432-CPD-11 9181-1.7/1 12

The delivery note accompanying components of the BBR VT CONA CMI BT Post-tensioning System will contain the CE marking.

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Assembly and installation of BBR VT CONA CMI BT tendons must only be carried out by qualified BBR PT Specialist Companies. Find the local BBR PT Specialist Company by visiting the BBR Network website www.bbrnetwork.com.

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European Organisation for Technical Approvals Europische Organisation fr Technische Zulassungen Organisation Europenne pour lAgrment technique

ETAG 013

Guideline for European Technical Approval of Post-tensioning Kits for Prestressing of Structures

CWA 14646

Requirements for the installation of post-tensioning kits for prestressing of structures and qualification of the specialist company and its personnel

BBR E-Trace is the trading and quality assurance platform of the BBR Network linking the Holder of Approval, BBR VT International Ltd, BBR PT Specialist Companies and the BBR Manufacturing Plant. Along with the established BBR Factory Production Control, BBR E-Trace provides effective supply chain management including installation, delivery notes and highest quality standards, as well as full traceability of components.

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European technical approval


English translation, the original version is in German Handelsbezeichnung Trade name

ETA-12/0076

BBR VT CONA CMF BT Internes Spannverfahren mit flachen Verankerungen und 02, 03 und 04 Litzen BBR VT CONA CMF BT Internal Post-tensioning System with Flat Anchorages and 02, 03, and 04 Strands

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Zulassungsinhaber Holder of approval

BBR VT International Ltd. Bahnstrasse 23 8603 Schwerzenbach (ZH) Switzerland

Zulassungsgegenstand und Verwendungszweck

Litzen-Spannverfahren, intern, im Verbund oder ohne Verbund, fr das Vorspannen von Tragwerken Post-tensioning kit for prestressing of structures with internal bonded or unbonded strands

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Generic type and use of construction product

Geltungsdauer vom Validity from bis zum to

29.06.2012 28.06.2017

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Herstellwerk Manufacturing plant

BBR VT International Ltd. Bahnstrasse 23 8603 Schwerzenbach (ZH) Switzerland

Diese Europische technische Zulassung umfasst This European technical approval contains

49 Seiten einschlielich 26 Anhngen 49 Pages including 26 Annexes

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Table of contents EUROPEAN TECHNICAL APPROVAL ETA-12/0076 ...................................................................................... 1 TABLE OF CONTENTS .................................................................................................................................... 2 I LEGAL BASES AND GENERAL CONDITIONS ........................................................................................... 5 II SPECIFIC CONDITIONS OF THE EUROPEAN TECHNICAL APPROVAL......................................................... 6 1 1.1 1.2 2 DEFINITION OF PRODUCT AND INTENDED USE ....................................................................................... 6 Definition of product .......................................................................................................................... 6 Intended use...................................................................................................................................... 7 CHARACTERISTICS OF THE PRODUCT AND METHODS OF VERIFICATION .................................................. 7

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PT SYSTEM .................................................................................................................................................. 7 2.1 Designation and range of the anchorages and couplers................................................................... 7 2.1.1 Designation .............................................................................................................................. 7 2.1.2 Anchorage................................................................................................................................ 7 2.1.2.1 General .................................................................................................................................... 7 2.1.2.2 Restressable and exchangeable tendon.................................................................................. 8 2.1.3 Fixed coupler............................................................................................................................ 8 2.1.3.1 General .................................................................................................................................... 8 2.1.3.2 Sleeve coupler (FH, SH) .......................................................................................................... 8 2.1.4 Movable coupler (BH) .............................................................................................................. 8 2.1.5 Layout of the anchorage recesses ........................................................................................... 8 2.2 Designation and range of the tendons .............................................................................................. 9 2.2.1 Designation .............................................................................................................................. 9 2.2.2 Range ...................................................................................................................................... 9 2.2.2.1 CONA CMF BT n05-93 ............................................................................................................ 9 2.2.2.2 CONA CMF BT n05-100 .......................................................................................................... 9 2.2.2.3 CONA CMF BT n06-140 .......................................................................................................... 9 2.2.2.4 CONA CMF BT n06-150 ........................................................................................................ 10 2.3 Ducts ............................................................................................................................................... 10 2.3.1 Use of ducts ........................................................................................................................... 10 2.3.1.1 Bonded tendon....................................................................................................................... 10 2.3.1.2 Unbonded tendon .................................................................................................................. 10 2.3.2 Degree of filling ...................................................................................................................... 10 2.3.3 Round steel strip sheaths....................................................................................................... 10 2.3.4 Flat steel ducts ....................................................................................................................... 10 2.3.5 Plastic sheaths ....................................................................................................................... 11 2.3.6 Pre-bent smooth round steel ducts ........................................................................................ 11 2.4 Minimum radii of curvature .............................................................................................................. 11 2.4.1 Minimum radii of curvature for bonded and unbonded tendons other than monostrand tendons .................................................................................................................................. 11 2.4.2 Minimum radii of curvature for tendons with monostrands..................................................... 12 2.5 Support of tendons .......................................................................................................................... 12 2.5.1 Support of bonded and unbonded tendons other than monostrand tendons......................... 12 2.5.2 Support of monostrand tendons............................................................................................. 12 2.6 Friction losses ................................................................................................................................. 13 2.7 Slip at anchorages and couplers ..................................................................................................... 13 2.8 Concrete strength at time of stressing............................................................................................. 14 2.9 Centre spacing and edge distance of anchorages .......................................................................... 14 COMPONENTS ............................................................................................................................................ 15

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2.10 Strands ............................................................................................................................................ 15 2.11 Anchorages and couplers................................................................................................................ 15 2.11.1 General .................................................................................................................................. 15 2.11.2 Anchor heads ......................................................................................................................... 15 2.11.3 Bearing trumplates ................................................................................................................. 16 2.11.4 Trumpets ................................................................................................................................ 16 2.11.5 Coupler anchor heads H ........................................................................................................ 16 2.11.6 Ring wedges .......................................................................................................................... 16 2.11.7 Helix and additional reinforcement......................................................................................... 16 2.11.8 Protection caps ...................................................................................................................... 16 2.11.9 Material properties ................................................................................................................. 16 2.12 Permanent corrosion protection ...................................................................................................... 17 2.13 Dangerous substances.................................................................................................................... 17 2.14 Methods of verification .................................................................................................................... 17 2.15 Identification .................................................................................................................................... 17 3 EVALUATION OF CONFORMITY AND CE MARKING ................................................................................ 18 3.1 Attestation of conformity system ..................................................................................................... 18 3.2 Responsibilities ............................................................................................................................... 18 3.2.1 Tasks for the manufacturer factory production control........................................................ 18 3.2.2 Tasks of the approved body................................................................................................... 19 3.2.2.1 Initial type testing of the products........................................................................................... 19 3.2.2.2 Initial inspection of factory and of factory production control ................................................. 19 3.2.2.3 Continuous surveillance ......................................................................................................... 19 3.2.2.4 Audit testing of samples taken at the factory ......................................................................... 19 3.3 CE marking...................................................................................................................................... 19 4 ASSUMPTIONS UNDER WHICH THE FITNESS OF THE PRODUCT FOR THE INTENDED USE WAS FAVOURABLY ASSESSED .................................................................................................................... 20 4.1 Manufacturing.................................................................................................................................. 20 4.2 Design ............................................................................................................................................. 20 4.2.1 General .................................................................................................................................. 20 4.2.2 Anchorage recess .................................................................................................................. 20 4.2.3 Reinforcement in the anchorage zone ................................................................................... 20 4.2.4 Fatigue resistance.................................................................................................................. 21 4.2.5 Tendons in masonry structures Load transfer to the structure............................................ 21 4.2.6 Maximum prestressing force .................................................................................................. 21 4.3 Installation ....................................................................................................................................... 21 4.4 Stressing operation ......................................................................................................................... 21 4.5 Restressing ..................................................................................................................................... 22 4.6 Exchanging tendons........................................................................................................................ 22 4.7 Filling material ................................................................................................................................. 22 4.7.1 Grout ...................................................................................................................................... 22 4.7.2 Grease and wax ..................................................................................................................... 22 4.7.3 Recordings ............................................................................................................................. 22 4.8 Welding ........................................................................................................................................... 23 5 5.1 5.2 5.3 RECOMMENDATIONS FOR THE MANUFACTURER .................................................................................. 23 Recommendations for packing, transport and storage.................................................................... 23 Recommendations on installation ................................................................................................... 23 Accompanying information .............................................................................................................. 23

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ANNEXES ................................................................................................................................................... 24 ANNEX 1 ANNEX 2 ANNEX 3 OVERVIEW ON ANCHORAGES AND COUPLERS FOR BONDED AND UNBONDED TENDONS OTHER THAN MONOSTRAND TENDONS .................................................................................................. 24 OVERVIEW ON ANCHORAGES AND COUPLERS FOR MONOSTRANDS AND VT CMM BANDS ........... 25 ANCHOR HEADS ....................................................................................................................... 26 BEARING TRUMPLATE AND H-COUPLER ..................................................................................... 27 TRUMPETS............................................................................................................................... 28 WEDGES, SPRING AND PROTECTION CAP .................................................................................. 29 ANCHORAGES WITH MONOSTRANDS OR VT CMM BANDS .......................................................... 30 TENDON RANGES ..................................................................................................................... 31 MINIMUM RADIUS OF CURVATURE OF DUCT ............................................................................... 32

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ANNEX 4 ANNEX 5 ANNEX 6 ANNEX 7 ANNEX 8 ANNEX 9

ANNEX 10 MINIMUM WALL THICKNESS OF DUCT ......................................................................................... 33 ANNEX 11 MATERIAL CHARACTERISTICS ................................................................................................... 34 ANNEX 12 CONTENTS OF THE PRESCRIBED TEST PLAN .............................................................................. 35 ANNEX 13 AUDIT TESTING ........................................................................................................................ 36 ANNEX 14 MAXIMUM PRESTRESSING AND OVERSTRESSING FORCES .......................................................... 37 ANNEX 15 CONSTRUCTION STAGES .......................................................................................................... 38 ANNEX 16 MINIMUM CONCRETE STRENGTH HELIX ADDITIONAL REINFORCEMENT CENTRE SPACING AND EDGE DISTANCE .................................................................................................. 39 ANNEX 17 MINIMUM CONCRETE STRENGTH HELIX ADDITIONAL REINFORCEMENT CENTRE SPACING AND EDGE DISTANCE .................................................................................................. 40 ANNEX 18 MODIFICATION OF CENTRE SPACING AND EDGE DISTANCE ......................................................... 41 ANNEX 19 FREE TENDON LAYOUT WITH MONOSTRANDS OR VT CMM BANDS TENDON CONA CMF BT 0405 AND 0406.................................................................................................................. 42 ANNEX 20 DESCRIPTION OF INSTALLATION OF BONDED AND UNBONDED TENDONS OTHER THAN MONOSTRAND TENDONS ........................................................................................................... 43 ANNEX 21 DESCRIPTION OF INSTALLATION OF MONOSTRANDS OR VT CMM BANDS.................................... 44 ANNEX 22 SPECIFICATION ........................................................................................................................ 45 ANNEX 23 SPECIFICATION ........................................................................................................................ 46 ANNEX 24 STRAND SPECIFICATION ........................................................................................................... 47 ANNEX 25 REFERENCE DOCUMENTS ......................................................................................................... 48 ANNEX 26 REFERENCE DOCUMENTS ......................................................................................................... 49

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I
1

LEGAL BASES AND GENERAL CONDITIONS


This European technical approval is issued by sterreichisches Institut fr Bautechnik in accordance with: 1. 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 Construction Products Directive (CPD) , amended by the Council Directive 93/68/EEC of 22 July 1993 2, and Regulation (EC) 1882/2003 of the European Parliament and of the Council of 29 September 2003 3; 2. dem Salzburger Bauproduktegesetz, LGBl. Nr. 11/1995, in der Fassung LGBl. Nr. 47/1995, LGBl. Nr. 63/1995, LGBl. Nr. 123/1995, LGBl. Nr. 46/2001, LGBl. Nr. 73/2001, LGBl. Nr. 99/2001 und LGBl. Nr. 20/2010; the Salzburg Construction Products Act LGBl. 11/1995, amended by LGBl. 47/1995, LGBl. 63/1995, LGBl. 123/1995, LGBl. 46/2001, LGBl. 73/2001, LGBl. 99/2001, and LGBl. 20/2010; 3. Common Procedural Rules for Requesting, Preparing and the Granting of European technical approvals set out in the Annex of Commission Decision 94/23/EC 4; 4. Guideline for European technical approval of Post-Tensioning Kits for Prestressing of Structures, ETAG 013, Edition June 2002.

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sterreichisches Institut fr Bautechnik is authorised to check whether the provisions of this European technical approval are met. Checking may take place in the manufacturing plant. 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. 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. This European technical approval may be withdrawn by sterreichisches Institut fr Bautechnik, in particular pursuant to information by the Commission according to Article 5 (1) of Council Directive 89/106/EEC. Reproduction of this European technical approval including transmission by electronic means shall be in full. However, partial reproduction may be made with the written consent of sterreichisches Institut fr Bautechnik. 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. The European technical approval is issued by the Approval Body in its official language. This version corresponds to the version circulated within EOTA. Translations into other languages have to be designated as such.

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1 2 3 4

Official Journal of the European Communities L 40, 11.02.1989, page 12 Official Journal of the European Communities L 220, 30.08.1993, page 1 Official Journal of the European Union L 284, 31.10.2003, page 1 Official Journal of the European Communities L 17, 20.01.1994, page 34

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II
1 1.1

SPECIFIC CONDITIONS OF THE EUROPEAN TECHNICAL APPROVAL


Definition of product and intended use Definition of product The European technical approval (ETA) applies to a kit, the PT system

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BBR VT CONA CMF BT Internal Post-tensioning System with Flat Anchorage and 02, 03, and 04 strands,
comprising the following components: Tendon Internal tendons with 02 to 04 tensile elements Tensile element 7-wire prestressing steel strand with nominal diameters and maximum characteristic tensile strength as given in Table 1 Unbonded 7-wire prestressing steel monostrand with nominal diameters and maximum characteristic tensile strength as given in Table 1, factory-provided with a corrosion protection system consisting of a corrosion protection filling material and an HDPE-sheathing Table 1: Tensile elements Designation Nominal diameter mm 12.5 12.9 15.3 15.7
1 MPa = 1 N/mm2

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Nominal cross sectional area mm2 93 100 140 150

Maximum characteristic tensile strength MPa

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05
06

1 860

NOTE

Anchorage and coupler

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Anchorage of the strands with ring wedges End anchorage Fixed (passive) anchor or stressing (active) anchor as end anchorage for 02, 03, and 04 strands Fixed or stressing coupler Sleeve coupler for 02, 03, and 04 strands Movable coupler Sleeve coupler for 02, 03, and 04 strands Bearing trumplate for 02, 03, and 04 strands Helix and additional reinforcement in the region of the anchorage Corrosion protection for tensile elements, anchorages and couplers
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1.2

Intended use The PT system is intended to be used for the prestressing of structures. Use categories according to type of tendon and material of structure: Internal bonded tendon for concrete and composite structures Internal unbonded tendon for concrete and composite structures For special structures according to Eurocode 2 and Eurocode 4, and Eurocode 6 Optional use categories: Restressable tendons Exchangeable tendons The provisions made in the European technical approval are based on an assumed intended working life of the PT system of 100 years. The indications given on the working life of the PT system cannot be interpreted as a guarantee given by the manufacturer or the Approval Body, but are to be regarded only as a means for selecting the appropriate product in relation to the expected, economically reasonable working life of the construction works.

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Characteristics of the product and methods of verification

PT system
2.1 Designation and range of the anchorages and couplers End anchorages can be used as fixed or stressing anchors. Couplers are fixed or movable. The principal dimensions of anchorages and couplers are given in the Annexes 3 to 7, and 16 and 17. 2.1.1 Designation End anchorage e.g. Stressing (S) or fixed (F) Anchorage Designation of the tendon with information on number, cross sectional area and characteristic tensile strength of the strands Coupler, e.g. Fixed (F), stressing (S) or movable (B) Coupler anchor head (H) for sleeve coupler Designation of the tendon with information on number, cross sectional area and characteristic tensile strength of the strands 2.1.2 Anchorage The anchor heads of the stressing and fixed anchorages are identical. A differentiation is needed for the construction works. The wedges of inaccessible fixed anchors shall be secured 2.1.2.1 General F H CONA CMF BT 0206-150 1860 S A CONA CMF BT 0206-150 1860

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with springs and/or a wedge retaining plate. An alternative is pre-locking each single strand with ~ 0.5 Fpk and applying a wedge retaining plate. Where Fpk ........ Nominal value of maximum force of single strand 2.1.2.2 Restressable and exchangeable tendon

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Significant to a restressable and exchangeable tendon is the excess length of the strands. The extent of the excess length depends on the jack used for restressing or releasing. The protrusions of the strands require a permanent corrosion protection and an adapted cap. 2.1.3 Fixed coupler The prestressing force at the second construction stage shall not be greater than that at the first construction stage, neither during construction, nor in the final state, nor due to any load combination. 2.1.3.2 Sleeve coupler (FH, SH) The coupler anchor heads H are of the same basic geometry as the anchor heads of the fixed and stressing anchors. Compared to the anchor heads of the fixed and stressing anchors, the coupler anchor heads H are higher and provide an external thread for the coupler sleeve. The connection between the coupler anchor heads H of the first and second construction stages is achieved by means of a coupler sleeve. 2.1.4 Movable coupler (BH) The movable coupler is a sleeve coupler in a coupler sheathing box made of steel or plastic. Length and position of the coupler sheathing box shall be for the expected strain displacement, see Clause 4.3. The coupler anchor heads and the coupler sleeves of the movable couplers are identical to the coupler heads and the coupler sleeves of the fixed couplers. A 100 mm long and at least 3.5 mm thick HDPE insert shall be installed at the deviating point of the strands at the end of the trumpet. This insert is not required for a plastic trumpet where the duct is slipped over the plastic trumpet. 2.1.5 Layout of the anchorage recesses All anchor heads have to be placed perpendicular to the axis of the tendon, see Annex 15. The dimensions of the anchorage recesses shall be adapted to the prestressing jacks used. The ETA holder shall save for reference information on the minimum dimensions of the anchorage recesses. The formwork for the anchorage recesses should be slightly conical for ease of removal. In case of internal anchorages fully embedded in concrete, the recesses shall be designed so as to permit a reinforced concrete cover with the required dimensions and in any case with a thickness of at least 20 mm. In case of exposed anchorages, concrete cover of the anchorage and bearing trumplate is not required. However, the exposed surface of the bearing trumplate and the cap shall be provided with corrosion protection. 2.1.3.1 General

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2.2 2.2.1

Designation and range of the tendons Designation Tendon, e.g. Internal PT Number of strands (02 to 04) CONA CMF BT 02 06-150 1860

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Type of strand (05 or 06) Cross-sectional area of strands (93, 100, 140, or 150 mm2) Characteristic tensile strength of strands The tendons comprise 02, 03, or 04 tensile elements, 7-wire prestressing steel strands or monostrands according to Annex 24. 2.2.2 Range Prestressing and overtensioning forces are given in the corresponding standards and regulations in force at the place of use. The maximum prestressing and overstressing forces are listed in Annex 14. The tendons consist of 02, 03, or 04 strands. If monostrands are used, they are factory-provided with a corrosion protection system consisting of corrosion protection grease and an HDPEsheathing. 2.2.2.1 CONA CMF BT n05-93 7-wire prestressing steel strand Nominal diameter .......................................... 12.5 mm Nominal cross-sectional area........................... 93 mm2

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HDPE-sheathed and greased strand Mass of sheathed and greased strand........ 0.85 kg/m External diameter of strand sheathing ........ 16.5 mm Annex 8 lists the available tendon range for CONA CMF BT n05-93 2.2.2.2 CONA CMF BT n05-100 7-wire prestressing steel strand Nominal diameter .......................................... 12.9 mm

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Nominal cross-sectional area......................... 100 mm2 HDPE-sheathed and greased strand Mass of sheathed and greased strand........ 0.90 kg/m External diameter of strand sheathing ........ 17.0 mm Annex 8 lists the available tendon range for CONA CMF BT n05-100 2.2.2.3 CONA CMF BT n06-140 7-wire prestressing steel strand

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Nominal diameter .......................................... 15.3 mm Nominal cross-sectional area......................... 140 mm2 HDPE-sheathed and greased strand

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Mass of sheathed and greased strand........ 1.23 kg/m External diameter of strand sheathing ........ 19.5 mm Annex 8 lists the available tendon range for CONA CMF BT n06-140 2.2.2.4 CONA CMF BT n06-150 7-wire prestressing steel strand Nominal diameter .......................................... 15.7 mm Nominal cross-sectional area......................... 150 mm2 HDPE-sheathed and greased strand Mass of sheathed and greased strand........ 1.31 kg/m External diameter of strand sheathing ........ 20.0 mm Annex 8 lists the available tendon range for CONA CMF BT n06-150

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2.3 2.3.1

Ducts Use of ducts For bonded tendons in general corrugated ducts either in steel or in plastic shall be used. Smooth steel ducts may be used if permitted at the place of use.

2.3.1.1 Bonded tendon

2.3.1.2 Unbonded tendon For unbonded tendons smooth ducts or monostrands can be used. 2.3.2 Degree of filling The degree of filling, f, for bonded and unbonded tendons other than monostrand tendons in round ducts shall generally be between 0.25 and 0.35. The minimum radii of curvature can be defined with the equation given in Clause 2.4. Typical degrees of filling, f, and corresponding minimum radii of curvature, Rmin, are given in Annex 9. The degree of filling is defined as cross sectional area of prestressing steel f = cross sectional area of inner diameter of sheath 2.3.3 Round steel strip sheaths Steel strip sheaths in conformity with EN 523 5 shall be used. The degree of filling, f, shall be according to Clause 2.3.2 and the minimum radii of curvature to Clause 2.4. Annex 9 gives internal duct diameters and minimum radii of curvature in which the pressure under the strand, pR, has been set to 140 kN/m and 200 kN/m respectively. Different duct diameter and smaller radii of curvature are acceptable according to the respective standards and regulations in force at the place of use. 2.3.4 Flat steel ducts For tendons with 02, 03, or 04 strands flat ducts, either smooth or corrugated, may be used, whereas EN 523 applies accordingly. The flat ducts shall be free of any kinks.

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Annex 9 gives minor and major internal flat duct dimensions and minimum radii of curvature, both minor and major, in which the pressure under the strand, pR, has been set to 140 kN/m and 200 kN/m respectively. Different duct dimensions and smaller radius of curvature are acceptable according to the respective standards and regulations in force at the place of use.
5

Reference documents are listed in the Annexes 25 and 26

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2.3.5

Plastic sheaths Corrugated plastic sheaths made of HDPE or PP conforming to ETAG 013, Annex C.3, shall be used. Alternatively smooth plastic ducts according to EN 12201 may be used if permitted at the place of use. The degree of filling, f, shall conform to Clause 2.3.2 and the minimum radii of curvature to Clause 2.4. Annex 10 gives duct diameters and minimum wall thicknesses for corrugated and smooth plastic ducts according to Clause 2.3. Different internal diameters, wall thicknesses or materials are acceptable according to the respective standards and regulations in force at the place of use.

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2.3.6

Pre-bent smooth round steel ducts If permitted at the place of use, smooth steel ducts according to EN 10255, EN 10216-1, EN 10217-1, EN 10219-1 or EN 10305-5 can be used. The degree of filling, f, shall conform to Clause 2.3.2 and the minimum radii of curvature to Clause 2.4. The ducts shall be pre-bent and free of any kinks. The minimum wall thickness of the steel ducts shall meet the requirements of Annex 10. Different internal diameters or wall thicknesses are acceptable according to the respective standards and regulations in force at the place of use.

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2.4 2.4.1

Minimum radii of curvature Minimum radii of curvature for bonded and unbonded tendons other than monostrand tendons The minimum radii of curvature for prestressing steel strands, Rmin, given in Annex 9 correspond to a prestressing force of the tendon of 0.85 Fp0.1 a nominal diameter of the strand of d = 12.9 mm and d = 15.7 mm a maximum pressure under the prestressing steel strands of pR, max = 140 kN/m and 200 kN/m a concrete compressive strength of fcm, 0, cube 21 MPa. In case of different tendon parameters or a different pressure under the prestressing steel strands, the calculation of the minimum radii of curvature of the tendon for round ducts can be carried out using the equation k andp = max d 400 3 000
R

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Fpm, 0

Rmin

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Table 2: Factor kn Number of strands n f ~ 0.25 0.68 0.61 Factor kn f ~ 0.30 0.87 0.71 0.65 f ~ 0.35 0.88

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02 03 04

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Where Rmin ........... m .......... minimum radii of curvature Fpm, 0 ........ kN ......... prestressing force of the tendon pR .......... kN/m ....... design pressure under the strands kn ............... .......... factor to account for number of strand and duct diameter, see Table 2

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d ..............mm ........ nominal diameter of the strand n ................ .......... number of strands f ................. .......... degree of filling For tendons with predominantly static loading, reduced minimum radii of curvature can be used. Recommended values for the pressure under the prestressing steel strands are pR, max = 140 200 kN/m for internal bonded tendons pR, max = 800 kN/m for smooth steel duct and predominantly static loading In case of reduced minimum radii of curvature, the degree of filling, f, as defined in Clause 2.3.2, shall be between 0.25 and 0.30 to allow for proper tendon installation. Depending on the concrete strength at the time of stressing, additional reinforcement for splitting forces may be required in the areas of reduced minimum radii of curvature. Standards and regulations on minimum radii of curvature or on the pressure under the prestressing steel strands in force at the place of use shall be observed. 2.4.2 Minimum radii of curvature for tendons with monostrands The minimum radius of curvature Rmin of internal tendons with monostrands is 2.5 m. If this radius is adhered to, the verification of prestressing steel outer fibre stresses in curved sections is not required. The minimum radius of curvature for deviation of a tendon with multistrand anchorages in the anchorage zone is 3.5 m. For tendons with nearly straight tendon layout, an HDPE sheathing with a thickness of 1 mm may be used if acceptable at the place of use. For free tendon layout in slabs with a thickness of 45 cm see Annex 19. 2.5 2.5.1 Support of tendons Support of bonded and unbonded tendons other than monostrand tendons Spacing of supports is between 1.0 to 1.8 m. In the region of maximum tendon curvature a spacing of 0.8 m shall be applied and 0.6 m in case the minimum radii of curvature is smaller than 4.0 m. The tendons shall be systematically fixed in their position so that they are not displaced by placing and compacting of concrete. 2.5.2 Support of monostrand tendons Individual monostrands shall be fixed in their position. Spacing of supports is: 1 Normally Individual monostrands with 02, 03, or 04 strands ......................................... 1.00 to 1.30 m 2 Free tendon layout in 45 cm thick slabs In the region of transition between a) high tendon position and anchorage (e.g. cantilever)................................ 1.50 m b) low and high tendon position or low tendon position and anchorage ........ 3.00 m
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In regions of the high or low tendon position the tendons shall be connected in an appropriate way to the reinforcement mesh, at least at two points with spacing of 0.3 to 1.3 m. The reinforcement mesh shall be fixed in its position. Special spacers for tendons are therefore not required. For details see Annex 19. 2.6 Friction losses For the calculation of loss of prestressing force due to friction Coulombs law applies. Friction losses in anchorages are low and do not have to be taken into consideration in design and execution. The calculation of the friction losses is carried out using the equation F x = F0 e Where Fx .......... kN .......... prestressing force at a distance x along the tendon F0.......... kN .......... prestressing force at x = 0 m ........... rad-1 ........ friction coefficient, see Table 3 k ........... rad/m...... wobble coefficient, see Table 3 ........... rad.......... sum of the angular displacements over distance x, irrespective of direction or sign x ........... m ............ distance along the tendon from the point where prestressing force is equal to F0
NOTE 1 rad = 1 m/m = 1

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- ( + k x)

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Table 3: Friction parameters Recommended values Type of duct rad Steel strip sheath Smooth steel duct Corrugated plastic sheath Smooth plastic duct Monostrand
NOTE
-1

Range of values rad


-1

k rad/m

k rad/m

0.18 0.18 0.12 0.12 0.06 0.009 0.005

0.17 - 0.19 0.16 - 0.24 0.10 - 0.14 0.10 - 0.14 0.05 - 0.07 0.008 0.011 0.004 - 0.007

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As far as acceptable at the place of use, due to special measures like oiling or for a tendon layout with only few deviations the friction coefficient can be reduced by 10 to 20 %. Compared to e.g. the use of prestressing steel or sheaths with a film of rust this value increases by more than 100 %.

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2.7

Slip at anchorages and couplers Slip at stressing and fixed anchorages and at fixed couplers, first and second construction stages, is 6 mm. Slip at movable couplers is twice this amount. At the stressing anchorage and at

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Page 14 of European technical approval ETA-12/0076 Validity from 29.06.2012 to 28.06.2017

the first construction stage of fixed couplers the slip is 4 mm, provided a prestressing jack with a wedging system and a wedging force of around 25 kN per strand are used. 2.8 Concrete strength at time of stressing Concrete in conformity with EN 206-1 shall be used. At the time of stressing the mean concrete compressive strength, fcm, 0, shall be at least the value given in Table 4. The concrete test specimen shall be subjected to the same curing conditions as the structure. For partial prestressing with 30 % of the full prestressing force the actual mean value of the concrete compressive strength shall be at least 0.5 fcm, 0, cube or 0.5 fcm, 0, cylinder. Intermediate values may be interpolated linearly according to EN 1992-1-1. The helix, additional reinforcement, and centre spacing and edge distance corresponding to the concrete compressive strengths shall be taken from the Annexes 16 and 17, see also the Clauses 2.11.7 and 4.2.3. Table 4: Compressive strength of concrete

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Mean concrete strength Cube strength, 150 mm cube fcm, 0, cube MPa MPa 21 17

fcm, 0 25 20

Cylinder strength, f 150 mm cylinder diameter cm, 0, cylinder Where

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fcm, 0, cube 150 ............ Mean concrete compressive strength at time of stressing, determined at cubes, 150 mm fcm, 0, cylinder 150 ...... Mean concrete compressive strength at time of stressing, determined at cylinders, diameter 150 mm 2.9 Centre spacing and edge distance of anchorages In general, spacing and distances shall not be less than the values given in the Annexes 16 and 17. However, a reduction of up to 15 % of the centre spacing of tendon anchorages in one direction is permitted, but should not be less than the outside diameter of the helix and the placing of additional reinforcement shall still be possible. In this case the spacing in the perpendicular direction shall be increased by the same percentage, see Annex 18. The corresponding edge distance is calculated by ac ae = 2 10 + c and bc be = 2 10 + c bc be = 2 10 + c ac ae = 2 10 + c

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Where ac, ac .......mm ....... Centre spacing before and after modification

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bc, bc .......mm ....... Centre spacing in the direction perpendicular to ac, before and after modification ae, ae ......mm ....... Edge distance in the direction along to ac, before and after modification be, be ......mm ....... Edge distance in the direction perpendicular to ae, before and after modification

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c .............mm ....... Concrete cover Standards and regulations on concrete cover in force at the place of use shall be observed. The minimum values for ac, bc, ae, and be are given in the Annexes 16 and 17.
NOTE The replacement of the additional stirrup reinforcement by a helix according to the Annexes 16 and 17 does not prevent the modification of centre spacing and edge distance. The external dimensions of the rectangular helix replacing stirrups have to be adapted to the modified centre spacing and edge distance.

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Components
2.10 Strands Only 7-wire prestressing steel strands or monostrands with characteristics according to Table 5 shall be used, see also Annex 24. The corrosion protection system of the monostrand is as specified in ETAG 013, Annex C.1, see also the Annexes 22 and 23. Table 5: Prestressing steel strands Max. characteristic tensile strength 1) Nominal diameter fpk d Ap M M MPa mm mm
2

1 860 12.5 93 0.73 0.85 12.9 100 0.78 0.90 15.3 140 1.09 1.23 15.7 150 1.17 1.31

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Nominal cross sectional area Mass of prestressing steel Mass of monostrand


1)

kg/m kg/m

Prestressing steel strands with a characteristic tensile strength below 1 860 MPa may also be used.

In a single tendon only strands spun in the same direction shall be used.

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2.11

Anchorages and couplers The components of anchorages and couplers shall conform to the specifications given in the Annexes 3 to 7 and the technical documentation 6. Therein the component dimensions, materials and material identification data with tolerances are given.

2.11.1 General

2.11.2 Anchor heads The anchor heads are made of steel and contain regularly arranged conical holes drilled in parallel to accommodate prestressing steel strands and wedges. The back exits of the bore holes are provided with bell mouth openings or plastic ring cushions. In addition, threaded bores may
6

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The technical documentation of the European technical approval is deposited at sterreichisches Institut fr Bautechnik and, insofar as is relevant to the tasks of the approved body involved in the attestation of the conformity procedure, is handed over to the approved body.

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Page 16 of European technical approval ETA-12/0076 Validity from 29.06.2012 to 28.06.2017

be provided to fix protection caps and wedge retaining plates. At the back of the anchor head there may be a step, for ease of centring the anchor head on the bearing trumplate. 2.11.3 Bearing trumplates The bearing trumplates made of cast iron transmit the force via three anchorage planes to the concrete. Two identical bearing trumplates, with and without a front air-vent situated at the interface plane to the anchor head, are available. A grout inlet or ventilation tube can be fitted to this air-vent. On the tendon-side end there is an inner thread to accommodate the trumpet. 2.11.4 Trumpets The conical trumpets made of steel or HDPE may have either a corrugated or a plain surface. At the duct-side end there is a radius for the deviation of the strands and a smooth surface, to ensure a good transition to the duct. The opposite end is connected to the bearing trumplate. HDPE trumpets are equipped with a blind air-vent which might be opened and to which a grouting or ventilation tube can be connected. In the case of trumpets made completely out of steel sheet, a 100 mm long and at least 3.5 mm thick HDPE insert shall be installed at the deviating point of the strands on the steel duct side. 2.11.5 Coupler anchor heads H The coupler anchor heads H for the sleeve coupler are made of steel and have the same basic geometry as the anchor heads of the fixed or stressing anchorages. Compared to the anchor heads of the fixed and stressing anchors, the coupler anchor heads H are higher and provide an external thread for the coupler sleeve. At the back of the coupler anchor heads H there is a step for ease of centring the coupler anchor head on the bearing trumplate. The coupler sleeve is a steel tube with an inner thread and is provided with ventilation holes. Ring cushions shall be inserted in the coupler head H2. 2.11.6 Ring wedges The ring wedges are in three pieces, which are held together by spring rings. Three types of ring wedges are used. Within one anchorage or coupler only one type of ring wedge shall be used. The wedges of inaccessible fixed anchors and couplers shall be secured with springs and/or a wedge retaining plate. An alternative is pre-locking each single strand with ~ 0.5 Fpk and applying a wedge retaining plate as per Clause 2.1.2.1. 2.11.7 Helix and additional reinforcement The helix and the additional reinforcement are made of ribbed reinforcing steel. The end of the helix at the anchorage side is welded to the following turn. The helix shall be placed exactly in the tendon axis. The dimensions of the helix and the additional reinforcement shall conform to the values specified in the Annexes 16 and 17. If required for a specific project design, the reinforcement given in the Annexes 16 and 17 may be modified in accordance with the respective regulations in force at the place of use as well as with the relevant approval of the local authorities and of the ETA holder to provided equivalent performance. 2.11.8 Protection caps Protection caps are made of steel or plastic. They are provided with air-vents and fixed with screws or threaded rods.

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2.11.9 Material properties Annex 11 lists the material properties and the standard/specification of the components

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2.12

Permanent corrosion protection To protect the tendons from corrosion, the ducts, couplers and anchorages have to be completely filled with grout according to EN 447, special grout according to ETAG 013, grease according ETAG 013, Annex C.4.1, or wax according ETAG 013, Annex C.4.2, as applicable at the place of use. The corrosion protection materials used for monostrands are specified in ETAG 013, Annex C.1, see also the Annexes 22 and 23. As an alternative grease or wax may be used, if according to the standards and regulations in force at the place of use. With exposed anchorages, not fully embedded in concrete, an adequate corrosion protection for the exposed parts shall be applied.

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2.13

Dangerous substances The release of dangerous substances is determined according to ETAG 013, Clause 5.3.1. The PT system conforms to the provisions of Guidance Paper H7 relating to dangerous substances. A declaration in this respect has been made by the manufacturer. In addition to the specific clauses relating to dangerous substances in the European technical approval, there may be other requirements applicable to the product falling within their scope (e.g. transposed European legislation and national laws, regulations and administrative provisions). In order to meet the provisions of the Construction Products Directive, these requirements also need to be complied with, when and where they apply.

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2.14

Methods of verification The assessment of the fitness of the "BBR VT CONA CMF BT Flat Anchorage System for Internal Post-tensioning with 02, 03, and 04 strands" for their intended use in relation to the requirements for mechanical resistance and stability in the sense of Essential Requirement 1 of the Council Directive 89/106/EEC has been made in conformity to the Guideline for European technical approvals of "Post-Tensioning Kits for Prestressing of Structures", ETAG 013, Edition June 2002.

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2.15

Identification The European technical approval for the "BBR VT CONA CMF BT Flat Anchorage System for Internal Post-tensioning with 02, 03, and 04 strands" is issued on the basis of agreed data, deposited with sterreichisches Institut fr Bautechnik, which identifies the BBR VT CONA CMF BT System that has been assessed and judged. Changes to the production process of the BBR VT CONA CMF BT Post-tensioning System, which could result in this deposited data being incorrect, should be notified to sterreichisches Institut fr Bautechnik before the changes are introduced. sterreichisches Institut fr Bautechnik will decide whether or not such changes affect the European technical approval and consequently the validity of the CE marking on the basis of the European technical approval and, if so, whether further assessment or alterations to the European technical approval are considered necessary.

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7

Guidance Paper H: A harmonised approach relating to dangerous substances under the Construction Products Directive, Rev. September 2002.

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3 3.1

Evaluation of conformity and CE marking Attestation of conformity system The system of attestation of conformity assigned by the European Commission to this product in accordance with the Council Directive 89/106/EWG of 21 December 1988, Annex III 2. (i), referred to as System 1+, provides for: Certification of the conformity of the product by an approved certification body on the basis of (a) Tasks for the manufacturer (1) Factory production control; (2) Further testing of samples taken at the factory by the manufacturer in accordance with a prescribed test plan 8; (b) Tasks for the approved body (3) Initial type testing of the product; (4) Initial inspection of factory and of factory production control;

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(5) Continuous surveillance, assessment and approval of the factory production control; (6) Audit testing of samples taken at the factory. 3.2 3.2.1 Responsibilities Tasks for the manufacturer factory production control At the manufacturing plant, the manufacturer shall implement and continuously maintain a factory production control system. All the elements, requirements and provisions adopted by the manufacturer shall be documented systematically in the form of written operating and processing instructions. The factory production control system shall ensure that the product is in conformity with the European technical approval. Within the framework of factory production control, the manufacturer shall carry out tests and controls in accordance with the prescribed test plan and in accordance with the European technical approval. Details of the extent, nature and frequency of testing and controls to be performed within the framework of the factory production control shall correspond to this prescribed test plan, which forms part of the technical documentation of the European technical approval. The results of factory production control shall be recorded and evaluated. The records shall include at a minimum the following information. Designation of the products and the basic materials; Type of check or testing; Date of manufacture of the products and date of testing of the products or basic materials or components; Results of check and testing and, if appropriate, comparison with requirements; Name and signature of the person responsible for the factory production control. The records of the factory production control shall be submitted to the approved body and shall be filed for at least 10 years time. On request, the records shall be presented to sterreichisches Institut fr Bautechnik.
8

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The prescribed test plan has to be deposited with sterreichisches Institut fr Bautechnik and is handed over only to the approved body involved in the conformity attestation procedure. The prescribed test plan is also referred to as control plan.

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If the test results are unsatisfactory, the manufacturer shall immediately implement measures to eliminate the defects. Construction products or components which are not in conformity with the requirements shall be removed. After elimination of the defects, the respective test if verification is required for technical reasons shall be repeated immediately. The basic elements of the prescribed test plan conform to ETAG 013, Annex E.1, and are specified in the quality management plan of the "BBR VT CONA CMF BT Flat Anchorage System for Internal Post-tensioning with 02, 03, and 04 strands". Annex 12 lists the contents of the prescribed test plan. 3.2.2 Tasks of the approved body 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 procedure or factory plant. In such cases, the necessary initial type testing shall be agreed between sterreichisches Institut fr Bautechnik and the approved body involved. 3.2.2.2 Initial inspection of factory and of factory production control The approved body shall ascertain that, in accordance with the prescribed test plan, the manufacturing plant, in particular personnel and equipment, and the factory production control are suitable to ensure a continuous and orderly manufacturing of the PT system according to the specifications given in Section II as well as in the Annexes of the European technical approval. 3.2.2.3 Continuous surveillance The kit manufacturer shall be inspected at least once a year. Each component manufacturer of the components listed in Annex 13 shall be inspected at least once every 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. On demand the results of product certification and continuous surveillance shall be made available by the approved body to sterreichisches Institut fr Bautechnik. If the provisions of the European technical approval and the prescribed test plan are no longer fulfilled, the certificate of conformity shall be withdrawn and sterreichisches Institut fr Bautechnik informed immediately. 3.2.2.4 Audit testing of samples taken at the factory During surveillance inspection, the approved body shall take samples at the factory of components of the PT system or of individual components, for which the European technical approval has been granted, for independent testing. For the most important components Annex 13 summarises the minimum procedures that shall be implemented by the approved body. 3.3 CE marking The delivery note of the components of the PT system shall contain the CE marking. The initials CE shall be followed by the identification number of the certification body and shall be accompanied by the following information. Name or identification mark and address of the manufacturer The last two digits of the year in which the CE marking was affixed Number of the European technical approval Number of the certificate of conformity
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3.2.2.1 Initial type testing of the products

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Product identification (trade name) 4 4.1 Assumptions under which the fitness of the product for the intended use was favourably assessed Manufacturing "BBR VT CONA CMF BT Flat Anchorage System for Internal Post-tensioning with 02, 03, and 04 strands" is manufactured in accordance with the provisions of the European technical approval. Composition and manufacturing process are deposited at sterreichisches Institut fr Bautechnik. 4.2 4.2.1 Design General Design of the structure shall permit correct installation and stressing of the tendons. The reinforcement in the anchorage zone shall permit correct placing and compacting of concrete. 4.2.2 Anchorage recess The dimensions of the anchorage recesses are to be adapted to the prestressing jacks used. The ETA holder shall save for reference information on the minimum dimensions of the anchorage recesses and appropriate clearance behind the anchorage. In case of anchorages fully embedded in concrete, the recesses shall be designed so as to permit a reinforced concrete cover with the required dimensions and in any case with a thickness of at least 20 mm. In case of exposed anchorages concrete cover of the anchorage and bearing trumplate is not required. However, the exposed surface of the bearing trumplate and the cap shall be provided with a corrosion protection. 4.2.3 Reinforcement in the anchorage zone Verification of the transfer of prestressing forces to structural concrete is not required if the centre spacing and edge distances of the anchorages as well as grade and dimensions of additional reinforcement, see the Annexes 16 and 17, are conformed to. In the case of grouped anchorages the additional reinforcement of the individual anchorages can be combined, provided appropriate anchorage is ensured. However, the number, cross section and position with respect to the bearing trumplates shall remain unchanged. Centre spacing and edge distances as well as concrete strength and reinforcement for larger tendons in terms of strength, nominal diameter and number of strands are as well applicable to smaller tendons.
NOTE For example it is fully applicable to fit a tendon CMF BT 0305-93 into an anchorage zone, detailed and executed for a CMF BT 0406-150 tendon.

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The reinforcement of the structure shall not be employed as additional reinforcement. Reinforcement exceeding the required reinforcement of the structure may be used as additional reinforcement, if appropriate placing is possible. The forces outside the area of the additional reinforcement shall be verified and, if necessary, dealt with by appropriate reinforcement.

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If required for a specific project design, the reinforcement given in the Annexes 16 and 17 may be modified in accordance with the respective regulations in force at the place of use as well as with the relevant approval of the local authority and of the ETA holder to provide equivalent performance.

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4.2.4

Fatigue resistance Fatigue resistance of the tendons has been tested with an upper force of 0.65 Fpk and with a stress range of 80 N/mm2 up to 2 106 load cycles.

4.2.5

Tendons in masonry structures Load transfer to the structure Load transfer of prestressing force from the anchorages to masonry structures shall be via concrete or steel members, designed according to the European technical approval, especially according to the Clauses 2.8, 2.9, 2.11.7, and 4.2.3 or Eurocode 3, respectively. The concrete or steel members supporting the anchorages shall have dimensions that permit a force of 1.1 Fpk to be transferred to the masonry. The verification shall be performed according to Eurocode 6 as well as to the respective standards and regulations in force at the place of use.

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4.2.6

Maximum prestressing force Annex 14 lists the maximum prestressing and overstressing forces.

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4.3

Installation Assembly and installation of tendons shall only be carried out by qualified PT specialist companies with the required resources and experience in the use of multi strand internal posttensioning systems, see ETAG 013, Annex D.1, and CWA 14646. The respective standards and regulations in force at the place of use shall be considered. The companys PT site manager shall have a certificate, stating that she or he has been trained by the ETA holder and that she or he possesses the necessary qualifications and experience with the "BBR VT CONA CMF BT Flat Anchorage System for Internal Post-tensioning with 02, 03, and 04 strands". The tendons may be manufactured on site or in the factory (prefabricated tendons). To avoid confusion it is recommended to, in general, use on one site prestressing steel strands with one nominal diameter only. Bearing trumplate, anchor head and coupler anchor head shall be placed perpendicular to the tendons axis. Couplers shall be situated in a straight tendon section. At the anchorages and couplers the tendon layout shall provide a straight section over a length of at least 250 mm beyond the end of the trumpet. Before placing the concrete a final check of the installed tendons has to be carried out. In case of a movable coupler it shall be ensured by means of appropriate position and length of coupler sheathing box and trumpet that a displacement of the movable coupler of at least 1.15 l + 30 mm is possible without any hindrance, where l in mm is the maximum expected displacement of the coupler at stressing.

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4.4

Stressing operation With a mean concrete compressive strength in the anchorage zone according to the values laid down in the Annexes 16 and 17 full prestressing may be applied. Stressing and, if applicable, wedging shall be carried out using a suitable prestressing jack. The wedging force shall correspond to approximately ~ 25 kN per wedge.

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After realising the prestressing force from the prestressing jack, the tendon length reduces by the amount of wedge draw-in, slip, at the anchor head.

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Elongation and prestressing forces shall be checked continuously during the stressing operation. The results of the prestressing operation shall be recorded and the measured elongations shall be compared with the prior calculated values. The ETA holder shall save information on the prestressing jacks and the appropriate clearance behind the anchorage. The safety-at-work and health protection regulations shall be complied with.

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4.5

Restressing Restressing of tendons in combination with release and reuse of wedges is permitted, whereby the wedges shall bite into at least 15 mm of virgin strand surface and no wedge bites shall remain inside the final length of the tendon between anchorages. For tendons remaining restressable throughout the working life of the structure, wax or grease shall be used as filling material for corrosion protection. Moreover, a strand protrusion at the stressing anchor has to remain with a length compatible with the prestressing jack used.

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4.6

Exchanging tendons Exchange of tendons is permitted. The specifications for the exchangeable tendons shall be defined during the design phase. The radii of curvature should be reasonable larger than the minimum radii given in Clause 2.4 as to not impair the plastic duct or monostrand sheathing by wear due to stressing of the tendon. Exchangeable tendons are unbonded. For exchangeable tendons, wax or grease shall be used as filling material for corrosion protection. Moreover, a strand protrusion has to remain at the stressing anchor with a length allowing safe release of the complete prestressing force. Stressing and fixed anchorages shall be accessible and adequate space has to be provided behind the anchorages.

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4.7 4.7.1

Filling material Grout Grout shall be injected through the inlet holes until it escapes from the outlet tubes with the same consistency. To avoid voids in the hardened grout special measures shall be applied for long tendons, tendon paths with distinct high points or inclined tendons. All vents and grouting inlets shall be sealed immediately after grouting. The standards to be observed for cement grouting in prestressing ducts are EN 445, EN 446, and EN 447 or the standards and regulations in force at the place of use shall be applied for ready mixed grout.

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4.7.2

Grease and wax The specifications in ETAG 013, Annex C.4, and the recommendations of the supplier are relevant for grease and wax. The filling procedure with grease and wax shall follow a similar procedure as the one specified for filling with grout.

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4.7.3

Recordings The results of the filling operation shall be recorded. The respective standards and regulations in force at the place of use shall be observed.

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4.8

Welding Ducts may be welded. The helix may be welded to the bearing trumplate to secure its position. After installation of the tendons further welding shall not be carried out on the tendons. In case of welding operations near tendons precautionary measures are required to avoid damage.

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5 5.1

Recommendations for the manufacturer Recommendations for packing, transport and storage During transport of prefabricated tendons a minimum diameter of curvature of 1.65 m shall be observed. The ETA holder shall have instructions related to Temporary protection of prestressing steels and components in order to prevent corrosion during transportation from the production site to the job site; Transportation, storage and handling of the tensile elements and of other components in order to avoid any mechanical, chemical or electrochemical changes; Protection of tensile elements and other components from moisture; Keeping tensile elements away from areas where welding operations are performed.

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5.2

Recommendations on installation The manufacturers installation instructions shall be followed, see ETAG 013, Annex D.3. The respective standards and regulations in force at the place of use shall be observed. For the installation see also the Annexes 20 to 22.

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5.3

Accompanying information It is the responsibility of the ETA holder to ensure that all necessary information on design and installation is submitted to those responsible for the design and execution of the structures executed with "BBR VT CONA CMF BT Flat Anchorage System for Internal Post-tensioning with 02, 03, and 04 strands". On behalf of sterreichisches Institut fr Bautechnik
The original document is signed by:

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Rainer Mikulits Managing Director

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Internal Post-tensioning System


CONA CMF BT

Annex 1
of European technical approval

Overview on anchorages and couplers for bonded and unbonded tendons other than monostrand tendons

ETA-12/0076
OIB-250-001/07-022

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Internal Post-tensioning System


CONA CMF BT

Annex 2
of European technical approval

Overview on anchorages and couplers for monostrands and VT CMM Bands

ETA-12/0076
OIB-250-001/07-022

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Dimensions in mm Number of strands Anchor head Diameter Height head A1-A4 Height head A5-A8 A HA mm mm mm

0205
90 50 65

0305
100 50 65

0405
100 50 65

0206 90 50 65

0306 100 50 65

0406 100 50 65

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Internal Post-tensioning System


Anchor heads
CONA CMF BT

Annex 3
of European technical approval

ETA-12/0076
OIB-250-001/07-022

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Dimensions in mm

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Number of strands Coupler head H1 Nominal diameter Height Coupler head H2 Diameter Height Coupler sleeve H1 Diameter Length AH mm HAH mm AH mm HAH mm H LH mm mm

0205
90 50 90 65 114 180

0305
100 50 100 65 121 180

0405
100 55 100 65 130 180

0206 90 50 90 65 114 180

0306 100 50 100 65 121 180

0406 100 55 100 65 130 180

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Internal Post-tensioning System


Bearing trumplate and H-coupler
CONA CMF BT

Annex 4
of European technical approval

ETA-12/0076
OIB-250-001/07-022

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Dimensions in mm

Internal Post-tensioning System


Trumpets
CONA CMF BT

Annex 5
of European technical approval

ETA-12/0076
OIB-250-001/07-022

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Dimensions in mm Number of strands Wedge retaining plate KS Minimum diameter KS DKS mm mm

0205
65 5

0305
73 5

0405
75 5

0206 65 5

0306 73 5

0406 75 5

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Thickness

Internal Post-tensioning System


Wedges, spring and protection cap
CONA CMF BT

Annex 6
of European technical approval

ETA-12/0076
OIB-250-001/07-022

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Dimensions in mm

Internal Post-tensioning System


CONA CMF BT

Annex 7
of European technical approval

Anchorages with monostrands or VT CMM Bands

ETA-12/0076
OIB-250-001/07-022

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CONA CMF n05-93 Number of strands Nominal crosssectional area of prestressing steel Ap mm 186 279 372
2

Nominal mass of prestressing steel M kg/m 1.45 2.18 2.91

Characteristic value of maximum force of tendon fpk = 1 860 MPa Fpk kN 346 519 692

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02 03 04
CONA CMF n05-100 Number of strands

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Nominal crosssectional area of prestressing steel Ap mm 200 300 400


2

Nominal mass of prestressing steel M kg/m 1.56 2.34 3.12

Characteristic value of maximum force of tendon fpk = 1 860 MPa Fpk kN 372 558 744

02 03 04
CONA CMF n06-140

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Number of strands n 02 03 04 CONA CMF n06-150

Nominal crosssectional area of prestressing steel Ap mm2 280 420 560

Nominal mass of prestressing steel M kg/m 2.19 3.28 4.37

Characteristic value of maximum force of tendon fpk = 1 860 MPa Fpk kN 520 780 1 040

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Number of strands n 02 03 04

Nominal crosssectional area of prestressing steel Ap mm2 300 450 600

Nominal mass of prestressing steel M kg/m 2.34 3.52 4.69

Characteristic value of maximum force of tendon fpk = 1 860 MPa Fpk kN 558 837 1 116

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Internal Post-tensioning System


Tendon ranges
CONA CMF BT

Annex 8
of European technical approval

ETA-12/0076
OIB-250-001/07-022

electronic copy

Page 32 of European technical approval ETA-12/0076 Validity from 29.06.2012 to 28.06.2017

Inner diameter of round duct, di, and minimum radii of curvature, Rmin, for pR, max = 140 kN/m
Number of strands f 0.25 di mm 30 40 45 40 50 55 Rmin m 1.7 1.8 2.6 2.0 2.7 3.9 di mm 30 35 40 35 45 50 f 0.30 Rmin m 1.8 2.1 2.6 2.6 3.2 3.9 di mm 30 35 40 35 40 45 f 0.35 Rmin m 1.8 2.6 2.6 2.6 3.9 3.9

n05 n06

electronic copy

0205 0305 0405


0206 0306 0406

Inner diameter of round duct, di, and minimum radii of curvature, Rmin, for pR, max = 200 kN/m
Number of strands f 0.25 di mm 30 40 45 40 50 55 Rmin m 1.7 1.7 1.8 2.0 2.0 2.7 di mm 30 35 40 35 45 50 f 0.30 Rmin m 1.7 1.7 1.8 2.0 2.2 2.7 di mm 30 35 40 35 40 45 f 0.35 Rmin m 1.7 1.8 1.8 2.0 2.7 2.7

n05 n06

electronic copy

0205 0305 0405


0206 0306 0406

Inner dimensions, di, of flat ducts and minimum radii of curvature, Rmin, for pR, max = 140 kN/m

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Number of strands

Inner dimensions di major mm 40 55 70 40 55 70 di minor mm 20 20 25 20 20 25

Radii of curvature Rmin major m 1.7 1.7 1.7 2.0 2.0 2.0 Rmin minor m 2.0 3.0 4.0 3.0 4.5 6.0

n05 n06

0205 0305 0405


0206 0306 0406

Inner dimensions, di, of flat ducts and minimum radii of curvature, Rmin, for pR, max = 200 kN/m

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Number of strands

Inner dimensions di major mm 40 55 70 40 55 70 di minor mm 20 20 25 20 20 25

Radii of curvature Rmin major m 1.7 1.7 1.7 2.0 2.0 2.0 Rmin minor m 1.7 2.1 2.8 2.1 3.1 4.2

n05 n06

0205 0305 0405


0206 0306 0406

electronic copy

Internal Post-tensioning System


Minimum radius of curvature of duct
CONA CMF BT

Annex 9
of European technical approval

ETA-12/0076
OIB-250-001/07-022

electronic copy

Page 33 of European technical approval ETA-12/0076 Validity from 29.06.2012 to 28.06.2017

Diameters and wall thickness, tmin, of plastic ducts Corrugated plastic ducts up to pR,max = 200 kN/m Internal Wall diameter thickness di tmin mm mm 30 35 40 35 40 45 1.5 1.5 1.5 1.5 2 2 Smooth plastic ducts up to pR,max = 350 kN/m Outer diameter do mm 40 50 63 40 50 63 Internal diameter di mm 36 45 57 36 45 57 Wall thickness tmin mm 2 2.5 3 2 2.5 3

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Number of strands
n05 n06

0205 0305 0405


0206 0306 0406

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Wall thickness, tmin, of steel ducts Number of Wall strands thickness n05 n06 tmin mm

0205 0305 0405

0.6 0.9

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0206 0306 0406

1.1

Inner dimensions and wall thickness, tmin, of flat plastic ducts Corrugated flat plastic ducts up to pR,max = 200 kN/m Wall Inner dimensions thickness di major di minor tmin mm mm mm 40 70 70 40 70 75 20 20 20 20 20 25 2 2 2 2 2 2

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Number of strands
n05 n06

0205 0305 0405


0206 0306 0406

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Internal Post-tensioning System


Minimum wall thickness of duct
CONA CMF BT

Annex 10
of European technical approval

ETA-12/0076
OIB-250-001/07-022

electronic copy

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Page 34 of European technical approval ETA-12/0076 Validity from 29.06.2012 to 28.06.2017

Material properties Component Anchor head A CONA CMF 0205 to 0406 Coupler anchor head H CONA CMF 0205 to 0406 Bearing trumplate CONA CMF 0205 to 0406 Standard / Specification EN 10083-1 EN 10083-2 EN 10083-1 EN 10083-2 EN 1561 EN 1563 EN 10210-1 EN 10025-2 EN ISO 1872-1 EN 10025-2 EN 10084 EN 10277-2 EN 10270-1 Ribbed reinforcing steel Re 500 MPa 1) Ribbed reinforcing steel Re 500 MPa 1) EN 523 ETAG 013, Annex C.3

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Coupler sleeve H CONA CMF 0205 to 0406 Wedge retaining plate, cover plate KS CONA CMF 0205 to 0406 Trumpet Type A, Type F, Type FH Transition pipe Ring wedge Type H05 Ring wedge Type H Ring wedge Type F Spring Type A Helix Additional reinforcement (stirrups) Ducts
1)

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Ribbed reinforcing steel with Re 460 MPa may be placed according to the Annexes 16 and 17

Internal Post-tensioning System


Material characteristics
CONA CMF BT

Annex 11
of European technical approval

ETA-12/0076
OIB-250-001/07-022

electronic copy

Page 35 of European technical approval ETA-12/0076 Validity from 29.06.2012 to 28.06.2017

Contents of the prescribed test plan


Component Material Bearing trumplate Detailed dimensions Visual inspection 3) Material Anchor head and coupler anchor head Detailed dimensions 2) Visual inspection 3), 4) Material Treatment, Hardness 5), 6) Ring wedge Detailed dimensions 2) Test Check Check Test Check Check Check Check Check Check Test Check Check Check Check "CE" bulk full Item Test / Check Check Test Check Check Test Check Check Test full Visual inspection 3), 7) Material Coupler sleeve Detailed dimensions Visual inspection 3) Steel strip sheath Steel duct
9)

Traceability

Minimum frequency 100 % 3% 2 specimens 100 % 100 % 5% 2 specimens 100 % 100 % 0,5% 2 specimens 5% 2 specimens 100 % 100 % 5% 2 specimens 100 % 100% 100% 100 % 100 % 100 % each coil each coil 100 % 100 % 100 %

Documentation "3.1" 1) Yes No "3.1" 1) Yes No "3.1" 1) Yes Yes No "3.1" Yes No "CE" No "2.2" 8) No "CE" 9) No No "CE" 10) "CE" 10) "CE" 10)
1)

full

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full

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Material Visual inspection 3) Material Visual inspection 3) Material Diameter Visual inspection 3) Cement Admixtures, additions Material

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Strand

full full bulk full

Constituents of filling material as per EN 447 Plastic duct, ETAG 013, Annex C.3
1) 2)

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"3.1": Inspection certificate type "3.1" according to EN 10204 Other dimensions than 4) 3) Visual inspections include e.g.: Main dimensions, gauge testing, correct marking or labelling, appropriate performance, surface, fins, kinks, smoothness, corrosion, coating etc., as detailed in the prescribed test plan 4) Dimensions: All conical bores of the anchor heads and coupler anchor heads regarding angle, diameter and surface condition, thread dimensions of all anchor heads and coupler anchor heads. 5) Geometrical properties 6) Surface hardness 7) Teeth, cone surface 8) "2.2": Test report "2.2" according to EN 10204 9) If the basis for CE marking of prestressing steel is not available, an approval or certificate according to the respective standards and regulations in force at the place of use shall accompany each delivery. 10) If the basis for CE marking of constituents of filling materials and of plastic ducts is not available, an approval or certificate according to the respective standards and regulations in force at the place of use shall accompany each delivery. full ..... Full traceability of each component to its raw materials. bulk ... Traceability of each delivery of components to a defined point.

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Internal Post-tensioning System


Contents of the prescribed test plan
CONA CMF BT

Annex 12
of European technical approval

ETA-12/0076
OIB-250-001/07-022

electronic copy

Page 36 of European technical approval ETA-12/0076 Validity from 29.06.2012 to 28.06.2017

Audit testing Sampling 2) Number of components per visit

Component

Item

Test / Check

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Anchor head, Coupler anchor head

Material according to specification Detailed dimensions Visual inspection 1) Material according to specification

Test / Check 1 Test Check Test / Check Test Test Test Check Test / Check 1 Test Check 2 2 1 5 5

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Treatment Ring wedge Detailed dimensions Main dimensions, surface hardness Visual inspection 1)

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Material according to specification Coupler sleeve Detailed dimensions Visual inspection 1) Single tensile element test Single tensile element test according to ETAG 013, Annex E.3

Test

1 Series

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1)

2)

Visual inspection means, e.g.: main dimensions, gauge testing, correct marking or labelling, appropriate performance, surface, fins, kinks, smoothness, corrosion protection, corrosion, coating etc., as given in the prescribed test plan. All samples shall be randomly selected and clearly identified.

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Internal Post-tensioning System


Audit testing
CONA CMF BT

Annex 13
of European technical approval

ETA-12/0076
OIB-250-001/07-022

electronic copy

Page 37 of European technical approval ETA-12/0076 Validity from 29.06.2012 to 28.06.2017

Maximum prestressing and overstressing forces, 05 strand Maximum prestressing force 1), 3) Force Maximum overstressing force 1), 2), 3) 0.95 Fp0.1 CONA CMF BT Tendon designation Characteristic tensile strength n Number of strands

electronic copy

0.9 Fp0.1

n05-93
1 770 kN 261 392 522 1 860 kN 274 410 547

n05-100
1 770 kN 281 421 562 1 860 kN 295 443 590

n05-93
1 770 kN 276 413 551 1 860 kN 289 433 578

n05-100
1 770 kN 296 445 593 1 860 kN 312 467 623

MPa

02 03 04

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Maximum prestressing and overstressing forces, 06 strand Maximum prestressing force 1), 3) Force 0.9 Fp0.1 0.95 Fp0.1 CONA CMF BT Tendon designation n06-140 Characteristic tensile strength n Number of strands MPa 02 03 04
1)

Maximum overstressing force 1), 2), 3)

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n06-150 1 770 kN 421 632 842 1 860 kN 443 664 886

n06-140 1 770 kN 414 621 828 1 860 kN 435 653 870

n06-150 1 770 kN 445 667 889 1 860 kN 467 701 935

1 770 kN 392 589 785

1 860 kN 412 618 824

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The given values are maximum values according to EN 1992-1-1. The actual values shall be taken from the standards and regulations in force at the place of use. Conformity with the stabilisation and crack width criteria in the load transfer test has been verified to a load level of 0.80 Fpk. 2) Overstressing is permitted if the force in the prestressing jack can be measured to an accuracy of 5 % of the final value of the prestressing force. 3) For strands according to prEN 10138-3, 09.2000, the values shall be multiplied by 0.98 Where Fpk ...........Characteristic value of maximum force of tendon Fp0.1 .........Characteristic value of 0.1 % proof force of the tendon

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Internal Post-tensioning System


CONA CMF BT

Annex 14
of European technical approval

Maximum prestressing and overstressing forces

ETA-12/0076
OIB-250-001/07-022

electronic copy

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Page 38 of European technical approval ETA-12/0076 Validity from 29.06.2012 to 28.06.2017

Internal Post-tensioning System


Construction stages
CONA CMF BT

Annex 15
of European technical approval

ETA-12/0076
OIB-250-001/07-022

electronic copy

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Page 39 of European technical approval ETA-12/0076 Validity from 29.06.2012 to 28.06.2017

BBR VT CONA CMF BT Strand arrangement

0205

0305

0405

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Nominal diameter Cross sectional area Cross sectional area Charact. value of maximum force 2) Charact. value of 0.1 % proof force Max. prestressing force
2) 2)

7-wire prestressing steel strand 1) Maximum characteristic tensile strength 1 860 in 0.49 0.51 0.49 mm 12.5 12.9 12.5 2 mm 93 100 93 Tendon 2 Ap mm 186 200 279 Fpk kN 346 372 519 Fp0.1 kN 304 328 456 0.90 Fp0.1 kN 274 295 410

0.51 12.9 100 300 558 492 443

0.49 12.5 93 372 692 608 547

0.51 12.9 100 400 744 656 590 623

Max. overstressing force

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Cube Cylinder

kN 289 312 433 467 578 0.95 Fp0.1 Minimum concrete strength Helix Additional reinforcement Centre spacing and edge distance Minimum concrete strength 3) 3) 3) 3) 3) fcm, 0 MPa 21 25 21 25 21 3) 3) 3) 3) 3) fcm, 0 MPa 17 20 17 20 17 Helix Ribbed reinforcing steel Re 500 MPa mm mm mm / / / mm E mm
4)

25 3) 20

3)

Outer diameter Bar diameter Length, approximately Pitch Number of pitches Distance Number of stirrups Bar diameter Spacing Distance from anchor plate Minimum outer dimensions Min. centre spacing Min. edge distance

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Additional reinforcement Ribbed reinforcing steel Re 500 MPa 4 4 4 4 mm 8 8 10 10 mm 50 50 50 50 F mm 35 35 35 35 A/B mm 160 / 120 160 / 120 190 / 130 160 / 120 Centre spacing and edge spacing ac / bc mm 180 / 140 180 / 140 210 / 150 180 / 140 ae' / be' mm 80 / 60 80 / 60 95 / 65 80 / 60

5)

7 10 50 35 320 / 155 340 / 175 160 / 80

7 10 50 35 320 / 155 340 / 175 160 / 80

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c concrete cover 1) Prestressing steel strand with characteristic tensile strength below 1 860 MPa may also be used 2) For strands according to prEN 10138-3, 09.2000, the values shall be multiplied by 0.98 3) Both concrete strength are applicable to tendons with strands of both nominal diameters 12.5 and 12.9 mm 4) Additional reinforcement may be replaced by a rectangular helix of identical diameter and external dimensions, and number of turns equal to number of stirrups plus one 5) Reinforcing steel with Re 460 MPa requires a stirrup spacing of 40 mm and one additional stirrup

Internal Post-tensioning System


CONA CMF BT

Annex 16
of European technical approval

Minimum concrete strength Helix Additional reinforcement Centre spacing and edge distance

ETA-12/0076
OIB-250-001/07-022

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Page 40 of European technical approval ETA-12/0076 Validity from 29.06.2012 to 28.06.2017

BBR VT CONA CMF BT Strand arrangement

0206

0306

0406

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Nominal diameter Cross sectional area Cross sectional area Charact. value of maximum force 2) Charact. value of 0.1 % proof force Max. prestressing force
2) 2)

7-wire prestressing steel strand 1) Maximum characteristic tensile strength 1 860 in 0.6 0.62 0.6 mm 15.3 15.7 15.3 2 mm 140 150 140 Tendon 2 Ap mm 280 300 420 Fpk kN 520 558 780 Fp0.1 kN 458 492 687 0.90 Fp0.1 kN 412 443 618

0.62 15.7 150 450 837 738 664

0.6 15.3 140 560 1 040 916 824

0.62 15.7 150 600 1 116 984 886 935

Max. overstressing force

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Cube Cylinder

kN 435 467 653 701 870 0.95 Fp0.1 Minimum concrete strength Helix Additional reinforcement Centre spacing and edge distance Minimum concrete strength 3) 3) fcm, 0 MPa 21 25 25 25 3) 3) fcm, 0 MPa 17 20 20 20 Helix Ribbed reinforcing steel Re 500 MPa mm mm mm mm E mm
4)

Outer diameter Bar diameter Length, approximately Pitch Number of pitches Distance Number of stirrups Bar diameter Spacing Distance from anchor plate Minimum outer dimensions Min. centre spacing Min. edge distance

240 / 110 10 240 45 6 15

240 / 130 10 285 45 7 15


5)

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Additional reinforcement mm mm F mm A/B ac / bc ae' / be'

Ribbed reinforcing steel Re 500 MPa 4 4 6 10 10 10 50 50 50 35 35 35 290 / 155 310 / 175 145 / 80

7 10 50 35 290 / 180 310 / 200 145 / 90

mm 190 / 130 160 / 120 Centre spacing and edge spacing mm 210 / 150 180 / 140 mm 95 / 65 80 / 60

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c concrete cover 1) Prestressing steel strand with characteristic tensile strength below 1 860 MPa may also be used 2) For strands according to prEN 10138-3, 09.2000, the values shall be multiplied by 0.98 3) Both concrete strength are applicable to tendons with strands of both nominal diameters 15.3 and 15.7 mm 4) Additional reinforcement may be replaced by a rectangular helix of identical diameter and external dimensions, and number of turns equal to number of stirrups plus one 5) Reinforcing steel with Re 460 MPa requires a stirrup spacing of 40 mm and one additional stirrup

Internal Post-tensioning System


CONA CMF BT

Annex 17
of European technical approval

Minimum concrete strength Helix Additional reinforcement Centre spacing and edge distance

ETA-12/0076
OIB-250-001/07-022

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Page 41 of European technical approval ETA-12/0076 Validity from 29.06.2012 to 28.06.2017

Centre spacing and edge distance

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ac, bc ae, be

a c > bc ae > be

Modification of centre spacing and edge distance shall be in accordance with the Clauses 2.9 and 4.2.3.

bc

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0.85 bc and Helix, outside diameter 1)


Ac b c = ac bc a c bc

ac Ac

Corresponding edge distances ae ac = 2 10 + c and be bc = 2 10 + c

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c..... Concrete cover


1)

The outer dimensions of the additional stirrup reinforcement shall be adjusted accordingly. Further modifications of reinforcement have to be in accordance with Clause 4.2.3.
NOTE The replacement of the additional stirrup reinforcement by a helix according to the Annexes 16 and 17 does not prevent the modification of centre spacing and edge distance. The external dimensions of the rectangular helix replacing stirrups have to be adapted to the modified centre spacing and edge distance.

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Dimensions in mm

Internal Post-tensioning System


Modification of centre spacing and edge distance
CONA CMF BT

Annex 18
of European technical approval

ETA-12/0076
OIB-250-001/07-022

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Page 42 of European technical approval ETA-12/0076 Validity from 29.06.2012 to 28.06.2017

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Dimensions in mm

Internal Post-tensioning System


CONA CMF BT

Annex 19
of European technical approval

Free tendon layout with monostrands or VT CMM Bands Tendon CONA CMF BT 0405 and 0406

ETA-12/0076
OIB-250-001/07-022

electronic copy

Page 43 of European technical approval ETA-12/0076 Validity from 29.06.2012 to 28.06.2017

Installation of tendons with prestressing steel strands other than monostrands


1) Preparatory work The components of the prestressing kit shall be stored in such a way as to avoid any damage or corrosion. 2) Anchorage recesses Adequate clearance to accommodate and to use the prestressing jack shall be ensured, see also the Clauses 2.1.5 and 4.2.2.

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3) Fixing the bearing trumplates Two slots are provided to fix the bearing trumplates to the formwork. The trumpet is screwed into the bearing trumplate. The helix is either welded to the bearing trumplate, see also Clause 4.8, or placed by fixing it to the existing reinforcement. 4) Placing of sheaths The sheaths are placed on supports with spacing according to Clause 2.5 and minimum radii of curvature according to Clause 2.4. The sheaths have to be connected in a water-proof way. The sheaths shall be supported such that any movement is prevented. The same applies to prefabricated tendons. 5) Installation of tensile elements prestressing steel The prestressing steel is pushed or pulled into the sheath before or after concreting the structure. 6) Installation of inaccessible fixed anchorages After passing the strands through the anchor head, they are anchored individually in the cones by means of ring wedges. After the assembly the wedges are secured with springs or a wedge retaining plate. An alternative is pre-locking each individual strand with ~ 0.5 Fpk and applying a wedge retaining plate. 7) Checking the tendons before concreting Before concreting the structure the fixation and position of the entire tendon have to be checked and corrected if necessary. The sheaths shall be checked for any damage. 8) Assembly of anchor head / coupler anchor head 1.BA After passing the strands through the anchor head, they are anchored individually in the cones by means of ring wedges. The same applies for the coupler anchor head 1.BA of a fixed coupler in the first construction stage.

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9) Prestressing At the time of stressing the mean concrete compressive strength shall be at least according to Table 4 and Clause 2.8. Stressing and possible wedging has to be carried out with a suitable prestressing jack and in accordance with Clause 4.4. The elongations of the tendon and the prestressing forces shall be checked and recorded systematically during the stressing operation. Restressing of the tendons is allowed in accordance with Clause 4.5. 10) Installation of fixed coupler anchor head 2.BA The function of the fixed coupler is to connect two tendons, whereas the first tendon is stressed before the second tendon is installed and stressed.

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The coupler anchor head H, 2.BA is assembled with ring wedges and a wedge retaining plate. It is connected to the already tensioned coupler anchor head H, 1.BA by means of a threaded coupler sleeve. 11) Assembly of movable coupler The movable coupler serves to lengthen unstressed tendons. The axial movement during stressing is ensured by a coupler sheathing box suitable to the expected elongation at the position of the coupler. The assembly of the coupler anchor heads is performed in accordance with the Points 8) and 10) and Clause 2.1.4. 12) Filling of tendons Grout shall be injected through the inlet holes until it escapes from the outlet tubes with the same consistency. All vents and grouting inlets shall be sealed immediately after grouting, see also Clause 4.7.

electronic copy

Grease or wax has to be injected in accordance with ETAG 013 and the recommendations of the supplier. More detailed information on installation can be obtained from the ETA holder.

Internal Post-tensioning System


CONA CMF BT

Annex 20
of European technical approval

Description of installation of bonded and unbonded tendons other than monostrand tendons

ETA-12/0076
OIB-250-001/07-022

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Page 44 of European technical approval ETA-12/0076 Validity from 29.06.2012 to 28.06.2017

Installation of tendons with monostrands or VT CMM Bands


1) Preparatory work The components of the prestressing kit shall be stored in such a way as to avoid any damage or corrosion. 2) Anchorage recesses Adequate clearance to accommodate and to use the prestressing jack shall be ensured, see also the Clauses 2.1.5 and 4.2.2. 3) Fixing the bearing trumplate Two slots are provided to fix the bearing trumplate to the formwork. The transition pipes are pushed into the anchor head and the helix is either welded to the bearing trumplate, see also Clause 4.8, or placed by fixing it to the existing reinforcement. 4) Placing of monostrands or VT CMM Bands The strands are placed on supports with spacing according to Clause 2.5 and minimum radii of curvature according to Clause 2.4. The strands shall be supported such as any movement is prevented. The same applies for prefabricated tendons. Installation in free tendon layout shall be according to Clause 2.5.2 and Annex 19.

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5) Installation of inaccessible fixed anchorages VT CMM Band are cut longitudinally to separate the individual strands. This is not applicable to monostrands. Removal of the PE-sheathing at the end and inserting the felt sealing on each single strand in the region of the transition pipe. The same applies to accessible fixed anchorages and stressing anchorages. After pushing the strands through the anchor head the removed PE-sheathing is placed back to protect the excess strand length of the stressing anchorage. The strands passing through the anchor head of the inaccessible fixed anchorage are anchored individually in the cones by means of ring wedges. After assembly the wedges are secured with springs or a wedge retaining plate. An alternative is pre-locking each individual strand with ~ 0.5 Fpk and applying a wedge retaining plate. The protection cap is filled with grease and connected to the head.

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6) Similar procedures In accordance with the installation of tendons with prestressing steel strand other than monostrands, see Annex 20, the following procedures are applied: - Checking of the tendons before concreting - Assembly of anchor head / coupler anchor head 1.BA - Prestressing - Installation of fixed coupler anchor head 2.BA 7) Fixed and stressing coupler type FH, SH 1) The couplers type FH and SH can be executed with monostrand and VT CMM Band tendons. 8) Filling of anchorages Stressing anchorages, accessible fixed anchorages, coupler anchorages 1.BA, and finally installed fixed couplers shall be filled with grease and protected with a cap in accordance with Point 5). The latter does not apply to couplers.

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More detailed information on installation can be obtained from the ETA holder.

1)

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The movable coupler type BH cannot be executed with monostrands or VT CMM Bands

Internal Post-tensioning System


CONA CMF BT

Annex 21
of European technical approval

Description of installation of monostrands or VT CMM Bands

ETA-12/0076
OIB-250-001/07-022

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Page 45 of European technical approval ETA-12/0076 Validity from 29.06.2012 to 28.06.2017

Sheathing base material specification for monostrand / VT CMM Band


Characteristics Melt index Test method / Standard ISO 1133 (10 minutes at 2.16 kg) DIN 53479 ISO 6964 ISO 4437 ISO 4437 EN ISO 527-2 EN ISO 527-2 ISO/TR 10837 Acceptance Criteria 0.25 g 0.95 g/cm3 2.3 +/- 0.3 % Index max. C2 Index max. 3 22 MPa 1) > 600 % 1) > 350 % 1) 20 minutes at 210 C in O2 without degradation (oxygen induction time)

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Density Carbon black - Content - Dispersion - Distribution Tensile strength (23 C) Elongation - at 23 C - at - 20 C Thermal stability
1)

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Standardised specimen according to ISO 1 BA, loading speed 100 mm/minute

Manufactured sheathing specification for monostrand / VT CMM Band


Characteristics Tensile strength at 23 C Elongation - at 23 C - at - 20 C Surface of sheathing Test method / Standard EN ISO 527-2 EN ISO 527-2 EN ISO 527-2 Acceptance Criteria 18 MPa 1) 450 % 1) 250 % 1) No visual damage No bubbles No traces of filling material visible NF C 32-060 No cracking after 72 hours in a tensio-active liquid at 50 C 25 % 25 %

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Environmental stress cracking Temperature resistance Variation of tensile strength at 23 C after conditioning for 3 days at 100 C Variation of elongation at 23 C after conditioning for 3 days at 100 C Resistance to externally applied agents: Mineral oil Acids Bases Solvents Salt spray Sheathing minimum thickness
1) 2)

EN ISO 527-2

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EN ISO 527-2

EN ISO 175

Variation of tensile strength 25 % Variation of elongation 25 % Variation of volume 5 % 1.0 mm 2)

prEN 496

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Standardised specimen according to ISO 1 BA, loading speed 100 mm/minute The actual value has to conform to standards and requirements in force at the place of use.

Internal Post-tensioning System


Specification
CONA CMF BT

Annex 22
of European technical approval

ETA-12/0076
OIB-250-001/07-022

electronic copy

Page 46 of European technical approval ETA-12/0076 Validity from 29.06.2012 to 28.06.2017

Monostrand / VT CMM Band specification


Characteristics Impact resistance Friction between sheathing and strand Squeezing - Transverse deformation under load - Residual transverse deformation after removal of load Leak tightness
1)

Test method / Standard Clause C.1.3.2.1 Clause C.1.3.2.2


1) 1)

Acceptance Criteria No tear or penetration of sheathing 60 N/m

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Clause C.1.3.2.3 1)

3% 2.5 %

Clause C.1.3.2.3

1)

No water leaking through specimen

In ETAG 013, June 2002

Grease specification of the monostrand / of the VT CMM Band

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Characteristics Cone penetration, 60 strokes (1/10 mm) Dropping point Oil separation at 40 C Oxidation stability Corrosion protection 168 hours at 35 C 168 hours at 35 C Corrosion test Content of aggressive elements Cl-, S2-, NO3SO421)

Test method / Standard ISO 2137 ISO 2176 DIN 51817 DIN 51808

Acceptance Criteria 250 - 300 150 C at 72 hours 2.5 % at 7 days 4.5 % 100 hours at 100C 0.06 MPa 1 000 hours at 100C 0.2 MPa

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NF X41-002 (salt spray) 1) Pass NF X41-002 (distilled No corrosion 1) water spray) DIN 51802 NF M07-023 2) NF M07-023 2) Grade 0 50 ppm (0.005 %) 100 ppm (0.010 %)

2)

Test sample consists of a structural steel plate S355 with a surface roughness comparable to the prestressing wire and strand. The plate is covered with a layer of grease of a maximum thickness corresponding to the declared mass of the filling material per linear meter (based on nominal strand diameter). Applied accordingly to grease.

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Grease properties after monostrand / VT CMM Band manufacturing


Characteristics Dropping point - variation during monostrand manufacturing Oil separation variation during monostrand manufacturing Test method / Standard Acceptance Criteria 10 %

ISO 2176

DIN 51808

at 72 hours 3.0 % at 7 days 5.0 %

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Internal Post-tensioning System


Specification
CONA CMF BT

Annex 23
of European technical approval

ETA-12/0076
OIB-250-001/07-022

electronic copy

Page 47 of European technical approval ETA-12/0076 Validity from 29.06.2012 to 28.06.2017

Seven-wire strands according to prEN 10138-3 1)


Steel name Y1860S7 fpk d Ap m MPa mm mm2 kg/m % Fpk Fm,max
2)

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Tensile strength Diameter Nominal cross-sectional area Nominal mass per metre Permitted deviation from nominal mass Characteristic value of maximum force Maximum value of maximum force Characteristic value of 0.1% proof force

1 860 12.5 93 0.726 3 12.9 100 0.781 2 173 199 152 186 214 164 3.5 195 000 3) 260 299 229 279 321 246 15.3 140 1.093 15.7 150 1.172

kN kN kN % MPa

Fp0.1 Agt Ep

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Minimum elongation at max. force, L0 500 mm Modulus of elasticity

Steel name Tensile strength Diameter fpk d Ap m MPa mm mm


2

Y1770S7 1 770 12.5 93 0.726 3 12.9 100 0.781 2 165 190 145 177 204 156 3.5 195 000 3) 248 285 218 266 306 234 15.3 140 1.093 15.7 150 1.172

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Nominal cross-sectional area Nominal mass per metre Permitted deviation from nominal mass Characteristic value of maximum force Maximum value of maximum force Characteristic value of 0.1% proof force
2)

kg/m %

Fpk Fm,max Fp0.1 Agt Ep

kN kN kN % MPa

Minimum elongation at max. force, L0 500 mm

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Modulus of elasticity
1) 2) 3)

Suitable strands according to standards and regulations in force at the place of use may also be used. For strands according to prEN 10138-3, 09.2000, the value shall be multiplied by 0.98 Standard value

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Internal Post-tensioning System


Strand specification
CONA CMF BT

Annex 24
of European technical approval

ETA-12/0076
OIB-250-001/07-022

electronic copy

Page 48 of European technical approval ETA-12/0076 Validity from 29.06.2012 to 28.06.2017

Reference documents Guideline for European Technical Approval


ETAG 013, 06.2002 Guideline for European Technical Approval of Post-Tensioning Kits for Prestressing of Structures

electronic copy

Standards
EN 206-1, 12.2000 EN 206-1/A1, 07.2004 EN 206-1/A2, 06.2005 EN 445, 10.2007 EN 446, 10.2007 EN 447, 10.2007 EN 523, 08.2003 EN 1561, 10.2011 EN 1563, 12.2011 EN 1992-1-1, 12.2004 EN 1992-1-1/AC, 11.2010 EN 10025-2, 11.2004 EN 10025-2/AC, 06.2005 EN 10083-1, 08.2006 Concrete - Part 1: Specification, performance, production and conformity Grout for prestressing tendons - Test methods Grout for prestressing tendons - Grouting procedures Grout for prestressing tendons - Basic requirements Steel strip sheaths for prestressing tendons - Terminology, requirements, quality control Founding - Grey cast irons Founding - Spheroidal graphite cast irons Eurocode 2: Design of concrete structures - Part 1-1: General rules and rules for buildings Hot rolled products of structural steels - Part 2: Technical delivery conditions for non-alloy structural steels Steels for quenching and tempering - Part 1: General technical delivery conditions Steels for quenching and tempering - Part 2: Technical delivery conditions for non alloy steels Case hardening steels - Technical delivery conditions Metallic products - Types of inspection documents Hot finished structural hollow sections of non-alloy and fine grain steels Part 1: Technical delivery conditions Seamless steel tubes for pressure purposes - Technical delivery conditions Part 1: Non-alloy steel tubes with specified room temperature properties Welded steel tubes for pressure purposes - Technical delivery conditions Part 1: Non-alloy steel tubes with specified room temperature prope Cold formed welded structural hollow sections of non-alloy and fine grain steels Part 1: Technical delivery conditions Non-alloy steel tubes suitable for welding and threading - Technical delivery conditions Steel wire for mechanical springs - Part 1: Patented cold drawn unalloyed steel wire Bright steel products - Technical delivery conditions - Part 2: Steels for general engineering purposes

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EN 10083-2, 08.2006 EN 10084, 04.2008 EN 10204, 10.2004 EN 10210-1, 04.2006 EN 10216-1, 05.2002 EN 10216-1/A1, 03.2004 EN 10217-1, 05.2002 EN 10217-1/A1, 01.2005 EN 10219-1, 04.2006 EN 10255+A1, 04.2007 EN 10270-1, 10.2011 EN 10277-2, 03.2008

Internal Post-tensioning System


Reference documents
CONA CMF BT

Annex 25
of European technical approval

ETA-12/0076
OIB-250-001/07-022

electronic copy

Page 49 of European technical approval ETA-12/0076 Validity from 29.06.2012 to 28.06.2017

EN 10305-5, 01.2010 EN 12201-1, 09.2011 EN ISO 175, 03.2000

Steel tubes for precision applications - Technical delivery conditions Part 5: Welded and cold sized square and rectangular tubes Plastic piping system for water supply - polyethylene (PE) - Part 1: General Plastics - Methods of test for the determination of the effects of immersion in liquid chemicals Plastics - Determination of tensile properties - Part 2: Test conditions for moulding and extrusion plastics Plastics - Polyethylene (PE) moulding and extrusion Part 1: Designation system and basis for specifications materials -

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EN ISO 527-2, 05.1996 EN ISO 1872-1, 05.1999 EN ISO 1874-1, 11.2010 prEN 496, 05.1991 prEN 10138-3, 08.2009

Plastics - Polyamide (PA) moulding and extrusion materials - Part 1: Designation system and basis for specification Plastics piping systems - plastics pipes and fittings - measurements of dimensions and visual inspection of surfaces Prestressing steels - Part 3: Strand Prestressing steels - Part 3: Strand Requirements for the installation of post-tensioning kits for prestressing of structures and qualification of the specialist company and its personnel Plastics - Determination of the melt mass-flow rate (MFR) and the melt volumeflow rate (MVR) of thermoplastics Petroleum products - Lubricating grease and petrolatum - Determination of cone penetration Petroleum products - Lubricating grease - Determination of dropping point Buried polyethylene (PE) pipes for the supply of gaseous fuels - Metric series Specifications Polyolefin pipes and fittings - Determination of carbon black content by calcination and pyrolysis - Test method and basic specification Determination of the thermal stability of polyethylene (PE) for use in gas pipes and fittings Polyolefin insulation and sheath for communication cables Liquid fuels - Determination of chlorides in crude petroleum and petroleum products Protection against physical, chemical and biological agents - Salt spray test Testing lubricating greases for their corrosion-inhibiting properties by the SKF Emcor method Testing of lubricants - Determination of oxidation stability of greases, oxygen method Testing of lubricants - Determination of oil separation from greases under static conditions Testing of plastics and elastomers - Determination of density

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prEN 10138-3, 09.2000 CWA 14646, 01.2003 ISO 1133, 01.1997 ISO 2137, 11.1985 ISO 2176, 03.1995 ISO 4437, 06.2007 ISO 6964, 12.1986 ISO/TR 10837, 07.1991 NF C32-060, 05.1996 NF M07-023, 02.1969 NF X41-002, 08.1975 DIN 51802, 04.1990 DIN 51808, 01.1978 DIN 51817, 04.1998 DIN 53479, 10.1991

Internal Post-tensioning System


Reference documents
CONA CMF BT

Annex 26
of European technical approval

ETA-12/0076
OIB-250-001/07-022

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