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VSL Australia Post-Tensioning Systems OCT 2019 INTRODUCTION VSL CAPABILITIES MULTISTRAND POST-TENSIONING STRAND PROPERTIES – TO AS 4672 10 TENDON PROPERTIES 10 SELECTED DESIGN CONSIDERATIONS 11 VSL STRESSING ANCHORAGE TYPE SC LIVE END 12 VSL COUPLING ANCHORAGE TYPE KAS - FOR USE WITH SC ANCHORAGE 13 INTERMEDIATE ANCHORAGE TYPE Z 14 VSL DEAD END ANCHORAGE 15 SHEATHING & CORROSION PROTECTION 16 DIMENSIONS OF PT-PLUS® DUCTS 16 ECCENTRICITY OF TENDONS 16 STRESSING SEQUENCE 17 STRESSING 17 GROUTING 17 JACK CLEARANCE REQUIREMENTS 18 STRESSING JACK DETAILS 18 SLAB POST-TENSIONING 21 STRAND PROPERTIES – TO AS 4672 22 TENDON PROPERTIES 22 SELECTED DESIGN CONSIDERATIONS 23 VSL STRESSING ANCHORAGE TYPE S5 – S6 LIVE END 24 VSL DEAD END ANCHORAGES TYPE H – TYPE P 25 VSL SLAB COUPLING ANCHORAGE TYPE S 26 JACK CLEARANCE REQUIREMENTS 27 STRESSING JACK DETAILS 27 INTERNAL STRESSING POCKET 27 ANCHORAGE REINFORCEMENT – S5-3, S5-4, S5-5, S6-3, S6-4 ANCHORS 28 ANCHORAGE REINFORCEMENT – S6-5 ANCHORS 28 ANCHORAGE REINFORCEMENT - TIES 29 STRESSING JACK DETAILS 29 GROUND ANCHORS 32 VSL PERMANENT ANCHOR FULLY ENCAPSULATED 33 VSL TEMPORARY ANCHOR 33 VSL PERMANENT GROUND ANCHORS - 15.2mm STRAND 34 VSL CT STRESSBAR GROUND ANCHORS 34 VSL TEMPORARY GROUND ANCHORS 34 VSL PERMANENT GROUND ANCHORS BEARING PLATE AND ANCHORHEAD 35 STRESSING 36 FLAT JACKS 39 CONTACT US 40 Post-tensioning is, even so being a mature technology, still a fantastic tool for the design engineer to actively define the internal load path in concrete structures by superposing a favorable internal stress state This permits to minimize deformations, helps to increase slenderness of members, reduces reinforcement congestion, enables segmental construction without need for wet joints and allows the use of high strength steel This brochure gives an overview of the available post-tensioning systems and their fields of application It provides guidance to practising engineers in the design of post-tensioned structures using VSL post-tensioning systems VSL is a recognised leader in the field of special construction systems Well proven technical systems and sound in-house engineering are the basis of the group’s acknowledged reputation for innovative conceptual structural solutions VSL has developed, manufactured and installed durable, state-of-the-art post-tensioning systems for over 60 years The VSL post-tensioning systems comply with international standards and approval guidelines for use on both new and existing structures VSL does not only select and offer the best suited post-tensioning hardware and layout for a given project but proposes also innovative detailing of the permanent work and construction techniques with the aim to improve durability, increase site safety and reduce construction time and costs VSL likes to work in partnership with owners and clients right from the conceptual stage VSL’s engineers can work closely with the design engineer during the design development stage and with the contractor's estimating team during the tender stage What differentiates VSL from other players in the market, is its holistic approach, which is fundamental in arriving at well balanced technical solutions respecting equally permanent work and construction aspects VSL’s biggest asset however is the quality of its highly experienced, multicultural staff /// VSL has evolved from a specialist post-tensioning company into a multi-discipline construction partner, capable of providing contractors and engineers with construction and engineering services for highly complex and demanding projects Well-proven technical systems and in-house engineering form the basis of the group’s reputation for innovative conceptual designs and engineering solutions that ensure reliability, quality and efficiency VSL take this engineering ability through to execution of works on site to be a one stop shop for specialist construction VSL’s capabilities can be categorised into four different services: /// SYSTEMS & TECHNOLOGIES We ensure the development and constant improvement of our portfolio of in-house technologies Our Services: Post-tensioning systems Ground Anchors VSoL Walls – Retained Earth System VSL Stress Bars Engineered Precast Structures Stay Cables /// REPAIRS & STRENGTHENING We offer tailored services to ensure the stability of your structure’s life cycle, from inspections and assessment through to repair works and upgrading Our Services Structural Diagnostics & Monitoring Repairs & Strengthening Infrastructure Protection High Strength Concrete Solutions & Products /// /// CIVIL CONSTRUCTION We help our clients with construction designs and methods, and provide operational skills for specific applications Our Services: Bridge Construction Containment Structures Heavy lifting Engineered Precast Structures Offshore Structures /// GROUND ENGINEERING We are specialists in ground engineering and special foundations thanks to our long history of proven design and build capabilities gained on the most complex and varied projects Our Services Diaphragm walls Micro Compaction Subsurface grouting Micro Piling & Ground Anchors High Directional drilling & Coring Ground Freezing VSL Multistrand Post-Tensioning /// /// Since 1954, designers and constructors of bridges, buildings and civil engineering worldwide over have relied on the VSL Multistrand post-tensioning system These conventional uses of post-tensioning have been augmented by numerous applications of the system to projects such as stayed structures, offshore platforms, towers, tanks, silos, nuclear power plants, underground and submerged structures Patented in 36 countries, the VSL strand system complies in all respects with the Recommendations for the Acceptance and Application of Post-Tensioning Systems of the Fédération Internationale de la Précontrainte (FIP) and is approved in every country where the use of post-tensioning systems is subject to an official authorisation The VSL Multistrand system comprises from three to fifty-five strands (either 12.7 or 15.2mm diameter), round duct and anchorages Prestressing force is applied to the tendons after the casting and curing of surrounding concrete All strands are stressed simultaneously using a hydraulic jack and are fastened at the live end by wedge grips The free space inside the duct is then pressure-filled with cement grout A number of features are incorporated as a result of many years of experience in the field:     Stressing carried out in any number of stages; Accurate control of prestress force; No need to determine tendon length in advance; Simultaneous stressing of all strands in a tendon, with individual locking of each strand at the anchorage point; VSL stressing equipment is easily operated to ensure a safe and rapid stressing procedures Special emphasis has been placed on rationalised manufacturing of equipment and anchorage parts as well as efficient work site practice PT Strands, Australia Ballina Bypass, Australia Westlink M7, Sydney, Australia /// Nominal Diameter – Grade Nominal Steel Area Nominal Mass Minimum Breaking Load (mm)-(MPA) (mm2) (kg/m) 12.7 Super 15.2 EHT 98.6 143 0.774 1.122 Strand Type 12.7mm Super Tendon No of Strands Unit 5-4 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 5-7 5-12 5-19 5-22 5-27 5-31 5-37 5-42 5-48 5-55 Min Elong To Fracture in 500mm (%) Relaxation After 1,000 Hrs at 0.8 Breaking Load (%) Modulus of Elasticity (kN) Minimum Proof Load (0.2% Offset) (kN) 184 261 156 222 3.5 3.5 3.5 3.5 185-205 185-205 Minimum Breaking Load (kN) Steel Duct Internal Diameter (mm) 368 552 736 920 1104 1288 1472 1656 1840 2024 2208 2392 2576 2760 2944 3128 3312 3496 3680 3864 4048 4232 4416 4600 4784 4968 5152 5336 5520 5704 5888 6072 6256 6440 6624 6808 6992 7176 7360 7544 7728 7912 8096 8280 8464 8648 8832 9016 9200 9384 9568 9752 9936 10120 40 40 40 50 50 50 70 70 70 70 70 85 85 85 85 85 85 85 90 90 90 95 95 95 95 95 105 105 105 105 115 115 115 115 115 115 120 120 120 120 120 130 130 130 130 130 130 135 135 135 135 135 135 135 Strand Type 15.2mm EHT Tendon No of Strands Unit 6-3 6-4 6-7 6-12 6-19 6-22 6-27 6-31 6-37 6-42 6-48 6-55 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 (GPa) Minimum Breaking Load (kN) Steel Duct Internal Diameter (mm) 522 783 1044 1305 1566 1827 2088 2349 2610 2871 3132 3393 3654 3915 4176 4437 4698 4959 5220 5481 5742 6003 6264 6525 6786 7047 7308 7569 7830 8091 8352 8613 8874 9135 9396 9657 9918 10179 10440 10701 10962 11223 11484 11745 12006 12267 12528 12789 13050 13311 13572 13833 14094 14355 40 40 50 70 70 70 85 85 85 85 85 95 95 95 95 95 95 95 105 105 105 115 115 115 115 115 120 120 120 120 130 130 130 130 130 130 135 135 135 135 135 145 145 145 145 145 145 155 155 155 155 155 155 155 Note: 10 /// Intermediate Duct diameters may be available on application Duct diameters are for corrugated steel duct Duct external dia = inside dia + 6mm nominal Corrugated PT-Plus duct is also available, refer to page 16 For special applications, other strand and tendon capacities are available Anchorage size up to 6-91 available on special order from overseas 12.9mm, 15.2mm and 15.7mm minimum breaking 300kN breaking load strand available as special order from overseas Helix anchorage for slab tendon and typical detail at slab edge Note: 28 /// Reinforcement shown is indicative, actual anchorage reinforcement is to be as detailed by the consulting engineer, anchorage reinforcement shall be located centrally about and hard up against cast in anchor as shown Min concrete cylinder strength at jacking = 22MPa Generally and 25 MPa for S6-5 Reinforcement for helix is round bar with fy = 250MPa Anchorage at slab edge and anchorage at slab beam Detailing at the slab edge and beam Strand Type 12.7mm Strand 15.2mm Strand Dimensions (mm) Tendon Unit No of Ties each side A B S5-2 S5-3,S5-4 S5-5 S5-2, S6-3 S6-4 S6-5 2 2 2+2 100 200 200 200 200 200 60 80 90 90 90 100 Note: Reinforcement shown is indicative, actual anchorage reinforcement is to be as detailed by the consulting engineer, anchorage reinforcement shall be located centrally about and hard up against cast in anchor as shown Min concrete cylinder strength at jacking = 22MPa generally and 25 MPa for S6-5 Reinforcement for helix is round bar with fy = 250 MPa /// 29 Ground Anchors 30 /// /// 31 Anchors may be constructed in virtually any type of ground to provide large concentrated forces in precise locations to carry any combination of applied loads Ground anchors are more specifically referred to as rock anchors or soil anchors, depending on whether the anchor takes its bond in rock or soil Each anchor consists of a high- tensile steel tendon inserted into a drilled hole At the lower end the anchor is bonded to the rock or soil by high strength cement grout The top of the anchor is fitted with a VSL stressing anchorage Once the grout has achieved sufficient strength, the anchor tendon is stressed to the required force using a calibrated jack This force is maintained by the stressing anchorage after release of the jack Corrosion protection is provided by the cement grout in temporary anchors and by full encapsulation of the entire anchor in a thick walled polyethylene sheath for permanent anchors VSL Rock Anchors range in ultimate capacities up to 23,750kN Tendons are constructed from either a number of 12.7mm or 15.2mm diameter, high tensile steel strands or single VSL stressbars VSL Soil Anchors are used in alluvial soils, stiff clays or highly weathered rock The ultimate capacity of these anchors is determined by the capability of the ground in the bond zone to transfer the load from the anchor Anchor details are similar to rock anchors VSL Soil Nails are used to reinforce soil in an excavation or embankment They are formed by inserting VSL Bar into a drilled hole which is filled with cement grout Corrosion protection similar to ground anchors can be provided depending on the application Soil nails have no or only nominal initial applied force VSL Rock Bolts are used to strengthen and stabilise jointed rock, and to stabilise defined blocks of rock They are formed by inserting VSL Bar into a drilled hole and anchoring it in place with either a mechanical anchorage, a chemical anchorage or cement grout The bar is stressed to apply an initial force William Street Underground Metro Station, Perth, Australia 32 /// Hale Street Link, Brisbane, Australia Lake Narracan Dam, Victoria, Australia /// 33 No of Strands 15.2mm (mm) Ultimate Capacity (kN) Drill Hole Dia (mm) Sheath Diameters (mm) ID OD ID OD Tendon Unit 14 27 55 65 91 522 1000 2000 3500 6750 13750 16250 22750 100 130 150 175 215 310 310 350 50 65 80 100 130 210 210 250 65 80 100 120 150 230 230 270 59 70 84 102 130 225 225 260 63 75 90 110 140 235 235 270 VSL50 VSL100 VSL190 VSL290 VSL670 VSL1250 VSL1650 VSL1700 Note: Where block outs, voids or drill hole casing are required, drill hole diameters and bearing plate dimensions should be confirmed with your local VSL office Drill hole sizes are based on 10mm external cover Bar Dia (mm) Ultimate Capacity (kN) 20* 23* 26 29 32 36 38 50 56 315 450 579 714 865 1025 1295 2022 2501 Permanent Encapsulated Corrugated Sheath (mm) Drill Hole Dia (mm) ID OD 100 125 125 150 150 150 150 150 175 50 65 65 80 80 80 80 80 100 65 80 80 100 100 100 100 100 120 Epoxy Coated Drill Hole Dia (mm) Temporary Drill Hole Dia (mm) Jack Type Required 75 87 87 100 100 112 112 112 165 50 75 75 87 100 100 100 100 125 B55 B55 B55 B90 B90 B90 B100 VSL190 VSL190 Note: *Denotes non preferred bar size Please check with your local VSL office regarding availability No of Strands 15.2mm (mm) Ultimate Capacity 15.2mm Super (kN) Minimum Drill Hole Dia (mm) Jack Type Required 12 24 1566 3132 4698 6264 75 100 130 150 VSL190 VSL290 VSL460 VSL670 No of Strands 15.2mm (mm) Ultimate Capacity 15.2mm Super (kN) Minimum Drill Hole Dia (mm) Jack Type Required 14 24 1290 2580 4420 75 100 125 VSL100 VSL290 VSL460 Note: 34 /// Anchors for 15.2mm and 12.7mm system are compatible with 250 kN super strand Dimensions (mm) No of Strand Tendon Unit A B C D H 14 27 55 65 91 6-3 6-4 6-12 6-19 6-27 6-55 6-65 6-91 200 200 300 400 500 670 700 850 30 35 45 60 80 120 140 160 80 110 180 220 270 360 380 470 60 60 80 100 130 190 190 200 61 78 137 167 194 288 ** ** Bar Dia (mm) A (mm) B (mm) 20* 23* 26 29 32 36 38* 40 56 150 150 200 225 250 250 300 300 350 25 25 40 50 50 50 50 60 70 Notes: 10 * Denotes non preferred bar size Please check with your local VSL office regarding availability ** Denotes hole dimension to be site specific Details given may be varied for particular applications For strand anchors the maximum configuration size is shown Lesser number of strands may be specified Additional capacities available on request Drill hole sizes are based on 10mm external cover Anchors can be monitorable and restressable Removable ground anchors are available Electrically isolated ground anchors are available Bearing plate dimensions are suitable for 15.2mm super and 15.2mm EHT strands /// 35     Jack sizes are the same as for multistrand or stressbar systems Additional special purpose jacking chairs are provided to permit test loading Load cells can be provided that screw onto the anchor head to permit load measurement at any time, or permanently attached to enable continuous load monitoring Both hydraulic and electrical load cells are available Northwest Transitway, Sydney, Australia Lake Narracan Dam, Victoria, Australia Lapstone Hill, Australia Landsboroug Maleny Road, Australia 36 /// Lake Narracan Dam, Victoria, Australia Flat Jacks /// 37 38 /// Flat jacks are widely used for a multitude of civil engineering and construction applications such as:          Underpinning Prestressing of columns Counteracting sinking coundations Prestressing of road woks or airport runways Prestressing concrete in confined spacing Lifting and lowering of bridge superstructures for bridge bearing adjustments Counteracting loads applied during backfilling Lifting heavy weights Pile testing The VSL flat jack is constructed of two moulded steel sections welded together to form a containment vessel Hydraulic fluid or grout is injected all pressures of up to 13.5 Mpa into a peripheral ring, moving the lifting plates apart, so that a force is applied with a maximum lifting stroke of 25mm per jack Type 150c 220c 250c 270c 300c 350c 420c 480c 600c 750c 870c 920c *1150c Note: Outside Diameter D (mm) Maximum Force at 13.5MPA (kN) Effective Area at Zero Extensions 103 (mm) Thickness T** (mm) Maximum Travel E (mm) Installation Gap (mm) 150 220 250 270 300 350 420 480 600 750 870 920 *1150 155 390 525 605 780 1080 1605 2170 3470 5400 7365 8975 13635 11.5 29 39 45 58 80 119 161 257 400 547 665 1010 28 28 28 28 28 28 28 28 28 28 28 28 28 25 25 25 25 25 25 25 25 25 25 25 25 25 32 32 32 32 32 32 32 32 32 39 39 39 54 *1150c Flat Jacks are specially produced to order and could be subject to a delay **Flat Jack thickness may vary +-3mm Cross City Tunnel, Australia Cross City Tunnel, Australia /// 39 VSL Australia NSW Office – Head Office Address: Pioneer Avenue Thornleigh NSW 2120 Phone: 02 9484 5944 40 /// 42 ///