BBR Katalog

PRESTRESSING
TECHNOLOGY
www.structuralsystems.com.au
Post-STRESSING TECHNOLOGY
Emirates Tower - Dubai
Introduction
PAGE 03
Post-Tensioning Design data
PAGE 04
Multi-Strand Post-TensioninG
PAGE 05
Slab Post-Tensioning
PAGE 17
Multi-Wire Post-Tensioning
PAGE 28
Bar Post-Tensioning
PAGE 31
Ground Anchor SYSTEMS
PAGE 35
External PRESTRESSING
PAGE 38
Cable Stay SYstemS
PAGE 40
INCREMENTALLAUNCHINGSYSTEMS PAGE 44
HEAVYLIFTINGSYSTEMS
PAGE 45
LOADHANDLING SYSTEMS
PAGE46
Data contained herein is subject to change without notice. Use of information and details presented in this document should
be verified by a qualified engineer for suitability to specific applications.
introduction
Structural Systems is a specialist professional Engineering
and Contracting Company, which provides innovative
skills and services to the Construction and Mining
Industries both nationally and internationally. Operations
commenced as BBR Australia Pty Ltd in 1961 and
became the public company, Structural Systems Limited
in 1987.
Our innovative design, advanced construction techniques
and effective project management skills make Structural
Systems the leader in the design and installation of
prestressing systems.
The wide range of services and systems offered in
this brochure are readily available through our network
of offices and a Structural Systems representative is
available to talk directly to you regarding your project.
Wandoo Concrete Gravity Structure - Western Australia
Eleanor Schonell Bridge - Queensland
PRESTRESSING TECHNOLOGY
POST-TENSIONING DESIGN DATA

STRAND PROPERTIES
STANDARD
AS 4672
(1)
BS 5896
(2)
prEN 10138-3
(3)
Notes:
NOMINAL
DIAMETER
mm
STEEL AREA
12.7 super
15.2 super
15.2 EHT
12.9 super
15.7 super
MASS
kg/lm
STRAND
MBL / Fm
kN
MIN. PROOF
LOAD
kN
STRAND
RELAXATION
(%)
MODULUS OF
ELASTICITY
MPa
100.1
143.3
143.3
0.786
1.125
1.125
184
250
261
156.4
212.5
221.9
2.5
2.5
2.5
180 to 205x10
180 to 205x10
180 to 205x10
100
150
0.785
1.180
186
265
158.1
225.3
2.5
2.5
180 to 205x10
180 to 205x10
140
150
140
150
1.093
1.172
1.093
1.172
248
266
260
279
213.0
229.0
224.0
240.0
2.5
2.5
2.5
2.5
180
180
180
180
NOMINAL
DIAMETER
mm
STEEL AREA
MASS
kg/lm
WIRE
MBL
kN
MIN. PROOF
LOAD
kN
STRAND
RELAXATION
(%)
MODULUS OF
ELASTICITY
MPa
7 LR
38.5
0.302
64.3
54.7
(4)
2.0
195 to 205x10
7 LR
38.5
0.302
64.3
53.4
(5)
2.5
195 to 205x10
(7)
mm
15.2 regular
15.7 regular
15.2 super
15.7 super
(4)
(4)
(4)
(5)
(5)
(5)
(5)
(5)
(5)
(6)
3
3
3
3
3
to
to
to
to
205x10
205x10
205x10
205x10
3
3
3
3
All strands are 7 wire low relaxation steel.
WIRE PROPERTIES
STANDARD
AS 4672
(1)
BS 5896
(2)
Notes:

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(7)
mm
(6)
Australian / New Zealand Standard AS 4672 Steel Prestressing Materials.

British Standard BS 5896 High Tensile steel wire and strand for the Prestressing of Concrete.
European Standard prEN 10138-3 Prestressing steels - Part 3: Strand.
At 0.2% Offset. Refer AS 4672.
At 0.1% Offset. Refer BS 5896 or prEN 10138-3 as applicable.
Relaxation after 1000 hrs at 0.7 x Breaking Load.
MBL = Minimum Breaking Load (to AS 4672 and BS 5896). Fm = Characteristic Force (to prEN 10138-3).
MAXIMUM JACKING FORCES - RECOMMENDED VALUES

SSL POST TENSIONING SYSTEM
STANDARD
AS 3600
BBR CONA MULTI SYSTEM

BBR VT CONA CMI SYSTEM
SLAB SYSTEM
WIRE SYSTEM
BAR SYSTEM
Notes:

80%
80%
85%
80%
75%
BS 8110
MBL
MBL
MBL
MBL
MBL
80%
80%
80%
80%
75%
MBL
MBL
MBL
MBL
MBL
In some cases higher or lower jacking forces are permitted by local standards.
MBL = Minimum Breaking Load of tendon.
PRESTRESSING LOSSES - TYPICAL DATA

SYSTEM
BBR CONA MULTI
BBR VT CONA CMI
SLAB
ANCHORAGE & JACKING LOSS (%)
2 to 4
0.9 to 1.2
2 to 5
0 to 1
0 to 1
DRAW-IN ALLOWANCE (mm)
2 to 3
1 to 2
0.15 to 0.20
0.20 to 0.22
0.12 to 0.16
0.15 to 0.20
0.10 to 0.15
0.10 to 0.15
0.15 to 0.20
0.20
0.10 to 0.15
0.10 to 0.15
0.10 to 0.15
0.15
0.016 to 0.024
0.008 to 0.016
0.006
0.006
0.016
0.008 to 0.012
0.008 to 0.016
TENDON
WOBBLE
(k) rad/m
DUCT
FRICTION
Round Steel Duct

Flat Steel Duct
Polyethylene Duct
Greased & Sheathed
Round Steel Duct 50mm
Round Steel Duct > 50mm
Flat Steel Duct
Greased & Sheathed
To reduce excess friction, it may be possible to flush the tendon with water or water soluble oil.
If the duct or strand has a film or rust or the ducts are full of water, the friction values can increase significantly.
BAR
0.016 to 0.024
Notes:
WIRE
0.008
MULTI-STRAND POST-TENSIONING
multi-strand post-tensioning
Structural Systems have two distinct systems available
for multi-strand applications. These systems are BBR
Cona Multi, and BBR VT Cona CMI.
BBR CONA MULTI

The BBR Cona Multi has been offered for the last 40
years and is available in standardised tendon sizes
from:
7 strands up to 61 strands for 12.7mm and 12.9mm
strand, or
strand.
European Approval ETA - Testng of Anchor Head
BBR CONA MULTI - M1

The BBR Cona Multi can be used with galvanised steel
and polyethylene ducting. The system is a bonded
system with the ducting being pressure filled with a
cementitious grout.
Standard applications use the M1 range, with the M3
range being used for cryogenic applications, and other
specialist applications. Please consult SSL for details on
which system best suits your applications.
BBR VT CONA CMI

The BBR VT Cona CMI is a revolutionary, state of the art,
bonded, post-tensioning system incorporating worlds
best practice, and is available in standard tendon sizes
from:
strand.
BBR VT CONA
CMI
The system has been granted European Technical
Approval in accordance with the testing procedures
contained within ETAG013 and is CE marked.
These tests included static tests,

fatigue tests, load transfer and
cryogenic tests.
European Technical Approval provides clear independent
review, full and complete system testing to the highest
European standard, quality assurance, and independent
auditing of all systems components. Every product
is tested to the same standards and afterwards an
independent auditor ensures that what is delivered
and installed on site fully complies with that which was
tested.
On completion of the tests, the approval body evaluated
the test results, drawings, specifications and the complete
system. The package was then circulated to all member
states of the EU for ratification.
Copies of the BBR VT European Approval Documents
are available for download from www.bbrnetwork.com
and www.structuralsystems.com.au.
The BBR VT Cona CMI has significant advantages over
the BBR Cona Multi as well as significant competitive
advantage over other ETAG approved systems. These
advantages include:
Less space is required in the anchor zone which
results in less concrete, slimmer structures and less
eccentricity in the anchors.
Significantly lower concrete strength prior to
stressing resulting in shorter construction cycles.
Less reinforcement in the anchorage zone resulting
in time and cost savings.
BBR VT CONA CMI

TECHNICAL DATA OF ANCHORAGES
BBR VT Cona CMI (Max No of Strands)
Strand
mm2
Cross Sectional Area
mm2
140
150
560
12
140
600
150
980
140
1050
150
1680
1800
Charact. Tensile Strength
Rm
MPa
1770
1860 1770 1860
1770
1860 1770 1860
1770
1860 1770 1860
Charact. Maximum Force
Fm
kN
992
1040 1064 1116
1736
1820 1862 1953
2976
3120 3192 3348
BBR VT Cona CMI (Max No of Strands)
12
Helix and Additional Reinforcement

MPa
19
23
28
Outer Diameter
mm
180
150
150
Bar Diameter
mm
14
12
12
Length, approx.
mm
182
181
Pitch
mm
50
4
mm
15
3
mm
12
12
10
10
14
14
14
14
14
12
14
16
16
14
Min. Concrete Strength (cyl.)
fcm.0
31
35
19
23
28
31
35
19
23
28
31
35
150
230
200
200
180
180
330
280
280
260
260
12
14
14
14
14
14
14
14
14
14
14
216
216
232
232
277
277
277
332
332
332
382
282
50
60
60
50
50
60
60
60
50
50
50
50
50
15
15
15
18
18
18
18
18
20
20
20
20
20
Helix
Number of Pitches
E
Distance
Additional Reinforcement
Number of STIRRUPS
Bar Diameter
mm
60
55
40
50
55
60
65
65
60
60
55
70
65
50
mm
30
30
30
30
33
33
33
33
33
35
35
35
35
35
BxB
mm
220
200
180
170
290
270
240
230
220
390
350
320
310
290
Min. Centre Spacing
ac,bc
mm
235
215
195
190
310
285
260
250
240
405
370
340
325
310
Min. Edge Distance (plus c)
ae,be
mm
110
100
90
85
145
135
120
115
110
195
175
160
155
145
Anchor Diameter
DA
mm
130
170
225
Anchor Length
LA
mm
327
454
627
Coupler FK Diameter
DFK
mm
185
205
240
Coupler FK Length
LFK
mm
945
1152
1435
Spacing
Distance from Anchor Plate
Outer Dimensions
Centre and Edge Spacing
Dimensions of Anchorages
FIXED COUPLER FK
STRESSING AND FIXED ANCHORAGE
CENTRE AND EDGE DISTANCES
STRESSING ANCHORAGE RECESS DETAILS

Strand Size
BBR VT Cona CMI
15.2mm / 15.7mm
Anchorage Unit
Maximum No. Strands
406
4
706
7
1206
12
1906
19
2206
22
2706
27
3106
31
DIMENSIONS (mm)
Recess - Inner
Recess - Outer
Recess Depth
200 x 200
250 x 250
130
240 x 240
290 x 290
135
295 x 295
350 x 350
140
350 x 350
400 x 400
160
380 x 380
420 x 430
170
430 x 430
480 x 480
180
430 x 430
480 x 480
185
MULTI STRAND POST-TENSIONING
BBR VT CONA CMI

TECHNICAL DATA OF ANCHORAGES
BBR VT Cona CMI (Max No. of Strands)
19
22
27
31
Strand
mm2
140
150
140
150
140
150
140
150
Cross Sectional Area
mm2
2660
2850
3080
3300
3780
4050
4340
4650
Charact. Tensile Strength
Rm
MPa
1770
1860 1770 1860
1770
1860 1770 1860
1770
1860 1770 1860
1770
1860 1770 1860
Charact. Maximum Force
Fm
kN
4712
4940 5054 5301
5456
5720 5852 6138
6696
7020 7182 7533
7688
8060 8246 8649
BBR VT Cona CMI (Max No. of Strands)
19
22
27
31
Helix and Additional Reinforcement

Min. Concrete Strength (cyl.)
fcm.0
MPa
19
23
28
31
35
19
23
28
31
35
19
23
28
31
35
19
23
28
31
35
Outer Diameter
mm
420
360
360
330
330
475
420
360
360
330
520
475
430
420
360
560
520
475
430
430
Bar Diameter
mm
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
14
Length, approx.
mm
457
457
432
432
382
482
482
482
482
382
532
532
532
427
432
532
532
582
467
432
Pitch
mm
50
Helix
50
50
50
50
50
50
50
50
50
50
50
50
50
40
50
50
50
50
40
9.5
9.5
10
10
10
10
11
11
11
11
11
11
12
12
mm
27
27
27
27
27
31
31
31
31
31
35
35
35
35
35
35
35
35
35
35
mm
16
16
16
16
16
16
20
20
20
16
20
20
20
20
20
20
20
20
20
20
Number of Pitches
Distance
Additional Reinforcement
Number of STIRRUPS
Bar Diameter
Spacing
mm
65
65
65
65
65
65
75
70
65
55
80
80
75
70
60
85
75
70
65
60
mm
42
42
42
42
42
46
46
46
46
46
50
50
50
50
50
50
50
50
50
50
BxB
mm
490
450
410
390
370
530
480
440
420
400
590
540
490
470
440
630
580
530
500
480
Min. Centre Spacing
ac,bc
mm
510
465
425
410
390
550
500
460
440
420
610
555
505
485
460
650
595
545
520
495
Min. Edge Distance (plus c)
ae,be
mm
245
225
205
195
185
265
240
220
210
200
295
270
245
235
220
315
290
265
250
240
Anchor Diameter
DA
mm
280
310
360
360
Anchor Length
LA
mm
744
946
1090
975
Coupler FK Diameter
DFK
mm
290
310
390
390
Coupler FK Length
LFK
mm
1600
1821
2466
2242
Distance from Anchor Plate

Outer Dimensions
Centre and Edge Spacing
Dimensions of Anchorages
Note: Intermediate and larger sizes available on request.
STRESSING AND FIXED ANCHORAGE
FIXED COUPLER FK
CENTRE AND EDGE DISTANCES
Structural Systems has gained certification

from BBR as a PT Specialist Company
authorised to install the BBR VT Cona CMI
systems and all other BBR ETAG approved
post tensioning systems.
7
5
BBR VT CONA CMI

SYSTEM COMPONENT DETAILS
BEARING TRUMPLATES
No. Strands
Bearing TRUMPLATE
Diameter P (mm)
Height HP (mm)
12
19
22
27
31
130
120
170
128
225
150
280
195
310
206
360
250
360
250
BEARING TRUMPLATE
ANCHOR AND COUPLER HEADS

No. Strands
12
19
22
27
31
Anchor Head
Diameter A (mm)
Height HA1 (mm)
100
50
130
55
160
65
200
85
225
95
255
105
255
110
Coupler Head K
Diameter K (mm)
Height HK (mm)
185
85
205
85
240
90
290
95
310
105
390
125
390
130
COUPLER HEAD TYPE K
ANCHOR HEAD
PLASTIC TRUMPETS
No. Strands
12
19
22
27
31
Trumpet A
Diameter TA (mm)
Length LTA (mm)
72
230
88
328
127
509
153
580
170
715
191
871
191
757
Trumpet K
Diameter TK (mm)
Length LTK (mm)
185
539
203
640
240
730
275
775
305
840
375
1265
375
1150
TRUMPET TYPE A
TRUMPET TYPE K
MULTI STRAND POST-TENSIONING
BBR VT CONA CMI

TENDON PROPERTIES
TENDON
UNIT
MAXIMUM MAXIMUM MINIMUM

STRANDS
STEEL
STEEL
NO.
DUCT ID/ DUCT ID/
OD
OD
mm
406
706
1206
1906
2206
2706
3106
Notes:

4
7
12
19
22
27
31
45
60
80
100
105
120
130
/
/
/
/
/
/
/
50
65
85
105
110
125
135
mm
MINIMUM RADII
OF CURVATURE
/ MINIMUM
STRAIGHT
PORTION
m
TENDON MIN BREAKING LOAD to prEN 10138-3
15.2 regular
15.7 regular
15.2 super
15.7 super
45 / 50
55 / 60
70 / 75
90 / 95
95 / 100
105 / 110
110 / 115
2.0 / 0.8
4.0 / 0.9
5.2 / 1.0
6.5 / 1.1
7.0 / 1.15
7.7 / 1.3
8.4 / 1.3
992
1736
2976
4712
5456
6696
7688
1064
1862
3192
5054
5852
7182
8246
1040
1820
3120
4940
5720
7020
8060
1116
1953
3348
5301
6138
7533
8649
kN
Table indicates maximum number of strands that can be accomodated by the tendon stressing unit.
Larger ID ducting should be selected for tendons > 80m, or if strands are installed after concreting, or where tight or extended curvatures occur.
Plastic sheaths conforming to ETAG013 should be used. Alternatively, corrugated polyethylene ducting may be used if permitted in the local region.
Refer page 4 for additional design data and details.
Maximum jacking force is usually 0.8 x MBL.
For radii of curvature and straight portion diagram refer to BBR CONA Multi System.
STRESSING ANCHORAGE
FIXED ANCHORAGE
FIXED COUPLER FK
BBR CONA MULTI

Tendon Properties
Tendon Unit

Maximum
Strands
No.
Metal Duct
Tendon MBL to AS4672
ID/OD
mm
Tendon MBL to BS5896

or prEN 10138-3
kN
kN

705
7
50 / 57

1205
12
70 / 77

1905
19
85 / 92

3105
31
105 / 112

4205
42
120 / 127

6105
61
150 / 157
Using 12.7mm strand

1288
2208
3496
5704
7728
11224
Using 12.9mm strand

1302
2232
3534
5766
7812
11346

406
4
50 / 57

706
7
65 / 72

1206
12
80 / 87

1906
19
100 / 107

2206
22
110 / 117

3106
31
120 / 127

4206
42
135 / 142

5506
55
150 / 157
15.2mm/15.2 EHT strand

1000 / 1044
1750 / 1827
3000 / 3132
4750 / 4959
5500 / 5742
7750 / 8091
10500 / 10962
13750 / 14355
15.7mm BS / 15.7 EN strand

1060 / 1116
1855 / 1953
3180 / 3348
5035 / 5301
5830 / 6138
8215 / 8649
11130 / 11718
14575 / 15345
Notes:
Table indicates maximum number of strands that can be accomodated by the tendon stressing anchorage unit.
Duct sizes are quoted for typical situations. It may be possible to slightly reduce duct size in some situations. Consideration should be given to the use of larger
ducts where tight or extended curvatures occur. Refer to SSL office for advice. Alternate duct sizes are generally available in 5mm ID increments
Partial tendons are also permissible.

(i.e. a 15No. 12.7mm strand tendon would be specified as 1905-15, supplied with a 1905 stressing anchorage and would have a MBL of 15 x 184 = 2760 kN, etc.)
Maximum Multi-strand Jacking force is usually 0.8 x MBL.
Refer page 5 for additional design data and details on standards.
MBL = Minimum Breaking Load
stressing Anchorages (Live Ends)

Structural Systems has been offering the BBR Cona Multi
post-tensioning system for over 40 years. This multistrand system is predominantly used in civil structures
including bridges, silos, tanks and off-shore structures
and is a robust and reliable bonded prestressing
system.
The BBR Cona Multi system consists of up to 61 No.
12.7mm/12.9mm or 91 No. 15.2mm/15.7mm strands to
form tendons which are installed inside round ducting.
The individual strands are anchored in a common
anchor head with a wedge grip system and the strands
are simultaneously stressed. Individual strand stressing
is possible in some circumstances. After stressing the
ducting is pressure filled with a cementitious grout.
The choice between the anchorage types depends on
structural requirements, availability and dimensional
constraints.
10
For standard applications type M1 anchorages are

generally preferred. Type M3 are used for cryogenic
applications or where it maybe necessary to use a
rectangular anchorage for clearance reasons. (It is
recommended that SSL is consulted for non-standard
plate sizes).
grout inlet
wedge
grips
duct
p.e. trumpet
anchor
head
anchorAGE casting
anchorage Type M1
MULTI-STRAND post-tensioninG
two typical anchorages. Several other BBR anchorage

configurations are also available and there may be some
variations in dimensions to those shown. The designer
should check with Structural Systems for full and current
technical information on the preferred anchorage type.
The type of stressing anchorage used may vary

depending on the application, size and number of
anchorages required, type of tendon sheathing, project
location and availability of components. The tables
below provide performance and dimensional data for
STRESSING ANCHORAGE TYPE M1 - ANCHORAGE CASTING WITH P.E. TRUMPET (LIVE END)
STRAND SIZE
TYPE M1 ANCHORAGE DETAILS
12.7mm / 12.9mm
Anchorage Unit
Maximum No. Strands
705
7
1205
12
1905
19
3105
31
4205
42
6105
61
15.2mm / 15.7mm
Anchorage Unit
Maxiumum No. Strands
406
4
706
7
1206
12
1906
19
2206
22
3106
31
4206
42
Dimensions (mm)
AxA
B
C
Inside Dia. D
Outside Dia. E
Anchor Nom. Dia. F
Nom. Height G
165
155
100
77
55
120
55
215
345
85
110
77
150
55
265
415
100
139
92
190
65
335
485
116
179
112
240
80
350
550
125
193
117
350
80
395
605
145
223
137
290
100
460
725
175
265
157
350
120
Notes: Local zone and general zone anchorage reinforcement is normally required for all unit types and details are usually determined by the Designer to suit the specific application.
Unless otherwise specified by the Designer, multi-strand tendons will normally be supplied with Type M1 stressing anchorages.
Tendon grouting is achieved via 19mm poly pipe inlets at all anchorages and at intermediate venting points.
Anchorage type m1
Stressing Anchorage Type M3 - Fabricated Plate Anchorage (LIVe END)

Strand size Type M3 Anchorage details

12.7mm / 12.9mm
Anchorage Unit
705
1205
1905
3105

Maximum No. Strands
7
12
19
31
15.2mm / 15.7mm

Anchorage Unit
Maximum No. Strands
Dimensions
A x A

(mm)
B
C
Outside Dia. D
Outside Dia. E
-
-
4205
42
6105
61
406
4
706
7
1206
12
1906
19
2206
22
3106
31
4206
42
5506
55
175
220
20
90
55
220
435
30
115
75
270
545
40
140
90
345
785
55
195
110
375
820
60
210
115
440
910
70
232
140
600
1230
100
275
160
600
1400
120
325
160
Notes: Local zone and general zone anchorage reinforcement is normally required for all unit types and details are usually determined by the Designer to suit the specific application.
Unless otherwise specified by the Designer, SSL Multi-strand tendons will normally be supplied with Type M1 stressing anchorages.
Tendon grouting is achieved via 19mm poly pipe inlets at all anchorage ends and at intermediate venting points.
Anchorage type m3
11
Dead End AnchorageS - Bulb Type & Swage Type

Strand Size
Anchorage Unit

Bulb Type Anchorage (mm)

A
B
C
12.7mm and 12.9mm

705
175
150

1205
300
250

1905
375
300

3105
450
425

4205
600
450

6105
700
550

15.2mm and 15.7mm
406
150
150

706
200
170

1206
350
300

1906
450
350

2206
500
350

3106
550
475

4206
700
550

5506
800
600
swage Type Anchorage (mm)

D
E
F
600
1000
1000
1100
1100
1200
150
200
250
350
450
700
150
200
250
300
375
450
250
350
500
650
850
1000
600
600
1000
1000
1000
1100
1200
1200
150
200
250
300
300
350
400
550
150
200
250
300
300
350
350
475
250
350
500
500
500
650
850
1000
Notes:
Local zone and general zone anchorage reinforcement is normally required for all unit types and details are usually determined by the Designer to suit the specific application
Swage type dead end anchorages recommended for tendon units 3105/1906 and larger
bulb type dead end
swage type dead end

Note:
Transfer beams in buildings
12
For swage type, strand length F shall be

debonded (using grease or similar).
MULTI-STRAND post-tensioning
Coupling Anchorage - Type K

Strand size
Type K Coupling Anchorage details
12.7mm / 12.9mm

Anchorage Unit
Maximum No. Strands
705
7
1205
12
1905
19
3105
31
-
-
-
-
15.2mm / 15.7mm

Anchorage Unit
Maximum No. Strands
406
4
706
7
1206
12
1906
19
2206
22
3106
31
4206
42
168
550
208
650
258
700
328
900
328
950
405
1100
460
1200
Diameter (mm) N
Trumpet length (mm)
P (approx)
Notes:
Unless otherwise specified by the Designer, multi-strand coupling anchorages will normally be supplied as Type K
Refer to SSL for details and availability of larger K type coupler units
Coupling Anchorage - Type C

Strand size
Type C Coupling Anchorage details
12.7mm / 12.9mm
Anchorage Unit

Maximum No. Strands
705
7
1205
12
1905
19
3105
31
-
-
4205
42
6105
61
Dimensions (mm)
Q
R

S
108
170
550
108
200
650
108
230
740
108
340
1140
-
-
-
148
385
1320
refer
to
SSL
15.2mm / 15.7mm
Anchorage Unit

Maximum No. Strands
406
4
706
7
1206
12
1906
19
2206
22
3106
31
4206
42
5506
55
Dimensions (mm)
Q
R

S
125
160
520
125
200
630
125
230
730
125
270
860
125
300
930
145
350
1090
refer
to
SSL
refer
to
SSL
Notes:
Unless otherwise specified by the Designer, SSL Multi-strand Coupling Anchorages will normally be supplied as Type K
Refer to SSL for details and availability of larger C type coupler units
13
Stressing Anchorage Recess details
Strand size
Recess details
12.7mm / 12.9 mm Tendon Unit
705
1205
1905
3105
15.2mm / 15.7mm Tendon Unit
406
706
1206
1906
Dimensions (mm)

230
140
310
270
140
370
340
150
400
420
165
510
F x F
G
H x H
4205
6105
2206
3106
4206
5506
420
165
510
460
185
560
560
200
660
650
225
750
Notes: Depth G achieves 50mm cover to trimmed strand ends.

Alternative or smaller recesses may be possible depending on actual conditions and jack used. Refer to your local Structural Systems office.
Space Requirements for Stressing Jacks

Strand size
Space Requirements
705
1205
1905
3105
406
706
1206
1906
-
2206
4205
6105
3106
4206
5506

Jack unit CC 110 CC 200 CC 300 CC 600 CC 600 CC 630 CC 1000 CC 1200
Dimensions (mm)
A
710
750
810
1200
1200
1000
1130
1300

B
1400
1500
1600
2400
2400
2000
2300
2600
C
250
300
330
500
500
600
600
600

E
200
230
260
400
400
500
420
450

F
595
620
675
1100
1100
950
950
1050
Notes: Details based on jacks having 200mm working stroke. Alternative jacks may be available and/or more suitable. Contact SSL for further details

Check jack size and availability with your local SSL office
14
MULTI-STRAND post-tensioning
Tendon Curvature
A straight portion L adjacent to the anchorage must be observed to limit the screw pull of the strand bundle against
the anchorage. Reduction may be allowed in certain specific instances.
Tendon Curvature Limitations

12.7mm / 12.9mm
15.2mm / 15.7mm
705
406
1205
706
1905
1206
3105
1906
-
2206
4205
3106
6105
4206
5506
Minimum Radius, R (m)

Minimum Straight

Portion, L (m)
4
0.8
4.5
0.9
5
1.0
6
1.1
6.5
1.15
8
1.3
8
1.3
10
1.5
Sheathing and Corrosion Protection

For conventional applications, corrugated galvanised steel ducts are used with a wall thickness of 0.3mm.
For applications requiring enhanced corrosion protection and improved fatigue resistance of the tendons, use
of corrugated plastic duct is recommended. This fully encapsulated, watertight system offers superb corrosion
protection, and the plastic duct eliminates fretting fatigue between the strand and duct. It also provides reduced duct
friction. All ducts are manufactured in a variety of standard lengths and are coupled on site. Steel ducts are available
in diameters ranging from 40mm to 160mm in approximately 5mm increments.
Tendon Sheathing and Corrosion Protection

Polyethylene Duct Details
TENDON TYPE
12.7mm/12.9mm
DUCT DIMENSIONS (mm)
15.2mm/15.7mm
O.D.
I.D.
Galv. Steel Duct
WALL THICKNESS
705
406
61
48
2.0
1205
706
75
65
2.0
1905
1206
94
82
2.0
3105
1906
110
98
2.0
4205
3106
125
110
2.0
6105
4206
160
138
2.0
(refer page 6)
Polyethylene Duct
(refer left)
Notes: Check with SSL office for availability and lead time for standard and/or alternative polyethylene

duct sizes
Eccentricity of Tendons
TENDON eCcentricity

TYPE
e mm

705/406
10
1205/706
11
1905/1206
14
3105/1906
15
2206
21
4205/3106
25
6105/4206
28
Notes: e is indicative only and depends

on actual duct ID and number of

strands in tendon
15
Minimum Distance for Bearing Plates to concrete Edges and between
Adjacent Anchorages
The minimum required distance of the bearing plates
to concrete edges and to adjacent anchorage bearing
plates depends in general on:

the post-tensioning force to be transmitted

the concrete strength

the bearing plate dimensions

the reinforcing steel behind the bearing plate

structural requirements
ao

bo

Dsp

fc
= min. distance between axis of two

anchorages
= min. distance from concrete edge to
anchorage axis
= suggested outside diameter of reinforcing
steel spirals
= nominal concrete cylinder strength
Prestressing forces can usually be applied at 80% of

nominal concrete cylinder strength.
MINIMUM ANCHORAGE SPACING AND EDGE DISTANCES

DETAILS
mm
fc
MPa
ao
bo
Dsp
ao
bo
Dsp
ao
bo
Dsp
32
40
50
Notes:
12.7mm & 12.9mm STRAND UNITS

705
1205
1905
3105
4205
406
706
1206
1906
2206
3106
4205
220
130
200
205
125
190
195
120
180
290
155
250
270
150
240
255
145
230
365
190
320
340
185
310
320
180
300
465
235
410
435
225
390
410
220
380
545
275
480
505
260
460
475
250
440
205
120
180
200
120
180
200
120
180
270
145
230
255
145
230
250
145
230
355
180
300
330
175
290
310
175
290
450
225
390
420
215
370
395
210
360
480
240
425
450
230
400
420
225
390
570
285
520
535
275
490
500
265
470
665
335
590
620
310
560
585
300
540
The above details are provided as a guide only and designers should normally satisfy themselves by calculation that the adopted details are suitable for the actual application.
Tung Chung Bridge - Hong Kong
16
15.2mm & 15.7mm STRAND TENDON UNITS
Mt Henry Bridge - Western Australia
slab POST-TENSIONING
slab post-tensioning
Designers, builders, owners and end users of buildings
require more efficiencies today than ever before. The
Structural Systems Slab Post-Tensioning System offers
all the stakeholders in a building project many benefits
including:

Reduced structural depths

Greater clear spans
Design flexibility
Formwork versatility
Reduced construction costs
Enhanced construction speed
Improved durability
Minimum maintenance costs
The system is comprised of high-strength steel strands

placed inside flat ducting, anchored at one end by
deforming the strand and casting it into the concrete,
then at the other end by means of a steel anchorage

casting and anchor block(s) with gripping wedges. After
the concrete has reached a suitable transfer strength,
the individual strands have a specified load applied by
calibrated jacks. The duct is filled with a water/cement
grout mixture to ensure that the system is bonded and
corrosion protection is maintained in service.
Applications for the Structural Systems Slab PostTensioning System include:
Low to high rise residential and commercial
buildings
Industrial floor slabs on grade
Transfer floor structures
Car parks
Water tank bases and walls
Transverse stressing of bridge decks
Al Nuaimiah Towers - Dubai
West India Quay - London
17
live end anchorages
duct
grout tube
grout tube
anchorage block
duct
strand
wedge grips
anchorage casting
Notes:
anchorage casting
strands
wedge
Similar non-reusable recessformers are used at angled edges
barrel
S
tandard flat duct is produced from
0.4mm galvanised steel sheet
Stressing Anchorage (Live Ends)

STRAND SIZE
TENDON UNIT
No. STRANDS
12.7 mm
and
12.9 mm
205
305
505
605
15.2 mm
and
15.7 mm
206
406
506
Notes:

ANCHORAGE
CASTING
RECESS FORMER
FLAT DUCT SIZE

mm
A
mm
B
mm
C
mm
D
mm
E1
mm
E2
mm
F1
mm
F2
mm
2
3
4 or 5
6
155
150
215
270
135
150
220
265
67
75
79
79
100
100
100
100
150
180
265
265
150
180
315
315
100
100
80
80
100
100
100
100
43
43
70
90
2
3 or 4
5
155
215
270
135
220
265
67
79
79
100
100
100
150
265
265
150
315
315
100
80
80
100
100
100
43 x 19
70 x 19
90 x 19
x
x
x
x
19
19
19
19
Tendon units 205, 605, and 206 are supplied with individual barrel anchorages in lieu of anchorage blocks.
Grout tubes are 13mm ID or 19mm ID polyethylene pipe supplied to each end of tendon. Additional intermediate vents can also be supplied (designer to specify requirements).
All sizes are nominal. Some dimensions have been rounded up for normal space, detailing and tolerance requirements.
Dead-End Anchorages
bulbed strand ends
duct
grout tube
dead end plate

duct
grout tube
grout tube
swage plate
duct
swaged strand ends
spacer plate
(not always required)
bulb-type
swage-type

Strand size tendon UNIT

Bulb-Type Dead-End Anchorage

Swage-type dead-end anchorage
DIMENSIONS (mm) dimensions (mm)
A
B
C d
E
F

12.7mm

and

12.9mm

105
205
305
405
505
605
75
135
230
270
350
400
50
50
50
50
50
50
600
600
600
600
600
750
100
125
200
250
300
350
75
75
75
75
75
75
100
150
350
500
500
600

15.2mm

and

15.7mm

106
206
306
406
506
75
135
230
270
350
50
50
50
50
50
750
750
750
750
750
125
150
225
300
350
75
75
75
75
75
100
250
450
600
600
18
coupling anchorages
Coupling Anchorage - 505, 406 & 506
grout tube
duct
swaged strand ends
anchorage
casting
coupling block
wedge grips
Coupling Anchorage - 405
Grout Pump
Coupling Anchorages

Strand Size
Coupling

Unit

12.7mm / 12.9mm

15.2mm / 15.7mm
Coupling Anchorage Details

Dimensions (mm)
B
C
405
505
100
100
220
220
80
110
220
220
506
100
240
120
265
Note: 3 and 4-strand units are coupled using the applicable 5-strand coupler, uno.
19
Anchorage Reinforcement slab system
TENDON
UNIT
No. OF
STRANDS
205
305
505
605
206
406
506
2
3
4 or 5
6
2
3 or 4
5
Notes:

SPIRAL TYPE
LIGATURE TYPE
A
mm
B
mm
N
No.
C
mm
D
mm
90
100
100
110
90
110
110
200
260
260
300
200
300
300
4
4
5
7
4
7
7
200
200
200
200
200
200
200
100
100
130
150
110
130
150
N
No.
2
2
2
2
2
2
2
x
x
x
x
x
x
x
1
1
2
4
2
2
4
17
17
22
25
17
22
25
Reinforcement size 10dia, grade 500MPa to AS/NZS 4671 or grade 460 to BS4449.
fcp = min required air-cured concrete cylinder strength at anchorage at time of stressing.
Details shown are generally satisfactory for most standard situations, however designers should satisfy themselves of the adequacy of local zone anchorage
reinforcement for specific situations.
2x2 ligature
2x1 ligature similar
Spiral Type
2x4 ligature
suggested allowances strand offsets for 19mm flat duct

Strand Size
12.7mm / 12.9mm
15.2mm / 15.7mm
7mm
8mm
12mm
11mm
2.5mm
1.5mm
strand at tendon high point

20
fcp
MPa
strand at tendon low point
Jacking Clearances
double ram jack
single ram jack
Jacking Clearances

Strand Size

A
mm
B
mm
C
mm
D
mm
E
mm
500
600
900
900
750
850
450
450
70
70
12.7mm / 12.9mm
15.2mm / 15.7mm
internal stressing pockets

Notes: Internal Stressing Pockets are used where standard edge stressng is impractical, subject to design check.

Details shown provide typical pocket spacing requirements. Actual details may vary.
Stressing Pocket
21
SLAb post-tensioning applications - suspended slabs

Post-tensioning provides many benefits to a wide range
of suspended structures. These benefits include:
Reduced construction cost

Faster construction
Water resistant properties
Early formwork stripping
Floor to floor height reduction
Reduced foundation load
Improved deflection control
Greater column free areas
Many types of suspended slab structures typically

realise the benefits of post tensioning, such as:
Carparks
Apartment buildings
Commercial office space
Retail centres
Vertical load transfer structures
Hospitals
Storage facilities
Public buildings such as stadiums, exhibition
centres, schools and institutional facilities
Peppers Pier Resort - Queensland
22
Wollongong Links Project - NSW
Different formwork systems are compatible with posttensioning, namely:
Conventional plywood systems

Permanent metal deck systems
Ribbed slabs
Precast systems
Structural Systems has many years of experience in the

design and installation of post-tensioned suspended
slabs and can bring measurable benefits to your
project.
Design of post-tensioned - suspended slabs

Structural Systems can offer design input from initial
advice to fully detailed design for construction drawings.
Typical post-tensioned floor configuration and details are:
The design of post-tensioned suspended slabs requires

sound engineering consideration in order to maximize
the benefits for all stakeholders in a project.
banded slab
DEFINITIONS
Lb = Band Span
Ls = Slab Span
L = Design Span (Greater of L1 & L2)
Note: For Slab End Spans,
Add 15-20% to Slab Thickness from charts
flat slab
flat plate
T = Internal Slab Thickness

D = Overall Band Depth
Bw = Suggested Band Width Approx. (suit formwork)
P = Overall Drop Panel Depth (1.8xT)
TYPICAL DESIGN LOADS

LL = 5kPa, ADL = 1kPa



LL = 2.5kPa, ADL = 0.5kPa
Specifying Post-Tensioning
It is important that the design requirements are achieved
on site. Good engineering notation can greatly assist in
achieving this, with particular attention to the following;
The System. State that the design is based on
the Structural Systems SLAB post-tensioning system.
This ensures that a fully tested and code compliant
system will be installed.
Concrete. Nominate the 28 day characteristic
compressive strength and shrinkage characteristics
required. Some projects may have additional
requirements.
Concrete Strength at Transfer fcp. This is the
minimum compressive strength that is required prior to
fully stressing the tendons. Concrete testing of site and
air cured specimens should be carried out to ensure this
strength has been achieved prior to application of the
final stressing.
Tendons. Clearly indicate the type and location of

anchorages and number of strands in each tendon. Check
that stressing access is possible at live ends.
Profiling. High and low points should be nominated.
Full tendon profiles can then be determined on installation
shop drawings. Profiles are usually parabolic.
Stressing Procedure. A two stage stressing procedure
is usually specified. Initial or 25% load is applied at 24
hours after the slab pour, and final or 100% load is applied
when the concrete transfer strength is released.
Grout. A water/cement ratio of not more than 0.45
is usually sufficient to ensure adequate grouting and
strength.
23
Detailing of post-tensioned - suspended slabs
Structural detailing is an art that engineers develop with

experience and it is an essential part of a cost effective
and reliable structure. Below are a selection of tried and
proven details that Structural Systems recommend for a
range of situations. A key factor in achieving a successful
Post-Tensioned Structure is a sound understanding of and
a considered allowance for normal concrete shrinkage
movements.
Construction
Structural Systems designers have worked closely over
many years with builders and construction personnel
resulting in a well understood system that enhances the
construction process. An appreciation of the construction
process will enable all parties involved in the on site
works to benefit from the system. The typical construction
sequence is as follows;
Erect formwork
Install bottom reinforcement
Install post-tensioning
Install top reinforcement
Prepour inspection and pour concrete
Strip edge forms
Initial/Partial stressing of tendons
Final/Full stressing of tendons
Obtain engineers approval and cut
off excess tendon strand
Grout the tendons
Strip formwork and back prop
as required
Cabrini Hospital - Melbourne
24
slab post-tenSioning
Slab post-tensionING applications - slab on ground

The post-tensioning of slabs on ground is providing
many developers and builders with a cost effective
pavement solution. Benefits realised with post tensioned
slabs on ground include:
Large joint free slab areas
Reduced construction costs
Less sub base preparation and/or
excavation
Faster construction time
Reduced on going maintenance costs
Facilities that have adopted a post-tensioned slab on
ground system include:
Distribution warehouses
Container Pavement, Port Botany - NSW
Freezer stores
Container terminal facilities
Rail freight facilities
Aircraft hangers
Water retaining structures
Sporting venues
Raft slabs
Design
The design of post-tensioned slabs on ground involves
the careful analysis of the loads applied to the slab,
the interaction between the slab and the ground that
supports it, restraint forces and temperature effects.
Structural Systems has refined the design process and
has achieved outstanding results on many projects.
Our design and construction expertise for preliminary
design advice through to final design and construction
activities is available to assist builders, engineers and
developers in achieving optimum solutions for slab on
ground applications.
Computer modelling and Analysis
25
DEsign of post-tensioned slab on ground

Points to consider in the design process include:
Design Loads and Load Configurations
a) typical design racking layout
DATA

- Design Axle load P

- Wheel Spacing W (2 or 4 wheels etc.)
- Axle Load Repetitions
- Wheel Contact Stress
Typical racking storage
Sub-grade Friction
b) design wheel / axle details
Thermal Effects
Daily ambient temperature variations give rise to
temperature gradient stresses through the slab depth
which need to be accounted for in the design. Typical
gradients of 0.02 C/mm and 0.04 C/mm are often
used for internal and external slabs respectively causing
bottom fibre tensile stresses that are additional to the
load stresses.
Warehouse floor construction using laser screeds
26
Normal elastic and shrinkage movements give rise to

frictional restraint stresses between the slab and the
prepared subgrade. The typical design friction coefficient
for concrete laid on a plastic membrane over clean sand
bedding is around 0.5 to 0.6.
Sub-base Parameters
A typical slab design will include the analysis of the
slab supported by the ground sub-base. Modelling of
the sub-base requires geotechnical data such as CBR,
and/or the modulus of sub-grade reaction.
Raft Foundation - The Moorings, Western Australia
Slab post-tenSioning
DEsign of post-tensioned slab on ground

Good detailing of post-tensioned slabs on ground is vital in
achieving a successful and relatively crack free slab.
The following diagrams indicate key details typically

recommended by Structural Systems:
Column blockout detail
typical warehouse plan
Note: As a guide, allow for total slab edge & M.J. movements of approximately 0.5mm per metre length of slab

(e.g for 60m long slab, each edge moves approx 15mm over the normal life of the slab),
Construction
Pour Sequence
Structural Systems design and construction experience

is based on being the leader in the field of posttensioned slabs on ground. The combination of innovative
design and expedient site practices ensures that the
construction phase is a seamless operation. The main
items to consider for the construction phase are;
The sequence of slab pours and their respective stressing

requirements should be optimized to ensure the best
programme outcome.
Pour Size
A pour size of between 1500m2 and 2000m2 should
typically be considered and planned.
Curing and Weather Protection

With large pours the slab is initially susceptible to
shrinkage effects hence it is important to cure and
protect the slab from extreme conditions such as heat,
high evaporation or extreme cold. The construction
of warehouse roofs prior to pouring slabs is a typical
technique adopted to provide some protection.
27
PreSTRESSING TECHNOLOGY
multi-wire post-tensioning
The BBR SSL Multi-Wire System is more compact
than the multi-strand system and is often preferred for
coupled cables in incrementally launched bridges, and is
ideally suited where cables are to be prefabricated and
where restressing or destressing is required.
The multi-wire tendon is composed of a bundle of 7mm
dia. wires (plain or galvanised). Each individual wire is
fixed in the anchorage with a multi-wire button head,
which is cold-formed onto the wire by means of special
machines.
Each wire is mechanically fixed in the anchor head
and reaches the full rupture load of the prestressing
steel without any slippage. Therefore the wire
bundle can sustain the maximum ultimate load.
The prestressing force is transmitted to the concrete
under precisely known conditions without any risk
of slippage of the prestressing steel.
Monitoring of the prestressing force and if
necessary restressing can be carried out reliably
and economically. If required, the tendon can also
be completely destressed.
The anchorage resists with a high degree of safety
dynamic loads and also exceptional effects such as
shock loads.
Centrepoint Tower - Sydney
Typical applications include:

Coupled cables in incremtally launched bridges.
Cable stay applications.
Restressable tendons.
Heavy lifting and lowering cables.
Restressable ground anchors.
Narrows Bridge Duplication - Western Australia
28
MULTI-wire POST-TENSIONING
Standard Tendons
The anchoring method allows the production of posttensioning tendons with any number of single wires and
therefore with any given magnitude of prestressing force.
The most commonly used wire diameter is 7 millimetres.
With the following range of STANDARD TENDONS, all

prestressing requirements occurring in the construction
of bridges, buildings and other structures can be met.
For special applications, eg; nuclear vessels, tendons up
to 15,000 kN ultimate capacity are available.
Standard SSL - BBR Wire Tendons

Number of wires, dia. 7mm
19
31
42
55
61
85
109
121
143
Minimum Breaking Load (Rm = 1670 MPa) kN

Stressing force at 0.8 x MBL
kN
Stressing force at 0.75 x MBL
kN
514
412
386
1222
977
916
1993
1595
1495
2701
2160
2025
3537
2829
2652
3922
3138
2942
5466
4372
4099
7009
5607
5257
7780
6224
5835
9195
7356
6896
Tendon nominal cross sectional area
mm2
308
731
1194
1617
2118
2349
3273
4197
4659
5506
Weight of tendon wire

Duct I.D.
kg/m
mm
2.42
35
5.74
50
9.36
55
12.68 16.61 18.42

65
80
85
25.67
100
32.92 36.54
110
120
43.19
130
Notes:
Rm = Characteristic Tensile Strength to AS 4672 and/or BS 5896
Grouting of Ducts
SSL has developed grouting methods utilising special
colloidal mixers which result in an optimal grouting of the
tendon ducts.
The prestressing force can be measured with an accuracy

of 2% by using calibrated 150mm face bourdon type
pressure gauges.
Prestressing Equipment
The prestressing equipment consist of a hydraulic
jack, trestle and pull-rod, which is connected to the
stressing anchorage. For tendon elongations greater
than the stroke of the jack, the pull-rod is temporarily
anchored with a lock-nut and the jack is recycled.
Prestressing Jacks

Stressing Jack Type
NP 60
NP 100
NP 150
NP 200
NP 250
NP 300
GP 500
GP 800
Maximum Jacking Force

Jack Diameter
Stroke
Weight
Clearance Requirement A
620
160
100
28
1700
1030
205
100
50
1700
1545
250
100
83
1700
2060
290
100
117
2000
2575
315
100
147
2000
3090
350
100
196
2000
5150
560
400
1260
2500
8000
660
400
2000
2500
29
Notes:
kN
mm
mm
kg
mm
Check jack size and availability with your local SSL office
multi-wire post-tensioning
Stressing Anchorage Type L
Number of wires
dia. 7mm
Anchor
12
19
31
42 55
61 85 109 121 143
a mm 63
74
91 108 123 135 156 180 205 240 245
Trumpet Length b mm 250 250 250 280 300 300 300 340 360 400 500
Diameter
c mm 70
88 102 123 138 153 171 193 219 240 252
Bearing Plate d mm 140 170 200 245 285 315 345 400 450 500 520
Thickness
Stressing Anchorage Type A
dt mm 14
16
20
25
30 35
40 50
12
19
31
42
55
61
85 109 121 143
e mm 25
27
36
43
49
56
67
78
Number of wires
dia. 7mm
Anchor
60
70
70
85 140 145
Elongation, max f mm 200 200 200 200 200 250 250 350 350 400 400
Trumpet length g mm 170 185 200 280 310 335 360 390 420 450 500
Fixed Anchorage Type S
Diameter
h mm 37
Bearing plate
i mm 140 170 200 235 270 300 330 380 430 480 500
Thickness
it mm 16
Number of wires
dia. 7mm
Fan length
49
59
76
87
97 105 120 135 145 160
20
25
30
40
45
50
60
70
80
80
12
19 31
42
55
61
85 109 121 143
k mm 460 550 660 830 880 960 1010 1060 1180 1220 1260
Anchor plate, sq l mm 120 160 200 250 280 320 350 400 450 470 520
rectangular
l mm 70
90 120 140 160 180 200 240 260 280 300
w mm 200 270 340 420 500 560 600 660 760 790 900
Fixed Coupling Type LK
Number of wires
dia. 7mm
12
19
31
42
55
61
85 109 121 143
Trumpet length q mm 230 260 290 350 410 430 470 570 630 680 730
Diameter
Movable Coupling Type LK 1
r mm 70
Number of wires
dia. 7mm
88 102 123 138 153 171 193 219 250 260
12
19
31
42
55
61
85 109 121 143
Trumpet length min s mm 600 620 670 750 810 880 950 1080 1150 1220 1260
Diameter
t mm 70
88 102 123 138 153 171 193 219 250 260
Special Application Anchorages

Details of Anchorages for various special applications are also available on request .
30
bar POST-TENSIONING
bar post-tensioning
Macalloy 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.
The robust coarse thread (CT) on the Macalloy bar
ensures rapid and reliable assembly. This is particularly
suitable for onsite use and reuse.
Typical Applications
Corrosion Protection
Buildings
Prestressed Beams and Columns
Precast Connections
Temporary Bracing
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 excellent protection. Anchorage recesses
must also be filled with cement mortar to protect
these end zones.
Bridges
Stay Cables and Hangers
Precast Segments
Strengthening (Timber & Steel Bridges)
Tension Piles and Caissons
Wharves & Jetties
Stressed Deck Planks
Tie Backs

Soil and/or Rock Anchors
Permanent and Temporary Anchors
Uplift Anchors (Dam & Foundation)
Tunnel Roof Bolting
Soil Nails and Rock Bolts
Slope Stabilisation
Crane and Tower Bases
Specialist Engineering
Heavy Lifting
Formwork Ties and Hangers
Frame Ties
Pile Testing
Architectural Ties and Stays
When bars are used in an exposed environment then

other corrosion protection systems are available for the
bar and fittings. These include:
greased and sheathing bar
denso wrapping
epoxy painting
Temporary Bar Anchors

Anchors used in a temporary environment may be
used without protection apart from grout required to the
bond length.
Permanent Bar Anchors

These anchors require installation into corrugated
polyethylene sheathing or galvanised duct similar to
strand anchors to provide multiple levels of protection.
This is accomplished by the internal grout and sheathing
barrier.
Bearing Plate
Nut
Bar
Characteristic Properties
Macalloy Bar Properties are listed in the following
tables.
Washer
Coupler
Macalloy 1030 Bar Components
31
BAR post-tensioning
RANGE OF MACALLOY 1030 BAR
NOMINAL
DIAMETER
NOMINAL CROSS
SECTION AREA
mm
mm2
MACALLOY 1030
kg/m
*MACALLOY S1030
kg/m
20
25
26.5
32
36
40
50
75
315
491
552
804
1018
1257
1963
4185
4.09
4.58
6.63
8.35
10.30
15.72
33.00
2.53
4.09
6.63
10.30
-
MASS OF BAR
MAJOR DIAMETER
OF THREADS
mm
MIN. HOLE
DIAMETER IN
STEELWORK
mm
22.0
28.9
30.4
36.2
40.2
45.3
54.8
77.2
24
31
33
40
44
49
59
82
MECHANICAL PROPERTIES OF MACALLOY 1030 BAR

GRADE
CHARACTERISTIC
ULTIMATE TENSILE
STRENGTH
MPa
MINIMUM 0.1% PROOF

STRESS
MINIMUM
ELONGATION
MPa
APPROXIMATE
MODULUS OF
ELASTICITY
GPa
Macalloy 1030
25-50mm
1030
835
170
Macalloy 1030
75mm
1030
835
205
*Macalloy S1030
1030
835
10
185
CHARACTERISTIC LOADS FOR MACALLOY 1030 BAR

NOMINAL DIAMETER
CHARACTERISTIC BREAKING LOAD (MBL)
mm
*MACALLOY S1030
kN
MACALLOY 1030
kN
*MACALLOY S1030
kN
20
25
26.5
32
36
40
50
75
506
569
828
1049
1295
2022
4311
323
506
828
1295
-
410
460
670
850
1050
1639
3495
262
410
670
1050
-
* Macalloy S1030 is made from stainless steel
32
MINIMUM 0.1% PROOF LOAD
MACALLOY 1030
kN
bar POST-TENSIONING
MACALLOY 1030 COMPONENT PARAMETERS

ITEM
UNIT
NOMINAL BAR DIAMETER - mm
Bars
Sectional area
Mass per metre
Metre run of bar per tonne
Characteristic failing load
Prestress at 70% characteristic
Minimum centres for anchorage
mm2
kg
m
kN
kN
mm
201
314.2
2.466
405
314
220
100
251
490.9
4.069
246
506
354
100
26.5
551.5
4.560
219
569
398
110
32
804.3
6.661
150
828
580
125
*Flat Nuts
Nut reference
Length
Width across flats (DIA for 75mm bar)
Weight
mm
mm
kg
FSSN20
25
42
-
FN25
33
46
-
FN26.5
37
50
0.46
FN32
41
56
0.56
*Flat
Washers
Washer reference
Outside diameter
Thickness
mm
mm
FSSW20 FSW25 FSW26.5 FSW32 FSW36 FSW40 FSW50

50
60
65
70
75
80
105
5
5
5
5
5
5
5
Couplers
Coupler reference
Outside diameter
Length - standard
Length - stainless
Weight
mm
mm
mm
kg
FSSC20
35
65
-
FC25
42.5
85
80
-
FC26.5
42.5
90
0.54
FC32
50
115
95
0.94
FC36
57.5
130
1.50
FC40
62.5
140
120
1.78
FC50
76
170
3.10
FC75
110
230
9.00
End Plates Plate reference

Length
Width
Thickness - standard
Hole diameter
Thickness - threaded
mm
mm
mm
mm
mm
FSSP20
100
100
25
26
-
FP25
100
100
40
35
40
FP26.5
110
110
40
36
40
FP32
125
125
50
41
50
FP36
140
140
50
45
50
FP40
150
150
60
52
60
FP50
200
175
60
61
70
FP75
300
250
75
82
110
Ducts
Sheathing i/d
Coupler-sheathing i/d recommended
Coupler-sheathing minimum
mm
mm
mm
41
50
45
41
59
52.5
41
59
52.5
50
66
60
50
71
65
61
75
70
71
91
90
91
125
125
Grouting
flange
Flange reference
Length /o/dia
Height
mm
mm
GF25
125
40
GF25
125
40
GF32
140
40
GF36
140
40
Threads
Standard
thread
lengths
(see fig on
p30)
Pitch
Length - Jacking end (standard) S1

- Dead end (standard) S2

- Coupler (standard)
X1 (min)
X2 (min)
X3 (min)
mm
mm
mm
mm
mm
mm
mm
2.5
250
100
40
75
42
12
6.0
250
100
45
82
49
12
6.0
250
100
50
91
53
12
6.0
250
100
60
105
57
12
6.0
250
100
65
115
62
12
8.0
250
100
75
130
71
16
8.0
250
100
85
165
91
16
8.0
360
160
150
235
116
16
36
40
50
75
1017.9 1256.6 1963.5 4185.4
8.451 10.410 16.020 33.200
118
96
62
30
1049
1295
2022
4311
734
907
1415
3018
140
150
175
250
FN36
46
62
0.74
FN40
51
65
0.86
FN50
71
90
2.55
FN75
100
135
7.70
-
* Spherical nuts and washers are available if required for rotation.
20mm bar available in stainless steel grade only.

Bar range available on request
Sydney Hockey Centre, Homebush - NSW
33
MACALLOY 1030 BAR END THREAD DIMENSIONS
X1 = live end
X2 = dead end
X3 = length of bar past nut or thru threaded plate
S1 = live end thread
S2 = dead end thread
L = length over plates
MACALLOY 1030 TYPICAL END BLOCK ARRANGEMENT
MACALLOY 1030 SUGGESTED MILD STEEL END BLOCK REINFORCEMENT

NB: Helix and links must be used together with minimum 35 MPa concrete - see figure above
MACALLOY
DIAMETER
Notes:

HELIX
LINKS
mm
ROD DIAM.
mm
I/D
mm
PITCH
mm
TURNS
No.
ROD DIAM.
mm
SPACING
mm
NUMBER
25
26.5
32
36
40
50
75
12
12
12
12
12
16
20
130
130
165
195
220
250
350
40
40
40
40
40
50
75
5
5
6
7
7
8
8
8
8
8
8
8
10
16
70
70
80
80
80
100
100
3
3
3
4
4
4
6
A longitudinal length of rod may be used to attach the links but it is not required as part of the reinforcement
A more detailed explanation of the Macalloy Post Tensioning System is available in the Macalloy Design Data Handbook
There are many permutations possible to achieve satisfactory construction details, and advice is readily available from Structural Systems
OTHER MACALLOY BAR SYSTEMS ALSO AVAILABLE
34
Macalloy
Macalloy
Macalloy
Macalloy
Macalloy
460 carbon steel tendons

S460 stainless steel tendons
Guy Linking stainless steel bar tendons
Guy Linking stainless steel cable tendons
17MHS Sheet piling ties
Macalloy 500 Reinforcing bars

Macalloy 500 Tie bars
Macalloy 650 Stainless Tie bars
Macalloy-Tensoteci Galvanised cable tendons
ground anchor systemS
ground anchor SystemS

Structural Systems Ground Anchors have been utilised
world wide in conjunction with our construction
partners the BBR group of Switzerland. Ground
Anchors comprised of wires, strands or bars can be
installed into rock or soil and secured by injecting
with cement grout.
Standard Structural Systems Ground Anchors can
provide an ultimate load of between 368kN and
23,750kN depending on the configuration.
SSL BBR Anchors have been the largest and longest
installed anywhere around the world and our technical
expertise in this field is internationally recognised.
Ross River Dam - Queensland
Typical applications of Structural Systems Ground

Anchors include:
retaining structure tie backs
resistance of uplift forces
slope stabilization
underground structures
dam stabilization
tension foundations
soil nailing (bar type anchors)
Transporting worlds longest ground anchors - Canning Dam - Western Australia
Transporting ground anchors
Anchor installation
Anchor Fabrication - Canning Dam - Western Australia
35
ground anchor SystemS

STRAND TYPE ANCHORS
36
ground anchor systemS
TYPICAL GROUND ANCHOR TENDON CONFIGURATIONS

TENDON STRAND MAXIMUM
/ BAR SIZE
STRANDS
PER UNIT
MINIMUM
BREAKING
LOAD
mm
STRAND
15.2mm
or
15.7mm
BORE HOLE DIAMETER
TEMPORARY PERMANENT CORRUGATED

ANCHORS
ANCHORS
mm
mm
mm
No.
kN
2
4
7
12
19
22
27
31
42
55
65
91
500
1000
1750
3000
4750
5500
6750
7750
10500
13750
16250
22750
76
89
102
114
165
165
178
178
229
241
254
311
368
736
1288
76
89
102
STRAND
12.7mm
or
12.9mm
MACALLOY BAR
26.5
32
40
50
75
Notes:

102
127
152
178
216
216
216
216
311
311
311
356
50 / 65
65 / 85
80 / 100
100 / 120
125 / 165
125 / 165
125 / 165
125 / 165
210 / 230
210 / 230
210 / 230
250 / 270
SMOOTH
BEARING PLATE
SIZE
TYPICAL
mm
mm
55
67
82
102
150
150
150
150
225
225
225
257
/
/
/
/
/
/
/
/
/
/
/
/
63
75
90
110
160
160
160
160
235
235
235
270
200 x 200 x 32
200 x 200 x 36
300 x 300 x 50
350 x 350 x 60
400 x 400 x 70
450 x 450 x 80
500 x 500 x 80
500 x 500 x 90
600 x 600 x 100
700 x 700 x 120
700 x 700 x 140
900 x 900 x 160
under development - refer SSL
91+
2
4
7
PERMANENT ANCHOR
SHEATH SIZE ID / OD
102
127
152
50 / 65
65 / 80
80 / 100
55 / 63
67 / 75
82 / 90
200 x 200 x 32
200 x 200 x 36
250 x 250 x 40
larger sizes on request - refer SSL

1
1
1
1
1
569
828
1295
2022
4311
76
102
102
127
152
127
152
152
175
203
65 / 80
80 / 100
80 / 100
100 / 127
130 / 150
n/a
n/a
n/a
n/a
n/a
200
250
300
300
400
x
x
x
x
x
200
250
300
300
400
x
x
x
x
x
40
50
60
60
90
Strand tendons are based on MBL = 184kN (12.7mm strand) and MBL = 250kN (15.2mm strand) (Higher strand / anchor capacities available on request)
Details listed apply to typical applications and may vary to suit actual applications
Macalloy Bar tendons are more commonly used for short anchor lengths
Macalloy Bar anchor details exclude allowance for coupling of bars - refer SSL for details if required
37
external
pREStReSSING
External prestressing was first used in the late 1920s
and has recently undergone a resurgence being
used in bridges, both for new construction as well as
strengthening of existing structures.
Features of External Prestressing

External prestressing is characterised by the following
features:
The prestressing tendons are placed on the outside
of the physical cross section (mostly in concrete)
of the structure.
External post-tensioning - Navia, Spain
readily carried out compared to internal, bonded

prestressing.
c) Due to the absence of bond, it is possible to
restress, destress and exchange any external
prestressing cable, provided that the structural
detailing allows for these actions.
d) Improves the concrete placing due to the absence
of tendons in the webs.
The forces exerted by the prestressing tendons

are only transferred to the structure at the
anchorages and at deflectors.
e) Improvement of conditions for tendon installation

which can take place independently from the
concrete works.
No bond is present between the tendon and

the structure, except at anchorage and deflector
locations.
f) Reduction of friction losses, because the

unintentional angular changes, known as wobble,
are practically eliminated. Furthermore with
the use of a polyethylene sheathing the friction
coefficient is drastically reduced compared to
internal bonded prestressing using corrugated
metal ducts.
Advantages of External Prestressing

Compared to internal bonded post-tensioning the external
prestressing has the following distinct advantages:
a) The application of external prestressing can be
combined with a broad range of construction
materials such as steel, timber, concrete,
composite structures and plastic materials. This
can considerably widen the scope of the posttensioning applications.
b) Due to the location and accessibility of the
tendons, monitoring and maintenance can be
38
g) External prestressing tendons can easily and

without major cost implication be designed to be
replaceable, de-stressable and re-stressable.
h) Generally the webs can be made thinner, resulting
in an overall lighter structure.
i) Strengthening capabilities.
As an overall result, better concrete quality can be obtained
leading to a more durable structure.
external POST-TENSIONING
Typical Applications for External

Prestressing
- Alternatively a fabricated steel bearing plate

anchorage can be used in lieu of the cast
anchorage.
Typical applications where external tendons are feasible,

practical and economical, are:
- Repair work and strengthening of all kinds of
structures
- Precast segmental construction
- Simple and continuous spans
- Underslung structures
- Incremental launching procedure, in particular
concentric prestressing
Basic Type
The basic SSL BAR CONA External tendon is practically
identical to the SSL Multi-Strand System for internal
applications:
ANCHORAGE CASTING
Fig. 1. Standard Cona Compact Anchorage Assembly
- The tendon is formed from standard 15.2mm/

15.7mm diameter strands with minimum breaking
load of 250 kN or 279 kN.
- The tendon is filled with cement grout after it has
been tensioned. Depending on requirements,
the anchor heads may be protected by a cap, or
alternatively the anchorage recess is filled with nonshrink concrete.
- The duct is from high density polyethylene and

continuous from one anchorage to the other.
The tendon sheathing passes freely through
intermediate diaphragms and through deflectors
with a metal or HDPE sleeve providing the required
penetration.
- A standard CONA Compact anchorage assembly
consisting of anchor head, wedges, anchorage
casting and polyethylene trumpet safely
transfers the prestressing forces to the structure
(see Fig. 1).
Fig. 2. SSL-CONA External with anchorage casting
SSL CONA EXTERNAL TENDONS

Main Dimensions
NUMBER OF
STRANDS
15.2mm / 15.7mm
7
12
19
31
42
DIMENSIONS (mm)
TYPE
706
1206
1906
3106
4206
A1 x A1
E1
AD/ID
ad/id
215
265
335
395
500
150
180
230
290
340
52
65
80
97
116
105
115
130
150
155
355
425
511
650
950
109
138
178
222
283
75
80
90
100
160
75 / 66.4
90 / 79.8
110 / 97.4
140 / 124
210 / 200
90 / 79.8
110 / 97.4
140 / 114.4
180 / 147.2
243 / 225
39
PreSTRESSING TECHNOLOGY
cable stay
systemS
Structural Systems can provide strand (BBR HiAm
ConaTM) stay cables, wire (DinaTM / HiAmTM) stay cables,
and Carbon stay cables for a wide variety of structures,
drawing on both local and global expertise and resources
of the BBR Network. For suspension bridges, BBR
Technology can also be used for the main suspension
cables as well as for the hangers.
Stay cables may be plain strand / wire unsheathed for
temporary applications.
Sydney Athletics Centre - New South Waies
Eleanor Schonell Bridge - Queensland
40
For permanent stay cable applications, galvanised,

waxed and individually sheathed strands, enclosed in
an external sheath are adopted; or wires enclosed in
a sheath and the voids filled with a flexible corrosion
protection compound.
In recent years a fatigue stress range of 200 N/mm2
for 2x106 load cycles in combination with angular
rotations at the anchorages has been adapted and is
now specified by most codes and recommendations.
BBR Stay Cable Technology has fulfilled such fatigue
testing.
cable stay systemS
Strand Stay Cables

BBR HiAm ConaTM Parallel Strand Stay Cables Installation
is typically performed on site using the strand-by-strand
method. Each strand is tensioned immediately after
installation, using the BBR isostress tensioning method,
ensuring an equal force distribution among the strands
of an individual cable. Alternatively, fully or partially
prefabricated cables can be installed and tensioned.
Standard Anchorage Components
Strands are generally 15.7mm diameter, low relaxation

grade, minimum guaranteed ultimate tensile stress of
1770 N/mm2 or 1860 N/mm2 and subject to fatigue
testing by the manufacturer. Strands are galvanized,
waxed and individually sheathed with a continuous and
wear resistant HDPE coating, providing each strand with
an individual multilayer protection system. Alternatives
may also be available upon request. A ring nut screwed
on anchor heads transfers the cable loads by contact
pressure to the supporting bearing plates, and allows
adjustment of stay force. All anchorage components are
designed for a stress range greater than 300 N/mm2 and
to withstand the ultimate breaking load of the strand
bundle with adequate safety.
Supplemental internal or alternatively external damping

devices protect the stay cable from vibrations.
Another effective countermeasure against wind and
rain-induced vibrations is the use of a helical rib on
the outside of the HDPE, architecturally coloured
co-extruded stay pipe.
Final stay cable force may also be adjusted using a
specially designed multi-strand jack acting on the entire
stay cable. Individual strands can be re-stressed at any
time during or after the installation, allowing not only
for a re-stressing but also for the selective removal,
inspection and replacement of individual strands or the
entire stay cable.
STRAND DIAMETER: 15.7mm to prEN 10138-3 (refer design DATA)
HiAm CONA
Type
Forces
Structure
Axial Cable Force
Bearing Plate / Steel Guide

Pipe
Ultimate Working
Short
Fatigue
Term
Steel 355 MPa yield stress

structural grade
Anchorage
Stay Pipe Weight

HDPE
BBR HiAm Anchorage System
Cable
SDR32
Plate
Guide Pipe
Diam. CBP
Diam. DGP
kN
mm
mm / mm
mm
mm
153
30
57
70.0 / 5.0
75
377
460
90
85
101.6 / 5.0
1953
879
1074
210
133
12 06
3348
1507
1841
360
19 06
5301
2385
2916
570
22 06
6138
2762
3376
27 05
7533
3390
31 06
8649
37 06
42 06
IA
Diam.
S
mm
mm
mm / mm
kg/m
390
190
1000
1.3
110
400
200
1500
63 / 4.0
4.7
152.4 / 4.5
165
410
210
2000
90 / 4.0
10.3
170
193.7 / 5.6
210
420
220
2125
110 / 4.0
17.1
210
244.5 / 6.3
260
435
235
2250
125 / 4.0
26.4
660
225
244.5 / 6.3
275
435
235
2375
140 / 4.4
30.7
4143
810
248
273.0 / 6.3
305
450
250
2500
160 / 5.0
37.8
3892
4757
930
264
298.5 / 7.1
325
445
245
2625
160 / 5.0
43.1
10323
4645
5678
1110
288
323.9 / 7.1
355
465
265
2750
180 / 5.7
51.6
11718
5273
6445
1260
305
323.9 / 7.1
375
465
265
2850
180 / 5.7
58.2
MBL
Fwl
Fext
Ffat
100%
45%
55%
200 MPa
kN
kN
kN
1 06
279
126
3 06
837
7 06
Diam.
GA
OD / e
HA
Stressing Fixed
Cable
OD / e
48 06
13392
6026
7366
1440
327
356.6 / 8.0
400
480
280
2950
200 / 6.3
66.8
55 06
15345
6905
8440
1650
349
368.0 / 8.0
425
480
280
3050
200 / 6.3
75.9
61 06
17019
7659
9360
1830
367
406.4 / 8.0
450
495
295
3150
225 / 7.1
84.8
69 06
19251
8663
10588
2070
389
406.4 / 8.0
475
500
300
3250
225 / 7.1
95.3
73 06
20367
9165
11202
2190
400
419.0 / 8.0
490
490
290
3350
250 / 7.9
1101.7
75 06
20925
9416
11509
2250
405
457.0 / 10.0
495
510
310
3450
250 / 7.9
104.3
85 06
23715
10672
13043
2550
430
457.0 / 10.0
525
515
315
3550
280 / 8.8
119.0
91 06
25389
11425
13964
2730
445
508.0 / 11.0
545
525
325
3650
280 / 8.8
126.8
97 06
27063
12178
14885
2910
458
508.0 / 11.0
560
525
325
3750
280 / 8.8
134.7
109 06
30411
13685
16726
3270
485
508.0 / 11.0
595
525
325
3850
315 / 9.9
152.4
121 06
33759
15192
18567
3630
510
559.0 / 12.5
625
545
345
3950
315 / 9.9
168.1
35433
15945
19488
3810
522
559.0 / 12.5
640
555
355
4050
315 / 9.9
176.0
127 06
Notes:
e = nominal wall thickness
41
cable stay systemS

BBR HIAM Stay Cables
Cable Size (wires per cable)
n 7 No.
56
91
Cable
FUnom
kN
3600
5850
7775 10475 12595 14330 16840 19345 21465 23585 25320 27055
Fmax
kN
1620
2635
3500
4715
5670
6450
7580
Steel Weight
kg/m
16.9
27.5
36.6
29.2
59.2
67.4
79.2
91
100.9
111
Cable Weight
kg/m
23.8
33.2
43.8
58.0
71.2
78.4
93.8
104
118.7
128
Breaking Load
Max. Working Load
HDPE Stay Pipe
PE
Wall Thickness
HDPE Telescope Pipe
PE t
Wall Thickness
Steel Guide Pipe
(outer/inner diameter)
121
163
196
223
262
301
8705
334
367
394
421
9660 10615 11395 12175

119
127.2
138.3 145.5
mm
110
110
125
140.0
160
160.0
180
180
200
200
210
210
mm
10.0
10.0
11.4
12.8
14.6
14.6
16.4
16.4
18.2
18.2
19.1
19.1
mm
140
140
160
180.0
200
200.0
225
225
250
250
250
250
mm
12.8
12.8
14.6
16.4
18.2
18.2
20.5
20.5
22.8
22.8
18.0
18.0
mm 229.0 / 267.0 / 298.5 / 343.0 / 355.6 / 368.0 / 406.4 / 445.0 / 445.0 / 470.0 / 495.0 / 495.0 /
mm
211.4
251
282.5
311.0
330.6
352.0
378.0
405.0
416.6
435.0
455.0
470.0
Bearing Plate
mm
365
430
480
545.0
590
625.0
675
730
755
795
830
850
ThicknesS
mm
45
55
60
70
75
75
85
95
95
100
110
105
Centre Hole
mm
211
251
282
311.0
330
352.0
378
405
417
435
455
470
Socket Outer Diameter
mm
195
235
265
295
315
335
360
385
400
420
435
450
Length Stressing Anchorage
LHM
mm
355
425
480
550
605
635
665
710
755
790
815
845
Length Fixed Anchorage
LHF
mm
320
370
415
465
505
525
540
575
605
635
650
675
Lock Nut
mm
245
290
330
365
390
420
450
480
500
520
540
560
HM
mm
75
90
105
120
125
135
150
160
165
170
180
185
Protection Cap
mm
219
259
289
319
339
359
389
409
429
449
459
479
LSm
mm
283
338
378
433
483
503
518
553
593
623
638
663
Weight of Anchorage
(excl. Anchor Plate and Guide Pipe)
42
LSf
mm
178
203
213
228
253
253
253
268
283
288
293
303
stress.
kg
93
157
226
314
391
465
567
668
787
898
998
1110
fixed
kg
86
142
203
281
347
412
495
600
682
779
861
957
cable stay systemS
BBR Dina STAY CABLES

Cable Size (wires per cable)
n7
No.
13
22
31
37
55
70
91
103
121
145
157
181
199
Cable
FUnom
kN
835
1415
1990
2380
3535
4500
5850
6620
7775
9320
10090
11635
12790
Fmax
kN
375
635
895
1070
1590
2025
2635
2980
3500
4195
4540
5235
5755
Steel Weight
kg/m
3.9
6.6
9.4
11.2
16.6
21.1
27.5
31.1
36.6
43.8
47.4
54.7
60.1
Cable Weight
kg/m
6.4
8.8
12.4
15.8
20.7
27.6
33.2
39.0
43.8
53.1
56.4
67.2
72.0
Breaking Load
Max. Working Load
HDPE Stay Pipe
PE
Wall Thickness
HDPE Telescope Pipe
PE
Wall Thickness
Steel Guide Pipe
Stressing Anchorage
Tm
(inner / outer diameter)

Fixed Anchorage
Tf
(inner / outer diameter)

Bearing Plate
63
75
90
90
110
110
125
125
140
140
160
160
5.8
5.8
6.9
8.2
8.2
10.0
10.0
11.4
11.4
12.8
12.8
14.6
14.6
mm
75
75
90
110
110
140
140
160
160
180
180
200
200
mm
4.3
4.3
5.1
6.3
6.3
12.8
12.8
14.6
14.6
16.4
16.4
18.2
18.2
mm
139.7 /
146.0 /
168.3 /
177.8 /
203.0 /
229.0 /
254.0 /
267.0 /
292.0 /
305.0 /
318.0 /
330.0 /
355.6 /
mm
125.5
136.0
155.7
165.2
190.4
211.4
238.0
245.0
267.0
285.0
298.0
310.0
327.2
mm
139.7 /
146.0 /
168.3 /
177.8 /
203.0 /
229.0 /
254.0 /
267.0 /
292.0 /
305.0 /
318.0 /
330.0 /
355.6 /
mm
125.5
136.0
155.7
165.2
190.4
211.4
238.0
245.0
267.0
285.0
298.0
310.0
327.2
Bm
mm
230
260
285
305
350
380
420
435
470
510
525
560
590
Thickness
tm
mm
30
35
35
40
45
50
55
60
60
65
65
70
75
Centre Hole
Zm
mm
125
136
155
165
190
211
238
245
267
285
298
310
327
Fixed Plate
Bf
mm
180
210
240
270
305
405
430
415
440
480
495
530
555
Thickness
tf
mm
25
35
35
45
45
70
80
60
65
75
75
80
90
Centre Hole
Zf
mm
110
110
125
145
145
175
175
195
195
215
215
235
235
ZH
mm
100
120
140
150
175
195
220
230
250
270
280
295
310
Length
LZH
mm
90
105
115
130
160
190
205
225
245
255
270
290
305
Length Fixed Anchorage
LHF
mm
45
55
60
60
75
75
90
90
100
105
110
115
125
Stressing Anchorage
Mf
mm
140
160
180
195
225
250
280
290
315
340
355
370
390
HMf
mm
30
35
40
45
55
60
70
70
75
80
85
90
95
Mr
mm
130
135
155
175
185
220
230
250
255
280
285
310
315
HMr
mm
30
40
45
50
55
65
70
75
80
85
90
95
100
Sm
mm
129
149
169
179
199
219
249
259
279
299
309
319
339
LSm
mm
98
108
113
128
153
178
188
203
218
223
238
253
265
Sf
mm
125
130
150
170
180
215
225
245
250
275
280
305
310
LSf
mm
34
34
34
34
34
34
34
34
34
34
34
34
34
stress.
kg
15
19
26
34
48
69
86
102
125
150
169
199
230
fixed
kg
11
12
16
22
24
35
40
49
52
65
69
85
90
Fixed Anchorage
PROTECTION CAP
63
mm
Stressing Plate
STRESSING SLEEVE Outer Diameter
Lock Nut
mm
Stressing Anchorage
Fixed Anchorage
Weight of Anchorage
(excl. Anchor Plate and Guide Pipe)
43
INCREMENTAL
LAUNCHING
systemS
The Incremental Launching method combines the
advantages of pre-cast segmental construction with
those of segmental cast insitu methods.
Bridges are cast in segments behind an abutment under
controlled conditions, as a result, high concrete quality
and precise dimensions are assured. Reinforcement
crosses each joint in addition to the bonded prestressing tendons as each new segment is cast directly
Incremental Launching Girder
against the already hardened one in front. The concentric

pre-stress required during launching guarantees an
excellent, relatively maintenance free performance of the
bridge during its whole lifetime.
By avoiding costly and time-consuming false work and
by concentrating all construction activities in the small
fabrication area, considerable saving in cost and time
against conventional bridge construction are achieved.
The main characteristics of the incremental launching method are:

Production of a continuous, site cast concrete superstructure.
Casting in long sections in a stationary, multiple use form behind an
abutment.
After longitudinal shifting (launching) of a completed section along the
bridge axis, the next section is cast against the previous one and stressed
together.
In this sequence the overall superstructure grows by adding new sections,
step-by-step as the progressively completed girder is launched.
Temporary sliding bearings and guides at each pier facilitate the steady
travel of the structure.
A steel launching nose at the front sliding bearings, and a casting bay
behind the abutment.
Some preferred requirements are:
The girders should have a constant curvature in horizontal and vertical
alignment.
The section should be continuous over the whole bridge with preferably a
constant depth.
Span should be limited to 50-60 metres.
Span/depth ratios should be in the range of 14 to 18.
Mt Henry Bridge - Western Australia
These are not exclusive but provide a guide to the standard range of
applications.
Tonkin Hwy Bridge over Albany

Hwy - Western Australia
44
HEAVY LIFTING SYSTEMS
HEAVY LIFTING SystemS

In many instances, it is advantageous for extremely
large and heavy components to be prefabricated
away from their final location. In most cases they
must be lowered, jacked horizontally or lifted into
their final position. When their weight or size exceeds
the capacity of available cranage other heavy lifting
facilities must be considered.
Structural Systems has developed specialised lifting
equipment for this application. The combination of
the proven BBR Buttonhead Prestress Cable together
with electrically operated hydraulic jacking units allows
virtually unlimited loads to be moved quickly and safely
over any distance. The lifting or lowering operation can
be accurately controlled through the hydraulic system
which allows simultaneous or individual operation of
each lifting unit.
Perth Convention Exhibition Centre - Before Roof Lift
12 outlet isoflow pump and control panel

Perth Convention Exhibition Centre - After Roof Lift
43
5
preSTRESSING TECHNOLOGY
load handling systemS

Construction procedures involving load handling
systems often result in considerable savings as
compared to conventional building methods using
traditional scaffolds for casting concrete or installing
steel structural elements in place.
The application of load handling systems requires
full consideration at the structural design stage, well
in advance of detailing or construction planning, as
selecting or designing the necessary temporary works
and choosing the related equipment must be performed
as early as possible.
Structural Systems has extensive experience in the
field of load handling and can provide all required
services for design as well as supply and operation of
equipment.
Raising roof segment - Docklands Stadium
Typical Applications
Lifting, Lowering and Shifting of Heavy Loads
Heavy, fragile or awkward structural elements can be
either fabricated on or off site, then manoeuvred into
position by using jacking systems and tendons from
bar, strand or wire. Examples include roof structures,
bridge spans, precast concrete elements, and heavy
industrial components. It is often preferred to assemble
a large module adjacent to its final location then shift it
into position, on the basis of safety, ease of assembly
or time constraints. In some instances bridge pier
headstocks are constructed parallel to traffic, then
rotated to minimise traffic disruption. Some of SSLs
systems incorporate special hydraulic and monitoring
systems to allow for high accuracy movement regardless
of any differential loadings.
Specialist Formwork & Access

Occasionally access systems or working platforms may
be located in areas which cannot be serviced using
conventional cranage. In these instances where standard
options fail, the compact yet powerful systems SSL offer
allow for an effective solution to be developed. Examples
of this application may be underbridge platforms, fitting
of chimney liners and lift shaft installations. Additionally
we have developed specialist platforms for use on high
rise buildings, bridges, tanks and silo structures to
permit necessary works such as post-tensioning and
repair or inspection. SSL also have free spanning access
walkways up to 40m. The use of our specialist hardware
such as cable stays can allow formwork solutions to
be developed where the formwork and false work is
supported from above rather than below. This may be
essential in some locations where it is not possible due
to access, and cost or time.
Tendon Installation & Transport
As part of our diverse operations, we have developed
systems for use on cable stay bridges or large dam
projects where tendons up to 150m and weights greater
than 17 tonnes need translation and fitting to the structure.
A further example is the stay cables incorporated in
Centrepoint tower, were fabricated in Melbourne prior to
shipment and installation in Sydney.
Ringwood Rail Bridge Sliding Operations - Victoria
46
load handling systemS
Flat Jacks
Flat jacks are used for a variety of applications where structures are
required to be lifted or preloaded and installation heights are to be kept
to a minimum.
Structural Systems can provide 2 types of flat jacks:
Pan Type
Contstructed of two moulded steel sections welded together
used with a top and bottom plate. These can be inflated with oil
or grout and are generally used only once (see Table A).
Pan Type
Safety Lock Nut Type

Solid ram, low height hydraulic jacks with safety lock nut for
mechanical load handling, used mainly for bearing replacement
work (see Table B). For heavy loads multiples of the jacks are
used linked through a manifold system.
Safety Lock Nut Type
TABLE A - PAN TYPE

TYPE
D OUTSIDE
DIAMETER
mm
MAXIMUM FORCE
AT 13.5 MPa
kN
EFFECTIVE AREA AT
ZERO EXTENSION
103mm2
T
THICKNESS1
mm
E
MAXIMUM TRAVEL
mm
INSTALLATION
GAP
mm
9T
16T
39T
52T
60T
78T
108T
160T
217T
347T
540T
738T
898T
1364T
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
Notes:
[1] flat jack thickness may vary slightly
TABLE B - SAFETY LOCK NUT TYPE

TYPE
60T
100T
150T
200T
250T
300T
Notes:
OUTSIDE DIAMETER
THICKNESS
MAXIMUM TRAVEL
INSTALLATION GAP
mm
MAXIMUM FORCE
AT 10,000 PSI
kN
mm
mm
mm
138
188
205
240
300
305
600
1000
1500
2000
3000
3000
110
162
192
155
150
170
28
50
50
50
50
50
125
180
210
170
165
185
Jacks come complete with spherical testing
47
VICTORIA
NEW SOUTH WALES
QUEENSLAND
STRUCTURAL SYSTEMS
112 Munro Street, South Melbourne
VIC 3205 Australia
T. +61 3 9296 8100
F. +61 3 9646 7133
STRUCTURAL SYSTEMS
20 Hilly Street, Mortlake
NSW 2137 Australia
T. +61 2 8767 6200
F. +61 2 8767 6299
STRUCTURAL SYSTEMS
Unit 2, 16 Maiella Street, Stapylton
QLD 4207 Australia
T. +61 7 3442 3500
F. +61 7 3442 3555
WESTERN AUSTRALIA
STRUCTURAL SYSTEMS
24 Hines Road, OConnor
WA 6163 Australia
T. +61 8 9267 5400
F. +61 8 9331 4511
MIDDLE EAST REGION

Bahrain, Oman, Qatar,
U.A.E.
NASA STRUCTURAL SYSTEMS LLC

Head Office
Suite 302 Sara Building, Garhoud
PO Box 28987
DUBAI United Arab Emirates
T. +97 14 2828 595
F. +97 14 2828 386
www.bbrstructuralsystems.com
UNITED KINGDOM
STRUCTURAL SYSTEMS
12 Collett Way
Great Western Industrial Park
Southall, Middlesex UB2 4SE
T. +44 208 843 6500
F. +44 208 843 6509
IRELAND
STRUCTURAL SYSTEMS
Unit 13, Block G
Maynooth Business Campus, Maynooth
Co. Kildare, Ireland
T. +353 1628 9124
F. +353 1628 9124
POLAND
STRUCTURAL DESIGN SERVICES sp.z o.o.

Twarda 30
00-831 Warszawa
Poland
T. +48 226 979 246
+48 226 979 247
F. +48 226 979 248
Structural Systems operate throughout Australia, South East Asia, the Middle East and the United Kingdom.
For more information on Structural Systems and the many services we provide,
visit: www.structuralsystems.com.au

BBR Katalog

Caricato da

Informazioni sul documento

Descrizione originale:

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

BBR Katalog

Caricato da

Copyright:

Formati disponibili

PRESTRESSING

Emirates Tower - Dubai

Post-Tensioning Design data

Ground Anchor SYSTEMS

Cable Stay SYstemS

Wandoo Concrete Gravity Structure - Western Australia

Eleanor Schonell Bridge - Queensland

POST-TENSIONING DESIGN DATA

All strands are 7 wire low relaxation steel.

Australian / New Zealand Standard AS 4672 Steel Prestressing Materials.

MAXIMUM JACKING FORCES - RECOMMENDED VALUES

BBR CONA MULTI SYSTEM

PRESTRESSING LOSSES - TYPICAL DATA

BBR CONA MULTI

BBR VT CONA CMI

ANCHORAGE & JACKING LOSS (%)

DRAW-IN ALLOWANCE (mm)

Round Steel Duct

BBR CONA MULTI

BBR CONA MULTI - M1

BBR VT CONA CMI

These tests included static tests,

BBR VT CONA CMI

Cross Sectional Area

Charact. Tensile Strength

1860 1770 1860

1860 1770 1860

1860 1770 1860

Charact. Maximum Force

1040 1064 1116

1820 1862 1953

3120 3192 3348

BBR VT Cona CMI (Max No of Strands)

Helix and Additional Reinforcement

Min. Concrete Strength (cyl.)

Min. Centre Spacing

Min. Edge Distance (plus c)

STRESSING AND FIXED ANCHORAGE

CENTRE AND EDGE DISTANCES

STRESSING ANCHORAGE RECESS DETAILS

BBR VT Cona CMI

MULTI STRAND POST-TENSIONING

BBR VT CONA CMI

Cross Sectional Area

Charact. Tensile Strength

1860 1770 1860

1860 1770 1860

1860 1770 1860

1860 1770 1860

Charact. Maximum Force

4940 5054 5301

5720 5852 6138

7020 7182 7533

8060 8246 8649

BBR VT Cona CMI (Max No. of Strands)

Helix and Additional Reinforcement

Min. Centre Spacing

Min. Edge Distance (plus c)

Distance from Anchor Plate

Note: Intermediate and larger sizes available on request.

STRESSING AND FIXED ANCHORAGE

CENTRE AND EDGE DISTANCES

Structural Systems has gained certification

Similar non-reusable recessformers are used at angled edges