SERVOTEST SYSTEMS POST - TENSIONING SYSTEMS OF REINFORCED CONCRETE CONSTRUCTIONS

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1 SERVOTEST SYSTEMS POST - TENSIONING SYSTEMS OF REINFORCED CONCRETE CONSTRUCTIONS

2 SERVOTEST SYSTEMS The Russian company "Servotest Systems" (STS) provides a full cycle of design and manufacturing of system components for post-tensioning of concrete structures. The company performs work on the development of regulatory - technical documentation, supervision, installation supervision, technology transfer and performs the full range of construction works on post-tensioning concrete structures. Working together for twenty years with the research, design and construction organizations allowed to create the modern national technologies of post-tensioning concrete structures construction and to apply STS the system in more than 300 objects: bridges, overpasses, buildings, structures of industrial and civil construction, protective shells for nuclear power stations, and silos and other in the CIS. Requirements of Russian regulatory and technical documents for the construction of post-tensioning reinforced concrete constructions are often different from those of foreign regulations and standards, so the materials, equipment, and STS technology are based on Russian requirements, taking into account the positive experience of foreign post-tensioning technologies. Based on the experience of work on the construction of post-tensioning structures, our company has developed an extensive catalog of SPT-STS, which represents the greatest amount of options and requirements for modern materials, products, equipment and technology for the construction of post-tensioning concrete structures. We hope the material presented will be useful not only to manufacturers and designers of work, it will also expand the concept of the posttensioning concrete to students, staff of research institutes, including Customers and Inspectors. General manager Sitnikov Sergey L. Ph.D., Academician of the Academy of Quality Problems

3 CONTENTS POST - TENSIONING SYSTEM - STS 4 POST-TENSIONED CONSTRUCTIONS 7 DUCTS 10 HIGH STRENGTH ROPES/CABLES 12 ELEMENTS AND TECHNOLOGIES OF SPT-STS 14 TECHNOLOGICAL OPERATIONS 18 ANCHORING SYSTEMS 22 COUPLING SYSTEMS 28 HYDRAULIC EQUIPMENT 35 OPTIONAL EQUIPMENT 38

4 Post-tensioning System - STS POST-TENSIONING SYSTEM - STS РThe Russian post-tensioning system STS is a complete technology package that includes the design, manufacture and supply of materials, products, equipment and technology for the building of various post-tensioning constructions. In recent years emergence of a number of new materials and technologies allowed to increase the quality and efficiency of products and equipment, being used in SPT-STS. The usage of high-strength cables in post-tensioned constructions has given The first experience of application the equipment for stressing of strand tendons was used in 1992 during the reconstruction of the Avtozavodsky Bridge over the river Moscow. Since that time, a large practical experience in the design, manufacture, and application of post-tensioning system has been gained on more than 300 construction sites in Russia and the CIS. A great contribution to the creation of the Russian posttensioning system was made by the research and design institutes: TsNIIS, NIIZhB, SOYUZDORNII, ROSDORNII, IMASH RAN, SOYUZDOPROEKT, PROMOS, ATOMENERGOPROEKT, MGTU, MIIT, and also the Construction Organizations: Corporation TRANSSTROY, MOSTOTREST, SK MOST. Peculiarities of Russian regulations and specific climatic conditions of the buildings construction imposed a series of strength and technological requirements for the SPT-STS. In addition to providing these requirements the technologies applied in SPT -STS significantly reduce human factor influence on the quality of work performed. the development of new technologies such as: cable-stayed systems for bridges and structures, structures moving in the horizontal (shifting) and vertical directions, beam bed production of posttensioned constructions on the construction sites, strengthening and broadening of bridges and viaducts, etc. 4

5 Post-tensioning System - STS SPT - STS has been developed, tested and manufactured in accordance with Russian regulations: SNIPs, Standards, Technical regulations and Recoendations. It corresponds to the number of international regulatory requirements and recoendations (PTI, ACI, fib). of Materials, products and equipment production as well as construction work in STS is performed in accordance with ISO The activities of STS: NEW MATERIALS, EQUIPMENT AND TECHNOLOGIES DEVELOPMENT ENGINEERING SERVICES TECHNOLOGICAL PROCESS REGULATIONS DEVELOPMENT CONSTRUCTIONS DESIGN MATERIALS AND EQUIPMENT MANUFACTURE AND SUPPLY EQUIPMENT AND MATERIALS TESTING STRAND TENDONS INSTALLATION AND STRESSING GROUTING CONTRACT SUPERVISION AND INSPECTION 5

6 Post-tensioning System - STS ANCHOR - THE BASIS OF POST-TENSIONING SYSTEM Tendon anchors Main unifi ed element of anchors is a threefold wedge. Wedge design provides: ANCHORING HIGH RELIABILITY DUE TO EACH STRAND INDIVIDUAL FIXING. INTERCHANGEABLE WEDGES IN ALL TYPES OF ANCHORS. STRANDS REQUIRED NUMBER FIXING IN ANCHORS. WEDGES MULTIPLE USAGES UNDER STRESS WITH INTERCEPTION. STRESSING OR STRESS MEASUREMENT IN A SEPARATE STRAND. A SEPARATE WEDGE REPLACING. WEDGES COMPACT ARRANGEMENT IN THE ANCHOR.. 6

7 Post-tensioned Constructions POST-TENSIONED CONSTRUCTIONS Shells: silos, protective shells for nuclear power stations, storage tanks for liquids and gases Post-tensioning on a loop 360: SPZO AES Post-tensioning on a loop 90 and 180: raw meal silo BRIDGES AND VADUCTS Spans made of post-tensioning factory-built beams with stressing at the stops Pre-Post-tensioning bridge elements: 24 and 33 m 7

8 Post-tensioned Constructions Length compound post-tensioning elements up to 42m with tension on the concrete Beams elements length of 12-14m with further tendons/sheaves tension at the site Monolithic/cast post-tensioning concrete span structures Slabby with one edge Ribbed plate Lightweight with one edge Weight reduction of concrete due to the internal cavity 8

9 Post-tensioned Constructions Box girder Constant height design of the span over 40-meters. It is constructed section by section on the scaffolding or by method of cyclic longitudinal launching. Variable cross section construction for covering spans of more than 60 meters. Constructed, for example, by the method of balanced concreting. Technology: sections manufacturing on the casting yard in the special beds with further installation and tendons tension. Precast box structure constructed by segmental/ balanced method. 9

10 Ducts DUCTS Ducts are designed to form the longitudinal and transverse channels (through holes) in a concrete structure into which high-strength stressed reinforcement is set. Filling channels space with high-strength ropes shall be not less than 35% and not more than 50% relative to duct internal cross-sectional area. Depending on used high-ropes diameter of 15.3 and 15.7 and cables number in the beam the diameter of the duct is prescribed. For beams with a number of more than 31 channels cable diameters are determined individually. As a rule, channels in reinforced concrete structures are formed by the ducts installation in the decking before concreting, the ducts here are tightness and tubes. In SPT-STS corrugated metal and plastic ducts are used. Ducts in use type, size and material are defi ned by design features and regulatory documents requirements. During ducts installation in the decking special attention should be given to fi xing them in the project position with the required accuracy, evenness, strength fastening on the bias and tightness in the concreting Recoended channels diameters: Ropes number diameter in the beam Inner diameter, / process according to the Technological regulations for construction. For external (truss) post-tensioning elements as a protection against external infl uences smooth tubes according to GOST from the HDPE can be applied. The local application of metal smooth tubes in curvatures at small radius is possible. METAL DUCTS ACCORDING TO TU # Metal ducts are corrugated metal tubes manufactured from steel strips by rolling. Corrugation (gofers) are made in the form of double start tread, which allows to connect duct sections with the help of couplings. Coupling is a segment of a corrugated tube 300 length and a diameter 5 more than the duct diameter. Delivery of metal ducts is made in frame containers of 6 m. Storage time of metal ducts in the open area is limited. Typical dimensions of metal ducts: metal duct inner diameter, coupling inner diameter, 1 rm duct weight, kg coupling weight, kg ,57 0, ,67 0, ,86 0, ,91 0, ,96 0, ,06 0, ,16 0,36 10

11 Ducts PLASTIC CORRUGATED DUCTS ACCORDING TO TU # Plastic ducts are special corrugated plastic tubes made of extruded polyethylene. Corrugations are made in large rings form and ducts have longitudinal grooves connecting corrugation rings. Ducts connection is provided due to smooth plastic couplings mounted on the top of ducts. Typical dimensions of plastic ducts: duct inner diameter, coupling inner diameter, 1 rm duct weight, kg coupling weight, kg ,198 0, ,434 0, ,588 0, ,788 0, ,94 0, ,93 0, ,15 0, ,45 0, ,58 0,23 22х38 37х53 0,25 0,08 25х76 40х91 0,45 0,12 Plastic ducts are recoended for use in buildings in the aggressive corrosive environments: structures in the sea environment, facilities in environment with high temperature and humidity, tanks with oil or chemical liquids, structures with high electromagnetic fi elds, etc. Delivery of plastic ducts is made in frame containers of not more than 6 m length. Long term storage of plastic ducts in the open area is allowed. 11

12 High strength ropes/cables HIGH STRENGTH ROPES/CABLES As the post-tensioning tendons, for coupling with concrete, steel reinforcement seven wires ropes diameters of 15.3 and 15.7 (0.6) are used. Reinforcing cables are distinguished with geometrical and strength characteristics. High strength rope from round wires Plastically compacted high strength rope ("Compact") SEVEN WIRES HIGH STRENGTH ROPES EN , GOST P AND GOST Diameter GOST ,2 15,3 15,3 EN , GOST Р ,2 "Compact" 15,2 "Compact" 15,7 15,7 Tensile strength, σ v σ MPa Nominal cross-sectional area Mass of 1 m cable kg 1,099 1,093 1,289 1,172 Allowable deviation from nominal mass % ±2 Minimum breaking strength, Pu, min kn Maximum breaking strength, Pu, max kn Proof stress load σ 0, 1 kn 197, at Р0, Minimum elongation before rupture % 4,0 3,5 Modulus of elasticity E p MPa For high strength ropes except strength characteristics the following are normalized: fatigue strength; magnitude of stress relaxation during the period of 1000 hours; resistance to aggressive environment (the tendency to stress corrosion cracking). The table shows reinforcing ropes types widely used in post-tensioning structures. Reinforcement ropes with other geometrical and strength characteristics are given in EN , GOST P and GOST For these ropes you require conducting additional procedures and approvals to be used together with anchors and tendon post-tensioning equipment. SEVEN WIRES HIGH STRENGTH ROPES TENDONS Table 1. GOST Rope diameter 15,2, cross-sectional area139 2 Cables number of in tendon pcs Tendon cross area section m tendon mass kg 2,198 4,396 7,693 13,188 14,287 20,881 Tensile strength σв 1670 MPa Beam minimum breaking strength kn

13 High strength ropes/cables Table 2. EN , GOST Р Rope diameter 15,3 ; cross-sectional area Cables number of in tendon pcs Tendon cross area section m tendon mass kg 2,18 4,36 7,63 13,08 14,17 20,71 27,25 33,79 40,33 50,14 59,95 Beam minimum breaking strength Beam minimum breaking strength Tensile strength σв 1770 MPa kn Tensile strength σв 1860 MPa kn Table 3. EN , GOST Р Rope diameter 15,2 "Compakt"; cross-sectional area Cables number of in tendon pcs Tendon cross area section m tendon mass kg 2,578 5,156 9,023 15,470 16,760 24,491 32,225 39,960 47,693 59,294 70,895 Beam minimum breaking strength Beam minimum breaking strength Tensile strength σв 1820 MPa kn Tensile strength σв 1860 MPa kn Table 4. EN , GOST Р Rope diameter 15,7.; cross-sectional are Cables number of in tendon pcs Tendon cross area section m tendon mass kg 2,34 4,69 8,20 14,06 15,20 22,27 29,30 36,33 43,40 53,90 64,50 Beam minimum breaking strength Beam minimum breaking strength Tensile strength σв 1770 MPa kn Tensile strength σв 1860 MPa kn SEVEN WIRES HIGH STRENGTH ROPES 1 7 IN ANTICORROSIVE PROTECTION As the post-tensioning tendons working without coupling with concrete seven wires high strength ropes are used in double anticorrosive protection: grease + plastic tube. The strength and geometrical characteristics of these cables are shown in Tables 1-4, as well as high strength ropes diameters in the anticorrosive protection are presented in Tab. Number 5. Table 5 Rope diameter 15,3 15,2 15,7 Single rope Tube with a rope diameter, not less 1 m tube with rope mass, not less kg Tube wall ,3 18,2 18,8 Tube wall 2 19,3 19,2 19,8 Tube wall 1.5 1,218 1,403 1,303 Tube wall 2 1,242 1,427 1,335 13

14 Elements and Technologies ELEMENTS AND TECHNOLOGIES OF SPT-STS ANCHORAGE SYSTEMS SPT-STS for tendons from the ropes, working with coupling with concrete include: High-strength reinforcement Tendons of high strength ropes from 1 to 55 pcs; Anchorages Wedge anchorages type AKS, AKP, AKSU, AAA - systems providing tension and fastening of stretched high strength ropes and transmitting tension forces to concrete consist of: anchor clips providing stretched ropes fastening; BKA: concreted framed anchor Crimp-type anchors concreted BOA is a system providing stretched reinforcing ropes fastening with special crimping sleeves and tensile force transmission on the concrete, consisting of: base plate; crimping sleeves on each tendon reinforcing ropes. АКС: cup wedge anchor threefold wedges providing fi xation of each tendon reinforcing beam in anchor clip; AKP: slab wedge anchor anchor plates transmitting tension force from anchor to concrete BOA: concreted crimping anchor Wedge anchors are divided into active and passive. From the active anchors tension of reinforcing ropes tendons is made by hydraulic jacks. Passive anchors are similar in structure and composition as active ones, but tension is not performed from the passive anchors. Couplers Couplers such as SPA, SPZ, SKO, SK, CPT, CPM are devices providing coupling of reinforcing ropes tendons, consisting of: bearing plate transmitting tensile force on the concrete; AKSU: cup wedge anchor shortened SPA: active fl oating coupling coupler case ("Crown", "Star", sleeve, shoe, pipe - depending on coupling type) providing stretched tendons fastening; AKD: disc anchor wedge Anchor framed concreted type BKA is a system providing a stretched reinforcement ropes direct fastening in the concrete and tension force transfer on the concrete. SPZ: fl oating coupler with the star threefold wedges and crimping sleeves providing reinforcing ropes fi xation in coupler case, in forward as well as in backward tendons direction. 14

15 Elements and Technologies SPT: fl oating coupler SKO: crimping wedge coupler SPM: pipe fl oating coupler on couplings SK: wedge coupler "SPT-STS" PECULIARITIES General Terms SPT-STS system meets all the Russian standards requirements for building structures design and construction, all its components are manufactured in accordance with State standards and specifi cations. The imported materials and products used have Certifi cates of compliance with regulations and standards of the Russian Federation. Specifi c materials selection, products and technologies in SPT-STS is performed by a project organization on the basis of regulatory documents requirements according to which the design is conducted. All items supplied by SPT-STS pass a corresponding output control and are accompanied by passports (certifi cates). The choice of post-tensioning elements As noted above, the SPT - STS provides application of seven wires steel high strength ropes tendons 12.5, 15.2, 15.3 and 15.7 with a temporary tensile strength 1670, 1770, 1820, and 1860 MPa issued in accordance with GOST R GOST , and EN as posttensioning reinforcement. Tendons of rope reinforcements are located in closed conduits and are subject after tension and anchoring to grouting with cement mortar, which provides a bond between post-tensioning reinforcement and structures concrete (joint work). Applied tendons power defi ned by ropes nominal crosssectional area, their temporary resistance to tensile stress, controllable tensioning and ropes number in the tendon is determined by building structure design, its service and facilities conditions and must comply with the Russian Federation regulatory documents requirements. Tension force value is determined during the design in accordance with the following criteria: - strength properties implementation of high strength steel used in reinforcement ropes. A number of regulations limit the minimal tensile stress in post-tensioning reinforcement at the stage of operation the value of 40-50% of the design strength. - reinforcing ropes strength. Stresses in the reinforcement ropes are limited to the values of the design strength. In the project there should be specifi ed magnitude of controlled stress in reinforcing rope tendon, equal to stress in the tendon at the exit from the anchor from the concrete side at the moment of prestress (tension in the separate ropes in anchors range and tensioning jack may be somewhat higher, as it is necessary to take into account the emergence of losses due to friction, occurring in these zones). SPT-STS provides performance under controlled stress in the tendon which is equal to 80% of guaranteed tendon breaking strength with tension force accuracy of 5%. - reinforced concrete structures crack resistance. Absence or appearance of cracks due to permanent or total (permanent and temporary) loads. Post-tensioning application increases design crack resistance at the usage stage signifi cantly, but creates longitudinal cracks risk of in the compressed concrete and normal cracks in the tension zone due to excessive post-tensioning. - structure deformation. Construction defl ection from the permanent loads reduction, up to their complete elimination, and structure stiffness increase while working for temporary loads by eliminating cracks appearance or cracks growth limitation. In this case one must take into account emergence of extra longitudinal displacement due to elastic reduction in the process of structures posttensioning and in the concrete creep processes. - stress regulation in the construction. A signifi cant change of existing efforts in structural section in the fi rst place, during the operation stage, which стр. 16 in its turn can result in a substantial redistribution of materials: concrete and reinforcement - along the structure length. In some cases, absence of experience in the posttensioning reinforcement design, uncontrollable regulation of stress can lead to overrunning of post-tensioning 15

16 Elements and Technologies reinforcement and concrete, including overestimation of strength requirements for concrete. Requirements for Concrete The class of concrete in compression, as well as the category of crack stability zones of reinforced concrete structures with reinforcing ropes tendons are determined by design standards. Typically, the required design class of concrete is not lower than B35. Standards allow transmit force to concrete, including the post-tensioning force, in case concrete strength is below the project one (transfer resistance). In practice of bridge structures full post-tensioning force transmission to concrete at a maturing strength not less than 80% of design strength corresponding to compressive strength class B28 is coonly used. The size and location of ducts/channels Post-tensioning tendons can be placed in straight as well as smoothly curved (curved) channels formed by ducts. Channel section should be suffi cient to accoodate reinforcement ropes tendon consists of during installation and cement mortar providing bond between ropes and concrete surrounding channel. Coupling of ropes with cement mortar is carried out by lay ropes and hardened mortar adhesion from ropes and coupling of hardened concrete with surrounding concrete is made by ducts circular or spiral ridges (ripples). Channels size and location recoended for using SPT-STS and meeting the requirements of SP Ropes number in t tendon, pc Duct diameter, d (internal) / db (external), Tendon eccentricity relative to channel axis, Minimum curvature radius, m Curvature beginning from anchor minimum distance, m Distance between channels, Protective channel layer, Steel HDPE Steel Steel Steel n d/dв d/dв e R min L min /65 60/ d+60 d/ /75 80/ d+60 d/ /90 90/ d+75 d/ / / d+80 d/ / / d+85 d/ / / d+90 d/2+70 Anchors location Anchors location at post-tensioning design end is determined by project. Minimum distance between anchor axes and minimum distance from anchor axis to concrete structure edge is shown in anchors characteristics tables. In these tables indirect reinforcement (spiral) characteristics are shown. Stress losses account When checking post-tensioning structural elements bearing capacity at all stages of installation and operation stress losses reduction in reinforcing ropes is taken into account. Procedure and composition of accountable prestress losses is regulated by design standards. Some of these losses occur in the process of post-tensioning tendons tension and their value depends on characteristics of pre-tensioning system in use, in particular, friction loss of the reinforcing ropes on channels surface and losses arising at reinforcing ropes anchoring. Friction loss defi nition Δσ is performed as follows: - (ωx + δθ) (1) Δσ = σ where σp - controlled stress tension; e - natural logarithms base; δ - friction coeffi cient on curved sections; ω - coeffi cient taking into account additional friction emergence due to local channels deviations from design position (channel roughness); x - distance from tensioning anchor prior to beam cross section; θ - total angle bend prior to beam cross-section. Friction coeffi cients values for tendons from seven wires high strength ropes. Type of channel ω δ Channel formed by nonremovable, corrugated steel duct, new The same, subject to corrosion Channel formed by corrugated, nonremovable duct of pnvd Channel formed by smooth, nonremovable steel tube Concrete channel formed by a polyethylene extractable tube

17 Elements and Technologies Losses arising at reinforcing ropes anchoring This type losses value depends on reinforcing rope bias value relatively to anchor holder of active anchor in threefold wedges pressing process (the value indicated in the table). These losses defi nition is allowed to perform on the following approximate formula: Δσ=Δl Ep/l Where Δl - reinforcing element deformation relative to anchor at wedging of collets; Ep - reinforcement tendon/edge beam elasticity modulus; l tendon section length, reduced by half, where there is this factor infl uence. Elastic (flexible) reinforcement extract In the tensioning process there is extractor hood from reinforcing ropes tendon - extension due to elastic tension deformations. Extractor hood of beam is performed as follows: Δ p = i = n 1 E p i= 1 σ p, i 1 σ i p, i δ / R + ω where σ - stress in tendon at the beginning p i 1 p, i,,σ, and the end of tendon i - section, calculated by the formula = ( δ / Ri + ω) ( xi xi 1 ) σ p, i σ p, i 1 e, σ = σ where p,0 p R i - tendon i - section curvature for a straight section δ / R i = 0 x i-1, x i - coordinates of the beginning and end of beam i - section e, δ, ω, σp, E p - see above. Tension control Each beam tension control is carried out according to: force transmitted to reinforcing element by hydro-jack. The force is determined by gauge measuring pressure of working fl uid in hydraulic jack cavity tension (accuracy class not less than 1). Hydraulic jacks calibration and gauge verifi cation must be performed with the desired frequency. Controlled stress accuracy of is not more than ± 5%; tendon extractor hood. Tendon extractor hood on the project is compared with measured displacement of one of tendon rope ends relatively to the end of compressed structure (in the range of beam tension force of 20% up to 100% of controlled stress). At design organization request the following is also measured: technological extension of tendon "tails", deformation occurring in passive anchor, and in some cases, elastic compression of the structure in tension. Measured displacement deviation from corrected design hood for a single beam must not exceed ± 10%; for a group of beams ± 5%. Deformation type for beam tension Deformation value Δl Reinforcing rope displacement relative to anchor cage of passive wedge anchor 6 ±2 Смещение арматурного каната относительно анкерной обоймы пассивного клинового анкера 4 Reinforcing ropes displacement of concreting crimping anchor BOA relative to base plate (holder) 2 Reinforcing ropes displacement relative to concreted frame anchor type BKA 6 Technological "tails" extension of a beam in the jack 5 /m Peculiarities of grouting technology Grouting of channels with stretched tendons is produced from one end to another, from the lowest point (if there is bias) toward recovery. In all high points of polygonal channels drain control tubes must be installed. 17

18 Technologikal Operations TECHNOLOGICAL OPERATIONS All post-tensioning concrete technological operations shall be carried out strictly in accordance with specially designed Technological regulations approved by Contractor of works, agreed with Customer of building, Chief Engineer of the project, Construction Inspection and Post-tensioning Supplier. 1. Reinforcing cage and ducts installation 2. Support cups and coils of indirect reinforcement installation Method number 1: fi lling by pushing one rope directly from factory bay with the machine for high strength ropes pushing (UPK). 3. Installation of high ropes into ducts Depending on design features, high strength ropes installation into ducts is produced both before and after concreting of reinforced concrete structures. High strength ropes installation after concreting is recoended only in exceptional cases, with obligatory technological requirements implementation for this type of work from the Post-tensioning Supplier. Before starting work on high strength ropes installation bays with ropes must be installed in special metal "kasetnitsy." High ropes into channels installation can be performed in three ways. 18

19 Technologikal Operations Method number 2: fi lling of previously formed tendon on assembly fi xture with the help of a winch. It is used for great channels length (over 100m) and a large number of kinks. Method number 3: fi lling of ropes tendon with a drum. It is used in cramped conditions on the site. Construction with the installed reinforcing ropes tendons 19

20 Technologikal Operations 4. Installation of anchors, anchor clips and cones Concreted crimp anchors BOA-4 installation Anchors AKS-19 installation 5. Reinforcing tendons tension Tendons tension of 12 reinforcing ropes Tendons tension of 19 reinforcing ropes Tendons tension of 31 reinforcing ropes 20

21 Technologikal Operations 6. Ducts grouting Cement grouting preparation Grouting selection - cylinder of subsidence fi lling Grouting strength measurement Anchor channels grouting with covers for grouting Anchor tendons after grouting Channel grouting check 21

22 Anchoing Systems ANCHORING SYSTEMS ANCHOR WEDGE DISC Type: AKD G- min distance between anchors axes; min distance to the edge - 0.5G + protective layer Delivery set AKD-N (N-number of ropes): 1. Wedges N pieces; 2. Adaptor AKD-N; 3. Special grease N g; 4. Injection hole plug; 5. Mounting fi ttings, gasket. Rope diameter: 15.3 and 15.7 (0.6 ") Anchor type Ropes number А Б В Г Д Е n Ж И AKD AKD AKD AKD Dimensions are for anchors AKD for concrete, it is guaranteed at least B 32, before tendons tension. Сonfi nement reinforcement spiral shall be made from rod/bar reinforcement, class not lower than А400 (III). СConfi nement reinforcement spiral is not included in AKD scope of supply. STS reserves the right to extend anchors number and change the design. 22

23 Anchoing Systems ANCHOR CUP WEDGE Type: AKS G- min distance between anchors axes; min distance to the edge - 0.5G + protective layer Delivery set AKS-N (N-number of ropes): 1. Anchoring clip of AK-N; 2. Wedges N pieces; 3. Supporting cup OS-N; 4. Adaptor AKS-N; 5. Special grease N g; 6. Injection hole plug; 7. Mounting fi ttings, gasket. Anchor type Ropes number Rope Diameter: 15.3 and 15.7 (0.6 ") А Б В Г Д Е n Ж И З AKS AKS AKS AKS AKS AKS AKS AKS AKS Dimensions are for anchors AKD for concrete, it is guaranteed at least B 28, before tendons tension. Сonfi nement reinforcement spiral shall be made from rod/bar reinforcement, class not lower than A400 (III). Confi nement reinforcement spiral is not included in AKD scope of supply. STS reserves the right to extend anchors number and change the design. 23

24 Anchoing Systems CUP WEDGE ANCHOR SHORTENED Type: AKSU G- min distance between anchors axes; min distance to the edge - 0.5G + protective layer Delivery set AKSU-N (N-number of ropes): 1. Anchoring clip of AK-N; 2. Wedges N pieces; 3. Supporting cup OSU-N; 4. Adaptor AKSU-N; 5. Special grease N g; 6. Injection hole plug; 7. Mounting fi ttings, gasket. Anchor type Ropes number Rope diameter: 15.3 and 15.7 (0.6 ") А Б В Г Д Е n Ж И З AKSU x AKSU x AKSU x AKSU x AKSU x AKSU x Dimensions are for anchors AKD for concrete, it is guaranteed at least B 32, before tendons tension. Сonfi nement reinforcement spiral shall be made from rod/bar reinforcement, class not lower than A400 (III). Confi nement reinforcement spiral is not included in AKD scope of supply. STS reserves the right to extend anchors number and change the design. 24

25 Anchoing Systems ANCHOR PLATE WEDGE Type: AKP G- min distance between anchors axes; min distance to the edge - 0.5G + protective layer Delivery set AKP-N (N-number of ropes): 1. Anchoring clip of AK-N; 2. Wedges N pieces; 3. Bearing plate OP-N; 4. Special grease N g; 5. Injection hole plug; 6. Mounting fi ttings, gasket. Rope diameter: 15.3 and 15.7 (0.6 ") Anchor type Ropes number А А Б В Г Д Е n Ж И AKP х х AKP х х AKP х х AKP х х AKP х х AKP х х AKP х х AKP х х Dimensions are for anchors AKD for concrete, it is guaranteed at least B 28, before tendons tension. Сonfi nement reinforcement spiral shall be made from rod/bar reinforcement, class not lower than A400 (III). Confi nement reinforcement spiral is not included in AKD scope of supply. STS reserves the right to extend anchors number and change the design. 25

26 Anchoing Systems CONCRETED FRAMED ANCHOR Type: BKA Type II Type I Additional reinforcement/ post reinforcement Seal Delivery set BKA-N (N-number of ropes): 1. Seal BKA-N 2. Sleeve "05» N pieces. Rope diameter: 15.3 and 15.7 (0.6 ") Anchor type Ropes number Option Type А Б В Г Д Е n И Seal dвн-ssec З BKA I BKA I см 2 - BKA I см 2 - BKA I I см 2 - BKA II II ,4см BKA II I ,8см BKA II I ,8см BKA II II ,8см BKA II II см BKA II II см Dimensions are for anchors AKD for concrete, it is guaranteed at least B 28, before tendons tension. Сonfi nement reinforcement spiral shall be made from rod/bar reinforcement, class not lower than A400 (III). Confi nement reinforcement spiral is not included in AKD scope of supply. STS reserves the right to extend anchors number and change the design. 26

27 Anchoing Systems CONCRETED CRIMPING ANCHOR Type: BOA Seal Delivery set BOA -N (N-number of ropes): 1. Seal BOA-N 2. Crimp sleeve with a spring N pieces; 3. Bearing plate BOA-N; 4. Mounting BOA-N. Rope diameter: 15.3 and 15.7 (0.6 ") Anchor type Ropes number А Б В Г Д Е n И Seal dвн- Ssec З / sm 2 BOA BOA см2 110 BOA см2 160 BOA см2 160 BOA ,4см2 160 BOA ,8см2 190 BOA ,8см2 190 BOA ,8см2 200 Dimensions are for anchors AKD for concrete, it is guaranteed at least B 28, before tendons tension. Сonfi nement reinforcement spiral shall be made from rod/bar reinforcement, class not lower than A400 (III). Confi nement reinforcement spiral is not included in AKD scope of supply. STS reserves the right to extend anchors number and change the design. 27

28 Coupler Systems COUPLER SYSTEMS WEDGE COUPLER (fixed) Type: SK Other reinforcement dimensions are shown on page 23 Сup wedge anchor AKS Passive wedges fixation system conditionally is not shown Delivery set SK -N (N-number of ropes): 1. Sole timber SK-N; 2. Wedges 2 N pieces; 3. Bearing cup OS-N; 4. Adaptor AKS-N; 5. Case SK-N 6. Special grease 2 N g; 7. Injection hole plug; 8. Mounting fi ttings, gasket. Coupler Type Ropes number Rope diameter: 15.3 and 15.7 (0.6 ") А Б В Ж З И SK SK SK SK SK SK Dimensions are for anchors AKD for concrete, it is guaranteed at least B 28, before tendons tension. Сonfi nement reinforcement spiral shall be made from rod/bar reinforcement, class not lower than A400 (III). Confi nement reinforcement spiral is not included in AKD scope of supply. STS reserves the right to extend anchors number and change the design. 28

29 Coupler Systems CRIMPING WEDGE COUPLER (fixed) Type: SKO Other reinforcement dimensions are shown on page 23 Сup wedge anchor AKS Delivery set SK -N (N-number of ropes): 1. "Star" SKO-N; 2. Wedges N pieces; 3. Crimp sleeve with a spring N pieces; 4. Bearing cup OS-N; 5. Adaptor AKS-N; 6. Case SKO-N 7. Special grease 2 N g; 8. Injection hole plug; 9. Mounting fi ttings, gasket. Rope diameter: 15.3 and 15.7 (0.6 ") Coupler type Ropes number А Б В Ж З И СКО СКО СКО СКО СКО СКО Dimensions are for anchors AKD for concrete, it is guaranteed at least B 28, before tendons tension. Сonfi nement reinforcement spiral shall be made from rod/bar reinforcement, class not lower than A400 (III). Confi nement reinforcement spiral is not included in AKD scope of supply. STS reserves the right to extend anchors number and change the design. 29

30 Coupler Systems TUBULAR COUPLER (fixed) Type: ST Gued tape Other reinforcement dimensions are shown on page 23 Сup wedge anchor AKS Delivery set ST -N (N-number of ropes): 1. Coupling ST-N; 2. Anchoring clip AK-N; 3. Anchoring clip AO-N 4. Wedges N pieces; 5. Crimp sleeve with a spring N pieces; 6. Bearing cup OS-N; 7. Adaptor AKS-N; 8. Case ST-N 9. Special grease N g; 10. Injection hole plug; 11. Mounting fi ttings, gasket. Rope diameter: 15.3 and 15.7 (0.6 ") Coupler type Ropes number А Б Ж З И ST ST ST ST ST ST Dimensions are for anchors AKD for concrete, it is guaranteed at least B 28, before tendons tension. Сonfi nement reinforcement spiral shall be made from rod/bar reinforcement, class not lower than A400 (III). Confi nement reinforcement spiral is not included in AKD scope of supply. STS reserves the right to extend anchors number and change the design. 30

31 Coupler Systems COUPLER FLOATING WITH A STAR (crimp) Type: SPZ Casing length depends on reinforcing element Delivery set SPZ -N (N-number of ropes): 1. "Star" SKO-N; 2. Crimp sleeve with a spring N pieces; 3. Case SKO-N 4. Mounting fi ttings, gasket Coupler type Ropes number Rope diameter: 15.3 and 15.7 (0.6 ") А Б В Ж З И SPZ SPZ SPZ SPZ SPZ SPZ STS reserves the right to extend anchors number and change the design. 31

32 Coupler Systems TUBULAR COUPLER FLOATING (crimp) Type: SPT Casing length depends on reinforcing element Delivery set SPZ -N (N-number of ropes): 1. Coupling SPT-N; 2. Anchoring clip AO-N 2 pcs. 3. Crimp sleeve with a spring N pieces; 4. Case SPT-N 5. Mounting fi ttings Rope diameter: 15.3 and 15.7 (0.6 ") Ropes А Б Ж З И Coupler type number SPT SPT SPT SPT SPT SPT STS reserves the right to extend anchors number and change the design. 32

33 Coupler Systems COUPLER FLOATING ACTIVE Type: SPA Seal Seal ΔL beam extraction E = V / 2 + protective layer thickness Delivery set SK -N (N-number of ropes): 1. "Buckle" SPA-N; 2. Wedges 2 N pieces; 3. Seal SPA N pcs. 4. Mounting fi ttings Rope diameter: 15.3 and 15.7 (0.6 ") Anchor type Ropes number А Б В Г Д 1) Ж 1) З Силовое кольцо dвн-sсеч И SPA SPA см2 40 SPA см2 60 SPA ,4см2 70 SPA ,8см2 85 1) Depends on concrete surface shape STS reserves the right to extend anchors number and change the design. 33

34 Coupler Systems FLOATING COUPLER ON COUPLINGS (wedge or crimp) Type: SPM Casing length depends on reinforcing element Delivery set SPM -N (N-number of ropes): 1. Coupling SPM-1 Npcs; 2. Wedges or Crimp sleeve with a spring 2 N pieces; 3. Seal SPM-N 2 pieces; 4. Case SPM-N; 5. Mounting fi ttings. Rope diameter: 15.3 and 15.7 (0.6 ") Coupler type Ropes number Ж З И SPM SPM SPM SPM SPM SPM SPM SPM SPM SPM STS reserves the right to extend anchors number and change the design. 34

35 Hydraulic Equipment HYDRAULIC EQUIPMENT JACKS FOR TENDONS TENSIONING Type: DN DN-1 DN-4 DN-19 DN-55 h E1 D H B=b+L L b E Type Ropes number, max Tensile force, kn Operating pressure, MPa Piston area, cm 2 Stroke, Weight, kg DN (27,1) 70 38, DN (22) 50 43, DN (113) , DN-4С 4 911(92,9) , DN (161,4) , DN (322,9) , DN (435) , DN-31 (25) 31 (25) 7319(746,1) , DN-55 (46) 55 (46) 13382(1365) , Sizes, D=115; L=530; D=130; L=1183; D=248; L=825; D=240; L=620; D=306; L=800; D=397; L=900; D=450; L=950; D=600; L=1055; D=834; L=1088; Jack Dimensions, H=130; h=50; b=750; E=65; E1=65; На стенде H=260; h=140; b=1090; E=145; E1=145; На стенде H=320; h=150; b=1050; E=170; E1=170; H=375; h=160; b=1180; E=215; E1=215; H=800; h=390; b=1350; E=420; E1=420; H=510; h=210; b=1300; E=370; E1=315; H=690; h=250; b=1350; E=425; E1=425; 35

36 Hydraulic Equipment Type: DNN DNN-1 DNN-4 Mark Ropes number, max Tensile force, kn Operating pressure, MPa Pistons area cm 2 Piston stroke h, Weight, kg Main dimensions, DNN (22,2) 70 31, DNN (99,1) , В=207; В1=74 Н=50; L=402 В=265; В1=80 B2=73; Н=155 L=600 36

37 Hydraulic Equipment HYDRAULIC PUMP STATIONS RN2-70/4,5 SN70/3/40.3.P SN70/5/60.3.P PUSH THROUGH MACHINE Type: UPK Specifi cations: effort to push N pushing speed 1m/sec operating pressure MPa dimension guiding rail length rotation angle of guiding rail weight 800 Н, (0,082тс) 1 m/sec 20 MPa 500 х 820 х kg 37

38 Optional Equipment OPTIONAL EQUIPMENT DEVICE FOR MIXING MORTAR AND GROUTING Type: USI 30/100/160 USI technical characteristics: mixing tank: capacity of 100 liters storage-mixing tank: capacity of 160 l dispensing water tank: capacity of 70 l electric motor: voltage of 380 V power of 5.5 kw screw pump : supply ( ) l / min operating pressure 2 MPa weight 400 kg dimension PRESS (COMPRESSION APPARATUS) FOR PRODUCTION OF FRAMED CONCRETED ANCHORS Type: GPF-3 GPF-3 technical characteristics: operating pressure of 35 MPa operating force of 58 kn (5.9 ts) stroke 100 dimensions ability to adjust anchors size weight 50 kg 38

39 Optional Equipment PRESS (COMPRESSION APPARATUS) FOR CRIMPING ANCHORS Type: UZM UZM Specifi cations: operating pressure of 70MPa operating force of kn (35.8 ts) stroke 105 dimensions of Weight 67 kg DEVICES FOR GROUTING Performing of channels grouting technology with strained tendons requires accessories: Caps for grouting (reusable), mounted on anchor with strained tendons; Universal removable half couplings on ducts PM- 90, for pouring channels top points. 39

40 117545, Moscow, 1 Dorozhnyi proezd, 9 tel./fax: +7 (495) , +7 (495) , +7 (495) , +7 (495)

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