Page 1 of European Technical Approval ETA-10/0246 Issued on

Transcription

1 Page 1 of European Technical Approval ETA-10/0246 Issued on VTT EXPERT SERVICES Ltd PL VTT Puh Telekopio Rakennustuotedirektiivin (89/106/EEC) artiklan 10, neuvoston direktiivi 21. joulukuuta 1988, mukaisesti notifioitu tuotehyväksyntälaitos EOTAN JÄSEN Eurooppalainen tekninen hyväksyntä ETA-10/0246 European Technical Approval Kauppanimi: Trade name Hyväksynnän haltija: Holder of approval: Tuotetyyppi ja sen käyttötarkoitus: Generic type and use of construction product: Peikko FatBar 36, FatBar 39 jälkijännitysjärjestelmä Peikko FatBar 36, FatBar 39 post tensioning kit Peikko Group Oy Voimakatu 3 FI Lahti, Finland RAKENTEIDEN JÄLKIJÄNNITYSJÄRJESTELMÄ POST-TENSIONING KIT Voimassaoloaika: Validity from/to Valmistuspaikka: Manufacturing plants: Factory 1 Factory 3 Tämä hyväksyntä sisältää This European Technical Approval contains sivuja/liitteitä pages/annexes 29 sivua, jossa 6 liitettä 29 pages including 6 annexes E TA Eurooppalainen tekninen hyväksyntäorganisaatio European Organisation for Technical Approvals

2 Page 2 of European Technical Approval ETA-10/0246 Issued on EI LEGAL BASES AND GENERAL CONDITIONS 1. This European Technical Approval is issued by the VTT Expert Services Ltd in accordance with: - Council Directive 89/106/EEC of 21 December 1988 on the approximation of laws, regulations and administrative provisions of Member States relating to construction products 1, modified by the Council Directive 93/68/EEC 2 and Regulation (EC) N 1882/2003 of the European Parliament and of the Council 3, - Laki rakennustuotteiden hyväksynnästä (230/2003) luvut 3 ja 10, Ympäristöministeriön asetus rakennustuotteiden hyväksynnästä 3 sekä Ympäristöministeriön antama valtuutuspäätös (19/629/2009), - 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 ; - Guideline for European Technical Approval of Post-Tensioning Kits for Prestressing of Structures. ETAG 013, Edition June VTT Expert Services Ltd is authorised to check whether the provisions of this European Technical Approval are met. Checking may take place in the manufacturing plant(s). Nevertheless, the responsibility for the conformity of the products to the European Technical Approval and for their fitness for the intended use remains with the holder of the European Technical Approval. 3. This European Technical Approval is not to be transferred to manufacturers or agents of manufacturer other than those indicated on Annex 1; or manufacturing plants other than those indicated on page 1 of this European Technical Approval. 4. This European Technical Approval may be withdrawn by the VTT Expert Services Ltd pursuant to Article 5 (1) of the Council Directive 89/106/EEC. 5. Reproduction of this European Technical Approval including transmission by electronic means shall be in full. However, partial reproduction can be made with the written consent of the VTT Expert Services Ltd. 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. 6. The European Technical Approval is issued by VTT Expert Services Ltd in English. This version corresponds to the version circulated within EOTA. Translations into other languages have to be designated as such. 1 Official Journal of the European Communities Nº L 40, , p Official Journal of the European Communities Nº L 220, , p official Journal of the European Union Nº L 284, , p Official Journal of European Communities Nº L 17, , p. 34

3 Page 3 of European Technical Approval ETA-10/0246 Issued on II SPECIFIC CONDITIONS OF THE EUROPEAN TECHNICAL APPROVAL 1. Definition of the product and intended use 1.1 Definition of the construction product Peikko FatBar is the bar tendon post-tensioning kit which consists of the following components: Tensile element: Plain bar tendon according to pren :2009 with threads at both ends, with diameters and tensile strength as shown in Table 1. Anchorage: Square steel anchor plate with an unthreaded hole, domed steel anchor nut and steel washer. Ducts Appropriate plastic ducts according to EN and Intended use The Peikko FatBar post-tensioning system is intended to be used for prestressing applications in normal weight concrete structures as internal unbonded bar tendons. The provisions made in this ETA are based on an assumed intended working life of 50 years for permanent corrosion protection. The indications given on the working life cannot be interpreted as a guarantee given by the manufacturer or the Approval Body, but are to be regarded only as a means for choosing the appropriate product in relation to the expected, economically reasonable working life of the construction works. 2. Characteristics of product and methods of verification Peikko FatBar post-tensioning kit is an internal unbonded system. The kit supplied by Peikko Group Oy comprise of plain bars, complying with pren :2009, with threads at both ends having 36 mm or 39 mm nominal diameter, anchor plate, domed nut and washer. The additional components not supplied by Peikko Oy are to comply with ETAG 013.and/or standards defined in the ETA. 2.1 Anchorages Stressing anchorage The anchorage at the stressing end consists of square steel plate, domed steel nut and a washer. Details are given in Annexes 1 thru 3. The prestressing force is applied to the tendon by a jack bearing on the steel plate and locked in place by domed nut. The steel plate ensures the transmission of prestressing force into the concrete. Corrosion protection is presented in Annex 6:

4 Page 4 of European Technical Approval ETA-10/0246 Issued on Fixed anchorage The fixed anchorage also consists of square steel plate, domed nut and a washer. Details are given in Annexes 1 thru 3. No jacking is required at this end. The bar tendon is locked in place by the domed nut before the prestressing force is applied at the opposite (stressing) end. If the fixed anchorage is to be used as a buried passive anchor, then tendon must be locked by domed nut before concreting. 2.2 Tendons The tendons consist of plain high tensile bars with threads at both ends complying with pren :2009. The tendons, type Y 1050H, have nominal diameter 36 and 39 mm and they have the properties according to the table 1. Table 1: Tendons Designation Nominal bar diameter d [mm] Characteristic value of maximum force F pk [kn] Characteristic value of 0,1% proof force (yield force) F p0,1k [kn] Maximum prestress force* F 0 [kn] FatBar FatBar * The maximum prestress force applied is according to EN i.e min {k 1. f pk ;k 2. f p0,1k } with recommended values for k 1 =0,8 and k 2 =0,9 respectively. For certain countries where national provisions are more restrictive, lower prestressing forces than specified above must be applied. Fatigue resistance has been tested with a constant upper load of 65% of the characteristic force (F pk ) and with a stress variation of 80 N/mm 2 up to 2 x 10 6 load cycles. 2.3 Bursting reinforcement The products are reinforced. Additional reinforcement is placed in the anchorage zone and is complying with EN Reinforcement is according to Annex 5 of this ETA. 2.4 Ducts Ducts are made of smooth black plastic tubes (annex ). Ducts fulfil the requirements of EN and 2. Diameter of the ducts are so large, that thickness of the corrosion protection grout is at least 5 mm. MOP shall be 1 MPa and tolerance grade shall be A. 2.5 Corrosion protection Bar active end Anchor plates which are not embedded in concrete are galvanized with hot dipped zinc coating according to EN ISO and EN ISO Thickness of the hot dipped zinc coating is according to EN ISO

5 Page 5 of European Technical Approval ETA-10/0246 Issued on The top of the bar, a nut and a washer are protected against corrosion with grease. The plastic cap (annexes 6.3 and 6.5) is filled with grease, which is complying with ETAG 013 Clause C Bar structure The bar is sheathed with a PE tube. The gap between the bar and PE-tube is filled with grout (annex ). The thickness of grouting shall be at least 5 mm. Grout and grouting shall fulfil the requirements of the standards EN 446 and EN 447 or ETAG 013 Clause C 4.3. Grout is not part of the ETA Bar passive end Passive end of the bar is surrounded by concrete which provide protection against corrosion. 2.6 Friction losses In post-tensioned systems frictional losses can occur due to contact between the steel and the sides of the duct by means of (I) intentional variation in tendon profile and (ii) unintentional deviation of tendon (wobble). Frictional loss can be estimated based on Eurocode 2, EN 1992:1-1:2004 as described below: where: P ( x) P max.(1 e. kx ) P (x) = (kn) Frictional loss P = (kn) Force at the active end during tensioning at the distance x = 0 m K max = (rad/m) unintentional angular displacement or wobble factor. EN recommends 0,005<k<0, 01 (rad/m). = friction coefficient between bar and duct. EN recommends 0,33 for plain bars. The Peikko post-tensioning bar system is intended to be used as straight bars; as such there is no frictional loss due to intentional curvature of the tendon. Therefore the only frictional loss that may be considered is due to wobble which can be calculated from equations shown above. 2.7 Slip at anchorages Slip at anchorages as shown in table 2 shall be considered in design and for determination of tendon elongation. Table 2. Slip values Designation Nominal bar diameter, mm Anchor plate Slip to be considered for elongation Slip at stressing anchorage, mm Slip at load transfer from jack onto the anchorage Slip at fixed anchorage, mm Slip to be considered for elongation FatBar Square 1,0 0,7 1,0 FatBar Square 1,0 0,7 1,0

6 Page 6 of European Technical Approval ETA-10/0246 Issued on Centre and edge distances The centre and edge distances of tendon anchorages corresponding to different concrete strength are shown in Annex Concrete cover All applicable standards and regulations that dictate the required concrete cover for the place of use should be considered. The concrete cover of the tendon in any case should be higher of 20mm or concrete cover needed for reinforcement placed in the same cross section Concrete strength The mean cylindrical compressive strength of concrete at which full prestressing is permitted, f cm,0 specified by the designer of the structure shall be greater than or equal to 25 MPa. In case of partial stressing of anchorage to 50% of F 0, the mean concrete strength could be reduced by 30% Dangerous substances The release of dangerous substances is determined according to ETAG 013, Clause The PT system conforms to the provisions of Guidance paper H 5 relating to dangerous substances. A declaration in this respect has been made by the manufacturer. In addition of the specific clauses relating to dangerous substances contained in this European Technical Approval, there may be other requirements applicable to the products falling within its scope (e.g. transposed European legislation and national laws, regulations and administrative provisions). In order to meet the provisions of the Construction Products directive, these requirements need also to be compiled with, when and where they apply. 3. Evaluation of conformity and CE marking 3.1 Attestation of Conformity system The system of attestation of conformity assigned by European Commission in mandate 98/456/EC is system 1+, with audit testing of samples, described in Council Derivative 89/106/EEC of 21 December 1988, Annex III and is detailed as follows: (a) Tasks for the manufacturer (1) Factory production control (2) Further testing of samples taken at the factory by the manufacturer in accordance with a prescribed test plan (b) Tasks for the approved (notified) body: (1) Initial type testing of the product (2) Initial inspection of factory and of factory production control (FPC) (3) Continuous surveillance, assessment and approval of factory production control (FPC) (4) Audit testing of samples taken at the factory 5 Guidance paper H: A harmonized approach relating to dangerous substances under the Construction products Directive, Rev. September 2002.

7 Page 7 of European Technical Approval ETA-10/0246 Issued on Responsibilities Tasks of the manufacturer Factory Production Control The kit manufacturer shall keep available an updated list of all component manufacturers. The list is provided to the Notifed Body and to the Approval body. In accordance with ETAG 013 clause , the manufacturer shall exercise a permanent internal control of the production. All the elements, requirements and provisions adopted by the manufacturer shall be documented in a systematic manner in the form of written policies and procedures, including records of results performed. This production control system shall ensure that the product is in conformity with this European Technical Approval. The kit manufacturer may use only initial materials stated in the technical documentation of this European Technical Approval. The factory production control shall be in accordance with the Control plan of relating to this European Technical Approval, ETA 10/0246 issued on which is part of the technical documentation of this ETA. The Control plan is laid down in the context of the factory production control system operated by the manufacturer and deposited with VTT Expert Services Ltd 6. The basic elements of the Control Plan comply with ETAG 013, Annex E1 (see table 3). The results of factory production control shall be recorded and evaluated in accordance with the provisions of the control plan. The records shall include at least the following information: - Designation of the products and of the basic materials - Type of control or testing - Date of manufacture of the products and date of testing of basic materials or products or components - Result of control and testing and, if appropriate, comparison with requirements, - Name and signature of person responsible for factory production control. The records of factory production control shall be kept for at least 10 years time. And on request, the records shall be presented to VTT Expert Services Ltd. If test results are unsatisfactory, the kit manufacturer shall immediately take measures to eliminate the defects. Construction products which are not in compliance with the requirements shall be handled in such a way that they cannot be mistaken for products in compliance with requirements. After elimination of the defect, the relevant test shall be repeated if technically possible and necessary to verify the defect elimination Other tasks of the manufacturer The kit manufacturer shall, on the basis of contract, involve a body which is notified for the tasks referred to in section 3.1 in the field of Post Tensioning Kits for Prestressing of Structures in order to 6 The prescribed test plan has been deposited to VTT Expert Services Ltd and is handed over only to the approved body involved in the attestation conformity procedure. The prescribed test plan is also referred to as control plan.

8 Page 8 of European Technical Approval ETA-10/0246 Issued on undertake the actions laid down in section For this purpose, the control plan referred to in sections and shall be handed over to the notified body involved. The manufacturer shall make a declaration of conformity, stating that the construction product is in conformity with the provisions of the ETA 11/xxx issued on xx.yy At least once a year specimens shall be taken from the manufacturing plant and one series of single tensile element test shall be performed according to ETAG 013 Annex E3. The results of these test series shall be made available to the notified body. At least once a year, each component manufacturer shall be audited by the kit manufacturer (ETAG 013, ) Table 3. Content of control plan Component Item Test/ Check Traceability Minimum frequency Documentation Tensile element Material 6 Check CE 2 100% CE 2 Diameter Test each bundle no Visual inspection 3 Check each bundle no Thread of the Thread form Check each bundle no bars Detailed dimensions 5 Test 3% yes 2 specimen Anchor plate Material 1 Check Full 4 100% Detailed dimensions 5 Test 3% 2 specimen yes Domed anchor nut, washer Duct According to EN and 2 Grout according to EN 447 Materials of the corrosion protection systems Components of the corrosion protection system (tube, cap, etc.) Visual inspection 3 Check 100% no Material 1 Check Full 4 100% Detailed dimensions 5 Test 5% yes 2 specimen Treatment, hardness Test 0,5% yes 2 specimen Visual inspection 3 Check 100% CE 2 Material 6 Check Full!00% CE 2 /Suppliers certificate Visual inspection 3 Check 100 % no Cement 6 Check Full 4 100% CE 2 /Suppliers certificate Additions 6 Check Bulk 100% CE 2 /Suppliers certificate Material 6 Check Full % (metal) Yes (others) Visual inspection 3 Check Full % no 1 "2.2" : Test report type "2.2" according to EN (this applies to simple steel bearing plates only), 3.1." : Inspection certificate type "3.1" according to EN If the basis of "CE"-marking is not available, the prescribed test plan has to include appropriate measures, only for the time until the harmonized technical specification is available. 3. Visual inspections means e.g.: main dimensions, gauge testing, correct marking or labelling, appropriate performance, surface, fins, kinks, smoothness, corrosion, coating, etc., as given in the prescribed test plan 4. full : Full traceability of each component to its raw material. bulk : Traceability of each delivery of components to a defined point. 5. Detailed dimensions mean measuring of all dimensions and angles including threads according to the specification as given in the prescribed test plan 6. Material checks are included for information only as these are not part of the prescribed test plan

9 Page 9 of European Technical Approval ETA-10/0246 Issued on Tasks of approved bodies Initial type-testing of the product For initial type-testing, the results of the tests performed as part of the assessment for this European Technical Approval may be used unless there are changes in the manufacturing process or factory plant. In such cases, the necessary initial type-testing shall be agreed between VTT Expert Services Ltd and the notified bodies involved Initial inspection of factory and of factory production control The notified 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 kit (Post Tensioning kit) according to the specification mentioned in section II as well as in the Annexes of this European Technical Approval Continuous surveillance The approved body shall audit the manufacturer s factory and factory production control system at least once a year to ensure that the PT system continues to comply with this ETA. Each factory of the components shall be audited at least once in five years. The results of product certification and continuous surveillance shall be made available on demand by the approved body to VTT Expert Services Ltd. If the provisions of the European Technical Approval and the control plan are not longer fulfilled, the certificate of conformity shall be withdrawn and VTT Expert Services Ltd shall be informed immediately Audit testing of samples taken at the factory During surveillance inspections, the approved body shall take samples at the manufacturing plant of components of the PT system or of individual components for independent testing. Audit testing is described in control plan. Basic elements are described in ETAG 013, Annex E Certification The approved (notified) body shall issue a certificate of conformity as evidence of compliance with this ETA. 3.3 CE marking The delivery note, associated with the components of the PT system, shall contain the CE marking. The symbol CE shall be accompanied by the following information: - Identification number of the certification body - Name or identifying mark and address of manufacturer and manufacturing plant; - The last two digits of the year in which the CE marking was affixed; for the first time - Number of the European Technical Approval; - The use categories - Number of the EC certificated of conformity; - Identification of the product (trade name).

10 Page 10 of European Technical Approval ETA-10/0246 Issued on Assumptions under which the fitness of the product for the intended use was favourably assessed 4.1 Manufacturing The product is manufactured in accordance with the provisions of the European Technical Approval using the automated manufacturing process as identified during the inspection of the plant by the VTT Expert Services Ltd and the approved body and laid down in the technical documentation. 4.2 Recommendations for packaging, transport and storage The ETA holder shall keep available instructions concerning: - Temporary protection of bars and components in order to prevent corrosion during Transportation from the production site to the job site. - Transportation, storage and handling of the bars and of other components as to avoid any mechanical, chemical or electrochemical changes. - Protection of bars and other components from moisture - Shielding of bars when welding operation is performed. 4.3 Recommendations on installation The Peikko FatBar post-tensioning bar system shall be installed by an experienced specialist PT contractor in accordance with the installation instructions given in Annex 5 using specified equipment. 4.4 Recommendations on use, maintenance, repair Maintenance The Peikko Post-tensioned bar system requires no maintenance provided that it is protected from mechanical damage and corrosion. Protection may also be required against fire damage. Occasionally, there may be a requirement to reassess the tensile load in a tendon, some time after installation and stressing. Provided that access can be gained to one end, where a nut and bearing plate exist and that the thread beyond the nut is of sufficient length and not corroded, a jack can be reattached and the load in the tendon assessed Repair If any part of the Peikko FatBat post-tensioning bar system suffers from mechanical damage or corrosion, or is subject to extreme heat as a result of a fire, then Peikko Oy must be contacted to assess the damage. Light surface corrosion is generally permitted provided no pitting corrosion is present.

11 Page 11 of European Technical Approval ETA-10/0246 Issued on Accompanying information It is the responsibility of the ETA holder to ensure that all necessary information (design and installation) is submitted to those responsible for design and execution of the works constructed with the Peikko FatBat post-tensioning system. On behalf of VTT Expert Services Ltd Espoo Lina Markelin-Rantala Team Manager Liisa Rautiainen Assessment Manager

12 Page 12 of European Technical Approval ETA-10/0246 Issued on

13 Page 13 of European Technical Approval ETA-10/0246 Issued on

14 Page 14 of European Technical Approval ETA-10/0246 Issued on

15 Page 15 of European Technical Approval ETA-10/0246 Issued on

16 Page 16 of European Technical Approval ETA-10/0246 Issued on

17 Page 17 of European Technical Approval ETA-10/0246 Issued on

18 Page 18 of European Technical Approval ETA-10/0246 Issued on Annex 6: Installation Procedures FatBar Installation Procedure and Corrosion Protection CONTENTS 1. GENERAL RECOMMENDATIONS FOR STORAGE AND HANDLING Storage Handling Maintenance Repair DUCTS OVERALL AND THREADED LENGTH OF BAR Bar Length Thread Length INSTALLATION AND STRESSING Installation consideration during design Operator Equipment Safety Measures before stressing The Stressing Operation Operations after Stressing GROUT AND GROUTING Grout Grouting CORROSION PROTECTION Bar Active End The Bar in Structure Bar Passive End... 24

19 Page 19 of European Technical Approval ETA-10/0246 Issued on GENERAL This guide is intended for individuals who are involved in handling, storage, installation and tensioning of the Peikko FatBar tendons. Further information and advice is available from Peikko Group Oy. Peikko Group Oy may be called upon to carry out stressing operation. In addition stressing jacks and other necessary accessories may also be rented from Peikko Group Oy. 2. RECOMMENDATIONS FOR STORAGE AND HANDLING a. Storage Bars, nuts, washers and other parts should be stored in manufacturer packaging or on suitable platforms. The platform must be properly supported and leveled so that bars are not subjected to unnecessary bending. If the bars cannot be stored in transportation platforms, then they should be stacked on top of beams, which must be spaced at a maximum of 2,5m. Additional planks must be added between each bar. All delivered packages and platforms should be protected using temporary covers. In addition all materials must be stored at a raised height so that air can circulate underneath. During storage it must be checked that the delivered items and materials are according to the order and are not damaged during transportation. The supplier should be contacted immediately in case of visible damage or deficiencies. b. Handling All steel parts supplied by the manufacturer should not be welded or subject to local heating as such actions can lead to change in metallurgical properties of the steel. Bar threads must be clean before the nuts are installed. Bar threads can be lightly oiled to assist assembly. Bars should be handled in such a way that the protective coating that prevents concrete from bonding with the bar is not broken from the bar surface. c. Maintenance FatBar does not need any maintenance, if the bar is being protected from high heat ( > 200 C), mechanical stress and corrosion. As needed, after the initial tensioning the tensile load in the bar needs to be reassessed to ensure that the bar has sufficient tension.

20 Page 20 of European Technical Approval ETA-10/0246 Issued on d. Repair If the bar suffers damage due to mechanical stress, corrosion or from high heat, then the manufacturer must be contacted to assess the damage. Repair instructions for Denso tape or PE-tube can be obtained from the manufacturer. 3. DUCTS The bar is sheathed with a smooth black PE-tube ( Annex ). PE-tube (=duct) fill the requirements of EN and EN The gap between the bar and PE-tube is filled with grout in accordance with clause 6 in this instruction. The bar in the PE-tube is centred spacers at using spacers at a distance of max 0,8 m. Diameter of the PE-tube is so large, that the thickness of the grout is at least 5 mm. The PE-tube is secured in their positions. Spacing of PE-tube support is up to 2,5 m. 4. OVERALL AND THREADED LENGTH OF BAR a. Bar Length For determination of bar length following must be considered: Structural thickness i.e. distance between anchor plates Thickness of anchor plates Thickness of washers Height of the nut Minimum free length of threaded portion of the bar is shown in Table 1 and Fig. 1. As shown in Table 1, the minimum free length of the threaded portion should be such that it is 2 times the bar diameter on the active end, and 1 times the bar diameter on passive end respectively. Table1: Free length of threaded portion of bar (Lb) from the top of nut. FatBar 36 FatBar 39 Stressing end / Active end min. 72 mm min. 78 mm Fixed end / Passive end min. 36 mm min. 39 mm

21 Page 21 of European Technical Approval ETA-10/0246 Issued on Figure 1: Free length of the threaded portion (Lb) b. Thread Length Standard lengths of threads are shown in table 2. However, if required the manufacturer can provide longer thread lengths, provided they are specified in the purchase order. Table2: Standard thread lengths FatBar 36 FatBar 39 Stressing end / Active end 220 mm 220 mm Fixed end / Passive end 220 mm 220 mm 5. INSTALLATION AND STRESSING a. Installation consideration during design During design phase consideration must be given to the free length necessary for attaching the jack plus elongation of the bar under working load. Also it must be ensured that at least one bar end is free for prestressing and that it is not corroded. b. Operator On-site stressing service can be contracted from Peikko Group Oy. However if a third-party contractor is employed, then the stressing equipment used by the contractor must be approved by Peikko Group Oy. The third-party contractor must have both the experience and certification needed for post-tensioning works. c. Equipment Jacks must be used according to operating manual that accompanies jacking equipment. Jacking and pressure gauge calibration certificates issued by official calibration authorities must always accompany the equipment, and it should not be more than one year old. Equipment must be re-calibrated if the

22 Page 22 of European Technical Approval ETA-10/0246 Issued on accompanying certificate is more than one year old or if it was used in more than 100 jacking operations or 40hrs of jacking, whichever comes first. d. Safety On-site safety must be according to safety regulations of respective country as well as safety requirement of the work site. Stressing operators must be equipped with personal safety equipment such as hard hat, protection goggles, gloves and safety shoes. The area of stressing work must be cleared of individuals who are not involved in stressing operation. Also the passive end of the bar must be cleared. Barricades must be erected in line with the exposed ends. In case of a scenario of bar rupture, it must be ensured that the ruptured piece is not airborne in the surrounding area. Barricades must also be strong enough to absorb energy from rupture. The area which is in line with stressing bars must be free of all jack equipment and stressing operators. During jacking, the nuts must be tightened with proper equipment (Annex 5.2) and never with fingers. e. Measures before stressing Before stressing it must be checked that the bars are installed according to the design and installation instructions and are in condition that is suitable for prestressing. Before the application of prestress following items must be checked: 1. The concrete and joining material have gained the required strength. 2. Stressing procedure and jack user instructions are available at the site and that stressing operator is well versed with their contents. 3. Space needed for jack must be sufficient (during loading of the jack and at the end of stressing operation). 4. The shape and inclination of the surface supporting the jack must be according to operational plan. 5. Angle between the anchor plate and bar must be 90 ±2. If this requirement cannot be satisfied then contact the designer who may rectify the problem. 6. Recalibration is not required if the calibration certificate is valid and if the requirements of section 4.3 are met. 7. The jack should at all times be supported independently or using the stressing bridge (Annex 5.1) made specifically for this purpose. Jack should never be permitted to hang on the bar as this could damage the threads and cause bending of the bar. 8. The hose connecting the jack and hydraulic unit should be in a relaxed curve and never be trapped against a sharp curve. Damaged hose or hydraulic unit must be replaced immediately. f. The Stressing Operation Bar stressing plan prepared by a designer should include at least following items: Maximum prestressing force Bar elongation Bar stressing sequence In the beginning of stressing operation the initial zero point of bar elongation reading should be taken when the jack is starting to take load and all the slack in the bar is taken up. Thereafter the stressing operation should be carried out under a steady increase in pressure, and pressure gauge reading should be closely monitored. The pressure reading must be converted to an equivalent jacking force using pressure to force conversion table supplied by jack manufacturer. When a desired force level is reached, bar elongation must

23 Page 23 of European Technical Approval ETA-10/0246 Issued on be measured. If the jacking force and elongation are not in close proximity to the estimated values provided by the designer then contact the designer for consultation. With short bars, elongation measurements can be difficult and it may be that the measured values may differ significantly with those provided by the designer. If there are any irregularities during jacking operation such as uneven growth of bar elongation with pressure, sharp noise etc, and the operation must be stopped and cause investigated. Bar stressing can be carried on up to temperature -10 C. In such a case care must be taken to check that the hydraulic oil functions at below freezing temperature. Stressing operation must be properly documented such that it includes following information: Date of stressing Project, Bar locations Concrete o Date of casting o Strength development Bars in use o Bar diameter [mm] o Bar cross-sectional area [mm 2 ] o Characteristic tensile strength [N/mm 2 ] o Characteristic 0,1% proof stress [N/mm 2 ] o Characteristic value of maximum force [kn] o Characteristic 0,1% proof force [kn] o Modulus of Elasticity[N/mm 2 ] Anchor plates o Anchor plate size at stressing/active end o Anchor plate size at fixed/passive end o Centre to centre spacing o Edge distance For individual Bars o Bar identification code o diameter o jacking pressure force o bar elongation o observations When the required bar tension is reached, nut tightening must be ensured by tightening the nut with a wrench. g. Operations after Stressing After the completion of jacking (Annex 6.1) and tightening of nuts (Annex 6.2), if the bar head sticks out too long from the top of nut then it may be reduced in length. The cut off point should be at least twice the bar diameter from the top of nut. Cutting operation may be done using an angled cutter or sawing so that bar does not warm up too much inside the nut. Cutting may be done continuously for up to a maximum 20seconds, after which the bar can be drenched with cold water to prevent over heating, and then cutting continued in similar steps. Surrounding bars should be protected from sparks generated from cutting.

24 Page 24 of European Technical Approval ETA-10/0246 Issued on GROUT AND GROUTING a. Grout Grout is used as corrosion protection. Grout and grouting fill the requirements of EN 446 and EN 447. b. Grouting Grouting will be performed after stressing (Annex 6.3 and 6.4). Grout will be injected between the bar and the duct from bottom to top. Injection hose will be attached to grout hole that is located at the bearing plate at the fixed end (Annex 6.3 ). Air vent hole locates at the bearing plate at the stressed end (Annex 6.4). Grouting speed shall be between 5 and 15 m/min. Only mixing and grouting equipment, which the ETA holder has permitted, shall be used. All grouting inlets shall be sealed immediately after grouting to prevent escaping of grout from the ducts. All grouting operations shall be recorded in detail in an injection data sheet. 7. CORROSION PROTECTION a. Bar Active End Anchor plates which are not embedded in concrete are galvanized with hot-dipped zinc coating as per EN ISO and EN ISO Thickness of the hot-dipped zinc coating is according to EN ISO standard. The top end of the bar, a nut and a washer are protected against corrosion by grease. The plastic cap (annex 6.3) as filled whit grease. Grease complying with ETAG 013 Clause C.4.1. b. The Bar in Structure The bar is protected against corrosion by grout in the duct (annex 6.3 and 6.4). c. Bar Passive End Passive end of the bar is surrounded by concrete which also provides protection against corrosion.

25 Page 25 of European Technical Approval ETA-10/0246 Issued on Annex 6 References Guildeline for European Technical Approval ETAG 013 ( ) Guideline for European Technical Approval of Post-Tensining Kits for Prestressing of Structures Eurocode 2 Eurocode 2: Design of concrete structures Eurocode 3 Eurocode 3: Design of steel structures EN A1+A2 ( ) Concrete Part 1: Specification, performance, production and conformity EN Series ( ) Hot rolled products of structural steels Series EN ( ) Quenched and tempered steels Part 2: Technical delivery conditions for unalloyed quality steels (Historical standard) EN ( ) Metallic products Types of inspection documents EN ( ) Steel castings for general engineering uses ISO 37:2009 Rubber, vulcanized or thermoplastic -- Determination of tensile stress-strain properties EN ( ) Plastics piping systems for water supply Polyethylene (PE) Part 1: General EN ( ) Plastics piping systems for water supply Polyethylene (PE) Part 2: Pipes EN 12068:1998 Cathodic protection. External organic coatings for the corrosion protection of buried or immersed steel pipelines used in conjunction with cathodic protection. Tapes and shrinkable materials. EN 13507:2001 Thermal spraying. Pre-treatment of surfaces of metallic parts and components for thermal spraying. EN ISO 1461 ( ) Hot dip galvanized coatings on fabricated iron and steel articles Specification and test methods (ISO61:1999) EN ISO Zinc coatings -- Guidelines and recommendations for the protection against corrosion of iron and steel in structures -- Part 1: General principles of design and corrosion resistance EN ISO Zinc coatings -- Guidelines and recommendations for the protection against corrosion of iron and steel in structures -- Part 2: Hot dip galvanizing EN ISO 14919:2001 Thermal spraying -- Wires, rods and cords for flame and arc spraying -- Classification - - Technical supply conditions EN ISO 2063:2005 Thermal spraying -- Metallic and other inorganic coatings -- Zinc, aluminum and their alloys EN15311:2007 Thermal spraying. Components with thermally sprayed coatings. Technical supply conditions EN ISO to Paints and varnishes Corrosion protection of steel structures by protective paint systems pren Prestressing steels Part 1: General requirements pren Prestressing steels Part 4: Bars EN 446:3007 Grout for prestressing tendons. Grouting procedures EN 447:2007 Grout for prestressing tendons. Basic requirements

26 Page 26 of European Technical Approval ETA-10/0246 Issued on

27 Page 27 of European Technical Approval ETA-10/0246 Issued on

28 Page 28 of European Technical Approval ETA-10/0246 Issued on

29 Page 29 of European Technical Approval ETA-10/0246 Issued on