Prestressing system

FREYSSIBAR

prestressing system

The FREYSSIBAR

Developed by Freyssinet, this prestressing system comprises of a wide range of fully threaded bar and complementary anchoring, coupling and extension devices. It is used for post-tension cables, prestressed ground anchors and for any application involving temporary or permanent tie rods: lifting, suspension, prestressed splices, etc.

SUMMARY: : SUMMARY
Page 3 : TECHNOLOGY: The FREYSSIBAR The anchorages The accessories

QUALITY CONTROL
Page 4 : INSTALLATION: Shimming of the anchorages Tensioning Safety factors Tensioning jacks : INSTALLATION: Tensioning pumps The injection compounds Mixing, melting, and injection equipment

Page 5

Pages 6 to 9 : GEOMETRICAL CHARACTERISTICS Types of anchorages Sketches of the types of anchorages Sketches of common accessories Page 10 : PRESTRESSED GROUND ANCHORS

TECHNOLOGY
The FREYSSIBAR
The bars are hot rolled from high strength alloyed steel. They are subsequently cold worked by stretching and then threaded over their full length by cold rolling. The standard range of nominal diameters is: 26.5; 32; 36; 40 and 50 mm. Larger diameter bars can be delivered on request. The fabrication process provides a high quality thread ensuring good fatigue resistance and a low susceptibility to stress corrosion. The geometry of the thread is specifically designed to ensure ease of use on site, providing fast, accurate and easy tightening. Bars are available in maximum lengths of 11.7 meters. Beyond this length, extension sleeves allow bars to be connected together.

The anchorages
The anchor devices are designed to anchor the force in the tendon and transfer it to the structure. Three types of anchorages are available: standard anchorages with a nut and washer, hinge anchorages using a nut with a spherical seat, and fixed anchorages using a threaded end plate. All nuts are hot forged. Also, couplers allow primary bars to be connected to secondary bars.

The accessories
Freyssinet offer a full range of sheathing that is easy to install. In particular: Steel strip corrugated sheath, threaded over its full length, which allows easy and fast connections. High density polyethylene tube, with elements butt welded by means of a heating mirror to achieve a leak free and non corrodible envelope. Sheathing accessories specific to the tensioning and coupling devices, required to fit the coupler geometry. The length of the ducting element used is defined case by case, so as to allow the coupler displacement over a sufficient length during the tensioning operations.

QUALITY CONTROL
The fabrication of the bars and the anchorages is carried out under a quality assurance system in compliance with the quality standard ISO 9000 : 2000. Bars and anchorages comply with the requirements of international standards related to prestressing tendons and anchorages.

INSTALLATION
The accuracy of the prestressing force actually introduced into the structure and the durability of the tendons depend on the quality of the installation works.

Shimming of the anchorages

When anchorages are applied onto an existing concrete element, it is recommended to shim under the bearing plate using a non-shrink mortar, free from chloride.

Tensioning
The tensioning equipment provided by Freyssinet ensures the accuracy of the load applied within +/- 2%. This is achieved through regular calibration of the pump pressure gauge and the jacks.

Safety factors
The tensioning force in the prestressing bars is given by the relevant design standards. Recommendations are given below as examples: (Note: Fpk means the guaranteed tendon tensile breaking load). A) In post-tensioned structures, the French rules (BPEL91 revision 99) limit the stressing force to 0.70 Fpk. B) In prestressed ground anchors, the norm EN 1537 prescribes a final force limited to 0.60 Fpk. The tensile force for the preliminary inspection and reception tests being less than 0.80 Fpk. C) In case of re-use, the tensioning force of the bar is limited to 0.60 Fpk for the first use, and to 0.50 Fpk for all subsequent uses.

Two types of jacks can be used: with a tie rod connected to the tendon or with a direct connection. Jacks should be used in conjunction with Freyssinet hydraulic pumps, with high pressure and a low flow rate to allow a progressive tensioning of the bar.

Tensioning jacks

JACKS WITH DIRECT CONNECTION AND HINGE

References
Units (mm) Capacity (t) Stroke (mm) Piston cross section (cm2) Pressure maxi (bars) Overlength A (mm) D (mm) Weight (kg)

CF 77
26.5-32-36 770 12 110 700 195 195 26

CF 110
26.5-32-36-40 1 100 12 159.4 700 200 200 30

VP 230
50 2 300 20 150.59 1 500 250 250 65 Tensile rod Key D A

JACKS WITH A TIE ROD

References
Units (mm) Capacity (t) Stroke (mm) Piston cross section (cm2) Pressure maxi (bars) Overlength A (mm) B (mm) D1 (mm) D2 (mm) Weight (kg)

80 VAD 90
26.5-32-36-40 1 000 100 127.2 790 215 700 160 160 63

150 VAD 90
26.5-32-36-40-50 1 700 100 240 710 215 740 200 243 91 Special sleeve Nut Key D1 A B D2

Notes : A/ Diameter adaptations must be indicated when ordering the jacks, in the following manner: CF 110 for 26.5 and 40 mm : CF 110-ADP-26.5/40 B/ Bars fitted with hinge anchorages shall be tensioned exclusively by means of a jack with a hinge.

Tensioning pumps TENSIONING PUMPS

With associated hoses
Working pressure (bars) Tank capacity (l) Flow rate (l/min) Weight (kg) 1 500 9 2.45 27

Bars are stressed using hydraulic tensioning pumps, hand actionned or motorized, with low flow rate for a progressive stressing.

The injection compounds

The bars and the anchor heads should be protected against corrosion either by using a cement mortar or a wax. Freyssinet recommends the ready mix SUPERSTRESSCEM for the standard applications and the thixothropic and retarded cement mix SMARTGEL, which avoids any segregation or settlement of the grout, in case of vertical or highly inclined tendons. To allow for subsequent re-tensioning of the bars, the injection must be achieved with a flexible anti-corrosion product. Freyssinet recommends the Freyssinet/Elf CP-HPF wax, specially designed for prestressing and stay cables. Safety recommendation Prestressing bars shall not be welded or submitted to any local heating or welding spray.

SPECIAL CEMENT GROUT

Cement Mix rate Conditions of use Specificity NF P 15 301 Water/cement Admixture/cement Mix temperature Injection duration

SUPERTSTRESSCEM
CPA-CEM I 42.5 PM ES CP2 38% 0.82% 20C +/- 15C 4 hours Admixture in hydro-soluble pocket Cement in bags of 50 kg

SMARTGEL
CPA-CEM I 52.5 PM ES CP2 35% 9.5% 20C +/-15C 24 hours Thixotropic retarded Cement in bags of 25 kg

WAX
Type Melting point Salt spray resistance test (ASTM B117) Packing

CP-HPF
Microcrystalline 82 C 3 000 hours 170 kg barrel or 25 kg plate

The injection equipment

Freyssinet has designed specific injection equipment which ensures the proper filling of the ducts.

CEMENT GROUT MIXING AND INJECTION UNIT MMJ100

Volume of mixing tanks (liters) Flow rate (l/min) Weight (kg) 2 X 100 18 350

WAX MELTING AND INJECTION UNIT

Flow rate (l/min) Weight (kg) 4.3 340

TYPES OF ANCHORAGE - GEOMETRICAL CHARACTERISTICS

Types Items Characteristics Units Nominal diameters of bars (mm) Sketches references

26.5 Item reference Steel grade Transversal cross sectional area Linear mass Characteristics breaking load : Fpk Bars 0,1% proof load MPa mm2 kg/m KN KN B26.5 1030 552 4.56 568 461

32 B32 1030 804 6.66 828 672

36 B36 1030 1018 8.45 1048 850

40 B40 1030 1257 10.41 1295 1049

50 B50 1030 1964 16.02 2022 1640

Tensioning force at 0.70 x Fpk Thread pitch Average secant modulus Item reference Nut Length Width on flat surfaces Item reference Standard anchorage Washer External diameter Thickness Item reference

KN mm GPa

398 6 170 N26.5

580 6 170 N32 42 56 W32 70 6 FP32 125 35 10x10 SN32 51 56 SP32 125 40

734 6 170 N36 47 62 W36 75 6 FP36 140 40 10x10 SN36 56 62 SP36 140 45 TEP36 140 50 20 200 50.8 2 1/2 M8

906 8 170 N40 52 65 W40 80 6 FP40 150 40 10x10 SN40 60 65 SP40 150 50 TEP40 150 60 25 250 57.2 2 1/2 M8

1416 8 170 N50 72 90 W50 105 6 FP50 185 45 12x10 SN50 71 90 B50 185 60 TEP50 185 70 25 250 70 2 1/2 M8

mm mm

38 50 W26.5

mm mm

65 6 FP26.5

Square plate

Width** Thickness Option : with injection groove : width x depth Item reference

mm mm mm2

110 30 10x10 SN26.5

FP G SN

Nut Hinge anchorage Square plate

Length Width on flat surfaces Item reference Width** Thickness Item reference

mm mm

45 50 SP26.5

mm mm

110 35

SP

TEP26.5 TEP32 mm mm mm mm mm mm " 110 40 15 200 42.9 2 1/2 M8 125 50 20 200 48.5 2 1/2 M8

Fixed Threaded anchorage plate

Width** Thickness Option : with welded cap/length Length

TEP CW T V

Options

Formwork tube*

External diameter Thickness Air vent connection

Cap fixing threaded holes

Thread

*On request the tube is welded to the plate **Wider plates are available on request

Steel corrugated sheath

V W N

HDPE tube
V W N

With shimming of anchorage

V W N

STANDARD ANCHORAGE

FP

FP

* Mortar
V

FP

SN

SN

SN

HINGE ANCHORAGE

SP

SP

* Mortar SP
V CW

CW

CW

FIXED ANCHORAGE

TEP

TEP

* Mortar

TEP

References are related to the table on page 6

*T is not welded to the plate

COMMON ACCESSORIES - GEOMETRICAL CHARACTERISTICS

Nominal diameters of bars (mm) Types Items Characteristics Units
26.5 Item reference Length Item reference Length Item reference Sleeves External diameter Length Internal diameter Thickness Steel corrugated sheath Ducts Volume of grout Duct connection element : internal diameter External diameter mm mm mm mm L/m mm mm CS26.5 95 CL26.5 210 C26.5 45 90 45 0.45 0.10 32 CS32 100 CL32 220 C32 50 115 50 0.45 0.12 36 CS36 120 CL36 220 C36 60 130 55 0.45 0.14 40 CS40 120 CL40 220 C40 65 140 60 0.45 0.16 50 CS50

Sketches references

Standard caps Caps Long caps

CS
150 CL50

CL
280 C50 76 170 75 0.50 0.25

G1

mm

50

55

65

70

85

G'1

mm mm L/m

63 5.8 0.15 GR26.5

63 5.8 0.13 GR32 76.2 2

75 6.8 0.19 GR36 88.9 2

75 6.8 0.17 GR40 95 2

90 8.2 0.23 GR50 114.3 2

HDPE tube

Thickness Volume of grout Item reference External diameter

G2

mm mm

70 2

Duct for the prolongation sleeve

Thickness

GR

Minimum length ( add L sleeve displacement) ,

mm

180 + L 205 + L 220 + L 230 + L 260 + L

Item reference External diameter Thickness Minimum length Connexion Air vents Half shell Air vent tube length mm Thread mm mm mm "

GC26.5 88.9 2 210 1/2 600

GC32 88.9 2 235 1/2 600

GC36 101.6 2 255 1/2 600

GC40 114.3 2 265 1/2 600

GC50 152.4

Duct for the coupling sleeve

GC
2 320 1/2 600

V F

CS

CL

CAPS

Standard cap

Long cap for re-tension

Steel corrugated sheath

HDPE tube
(V)

EXTENSION DEVICES

(V)

G1

GR GC

C (V)

G2

GR GC

C (V)

COUPLERS

C G1

MISCELLANEOUS

G1 Connection of steel strip sheath Freyssinet Vent

References are related to the table on page 8

Prestressed Ground Anchors

Hinge anchorage Bearing plate Corrugated duct Spacer End element

PERMANENT

Cap

Flexible anti-corrosion product

Smooth duct

Hinge anchorage

Bearing plate

Spacer

10

TEMPORARY

Cap

Smooth duct

List of components will be provided on request

Applications

PRESTRESSING OF PRECAST ELEMENTS

LAUNCHING FRONT NOSE ASSEMBLY

ROOF HANGERS

SPAN PRESTRESSING

MOBILE FORMWORK TRAVELLERS HANGERS

PRESTRESSED GROUND ANCHORS

ANCHORAGE OF SUSPENSION CABLES

Photos : Adrian Hall Francis Vigouroux Freyssinet & subsidiaries photographic library July 2004

1 bis, rue du Petit-Clamart 78148 Vlizy Cedex - France Tl. : +33 (1) 46 01 84 84 Fax : +33 (1) 46 01 85 85 www.freyssinet.com freyssibar@freyssinet.com