Pre Stressing

PRESTRESSING TECHNOLOGY
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Post-STRESSING TECHNOLOGY
Introduction Post-Tensioning Design data Multi-Strand Post-TensioninG Slab Post-Tensioning Multi-Wire Post-Tensioning Bar Post-Tensioning
Emirates Tower - Dubai
PAGE 03 PAGE 04 PAGE 05 PAGE 17 PAGE 28 PAGE 31 PAGE 35 PAGE 38 PAGE 40
Ground Anchor SYSTEMS External PRESTRESSING Cable Stay SYstemS
INCREMENTALLAUNCHINGSYSTEMS PAGE 44 HEAVYLIFTINGSYSTEMS LOADHANDLING SYSTEMS PAGE 45 PAGE46
www.structuralsystems.com.au Data contained herein is subject to change without notice. Use of information and details presented in this document should be verified by a qualified engineer for suitability to specific applications.
introduction
Structural Systems is a specialist professional Engineering and Contracting Company, which provides innovative skills and services to the Construction and Mining Industries both nationally and internationally. Operations commenced as BBR Australia Pty Ltd in 1961 and became the public company, Structural Systems Limited in 1987. Our innovative design, advanced construction techniques and effective project management skills make Structural Systems the leader in the design and installation of prestressing systems. The wide range of services and systems offered in this brochure are readily available through our network of offices and a Structural Systems representative is available to talk directly to you regarding your project.
Wandoo Concrete Gravity Structure - Western Australia
Eleanor Schonell Bridge - Queensland
POST-TENSIONING DESIGN DATA

STRAND PROPERTIES
STANDARD NOMINAL DIAMETER mm 12.7 super 15.2 super 15.2 EHT 12.9 super 15.7 super 15.2 regular 15.7 regular 15.2 super 15.7 super STEEL AREA mm
2
MASS kg/lm 0.786 1.125 1.125 0.785 1.180 1.093 1.172 1.093 1.172
STRAND MBL / Fm kN 184 250 261 186 265 248 266 260 279
(7)
MIN. PROOF LOAD kN 156.4 212.5 221.9 158.1 225.3

(4) (4) (4)
STRAND RELAXATION (%) 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5
(6)
MODULUS OF ELASTICITY MPa 180 to 205x10 180 to 205x10 180 to 205x10

3 3 3
AS 4672
(1)
100.1 143.3 143.3 100 150 140 150 140 150
BS 5896
(5) (5)
(2)
180 to 205x10 180 to 205x10 180 180 180 180 to to to to
3 3
prEN 10138-3
(3)
213.0 229.0 224.0 240.0
(5) (5) (5) (5)
205x10 205x10 205x10 205x10
3 3 3 3
Notes:
All strands are 7 wire low relaxation steel.
WIRE PROPERTIES
STANDARD NOMINAL DIAMETER mm 7 LR 7 LR STEEL AREA mm
2
MASS kg/lm 0.302 0.302
WIRE MBL kN 64.3 64.3
(7)
MIN. PROOF LOAD kN 54.7 53.4

(4)
STRAND RELAXATION (%) 2.0 2.5
(6)
MODULUS OF ELASTICITY MPa 195 to 205x10

3
AS 4672
Notes: (1) (2) (3) (4) (5) (6) (7)
(1)
38.5 38.5
BS 5896
(2)
(5)
195 to 205x10
Australian / New Zealand Standard AS 4672 Steel Prestressing Materials. British Standard BS 5896 High Tensile steel wire and strand for the Prestressing of Concrete. European Standard prEN 10138-3 Prestressing steels - Part 3: Strand. At 0.2% Offset. Refer AS 4672. At 0.1% Offset. Refer BS 5896 or prEN 10138-3 as applicable. Relaxation after 1000 hrs at 0.7 x Breaking Load. MBL = Minimum Breaking Load (to AS 4672 and BS 5896). Fm = Characteristic Force (to prEN 10138-3).
MAXIMUM JACKING FORCES - RECOMMENDED VALUES

SSL POST TENSIONING SYSTEM AS 3600 BBR CONA MULTI SYSTEM BBR VT CONA CMI SYSTEM SLAB SYSTEM WIRE SYSTEM BAR SYSTEM
Notes:
STANDARD BS 8110 80% 80% 80% 80% 75% MBL MBL MBL MBL MBL
80% 80% 85% 80% 75%
MBL MBL MBL MBL MBL
In some cases higher or lower jacking forces are permitted by local standards. MBL = Minimum Breaking Load of tendon.
PRESTRESSING LOSSES - TYPICAL DATA

SYSTEM ANCHORAGE & JACKING LOSS (%) DRAW-IN ALLOWANCE (mm) DUCT FRICTION Round Steel Duct Flat Steel Duct Polyethylene Duct Greased & Sheathed Round Steel Duct 50mm Round Steel Duct > 50mm Flat Steel Duct Greased & Sheathed BBR CONA MULTI 2 to 4 6 0.15 to 0.20 0.10 to 0.15 BBR VT CONA CMI 0.9 to 1.2 6 0.20 to 0.22 0.10 to 0.15 SLAB 2 to 5 6 0.15 to 0.20 0.20 0.10 to 0.15 WIRE 0 to 1 2 to 3 0.12 to 0.16 0.10 to 0.15 BAR 0 to 1 1 to 2 0.15 to 0.20 0.10 to 0.15 0.15 0.008 to 0.016 0.008
TENDON WOBBLE (k) rad/m
0.016 to 0.024 0.008 to 0.016
0.006 0.006 0.016 to 0.024
0.016 0.008 to 0.012
Notes:
To reduce excess friction, it may be possible to flush the tendon with water or water soluble oil. If the duct or strand has a film or rust or the ducts are full of water, the friction values can increase significantly.
MULTI-STRAND POST-TENSIONING
multi-strand post-tensioning
Structural Systems have two distinct systems available for multi-strand applications. These systems are BBR Cona Multi, and BBR VT Cona CMI.
BBR CONA MULTI

The BBR Cona Multi has been offered for the last 40 years and is available in standardised tendon sizes from: 7 strands up to 61 strands for 12.7mm and 12.9mm strand, or 4 strands up to 55 strands for 15.2mm and 15.7mm strand.
European Approval ETA - Testng of Anchor Head
BBR CONA MULTI - M1

The BBR Cona Multi can be used with galvanised steel and polyethylene ducting. The system is a bonded system with the ducting being pressure filled with a cementitious grout. Standard applications use the M1 range, with the M3 range being used for cryogenic applications, and other specialist applications. Please consult SSL for details on which system best suits your applications.
These tests included static tests, fatigue tests, load transfer and cryogenic tests. European Technical Approval provides clear independent review, full and complete system testing to the highest European standard, quality assurance, and independent auditing of all systems components. Every product is tested to the same standards and afterwards an independent auditor ensures that what is delivered and installed on site fully complies with that which was tested. On completion of the tests, the approval body evaluated the test results, drawings, specifications and the complete system. The package was then circulated to all member states of the EU for ratification. Copies of the BBR VT European Approval Documents are available for download from www.bbrnetwork.com and www.structuralsystems.com.au. The BBR VT Cona CMI has significant advantages over the BBR Cona Multi as well as significant competitive advantage over other ETAG approved systems. These advantages include: Less space is required in the anchor zone which results in less concrete, slimmer structures and less eccentricity in the anchors. Significantly lower concrete strength prior to stressing resulting in shorter construction cycles. Less reinforcement in the anchorage zone resulting in time and cost savings.
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BBR VT CONA CMI

The BBR VT Cona CMI is a revolutionary, state of the art, bonded, post-tensioning system incorporating worlds best practice, and is available in standard tendon sizes from: 4 strands up to 61 strands for 15.2mm and 15.7mm strand.
BBR VT CONA CMI

The system has been granted European Technical Approval in accordance with the testing procedures contained within ETAG013 and is CE marked.
BBR VT CONA CMI

TECHNICAL DATA OF ANCHORAGES
BBR VT Cona CMI (Max No of Strands) Strand Cross Sectional Area Charact. Tensile Strength Charact. Maximum Force BBR VT Cona CMI (Max No of Strands) Helix and Additional Reinforcement Min. Concrete Strength (cyl.) Helix Outer Diameter Bar Diameter Length, approx. Pitch Number of Pitches Distance Additional Reinforcement Number of STIRRUPS Bar Diameter Spacing Distance from Anchor Plate Outer Dimensions Centre and Edge Spacing Min. Centre Spacing Min. Edge Distance (plus c) Dimensions of Anchorages Anchor Diameter Anchor Length Coupler FK Diameter Coupler FK Length DA LA DFK LFK mm mm mm mm 130 327 185 945 170 454 205 1152 225 627 240 1435 ac,bc ae,be mm mm 235 110 215 100 195 90 190 85 310 145 285 135 260 120 250 115 240 110 405 195 370 175 340 160 325 155 310 145 F BxB mm mm mm mm 3 12 60 30 220 3 12 55 30 200 4 10 40 30 180 3 10 50 30 170 5 14 55 33 290 4 14 60 33 270 3 14 65 33 240 3 14 65 33 230 4 14 60 33 220 7 12 60 35 390 6 14 55 35 350 5 16 70 35 320 5 16 65 35 310 6 14 50 35 290 E mm mm mm mm mm 180 14 182 50 4 15 150 12 181 50 4 15 150 12 216 60 4 15 150 12 216 60 4 15 230 14 232 50 5 18 200 14 232 50 5 18 200 14 277 60 5 18 180 14 277 60 5 18 180 14 277 60 5 18 330 14 332 50 7 20 280 14 332 50 7 20 280 14 332 50 7 20 260 14 382 50 8 20 260 14 282 50 6 20 fcm.0 MPa 19 23 28 31 35 19 23 28 31 35 19 23 28 31 35 Rm Fm mm2 mm2 MPa kN 140 560 1770 992 4 150 600 1860 1770 1860 1040 1064 1116 4 140 980 1770 1736 7 150 1050 1860 1770 1860 1820 1862 1953 7 140 1680 1770 2976 12 150 1800 1860 1770 1860 3120 3192 3348 12
STRESSING AND FIXED ANCHORAGE
FIXED COUPLER FK
CENTRE AND EDGE DISTANCES
STRESSING ANCHORAGE RECESS DETAILS

Strand Size 15.2mm / 15.7mm DIMENSIONS (mm) Anchorage Unit Maximum No. Strands Recess - Inner Recess - Outer Recess Depth 406 4 200 x 200 250 x 250 130 706 7 240 x 240 290 x 290 135 BBR VT Cona CMI 1206 12 295 x 295 350 x 350 140 1906 19 350 x 350 400 x 400 160 2206 22 380 x 380 420 x 430 170 2706 27 430 x 430 480 x 480 180 3106 31 430 x 430 480 x 480 185
MULTI STRAND POST-TENSIONING
BBR VT CONA CMI

TECHNICAL DATA OF ANCHORAGES
BBR VT Cona CMI (Max No. of Strands) Strand Cross Sectional Area Charact. Tensile Strength Charact. Maximum Force Rm Fm mm2 mm2 MPa kN 140 2660 1770 4712 19 150 2850 1860 1770 1860 4940 5054 5301 19 140 3080 1770 5456 22 150 3300 1860 1770 1860 5720 5852 6138 22 140 3780 1770 6696 27 150 4050 1860 1770 1860 7020 7182 7533 27 140 4340 1770 7688 31 150 4650 1860 1770 1860 8060 8246 8649 31
BBR VT Cona CMI (Max No. of Strands) Helix and Additional Reinforcement Min. Concrete Strength (cyl.) Helix Outer Diameter Bar Diameter Length, approx. Pitch Number of Pitches Distance Additional Reinforcement Number of STIRRUPS Bar Diameter Spacing Distance from Anchor Plate Outer Dimensions Centre and Edge Spacing Min. Centre Spacing Min. Edge Distance (plus c) Dimensions of Anchorages Anchor Diameter Anchor Length Coupler FK Diameter Coupler FK Length DA LA DFK LFK mm mm mm mm ac,bc
ae,be
fcm.0
MPa
19
23
28
31
35
19
23
28
31
35
19
23
28
31
35
19
23
28
31
35
mm mm mm mm
420 14 457 50 9.5
360 14 457 50 9.5 27
360 14 432 50 9 27
330 14 432 50 9 27
330 14 382 50 8 27
475 14 482 50 10 31
420 14 482 50 10 31
360 14 482 50 10 31
360 14 482 50 10 31
330 14 382 50 8 31
520 14 532 50 11 35
475 14 532 50 11 35
430 14 532 50 11 35
420 14 427 40 11 35
360 14 432 50 9 35
560 14 532 50 11 35
520 14 532 50 11 35
475 14 582 50 12 35
430 14 467 40 12 35
430 14 432 50 9 35
mm
27
7 mm mm F BxB mm mm 16 65 42 490
7 16 65 42 450
7 16 65 42 410
7 16 65 42 390
7 16 65 42 370
8 16 65 46 530
7 20 75 46 480
7 20 70 46 440
7 20 65 46 420
8 16 55 46 400
8 20 80 50 590
7 20 80 50 540
7 20 75 50 490
7 20 70 50 470
8 20 60 50 440
8 20 85 50 630
8 20 75 50 580
8 20 70 50 530
8 20 65 50 500
8 20 60 50 480
mm mm
510 245
465 225
425 205
410 195
390 185
550 265
500 240
460 220
440 210
420 200
610 295
555 270
505 245
485 235
460 220
650 315
595 290
545 265
520 250
495 240
280 744 290 1600
310 946 310 1821
360 1090 390 2466
360 975 390 2242
Note: Intermediate and larger sizes available on request.
STRESSING AND FIXED ANCHORAGE
FIXED COUPLER FK
CENTRE AND EDGE DISTANCES
Structural Systems has gained certification from BBR as a PT Specialist Company authorised to install the BBR VT Cona CMI systems and all other BBR ETAG approved post tensioning systems.
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BBR VT CONA CMI

SYSTEM COMPONENT DETAILS BEARING TRUMPLATES
No. Strands Bearing TRUMPLATE Diameter P (mm) Height HP (mm) 4 130 120 7 170 128 12 225 150 19 280 195 22 310 206 27 360 250 31 360 250
BEARING TRUMPLATE
ANCHOR AND COUPLER HEADS

No. Strands Anchor Head Coupler Head K Diameter A (mm) Height HA1 (mm) Diameter K (mm) Height HK (mm) 4 100 50 185 85 7 130 55 205 85 12 160 65 240 90 19 200 85 290 95 22 225 95 310 105 27 255 105 390 125 31 255 110 390 130
ANCHOR HEAD
COUPLER HEAD TYPE K
PLASTIC TRUMPETS
No. Strands Trumpet A Trumpet K Diameter TA (mm) Length LTA (mm) Diameter TK (mm) Length LTK (mm) 4 72 230 185 539 7 88 328 203 640 12 127 509 240 730 19 153 580 275 775 22 170 715 305 840 27 191 871 375 1265 31 191 757 375 1150
TRUMPET TYPE A
TRUMPET TYPE K
MULTI STRAND POST-TENSIONING
BBR VT CONA CMI

TENDON PROPERTIES
TENDON UNIT MAXIMUM MAXIMUM MINIMUM STRANDS STEEL STEEL NO. DUCT ID/ DUCT ID/ OD OD mm 406 706 1206 1906 2206 2706 3106
Notes:
mm 45 / 50 55 / 60 70 / 75 90 / 95 95 / 100 105 / 110 110 / 115
MINIMUM RADII OF CURVATURE / MINIMUM STRAIGHT PORTION m 2.0 / 0.8 4.0 / 0.9 5.2 / 1.0 6.5 / 1.1 7.0 / 1.15 7.7 / 1.3 8.4 / 1.3
TENDON MIN BREAKING LOAD to prEN 10138-3 kN 15.2 regular 992 1736 2976 4712 5456 6696 7688 15.7 regular 1064 1862 3192 5054 5852 7182 8246 15.2 super 1040 1820 3120 4940 5720 7020 8060 15.7 super 1116 1953 3348 5301 6138 7533 8649
4 7 12 19 22 27 31
45 60 80 100 105 120 130
/ / / / / / /
50 65 85 105 110 125 135
Table indicates maximum number of strands that can be accomodated by the tendon stressing unit. Larger ID ducting should be selected for tendons > 80m, or if strands are installed after concreting, or where tight or extended curvatures occur. Plastic sheaths conforming to ETAG013 should be used. Alternatively, corrugated polyethylene ducting may be used if permitted in the local region. Refer page 4 for additional design data and details. Maximum jacking force is usually 0.8 x MBL. For radii of curvature and straight portion diagram refer to BBR CONA Multi System.
STRESSING ANCHORAGE
FIXED ANCHORAGE
FIXED COUPLER FK
BBR CONA MULTI

Tendon Properties
Tendon Unit Maximum Strands No. Metal Duct Tendon MBL to AS4672 ID/OD mm kN Using 12.7mm strand 1288 2208 3496 5704 7728 11224 15.2mm/15.2 EHT strand 1000 / 1044 1750 / 1827 3000 / 3132 4750 / 4959 5500 / 5742 7750 / 8091 10500 / 10962 13750 / 14355 Tendon MBL to BS5896 or prEN 10138-3 kN Using 12.9mm strand 1302 2232 3534 5766 7812 11346 15.7mm BS / 15.7 EN strand 1060 / 1116 1855 / 1953 3180 / 3348 5035 / 5301 5830 / 6138 8215 / 8649 11130 / 11718 14575 / 15345
705 7 50 / 57 1205 12 70 / 77 1905 19 85 / 92 3105 31 105 / 112 4205 42 120 / 127 6105 61 150 / 157 406 4 50 / 57 706 7 65 / 72 1206 12 80 / 87 1906 19 100 / 107 2206 22 110 / 117 3106 31 120 / 127 4206 42 135 / 142 5506 55 150 / 157
Notes:
Table indicates maximum number of strands that can be accomodated by the tendon stressing anchorage unit. Duct sizes are quoted for typical situations. It may be possible to slightly reduce duct size in some situations. Consideration should be given to the use of larger ducts where tight or extended curvatures occur. Refer to SSL office for advice. Alternate duct sizes are generally available in 5mm ID increments Partial tendons are also permissible. (i.e. a 15No. 12.7mm strand tendon would be specified as 1905-15, supplied with a 1905 stressing anchorage and would have a MBL of 15 x 184 = 2760 kN, etc.) Maximum Multi-strand Jacking force is usually 0.8 x MBL. Refer page 5 for additional design data and details on standards. MBL = Minimum Breaking Load
stressing Anchorages (Live Ends)

Structural Systems has been offering the BBR Cona Multi post-tensioning system for over 40 years. This multistrand system is predominantly used in civil structures including bridges, silos, tanks and off-shore structures and is a robust and reliable bonded prestressing system. The BBR Cona Multi system consists of up to 61 No. 12.7mm/12.9mm or 91 No. 15.2mm/15.7mm strands to form tendons which are installed inside round ducting. The individual strands are anchored in a common anchor head with a wedge grip system and the strands are simultaneously stressed. Individual strand stressing is possible in some circumstances. After stressing the ducting is pressure filled with a cementitious grout. The choice between the anchorage types depends on structural requirements, availability and dimensional constraints. For standard applications type M1 anchorages are generally preferred. Type M3 are used for cryogenic applications or where it maybe necessary to use a rectangular anchorage for clearance reasons. (It is recommended that SSL is consulted for non-standard plate sizes).
grout inlet
wedge grips p.e. trumpet anchor head anchorAGE casting
duct
anchorage Type M1
10
MULTI-STRAND post-tensioninG
The type of stressing anchorage used may vary depending on the application, size and number of anchorages required, type of tendon sheathing, project location and availability of components. The tables below provide performance and dimensional data for
two typical anchorages. Several other BBR anchorage configurations are also available and there may be some variations in dimensions to those shown. The designer should check with Structural Systems for full and current technical information on the preferred anchorage type.
STRESSING ANCHORAGE TYPE M1 - ANCHORAGE CASTING WITH P.E. TRUMPET (LIVE END)
STRAND SIZE 12.7mm / 12.9mm 15.2mm / 15.7mm Anchorage Unit Maximum No. Strands Anchorage Unit Maxiumum No. Strands AxA B C Inside Dia. D Outside Dia. E Anchor Nom. Dia. F Nom. Height G 705 7 406 4 165 155 100 77 55 120 55 TYPE M1 ANCHORAGE DETAILS 1205 12 706 7 215 345 85 110 77 150 55 1905 19 1206 12 265 415 100 139 92 190 65 3105 31 1906 19 335 485 116 179 112 240 80 2206 22 350 550 125 193 117 350 80 4205 42 3106 31 395 605 145 223 137 290 100 6105 61 4206 42 460 725 175 265 157 350 120
Dimensions (mm)
Notes: Local zone and general zone anchorage reinforcement is normally required for all unit types and details are usually determined by the Designer to suit the specific application. Unless otherwise specified by the Designer, multi-strand tendons will normally be supplied with Type M1 stressing anchorages. Tendon grouting is achieved via 19mm poly pipe inlets at all anchorages and at intermediate venting points.
Anchorage type m1
Stressing Anchorage Type M3 - Fabricated Plate Anchorage (LIVe END)

Strand size Type M3 Anchorage details 12.7mm / 12.9mm Anchorage Unit 705 1205 1905 3105 Maximum No. Strands 7 12 19 31 15.2mm / 15.7mm Anchorage Unit Maximum No. Strands 406 4 175 220 20 90 55 706 7 220 435 30 115 75 1206 12 270 545 40 140 90 1906 19 345 785 55 195 110 - - 2206 22 375 820 60 210 115 4205 42 3106 31 440 910 70 232 140 6105 61 4206 42 600 1230 100 275 160 5506 55 600 1400 120 325 160
Dimensions A x A (mm) B C Outside Dia. D Outside Dia. E
Notes: Local zone and general zone anchorage reinforcement is normally required for all unit types and details are usually determined by the Designer to suit the specific application. Unless otherwise specified by the Designer, SSL Multi-strand tendons will normally be supplied with Type M1 stressing anchorages. Tendon grouting is achieved via 19mm poly pipe inlets at all anchorage ends and at intermediate venting points.
Anchorage type m3
11
Dead End AnchorageS - Bulb Type & Swage Type
Strand Size Anchorage Unit Bulb Type Anchorage (mm) A B C 600 1000 1000 1100 1100 1200 600 600 1000 1000 1000 1100 1200 1200 swage Type Anchorage (mm) D E F 150 200 250 350 450 700 150 200 250 300 300 350 400 550 150 200 250 300 375 450 150 200 250 300 300 350 350 475 250 350 500 650 850 1000 250 350 500 500 500 650 850 1000 12.7mm and 12.9mm 705 175 150 1205 300 250 1905 375 300 3105 450 425 4205 600 450 6105 700 550 15.2mm and 15.7mm 406 150 150 706 200 170 1206 350 300 1906 450 350 2206 500 350 3106 550 475 4206 700 550 5506 800 600
Notes: Swage type dead end anchorages recommended for tendon units 3105/1906 and larger
Local zone and general zone anchorage reinforcement is normally required for all unit types and details are usually determined by the Designer to suit the specific application
bulb type dead end
swage type dead end

Note: For swage type, strand length F shall be debonded (using grease or similar).
Transfer beams in buildings
12
MULTI-STRAND post-tensioning
Coupling Anchorage - Type K

Strand size 12.7mm / 12.9mm 15.2mm / 15.7mm Anchorage Unit Maximum No. Strands Anchorage Unit Maximum No. Strands Type K Coupling Anchorage details 705 7 406 4 168 550 1205 12 706 7 208 650 1905 19 1206 12 258 700 3105 31 1906 19 328 900 - - 2206 22 328 950 - - 3106 31 405 1100 4206 42 460 1200
Diameter (mm) N Trumpet length (mm) P (approx)

Notes:
Unless otherwise specified by the Designer, multi-strand coupling anchorages will normally be supplied as Type K Refer to SSL for details and availability of larger K type coupler units
Coupling Anchorage - Type C

Strand size 12.7mm / 12.9mm Anchorage Unit Maximum No. Strands Dimensions (mm) Q R S 15.2mm / 15.7mm Anchorage Unit Maximum No. Strands Dimensions (mm) Q R S
Notes:
Type C Coupling Anchorage details 705 7 108 170 550 406 4 125 160 520 1205 12 108 200 650 706 7 125 200 630 1905 19 108 230 740 1206 12 125 230 730 3105 31 108 340 1140 1906 19 125 270 860 - - - - - 2206 22 125 300 930 4205 42 148 385 1320 3106 31 145 350 1090 6105 61 refer to SSL 4206 42 refer to SSL 5506 55 refer to SSL
Unless otherwise specified by the Designer, SSL Multi-strand Coupling Anchorages will normally be supplied as Type K Refer to SSL for details and availability of larger C type coupler units
13
Stressing Anchorage Recess details
Strand size 12.7mm / 12.9 mm Tendon Unit 15.2mm / 15.7mm Tendon Unit Dimensions (mm) F x F G H x H 705 406 230 140 310 1205 706 270 140 370 Recess details 1905 1206 340 150 400 3105 1906 420 165 510 - 2206 420 165 510 4205 3106 460 185 560 6105 4206 560 200 660 5506 650 225 750
Notes: Depth G achieves 50mm cover to trimmed strand ends. Alternative or smaller recesses may be possible depending on actual conditions and jack used. Refer to your local Structural Systems office.
Space Requirements for Stressing Jacks

Strand size 12.7mm / 12.9mm Tendon Unit 15.2mm / 15.7mm Tendon Unit 705 406 Space Requirements 1205 706 1905 1206 3105 1906 - 2206 4205 3106 6105 4206 5506
Jack unit CC 110 CC 200 CC 300 CC 600 CC 600 CC 630 CC 1000 CC 1200 Dimensions (mm) A 710 750 810 1200 1200 1000 1130 1300 B 1400 1500 1600 2400 2400 2000 2300 2600 C 250 300 330 500 500 600 600 600 E 200 230 260 400 400 500 420 450 F 595 620 675 1100 1100 950 950 1050
Notes: Details based on jacks having 200mm working stroke. Alternative jacks may be available and/or more suitable. Contact SSL for further details Check jack size and availability with your local SSL office
14
MULTI-STRAND post-tensioning
Tendon Curvature
A straight portion L adjacent to the anchorage must be observed to limit the screw pull of the strand bundle against the anchorage. Reduction may be allowed in certain specific instances.
Tendon Curvature Limitations

12.7mm / 12.9mm 15.2mm / 15.7mm 705 406 4 0.8 1205 706 4.5 0.9 1905 1206 5 1.0 3105 1906 6 1.1 - 2206 6.5 1.15 4205 3106 8 1.3 6105 4206 8 1.3 5506 10 1.5
Minimum Radius, R (m) Minimum Straight Portion, L (m)
Sheathing and Corrosion Protection

For conventional applications, corrugated galvanised steel ducts are used with a wall thickness of 0.3mm. For applications requiring enhanced corrosion protection and improved fatigue resistance of the tendons, use of corrugated plastic duct is recommended. This fully encapsulated, watertight system offers superb corrosion protection, and the plastic duct eliminates fretting fatigue between the strand and duct. It also provides reduced duct friction. All ducts are manufactured in a variety of standard lengths and are coupled on site. Steel ducts are available in diameters ranging from 40mm to 160mm in approximately 5mm increments.
Tendon Sheathing and Corrosion Protection Polyethylene Duct Details

TENDON TYPE
12.7mm/12.9mm 15.2mm/15.7mm O.D.
DUCT DIMENSIONS (mm)

I.D. WALL THICKNESS
Galv. Steel Duct

(refer page 6)
705 1205 1905 3105 4205 6105
406 706 1206 1906 3106 4206
61 75 94 110 125 160
48 65 82 98 110 138
2.0 2.0 2.0 2.0 2.0 2.0

Polyethylene Duct
(refer left)
Notes: Check with SSL office for availability and lead time for standard and/or alternative polyethylene duct sizes
Eccentricity of Tendons
TENDON eCcentricity TYPE e mm 705/406 10 11 14 15 21 25 28 1205/706 1905/1206 3105/1906 2206 4205/3106 6105/4206
Notes: e is indicative only and depends on actual duct ID and number of strands in tendon
15
Minimum Distance for Bearing Plates to concrete Edges and between Adjacent Anchorages
The minimum required distance of the bearing plates to concrete edges and to adjacent anchorage bearing plates depends in general on: the post-tensioning force to be transmitted the concrete strength the bearing plate dimensions the reinforcing steel behind the bearing plate structural requirements ao bo Dsp fc = min. distance between axis of two anchorages = min. distance from concrete edge to anchorage axis = suggested outside diameter of reinforcing steel spirals = nominal concrete cylinder strength
Prestressing forces can usually be applied at 80% of nominal concrete cylinder strength.
MINIMUM ANCHORAGE SPACING AND EDGE DISTANCES

fc MPa 32 DETAILS mm ao bo Dsp ao bo Dsp ao bo Dsp 12.7mm & 12.9mm STRAND UNITS 705 220 130 200 205 125 190 195 120 180 1205 290 155 250 270 150 240 255 145 230 1905 365 190 320 340 185 310 320 180 300 3105 465 235 410 435 225 390 410 220 380 4205 545 275 480 505 260 460 475 250 440 15.2mm & 15.7mm STRAND TENDON UNITS 406 205 120 180 200 120 180 200 120 180 706 270 145 230 255 145 230 250 145 230 1206 355 180 300 330 175 290 310 175 290 1906 450 225 390 420 215 370 395 210 360 2206 480 240 425 450 230 400 420 225 390 3106 570 285 520 535 275 490 500 265 470 4205 665 335 590 620 310 560 585 300 540
40
50
Notes:
The above details are provided as a guide only and designers should normally satisfy themselves by calculation that the adopted details are suitable for the actual application.
Tung Chung Bridge - Hong Kong
Mt Henry Bridge - Western Australia
16
slab POST-TENSIONING
slab post-tensioning
Designers, builders, owners and end users of buildings require more efficiencies today than ever before. The Structural Systems Slab Post-Tensioning System offers all the stakeholders in a building project many benefits including: Reduced structural depths Greater clear spans Design flexibility Formwork versatility Reduced construction costs Enhanced construction speed Improved durability Minimum maintenance costs then at the other end by means of a steel anchorage casting and anchor block(s) with gripping wedges. After the concrete has reached a suitable transfer strength, the individual strands have a specified load applied by calibrated jacks. The duct is filled with a water/cement grout mixture to ensure that the system is bonded and corrosion protection is maintained in service. Applications for the Structural Systems Slab PostTensioning System include: Low to high rise residential and commercial buildings Industrial floor slabs on grade Transfer floor structures Car parks Water tank bases and walls Transverse stressing of bridge decks
The system is comprised of high-strength steel strands placed inside flat ducting, anchored at one end by deforming the strand and casting it into the concrete,
Al Nuaimiah Towers - Dubai
West India Quay - London
17
live end anchorages
grout tube duct grout tube
anchorage block
strand
duct
wedge grips anchorage casting wedge

strands barrel
anchorage casting
Notes: Similar non-reusable recessformers are used at angled edges S tandard flat duct is produced from 0.4mm galvanised steel sheet
Stressing Anchorage (Live Ends)

STRAND SIZE TENDON UNIT No. STRANDS ANCHORAGE CASTING A mm
155 150 215 270 155 215 270
RECESS FORMER D mm
100 100 100 100 100 100 100
B mm
135 150 220 265 135 220 265
C mm
67 75 79 79 67 79 79
E1 mm
150 180 265 265 150 265 265
E2 mm
150 180 315 315 150 315 315
F1 mm
100 100 80 80 100 80 80
F2 mm
100 100 100 100 100 100 100
FLAT DUCT SIZE mm

43 43 70 90 x x x x 19 19 19 19
12.7 mm and 12.9 mm 15.2 mm and 15.7 mm

Notes:
205 305 505 605 206 406 506
2 3 4 or 5 6 2 3 or 4 5
43 x 19 70 x 19 90 x 19
Tendon units 205, 605, and 206 are supplied with individual barrel anchorages in lieu of anchorage blocks. Grout tubes are 13mm ID or 19mm ID polyethylene pipe supplied to each end of tendon. Additional intermediate vents can also be supplied (designer to specify requirements). All sizes are nominal. Some dimensions have been rounded up for normal space, detailing and tolerance requirements.
Dead-End Anchorages
bulbed strand ends grout tube duct dead end plate swage plate
duct grout tube grout tube
duct
spacer plate (not always required)
swaged strand ends
bulb-type
Strand size tendon UNIT 12.7mm and 12.9mm 15.2mm and 15.7mm 105 205 305 405 505 605 106 206 306 406 506
swage-type
Bulb-Type Dead-End Anchorage Swage-type dead-end anchorage DIMENSIONS (mm) dimensions (mm) A B C d E F 75 135 230 270 350 400 75 135 230 270 350 50 50 50 50 50 50 50 50 50 50 50 600 600 600 600 600 750 750 750 750 750 750 100 125 200 250 300 350 125 150 225 300 350 75 75 75 75 75 75 75 75 75 75 75 100 150 350 500 500 600 100 250 450 600 600
18
coupling anchorages Coupling Anchorage - 505, 406 & 506

duct
grout tube
swaged strand ends
anchorage casting
coupling block wedge grips
Coupling Anchorage - 405
Grout Pump
Coupling Anchorages
Strand Size Coupling Unit 12.7mm / 12.9mm 15.2mm / 15.7mm 405 505 506 A 100 100 100 Coupling Anchorage Details Dimensions (mm) B C 220 220 240 80 110 120 D 220 220 265
Note: 3 and 4-strand units are coupled using the applicable 5-strand coupler, uno.
19
Anchorage Reinforcement slab system
TENDON UNIT 205 305 505 605 206 406 506
Notes:
No. OF STRANDS 2 3 4 or 5 6 2 3 or 4 5
SPIRAL TYPE A mm 90 100 100 110 90 110 110 B mm 200 260 260 300 200 300 300 N No. 4 4 5 7 4 7 7 C mm 200 200 200 200 200 200 200
LIGATURE TYPE D mm 100 100 130 150 110 130 150 N No. 2 2 2 2 2 2 2 x x x x x x x 1 1 2 4 2 2 4
fcp MPa 17 17 22 25 17 22 25
Reinforcement size 10dia, grade 500MPa to AS/NZS 4671 or grade 460 to BS4449. fcp = min required air-cured concrete cylinder strength at anchorage at time of stressing. Details shown are generally satisfactory for most standard situations, however designers should satisfy themselves of the adequacy of local zone anchorage reinforcement for specific situations.
Spiral Type
2x2 ligature 2x1 ligature similar
2x4 ligature
suggested allowances strand offsets for 19mm flat duct

Strand Size 12.7mm / 12.9mm 15.2mm / 15.7mm A 7mm 8mm B 12mm 11mm e 2.5mm 1.5mm
strand at tendon high point 20 www.structuralsystems.com.au
strand at tendon low point
Jacking Clearances
double ram jack
single ram jack
Jacking Clearances
Strand Size 12.7mm / 12.9mm 15.2mm / 15.7mm A mm 500 600 B mm 900 900 C mm 750 850 D mm 450 450 E mm 70 70
internal stressing pockets

Notes: Internal Stressing Pockets are used where standard edge stressng is impractical, subject to design check. Details shown provide typical pocket spacing requirements. Actual details may vary.
Stressing Pocket
21
SLAb post-tensioning applications - suspended slabs

Post-tensioning provides many benefits to a wide range of suspended structures. These benefits include: Reduced construction cost Faster construction Water resistant properties Early formwork stripping Floor to floor height reduction Reduced foundation load Improved deflection control Greater column free areas
Wollongong Links Project - NSW
Many types of suspended slab structures typically realise the benefits of post tensioning, such as: Carparks Apartment buildings Commercial office space Retail centres Vertical load transfer structures Hospitals Storage facilities Public buildings such as stadiums, exhibition centres, schools and institutional facilities
Different formwork systems are compatible with posttensioning, namely: Conventional plywood systems Permanent metal deck systems Ribbed slabs Precast systems
Structural Systems has many years of experience in the design and installation of post-tensioned suspended slabs and can bring measurable benefits to your project.
Peppers Pier Resort - Queensland
22
Design of post-tensioned - suspended slabs

The design of post-tensioned suspended slabs requires sound engineering consideration in order to maximize the benefits for all stakeholders in a project. Structural Systems can offer design input from initial advice to fully detailed design for construction drawings. Typical post-tensioned floor configuration and details are:
banded slab
flat slab
flat plate
DEFINITIONS Lb = Band Span Ls = Slab Span L = Design Span (Greater of L1 & L2) Note: For Slab End Spans, Add 15-20% to Slab Thickness from charts
T = Internal Slab Thickness D = Overall Band Depth Bw = Suggested Band Width Approx. (suit formwork) P = Overall Drop Panel Depth (1.8xT)
TYPICAL DESIGN LOADS LL = 5kPa, ADL = 1kPa LL = 4kPa, ADL = 1kPa LL = 3kPa, ADL = 1kPa LL = 2.5kPa, ADL = 0.5kPa
Specifying Post-Tensioning
It is important that the design requirements are achieved on site. Good engineering notation can greatly assist in achieving this, with particular attention to the following; The System. State that the design is based on the Structural Systems SLAB post-tensioning system. This ensures that a fully tested and code compliant system will be installed. Concrete. Nominate the 28 day characteristic compressive strength and shrinkage characteristics required. Some projects may have additional requirements. Concrete Strength at Transfer fcp. This is the minimum compressive strength that is required prior to fully stressing the tendons. Concrete testing of site and air cured specimens should be carried out to ensure this strength has been achieved prior to application of the final stressing. Tendons. Clearly indicate the type and location of anchorages and number of strands in each tendon. Check that stressing access is possible at live ends. Profiling. High and low points should be nominated. Full tendon profiles can then be determined on installation shop drawings. Profiles are usually parabolic. Stressing Procedure. A two stage stressing procedure is usually specified. Initial or 25% load is applied at 24 hours after the slab pour, and final or 100% load is applied when the concrete transfer strength is released. Grout. A water/cement ratio of not more than 0.45 is usually sufficient to ensure adequate grouting and strength.
Detailing of post-tensioned - suspended slabs
Structural detailing is an art that engineers develop with experience and it is an essential part of a cost effective and reliable structure. Below are a selection of tried and proven details that Structural Systems recommend for a range of situations. A key factor in achieving a successful Post-Tensioned Structure is a sound understanding of and a considered allowance for normal concrete shrinkage movements.
Construction
Structural Systems designers have worked closely over many years with builders and construction personnel resulting in a well understood system that enhances the construction process. An appreciation of the construction process will enable all parties involved in the on site works to benefit from the system. The typical construction sequence is as follows; Erect formwork Install bottom reinforcement Install post-tensioning Install top reinforcement Prepour inspection and pour concrete Strip edge forms Initial/Partial stressing of tendons Final/Full stressing of tendons Obtain engineers approval and cut off excess tendon strand Grout the tendons Strip formwork and back prop as required
Cabrini Hospital - Melbourne
24
slab post-tenSioning
Slab post-tensionING applications - slab on ground

The post-tensioning of slabs on ground is providing many developers and builders with a cost effective pavement solution. Benefits realised with post tensioned slabs on ground include: Large joint free slab areas Reduced construction costs Less sub base preparation and/or excavation Faster construction time Reduced on going maintenance costs Facilities that have adopted a post-tensioned slab on ground system include: Distribution warehouses Freezer stores Container terminal facilities Rail freight facilities Aircraft hangers Water retaining structures Sporting venues Raft slabs
Container Pavement, Port Botany - NSW
Design
The design of post-tensioned slabs on ground involves the careful analysis of the loads applied to the slab, the interaction between the slab and the ground that supports it, restraint forces and temperature effects. Structural Systems has refined the design process and has achieved outstanding results on many projects. Our design and construction expertise for preliminary design advice through to final design and construction activities is available to assist builders, engineers and developers in achieving optimum solutions for slab on ground applications.
Computer modelling and Analysis
25
DEsign of post-tensioned slab on ground

Points to consider in the design process include:
Design Loads and Load Configurations
a) typical design racking layout
DATA
- Design Axle load P - Wheel Spacing W (2 or 4 wheels etc.) - Axle Load Repetitions - Wheel Contact Stress
Typical racking storage
Sub-grade Friction
b) design wheel / axle details
Thermal Effects
Daily ambient temperature variations give rise to temperature gradient stresses through the slab depth which need to be accounted for in the design. Typical gradients of 0.02 C/mm and 0.04 C/mm are often used for internal and external slabs respectively causing bottom fibre tensile stresses that are additional to the load stresses.
Normal elastic and shrinkage movements give rise to frictional restraint stresses between the slab and the prepared subgrade. The typical design friction coefficient for concrete laid on a plastic membrane over clean sand bedding is around 0.5 to 0.6.
Sub-base Parameters
A typical slab design will include the analysis of the slab supported by the ground sub-base. Modelling of the sub-base requires geotechnical data such as CBR, and/or the modulus of sub-grade reaction.
Warehouse floor construction using laser screeds
Raft Foundation - The Moorings, Western Australia
26
Slab post-tenSioning
DEsign of post-tensioned slab on ground

Good detailing of post-tensioned slabs on ground is vital in achieving a successful and relatively crack free slab. The following diagrams indicate key details typically recommended by Structural Systems:
Column blockout detail
typical warehouse plan
Note: As a guide, allow for total slab edge & M.J. movements of approximately 0.5mm per metre length of slab (e.g for 60m long slab, each edge moves approx 15mm over the normal life of the slab),
Construction
Structural Systems design and construction experience is based on being the leader in the field of posttensioned slabs on ground. The combination of innovative design and expedient site practices ensures that the construction phase is a seamless operation. The main items to consider for the construction phase are;
Pour Sequence
The sequence of slab pours and their respective stressing requirements should be optimized to ensure the best programme outcome.
Curing and Weather Protection

With large pours the slab is initially susceptible to shrinkage effects hence it is important to cure and protect the slab from extreme conditions such as heat, high evaporation or extreme cold. The construction of warehouse roofs prior to pouring slabs is a typical technique adopted to provide some protection.
Pour Size
A pour size of between 1500m2 and 2000m2 should typically be considered and planned.
PreSTRESSING TECHNOLOGY
multi-wire post-tensioning
The BBR SSL Multi-Wire System is more compact than the multi-strand system and is often preferred for coupled cables in incrementally launched bridges, and is ideally suited where cables are to be prefabricated and where restressing or destressing is required. The multi-wire tendon is composed of a bundle of 7mm dia. wires (plain or galvanised). Each individual wire is fixed in the anchorage with a multi-wire button head, which is cold-formed onto the wire by means of special machines. Each wire is mechanically fixed in the anchor head and reaches the full rupture load of the prestressing steel without any slippage. Therefore the wire bundle can sustain the maximum ultimate load. The prestressing force is transmitted to the concrete under precisely known conditions without any risk of slippage of the prestressing steel. Monitoring of the prestressing force and if necessary restressing can be carried out reliably and economically. If required, the tendon can also be completely destressed. The anchorage resists with a high degree of safety dynamic loads and also exceptional effects such as shock loads.
Centrepoint Tower - Sydney
Typical applications include: Coupled cables in incremtally launched bridges. Cable stay applications. Restressable tendons. Heavy lifting and lowering cables. Restressable ground anchors.
Narrows Bridge Duplication - Western Australia
28
MULTI-wire POST-TENSIONING
Standard Tendons
The anchoring method allows the production of posttensioning tendons with any number of single wires and therefore with any given magnitude of prestressing force. The most commonly used wire diameter is 7 millimetres. With the following range of STANDARD TENDONS, all prestressing requirements occurring in the construction of bridges, buildings and other structures can be met. For special applications, eg; nuclear vessels, tendons up to 15,000 kN ultimate capacity are available.
Standard SSL - BBR Wire Tendons

Number of wires, dia. 7mm Minimum Breaking Load (Rm = 1670 MPa) kN Stressing force at 0.8 x MBL kN Stressing force at 0.75 x MBL kN Tendon nominal cross sectional area Weight of tendon wire Duct I.D.
Notes:
8 514 412 386 308 2.42 35
19 1222 977 916 731 5.74 50
31 1993 1595 1495 1194 9.36 55
42 2701 2160 2025 1617
55 3537 2829 2652 2118
61 3922 3138 2942 2349
85 5466 4372 4099 3273 25.67 100
109 7009 5607 5257 4197
121 7780 6224 5835 4659
143 9195 7356 6896 5506 43.19 130
mm2 kg/m mm
12.68 16.61 18.42 65 80 85
32.92 36.54 110 120
Rm = Characteristic Tensile Strength to AS 4672 and/or BS 5896
Grouting of Ducts
SSL has developed grouting methods utilising special colloidal mixers which result in an optimal grouting of the tendon ducts.
The prestressing force can be measured with an accuracy of 2% by using calibrated 150mm face bourdon type pressure gauges.
Prestressing Equipment
The prestressing equipment consist of a hydraulic jack, trestle and pull-rod, which is connected to the stressing anchorage. For tendon elongations greater than the stroke of the jack, the pull-rod is temporarily anchored with a lock-nut and the jack is recycled.
Prestressing Jacks
Stressing Jack Type Maximum Jacking Force Jack Diameter Stroke Weight Clearance Requirement A
Notes:
NP 60 620 160 100 28 1700
NP 100 1030 205 100 50 1700
NP 150 1545 250 100 83 1700
NP 200 2060 290 100 117 2000
NP 250 2575 315 100 147 2000
NP 300 3090 350 100 196 2000
GP 500 5150 560 400 1260 2500
GP 800 8000 660 400 2000 2500
kN mm mm kg mm
Check jack size and availability with your local SSL office
29
multi-wire post-tensioning
Stressing Anchorage Type L
Number of wires dia. 7mm Anchor Diameter Thickness 8 12 74 19 31 42 55 61 85 109 121 143 a mm 63 c mm 70 dt mm 14 91 108 123 135 156 180 205 240 245 Trumpet Length b mm 250 250 250 280 300 300 300 340 360 400 500 88 102 123 138 153 171 193 219 240 252 16 20 25 30 35 40 50 60 70 70 Bearing Plate d mm 140 170 200 245 285 315 345 400 450 500 520
Stressing Anchorage Type A
Number of wires dia. 7mm Anchor
12 27
19 36
31 43
42 49
55 56
61 67
85 109 121 143 78 85 140 145
e mm 25
Elongation, max f mm 200 200 200 200 200 250 250 350 350 400 400 Trumpet length g mm 170 185 200 280 310 335 360 390 420 450 500 Diameter Bearing plate Thickness h mm 37 it mm 16 8 49 20 12 59 25 76 30 87 40 42 97 105 120 135 145 160 45 55 50 61 60 70 80 80 i mm 140 170 200 235 270 300 330 380 430 480 500
Fixed Anchorage Type S
Number of wires dia. 7mm Fan length rectangular
19 31
85 109 121 143
k mm 460 550 660 830 880 960 1010 1060 1180 1220 1260 l mm 70 90 120 140 160 180 200 240 260 280 300
Anchor plate, sq l mm 120 160 200 250 280 320 350 400 450 470 520 w mm 200 270 340 420 500 560 600 660 760 790 900
Fixed Coupling Type LK
Number of wires dia. 7mm Diameter
12
19
31
42
55
61
85 109 121 143
Trumpet length q mm 230 260 290 350 410 430 470 570 630 680 730 r mm 70 88 102 123 138 153 171 193 219 250 260
Movable Coupling Type LK 1
Number of wires dia. 7mm Diameter
12
19
31
42
55
61
85 109 121 143
Trumpet length min s mm 600 620 670 750 810 880 950 1080 1150 1220 1260 t mm 70 88 102 123 138 153 171 193 219 250 260
Special Application Anchorages

Details of Anchorages for various special applications are also available on request .
30
bar POST-TENSIONING
bar post-tensioning
Macalloy Bar Systems are ideal for the economic application of post-tensioning forces on relatively short tendons. Through the use of threaded connections and anchorages they are simple to use and lend themselves to many applications. The robust coarse thread (CT) on the Macalloy bar ensures rapid and reliable assembly. This is particularly suitable for onsite use and reuse.
Typical Applications
Buildings Prestressed Beams and Columns Precast Connections Temporary Bracing Bridges Stay Cables and Hangers Precast Segments Strengthening (Timber & Steel Bridges) Tension Piles and Caissons Wharves & Jetties Stressed Deck Planks Tie Backs Soil and/or Rock Anchors Permanent and Temporary Anchors Uplift Anchors (Dam & Foundation) Tunnel Roof Bolting Soil Nails and Rock Bolts Slope Stabilisation Crane and Tower Bases Specialist Engineering Heavy Lifting Formwork Ties and Hangers Frame Ties Pile Testing Architectural Ties and Stays
Corrosion Protection
All bars and fittings must receive protection when installed under permanent conditions. In normal concrete construction the use of galvanised duct, injected with grout, provides excellent protection. Anchorage recesses must also be filled with cement mortar to protect these end zones. When bars are used in an exposed environment then other corrosion protection systems are available for the bar and fittings. These include: greased and sheathing bar denso wrapping epoxy painting
Temporary Bar Anchors

Anchors used in a temporary environment may be used without protection apart from grout required to the bond length.
Permanent Bar Anchors

These anchors require installation into corrugated polyethylene sheathing or galvanised duct similar to strand anchors to provide multiple levels of protection. This is accomplished by the internal grout and sheathing barrier.
Bearing Plate
Nut
Bar
Characteristic Properties
Macalloy Bar Properties are listed in the following tables.
Washer Coupler
Macalloy 1030 Bar Components
31
BAR post-tensioning
RANGE OF MACALLOY 1030 BAR
NOMINAL DIAMETER mm 20 25 26.5 32 36 40 50 75 NOMINAL CROSS SECTION AREA mm2 315 491 552 804 1018 1257 1963 4185 MASS OF BAR MACALLOY 1030 kg/m 4.09 4.58 6.63 8.35 10.30 15.72 33.00 *MACALLOY S1030 kg/m 2.53 4.09 6.63 10.30 MAJOR DIAMETER OF THREADS mm 22.0 28.9 30.4 36.2 40.2 45.3 54.8 77.2 MIN. HOLE DIAMETER IN STEELWORK mm 24 31 33 40 44 49 59 82
MECHANICAL PROPERTIES OF MACALLOY 1030 BAR

GRADE CHARACTERISTIC ULTIMATE TENSILE STRENGTH MPa 1030 1030 1030 MINIMUM 0.1% PROOF STRESS MPa 835 835 835 MINIMUM ELONGATION % 6 6 10 APPROXIMATE MODULUS OF ELASTICITY GPa 170 205 185
Macalloy 1030 25-50mm Macalloy 1030 75mm *Macalloy S1030
CHARACTERISTIC LOADS FOR MACALLOY 1030 BAR

NOMINAL DIAMETER mm 20 25 26.5 32 36 40 50 75
* Macalloy S1030 is made from stainless steel
CHARACTERISTIC BREAKING LOAD (MBL) MACALLOY 1030 kN 506 569 828 1049 1295 2022 4311 *MACALLOY S1030 kN 323 506 828 1295 -
MINIMUM 0.1% PROOF LOAD MACALLOY 1030 kN 410 460 670 850 1050 1639 3495 *MACALLOY S1030 kN 262 410 670 1050 -
32
bar POST-TENSIONING
MACALLOY 1030 COMPONENT PARAMETERS

ITEM Bars Sectional area Mass per metre Metre run of bar per tonne Characteristic failing load Prestress at 70% characteristic Minimum centres for anchorage Nut reference Length Width across flats (DIA for 75mm bar) Weight Washer reference Outside diameter Thickness Coupler reference Outside diameter Length - standard Length - stainless Weight UNIT mm2 kg m kN kN mm mm mm kg mm mm mm mm mm kg mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm
201 314.2 2.466 405 314 220 100
NOMINAL BAR DIAMETER - mm 251 490.9 4.069 246 506 354 100 FN25 33 46 26.5 551.5 4.560 219 569 398 110 FN26.5 37 50 0.46 32 804.3 6.661 150 828 580 125 FN32 41 56 0.56 36 40 50 75 1017.9 1256.6 1963.5 4185.4 8.451 10.410 16.020 33.200 118 96 62 30 1049 1295 2022 4311 734 907 1415 3018 140 150 175 250 FN36 46 62 0.74 FN40 51 65 0.86 FN50 71 90 2.55 FN75 100 135 7.70 FC75 110 230 9.00 FP75 300 250 75 82 110 91 125 125 8.0 360 160 150 235 116 16
*Flat Nuts
FSSN20 25 42 -
*Flat Washers Couplers
FSSW20 FSW25 FSW26.5 FSW32 FSW36 FSW40 FSW50 50 60 65 70 75 80 105 5 5 5 5 5 5 5 FSSC20 35 65 FSSP20 100 100 25 26 41 50 45 2.5 250 100 40 75 42 12 FC25 42.5 85 80 FP25 100 100 40 35 40 41 59 52.5 GF25 125 40 6.0 250 100 45 82 49 12 FC26.5 42.5 90 0.54 FP26.5 110 110 40 36 40 41 59 52.5 GF25 125 40 6.0 250 100 50 91 53 12 FC32 50 115 95 0.94 FP32 125 125 50 41 50 50 66 60 GF32 140 40 6.0 250 100 60 105 57 12 FC36 57.5 130 1.50 FP36 140 140 50 45 50 50 71 65 GF36 140 40 6.0 250 100 65 115 62 12 FC40 62.5 140 120 1.78 FP40 150 150 60 52 60 61 75 70 8.0 250 100 75 130 71 16 FC50 76 170 3.10 FP50 200 175 60 61 70 71 91 90 8.0 250 100 85 165 91 16
End Plates Plate reference Length Width Thickness - standard Hole diameter Thickness - threaded Ducts Sheathing i/d Coupler-sheathing i/d recommended Coupler-sheathing minimum Flange reference Length /o/dia Height Pitch Length - Jacking end (standard) S1 - Dead end (standard) S2 - Coupler (standard) X1 (min) X2 (min) X3 (min)
Grouting flange Threads Standard thread lengths (see fig on p30)
* Spherical nuts and washers are available if required for rotation.

1
20mm bar available in stainless steel grade only. Bar range available on request
Sydney Hockey Centre, Homebush - NSW
33
MACALLOY 1030 BAR END THREAD DIMENSIONS
X1 = live end X2 = dead end X3 = length of bar past nut or thru threaded plate S1 = live end thread S2 = dead end thread L = length over plates
MACALLOY 1030 TYPICAL END BLOCK ARRANGEMENT
MACALLOY 1030 SUGGESTED MILD STEEL END BLOCK REINFORCEMENT

NB: Helix and links must be used together with minimum 35 MPa concrete - see figure above
MACALLOY DIAMETER mm 25 26.5 32 36 40 50 75
Notes:
HELIX ROD DIAM. mm 12 12 12 12 12 16 20 I/D mm 130 130 165 195 220 250 350 PITCH mm 40 40 40 40 40 50 75 TURNS No. 5 5 6 7 7 8 8 ROD DIAM. mm 8 8 8 8 8 10 16
LINKS SPACING mm 70 70 80 80 80 100 100 NUMBER 3 3 3 4 4 4 6
A longitudinal length of rod may be used to attach the links but it is not required as part of the reinforcement A more detailed explanation of the Macalloy Post Tensioning System is available in the Macalloy Design Data Handbook There are many permutations possible to achieve satisfactory construction details, and advice is readily available from Structural Systems
OTHER MACALLOY BAR SYSTEMS ALSO AVAILABLE

Macalloy Macalloy Macalloy Macalloy Macalloy 460 carbon steel tendons S460 stainless steel tendons Guy Linking stainless steel bar tendons Guy Linking stainless steel cable tendons 17MHS Sheet piling ties Macalloy 500 Reinforcing bars Macalloy 500 Tie bars Macalloy 650 Stainless Tie bars Macalloy-Tensoteci Galvanised cable tendons
34
ground anchor systemS
ground anchor SystemS

Structural Systems Ground Anchors have been utilised world wide in conjunction with our construction partners the BBR group of Switzerland. Ground Anchors comprised of wires, strands or bars can be installed into rock or soil and secured by injecting with cement grout. Standard Structural Systems Ground Anchors can provide an ultimate load of between 368kN and 23,750kN depending on the configuration. SSL BBR Anchors have been the largest and longest installed anywhere around the world and our technical expertise in this field is internationally recognised. Typical applications of Structural Systems Ground Anchors include: retaining structure tie backs resistance of uplift forces slope stabilization underground structures dam stabilization tension foundations soil nailing (bar type anchors)
Transporting worlds longest ground anchors - Canning Dam - Western Australia Transporting ground anchors
Ross River Dam - Queensland
Anchor installation
Anchor Fabrication - Canning Dam - Western Australia
35
ground anchor SystemS

STRAND TYPE ANCHORS
36
ground anchor systemS
TYPICAL GROUND ANCHOR TENDON CONFIGURATIONS

TENDON STRAND MAXIMUM / BAR SIZE STRANDS PER UNIT mm No. STRAND 2 4 7 12 19 22 27 31 42 55 65 91 91+ STRAND 12.7mm or 12.9mm MACALLOY BAR 26.5 32 40 50 75
Notes:
MINIMUM BREAKING LOAD kN 500 1000 1750 3000 4750 5500 6750 7750 10500 13750 16250 22750 368 736 1288
BORE HOLE DIAMETER
PERMANENT ANCHOR SHEATH SIZE ID / OD SMOOTH mm 55 67 82 102 150 150 150 150 225 225 225 257 / / / / / / / / / / / / 63 75 90 110 160 160 160 160 235 235 235 270
TEMPORARY PERMANENT CORRUGATED ANCHORS ANCHORS mm mm mm 76 89 102 114 165 165 178 178 229 241 254 311 76 89 102 102 127 152 178 216 216 216 216 311 311 311 356 102 127 152 50 / 65 65 / 85 80 / 100 100 / 120 125 / 165 125 / 165 125 / 165 125 / 165 210 / 230 210 / 230 210 / 230 250 / 270 50 / 65 65 / 80 80 / 100
BEARING PLATE SIZE TYPICAL mm 200 x 200 x 32 200 x 200 x 36 300 x 300 x 50 350 x 350 x 60 400 x 400 x 70 450 x 450 x 80 500 x 500 x 80 500 x 500 x 90 600 x 600 x 100 700 x 700 x 120 700 x 700 x 140 900 x 900 x 160 200 x 200 x 32 200 x 200 x 36 250 x 250 x 40
15.2mm or 15.7mm
under development - refer SSL 55 / 63 67 / 75 82 / 90
2 4 7
larger sizes on request - refer SSL 1 1 1 1 1 569 828 1295 2022 4311 76 102 102 127 152 127 152 152 175 203 65 / 80 80 / 100 80 / 100 100 / 127 130 / 150 n/a n/a n/a n/a n/a 200 250 300 300 400 x x x x x 200 250 300 300 400 x x x x x 40 50 60 60 90
Strand tendons are based on MBL = 184kN (12.7mm strand) and MBL = 250kN (15.2mm strand) (Higher strand / anchor capacities available on request) Details listed apply to typical applications and may vary to suit actual applications Macalloy Bar tendons are more commonly used for short anchor lengths Macalloy Bar anchor details exclude allowance for coupling of bars - refer SSL for details if required
37
external pREStReSSING
External prestressing was first used in the late 1920s and has recently undergone a resurgence being used in bridges, both for new construction as well as strengthening of existing structures.
External post-tensioning - Navia, Spain
Features of External Prestressing

External prestressing is characterised by the following features: The prestressing tendons are placed on the outside of the physical cross section (mostly in concrete) of the structure. The forces exerted by the prestressing tendons are only transferred to the structure at the anchorages and at deflectors. No bond is present between the tendon and the structure, except at anchorage and deflector locations.
readily carried out compared to internal, bonded prestressing. c) Due to the absence of bond, it is possible to restress, destress and exchange any external prestressing cable, provided that the structural detailing allows for these actions. d) Improves the concrete placing due to the absence of tendons in the webs. e) Improvement of conditions for tendon installation which can take place independently from the concrete works. f) Reduction of friction losses, because the unintentional angular changes, known as wobble, are practically eliminated. Furthermore with the use of a polyethylene sheathing the friction coefficient is drastically reduced compared to internal bonded prestressing using corrugated metal ducts. g) External prestressing tendons can easily and without major cost implication be designed to be replaceable, de-stressable and re-stressable. h) Generally the webs can be made thinner, resulting in an overall lighter structure. i) Strengthening capabilities. As an overall result, better concrete quality can be obtained leading to a more durable structure.
Advantages of External Prestressing

Compared to internal bonded post-tensioning the external prestressing has the following distinct advantages: a) The application of external prestressing can be combined with a broad range of construction materials such as steel, timber, concrete, composite structures and plastic materials. This can considerably widen the scope of the posttensioning applications. b) Due to the location and accessibility of the tendons, monitoring and maintenance can be
38
external POST-TENSIONING
Typical Applications for External Prestressing

Typical applications where external tendons are feasible, practical and economical, are: - Repair work and strengthening of all kinds of structures - Precast segmental construction - Simple and continuous spans - Underslung structures - Incremental launching procedure, in particular concentric prestressing
- Alternatively a fabricated steel bearing plate anchorage can be used in lieu of the cast anchorage.
Basic Type
The basic SSL BAR CONA External tendon is practically identical to the SSL Multi-Strand System for internal applications: - The tendon is formed from standard 15.2mm/ 15.7mm diameter strands with minimum breaking load of 250 kN or 279 kN. - The duct is from high density polyethylene and continuous from one anchorage to the other. The tendon sheathing passes freely through intermediate diaphragms and through deflectors with a metal or HDPE sleeve providing the required penetration. - A standard CONA Compact anchorage assembly consisting of anchor head, wedges, anchorage casting and polyethylene trumpet safely transfers the prestressing forces to the structure (see Fig. 1). - The tendon is filled with cement grout after it has been tensioned. Depending on requirements, the anchor heads may be protected by a cap, or alternatively the anchorage recess is filled with nonshrink concrete.
ANCHORAGE CASTING
Fig. 1. Standard Cona Compact Anchorage Assembly
Fig. 2. SSL-CONA External with anchorage casting
SSL CONA EXTERNAL TENDONS

Main Dimensions
NUMBER OF STRANDS 15.2mm / 15.7mm 7 12 19 31 42 DIMENSIONS (mm) TYPE 706 1206 1906 3106 4206 A1 x A1 215 265 335 395 500
B
C 52 65 80 97 116
D 105 115 130 150 155
E1 355 425 511 650 950
G 75 80 90 100 160
AD/ID 75 / 66.4 90 / 79.8 110 / 97.4 140 / 124 210 / 200
ad/id 90 / 79.8 110 / 97.4 140 / 114.4 180 / 147.2 243 / 225
150 180 230 290 340
109 138 178 222 283
39
PreSTRESSING TECHNOLOGY
cable stay systemS

Structural Systems can provide strand (BBR HiAm ConaTM) stay cables, wire (DinaTM / HiAmTM) stay cables, and Carbon stay cables for a wide variety of structures, drawing on both local and global expertise and resources of the BBR Network. For suspension bridges, BBR Technology can also be used for the main suspension cables as well as for the hangers. Stay cables may be plain strand / wire unsheathed for temporary applications. For permanent stay cable applications, galvanised, waxed and individually sheathed strands, enclosed in an external sheath are adopted; or wires enclosed in a sheath and the voids filled with a flexible corrosion protection compound. In recent years a fatigue stress range of 200 N/mm2 for 2x106 load cycles in combination with angular rotations at the anchorages has been adapted and is now specified by most codes and recommendations. BBR Stay Cable Technology has fulfilled such fatigue testing.
Sydney Athletics Centre - New South Waies
Eleanor Schonell Bridge - Queensland
40
cable stay systemS
Strand Stay Cables

BBR HiAm ConaTM Parallel Strand Stay Cables Installation is typically performed on site using the strand-by-strand method. Each strand is tensioned immediately after installation, using the BBR isostress tensioning method, ensuring an equal force distribution among the strands of an individual cable. Alternatively, fully or partially prefabricated cables can be installed and tensioned. Strands are generally 15.7mm diameter, low relaxation grade, minimum guaranteed ultimate tensile stress of 1770 N/mm2 or 1860 N/mm2 and subject to fatigue testing by the manufacturer. Strands are galvanized, waxed and individually sheathed with a continuous and wear resistant HDPE coating, providing each strand with an individual multilayer protection system. Alternatives may also be available upon request. A ring nut screwed on anchor heads transfers the cable loads by contact pressure to the supporting bearing plates, and allows adjustment of stay force. All anchorage components are designed for a stress range greater than 300 N/mm2 and to withstand the ultimate breaking load of the strand bundle with adequate safety.
Standard Anchorage Components
Supplemental internal or alternatively external damping devices protect the stay cable from vibrations. Another effective countermeasure against wind and rain-induced vibrations is the use of a helical rib on the outside of the HDPE, architecturally coloured co-extruded stay pipe. Final stay cable force may also be adjusted using a specially designed multi-strand jack acting on the entire stay cable. Individual strands can be re-stressed at any time during or after the installation, allowing not only for a re-stressing but also for the selective removal, inspection and replacement of individual strands or the entire stay cable.
STRAND DIAMETER: 15.7mm to prEN 10138-3 (refer design DATA)

Type Forces Axial Cable Force HiAm CONA Ultimate Working MBL 100% kN 1 06 3 06 7 06 12 06 19 06 22 06 27 05 31 06 37 06 42 06 48 06 55 06 61 06 69 06 73 06 75 06 85 06 91 06 97 06 109 06 121 06 127 06
Notes:
Structure Bearing Plate / Steel Guide Pipe Steel 355 MPa yield stress structural grade Plate Diam. CBP mm 57 85 133 170 210 225 248 264 288 305 327 349 367 389 400 405 430 445 458 485 510 522 Guide Pipe Diam. DGP OD / e mm / mm 70.0 / 5.0 101.6 / 5.0 152.4 / 4.5 193.7 / 5.6 244.5 / 6.3 244.5 / 6.3 273.0 / 6.3 298.5 / 7.1 323.9 / 7.1 323.9 / 7.1 356.6 / 8.0 368.0 / 8.0 406.4 / 8.0 406.4 / 8.0 419.0 / 8.0 457.0 / 10.0 457.0 / 10.0 508.0 / 11.0 508.0 / 11.0 508.0 / 11.0 559.0 / 12.5 559.0 / 12.5 mm 75 110 165 210 260 275 305 325 355 375 400 425 450 475 490 495 525 545 560 595 625 640
Anchorage
Stay Pipe Weight HDPE
Short Fatigue Term Fext 55% kN 153 460 1074 1841 2916 3376 4143 4757 5678 6445 7366 8440 9360 10588 11202 11509 13043 13964 14885 16726 18567 19488 Ffat 200 MPa kN 30 90 210 360 570 660 810 930 1110 1260 1440 1650 1830 2070 2190 2250 2550 2730 2910 3270 3630 3810
BBR HiAm Anchorage System SDR32 Diam. GA mm 390 400 410 420 435 435 450 445 465 465 480 480 495 500 490 510 515 525 525 525 545 555 HA Stressing Fixed mm 190 200 210 220 235 235 250 245 265 265 280 280 295 300 290 310 315 325 325 325 345 355 mm 1000 1500 2000 2125 2250 2375 2500 2625 2750 2850 2950 3050 3150 3250 3350 3450 3550 3650 3750 3850 3950 4050 IA Diam. S OD / e mm / mm / 63 / 4.0 90 / 4.0 110 / 4.0 125 / 4.0 140 / 4.4 160 / 5.0 160 / 5.0 180 / 5.7 180 / 5.7 200 / 6.3 200 / 6.3 225 / 7.1 225 / 7.1 250 / 7.9 250 / 7.9 280 / 8.8 280 / 8.8 280 / 8.8 315 / 9.9 315 / 9.9 315 / 9.9
Cable
Fwl 45% kN 126 377 879 1507 2385 2762 3390 3892 4645 5273 6026 6905 7659 8663 9165 9416 10672 11425 12178 13685 15192 15945
Cable
kg/m 1.3 4.7 10.3 17.1 26.4 30.7 37.8 43.1 51.6 58.2 66.8 75.9 84.8 95.3 1101.7 104.3 119.0 126.8 134.7 152.4 168.1 176.0
279 837 1953 3348 5301 6138 7533 8649 10323 11718 13392 15345 17019 19251 20367 20925 23715 25389 27063 30411 33759 35433
e = nominal wall thickness
41
cable stay systemS

BBR HIAM Stay Cables
Cable Size (wires per cable) Cable Breaking Load Max. Working Load Steel Weight Cable Weight HDPE Stay Pipe Wall Thickness HDPE Telescope Pipe Wall Thickness Steel Guide Pipe (outer/inner diameter) Bearing Plate ThicknesS Centre Hole Socket Outer Diameter Length Stressing Anchorage Length Fixed Anchorage Lock Nut Protection Cap B t
Z A T PE t PE
n 7 No. FUnom Fmax kN kN kg/m kg/m mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm kg kg
56 3600 1620 16.9 23.8 110 10.0 140 12.8

211.4
91 5850 2635 27.5 33.2 110 10.0 140 12.8

251
121
163
196
223
262
301
334
367
394
421
7775 10475 12595 14330 16840 19345 21465 23585 25320 27055 3500 36.6 43.8 125 11.4 160 14.6
282.5
4715 29.2 58.0 140.0 12.8 180.0 16.4

311.0
5670 59.2 71.2 160 14.6 200 18.2

330.6
6450 67.4 78.4 160.0 14.6 200.0 18.2

352.0
7580 79.2 93.8 180 16.4 225 20.5

378.0
8705 91 104 180 16.4 225 20.5

405.0
9660 10615 11395 12175 100.9 118.7 200 18.2 250 22.8
416.6
111 128 200 18.2 250 22.8

435.0
119 210 19.1 250 18.0

455.0
127.2 210 19.1 250 18.0

470.0
138.3 145.5
mm 229.0 / 267.0 / 298.5 / 343.0 / 355.6 / 368.0 / 406.4 / 445.0 / 445.0 / 470.0 / 495.0 / 495.0 / 365 45 211 195 355 320 245 75 219 283 178 93 86 430 55 251 235 425 370 290 90 259 338 203 157 142 480 60 282 265 480 415 330 105 289 378 213 226 203 545.0 70 311.0 295 550 465 365 120 319 433 228 314 281 590 75 330 315 605 505 390 125 339 483 253 391 347 625.0 75 352.0 335 635 525 420 135 359 503 253 465 412 675 85 378 360 665 540 450 150 389 518 253 567 495 730 95 405 385 710 575 480 160 409 553 268 668 600 755 95 417 400 755 605 500 165 429 593 283 787 682 795 100 435 420 790 635 520 170 449 623 288 898 779 830 110 455 435 815 650 540 180 459 638 293 998 861 850 105 470 450 845 675 560 185 479 663 303 1110 957
LHM LHF
M
HM
S
LSm LSf Weight of Anchorage (excl. Anchor Plate and Guide Pipe) stress. fixed
42
cable stay systemS
BBR Dina STAY CABLES

Cable Size (wires per cable) Cable Breaking Load Max. Working Load Steel Weight Cable Weight HDPE Stay Pipe Wall Thickness HDPE Telescope Pipe Wall Thickness Steel Guide Pipe Stressing Anchorage (inner / outer diameter) Fixed Anchorage (inner / outer diameter) Bearing Plate Stressing Plate Thickness Centre Hole Fixed Plate Thickness Centre Hole STRESSING SLEEVE Outer Diameter Length Length Fixed Anchorage Lock Nut Stressing Anchorage Bm tm Zm Bf tf Zf ZH LZH LHF Mf HMf Fixed Anchorage Mr HMr PROTECTION CAP Stressing Anchorage Sm LSm Fixed Anchorage Sf LSf Weight of Anchorage (excl. Anchor Plate and Guide Pipe) stress. fixed Tf Tm PE PE n7 FUnom Fmax No. kN kN kg/m kg/m mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm kg kg 13 835 375 3.9 6.4 63 5.8 75 4.3
139.7 / 125.5 139.7 / 125.5
22 1415 635 6.6 8.8 63 5.8 75 4.3

146.0 / 136.0 146.0 / 136.0
31 1990 895 9.4 12.4 75 6.9 90 5.1

168.3 / 155.7 168.3 / 155.7
37 2380 1070 11.2 15.8 90 8.2 110 6.3

177.8 / 165.2 177.8 / 165.2
55 3535 1590 16.6 20.7 90 8.2 110 6.3

203.0 / 190.4 203.0 / 190.4
70 4500 2025 21.1 27.6 110 10.0 140 12.8

229.0 / 211.4 229.0 / 211.4
91 5850 2635 27.5 33.2 110 10.0 140 12.8

254.0 / 238.0 254.0 / 238.0
103 6620 2980 31.1 39.0 125 11.4 160 14.6

267.0 / 245.0 267.0 / 245.0
121 7775 3500 36.6 43.8 125 11.4 160 14.6

292.0 / 267.0 292.0 / 267.0
145 9320 4195 43.8 53.1 140 12.8 180 16.4

305.0 / 285.0 305.0 / 285.0
157 10090 4540 47.4 56.4 140 12.8 180 16.4

318.0 / 298.0 318.0 / 298.0
181 11635 5235 54.7 67.2 160 14.6 200 18.2

330.0 / 310.0 330.0 / 310.0
199 12790 5755 60.1 72.0 160 14.6 200 18.2

355.6 / 327.2 355.6 / 327.2
230 30 125 180 25 110 100 90 45 140 30 130 30 129 98 125 34 15 11
260 35 136 210 35 110 120 105 55 160 35 135 40 149 108 130 34 19 12
285 35 155 240 35 125 140 115 60 180 40 155 45 169 113 150 34 26 16
305 40 165 270 45 145 150 130 60 195 45 175 50 179 128 170 34 34 22
350 45 190 305 45 145 175 160 75 225 55 185 55 199 153 180 34 48 24
380 50 211 405 70 175 195 190 75 250 60 220 65 219 178 215 34 69 35
420 55 238 430 80 175 220 205 90 280 70 230 70 249 188 225 34 86 40
435 60 245 415 60 195 230 225 90 290 70 250 75 259 203 245 34 102 49
470 60 267 440 65 195 250 245 100 315 75 255 80 279 218 250 34 125 52
510 65 285 480 75 215 270 255 105 340 80 280 85 299 223 275 34 150 65
525 65 298 495 75 215 280 270 110 355 85 285 90 309 238 280 34 169 69
560 70 310 530 80 235 295 290 115 370 90 310 95 319 253 305 34 199 85
590 75 327 555 90 235 310 305 125 390 95 315 100 339 265 310 34 230 90
43
INCREMENTAL LAUNCHING systemS

The Incremental Launching method combines the advantages of pre-cast segmental construction with those of segmental cast insitu methods. Bridges are cast in segments behind an abutment under controlled conditions, as a result, high concrete quality and precise dimensions are assured. Reinforcement crosses each joint in addition to the bonded prestressing tendons as each new segment is cast directly
Incremental Launching Girder
against the already hardened one in front. The concentric pre-stress required during launching guarantees an excellent, relatively maintenance free performance of the bridge during its whole lifetime. By avoiding costly and time-consuming false work and by concentrating all construction activities in the small fabrication area, considerable saving in cost and time against conventional bridge construction are achieved.
The main characteristics of the incremental launching method are: Production of a continuous, site cast concrete superstructure. Casting in long sections in a stationary, multiple use form behind an abutment. After longitudinal shifting (launching) of a completed section along the bridge axis, the next section is cast against the previous one and stressed together. In this sequence the overall superstructure grows by adding new sections, step-by-step as the progressively completed girder is launched. Temporary sliding bearings and guides at each pier facilitate the steady travel of the structure. A steel launching nose at the front sliding bearings, and a casting bay behind the abutment. Some preferred requirements are: The girders should have a constant curvature in horizontal and vertical alignment. The section should be continuous over the whole bridge with preferably a constant depth. Span should be limited to 50-60 metres. Span/depth ratios should be in the range of 14 to 18.
Mt Henry Bridge - Western Australia
These are not exclusive but provide a guide to the standard range of applications.
Tonkin Hwy Bridge over Albany Hwy - Western Australia
44
HEAVY LIFTING SYSTEMS
HEAVY LIFTING SystemS

In many instances, it is advantageous for extremely large and heavy components to be prefabricated away from their final location. In most cases they must be lowered, jacked horizontally or lifted into their final position. When their weight or size exceeds the capacity of available cranage other heavy lifting facilities must be considered. Structural Systems has developed specialised lifting equipment for this application. The combination of the proven BBR Buttonhead Prestress Cable together with electrically operated hydraulic jacking units allows virtually unlimited loads to be moved quickly and safely over any distance. The lifting or lowering operation can be accurately controlled through the hydraulic system which allows simultaneous or individual operation of each lifting unit.
Perth Convention Exhibition Centre - Before Roof Lift
12 outlet isoflow pump and control panel Perth Convention Exhibition Centre - After Roof Lift
43 5
preSTRESSING TECHNOLOGY
load handling systemS

Construction procedures involving load handling systems often result in considerable savings as compared to conventional building methods using traditional scaffolds for casting concrete or installing steel structural elements in place. The application of load handling systems requires full consideration at the structural design stage, well in advance of detailing or construction planning, as selecting or designing the necessary temporary works and choosing the related equipment must be performed as early as possible. Structural Systems has extensive experience in the field of load handling and can provide all required services for design as well as supply and operation of equipment.
Raising roof segment - Docklands Stadium
Typical Applications
Lifting, Lowering and Shifting of Heavy Loads Heavy, fragile or awkward structural elements can be either fabricated on or off site, then manoeuvred into position by using jacking systems and tendons from bar, strand or wire. Examples include roof structures, bridge spans, precast concrete elements, and heavy industrial components. It is often preferred to assemble a large module adjacent to its final location then shift it into position, on the basis of safety, ease of assembly or time constraints. In some instances bridge pier headstocks are constructed parallel to traffic, then rotated to minimise traffic disruption. Some of SSLs systems incorporate special hydraulic and monitoring systems to allow for high accuracy movement regardless of any differential loadings. Specialist Formwork & Access Occasionally access systems or working platforms may be located in areas which cannot be serviced using conventional cranage. In these instances where standard options fail, the compact yet powerful systems SSL offer allow for an effective solution to be developed. Examples of this application may be underbridge platforms, fitting of chimney liners and lift shaft installations. Additionally we have developed specialist platforms for use on high rise buildings, bridges, tanks and silo structures to permit necessary works such as post-tensioning and repair or inspection. SSL also have free spanning access walkways up to 40m. The use of our specialist hardware such as cable stays can allow formwork solutions to be developed where the formwork and false work is supported from above rather than below. This may be essential in some locations where it is not possible due to access, and cost or time. Tendon Installation & Transport As part of our diverse operations, we have developed systems for use on cable stay bridges or large dam projects where tendons up to 150m and weights greater than 17 tonnes need translation and fitting to the structure. A further example is the stay cables incorporated in Centrepoint tower, were fabricated in Melbourne prior to shipment and installation in Sydney.
Ringwood Rail Bridge Sliding Operations - Victoria
46
load handling systemS
Flat Jacks
Flat jacks are used for a variety of applications where structures are required to be lifted or preloaded and installation heights are to be kept to a minimum. Structural Systems can provide 2 types of flat jacks: Pan Type Contstructed of two moulded steel sections welded together used with a top and bottom plate. These can be inflated with oil or grout and are generally used only once (see Table A). Safety Lock Nut Type Solid ram, low height hydraulic jacks with safety lock nut for mechanical load handling, used mainly for bearing replacement work (see Table B). For heavy loads multiples of the jacks are used linked through a manifold system.
Safety Lock Nut Type Pan Type
TABLE A - PAN TYPE

TYPE D OUTSIDE DIAMETER mm 120 150 220 250 270 300 350 420 480 600 750 870 920 1150 MAXIMUM FORCE AT 13.5 MPa kN 85 155 390 525 605 780 1080 1605 2170 3470 5400 7385 8975 13635 EFFECTIVE AREA AT ZERO EXTENSION 103mm2 6.4 11.5 29 39 45 58 80 119 161 257 400 547 665 1010 T THICKNESS1 mm 25 25 25 25 25 25 25 25 25 25 25 25 25 25 E MAXIMUM TRAVEL mm 25 25 25 25 25 25 25 25 25 25 25 25 25 25 INSTALLATION GAP mm 38 38 38 38 38 38 38 38 38 38 45 45 45 50
9T 16T 39T 52T 60T 78T 108T 160T 217T 347T 540T 738T 898T 1364T
Notes:
[1] flat jack thickness may vary slightly
TABLE B - SAFETY LOCK NUT TYPE

TYPE OUTSIDE DIAMETER mm 60T 100T 150T 200T 250T 300T
Notes:
MAXIMUM FORCE AT 10,000 PSI kN 600 1000 1500 2000 3000 3000
THICKNESS mm 110 162 192 155 150 170
MAXIMUM TRAVEL mm 28 50 50 50 50 50
INSTALLATION GAP mm 125 180 210 170 165 185
138 188 205 240 300 305

Jacks come complete with spherical testing
47
VICTORIA
STRUCTURAL SYSTEMS 112 Munro Street, South Melbourne VIC 3205 Australia T. +61 3 9296 8100 F. +61 3 9646 7133 STRUCTURAL SYSTEMS 20 Hilly Street, Mortlake NSW 2137 Australia T. +61 2 8767 6200 F. +61 2 8767 6299 STRUCTURAL SYSTEMS Unit 2, 16 Maiella Street, Stapylton QLD 4207 Australia T. +61 7 3442 3500 F. +61 7 3442 3555 STRUCTURAL SYSTEMS 24 Hines Road, OConnor WA 6163 Australia T. +61 8 9267 5400 F. +61 8 9331 4511 NASA STRUCTURAL SYSTEMS LLC Head Office Suite 302 Sara Building, Garhoud PO Box 28987 DUBAI United Arab Emirates T. +97 14 2828 595 F. +97 14 2828 386 www.bbrstructuralsystems.com STRUCTURAL SYSTEMS 12 Collett Way Great Western Industrial Park Southall, Middlesex UB2 4SE T. +44 208 843 6500 F. +44 208 843 6509 STRUCTURAL SYSTEMS Unit 13, Block G Maynooth Business Campus, Maynooth Co. Kildare, Ireland T. +353 1628 9124 F. +353 1628 9124 STRUCTURAL DESIGN SERVICES sp.z o.o. Twarda 30 00-831 Warszawa Poland T. +48 226 979 246 +48 226 979 247 F. +48 226 979 248
NEW SOUTH WALES
QUEENSLAND
WESTERN AUSTRALIA
MIDDLE EAST REGION Bahrain, Oman, Qatar, U.A.E.
UNITED KINGDOM
IRELAND
POLAND
Structural Systems operate throughout Australia, South East Asia, the Middle East and the United Kingdom. For more information on Structural Systems and the many services we provide, visit: www.structuralsystems.com.au

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PRESTRESSING TECHNOLOGY

PAGE 03 PAGE 04 PAGE 05 PAGE 17 PAGE 28 PAGE 31 PAGE 35 PAGE 38 PAGE 40

Ground Anchor SYSTEMS External PRESTRESSING Cable Stay SYstemS

INCREMENTALLAUNCHINGSYSTEMS PAGE 44 HEAVYLIFTINGSYSTEMS LOADHANDLING SYSTEMS PAGE 45 PAGE46

Wandoo Concrete Gravity Structure - Western Australia

Eleanor Schonell Bridge - Queensland

POST-TENSIONING DESIGN DATA

MIN. PROOF LOAD kN 156.4 212.5 221.9 158.1 225.3

MODULUS OF ELASTICITY MPa 180 to 205x10 180 to 205x10 180 to 205x10

100.1 143.3 143.3 100 150 140 150 140 150

180 to 205x10 180 to 205x10 180 180 180 180 to to to to

213.0 229.0 224.0 240.0

(5) (5) (5) (5)

205x10 205x10 205x10 205x10

All strands are 7 wire low relaxation steel.

MASS kg/lm 0.302 0.302

WIRE MBL kN 64.3 64.3

MIN. PROOF LOAD kN 54.7 53.4

STRAND RELAXATION (%) 2.0 2.5

MODULUS OF ELASTICITY MPa 195 to 205x10

MAXIMUM JACKING FORCES - RECOMMENDED VALUES

80% 80% 85% 80% 75%

MBL MBL MBL MBL MBL

PRESTRESSING LOSSES - TYPICAL DATA

TENDON WOBBLE (k) rad/m

0.016 to 0.024 0.008 to 0.016

0.006 0.006 0.016 to 0.024

0.016 0.008 to 0.012

BBR CONA MULTI

BBR CONA MULTI - M1

BBR VT CONA CMI

BBR VT CONA CMI

BBR VT CONA CMI

STRESSING AND FIXED ANCHORAGE

CENTRE AND EDGE DISTANCES

STRESSING ANCHORAGE RECESS DETAILS

MULTI STRAND POST-TENSIONING

BBR VT CONA CMI

420 14 457 50 9.5

360 14 457 50 9.5 27

280 744 290 1600

310 946 310 1821

360 1090 390 2466

360 975 390 2242

Note: Intermediate and larger sizes available on request.

STRESSING AND FIXED ANCHORAGE

CENTRE AND EDGE DISTANCES

BBR VT CONA CMI

ANCHOR AND COUPLER HEADS

COUPLER HEAD TYPE K

MULTI STRAND POST-TENSIONING

BBR VT CONA CMI

mm 45 / 50 55 / 60 70 / 75 90 / 95 95 / 100 105 / 110 110 / 115

45 60 80 100 105 120 130

50 65 85 105 110 125 135

BBR CONA MULTI

stressing Anchorages (Live Ends)

wedge grips p.e. trumpet anchor head anchorAGE casting

Stressing Anchorage Type M3 - Fabricated Plate Anchorage (LIVe END)

Dimensions A x A (mm) B C Outside Dia. D Outside Dia. E

bulb type dead end

swage type dead end

Transfer beams in buildings

Coupling Anchorage - Type K