VSL Post-Tensioning Systems have been used commonly throughout the world since 1956. They are technically mature and have earned a reputation for quality and reliability. Today, VSL is a recognized leader in post-tensioning and related engineering. VSL Post-Tensioning is used in virtually every area of concrete construction. While used primarily in bridges and buildings, the system is also employed for the construction of concrete containment structures, anchoring in rock and soil, structural strengthening and repair, lifting and sliding of heavy loads, and many other applications.
Bank of China, Hong Kong
Tsing Ma and Kap Shui Mun Bridges, Hong Kong
Harbour Front, Hong Kong
The VSL technology is based on the principle of post tensioning. The prestress is permanently introduced into the structure after the concrete has hardened. This is achieved by the stressing of suitably arranged, highstrength prestressing tendons. VSL PostTensioning generates favorable stress conditions in the structure, enabling efficient use of building materials while controlling deformations under service conditions.
Gateway I, Hong Kong
This publication comprises a summary of the VSL PostTensioning Systems and contains important information of design and construction. The dimensions
VSL Post-Tensioning Systems have been used commonly throughout the world since 1956. They are technically mature and have earned a reputation for quality and reliability. Today, VSL is a recognized leader in post-tensioning and related engineering. VSL Post-Tensioning is used in virtually every area of concrete construction. While used primarily in bridges and buildings, the system is also employed for the construction of concrete containment structures, anchoring in rock and soil, structural strengthening and repair, lifting and sliding of heavy loads, and many other applications.
Bank of China, Hong Kong
Tsing Ma and Kap Shui Mun Bridges, Hong Kong
Harbour Front, Hong Kong
The VSL technology is based on the principle of post tensioning. The prestress is permanently introduced into the structure after the concrete has hardened. This is achieved by the stressing of suitably arranged, highstrength prestressing tendons. VSL PostTensioning generates favorable stress conditions in the structure, enabling efficient use of building materials while controlling deformations under service conditions.
Gateway I, Hong Kong
This publication comprises a summary of the VSL PostTensioning Systems and contains important information of design and construction. The dimensions
and strengths indicated are subject to change as VSL continuously improves its systems. Additional tendon sizes are available upon request. Alternate dimensions, special conditions and various
in Raleigh. Operating Unit 4.5 covers Europe, Middle East, Africa and South America, with the regional office in France. This arrangement gives VSL continuous access to the latest construction technologies employed throughout the world. Our local based offices allow VSL to be close to our clients and offer our construction solutions effectively. Bee-Do Bridge, South South K orea
Rambler Ram bler Channel Bri dge, Hong Kong
The scope of VSL's value-added services is tailored to suit client needs.
strengths may all be accommodated. accommodated. Your local VSL Representative will furnish additional details regarding specific applications. applications.
As a subsidiary of VSL International of Switzerland and a member of BOUYGUES S.A. of France, VSL is part of a major international construction group with a combined workforce of over 80,000. VSL International Ltd. further divides its subsidiaries and licensees into five Operating Units (OU's). Operating Unit 1 covers South East Asia with the regional office in Australia. Operating Unit 2 covers North East Asia with the regional office in Hong Kong. Operating Unit 3 covers the United States with the regional office
Koshiki Daimyojin Bridge, Japan
With offices throughout the world, VSL offers a comprehensive range of professional services for any post-tensioning project. These locally based services include feasibility studies, structural design assistance, contractor consulting and field installation, all aimed at finding the best solution and insuring the best value for money.
As a technical leader in the posttensioning industry, VSL works continuously, through its quality assurance program, to refine, improve, and expand the scope of its systems and services. Subscribing to the philosophy that what is good today may always be made better for tomorrow, VSL has always attracted the most talented and motivated people, all with one goal: to be your most valued construct construct ion partner.
The VSL multistrand system is characterized by the following features: • standardized tendon units with up to 55 strands of 13mm (0.5") or 15 mm (0.6") diameter; • wide selection of anchorage types; • ducts of steel or plastic PT-PLUS™; • grouting with cement mortar or other materials; • economical tendon manufacture on-site or in the factory; • no need to determine tendon length in advance; • simultaneous stressing of all strands in a tendon but individual locking of each strand at the anchorage; • stressing in any number of steps; • simple and reliable equipment for installation, stressing and grouting.
VSL Multistrand System Components Grout tube
Stressing anchorage
Grout tube
Grout tube
Grout tube
Grout tube
Dead end anchorage
Strand Properties 15 mm (0.6")
13 mm (0.5") EN138 or BS 5896 Super 12.9 100 0.785 1580 1) 1860 186
Strand type Nominal diameter Nominal area Nominal mass Yield strength Tensile strength Min. breaking load Young's modulus Relaxation 3)
mm mm 2 kg/m MPa MPa kN GPa %
ASTM A416 Grade 270 12.7 98.7 0.775 1670 2) 1860 183.7
EN138 or BS 5896 Super 15.7 150 1.18 1) 1500 1770 265
ASTM A416 Grade 270 15.2 140 1.1 2) 1670 1860 260.7
cicra 195 max 2.5
1) Measured at 0.1% residual strain (0.1% offset method) 2) Measured at 1% extension (1% extension under load method) 3) After 1000 hrs at 20º C (EN & BS, low relaxation to ASTM)
Tendon Properties STRAND TYPE 13 mm (0.5")
Tendon unit
5-4
5-7
5-12
5-19
5-22
5-27
5-31
5-37
5-42
5-48
5-55
No. of strands
2 3 4 5 6 7 8 9 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
Duct ID/OD
4)
Min. (mm)
Nominal (mm)
36/39
36/39
51/54
51/54
60/67
65/72
75/82
80/87
80/87
95/102
95/102
100/107
95/102
100/107
110/117
110/117
120/127
120/127
130/137
130/137
130/137
135/142
STRAND TYPE 15 mm (0.6") Min. Breaking load (kN)
12.9
12.7
372 558 744 930 1116 1302 1488 1674 1860 2046 2232 2418 2604 2790 2976 3162 3348 3534 3720 3906 4092 4278 4464 4650 4836 5022 5208 5394 5580 5766 5952 6138 6324 6510 6696 6882 7068 7254 7440 7626 7812 7998 8184 8370 8556 8742 8928 9114 9300 9486 9672 9858 10044 10230
367 551 735 919 1102 1286 1470 1653 1837 2021 2204 2388 2572 2756 2939 3123 3307 3490 3674 3858 4041 4225 4409 4593 4776 4960 5144 5327 5511 5695 5878 6062 6246 6430 6613 6797 6981 7164 7348 7532 7715 7899 8083 8267 8450 8634 8818 9001 9185 9369 9552 9736 9920 10104
4) Corrugated plastic PT-Plus™ ducts are also available, refer to page 11
Tendon unit
6-3 6-7
6-12
6-19
6-22
6-27
6-31
6-37
6-42
6-48
6-55
No. of strands
2 3 4 5 6 7 8 9 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
Duct ID/OD
4)
Min. (mm)
Nominal (mm)
36/39
36/39
55/62
65/72
75/82
80/87
90/97
100/107
100/107
100/107
110/117
110/117
120/127
120/127
130/137
130/137
135/142
135/142
150/160
160/170
160/170
170/180
Min. Breaking load (kN)
15.7
15.2
530 795 1060 1325 1590 1855 2120 2385 2650 2915 3180 3445 3710 3975 4240 4505 4770 5035 5300 5565 5830 6095 6360 6625 6890 7155 7420 7685 7950 8215 8480 8745 9010 9275 9540 9805 10070 10335 10600 10865 11130 11395 11660 11925 12190 12455 12720 12985 13250 13515 13780 14045 14310 14575
521 782 1043 1304 1564 1825 2086 2346 2607 2868 3128 3389 3650 3911 4171 4432 4693 4953 5214 5475 5735 5996 6257 6518 6778 7039 7300 7560 7821 8082 8342 8603 8864 9125 9385 9646 9907 10167 10428 10689 10949 11210 11471 11732 11992 12253 12514 12774 13035 13296 13556 13817 14078 14339
MULTI
STRAND
POST- TENSIONING
Stressing Anchorage VSL Type EC
Grout connection
Duct
Anchor block Casting Wedges Strands
G
AC
F E
A
A
B
D
Dimensions Tendon unit
5-4 5-7 5-12 5-19 5-22 5-27 5-31 5-37 5-42 5-48 5-55 6-3 6-4 6-7 6-12 6-19 6-22 6-27 6-31 6-37 6-42
A
B
C
D
E
135 165 215 265 290 315 315 370 390 430 465 135 165 215 265 315 315 370 390 430 465
60 60 60 70 77 92 100 107 112 122 150 60 60 60 75 92 100 112 122 142 145
85 110 150 180 200 220 230 250 290 290 320 90 110 150 180 220 230 250 270 300 320
100 100 160 210 215 300 300 320 340 340 340 100 100 160 210 300 300 320 340 340 340
58 85 120 145 150 175 175 200 217 235 250 58 85 120 145 175 175 200 217 235 250
Dimensions in mm Dimensions are valid for: Nominal concrete strength at 28 days: 35 MPa (cube), 28 MPa (cylinder). Maximum prestressing force may be applied when concrete reaches 25 MPa (cube) or 20 MPa (cylinder). Max prestressing force is 75% of min. tendon breaking load (temporary overstressing to 80%).
F Ext. Dia. 39 54 72 87 102 107 107 117 127 137 142 39 54 72 87 107 107 117 127 137 142
G 95 125 150 200 230 250 250 305 325 365 400 95 125 150 200 250 250 305 325 365 400
Subject to modification
MULTI
STRAND
POST- TENSIONING
Stressing Anchorage VSL Type E
Grout tube
Bearing plate (steel) Duct Anchor block Wedges
Sleeve
Strands
AD
F
C
A
E
B
A
Dimensions Tendon unit 5-1 5-3 5-4 5-7 5-12 5-19 5-22 5-27 5-31 5-37 5-42 5-48 5-55 6-1 6-2 6-3 6-4 6-7 6-12 6-19 6-22 6-27 6-31 6-37 6-42 6-48 6-55
A
B
C
D
E
70 115 130 175 230 290 315 370 370 405 500 500 500 75 110 135 160 205 270 340 370 435 435 480 580 580 580
15 20 20 25 35 40 45 55 55 60 70 70 70 15 15 20 25 35 40 50 55 65 65 70 90 90 90
45 60 60 60 60 75 82 97 105 112 117 127 155 60 60 60 60 70 78 97 107 117 127 147 147 147 187
45 85 85 110 150 180 200 220 230 250 290 290 320 55 90 90 120 135 180 220 230 250 270 300 320 340 360
70 190 190 190 370 470 480 550 550 570 680 680 680 70 190 190 190 290 460 590 690 690 690 830 950 950 950
Dimensions in mm Dimensions are valid for: Nominal concrete strength at 28 days: 35 MPa (cube), 28 MPa (cylinder). Maximum prestressing force may be applied when concrete reaches 25 MPa (cube) or 20 MPa (cylinder). Max prestressing force is 75% of min. tendon breaking load (temporary overstressing to 80%).
F Ext. Dia. 36 36 39 54 72 87 102 107 107 117 127 137 142 36 36 39 54 72 87 107 107 117 127 137 160 160 170 Subject to modification
Couplers VSL Type K and V Grout tube Coupling block V
Casting type EC or Bearing plate type E Coupling Duct
block K
Sleeve Omega ring Wedges
Compression fittings
Tension ring
Compression fittings with retainer plates
Couplers Type K
Couplers Type V
Fixed coupler.
Movable coupler.
For coupling to a tendon which has been placed and stressed.
For coupling to a tendon which has already been placed, but not stressed.
Cast-in casting
A
type EC
D
B
∆L=Elongation
Coupler type K Tendon unit 5-3 5-4 5-7 5-12 5-19 5-22 5-27 5-31 5-37 5-42 5-48 5-55 6-2 6-3 6-4 6-7 6-12 6-19 6-22 6-27 6-31 6-37
A 430 440 440 510 590 660 860 1010 1080 1080 1370 1370 380 490 520 630 730 860 930 1090 1090 1390
E+1.5 ∆L
F
of tendon 1
Coupler type V B 110 110 110 110 110 110 110 110 150 150 150 170 128 128 128 128 128 128 128 138 150 170
øC 130 150 170 200 240 260 310 350 390 395 420 490 150 150 160 200 240 280 310 330 350 440
Tendon unit
D
E
F
øG
5-3
290
175
230
130
5-7
410
175
330
170
5-12
510
175
420
200
5-19
600
175
490
240
5-22
690
175
570
260
5-31
1000
175
870
350
6-2
230
200
185
130
6-3
330
205
250
150
6-4
360
205
280
160
6-7
470
205
370
190
6-12
570
205
460
240
6-19
700
205
570
280
Dimensions in mm Dimensions are valid for: Nominal concrete strength at 28 days: 35 MPa (cube), 28 MPa (cylinder). Maximum prestressing force may be applied when concrete reaches 25 MPa (cube) or 20 MPa (cylinder). Max prestressing force is 75% of min. tendon breaking load (temporary overstressing to 80%).
Subject to modification
Dead End Anchorage VSL Type H Grout tube
Duct Tension ring Bulbs
Seal
Spacer
Type II Type I
AxB
C D
Strand type 15 mm (0.6")
Strand type 13 mm (0.5") Tendon unit 5-3 5-4 5-7 5-12 5-19 5-22 5-31 5-37 5-42 5-55
Alternative 1 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 3
Type
A
B
C
D
I I I II II II I II II II II II II II II II II II II II
230 310 150 370 170 350 310 470 310 570 390 670 470 770 470 870 570 1170 870 570
70 70 170 70 190 190 270 190 390 190 390 310 430 310 550 350 550 350 430 670
930 930 930 1130 1130 1130 1130 1130 1130 1130 1130 1330 1330 1530 1530 1530 1530 1830 1830 1830
1280 1280 1280 1280 1280 1280 1280 1480 1480 1680 1680 1680 1680 1980 1980 1980
Tendon unit 6-3 6-4 6-7 6-12 6-19 6-22 6-31 6-37 6-42
6-55
Alternative 1 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 3 1 2 3
Dimensions in mm Dimensions are valid for: Nominal concrete strength at 28 days: 35 MPa (cube), 28 MPa (cylinder). Maximum prestressing force may be applied when concrete reaches 25 MPa (cube) or 20 MPa (cylinder). Max prestressing force is 75% of min. tendon breaking load (temporary overstressing to 80%).
Type
A
B
C
D
I I I II II II I II II II II II II II II II II II II II II
290 390 190 450 210 430 390 570 390 690 470 810 570 1050 690 1050 810 690 1410 1050 690
90 90 210 90 230 230 330 230 470 230 490 260 510 370 510 370 510 650 370 510 790
950 950 950 1150 1150 1150 1150 1150 1150 1150 1150 1550 1550 1850 1850 1850 1850 1850 2150 2150 2150
1330 1330 1330 1330 1330 1330 1330 1700 1700 2000 2000 20000 2000 2000 2300 2300 2300
Subject to modification
Intermediate Anchorage VSL Type Z and ZU
Intermediate Anchorage Type Z
Intermediate Anchorage Type ZU
Centre-stressing anchorages are used for ring tendons in circular structures, or for those tendons where the ends cannot be fitted with normal stressing anchorages.
Tendon
2
Tendon
Intermediate anchorage type Z
Intermediate anchorage type Z
Tendon unit
A
B
C
D
5-2 1) 5-4 1) 5-6 5-12 5-18 5-22
130 160 200 280 320 350
60 70 90 140 160 160
80 90 130 140 180 200
60 65 85 90 110 120
400 560 170 500 720 200 700 990 240 1000 1490 320 1300 1910 360 1450 2110 390
6-2 1) 6-4 1) 6-6 6-12 6-18 6-22
140 170 210 300 380 400
70 80 100 160 180 180
90 100 140 160 200 250
65 70 90 100 120 145
450 900 1000 1350 1450 1500
F 2)
1
G 2)
620 1180 1400 1960 2280 2380
Dimensions in mm 1) Tension ring only on side 2 2) Dependent upon the shape of the concrete surface. The values stated apply for surfaces which are not curved.
H
180 210 250 340 420 440
Tendon unit
A
B
C
D
F
2)
G 2)
H
5-2 5-4 5-6
165 165 185
103 103 113
80 88 95
60 65 70
450 560 650
655 815 925
200 200 220
170 170 200
105 105 120
90 92 100
65 65 75
450 560 650
655 815 925
210 210 240
6-2 6-4 6-6
1) 1)
1) 1)
Subject to modification
Selected Design Considerations
Tendon Supports
Spacing and Cover of Ducts In determining minimum spacing and concrete cover requirements, reference should be made to applicable standards and recommendations.
Recommended spacing: Standard steel ducts Plastic ducts PT-PLUS™:
0.8 to 1.2m 0.8 to 1.0m
Minimum Radii of Tendon Curvatures and Minimum Tangent Length Minimum radius of tendon curvature Minimum tangent length
Minimum breaking load of tendon (MN)
Tendon Force Losses The effective prestressing force at a specific place and time differs from the initial prestressing force for various reasons.
The following values may be assumed for design: Tendon in standard steel ducts:
Significant factors include:
µ= 0.2 (range 0.16~0.22)
• • • •
Tendon in plastic ducts PT-PLUS™:
friction losses due to curvature of the tendon; shrinkage and creep of the concrete; relaxation of the prestressing steel; draw-in of the wedges during lock-off.
The friction losses along the tendon can be determined with the following formula: Px = Po e -(µ α+kx) , where x = Distance from stressing end (in meters) Px = Prestressing force at x Po = Prestressing force at stressing end µ = Coefficient of friction α = sum of all angular deviations (in radians) over the distance x k = Wobble friction coefficient due to minor unavoidable tendon curvatures (placing tolerances) The friction coefficients µ and k can vary fairly widely and depend upon various factors, including: the nature and surface condition of the prestressing steel; the type, diameter and surface condition of the duct; and the installation method.
µ = 0.14 (range 0.12~0.15)
k= 0.001 (range 0.0008~0.0012) k= 0.001 (range 0.0008~0.0012)
For calculating the losses due to shrinkage and creep of the concrete, reference should be made to the technical literature and to the standards applicable to each project. The relaxation of the prestressing steel depends primarily upon the types of steel (relaxation class), the magnitude of the prestress and the temperature. For low relaxation strands commonly used today, the maximum loss is 2.5% after 1000 hours at 20˚ C and an initial stress of 70% of the nominal tensile strength. Further information can be found in the relevant prestressing steel standards and manufacturer's literature. Independent of the type of jack or tendon, a loss due to wedge draw-in of approximately 6mm occurs at lock-off. If necessary, this can be compensated for by suitable procedures.
Sheathing and Corrosion Protection For conventional applications, corrugated galvanised steel ducts are used. For applications requiring enhanced corrosion protection and improved fatigue resistance of the tendons, use of the VSL PT-PLUS™ System with corrugated plastic duct is recommended. This fully encapsulated and watertight system offers superb corrosion protection, and the plastic duct eliminates fretting fatigue between the strand and duct. It also
provides reduced duct friction. The PT-PLUS™ System may, in conjunction with VSL CS Anchorages, be configured with special details and installation techniques to provide Electrically Isolated Tendons. These tendons may be electrically monitored at any time throughout the life of the structure. All ducts are manufactured in a variety of standard lengths and are coupled on site.
Dimensions of Plastic Ducts PT-PLUS™ Strand Type
Strand Type
Duct
13 mm (0.5")
15 mm (0.6")
Dimensions (mm)
Tendon unit
Tendon unit
d
D
5-12 5-19 5-31 5-43 5-55
6-7 6-12 6-19 / 6-22 6-31 6-37
59 76 100 130 130
73 91 116 146 146
s 2 2.5 3 3 3
Other units on request
Steel Duct Plastic Duct PT-PLUS™ Strand bundle
Centre line of duct e
St ran d Typ e 13 mm (0 .5" )
Tendon unit 5-1 5-3 5-7 5-12 5-19 5-22 5-27 5-31 5-37 5-42 5-48 5-55
Steel duct e (mm) 4 7 8 11 13 12 13 14 23 26 17 23
Plastic duct e (mm) 7 9 22 17 14 32 28 24 14
Centre of gravity of strands
Stra nd Typ e 15 mm (0. 6")
Tendon unit 6-1 6-3 6-4 6-7 6-12 6-19 6-22 6-27 6-31 6-37
Steel duct e (mm) 5 6 6 10 14 17 14 13 22 25
Plastic duct e (mm) 9 12 18 15 32 28 22
Strand Position at High Point of Tendon
e
Strand Position at Low Point of Tendon
MULTI
STRAND
POST- TENSIONING
Dead End Anchorage VSL Type L Duct B
Hairpin Bar Reinforcement Hairpin bar Required cross-sectional area of hairpin bars:
Duct A
As
•
n
As
Grout tube øA
= Po •
π
2
[mm ] = Cross-section area of one hairpin bar
n
[-]
= number of hairpin bars
Po
[kN]
= Prestressing force in the tendon
øAext.
[mm]
= External diameter of duct
T
[mm]
= Concrete thickness
X
[mm]
= Required anchoring length according to applicable standard
Yield strength of hairpin bars:
≥ 400
MPa
Concrete cover to ducts shall not be less than the external duct diameter.
T øB
Layout of L-Anchorages: a
b
c
T ≥ 3 • øA ext.
T ≥ 4 • øA ext.
T ≥ 4 • øA ext.
Hairpin bar reinforcement T
Strand Type 15 mm (0.6")
Strand Type 13 mm (0.5")
Tendon unit
øA Internal/external
øB Internal/external
R min.
Tendon unit
øA Internal/external
øB Internal/external
R min.
5-4 5-7 5-12 5-19 5-22 5-31
42/45 60/67 80/87 90/97 95/102 110/117
36/39 51/54 65/72 80/87 85/92 100/107
600 600 900 1100 1200 1400
6-2 6-3 6-4 6-7 6-12 6-19
42/45 42/45 65/72 75/82 90/97 110/117
36/39 36/39 55/62 60/67 80/87 95/102
600 600 600 750 1000 1300
Dimensions in mm Dimensions are valid for: Nominal concrete strength at 28 days: 25 MPa (cube), 20 MPa (cylinder). Maximum prestressing force may be applied when concrete reaches 80% of its nominal strength. Maximum prestressing force is 75% of min. tendon breaking load (temporary overstressing to 80%).
Dead End Anchorage VSL Type LD When loops with a smaller radius are required, special half round ducts are available upon request. VSL Type LD Loops are available with a 590 mm radius. The tendon sizes available are the same as Type L - the difference is in duct configuration as indicated. A tight radius is good for nailing of precast box segments to piers.
Duct sized such that only two (2) layers of strand occur in the loop.
Subject to modification
Stressing The unique feature of the VSL Post-Tensioning system lies in its special procedure for locking the wedges. The wedges always remain in contact with the strands during the stressing operation. As the pressure in the jack is released, the wedges automatically lock in the conical holes of the anchor head.
Placing of anchor block
Placing of anchor block and wedges
Positioning of the jack Positioning of jack
Stressing
Seating of wedges
Stressing, measuring, seating of wedges
Grouting VSL grouting equipment includes mixer and pump in one unit. Grouting is usually carried out as soon as possible after stressing.
Grouting equipment
Grouting of tendon
Push Through Machine
Hydraulic Pump
Jack type 60˚
ZPE-23FJ ZPE-30 ZPE-3 ZPE-60 ZPE-7/A ZPE-12/St2 ZPE-200 ZPE-19 ZPE-460/31 ZPE-500 ZPE-750 ZPE-1000 ZPE-1250
Concrete cover according to applicable standard
A min.
B
C
D
E
30 30 30 30 50 50 50 60 80 80 80 90
300 600 550 650 800 700 1100 850 700 1150 1350 1300 1350
1200 1100 1000 1100 1200 1300 2100 1500 1500 2000 2300 2200 2250
116 140 200 180 300 310 330 390 485 585 570 790 660
90 100 150 140 200 200 210 250 300 330 365 450 375
Dimensions in mm D
B
E
C
E
Stressing Jack Data
Type I (ZPE-23 FJ) Designation Type Length (mm) Diameter (mm) Stroke (mm) Piston area (cm 2) Capacity (kN) (bar) Weight (kg) Used for 13 mm (0.5") tendon types Used for 15 mm (0.6") tendon types
Type II (ZPE-19)
ZPE-23FJ
ZPE-30
ZPE-3
ZPE-60
I 790 116 200 47.10 230 488 23 5-1
III 720 140 250 58.32 320 549 28 5-1
6-1
6-1
III 475 200 160 103.6 500 483 47 5-2 5-3 6-2
III 615 180 250 126.4 632 500 74 5-2 to 5-4 6-2 6-3
ZPE-7/A ZPE-12/St2
III 690 280 160 203.6 1064 523 115 5-6 5-7 6-4
ZPE-200
II 550 310 100 309.4 1850 598 151 5-12
III 960 315 300 325.7 2000 614 305 5-12
6-6 6-7
6-6 6-7
Type III (ZPE-500) ZPE-19 ZPE-460/31 ZPE-500
II 750 390 100 500.3 2900 580 294 5-18 5-19 6-12
II 580 485 100 804.0 4660 580 435 5-22 5-31 6-18 6-19
III 1000 550 200 894.6 5000 559 1064 5-22 5-31 6-18 to 6-22
ZPE-750
II 1185 520 150 1247.0 7500 601 1100 5-31 5-37 6-31
ZPE-1000 ZPE-1250
III 1200 790 200 1809.5 10000 553 2290 5-37 to 5-55 6-31 to 6-43
II 1290 620 150 2168.0 12500 577 1730 5-37 to 5-55 6-31 to 6-55
Subject to modification
Harbour Front (Hunghom Marine Redevelopment), Hunghom, Hong Kong
Owners and designers of the buildings of today and tomorrow need to incorporate sufficient flexibility into their structures to accommodate the changing needs of the users of the building. Post-tensioning offers larger spans with reduced structural depth, resulting in larger column-free areas. Internal tenancy layouts are thus not restricted by tight column grids. Positive deflection and crack control and, if necessary, crackfree water-tight slabs offer the designer the opportunity to
break free of the limitations of the passive methods of reinforced concrete or structural steel. VSL Post-Tensioning is more economical than other systems, especially when faster construction cycles are considered. There is less material handling on site and also a reduced site labour force which minimises congestion on site. Most importantly, there is the quality and service of VSL specialized high-performance teams and optimum back-up on site.
The VSL Post-Tensioning slab system has been used in many prestigious buildings and structures throughout the Far East. The system uses up to five strands in flat-shaped ducting and anchorages. The strands are individually stressed and are gripped by wedge action. After stressing, the duct is subsequently filled with a cementitious grout, which is injected under pressure, so that the strands are fully bonded to the surrounding concrete.
Construction Sequence
Stressing
Placing tendons Concreting
Grouting
Strand Properties 15 mm (0.6")
13 mm (0.5") EN138 or BS 5896 Super 12.9 100 0.785 1580 1) 1860 186
Strand type Nominal diameter Nominal area Nominal mass Yield strength Tensile strength Min. breaking load Young's modulus Relaxation 3)
mm mm 2 kg/m MPa MPa kN GPa %
ASTM A416 Grade 270 12.7 98.7 0.775 1670 2) 1860 183.7
EN138 or BS 5896 Super 15.7 150 1.18 1) 1500 1770 265
ASTM A416 Grade 270 15.2 140 1.1 2) 1670 1860 260.7
cicra 195 max 2.5
1) Measured at 0.1% residual strain (0.1% offset method) 2) Measured at 1% extension (1% extension under load method) 3) After 1000 hrs at 20º C (EN & BS, low relaxation to ASTM)
Tendon Properties
Duct Dimensions Min. breaking load (kN)
Strand type
13 mm (0.5") 15 mm (0.6")
Tendon unit 5-4 5-5 6-4 6-5
Number of strands 4 5 4 5
Duct Dimension in mm (Height x Width)
BS 5896 ASTM A416 Super Grade 270 744 735 930 919 1060 1043 1325 1304
Standard flat duct
Corrugated flat duct
Plastic duct PT-PLUS™
20 x 75
25 x 80
35 x 86
25 x 90
25 x 90
not available
Selected Design Considerations • Spacing of tendon supports:
0.75 to 1.2 m (conventional steel ducts) 0.75 to 1.0 m (plastic ducts PT-PLUS™)
• Minimum radius of curvature:
2.5 m 6.0 m
• Min. straight length at anchorage:
0.75 m
(vertical profile) (horizontal profile)
• A wedge draw-in of approximately 6 mm occurs at lock-off • Friction losses can vary fairly widely from one tendon to another and from one structure to another, depending on factors such as surface condition of strands, type and surface condition of ducts, material properties, installation methods and workmanship on-site. In general, the following friction parameters can be used, without additional consideration for anchorage losses: - Tendons in standard steel ducts: - Tendons in plastic ducts:
µ k µ k
= 0.20 = 0.001 = 0.14 = 0.001
(range: 0.16 ~ 0.22) (range: 0.0008 ~ 0.0012) (range: 0.12 ~ 0.15) (range: 0.0008 ~ 0.0012)
BONDED S
LAB
POST- TENSIONING
Stressing Anchorage VSL Type S E Grout tube
Wedges Strands
Duct
Casting Recess former
Anchor block
F
Type S 5-4 S 5-5 S 6-4 S 6-5
A 265 265 315 315
B 100 100 105 105
C 240 240 254 266
D 73 73 82 82
E 90 90 100 100
F 305 305 338 338
X 350 350 400 400
Subject to modification
Couplers VSL Type SK 600
D C
Grout tube Compression fittings Coupling block Flat duct B Casting Wedges
Strands
Type S 5-4 S 5-5 S 6-4 S 6-5
A 265 265 265 265
B 110 110 110 110
C 95 95 95 95
D 215 215 215 215
Subject to modification Dimensions in mm. Dimensions are valid for a concrete transfer strength of 25 MPa (Cube), 20 MPa (Cylinder).
Dead End Anchorage VSL Type H and Type P C
Type H
Grout tube AxB Seal
Flat duct
Type H 5-4 H 5-5 H 6-4 H 6-5
Bulb
A 310 390 390 490
B 70 70 90 90
C 750 750 950 950
B 75 75 80 80
C 370 370 435 435
Type P C Grout tube
AxB
Seal
P-plate Compression fittings
Type P 5-4 P 5-5 P 6-4 P 6-5
Dimensions in mm. Dimensions are valid for a concrete transfer strength of 25 MPa (Cube), 20 MPa (Cylinder).
A 250 300 260 410
VSLAB ™ Encapsulated Two Strand System F
E G Grout cap End anchor head Bearing plate
A C
Half shell
Duct
G
Clip Grout vent
B D
Wedge Gasket
High performance grout Encapsulated strand
Type
A
B
C
D
E
F
G
SA5-2
163
163
150
90
105
130
40
k5-2
163
163
150
90
105
130
70
Anchorage Reinforcement Details at Slab Edge Extra links where shown for S6-5 only
Anchorage at Slab Edge
Extra links where shown for S6-5 only
Grout vent
Place innermost links hard against casting as shown
Grout vent
Details at Edge Beam
Plan
Anchorage at Edge Beam The above sketches show the preferred arrangement for the local confinement reinforcement at the anchorages. Please consult your local VSL representatives for more details.
BONDE D S
LAB
POST- TENSIONING S
YSTEMS
Stressing Jack Clearance Requirements Jack type ZPE-23FJ B=Strand projection
C
DKP-5
A
DKP-6
Tendon unit 5-4 5-5 6-4 6-5 5-4 5-5 6-4 6-5
A (mm) 1100 1100 1100 1100 800 800 850 850
B (mm) 260 260 260 260 260 260 400 400
C (mm) 280 400 280 400 250 320 300 400
ZPE-23FJ DKP-5
DKP-6
Stressing Jack Data DKP-5/DKP-6
Jack type A B C D Stroke Piston area Capacity
B
A
ZPE-23FJ
Weight
(mm) (mm) (mm) (mm) (mm) (cm 2) (kN) (bar) (kg)
B
A
Internal Stressing Pocket 13 mm and 15 mm strand Details shown are typical and may vary for particular applications
B
A
Plan 450 30
420
Section A
50
Section B
790 116 195 200 47.10 230 488 23
560 162 105 150 200 31.03 147 473 19
615 240 84 165 200 49.26 230 467 30
External post-tensioning is well suited to bridges due to the resulting economies in construction costs and the high degree of corrosion resistance provided by the system. External tendons are easy to inspect and can be replaced if necessary. They are ideal for strengthening existing structures and have a multitude of applications in addition to bridges.
VSL ext ernal tendons consist of : • strand bundle; • polyethylene duct; • end and intermediate anchorages as well as tendon couplers; • grouting compound. External tendons, usually guided over deviation saddles, have many similarities to stay cables and permanent soil and rock anchors. Detailed information about design and construction is given in the VSL publication "External Post-Tensioning".
Bois de Rosset Viaduct, Switzerland
VSL External Post-tensioning System Components
Tendon deviation saddle
Stressing anchorage
Strand bundle and sheathing
Dead end anchorage
A wide selection of VSL anchorage types is available to meet the full range of practical requirements. In addition to the anchorages illustrated here, intermediate anchorages and couplers are also available . The strand bundle can be assembled from uncoated or individually greased and sheathed strands. The anchorages for these two types of tendon differ only in detail, the principle remains the same.
Ext ernal prestressing components, Anchora ge Type ECR
Ext ernal tendons at deviation saddle
B
Dimensions (mm)
Tendon
øE 1)
unit
A
B
øC
D
5-12
270
125
222
110
65 / 3.6
5-19
310
150
258
125
90 / 5.1
5-31
370
165
320
150
110 / 6.3
5-43
430
200
390
180
125 / 7.1
5-55
520
220
420
200
140 / 8.0
6-7
250
125
222
110
63 / 3.6
6-12
310
150
258
125
90 / 5.1
6-19
390
165
300
150
110 / 6.3
6-31
430
200
390
180
140 / 8.0
6-37
520
220
420
200
160 / 9.1
Notes : 1. Nominal external duct diameter / wall thickness 2. Other sizes are available upon request
øE
A
Anchorage Type EC R
D
øC
øE
Anchorage Type CS
Dead end anchorage with split bearing plate
Parallel monostrand tendon, guide tubes and stay pipe
Damper and neoprene boot
Guide pipe
VSL Staycable System 200 Bundle of monostrands Grease
HDPE stay pipe
Transition pipe
PE sheath
Strand
VSL Staycable System 200 SSI Bundle of monostrands
Adjustable stressing anchorage with threaded anchorage head and ring nut
Guide tube/ Extension tube
HDPE stay pipe
Grease
Guide tube/ Extension tube PE sheath
Strand
VSL Stay Cable System VSL Stay Cable System has been developed to fulfil the stringent requirements for the design, construction and maintenance of cable stayed bridges.
VSL Stay Cable System consists of: • a tendon made of multiple parallel 15mm high tensile steel strands; • each strand having an extruded coating of grease and polyethylene; • each strand having an individual polyethylene guide tube continuous from anchorage to anchorage (option for system 200 SSI only); • an outer sheath of thick walled polyethylene pipe; • anchorages that are prefabricated in the factory.
The feat ures of t he syst em are: • • • • • • • • •
high fatigue resistance of 200 MPa at 45% of tendon capacity through 2,000,000 load cycles; high degree of corrosion resistance with multi-layers of corrosion protection; excellent corrosion protection of strands during construction provided by extruded coating; simple erection of stay cable assembly without the weight of the tendon strands; simple Single Strand Installation of the tendon into the erected stay assembly; all strands are parallel within guide tubes with no risk of intertwining; no requirement for on-site grouting of cable; easy to adjust or monitor the tendon force at any stage of the cable life; able to remove and replace individual strands or entire cable for inspection or repair at any time without dismantling the installed anchorages; • Single strand stressing.
VSL Stay Cable System 200 H
min. 220
M K min
Connection sleeve
Boot Damper Pregrouted section
T
Bearing Pmin plate
S min
Transition pipe
Pregrouted section
.
O
O
50
M min
M min
Protection cap
R
L min
L min
Split shim
i i i
øG
I
i
i
i
O
P min
(mm)
i l (mm)
(mm)
219/6.3
1100
90
267/6.3
1350
105
273/6.3
1500
115
324/7.1
1650
135
355.6/8
1850
150
406/8.8
2100
155
419/10
2200
175
419/10
2400
190
508/11
2600
190
508/11
2700
220
559/12.5
2900
230
Dimensions in mm 1) Tendon units 6-4 and 6-7: dimensions on request. 2) Strand in accordance with Euronorm 138-79 super; other types of strand with 15 mm (0.6) diameter see VSL's
. 3) Valid for nominal concrete strength at 28 days: 45 MPa (cube), 36 MPa (cylinder). Local zone reinforcement not shown. 4) External diameter / wall thickness.
5) Min. height of anchor head allow an adjustability of ± 20 mm. 6) Dimensions valid only for load monitoring/adjustment. Min. required length for removal of cable to be determined acc. to project. 7) Threaded holes in bearing plate.
The VSL anchors are of similar construction, whether intended for installation in rock or in soil, and consist basically of the following three parts: • bond length; • free length; • anchor head for attaching to the component to be anchored. Depending upon the intended application and service life of the anchor, the type of rock or soil and the magnitude of force to be transmitted, each of these parts must be capable of satisfying the most varied requirements. These factors therefore influence the individual components of which the anchor will be constructed and the dimensions of the anchoring length and of the borehole. The anchor head is the main characterisic feature of the VSL anchor. It always consists of a stressing anchorage selected from the VSL prestressing systems. The other parts of the anchor may, however, be adapted to the particular requirements in regard to their length, load-carrying capacity, form and individual components. Depending upon its construction, the VSL anchor may then be used as a temporary or permanent anchor, as a test anchor or surveillance anchor, in certain circumstances it may comprise special protective measures against corrosion and mechanical damage. Further information about the soil and rock anchors will be found in the following VSL publications, which are obtainable on request: • VSL Measuring Technique; • VSL Soil and Rock Anchors - Examples from Practice.
Tie-down for a tall building
Securing a slope
Strengthening of a gravity dam
GROUN D A
NCHORS
Permanent VSL Strand Anchor Fully Encapsulated Section A.A Grout tube Bare clean strand
Corrugated sheath Anchor block
Internal spacer Bore hole
Be
External spacer
Smooth sheath (Polyethylene) or corrugated sheath
Section B.B Grout
Grout tubes
Grout tubes Bare clean strand
Smooth sheath
Greased and plastic coated strand External spacer
External spacer
Bore hole
Temporary VSL Strand Anchor Section A.A
Anchor block Bearing plate
Section B.B Bare clean strand
Spacer Bore hole
Bore hole
Stressing Anchorage VSL Anchorage Type E The VSL stressing anchorage Type E, is composed basically of an anchor block, wedges and bearing plate. A protective cap may also be fitted over the anchorage, if the latter must be accessible for surveillance purposes.
Fig. a: VSL anchorage Type ER
All the strands of an anchor are stressed simultaneously, but they are locked off individually by wedges in the conical bores in the anchor block. The range of VSL anchorages Type E enables tendons of 1 to 55 strands to be stressed, the principle of anchoring being the same from the smallest to the largest unit. The VSL stressing anchorages Type E are designed in principle to meet all the special requirements which may be demanded of an anchor. These requirements must certainly be known in advance to enable the anchor to be designed in detail accordingly. This is particularly necessary when the anchor is: • a surveillance anchor; • required to be restressed later; • required to be detensioned and again restressed; • required to be removed after use.
Surveillance Anchors A surveillance anchor is an anchor at which observations are carried out periodically and enables the stressing force to be read at any time. The table shows diagrammatically various forms of construction of the anchorage. The choice of a suitable type will depend upon the access available to the anchor, its required service life and economical considerations. For alternatives B and C, an anchor head of Type E is used, with a thread on it's external cylindrical surface. Restressi ng of Anchors Where force losses are to be expected as a consequence of soil movements or structural deformations, the anchor should be so constructed that it can be restressed. Anchor block for surveillance anchors: Alternative
A
B
C
Diagrammatic Presentation VSL anchor head
Type E normal
Type E with thread Type E normal
Force measurement with
Stressing jack
Stressing jack with coupling
Load cell, installed permanent or only when measuring
Protection of strand
Required
None
None
Fig. b: VSL anchorage Type E A
Alternatives A and B in the table are also suitable for restressing. To restress, the anchor block is lifted off from the bearing plate and shims are inserted between them. A third solution is to use VSL anchorage Type ER, which has a ring nut enabling the prestressing force to be adjusted (Fig. a).
Detensioning and Restressing of Anchors Where an anchor is to be detensioned later, an arrangement is required consisting of a different type of wedge and an accessory device incorporated in between the jack and the anchor head. With this arrangement the wedges can be released and again locked at any time thus enabling the anchor to be completely detensioned in one or more stages. Where strands must be cut off and not project beyond the anchor block, a VSL anchorage Type EA can be used (Fig. b). This works on the principle of an adjusting ring nut and a coupler being used for destressing.
Removable Anchors For temporary rock or soil anchors which are required to be removed after use, the VSL Removable Anchor System can fulfill such a special requirement. After destressing of the anchor, the entire strand tendon can be removed. All that is left behind in the ground is a small piece of steel component and the grout column with plastic sheathing which would not affect neighbouring foundation activities in the future. For details of the VSL Rock and Soil Anchor Systems please contact your local VSL branch office.
VSL Permanent Ground Anchors (Strand Type) Number of 15mm strands
Ultimate capacity (kN)
Drill hole dia. (mm)
4 7 12 19 27 31 37 43 55
1060 1855 3180 5035 7155 8215 9805 11395 14575
130 150 175 200 215 275 310 325 350
Jack type required
Sheath Diameter (mm) Smooth ID OD
Corrugated ID OD 65 80 100 125 125 150 150 200 250
85 100 125 165 165 195 195 256 270
70 84 102 130 130 160 160 210 260
75 90 110 140 140 170 170 220 270
ZPE-7/A ZPE-12/St2 ZPE-19 ZPE-460/31 ZPE-750 ZPE-750 ZPE-1000 ZPE-1000 ZPE-1250
Note: Where block outs, voids or drill hole casing are required, drill hole diameters and bearing plate dimensions should be confirmed with the local VSL office.
VSL Permanent Ground Anchors (Stressbar Type) Permanent Encapsulated Bar dia. mm
Ultimate capacity (kN)
Drill hole dia. mm
15 *15 **20 20 23 **25 26 29 32 36 38 40 56
190 191 188 325 450 295 575 715 870 1050 1225 1295 2460
100 100 100 100 125 125 125 150 150 150 150 150 175
Epoxy Coated
Temporary
Drill hole dia. mm
Drill hole dia. mm
75 75 75 75 87 87 87 100 100 112 112 112 165
50 50 50 50 75 75 75 87 100 100 100 100 125
Corrugated sheath mm ID OD 50 50 50 50 65 65 65 80 80 80 80 80 100
65 65 65 65 85 85 85 100 100 100 100 100 125
Jack type required ZPE-3 ZPE-3 ZPE-3 ZPE-3 ZPE-3 ZPE-3 ZPE-60 ZPE-7/A ZPE-7/A ZPE-7/A ZPE-200 ZPE-200 ZPE-19
Drill hole sizes are based on 10mm external cover *VSL Deformed Tie Bar **VSL Threadlok Bar
VSL Temporary Ground Anchors
VSL Temporary Ground Anchors
13mm Strand
15mm Strand
No. of 13 mm strands
Ultimate capacity kN
Minimum drill hole dia. mm
7 12 19 27
1362 2232 3534 5022
100 125 150 175
Jack type required ZPE-7 / A ZPE-12 / St2 ZPE-19 ZPE-460 / 31
No. of 15 mm strands
Ultimate capacity kN
Minimum drill hole dia. mm
7 12 19 27
1855 3180 5035 7155
100 125 150 175
Jack type required ZPE-12/St2 ZPE-19 ZPE-460/31 ZPE-500
New Airport Passenger Terminal Building Roof sliding, Hong Kong
Today's civil engineering structures and industrial plants are often assembled from large, heavy prefabricated components. This may be done for economic or technical reasons, or to save construction time. For projects in which cranes or other conventional handling equipment cannot be used because of excessive weight, dimensions or space limitations, VSL Heavy Lifting will often provide the most effective solution. VSL Heavy Lifting provides builders, engineers and owners with a broad range of advantages, including: • custom-designed solutions for each project; • the highest level of safety, based upon sound engineering practices and over two decades of experience; • economy and efficiency through the use of advanced an reliable hydraulic equipment.
Unique Solutions VSL will plan lifting, lowering or sliding operations and design the necessary temporary structures to suit your requirements. Sound engineering, clear thinking, the ability to innovate, and years of successful experience give you a guarantee of reliable and cost-effective solutions.
Tsing Ma Bridge, Hong Kong Lifti ng of portal beams, formwork and steel t russes (weight 270 ~ 420 to nnes)
Loire River Bridge, France Lift ing of 162 m long steel portal (2,400 tonnes) for the main span
Safety Safety is VSL's first priority. Our specialised hydraulic lifting equipment is designed for the highest level of reliability, and all equipment is rigorously tested and serviced through VSL's quality control and maintenance programme. VSL field services are also based upon a total commitment to safety, the extensive experience of our personnel and VSL's exceptional record provide further assurance of reliable performance.
Flexibility VSL's heavy lifting equipment includes a large selection of hydraulic jacks, pumps, control units, monitoring devices and jacking frames. This range of equipment gives us the capability to perform virtually any project requiring lifting, lowering or sliding.
Segment Erect ion, Normandy Bridge, France
Flat Jacks Flat jacks are widely used for a multitude of civil engineering and construction applications such as: • under pinning; • prestressing of columns; • counteracting sinking foundations; Pump • prestressing of road works or airport runways; • prestressing concrete in confined spaces; • lifting and lowering of bridge superstructures for bridge bearing adjustments; • counteracting loads applied during backfilling; • lifting heavy weights; Flat Jack • 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 at pressures of up to 13.5MPa into the peripheral ring, moving the lifting plates aparts, so that a force is applied with a maximum lifting stroke of 25mm per jack. Other shapes of flat jacks are available upon request.
Type
Outside diameter D mm
Maximum force at 13.5MPa kN
Effective area at zero extension 103mm2
T Thickness ** mm
E Maximum travel mm
Installation gap mm
120c 150c 220c 250c 270c 300c 350c 420c 480c 600c 750c 870c 920c *1150c
120 150 220 250 270 300 350 420 480 600 750 870 920 1150
85 155 390 525 605 780 1080 1605 2170 3470 5400 7385 8975 13635
6.4 11.5 29 39 45 58 80 119 161 257 400 547 665 1010
25 25 25 25 25 25 25 25 25 25 25 25 25 25
25 25 25 25 25 25 25 25 25 25 25 25 25 25
38 38 38 38 38 38 38 38 38 38 45 45 45 50
* 1150c Flat Jacks are specially produced to order and require longer lead times ** Flat Jack thickness may vary ±3mm
Plan
Closed
Fully Inflated
Hong Kong Stadium, Hong Kong
Bar Systems VSL has been manufacturing and designing bar systems in Australia for use by the construction industry since 1971. These have proven to be one of the most popular tools of Engineers wishing to induce and control loads and forces in structures. The systems range from High Tensile Cold Worked Stressbar to Low Tensile Architectural Tendons, all with compact and easy to assemble fittings. A range of diameters is available to give a wide selection of bar forces. The prestressing force is anchored at the end of the bar by a rolled thread, nut, washer and bearing plate. Where necessary bars can be joined with threaded couplers, and clevis fittings may be used where pin connections are required. The VSL bar system complies with the requirements of AS1313, AS1314, BS4486, ASTM-A722 and ISO 6934.
VSL Bar Configurations Thread Details
Architectural
Max. Bar Length m Export containers
VSL Bar
Fully
Short
Right
Left
Cold
Hot
Components
system
CTA
CTS
hand
hand
rolled
rolled
available
20ft.
40ft.
•
• •
• •
• •
• •
• •
5.85
11.85
5.85
5.85+6.0
5.85
11.85
5.85
11.85
CT Stress Bar
15-40mm CT Bar 56-73mm CT Bar Deformed Bar
15mm Tie Bar
•
•
•
Threadlok Bar
20-25mm
•
•
•
Application VSL bar systems are ideal for the economic application of post-tensioning forces on relatively short tendons. Through the use of threaded connections and anchorages they are simple to use and lend themselves to many applications.
Typical Applications are: Buildings • Prestressed Beams and Columns • Precast Connections Bridges • Stay Cable Hangers • Prestressed Segments • Strengthening (Timber & Steel Bridges) • Tension Piles and Caissons Wharves & Jett ies • Stressed Deck Planks • Tie Backs
Anchors • Permanent and Temporary Ground Anchors • Uplift Anchors (Dam & Foundation) • Roof Bolting • Slope Stabilisation • Crane Bases • Light Towers Specialist Engineering • Heavy Lifting • Formwork Ties or Hangers • Frame Ties • Pile Testing • Architectural Ties
Charact erist ic Propert ies VSL Bar Properties are nominally as listed in the Tables.
Corrosion Protect ion All bars and fittings must receive protection when installed under permanent conditions. In normal concrete construction the use of galvanised duct, injected with grout, provides good protection. Anchorage recesses must also be filled with cement mortar to protect these ends.
Bars When bars are used in an exposed environment then one of the following coating systems may be used: • single coat of inorganic zinc; • three coat epoxy paint system; • molybond coated bar ends only; • greased and sheathed in poly tube; • galvanising - (Threadlok Bar only). A combination of the above systems may also be specified. Consideration must also be given to the threaded ends to ensure correct installation of fittings after coating. Fittings Fittings may be treated as above but with preference given to galvanising.
Temporary Bar Anchors Anchors used in a temporary environment may be used without protection apart from grout cover.
Permanent Bar Anchors These anchors require installation into corrugated polyethylene sheathing to provide multiple levels of protection. This is accomplished by the internal grout and sheathing barrier. Additional protection may also be used by incorporating the above bar coatings.
STRESSBAR
VSL CT Stressbar Characteristic Properties Nominal Nominal Nominal Nominal tensile Nominal 0.1% Characteristic Strength Minimum Appr. Modulus Major Dia. Thread kN Dia. area mass strength proof stress elongation of elasticity of thread pitch mm
sq. mm
kg/m
MPa
MPa
%
kN/sq.mm
mm
mm
15
177
1.52
1080
930
190
165
6
170
17.2
6
20
314
2.39
1030
835
325
260
6
170
21.2
6
23
415
3.46
1080
930
450
385
6
170
25.2
6
26
531
4.40
1080
930
575
495
6
170
28.2
6
29
661
5.44
1080
930
715
615
6
170
31.2
6
32
804
6.59
1080
930
870
750
6
170
34.4
6
36
1018
7.86
1030
835
1050
850
6
170
37.4
6
38
1134
9.23
1080
930
1225
1055
6
170
40.4
6
40
1257
9.72
1030
835
1295
1050
6
170
41.4
6
56
2463
20.74
1000
810
2460
1995
6
205
58.5
6
73
4185
34.68
1000
810
4190
3390
6
205
76.5
6
Max. force 0.1% Proof
Note: 1. Relaxation properties, as per AS1313, are 4% maximum at 1000 hrs when loaded to 70% of minimum breaking load. 2. Fatique results exceed two million cycles when loaded over a stress range of 80 N/sq.mm. (For unbonded tendon only). 3. Minimum bending diameter = 200 x Bar Dia.
C
Stroke E
L
200
D
Hydraulic Stressing Jack and Accessories
Jack Clearance Details (mm) Jack
F
Recess Details (mm) Bar
model
F
G
H
RH303
390
75
125
ZLP-100/80
560
150
150
ZLP-200
1120
110
200
ZPE-460 / 31
750
250
300
Jack Details
Recommended
Minimum
Normal bar
Jack
Dia.
A
B
C
A
B
C
Dia.
model
15, 20
125
125
75
100
100
70
15, 20
RH303
23, 26
150
150
80
130
130
29, 32, 36
150
150
100
130
38, 40
175
175
112
56
220
220
73
320
320
Jack Dimension (mm) Capacity Weight Stroke
kN
kg
121 180
76
295
13.5
75
23, 26, 29
130
90
32, 36, 38 ZLP-100/80 280 270
80
996
56
150
150
100
46
250
200
200
200
56
200 612
300
1980
249
250
300
300
200
73
ZPE-460/31 485 410
100
4570
295
ZLP-200
D
E
Permanent VSL Stressbar Anchor Fully Encapsulated
Nitroseal PX220 Spherical nut Hot-Dip galvanized protective cap
Protective grease
Protective grease Spherical washer
Grout tube inner
Hot-Dip galvanized bearing plate with trumpet Grout Grout tube outer O-ring H.D.P.E. smooth or corrugated bore sheathing over free length
A
External spacers at 1500 max. centres Corrugated sheathing (Polyethylene)
A
CT Stressbar Internal spacers at 1500 max. centres
Corrugated sheathing (Polyethylene)
Grout tube outer Grout tube inner Bore hole
CT Stressbar Internal spacers
Section A-A Steel nose cone
Temporary VSL Stressbar Anchor Spherical nut
Spherical washer Heat shrink & sleeve
Grout tube
Bearing plate
B
Grout A
Greased bar over free length H.D.P.E. smooth sheathing over free length Grout tube
B
Spacers CT Stressbar epoxy coated if required
Bore hole
CT Stressbar
Spacers at 1500 max. centres Heat shrink
Section B-B
F5 Freeway, Heathcot e NSW
VSL RETAINED EARTH is a composite soil reinforcing system which employs welded wire mesh to improve the shear and compressive strength of an earth backfill. A RETAINED EARTH structure is a stable, unified gravity mass which may be designed for use in a broad variety of civil engineering applications. In projects ranging from commercial retaining walls to highway bridge abutments, VSL RETAINED EARTH has found widespread use and acceptance as a major construction system. The effective principle of RETAINED EARTH involves the transfer of stresses from the soils to the reinforcing mesh through bearing. Bearing pressure is developed on the projected areas of the mesh crossbars, and the pressure is in turn transferred to the longitudinal bars. The longitudinal bars are thus placed in tension, which enables the soil mass to withstand loads in the direction of the reinforcement. In addition to the significant performance advantages, the VSL RETAINED EARTH system is also extremely economical to design and construct. The system consists of only three components, reinforcing mesh, precast facing panels and backfill material. This simplicity allow construction to proceed easily and rapidly. Cost savings of up to 50% are regularly realised when compared with traditional stabilisation systems.
Fast , Easy and Economical The construction of a RETAINED EARTH structure is extremely straightforward. A five-man crew using standard construction equipment will average 75 square metres of wall per shift, and can place up to 140 square metres per shift.
Perspective View VSL RETAINED EARTH Retaining Wall
Complete Capabilities VSL provides the client with a complete range of design and engineering services for a RETAINED EARTH structure. VSL employs the most advanced Computer Aided Design (CAD) systems available. Services provided include analysis of external stability, internal stability, bridge load, overturning and base sliding. In addition, VSL furnishes all preliminary drawings, shop drawings and complete erection sequencing documents as required.
Complete Flexi bilit y The VSL RETAINED EARTH concrete facing panels are available in a broad range of textures and colours. Because local materials are used in the production of these precast panels, the exposed surface can easily be coloured to complement the natural surroundings. Standard RETAINED EARTH panel treatments include raised relief, sandblast finish, exposed aggregate, and conventional smooth face concrete. These are only a very few of the possibilities however. Non-concrete faces, such as welded mesh or steel faced are also available and can be used to make temporary structures. Temporary wall with welded mesh face
Fractured fi n finish
Ashlar f inish
Steel face finish
Raised relief finish
Central Plaza Buil ding, Hong Kong
THE VSL Climbform System is a self climbing heavy duty construction platform used primarily to lift static panel vertical wall formwork. The system provides the wall designer with complete flexibility in both the structural design and selection of finishes.
Standard feat ures include: • custom designed formwork panels which may be ganged in any shape or size to lift as one unit; • form heights ranging from 2.5 to 4.0 metres; • unobstructed access to the forms for: - cleaning and oiling - fixing of door frames and blockouts - reinforcement and reinforcing fabric fixing, including prefabricated reinforcement; • truss members of fixed height assembled in "Meccano like fashion" to form a platform of any plan shape or size; • easy levelling and plumbing of the external platform, which is typically supported on four, six or eight seatings; • variation of wall thickness by moving the internal or external forms; • parking the internal platforms at mid-lift to facilitate blockout and reinforcement fixing; • cycle times as low as three days; • access to external walls for curing; • hanging access stairway.
VSL Cli mbform an d Table Formwork Systems
Optio nal feat ures include: • support of concrete placing booms on the platform; • access hatches and/or temporary platforms to install precast stairs; • external trailing platforms for: - patching of the tie-bolt holes - concrete finishing and curing - welding of beam stubs/brackets to support steel floor beams; • provision to allow manhoists to service the top working platform; • provision to locate tower cranes within internal and corridor platforms; • collapsible door formers.
Tsing Ma Bridge, Hong Kong Climbformed piers and Slipformed pylons
The VSL Climform System is recognised as the most powerful commercial formwork system available in the world today and has been specified on the largest and tallest vertical structures in Asia and Australia. The VSL Slipform System has been used in the construction of silos, storage tanks, containment structures, chimneys, cooling stacks and bridge piers and pylons for over 20 years. Slipforming is advantageous when rapid construction between 2 and 6 m per 24 hours is required which results from continuous working and forms a monolithic structure free from construction joints. The system is raised by hydraulic jacks with upper working platforms for reinforcement fixing and concrete placement and a suspended scaffolding for finishing works.
Alsons Cement Plant, Philippines
VSL Formtravellers have been developed in conjunction with the in-house design of balanced or free cantilevering bridge structures. The formtraveller of either overhead truss or underslung type, is a hydraulically driven falsework system with built in working platforms and formwork panels. VSL services include design, supply, 1st assembly and commissioning, or a total turnkey package incorporating the operation of the system with the post-tensioning application. VSL System Formwork services include the design of the formwork systems, hire of the Climbform and Slipform Systems, prefabrication of forms and platforms, supervision and 1st assembly of the formwork and running of the systems.
Phu Luong Bridge, Vietnam
As a specialist involved in the design and construction of bridges, VSL has considerable experience and expertise in: • • • •
conceptual, preliminary and final detailed design of bridge structure; developing construction methods with full engineering; full design and detailing for formwork and erection systems; on-site construction of selected elements of the structure, from post-tensioning through to entire bridge superstructures.
The application of this knowledge by VSL assists owners, developers, main contractors and consultants with initial design concepts, alternative designs and construction methods. The result for the project is that: • the cost is minimised; • the methods are simplified; • the time is reduced;
• the quality is enhanced; • the safety is improved; • the value of the structure is increased;
Some of the very different projects successfully carried by VSL are:
Phu Luong Bridge, VIETNAM Balanced Cantilever Construction
VSL Scope of Work: Design of the four lane main superstructure consisting of a main span of 102 m and side spans of 65m. Design, supply and commissioning of the travelling formwork system and supply of the post-tensioning, bearings and movement joints.
Tsing Ma Bridge, HONG KONG Pylons and Approach Pier Construction
VSL Scope of Work: Construction of two number 206m high concrete pylons by slipforming including all concreting and reinforcement fixing. Heavy lifting of steel trusses for portal beams up to 420 tons. Design, supply and operation of the 4 VSL Climbforms Systems for the 60m high approach piers.
Ma On Shan Pipe Bridge , HONG KONG Incremental Launch Construction
VSL Scope of Work: Alternative design and construction of superstructure including casting of segments, reinforcement fixing and post-tensioning. The bridge has a length of 330m and spans of 33m for carrying 2 No. 1.2m diameter pipes crossing the river to the waste water treatment plant.
Deck ing Over Roadway, Lam Tin, HONG KONG Precast Girder Construction
VSL Scope of Work: Supply and erect 87 No. 300 ton, 3m deep precast beams. Design, supply and operation of the erection gantry and launching.
Seoul Expressway Phase 1, KOREA Precast Segmental Construction
VSL Scope of Work: Design and commissioning of formwork for the 3,600 precast box girder segments. The production on CAD of segment fabrication shop drawings. The design of the erection truss and full erection of the segments. Supply and installation of permanent and temporary posttensioning.
Hung Hom By-Pass, HONG KONG Precast Segmental Construction
VSL Scope of Work: Supply and installation of post-tensioning, bearings and movement joints. Supply and operation of the erection gantry for the erection of 1650 No. precast segments. The spans vary from 26 to 45 m with segment weight 40~83 tons.
Struct ural Bearings Positioned between two structures to accommodate load transfer and relative movements which may cause damage. Bearings can be divided into two types, namely elastomeric and mechanical (disc or pot bearings). VSL services include design, testing, supply and installation.
Slip Joint s The slip joint has been developed to fill the need for a reliable and easily applied slip joint material on load bearing brickwork or under cast concrete slabs. It is designed to centralise loads and accommodate shrinkage and movement. Composed of polished stainless steel sliding against PTFE coated high grade natural rubber.
Movement Joint s Single Element Used in building, pedestrian and vehicular structures to seal the gap between two structures so that they can move independently without adversely affecting each other. The joints are of either aluminium or steel with a flexible seal spanning between them and can accommodate movement ranges between 15 mm to 40 mm.
Movement Joint s Mult i Element Used in highway and bridge structures with large movements due to the effects of concrete shrinkage, thermal and seismic effects or differential settlement and ground movements. Typical movement ranges from 65 mm per single seal upto 1 m when connected together. VSL services include design, supply, 1st installation and long term maintenance.
POST-TENSIONING SYSTEM
The Company
1
Multistrand Post-Tensioning
3
Bonded Slab Post-Tensioning
15
External Post-Tensioning
21
Stay Cables
23
Ground Anchors
25
Heavy Lifting
29
Stressbar
31
Retained Earth
35
System Formwork
37
Bridge Engineering
39
Structural Products
41
BEARINGS, MOVEMENT JOINTS & SYSTEM FORMWORK
ISO 9001: 1994
ISO 9002: 1994
Certificate No: CC421
Certificate No: CC416
