The Tetron Disc Bearing Type 3

The design of Tetron Disc Bearings is based upon many years of experience in solving the problems of structural movement in civil engineering and incorporates: Low sliding friction - Very important for slender pier designs. Low rotational resistance - Point of load application moves about 5% of base dimension at full rotation. Unlimited sliding movement - Range of movement unrestricted regardless of size or type. Seizure-free movement No lubrication necessary in service . Top Plate

Material specification of disc bearings

Rubber disc: Natural Rubber (+anti-ozonants) to BS.1154 Ring: High grade heat treated steel or solid base plate Side Restraints (D3F only): Steel to BS EN 10025 S275 Pins for side restraint: Special spring steel minimum Yield strength 1100 N/mm. Seal and sliding surface: BS EN 10088 Grade 1.4401 or 1.4404 (was 316S31) Top plate, rocker and Base plate: Steel to BS EN 10025 S275 or BS EN 10025 S355 P.T.F.E.: BS 6564 Socket head cap screws: BS.4168 Grade 12.9 Recommended HD bolt: BS 3692 Grade 8.8 (zinc plated) Cast-in sockets Mild Steel to BS EN 10025 S275 or equivalent If extreme corrosion resistance is required, cast iron base plates can be supplied. All materials used comply with the requirements of BS.5400: Section 9.2 1983 All permanently exposed steel parts are fully corrosion protected. Several different treatments are available, full technical data on request.

Stainless Steel Sliding Surface

Side Restraints ('F' Type only)

Components
Pure P.T.F.E Tetron Disc bases and rockers, and all sliding plates are made of corrosion protected mild steel. Sliding plates are faced with a smooth surface of high quality stainless steel. Sliding surfaces are pure dimpled P.T.F.E. discs incorporating grease pockets which allows a permanent reservoir of lubricant. Elastomer used for rotational purposes in Tetron Disc bearings is high grade natural rubber. A mastic seal is provided around the rocker to prevent ingress of moisture into the base unit. Ring

Rocker

Filled P.T.F.E. (on edge)

Seal

Elastomeric Disc

Transit Brackets

Tetron is a registered trade mark

Base Plate

General
In a bearing that is free sliding in all directions (e.g. the D3E range) positive fixing to the main structure may not be required if the bearing is always subjected to adequate vertical loading. Horizontal movement will occur on the plane of least resistance which is, of course, the bearing sliding surface. Nevertheless, it is prudent to provide fixings to guard against displacement during installation, impact vibration and accidental unloading. In a light structure the bearing fixings must be vibration resistant otherwise they may work loose. Consideration should always be given to the practicability of removing and replacing the bearings, should this prove to be necessary. Most cases of bearing malfunction are attributable to faulty installation and almost all bearing damage occurs during installation or even earlier during handling and storage. Careless handling on site and the ingress of dirt can easily lead to abnormally high frictional resistance. Tetron bearings are normally delivered in a condition to discourage unnecessary dismantling and bolts or straps are used to connect together the upper and lower parts of the bearings. These temporary fixings, as well as excluding dirt during installation, prevent accidental displacement between the parts of the bearings but they must be removed before the bearings are called upon to slide or rotate. However, they are not structural fixings and should be supplemented, for example by wedges, during installation. Bearings should be clearly identified, and Freyssinet can help by marking them with such details as type and location when requested. Marking is particularly important where the top plate is to be offset. Bearings should be transported and unloaded carefully and then stored under cover in clean, dry conditions until required. An inspection should be carried out shortly before installation and bearings that have been damaged in store should not be accepted almost certainly they will not work correctly, unless they are repaired. As much preparatory work as possible should be carried out, before bringing a bearing to its actual location. The seating should be level and this usually necessitates the use of a mortar bedding composed of sand and either cement, polyester resin or epoxy resin, with a cube crushing strength of at least 35N/mm. If the bearing is located directly on steelwork, the seating area should be machined.

Base Fixings
A D3E and D3M type bearings are free sliding in all directions with a low coefficient of friction, so that theoretically the bases do not require mechanical fixing, (figure 1) but see notes above. All other types of bearings can resist horizontal loading and so their bases should be fixed. There are several ways of achieving this. The fixing bolts and sockets can be attached to the bearing base with a rubber washer between the socket and base. It is then possible to cast in the fixings and grout the bearing in one operation. The bearing may be supported on temporary packs, aligned, levelled and a chemical resin grout poured around the sockets and under the bearing (Fig 2) using some simple shuttering. The fixings should not be over-tightened when the grout has set; otherwise the bearing may be distorted due to compression in the washers. Nevertheless, rubber washers must be used to prevent the sockets carrying vertical loading. This is the preferred method of fixing and ensures bearing removeability. In special cases, a large recess can be left in the abutment into which the bearing base is placed bodily, bedded upon and surrounded with cement/sand or epoxy resin mortar (see fig.3). The recess must be correctly reinforced on all sides. This method does not meet the removeability requirement. Clearly sockets provide the easiest castin fixings with removal in view, for all types of bearing.

Top Fixings
For similar reasons, top fixings must be provided for all bearings (optional for the D3E types). A completed precast concrete structure may be lowered on to a skim of mortar on the top of the bearing, to eliminate soffit irregularities. The mortar mix needs careful control to ensure that it is not totally squeezed out by the weight of the superstructure, which must be supported until it has set. The fixing sockets for the top of the bearing should be ready cast into the soffit, but this requires accurate casting, using a jig drilled mould insert to match the bolting arrangement in the bearing. Alternatively the sockets may be replaced by a single plate cast in flush with the soffit and tapped to receive the bearing fixing bolts. Where a concrete superstructure is cast in-situ, the bearing top plates, with dowels can be built into the soffit shuttering. The area around the mould cut out must be carefully sealed to ensure that concrete does not leak into the working parts of the bearing during placing, and all sliding plates must be propped to prevent them distorting under the weight of wet concrete. A disc type bearing will compress by perhaps 2% of its total height during the casting operation, which must be provided for, to facilitate the removal of the shuttering. Subsidiary spreader plates, with a special taper, may be required to accommodate a superstructure with an inclination or cross fall. When intermediate tapered plates are used, the plane of movement in sliding bearings must be horizontal and may not coincide with the soffit of the superstructure. Great care must be exercised to ensure that D3F lateral restraint bearings are correctly orientated.

Figure 1

Figure 2

Notes It cannot be stressed too strongly that bearings should not be dismantled on site because the effects of dirt on the sliding surfaces are highly deleterious. Where appropriate, bearings should be requested with top plates pre-set to accommodate anticipated movements to prevent unnecessary dismantling on site. In all cases the transit bolts connecting the bearing top plate to its base must be removed after the mortar has set and before the bearing is called upon to rotate or slide.

3
Figure 3

REMOVEABLE BEARINGS Removable bearings can be removed from the structure with a minimum of jacking when used in conjunction with cast in sockets or similar devices.

Tetron D3T Fixed (Fixed in all directions, free to rotate in all directions.)

Note it may not be possible to achieve the maximum vertical and horizontal design load effects simultaneously. Working stress design (kN) Max. load vertical 500 800 1000 1250 1600 2000 2500 3250 4000 5000 6500 8000 10000 12500 16000 20000 25000 30000 100 150 150 190 220 250 280 300 360 500 600 650 700 900 1000 1300 1600 2000 500 800 1000 1250 1600 2000 2500 3250 4000 5000 6500 8000 10000 12500 16000 20000 25000 30000 Max. load horizontal All Vertical Permanent Vertical 300 500 650 800 1000 1350 1600 2100 2600 3200 4200 5200 6500 8000 10000 13000 16000 20000 BS.5400: Section 9.1 Design load effects (kN) Serviceability Limit State Horizontal 100 200 220 250 280 320 360 390 450 630 700 800 890 990 1100 1500 1900 2200 G K Ultimate Limit State Vertical 750 1200 1500 1900 2500 3300 4000 5500 7000 9000 12000 15000 18000 22000 25000 33000 40000 50000 Horizontal 160 260 290 320 370 430 520 560 580 800 1000 1100 1200 1500 1700 2200 2700 3400

Bearing Type

Principal dimensions (mm)

D3T 50 D3T 80 D3T 100 D3T 125 D3T 160 D3T 200 D3T 250 D3T 325 D3T 400 D3T 500 D3T 650 D3T 800 D3T 1000 D3T 1250 D3T 1600 D3T 2000 D3T 2500 D3T 3000 4

58 235 170 195 120 170 130 M12 75 340 235 280 155 235 175 M20 80 355 250 295 170 250 190 M20 83 375 270 315 190 270 210 M20 92 395 290 335 210 290 230 M20 97 460 335 385 240 335 260 M20 97 485 360 410 270 360 285 M20 116 575 410 475 280 410 310 M20 127 615 450 515 330 450 350 M24 132 680 515 580 390 515 410 M30 141 770 570 645 420 570 440 M30 156 835 635 710 490 635 510 M30 175 950 710 805 540 710 560 M30 179 1015 785 870 620 785 640 M30 203 1140 870 970 680 870 700 M30 203 1260 985 1090 780 985 800 M30 232 1425 1100 1220 875 1100 895 M42 257 1550 1230 1350 1000 1230 1030 M42

Tetron D3E Free Sliding (Free sliding in all directions, free to rotate in all directions.)

Working stress design (kN) Max. rotation (Radians) All Vertical 500 800 1000 1250 1600 2000 2500 3250 4000 5000 6500 8000 10000 12500 16000 20000 25000 30000 300 500 650 800 1000 1350 1600 2100 2600 3200 4200 5200 6500 8000 10000 13000 16000 20000 Permanent Vertical 0.026 0.026 0.026 0.026 0.026 0.026 0.024 0.022 0.022 0.020 0.018 0.016 0.016 0.014 0.012 0.012 0.012 0.012 500 800 1000 1250 1600 2000 2500 3250 4000 5000 6500 8000 10000 12500 16000 20000 25000 30000 Max. load Vertical

BS.5400: Section 9.1 Design load effects (kN) Serviceability Limit State ULS Vertical 750 1200 1500 1900 2500 3300 4000 5500 7000 9000 12000 15000 18000 22000 25000 33000 40000 50000

Bearing Type G 130 175 190 210 230 260 285 310 350 410 440 510 560 640 700 800 895 1030

D3E 50 D3E 80 D3E 100 D3E 125 D3E 160 D3E 200 D3E 250 D3E 325 D3E 400 D3E 500 D3E 650 D3E 800 D3E 1000 D3E 1250 D3E 1600 D3E 2000 D3E 2500 D3E 3000

Principal dimensions (mm) A B* C* D* E* F 60 235 170 195 120 170 73 340 235 280 155 235 78 355 250 295 170 250 82 375 270 315 190 270 86 395 290 335 210 290 92 460 335 385 240 335 99 485 360 410 270 360 112 515 375 455 280 410 128 555 420 495 330 450 128 620 465 560 390 515 137 675 510 615 420 570 147 740 575 680 490 635 162 815 635 755 540 710 168 910 700 840 620 785 183 1000 780 925 680 870 193 1155 875 1055 770 985 213 1270 970 1170 865 1100 228 1440 1080 1310 950 1230

Dimensions B, C, D & E are for zero movement, and specified movement has to be added to above in increments of 100mm.

Tetron D3F Sliding Guided (Sliding, guided in one direction, free to rotate in all directions.)

Note it may not be possible to achieve the maximum vertical and horizontal design load effects simultaneously. Working stress design (kN) Serviceability Limit State Horizontal 100 200 220 250 280 320 360 390 450 630 700 800 890 990 1100 1500 1900 2200 BS.5400: Section 9.1 Design load effects (kN) Ultimate Limit State Vertical 750 1200 1500 1900 2500 3300 4000 5500 7000 9000 12000 15000 18000 22000 25000 33000 40000 50000 Horizontal 150 260 290 300 310 410 510 520 580 720 900 920 1200 1400 1600 1800 2200 2800

Principal dimensions (mm) Permanent Max. load Max. load All Vertical Vertical Vertical horizontal A B C* D* E* F G K D3F 50 79 260 170 195 120 170 130 M12 500 100 500 300 D3F 80 103 345 235 280 155 235 175 M20 800 150 800 500 D3F 100 108 360 250 295 170 250 190 M20 1000 150 1000 650 D3F 125 117 405 270 315 190 270 210 M20 1250 190 1250 800 D3F 160 121 425 290 335 210 290 230 M20 1600 220 1600 1000 D3F 200 129 475 335 385 240 335 260 M20 2000 250 2000 1350 D3F 250 129 500 360 410 270 360 285 M20 2500 280 2500 1600 D3F 325 138 565 410 475 280 410 310 M20 3250 300 3250 2100 D3F 400 158 605 450 515 330 450 350 M24 4000 360 4000 2600 D3F 500 158 680 515 580 390 515 410 M30 5000 500 5000 3200 D3F 650 167 745 570 645 420 570 440 M30 6500 600 6500 4200 D3F 800 177 810 635 710 490 635 510 M30 8000 650 8000 5200 D3F 1000 192 905 710 805 540 710 560 M30 10000 700 10000 6500 D3F 1250 198 970 785 870 620 785 640 M30 12500 900 12500 8000 D3F 1600 213 1070 870 970 680 870 700 M30 16000 1000 16000 10000 D3F 2000 227 1215 985 1090 780 985 800 M36 20000 1300 20000 13000 D3F 2500 267 1360 1100 1220 875 1100 895 M42 25000 1600 25000 16000 D3F 3000 282 1490 1230 1350 1000 1230 1030 M42 30000 2000 30000 20000 Rotation as for D3E type Dimensions C & E are for zero movement, and specified movement has to be added to above in increments of 100mm.

Bearing Type

NOTES

1.

Base contact stress of the bearings illustrated approaches 20N/mm.

2.

Sliding plate dimensions of 100mm. The bearings may then be described in a code, for example, thus:

BEARING OR MOVEMENT (cm)

LATERAL MOVEMENT (cm)

BEARING

PRINCIPAL MOVEMENT (cm)

3.

The height A is nominal; manufacturing tolerances give a variation of 3mm on tabulated figure.

4.

The size of fixing bolts listed in the tables assumes assistance from friction due to the minimum vertical load normally present in service.

5.

Larger capacity bearings are available details on request.

Standard Fixing Socket for removable bearings D3E, D3F and D3T
Bearing Base or Top Plate

Available as an extra from Freyssinet Ltd.

3mm Natural Rubber

Bolt I.S.O. metric (Grade 8.8, 10.9 or 12.9) Zinc plated. Mild Steel Socket

Bolt M12 M16 M20 M24 M30 M36 M42 M48 M56 M64

'A' 25 40 40 40 50 70 90 100 100 120

'B' 60 70 100 160 220 220 220 250 350 400

SMALL BEARINGS - SIMPLIFIED FIXING A simplified method is often preferred for the smaller sizes of disc bearing where cast-in sockets are not specified.

Tetron D3M Free Sliding (Free sliding in all directions, free to rotate in all directions.)

Working Stress design (kN) D 160 170 235 250 270 290 335 360 300 500 800 1000 1250 1600 2000 2500 Max. load vertical

Bearing Type

B*

C*

D3M 30 D3M 50 D3M 80 D3M 100 D3M 125 D3M 160 D3M 200 D3M 250

53 56 69 79 83 87 96 100

160 170 235 250 270 290 335 360

200 220 290 305 325 345 390 435

Max. rotation (Radians) 0.028 0.028 0.026 0.026 0.026 0.026 0.026 0.024

Dimensions, B & C care for zero movement, and specified movement has to be added to above in increments of 50mm. The D3M free sliding bearing is intended to locate by friction only, so adequate vertical loading must always be present to prevent slip.

NOTES

1.

Sliding plate dimensions shown are for zero movement . Add to these the amount of sliding required in increments of 50mm. The bearing may then be described in code, for example, thus:

BEARING

LATERAL MOVEMENT (cm)

PRINCIPAL MOVEMENT (cm)

2.

Base contact stresses are approximately 20 N/mm at maximum rated load.

3.

The height A is nominal; manufacturing tolerances give a variation of 3mm on tabulated figures.

General arrangement drawings

We suggest that before detailing general arrangement drawings are obtained with the latest information on dimensions and material specifications as the information in this publication is subject to change and updating.

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Issue: 06 22/03/11

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