TTM Post Tensioning

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- Post tensioning anchor system

English

Post Tensioning – Rev. H – page 1

INDEX

page 1. STRAND 3 2. ACTIVE ANCHORAGES “M” SERIES 4 2.1 Active Anchorages “M” 5 2.2 Anchorages “M15” 6 2.3 Anchorages “M13” 7 2.4 Accessories for injection on “M” anchorages 8 3. ACTIVE ANCHORAGES “ME” SERIES 10 4. SINGLE WIRE STRAND ANCHORAGES “E” SERIES 11 4.1 Anchorages “E” 13 4.2 Anchorages “EX” 16 5. PASSIVE ANCHORAGES “D” SERIES 17 5.1 Passive anchorages “D15” 18 5.2 Passive anchorages “D13” 19 6. PASSIVE ANCHORAGES “S” SERIES 20 7. “C15” COUPLERS 22 8. COUPLERS “G” SERIES 23 8.1 Couplers “G15” 24 8.2 Couplers “G13” 25 8.3 Couplers “G” – application 26 9. COUPLERS “F” SERIES 29 10. COUPLERS “K” SERIES 30 11. ELEMENTARY ANCHORAGES 31 12. METAL SHEATHS “ST” 31 13. ELEMENTS FOR CALCULATING LOSSES 33 13.1.1 Instantaneous losses 33 13.1.2 Drop in tension through friction 33 13.1.3 Drop in tension through wedge displacement 34 13.2 Deferred losses 35 13.2.1 Drop in tension through relaxation 35 13.2.2 Drop in tension through relaxation 35 13.2.3 Drop in tension through viscosity 36 13.3 Evaluation of elongation during tensioning of cables 36 13.3.1 Displacement of clamps on active anchors 36 13.3.2 Displacement of clamps and deformation on fixed anchors 36 13.3.3 Deformation of jacks 37 13.3.4 Tension values on post tensioned strand anchorages 37


13.3.5 Tensioning values on post tensioned bar anchorages 38 13.3.6 Tension limit for precompressed steels 38 14. GROUTING 39 14.1 Grouting with cap 40 14.2 Grouting with plug 41 15. DISTANCES BETWEEN ANCHORAGES 49 15.1 Distances from edges 49 15.2 Recesses 50 16. “MS” STAY CABLES SYSTEM 51 16.1 Adjustable anchorages “MSA” type 52 16.2 Fixed anchorages “MSD” type 53 17. BARS 54 17.1 “TTB” bar anchor system 56 18. EQUIPMENT 57 18.1.1 Hydraulic pump - series “TTM-A” 57 18.1.2 Hydraulic pump - series “TTM 450-A” 58 18.1.3 Stressing controllers – series “TTM 250-A” 59 18.2 Stressing jacks series “TTM 60 18.3 Sample pressuremeter “S1000” 62 18.4 Bar stressing jacks 63 18.5.1 Bar stressing jacks series “DD” 66 18.5.2 Bar stressing jacks series “DX” 67 18.6 Stressing controller - series “TTM-E” 69 18.7 Stressing jacks series “M” 70 18.8 Jack for extrusions - type “M300” 74 18.9 Strand opener jack - type S 4000 75 18.10 Wedge jacks –type B300KN 77 18.11 Injection pump- type “T” 79 18.12 Strand forcing machine- type “TTM-S4” 83 18.12.1 Inserter caps 90 18.13 Reel carriers - type “B1500” 91 18.14 Load cells - series “DI” 92 19. SITES 19.1 Sites in Italy 97 19.2 Sites Abroad 100 Revision catalogue : H Date issued : January 2005


1 - STRAND

STRAND FEATURES

Diameter Standard Strand type

Rated diameter

Rated area Mass Ultimate

strength

Elastic limit at 1%

Relaxation after 1000 h. a 0,7 -

0,8 pkf

mm mm cu g/m kN kN % %

BS 5896/80 normal super

12.5 12.9

93 100

730 785

164 186

139 158

2.5 2.5

4.5 4.5 0.5"

(T13) ASTM A416/98 Quality

270 12.7 98.7 775 183.7 156 2.5 3.5

0.6" (T15)

French Standard and

pr EN 10138

normal super

15.2 15.7

140 150

1095 1170

260 279

230 248

2.5 2.5

4.5 4.5

0.6" (T15) BS 5896/80 normal

super 15.2 15.7

139 150

1090 1180

232 265

197 225

2.5 2.5

4.5 4.5

0.6" (T15) ASTM A416/98 Quality

270 15.24 140 1102 260.7 221 2.5 3.5

0.6" (T15)

ASTM A779/90

Compact 15.2 165 1290 300 264 2.5 4.5

Modulus = 196 +/- 10 kN / mm2

The strand used for post tensioning is produced by SIDERURGICA LATINA MARTIN S.p.A. in compliance with the law and according to the qualification procedures below: - internal statistical controls; - controls carried out by an official laboratory; - elaboration of results obtained to verify the statistical compliance with the rules contained in the

Technical Standards. The techniques used enable the production of stabilised and qualified strand. The advantages offered by this product are: - reduced relaxation; - improved behaviour at low and high temperatures compared with traditional products; - raising of proportional limit to 0,01%; - noticeable reduction in production costs of c.a.p. finished products.


2 - ACTIVE ANCHORAGES “ M ”SERIES

The “M” system has been designed to meet the requirement of reducing the dimensions of the anchorages and the distance between them. Simulations using calculation programmes and finished parts and laboratory tests have made possible the designing of an anchor which, by spreading the load in a particular way, generates tension in compliance with the law. The experience of the companies in the group in the metallurgical sector guarantees the use of quality materials and suitable production processes.

All the anchorage plates are made of carbon steel C40-45 UNI EN 10083/1. Given the chemical composition of the steel, the plate must for no reason be welded to reinforcement structures or supports; every weld is a potential breakage point of the plate under load. Conversely, castings, being carried out using spheroid iron, can be welded to the reinforcement without requiring any particular measures. The centring of the steel reinforcement to the casting by welding is highly recommended.


2.1 – Active anchorages “M”

The active ANCHORAGES series “M” is made up of the following parts: casting, anchorage plate, clamps and HDPE fitting to connect the casting to the metal sheath without sudden deviations. Casting – The castings have a supporting plane for the turned plate, coupling holes to cap and the ¾"injection inlet. The castings are made of spheroid iron EN-GJS 500-7 EN-JS-1050 (Italy UNI ISO 4544 GS 500-7, France NF A 32-201 FGS 500-7, Germany DIN 1693 GGG50, Great Britain BS 2789 500-7, ISO R 1083 50-7, Japan J.S.I. G 5502 FCD 50) which provides high resistance to stress and, as it can be welded, guarantees greater safety during installation. Anchorage plate – The strand is blocked on a separating plate, with conical C40-45 UNI EN 10083/1 steel truncated bores and with either 16NiCr4Pb UNI EN 10277-4 or 9SMnP28 UNI 4838 type steel 7015-T15 clamps. Connection Pipe – The connection between the anchorage and sheath is by means of a tube passage which guarantees a correct deviation of the strand, minimizing the loss values. The connection is supplied either in HDPE or steel depending on its use. Connecting to support – All the castings have two equidistant slots which facilitate bolting them to the support. Grouting – All the castings have a ¾” gas threaded hole for injecting, which enables connecting of the injection equipment we supply. For further details regarding injection, turn to the chapter dedicated to “Equipment” .


2.2 - Anchorages “M 15”

ØI

E

H

L C D

ØB

Ø F

A x

A G

A

A

Type Final load A B C D E F G H I L

T15 T15S T15C

259 279 300

per cable per cable per cable (kN) (kN) (kN) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm)

4M15 1036 1116 1200 130 105 106 300 330 220 45/50 50 12 45 7M15 1813 1953 2100 160 125 133 340 390 260 62/67 55 12 45 9M15 2331 2511 2700 195 146 163 360 400 270 72/77 60 14 45

12M15 3108 3348 3600 225 160 185 385 430 320 80/85 65 14 45 15M15 3885 4185 4500 235 176 197 430 450 360 85/90 70 16 45 19M15 4921 5301 5700 265 200 215 430 500 400 95/100 75 16 56 22M15 5698 6138 6600 310 230 260 490 570 430 100/105 80 20 61 27M15 6993 7533 8100 330 250 277 500 650 470 110/115 90 20 70 31M15 8029 8649 9300 355 270 297 525 700 535 115/120 90 20 86 37M15 9583 10323 11100 375 280 314 590 730 560 130/135 90 20 86

The company reserves the right to change its products and specifications without notice.

All documents are in compliance with the Memorandum dated 15 October 1996 n° 252 AA.GG./S.T.C. and have ministerial registration


2.3 - Anchorages “M 13”

ØI

E

H

L C D

ØB

Ø F

A x

A G

A

A

Final load A B C D E F G H I L T13 T13S 173 186 per cable per cable (kN) (kN) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm)

7M13 1211 1302 130 105 106 300 330 220 45/50 50 12 45 9M13 1557 1674 160 125 133 340 390 260 62/67 55 12 45

12M13 2076 2232 195 146 163 360 400 270 72/77 60 14 45 15M13 2595 2790 225 160 185 385 430 320 80/85 65 14 45 19M13 3287 3534 235 176 197 430 450 360 85/90 70 16 45 22M13 3806 4092 265 200 215 430 500 400 95/100 75 16 56 27M13 4671 5022 310 230 260 490 570 430 100/105 80 20 61 31M13 5363 5766 330 250 277 500 650 470 110/115 90 20 70 37M13 6401 6882 355 270 297 525 700 535 115/120 90 20 86 42M13 7266 7812 375 280 314 590 730 560 130/135 90 20 86




2.4 – Grouting accessories on anchorages “M”

All the castings are supplied equipped with protective covers for the threaded holes. The protected holes are: - ¾” gas hole for grouting - three holes for connecting to cap

The casting is connected to the forming mould by bolts housed in lateral slots, (the head of the bolt must remain buried in the concrete).

DD-3050-A type valves fitted with ¾” DD-6009 type tubes, L=100 mm and DD-6008 type L=200 mm The three holes for connecting to the cap must remain protected by the covers during the grouting phase which will be removed at the moment the threaded bars are screwed in to hold the cap. The ¾” gas hole for grouting must be protected by a cover during all the grouting phase. This hole can be connected up to: - a PVC tube with relative valve in

applications with cap - a corrugated tube with valve for forming

moulds using a special connecter


All the transition cones are made of HDPE and have on the back the wording shown on the casting. We therefore recommend to control compatibility of components before installing.

All the transition cones have little steps which indicate the internal dimension so as to enable the use of sheaths with different diameters. The cone must always be positioned external to the sheath, cut in the position in compliance with the diameter of the metal sheath used; a suitable binding using PVC tape guarantees sealing against grouting leaking in during the grouting phase.

The castings have the following bores: 4M15, 7M15 ½ “ threaded grouting hole and only two holes for connecting to cap. 9M15, 12M15, 15M15, 19M15, 22M15, 27M15, 31M15 and 37M15 3/4 “threaded grouting hole and three holes for connecting to cap.

Each cone must be fully screwed down so that the stop is up against the casting. Silicone or glues are not required to be used because the threading is shaped so as to guarantee the seal.


3 – ACTIVE ANCHORAGES - SERIES “ME” A feature of the “ME” active anchorage series is that they can be replaced after a period of time. They are made up of a “M” type casting, specifically connected to a HDPE sheath with a transition cone. The cone enables the grouting to remain inside, preventing the same from adhering to the internal walls of the casting, guaranteeing that the cable can be dismantled and at the same time providing a perfect seal. The grouting of the heads for external pre-stressing can be carried out using cementitious mixture, wax or grease. The strands can be nude or protected by grease and HDPE. When using nude strand, provision must be made, in some cases, to use local protection of the clamps with grease.

Type Final Load A B C D E F G H L T15 T15S T15C

259 279 300

per cable per cable per cable (kN) (kN) (kN) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm)

4ME15 1036 1116 1200 130 106 63/3.6 135 50 330 220 12 310 7ME15 1813 1953 2100 160 133 75/4.3 160 55 390 260 12 360 9ME15 2331 2511 2700 195 163 90/5.1 177 60 400 270 14 430 12ME15 3108 3348 3600 225 185 110/6.3 195 65 430 320 14 450 15ME15 3885 4185 4500 235 197 110/6.3 210 70 450 360 16 520 19ME15 4921 5301 5700 265 215 110/6.3 245 75 500 400 16 600 22ME15 5698 6138 6600 310 260 125/7.1 265 80 570 430 20 660 27ME15 6993 7533 8100 330 277 140/8.0 295 90 650 470 20 700 31ME15 8029 8649 9300 355 297 140/8.0 295 90 700 535 20 760 37ME15 9583 10323 11100 375 314 160/9.31 330 90 730 560 20 800




4 – MONO STRAND ANCHORAGES –SERIES “E”

The “E” series mono strand anchorage is produced in full compliance with the Italian regulations in force and according to the “FIP recommendations”. The “E” series mono strand anchorage comprises the following parts: casting, clamps and HDPE joint for connecting the casting to the strand coated with high density polyethylene. Castings – All the castings have holes for connection to the forming mould and set up to receive the connection of a step which separates the anchorage from the mould. All the castings are made of spheroid iron EN-GJS 500-7 EN-JS-1050 (Italy: UNI ISO 4544 GS 500-7, France: NF A 32-201 FGS 500-7, Germany: DIN 1693 GGG50, U.K: BS 2789 500-7, ISO R 1083 50-7, Japan: J.S.I. G 5502 FCD 50), which offers high resistance to stress and, as it can be welded, guarantees increased safety during installation. Wedges – Anchorage of the strand is achieved using 7015-T15 type 16NiCr4Pb UNI EN 10277-4 steel or 7017-T15 type 9SMnP28 UNI 4838 steel clamps. Joint – The connection between the anchorage and sheath is by means of a transition pipe that guarantees correct sealing of the anchorage.


Poket former type DD-7004

Strand

Spring Ø150 P.60 wire 6 L.180 mmTransition pipe type DD-0115C0

HDPE pipe

Gasket type DD-7025

Nut type DD-9000

Anchorage type 1E15


4.1 - “E” Anchorages

B

CA

F H

G

ØE

ØD

Type Final load A B C D E F G H T15 T15S T15C per cable per cable per cable (kN) (kN) (kN) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) 1E15 259 279 300 42 50 175 100 6 114 79 150




The rear joint is coupled to the casting by means of a push-fit device that guarantees sealing during the jet grouting phase.

Support for connecting to forming mould DD-7009-B without threaded pin for connecting to infill mould. The support can be re-used.

The E series anchorages are available in the following versions: - 1E15 anchorage made of sanded

spheroid iron. - 1E15-A anchorage made of sanded

spheroid iron and coated with anti-rust paint.

- 1E15-B anchorage made of sanded spheroid iron, coated with anti-rust paint, and machined for connecting up to polyethylene pipe fitting DD-0115-CO.

DD-0115-CO polythene joint for 1E15-B anchorages, can be assembled only on anchorages machined for connecting.

Support for connecting to infill mould DD-7009-A with threaded pin for connecting to infill mould. The support can be re-used.


Nut for support for connecting to infill mould DD-9000 with threaded pin for fixing to infill mould.

Connection DD-0115CO can be coupled to coated strand, guaranteeing no infiltration.

DD-7025 type Neoprene washers for sealing against infiltrations.

Connection to infill mould

Cables for single strand cut to size


4.2 - “EX” Anchorages

Anchorage “EX” offers the possibility of installing an anchor completely covered by HDPE so as to guarantee perfect protection against corrosion of all the components used for a long period of time. Connection to infill mould - All heads are equipped with two equidistant holes so as to facilitate fixing to the infill mould by means of two bolts. Accessories - All heads are equipped with a series of accessories which complete the system.

In correspondence to the movable parts, protection from infiltrations is guaranteed by suitable sealing.


5– PASSIVE ANCHORAGES SERIES “D” The series “D” passive anchorage is made up of the following parts: casting, anchorage plate complete with springs and clamps, HDPE connection or steel for fitting the casting to the metal sheath without sudden variations. Casting – The castings have a supporting plane for the turned plate, coupling holes to cap and the ¾"grouting inlet. The castings are made of spheroid iron EN-GJS 500-7 EN-JS-1050 (Italy UNI ISO 4544 GS 500-7, France NF A 32-201 FGS 500-7, Germany DIN 1693 GGG50, Great Britain BS 2789 500-7, ISO R 1083 50-7, Japan J.S.I. G 5502 FCD 50) which provides high resistance to stress and, as it can be welded, guarantees greater safety during installation. Anchorage plate – The strand is blocked on a separating plate, with conical C40-45 UNI EN 10083/1 steel truncated bores and with either 16NiCr4Pb UNI EN 10277-4 or 9SMnP28 UNI 4838 type steel 7015-T15 clamps. Connection – The connection between the anchorage and sheath is by means of a tube passage which guarantees a correct deviation of the strand, reducing loss values to a minimum. The connection is supplied either in HDPE or steel depending on its use. Connecting to infill mould –All the castings have two equidistant slots which facilitate bolting them to the mould. Grouting – All the castings have a ¾” gas threaded hole for injecting, which enables connecting of the grouting equipment we supply. For further details regarding grouting, turn to the chapter dedicated to “Equipment” .

Series”D”anchorage


5.1 – Passive anchorages “D 15”

ØI

E

H

L C D

ØB

Ø F

A x

A G

A

A

Type Final load A B C D E F G H I L

T15 T15S T15C

259 279 300

per cable per cable per cable (kN) (kN) (kN) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm)

4D15 1036 1116 1200 130 105 106 300 330 220 45/50 50 12 92 7D15 1813 1953 2100 160 125 133 340 390 260 62/67 55 12 94 9D15 2331 2511 2700 195 146 163 360 400 270 72/77 60 14 94

12D15 3108 3348 3600 225 160 185 385 430 320 80/85 65 14 94 15D15 3885 4185 4500 235 176 197 430 450 360 85/90 70 16 102 19D15 4921 5301 5700 265 200 215 430 500 400 95/100 75 16 119 22D15 5698 6138 6600 310 230 260 490 570 430 100/105 80 20 132 27D15 6993 7533 8100 330 250 277 500 650 470 110/115 90 20 132 31D15 8029 8649 9300 355 270 297 525 700 535 115/120 90 20 145 37D15 9583 10323 11100 375 280 314 590 730 560 130/135 90 20 145




5.2 – Passive anchorages “D 13”

ØI

E

H

L C D

ØB

Ø F

A x

A G

A

A

Type Final load A B C D E F G H I L T13 T13S 173 186 per cable per cable (kN) (kN) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm)

7D13 1211 1302 130 105 106 300 330 220 45/50 50 12 92 9D13 1557 1674 160 125 133 340 390 260 62/67 55 12 94

12D13 2076 2232 195 146 163 360 400 270 72/77 60 14 94 15D13 2595 2790 225 160 185 385 430 320 80/85 65 14 94 19D13 3287 3534 235 176 197 430 450 360 85/90 70 16 102 22D13 3806 4092 265 200 215 430 500 400 95/100 75 16 119 27D13 4671 5022 310 230 260 490 570 430 100/105 80 20 132 31D13 5363 5766 330 250 277 500 650 470 110/115 90 20 132 37D13 6401 6882 355 270 297 525 700 535 115/120 90 20 145 42D13 7266 7812 375 280 314 590 730 560 130/135 90 20 145




6 – SERIES “S” PASSIVE ANCHORAGES The “S” series single strand anchorage is produced in full compliance with the Italian regulations in force and according to the “FIP recommendations”. In this type of anchorage the strands, in correspondence with the end, are opened so as to improve adherence to the reinforced concrete. The strands are positioned alternately so as to distribute the stress in the reinforced concrete uniformly.

Single strand 1S15

Post Tensioning – Rev.G – page 21

F

G

H

IE

D

C

B

A

Type Final load A B C D E F G H I T15 T15S T15C

259 279 300

per cable per cable per cable (kN) (kN) (kN) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm)

4S15 1036 1116 1200 210 - 80 80 800 250 50 100 10 7S15 1813 1953 2100 240 80 - - 800 350 50 100 10 9S15 2331 2511 2700 - - 160 160 800 400 60 150 12

12S15 3108 3348 3600 400 80 240 160 800 400 60 150 14 15S15 3885 4185 4500 - - 320 160 800 400 60 150 14 19S15 4921 5301 5700 - - 320 240 900 400 70 220 14 22S15 5698 6138 6600 480 160 320 320 1000 450 70 250 16 27S15 6993 7533 8100 480 160 - - 1000 470 110/115 260 20



Post Tensioning – Rev.G – page22

7 - COUPLER “C15” The “C” type series of joints are made in full compliance with the Italian regulations in force and according to “FIP recommendations”. The “C” type joint enables connecting of cables during construction, for example, of bridges under construction. Coupling is carried out using single strand collars equipped internally with preloaded clamps with a spring device.

ØA

C+

F+ I

D+

E+

ØB

I

I

I

Type A B C D E F ( mm ) ( mm ) ( mm ) ( mm ) ( mm ) ( mm )

7C13 140 45/50 675 300 9C13 159 62/67 800 340

12C13 177 72/77 950 400 800 15C13 193 80/85 1250 400 800 1.200 19C13 193 85/90 1250 400 800 1.200 22C13 193 95/100 1300 400 800 1.200 27C13 193 100/105 1385 400 800 1.800 4C15 140 45/50 675 300 800 7C15 159 62/67 800 340 800 9C15 177 72/77 950 400 800 1.200

12C15 193 80/85 1250 400 800 1.200 15C15 193 85/90 1250 400 800 1.800 19C15 193 95/100 1300 400 800 1.800 22C15 219 100/105 1385 400 27C15 244 110/115 1700 400



8 - “G” SERIES COUPLER The “G” series coupler is made up of the following: casting, anchoring plate and coupler, clamps, metal grip connection and HDPE or steel connection. Casting – The castings have a supporting plane for the turned plate, coupling holes to cap and the ¾"injection inlet. The castings are made of spheroid iron EN-GJS 500-7 EN-JS-1050 (Italy UNI ISO 4544 GS 500-7, France NF A 32-201 FGS 500-7, Germany DIN 1693 GGG50, Great Britain BS 2789 500-7, ISO R 1083 50-7, Japan J.S.I. G 5502 FCD 50) which provides high resistance to stress and, as it can be welded, guarantees greater safety during installation. Anchoring plate – The strand is blocked on a separating plate, with conical C40-45 UNI EN 10083/1 steel truncated bores and with either 16NiCr4Pb UNI EN 10277-4 or 9SMnP28 UNI 4838 type steel 7015-T15 clamps. Connection – The connection between the anchoring and sheath is by means of a transition tube passage which guarantees a correct deviation of the strand, reducing loss values to a minimum. The connection is supplied either in HDPE or steel depending on its use. Connecting to infill mould –All the castings have two equidistant slots which facilitate bolting them to the mould. Grouting – All the castings have a ¾” gas threaded hole for grouting, which enables connecting of the injection equipment we supply. For further details regarding injection, turn to the chapter dedicated to “Accessories” .


8.1 - Couplers “G 15”

B C D

ØA

E x

E

Type A B C D E Ø SHEATH

( mm ) ( mm ) ( mm ) ( mm ) ( mm ) ( mm ) 7G15 160 450 133 340 160 62/67 9G15 200 550 175 350 200 72/77

12G15 248 650 185 385 225 80/85 15G15 265 750 197 430 235 85/90 19G15 280 880 215 430 265 95/100 22G15 300 1000 240 490 300 100/105 27G15 340 1150 277 500 330 110/115

The company reserves the right to change its products and specifications without notice. All documents are in compliance with the Memorandum dated 15 October 1996 n° 252 AA.GG./S.T.C. and have ministerial registration


8.2 - Couplers “G 13”

B C D

ØA

E x

E

Type A B C D E Ø SHEATH ( mm ) ( mm ) ( mm ) ( mm ) ( mm ) ( mm )

9G13 160 450 133 340 160 62/67 12G13 200 550 175 350 200 72/77 15G13 248 650 185 385 225 80/85 19G13 265 750 197 430 235 85/90 27G13 280 1000 215 430 265 95/100

The company reserves the right to change its products and specifications without notice. All documents are in compliance with the Memorandum dated 15 October 1996 n° 252 AA.GG./S.T.C. and have ministerial registration


8.3 - “G” Couplers- application

Coupler assembled

The wedges complete with springs are protected by a steel casing which guarantees its tightness.

Coupler tensioned

Coupler

The coupler is made up of a forged plate provided with tensioning and gripper bores. Gripping of the strand is achieved by means of a spring device that holds the strand once inserted in the external bores.

Coupler 19G15 being tensioned


The « G » type anchoring plates are forged out of C40-45 UNI EN 10083/1 steel and provide high machining features to the item, in particular reducing all the possible problems of defects connected with rolling the material.

The plates are provided with a rear recess where a steel cover contains the springs and wedges. The cover is fixed to the plate by special screws which guarantee correct attachment and suitable resistance to feeding by the strand feeder. The cover is fitted with a ½” threaded collar which allows correct connection to the injection devices. The discharge on the cover guarantees correct filling of the rear part and protection for the blocking devices. All couplers are guaranteed to be traceable and identifiable.


The front fitting of the DD-CU type coupler made of HDPE

Coupler 19G15

Fitting for coupler DD 1915CU


9 - “F” TYPE COUPLERS

202

57

98

L + s + 100

(*) E = 45 + n x B

E E

G

1T15 2T15

D

50

E CE

F

D

BA

3T15

> 300

4T15

50

Type Final load A B C D E F G 0,6" nor 0,6"sup 0,6"com 259 279 300 for cable for cable for cable (KN) (KN) (KN) (mm) (mm) (mm) (mm) (mm) (mm) (mm)

1F15 259 279 300 200 98 55 60 (*) 180 20


Post Tensioning – Rev.H – page 30

10 – COUPLER “K” SERIES

The “K” series single strand anchorage is produced in full compliance with the Italian regulations in force and according to the “FIP recommendations”. These connections have been studied for post tensioning of tanks or circular structures. The “K” series connection carries out the role of active and passive head in the case of circular cables, whereas it is a classic coupler for cables in slab. They can be tensioned using “M” and “TTM” series jacks using a special curved device that allows a controlled deviation of the strand.

The device is made up of steel sectors, the number of which varies according to the deviation angle required; as the angle varies, so does the loss of tension, which must be evaluated through experiments for each individual case.

Type A B C D E F G H ( mm ) ( mm ) ( mm ) ( mm ) ( mm ) ( mm ) ( mm ) ( mm )

2K15 55 85 70 90 100 170 560 140 4K15 60 90 80 100 160 200 710 170 6K15 80 110 100 140 230 240 860 210 8K15 85 115 130 150 320 300 950 270 12K15 90 120 160 160 400 330 1.200 300



11 –ELEMENTARY ANCHORAGES This series of wedges studied for anchorage single or multiple strand to anchorage plates is made for single use and is available for different applications.

Wedges T15

Conical bushes complete with markings for post-tension use in tensioning strand from 15.2 to 15.7mm. Bushes 7010-T15 C40-45 UNI EN 10083/1

Spherical bushes T15/T13

Grip extrusions T15

Grip extrusions. - Bushes T15 C40-45 UNI EN 10083/1, - T15 type 9SMnP28UNI483 steel shells

Wedges for post-tension used on single use anchorages. - 7015-T15 type, 6NiCr4Pb UNI EN 10277-4

steel clamps - 7017-T15 type, 9SMnP28 UNI 4838 steel

clamps

Bushes T15/T13

Conical spherical bushes complete with markings for post-tension use in tensioning strand from 15.2 to 15.7mm. - Bushes 7020-T15 C40-45 UNI EN 10083/1,

T15 coupler connections for strand

Sleeves for post-tensioning used on strand couplers.. - 7030-T15 type sleeve with 12NiCr3Pb UNI

EN 10084-97 steel wedges, - 7034-T15 type sleeve with 9SMnP28 UNI

4838 steel wedges.


12 – CORRUGATED METAL SHEATHS “ST”

The metal sheaths are the most inexpensive way for creating vacuums in post tensioned elements because they supply good secondary protection against corrosion and an excellent constraint between the cables and the concrete. The primary protection against corrosion is given by the alkalinity of the injection and the concrete itself.

The sheaths are available in different versions and are produced in cold rolled Fe P01 UNI 5961/67 steel clinched sheet. The characteristics may vary in:

- Diameter - bar length - thickness of sheet steel used

On request they can be supplied galvanised. The sheaths are supplied in bundles; on each bar is assembled a connection sleeve external to the bar.

Corrugated sheaths recommended for use with strand T15 and T15S Number strands Internal diameter Injection cement Rectilinear part

after curvature Minimum Radius

(mm)

Litres/meter

Cement Kg/meter

Minimum (mm)

Minimum (mm)

4 45 1,2 1,9 500 3000 7 62 2,3 3,6 700 3500 9 72 2,8 4,5 800 4000

12 80 3,6 5,8 1000 4000 15 85 3,8 6,1 1100 4500 19 95 4,7 7,5 1200 5000 22 100 5,2 8,4 1300 5000 27 110 6,2 9,9 1300 5000 37 130 8,6 13,8 1500 6000

The thicknesses of the sheaths may vary from 0.3 to 0.6 mm. The dimensions in the table are indicative and must be compared with the operating instructions for each individual project.


13 – LOSS CALCULATION ELEMENTS In order to carry out calculations it is necessary to distinguish between immediate and deferred drops in tension.

13.1.1 – Immediate losses Are divided into : - Loss due to friction - Loss due to inserting of wedges - Loss due to elastic deformation of the concrete They occur during the stressing phase, reducing the tension generated by the jack.

13.1.2 – Loss of tension due to friction In compliance with CEB-FIP Model Code dated 1990 the tensions ( )xpoσ , in a specific section placed at an x distance from the active head, is reduced with respect to the tension .max,poσ ; the difference between the two tensions corresponds to the loss by friction. The value of ( )xpoσ is calculated using the following formula:

( )xpoσ = ( )Kxfpo e +−⋅ ασ .max,

where : e = base of Neperiano logarithm

f = friction coefficient α = sum of angular calculations calculated up to section x , evaluated in radians K = conventional deviation of the rectilinear cable per linear meter.

( )xpoσ = tension in the section with “x” coordinate

poσ = tension at the active anchoring level


In the case of internal post-tension f = 0,55 steel/concrete f = 0,30 steel/concrete BS 8110 f = 0,25 steel/galvanised steel

f = 0,18-0,22 strand Euro code 2)

0,005 < K < 0,010 rad/m In the case of external post-tension For saddles with curvature radius between 2.5 and 4 m it can be assumed that: K = 0 0,25 ≤≤ f 0,30 strand on metal saddle 0,20 ≤≤ f 0,25 greased stand on metal saddle 0,05 ≤≤ f 0,07 bundle of strand individually coated on metal saddle 0,12 ≤≤ f 0,15 nude strand in HDPE sheath,, on metal saddle

13.1.3 – Loss of tension on inserting wedges During the blocking of the wedges in the anchoring, the loss of elongation of the strand is damped by friction with the sheath; this is the opposite to what happens during the stressing phase. The loss of tension, which reaches its maximum in correspondence with the anchoring, progressively and symmetrically decreases and stops at a “d” distance from the anchoring.

p(x)

σp0g(x)

d

σ'p(x)

x distanza dall' ancoraggio Distance from anchoring

Fig. – Tension along the cable and following wedging of the clamps.

+⋅

⋅=

KlfEg

dpo

p

ασ

+⋅−=′ K

lfdpopoασσ 2


13.2 – Deferred losses They are divided into : - Loss due to shrinkage - Loss due to viscosity - Loss due to relaxation of the steel They occur during the life of the work caused by phenomena strictly connected to the behaviour of the concrete (shrinkage and viscosity) and the steel.

13.2.1 – Loss of tension due to relaxation The high resistance steels, subjected over a period of time to constant tension, undergo stretching. The final loss of tension value depends on the duration of the post-tension application. To determine the overall loss due to relaxation we suggest the following formula

( ) ( )xf pi

pk

xpip

σµσ

ϕσ ⋅

−⋅=∆ 0100010

6

where: 1000ϕ relaxation value guaranteed by the producer at 1000 hours

( )xpiσ value in initial tension in the section placed at x distance

pkf yield point of the strand

oµ =0,43 for low relaxation strand =0,30 for medium relaxation strand

13.2.2 – Loss of tension due to shrinkage Shrinkage is a phenomena tied to the shrinkage of the concrete that occurs during hardening. As the post-tension cables are closely connected to the concrete matrix, they are subject to the same deformation variations. The final losses of tension due to shrinkage, in the case of constant thermo-hygrometric conditions, depend on the age of the concrete at the moment of tensioning. The mathematical formula that expresses this connection is:

rprf ε⋅Ε=∆ where

pΕ = elastic modulus of the strand

rε = final deformation due to shrinkage


13.2.3 – Loss of tension due to viscosity Deformation due to viscosity is due to a shrinkage of the concrete which is in relation to the time and level of tension. The final losses of tension due to shrinkage, in the case of constant thermo-hygrometric conditions, depend on the age of the concrete at the moment of tensioning, and also to the duration and intensity of the load applied. Slow deformation under load, save more precise evaluations, must be assumed to be twice the elastic deformation, always given that the structure is stressed not prior to 14 days of maturing.

14.3 – Evaluations of elongations during tensioning of cables During tensioning of cables it is necessary to compare the actual elongations with the theoretical elongations envisaged in the calculations to which the corrective terms must be added in order to obtain the true elongations. The elongations registered on site are the sum of the following elements:

ao LL ∆=∆ + bL∆ + cL∆ + dL∆

aL∆ = elongation of the strand calculated considering the extra length necessary for the jack to grip it.

bL∆ = elastic deformation of the concrete. Usually, the elongation measured on the jack

included the elastic shrinkage of the concrete cL∆ = sum of the deformations of the anchoring devices and re-entry of the clamps in the

conical seats dL∆ = re-entry of gripper clamps and internal deformations of the jack

13.3.1 – Draw-in of wedges on the active anchoring The loss of elongation due to draw-in of the wedges occurs during the locking phase of the same following tensioning

dL∆ = 3-4 mm for tensioning with jacks equipped with wedging system

dL∆ = 12 mm for tensioning with jacks not equipped with wedging system, series MX

13.3.2 – Re-entry of clamps and deformation of fixed anchoring Usually, deformation of anchorings under load is always limited to and does not exceed 1mm. Draw-in of wedges on passive anchorages causes a translation of the cable towards the tensioning jack. The values remain about 4-5mm.


13.3.3 – Deformations of jacks These deformations must be assumed from the measure of the elongation of the strand when the readings have been taken on the piston of the jack. The internal losses at the jacks are considered:

jacks series TTM = 8 mm jacks series M = 7 mm

jacks series MX = 9 mm jacks series DD = 4 mm

When the elongations are taken directly on the strand these values must not be taken into consideration.

13.3.4 – Tensioning values on strand post-tensioned anchorings (Ministerial Decree 9 January 1996)

Technical standards for calculations, carrying out and testing of the reinforced concrete, normal and precompressed structures and for metal structures. Maximum load applicable on single strand Maximum tensioning pull ( Pi ) must be limited to: Pi = 0,85 x fp(1)k x nominal Area Pi = maximum load in KN Strand characteristics

Diameter Standard Type of stand

Nominal diameter

Nominal area fptk fp(1)k Mass

Tension1%

elong.

Yield point (Ptk)

Elastic limit

at 0,1% Pt0,1k )

Relaxation after 1000

h.0,7 - 0,8 fpt

mm mm2 N/mm2 N/mm2 gr./m KN KN KN % %

(T15) pr EN 10138 normalsuper

15.2 15.7

140 150

18601860

1670 1670

10931172

234 251

260 279

230 248

2.52.5

4.5 4.5

(T15)

ASTM A779/00

pr EN 10138

Compact 15.2 165 1860 1670 1289 270 307 264 2.5 4.5

Elastic modulus = 196 +/- 10 KN / mm2


13.3.5 - Tensioning values on bar post-tensioned anchorings (Ministerial Decree 9 January 1996)

Technical standards for calculations, carrying out and testing of the reinforced concrete, normal and precompressed structures and for metal structures. Maximum pull applicable on single bar Maximum tensioning pull ( Pi ) must be limited to: Pi = 0,85 x Fpyk Pi = maximum tensioning pull in KN

13.3.6 - Tensioning limits for pre-stressing steel (Ministerial Decree 9 January 1996)

Technical standards for calculations, carrying out and testing of the reinforced concrete, normal and precompressed structures and for metal structures. The tensions must be limited to the following values refer to those characteristics guaranteed by the producer. Post-stressed casing structure:

ptksp

pykspi

ptksp

kpspi

ptksp

kpspi

ff

ff

ff

60,085,0

bars

60,085,0

strand

60,085,0

braidor wire

)1(

)2,0(

≤≤

≤≤

≤≤

σσ

σσ

σσ

Pre-stressing steel fpy yield tension ( bars ) fp(1) tension at 1% of deformation under load fp(0,2) tension at 0,2% of residual deformation fpt characteristic tension fpyk characteristic yield tension (bars) fp(1)k characteristic tension at 1% of deformation under load fp(0,2)k characteristic tension at 0,2% of residual deformation fptk characteristic yield tension

Post Tensioning– Rev.H – page 39

14 - GROUTING Grouting of the anchorings can be carried out using different technical solutions which must be clarified with the Company before starting work on the site. The cap is made up of a cover equipped with a seal fixed to the casting by means of suitable tie rods which vary in length and size depending on the different applications. A special closing disc tightens the seal and the cap to the grouting. The disc guarantees the possibility of turning the cap to the most suitable position and such so as to allow all the air to exit. For the accessories refer to the appropriate chapter.

Grouting must be carried out at temperatures of not less than 5° C and the following water cement-additive ratio must be adhered to:

- 50 Kg cement - 20 litres of water, - 500 gr. additive

The applicable grouting systems are : - infilling of heads, - use of reusable caps - use of mono use caps.

The most used system for carrying out grouting is by re-usable caps. This system allows homogenous infilling without air bubbles both when using the “M” and “G” anchoring series.

Internationally the system using caps is coupled with the vacuum technology to improve the grouting. A suitable range of accessories guarantees the maintenance of pressure in the recess and complete discharge of the air.

Grouting cap on coupler 19G15


14.1 – Grouting with cap A metal cap, complete with seal, confines the grouting to the anchorage plate side. The grouting is through the ¾” hole in the casting in which the connection is inserted.

The connection for the grouting is a valve that can be connected either to the corrugated polyethylene tube or a rigid threaded ¾” tube. After use the cap is removed and saved.


14.2 – Grouting

Grouting of the head is the most economic system for grouting the cable which is always carried out through the ¾” hole by inserting either the corrugated or rigid PVC tube according to requirements.

Grouting

Connection using a HDPE corrugated tube tin which the valve is inserted.


Valve type DD-3050-A

Re-useable valve type DD-3050-A diam. 25 mm.This valve enables interception of the mixture, it can be connected directly to the DD20x25 diam. 25 mm corrugated tube and is re-usable if the conical shut-off part is greased.


Gate valve type DD-1003-A diam. 25 mm This valve enables interception of the mixture, it can be connected directly to the DD20x25 diam. 25 mm corrugated tube and is usually used to close the bleed tube.


Gate valve type DD-1016-A diam. 20 mm This gate valve can e connected to the 20 mm diam. type DD15x20. corrugated tube.

Post Tensioning – Rev .H – page 43

Valve type DD-3050-A with tube DD20x25

Re-useable valve type DD-3050-A connected to corrugated tube type DD 20x25. This valve is used for primary groutings; considered to be re-usable 4 times if appropriately greased on the inside.


Re-useable valve type DD-1003-A connected to corrugated tube type DD 20x25. This valve is used for primary bleeders; considered to be re-usable twice if appropriately greased on the inside..


Re-useable valve type DD-1016-A connected to corrugated tube type DD 15x20. This valve is used for secondary bleeders; considered to be re-usable twice if appropriately greased on the inside.


Corrugated tube type DD 20x25 o DD15x20

Corrugated pipe for grout and vent - DD 20x25 diam. 25 mm corrugated tube for

primary injections and bleeders - DD 15x20 diam. 20 mm corrugated tube for

secondary vent

Rigid PVC tube type DD-6010 e DD-6009

Threaded rigid PVC tube sections - Threaded tube sections L=200 mm ¾” type

DD-6010 - Threaded tube sections L=100 mm ¾” type

DD-6009 - Threaded tube sections L=200 mm 1/2” type

DD-6008 - Threaded tube sections L=100 mm 1/2” type

DD-6007

Rigid PVC tube type DD-6010 and DD-6009 with type DD-1017-A connection


Connection: - Re-usable valve type DD-3050-A, - Connector type DD-1017-A, - Threaded tube sections L=100 mm ¾” type

DD-6009 Type DD-3050-A valves coupled with ¾” type DD-6009 L=100 mm tubes and type DD-6008 L=200 mm

Connection: - Re-usable valve type DD-1003-A, - Connector type DD-1017-A, - Threaded tube sections L=100 mm ¾” type

DD-6009 Type DD-1003-A valves coupled with ¾” type DD-6009 L=100 mm tubes and type DD-6008 L=200 mm


Connector type DD-1017-A

Connector type DD-1017-A for coupling between:

- ¾”threaded tube sections type DD-

6009 and DD-6010, - valves DD-3050-A and DD-1003-A,

Connector type DD-1017-B

Connector type DD-1017-B for coupling between: - corrugated tube DD20x25 mm, - female ¾” coupling

Connector type DD-1033-B and DD-1034-B

Connector type DD-1033-B 1/2" corrugated tube DD15x20 Connector type DD-1034-B 1/2" corrugated tube DD20x25


Connector type DD-1033-B 1/2" corrugated tube DD15x20 mm

- Connector type DD-1017-B and corrugated tube DD20x25 mm

- Connector type DD-1033-B 1/2" corrugated tube DD15x20 mm

- Connector type DD-1034-B 1/2" corrugated tube DD20x25 mm

Connector type DD-1034-B 1/2" corrugated tube DD20x25 mm

Connector type DD-1034-B and DD-1033-B

Connector attachment to casting “M”

Attachment to castings series “M” Anchorings: 4M15 and 7M15 connection series DD-1034 Anchorings: 9M15 12M15, 15M15, 19M15 22M15, 27M15, 31M15 and 37M15 connection series DD-1017-B


Connector type DD-1033-B corrugated tube DD15x20 mm. and check nut DD-8000

Type DD-1001 cover made of soft material so as to fit on all the sheath sizes. The item is mono use.

Bleeder cover type DD-1001

Check nuts for threaded connectors: Nut DD-9000 for coupling with ¾” thread Nut DD-8000 for coupling with 1/2" thread

Connector type DD034-B 1/2" corrugated tube DD20x25 mm. and check nut DD-8000

Connector series G with coupling for injection


15 – DISTANCES BETWEEN THE ANCHORINGS

15.1 – Distances from edges

2A A B A

AB

B Minimun anchorage centres (mm) A Minimun edges clearances (mm) fc min fc min Type

23 33 43 Type

23 33 43 4M15 250 205 180 4M15 135 110 105 7M15 330 275 240 7M15 175 150 135 9M15 370 310 270 9M15 210 180 160

12M15 430 360 315 12M15 240 200 180 15M15 480 400 350 15M15 265 230 205 19M15 540 450 395 19M15 290 250 225 22M15 580 485 425 22M15 325 270 245 27M15 630 540 470 27M15 360 310 270




15.2 – Recess

C

B x

B

a

a

A

A x

AB x B

4M15 7M15 9M15 12M15 15M15 19M15 22M15 27M15A x A 130 160 200 225 235 265 300 330 B x B 170 200 240 265 275 325 340 370

C 100 100 100 100 100 110 115 120 a° 10 10 10 15 15 15 20 20


All documents are in compliance with the Memorandum dated 15 October 1996 n° 252 AA.GG./S.T.C. and have ministerial registration The fixing of the heads to the forming mould must guarantee a perfect seal to avoid the concrete entering the recess during injection grouting.

The heads are supplied with turned supporting planes. If the coupling surfaces with the anchoring does not provide an adequate seal for the system, rubber or silicone seals will have to be used.


16 – “MS” STAY CABLES SYSTEM The “MS” stay cable system is the result of years of experience in the metallurgical sector. The research into better materials, coupled with production cycles so as to guarantee a very high level of purity of the material, has led to the achievement of high performance of the anchorages, able to meet the highest fatigue standards required by international regulations. The metallurgical experience of the companies in the group has enabled the “MS” anchorages to receive the best materials, the best heat treatments, the best protective coverings available on the market today, all elements which give the anchorage excellent mechanical-structural features, to guarantee the structures where they are installed, very high strength and preservation over the years. Steels The steels used in making the anchorage are very high quality and vacuum cast, with tests for inclusions carried out with the best control systems the market can offer. All the heads are made of forged steel and checked using non destructive systems, so as to ensure the pureness of the material, an essential quality for elements as important as anchorage for stays. Treatments All the materials used in producing anchorages are normalized and stabilized following special treatments, so as to guarantee very high performance of the materials used over the years. Surface protection Protection of the surfaces of the anchorage head can be further improved by special protective treatment against corrosion, which is NIPRE®, that guarantees resistance against rust in saline fog, four times higher than chrome. NIPRE ® is a surface treatment that improves the characteristics of the items, increasing the surface hardness characteristics, improving the friction coefficient and giving the item a grey metallic colour, characteristic of the treatment. The surfaces do not change their measurements and there is no addition of material, an important feature for elements undergoing fatigue. Anchorages The “MS” series has two types of anchorages:

- active anchorage “MSA” - passive anchorage “MSD”

The anchorage system for the MS stays is a mechanical anchorage protected by injections of wax in the anchorage zone of the strand. The stand used is T15S 15,7 mm. Galvanised, waxed and protected with a coating of high density polyethylene. The anchorages are tested for a load varying from 150 N/mm2 to 200 N/mm2. The active anchorages are prepared for adjustment using a toroidal jack, a ring nut is available for accurate adjustment of elongation of the whole cable. Sheaths The sheaths used to protect the stays externally may be:

- HDPE (polyethylene), - Stainless steel, - Aluminium.

The sheaths are the external protection of the cable and the choice must be made in agreement with the architectonical requirements of the project. The sheaths are coupled with anti-vandalism tubes that protect the anchorage-sheath connection at the end section of the cable.

Post Tension – Rev. H – page 52

16.1 – Adjustable type “MSA” anchorage The “MSA” adjustable anchorages are made using an anchorage plate placed on a threaded pin, which coupled with a ring nut, enables adjustment to be carried out during anchorage. The adjustments are reached by tightening or loosening the ring nut using a special toroidal jack of adequate capacity. The length of the threaded pin varies depending on the adjustments required by the project. Inside the regulating pin there is a space to contain wax or grease to protect the parts of the strand not covered by the HDPE protection. The head has a deviator complete with damper, made to deviate the strand inside the sheath and at the same time to dampen the vibrations the cable is subjected to. A protective cap cover all the head protecting it from corrosion.

Type A B D E F G H

(mm) (mm) (mm) (mm) (mm) (mm) (mm) 19MSA15 140/8.0 254.0/5 30 70 360x360 292 232 31MSA15 180/10.2 273.0/5 45 85 420x420 310 249 37MSA15 200/11.4 298.5/5 50 90 470x470 345 270 55MSA15 225/12.8 323.9/5 50 105 560x560 400 300 61MSA15 250/14.2 381.0/5 60 110 600x600 450 350 73MSA15 280/15.9 406.4/5 70 115 630x630 470 370 91MSA15 315/17.9 457.2/5 70 120 700x700 505 405

109MSA15 315/17.9 457.2/5 80 125 750x750 526 426 127MSA15 355/20.1 508.0/5 90 130 800x800 570 470


All documents are in compliance with the Memorandum dated 15 October 1996 n° 252 AA.GG./S.T.C. and have ministerial registration .


16.2 – Fixed “MSD” type anchorages

The fixed “MSD” anchorages are made using an anchorage plate positioned on a holder box which holds wax or grease to protect the parts of the strand not covered by the HDPE protection. The head has a deviator complete with damper, made to deviate the strand inside the sheath and at the same time to dampen the vibrations the cable is subjected to. The protective cap is smaller in size to protect only the part of the anchorage for the strand.

Type A B C D F G (mm) (mm) (mm) (mm) (mm) (mm)

19MSD15 140/8.0 254.0/5 200 30 360x360 292 31MSD15 180/10.2 273.0/5 200 45 420x420 310 37MSD15 200/11.4 298.5/5 200 50 470x470 345 55MSD15 225/12.8 323.9/5 200 50 560x560 400 61MSD15 250/14.2 381.0/5 200 60 600x600 450 73MSD15 280/15.9 406.4/5 200 70 630x630 470 91MSD15 315/17.9 457.2/5 200 70 700x700 505

109MSD15 315/17.9 457.2/5 200 80 750x750 526 127MSD15 355/20.1 508.0/5 200 90 800x800 570


All documents are in compliance with the Memorandum dated 15 October 1996 n° 252 AA.GG./S.T.C. and have ministerial registration .


17 - BARS The high-tensile strength bars are used for post tension and geotechnical applications. They are continuous threaded and diameters vary from 26,5 to 47 mm and operating load of between 568 kN and 1820 kN. The main applications are: - Continuous or prefabricated pre-stressed concrete structures - Additional reinforcement for RC work - Permanent and temporary tie bars, - Permanent and temporary mono-bar tension rods with anti-corrosion protection

Technical characteristics of high-tensile strength bars Diameter 18 26,5 32 36 40 47

Area ( cm2) 2,41 5,55 8,04 10,20 12,57 17,35 Mass ( Kg/m) 1,96 4,48 6,53 8,27 10,21 14,10 Fpyk ( KN) 230 525 760 970 1190 1650 Fptk ( KN) 255 580 850 1070 1320 1820

fpyt / fptk 950/1050 950/1050 950/1050 950/1050 950/1050 950/1050 Type Y 1050 Y 1050 Y 1050 Y 1050 Y 1050 Y 1050

Diameter 26,5 32 36

Area ( cm2) 5,51 8,04 10,20 Mass ( Kg/m) 4,48 6,53 8,27 Fpyk ( KN) 460 671 850 Fptk ( KN) 568 828 1049

fpyt / fptk 835/1030 835/1030 835/1030 Type Y 1030 Y 1030 Y 1030


The quality of the material is identified by painting the bars in the cutting zone. The following colours are used for the following types:

- Green: 950/1050, - Blue: 1080/1230, - Yellow: 835/1030.

Average strength bars prior to tensioning


17.1 – “TTB” series bar system The anchorage is made up of the following parts: plate and tightening nut.

Typology Threaded bars

Steel Quality (N/mm2) 835/1030 900/1050 1080/1230 Nominal Diameter (mm) 27 32 36 26 32 36 27 32 36

a distance from edge 200 220 250 200 220 250 220 250 280b distance between centres 120 130 145 120 130 145 130 145 160c thickness 30 35 40 30 35 40 35 40 45

Strength of concrete class

B35 d width 140 160 180 145 180 200 160 180 200a distance from edge 190 200 230 190 200 230 200 230 260b distance between centres 110 120 135 110 120 135 120 135 150c thickness 30 35 40 30 35 40 35 40 45

Strength of concrete class

B45 d width 140 160 180 145 180 200 160 180 200



18 - EQUIPMENT

18.1.1 - TTM-A type hydraulic pump

All the machines are equipped with control panels L=10 m which allow all the operating phases of the machine to be controlled. Special calibrating valves enable the operator to manually adjust the pressure very easily and precisely in the two machine circuits. All the equipment exiting the company are in compliance with CE directives, equipped with relative markings according to the machinery regulations and completely calibrated with 6 months validity.

Controller TTM 450-A

Controller TTM450-A, designed for small operations with max. 6 TTM250KN jacks or DD series bar tensioning for all types of jacks. The limited size makes it an excellent machine for tensioning bars anchor. The machine is made for intermittent operations and can reach max pressures of 600 bar and 550 bar for continuous services.

Controller TTM 250-A, designed for small operations with single TTM250KN jack or DD series bar tensioning jacks. The limited sizes and weight together with an operating pressure of 550 bar. makes it a simple and practical means for small operations.



Controller TTM550-A, designed for heavy duty with TTM250KN jack where continuous operating is required. Its characteristics make it flexible and robust and usable for draw out tests and tensioning of post tensioned structures, it can work with a maximum of 19 TTM250KN or 9 TTM250KN-400 jacks. The machine is made for heavy duty and can reach max. pressures of 700 bar and pressures for continuous operating services of 550 bar.


18.1.2 -“TTM450-A” SERIES OF HYDRAULIC PUMP The “TTM-A” series of hydraulic pump are available in six models which differ according to use required and characteristics. This type of controller is set up with a two tube exit for driving the TTM and DD series of jacks. All the machines are equipped with three control circuits: pulling wedging and return, where the wedging-return circuit is the circuit itself. All the circuits are supplied with calibration valves and safety valves to avoid overpressure. The control gauges installed are analogue, but can be coupled to a digital gauge with 1 bar precision. The 450, 550 and 600 series of controllers are made to use up to 12 single strand jacks at the same time. The 650, 700 and 750 series of controllers are made to work with DD type jacks or simple jacks; they are not equipped for the wedging circuit as these jacks are not called on for this type of operation.

Controller TTM-A

Type Weight Max. Pressure Capacity Voltage/ Amperes

Dimensions

(Kg) bar. KW TTM450-A 170 450-500 4.5 380/16 TTM TTM550-A 175 550-600 5.5 380/32 TTM TTM600-A 180 600-700 10 380/63 TTM TTM650-A 150 450-500 4.5 380/16 DD TTM700-A 170 550-600 5.5 380/32 DD TTM750-A 180 600-700 7.5 380/63 DD

Subject to change Further data available on request


18.1.3 -“TTM 250-A”SERIES OF TENSIONING CONTROLLERS The “TTM-250-A” series of hydraulic pump are available in six models which differ according to use required and characteristics. This type of controller is set up with a two tube exit for driving the TTM and DD series of jacks. All the machines are equipped with three control circuits: pulling. wedging and return, where the wedging-return circuit is the circuit itself. All the circuits are supplied with calibration valves and safety valves to avoid overpressure. The control gauges installed are analogue, but can be coupled to a digital gauge with 1 bar precision. The 250-A, 250-B and 250-C series of controllers are made to use up to 3-4 TTM 250 KN-200 type single strand jacks at the same time. The function change is achieved using the control panel change, which being equipped with several connections enables the controller to have different functions depending on the number of circuits.


Type Weight Max. Pressure Capacity Voltage/ Amperes

Dimensions Use

(Kg) bar. KW (mm) TTM200-A 50 450-550 1,5 380/16 600x500x300 TTM-DD TTM250-A 60 450-550 1,5 380/16 600x500x300 TTM-DD TTM300-A 80 450-550 1,5 380/16 600x500x300 TTM-DD

Subject to change Further data available on request


18.2 - “TTM” series of stressing jacks The “TMT” series of jacks are available in three models which differ according to characteristics and use. All the jacks are set up with automatic wedging circuit and 4 metre long flexible tubes. This jack is mainly used for stressing on TTR heads The TTM250 KN jacks are supplied together with the following equipment:

- Controller TTM 450 KN - Manifold DD-MF

Stressing jacks TTM 250KN-200 and TTM 250KN-100

Characteristics U.M. TTM 250 KN TTM 300 KN TTM 350 KN Capacity KN 250 300 350 Stroke mm. 200 200 200 Weight Kg. 22 25 29 Tensioning section cm2 47.2 58.32 65 Maximum tensioning pressure bar 550 550 550 Maximum return pressure bar 180 180 180 Maximum locking pressure bar 180 180 180 Tensioning extension mm. 250 280 300 Max diameter. mm. 85 110 120 Length mm. 930 930 950

Subject to modification Further data is available on request


Jack TTM250KN-C-100

TTM250KN-C-100 jack with 100 mm. stroke without locking with short grip (90mm) for single tensioning of short strand.

Jack TTM250KN-100 Jack TTM250KN-100 with 100 mm. stroke

complete with locking with grip at 250 mm.

The main uses of the TTM250KN jacks are for tensioning on TTR heads or as single strand jacks on TTM anchorings.

The TTM250 KN jacks are supplied together with the following equipment:

- controller TTM-A. - manifold DD-MF, - hydraulic extension, - release cone

The equipment is complete with calibration certificate in compliance with EURO NORM EN 1537-2002 paragraph 8.4.2. and calibration is valid for six months; calibration accompanies the machine and tensioning jacks.

Jack TTM250KN-200

Jack TTM250KN-200 with 200 mm. stroke

complete with locking with grip at 250 mm. available also with 400 mm. stroke

18.2.1 – Release cone

Release cone type TR-15

Type TM-15 release cone can operate only on anchorings in the series:

- TTM, - M - G

- On all multi strand anchorings

TR-15 Cod. 25057 type release cone for mono strand T15 anchorings, it must be used on TTM250-KN jacks.

Release cone type TM-15 Type TM-15 Cod. 25060 release cone for mono strand T15 anchorings, it must be used on TTM250-KN-M jacks.


18.3 –Master gauge S1000 The master gauge S1000 can carry out calibrations to compare the hydraulic system in use by means of connections upstream and downstream of the circuit. It is supplied in a suitable insulated aluminium box inside which is enclosed a digital gauge with four digit read-out and 1 bar minimum read-out. The read-out takes place by means of hydraulic insertion of a digital transducer with 1-1.000 bar. scansion which enables viewing of the pressure at the point of application. The instrument can be supplied on request with different certifications:

- internal calibration, comparator gauge - official calibration through authorised laboratory

The master gauges are set for an operating pressure of 1.000 bar. They are supplied with CE markings, completely protected and equipped with identification serial number for periodical controls carried out by our technical service.

Master gauge transducer S1000

Master gauge S1000

Master gauge transducer S1000 with strand inserted


18.4 – Barstressing jacks The DD series of jacks are available in four models that differ according to use characteristics. All the jacks are provided with flexible 10 metre long tubes and spanners of different sizes for all the types of bars from 26.5mm to 50mm.

Jack DD2000KN The equipment, supplied complete with operating instructions and CE markings, is identified by a serial number and construction type for each component of the equipment itself. The equipment is complete with calibration with six months validity. The DD jack series is supplied complete with the following parts: - Tensioning cylinder, - Hydraulic extensions, 10 metres long - Additional wrenches for nuts associated with the capacity of the bar, - Wrench for pre-fixing of the nut, - Coupling


The DD jacks series are provided with automatic tightening. By means of a special wrench inserted in the jack it is possible, maintaining the bar under tension, to proceed to tighten the nut; this avoids the use of saddles and manual tightening operations. The DD jacks series are provided with two robust handles which facilitate handling and can operate with all the controllers with the following characteristics: - Operating pressure 550 bar, - Exchange hydraulic circuit, forward and return, (with return in discharge)

Jack DD700KN

Tightening is by means of a chain transmission (inside the jack) operated by a special lever. The lever has a special device that allows both tightening and loosening of the nut. The chain connects the gears which enable the nut to be tightened; the group is protected by a robust guard. All the DD jack series are supplied complete with the indispensable accessories for correct tensioning:


- long-life coupling, - lengths of bar for extensions, - long-life round rear nut

Internal wrench for DD jacks

Ratchet for DD jacks

Nat long life nut for DD jacks

Long life coupling for DD jacks

The accessories are kept in a tool box and help to facilitate the operations associated with: - Long-life coupling, enables connecting of the

bars with minimum protrusion of 10-13 cm. and to carry out tensioning reducing the passive swarf only to the length engaged in the coupling. The couplings are made of high strength steel which guarantees several re-uses.

- Coupling 26,5 mm. long life, - Coupling 32 mm. long life, - Coupling 36 mm. long life, - Coupling 40 mm. long life, - Coupling 47 mm. long life, - Rear long-life nut, is made with spherical

rest, so as to guarantee the correct squareness of the anchorage, they are made of high strength steel which guarantees several re-uses.

- Nut 26,5 mm. long life, - Nut 32 mm. long life, - Nut 36 mm. long life, - Nut 40 mm. long life, - Nut 47 mm. long life, - The bar is a length of the bar having the same

characteristics as the bar under tension. - Reversible ratchet, unique for all types of

jacks which permits tightening and loosening of the nut. It is equipped with a suitable lever to facilitate tightening.


18.5.1 – Jacks for tensioning “DD” series bars

Jack DD1200KN

Characteristics U.M. DD700KN DD1200KN DD2000KN DD2600KN Capacity KN 700 1.200 2.000 2.600 Stroke mm 50 50 50 50 Weight Kg 42 54 95 135 Tensioning section cm2 132,47 235,5 418,40 521,5 Maximum tensioning pressure bar 550 550 550 550 Maximum return pressure bar 100 100 100 100



18.5.2 - Jacks for tensioning “DX” series bars

The DX series of jacks are supplied complete with the following parts: - Tensioning cylinder - 10 metre long hydraulic extensions The series D jacks are without mechanical tightening and are used for tensioning on joints, where tightening of the nut is carried out manually due to its limited movement.

Jack DX700KN

Characteristics U.M. DX700KN DX1200KN DX2000KN DX2600KN Capacity KN 700 1.200 2.000 2.600 Stroke mm 50 50 50 50 Weight Kg 35 43 68 95 Tensioning section cm2 132,47 235,5 418,40 521,5 Maximum tensioning pressure bar 550 550 550 550 Maximum return pressure bar 100 100 100 100 Maximum locking pressure mm 150 150 150 150 Tensioning extension mm 200 270 360 430 Max diameter. mm 230 300 370 490 Length



Tensioning concrete beam with DD2000KN jack

tensioning bar with DD2000KN jack and TTM250-A controller of 40 mm diam bar.


18.6 - “TTM-E”D series hydraulic pump The “TTM-E” series of hydraulic pump are available in six models which differ according to use required and characteristics. This type of pump is set up with a three tube exit for driving the M type tensioning series of jacks. All the controllers are equipped with three control circuits: pulling wedging and return, where the wedging-return circuit is the circuit itself. All the services are supplied with calibration valves. The control gauges installed are analogue, but can be coupled to a digital gauge with 1 bar precision. The machines are equipped with control panels L=10 m which allow all the operating phases of the machine to be controlled. Special calibrating valves enable the operator to manually adjust the pressure very easily and precisely in the three machine circuits. All the machines are provided with three control gauges to view the pressure in the individual circuits; they are equipped with release valves and safety valves to avoid overpressure. All the equipment supplied is manufactured in compliance with the machinery regulations and has CE markings.

Controller TTM 2000-E

Type Weight Max. Pressure Capacity Voltage/ Amperes Dimensions Use

(Kg) bar. KW ( mm) TTM1000-E 400 550-600 10 380/32 850x550x1200 M TTM2000-E 450 550-600 10 380/32 850x550x1200 M TTM3000-E 500 550-600 12.5 380/63 850x550x1200 M TTM4000-E 550 550-600 12.5 380/63 M TTM5000-E 600 550-600 15 380/63 M TTM6000-E 700 550-600 30 380/63 M Subject to modification Further data is available on request

Post Tensione – Rev. H – pagina 70

18.7 – Tensioning jacks series “M”

The “M” series of jacks are available in nine models which differ according to the use characteristics. They are provided with an automatic locking circuit and 10 metre long flexible tubes; they are also equipped with a device rotating on an axis, restricted tensioning extension, low operating pressure. The jacks are equipped with a metal support, studied in particular to achieve the required inclinations in the tensioning operations. The support is integral with two bearings which enable the jack to turn on its axis, facilitating insertion of the stand protruding from the head. The restricted tensioning extension, the rotation of the jack on its axis and the support enable rapid operations and limited effort during handling.

Jack M6800KN

Characteristics U.M. M 1600 KN M 1800 KN M 2800 KN M 3000 KN M 3600 KN M 4800 KN M6800KNCapacity KN 1600 1800 2800 3000 3600 4800 6800 Stroke mm 250 250 250 200 250 250 250 Weight Kg 180 210 280 600 640 730 1200 Tensioning section cm2 155.51 320.18 361 424.49 564.21 725.71 879.2 Maximum tensioning pressure bar 700 700 700 700 700 70 700 Maximum return pressure bar 250 250 250 250 250 250 250 Maximum locking pressure bar 250 250 250 250 250 250 250 Tensioning extension mm 400 400 400 450 450 500 600 Max diameter. mm 250 320 340 380 400 520 660 Length mm 1000 1000 1000 1000 1000 1150 1200



Jack M9800KN-37

Jack M6800KN-27

Jack M4800KN-19

All the jacks in the M series are supplied complete with internal parts and accessories for tensioning.. The jacks in the M series are classified into type M6800KN and in internal part, which if different from standard, is classified as M6800KN-22 ( 22 stands ) The jacks are powered by three tubes which guarantee the following functions :

- pull, - return, - wedging, All the jacks require a comb for correct use in facilitating the insertion of the jack on the cable.

Strand comb plate 27 strands

For tensioning of active anchorings , all the jacks require a distribution cover that allows the jack to rest correctly against the anchoring. Only on G type joints does the jack rest directly on the steel plate.


Jack M3600KN-15

Jack M3000KN

Jack M1800KN

The main characteristics of the M series jacks are :

- rotation on a 350° axis, - reduced grip edge, - automatic wedging by means of

hydraulic circuit, - reduced overall size, - front grip, - easy to manoeuvre, - easy for maintenance, - easy inspection/cleaning of the

engagement clamps,

The jacks are identified by an imprinted serial number and equipped with certificate of calibration.


Joint tensioning 19G15

Joint tensioning 19G15 with jack M4800KN


18.8 – Jack for extrusions “M 300” The M300 jack for extrusions has been produced to carry out extrusion anchorings on T15 and T13 strands. The extrusion anchoring consists in a passive blocking installed on the end section of a strand by extrusion. Anchoring is by means of a calibrated die that guarantees a constant ratio of drawing over the years. Jack M300 is supplied complete with the following parts: - Cylinder, - Hydraulic extensions, 10 metres in length, - Die and extrusion pin The jacks can function with all the controllers that have the following characteristics: - Operating pressure 550 bar, - Hydraulic circuit in exchange, forward and return with return in discharge.

Jack M300

Type Weight Max. Pressure Capacity Dimensions Use ( Kg ) bar. KN ( mm)

M300 75 450-550 350 1200x150x150 TTM-DD



18. 9 –Untwister jack type S 4000 The type S 4000 jack opens the strand and forms “S” series passive anchorings. The “S” series passive anchorings have been produced in compliance with Italian regulations in force and FIP recommendations. In this type of anchoring, the wire strand, in correspondence with the passive end, is opened in order to improve adherence to the concrete. The wire stands are placed in opposite directions in order to spread the force uniformly in the concrete.


The jack has been produced to open the wire strand at one end, allowing the strand itself, if correctly covered in the concrete, to have sufficient adherence to allow the anchorage of the tie-rod and thus eliminating the requirement for passive anchoring. The jack is very simple to use and is equipped with a gripper with mechanical closing which enables it, on closing, to strike the end of the wire strand, causing it to open. The gripper is made up of two conical sliding clamps equipped with an insert that can be replaced when worn


18.10 – Wedging jack type B300KN Jack B300KN has been designed to enable mechanical wedging of clamp on series 1E15 anchorages and the use of the anchorage itself as passive anchoring completely buried in the concrete. The principle of mechanically controlled wedging, is to eliminate drown-in of the clamps in the anchoring cones. The elimination of drown-in of the clamps is achieved using the B300KN jack which presses the clamp at such a thrust force that further loads applied after anchoring do not cause additional entry and the anchoring of the wire strand remains stable, guaranteeing the holding capacity of the passive anchoring.

Type of strand Push value Load applied Strand ( bar ) ( KN )

T15 200 157 EN 10138 T15S 230 180 EN 10138 T15C 270 211 ASTM A779/90

- B300KN jack push section 78,5 cm2


B300KN jack locking type operation:

- Connect the jack to a controller that has an operating pressure of 350-400 bar. and the

possibility of feeding an exchange circuit sufficient to enable operation of the two way cylinder, - Power the controller and adjust the pull pressure as prescribed, - Connect the hydraulic tubes to the B300KN jack and check correct insertion of the hydraulic

feed tubes, - Insert an 1E15 anchorage in the clamp, - Do NOT grease the clamp or the plate taper, before blocking; the blocking of the clamp and

holding of the same must have precedence, - Operate the jack B300KN towards the plate and wedge the clamp. - The jack is equipped with a treated punch which guarantees many work cycles conserving the

rod of the jack, - if the anchorage is equipped with a rear connection, it must be wedged preserving the integrity

of the connection, - with anchoring wedged only where required and previously provided for, must be placed

against the rear connection,

Rear connection for anchoring 1E15

Jack B300KN operating

Post Tensioning– Rev. H – page 79

18.11 - “T” type grouting pump The “T” type grouting pump is designed to guarantee maximum versatility with regard to site requirements and use in severe conditions. It is supplied on wheels with robust tyres, it can be towed on-site and is equipped with all the safety devices necessary for use. The machine has two tanks: one for mixing the colloidal mix and one as a tank for the mix. The turbo mixer has a turbine capable of mixing material at 1500 rpm/min. All the grouting pumps are fitted as standard with a gauge, gauge saving device and push-button pad with a 10 metre extension. The “fast-on” fittings, litre-counters, plastic accessories, grouting tubes of various lengths, syringe and the Saunders flow closing valve are considered to be accessories

T500 Grouting pump

Saunder valves are closing membrane valves recommended for intercepting mud and cement mixes .They have the properties of being self-cleaning and if cleaned frequently they do become enctrusted The litre counter, considered as an accessory is a simple mechanical, turbine fluid measuring device; it is made of plastic and is applied on customer request. All the pumps have push-button pad control, equipped with a 10 metre long cable. Cables of up to 50 m. can be requested. The extension for the push-button pad is supplied on request and is necessary in all those cases where the operator has to control the machine from a distance, supervising the grouting zone. The grouting syringe is supplied on request, depending on the type of valve used and on the grouting system applied Gauge and gauge protection device. The gauge fitted to the machine is not calibrated; calibration must be specified during ordering.


Saunders valves are valves that close with a membrane and are recommended for intercepting mud and cement mixes. They have the properties of being self-cleaning and of not becoming encrusted, if cleaned frequently. The litre counter is a simple mechanical, turbine fluid measuring device; it is made of plastic and is applied on customer request. All the pumps have push-button pad control, equipped with a 10 metre long cable, but extension cables of up to

50 m. can be requested. The extension for the push-button pad is necessary in all those cases where the operator has to control the machine from a distance, supervising the grouting zone. The grouting syringe is supplied on request, depending on the type of valve used and on the grouting system applied.

The gauge fitted to the machine is not calibrated; calibration – if required – must be requested with order

Characteristics Model T500 Model T400 Weight 900 900 Dimensions 1900x1500x1900 mm 1900x1500x1900 mm Mixer capacity 190 litres 190 litres Mixing time 40” 40” Agitator capacity 200 litres 200 litres Max. grouting pressure 10-20 bar. 10-20 bar. Max. grouting capacity 25-40 litres/minute 15-25 litres/minute Agitator power 10 KW 10 KW Pump power 7,5 KW 7,5 KW



type DD5001gauge protector

DD7169-B type rubber gasket

The DD5001 gauge protector for T500 pumps is a device that guarantees suitable pump protection from the injected mix. This device is comprised of two parts separated by a membrane that ensures pressure transmission to the valve via oil. When the mix depresses the membrane it transmits pressure to the oil that in turn transmits to the gauge. The gauge protector can be supplied with a bronze “fast-on” connector that facilitates its insertion into pressurised hoses, removal and washing. It is essential to wash the device correctly for it to operate properly. DD5001 gauge protector cod. 31115 DD7169-B gasket cod. 31116 The DD5001 type gauge protector is provided with a lateral hole for washing the device where it comes into contact with the cement mix; a water pie can be attached to this fitting. The DD7169-B type rubber gasket permits separation of the two mix-oil parts of the gauge protector.

Saunders valve The 1” Saunders valve cod. 99999 is the unique element that guarantees safe fluid interception. Closing takes place via a rubber gasket that guarantees a self-cleaning effect of the seat.


1” female bronze "fast-on" coupling

1” male bronze "fast-on" coupling

Grouting pliers

Grouting pliers cod. 31117 Male 1” “fast-on” coupling cod. 30477 Female 1” “fast-on coupling cod. 30476 DD5001 gauge protection device cod. 31115 DD7169-B gasket cod. 31116 Gauge in glycerine cod. 99999 1” Saunders valve cod. 99999

All conduits and couplings have bronze “fast-on” fittings that guarantee rapid coupling and an excellent seal.

Grouting pliers complete with “fast-on” coupling

The syringe permits coupling to the following valves: - Tab valves type DD-1003-A - Re- useable valves type DD-3050-A,

- Syringe on re- useable valves type DD-3050-A,

Syringe on valve type DD-1003-A


18.12 - “TM-S4”Strand pushing machine The TM-S4 strand pushing machine is made up of the following parts:

- TM S4/A Head - Hydraulic pump TM-S4 - Hydraulic extensions - Pushbutton control panel - Electric extensions for control panel

The two machines are connected hydraulically by flexible tubes and allow the strand to be inserted electrically, governing the length parameters, speed and force applied. The machine, of very simple conception, comprises an hydraulic controller powered by a 7.5 KW electric motor, which is governed by an electronic control, which by means of two pushbutton control panels inserts the strand into the sheaths. The two operators, at the opposite ends of the beam, have the possibility, via the electric controls supplied by the two control panels, to stop the feed of the strand or to carry out the millimetric calibration required in some uses.

Inserting Strand using strand pusher TM-S4


Head TM S4/A The TM S4/A head, designed to guarantee inserting of feed up to 150 metres, is equipped with powered wheels driven by an hydraulic motor and hydraulic squeezing of the strand on the wheels. The squeezing force on the powered wheels can be adjusted by means of two hydraulic cylinders inside the head.

Strand pusher head TM-S4/A

A robust guard protects the powered wheels from danger and a strand guide device placed at the entrance and exit of the machine, stops the strand from coming off the wheels during the inserting operations. The TM-S4 strand pusher is equipped with an hydraulic motor that guarantees the simultaneous drive of the two lower wheels via a belt transmission. The two squeezing cylinders guarantee a pressure on the strand, adjustable according to the push to be applied during the various inserting phases. Two 48mm diameter tubes, fixed to the lower part of the machine, facilitate attachment to site structures via couplings.


TM-S4 Hydraulic Controller The TM-S4 controller is assembled on a robust metal structure equipped with wheels and supports for lifting, so as to facilitate handling operations on the site.

TM S4 Controller

The TM S4 controller is equipped with pushbutton controls for electrically controlled commands; opening/closing wheels, inserting pressure/wheels pressure control and switching on/off of the machine are on the control panel.


- switching on and off on control panel - manual drive of the pressing devices on

panel, via lever hydraulic distributor, - control of squeezing and pushing pressures

via gauges, - outputs with rapid fit couplings in the top

section: motor drive, strand squeeze drive.

- phase inverter at the rear, - connectors for inserting control panels ( the

machine can function with one or two control panels),

- extensions for control panels in 50 metre lengths,

- 10 metre hydraulic extensions for connecting controller-strand pusher.

The TTM S4 controller can operate with one or two pushbutton panels; usually when there is only one control panel the lengths to be inserted are few and the inserting operations can be managed by the machine with one operator only.

When there is only one control panel the operator can only govern the “forward” and “return” functions With two control panels all the operations are possible. As for all the electric devices, the control panels are delicate and although designed for use on building sites and heavy duty operation, after use it is advisable to store them where they can be protected. Electric extensions for control panels are supplied in 50m lengths and can be connected up to a distance of 300m.


Strand pusher C60-S6 The C60-S6 strand pusher, designed to guarantee threading of strand up to 250m,is equipped with six driving wheels driven by two hydraulic motors and hydraulic squeezing of the strand in the wheels. The squeezing force on the powered wheels can be adjusted by means of two hydraulic cylinders inside the head.

Strand pusher head C60-S6 A robust guard protects the powered wheels from danger and a strand guide device placed at the entrance and exit of the machine, stops the strand from coming off the wheels during the inserting operations. Two 48mm diameter tubes, fixed to the lower part of the machine, facilitate attachment to site structures via couplings


Controller C60 The C60 controller is assembled on a robust metal structure equipped with wheels and supports for lifting, so as to facilitate handling operations on the site.

Hydraulic controller C60

The C60 controller is equipped with: - switching on and off on control panel - manual drive of the pressing devices on panel, via lever hydraulic distributor, - control of squeezing and pushing pressures via gauges, - outputs with rapid fit couplings in the lateral section: motor drive, strand squeeze drive. - phase inverter on the side, - connectors for inserting control panels (the machine can function with one or two control

panels), with only one control panel, the main one is used), - extensions for control panels: in 50 metre lengths, 10 metre hydraulic extensions for connecting

controller-strand pusher.


Pushbutton control for strand pusher C60-S6 The C 60 controller can operate with one or two pushbutton panels; usually when there is only one control panel the lengths to be inserted are few and the inserting operations can be managed by the machine with one operator only.

Pushbutton pad with speed adjustment for controller C60 When there is only one control panel the operator can only govern the “forward” and “return” functions With two control panels all the operations are possible. As for all the electric devices, the control panels are delicate and although designed for use on building sites and heavy duty operation, after use it is advisable to store them where they can be protected.

Electric extensions for control panels are supplied in 50m lengths and can be connected up to a distance of 300m.


18.12.1 - Tips for threading The tips have been designed to prevent the corrugated sheaths from getting cut due to contact with the strand during threading and to facilitate the entry of the strand in the sheath.

DD-2015-PU Cod. 13006 type tips

The plastic tips are to be considered as re-usable; because of the material used (plastic), be careful not to fit them onto hot strand as this would cause them to melt. In those cases where threading is very difficult and where the plastic tips break because of the roughness of the positioning of the sheaths, TT-5077 type steel tips are recommended because they offer greater resistance to knocks. Due to the material used they can be re-used several times, their cost implies careful use

Type DD-2015-PU tips for T15 and T15,7 mm. strand Cod. 13006

Standard box of 700 pieces

TT-5077 type tips

TT-5077 type re-usable steel tips with wedges locking. The TT-5077 tips have clamp locking and guarantee very strong grip on the strand. They are provided with milling and stops so as to facilitate removal and saving when their use is finished.


18.13 – Uncoiler “B1500” The B1500 Uncoiler has been designed to make the threading operations of the strand into the sheaths easier. It is usually used in combination with a strand pusher and guarantees unwinding of the strand without tangling at a high unwinding speed. It is set up to host coils of different dimensions and by connecting the two shoulders it can adapt to coils of different diameters.

The B1500 Uncoiler does not require special anchoring to the ground, its own weight is sufficient to guarantee its stability when being used. Use and advice The coil of strand is inserted between the two shoulders, before cutting the metal band straps, the correct tightening of the closing tie-rods, which guarantee correct blocking and safety of the operations, must be checked. On cutting the band straps the unwinding direction shown on the coil must be complied with to guarantee the strand will unwind smoothly.


18.14 – “DI” load cells “DI” load cells have the main characteristic of being hydraulic, without gaskets and of being entirely made of AISI 303 steel. Because of these characteristics, they are ideal for fitting to temporary or permanent tie-bars for monitoring the tension of the anchor over time. They are available with analogue and digital reading on request.

Load cell with plate 4 TTM-F15


Capacity Model A B C D Precision Overload Material Unitary weight

( KN ) ( mm) ( mm) ( mm) ( mm) ( gr ) 500 DI-500KN 70 165 40 195 +/- 1% F.S. 120 % AISI 304 4,5 750 DI-750KN 90 205 40 195 +/- 1% F.S. 120 % AISI 304 5,5

1000 DI-1000KN 110 230 40 195 +/- 1% F.S. 120 % AISI 304 7,5 1000 DI-1000SKN 135 250 40 195 +/- 1% F.S. 120 % AISI 304 7,5 1500 DI-1500KN 160 300 40 195 +/- 1% F.S. 120 % AISI 304 10 2500 DI-2500KN 180 360 40 195 +/- 1% F.S. 120 % AISI 304 16 2500 DI-2500SKN 220 380 40 195 +/- 1% F.S. 120 % AISI 304 16

Subject to modification More information available on request

Anchor Cell type Cell load Max. cell load Strand ext. diam. ( KN ) ( KN ) ( mm )

3TTM15 DI-750KN 750 900 80 4TTM15 DI-750KN 750 900 80 5TTM15 DI-750KN 750 900 100 6TTM15 DI-1000KN 1.000 1.200 100 7TTM15 DI-1500KN 1.500 1.800 100 9TTM15 DI-1500KN 1.500 1.800 105

12TTM15 DI-2500KN 2.500 3.000 125 15TTM15 DI-2500KN 2.500 3.000 135 19TTM15 ***** ***** ***** 150 22TTM15 ***** ***** ***** 175 27TTM15 ***** ***** ***** 195 Subject to modification More information available on request


Characteristics:

- Maximum load without calibration alterations: 120% of capacity. - Scale end precision 1% for analogue reading 0.5% for digital - Material - AISI 304 - The cell ha a lock ring for inter-placement on the anchor plate; if the dial already has an

under-plate, this lock ring is not necessary.

The load cells are provided with CE marking are completely protected and have serial numbers for identification. .

TTR anchor tensioning on DI load cell with jack type TTM 250KN-200

The load cell must be supported on a flat, non-deforming surface so as to permit square cell loading, with no transverse components. The applied load must also be perpendicular to the cell for correct operation and therefore, the bore hole must be made with special care if hydraulic cells must be installed. Hydraulic cells require all the strands to be tensioned at the same time to guarantee even load distribution. The cell makes a direct reading in KN. The applied load reading suffers various losses and therefore, with a tension control unit calibrated to the load application, we read a load loss after clamping of more than 30%. This loss is directly dependent on the lengthening loss of the tie-bar that will be greatest when the free part is shortest and when the tension value applied to the tie-bar is lowest. The measured cell loss derives from the sum of the following losses:

- Clamping loss, (clamp return clamping P )


- Losses in the jack, (jack lengthening jack P ) - Losses from angular deviation, ( deviation in the anchor angular dev. P ) - Losses from offset load, (small transverse components transverse P)

Tot. P. = clamping P + jack P+ angular dev. P + transverse P PTot. is the total load loss

Application of anchorage TTM on DI type load cell

Tensioning During the tensioning phase attention must be paid to apply over tension which compensates the loss of load stated above so as to reach the project load required.


Application of TTM anchoring on load cell DI and with Cap TTM-L

Application of load cell on “M” type jack


19 – SITES

19.1 – Sites in Italy

Application of seismic restraints on tensioned cofferdam

Assembly of high strength bars and application of seismic check devices.

Our company is specialised in assembling mixed concrete-steel structures. Above is an example of a anti-falling rocks cofferdam where the structure, tensioned with continuous threading bars, required anti-seismic restraints

Coupling tensioning 19G15

Coupling 19G15

Pre-stressing of viaduct using 19G15 couplings


Lifting and handling blocks

Lifting “1” block

With the availability of our equipment and personnel we are able to build blocks (with relative supply of forming moulds), lift and assemble them. Highly specialised teams carry out the laying of the centring, assistance with grouting and handling of trucking.


pre-stressing of a slab for tunnel

Post-tensioning of RC staging

Our company has its own pre-stressing system and having in its employ specialised technicians, is in a position to offer companies a complete supply and laying service.

Unbonded post-tensioning floors

Beams made with unbonded cables

Example of floor laid in place with unbonded cables


19.2 - Sites abroad With the availability of our equipment and highly qualified personnel our Company has become specialised in constructing bridges and viaducts supplying all requirements and using our post-tensioning system.

Preparing pier head Laying pier head block and assembly of Dywidag form traveller

Laying the key segment

Making the final segment


Tibola bridge: Site for prefabrication of beams Bridge crane launching girder

Fatala Bridge: the first cast in situ segment, 12.5m high The central span is 160m

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--Uffici operativi: Via Alberto da Giussano, 9 – 20010 Corbetta(MI) Italy Tel. +39 02 97480217 – fax +39 02 97277523 [email protected] - www.ttmsrl.it Sede legale: Via Oger Martin, 21 – 03024 Ceprano (FR) Italy Tel. +39 0775 91991 – fax +39 0775 9199222 C.F. P.IVA 02183230602

TTM Post Tensioning

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Transcript of TTM Post Tensioning