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MEMBRE DE L'EOTA
MEMBER OF EOTA
Le présent agrément 92 pages comprenant 40 pages d'annexes (dessins) faisant partie intégrante du
technique européen document.
contient : 92 pages including 40 pages of Annexes (drawings) which form an integral part of
This European Technical the document
Approval contains:
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FREYSSINET PRESTRESSING SYSTEM – EUROPEAN TECHNICAL APPROVAL
CONTENTS
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FREYSSINET PRESTRESSING SYSTEM – EUROPEAN TECHNICAL APPROVAL
LIST OF DRAWINGS
LIST OF TABLES
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FREYSSINET PRESTRESSING SYSTEM – EUROPEAN TECHNICAL APPROVAL
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FREYSSINET PRESTRESSING SYSTEM – EUROPEAN TECHNICAL APPROVAL
A.2 SETRA is authorized to check whether the provisions of this European Technical
Approval are met. Checking may take place in the manufacturing plant(s). Nevertheless, the
responsibility for the conformity of the products to the European Technical Approval and for
their fitness for the intended use remains with the holder of the European Technical Approval.
A.6 The European Technical Approval is issued by the approval body in its official
language(s). This (These) version(s) corresponds (correspond) fully to the version circulated
in EOTA. Translations into other languages have to be designated as such.
1
Official Journal of the European Communities No L 40, 11.2.1989, p. 12
2
Official Journal of the European Communities No L 220, 30.8.1993, p. 1
3
Official Journal of the European Union No L 284, 30.10.2003, p. 1
4
JORF du 14 juillet 1992
5
Official Journal of the European Communities No L 17, 20.1.1994, p. 34
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FREYSSINET PRESTRESSING SYSTEM – EUROPEAN TECHNICAL APPROVAL
The Freyssinet prestressing kit is a post-tensioning kit designed for both internal and external
prestressing. A prestressing cable consists of a bundle of 7-wire strands in accordance with
section G.1 and is referred to as the ‘tensile element’. When fitted with its anchorages, the
prestressing tendon is referred to as the ‘prestressing unit’.
In the case of unbonded internal prestressing, however, monostrands (strands with individual
protection by grease or wax and plastic sheath) may be used without any duct, the strands
being placed in the structure according to the design requirement.
Prestressing strands can be made in accordance with European and national provisions.
Freyssinet stressing anchorages anchor each strand individually by means of a conical wedge
inserted in a conical hole of anchorage block. The diameter of the internal thread of the
Freyssinet anchor wedge depends on the strand nominal diameter, T13 or T15 (drawings 1
and 2).
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FREYSSINET PRESTRESSING SYSTEM – EUROPEAN TECHNICAL APPROVAL
Different active anchorage models are available, to meet specific construction needs.
Coupler CI
It consists of individual type P strand connectors (see paragraph B.1.1.4 below) connecting
each strand of the primary tendon to its counterpart in the secondary tendon (drawing 17). It is
used for prestressing units with 1 to 37 strands T13 or T15.
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FREYSSINET PRESTRESSING SYSTEM – EUROPEAN TECHNICAL APPROVAL
• strand connector P 15 is used with T15 and T15S strands (drawing 7).
Movable couplers are used for prestressing units with 1 to 37 strands T13 or T15
(drawing 18).
The length of the coupler resevation is obtained by the formula L = M + U, where U is the
connector displacement including provision for stressing tolerance according to national
regulations and M is a fixed dimension depending on the tendon type including necessary
installation tolerance given in the table of relevant drawings.
- -Ducts, used to isolate, guide and protect tensile elements (see section G.2).
- Injection materials for anchorages and ducts, such as cement grout, grease and wax.
- Tubes or specific elements for deviation of external cables at given locations in the
structure. These deviators are generally made out of steel plain pipes. The specific
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FREYSSINET PRESTRESSING SYSTEM – EUROPEAN TECHNICAL APPROVAL
elements may include reservations inside the concrete reinforcement or construction steel
saddles to obtain the cable deviator.
- Bursting steel reinforcement, for the concrete confinement at anchorages and deviators, to
complete the general structural reinforcement and ensure prestressing force transfer.
- Specific accessories to facilitate cable placing and stressing, tendon grouting, de-
tensioning and replacement of tendon, such as vents, duct drainage, tendon supports,
temporary and permanent protection caps of anchorages and couplers, coupling elements
between duct sections and for duct connection to anchorages.
The prestressing kit described in this ETA can be used for new structures, for repair and
reinforcement of existing structures with following basic categories of use:
• Internal bonded tendon for concrete and composite system
• Internal unbonded tendon for concrete and composite system
• External tendon for concrete structures with a tendon path situated outside the cross-
section of the structure but inside its envelope.
The prestressing kit described in this ETA offers additionally optional categories of use for
which standard tendon characteristics are improved. These options are as follows:
1. restressable tendon (external or internal),
2. exchangeable tendon (external or internal),
3. tendon for cryogenic applications,
4. internal bonded tendon with plastic ducts,
5. encapsulated tendon,
6. electrically isolated tendon,
7. tendon for use in structural steel or composite construction as external tendon,
8. tendon for use in structural masonry construction as internal and/or external tendon,
9. tendon for use in structural timber construction as internal and/or external tendon.
PT-anchorage zones have to be designed to resist 1,1 Fpk according to the relevant Eurocode
in case of use with other materials than concrete.
The prestressing kit described in this ETA can be used in any type of structure and is used
more frequently in:
• bridges (superstructures, piers, abutments, foundations),
• buildings (floors, foundations, core walls, walls, columns, shear walls, lateral load
resisting frames, foundations),
• reservoirs (walls, slabs, roofs),
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FREYSSINET PRESTRESSING SYSTEM – EUROPEAN TECHNICAL APPROVAL
• silos (walls),
• nuclear containment structures,
• offshore structures (all parts),
• floating installations and platforms (all parts),
• retaining walls,
• dams,
• tunnels (longitudinal and transverse/hoop tendons),
• large diameter pipes,
• roads and airports.
Fixed Couplers
Couplers CM
Model NB
Movable
Model C
Model X
Model F
Categories of Use
CI
Bonded Internal Tendon for Concrete
and Composite Structures
3 to 55 1 to 37 3 to 37 1 to 4 1 to 2 1 to 55
Unbonded Internal Tendon for
Concrete and Composite Structures
3 to 55 1 to 37 3 to 37 1 to 4 1 to 2
External Tendon for Concrete and
Composite Structures
3 to 37 1 to 37 1 to 2
Options
(a) Restressable Tendon 3 to 55 1 to 4 1 to 2
(b) Replaceable Tendon 3 to 55 1 to 4 1 to 2
(c) Tendon for Cryogenic
Applications
3 to 55
(d) Bonded Internal with Plastic
Duct
3 to 55 1 to 37 3 to 37 1 to 4 1 to 2
(e) Encapsulated Tendon 3 to 55 1 to 37 3 to 37 1 to 4 1 to 2
(f) Electrically Isolated Tendon 3 to 37 3 to 37 3 to 37
(g) External Cable for Steel or
3 to 37 1 to 2
Composite Structures
(h) Internal/External Tendon for
3 to 37 1 to 4 1 to 2
Masonry Structures
(i) Internal/External Tendon for
Timber Structures
3 to 37 1 to 2
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Structures Options
Restressable
Exchangeable
Cryogenic
Encapsulated
Isolated
Electrical
Pre- Anchorage & Anchor Typical
Concrete
Masonry
Timber
stressing Coupler Type Model Duct Tensile Element Injection Protection Drawings
Steel
[3]
Type Sealing
Table 3bis. Choice of Kit Elements for Basic and Optional Categories of Use
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FREYSSINET PRESTRESSING SYSTEM – EUROPEAN TECHNICAL APPROVAL
Notes
Standard Anchorage as per typical drawings, Isolated Anchorage: interposition of isolating
liner and seal inside trumplate and at contact to anchor block
Cachetage: see drwg 29, Cap: see drwg 30, Extended Cap: see drwg 31
Duct out of Steel or Plastic: Corrugated or Smooth, unless otherwise marked.
[1]
Corrugated duct only
[2]
Smooth duct only
[3]
References given to drawings are not exhaustive
[4]
e.g. see drwgs 8, 9, 17, 18, 19, 20, 21, 22, 27, 29
[5]
e.g. see drwgs 8, 17, 18, 19, 20, 21, 22, 23, 27
The provisions made in this ETA are based on an assumed intended working life of the PT
System of 100 years. The indications given on the working life can not be interpreted as a
guarantee given by the producer, but are to be regarded only as a means for choosing the right
products in relation to the expected economically reasonable working life of the structures.
Chapters E to K of this ETA, including drawings attached to it, detail the characteristics of
products.
The assessment of the aptitude of the kit for its intended use, in relation to the requirements
for mechanical resistance and stability in the sense of the Essential Requirement 1 has been
made in compliance with the Guideline for European Technical Approval (ETAG 013) of
“Post-Tensioning Kits for Prestressing of Structures”. Performances examined in conformity
to the ETAG satisfy the pertinent essential requirements. These are mainly performances
related to static load, transfer on concrete and resistance to fatigue. Methods for check,
evaluation and assessment of aptitude for use and test procedures according to those detailled
in ETAG.
According to the manufacturer declaration the post-tensioning kit does not contain any
dangerous substances.
In addition to the specific clauses relating to dangerous substances contained in the ETA,
there may be other requirements, applicable to the products falling within its scope (e.g.
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transposed European legislation and national laws, regulations and administrative provisions).
In conformity with the provisions of the European directive 89/106/EEC, these requirements
must also be complied with wherever they apply.
B.3.2 Responsabilities
The type and frequency of checks and tests conducted during production and on the final
product as part of the continuous internal production control are described in the prescribed
test plan, Chapter C of this ETA. All the tests are conducted according to written procedures,
by means of adequate calibrated measuring devices. Results are recorded logically and
systematically.
If test results do not comply, the produced lot is inspected in detail. It may be rejected,
completely or partially. Defectuous parts may be retreated in order to eliminate defects and
checks and tests are then repeated.
Products non complying with the ETA are marked and separated from complying products.
6
Official Journal of the European communities L201/112 of 3 July 1998
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Each main component has a prescribed inspection plan, established by Freyssinet and applied
by its manufacturers. Production control methods are defined in the Freyssinet Quality
Assurance Plan PAQ ATE PRE.
The main production centre is checked at least once a year by the Certification Body. Each
component producer is checked at least once every five years by the Certification Body.
The Certification Body checks inspection results, control tests as well as results of production
control results and establishes the conformity to the ETAG.
Corrective measures are taken by the Manufacturer when defects have been met. These
measures are:
• corrective intervention, following the notification of the Certification Body,
• control strengthening and higher test frequence,
• setting-up of modifications.
During continuous surveillance auditing, the Certification Body takes samples to test in
independent laboratories. Samples are taken according to the requirements of the table
attached in the chapter D of this ETA.
During the certificate validity the ETA holder supplies once a year to the Certification Body
anchorages and strands necessary for a test series according to Annex E of ETAG 013 and
sends them to the laboratory designated by the Certification Body. These well-identified parts
and reinforcement are from the same construction site. If possible construction sites are
chosen in such a way that the tensile steel manufacturer will be different from year to year.
B.3.2.3 CE Marking
The CE marking must comply with the European Council Directive 89/106/CEE, and to the
EC guideline "D" related to the marking. The delivery bill accompagnying the PT kit
components shall bear the conformity CE marking symbol and the following mentions:
All other information must be clearly distinct from the CE marking and the related mentions.
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B.4 ASSUMPTIONS UNDER WHICH THE FITNESS OF THE PRODUCTS FOR THE
INTENDED USE WAS ASSESSED
The ETA is issued under the following assumptions:
The ETA is issued for the Freyssinet post-tensioning kit on basis of information and
documents submitted by Freyssinet to Sétra, with identification of product tested and
assessed. Any modification of characteristics of product or factory production process which
might modify the conformity of the kit shall be notified to the Sétra prior to its application.
The Sétra will decide if this modification affects the ETA and if a more detailled assessment
or amendment of ETA are required.
A Quality Assurance Plan related to the prestressing kit ETA is established and regularly
updated by Freyssinet ; it is made available to the Sétra. A list of sub-contractors and
component suppliers is part of this Quality Assurance Plan.
Freyssinet is committed to impose the requirements of the present ETA and ETAG 013 upon
the producer of his prestressing kit, as well as upon his subcontractors and suppliers.
The designer of the structure is assumed to respect specifications set by applicable standards,
e.g. Eurocodes or equivalent applicable national standards, and to adapt his design in
accordance with the construction methods foreseen and the instructions of the ETA holder.
The arrangement of anchorages shall respect the specifications of chapter J as to edge and axis
distances and bursting steel.
Following components, not detailed in the present ETA, conform European standards or
equivalent applicable national standards or regulations:
• Prestressing steel : prEN 10138
• Monostrands : ETAG 013 Annex C1, XP A 35 037
• Steel corrugated sheaths : EN 523
• Steel pipes: prEN 10255, ISO 4200, EN 10216-1, EN 10217-1
• Smooth plastic pipes: prEN 12201
• Cement grout: EN 445, EN 447
• Bursting steel: prEN 10080, EN 10025
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Transport and handling of prestressing steel and steel components of the kit shall be done in
such a manner as to avoid any mechanical, chemical or physical damage.
Prestressing steels and steel components shall be stored free from humidity. Plastic
components and ducts shall be protected from UV radiation.
Prestressing steels and steel components shall be protected or kept away from welding areas.
The specialist company shall establish a Unique Document in conformity with the Guidance
Directive 89/391/CEE dated 1989.06.12, identifying and analysing recurring risks bound to
installation of prestressing.
The technician in charge of the prestressing works shall modify this Unique Document to
account for the particular and not recurring risks of his working site.
During stressing, standing behind or immediatly close to a jack is strictly forbidden, as well as
behind a passive anchorage while stressing at the other end. Wherever necessary, safety rails
shall be installed and passing zones for personnel shall be kept free.
Since any disorder in the structure may result in damage of PT tendons, a specialist company
should repair as soon as possible according to adequate procedures.
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The following table summarises the test procedures necessary to ensure that all kit
components meet the ETA specifications. Sétra has adapted Table E.1 of ETAG 013
according to the importance of the components for the performance of the Freyssinet PT-
system.
1 2 3 4 5 6
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1 2 3 4 5 6
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Sampling – No. of
Component Item Test/Check
components per visit
Trumplatee Material according to Test / Check 1
specification
for anchorages C Detailed dimensions Test
Main dimensions1 Check
Machined anchor block Material according to Test / Check 1
specification
for anchorages C Detailed dimensions Test
Main dimensions1 Check
Cast iron anchor parts Material according to Test / Check 1
specification
for anchorages F, X, Detailed dimensions Test
or couplers CI Main dimensions1 Check
Wedge, swage Material according to Test / Check 3
specification
Heat treatment Test 2
(if applicable)
Detailed dimensions Check 1
Main dimensions Test 5
Surface hardness
Visual Inspection1 Check 5
Single tensile element Single tensile element test Test 1 series
test according to Annex E.3
All samples taken at random and clearly identified.
1
visual inspection relates to main dimensions, calibration tests, correctness of marking or tag,
adequate performing, surface aspect, absence of burrs or faults, absence of cavities, corrosion etc.
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Internal prestressing units bonded to the concrete consist of bare strands in a thin-wall
corrugated duct made of steel (see G.2.1), plastic (see G.2.2) or smooth steel pipes (see G.2.3)
and injected with a cement grout in accordance with EN 447 or Annex C4 of ETAG013.
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Unbonded internal prestressing tendons allow re-stressing and the steel part of tensile
elements is replaceable.
Other than in exceptional circumstances, external prestressing tendons are replaceable and re-
stressable, and are one of the following types:
• Standard type: with double tube where the tendon passes through the concrete of the
structure, to ensure the independence of the tensile element and its duct from the
structure and to enable extraction. The duct is injected with cement grout.
• Type W: with a duct injected with a flexible corrosion-inhibiting product enabling the
tensile element to be extracted.
• Type GI: with monostrands housed in a general duct injected or not with cement grout
before tensioning.
‘AD n C 15’ anchorages can be used to make electrically isolated prestressing tendons if the
measures described in paragraph E.2.4 have been taken.
Where tendons pass through concrete a double casing is realised by means of a second tube
used as a concrete formwork which ensures the independence of the HDPE tube from the
concrete.
E.2.3.2 GI Tendons
Tensile elements consist of monostrands grouped together in a plastic duct, injected or not
with cement grout prior to tensioning. The anchorage head is protected by a permanent cap
filled either with a soft corrosion protection material fully compatible with that of
monostrands or injected with cement grout.
E.2.3.3 W Tendons
Tensile elements are housed in a continuous HDPE plain tube. At the anchorages, the
trumplates are fitted with a plastic trumpet welded to the tube. A watertight gasket between
the two parts allows dismantling. Double tubing is not necessary to ensure dismantling.
After tensioning, the tendon is injected with a soft corrosion protection material, such as a
microcristaline petroleum wax. The anchorage head is protected by a permanent cap which
allows the injection of the tendon.
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Model C internal prestressing anchorages can be used to make prestressing tendons for
cryogenic applications.
Freyssinet prestressing anchorages can be used to make prestressing tendons with a watertight
casing when used with a watertight plastic duct, a permanent cap to cover the anchorage head
and watertight connections between each section of the casing.
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Model F and C anchorages are used in the case of steel structures, without the standard load-
spreading component (trumplate) which is replaced by a bearing plate of a size in accordance
with the strength of the steel of the structure (see EN 1993 and EN 1994).
Model F and C anchorages are used in the case of masonry structures, without the standard
load-spreading component (trumplate) which is replaced by a bearing plate of a size in
accordance with the strength of the masonry of the structure (see EN 1996).
Model F (one strand only) and C anchorages are used in the case of timber structures, without
the standard load-spreading component (trumplate) which is replaced by a bearing plate of a
size in accordance with the strength of the timber of the structure (see EN 1995).
‘1 F’ anchorages can be used for timber structures if adequately embedded by means of epoxy
resin.
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In the case of stressing anchorages for units comprising monostrands, the strands may be
tensioned either collectively with a multistrand jack, or individually with a monostrand jack,
proceeding in several loading stages, if cement grouted before tensioning.
E.3.2 Measurement of friction coefficient and load transfer percentage from stressing
end to the other
In the case of prestressing tendons with monostrands (type GI) or injected with a flexible
filling product (type W), it is possible to adjust the prestressing load at any time during
service life if tendon overlengths have been maintainted. The overlengths are protected by an
adequately long protection cap.
When an ‘A n C15(or C13)’ or ‘AD n C15(or C13)’ anchorage uses a threaded block, the load
in the tensile element can be monitored with a special ring jack installed between the anchor
block threaded ring and the anchorage trumplate.
A non-grouted tendon can be detensioned with a monostrand jack and a detensioning stool if
the strand overlengths have not been cut off.
If the strands have been cut off, the tendon can only be detensioned by heating the wedges
with a blow torch, one by one. Special precautions must be taken at the other end to contain
any strand expulsion within special protective systems.
Once detensioning has been performed as described in paragraph 3.5, and on condition that
both ends can be easily accessed, a tendon can be replaced without demolishing.
In the case of tendons with type CI couplers, this operation is possible only for the primary
part of the tendon, before concreting of the secondary part.
When the prestressing tendon consists of monostrands, each strand can be replaced by a
strand of the same sectional area if the alignment of the tensile element is straight or slightly
deviated, and by a strand of smaller sectional area in other cases. When a new strand is
threaded in, a protective product of the same quality as that of the strand replaced must be
introduced into the individual sheath left in place.
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E.3.7 Prestressing tendon allowing for load monitoring, retensioning, and replacement
without damage to the duct
An unbonded prestressing tendon is fitted with a model C anchorage with standard wedges
extended by a clamping length mounted on a common retaining plate (drawing 1). The entire
tendon is retensioned after pulling on the overlength and inserting a special bearing ring
adapted to the jack. Detensioning is made possible by the wedge-retaining plate which
prevents wedge assemblies being pulled back into the anchorage when the tendon is
detensioned. Strand overlengths are retained (jack gripping length plus any elongation) and
are protected by a special long cap injected with flexible filling material (drawing 33).
E.3.9 Equitension
In the case of a prestressing unit with model C anchorages, when it is to be ensured that the
initial length of each strand is the same prior to tensioning, a pre-tensioning operation can be
carried out with the equitension jack. It has as many tensioning chambers as there are strands
to be tensioned, and takes up any slack in the strands individually.
Maximum forces beneath the anchorage during tensioning, F0, must be taken from standards
or regulations in place of use.
Values shown in the following table, comply French regulations which are identical to the
values recommended by Eurocode2.
The number of strands in a tendon may be decreased either by reducing the number of drilled
holes in the anchor block (special order to factory) or by leaving out strands in the anchorages
or couplers. In both cases the strands are placed in the best possible symmetrical manner. The
provisions for tendons with completely filled anchorages and couplers also apply to partially
filled ones.
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Tensile Strength
1770 1770 1860 1860 1860 1860 1820
(N/mm²)
Diametre (mm) 15,3 15,7 12,5 12,9 15,3 15,7 15,24
1 196 211 137 148 206 221 196
2 392 421 274 295 412 443 392
3 589 632 410 443 618 664 589
4 785 842 547 590 824 886 785
5 981 1053 684 738 1031 1107 981
6 1177 1264 821 886 1237 1328 1177
7 1373 1474 958 1033 1443 1550 1373
Number of Strands
Table 5. Maximum Force with Stressing Limit Fo = min{0,8 Fpk,0,9 Fp0,1%} acc. Eurocode 2 and
prEN 10138-3:2006 (only informative)
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F – ANCHORAGES
Freyssinet active anchorages are based on the wedge principle and use the Freyssinet C-
wedge. Each wedge is anchored in a conical hole of the anchor head, which is either a steel
block for anchorage models C, or a cast iron part for strand couplers and for anchorage
models F and X. Depending on situations, the anchorage block seats on a cast iron load
spreading part, called trumplate, or on a steel plate for structures other than concrete ones, the
dimensions of which depend of the strength of the structure.
The Freyssinet anchor wedge is a conical one-use wedge, consisting of three matching
wedges held together by a circlip. Two models of wedges are available:
- the C13 wedge used with T13 and T13S strands,
- the C15 wedge used with T15 and T15S strands.
Its internal diametre is adapted to the strand diameter class: either T15/T15S (C15 wedge), or
T13/T13S (C13 wedge).
Anchorage wedges are precision machined from hot-rolled or cold-drawn rods of cement steel
defined by reference to standard EN 10084 and are case hardened. The steel grade is
16MnCr5.
Internal fixed anchorages are made with anchor swages made by swaging a tubular section
enclosing a spiral spring onto each strand using a special Freyssinet jack. There are two
standard versions and a compact version:
Swages are turned from hot-rolled bars of tempered and quenched structural alloy steel
defined in reference to standard EN 10083-1. The used grades are 34CrMo4 and 36CrNiMo4.
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It is made from a non-alloy quenched and tempered structural steel, defined by reference to
standard EN 10083-1 (C45).
Note 1: electrically isolated anchorages may be made with blocks of larger dimensions than
the standard blocks in order to reduce compressive stress on the electrical isolation plate .
Note 2: blocks for type ‘NB’ embedded anchorages are made with cylindrical holes.
Note 3: when an external thread is necessary for monitoring prestressing load, the anchor
block shall have a larger diameter in order to cut the thread outside the original anchor block
size.
Except for anchorage wedges, all uncoated components are packaged in sealed containers, are
rust-free and slightly oiled.
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Anchorage wedges are packaged in white buckets. They are suitably protected against
oxidation. The buckets containing type C15 wedges are colour-coded differently to those of
type C13 wedges.
Bursting steel is fixed to general reinforcing bars at locations given in this ETA.
Tightness at connection between anchorage and duct if realised either by adhesive tape or
heat-shrink sleeves. For F anchorage models used with monostrands the sealing between
anchorage and monostrands is realised by means of a mastic plug.
Size of anchorage reservation and clearance for placing the stressing jack should be checked
at the design stage (see drawings 34 to 44).
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Loop tendons are stressed simultaneously at both ends by means of single-strand jacks (see
drawings 45 and 46).
Exchangeable external prestressing tendons injected with cement grout are realised by means
of a double duct at deviation or anchoring points :
• A minimum gap of 10mm between the two ducts is required.
• External shuttering tube, generally out of steel,
• Tendon duct, continuous between anchorages (see drawing 14)
Model «NB n C 15» anchorages consist of an anchor block with cylindrical holes and swages.
Type T13D swage is used for T13 and T13S strands, and type T15DC for T15 and T15S
strands.
Swages are realised before concreting and maintained in position with a locking template.
The prestressing force of the secondary tendon at the coupler shall not exceed that of the
primary cable.
Each strand of the primary cable is connected to the corresponding srand of the secondary
cable by means of a type P strand connector. The complet assembly is covered with a cap
ensuring the same functions as the one for fixed couplers. This cap must allow for the
elongation of first phase cable and the resulting displacement of strand connectors. In
practice, the cap length is therefore adapted to each case.
When directly embedded in the concrete structure, without overall duct, monostrands are
fixed on supports arranged within the general steel reinforcement. In case of large cable units
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FREYSSINET PRESTRESSING SYSTEM – EUROPEAN TECHNICAL APPROVAL
When monostrands are placed in a general duct (see drawings 10 to 12), the duct is injected
with cement grout and tensioning is done after the grout has reached a strength of 10 MPa.
When multi-strand anchorages are used, the precise arrangement of strands in the anchor zone
during concreting or injection of duct is secured by the use of a temporary stuffing box
(drawing 32). After removal of the stuffing box, ends of strands are freed from their sheath to
receive the anchor block, to be stressed and injected by grease under pressure.
The envelope of electrically isolated tendons consists of plastic ducts with thermo-shrink PE
connections. In particular multi-strand fixed couplers type «CI n C 15 EI» and movable
couplers type «CM n C 15 EI» are isolated in a PE or PP cap. An isolating plate is inserted
between the trumplate and the anchor block before stressing.
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These strands may also be ordered according to national standards applicable in the country
concerned, e.g in France to XPA 35-045-3 standard for bare strands.
Monostrands are covered in France by the XP A 35-037 standard, and designated by S 12,5
(or 12,9 or 15,2 or 15,7) 1770 (or 1820 or 1860) – A + (Z or ZA) + G + P. The G attribute
means protection with grease and P means sliding, i.e. the strand is free to slide in its
individual sheath, even embedded in concrete, allowing for its stressing without any bond to
the concrete of the structure.
The maximum stressing force F0 at anchorage indicated in the following table for a single
strand has been calculated in accordance with Eurocode 2. It must be adapted to the
applicable national regulations.
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Tm D S Fpk M Fp0.1% Fo To
MPa mm mm² kN kg/m kN kN N/mm²
1770 12.5 93 165 0.726 145 130.5 1416
1770 12.9 100 177 0.781 156 140.4 1416
1770 15.3 140 248 1.093 218 196.2 1416
1770 15.7 150 266 1.172 234 210.6 1416
1860 12.5 93 173 0.726 152 136.8 1488
1860 12.9 100 186 0.781 164 147.6 1488
1860 15.3 140 260 1.093 229 206.1 1488
1860 15.7 150 279 1.172 246 221.4 1488
D Nominal diametre
Fpk Characteristic value of maximum load (equal to fpk.Ap in Eurocode 2 or Fm in prEN)
Fp0.1% characteristic value of load at 0,1% elasticity limit
Fo Indicative maximum force at stressing anchorage: Fo = Min { 0,8 Fpk ; 0,9 Fp0.1%}
m Nominal mass per metre
S Nominal area
To Tensile stress under Fo
Tm Tensile stress at break
Table 6. Maximum Force at Stressing Anchorage for a Single Strand acc. to Eurocode 2 and
prEN 10138-3:2006 (only informative)
G.2 DUCTS
The Freyssinet prestressing kit for post-tensioning may be used with different types of duct
depending the project and the use categories of tendons.
The typical internal diametre of ducts is defined on the drawings in Annex K for each
anchorage model, which may be increased if required by the project specifications or the
national regulations. In the case of prefabricated cables threaded in one operation, the duct
internal diametre may be increased in sections with large deviation curvature to facilitate
threading.
Steel strip sheaths are either circular or oval, generally corrugated to ensure a mechanical
bond with the concrete. The overall external dimensions of steel strip sheaths are about 6 mm
larger than the internal dimensions because of corrugation. This must be taken into account in
the design.
Steel strip sheaths are made from cold-formed (if corrugated) steel strip wound helically and
welded along the edges or locked together by crimping.
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Diametre 25-35 35-45 45-55 55-65 65-75 75-85 85- 100- 130-
(mm) 100 130 160
min. Category 0,25 0,25 0,30 0,30 0,35 0,35 0,40 0,40 0,40
thickness 1
of sheath Category
0,40 0,45 0,45 0,50 0,50 0,60 0,60 0,60
(mm) 2
Table 7. Thickness of Steel Strip Sheaths
Sheath sections are connected together with helical sleeves screwed onto the ends of the
sheaths. The watertightness at connections is obtained by adhesive tape or heat-shrink sleeves.
The ducts may be circular or flat, but are always corrugated to ensure a bond with the
concrete. The overall outer dimensions of a corrugated plastic duct are about 13 mm larger
than its internal dimensions because of corrugation. This must be taken into account in the
design.
Plastics ducts are sensitive to wear induced by movement of the strands in the duct during
tensioning. Duct thickness is selected in accordance with the severity of the tendon alignment
(total length and radii of curvature).
Special precautions must be taken if the temperature of the surrounding concrete is likely to
exceed 60°C during setting or if the external pressure is likely to exceed 0,5 bar.
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G.2.2.1 Plyduct
The Plyduct sheath is circular, made out of a polyethylene strip. It is 2,5 mm thick for duct
diameters up to 95 mm and 3,0 mm thick for larger diameters. Sheath sections are connected
by a sleeve of the same design as the basic sheath screwed onto the sections to be joined
together. Watertightness at connections is obtained by heat-shrink sleeves coated on the inside
with a hot-melt resin which are shrunk onto the sheath with a hot-air blower. The dimensions
of the heat-shrink sleeves are chosen so as to have a residual thickness of at least 1,5 mm after
shrinking.
The steel pipes used as prestressing ducts are generally chosen in compliance with one of the
following standards: EN 10305-3 (welded cold-sized tubes), EN 10216-1 (seamless tubes),
EN 10217-1 (welded steel tubes) or prEN 10219 (fine-grain steel pipe).
Pipes can be zinc-coated by hot-dip galvanising in accordance with standard EN ISO 1461, if
allowed by the applicable national regulations.
The polyethylene used is PE80 or PE100. Nominal pressure class (table 2 of standard
EN 12201-2) is chosen as follows:
• Class PN4.0 at least, for injection prior to tensioning of monostrands,
• Class PN6.3 at least, for injection at ambient temperature,
• Class PN10 at least, for injection at temperatures exceeding 60°C (wax injection).
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EN 12201-2 PE 80 PE 100
Series Low pressure Pressure Pressure
PN** 6.3 10 10
SDR 21 13.6 17
Nominal external Thickness Thickness Thickness
diameter
(mm) (mm) (mm) (mm)
50 3.7* 3.7
63 4.7* 4.7
75 5.5* 5.5
90 6.6* 6.6
110 5.3 8.1
125 6.0 9.2
140 6.7 10.3
160 7.7 11.8
180 8.6 10.7
200 9.6
SDR: ratio of external diameter to nominal wall thickness
* these pipes have not standardised dimensions
** PN values are based on a global service factor C = 1.25
Table 8. Dimensions of Smooth HDPE Tubes
Ducts for external prestressing are delivered in straight lengths. The most common lengths are
6 and 12 m. Lengths of pipe are connected by mirror welding or by means of polyethylene
sleeves electro-welded.
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Close to anchorages the duct must guide the tensile element so that its strands bear against the
deviation zone of the trumplate and enter the holes in the anchorage head at the correct angle:
in practice the cable lay-out must be straight on a length of at least 6 times the duct internal
diametre, between the trumplate end and the start of the curved section.
Minimum Curvature
Stand Type Duct Type
Radius
Flat duct steel 100 internal diametre 2
Plastic 100 internal diametre
Bare Strand Steel 100 internal diametre
Circular duct
Plastic 100 internal diametre
Tube Steel 3,0 m
Strands directly
incorporated in concrete
(in group of three strands Deviation 1,7 m for T13 1
Monostrand maximum) or placed in a 2,5 m for T15 1
duct injected with cement
grout before tensioning
Deviation 2,5 m
Single strand
Dead anchorage 0,6 m
(180° hoop)
1
according to ENV 1992-1-5:1994
2
concrete stability against splitting to be checked and simultaneous stressing at both ends
3
flat duct dimension in the considered direction
Table 9. Minimum Curvature Radius for Internal Prestressing
In the case of bonded prestressing, the minimum radius of steel tubes can be reduced down to
20 times the internal diameter, assuming that:
- the resulting radius is not less than 1,1 m for T13 strands and 1,3 m for T15 strands,
- the tensile stress does not exceed 70% of strand guaranteed tensile strength where the
radius is less than 3,0 m,
- the sum of angular deviations along the cable is less than 3π/2 radians,
- the sharply curved zone is considered as a dead anchorage if the angular deviation exceeds
π/2 radians.
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The maximum distance between duct supports is 1,0 m for straight sections or with high
curvature radius and 0,5 m for sections with small radius. In the case of smooth steel pipes, at
least one support at each elementary length but the distance shall not exceed 3 m.
Any axial thrust along the pipe must be balanced by appropriate arrangements at the bottom
of the formwork. Similarly, the spacing of supports and the attachment of the duct must take
account of the buoyancy effect in fresh concrete.
Flat ducts are more sensitive to accidental crushing before tendon threading than circular
ducts. For this reason the tendons should be threaded into the duct before concreting. If it is
not possible to thread the tendons before concreting, measures must be taken to protect the
duct from crushing, or the ducts must be threaded with temporary “dummy” strands which
will be removed before the real tendons are threaded.
When ducts cross over each other in layers, contact between ducts should be avoided, and it
may be advisable to strengthen the area of intersection with a half-sleeve in order to prevent
any risk of communication between ducts during cement grouting.
In the case of corrugated plastic sheaths, a plastic half-shell must be placed between the duct
and its support in all areas where tendon is deviated.
The tolerance on the position of tendons in concrete parts must meet the requirements of draft
standard ENV 13670-1. Special attention must be given to tendon breakout induced by
deviated cables near an outside surface: the local positioning tolerance will have to be
determined in accordance with the lay-out of the passive reinforcement.
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H – TENSIONING
Tensioning of secondary cables shall be such as to avoid the force at coupler end to exceed
that of the primary cables after blocking.
Force readings must take into account calibration of tensioning equipment and losses due to
friction in anchorages as given in the following table:
3 to 13 C 15 2% 3% 1% 2%
19 to 55 C 15 and 25 CC 15 2,5 % 3,5 % 1% 2%
1 F 13/15 1% 2% 0% 1%
3 to 4 F 13/15 1% 2% 1% 2%
1 to 2 X 15 1% 2% 0% 1%
* tensioning using jack with curved front adaptor-fitting
Table 11. Friction Loss in Anchorages
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I – PROTECTION OF TENDONS
If storage of strands on site is longer or if tendon injection cannot be done in due time after
tensioning (delay exceeding four weeks), this temporary protection must be regularly
renewed, in conformity with applicable specifications. This lubrication may also be used to
reduce friction coefficient of cable inside duct.
Cement grout is a stable, uniform mix of Portland cement, additives and water obtained by a
mechanical mixing process. It is screened and kept agitated in a storage tank until injected
into the duct.
I.2.2 Wax
The wax for injecting prestressing tendons shall be a petroleum wax meeting the requirements
of paragraph C.4.2 of ETAG 013.
I.2.3 Grease
The grease for Freyssinet prestressing tendons shall be a mineral-oil-based grease meeting the
requirements of paragraph C.4.1 of ETAG 013.
Mixers, wax melting units, and pumps supplied by Freyssinet for injecting tendons are all subject to
anEC declaration of conformity with the applicable regulations governing new or rented equipment.
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The coefficients of friction (µ) and of wobble (k), as defined in European standard
pr EN1992-1-1 to obtain the prestressing force with the equation P(x) = Pmax e-µ(θ+kx), vary in
accordance with uses (internal or external prestressing, standard strands or monostrands), the
type and stiffness of ducts (steel or HDPE strip sheath or pipe), surface treatments, lubrication
of the strands, whether with soluble oil or grease.
The acceptable variation of the coefficient of friction is usually ±25%. The coefficient of
friction can rise significantly in deviation zones with a curvature radius less than 6 metres.
The coefficients in the following table are for information only (and must be adapted to each
project).
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The elongation loss with or without hydraulic blocking shall be accounted for in tensioning
calculations by using the values given in the following table.
Pull-in at min 4 4 6 6
stressing
mean 5 6 7 8
anchorage
mm max 6 8 8 9
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In the case of an active anchorage the necessary clearance for jack placing and actioning is
described in the drawings given in Part K thereafter.
For external passive anchorages a minimal clearance of 500 mm allows the installation of
wedges on protruding strands.
Anchorages must have a sufficient edge distance and be separated from each other by a
minimum centre distance. These distances are derived from reference dimensions a and b of
the test specimens.
In what follows, it is considered that anchorages are positioned relative to two orthogonal
directions x and y, with the smaller dimension of the trumplate aligned along axis x.
Notations:
• A, B: plane dimensions of the trumplate (A %
• a, b: side lengths of test specimen (a E
• x, y: minimum centre distance between two anchorages in the structure in x- and y-
directions,
• x’, y’: minimum edge distance between anchorages and the closest external surface in
x- and y-directions,
• fcm,o: mean compressive strength measured on cylinder required before tensioning.
B B
x’ x’
A A
x x
y’ y’ y y y’
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The values of a and b are given in the table below for three different concrete strengths fcm,o.
a = b (mm)
fcm,o (MPa)
Unité 24 44 60
3 C15 220 200 180
If the project calls for a value fcm,o other than any of those in the two tables directly above, the
appropriate values of x and y can be determined by interpolation. However, full tension
cannot be exerted when fcm,o is less than the lowest value indicated in tables 14 and 15 (e.g.
24 MPa for model C anchorages).
For partial tensioning or for a tension of less than Min{0.8 Fpk; 0.9Fp0.1%}, the required value
for fcm,o can be determined by interpolation considering that at 50% of the total force, the
required concrete strength can be reduced to 2/3 of the values given in the two tables above
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and at 30% of the total force, the required concrete strength can be reduced to 1/2 of the
values given in the same tables.
In anchorage zone prestressing tendons impose to the structure concentrated forces requiring a
specific arrangement of reinforcement. In case of concrete structures, bursting reinforcement
consists in:
• Surface reinforcement,
• Anchorage bursting reinforcement,
• General reinforcement to equilibrate mechanically the concerned piece within the
structure, the dimensions of which result from the design rules of reinforced concrete.
Anchorage bursting reinforcement as defined thereunder results from load transfer testing.
If required the local zone reinforcement specified in the ETA may be modified for a specific
project design in accordance with national regulations and relevant approval of the local
authorities and of the ETA holder to provide equivalent performance.
C C0 C C C0
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RUVHH
WDEOHV
HTXLYDOHQWVWLUUXSV
In the case of several rows of anchorages, as a rule W = L = Lo. In the case of a single row of
anchorages, W is reduced and L is increased, but the minimum value of E shown in the
following table is retained.
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C0
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Note : the number of turns must be increased by one and a half if the last turn is open.
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∅10
type q’ty N L1 L2 L3 h
A 3F13 1 12 8 320
A 4F13 2 3 8 320 20 160 140
3 3 8 320 20 160 140
see bar types below
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bar types
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K DRAWINGS
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