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BBRVT International Ltd is theTechnical Headquarters and Business Development Centre ofthe BBR Network located in Switzerland.The shareholders of BBRVT International Ltd are: BBRHolding Ltd (Switzerland), a subsidiary of theTectus Group (Switzerland); KB Spennteknikk AS(Norway), BBR Polska Sp. z o.o. (Poland) andVORSPANN-TECHNIK GmbH & Co. KG (Austria/ Germany), all members of the KB Group (Norway); BBR Pretensados yTécnicas Especiales,S.L. (Spain), a member of the FCC Group (Spain).

The BBR Network is recognized as the leading group of specialized engineeringcontractors in the field of post-tensioning, stay cable and related constructionengineering.The innovation and technical excellence, brought together in 1944by its three Swiss founders – Antonio Brandestini, Max Birkenmaier and MirkoRobin Ros – continues, more than 60 years later, in that same ethos andenterprising style.From technical headquarters in Switzerland, the BBR Network reaches outaround the globe and has at its disposal some of the most talented engineersand technicians, as well as the very latest internationally approved technology.

The Global BBR NetworkWithin the Global BBR Network, established traditions and strong local roots arecombined with the latest thinking and leading edge technology. BBR grants eachlocal BBR Network member access to the latest technical knowledge andresources – and facilitates the exchange of information on a broad scale andwithin international partnering alliances. Such global alliances and co-operationscreate local competitive advantages in dealing with, for example, efficienttendering, availability of specialists and specialized equipment or transfer oftechnical know-how.

Activities of the NetworkAll BBR Network members are well-respected within their local businesscommunities and have built strong connections in their respective regions.Theyare all structured differently to suit the local market and offer a variety ofconstruction services, in addition to the traditional core business of post-tensioning.

BBRTechnologiesBBR technologies have been applied to a vast array of different structures– such as bridges, buildings, cryogenic LNG tanks, dams, marine structures,nuclear power stations, retaining walls, tanks, silos, towers, tunnels, wastewatertreatment plants, water reservoirs and wind farms.The BBR brands andtrademarks – CONA, BBRV, HiAm, DINA, SWIF, BBR E-Trace andCONNAECT – are recognized worldwide.The BBR Network has a track record of excellence and innovative approaches– with thousands of structures built using BBR technologies.While BBR’shistory goes back over 60 years, the BBR Network is focused on constructingthe future – with professionalism, innovation and the very latest technology.

Every effort is made to ensure that the content of this publication is accurate but the publisherBBRVT International Ltd accepts no responsibility for effects arising there from.© BBRVT International Ltd 2010

Strong, fast, greenWithin the BBR Network, we have a long history of

innovation founded on listening to what our customers want

and then going the extra mile to deliver it – the

BBRVT CONA CMX® range of post-tensioning is our

response to current needs.This brochure is the ultimate ‘must-

have’ guide for designers and engineers, as it contains details of

the complete range of BBRVT CONA CMX technology.

You will see that we’ve focused on creating a sound solution which

offers benefits for all types of construction applications and to all

stakeholders. We have combined the requirement for strength and

reliability with a completely flexible and environmentally responsible

approach.When this comes together with the expertise and

professionalism of the BBR Network to advise on and install post-

tensioning systems, it is an unbeatable combination – and we are

sure you will agree that there’s no finer solution on the market!

Our new technology allows more freedom than ever before for

architectural and design creativity and it can save valuable program

time, while reducing impact on budgets and the environment. But

there’s even more, we’ve had our systems independently tested –

and have even gone beyond the requirements of international

norms. Our CONA CMX range has EuropeanTechnical Approval

(ETA) and, thus, bears the CE marking.

You may have guessed by now that we are very proud of our BBR

VT CONA CMX range of post-tensioning technology – and we

believe that you will be too!

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Check system specificationsAll system specifications arecontained in a separatebrochure within which allrelevant detailed technicaldata can be found.

Check ETACONA CMX systems haveEuropeanTechnical ApprovalETA which can bedownloaded onwww.bbrnetwork.com orobtained at BBRVTInternational Ltd.

How to use this brochure

2 Post-tensioning – the clever way

10 State-of-the art internationalpost-tensioning certification

16 BBRVT CONA CMX

18 CONA CMI – internal PT system

22 CONA CME – external PT system

24 CONA CMF – flat anchoragePT system

26 CONA CMM – monostrandPT system

30 CONA CMB – band PT system

Post-tensioning – the clever wayOwners, designers, builders and end users of any structures require more efficiencies today than ever before. BBRVT

CONA CMX post-tensioning offers all stakeholders in a project many benefits. For over 60 years, BBR post-

tensioning technology has been applied to thousands of different structures in the civil engineering and building

construction industry.All CONA CMX systems are backed by the EuropeanTechnical Approval ETA and the

associated Certificate of Conformity.

Post-tensioning (PT) is a fiendishly clever wayof reinforcing concrete while you are building– occasionally even allowing the constructionof something which might otherwise havebeen impossible. But it can also be combinedwith other structural materials, such as steel,masonry and timber structures. PT providesactive reinforcement and places the concretestructure under compression in those regionswhere load causes tensile stress.Since the first applications in the early 1950s,BBR PT technology has advanced significantly– particularly in the field of performance,quality assurance and durability, as well ascorrosion protection. Massive developmentsin the PT method over the past decades,mean that it is now a significant feature inconstruction and is applied in bridges,buildings, arenas, dams, nuclear power stations,wind farms, cryogenic LNG tanks, silos,wastewater treatment plants, waterreservoirs, marine structures, retaining walls,towers and tunnels.

Post-tensioning vs. pre-tensioningBoth post-tensioning and pre-tensioningcreate prestressed concrete. Pre-tensionedsystems, however, must be fabricated in aprecast plant and are limited to straight,harped or circular tendons. In addition,construction of continuous structures is verylimited with this method.Post-tensioning, on the other hand, allowsalmost any shape to be constructed and isable to match nearly any design requirement.Internal, bonded, unbonded and externalpost-tensioning is usually performed on theproject site and provides superior corrosionprotection features.

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Pre-tensioning

Post-tensioning

Internal bonded vs. unbondedpost-tensioningInternal bonded post-tensioning systems canrange from a single strand to multiplestrands (multi-strand) in one tendon.Thetendons are inserted into a metal or plasticduct that is embedded in the concrete. Byfilling the duct with special cementitiousgrout, the tendon is ‘bonded’ with thesurrounding concrete.The grout creates analkaline environment which ensurescorrosion protection of the prestressingsteel.Unbonded PT concrete differs from bondedpost-tensioning in that it provides eachindividual tendon with permanent freedomof movement relative to the concrete.

Internal vs. external post-tensioningTendons installed in the formwork prior topouring the concrete are known as internaltendons.External tendons are placed on the outersurface of concrete structures.This type ofpost-tensioning allows access for maintenanceand replacement and is therefore the solutionof choice for bridge enhancements andrefurbishments, but can also be applied tomany other types of structure.

Key benefits of post-tensioned structures

� Greater flexibility of design – PT allows highly creative architectural approaches andvery demanding geometry requirements.

� Increased deflection control and improved crack control – virtually crack-freeconcrete delivers long-term durability.

� Faster construction program – early strength stressing promotes a faster cycle time,allowing the structure to progress more rapidly.

� Lower construction material costs – PT can decrease the size of a structuralmember and reduce the quantity of concrete and steel required for thesuperstructure.

� Reduced environmental impact – less material creates fewer carbon emissions interms of production and transportation.

� Reduced construction costs – a faster cycle time and decreased amount of materialminimize costs.

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External post-tensioning

Internal bonded post-tensioningMulti-strand systemsBonded internal post-tensioning systems arecomprised of tendons from 1 to 73 or evenmore strands – see BBRVT CONA CMIinternal bonded.They have been extensivelyused in civil construction applicationsincluding various types of bridges (both cast-in-situ and precast segmental), tanks and silos,but have also been applied successfully tocommercial buildings for large structuralmembers such as beams and girders. Largemulti-strand tendons for cryogenicapplications are installed in LNG tankprojects.The advantages of internal bondedtechnology are:� The tendon can be easily ‘weaved’ inorder to match exactly the designer’sspecifications with a few limitations

� Extremely long span bridges can beconstructed without the use oftemporary intermediate supports

� Increased load-carrying capacity of largestructural elements

� Reduced structural depths� A fully bonded tendon cannotcompletely lose its tension in accidents.Bonded PT provides resistance toprogressive collapse because any loss oftendon force would be localized

Corrosion protectionProtection against corrosion is provided bywaterproofing, dense impermeable concrete,sealed ducts and good quality grouts – amultilayer protection strategy. PT has beenprovided with a first protective barrieragainst corrosion – namely grout.Thesecond protective barrier is provided by theducting. Enhanced corrosion protection andimproved fatigue resistance can be achievedwith corrugated plastic ducts such as BBRVTPlastic Ducts. Segmental plastic ductcouplers are the ideal solution for joints ofprecast structures.The highest protectionstandard can be provided with electrically-isolated tendons.

Slab post-tensioningSlab or flat anchorage PT technology, such asthe BBRVT CONA CMF or CMM SINGLEbonded system, is the preferred solutionwhen it comes to thin structural elements.Typical applications include suspended slabsof car parks, apartment buildings, commercialoffice space, retail centres, hospitals, stadiaand slabs on ground for distributionwarehouses, terminal facilities, hangars andsporting venues. But it has also been

successfully installed on vertical structuralmembers and bridge decks.A flat anchorage system is comprised ofstrands placed inside flat ducting andanchored by means of flat anchorages.Corrosion protection is ensured by a grout.The design of slab PT structures requiressound engineering consideration in order tomaximize the benefits for all stakeholders:� Reduced slab depths� Early formwork stripping� Floor-to-floor height reduction which canallow extra floors to be added or anoverall saving in cladding costs

� Greater clear spans and column-free areas.� PT slabs require less concrete, thusenabling fewer shear walls, smallercolumns and reduced foundation loads

� Minimized dead loads require lessgroundwork

� Reduced maintenance costs – joints in afloor slab – for example – can bereduced or even eliminated, thusminimizing joint maintenance

� Less sub base preparation and/orexcavation

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Internal unbonded post-tensioning

� A tendon can be de-stressedbefore attempting repairwork

� No grouting procedure

� Easy and swift installation oftendons

� Light and flexible design

Monostrand technologyUnbonded internal PT tendons such as theBBRVT CONA CMM unbonded system aretypically applied in construction for elevatedslabs, slabs on grade, girders, beams andmore.As they remain unbonded to thesurrounding concrete throughout theirservice life, they can move in relation to thestructural element. Protection againstcorrosion is ensured with soft filling materialssuch as grease and plastic sheathing formedin an extrusion process. If the tendon oranchorage becomes damaged, the cable cande-stress and burst out of the slab.

High capacity tendonsMulti-strand unbonded PT systems, such asBBRVT CONA CMI internal unbonded, areused for special applications includingprestressing of nuclear vessels. Such highcapacity tendons are either filled with greaseor wax, but can also be protected withcirculating dry air. BBRVT CONA CMFunbonded tendons are a possible solutionfor thin structural construction elements.

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� External PT can becombined with a broad rangeof construction materialsincluding concrete, steel,masonry and timber

� Monitoring, inspection andmaintenance can be easilycarried out

� Option for restressing,destressing and replacingexternal cables

� Improved concrete placingand tendon installation

External post-tensioning tendons, such as theBBRVT CONA CME external or BBRVTCONA CMB band system, are placedoutside of the cross-section of the structureand transfer the forces to the structure onlyat the anchorages and deviators.They arenot bonded to the structure.Typicalapplications are for the prestressing ofbridges, wind towers, precast segmentalconstruction and repair and strengtheningworks to all kinds of structures.External PT systems are grouted orgreased/waxed in HDPE ducts, but can alsobe double sheathed and greased/waxed.

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External post-tensioning

The best proof is experienceThe BBR Network’s long history of innovative development began during the SecondWorldWar. Max Birkenmaier,

Antonio Brandestini and Mirko Robin Ros explored the savings to be made by using pre-tensioned reinforcement

for concrete support girders. BBR developed and produced a button heading anchorage configuration from cold

drawn high tensile wire.This anchoring method was named BBRV. In the 1950s, the Swiss BBRV kit was the only

reliable PT system available on the construction market.

Subsequently, BBR developed a completerange of prestressing and post-tensioningsystems covering all structural engineeringapplications. Since those early applications,there have been many more stories to tell ofsuccesses and innovations.The BBRNetwork’s commitment to majortechnological innovation has beencontinuous and will also continue into thefuture.

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1944 Company founded by Max Birkenmaier,Antonio Brandestiniand Mirko Robin Ros

1945 BBR’s first product, the pre-tensioned small beam, was broughtto market

1948 Button head wire post-tensioning system BBRV patented

1952 Construction of first major bridge project – the AndelfingenViaduct for Swiss Federal Railways

1965 Prestressing of nuclear power vessels around the worldstarted

1972 Development of BBR CONA PT system

2005 Launch of latest European approved and CE-markedBBRVT CONA CMX PT series

2009 Launch of BBR E-Trace, the innovative trading and qualityassurance platform for CONA CMX systems

Professional installation practicePost-tensioning and grouting operations require the highest level of

professionalism which is exactly what the certified BBR PT Specialists and

members of the BBR Network deliver.These well-trained and experienced

staff are continuously educated through practical and theoretical training

courses to ensure professional execution of PT works.

Work on post-tensioning starts after anyformwork or reinforcement has beeninstalled.The ducting is laid out and theanchorages partially installed.When theconcrete has attained its minimum strengthand the strands have been pushed into theduct, the tendon is stressed with a hydraulicjack and locked-off at the anchorage.Theanchorage maintains the applied force in thetendon and transfers it to the surroundingconcrete.The duct is then filled with acementitious grout or flexible corrosioninhibitor. Grouting is carried out carefullyunder controlled conditions to ensure thatthe whole tendon is completely filled.Installation can also be performed with afully or partially prefabricated tendon.

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State-of-the-art international post-tensioningcertificationPost-tensioning kits for use in the European Community are required to have EuropeanTechnical Approval, which is

based on a set of defined testing procedures which must be fulfilled. Once the post-tensioning systems are placed on

the market, they are subjected to factory production control and independent and continuous surveillance. Post-

tensioning kits must be installed by trained Post-tensioning Specialist Companies to ensure professional and system-

conforming installation.

Legal basisWith the introduction of the Eurocode andaccording to the European ConstructionProducts Directive – (CPD), constructionproducts used in the European Community(EC) are required to carry “CE marking” – amandatory conformity mark. CE stands forConformité Européenne – "Europeanconformity". Post-tensioning kits can onlycarry CE marking if a EuropeanTechnicalApproval (ETA) has been obtained from anominated Approval Body and after an EC –Certificate of Conformity has been obtainedfrom an eligible Approved / Notified Body.The official guidance document giving therequirements for obtaining an ETA waspublished in 2002 within ETAG 013“Guideline for EuropeanTechnical Approvalof Post-tensioning Kits for Prestressing of

Structures” which details a set of testingprocedures which have to be fulfilled.The European Organization forTechnicalApprovals (EOTA) comprises the ApprovalBodies nominated to issue ETA after thetesting provisions stipulated in ETAG 013have been fulfilled and after Europeanconsultation has been successfullycompleted. European consultation involvescirculation of the technical documentation ofthe post-tensioning kit, with a summary ofthe tests performed on the system, to allnominated Approval Bodies within theEuropean Union.An ETA is valid for fiveyears and is issued for a proprietary post-tensioning kit to the Approval Holder with adesignated Kit Manufacturing Plant of thecomponents.As of 2008, use of CE markedpost-tensioning systems has been mandatory

throughout the whole of Europe and use ofthe Eurocode is mandatory from 2010onwards.The provisions made for Europeanapproved post-tensioning kits are based onan assumed intended working life of the PTsystem of 100 years.The EC – Certificate ofConformity attests that the manufacturing ofthe individual components is subject to thecontinuous surveillance of an independentauthority (Approved / Notified Body), whichchecks that the manufactured componentscomply with the components outlined in theparticular ETA.

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Definition of a post-tensioning kitA post-tensioning kit comprises all elementsthat make up the complete tendon which isbeing marketed and sold by the BBR Post-Tensioning Specialist Company (BBR PTSpecialist Company), who will take fullresponsibility for all components and theinstallation.For practical reasons, the reinforcement maybe provided by the contractor, but must fullycomply with the specifications and dimensionsgiven in the specific ETA and quality recordscollected by the BBR PT Specialist Company.The delivery notes for the proprietarycomponents of the specific BBRVT CONACMX PT kit contain the CE marking. Deliverynotes for standardized components must alsocontain CE marking – or a certificate ofconformity to the relevant national standard.At the end of a project, a definitive CEmarking record relating to the installed kit iscreated from the individual delivery noteswhich are archived for ten years.At the endof construction, the delivery notes with CEmarking and summarized definitive CEmarking record are the documents providedto the client. No other documents, such asdetailed test reports of the post-tensioningkits or detailed test reports on thecomponents, are required.

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Proprietary components

Fixed (passive) / stressing (live) anchor

Fixed or movable coupler units

Wedges

Bearing plates

Trumpets

Protection caps

Plastic duct

Special filling material

Standardized components

Seven-wire prestressing strand

Steel duct

Common filling material

Reinforcement

CE marking of CONA CMI system

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Typical testing provisionsETAG 013 “Guideline for EuropeanTechnicalApproval of Post-Tensioning Kits forPrestressing of Structures” details the fullscale tests the post-tensioning kit has toundergo.The basic testing provisions includethe following:

Static tensile tests for each anchorageand coupler typeA complete tendon is first stressed bymeans of standard stressing equipment to80% of the characteristic ultimate tensilestrength of the tendon (UTS).The load of80% UTS is then maintained for a durationof two hours, after which the tendon isstressed – by means of an external testingmachine – to failure. An efficiency of atleast 95% of the actual ultimate tensilestrength of the tendon and 2% elongationmust be achieved.

Fatigue tests for each anchorage andcoupler typeThe acceptance criteria is to pass twomillion load cycles with a stress range of80 MPa without fatigue failure in theanchorage components and with no morethan 5% of the tensile element cross-section being lost. Fatigue testing of post-tensioning systems is a new requirement inmany parts of the world and passing such atest requires particular care in detailing thecomponents of the anchorage and thetransition with the duct.

Load transfer tests for each anchoragetype and concrete strengthDuring a load transfer test, the anchoragecomponents, including relevantreinforcement and concrete with thedesired dimensions for a particularconcrete strength, are subjected to 10 loadcycles between 12% and 80% UTS, beforethe complete assembly is loaded to failure.An efficiency of at least 110% UTS mustbe achieved.Additional mandatory tests are described inETAG 013 – such as assembly and groutingtests, as well as a whole range of tests for

special applications. Examples include saddletests for external post-tensioning and testsunder cryogenic conditions.

Factory Production ControlETAG 013 specifies the minimum productioncontrol frequencies that have to be achieved,e.g. 100% material control, 5% dimensioncontrol, 100% visual check.Compliance with these and the completefactory production process are fully auditedby the Approved / Notified Body and anynon-conformity must be rectified prior toany CE marking.During the validity period of the ETA, theApproved / Notified Body continues toexert full control of the production – inaddition to the audits and testing by the KitManufacturer :� the ETA Holder and the Kit Manufacturerare audited every year

� each Component Manufacturer is auditedduring the five year validity of the ETA

� kit components are collected from siteannually for independent testing andchecking of the mechanical performance.

These provisions guarantee proper qualityand compliance of the kit componentsdelivered to site.

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State-of-the-art international post-tensioningcertification continued

State-of-the-art international post-tensioningcertification continued

BBR Post-tensioning SpecialistCompaniesEuropean Approved and CE marked post-tensioning kits must be installed by certifiedPT Specialist Companies.The BBR PTSpecialist Company is responsible, undersupervision of the ETA holder, forcompliance with all regulations set out in therelevant technical approvals for the post-tensioning kit and with the respectivestandards and regulations in force at theplace of use, and must ensure a professionalexecution of the post-tensioning works,which includes the following key points:� logistics and supply of a complete post-tensioning kit to the construction site

� full assembly and installation service ofthe post-tensioning kit on theconstruction site

� quality assurance and endorsement of allrelevant health and safety regulationsrelating to the work place

The key personnel of the BBR PT SpecialistCompany must be continuously trained inthe usage of the particular post-tensioningkits and be certified for the post-tensioningworks by the ETA Holder – BBRVTInternational Ltd.

An international passportensuring the highest standardsThe CE marking and the EuropeanTechnicalApproval create an international passportfor post-tensioning kits. CE marked BBRVTCONA CMX post-tensioning systemsinstalled by certified and responsible BBRPost-Tensioning Specialist Companiesprovide the highest level of quality andassure the owners of the structures towhich the post-tensioning kits are appliedthat only high quality and state-of-the-art

products are being used with the requiredlevel of safety.The key parameters of all CE marked post-tensioning systems are summarized in theparticular ETA which becomes the referencetechnical document defining the conditionsof use of the system.The full ETA documentis made available to designers, engineers,contractors and clients.

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BBRVT CONA CMXCE marked state-of-the-art postensioning kits

The BBR Network offers a complete rangeof post-tensioning systems, covering allpossible applications in structural and civilengineering.With the introduction of CEmarking for all construction products inEurope, EuropeanTechnical Approval (ETA),Euronorms (EN) and Eurocodes, wedeveloped and launched the BBRVT CONACMX post-tensioning range – the post-tensioning system for the 21st century –which is now used worldwide by the BBRNetwork.Its modular design means that a CONACMX post-tensioning kit can easily beconfigured to match very specialrequirements and therefore only the mostcommonly used configurations are describedin this brochure. Please contact the Swiss-based BBR Headquarters or your local BBRNetwork representative to discuss yourspecific needs.The modular BBRVT CONA CMX post-tensioning range is comprised of five mainsystems:� BBRVT CONA CMI – Internal post-tensioning system

� BBRVT CONA CME – External post-tensioning system

� BBRVT CONA CMF – Flat anchoragepost-tensioning system

� BBRVT CONA CMM – Monostrandpost-tensioning system

� BBRVT CONA CMB – Band post-tensioning system

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The main benefits of the BBRVT CONA CMX series are:

� modular system

� most compact and lightest anchorage system

� full stressing at lowest concrete strength

� widest range of standard tendons – ranging from 173 kN toover 20,000 kN characteristic ultimate resistance

� most tendon sizes

Seven-wire prestressing strandsSeven-wire strands are comprised of acentral wire, normally identified as ‘king wire’,and an external crown of six wires whichare twisted around the king wire. Strands

with a characteristic tensile strength equal to1,860 MPa are normally used; however steelstrands with a lower characteristic strength,1,770 MPa or 1,820 MPa, may also be used.

Characteristic values of strands according to prEN 10138-3

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BBRVT CONA CMIInternal bonded or unbonded post-tensioning system

Standard tendon sizesThe BBRVT CONA CMI post-tensioning kit isa multi-strand system for all types of internallypost-tensioned applications.The standardtendon sizes range from 1 to 73 seven-wireprestressing strands. Larger sizes are alsopossible and CONA CMI tendons with91 strands have already been used. Mostcommonly, 0.62’’ (15.7 mm) strands with across-sectional area of 150 mm2 and acharacteristic tensile strength of 1,860 MPaare used.The use of 0.5’’ (12.9 mm) strandswith a cross-sectional area of 100 mm2 anda characteristic tensile strength of 1,860 MPais also possible (*, see page 20).

Anchorage configurationThe main components in the anchor zone ofthe CONA CMI system are the wedges, anchorhead, load transfer element and trumpet.In the anchorage zone, the duct is connectedto the trumpet and the strand bundle isspread out towards the anchor head, whereeach strand is individually locked with specialBBR wedges.For the load transfer to the concrete, theCONA CMI BT (bearing trumplate) can beused for tendon sizes with 02 to 61 strands andthe CONA CMI SP (square plate) can be usedfor 01 to 73 strands.The CONA CMI BT (bearing trumplate)system makes use of an advanced andproprietary three plane load transfer, allowingfor very small centre and edge distances at theanchorages, as well as application of the fullpost-tensioning load at very low concretestrengths.The CONA CMI SP (square plate) isa more traditional system with a single planeload transfer to the concrete.

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Anchorage ACONA CMI BTwith BBRVT Plastic Duct

Anchorage ACONA CMI SPwith corrugated steel duct

Inaccessible fixed anchorage FA

Vent

Grouting inlet / vent (optional)

The stressing and fixed anchoragesThese anchorages are Type S stressing /active anchorages andType F fixed / passiveanchorages.The anchor heads of thestressing and fixed anchorages are identical.For construction works, the wedges ofinaccessible fixed anchorages are secured byspecial wedge retaining measures and areprotected by a cap during concreting. For re-stressable and exchangeable tendons, excessstrand length is required at the anchorage.The extent of the excess strand lengthdepends on the jack used for re-stressing orreleasing and the strand protruding beyondthe anchor head requires permanentcorrosion protection and an adequate cap.

Fixed, stressable and movablecouplersCONA CMI tendons can be coupled usingproprietaryType K overlap coupler fortendons ranging from 2 to 31 strands (largersizes on request) orType H sleeve coupler for1 to 73 strands. Both coupler types can serveas a stressing / active anchorage coupler(Type S) or fixed / passive anchorage coupler(Type F) bearing against the load transfer unitor as movable couplers (Type B) along thelength of the tendon.In the first stage of construction, the tendon isinstalled, stressed and anchored in the couplerwhich is placed in the section joint betweenthe first and second stage. Next, the secondstage tendon is put in place and coupling is

achieved by pushing the strands into thealready tensionedType K anchor head or bycoupling theType H anchor heads with aTypeH sleeve. In some countries, it is notpermitted for one section joint to have onlycouplers. In this situation, it is mandatory thatat least 30% of all tendons must becontinuous in order to obtain an evendistribution of the prestressing force in thestructure.The movable coupler serves to lengthenunstressed tendons and the tendonelongation during stressing is ensured by acylindrical sheathing box appropriate for theexpected elongation at the location of thecoupler. Movable couplers may be used tocouple continuity tendons at the constructionjoint.

Corrosion protectionThe strand bundle is enclosed in a corrugatedround steel or plastic duct. For specialapplications, such as loop tendons, smoothround steel or plastic ducts can be used.Theuse of flat steel or plastic ducts is also possiblefor smaller tendon sizes.The filling of thetendons in bonded applications is completedusing a high performance BBR grout. Forunbonded applications, the duct can beinjected with grease/wax or circulating dry air.The CONA CMI post-tensioning kits can alsobe executed as fully electrically isolatedtendons to provide the highest possible levelof corrosion protection and inspectability.

(*) Other prestressing strands approved atthe place of use, such as strands having across-sectional area of 140 mm2 or 93 mm2

respectively and/or a characteristic tensilestrength lower than 1,860 MPa can be usedwith the same anchorage components.

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Coupler KCONA CMI BT

Movable Coupler BKCONA CMI

Stressing coupler SK

Vent Grouting inlet / vent

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Available tendon sizes

Movable Coupler BHCONA CMI

Coupler HCONA CMI BT

Stressing anchorage SA

Grouting inlet / vent (optional)

Grouting inlet / vent

External post-tensioning system

Standard tendon sizesThe CONA CME post-tensioning kit is amulti-strand system for all types of externallypost-tensioned applications.The standardtendon sizes range from 1 to 61 seven-wireprestressing strands. Larger sizes are alsopossible and CONA CME tendons with 73strands have already been used. Mostcommonly, 0.62’’ (15.7 mm) strands with across-sectional area of 150 mm2 and acharacteristic tensile strength of 1,860 MPaare used (*, see Page 23).

Anchorage configurationThe main components in the anchor zone ofthe CONA CME system are the wedges,anchor head, load transfer element andtrumpet.In the anchorage zone, the duct is connectedto the trumpet and the strand bundle isspread out towards the anchor head, whereeach strand is individually locked with specialBBR wedges.For the load transfer to the concrete, theCONA CME BT (bearing trumplate) can beused for tendon sizes from 2 to 61 strandsand the CONA CME SP (square plate) canbe used for 1 to 73 strands.The CONA CME BT bearing trumplatesystem makes use of an advanced andproprietary three plane load transfer,allowing for very small centre and edgedistances at the anchorages, as well asapplication of the full post-tensioning load atvery low concrete strengths.The CONACME SP square plate is a more traditionalsystem with a single plane load transfer tothe concrete.

The stressing and fixed anchoragesThe anchorages areType S stressing / activeanchorages andType F fixed / passiveanchorages.The anchor heads of thestressing and fixed anchorages are identical.For construction works, the wedges ofinaccessible fixed anchorages are secured byspecial wedge retaining measures and are

protected by a cap during concreting. For re-stressable and exchangeable tendons, excessstrand length is required at the anchorage.The extent of the excess strand lengthdepends on the jack used for re-stressing orreleasing and the strand protruding beyondthe anchor head requires permanentcorrosion protection and an adequate cap.

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BBRVT CONA CME

Anchorage ACONA CME SPwith smooth steel duct

Anchorage ACONA CME BTwith smooth plastic duct

Fixed anchorage FA

Deviator

Saddle

Fixed and stressable couplersAlthough less common for external tendons,CONA CME tendons can be coupled usingproprietaryType K overlap coupler fortendons ranging from 2 to 31 strands (largersizes on request) orType H sleeve couplerfor 1 to 73 strands.

Deviator / saddleAn element that is specific to externalprestressing is the deviator/saddle.Thedeviator transfers the transversal forcesgenerated by the tendon to the structureand provides a smooth surface for thetendons.The deviator can be made ofconcrete, steel, HDPE or equivalent.

Corrosion protectionThe strand bundle is enclosed in a smoothround plastic or steel duct.The filling of thetendons is carried out using a highperformance BBR grout or grease/wax.Theuse of greased/waxed and HDPE sheathedmonostrand is a further possibility.

(*) Other prestressing strands approved atthe place of use, such as strands having across-sectional area of 140 mm2 and/or acharacteristic tensile strength lower than1,860 MPa can be used with the sameanchorage components.

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Available tendon sizes

Grouting inlets and vents not shown

Stressing anchorage SA

BBRVT CONA CMFFlat anchorage internal bonded or unbonded post-tensioning system

Standard tendon sizesThe CONA CMF post-tensioning kit is amulti-strand system for internally post-tensioned applications where the anchoringhas to be carried out in very thin concretecross-sections, such as slabs.The standardtendon sizes range from 2 to 4 seven-wireprestressing strands. Both 0.62’’ (15.7 mm)strands with a cross-sectional area of150 mm2 and 0.5’’ (12.9 mm) strands with across-sectional area of 100 mm2 arecommonly used, whereas the characteristictensile strength for both strands is1,860 MPa (*, see Page 25).

Anchorage configurationThe main components in the anchor zone ofthe CONA CMF system are the wedges,anchor head, load transfer element andtrumpet.In the anchorage zone, the duct is connectedto the trumpet and the strand bundle is

�24

Anchorage ACONA CMF BTwith flat steel duct

Fixed anchorage FA

spread out towards the anchor head, whereeach strand is individually locked with specialBBR wedges.For the load transfer to the concrete, theCONA CMF BT (bearing trumplate) is used,which makes use of an advanced andproprietary three plane load transferespecially developed for anchoring in thincross section.This allows for very smallcentre and edge distances at the anchorages,as well as application of the full post-tensioning load at very low concretestrengths.

The stressing and fixed anchoragesThe anchorages areType S stressing / activeanchorages andType F fixed / passiveanchorages.The anchor heads of thestressing and fixed anchorages are identical.For construction works, the wedges ofinaccessible fixed anchorages are secured byspecial wedge retaining measures and areprotected by a cap during concreting. For re-stressable and exchangeable tendons, excessstrand length is required at the anchorage.The extent of the excess strand lengthdepends on the jack used for re-stressing orreleasing and strand protruding beyond theanchor head requires permanent corrosionprotection and an adequate cap.

Fixed and stressable couplersCONA CMF tendons can be coupled usingproprietyType H sleeve couplers.Thecoupler can serve as a stressing / activeanchorage coupler (Type S) or fixed /passive anchorage coupler (Type F) bearingagainst the bearing trumplate or as movablecouplers (Type B) along the length of thetendon.

Corrosion protectionThe strand bundle is enclosed in acorrugated round steel or plastic duct. Forspecial applications, such as loop tendons,smooth round steel or plastic ducts can beused.The use of flat steel or plastic ducts isalso possible for smaller tendon sizes.Thefilling of the tendons in bonded applicationsis carried out using a high performance BBRgrout. For unbonded applications the ductcan be injected with grease/wax orcirculating dry air.

(*) Other prestressing strands approved atthe place of use, such as strands having across-sectional area of 140 mm2 or 93 mm2

respectively and/or a characteristic tensilestrength lower than 1,860 MPa can be usedwith the same anchorage components.

�25

Available tendon sizes

Coupler HCONA CMF BT

Stressing anchorage SAGrouting inlets and vents not shown

Standard tendon sizesThe CONA CMM SINGLE post-tensioningkit is a monostrand system with one strandfor internally unbonded or bondedapplications. Both 0.62’’ (15.7 mm) strandswith a cross-sectional area of 150 mm2 and0.5’’ (12.9 mm) strands with a cross-sectionalarea of 100 mm2 are commonly used,whereas the characteristic tensile strengthfor both strands is 1,860 MPa. For unbondedapplications, use of a compacted 0.6’’(15.2 mm) strand with a cross-sectional areaof 165 mm2 and a characteristic tensilestrength of 1,820 MPa is possible(*, see Page 27).

Anchorage configurationThe main components in the anchor zone ofthe CONA CMM SINGLE system are thewedge, monolithic anchorage and anindividual trumpet tube.

�26

In the anchorage zone, the strand is guidedinto the individual trumpet tube to themonolithic anchorage, where the strand isindividually locked with a special BBR wedge.The anchoring of the strand and loadtransfer to the concrete is done with one

BBRVT CONA CMM SINGLEMonostrand unbonded or bonded post-tensioning system

and the same unit, allowing for a higheconomy, small centre and edge distances atthe anchorage, as well as application of thefull post-tensioning load at very lowconcrete strengths.

Anchorage ACONA CMM SINGLE

Fixed anchorage FA

The stressing and fixed anchoragesThe anchorages are stressing / activeanchorage (Type S) and the fixed / passiveanchorage (Type F). Both types are identical.For construction works, the wedges ofinaccessible fixed anchorages are secured byspecial wedge retaining measures and areprotected by a cap during concreting. Forrestressable and exchangeable tendons,excess strand length is required at theanchorage.The extent of the excess strandlength depends on the jack used forrestressing or releasing and the strandprotruding beyond the anchor head requirespermanent corrosion protection and anadequate cap.

Fixed and stressable couplersCONA CMM SINGLE tendons can becoupled using proprietaryType H sleevecoupler, whereas the coupler can serve as astressing / active anchorage coupler (Type S)or fixed / passive anchorage coupler (Type F)during the first construction stage.

Corrosion protectionFor unbonded CONA CMM SINGLEapplications, the strands are greased/waxedand individually sheathed in the factory witha continuously extruded HDPE sheathing.For bonded CONA CMM SINGLE tendons,the single monostrand is enclosed in acorrugated round plastic duct, which is theninjected with a high performance BBR grout.

(*) Other prestressing strands approved atthe place of use, such as strands having across-sectional area of 140 mm2 or 93 mm2

respectively and/or a characteristic tensilestrength lower than 1,860 MPa or1,820 MPa respectively, can be used with thesame anchorage components.

�27

Coupler HCONA CMM SINGLE

Greased monostrand with HDPE sheathing andsingle strand with cement grouted plastic duct

Available tendon sizes

Stressing anchorage SA

BBRVT CONA CMMTWO / FOURMonostrand unbonded post-tensioning system

Standard tendon sizesThe CONA CMM TWO and FOUR post-tensioning kit is a monostrand system forinternally unbonded applications.Thestandard tendons have 2 or 4 seven-wireprestressing strands. Most commonly 0.62’’(15.7 mm) strands with a cross-sectionalarea of 150 mm2 and a characteristic tensilestrength of 1,860 MPa and specialcompacted 0.6’’ (15.2 mm) strands with across-sectional area of 165 mm2 and acharacteristic tensile strength of 1,820 MPaare used (*, see Page 29).

Anchorage configurationThe main components in the anchor zone ofthe CONA CMM system are the wedges,monolithic anchorage and individual trumpettubes.

In the anchorage zone, the strands areguided into the individual trumpet tubes tothe monolithic anchorage, where eachstrand is individually locked with special BBRwedges.The anchoring of the strand andload transfer to the concrete is carried outwith one and the same unit, allowing for ahigh economy, small centre and edge

distances at the anchorages, as well asapplication of the full post-tensioning loadat very low concrete strengths.

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Anchorage ACONA CMM FOUR

Fixed anchorage FA

The stressing and fixed anchoragesThe anchorages are stressing / activeanchorage (Type S) and the fixed / passiveanchorage (Type F). Both types are identical.For construction works, the wedges ofinaccessible fixed anchorages are secured byspecial wedge retaining measures and areprotected by a cap during concreting. Forrestressable and exchangeable tendons,excess strand length is required at theanchorage.The extent of the excess strandlength depends on the jack used forrestressing or releasing and strand protrudingbeyond the anchor head requires permanentcorrosion protection and an adequate cap.

Fixed and stressable couplersCONA CMM FOUR tendons can becoupled using proprietyType H sleevecoupler, whereas the couplers can serve as astressing / active anchorage coupler (Type S)or fixed / passive anchorage coupler (Type F)during the first construction stage.

Corrosion protectionFor CONA CMM TWO and FOURapplications, the monostrand are greased/waxed and individually sheathed in thefactory with a continuously extruded HDPEsheathing.

(*) Other prestressing strands approved atthe place of use, such as strands having across-sectional area of 140 mm2 and/or acharacteristic tensile strength lower than1,860 MPa or 1,820 MPa respectively, can beused with the same anchorage components.

�29

Coupler HCONA CMM FOUR

Available tendon sizes

Stressing anchorage SA

Standard tendon sizesThe CONA CMB post-tensioning kit is amulti-strand system for special external andalso internal unbonded post-tensionedapplications.The standard tendons rangefrom 1 to 16 seven-wire prestressing strands.Most commonly 0.62’’ (15.7 mm) strandswith a cross-sectional area of 150 mm2 anda characteristic tensile strength of 1,860 MPaand a compacted 0.6’’ (15.2 mm) strandswith a cross-sectional area of 165 mm2 anda characteristic tensile strength of 1,820 MPaare used (*, see Page 31).

Anchorage configurationThe main components in the anchor zone ofthe CONA CMB SP system are the wedges,anchor head, load transfer element andtrumpet.In the anchorage zone the strand bundle isspread out towards the anchor head, whereeach strand is individually locked with specialBBR wedges. For the load transfer to theconcrete, the CONA CMB SP (square plate)is used.

The stressing and fixed anchoragesThe anchorages are theType S stressing /active anchorages and theType F fixed /passive anchorages.The anchor heads of thestressing and fixed anchorages are identical.For restressable and exchangeable tendons,excess strand length is required at theanchorage.The extent of the excess strandlength depends on the jack used for

restressing or releasing and strandprotruding beyond the anchor head requirespermanent corrosion protection and anadequate cap.

Deviator / saddleAn element that is specific to externalprestressing is the deviator/saddle.The

deviator transfers the transversal forcesgenerated by the tendon to the structureand provides a smooth surface for thetendons.The deviator can be made ofconcrete, steel, HDPE or equivalent.

�30

BBRVT CONA CMBBand post-tensioning system

Anchorage ACONA CMB SP

CONA CMBStrand bundle

Fixed anchorage FA

Deviator

Saddle

Corrosion protectionThe strands are greased/waxed andindividually sheathed in the factory with acontinuously extruded HDPE sheathing andsubsequently grouped parallel and thencontained within an additional extrudedsmooth rectangular plastic sheath.

(*) Other prestressing strands approved atthe place of use, such as strands having across-sectional area of 140 mm2 and/or acharacteristic tensile strength lower than1,860 MPa or 1,820 MPa respectively can beused with the same anchorage components.

�31

Available tendon sizes

Stressing anchorage SA

Since 1944, BBR has developed andpioneered post-tensioning introducing manysystems over the past six decades. In specificmarkets, some of these earlier systems mightstill be used to complement special

Load transfer is achieved by a localdeformation of the strand and bond to theconcrete. Local BBR Network Members

�32

BBRVT CONA CMCCast-in and inaccessible bond anchorages

BBRVT Classical SystemsAdditional BBRVT post-tensioning systems

Flat onion anchorageCONA CMC

offer a variety of solutions, such as onion orloop anchorages which fully comply withregulations applicable at the place of use.

Bundle onion anchorageCONA CMC

applications – or, in some cases, they are stillthe locally approved systems.The BBRCONA, CONA compact, CONA multi,CONA single and CONA flat post-tensioningsystems have been used for decades and in

2005, the BBR post tensioning range wasfurther complemented with the post-tensioning systems previously used byVorspann-Technik (Austria / Germany).

BBR CONA compact BBR CONA flatBBR CONA multi

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And finally .....Having reached this page, you can certainly be in no doubt as

to our commitment to the finest technology and our

enthusiasm for delivering our projects.

Our six decades of experience has resulted in BBR

technology being applied to thousands of structures around

the world and, in the process, we have continued to refine and

enhance our range.The result is that we can supply simply the

best technology available – the BBRVT CONA CMX® system.

Technology does not however develop by itself – all

through the years, we have been fortunate enough

to have attracted some of the best engineers in the

business. It is their dedication which has maintained

the BBR reputation – and continues to do so today.

Our well-established worldwide network is

supported in the development of major structures

by our Special ProjectsTeam who will help to specify

and procure the systems required. So, local

knowledge synchronises with international know-

how to realise projects – some large, some smaller,

but always technically excellent and fit-for-purpose!

BBR VT International Ltd

Bahnstrasse 23

8603 Schwerzenbach (ZH)

Switzerland

Tel +41 44 806 80 60

Fax +41 44 806 80 50

www.bbrnetwork.com

info@bbrnetwork.com

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