Dywidag DSI Bonded PT System

DYWIDAG-SYSTEMS INTERNATIONAL
DYWIDAG Bonded Post-Tensioning Systems
32G 26D 32E 36C 36E 32D
6803 . 6861 . 5915 .

6803 . 6861 . 5915 . 6837 . 5909 . 6801 . 6919 . 6802 . 6815 . 6827 . 5920 . 6809 . 5937 . 6812 . 5932 . 6802 . 6904 . . 6815 . 6827 . 5920 . 6809 . 5937 . 6912 . 5932 . 6802 . 6904 .
6803 . 6861 . 5915 . 6837 . 5909 . 6801 . 6819 . 6802 . 6815 . 6827 . 5920 . 6809 . 5937 . 6812 . 5932 . 6802 . 6804 . 6801 . 6819 . 6815 . 5909 . 6901 . 5908 . 5915 . 6812 . 6804 . 6837 . 5909 . 6801 . 6819 . 6802 . 6815 . 6803 . 6861 . 5915 . 6837 . 68
6803 . 6861 . 5915 . 6837 . 5909 . 6801 . 6819 . 6802 . 6815 . 6827 . 5920 . 6809 . 5937 .
DYWIDAG Post-Tensioning Systems
DYWIDAG Post-Tensioning Systems are world renowned for reliability and performance, most suitable for all applications in post-tensioned construction. They embrace the whole spectrum from bridge construction, buildings, to civil applications, above and underground. The first ever structure built with a prototype DYWIDAG Post-Tensioning System using Bars was the arch-bridge Alsleben (Germany) in 1927. From that time on DYWIDAG has continuously improved its systems to keep up with the growing demand of modern construction technology. In addition to the traditional post-tensioning system using bars, that is mainly geared towards geotechnical applications, building rehabilitation and strengthening, DSI offers a complete product line in strand post-tensioning (bonded, unbonded and external) as well as stay-cables being able to fully serve the posttensioning construction. DYWIDAG Post-Tensioning Systems have always combined highest safety and reliability standards with most economical efficiency in their research and development. Dependable corrosion protec-
tion methods of the DYWIDAG Post-Tensioning Systems contribute to the longevity of modern construction. High fatigue resistance is achieved with optimized material selection and cautious detailing of all the components especially in their system assembly. We look back on many years of valuable experience in the field of post-tensioning which leads to our extremely versatile product range that offers economical solutions for practically any problem. This includes our highly developed, most sophisticated equipment which is easy to operate in all phases beginning with assembly, installation, stressing and finally grouting. DYWIDAG Post-Tensioning Systems are being developed and maintained by DYWIDAGSYSTEMS INTERNATIONAL and are serviced and distributed by a worldwide network of subsidiaries owned by the Dyckerhoff and Widmann AG (DYWIDAG). Our systems comply with the international specifications and recommendations (ASTM, AASHTO, BS, Eurocode, DIN, Austrian Code, SIA, FIP, EOTA, etc.). The American
construction market demanded a product range that is described in separate brochures. The quality of the DSI products and services is in full compliance with ISO 9001. DSI scope: - consulting - design and shop-drawing engineering - manufacturing and supply - installation or training and /or supervision of installation - inspection and maintenance
1 Water Tanks, Florida, USA 2 The Museum of Men, Spain 3 Krungthep Bridge Project, Thailand 4 Silver Legacy Hotel, Las Vegas, USA
Contents
DYWIDAG Post-Tensioning Systems using Strands Standard Strands Corrugated Sheathing PE/PP Sheathing Anchorages Installation Stressing Grouting Multiplane Anchorage MA Plate Anchorage SD Plate Anchorage SDR Mono Anchorage EV Bond Head Anchorage ZF/ZR Loop Anchorage HV Flat Anchorage FA Coupler M/ME (Floating Anchorage Block) Coupler R Coupler P Coupler D Equipment Overview Calculation of Elongation DYWIDAG Post-Tensioning Systems using Bars DYWIDAG Standard Bars Anchorages for Bar Tendons QR Plate Anchorage Solid Plate Anchorage, Rectangular Solid Plate Anchorage, Square Splices and Corrugated Sheathing Installation and Stressing Stressing Grouting Equipment Overview Calculation of Elongation
page 4 4 5 6 7 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 29 page 30 31 32 33 34 35 36 37 38 39 40 42
3
subject to modification, January 2001
Post-Tensioning Systems using Strands
Standard Strands
Strands are made from 7 individual cold-drawn wires, 6 helically wound outer wires and one center wire (king wire). The mechanical properties of the strand as well as corrosion protection properties are most important to DSI. Strands can be supplied either bare, galvanized or epoxy-coated without any loss in strength including the wedge anchorage. For a maximum in corrosion protection we offer electrically isolated systems using polyethylene (PE) or polypropylene (PP) sheathings. See also page 6.
V S V
Strands are usually packaged in so-called coils that can weigh up to 3.5 tons.
construction joint V V V
C V
V S V
D = draining V = vent G = grouting C = coupling S = stressing

P = post-grouting
D G P
D G P
Technical Data
type code/specification yield strength fp0.1k ultimate strength fpk nom. diameter cross-sectional area weight ultimate load modulus of elasticity relaxation3) after 1,000 h at 0.7 x ultimate load fpk [N/mm2] [N/mm2] [mm2] [mm2] [kg/m] [kN] [N/mm2] [%] 13 mm (0.5") ASTM A 416 prEN 10138 Grade 270 BS 5896 Super 1,6701) 1,5802) 1,860 1,860 12.70 12.90 98.71 100.00 0.775 0.785 183.7 186.0 15 mm (0.6") ASTM A 416 prEN 10138 ASTM A 416 Grade 250 BS 5896 Super Grade 270 1,5501) 1,5002) 1,6701) 1,725 1,770 1,860 15.24 15.70 15.24 139.35 150.00 140.00 1.094 1.180 1.102 240.2 265.0 260.7 ~195,000 max. 2.5 prEN 10138 BS 5896 Super 1,580 2) 1,860 15.70 150.00 1.18 279.0
In addition to standard strands, DSI offers a variety of special strands such as DYFORM with a guaranteed ultimate capacity of 309 kN. The technical data for these products is available upon request.
1) 2) 3)
yield measured at 1% effective elongation yield measured at 0.1% residual elongation applicable for relaxation class 2 according to Eurocode prEN 10138/BS 5896: or low relaxation complying with ASTM A 416, respectively.
4
Corrugated Sheathing
Metal ducts represent the most economical means to create a void for tensile elements. These thin-walled (0.25 - 0.35 mm), ribbed sheet metal ducts provide a fair secondary corrosion protection with excellent bond behavior between tendon and concrete. Primary corrosion protection is provided by the alkalinity of grout and concrete.
Dimensions of Corrugated Sheathing (Standard Size)

tendon type 0.5" 5901 5902 5903 5904 5905 5907 5909 5912 5915 5920 5927 5932 5937 5955 tendon type 0.6" 6801 6802 6803 6804 6805 6806 6807 6809 6812 6815 6819 6822 6827 6837 6861 I.D. mm 20 40 50 55 60 65 65 75 80 90 95 100 110 130 170 sheathing O.D. mm 25 45 55 60 65 70 70 80 85 95 100 105 118 138 178
I.D.
The tendon type number (e.g. 5901, 6801) is composed as follows: the first digit (5 or 6) identifies the nominal strand diameter in tenth of inches, i.e. 0.5" or 0.6"/ 0.62", the last two digits (..01) reference the number of used strands (= 1 strand). The second digit is an internal code. As regards the 0.6" tendon types, the accessories fit both Grade 250 (GUTS 1770 N/mm2) and Grade 270 (GUTS 1860 N/mm2) strands.
O.D.
tendon type 0.5" 5901 5902 5903 5904 5905 5907 5909 5912 5915 5920 5927 5932 5937 5955 1)
tendon type 0.6" 6801 6802 6803 6804 6805 6806 6807 6809 6812 6815 6819 6822 6827 6837 6861
min. center distances1) mm 36 72 90 99 108 117 117 117 144 162 171 180 198 235 306
support distances up to1) m 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8
wobble angle 1) /m 0.8 0.5 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3
coefficient of friction 1) 0.15 0.17 0.18 0.19 0.20 0.19 0.19 0.19 0.19 0.19 0.20 0.20 0.20 0.20 0.20
according to German approval
5
PE/PP Sheathing
Thick-walled polyethylene/ polypropylene (PE/PP) plastic ducts provide long-term secondary corrosion protection especially in aggressive environments such as waste water treatment plants, acid tanks or silos. Plastic ducts are an integral part in the electrically isolated tendons. The minute friction coefficients for strands inside PE sheathing enhance the fatigue life of tendons. Plastic ducts electrically isolate the tendon from the structure and thus provide a tool to inspect the integrity of the corrosion protection system. DYWIDAG-SYSTEMS INTERNATIONAL offers ducts in lengths between 4 and 6 m.
type
tendon type 0.5" 5905 5912 5919 5932 5909 5915 5927 5937
tendon type 0.6" 6805 6809 6815 6822 6807 6812 6819 6827
diameter I.D. mm 59 76 100 130 O.D. mm 73 91 116 147
wall thickness t mm 2,00 2.50 3.00 3.50
round duct
type flat duct
tendon type tendon type 0.5" 0.6" 5905 6804
axb mm 72/21
AxB mm 86/35
wall thickness t mm 2.00
6
Multiplane Anchorage MA
stressing anchorage
dead end anchorage accessible not accessible
coupling
ultimate load [kN] from to 1,302 17,019
The two-part multiplane anchorage is primarily used for longitudinal tendons in beams and bridges. The wedge plate with the conical anchor body and usually three load transfer planes introduces the prestressing force continuously into the member with minimal front area. The separation of anchor body and wedge plate makes it possible to insert the strand after casting the concrete. The wedge plate self-centers on the anchor body providing consistent assembly and installation as well as troublefree stressing.
pocket former for each anchorage system on request
SD
SDR Plate Anchorage SD/SDR
stressing anchorage
coupling
ultimate load [kN] from to 744 2,511
The single unit plate anchorage is designed for plate structures as well as transverse tendons in bridges. Small edge and center distances allow for an economical anchorage layout in condensed situations. The Plate Anchorage SDR has an enlarged plate that is designed to work with lower strength concrete (C20/25 according to EC2).
Mono Anchorage EV
Single unit anchorage used for one strand in slabs and similar structures.
ultimate load [kN] from to 265 279
stressing anchorage
coupling
7
Bond Head Anchorage ZF/ZR ZF Primarily used with prefabricated tendons, it is also possible to fabricate this anchorage on site. The strand wires are plastically deformed to ensure a safe load transfer up to ultimate capacity in the area of the bond head proven in static as well as in dynamic applications. Depending on the boundary conditions either two-dimensional or a threedimensional bond head anchorage pattern is available. ZR
stressing anchorage
coupling
Loop Anchorage HV
Often used in large plate-shaped structures, walls in off-shore structures or LNG tanks with generally static loadings. The 180 loop should be positioned in the center of the tendon to allow for non-slippage during two-end stressing.
stressing anchorage
coupling
Flat Anchorage FA
The Flat Anchorage of max. 4-0.62" or 5-0.52" strands in one plane to deviate into one oval duct is designed to be installed in thin members such as transverse post-tensioning of the top slab of box-girder bridges and prestressed flat slabs.
stressing anchorage
coupling
8
ME
Coupler M/ME (Floating Anchorage Block)
stressing anchorage
coupling
Cylindrical structures (water tanks, digestor tanks, large pipes or dome shells) that require circumferential posttensioning are the principal applications for the non-fixed coupler M/ME. The tendon anchorage consists of an anchorage block with wedge holes on both sides to accept bare or greased and sheathed strands. The strands actually overlap in the block and use the belt-buckle principle. The ring-tendon is very compact and requires a very small pocket only.
Coupler R
Coupler R is designed to couple on to already installed and stressed tendons. The coupler consists of a multiplane anchor body and a coupler wedge plate where the strands are overlapped. The continuing strands can be installed easily and independently.
fixed coupler
floating coupler
ultimate load [kN] from 1,395 to 7,533
Coupler P
Coupler P consists of a multiplane anchorage body, the standard wedge plate and a coupler ring that accepts the continuing strands with swaged anchorages instead of wedges. For similar applications both coupler R and P can be installed alternatively.
ultimate load [kN] from 1,395 to 7,533
fixed coupler
floating coupler
9
Coupler D
To lengthen unstressed tendons, e.g. in segmental bridge construction, coupler D is put to use. The splice chuck consists of two spring - loaded wedges that connect two strands individually.
ultimate load [kN] from 558 to 7,533
fixed coupler
floating coupler
Overview
Tendon Type 59 ..
59... Anchorage Type Multiplane Anchorage MA Plate Anchorage SD Plate Anchorage SDR Bond Head Anchorage ZF/ZR Loop Anchorage HV Flat Anchorage FA Coupler R Coupler P Coupler D 01 02 03 04 05 06 07 08 09 12 15 19 20 22 27 32 37 55
q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q
Tendon Type 68 ..
68... Anchorage Type Multiplane Anchorage MA Plate Anchorage SD Plate Anchorage SDR Mono Anchorage EV Bond Head Anchorage ZF/ZR Loop Anchorage HV Flat Anchorage FA Coupler M and ME (Floating Anchorage) Coupler R Coupler P Coupler D 01 02 03 04 05 06 07 08 09 10 12 15 19 22 27 37 61
q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q
10
Installation
DYWIDAG-SYSTEMS INTERNATIONAL has developed three different methods to insert strands into ducts. The selection of the insertion method depends on the boundary conditions of the structure and the job site.
Method 1 : Pushing
coil
pushing device
strand
tube
To push strands into the duct on the job site is very economical and can be done either before or after casting the concrete. The pushing equipment can be installed remotely and connected flexibly to the insertion point. DSI strand pushers provide relatively high speed of up to 8 m/s and require minimal operating personnel of only two men. These advantages make this method the preferred standard for strand installation.
crane
Method 2 : Pulling
reel
tendon (strands) tendon (strands) pulling rope
winch
To install strands while pulling them into the duct can be very efficient in special structures, for example where the loop anchorage is used. In normal cases the whole bundle of strands is pulled through winching with a steel cable.
DSI pulling head
Method 3 : Pre-Assembled Tendons
The prefabrication of tendons either in the shop or in the field can also be very economical, especially with shorter tendons and short shipping distances. Special uncoilers or hydraulic winches are necessary to properly install the tendons in the structure.
11 11
Stressing
DYWIDAG has developed a series of jacks and rams and hydraulic pumps in order to reach the target stressing load. The necessary versatility is provided by changing devices that make one unit adaptable for many different tendon sizes. DYWIDAG Equipment is designed to cover a wide spectrum of applications with jack capacities ranging from 250 kN up to 15,000 kN. DYWIDAG Rams are highly sophisticated, but still convenient to operate. They employ inner tube bundles with automatic gripping devices that guide the strand safely through the inside of the ram. This feature allows the stressing operation to be controlled with the highest degree of reliability as well as minimal wedge seating losses by benefiting from the power seating option. Power seating is a way of hydraulically pressing in the wedges with a predefined load individually and simultaneously rather than relying simply on friction seating. DYWIDAG Rams also make it possible to overstress and release the tendon to compensate for friction losses and maximize the stress level over the tendon length. Every ram has a pressure relief valve for safety reasons that activates to limit hydraulic pressure should the hydraulic pump malfunction. To further verify the stressing operation an additional gauge port is provided directly on the ram. Stressed tendons can be destressed with special wedges and a special ram configuration. Hydraulic pumps can be equipped with a convenient remote control device. Further information concerning the equipment is provided on page 25 and following.
jack HoZ 3000
hydraulic pump with a remote control
919 . 6803 . 6861 .

5920
5904 6804 6801 5920
measurement of piston stroke
12
Grouting
The durability of post-tensioned construction depends mainly on the success of the grouting operation. The hardened cement grout provides a bond between concrete and tendon as well as primary long-term corrosion protection for the prestressing steel. DYWIDAG has developed a grouting operation that is based on thixotropic and highly plasticized grout, and utilizes durable grouting equipment. Advanced methods such as pressure grouting, post-grouting and vacuum grouting are all results of many years of development. Grouting is always done from a low-point of the tendon. This can be one of the anchorages where a grout cap with grout hose is the port for the grout or along the tendon utilizing an intermediate grout saddle. All grouting components are threaded for easy, fast and positive connection (see page 26 and following).
draining operation
mixing and grouting unit
5915 . 6837 . 5909 . 6801

6819 5909 5907 6801 6802 6804
6819 5909 5907 6801 6802 6804 5905 5908
vacuum grouting
13
Multiplane Anchorage MA
Technical Data
type ultimate load 0.5" 12.9 mm GUTS (186kN per strand) 1860 N/mm2 kN 5907 1,302 5909 1,674 5912 2,232 5915 2,790 5919 3,534 5927 5,022 5932 5,952 5937 6,882 5955 10,230 type ultimate load 0.6" 15.7 mm GUTS (279kN per strand) 1860 N/mm2 kN 6805 1,395 6807 1,953 6809 2,511 6812 3,348 6815 4,185 6819 5,301 6822 6,138 6827 7,533 6837 10,323 6861 17,019
A mm 117 130 140 160 180 200 220 240 270 340
C1
C2
mm mm mm mm 150 36 90 190 170 40 100 200 180 43 125 300 220 44 180 350 250 51 200 400 280 55 220 450 300 66 220 550 315 75 240 600 390 90 350 600 490 143 405 800
Details of the Anchorage Zone

12.9 /15.7 mm, ultimate load 186/265 kN type type distances of the additional reinforcement 0.5" 0.6" anchorages helix GUTS GUTS center edge E F n e 1860 1770 distances distances N/mm2 N/mm2 mm mm mm mm mm 5907 6805 220 130 190 220 5 12 5909 6807 260 150 200 290 5 14 5912 6809 310 175 240 330 6 14 5915 6812 350 195 280 300 6 14 5919 6815 390 215 320 340 6 16 5927 6819 440 240 360 390 7 16 5932 6822 470 255 380 420 7 16 5937 6827 530 285 430 480 7 16 6837 620 340 540 550 7 20 68611) 800 420 680 705 8 25 1)
type 0.6" GUTS 1860

N/mm2
6805 6807 6809 6812 6815 6819 6822 6827 6837 68611)
1)
15.7mm, ultimate load 279 kN distances of the additional reinforcement anchorages helix center edge E F n e distances distances mm mm mm mm mm 240 140 210 240 5 14 280 160 250 335 6 14 340 190 310 365 6 16 380 210 350 350 7 16 420 230 390 440 8 16 480 260 450 350 6 20 520 280 490 430 7 20 580 310 550 480 8 20 680 360 650 910 10 20 880 460 850 855 10 25
2)
rectangular shape
2)
additional surface reinforcement in area G required
rectangular shape
additional surface reinforcement in area G required
alternative reinforcement on request
14
The values for the anchorage are based on FIP Code for concrete strengths of 25 N/mm2 (cube) or 21 N/mm2 (cylinder) (after 28 days)
Possible to apply to other code systems or concrete strengths. (e.g. ASTM, BS, DIN and concrete strengths of 35 N/mm2, 45 N/mm2 )
Max. prestressing load 75 % of ultimate load (GUTS) (short-term overstressing to 80 % is permissible)
Plate Anchorage SD
Technical Data
type ultimate load 0.5" 12.9 mm GUTS (186 kN per strand) 1860 N/mm2 kN 5904 744 5905 930 5907 1,302 5908 1,488 5909 1,674 5912 2,232 type ultimate load 0.6" 15.7 mm GUTS (279 kN per strand) 1860 N/mm2 kN 6803 837 6804 1,116 6805 1,395 6806 1,674 6807 1,953 6808 2,232 6809 2,511 A B C D
mm 125 135 150 165 170 180 190
mm mm mm 140 41 300 160 41 300 180 40 350 205 44 350 215 44 400 230 48 400 245 48 400

type 0.5" GUTS 1860 N/mm2 5904 5905 5907 5908 5909 5912 12.9/15.7 mm, ultimate load 186/265 kN type distances of the additional reinforcement 0.6" anchorages helix long. bars GUTS center edge E F n e G n g 1770 distances distances N/mm2 mm mm mm mm mm mm mm 6803 190/320 115/180 140 200 3 10 229 4 12 6804 200/360 120/200 150 200 3 10 289 5 12 6805 210/390 125/205 160 200 3 10 296 5 12 6806 230/430 135/235 175 250 4 10 296 6 12 6807 240/460 140/250 190 250 4 10 296 6 12 6808 300/460 170/250 240 250 4 10 242 5 14 6809 320/480 180/260 260 250 4 12 242 5 14 15.7 mm, ultimate load 279 kN distances of the additional reinforcement anchorages helix long. bars center edge E F n e G n g distances distances mm mm mm mm mm mm mm 200/320 120/180 140 250 4 10 229 4 12 215/360 130/200 150 250 4 10 289 5 12 230/390 135/205 160 250 4 10 290 5 12 245/430 145/235 175 250 4 12 246 5 14 260/460 150/250 190 250 4 12 246 5 14 320/460 180/250 240 300 5 14 242 5 16 340/480 190/260 260 300 5 14 242 5 16
Possible to apply to other code systems or concrete strengths. (e.g. ASTM, BS, DIN and concrete strengths of 25 N/mm2, 45 N/mm2 ) Max. prestressing load 75 % of ultimate load (GUTS) (short-term overstressing to 80 % is permissible)
type 0.6" GUTS 1860 N/mm2 6803 6804 6805 6806 6807 6808 6809
15
Plate Anchorage SDR
Technical Data
type ultimate load 0.5" 12.9 mm GUTS (186 kN per strand) 1860 N/mm2 kN 5902 372 5903 5904 744 type ultimate load 0.6" 15.7 mm GUTS (279 kN per strand) 1860 N/mm2 kN 6802 558 6803 837 6804 1,116
A mm 130 130 140
mm mm mm 180 50 350 180 50 350 200 52 350

12.9/15.7 mm, ultimate load type distances of the add. type distances of the 0.5 anchorages reinforce. 0.6" anchorages GUTS center edge GUTS center edge 1860 distances distances 1770 distances distances N/mm2 N/mm2 mm mm 5902 6802 160/240 100/140 5903 on request 6803 180/260 110/150 5904 6804 200/280 120/160 186/265 kN additional reinforcement helix stirrups E mm 170 170 170 F mm 200 200 200 n 4 4 4 e a x b G n g
mm mm mm mm 8 140/220 235 4 10 10 160/240 265 5 10 12 180/260 273 6 12
15.7 mm, type distances of the 0.6 anchorages GUTS center edge E 1860 distances distances 2 N/mm mm mm mm 6802 160/240 100/140 170 6803 180/260 110/150 170 6804 200/280 120/160 170
ultimate load 279 kN additional reinforcement helix stirrups F mm 200 200 200 n 4 4 4 e a x b G n g mm 12 12 14
mm mm mm 10 140/220 235 4 12 160/240 265 5 14 180/260 273 6
16
Mono Anchorage EV
Technical Data
type 0.6" GUTS 1860 N/mm2 6801 ultimate load 15.7 mm A B C D
(279 kN per strand)
279
mm 55
mm 130
mm 38
mm 140
Details of the Anchorage Zone Installation with min. Reinforcement1)

15.7 mm, ultimate load 265 kN 15.7 mm, ultimate load 279 kN type type center edge center edge 0.6" distances distances 0.6" distances distances GUTS GUTS 1770 1860 N/mm2 mm mm N/mm2 mm mm 6801 140/240 90/140 6801 160/240 100/140
1)
surface reinforcement required
Installation with min. Distances

type 0.6" GUTS 1770 N/mm2 6801 15.7 mm, ultimate load 265 kN distances of the additional reinforcement stirrup anchorages long. bars center edge axb e n g distances distances mm mm mm mm mm 100/190 70/115 80/110 8 2 8
type 0.6" GUTS 1860 N/mm2 6801
15.7 mm, ultimate load 279 kN distances of the additional reinforcement stirrup long. bars anchorages center edge axb e n g distances distances mm mm mm mm mm 120/200 80/120 100/120 10 2 10
Possible to apply to other code systems or concrete strengths. (e.g. ASTM, BS, DIN and concrete strengths of 25 N/mm2, 45 N/mm2 ) Max. prestressing load 75 % of ultimate load (GUTS) (short-term overstressing to 80 % is permissible)
17
Bond Head Anchorage ZF/ZR
ZF
ZR ZR
Technical Data
type ultimate load type ultimate load 0.5" 12.9 mm 0.6" 15.7 mm GUTS GUTS 1860 (186 kN per strand) 1860 (279 kN per strand) N/mm2 kN N/mm2 kN 5901 186 6801 279 5903 558 6803 837 5904 744 6804 1,116 5905 930 6805 1,395 5907 1,302 6807 1,953 5909 1,674 6809 2,511 5912 2,232 6812 3,348 5915 2,790 6815 4,185 5920 3,720 6819 5,301
mm 140 130 150 280 330 280 330 380 480
mm 140 240 300 280 280 300 300 300 300
mm 1000 1000 1000 1000 1000 1000 1000 1000 1000
= long = short
position type ZR ..05 ..07
position type ZF
..01
..03
..04
..09
..12
..15
..19

type 0.5" GUTS 1860 N/mm2 5901 5903 5904 5905 5907 5909 5912 5915 5920
1)
12.9/15.7 mm, ultimate load 186/265 kN additional reinforcement distances of the type helix anchorages 0.6" GUTS center edge E F n e 1770 distances distances 2 N/mm mm mm mm mm mm 6801 170/170 105/105 6803 220/400 110/200 6804 240/480 120/240 6805 280/280 160/160 200 300 5 10 6807 280/330 160/185 200 300 5 10 6809 380/280 210/160 200 300 5 10 6812 380/330 210/185 200 300 5 12 6815 380/380 210/210 200 300 5 14 6819 380/480 210/260 200 350 6 14
1)
type 0.6" GUTS 1860 N/mm2 6801 6803 6804 6805 6807 6809 6812 6815 6819
15.7 mm, ultimate load 279 kN distances of the additional reinforcement anchorages helix center edge E F n e distances distances mm mm mm mm mm 170/170 105/105 220/400 110/200 240/480 110/180 280/280 160/160 200 300 5 10 280/330 160/185 200 300 5 12 380/280 210/160 200 300 5 12 380/330 210/185 200 300 5 14 380/380 210/210 200 300 5 16 380/480 210/260 200 350 6 16
additional surface reinforcement in area G required The values for the anchorage are based on FIP Code for concrete strengths of 45 N/mm2 (cube) or 38 N/mm2 (cylinder) (after 28 days)
additional surface reinforcement in area G required Max. prestressing load 75 % of ultimate load (GUTS) (short-term overstressing to 80 % is permissible)
18
Loop Anchorage HV
Case 1
Case 2
Case 3
Caution: radius depends on duct (corrugated or smooth metal duct)! Ducts need to be pre-bent. Tendons need to be stressed simultaneouosly at both ends.
Z 3 (A + 5 mm)
Z = 4 (A + 5 mm)
Z 4 (A + 5 mm)
Technical Data Additional Reinforcement

type ultimate load 0.5" 12.9 mm GUTS (186 kN per strand) 1860 N/mm2 kN 5902 372 5903 558 5904 744 5905 930 5906 1,116 5907 1,302 5909 1,674 5912 2,232 5915 2,790 type 0.6" GUTS 1860 N/mm2 6803 6804 6805 6806 6807 6809 6812 6815 6819 ultimate load 15.7 mm
(279 kN per strand)
kN 837 1,116 1,395 1,674 1,953 2,511 3,348 4,185 5,301
mm 50 55 60 65 75 85 95 110 120
mm 40 45 50 55 60 75 80 90 95

type 0.5" GUTS 1860 N/mm2 5902 5903 5904 5905 5906 5907 5909 5912 5915 12.9/15.7 mm, ultimate load 186/265 kN type R As 0.6" GUTS 1770 N/mm2 mm cm2 6803 800 8.9 6804 800 11.9 6805 800 14.8 6806 800 17.8 6807 800 20.7 6809 1,000 24.9 6812 1,000 33.2 6815 1,500 41.4 6819 1,500 54.1 15.7 mm, ultimate load 279 kN type R As 0.6" GUTS 1860 mm cm2 N/mm2 6803 1,000 8.3 6804 1,000 11.1 6805 1,000 13.8 6806 1,000 16.6 6807 1,000 19.3 6809 1,250 24.9 6812 1,250 33.2 6815 1,750 41.4 6819 2,000 54.1
19
Flat Anchorge FA
Technical Data
type 0.5" GUTS 1860 N/mm2 5904 5905 ultimate load 12.9 mm
(186 kN per strand)
kN 744 930
type 0.6" GUTS 1860 N/mm2 6803 6804
ultimate load 15.7 mm

(279 kN per strand)
DA
DB
kN 837 1,116
mm 100 100
mm 255 330
mm 57 57
mm 115 220
mm 23 23
mm 75 75

type 0.5" GUTS 1860 N/mm2 5904 5905 12.9/15.7 mm, ultimate load 186/265 kN additional reinforcement type distances of the stirrups 0.6" anchorages GUTS center edge ax b n g 1770 distances distances N/mm2 mm mm mm mm 6803 305 190 160/280 4 10 6804 380 230 180/360 4 12 type 0.6" GUTS 1860 N/mm2 6803 6804 15.7 mm, ultimate load 279 kN distances of the additional reinforcement anchorages stirrups center edge axb n g distances distances mm mm mm mm 320 200 160/280 4 10 400 250 180/360 4 12
20
Coupler M/ME (Floating Anchorage Block)
Coupler M
Coupler ME
Technical Data
type 0.6" ultimate load 15.7 mm
(265 kN per strand)
ultimate load 15.7 mm

(279 kN per strand)
A mm 98 90 130 130 130 168 168
B mm 55 105 160 160 210 210 210
C mm 200 120 120 120 120 120 120
D mm 20 45 55 65 75 80 80
AD mm 60 60 70 70 70 70
BD mm 70 130 130 170 170 170
E mm 200 650 650 1,050 1,150 1,150
6801 6802 6804 6806 6808 6810 6812
kN 265 530 1,060 1,590 2,120 2,650 3,180
kN 279 558 1,116 1,674 2,232 2,790 3,348

15,7 mm, ultimate load 265/279 kN type X Y Z 0.6" mm mm mm 1) 180 60 6801 6802 130 155 50 6804 180 195 70 6806 180 195 70 6808 230 195 70 6810 230 235 90 6812 230 235 90
Block-Out Dimensions
type 0.6" 6801 6802 6804 6806 6808 6810 6812 L2 mm 550 700 700 1,350 1,500 1,500 LR mm 550 600 600 600 800 800
Case 1:If LR L2-1/2 I then L = s + 1/2 I + 285 mm + L2 Case 2:If LR > L2-1/2 I then L = s + 285 mm + L2 s = 0.2 x 1/2 I 120 mm
21
Coupler R
Technical Data
type 0.5" GUTS 1860 N/mm2 5909 5912 5915 5919 5927 5932 5937 type 0.6" GUTS 1860 N/mm2 6805 6807 6809 6812 6815 6819 6822 6827 ultimate load 12.9 mm
(186 kN per strand)
kN 1,953 2,511 3,348 4,185 5,301 6,138 7,533 ultimate load 15.7 mm
(279 kN per strand)
mm 226 226 248 266 320 340 380
mm 140 150 165 190 250 300 300
mm 105 105 105 110 120 125 135
mm 300 350 450 450 580 620 650
kN 1,395 1,953 2,511 3,348 4,185 5,301 6,138 7,533
mm 207 207 226 248 266 289 340 380
mm 140 140 150 165 190 205 275 300
mm 110 110 105 105 110 120 125 135
mm 330 330 350 450 450 580 620 650
Details of the Coupler Zone

type type 0.5" 0.6" GUTS GUTS 1860 1860 N/mm2 N/mm2 6805 5909 6807 5912 6809 5915 6812 5919 6815 5927 6819 5932 6822 5937 6827 12.9/15.7 mm, ultimate load 186/279 kN center distances length of space of anchorages for installation
mm 320 320 350 370 400 430 460 500
mm 2,000 2,000 2,000 2,000 2,000 2,000 2,000 2,000
22
Coupler P
Technical Data
type 0.5" GUTS 1860 N/mm2 5912 5915 5920 5927 5932 5937 type 0.6" GUTS 1860 N/mm2 6805 6809 6812 6815 6819 6827 ultimate load 12.9 mm
(186 kN per strand)
kN 2,232 2,790 3,534 5,022 5,952 6,882 ultimate load 15.7 mm

(279 kN per strand)
mm 236 264 294 308 339 365
mm 205 225 250 265 290 320
mm 135 145 150 155 170 180
mm 570 755 755 880 830 905
kN 1,395 2,511 3,348 4,185 5,301 7,533
mm 176 236 260 290 305 365
mm 165 205 225 250 265 320
mm 132 136 145 150 155 170
mm 510 570 755 755 880 905

type 0.5" GUTS 1860 N/mm2 5912 5915 5920 5927 5932 5937 12.9/15.7 mm, ultimate load 186/279 kN type center distances length of space 0.6" of anchorages for installation GUTS 1770 N/mm2 mm mm 6805 300 2,000 6809 360 2,000 6812 380 2,000 6815 420 2,000 6819 450 2,000 480 2,000 6827 500 2,000
23
Coupler D
1050 A = 2B+1200+ L+s s = 0,2 L 120
L+s 150
B dimensions in mm
Technical Data
type ultimate load type 0.6" 0.5" 12.9 mm GUTS (186 kN per strand) GUTS 1860 1860 kN N/mm2 N/mm2 5903 558 6803 5904 744 6804 5905 930 6805 5907 1,302 6807 5909 1,674 6809 5912 2,232 6812 5915 2,790 6815 5919 3,534 6819 5922 4,092 6822 5927 5,022 6827 ultimate load 15.7 mm
(279 kN per strand)
kN 837 1,116 1,395 1,953 2,511 3,348 4,185 5,301 6,138 7,533
mm 150 200 250 250 300 350 350 400 400 400
mm 100 110 120 125 140 160 180 200 220 240
mm 50 55 60 65 75 80 90 95 100 110
200 mm
46 mm

type 0.5" GUTS 1860 N/mm2 5903 5904 5905 5907 5909 5912 5915 5919 5922 5927 12.9/15.7 mm, ultimate load 186/279 kN type center distances center distances 0.6" coupler to coupler duct to coupler GUTS 1860 N/mm2 mm mm 6803 180 135 6804 200 150 6805 210 160 6807 225 170 6809 250 190 6812 290 215 6815 325 240 6819 360 265 6822 400 290 6827 430 315
24
Equipment Overview
Jacks
Tensa SM 200
HoZ 950/1,700
HoZ 3,000/4,000
15,000
jack type SM 200 HoZ 950/100 HoZ 1,700/150 HoZ 3,000/250 HoZ 4,000/250 6,800 9,750 15,000
59.. 68.. 01 02 03 04 05 06 07 08 09 12 15 20 22 27 32 37 55 01 02 03 04 05 06 07 08 09 10 12 15 19 22 27 37 61 q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q
Technical Data
jack type1) SM 200 HoZ 950/100 HoZ 1,700/150 HoZ 3,000/250 HoZ 4,000/250 6,800 9,750 15,000
1) 2)
length L mm 842 621 803 1,137 1,271 1,150 1,170 1,640
diameter D mm 98 203 280 385 482 560 680 980
stroke mm 200 100 150 250 250 300 300 500
piston area cm2 47.13 161.98 298.45 508.94 894.57 1237.01 1772.45 2695.29
capacity2) kN 198 972 1,745 3,054 4,204 6,803 9,748 15,000
weight kg 19 65 160 400 600 1,185 1,770 5,500
wedging incl. without friction
25
Equipment Overview
Block-Out Dimensions
H E F G
C B A
jack type SM 200 HoZ 950/100 HoZ 1,700/150 HoZ 3,000/250 HoZ 4,000/250 6,800 9,750 15,000
1) 2)
A 8801) 621 803 1,130 1,235 1,4211) 1,4701) 2,200
B 370 350 490 650 740 -
C 150 180 220 220 80 120 -
D 80 300 300 -
E 100 220 270 360 -
F 75 200 230 320 360 330 380 -
G 50 130 170 220 270 310 390 540
H 120 190 220 310 320 410 550 -
K 100 260 340 440 540 620 740 1,240
L2) 200/ 300/400 450/600 350/600 450/800 - /1,200 - /1,200 - /1,600
stroke incl. nec. strand protrusion (with/without power seating device)
26
Equipment Overview
Hydraulic Pumps
77 - 159 A
R 6.4
R 11.2 - 11.2/210
jacks1) pumps 77 - 159 A 77 - 193 A R3 R 6.4 R 11.2-11.2 R 11.2-11.2/210 ZP 57/28

1)
SM 200 q q q q
HoZ 950 q q q q
HoZ 1,700 q q q
HoZ 3,000
HoZ 4,000/250
6,800
9,750
15,000
q q for all pushing devices
q q
q q
for pistons without power seating
Width W H
Technical Data
pumps1) operation pressure MPa 70 70 70 60 55 16/22 capacity V min l/min 3.0 3.0 3.0 6.4 11.2/22.4 53/80 eff. oil amount I 10.0 10.0 13.0 70.0 170.0 175.0 weight kg 60 63 98 310 720 610 dimensions LxWxH mm 420/380/480 420/380/480 600/390/750 1,400/700/1,100 2,000/800/1,300 1,260/620/1,330
77-159 A 77-193 A R 3.0 R 6.4 R 11.2-11.2/210 ZP 57/58

1)
hydraulic pumps will be delivered without oil
27
Equipment Overview
Pushing Equipment
ESG 8 - 1
type
ESG 8 - 1
tensile or compression force kN 3.9
pushing speed m/s 6.1
weight kg 140
dimensions LxWxH mm 1,400/350/510
hydraulic pumps ZP 57/28
Grouting Equipment (mixing and pumping)
MP 2,000 - 5
MP 4,000 - 2
grouting equipment
MP 2,000 - 5 MP 4,000 - 2 P 13 EMRT
max injection pressure MPa 1.5 1.5 8.0
capacitiy l/h 420 1,500 3,000
weight kg 60 63 98
dimensions LxWxH mm 2,000/950/1,600 2,040/1,040/1,750 2,150/1,750/1,500
28
The stressing records are part of the structural design and serve as a basis for the stressing operation. Besides the prestressing data, they contain the sequence of stressing and directions for procedures directly connected with the stressing operation, such as lowering of the formwork and releasing of bearings. Calculation of Strand Tendon Elongation The total elongation Itot which the tendon has to achieve during stressing should be calculated as:
Calculation of Elongation
Itot = Ip + Ic + Isl + Ie
Ip = elongation of the strand tendon [mm]
Ip =
1 Ap Ep
lp
lp
= length of tendon [m]

Po
1
lc
2
Px,0dx
Px,0 = P0 e- X = prestressing force at the stressing end [kN] P0

x
Px,0 = prestressing force of the tendon at any point distance x [kN]

Po Pe
= angle of deflection between the stressing end and at any point distance x [rad] =
180
aH2 + aV2 + | ]
Pe Ap
= coefficient of friction (see p.5) = wobble angle (see p.5) = prestressing force at the stressing end after wedge draw-in [kN] = area of prestressing strands
le
Ic = elastic deformation of the concrete (shortening must be treated as a positive value) [mm]
cm l c
Ic =
Ec
cm
lc
= average stress in the concrete cross section at the center of gravity of all tendons due to prestressing force [MN/m2] = length of the concrete member [m]
Isl = sum of anchor plate impressions and wedge slip according to the anchorage type applied [mm]
slip lsl [mm]

accessible not accessible
stressing anchorage 1 -
dead end anchorage 4 3
bond head anchorage *)
coupler R 3
coupler D 6
coupler M 3 -
values are based on prestressing force acc. to German Code *) see German approval Ie = elongation of the prestressing steel in the jack and seating device (if applicable) [mm] Calculation of Prestressing Force Pe [kN] at Stressing End and Influence Length le [m] due to wedge draw-in In [mm] at stressing end during lock-off of tensioning jack In Ep Ap P0 1
Ie =
= average angle of deflection along the influence length l e of tendon

behind the stressing end [rad/m]
draw-in slip In [mm] Pe = P0 (1 - 2 le 1) at the stressing anchorage at the coupler M
tendon type 6801 - 6807 6809 - 6827 6802 - 6812 standard case 2* 2* 8
jack type special case 4** 4** -
values are based on prestressing force acc. to German Code *) with wedge seating **) without wedge seating modulus of elasticity [N/mm2] concrete class Ec strand partial prestressing full prestressing 12 24 B 25 30,000 B 35 34,000 B 45 37,000 B 55 39,000
Ep = 195,000 [N/mm2] 16 32 20 40 24 48
required cube strength of the concrete at stressing acc. to DIN 4227, Part 1
29
DYWIDAG Post-Tensioning Systems using Bars
BMW Building, Germany
1030 1080/1230 835/1030
2G 26D 32E 36C 36E

....... ..................................
Gschnitztal Bridge, Austria
30
DYWIDAG Standard Bars
DYWIDAG SMOOTH BAR The DYWIDAG Smooth Bar has threaded ends with a rolled on thread. The threads are manufactured in the shop to the specifications of the customer. The rolled thread of the smooth bar results in a characteristic low seating loss and high fatigue resistance. This is the reason why the smooth bar is best used for very short tendons.
DYWIDAG Bar Post-Tensioning has been successfully used for more than 40 years in post-tensioned construction. It has evolved over time and has been optimized to enhance its performance and increase its competitiveness. All accessories of the DYWIDAG Post-Tensioning System using Bars are threaded providing a fast, simple and positive assembly. The threadability of the anchor nut also offers the advantage of adjusting the prestress force in the tendon at any given time before the tendon is grouted. DYWIDAG High -Strength Bars are available in lengths up to 30 m.
DYWIDAG THREADBAR DYWIDAG THREADBARS are hot rolled in the steel mill and come with thread-like deformed ribs over the entire length of the bar. The bar can be cut anywhere and is instantly threadable without further preparation.
Technical Data1
bar type steel grade fp0.1k/fpk diameter diameter/type nom. cross - sectional area weight pitch yield load fp0.1k .A ultimate load fpk .A fatigue stress range steel: (0.55 fpk/0.9fp0.1k) fatigue stress range nut/coupler: 0.6 fpk bending elastic bending min. R cold bending min. R
1)
SMOOTH BAR N/mm2 835/1,030 1,080/1,230 mm 32 36 32G 36C 804 1,018 mm2 kg/m 6.31 7.99 mm 3.0 3.0 kN 671 1,099 kN 828 1,252 N/mm2 N/mm2 m m 290/230 98 19.50 4.80 290/230 98 12.10 5.40
26.5 26E 551 4.48 13.0 460 568
THREADBAR 835/1,030 1,080/1,230 32.0 36.0 26.5 32.0 36.0 32E 36E 26D 32D 36D 804 1,018 551 804 1,018 6.53 8.27 4.48 6.53 8.27 16.0 18.0 13.0 16.0 18.0 671 850 595 868 1,099 828 1,049 678 989 1,252 240/210 240/210 78 78 78 78
98
78
16.20 19.50 21.90 8.90 5.30 6.40 7.20 5.30
10.75 12.10 6.40 7.20
The values are based on the German Code (DIN). Possible to apply to other code systems or concrete strengths. (e.g. ASTM, BS and concrete strengths of 25 N/mm2, 35 N/mm2, 45 N/mm2 )
31
Anchorages for Bar Tendons
Bar Anchorages consist of one anchor body that transfers the load into the concrete and bears against the anchor nut. The anchor nut can accommodate a small angular mis-alignment due to construction tolerances. DYWIDAG-SYSTEMS INTERNATIONAL offers other anchor types in addition to the standard configurations described on the following pages. For special applications please contact one of our offices.
grout vent
sheathing stressing anchorage dead end anchorage
bar type steel grade fp0.1k/fpk diameter diameter/type QR plate anchorage solid plate anchorage, rectangular solid plate anchorage, squared
SMOOTH BAR THREADBAR 835/1,030 1,080/1,230 835/1,030 1,080/1,230 32.0 36.0 26.5 32.0 36.0 26.5 32.0 36.0 32G 36C 26E 32E 36E 26D 32D 36D q q q q q q q q q q q q q q q q q
32
QR Plate Anchorage
Technical Data
bar type steel grade fp0.1k /fpk nom. diameter diameter/type A B C width across flats A/F SMOOTH BAR THREADBAR N/mm2 835/1,030 1,080/1,230 835/1,030 1,080/1,230 mm 32.0 36.0 26.5 32.0 36.0 26.5 32.0 36.0 32G 36C 26E 32E 36E 26D 32D 36D mm 160 140 120 140 160 mm 180 165 130 165 180 mm 75 107 90 107 115 mm 65 60 50 60 65

bar type steel grade fp0.1k/fpk nom. diameter diameter/type concrete strength Y class B 25 X concrete strength class B 35 Y X concrete strength class B45 Y X N/mm2 mm center distances edge distances center distances edge distances center distances edge distances center distances edge distances center distances edge distances center distances edge distances SMOOTH BAR 835/1,030 1,080/1,230 32.0 36.0 32G 36C 280 160 320 180 2601) (380) 1501) (190) 2901) (440) 1651) (220) 230 135 260 150
1)
THREADBAR 835/1,030 1,080/1,230 26.5 32.0 36.0 26.5 32.0 36.0 26E 32E 36E 26D 32D 36D 200 250 280 120 145 160 220 280 320 130 160 180 (340) 190 230 2601)(380) (170) 115 135 1501)(190) (400) 210 260 2901)(440) (200) 125 150 1651)(220) 170 210 230 105 125 135 190 230 260 115 135 150
dimensions for QR plate stressing anchorage without additional reinforcement only
The values are based on the German Code (DIN). Possible to apply to other code systems or concrete strengths (e.g. ASTM, BS etc.)
33
Solid Plate Anchorage, Rectangular
The Solid Plate Anchorage is suitable for regular and lightweight concrete. In addition, the anchor plate can be cast in or dry placed after the concrete has hardened. The Solid Plate Anchorage is almost universal in use and very versatile, and frequently used in rehabilitation and strengthening applications.
Technical Data
bar type steel grade fp0.1k /fpk nom. diameter diameter/type A B C width across flats A/F SMOOTH BAR N/mm2 835/1,030 1,080/1,230 mm 32.0 36.0 32G 36C mm 120 150 mm 220 290 mm 82 100 mm 55 65 THREADBAR 835/1,030 1,080/1,230 32.0 36.0 26.5 32.0 36.0 32E 36E 26D 32D 36D 120 150 150 150 150 220 240 180 240 290 111 127 100 127 140 55 60 50 60 65
26.5 26E 120 150 86 46

bar type steel grade fp0.1k /fpk nom. diameter diameter/type concrete strength Y class B 25 X concrete strength class B 35 Y X concrete strength class B45 Y X N/mm2 mm SMOOTH BAR 835/1030 1,080/1,230 32.0 36.0 32G 36C 160 100 550 300 160 100 440 240 130 160 85 100 300 330 170 190 835/1,030 26.5 32.0 26E 32E 130 130 85 85 200 300 120 170 THREADBAR 1,080/1,230 36.0 26.5 32.0 36E 26D 32D 160 160 160 100 100 100 440 280 440 240 160 240 160 160 160 100 100 100 360 230 360 200 140 200 160 160 160 100 100 100 280 180 280 160 110 160
center distances edge distances center distances edge distances center distances edge distances center distances edge distances center distances edge distances center distances edge distances
36.0 36D 160 100 550 300 160 100 440 240 160 100 330 190
34
Solid Plate Anchorage, Square
Technical Data
bar type steel grade fp0.1k/fpk nom. diameter diameter/type A C width across flats A/F SMOOTH BAR THREADBAR N/mm2 835/1,030 1,080/1,230 835/1,030 1,080/1,230 mm 32.0 36.0 26.5 32.0 36.0 26.5 32.0 36.0 32G 36C 26E 32E 36E 26D 32D 36D mm 160 160 180 180 mm 72 100 117 117 mm 55 55 60 60 -

bar type steel grade fp0.1k/fpk N/mm2 nom. diameter mm diameter/type concrete strength center distances class B 25 edge distances concrete strength center distances class B 35 edge distances concrete strength center distances class B 45 edge distances SMOOTH BAR 835/1,030 1,080/1,230 32.0 36.0 32G 36C 240 140 220 130 200 120 THREADBAR 26.5 26E 835/1,030 32.0 32E 240 140 220 130 200 120 36.0 36E 230 135 26.5 26D 1,080/1,230 32.0 32D 230 135 36.0 36D -
35
Splices
DYWIDAG Splices are used to extend bars to any desirable length. The DYWIDAG Bar Post-Tensioning System uses 3 different connection variations for fixed and movable couplers:
1. Standard Coupler
2. Compensation Coupler
3. Transition Coupler
to join bars in the free length and at anchorages
to bridge gaps of bar end distances, for example in free cantilever and precast segmental construction
to couple bar tendons of different sizes or types
Corrugated Sheathing
Thin - walled flexible metal ducts are used to create the void for prestressing elements. The ducts are threadable along their entire length to enable easy and fast installation on the job site. A larger metal duct is placed in the areas where DYWIDAG Bar Couplers are used. These coupler ducts allow for movement of the coupler during stressing. A full line of grouting accessories services the DYWIDAG Post-Tensioning System using Bars.
Dimensions of Corrugated Sheathing (Standard Size)

bar type SMOOTH BAR THREADBAR steel grade fp0.1k/fpk N/mm2 835/1,030 1,080/1,230 835/1,030 1,080/1,230 nom. diameter mm 32 36 26.5 32.0 36.0 26.5 32.0 36.0 type/diameter 32G 36C 26E 32E 36E 26D 32D 36D internal diameter I.D. mm 44 51 38 44 51 38 44 51 external diameter O.D. mm 49 57 43 49 57 43 49 57
Technical Data
bar type SMOOTH BAR THREADBAR steel grade fp0.1k/fpk N/mm2 835/1,030 1,080/1,230 835/1,030 1,080/1,230 nom. diameter mm 32 36 26.5 32.0 36.0 26.5 32.0 36.0 type/diameter 32G 36C 26E 32E 36E 26D 32D 36D min. center distances mm 79 92 68 79 92 68 79 92 support distances m 0.5 - 2.5 0.5 - 2.5 wobble factor /m 0.3 0.3 friction factor 0.25 0.5
36
Installation
DYWIDAG-SYSTEMS INTERNATIONAL offers a full line of special installation accessories to facilitate field assembly and installation. Inexperienced workers are easily trained in the assembly due to all threaded components. On the other hand, tendons can be delivered to the job site prefabricated when desired.
Pocket Former The pocket former was developed as a principal accessory to provide just enough space in a block-out to position the ram onto the anchorage. Stressing
The small, light and conveniently operated DYWIDAG Bar Jacks facilitate the stressing operation. Heavy lifting aids are generally not necessary. The jack is pushed over a pullrod coupler that is threaded onto the bar protrusion behind the anchor nut. The jack is then fixed with a pulling nut. The tension load is hydraulically transferred. The anchor nut is tightened by an internal wrench.
37
Stressing
Stressing Notes Straight tendons are generally stressed from one end only. In order to reduce friction losses (especially in draped tendons) it is recommended to stress from both sides. The prestressing load can be adjusted up and down at any given time until the tendon is fully grouted by simply reinstalling the jack. This also makes it possible to partially stress tendons. Several controls during and after the stressing operation check the effective stressing load: - bar protrusion at the anchorage before and after stressing to evaluate the effective elongation - counter control for elongation during stressing operation - gauge control for hydraulic pressure - to comply with exceptional high demands on accuracy - for example on very short tendons special accessories can be introduced to minimize seating losses. Technical data about the DYWIDAG-Jacks are available on page 40.
bar protrusion
articulated jack nose
38
Grouting
Grout Cap The grout cap is threaded on the anchorage forcing the grout through grout channels in the anchor nut (slotted anchor nut) into the tendon.
The durability of post-tensioned construction depends to a great degree on the success of the grouting operation. The hardened cement grout provides a bond between concrete and tensile elements as well as primary longterm corrosion protection (alkaline medium) for the prestressing steel. DYWIDAG has developed a grouting operation that is based on thixotropic, highly plasticized grout, and utilizes durable grouting equipment. Advanced methods such as pressure grouting, post-grouting and vacuum grouting are all results of many years of development. Grouting is always done from a low-point of the tendon. This can be one of the anchorages where a grout cap with grout hose is the port for the grout or along the tendon utilizing an intermediate grout saddle. All grouting components are threaded for easy, fast and positive connection. Technical data on the grouting equipment is available on page 28.
mixing and pumping unit
Temporary Corrosion Protection Rust Ban A special emulsified oil (Rust Ban) provides an optimal temporary corrosion protection. The bar can be coated before shipping or as it arrives on the job site before it is inserted into the duct. There are means to even apply the oil after the bar is installed in the sheathing. Please inquire about other corrosion protection systems to suit special requirements.
unprotected bar (top); protected bar with Rust Ban (bottom)
Protection against Dirt and Water Special accessories have been developed to properly seal accessible anchorages against the environment. This is used for tendons that remain ungrouted over a long period of time or on winter job sites to avoid ice development in the tendon.
39
Equipment Overview
DYWIDAG Bar Jacks
jack 60 Mp Series 04
jack 110 Mp Series 03
bar type SMOOTH BAR THREADBAR steel grade 835/1,030 1,080/1,230 835/1,030 1,080/1,230 nom. diameter 32 36 26.5 32.0 36.0 26.5 32.0 36.0 diameter/type 32G 36C 26E 32E 36E 26D 32D 36D 60 Mp q q q q 110 Mp q q q q use 60 Mp if only stressed 55% to ultimate load can be stressed with 110 Mp on certain exceptions
Technical Data
jack types 60 60 110 110 Mp Mp Mp Mp Series Series Series Series 04 05 01 03 length L mm 401 456 494 594 O.D. mm 190 190 267 267 stroke mm 50 100 50 150 piston area cm2 132.5 132.5 235.6 235.6 capacity kN MPa 625 50 625 50 1100 50 1100 50 weight kg 36 44 46 54
Jack Dimensions (for Pocket Design)

jack types 60 60 110 110
1)
Mp Mp Mp Mp
Series Series Series Series
04 05 01 03
A mm 225 225 275 275
B mm 176 231 219 319
C1) mm 106 106 125 125
D1) mm 106 106 120 120
E mm 300 300 375 375
C and D are estimated values, exact measures depend on the bar diameter and strength
40
Equipment Overview
Necessary Bar Protrusion

bar type steel grade fp0.1k/fpk diameter/type nec. bar protrusion SMOOTH BAR THREADBAR 835/1,030 1,080/1,230 835/1,030 1,080/1,230 32G 36C 26E 32E 36E 26D 32D 36D 45 60 55 60 90 70 80 100
N/mm mm
Hydraulic Pumps
hand pump ZPH 1/5
hydraulic pump R 3.0
hydraulic pump type ZPH 1/5 77-159 A R 3.0 R 6.4

1)
operating pressure MPa 70 60 70 60
capacity l/min 10/1.6 3.01) 3.0 6.4
eff. oil amount l 4.5 10.0 13.0 70.0
weight kg 15 50 84 185
dimensions LxWxH mm x mm x mm 650/220/210 420/450/380 600/750/390 850/980/450
cm3/stroke
Grouting Equipment
see page 28
41
The stressing records are part of the structural design and serve as a basis for the stressing operation. Besides the prestressing data, they contain the sequence of stressing and directions for procedures directly connected with the stressing operation, such as lowering of the formwork and releasing of bearings. Calculation of Bar Tendon Elongation
The total elongation Itot [mm] which the bar has to achieve during stressing should be calculated as:
Itot = Ip + Ic + Isl
Ip = elongation of the bar tendon [mm] 1 Px,0dx Ap Ep 0
Ip =
Ip
P P 0,0 P ,l 0 P 0 P e
or in many cases it is accurate enough Ip = P0,l + P0,0 2 Ap Ep lp
x lp
- X Px,0 = P0 e Px,0 = prestressing force of the tendon at any point distance x [kN] P0,0 = prestressing force at the stressing end [kN] P0,l = prestressing force at the dead end x = angle of deflection between the stressing end and at any point distance x [rad] aH2 + aV2 + | ] = 180 [ = coefficient of friction (see page 36) = wobble angle (see page 36) Pe = prestressing force at the stressing end after anchor nut drawn - in [kN] Ap = area of prestressing bar (see page 31) Ep = modulus of elasticity of prestressing bar 195.000 [N/mm2]
le
x lp
Ip
= length of tendon [m]
Ic = elastic deformation of the concrete (shortening must be treated as a positive value) [mm]
Ic =
cm E
lc
lc
cm
= average stress in the concrete cross section at the center of gravity of all tendons due to prestressing force [MN/m2] = length of the concrete member [m] = modulus of elasticity of concrete (see page 29)
Ec Isl = sum of slip in the thread of the anchorages and couplers [mm]
lsl [mm] = For allowable stresses of 0.55 fpk the technical details are given in the Certificate of Approval for DYWIDAG Post-Tensioning Systems, for higher stresses the values increase in proportion.
42
Calculation of Prestressing Force Pe [kN] at Stressing End and Influence Length le [m] due to anchor nut drawn-in In [mm] at stressing end during lock-off tensioning jack In Ep Ap P0 1
1
Ie =
= average angle of deflection along the influence length le of tendon behind the stressing end [rad/m]
Pe = P0 (1 - 2 le
1)
Calculation of Existing Elongation lu = lub - lua In order to control the existing elongation the bar protrusions at the stressing end before and after stressing will be measured. The resulting elongation lu is the difference of these aforementioned values. The lu value must fairly well coincide with the calculated elongation.
lu = existing elongation lub = bar protrusion measured before stressing lua = bar protrusion measured after stressing
Calculation of Gauge Pressure p = 1,000 P0 Ak pr The gauge pressure corresponding to the total elongation ltot should be increased with the value of the pressure losses due to the internal friction in the jack.
p = required gauge pressure [1 MPa = 10 bar] P0 = Ap p = required prestressing force [kN] Ap = cross-sectional area of bar tendon [mm2] 2 p = steel stress at the stressing end [N/mm ] Ak = effective piston area of the jack [mm2] pr = friction loss in the jack. The positive sign applies for stressing, negative one for unstressing [Mp]
tendon type steel grade fp0.1k/fpk plate anchorage coupler
SMOOTH BAR pr [MPa] 835/1,030 1,080/1,230 0.05 0.10 0.10 0.10
THREADBAR pr [MPa] 835/1,030 1,080/1,230 0.10 0.15 0.10 0.15
43
DYWIDAG-SYSTEMS INTERNATIONAL GMBH
DSI Group HQ
DYWIDAG-SYSTEMS INTERNATIONAL P.O. Box 810268 81902 Munich, Germany Erdinger Landstrasse 1 85609 Aschheim Phone + 49 - 89 - 92 67- 0 Fax + 49 - 89 - 92 67- 2 52 E-mail: dsihv@dywidag-systems.com
Europe HQ
DYWIDAG-Systems International GmbH P.O. Box 810268 81902 Munich, Germany Erdinger Landstrasse 1 85609 Aschheim Phone + 49 - 89 - 92 67- 0 Fax + 49 - 89 - 92 67- 2 52 E-mail: dsihv@dywidag-systems.com
America HQ
DYWIDAG-SYSTEMS INTERNATIONAL USA INC. 320 Marmon Drive Bolingbrook, IL 60440 USA Phone + 1 - 6 30 - 7 39 11 00 Fax + 1 - 6 30 - 9 72 96 04 E-mail: dsiamerica@dsiamerica.com
Asia/Pacific HQ
www.dywidag-systems.com
04160- 1/02.01- 12.000 ka
Printed on bleached paper free from chlorine
DYWIDAG-SYSTEMS INTERNATIONAL PTY. LTD. P.O. Box 370 Charlestown NSW 2290, Australia 25 Pacific Highway Bennetts Green NSW 2290 Phone + 61 - 2- 49 48 90 99 Fax + 61 - 2- 49 48 40 87 E-mail: dsi@dywidag.com.au

Dywidag DSI Bonded PT System

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DYWIDAG-SYSTEMS INTERNATIONAL

DYWIDAG Bonded Post-Tensioning Systems

32G 26D 32E 36C 36E 32D

6803 . 6861 . 5915 .

DYWIDAG Post-Tensioning Systems

Post-Tensioning Systems using Strands

D = draining V = vent G = grouting C = coupling S = stressing

Dimensions of Corrugated Sheathing (Standard Size)

according to German approval

diameter I.D. mm 59 76 100 130 O.D. mm 73 91 116 147

wall thickness t mm 2,00 2.50 3.00 3.50

type flat duct

tendon type tendon type 0.5" 0.6" 5905 6804

wall thickness t mm 2.00

dead end anchorage accessible not accessible

ultimate load [kN] from to 1,302 17,019

pocket former for each anchorage system on request

SDR Plate Anchorage SD/SDR

dead end anchorage accessible not accessible

ultimate load [kN] from to 744 2,511

pocket former for each anchorage system on request

dead end anchorage accessible not accessible

pocket former for each anchorage system on request

dead end anchorage accessible not accessible

ultimate load [kN] from to 279 5,301

pocket former for each anchorage system on request

dead end anchorage accessible not accessible

pocket former for each anchorage system on request

dead end anchorage accessible not accessible

pocket former for each anchorage system on request

Coupler M/ME (Floating Anchorage Block)

dead end anchorage accessible not accessible

ultimate load [kN] from to 265 3,348

pocket former for each anchorage system on request

ultimate load [kN] from 1,395 to 7,533

tendon (strands) tendon (strands) pulling rope

DSI pulling head

Method 3 : Pre-Assembled Tendons

jack HoZ 3000

hydraulic pump with a remote control

919 . 6803 . 6861 .

5904 6804 6801 5920

measurement of piston stroke

mixing and grouting unit

5915 . 6837 . 5909 . 6801

6819 5909 5907 6801 6802 6804 5905 5908

Details of the Anchorage Zone

type 0.6" GUTS 1860

additional surface reinforcement in area G required

additional surface reinforcement in area G required

alternative reinforcement on request

Max. prestressing load 75 % of ultimate load (GUTS) (short-term overstressing to 80 % is permissible)

mm 125 135 150 165 170 180 190

Details of the Anchorage Zone

Plate Anchorage SDR

A mm 130 130 140

mm mm mm 180 50 350 180 50 350 200 52 350

Details of the Anchorage Zone

mm mm mm mm 8 140/220 235 4 10 10 160/240 265 5 10 12 180/260 273 6 12

mm mm mm 10 140/220 235 4 12 160/240 265 5 14 180/260 273 6