POST-TENSIONING SYSTEMS CIVIL ENGINEERING CONSTRUCTION

POST-TENSIONING SYSTEMS CIVIL ENGINEERING CONSTRUCTION

2 CCL extends the limits of construction techniques used to enhance the built environment. t CCL, the Company works to improve the performance of construction allowing its partners to design and build more efficient and durable structures, more rapidly, for the benefit of individuals and the community.

CCL multistrand systems... CCL EXPERIENCE CCL has a reputation for the design, manufacture, supply and installation of innovative, world-class post-tensioning systems. Working for clients across the world, CCL has the experience and a proven ability to create solutions that help reduce timescales and deliver exceptional results. CCL QULITY edicated to a programme of continuous research and development, CCL provides an exceptional service tailored to local and regional conditions and regulations. The Company operates a Quality Management System that complies with S EN ISO 9001 and all products are manufactured to exacting standards using high specification materials. CCL uses the latest software and finite element analysis for all product design and development. CCL products are approved and tested to the latest ETG and SHTO requirements. CCL COMMITMENT Involved in projects from conception, CCL offers assistance to help clients meet the requirements of the structure and local technical standards. The Company adds value throughout the project in terms of design, construction, systems, equipment and implementation. CCL has a reputation for delivering a responsive, flexible, cost-effective service and high quality civil engineering solutions worldwide. CCL SERVICE CCL operates a fully integrated supply chain through its own group companies to ensure quality from conception to construction and beyond. Its local companies and licensees have access to the CCL engineering, research and development, construction and supply resources to offer an optimal solution suited to the local market. CCL s global presence, experience and expertise enables the Company to offer clients a local solution backed by international engineering and construction techniques. CCL s philosophy is simple: to offer the client the best solution in terms of design, supply and construction for their market and project. 3

strand... The strand used in CCL Post-tensioning Systems is manufactured from seven cold drawn wires and is termed a 7 wire prestressing strand. It has a straight central wire, called a core or king wire, around which six wires are spun in one layer. The outer wire is tightly spun around the central wire with a lay length between 14 and 18 times the nominal strand diameter. The diameter of the central wire is at least three per cent greater than the diameter of the outer helical wires. Strands are supplied to site typically in 3-4 tonne coils. pren 138-3 : 200 Steel esignation Nominal ia. mm Tensile Strength MPa Steel rea mm 2 Nominal Mass Kg/m reaking Load F m 0.1% Proof Load F p 0.1 Max Strand Load F o Y17S7 Y1S7 Y1S7G Y17S7 Y1S7 Y1S7 Y17S7 Y1S7 Y1820S7G Y17S7 Y1S7 Y17S7 Y1S7.5.5.7.9.9 13.0 15.2 15.2 15.2 15.3 15.3 15.7 17 1 1 17 1 1 17 1 1820 17 1 17 93 93 1 0 0 2 139 139 15 1 1 0.72 0.72 0.875 0.781 0.781 0.797 1.08 1.08 1.289 1.093 1.093 1.172 15 173 208 177 18 190 24 259 300 248 20 2 145 152 183 15 14 17 21 228 24 218 2 234 131 137 15 1 148 194 205 2 19 20 211 15.7 1 1.172 279 24 221 STM 41/ 41M - 0 Steel esignation Nominal ia. Tensile Strength Cross Sectional rea reaking Load ia. (Grade) in mm ksi MPa in 2 mm 2 lbf 13 (2) 15 (2) 13 (2) 0.0 0.00 0.0.7 15.2.7 2 2 2 1725 1725 1 15 (2) 0.00 15.2 2 1 Maximum relaxation after 00 hours for % characteristic breaking load: 0% = 1%, % = 2.5%, % = 4.5%. 0.144 92.9 0.21 139.4 0.153 98.7 0.217 1.0 3000.1 500 2.2 41300 183.7 50 20.7 4

XM range... CCL s world-class product development ensures that the specification and mechanical properties of the CCL XM Multistrand Post-tensioning range are second to none. Versatile, lightweight and compact, but immensely strong, CCL s range of bespoke and standard systems gives engineers and contractors the flexibility they need to deliver cuttingedge contemporary structures on time and within budget. The type of anchorage is designated by type and size in the following order: XM - 0-19 - 15.7 - L System Type nchorage Size Maximum No. of Strands Nominal iameter Live End / ead End Example: XM-0-19-15.7-L Live End Multistrand nchorage with a size 0 Force Transfer Unit having 19 strands of Ø15.7mm. 13mm Tendons 15mm Tendons nchorage No. of Strands Ø Strand nchorage No. of Strands Ø Strand XM- 4.5/.9/13.0 XM-20.5/.9/13.0 XM-30 9.5/.9/13.0 XM-35.5/.9/13.0 XM- 18.5/.9/13.0 XM-45 19.5/.9/13.0 XM- 22.5/.9/13.0 XM-55 25.5/.9/13.0 XM-0 27.5/.9/13.0 XM- 31.5/.9/13.0 XM-75 37.5/.9/13.0 XM-.5/.9/13.0 XM-90 4.5/.9/13.0 XM-95 51.5/.9/13.0 XM-0 55.5/.9/13.0 XM- 3 15.2/15.3/15.7 XM-20 4 15.2/15.3/15.7 XM-30 7 15.2/15.3/15.7 XM-35 9 15.2/15.3/15.7 XM- 15.2/15.3/15.7 XM-45 13 15.2/15.3/15.7 XM- 15 15.2/15.3/15.7 XM-55 17 15.2/15.3/15.7 XM-0 19 15.2/15.3/15.7 XM- 22 15.2/15.3/15.7 XM-75 25 15.2/15.3/15.7 XM- 27 15.2/15.3/15.7 XM-90 31 15.2/15.3/15.7 XM-95 35 15.2/15.3/15.7 XM-0 37 15.2/15.3/15.7 It is possible to use CCL XM nchorages with a number of strands fewer than the maximum number specified. In this case, intermediate units can be modified from the existing designs provided strands lie as symmetrically as possible around the anchor head to ensure the force is safely centred. 5

XM range 13mm....5mm.9mm 13mm.7mm Compact Grade 17 Grade 1 Grade 17 Grade 1 Grade 1 Grade 1 nchorage No. of Strands Fpk Pmax Fpk Pmax Fpk Pmax Fpk Pmax Fpk Pmax Fpk Pmax XM- XM-20 4 58 1152 527 922 92 11 554 99 8 39 5 991 744 1302 595 42 759 1328 07 2 833 1458 7 117 XM-30 9 1481 1185 1557 45 1593 74 174 1339 17 13 1875 0 XM-35 1975 15 207 11 24 199 2232 178 2277 1821 20 2000 XM- 18 3 23 3114 2491 318 2549 3348 278 3415 2732 37 3000 XM-45 19 38 22 3287 2 333 0 3534 2827 305 2884 3958 31 XM- 22 321 2897 3 3044 3894 3115 92 3274 4174 3339 4583 3 XM-55 25 4115 32 4325 3 4425 35 4 3720 4743 3794 5208 41 XM-0 27 4444 355 4 373 4779 3823 22 18 52 98 525 XM- 31 53 82 532 5487 4390 57 413 5881 45 458 51 XM-75 37 091 4872 0 549 5239 882 5 20 51 78 1 XM- 584 528 919 5535 54 74 5952 7589 071 8333 XM-90 4 7572 058 7957 3 8142 514 855 845 8727 982 9583 7 XM-95 51 8395 71 8822 58 9027 7222 948 7589 97 7741 24 8499 XM-0 55 9054 7243 9514 711 9735 7788 230 8184 435 8348 11458 91 Fpk and Pmax stated are respectively the ultimate breaking load and the maximum jacking load per anchorage. ctual values are contained in the national regulations set by each country.

XM range 15mm... 15.2mm 15.3mm 15.7mm 15.2mm Compact Grade 17 Grade 1 Grade 17 Grade 1 Grade 17 Grade 1 Grade 1820 nchorage No. of Strands Fpk Pmax Fpk Pmax Fpk Pmax Fpk Pmax Fpk Pmax Fpk Pmax Fpk Pmax XM- XM-20 3 4 738 984 590 787 77 34 20 827 743 991 595 793 781 42 25 833 797 2 37 8 837 111 893 901 01 721 91 XM-30 7 1722 1378 18 1448 1735 1388 1823 1458 1859 1487 1953 152 22 182 XM-35 9 2214 1771 2327 181 2230 1784 2344 1875 2390 19 2511 2009 23 2 XM- 52 232 32 2482 74 2379 35 20 318 2549 3348 278 304 2883 XM-45 13 3198 2559 331 289 3221 2577 3385 28 3452 271 327 02 3904 33 XM- 15 390 52 3878 32 3717 74 390 35 3983 318 4185 3348 45 304 XM-55 17 4183 334 4395 351 4213 33 4427 3541 4514 311 4743 3794 55 84 XM-0 19 475 37 49 3930 48 377 4948 3958 45 3 5301 4241 5 455 XM- 22 5413 4330 588 45 5452 431 57 4583 5841 473 138 49 07 5285 XM-75 25 151 4921 44 5171 195 495 5 5208 38 53 975 55 78 00 XM- 27 43 5314 981 5584 91 5352 31 525 719 5735 7533 02 88 48 XM-90 31 727 2 15 4 782 145 72 458 8231 584 849 919 9309 7447 XM-95 35 811 889 9049 7239 873 938 9114 71 93 7434 975 78 511 88 XM-0 37 93 7282 95 753 919 7335 935 78 9824 7859 323 8258 11111 8889 Fpk and Pmax stated are respectively the ultimate breaking load and the maximum jacking load per anchorage. ctual values are contained in the national regulations set by each country. 7

metal ducts... In order to insert the strands within the structure, a void must be formed in the concrete. The most effective and economical way to do this is to cast metal spiral duct into the concrete at the desired position and profile. fter the strands have been stressed, the remaining void in the duct is grouted. This provides corrosion protection and bonds the strands to the duct. The corrugations within the duct provide an excellent bond between the grouted strands and the concrete structure. Metal uct Corrugated sheaths are made from rolled sheet with a minimum thickness of 0.3mm. The usual guide for the required diameter of duct is 2.5 times the nominal area of the strands encased inside the duct. The recommended number of strands per anchorage is shown on page 5. These should be checked against the local requirements and regulations. uct Coupler nchorage Ø Inside mm Ø Outside mm Ø Inside mm Ø Outside mm uct Weight Kg/m uct Length m uct rea mm 2 Support Spacing mm XM- 55 0 0 5 0.5 20 00 XM-20 55 0 0 5 0.5 20 00 XM-30 75 75 0.82 30 00 XM-35 85 85 90 0.93 00 00 XM- 85 85 90 1.01 00 00 XM-45 85 85 90 1.01 00 00 XM- 90 95 95 0 1.07 0 00 XM-55 0 5 5 1 1.19 7900 00 XM-0 0 5 5 1 1.19 7900 00 XM- 0 5 5 1 1.19 7900 00 XM-75 115 0 0 5 1.31 0 00 XM- 115 0 0 5 1.31 0 00 XM-90 5 130 130 135 1.45 300 00 XM-95 1 145 145 1.3 150 00 XM-0 1 145 145 1.3 150 00 uct weight is indicative and depends on the sheet thickness and manufacturing process. For coefficient of friction and unintentional angular displacement please refer to page 33. 8

plastic ducts... Plastic uct CCL supplies round plastic duct where enhanced corrosion protection or improved fatigue resistance is required. Manufactured from High-ensity Polyethylene (HPE) or Polypropylene, the duct provides excellent secondary corrosion protection in aggressive environments. lthough supplied typically in metre lengths for ease of transportation, it can be manufactured to specific lengths or coils according to project requirements. It is connected using specific clam shell couplers, with or without integrated grout vents, for ease of installation and to provide secure joints. The duct meets all applicable requirements of the fib and merican OT regulations. nchorage Ø uct Inside mm Ø uct Outside* mm uct Wall Thickness mm uct Length m uct rea mm 2 XM- 48 59 2.0 10 XM-20 48 59 2.0 10 XM-30 7 91 2.5 XM-35 7 91 2.5 XM- 7 91 2.5 XM-45 7 91 2.5 XM- 8 1 2.5 50 XM-55 0 11 3.0 7900 XM-0 0 11 3.0 7900 XM- 0 11 3.0 7900 XM-75 115 135 3.5 0 XM- 115 135 3.5 0 XM-90 1 152 4.0 130 XM-95 14 19 4.0 XM-0 14 19 4.0 * Over corrugations. uct weight is indicative and depends on the sheet thickness and manufacturing process. For coefficient of friction and unintentional angular displacement please refer to page 33. 9

XM live end anchorage 13mm & 15mm... The CCL XM Live End nchorages are primarily designed for longitudinal tendons in beams or bridges. Live end anchorages can be used as active or passive anchorages if they are accessible. Wedge The strands of the anchorage are simultaneously stressed by a jack bearing on the force transfer unit by means of a bearing ring. System Options CCL XM Systems are approved to ETG 013 for use in cryogenic applications, applications requiring plastic duct and those which call for full encapsulation. Contact CCL for a full list of approvals. ØE ØC nchor Head Force Transfer Unit eviation Cone uct Coupler 13mm Tendons nchorage No. of Strands * Ø C Ø uct** Ø E XM- 4 234 48 55/0 95 XM-20 300 55/0 5 XM-30 9 32 0 4 /75 43 130 XM-35 493 74 /85 48 155 XM- 18 74 /85 2 1 XM-45 19 74 /85 7 1 XM- 22 93 130 84 90/95 9 195 XM-55 25 742 98 0/5 7 215 XM-0 27 749 98 0/5 7 220 XM- 31 913 98 0/5 74 245 XM-75 37 01 175 115/0 25 XM- 01 175 115/0 84 2 XM-90 4 1118 190 3 5/130 87 5 XM-95 51 79 2 138 1/145 97 305 XM-0 55 89 2 138 1/145 98 3 ll dimensions in mm. * is the dimension for the straight part of the deviation cone that links to the duct through a duct coupler. **uct dimensions shown are for inside/outside diameter of metal ducts.

The prestressing force is applied to the strands and locked in place by the wedges in the anchor head which is supported on the force transfer unit cast into the concrete. The force transfer unit ensures the transmission of the prestressing force into the concrete. The force transfer unit and the deviation cone ensure the correct deviation of the strands from the anchor head to the duct. Wedge ØE ØC nchor Head Force Transfer Unit eviation Cone uct Coupler 15mm Tendons nchorage No. of Strands * Ø C Ø uct** Ø E XM- 3 234 48 55/0 45 95 XM-20 4 300 55/0 45 5 XM-30 7 32 0 4 /75 48 130 XM-35 9 493 74 /85 47 155 XM- 74 /85 54 1 XM-45 13 74 /85 3 1 XM- 15 93 130 84 90/95 0 195 XM-55 17 742 98 0/5 2 215 XM-0 19 749 98 0/5 7 220 XM- 22 913 98 0/5 245 XM-75 25 01 175 115/0 25 XM- 27 01 175 115/0 83 2 XM-90 31 1118 190 3 5/130 94 5 XM-95 35 79 2 138 1/145 94 305 XM-0 37 89 2 138 1/145 2 3 ll dimensions in mm. * is the dimension for the straight part of the deviation cone that links to the duct through a duct coupler. **uct dimensions shown are for inside/outside diameter of metal ducts. 11

XM dead end anchorage 13mm & 15mm... The CCL XM ead End nchorage operates as a non-accessible dead end of the tendon. The wedges are locked in place by the spring plate while the prestressing force is applied to the opposite (live) end of the tendon. The prestressing force in the strands is locked by the wedges in the anchor head which is supported on the force transfer unit cast into the concrete. Non-ccessible ead End G ØE ØF ØC Spring Plate Wedge nchor Head Force Transfer Unit eviation Cone uct Coupler uct 13mm Tendons nchorage No. of Strands * Ø C Ø E Ø F G Ø uct** XM- 4 234 48 95 95 55/0 XM-20 300 5 5 55/0 XM-30 9 32 0 4 43 130 130 /75 XM-35 493 74 48 155 155 /85 XM- 18 74 2 1 1 /85 XM-45 19 74 7 1 1 /85 XM- 22 93 130 84 9 195 195 90/95 XM-55 25 742 98 7 215 215 0/5 XM-0 27 749 98 7 220 220 0/5 XM- 31 913 98 74 245 245 0/5 XM-75 37 01 175 25 25 115/0 XM- 01 175 84 2 2 115/0 XM-90 4 1118 190 3 87 5 5 5/130 XM-95 51 79 2 138 97 305 305 1/145 XM-0 55 89 2 138 98 3 3 1/145 ll dimensions in mm. * is the dimension for the straight part of the deviation cone that links to the duct through a duct coupler. **uct dimensions shown are for inside/outside diameter of metal ducts.

If required, dead end anchorages can be used as buried passive anchorages with the provision of a sealing cap and a suitable grout vent. Threading of the strands must be completed before concreting. uried ead End G ØE ØF ØC Spring Plate Wedge nchor Head Force Transfer Unit eviation Cone uct Coupler uct 15mm Tendons nchorage No. of Strands * Ø C Ø E Ø F G Ø uct** XM- 3 234 48 45 95 95 55/0 XM-20 4 300 45 5 5 55/0 XM-30 7 32 0 4 48 130 130 /75 XM-35 9 493 74 47 155 155 /85 XM- 74 54 1 1 /85 XM-45 13 74 3 1 1 /85 XM- 15 93 130 84 0 195 195 90/95 XM-55 17 742 98 2 215 215 0/5 XM-0 19 749 98 7 220 220 0/5 XM- 22 913 98 245 245 0/5 XM-75 25 01 175 25 25 115/0 XM- 27 01 175 83 2 2 115/0 XM-90 31 1118 190 3 94 5 5 5/130 XM-95 35 79 2 138 94 305 305 1/145 XM-0 37 89 2 138 2 3 3 1/145 ll dimensions in mm. * is the dimension for the straight part of the deviation cone that links to the duct through a duct coupler. **uct dimensions shown are for inside/outside diameter of metal ducts. 13

XM basket dead end anchorages... asket dead end anchorages can be used in place of standard dead end anchorages. The prestressing force is transferred to the concrete by bond. rebar net is required to act as a spacer for the individual strands. asket dead ends are constructed on site using an extrusion rig. C nchorage No. of Strands 13mm/15mm C Ø uct* XM- 4/3-1300 220 220 55/0 XM-20 /4-1300 220 220 55/0 XM-30 9/7 1 1300 220 3 /75 XM-35 /9 1 1300 220 3 /85 XM- 18/ 1 1300 2 3 /85 XM-45 19/13 1 1300 2 /85 XM- 22/15 1 1300 2 90/95 XM-55 25/17 1 1300 3 0/5 XM-0 27/19 1 1300 3 0/5 XM- 31/22 1 1300 3 5 0/5 XM-75 37/25 1 1300 3 5 115/0 XM- /27 1300 14 3 0 115/0 XM-90 4/31 1300 14 0 0 5/130 XM-95 51/35 5 1775 0 0 1/145 XM-0 55/37 5 1775 0 0 1/145 ll dimensions in mm. *uct dimensions shown are for inside/outside diameter of metal ducts. 14

XM dead end anchorages... Compression Fitted ead End nchorage CCL ead End nchorages are used where the end of a prestressing cable is buried in concrete or is inaccessible during the stressing of the tendon. The dead end anchorage can accept the same strand configurations as the standard anchorage and uses the same tube unit to guide the strands. The strand passes through a parallel hole anchor head and is anchored by means of a compression fitting. The fitting is swaged onto the strand, ensuring a positive anchor, using a CCL Extrusion Rig activated by a hydraulic pump. retaining plate is fixed onto studs in the four tapped holes of the tube unit to ensure that the compression fittings bear evenly on the bearing plate. XM Plate ead End nchorage CCL XM ead End nchorages are used where prestressing force is required immediately behind the anchorages in inaccessible locations. The anchorages are made by threading plates onto the strands and swaging compression fittings to hold the plates in place. shorter length of strand is required to develop full prestressing force. XM Loop ead End nchorage further alternative for a dead end in inaccessible locations is the CCL Loop ead End nchorage. These are used in slabs, bridges, tanks and in vertically post-tensioned elements in walls and piers. The duct is placed in the formwork prior to concreting and the strands are installed after casting of the concrete. oth ends of the strands are stressed simultaneously. XM Loop ead End nchorage Straight uct Loop uct nchorage No. of Strands 13mm Ø Inside mm Ø Outside mm Ø Inside mm Ø Outside mm Min. Loop Radius mm XM- 4 55 0 0 5 00 XM-20 55 0 5 XM-30 9 75 75 0 XM-35 85 85 0 XM- 18 85 95 0 9 XM-45 19 85 95 0 9 Other numbers of strands can be accommodated. Please contact CCL for advice. 15

XM coupler anchorage... XM Coupler In continuous bridge deck construction, it is necessary to extend prestressing cables as construction proceeds. The first stage of stressing is carried out in the same way as with the standard anchorage except that a coupler ring replaces the anchor head. When first stage stressing and grouting is complete, the second stage strands are threaded into the wedges. The strand is deviated through a shaped trumpet that also prevents the ingress of concrete during casting. E Wedge ØG ØF ØC Coupler Ring Reducing Cone Retainer Coupler Extension Ring eviation Cone Force Transfer Unit uct Coupler uct nchorage No. of Strands 13mm/15mm * Ø C E Ø F Ø G Ø uct** XM- 4/3 234 48 7 0 95 185 55/0 XM-20 /4 300 7 0 5 195 55/0 XM-30 9/7 32 0 4 7 0 130 220 /75 XM-35 /9 493 74 7 0 155 245 /85 XM- 18/ 74 7 9 175 25 /85 XM-45 19/13 74 7 71 175 25 /85 XM- 22/15 93 130 84 7 75 195 285 90/95 XM-55 25/17 742 98 7 77 2 300 0/5 XM-0 27/19 749 98 7 84 215 305 0/5 XM- 31/22 913 98 7 8 235 325 0/5 XM-75 37/25 01 175 7 92 20 3 115/0 XM- /27 01 175 7 9 20 375 115/0 XM-90 4/31 1118 190 3 7 9 285 4 5/130 XM-95 51/35 79 2 138 7 1 300 430 1/145 XM-0 55/37 89 2 138 7 11 300 435 1/145 ll dimensions in mm. * is the dimension for the straight part of the deviation cone that links to the duct through a duct coupler. **uct dimensions shown are for inside/outside diameter of metal ducts. 1

coupler anchorages... Compression Fitting Couplers s an alternative to the standard coupler using wedges, a system with compression fittings can be provided. In addition to the standard live end anchorage it incorporates a cast coupler ring. which is inserted between the anchor head and the force transfer unit. The coupler ring incorporates slots to accommodate the compression fittings which are swaged to the strands of the second stage cable using an extrusion rig. The strand is deviated through a shaped trumpet that also prevents the ingress of concrete during casting. grout exit point contained in the trumpet should be located at the top to prevent any air being trapped during grouting. The small end of the trumpet should be securely taped to the duct. Moveable Couplers CCL Moveable Couplers use a special double-ended joint to connect the second stage of the tendon to the first. The special double-ended joints are extremely slim and use internal wedges to grip the strand. Unique safety pegs are used to ensure that the wedges grip the strand securely when fitting. The moveable couplers are staggered to allow for a very compact section. The assembly is contained within a steel or high-density polyethylene shroud. The double-ended joints can also be used to join monostrand systems or multistrand systems by coupling each strand individually. 17

XF live end anchorages... CCL onded Flat System The CCL XF nchorage is a flat system used mainly in slabs and transversally in bridge decks. It can also be used in transfer beams, containment structures and other civil applications and for both 13mm and 15mm strands. The system connects bare strands which run through a steel or plastic flat oval duct. The strands are stressed individually using a monostrand Jack. System Options CCL XF Systems are approved to ETG 013 for use in applications requiring plastic duct and those which call for full encapsulation. Contact CCL for a full list of approvals. F E G C I H J K 13mm XF imensions nchorage No. of Strands C E* F G H I J K XF--3-13 3 91 8 39 242 5 33 8 0 2 XF-20-5-13 5 95 155 39 300 83 33 171 11 2 XF-30--13 95 151 190 39 332 0 33 20 11 2 15mm XF imensions nchorage No. of Strands C E* F G H I J K XF--2-15 2 91 8 44 242 5 33 8 0 2 XF-20-4-15 4 95 155 44 300 83 33 171 11 2 XF-30-5-15 5 95 151 190 44 332 0 33 20 11 2 ll dimensions in mm. *imension E is the distance the anchor head protrudes from the force transfer unit (FTU). Overall thicknesses of 13mm and 15mm anchor heads are and 45mm respectively. Special 13mm wedges in 15mm form can be provided to allow 15mm systems to be used with 13mm strand. It is possible to use CCL XF nchorages with a number of strands fewer than the maximum number specified. In this case, strands are omitted from the standard anchor head. 18

XF coupler live end anchorages... The type of anchorage is designated by type and size in the following order: XF - 20-5 - 13 It can be noted that the 13mm and 15mm systems share the same FTU and deviation cone so are fully interchangeable. Only the anchor heads differ to suit 13mm or 15mm wedges. The wedges are available in three different sizes; 13mm, 15.2mm and 15.7mm. System Type nchorage Size Maximum No. of Strands Nominal iameter XF nchorages before Concreting eviation Cone uct Grout Entry XF nchorages after Concreting eviation Cone Force Transfer Unit Grout Entry uct Pocket Former Force Transfer Unit Shuttering Wedges nchor Head 13mm XF Flat Slab nchorages nchorage No. of Strands nchor Weight Kg uct Size mm uct rea mm 2 FTU nchor Head eviation Cone Pocket Former XF--3-13 3 3.58 19 x 43 73 002 7203 2 3 XF-20-5-13 5.7 19 x 57 004 7205 4 314 XF-30--13 8.9 19 x 90 15 005 720 5 315 15mm XF Flat Slab nchorages nchorage No. of Strands nchor Weight Kg uct Size mm uct rea mm 2 FTU nchor Head eviation Cone Pocket Former XF--2-15 2 3.77 19 x 43 73 002 02 2 3 XF-20-4-15 4.92 19 x 57 004 04 4 314 XF-30-5-15 5 8.98 19 x 90 15 005 05 5 315 19

XU anchorages... XU Live End nchorages The CCL Unbonded System is designed to work with both 13mm and 15mm nominal diameter strands. On completion of the stressing, the strand is cropped and the strand end and wedge are sealed with a grease filled plastic cap. G ØE ØF C XU Live End imensions nchorage C Ø E Ø F G XU-13 153 73 1 3 2 2 XU-15 184 81 78 5 2 ll dimensions in mm. The wedges are available in three different sizes; 13mm, 15.2mm and 15.7mm. Special 13mm wedges in 15mm form can be provided to allow 15mm systems to be used with 13mm strand. 20

XU coupler anchorages... The CCL XU System is a monostrand system mainly used in slabs. It can also be used in containment structures and remedial applications. The anchorages can be used for both 13mm and 15mm strands. The system connects to unbonded strands, therefore eliminating the need for duct. In some cases it is used as a monostrand bonded system or as a dead end system on multistrand applications. The strands are stressed individually using a monostrand Jack. XU nchorages before Concreting Concrete Excluder Force Transfer Unit (FTU) Sealing Washer ayonet Fitting XU nchorages after Concreting Pocket Former Concrete Excluder Slotted Nut Shuttering Sealing Cap Wedge Force Transfer Unit XU Live End nchorage nchorage nchor Weight Kg FTU Concrete Excluder Sealing Cap XU-13 0.89 92 9220 90 XU-15 1.54 90 9020 90 XU nchorage Reusable ccessories nchorage Pocket Former Slotted Nut ayonet Fitting Sealing Washer XU-13 9030 90 90 900 XU-15 9030 90 90 900 21

XT anchorages... XT nchorage These anchorages are predominately used on circular containment structures such as tanks, reservoirs, silos etc. and are stressed using monostrand jacks. The design allows the tendon to anchor the live end of the anchorage against the passive end, so acting also as a coupler anchorage. The body of the item is cast in a single unit to provide a compact self-contained anchorage. external post-tensioning... External post-tensioning is an increasingly popular method of strengthening both new and existing structures. It can be used to extend the life of old structures including bridges, car parks, factories and residential buildings and is a highly cost-effective alternative to traditional internal post-tensioning in new structures. In response to requirements to inspect and or replace tendons, an external post-tensioning system can be used. External tendons reduce congestion in concrete and offer a high degree of corrosion resistance whilst allowing inspection and in some cases replacement. Friction losses are also kept to a minimum as they occur only at the deviators and anchorage points. eviators at intermediate points normally take the form of steel pipes curved to a radius. 22

23 coupler anchorages... reinforcement... ursting Reinforcement nchorage XM- XM-20 XM-30 XM-35 XM- XM-45 XM- XM-55 XM-0 XM- XM-75 XM- XM-90 XM-95 XM-0 C25/30 Concrete Strength at Transfer f cm,0 (MPa) C35/45 C45/55 Ø 195 235 0 335 390 415 4 475 0 5 5 05 90 0 245 285 3 385 4 45 0 525 5 00 5 730 7 1 1 1 1 1 20 20 20 20 45 0 55 55 55 5 0 N 5.5 5.5 8.0 9.0.5 11.0 8.0 9.0 9.5.5.5 9.0.0 11.5.5 195 220 2 320 3 385 4 430 455 485 520 5 590 25 245 2 320 3 420 435 4 5 545 5 00 95 8 1 1 1 1 1 1 1 1 45 45 45 0 55 55 45 45 N 5.0 5.0 7.5 7.5 8.5.0 11.0 7.5 8.5 9.5 11.0 11.5.5 14.5 15.0 195 205 2 305 3 355 35 385 4 430 4 5 530 5 245 255 300 355 0 5 415 435 490 520 530 5 00 20 8 1 1 1 1 1 1 1 1 45 55 45 45 45 N 5.0 4.0 7.0.5 7.5 8.5 9.5 8.0 8.5 9.5.0.0 11.0.5 13.0 Helical Reinforcement fyk=0mpa* Ø C Ø C Ø Ø C Ø ll dimensions in mm. *eformed/ribbed rebar. N= No. of turns in Helix. Ø ØC

anchorage positioning... The positioning of ducts and anchorages should be set out taking into account the dimensions shown below. The concrete strength and required prestressing will affect the anchorage centres. Other configurations are also available to suit specific requirements. 1/2* 1/2 * *Subject to local reinforcement cover requirements Concrete Strength at Transfer f cm,0 (MPa) No. of Strands C25/30 C35/45 C45/55 nchorage 13mm 15mm XM- 4 3 245 245 245 245 245 245 XM-20 4 285 285 2 2 255 255 XM-30 9 7 3 3 320 320 300 300 XM-35 9 385 385 3 3 355 355 XM- 18 4 4 420 420 0 0 XM-45 19 13 45 45 435 435 5 5 XM- 22 15 0 0 415** 415** XM-55 25 17 525 525 4 4 435** 435** XM-0 27 19 5 5 5** 5** ** ** XM- 31 31 00 00 545 545 490** 490** XM-75 37 25 5 5 520** 520** XM- 27 5 5 00 00 530** 530** XM-90 4 31 730 730 5 5 XM-95 51 35 00 00 XM-0 55 37 7 7 95 95 20 20 ll dimensions in mm Concrete strengths shown are cylinder test strength/cube test strength. Smaller centre to centre dimensions can be achieved. Contact CCL for advice. For values of f cm,0 between C25/30 and C45/55, and can be determined by straight line interpolation. The mean compressive strength of concrete at which full prestressing is permitted, f cm,0 specified by the designer of the structure, must be greater than or equal to C25/30. In the case of partial stressing of a standard anchorage to % of Fpk, the minimum mean compressive strength of concrete could be reduced by 30%. The table above is based on the requirements of ETG 013 and typical concrete strengths. For CCL recommendation and full design rules outside the above please contact CCL for advice. ** If anchors are placed in individual pockets, dimensions shown work with smallest jack option of P25. If larger jacks are used, dimensions need to be adjusted in accordance with P25. 24

coupler anchorages... jack stressing pockets... C F Ø ØE Jack Size nchorage No. of Strands 13mm/15mm C o Ø Ø E F 10MG XM- XM-20 XM-30 4/3 /4 9/7 200 200 230 0 0 3 20 20 152 192 130 1 18 287 287 273 3000MG XM-30 XM-35 XM- XM-45 9/7 /9 18/ 19/13 255 2 305 305 3 3 137 142 192 2 2 2 18 2 23 23 8 323 3 354 XM- 18/ 330 137 2 23 375 00MG XM-45 XM- XM-55 19/13 22/15 25/17 330 3 3 142 144 142 2 283 300 23 253 2 379 388 388 XM-0 27/19 3 151 3 2 3 XM-* 22/15 5 144 283 253 453 000MG XM-55* XM-0 XM- XM-75 25/17 27/19 31/22 37/25 5 5 5 5 142 151 149 155 300 3 35 375 2 2 325 335 453 458 45 XM- /27 5 159 390 3 41 70MG XM-0* XM-* XM-75* XM-* XM-90 XM-95 XM-0 27/19 31/22 37/25 /27 4/31 51/35 55/37 475 475 475 475 475 475 475 ll dimensions in mm except where stated. * If anchors are placed in individual pockets, dimensions on P24 must be adjusted to meet dimension F or larger. Otherwise, smallest jack option should be used. 151 149 155 159 19 172 177 3 35 375 390 418 43 43 2 325 335 3 378 39 39 528 52 530 531 535 535 537 25

jack sizes CCL MG Jacks are simple to operate and easy to manoeuvre. The body of the jack can be rotated around its lifting points, enabling easy access to hydraulic connections. The jack innards can also be rotated, promoting easy alignment with the tendons. CCL Jacks may be operated in a vertical or horizontal position and feature hydraulic lock-off to ensure the correct seating of the wedges and to minimise load losses at transfer. The CCL MG Stressing Jacks used for the CCL XM System have the following features: utomatic gripping of the wedges on the strands Simultaneous stressing of all the strands of the tendon Support of the jack on the force transfer unit, by means of a temporary bearing ring Simultaneous hydraulic lock-off of all the wedges in the anchor head Partial stressing of the tendons with later recovery up to the final values of the prestressing force H Stressing by successive loadings of the jack when the final extension is greater than the full stroke of the CCL Jack ifferent jack innards requirement for each system size Ø ØE ØF G MG Jack imensions C Jack Size C* Ø Ø E Ø F G H** min Weight 10MG 322 388 2 25 232 342 42 275kg 3000MG 0 388 200 2 2 5 0 0 3kg 00MG 307 415 2 344 30 490 585 730 575kg 000MG 304 42 209 38 4 57 7 0kg 70MG 321 4 220 478 490 52 8 1kg ll dimensions in mm. * Stroke of jack. ** Minimum length of strand. 2

coupler anchorages... stressing options... There are two versions of innards available for the MG jack series, manual and auto release. The standard CCL MG Jack is fitted with manual innards. uto release innards are included on the CCL MG Jack. They are also available as a retrofit option via a separate kit compatible with the standard MG jack*. The auto release innards make the stressing process quicker and easier by eliminating the need to manually install / remove the jack wedges. CCL Stressing Sequence 1. Place the anchor head onto the strands, ensuring that the centre mark is at the top. Fit the wedges into the anchor head, then fit the bearing ring and lock-off plate. 3. Push the jack up to the anchorage. For jacks without auto release innards, insert the jack wedges into the pulling plate inside the rear of the jack. 2. Thread the jack onto the strands. suitable lifting device should support the weight of the jack. 4. ll stressing operations are controlled from the pump unit to ensure the operator s safety. Carry out stressing, lock-off and retraction. The lock-off pushes the lock-off plate forward, which seats the anchorage wedges firmly into the anchor head. Jack Selection Table nchorage XM- XM-20 XM-30 XM-35 XM- XM-45 XM- XM-55 XM-0 XM- XM-75 XM- XM-90 XM-95 No. Strands 13mm 4 9 18 19 22 25 27 31 37 4 51 No. Strands 15mm 3 4 7 9 13 15 17 19 22 25 27 31 XM-0 55 37 * Minor modification is required contact CCL for further details ** If anchors are placed in individual pockets, dimensions on P24 work with smallest jack option. 35 10MG 3000MG 00MG 000MG 70MG ** ** ** ** ** ** 27

monostrand jacks... Hollowram Jack Series CCL Hollowram Jacks have a compact, lightweight design and are intended for site use with the CCL SRL and SRX series pumps. They are designed to stress the XF and XU anchorages. The noses of the jacks can be changed easily to suit different applications. The standard HR jack is equipped with mechanical lock-off and the HRL jack is equipped with hydraulic lock-off. The type of jack for each application can be taken from the table below. HR Jack C E HRL Jack C E Hollowram Jack Clearance Jack nchorage Ø Strand C E Stroke Total Clearance* 2 HR XF 13 220 415 0 190 925 2 HR XF 15 220 415 0 190 925 2 HR XU 13 175 3 0 190 835 2 HR XU 15 175 3 0 190 835 2 HRL XF 13 275 775 0 190 13 2 HRL XF 15 335 830 0 190 1455 2 HRL XU 13 2 745 0 190 85 2 HRL XU 15 255 7 0 190 15 ll dimensions in mm. *Total clearance shown is based on jack stroke. Lower clearance is needed if elongation is less than the stroke. 28

stressing coupler anchorages... sequence... 1. fter removal of formwork the anchor head and wedges are threaded onto the strands. 2. Using the correct jack and nose combination with calibrated pump / gauge, the jack is threaded onto the strands and pushed up to the anchor head. 3. ll stressing operations are controlled from the pump unit to ensure the operator s safety. The jack is extended and when the load is reached, the jack lock-off system is applied which firmly seats the wedge into the anchor head. 4. The jack is then retracted and the wedge released so the jack can be removed when the full load is reached, or the operation can be repeated until the required load is achieved. XF SEQUENCE If missing out a strand it should be considered that the following should be omitted: XF--3-13 Position 1 XF-20-5-13 Position 3 XF-30--13 Position 3 XF--2-15 Position 2 XF-20-4-15 Position 2 XF-30-5-15 Position 3 1 1 2 2 1 2 3 4 3 5 5 3 4 XF--3-13 XF-20-5-13 XF-30--13 1 4 1 2 2 1 3 2 4 3 5 XF--2-15 XF-20-4-15 XF-30-5-15

stressomatic coupler anchorages... jacks... The primary items of equipment in the XF and XU operations are the CCL Stressing Jacks. The noses of the jacks can be changed to suit various applications and feature automatic gripping and lockoff on the strand. ll jacks need to be calibrated to a pump before use. The jacks can be used for partial stressing and successsive loading if necessary. The type of jack for each application can be taken from the table below. C E Stressomatic Jack Clearance Jack Ø Strand C E Stroke Total Clearance* Short Stroke 13 225 755 200 0 205 1385 Long Stroke 13 225 85 200 0 535 2045 300 Short Stroke 13/15 3 200 205 115 300 Long Stroke 13/15 3 200 4 2030 ll dimensions in mm. *Total clearance shown is based on jack stroke. Lower clearance is needed if elongation is less than the stroke. Stressomatic Jack Part Numbers Jack Weight Kg XU13 XU15 XF13 XF15 Jack Short Stroke (Inc Nose ssembly Plunger) 420-421 - Jack Long Stroke (Inc Nose ssembly Plunger) 41 430-431 - 300 Jack Short Stroke (Inc Nose ssembly Plunger) - 7420-7421 300 Jack Long Stroke (Inc Nose ssembly Plunger) 58-7430 - 7431 Specific noses are required to stress the XU or XF systems. Stressomatic Jack Nose Part Numbers Jack XU13 XU15 XF13 XF15 Jack Nose ssembly Plunger 190-9 - 300 Jack Nose ssembly Plunger - 7190-72 30

CCL pump units... CCL Pumps deliver multiple pressures to speed up the stressing operation while maintaining control for precise stressing when needed. Pumps can be supplied in various voltages with analogue or digital readouts. SR00 Pump SR00 pumps are heavy duty pumps to power MG Multistressing Jacks. They are specifically designed for site work and the high demands required to stress multiple strands simultaneously. Pump Multi Pump High Speed 3/415V 3Ph Hz Weight Kg 25 1105 SR3000 Pump SR3000 pumps are of a robust design and come complete with a protective frame as standard. The high build quality and specifications of the parts used ensure reliability and a low maintenance life for the unit. Pump SR3000 PT 1V 3Ph Hz Weight Kg 5 10 SR3000 PT 220/2V 3Ph Hz 5 11 SR3000 PT 3/415V 3Ph Hz 5 SRX Pump SRX pumps are designed as a compact lightweight alternative to the SR3000 unit and are capable of delivering excellent performance on small strand diameters. Supplied in various voltages this pump is ideal for site work. Pump SRX Pump 1V 3Ph Hz with nalogue Gauge Weight Kg 2 1700 SRX Pump 220/2V 3Ph Hz with nalogue Gauge 2 1703 SRX Pump 415V 3Ph Hz with nalogue Gauge 2 1702 SRL Pump Series SRL pumps have an ultra compact and lightweight design and are intended primarily for site use with the CCL Monostrand Jacks. The standard SRL pump can be used with the CCL HR Jack. The SRLL pump equipped with hydraulic lock-off function is compatible with CCL Stressomatic and CCL HRL Jacks. 31

installing and grouting... CCL Strand Installation For internal prestressing the ducts are placed prior to concreting. The strand is delivered to site in coils and placed in special dispensers to prevent it from uncoiling. efore or after concreting, strands are pushed or winched into the duct from one end and cut to length. The installation method depends on the length of the tendon and access conditions. Threading ullets Special threading bullets are fixed to the leading end of the strand (in the case of pushing) to ease the passage of the strands through the duct. Using CCL Strand Pushers the pushing can be controlled from both ends of the tendon (using remote controls) ensuring a safe and efficient operation. CCL Grouting The durability of any post-tensioning is affected by the quality of the grouting operation. The grout, as well as providing a bond between the concrete and the tendon, provides long-term corrosion protection for the steel strand. If the grouting is not carefully controlled and undertaken by experienced professionals, it will compromise the structure and affect its lifespan. Grouting is undertaken through the anchor using special threaded fittings and valves to ensure a clean and effective grouting operation. Intermediate vents are created along the tendon using grout saddles. 32

friction losses... In post-tensioned concrete, the effect of friction between strands and sheathing during stressing is a major factor in the loss of prestress. There are three main causes of friction loss in the post-tensioned tendon: Friction due to the deviation of the tendon through the anchorage Friction between the tendon and the duct due to unintentional lack of alignment (or wobble) of the duct Friction due to the curvature of the duct Friction loss in CCL XM nchorages determined from testing is 2% to 3%. Wedge Set fter the transfer of load from the jack to the anchorage, the strand and wedges draw a little further into the anchor head. This further movement is known as wedge set or draw-in. The wedge set leads to a loss of tension in the strand which must be taken into account in the loss and elongation calculations. The value for wedge set to be used in the calculations for all active anchorages stressed with jacks with hydraulic lock-off is: Wedge set = mm ± 2mm uct Friction Loss Friction Loss in the duct for post-tensioned tendons can be estimated from: P (x) = P max (1 - e -μ(θ+kx) ) Where: P (x) - Loss of force due to friction P max θ μ - Force at the active end during tensioning (after losses within the anchorage) - Sum of the angular displacements over a distance x (radians - irrespective of direction or sign) - Coefficient of friction between strand and duct (1/radian) k x - Unintentional angular displacement (radians per unit metre) - istance along the tendon from the point where the prestressing force is equal to P max NOTE: Some design software and country codes use a term K or k = wobble or unintentional friction (per unit metre). This is taken as K = μk, and the formulae is rearranged to suit. The values for coefficient of friction and unintentional angular displacement k should be in line with EN 1992 Eurocode 2: esign of Concrete Structures, as shown in the table below. pplication uct Type μ Non-Lubricated k Lubricated Minimum Maximum Corrugated Metal 0.19 0.17 0.005 0.01 Internal Prestressing HPE 0. 0. 0.005 0.01 Steel Smooth Pipe 0.24 0.1 0.005 0.01 External Prestressing HPE 0. 0. N/ N/ Steel Smooth Pipe 0.24 0.1 N/ N/ When the tendon to be controlled has two active / LE anchorages, i.e. with the tendon being able to be stressed with the jack at both ends, the measurement on site of the friction loss of the tendon is possible by comparing the load applied by one jack to the load measured on the other jack. 33

focus on outstanding technical solutions, durable products and practical post completion advice ensures CCL continues to deliver projects on an international basis, helping clients around the world create unique structures. Quality Standards CCL is an ISO registered company which operates a quality management system compliant with ISO9001. The Company s high performance anchorage systems are designed, manufactured and tested to exceed the latest European Standard ETG 013 and SHTO. CCL holds CRES approval for its post-tensioning systems. ll products are CE approved and certified. 34

CCL was established in 1935 to provide cutting-edge engineering solutions. Since then, the Company has grown and diversified to become one of the world s leading global engineering companies specialising in prestressed concrete technology. Every day, CCL products and services are used in prestigious building and civil engineering structures across the world. CCL s advanced solutions help engineers, planners and construction companies create visionary structures. The specifications, information and performance of the products manufactured by CCL and featured in this publication are presented in good faith and believed to be correct. etails may be changed without notice. CCL makes no representations or warranties as to the completeness or accuracy of the information. Information is supplied upon the condition that the persons receiving same will make their own determination as to its suitability for their purposes prior to use. In no event will CCL be responsible for damages of any nature whatsoever resulting from the use of, or reliance upon, information contained in this document. CCL does not warrant the accuracy or timeliness of the materials in this publication and accepts no liability for any errors or omissions therein. www.cclint.com CCL 09/2014