jännepunos käyttöseloste

Transkriptio

1 jännepunos käyttöseloste

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3 sisällys 1. NEDRI SPANSTAAL BV TARTUNNATTOMAT JÄNTEET JÄNNEMENETELMÄN KÄYTTÖSELOSTE 2. BBR VT CONA cmm unbonded post-tensioning system European Technical Approval 3. Assesment of CONA CMM-01 Strand with Special Anchorage Configuration & Reinforcements Load Transfer and Crack Width Evaluation ETA:sta poikkeavat sallitut ankkureiden sijoittelut (vain singel-ankkurit) 4. betoniyhdistyksen käyttöseloste tyyppi 2b jänneteräs 5. laadunvarmistus jännitystöissä 6. Työmaakohtainen työturvallisuussuunnitelma

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5 NEDRI SPANSTAAL BV TARTUNNATTOMAT JÄNTEET JÄNNEMENETELMÄN KÄYTTÖSELOSTE

6 NEDRI SPANSTAAL NEDRI SPANSTAAL BV TARTUNNATTOMAT BV TARTUNNATTOMAT JÄNTEET JÄNTEET JÄNNEMENETELMÄN JÄNNEMENETELMÄN KÄYTTÖSELOSTE KÄYTTÖSELOSTE NEDRI SPANSTAAL BV TARTUNNATTOMAT JÄNTEET JÄNNEMENETELMÄN KÄYTTÖSELOSTE 1. JÄNNEMENETELMÄN KUVAUS 1. Nedri JÄNNEMENETELMÄN Spanstaal BV:n - tartunnaton KUVAUS jänne on muovipäällysteinen jännepunos. Punoksen ja päällysteen välitila on täytetty pysyvästi plastisena säilyvällä rasvalla. Nämä suojatut jänteet Nedri asennetaan Spanstaal sellaisinaan BV:n - betonivaluun. tartunnaton jänne Suojauksella on muovipäällysteinen mahdollistetaan jännepunos. jännepunoksen Punoksen jännittäminen ja betonin päällysteen kovettumisen välitila on jälkeen. täytetty pysyvästi Jänneteräs plastisena liittyy ympäröivään säilyvällä rasvalla. betonirakenteeseen Nämä suojatut pysyvästi jänteet ilman asennetaan sellaisinaan betonivaluun. Suojauksella mahdollistetaan jännepunoksen jännittäminen betonin kovettumisen jälkeen. Jänneteräs liittyy ympäröivään betonirakenteeseen pysyvästi ilman Jokainen jännepunos ankkuroidaan ankkurikappaleella ja lukitaan ankkurin kiilapesään 1. JÄNNEMENETELMÄN KUVAUS Nedri Spanstaal BV:n - tartunnaton jänne on muovipäällysteinen jännepunos. Punoksen ja päällysteen välitila on täytetty pysyvästi plastisena säilyvällä tartuntaa. rasvalla. Nämä suojatut jänteet asennetaan sellaisinaan betonivaluun. Suojauksella mahdollistetaan tartuntaa. jännepunoksen jännittäminen betonin kovettumisen kartiokiilalla. jälkeen. Jänneteräs liittyy ympäröivään betonirakenteeseen pysyvästi ilman tartuntaa. Jokainen jännepunos ankkuroidaan ankkurikappaleella ja lukitaan ankkurin kiilapesään kartiokiilalla. Jännevoima siirtyy rakenteeseen pysyvästi pääteankkureiden välityksellä. Toimintaperiaatteet tartunnattomasta jänteestä on esitetty kuvissa 1. ja 2. Käytettävän jännetyypin ominaisuudet, nimellismitat ja -lujuudet on esitetty liitteessä 1. Jokainen jännepunos ankkuroidaan ankkurikappaleella ja lukitaan ankkurin kiilapesään Jännevoima kartiokiilalla. siirtyy rakenteeseen pysyvästi pääteankkureiden välityksellä. Toimintaperiaatteet tartunnattomasta jänteestä on esitetty kuvissa 1. ja 2. Käytettävän Jännevoima siirtyy jännetyypin rakenteeseen ominaisuudet, pysyvästi nimellismitat pääteankkureiden ja -lujuudet välityksellä. on esitetty liitteessä 1. Toimintaperiaatteet tartunnattomasta jänteestä on esitetty kuvissa 1. ja 2. Käytettävän jännetyypin ominaisuudet, nimellismitat ja -lujuudet on esitetty liitteessä 1. Aktiiviankkur Jännepunos Passiiviankkuri Aktiiviankkuri Jännepunos Passiiviankkuri Aktiiviankkur Jännepunos Passiiviankkuri Kuva 1. Yksittäispunosankkuri Kuva 1. Yksittäispunosankkuri Kuva 1. Yksittäispunosankkuri Kuva 2. Monipunosankkuri Kuva 2. Monipunosankkuri Kuva 2. Monipunosankkuri

7 NEDRI SPANSTAAL BV TARTUNNATTOMAT JÄNTEET JÄNNEMENETELMÄN KÄYTTÖSELOSTE 2. KÄYTETTÄVÄT JÄNNETERÄKSET 2.1 Jänneteräspunokset Jänteissä käytössä olevat teräspunokset ovat ominaisuuksiltaan samoja punoksia, joita käytetään päällystämättöminä sekä tehdasvalmisteisissa että paikalla valetuissa jännitetyissä rakenteissa tartuntajänteinä. Jänneteräksellä tulee olla voimassaoleva ja hyväksytty käyttöseloste. Jänneteräksestä on oltava ainetodistukset. Nimellisarvojen on vastattava suunnitelmissa edellytettyjä arvoja. 2.2 Jänneteräksen suojaus Jänneteräksen suojauksen muodostavat teräspunoksen päälle valettu muovipäällyste (liite 11) sekä punoksen ja päällysteen välitilan täysin täyttävä suojarasva. Jänteen tulee olla koko pituudeltaan suojattuna. Mahdolliset käsittelyn päällystevauriot korjataan välittömästi poistamalla päällystemuovin vaurioitunut kohta ja täydentämällä rasvaus, Vioittuneen kohdan päälle asennetaan halkaistu päällysputken kappale, joka tiivistetään teippaamalla. Vähäiset vauriot voidaan korjataan pelkästään teippaamalla. Väliankkureita käytettäessä jännittämistyön ajaksi poistettu päällystemuovi on asennettava takaisin paikalleen ja teipatava koko matkalta. Ankkuripäät on myös suojattava teipaamalla. 3. JÄNTEIDEN TUENTA Jänteet asennetaan muottiin tukien varaan. Jänteiden suurin sallittu tukiväli on 1000mm mm. Tiedot tukivälistä saa liitteestä 2. Pienin sallittu kaarevuussäde on 2,5 metriä. Jännitysankkurin kiinnitys päätymuottiin tehdään liitteen 3. mukaisilla asennusosilla. Valun sisälle jäävät kiinteät passiiviankkurit sidotaan kannatinteräkseen jänteiden tapaan tai välittömästi ankkureiden ympäristössä olevaan raudoitukseen, tarvittaessa työterästen avulla. 4. ANKKUROINTI 4.1 Ankkurityypit Jänteen pysyvään ankkurointiin tarkoitetut, sekä jännitysankkurit (aktiiviankkurit) että kiinteät ankkurit (passiiviankkurit) ovat perusosiltaan samanlaisia. Ankkuri on esitetty liitteessä 5. Väliankkurina voidaan käyttää liitteen 6. mukaista ankkurityyppiä (fixed coupler). Väliankkuri toimii työnaikaisena ankkurina ja jää paikalleen rakenteeseen. Liitteiden 5. ja 6. pysyvien ankkureiden runko on liitteen 4. mukainen levymäinen valuteräskappale, jonka välityksellä jännevoima siirtyy betonirakenteeseen. Ankkurilevyssä on kartionmuotoinen keskiöreikä jänneteräksen läpivientiä ja lukitusta varten. Jänneteräs lukitaan ankkurilevyyn kartiokiiloilla. Ankkureihin ei liity mitään vakioraudoitetta, vaan ankkurialueen raudoitus mitoitetaan ankkurin ja ankkuriryhmän aiheuttamalle halkaisuvoimalle tavalliseen tapaan rakennemittojen ja halkaisuvoiman perusteella. 4.2 Ankkureiden sijoittaminen rakenteeseen Ankkurit sijoitetaan normaalisti laattarakenteen reunaan tai työsaumaan yhteen vaakariviin ja pystysuunnassa laatan keskikorkeudelle. Ankkurit ovat vaakarivissä tasavälein tai ryhminä minimivälein. Rinnakkain niputettujen jänteiden ankkurit niputetaan vierekkäin toisiinsa kiinni. Ankkureiden pienimmät keskiö- ja reunaetäisyydet on esitetty liitteessä 7. ja 8. betonin lujuuden ollessa 24 Mpa / 150mm kuutio. Ankkurit on esitetty niiden tavallista käyttöä vastaavasti laatan reunaan sijoitettuina. Palo-sekä rasitusluokkien vaikutus reunaetäisyyksiin tulee tarkastella aina erikseen. Mikäli liitteessä esitetty sijoittelu ja siihen liittyvät reuna-sekä keskeisetäisyydet eivät ole suo-

8 NEDRI SPANSTAAL BV TARTUNNATTOMAT JÄNTEET JÄNNEMENETELMÄN KÄYTTÖSELOSTE raan sovellettavissa, voidaan ankkureiden sijoittelu tutkia betoninormien mukaisesti. Kaikissa tapauksissa ankkureiden aiheuttamat halkaisuvoimat on laskettava ja raudoitettava yleisten laskentamenetelmien ja betoninormien mukaisesti. Ankkureiden sijoittamisessa rakenteeseen on otettava huomioon jännitystunkin tilantarve. Tunkin vaatima tilantarve on esitetty liitteessä Ankkurin suurin voima Teräksen suurin sallittu voima saa olla heti jännitystyön päätyttyä enintään F0 = 0,90 Fp0,1 Jännitystyön aikana saa teräksen jännitys hetkellisesti nousta arvoon F0 = 0,95 Fp0,1 Suurimmat sallitut voimat on esitetty liitteessä 10. tunkin sylinterissä olevalta asteikolta, mittaamalla tunkin liikkuvan osan siirtymä tai mittaamalla jänteen veto-osan pituus ennen ja jälkeen jännittämisen. Jännityssuunnitelmassa esitetään jännevoiman edellyttämät venymät alkaen jännittämisvoimasta F0 = Jännevoimaan vaikuttavat tekijät Jänteen suunnanmuutosten ja tahattoman mutkaisuuden ns. aaltoisuuden aiheuttama kitkahäviö jännevoimassa lasketaan yleisen kaavan mukaisesti: Fx = F 0 e - μ * (α + k * x) jossa; 5. JÄNTEIDEN JATKOKSET Jänteiden jatkosankkuri Fixed Coupler Cona CMM on erikoisosa jännepunoksen jatkamiseen. Cona jatkosankkuri on erikseen esitetty liitessä 5. ja 6. Fx kn F0 kn jännevoima tutkittavassa jänteen pisteessä jännitysvoima ankkurin kohdalla (x = 0 m) 6. JÄNNITTÄMINEN 6.1 Laitteisto ja jännittäminen Jänteen jännittäminen suoritetaan hydraulisella tunkilla. Jännittäminen tehdään joko jänteen toisesta päästä tai molemmista päistä samanaikaisesti tai vuorotellen. Betonin vähimmäislujuus ennen jännitystöiden aloitusta on 24 Mpa / 150mm kuutio. 6.2 Voiman ja venymän mittaus Jännittämisvoima mitataan epäsuorasti nestepumpun manometrilla. Jännityslaitteiston pitää olla kalibroitu siten, että hydraulipaineen ja tunkin antaman vetovoiman riippuvuus (tunkin sylinterin tehollinen ala) tunnetaan tarkasti. Painemittarin pitää olla tarkastettu. Venymä määritetään suoraan mittaamalla matka, jonka jänne venyy jännitystyön aikana. Venymä saadaan joko suoraan μ rad -1 kitkakerroin μ = 0.06 rad-1 (CONA CMM n06-150) k rad/m aaltoisuusluku k = rad/m (= 0.50 /m) k = rad/m (= 0.25 /m) (CONA sauma pystyasenossa) α rad jänteen suunnanmuutosten summa ankkurin ja pisteen x välillä abs. kulmayksikköinä x m jänteen pituus ankkurista tutkittavaan pisteeseen tieto: 1 rad = 1 m/m = 1 Muovipäällysteellä ja rasvatäytöllä varustetulle punosjänteelle käytetään seuraavia kitka-arvoja: Kitkakerroin μ = 0,06 rad-1 Aaltoisuusluku k = 0,5 /m

9 NEDRI SPANSTAAL BV TARTUNNATTOMAT JÄNTEET JÄNNEMENETELMÄN KÄYTTÖSELOSTE Ankkurointiliukuma aiheuttaa vähennyksen jännevoimaan ankkurin läheisyydessä. Lukituskiilojen kiinnittymistä on tarkkailtava jännitystyön aikana ja ankkurointiliukumat on huomioitava laskennallisessa jänteen kokonaisvenymässä. Ankkurin lukitusliukuman suuruus on asennuskohteesta riipuen: Akt.ankkuri (S) A tai H 1.BA 6 mm L. pass.ankkuri (F) A tai H 2.BA 3 mm Pass.ankkuri (F) A CONA CMM mm Pass.ankkuri (F) A CONA CMM mm Liite 1. ETA sivu 37. Liite 2. ETA sivu 10. Liite 3. ETA sivu 33. Liite 4. ETA sivu 22. Liite 5. ETA sivu 21. Liite 6. ETA sivu 29. Liite 7. ETA sivu 30. Liite 8. ETA sivu 31. Liite 9. ETA sivu 32. Liite 10. ETA sivu 28. Liite 11. ETA sivu 23. Jännepunosjärjestelmän ETA-hyväksyntä on saatavissa Naulankanta OY:ltä tai ladattavissa KB- VT nettisivulta php?id=208&no_cache=1&cid=975&did=503&sech ash=50b4ab22 Pass.ankkuri (F) A CONA CMM mm Akt.ankkuri = Aktiiviankkuri L. pass.ankkuri = Lukittu passiiviankkuri Pass.ankkuri = Passiiviankkuri 7. ANKKUREIDEN SUOJAUS Kun jännitystyö on valmis sekä työ on hyväksytty, katkaistaan jänteiden päät. Katkaisu voidaan suorittaa joko polttoleikkaamalla, hydraulisella puristimella, sähkökatkaisupuikolla, katkaisulaikalla tai muulla tarkoitukseen soveltuvalla menetelmällä. Jänteen lukitus suojataan ankkuriin kuuluvalla kierrekannella, joka samalla toimii lukituskohdan rasvauksen jälkeen rasvasuojauksena. Ankkurivaraus täytetään tiiviisti kutistumattomalla, rakenteen rasitusluokkavaatimukset täyttävällä betonilla tai laastilla

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11 bbr vt cona cmm unbonded posttensioning system European Technical Approval

12 BBR VT CONA CMM Unbonded Post-tensioning System European Technical Approval ETA 06/0165

13 0432 ETA-06/0165 BBR VT CONA CMM Unbonded Post-tensioning System with 01, 02 and 04 Strands BBR VT International Ltd Bahnstrasse 23, 8603 Schwerzenbach (Switzerland) S P E C I M E N 0432-CPD /1 11 Responsible BBR PT Specialist Company The delivery note accompanying components of the BBR VT CONA CMM Post-tensioning System will contain the CE marking. Company Year PT Specialist Assembly and installation of BBR VT CONA CMM tendons must only be carried out by qualified BBR PT Specialist Companies. Find the local BBR PT Specialist Company by visiting the BBR Network website Company European Organisation for Technical Approvals Europäische Organisation für Technische Zulassungen Organisation Européenne pour l Agrément technique ETAG 013 Guideline for European Technical Approval of Post-tensioning Kits for Prestressing of Structures CWA 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.

14 ÖSTERREICHISCHES INSTITUT FÜR BAUTECHNIK A-1010 Vienna, Schenkenstrasse 4 Tel.: +43(0) Fax: +43(0) European technical approval relating to construction products mail@oib.or.at Member of EOTA English translation, the original version is in German Authorised and notified according to Article 10 of the Council Directive 89/106/EEC of 21 December 1988 on the approximation of laws, regulations and administrative provisions of Member States ETA-06/0165 Handelsbezeichnung Trade name Zulassungsinhaber Holder of approval Zulassungsgegenstand und Verwendungszweck Generic type and use of construction product Geltungsdauer vom Validity Herstellwerk from bis zum to Manufacturing plant Diese Europäische technische Zulassung umfasst This European technical approval contains Diese Europäische technische Zulassung verlängert This European technical approval extends BBR VT CONA CMM Spannverfahren ohne Verbund mit 01, 02 und 04 Litzen BBR VT CONA CMM Unbonded Post-tensioning System with 01, 02 and 04 Strands BBR VT International Ltd. Bahnstrasse 23 CH-8603 Schwerzenbach (ZH) Switzerland Litzen-Spannverfahren, intern, ohne Verbund, für das Vorspannen von Tragwerken Post-tensioning kit for prestressing of structures with internal unbonded strands BBR VT International Ltd. Bahnstrasse 23 CH-8603 Schwerzenbach (ZH) Switzerland 39 Seiten einschließlich 19 Anhängen 39 Pages including 19 Annexes ETA-06/0165 mit Geltungsdauer vom bis zum ETA-06/0165 with validity from to European Organisation for Technical Approvals Europäische Organisation für Technische Zulassungen Organisation Européenne pour lʼagrément technique

15 Page 2 of European technical approval ETA-06/0165 Validity from to , extends ETA-06/0165 with validity from to Member of EOTA Table of Contents EUROPEAN TECHNICAL APPROVAL ETA-06/ TABLE OF CONTENTS... 2 I LEGAL BASES AND GENERAL CONDITIONS... 5 II SPECIFIC CONDITIONS OF THE EUROPEAN TECHNICAL APPROVAL DEFINITION OF PRODUCT AND INTENDED USE Definition of product Intended use CHARACTERISTICS OF THE PRODUCT AND METHODS OF VERIFICATION... 7 PT SYSTEM Designation and range of the anchorages and couplers Designation Anchorage Fixed and stressing couplers Layout of anchorage recesses Designation and range of the tendons Designation Range CONA CMM n CONA CMM n CONA CMM n06c Friction losses Support of tendons Slip at anchorages Centre spacing and edge distances for anchorages Minimum radii of curvature of internal tendons Concrete strength at time of stressing COMPONENTS Strands Anchorages and couplers Anchor heads Couplers Ring wedges Helix and additional reinforcement Protection caps Material properties Permanent corrosion protection Corrosion protection of the strand Corrosion protection in anchorage and coupler zones Dangerous substances Methods of verification Identification EVALUATION OF CONFORMITY AND CE MARKING Attestation of conformity system Responsibilities Tasks for the manufacturer - factory production control OIB /06-031

16 Page 3 of European technical approval ETA-06/0165 Validity from to , extends ETA-06/0165 with validity from to Member of EOTA Tasks of the approved body Initial type testing of the products Initial inspection of factory and of factory production control Continuous surveillance Audit testing of samples taken at the factory CE marking ASSUMPTIONS UNDER WHICH THE FITNESS OF THE PRODUCT FOR THE INTENDED USE WAS FAVOURABLY ASSESSED Manufacturing Design General Anchorage recess Maximum prestressing forces Reinforcement in the anchorage zone Fatigue resistance Tendons in masonry structures Load transfer to the structure Installation Stressing operation Restressing Welding RECOMMENDATIONS FOR THE MANUFACTURER Recommendations on packaging, transport and storage Recommendations on installation Accompanying information ANNEXES ANNEX 1 OVERVIEW ON ANCHORAGES AND FIXED COUPLERS ANNEX 2 COMPONENTS OF ANCHORAGES AND FIXED COUPLERS ANNEX 3 ACCESSORIES ANNEX 4 TENDON RANGES ANNEX 5 MATERIAL PROPERTIES ANNEX 6 CONTENTS OF THE PRESCRIBED TEST PLAN ANNEX 7 AUDIT TESTING ANNEX 8 FORCES ANNEX 9 CONSTRUCTION STAGES ANCHORAGES AND FIXED COUPLERS...29 ANNEX 10 DIMENSIONS OF ANCHORAGES, HELIX AND ADDITIONAL REINFORCEMENT, CENTRE SPACING AND EDGE DISTANCE ANNEX 11 MODIFICATION OF CENTRE SPACING AND EDGE DISTANCE ANNEX 12 DIMENSIONS OF ANCHORAGE RECESSES ANNEX 13 FREE TENDON LAYOUT TRANSITION REGIONS...33 ANNEX 14 DESCRIPTION OF WORKSTEPS ANCHORAGE FIXED COUPLER 1 ST AND 2 ND CONSTRUCTION STAGE ANNEX 15 SPECIFICATION ANNEX 16 SPECIFICATION OIB /06-031

17 Page 4 of European technical approval ETA-06/0165 Validity from to , extends ETA-06/0165 with validity from to Member of EOTA ANNEX 17 TABLE OF STRANDS ANNEX 18 REFERENCE DOCUMENTS ANNEX 19 REFERENCE DOCUMENTS OIB /06-031

18 Page 5 of European technical approval ETA-06/0165 Validity from to , extends ETA-06/0165 with validity from to Member of EOTA I LEGAL BASES AND GENERAL CONDITIONS 1 This European technical approval is issued by Österreichisches Institut für Bautechnik in accordance with: Council Directive 89/106/EEC of 21 December 1988 on the approximation of laws, regulations and administrative provisions of Member States relating to construction products 1 Construction Products Directive (CPD), amended by the Council Directive 93/68/EEC of 22 July ; 1. 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 Act LGBl. 11/1995, amended by LGBl. 47/1995, LGBl. 63/1995, LGBl. 123/1995, LGBl. 46/2001, LGBl. 73/2001, LGBl. 99/2001 and LGBl. 20/2010; 2. Common Procedural Rules for Requesting, Preparing and the Granting of European technical approvals set out in the Annex of Commission Decision 94/23/EC 3 ; 3. Guideline for European technical approval of Post-Tensioning Kits for Prestressing of Structures, ETAG 013, Edition June 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 from the Commission according to Article 5 (1) of the Council Directive 89/106/EEC. 5 Reproduction of this European technical approval including transmission by electronic means shall be in full. However, partial reproduction may 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. 1 Official Journal of the European Communities L 40, , page 12 2 Official Journal of the European Communities L 220, , page 1 3 Official Journal of the European Communities L 17, , page 34 OIB /06-031

19 Page 6 of European technical approval ETA-06/0165 Validity from to , extends ETA-06/0165 with validity from to Member of EOTA II SPECIFIC CONDITIONS OF THE EUROPEAN TECHNICAL APPROVAL 1 Definition of product and intended use 1.1 Definition of product The European technical approval (ETA) applies to a kit, the PT system BBR VT CONA CMM Unbonded Post-tensioning System with 01, 02 and 04 Strands, comprising the following components. Tendon Unbonded tendons with 01, 02 or 04 tensile elements. Tensile element 7-wire prestressing steel strands with nominal diameters and maximum characteristic tensile strengths as given in Table 1, factory-provided with a corrosion protection system consisting of a corrosion-protective filling material and a HDPE-sheathing. Table 1: Tensile elements Nominal diameter Nominal cross sectional area Maximum characteristic tensile strength mm mm 2 MPa ) ) Compacted strand NOTE 1 MPa = 1 N/mm 2 Anchorage and coupler Anchorage of the strands with ring wedges; End anchorage Fixed (passive) anchor or stressing (active) anchor as end anchorage for 01, 02 and 04 strands; Fixed or stressing coupler Sleeve coupler for 01 and 04 strands; Helix and additional reinforcement in the region of the anchorage; Corrosion protection for tensile elements, anchorages and couplers. OIB /06-031

20 Page 7 of European technical approval ETA-06/0165 Validity from to , extends ETA-06/0165 with validity from to Member of EOTA 1.2 Intended use The PT system is intended to be used for prestressing of structures. Use categories according to type of tendon and material of structure: Internal unbonded tendon for concrete and composite structures; For special structures according to Eurocode 2, Eurocode 4 and Eurocode 6. The provisions made in the European technical approval are based on an assumed intended working life of the PT system of 100 years. The indications given on the working life of the PT system cannot 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 Characteristics of the product and methods of verification PT system 2.1 Designation and range of the anchorages and couplers End anchorages can be used as fixed or stressing anchors. Couplers are intended as fixed couplers only. The principal dimensions of the anchorages and couplers are given in the Annexes 2 and 3. Fixed couplers are for tendons with 01 or 04 prestressing strands, see Annex Designation Anchorage, e.g. (S) A CONA CMM 0106 (single) 140 Fixed (F) or stressing (S) Anchor block Designation of the tendon Fixed coupler, e.g. H CONA CMM 0106 (single) BA Coupler anchor head Designation of the tendon Construction stage 1 (1.BA) or 2 (2.BA) Anchorage The anchor heads of the fixed and stressing anchorages are identical. A differentiation is needed for the construction works. Fixed anchorages that are accessible may be prelocked; fixed anchorages that are not accessible shall be prelocked with a prelocking force as specified in Table 2. The ring wedges shall be secured with rings between the ring wedges and the covering cap Fixed and stressing couplers The prestressing force at the second construction stage shall not be greater than that at the first construction stage, neither during construction, nor in the final state, nor due to any load combination. The tendon of construction stage 2 is coupled by screwing the coupler sleeve entirely on the threaded part of the coupler anchor head 1.BA (construction stage 1). The coupler anchor OIB /06-031

21 Page 8 of European technical approval ETA-06/0165 Validity from to , extends ETA-06/0165 with validity from to Member of EOTA head 2.BA (construction stage 2) shall be prelocked with a prelocking force as specified in Table 2. At coupler anchor head H CONA CMM (single) 2.BA (construction stage 2), the ring wedges are secured with wedge holding rings and at coupler anchor head H CONA CMM (four) 2.BA (construction stage 2), the ring wedges are secured with a wedge holding plate Layout of anchorage recesses All anchor heads have to be placed perpendicular to the axis of the tendon, see Annex 10. In the Annexes 10 and 12 the minimum dimensions of the anchorage recesses are given. The dimensions of the anchorage recesses shall be adapted to the prestressing jacks used. The ETA holder shall save for reference information on the minimum dimensions of the anchorage recesses. The formwork for the anchorage recesses should be slightly conical for ease of removal. The anchorage recesses shall be designed in such a way as to permit a reinforced concrete cover with the required dimensions, and in any case with a thickness of at least 20 mm. 2.2 Designation and range of the tendons Designation Tendon, e.g. CONA CMM 0106 (single) 140 Unbonded PT Number of strands 0106 (single), 0206 (two), 0406 (four) Cross sectional area of strands (140, 150 or 165 mm 2 ) The characteristic tensile strength of the strands (1 770, or MPa) may be indicated optionally Range Prestressing and overstressing 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 Annex 8. The tendons consist of 01, 02 or 04 seven-wire prestressing steel strands, factory-provided with a corrosion protection system consisting of corrosion-protective grease and a HDPE-sheathing CONA CMM n wire prestressing steel strand Nominal diameter mm Nominal cross sectional area mm 2 Characteristic tensile strength or MPa HDPE sheathed and greased strand Mass of sheathed and greased strand kg/m External diameter of strand sheathing... 19,5 mm Annex 4 lists the available tendon range for CONA CMM n OIB /06-031

22 Page 9 of European technical approval ETA-06/0165 Validity from to , extends ETA-06/0165 with validity from to Member of EOTA CONA CMM n wire prestressing steel strand Nominal diameter mm Nominal cross sectional area mm 2 Characteristic tensile strength or MPa HDPE sheathed and greased strand Mass of sheathed and greased strand kg/m External diameter of strand sheathing mm Annex 4 lists the available tendon range for CONA CMM n CONA CMM n06c 165 Compacted 7-wire prestressing steel strand Nominal diameter mm Nominal cross sectional area mm 2 Characteristic tensile strength MPa HDPE sheathed and greased strand Mass of sheathed and greased strand kg/m External diameter of strand sheathing... 19,5 mm Annex 4 lists the available tendon range for CONA CMM n06c Friction losses For the calculation of loss of prestressing force due to friction Coulomb's law applies. Due to the grease filling of the HDPE-sheathing of the individual monostrands or VT CMM Bands, the friction coefficient μ is very low. The calculation of the friction losses is carried out using the equation ( + k x) F x = F 0 e Where F x...kn...prestressing force at a distance x along the tendon F 0...kN...prestressing force at x = 0 m... rad -1...friction coefficient; = 0.06 rad -1 (CONA CMM n06 140/150) or 0.05 rad -1 (CONA CMM n06c 165) k... rad/m...wobble coefficient; k = rad/m (= 0.5 /m)... rad...sum of the angular displacements over distance x, irrespective of direction or sign x... m...distance along the tendon from the point where prestressing force is equal to F 0 NOTE 1 rad = 1 m/m = 1 OIB /06-031

23 Page 10 of European technical approval ETA-06/0165 Validity from to , extends ETA-06/0165 with validity from to Member of EOTA If band-shaped tendons CONA CMM 150/165 with two or four strands are installed upright with flat-wise curvature and connected at support distances of 1.15 or 1.30 m, the wobble coefficient is k = rad/m (= 0.25 /m). Friction losses in anchorages are low and do not have to be taken into consideration in design and execution. 2.4 Support of tendons The individual monostrands or VT CMM Bands shall be fixed in their position. Spacing of supports is: 1 Normally Individual monostrands (01 strand) and VT CMM Bands with 02 and 04 strands to 1.30 m 2 Free tendon layout in 45 cm thick slabs In the transition region between a) high tendon position and anchorage (e.g. cantilever) m b) low and high tendon position or low tendon position and anchorage m In regions of the high or low tendon position the tendons shall be connected in an appropriate way to the reinforcement mesh at two points at least, with a spacing of 0.3 to 1.3 m. The reinforcement mesh shall be fixed in its position. Special spacers for tendons are therefore not required. For details see Annex Slip at anchorages Table 2 specifies the values of slip at anchorages which have to be taken into consideration in calculations of tendon elongation and forces in tendon. Table 2: Slip values Active anchorage Not accessible passive anchorage, prelocked 1) Accessible passive anchorage (S) A H 1.BA (F) A H 2.BA (F) A CONA CMM 0106 (F) A CONA CMM 0206 (F) A CONA CMM mm 3 mm 6 mm 8 mm 2) 1) 2) Prelocked with ~ 0.5 F pk If a more exact evaluation is required, slip for Y1860S7...9 mm Y1820S7G...7 mm OIB /06-031

24 Page 11 of European technical approval ETA-06/0165 Validity from to , extends ETA-06/0165 with validity from to Member of EOTA 2.6 Centre spacing and edge distances for anchorages In general, spacing and distances shall not be less than the values given in Table 3 and Annex 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 the placing of additional reinforcement shall still be possible, see Annex 11. In this case the spacing in the perpendicular direction shall be increased by the same percentage. The corresponding edge distance is calculated by a e = a c c a e = a c c b e = b c c b e = b c c Where a c, a c...mm... Centre spacing before and after modification b c, b c...mm... Centre spacing in the direction perpendicular to a c before and after modification a e, a e...mm... Edge distance before and after modification b e, b e...mm... Edge distance in the direction perpendicular to a e before and after modification c...mm... Concrete cover Standards and regulations on concrete cover in force at the place of use shall be observed. The minimum values for a c, b c, a e and b e are given in Table 3 and in Annex 10, where f cm, 0, cube Mean concrete compressive strength at time of stressing, determined at cubes, 150 mm f cm, 0, cylinder Mean concrete compressive strength at time of stressing, determined at cylinders, diameter 150 mm Table 3: Spacing of tendon anchorages Tendon CONA CMM 0106 CONA CMM 0206 CONA CMM 0406 Minimum centre spacing Minimum edge distance a c, b c a e, b e mm 180, , , 220 mm 70 + c, 50 + c 90 + c, 65 + c c, 90 + c c...concrete cover Standards and regulations on concrete cover in force at the place of use shall be observed. OIB /06-031

25 Page 12 of European technical approval ETA-06/0165 Validity from to , extends ETA-06/0165 with validity from to Member of EOTA 2.7 Minimum radii of curvature of internal tendons The minimum radius of curvature R min of internal tendons with strands of nominal diameter of 15.7 or 15.2 mm is 2.5 m. If this radius is adhered to, verification of prestressing steel outer fibre stresses in curved sections is not required. The minimum radius of curvature for deviation of a tendon with multistrand anchorages in the anchorage zone outside the transition tubes is 3.5 m. 2.8 Concrete strength at time of stressing Concrete in conformity with EN shall be used. At the time of stressing the mean concrete compressive strength, f cm, 0, shall be at least 24 MPa (cube strength, 150 mm cube) or 20 MPa (cylinder strength, 150 mm cylinder diameter). The concrete test specimen shall be subjected to the same curing 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 f cm, 0, cube or 0.5 f cm, 0, cylinder. Intermediate values may be interpolated linearly according to EN The helix, additional reinforcement, centre spacing and edge distance corresponding to the concrete compressive strengths shall be taken from Annex 10, see also Clauses and Components 2.9 Strands Table 4: Prestressing steel strands Max. characteristic tensile strength f pk MPa Nominal diameter d mm ) Nominal cross sectional area A p mm Mass of prestressing steel M kg/m Greased and sheathed strand Individual monostrands or VT CMM Bands Nominal mass per strand kg/m External diameter of HDPE-sheathing mm 19, ,5 1) Compacted strand The greased and sheathed strands may be either individual monostrands or VT CMM Bands. Only 7-wire prestressing steel strands as given in Table 4 and Annex 17 shall be used. The corrosion protection system of the strand is as specified in ETAG 013, Annex C.1, see also the Annexes 15 and Reference documents are listed in the Annexes 18 and 19. OIB /06-031

26 Page 13 of European technical approval ETA-06/0165 Validity from to , extends ETA-06/0165 with validity from to Member of EOTA 2.10 Anchorages and couplers The components of anchorages and couplers shall conform to the specifications given in the Annexes 2 and 3 and in the technical documentation 5. Therein the component dimensions, materials and material identification data with tolerances are given Anchor heads The anchor heads are made of cast iron with spheroidal graphite. They provide regularly arranged conical holes to accommodate 01, 02 or 04 strands and ring wedges. The load transfer to the concrete occurs in two planes. The anchor head has a cylindrical extension with an internal thread to screw-in a protection cap, which will be filled with corrosion protection grease to protect the ring wedges and the strands. The outlet end of the holes is formed in such a way as to allow the transition pipes to be inserted tension-proof. The transition pipes act as the transition from the anchor head to the sheathing of the strands Couplers Fixed couplers are provided with 01 and 04 strands. They consist of a coupler anchor head 1.BA (construction stage 1) and a coupler anchor head 2.BA (construction stage 2). The coupler anchor head 1.BA (construction stage 1) has the same basic body as the anchor heads of active and passive anchorages for 01 and 04 strands and a cylindrical extension to accommodate the coupler thread. The connection between coupler anchor heads 1.BA (construction stage 1) and 2.BA (construction stage 2) is by means of a coupler sleeve, a steel tube featuring an internal thread, a threaded bore to accommodate the filling device and a bore for ventilation. The coupler anchor head 2.BA (construction stage 2) for 01 strand is either a cast iron head with a conical hole or a steel body with a conical bore. The coupler anchor head 2.BA (construction stage 2) for 04 strands is a steel body with conical bores. All coupler anchor heads provide a machined external thread for the coupler sleeve. The end surface of the fixed coupler H CONA CMM 0406 (four) is provided with a BDSD-plate to permit settlement of the coupler during stressing Ring wedges The ring wedges are in three pieces, which are held together by spring rings. Two types of ring wedges are used. Within one anchorage or coupler only one type of ring wedge shall be used. Wedge holding rings serve to secure the ring wedges after prelocking. The fastening of the ring wedges of the prelocked coupler anchor head CONA CMM 0406 (four) 140/150/165 2.BA (construction stage 2) is made by means of a wedge holding plate Helix and additional reinforcement The helix and the additional reinforcement are made of ribbed reinforcing steel. The end of the helix on the anchorage side is welded to the following turn. The helix shall be placed in the tendon axis. The dimensions of the helix and the additional reinforcement shall conform to the values specified in Annex 10, see also Clause If required for a specific project design, the reinforcement given in Annex 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 authorities and of the ETA holder, to provided equivalent performance. 5 The technical documentation of the European technical approval is deposited at Österreichisches Institut für Bautechnik and, in so far as is relevant to the tasks of the approved body involved in the attestation of conformity procedure, is handed over to the approved body. OIB /06-031

27 Page 14 of European technical approval ETA-06/0165 Validity from to , extends ETA-06/0165 with validity from to Member of EOTA Protection caps Protection caps are made of plastic. They are provided with air vents and are screwed onto the anchor head Material properties Annex 5 lists the material properties and the standard/specification of the components Permanent corrosion protection The corrosion protection materials used are specified according to ETAG 013, Annex C.1, see also the Annexes 15 and Corrosion protection of the strand The strands are sheathed in the factory with an extruded HDPE-sheathing with a thickness of at least 1.0 mm. The actual thickness of the sheathing shall be in accordance with the standards and regulations in force at the place of use Corrosion protection in anchorage and coupler zones The voids inside the HDPE-sheathing are filled with corrosion protection grease. When mounting the anchorage, the sheathing is removed along the required length. During construction the strand excess lengths are temporarily protected with cut-off HDPE-sheaths. All voids of the anchorages are filled with corrosion protection grease according to the installation instructions in Annex 14. Anchorages which are prelocked receive their corrosion protection immediately after the prelocking operation by screwing-on of the protection cap and filling with corrosion protection grease Dangerous substances The release of dangerous substances is determined according to ETAG 013, Clause The PT system conforms to the provisions of Guidance Paper H 6 relating to dangerous substances. A declaration in this respect has been made by the manufacturer. In addition to the specific clauses relating to dangerous substances in the 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 Methods of verification The assessment of the fitness of "BBR VT CONA CMM Unbonded Post-tensioning System with 01, 02 and 04 Strands" for its intended use in relation to the requirements for mechanical resistance and stability in the sense of Essential Requirement 1 of Council Directive 89/106/EEC has been made in conformity to the Guideline for European technical approvals of "Post-tensioning Kits for Prestressing of Structures", ETAG 013, Edition June Guidance Paper H: A harmonised approach relating to Dangerous substances under the Construction Products Directive, Rev. September OIB /06-031

28 Page 15 of European technical approval ETA-06/0165 Validity from to , extends ETA-06/0165 with validity from to Member of EOTA 2.14 Identification The European technical approval for the "BBR VT CONA CMM Unbonded Post-tensioning System with 01, 02 and 04 Strands" is issued on the basis of agreed data, deposited at Österreichisches Institut für Bautechnik, which identifies "BBR VT CONA CMM Unbonded Post-tensioning System with 01, 02 and 04 Strands" that has been assessed and judged. Changes to the manufacturing process of the "BBR VT CONA CMM Unbonded Post-tensioning System with 01, 02 and 04 Strands", which could result in this deposited data being incorrect, should be notified to Österreichisches Institut für Bautechnik before the changes are introduced. Österreichisches Institut 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. 3 Evaluation of conformity and CE marking 3.1 Attestation of conformity system The system of attestation of conformity assigned by the European Commission to this product in accordance with 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 plan 7 ; (b) Tasks for the approved body (3) Initial type-testing of the product; (4) Initial inspection of factory and of factory production control; (5) Continuous surveillance, assessment and approval of factory production control; (6) Audit testing of samples taken at the factory. 3.2 Responsibilities Tasks for the manufacturer - factory production control At the manufacturing plant, the manufacturer shall implement and continuously maintain a factory 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 controls in accordance with the prescribed test plan and in accordance with the European technical approval. Details of the extent, nature and frequency of testing and controls to be performed within the framework of the factory production control shall correspond to the prescribed test plan, which forms part of the technical documentation of the European technical approval. 7 The prescribed test plan has been deposited at Österreichisches Institut für Bautechnik and is handed over only to the approved body involved in the conformity attestation procedure. The prescribed test plan is also referred to as control plan. OIB /06-031

29 Page 16 of European technical approval ETA-06/0165 Validity from to , extends ETA-06/0165 with validity from to Member of EOTA The results of factory production control shall be recorded and evaluated. The records shall include at a minimum the following information: Designation of the products and of the basic materials; Type of check or testing; Date of manufacture of the products and date of testing of the products or basic materials or components; Results of check and testing and, if appropriate, comparison with requirements; Name and signature of person responsible for factory production control. The records of factory production control shall be submitted to the approved body and shall be filed for at least 10 years time. On request, the records shall be presented to Österreichisches Institut für Bautechnik. lf test results are unsatisfactory, the manufacturer shall immediately implement measures to eliminate the defects. Construction products or components which are not in conformity with the requirements shall be removed. After elimination of the defects, the respective test - if verification is required for technical reasons - shall be repeated immediately. The basic elements of the prescribed test plan conform to ETAG 013, Annex E.1 and are specified in the quality management plan of the "BBR VT CONA CMM Unbonded Post-tensioning System with 01, 02 and 04 Strands". Annex 6 lists the contents of the prescribed test plan Tasks of the approved body Initial type testing of the products 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 procedure or factory plant. In such cases, the necessary initial type testing shall be agreed between Österreichisches Institut für Bautechnik and the approved body involved Initial inspection of factory and of factory production control The approved body shall ascertain that, in accordance with the prescribed test plan, 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 Continuous surveillance The kit manufacturer shall be inspected at least once a year. Each component manufacturer of the components listed in Annex 7 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 plan. 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 plan are no longer fulfilled, the certificate of conformity shall be withdrawn and Österreichisches Institut für Bautechnik informed immediately Audit testing of samples taken at the factory During surveillance inspections, the approved body shall take samples at the factory of 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 OIB /06-031

30 Page 17 of European technical approval ETA-06/0165 Validity from to , extends ETA-06/0165 with validity from to Member of EOTA Annex 7 summarises the minimum procedures that shall be implemented by the approved body. 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 the following information: Name or identification mark and address of the manufacturer The last two digits of the year in which the CE marking was affixed Number of the European technical approval Number of the certificate of conformity Product identification (trade name) 4 Assumptions under which the fitness of the product for the intended use was favourably assessed 4.1 Manufacturing "BBR VT CONA CMM Unbonded Post-tensioning System with 01, 02 and 04 Strands" is manufactured in accordance with the provisions of the European technical approval. Composition and manufacturing process are deposited at Österreichisches Institut für Bautechnik. 4.2 Design General Design of the structure shall permit correct installation and stressing of the tendons. The reinforcement in the anchorage zone shall permit correct placing and compacting of concrete Anchorage recess The anchorage recess shall be designed so as to permit a concrete cover of at least 20 mm at the protection caps or locking plates in the final state. Clearance is required for the handling of prestressing jacks. In order to allow for imperfections and to ease the cutting of the strand excess lengths it is recommended to increase the dimensions of the recesses. The forms for the recesses should be slightly conical for easy removal. If other prestressing jacks than those shown in Annex 12 are used, the ETA holder shall keep information on the prestressing jacks and minimum dimensions of the anchorage recesses. In case of failure the bursting out of prestressing steels shall be prevented. Sufficient protection is provided by e.g. a cover of reinforced concrete Maximum prestressing forces The prestressing and overstressing forces are specified in the respective standards and regulations in force at place of use. Annex 8 lists the maximum possible prestressing and overstressing forces. OIB /06-031