BBR Cona Cme Fix PDF
BBR Cona Cme Fix PDF
ETA – 07/0168
European Technical Approval
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ETA-07/0168
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BBR VT CONA CME
External Post-tensioning System
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BBR VT International Ltd
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Ringstrasse 2, 8603 Schwerzenbach (Switzerland)
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www.bbrnetwork.com
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Assembly and installation of BBR VT CONA CME tendons must only be carried
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ETAG 013 Guideline for European Technical Approval of Post-tensioning Kits for Prestressing of Structures
CWA 14646 Requirements for the installation of post-tensioning kits for prestressing of
structures and qualification of the specialist company and its personnel
BBR E-Trace is the trading and quality assurance platform of the BBR Network linking
the Holder of Approval, BBR VT International Ltd, BBR PT Specialist Companies and the
BBR Manufacturing Plant. Along with the established BBR Factory Production Control,
BBR E-Trace provides effective supply chain management including installation, delivery
notes and highest quality standards, as well as full traceability of components.
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2. dem Salzburger Bauproduktegesetz, LGBl. Nr. 11/1995, in der Fassung LGBl. Nr. 47/1995, LGBl.
Nr. 63/1995, LGBl. Nr. 123/1995, LGBl. Nr. 46/2001, LGBl. Nr. 73/2001, LGBl. Nr. 99/2001 und
LGBl. Nr. 20/2010;
the Salzburg Construction Product Regulation LGBl. ʋ 11/1995, amended by LGBl. ʋ 47/1995,
LGBl. ʋ 63/1995, LGBl. ʋ 123/1995, LGBl. ʋ 46/2001, LGBl. ʋ 73/2001, LGBl. ʋ 99/2001, and
LGBl. ʋ 20/2010;
3. Common Procedural Rules for the Requesting, Preparing and Granting of European technical
approvals set out in the Annex of Commission Decision 94/23/EC4;
4. Guideline for European technical approval of Post-Tensioning Kits for Prestressing of Structures,
ETAG 013, Edition June 2002.
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2 Österreichisches Institut für Bautechnik is authorised to check whether the provisions of this European
technical approval are met. Checking may take place at the manufacturing plant. Nevertheless, the
responsibility for the conformity of the products to the European technical approval and for their fitness
for the intended use remains with the holder of the European technical approval.
3 This European technical approval shall not be transferred to manufacturers or agents of
manufacturers other than those indicated on Page 1, or manufacturing plants other than those
indicated on Page 1 of this European technical approval.
4 This European technical approval may be withdrawn by Österreichisches Institut für Bautechnik, in
particular pursuant to information by the Commission on the according to Article 5 (1) of the Council
Directive 89/106/EEC.
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5 Reproduction of this European technical approval including transmission by electronic means shall be
in full. However, partial reproduction can be made with the written consent of Österreichisches Institut
für Bautechnik. In this case partial reproduction has to be designated as such. Texts and drawings of
advertising brochures shall not contradict or misuse the European technical approval.
6 The European technical approval is issued by the Approval Body in its official language. This version
corresponds to the version circulated within EOTA. Translations into other languages have to be
designated as such.
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1
Official Journal of the European Communities ʋ L 40, 11.02.1989, page 12
2
Official Journal of the European Communities ʋ L 220, 30.08.1993, page 1
3
Official Journal of the European Union ʋ L 284, 31.10.2003, page 1
4
Official Journal of the European Communities ʋ L 17, 20.01.1994, page 34
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Nominal diameter
sectional area tensile strength
mm mm2 MPa
15.3 140
1,860
15.7 150
2
Note 1 MPa = 1 N/mm
be interpreted as a guarantee given by the manufacturer or the Approval Body, but are to be regarded
only as a means for selecting the appropriate product in relation to the expected, economically
reasonable working life of the construction works.
2.1.1 General
End anchorages can be used as fixed and stressing anchors. Couplers are fixed couplers. The
principal dimensions of anchorages and couplers are given in the Annexes 2 to 4 and 8 to 10.
2.1.2 Designation
End anchorage, e.g. S A CONA CME 1906-150 1860
Stressing (S) or fixed (F)
Anchor head
Designation of the tendon
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with information on the number, cross sectional area and characteristic tensile strength of the
strands
2.1.3 Anchorage
2.1.3.1 General
The anchor heads of stressing and fixed anchorages are identical. A differentiation is needed for
the construction works.
The wedges of inaccessible fixed anchors shall be secured with springs and/or a wedge retaining
plate. An alternative is prelocking each single strand with ~ 0.5 ⋅ Fpk and applying a wedge retaining
plate.
Where
Fpk .......... Nominal value of maximum force of single strand
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a circle around the cones of the first construction stage by means of wedges in machined cones,
drilled at an inclination of 7 °.The wedges for the second construction stage are secured by means
of holding springs and a cover plate.
2.1.4.3 Sleeve coupler FH
The coupler anchor head H is of the same basic geometry as the anchor head of the fixed and
stressing anchors. Compared to the anchor head of the fixed and stressing anchors, the coupler
anchor head H is higher and provides an external thread for the coupler sleeve.
The connection between the coupler anchor heads H of the first and second construction stages is
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reinforced concrete cover with the required dimensions, and in any case with a thickness of at least
20 mm.
In case of an exposed anchorage not fully embedded in concrete, there is no concrete cover for the
anchorage and bearing trumplate. The exposed surfaces of the bearing trumplate and the cap shall
be provided with an appropriate corrosion protection.
External PT
Number of strands (04 to 31)
Type of strand
Cross-sectional area of strand (140 or 150 mm2)
Characteristic tensile strength of strand
The tendons comprise 04 to 31 tensile elements, seven wire prestressing steel strands according to
Annex 15.
2.2.2 Range
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Prestressing and overtensioning forces are given in the corresponding standards and regulations in
force at the place of use. The maximum prestressing and overstressing forces are listed in Table 14.
The tendons consist of 04, 07, 09, 12, 15, 19, 22, 24, 27 and 31 strands. By omitting strands in the
anchorages and couplers in the best possible radial symmetrical way, also tendons with numbers of
strands lying between the numbers given above can be installed. An unnecessary hole shall either
remain undrilled or shall be sealed with a short piece of strand and wedges shall be inserted. For
coupler anchor head K the cones of the outer pitch circle, second construction stage, may be equally
redistributed if strands are omitted. However, the overall dimensions of the coupler anchor head K
shall remain unchanged.
2.2.2.1 CONA CME n06-140
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Number of
N --- 04 07 09 12 15 19 22 24 27 31
strands
Nominal cross-
sectional area of Ap mm2 560 980 1,260 1,680 2,100 2,660 3,080 3,360 3,780 4,340
prestressing steel
Nominal mass of
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M kg/m 4.37 7.65 9.84 13.12 16.40 20.77 24.05 26.23 29.51 33.88
prestressing steel
Characteristic
ultimate
Fpk kN 992 1,736 2,232 2,976 3,720 4,712 5,456 5,952 6,696 7,688
resistance of
tendon
Characteristic
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ultimate
Fpk kN 1,040 1,820 2,340 3,120 3,900 4,940 5,720 6,240 7,020 8,060
resistance of
tendon
Number of
N --- 04 07 09 12 15 19 22 24 27 31
strands
Nominal cross-
sectional area of Ap mm2 600 1,050 1,350 1,800 2,250 2,850 3,300 3,600 4,050 4,650
prestressing steel
Nominal mass of
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M kg/m 4.69 8.20 10.55 14.06 17.58 22.27 25.78 28.13 31.64 36.33
prestressing steel
Characteristic
ultimate
Fpk kN 1,064 1,862 2,394 3,192 3,990 5,054 5,852 6,384 7,182 8,246
resistance of
tendon
Characteristic
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ultimate
Fpk kN 1,116 1,953 2,511 3,348 4,185 5,301 6,138 6,696 7,533 8,649
resistance of
tendon
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2.3 Duct
2.3.1 General
The inner diameter of the duct shall meet the requirements of Table 4.
cross sectional area of prestressing steel
f = cross sectional area of inner diameter of duct
Where
f ....... degree of filling
kD ..... duct coefficient
f kD 1)
Notes
1)
.......Minimum value according to ENV 1992-1-55, clause 1.6
2)
.......Not for wax injection in case of PE-duct
Number of strands 04 07 09 12 15 19 22 24 27 31
Minimum Radius Rmin m 2.0 2.0 2.5 2.7 3.0 3.0 3.2 3.3 3.5 4.0
Plastic Duct tmin mm 5.6 6.0 6.0 6.0 6.0 6.6 7.1 7.4 7.9 8.3
Steel Duct tmin mm 1.5 1.5 1.5 1.5 2.0 2.0 2.0 2.0 2.5 2.5
Notes
tmin .........Minimum wall thickness
Rmin........Minimum radius of curvature
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The minimum wall thicknesses given in Table 5 are appropriate for the minimal radius and grout or
grease as filling material. It is permitted to reduce these values by 15 % for a Radius R 1.5 ⋅ Rmin.
In case of wax injection the values of Table 5 shall be increased by 15 %.
5
Standards and Guidelines and other documents referred to in this European technical approval are listed in Annex 16.
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F x = F0 · e
Where
Fx ............ kN ................. prestressing force at a distance x along the tendon
F0............ kN ................. prestressing force at x = 0 m
μ ............. rad-1 .............. friction coefficient, see Table 6
α............. rad ................ sum of the angular displacements over the distance x, irrespective of
direction or sign
x ............. m................... distance along the tendon from the point where the prestressing force is
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equal to F0
Note 1 1 rad = 1 m/m = 1
Note 2 Wobble effects may be neglected for external tendons.
HDPE Steel
Tendon ΔFs μ μ
Where
ΔFs....... friction loss in anchorages and first construction stage of fixed couplers. It shall be taken into
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account for determining of the elongation and the prestressing force along the tendon.
In general, spacing and distances shall not be less than the values given in Tables 7 and 8 and
Annexes 8 to 10.
However, a reduction of up to 15 % of the centre spacing of tendon anchorages in one direction is
permitted, but should not be less than the outside diameter of the helix and placing of additional
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reinforcement shall still be possible. In this case the spacing in the perpendicular direction shall be
increased by the same percentage. The corresponding edge distance is calculated by
ac
ae = 2 – 10 + c
bc
be = 2 – 10 + c
Where
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Where
fcm, 0, cube 150 ..............Mean concrete compressive strength at time of stressing, determined at cubes,
150 mm
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compressive strength, fcm, 0, shall be at least as given in Table 9. The concrete test specimen shall be
subjected to the same hardening conditions as the structure.
For partial prestressing with 30 % of the full prestressing force the actual mean value of the concrete
compressive strength shall be at least 0.5 · fcm, 0, cube or 0.5 · fcm, 0, cylinder. Intermediate values may be
interpolated linearly according to EN 1992-1-1.
The helix, additional reinforcement, centre spacing and edge distance corresponding to the concrete
compressive strengths shall be taken from Annexes 8 to 10, see also clauses 2.11.6 and 4.2.4.
2.9 Deviator
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The deviator has to transfer the transversal (radial to the deviator) and longitudinal (tangential to the
deviator) forces generated by the tendon to the structure. Moreover, deviators have to provide a
smooth surface for the tendon. The deviator can be made of concrete, steel or equivalent in respect to
the structural and surface requirements. Permanent inserts for deviators of concrete can be made of
PE-HD or steel or equivalent in meeting the surface requirements.
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To avoid any kinking of the tendon it is recommended to provide an additional deviation, ¨Į, of ≥ 3 °,
see Annex 6.
For grouting or filling ducts with grease, vents shall be provided or vacuum grouting shall be applied.
2.9.1 Single tube deviator
The deviator is a pre-bent tube that is part of the tendon conduit, see Annex 6. The duct of the
tendon is jointed to both ends of the tube.
The jointing between duct and deviator can be by sleeves, collars or by welding
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Components
2.10 Strands
Only 7-wire prestressing steel strands with characteristics according to Table 10 shall be used, see
also Annex 15.
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Note
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1)
...... Prestressing steel strands with a characteristic tensile strength below
1,860 MPa may also be used.
In a single tendon only strands spun in the same direction shall be used. To avoid confusion at a given
construction site, only strands of the same nominal diameter and the same characteristic tensile
strength shall be used.
to 4 and in the technical documentation6. Therein the component dimensions, materials and material
identification data with tolerances are given.
2.11.1 Anchor heads
The anchor heads are made of steel and provide regularly arranged conical holes drilled in parallel to
accommodate prestressing steel strands and wedges. In addition, threaded bores may be provided
to fix protective caps and wedge retaining plates. At the back of the anchor head there may be a step
for ease of centring the anchor head on the bearing trumplate.
2.11.2 Bearing trumplates
The bearing trumplates made of cast iron transmit the force via 3 load transfer planes to the
concrete. Air-vents are situated at the top and at the interface plane to the anchor head. A ventilation
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tube can be fitted to these air-vents. On the tendon-side end there is an inner thread to
accommodate the trumpet.
6
The technical documentation of this European technical approval is deposited with Österreichisches Institut für Bautechnik and, in so
far as it is relevant to the tasks of the approved body involved in the attestation of conformity procedure, it is handed over to the
approved body.
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2.11.3 Trumpets
The conical trumpets A for the anchorages are made of PE and have either a corrugated or a plain
surface. At the duct side end there is a radius with a smooth surface for the deviation of the strand,
to ensure a smooth transition to the duct. The opposite end is connected to the bearing trumplate by
an external thread.
The conical trumpets CME-K and CME-H are made of steel or PE. The trumpets are mounted to the
coupler anchor head or to the coupler sleeve with screws. At the duct side end a tension ring with a
PE insert is placed.
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At the back of the coupler anchor head K and H there is a step for ease of centring the coupler
anchor head on the bearing trumplate.
The coupler sleeve is a steel tube with an inner thread and is provided with ventilation holes.
2.11.5 Ring wedges
The ring wedges are in three pieces, which are held together by spring rings. Two types of ring
wedge are used. Within one anchorage or coupler only one type of ring wedge shall be used.
In the case of fixed anchorages and couplers the wedges are held in place by springs and/or by
wedge retaining plates and cover plates.
2.11.6 Helix and additional reinforcement
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The helix and the additional reinforcement are made of ribbed reinforcing steel. The end turn of the
helix on the anchorage side is welded to the following turn. The helix shall be placed exactly in the
tendon axis. The dimensions of the helix and the additional reinforcement shall comply as specified
in Annexes 8 to 10, see also clause 4.2.4.
2.11.7 Protective caps
The protective caps are made of steel or plastic. They are provided with air vents and fixed with
screws or threaded rods.
2.11.8 Material properties
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Coupler sleeve
EN 10210-1
H CONA CME 0406 to 3106
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Trumpet
EN ISO 1872-1
Type A, Type K
Spring A, K EN 10270-1
Duct EN 10210-1
ETAG 013, Annex C.2
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The release of dangerous substances is determined according to ETAG 013, clause 5.3.1. The PT
system complies with the provisions of Guidance Paper H7 relating to dangerous substances.
A declaration in this respect was made by the manufacturer.
In addition to the specific clauses relating to dangerous substances in this European technical
approval, there may be other requirements applicable to the product falling within their scope (e.g.
transposed European legislation and national laws, regulations and administrative provisions). In order
to meet the provisions of the Construction Products Directive, these requirements also need to be
complied with, when and where they apply.
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2.15 Identification
The European technical approval for the "BBR VT CONA CME – External Post-tensioning System" is
issued on the basis of agreed data, deposited with Österreichisches Institut für Bautechnik, which
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identifies the "BBR VT CONA CME – External Post-tensioning System" that has been assessed and
judged. Changes to the production process of the "BBR VT CONA CME – External Post-tensioning
System", which could result in this deposited data being incorrect, should be notified to
Österreichisches Institut für Bautechnik before the changes are introduced. Österreichisches Institut
7
Guidance Paper H: A harmonised approach relating to dangerous substances under the Construction Products Directive, Rev.
September 2002.
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für Bautechnik will decide whether or not such changes affect the European technical approval and
consequently the validity of the CE marking on the basis of the European technical approval and, if so,
whether further assessment or alterations to the European technical approval are considered
necessary.
The system of attestation of conformity assigned by the European Commission to this product in
accordance with the Council Directive 89/106/EWG of 21 December 1988, Annex III, Section 2,
Clause i), referred to as System 1+, provides for:
Certification of the conformity of the product by an approved certification body on the basis of
(a) Tasks for the manufacturer
(1) Factory production control;
(2) Further testing of samples taken at the factory by the manufacturer in accordance with a
prescribed test plan8;
(b) Tasks for the approved body
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3.2 Responsibilities
3.2.1 Tasks for the manufacturer – Factory production control
At the manufacturing plant, the manufacturer shall implement and continuously maintain a factory
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production control system. All the elements, requirements and provisions adopted by the
manufacturer shall be documented systematically in the form of written operating and processing
instructions. The factory production control system shall ensure that the product is in conformity with
the European technical approval.
Within the framework of factory production control, the manufacturer shall carry out tests and checks.
Details of the extent, nature and frequency of testing and checks to be performed within the
framework of the factory production control shall correspond to the prescribed test plan7, which is
prepared and endorsed with the European technical approval. The prescribed test plan forms part of
the technical documentation5 of the European technical approval.
The results of factory production control shall be recorded and evaluated. The records shall include
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Bautechnik.
If the test results are unsatisfactory, the manufacturer shall immediately implement measures to
eliminate the defects. Construction products or components which are not in compliance with the
8
The prescribed test plan has to be deposited with Österreichisches Institut für Bautechnik and is handed over only to the approved
body involved in the conformity attestation procedure.
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requirements shall be removed. After elimination of the defects the respective test shall be repeated
immediately if technically required.
The basic elements of the prescribed test plan7 comply with ETAG 013, Annex E.1 and are specified
in the quality management plan of the "BBR VT CONA CME – External Post-tensioning System".
Test / Minimum
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Detailed 3%
Test full Yes
dimensions ≥ 2 specimen
Visual
Check 100 % No
inspection 3)
head Detailed 5%
Test Yes
dimensions 2) full ≥ 2 specimen
Visual
Check 100 % No
inspection 3), 4)
Treatment, 0.5 %
Test Yes
Hardness 5), 6) ≥ 2 specimen
full
Detailed 5%
Test Yes
dimensions 2) ≥ 2 specimen
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Visual
Check 100 % No
inspection 3), 7)
Detailed 5%
dimensions Test full ≥2 Yes
specimens
Visual
Check 100 % No
inspection 3)
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Visual
Check each coil No
inspection 3)
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Test / Minimum
Component Item Traceability Documentation
Check frequency
1)
"3.1": Inspection certificate type "3.1" according to EN 10204
2)
Other dimensions than 4)
3)
Visual inspections include e.g.: Main dimensions, gauge testing, correct marking or labelling,
check documents for appropriate performance, surface, fins, kinks, smoothness, corrosion,
coating etc., as detailed in the prescribed test plan7
4)
Dimensions: All conical bores regarding angle, diameter and surface condition, thread
dimensions of all anchor heads and coupler anchor heads.
5)
Geometrical properties
6)
Surface hardness
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7)
Teeth, cone surface
8)
"2.2": Test report "2.2" according to EN 10204
9)
If the basis for CE marking for prestressing steel is not available, an approval or certificate
according to the respective rules in force at the place of use shall accompany each delivery.
full: Full traceability of each component to its raw materials.
bulk: Traceability of each delivery of components to a defined point.
3.2.2 Tasks of the approved body
3.2.2.1 Initial type testing of the products
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For initial type testing the results of the tests performed as part of the assessment for the European
technical approval may be used, unless there are changes in the manufacturing process or factory
plant. In such cases, the necessary initial type testing shall be agreed between Österreichisches
Institut für Bautechnik and the approved body involved.
3.2.2.2 Initial inspection of factory and of factory production control
The approved body shall ascertain that, in accordance with the prescribed test plan7, the
manufacturing plant, in particular personnel and equipment, and the factory production control are
suitable to ensure a continuous orderly manufacturing of the PT system according to the
specifications given in Section II as well as in the Annexes of the European technical approval.
3.2.2.3 Continuous surveillance
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The kit manufacturer shall be inspected at least once a year. Each component manufacturer of the
components listed in Table 13 shall be inspected at least once every five years. It shall be verified
that the system of factory production control and the specified manufacturing process are
maintained, taking account of the prescribed test plan7.
The results of product certification and continuous surveillance shall be made available on demand
by the approved body to Österreichisches Institut für Bautechnik. If the provisions of the European
technical approval and the prescribed test plan7 are no longer fulfilled, the certificate of conformity
shall be withdrawn and Österreichisches Institut für Bautechnik informed immediately.
3.2.2.4 Audit testing of samples taken at the factory
During surveillance inspection, the approved body shall take random samples at the factory of
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components of the PT system or of individual components, for which the European technical
approval has been granted, for independent testing. For the most important components Table 13
given below summarises the minimum procedures that shall be implemented by the approved
body.
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Treatment Test 2
Main dimensions,
surface hardness and Test 5
surface finish
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1)
Visual inspection means, e.g.: main dimensions, gauge testing, correct marking or labelling,
checking documents for appropriate performance, surface, fins, kinks, smoothness, corrosion
protection, corrosion, coating etc., as given in the prescribed test plan7.
2)
All samples shall be randomly selected and clearly identified.
3.3 CE marking
The delivery note of the components of the PT system shall contain the CE marking. The symbol "CE"
shall be followed by the identification number of the certification body and shall be accompanied by
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4 Assumptions under which the fitness of the product for the intended use was favourably
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assessed
4.1 Manufacturing
"BBR VT CONA CME – External Post-tensioning System" is manufactured in accordance with the
provisions of the European technical approval. Composition and manufacturing process are deposited
at Österreichisches Institut für Bautechnik.
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4.2 Design
4.2.1 General
Design of the structure shall permit correct installation and stressing of tendon. Reinforcement in the
anchorage zone shall permit correct placing and compacting of concrete.
The design of the structure should consider protection of the external tendons against damage by
e.g. impact of vehicles, vibrations etc..
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CONA CME
Designation
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Characteristic
MPa 1,770 1,860 1,770 1,860 1,770 1,860 1,770 1,860
tensile strength fpk
--- --- kN kN kN kN kN kN kN kN
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CONA CME
Designation
n06-140 n06-150 n06-140 n06-150
Characteristic
MPa 1,770 1,860 1,770 1,860 1,770 1,860 1,770 1,860
tensile strength fpk
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--- --- kN kN kN kN kN kN kN kN
1)
The given values are maximum values according to EN 1992-1-1. The actual values shall be
taken from the standards and regulations in force at the place of use. Compliance with the
stabilisation and crack width criteria in the load transfer test was verified to a load level of
0.80 ⋅ Fpk.
2)
Overstressing is permitted if the force in the prestressing jack can be measured to an accuracy of
± 5 % of the final value of the prestressing force.
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Where
Fpk ........... Characteristic ultimate resistance of tendon
Fp0,1k ........ Characteristic force of tendon at 0.1 % elongation
4.2.4 Reinforcement in the anchorage zone
Verification of the transfer of the prestressing force to the structural concrete is not required if centre
spacing and edge distances of the tendon as well as grade and dimensions of additional
reinforcement, see Annexes 8 to 10, are complied with. In the case of grouped anchorages the
additional reinforcement of the individual anchorages can be combined, provided appropriate
anchorage is ensured. However, the number, cross section and position with respect to the bearing
trumplates of the additional reinforcement shall remain unchanged.
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The reinforcement of the structure shall not be employed as additional reinforcement. Reinforcement
exceeding the required reinforcement of the structure may be used as additional reinforcement if
appropriate placing is possible.
The forces outside the area of the additional reinforcement shall be verified and, if necessary, dealt
with by appropriate reinforcement.
If required for a specific project design, the reinforcement given in Annexes 8 to 10 may be modified
in accordance with the respective regulations in force at the place of use as well as with the relevant
approval of the local authority and of the ETA holder to provide equivalent performance.
4.2.5 Fatigue resistance
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Fatigue resistance of the tendons has been tested with a maximum force of 0.65 · Fpk and a stress
variation of 80 N/mm2 up to 2.0 · 106 load cycles.
4.2.6 Tendons in masonry structures – Load transfer to the structure
Load transfer of prestressing force from the anchorages to masonry structures shall be via concrete
or steel members designed according to the European technical approval, especially according to
clauses 2.6, 2.8, 2.11.6 and 4.2.4 or Eurocode 3, respectively.
The concrete or steel members supporting the anchorages shall have dimensions that permit a force
of 1.1 · Fpk to be transferred to the masonry. The verification shall be performed according to
Eurocode 6 as well as to the respective standards and regulations in force at the place of use.
Deviators shall be made of concrete or steel. The transfer of the forces from the deviator to the
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masonry shall be verified according to Eurocode 6 as well as to the respective standards and
regulations in force at the place of use.
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4.3 Installation
Assembly and installation of tendons may only be carried out by qualified PT specialist companies
with the required resources and experience in the use of multi strand external post-tensioning
systems, see ETAG 013, Annex D.1 and CWA 14646. The respective standards and regulations in
force at the place of use shall be considered. The company’s PT site manager shall have a certificate,
stating that she or he has been trained by the ETA holder and that she or he possesses the necessary
qualifications and experience with the "BBR VT CONA CME – External Post-tensioning System".
The tendons may be manufactured on site or in the factory (prefabricated tendons).
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Bearing trumplate, anchor head and coupler anchor head shall be placed perpendicular to the tendon
axis.
At the anchorages and couplers the tendon layout shall provide a straight section over a length as
specified in Annex 6.
In the case of the single plane coupler FK the prestressing steel strands shall be provided with
markers to be able to check the depth of engagement.
Bautechnik. The ETA holder shall save for reference information on the prestressing jacks and the
appropriate clearance behind the anchorage.
The safety-at-work and health protection regulations shall be complied with.
4.5 Restressing
Restressing of tendons in combination with release and reuse of wedges is permitted, whereby the
wedges shall bite into at least 15 mm of virgin strand surface and no wedge bites shall remain inside
the final length of the tendon between anchorages.
For tendons remaining restressable throughout the working life of the structure wax or grease shall be
used as filling material. Moreover, a strand protrusion has to remain with a length compatible with the
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prestressing jack used. The protruding strands shall be provided with an appropriate corrosion
protection.
Grout shall be injected through the inlet holes until it escapes from the outlet tubes with the same
consistency. To avoid voids in the hardened grout special measures shall be applied for long
tendons, tendon paths with distinct high points or inclined tendons. All vents and grouting inlets shall
be sealed immediately after grouting.
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The standards to be observed for cement grouting or special grout in ducts are EN 445, EN 446 and
EN 447 or the respective standards and regulations in force at the place of use shall be applied for
ready mixed grout.
4.6.3 Grease and wax
The specifications in ETAG 013 Annex C.4 and the recommendations of the supplier are relevant for
grease and wax.
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4.7 Welding
Ducts may be welded.
The helix may be welded to the bearing trumplate to secure its position.
After installation of the tendons further welding may not be carried out on the tendons. In case of
welding operations near tendons precautionary measures are required to avoid damage.
Plastic material may be welded after installation of the tendons.
− Keeping tensile elements away from areas where welding operations are performed.
It is the responsibility of the ETA holder to ensure that all necessary information on design and
installation is submitted to those responsible for the design and execution of the works constructed
with the "BBR VT CONA CME – External Post-tensioning System".
Rainer Mikulits
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Managing Director
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Dimensions in mm
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Number of strands 04 07 09 12 15 19 22 24 27 31
Anchor head
Diameter ØA mm 100 130 160 200 225 240 255
Height HA mm 50 55 60 65 75 85 95 100 105 110
Coupler head K
Diameter ØK mm 185 205 240 290 310 340 390
Height HK mm 85 85 90 90 90 95 105 120 125 130
Cover plate
Diameter ØD mm 182 202 240 276 306 336 380
Thickness DD mm 3 3 3 3 5 5 5
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Number of strands 04 07 09 12 15 19 22 24 27 31
Bearing trumplate
Diameter ØP mm 130 170 225 280 310 325 360
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Number of strands 04 07 09 12 15 19 22 24 27 31
Trumpet A
Diameter ØTA mm 72 88 127 127 153 153 170 191 191 191
Length LTA mm 200 328 623 508 694 579 715 871 871 757
Trumpet CME-K
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Diameter ØTK mm 190 208 245 245 280 280 310 335 380 380
Length LTK mm 308 340 428 428 473 473 498 597 734 734
Trumpet CME-H
Diameter ØTH mm 140 175 215 225 260 260 295 305 330 330
Length LTH mm 110 185 410 420 505 520 565 670 635 645
Tension Ring CME
Diameter ØB mm 165 185 200 200 220 220 240 246 250 250
Length LB mm 168 168 168 168 168 168 168 168 168 168
PE-Insert
Diameter ØI mm 104 124 140 140 158 158 178 184 188 188
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Length LI mm 220 220 220 220 220 220 220 220 220 220
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Number of strands 04 07 09 12 15 19 22 24 27 31
Minimum diameter Amin mm 110 140 170 170 210 210 240 250 270 270
Minimum height Hmin mm 85 90 90 95 105 115 125 130 140 140
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Number of strands 04 07 09 12 15 19 22 24 27 31
Minimum diameter Amin mm 110 140 170 170 210 210 240 250 270 270
Minimum wall thickness Jmin mm 3 3 3 3 3 3 3 3 3 3
Minimum cover thickness Fmin mm 5 5 5 5 5 5 5 5 5 5
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Number of strands 04 07 09 12 15 19 22 24 27 31
Straight length Lmin mm 560 720 950 1,210 1,620 1,650
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R1 R2 Rmin
Number of strands 04 07 09 12 15 19 22 24 27 31
Minimum radii of curvature Rmin m 2.0 2.0 2.5 2.5 2.7 3.0 3.2 3.3 3.5 4.0
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Strand arrangement
Strand mm² 140 / 150 140 / 150 140 / 150 140 / 150
Cross sectional area mm² 560 / 600 980 / 1,050 1,260 / 1,350 1,680 / 1,800
Charact. tensile strength1) fpk MPa 1,860 1,860 1,860 1,860
Charact. maximum force Fpk kN 1,040 / 1,116 1,820 / 1,953 2,340 / 2,511 3,120 / 3,348
0.90 Fp0.1k kN 806 / 864 1,411 / 1,512 1,814 / 1,944 2,419 / 2,592
0.95 Fp0.1k kN 851 / 912 1,490 / 1,596 1,915 / 2,052 2,554 / 2,736
Helix and additional reinforcement - Ribbed reinforcing steel Re 500 MPa
Min. concrete strength (cube) fcm,0 MPa 23 28 34 38 43 23 28 34 38 43 23 28 34 38 43 23 28 34 38 43
Min. concrete strength (cyl.) fcm,0 MPa 19 23 28 31 35 19 23 28 31 35 19 23 28 31 35 19 23 28 31 35
Helix
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Outer diameter mm 180 150 150 150 230 200 200 180 180 280 230 230 230 330 280 280 260 260
2)
Bar diameter mm 14 12 12 12 14 14 14 14 14 14 14 14 14 14 14 14 14 14
Length, approx. mm 182 181 216 216 232 232 277 277 277 282 282 337 337 332 332 332 382 282
Pitch mm 50 50 60 60 50 50 60 60 60 50 50 60 60 50 50 50 50 50
Number of pitches 4 4 4 4 5 5 5 5 5 6 6 6 6 7 7 7 8 6
Distance E mm 15 15 15 15 18 18 18 18 18 20 20 20 20 20 20 20 20 20
Additional reinforcement
Number of stirrups 3 3 4 3 5 4 3 3 4 5 5 4 4 7 6 5 5 6
2)
Bar diameter mm 12 12 10 10 14 14 14 14 14 12 14 14 14 12 14 16 16 14
Spacing mm 60 55 40 50 55 60 65 65 60 60 55 60 60 60 55 70 65 50
Distance from anchor plate F mm 30 30 30 30 33 33 33 33 33 35 35 35 35 35 35 35 35 35
Min. outer dimensions B mm 220 200 180 170 290 270 240 230 220 330 300 280 260 390 350 320 310 290
Center- and edge spacing
Min. centre spacing ac = bc mm 235 215 195 190 310 285 260 250 240 350 320 295 280 405 370 340 325 310
Min. edge distance (plus c) ae'=be' mm 110 100 90 85 145 135 120 115 110 165 150 140 130 195 175 160 155 145
Dimensions of anchorages
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1)
For strands with a tensile strength of 1,770 MPa see tables 2, 3 and 13
2)
Bar diameter of 14 mm can be replaced by 16 mm
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3)
Exemplary values
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Strand arrangement
Strand mm² 140 / 150 140 / 150 140 / 150 140 / 150
Cross sectional area mm² 2,100 / 2,250 2,660 / 2,850 3,080 / 3,300 3,360 / 3,600
Charact. tensile strength1) fpk MPa 1,860 1,860 1,860 1,860
Charact. maximum force Fpk kN 3,900 / 4,185 4,940 / 5,301 5,720 / 6,138 6,240 / 6,696
0.90 Fp0.1k kN 3,024 / 3,240 3,830 / 4,104 4,435 / 4,752 4,838 / 5,184
0.95 Fp0.1k kN 3,192 / 3,420 4,043 / 4,332 4,682 / 5,016 5,107 / 5,472
Helix and additional reinforcement - Ribbed reinforcing steel Re 500 MPa
Min. concrete strength (cube) fcm,0 MPa 23 28 34 38 43 23 28 34 38 43 23 28 34 38 43 23 28 34 38 43
Min. concrete strength (cyl.) fcm,0 MPa 19 23 28 31 35 19 23 28 31 35 19 23 28 31 35 19 23 28 31 35
Helix
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Outer diameter mm 375 330 330 280 280 420 360 360 330 330 475 420 360 360 330 475 430 420 360 360
2)
Bar diameter mm 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14
Length, approx. mm 432 432 382 432 332 457 457 432 432 382 482 482 482 482 382 532 532 482 532 432
Pitch mm 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50
Number of pitches 9 9 8 9 7 9.5 9.5 9 9 8 10 10 10 10 8 11 11 10 11 9
Distance E mm 27 27 27 27 27 27 27 27 27 27 31 31 31 31 31 32 32 32 32 32
Additional reinforcement
Number of stirrups 7 6 5 6 5 7 7 7 7 7 8 7 7 7 8 7 7 7 7 8
2)
Bar diameter mm 14 16 16 16 16 16 16 16 16 16 16 20 20 20 16 20 20 20 20 16
Spacing mm 60 65 65 55 60 65 65 65 65 65 65 75 70 65 55 80 80 70 65 55
Distance from anchor plate F mm 42 42 42 42 42 42 42 42 42 42 46 46 46 46 46 47 47 47 47 47
Min. outer dimensions B mm 440 400 360 350 330 490 450 410 390 370 530 480 440 420 400 560 510 460 440 420
Center- and edge spacing
Min. centre spacing ac = bc mm 455 415 380 365 345 510 465 425 410 390 550 500 460 440 420 575 525 480 460 435
Min. edge distance (plus c) ae'=be' mm 220 200 180 175 165 245 225 205 195 185 265 240 220 210 200 280 255 230 220 210
Dimensions of anchorages
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1)
For strands with a tensile strength of 1,770 MPa see tables 2, 3 and 13
2)
Bar diameter of 14 mm can be replaced by 16 mm
3)
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Exemplary values
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Strand arrangement
Outer diameter mm 520 475 430 420 360 560 520 475 430 430
2)
Bar diameter mm 14 14 14 14 14 14 14 14 14 14
Length, approx. mm 532 532 532 427 432 532 532 582 467 432
Pitch mm 50 50 50 40 50 50 50 50 40 50
Number of pitches 11 11 11 11 9 11 11 12 12 9
Distance E mm 35 35 35 35 35 35 35 35 35 35
Additional reinforcement
Number of stirrups 8 7 7 7 8 8 8 8 8 8
2)
Bar diameter mm 20 20 20 20 20 20 20 20 20 20
Spacing mm 80 80 75 70 60 85 75 70 65 60
Distance from anchor plate F mm 50 50 50 50 50 50 50 50 50 50
Min. outer dimensions B mm 590 540 490 470 440 630 580 530 500 480
Center- and edge spacing
Min. centre spacing ac = bc mm 610 555 505 485 460 650 595 545 520 495
Min. edge distance (plus c) ae'=be' mm 295 270 245 235 220 315 290 265 250 240
Dimensions of anchorages
Anchor diameter DA mm 360
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1)
For strands with a tensile strength of 1,770 MPa see tables 2, 3 and 13
2)
Bar diameter of 14 mm can be replaced by 16 mm
3)
Exemplary values
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ac = bc ac < bc
ae = be ae < be
Modification of Center and Edge distances must be in accordance with clause 2.6:
ac 0.85 · ac and
Helix, outside diameter 1)
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bc Ac
bc
Ac = a c · bc a c · bc
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c...Concrete cover
1)
The outer dimensions of the additional reinforcement shall be adjusted accordingly. Further
modifications of reinforcement have to be in accordance with clause 4.2.4.
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Installation
1 Preparatory work
The components of the prestressing kit shall be stored in such a way as to avoid any damage
or corrosion.
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2 Anchorage recesses
Adequate clearance to accommodate and to use the prestressing jack shall be ensured, see
also clauses 2.1.5 and 4.2.2.
3 Fixing the bearing trumplates
Four holes are provided to fix the bearing trumplates to the formwork. The trumpet is screwed
into the bearing trumplate. The helix is either welded to the bearing trumplate by means of
radial bars, see also clause 4.7, or positioned by fixing it to the existing reinforcement. The
trumpet and a piece of the duct are connected in a waterproof way. In the final position the
duct shall protrude at least 100 mm out of the formwork.
4 Installation of deviators
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head K, 2.BA, outer pitch circle, whereby the strands have to be marked to check the correct
depth of penetration.
The coupler anchor head H, 2.BA, is assembled with ring wedges which are secured in
accordance with clause 2.1.3.1. It is connected to the already tensioned coupler anchor
head H, 1.BA, by means of a threaded coupler sleeve.
9 Assembly of anchor block/coupler anchor 1.BA
After passing the strands through the anchor head, they are anchored individually in the
cones by means of ring wedges. The same applies for the coupler anchor head in the case of
fixed couplers in the first construction stage.
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10 Stressing
At the time of stressing the mean concrete compressive strength shall be at least according to
Table 9 and the provisions of clause 2.8. Stressing and possible wedging has to be carried
out with a suitable prestressing jack in accordance with clause 4.4.
The elongation of the tendon and the prestressing forces shall be checked and recorded
systematically during the stressing operation.
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More detailed information on installation can be obtained from the ETA holder.
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Grease specification
At 7 days ≤ 4.5 %
Corrosion protection
1)
168 hours at 35 °C NF X41-002 (salt spray) Pass
168 hours at 35 °C NF X41-002 (distilled water No corrosion
1)
spray)
2- 2)
SO4 NF M07-023 ≤ 100 ppm (0.010%)
Notes
1)
Test sample consists of a structural steel plate Fe 510 with a surface roughness comparable to
prestressing wire and strand. The plate is covered with a layer of grease of a maximum thickness
corresponding of the declared mass of filling material per linear meter of monostrand divided by the
nominal strand surface per linear meter (based on nominal strand diameter).
2)
Applied accordingly to grease.
Wax specification
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Corrosion protection
1)
168 hours at 35 °C NF X41-002 (salt spray) Pass
168 hours at 35 °C NF X41-002 (distilled water No corrosion
1)
spray)
Note
1)
Test sample consists of a structural steel plate Fe 510 with a surface roughness comparable to
prestressing wire and strand. The plate is covered with a layer of grease of a maximum thickness
corresponding of the declared mass of filling material per linear meter of monostrand divided by the
nominal strand surface per linear meter (based on nominal strand diameter).
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Strand
Diameter d mm 15.3 15.3 15.7 15.7
Nominal cross-sectional area Ap mm2 140 140 150 150
a)
Suitable strands according to standards and regulations in force at the place of use may also be used.
b)
Standard value
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Reference documents
Standards
EN 206-1 (12.2000), A1 (07.2004), A2 (06. 2005) Concrete - Part 1: Specification, performance, production and
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conformity
EN 445 (10.2007) Grout for prestressing tendons - Test methods
EN 446 (10.2007) Grout for prestressing tendons - Grouting procedures
EN 447 (10.2007) Grout for prestressing tendons - Specification for common grout
EN 1561 (10.2011) Founding - Grey cast irons
EN 1563 (12.2011) Founding - Spheroidal graphite cast irons
EN 1992-1-1 (12.2004), AC (01.2008), AC (11.2010) Eurocode 2: Design of concrete structures - Part 1-1:
General rules and rules for buildings
EN 10025-2 (11.2004), AC (06.2005) Hot rolled products of structural steels - Part 2: Technical delivery
conditions for non-alloy structural steels
EN 10083-1 (08.2006) Steels for quenching and tempering - Part 1: General technical delivery
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conditions
EN 10083-2 (08.2006) Steels for quenching and tempering - Part 2: Technical delivery conditions
for non alloy steels
EN 10084 (04.2008) Case hardening steels - Technical delivery conditions
EN 10204 (10.2004) Metallic products - Types of inspection documents
EN 10210-1 (04.2006) Hot finished structural hollow sections of non-alloy and fine grain structural
steels – Part 1: technical delivery requirements
EN 10216-1 (05.2002), A1 (03.2004) Seamless steel tubes for pressure purposes - Technical delivery
conditions - Part 1: Non-alloy steel tubes with specified room temperature
properties
EN 10217-1 (05.2002), A1 (01.2005) Welded steel tubes for pressure purposes - Technical delivery conditions -
Part 1: Non-alloy steel tubes with specified room temperature properties
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EN 10219-1 (04.2006) Cold formed welded structural hollow sections of non-alloy and fine grain
steels - Part 1: Technical delivery conditions
EN 10255 (08.2004), A1 (04.2007) Non-alloy steel tubes suitable for welding and threading - Technical
delivery conditions
EN 10270-1 (10.2011) Steel wire for mechanical springs - Part 1: Patented cold drawn unalloyed
spring steel wire
EN 10277-2 (03.2008) Bright steel products - Technical delivery conditions - Part 2: Steels for
general engineering purposes
EN 10305-5 (01.2010) Steel tubes for precision applications - Technical delivery conditions - Part
5: Welded cold sized square and rectangular tubes
EN 12201 (09.2011) Plastics piping systems for water supply, and for drainage and sewerage
under pressure - Polyethylene (PE)
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EN ISO 1872-1 (05.1999) Plastics - Polyethylene (PE) moulding and extrusion materials - Part 1:
Designation system and basis for specifications (ISO 1872-1:1993)
ENV 1992-1-5 (10.1994) Eurocode 2 - Design of concrete structures - Part 1-5: General rules -
Structures with unbonded and external prestressing tendons
prEN 10138-3 (04.2005) Prestressing steels - Part 3: Strands
CWA 14646 (01.2003) Requirements for the installation of post-tensioning kits for prestressing of
structures and qualification of the specialist company and its personnel
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OIB-250-006/06-056
KB Vorspann-Technik GmbH
Weitwörth 25
5151 Nussdorf a. H.
Austria
Tel +43 6272 40790
Fax +43 6272 40790 11
www.kb-vt.com
[email protected]
KB Vorspann-Technik GmbH
Bahnhofstrasse 108
82166 Gräfelfing
Germany
Tel +49 89 724 49 69 0
Fax +49 89 724 49 69 12
www.kb-vt.com
[email protected]