PRESTRESSING

TECHNOLOGY
www.structuralsystems.com.au
www. s t r u c t u r a l s y s t e ms . c o m. a u
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.
Structural Systems are a leading provider of post-tensioning
technology and value engineering solutions. With a wealth
of engineering and contracting experience obtained through
the successful completion of projects throughout Australia
and overseas since 1961.
Post-Tensioning is a method of reinforcing (strengthening)
concrete or other materials with high-strength steel strands.
The benefits post-tensioning brings to a structure include:
Large open plan column free floor spaces
Reduced construction costs
Faster construction
Water resistant properties
Floor to floor height reduction
Reduced foundation load
Improved deflection control
Greater column free areas
Reduced carbon footprint
Greater loading capacity
Larger spans
The technology reduces the amount of conventional
reinforcement and concrete required thus delivering a more
economical and environmentally friendly solution.
Structural Systems is committed to improving the standard
of design and construction in the post-tensioning industry
and is a founding corporate member of the Post-Tensioning
Institute of Australia Limited.
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01 INTRODUCTION
02 POST-TENSIONING DESIGN DATA
03 POST-TENSIONING
05 SLAB POST-TENSIONING
16 MULTI-STRAND POST-TENSIONING
30 MULTI-WIRE POST-TENSIONING
33 BAR POST-TENSIONING
37 EXTERNAL POST-TENSIONING
40 UNBONDED BAND POST-TENSIONING
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Notes: All strands are 7 wire relax 2 steel.
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Standard Nominal
Diameter
mm
Nominal Steel
Area
mm
2
Nominal Mass
Kg/lm
Strand
MBL / Fm
(7)
kN
Minimum
Proof Load
kN
Strand
Relaxation
%
Modulus of Elasticity
MPa
AS 4672
(1)
12.7 super
15.2 super
15.2 EHT
98.6
143
143
0.786
1.125
1.125
184
250
261
156
(4)
212
(4)
222
(4)
2.5
2.5
2.5
185 to 205x10
3
185 to 205x10
3
185 to 205x10
3
BS 5896
(2)
12.9 super
15.7 super
100
150
0.785
1.180
186
265
158.1
(5)
225.3
(5)
2.5
2.5
180 to 205x10
3
180 to 205x10
3
prEN 10138-3
(3)
15.2 regular
15.7 regular
15.2 super
15.7 super
140
150
140
150
1.093
1.172
1.093
1.172
248
266
260
279
213.0
(5)
229.0
(5)
224.0
(5)
240.0
(5)
2.5
2.5
2.5
2.5
180 to 205x10
3
180 to 205x10
3
180 to 205x10
3
180 to 205x10
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STRAND PROPERTIES
Notes: In some cases higher or lower jacking forces are permitted by local standards.
MBL = Minimum Breaking Load
SSL Post-Tensioning System Standard
AS 3600 EN 1992
BBR VT Cona CMI System 80% MBL 80% MBL
BBR VT Cona CME System 77% MBL 77% MBL
BBR VT Cona CMB System 80% MBL 80% MBL
Slab System 85% MBL 80% MBL
Wire System 80% MBL 80% MBL
Bar System 75% MBL 75% MBL
MAXIMUM JACKING FORCES RECOMMENDED VALUES
Notes: (1) Australia / New Zealand Standard AS 4672 steel prestressing materials
(2) British Standard BS 5896 High Tensile steel wire and strand for prestressing of concrete
(3) European Standard prEN 10138-3 prestressing steels Part 3: Strand
(4) At 0.2% offset, refer AS 4672
(5) At 0.1% offset, refer BS 5896 or prEN 10138-3 as applicable
(6) Relaxation after 1000 hrs at 0.7 x breaking load
(7) MBL = Minimum Breaking Load (to AS 4672 and BS 5896). Fm = Characteristic Force (to prEN 10138-3)
Standard Nominal
Diameter
mm
Nominal Steel
Area
mm
2
Nominal Mass
Kg/lm
Strand
MBL / Fm
(7)
kN
Minimum
Proof Load
kN
Strand
Relaxation
%
Modulus of Elasticity
MPa
AS 4672
(1)
7 LR 38.5 0.302 64.3 54.7
(4)
2.0 195 to 215x10
3
BS 5896
(2)
7 LR 38.5 0.302 64.3 53.4
(5)
2.5 195 to 205x10
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WIRE PROPERTIES
System
BBR VT Cona
CMI
BBR VT Cona
CME
BBR VT Cona
CMB
Slab Wire Bar
Anchorage & Jacking Loss (%) 0.8 to 1.2 0.8 to 1.2 0.9 to 1.2 2 (1) 0 to 1 0 to 1
Draw-In Allowance (mm) 6 6 6 6 2 to 3 1 to 2
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Round Steel Duct

Flat Steel Duct
Polyethylene Duct
Greased & Sheathed
0.16 to 0.24
N/A
0.10 to 0.14
N/A
0.16 to 0.24
N/A
0.10 to 0.12
N/A
N/A
N/A
0.06 to 0.12
N/A
0.15 to 0.20
0.20
0.10 to 0.15
N/A
0.12 to 0.16
N/A
0.10 to 0.15
N/A
0.15 to 0.20
N/A
0.10 to 0.15
0.10
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Round Steel Duct 50mm
Round Steel Duct > 50mm
Flat Steel Duct
Greased & Sheathed
0.016 - 0.024
0.008 - 0.016
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
0.016 - 0.024
N/A
0.016
0.008 - 0.012
N/A
N/A
0.008 - 0.016
0.008 - 0.016
N/A
N/A
PRE-STRESSING LOSSES - TYPICAL DATA
Notes: 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, the ducts are full of water, the friction values can increase significantly.
(1) Allow for 5% loss in effective jacking force at surface recessed stressing pans.
(*) Tendon wobble values listed are indicative only. Actual wobble is often dependent on construction technique and
workmanship.
Post-tensioning (PT) is an efficient way of reinforcing concrete while you are building often allowing the construction
of something which might otherwise have been impossible. It can also be combined with other structural materials,
such as steel and masonry structures. PT provides active reinforcement and places the concrete structure under
compression in those regions where load causes tensile stress.
Massive developments in post-tensining over the past decades means that it is now a mainstream component of the
construction industry and is applied in bridges, buildings, arenas, dams, nuclear power stations, wind farms, cryogenic
LNG tanks, silos, wastewater treatment plants, water reservoirs, marine structures, retaining walls, towers and tunnels.
Post-tensioning vs. pre-tensioning
Both post-tensioning and pre-tensioning create prestressed
concrete.
Pre-tensioned systems, however, must be fabricated in
a precast plant and are limited to straight, harped, or
circular tendons. In addition, construction of continuous
structures is very limited with this method.
Post-tensioning, on the other hand, allows almost any
shape to be constructed and is able to match nearly
any design requirement. Internal, bonded, unbonded
and external post-tensioning is usually performed on the
project site and provides superior corrosion protection
features.
Internal vs. external post-tensioning
Tendons installed in the formwork prior to pouring the
concrete are known as internal tendons. External tendons
are placed on the outer surface of concrete structures.
This type of post-tensioning allows access for maintenance
and replacement and is therefore the solution of choice
for bridge enhancements and refurbishments, it can also
be applied to many other types of structure.
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Internal bonded vs. unbonded
post-tensioning
Internal bonded post-tensioning systems can
range from a single strand to multiple strands
per tendon. The strands are inserted into a
metal or plastic duct that is then embedded
in the concrete. The duct is then filled with
cementitious grout, creating a bond with the
surrounding concrete. The grout creates an
alkaline environment which ensures corrosion
protection of the prestressing steel.
Unbonded PT differs from bonded post-
tensioning in that it provides each individual
tendon with permanent freedom of movement
relative to the concrete.
Note: Unbonded systems are not typically used in Australia.
Professional installation practice
Post-tensioning and grouting operations
require the highest level of professionalism
which is exactly what the certified BBR PT
specialists and members of the BBR Network
deliver. These well-trained and experienced
staff are continuously educated through
practical and theoretical training courses to
ensure professional execution of PT works. All
Structural Systems operatives are trained under
the Post-Tensioning Institute of Australias
(PTIAs) training programmes.
Installation of the post-tensioning starts
in conjunction with the non-tensioned
reinforcement and after the formwork has
been erected. The first step in the process
is to affix the anchorages and to layout the
ducting, then the high tensile steel strands are
installed. Once the concrete is poured and
has attained its transfer strength the tendon
is stressed utilising a hydraulic jack and then
locked off at the anchorage. The anchorage
maintains the applied force in the tendon and
transfers it to the surrounding concrete. The
duct is then filled with a cementitious grout or
flexible corrosion inhibitor. Grouting is carried
out carefully under controlled conditions to
ensure that the whole tendon is completely
filled. Installation can also be performed with
a fully or partially prefabricated tendon.
Key benefits of post-tensioning structures
Greater flexibility of design PT allows highly creative architectural approaches and very demanding geometry
requirements.
Increased deflection control and improved crack control virtually crack-free concrete delivers long term durability
Faster construction program early strength stressing promotes a faster cycle time, allowing the structure to progress
more rapidly.
Lower construction material costs PT can decrease the size of a structural member and reduce the quantity of
concrete and steel required for the superstructure.
Reduced environmental impact less material creates fewer carbon emissions in terms of production and transportation.
Reduced construction costs a faster cycle time and decreased amount of material minimise costs.
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Multi-strand post-tensioning is
predominantly used in civil structures
including bridges, silos, tanks and
off-shore structures and is also used
for transfer beams in buildings. It
is a robust and reliable bonded
prestressing system.
BBR VT Cona CMI
The BBR VT CONA CMI post-
tensioning system is a multi-strand
system for all types of internally
post-tensioned applications. The
standard tendon sizes range from 1
to 73 seven-wire prestressing strands.
Larger sizes are also possible and
CONA CMI tendons with 91 strands
have already been used. Most
commonly, 0.6-0.62 (15.2-15.7mm)
strands with a cross-sectional area of
150mm
2
and a characteristic tensile
strength of 1,860 MPa are used. The
use of 0.5 (12.7mm) strands with a
cross-sectional area of 100mm
2
and
a characteristic tensile strength of
1,860 MPa is also possible.
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 test, 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 system components.
Every product is tested to the
same standard 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.
The BBR VT CONA CMI system
has significant advantages over the
previous BBR Cona Multi system
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.
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Anchorage configuration
The main components in the anchor
zone of the CONA CMI system
are the wedges, anchor head,
trumplate/square plate and trumpet.
In the anchorage zone, the duct is
connected to the trumpet and the
strand bundle is spread out towards
the anchor head, where each strand
is individually locked with BBR
wedges.
For the load transfer to the
concrete, the CONA CMI BT (bearing
trumplate) can be used for tendon
sizes with 02 to 61 strands and the
CONA CMI SP (square plate) can be
used for 01 to 73 strands.
The CONA CMI BT (bearing
trumplate) system makes use of an
advanced and proprietary three plane
load transfer allowing for very small
centre and edge distances at the
anchorages, as well as application of
the full post-tensioning load at very
low concrete strengths. The CONA
CMI SP (square plate) is a system
with a single plane load transfer to
the concrete.
Technical data on the BBRVT CONA
CMI SP system can be found on
pages 24 to 27.
The stressing and fixed
anchorages
The BBR VT CONA CMI anchorages
are available in two types, these
are Type S stressing / active
anchorages and Type F fixed /
passive anchorages. The anchor
heads of the stressing and fixed
anchorages are secured by special
wedge retaining measures and
are protected by a cap during
concreting. For re-stressable and
exchangeable tendons, excess strand
length is required at the anchorage.
The extent of the excess strand
length depends on the jack used
for re-stressing or releasing and the
strand protruding beyond the anchor
head requires permanent corrosion
protection and an adequate cap.
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Fixed, stressable and movable
couplers
CONA CMI tendons can be coupled
using proprietary Type K overlap
coupler for tendons ranging from
2 to 31 strands (larger sizes on
request) or Type H sleeve coupler
for 1 to 73 strands. Both coupler
types can serve as a stressing /
active anchorage coupler (Type S)
or fixed / passive anchorage coupler
(Type F) bearing against the load
transfer unit or as movable couplers
(Type B) along the length of the
tendon.
In the first stage of construction,
the tendon is installed, stressed and
anchored in the coupler which is
placed in the section joint between
the first and second stage. Next,
the second stage tendon is put in
place and coupling is achieved by
pushing the strands into the already
tensioned Type K anchor head or
by coupling the Type H anchors
heads with a Type H sleeve. In
some countries, it is not permitted
for one section joint to have only
couplers. In this situation, it is
mandatory that at least 30% of
all tendons must be continuous in
order to obtain an even distribution
of the prestressing force in the
structure.
The movable coupler serves to
lengthen unstressed tendons and the
tendon elongation during stressing
is ensured by a cylindrical sheathing
box appropriate for the expected
elongation at the location of the
coupler. Movable couplers may be
used to couple continuity tendons at
the construction joint.
Corrosion protection
The strand bundle is enclosed in
a corrugated round steel or plastic
duct. For special applications, such
as loop tendons smooth round
steel or plastic ducts can be used.
The use of flat steel or plastic
ducts is also possible for smaller
tendon sizes. The filling of the
tendons in bonded applications is
completed using a high performance
grout. For unbonded applications,
the duct can be injected with
grease / wax. The CONA CMI
post-tensioning kits can also be
executed as fully electrically isolated
tendons to provide the highest
possible level of corrosion protection
and inspectability.
(*) Other prestressing strands approved at the place of use, such as strands having a cross-sectional area of 140mm
2
or 93mm
2
respectively and / or
a characteristic tensile strength lower than 1,860 MPa can be used with the same anchorage components.
Type of strands
Available tendon sizes
BBR VT CONA CMI
System 05 06
Mm 12.5 12.7 15.2 15.7
mm
2
93 100 140 150
MPa 1,860 1,860 1,860 1,860
BBR VT CONA CMI
Strands Characteristic ultimate resistance of tendon (kN)
System 05 06
Mm 12.5 12.7 15.2 15.7
01 173 186 260 279
02 346 372 521 558
03 519 558 781 837
04 692 744 1,042 1,116
05 1,302 1,395
06 1,562 1,674
07 1,211 1,302 1,823 1,953
08 2,083 2,232
09 2,344 2,511
12 2,076 2,232 3,125 3,348
13 3,385 3,627
15 3,906 4,185
16 4,166 4,464
19 3,287 3,534 4,948 5,301
22 5,729 6,138
24 6,250 6,696
25 6,510 6,975
27 7,031 7,533
31 5,362 5,766 8,072 8,649
37 9,635 10,323
42 10,937 11,718
43 11,197 11,997
48 12,499 13,392
55 14,322 15,345
61 15,884 17,019
69 17,968 19,251
73 19,009 20,367
Tendon sizes
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Dead end anchorages bulb type and swage type
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 properties
Notes: Duct sizes are indicative, use larger duct sizes for long tendons or aggressive profiles.
Duct couplers are overall +10mm larger than duct ID.
Notes: Swage type dead ends recommended for
1906 tendons and larger.
Local zone and several zone anchorage
reinforcement is normally required for all unit
types and details are usually determined by
the designer to suit the specific application.
Tendon
Unit
Maximum
Number of
Strands
Maximum
Steel Duct
ID/OD
mm
Minimum
Steel Duct
ID/OD
mm
Minimum radii of
curvature / minimum
straight portion
m
Tendon minimum breaking load to prEN 10138-3
kN
15.2 regular 15.7 regular 15.2 super 15.7 super
406 4 45/50 45/50 3.0/0.8 992 1064 1040 1116
709 7 60/65 55/60 4.0/0.9 1736 1862 1820 1953
906 9 70/75 60/65 4.5/1.0 2232 2394 2340 2511
1206 12 80/85 70/75 5.2/1.0 2976 3192 3120 3348
1506 15 90/95 80/85 5.8/1.25 3720 3990 3900 4185
1906 19 100/105 90/95 6.5/1.25 4712 5054 4940 5301
2206 22 105/110 95/100 7.0/1.4 5456 5852 5720 6138
2406 24 110/115 100/105 7.3/1.6 5952 6384 6240 6696
2706 27 120/125 105/110 7.7/1.6 6696 7182 7020 7533
3106 31 130/135 110/115 8.4/1.6 7688 8246 8060 8649
3706 37 140/145 125/130 9.2/2.0 9176 9842 9657 10323
4206 42 150/155 135/140 9.6/2.1 10416 11172 10962 11718
4806 48 160/165 145/150 10.2/2.4 11904 12768 12528 13392
5506 55 175/185 155/160 11.3/2.4 13640 14630 14355 15345
6106 61 180/185 160/165 11.7/2.5 15128 16226 15921 17019
Strand size Anchorage point Bulb type anchorage (mm) Swage type anchorage (mm)
A B C D E F
15.2mm and 15.7mm 0406 150 150 600 150 150 250
0706 200 170 600 200 200 350
0906 300 300 800 250 250 450
1206 350 300 1,000 250 250 500
1506 350 350 1,000 300 300 500
1906 450 350 1,000 300 300 500
2206 450 450 1,000 300 300 500
2406 450 450 1,000 300 300 600
2706 500 450 1,100 350 350 650
3106 550 475 1,100 350 350 650
3706 N/A N/A N/A 400 350 800
4206 N/A N/A N/A 400 350 850
4806 N/A N/A N/A 550 475 1000
5506 N/A N/A N/A 550 475 1000
6106 N/A N/A N/A 550 550 1200
Bulb type dead end Swage type dead end
Note: For swage
type,strand length F
shall be debonded (using
grease or similar).
2 9 www. s t r u c t u r a l s y s t e ms . c o m. a u
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Structural Systems operate
throughout Australia,
the Middle East,
South Africa
and the United Kingdom.
For more information on
Structural Systems and the many
services we provide, visit:
www.structuralsystems.com.au
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