Lockable Dowels cont/...

Corporate MembersAustralian Prestressing Services Pty Ltd (founding member) Structural Systems Pty Ltd (founding member) VSL Australia Pty Ltd (founding member)

Associate Members – suppliersAjax Foundry Pty Ltd Ancon Building ProductsHaggie Reid Pty Ltd Holcim (Australia) Pty Ltd OneSteel Wire Pty Ltd

Refobar Australia Sanwa Pty Ltd Severs Technical Systems Pty Ltd Usha Martin Australia Pty Ltd

Associate Members – consulting engineersABC ConsultantsArup Bornhorst + Ward Pty Ltd Costin Roe Consulting Pty Ltd Hyder Consulting Pty Ltd McVeigh Consultants Pty Ltd

Parsons BrinkerhoffSCP Consulting Pty Ltd Taylor Thomson Whitting

New MembersPTIA welcomes Ancon Building Products and Parsons Brinkerhoff as new Associate Members. We also welcome Feris Chehade (Univ of Sydney) and Akbar Rouhi (Curtain Univ of Technology) as new Student Members.

Member Companies

Ancon Lockable DowelsDowels transfer load across joints in concrete and are used with a sleeve component where movement is required. Ancon furthered this principle by engineering a shear load connector which could be locked after an initial phase of movement.

The lockable dowel comprises a stainless steel dowel, a box-section sleeve with an L-shaped void former, a locking plate and 1.5 litres of a two-part epoxy resin (Fig. 3).

One end of the dowel component is threaded with a nut and washer for additional anchorage and the other features a series of grooves to accept the locking plate.

The dowel and sleeve components allow shrinkage of the concrete to take place; the box-section sleeve allows lateral, longitudinal and some rotational movement to occur in this initial stage.

After a predetermined time, generally 60-120 days, when movement has

stabilised and the joint has been filled, the dowel is locked in position with the plate and the resin.

The void former allows inspection of the dowel before the joint is locked. The fan-shaped locking plate, which allows the dowel to be locked in any position in the sleeve, is inserted around one of the grooves on the dowel before the controlled amount of epoxy resin is inserted from the top of the slab. The void former is topped with cementitious material to complete the installation. When locked, the dowel continues to transfer vertical load but further movement is prevented from taking place. The lockable dowel range includes standard solutions for slab-to-slab and slab-to-wall joints. For more information, visit www.ancon.com.au/Lockable.

Left (Fig 3): Lockable dowel components.Far left (Fig 4): Once movement has stabilised and the joint has been filled, the plate and resin are used to lock the dowel. Ptnews

Newsletter 4 - 2010

PTIA Seminars On Web Site During 2010, PTIA conducted seminars with Concrete Institute of Australia in Melbourne, Hobart, Perth and Brisbane, and with IE(Aust) in Newcastle.

Copies of these and past presentations are on the PTIA web site, under the Downloads tab.

Copies of past PTIA Newsletters, and other news articles, can be found under the News and Events tab.

President’s Report

1

The construction industry in Australia continues to recover but activity is different across the country. Post-tensioning and supply companies operating in different states are seeing quiet varied results in their operating areas. This reflects the variation in general public optimism and activity in those states doing well and the more cautious approach where local

political concern exists.

We are hopeful all areas will improve and return prosperous actively for PTIA member companies in the coming months.

The good news is that stability seems to have returned to most material and labour costs ensuring a better control of activities for members. Of great significance to the PT suppliers, steel prices do seem to be stable until at least early next year allowing more accuracy and security in tendering.

PTIA continues to pursue training of site employees and this continues as a major priority. We consider proper training a major safety requirement for post-tensioning operators. It is important that contractors using PT on their projects ensure site staff involved with these activities have the training and experience necessary for the task.

PTIA continues to lobby site safety authorities and regulators to require a minimum level of training and experience of employees handling PT particularly those involved in the stressing process. Any assistance that members or contractors with whom you work can give in ensuring a better work place would be appreciated. Making clients and contractors aware of the importance of training will produce beneficial results for all concerned.

The PTIA Skills Training course is now part of the Steel Fixers Certificate III nationally accredited program. In 2011, a short version of this course, incorporating the White Card (Construction General Safety Induction), will be available for site engineers, site and project managers, and safety officers involved with PT. Please contact PTIA to make application for these courses.

The 2010 annual general meeting will be held in Brisbane on 24 November prior to the Concrete Institute seminar in Brisbane at which the Queensland Branch of PTIA will present on Innovations in Post-Tensioning Design & Applications. All members are welcome to attend.

On behalf of the Board of PTIA, I take this opportunity to wish you and your families a Merry Christmas and a Safe and Happy New Year.

Michael O’Neill President

“ensuring excellence and accreditation for the post-tensioning industry” POsT-TensIOnIng InsTITuTe OF AusTrAlIA lImITed ABN 86 121 218 228 PO Box 861, Five Dock NSW 2046

Telephone: 02 8765 6199 Facsimile: 02 9743 4013 Email: info@ptia.org.au Web: www.ptia.org.au

Ancon Lockable Dowels Speed Construction on Hospital Site

Bovis Lend Lease has installed over 5,000 Lockable Dowels in the post-tensioned concrete frame of the new Royal Children’s Hospital in Melbourne. Use of these dowels at temporary movement joints has replaced the need for one metre wide pour strips to be left and for slabs to be propped. This has improved site access and allowed building services, such as overhead cabling, to be installed without delay.

Accommodating Concrete ShrinkageIn long post-tensioned slabs, normal concrete shrinkage is accommodated either through the construction of temporary movement joints or by leaving ‘pour strips’. These joints or strips are then filled once movement has stabilised to create a monolithic slab.

Although commonly used, pour strips are not ideal as they require the slabs to be propped from below. This restricts site access and delays work until the props are removed. Pour strips also create an unnecessary trip hazard for site workers, use additional formwork and leave the soffit face marked.

Traditionally, the construction of temporary movement joints has also been problematic. Figure 1 illustrates a typical detail where a carbon steel reinforcing bar is located in a length of galvanised ducting to allow movement at a joint. Once shrinkage has stabilised, grout is pumped through a tube into the unseen ducting below, locking the bar in position to prevent further movement taking place. Unlike a proven dowel system, rebar does not transfer shear load and a support corbel is required below the slab. It is widely accepted that the performance achieved by these site-assembled components is unreliable. Corbels also require additional time, formwork and concrete to construct.

It was issues such as those outlined above with the traditional construction methods which led Ancon to develop a range of Lockable dowels; their use continues to increase across Australia and in europe as the benefits become more widely recognised.

RCH, MelbourneThe new Royal Children’s Hospital is the largest hospital redevelopment to be undertaken by the State of Victoria and one of the largest hospital projects in the country. The project is being delivered under the state’s Partnerships Victoria framework by the CHP consortium. The consortium comprises International Public Partnerships as sponsors, Bovis Lend Lease as contractor, Spotless Group as facilities manager and architects Billard Leece, Bates Smart and HKS (US).

It will create a 165,000m2 hospital facility on seven floors, with an additional 75,000m2 of car parking space in three basement levels.

The project is scheduled to be completed in two stages. Completion of the first stage is due late in 2011 and the second stage is due to be complete in 2014. Structural Systems was engaged to provide design, supply and installation of post-tensioning. They began construction on site in August 2008 and by the time of completion will have installed some 260 tonnes of post-tensioned beams throughout the building, including several multi-strand transfer beams.

Bovis Lend Lease used Ancon Lockable Dowels to replace traditional pour strips (Fig. 2). The major advantage to the contractor was the elimination of site delays caused by slab propping and simplification of the detailing and building of the temporary movement joints.

3

Top (Fig 1): The performance of site-assembled components is

unreliable and would normally require a support corbel.

Above (Fig 2): Lockable dowels at temporary movement joints.

Project Report

Gateway Upgrade Project

Location: Brisbane, Queensland

Client: Queensland Motorway Limited

Contractor: AbiGroup Contractors, Leighton Contractors,

VSL Australia Alliance

The Leighton-Abigroup-VSL Alliance has carried out the closing pour at the centre of the main span of the Gateway Bridge duplication, 65m above the Brisbane River.

October’s closure marked the end of 30 months of construction, six months ahead of schedule. The Alliance’s scope covered full construction of the 1.65km bridge including the 260m-long main span, which was built by form traveller.

It is one of the world’s longest bridges to be built using the cast-in-situ balanced cantilever method. The adjacent 1980s crossing will be refurbished to give a combined capacity of six lanes in each direction by early 2011.

Scope of Works:Abutment to abutment construction duplicating the existing Gateway Bridge

• Piled foundations

• Bridge Substructure

• Match Cast Segmental superstructure to Approaches

• Cast in-situ main span with Form Travellers

• Establishment and operation of casting yard – pre-stressed piles, Super tee beams, match cast segments, parapets and noise walls.

VSL has contributed fully as an Alliance Partner for the construction of the New Gateway Bridge. The involvement has been for the contribution of key staff, bridge construction equipment, post tensioning systems and the full array of technology and methodology required for the abutment to abutment scope of the Alliance team.

VSL’s network, experience and expertise has enabled the modification of specialised plant and has developed and designed the main span Form Traveller, which is one of the largest of its kind in the world.

Challenges Encountered:• Environmental aspects of construction in Brisbane river, including soft soil foundations

• erection of first match cast bridge in Queensland

• Operating Australia’s largest precast yard

• Construction of one of the longest balanced cantilever span in the world with a 300 years design life.

Quantities:Deck length: 1627mDeck width: 28mPost-tensioning * : 5,748tConcrete Qty * : 107,422 mRebar * : 18,570tMan hours (approx) * : 1.5 million *For Bridge & Yard

2

cont/ pg 4

Ancon Lockable Dowels Speed Construction on Hospital Site

Bovis Lend Lease has installed over 5,000 Lockable Dowels in the post-tensioned concrete frame of the new Royal Children’s Hospital in Melbourne. Use of these dowels at temporary movement joints has replaced the need for one metre wide pour strips to be left and for slabs to be propped. This has improved site access and allowed building services, such as overhead cabling, to be installed without delay.

Accommodating Concrete ShrinkageIn long post-tensioned slabs, normal concrete shrinkage is accommodated either through the construction of temporary movement joints or by leaving ‘pour strips’. These joints or strips are then filled once movement has stabilised to create a monolithic slab.

Although commonly used, pour strips are not ideal as they require the slabs to be propped from below. This restricts site access and delays work until the props are removed. Pour strips also create an unnecessary trip hazard for site workers, use additional formwork and leave the soffit face marked.

Traditionally, the construction of temporary movement joints has also been problematic. Figure 1 illustrates a typical detail where a carbon steel reinforcing bar is located in a length of galvanised ducting to allow movement at a joint. Once shrinkage has stabilised, grout is pumped through a tube into the unseen ducting below, locking the bar in position to prevent further movement taking place. Unlike a proven dowel system, rebar does not transfer shear load and a support corbel is required below the slab. It is widely accepted that the performance achieved by these site-assembled components is unreliable. Corbels also require additional time, formwork and concrete to construct.

It was issues such as those outlined above with the traditional construction methods which led Ancon to develop a range of Lockable dowels; their use continues to increase across Australia and in europe as the benefits become more widely recognised.

RCH, MelbourneThe new Royal Children’s Hospital is the largest hospital redevelopment to be undertaken by the State of Victoria and one of the largest hospital projects in the country. The project is being delivered under the state’s Partnerships Victoria framework by the CHP consortium. The consortium comprises International Public Partnerships as sponsors, Bovis Lend Lease as contractor, Spotless Group as facilities manager and architects Billard Leece, Bates Smart and HKS (US).

It will create a 165,000m2 hospital facility on seven floors, with an additional 75,000m2 of car parking space in three basement levels.

The project is scheduled to be completed in two stages. Completion of the first stage is due late in 2011 and the second stage is due to be complete in 2014. Structural Systems was engaged to provide design, supply and installation of post-tensioning. They began construction on site in August 2008 and by the time of completion will have installed some 260 tonnes of post-tensioned beams throughout the building, including several multi-strand transfer beams.

Bovis Lend Lease used Ancon Lockable Dowels to replace traditional pour strips (Fig. 2). The major advantage to the contractor was the elimination of site delays caused by slab propping and simplification of the detailing and building of the temporary movement joints.

3

Top (Fig 1): The performance of site-assembled components is

unreliable and would normally require a support corbel.

Above (Fig 2): Lockable dowels at temporary movement joints.

Project Report

Gateway Upgrade Project

Location: Brisbane, Queensland

Client: Queensland Motorway Limited

Contractor: AbiGroup Contractors, Leighton Contractors,

VSL Australia Alliance

The Leighton-Abigroup-VSL Alliance has carried out the closing pour at the centre of the main span of the Gateway Bridge duplication, 65m above the Brisbane River.

October’s closure marked the end of 30 months of construction, six months ahead of schedule. The Alliance’s scope covered full construction of the 1.65km bridge including the 260m-long main span, which was built by form traveller.

It is one of the world’s longest bridges to be built using the cast-in-situ balanced cantilever method. The adjacent 1980s crossing will be refurbished to give a combined capacity of six lanes in each direction by early 2011.

Scope of Works:Abutment to abutment construction duplicating the existing Gateway Bridge

• Piled foundations

• Bridge Substructure

• Match Cast Segmental superstructure to Approaches

• Cast in-situ main span with Form Travellers

• Establishment and operation of casting yard – pre-stressed piles, Super tee beams, match cast segments, parapets and noise walls.

VSL has contributed fully as an Alliance Partner for the construction of the New Gateway Bridge. The involvement has been for the contribution of key staff, bridge construction equipment, post tensioning systems and the full array of technology and methodology required for the abutment to abutment scope of the Alliance team.

VSL’s network, experience and expertise has enabled the modification of specialised plant and has developed and designed the main span Form Traveller, which is one of the largest of its kind in the world.

Challenges Encountered:• Environmental aspects of construction in Brisbane river, including soft soil foundations

• erection of first match cast bridge in Queensland

• Operating Australia’s largest precast yard

• Construction of one of the longest balanced cantilever span in the world with a 300 years design life.

Quantities:Deck length: 1627mDeck width: 28mPost-tensioning * : 5,748tConcrete Qty * : 107,422 mRebar * : 18,570tMan hours (approx) * : 1.5 million *For Bridge & Yard

2

cont/ pg 4

Lockable Dowels cont/...

Corporate MembersAustralian Prestressing Services Pty Ltd (founding member) Structural Systems Pty Ltd (founding member) VSL Australia Pty Ltd (founding member)

Associate Members – suppliersAjax Foundry Pty Ltd Ancon Building ProductsHaggie Reid Pty Ltd Holcim (Australia) Pty Ltd OneSteel Wire Pty Ltd

Refobar Australia Sanwa Pty Ltd Severs Technical Systems Pty Ltd Usha Martin Australia Pty Ltd

Associate Members – consulting engineersABC ConsultantsArup Bornhorst + Ward Pty Ltd Costin Roe Consulting Pty Ltd Hyder Consulting Pty Ltd McVeigh Consultants Pty Ltd

Parsons BrinkerhoffSCP Consulting Pty Ltd Taylor Thomson Whitting

New MembersPTIA welcomes Ancon Building Products and Parsons Brinkerhoff as new Associate Members. We also welcome Feris Chehade (Univ of Sydney) and Akbar Rouhi (Curtain Univ of Technology) as new Student Members.

Member Companies

Ancon Lockable DowelsDowels transfer load across joints in concrete and are used with a sleeve component where movement is required. Ancon furthered this principle by engineering a shear load connector which could be locked after an initial phase of movement.

The lockable dowel comprises a stainless steel dowel, a box-section sleeve with an L-shaped void former, a locking plate and 1.5 litres of a two-part epoxy resin (Fig. 3).

One end of the dowel component is threaded with a nut and washer for additional anchorage and the other features a series of grooves to accept the locking plate.

The dowel and sleeve components allow shrinkage of the concrete to take place; the box-section sleeve allows lateral, longitudinal and some rotational movement to occur in this initial stage.

After a predetermined time, generally 60-120 days, when movement has

stabilised and the joint has been filled, the dowel is locked in position with the plate and the resin.

The void former allows inspection of the dowel before the joint is locked. The fan-shaped locking plate, which allows the dowel to be locked in any position in the sleeve, is inserted around one of the grooves on the dowel before the controlled amount of epoxy resin is inserted from the top of the slab. The void former is topped with cementitious material to complete the installation. When locked, the dowel continues to transfer vertical load but further movement is prevented from taking place. The lockable dowel range includes standard solutions for slab-to-slab and slab-to-wall joints. For more information, visit www.ancon.com.au/Lockable.

Left (Fig 3): Lockable dowel components.Far left (Fig 4): Once movement has stabilised and the joint has been filled, the plate and resin are used to lock the dowel. Ptnews

Newsletter 4 - 2010

PTIA Seminars On Web Site During 2010, PTIA conducted seminars with Concrete Institute of Australia in Melbourne, Hobart, Perth and Brisbane, and with IE(Aust) in Newcastle.

Copies of these and past presentations are on the PTIA web site, under the Downloads tab.

Copies of past PTIA Newsletters, and other news articles, can be found under the News and Events tab.

President’s Report

1

The construction industry in Australia continues to recover but activity is different across the country. Post-tensioning and supply companies operating in different states are seeing quiet varied results in their operating areas. This reflects the variation in general public optimism and activity in those states doing well and the more cautious approach where local

political concern exists.

We are hopeful all areas will improve and return prosperous actively for PTIA member companies in the coming months.

The good news is that stability seems to have returned to most material and labour costs ensuring a better control of activities for members. Of great significance to the PT suppliers, steel prices do seem to be stable until at least early next year allowing more accuracy and security in tendering.

PTIA continues to pursue training of site employees and this continues as a major priority. We consider proper training a major safety requirement for post-tensioning operators. It is important that contractors using PT on their projects ensure site staff involved with these activities have the training and experience necessary for the task.

PTIA continues to lobby site safety authorities and regulators to require a minimum level of training and experience of employees handling PT particularly those involved in the stressing process. Any assistance that members or contractors with whom you work can give in ensuring a better work place would be appreciated. Making clients and contractors aware of the importance of training will produce beneficial results for all concerned.

The PTIA Skills Training course is now part of the Steel Fixers Certificate III nationally accredited program. In 2011, a short version of this course, incorporating the White Card (Construction General Safety Induction), will be available for site engineers, site and project managers, and safety officers involved with PT. Please contact PTIA to make application for these courses.

The 2010 annual general meeting will be held in Brisbane on 24 November prior to the Concrete Institute seminar in Brisbane at which the Queensland Branch of PTIA will present on Innovations in Post-Tensioning Design & Applications. All members are welcome to attend.

On behalf of the Board of PTIA, I take this opportunity to wish you and your families a Merry Christmas and a Safe and Happy New Year.

Michael O’Neill President

“ensuring excellence and accreditation for the post-tensioning industry” POsT-TensIOnIng InsTITuTe OF AusTrAlIA lImITed ABN 86 121 218 228 PO Box 861, Five Dock NSW 2046

Telephone: 02 8765 6199 Facsimile: 02 9743 4013 Email: info@ptia.org.au Web: www.ptia.org.au