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MEMBER OF EOTA

European Technical Approval ETA - 07/0035


English translation, the original version is in French (version originale en Français)
Version of 4th January 2013

Nom commercial: Systèmes de précontrainte par post-tension CCL;


gamme ‘X’
Système adhérent/non adhérent multi torons CCL ‘XM’
Système adhérent multi torons CCL ‘XMC’

Trade name: CCL ‘X’ Range Post-Tensioning Systems


CCL ‘XM’ Multistrand Bonded/Unbonded System
CCL ‘XMC’ Multistrand Bonded System

Détenteur de l'ATE: CCL Stressing International Ltd


Holder of approval: Unit 8 Park 2000 Millennium Drive
Leeds England
LS11 5BP

Type générique et utilisation Systèmes de précontrainte par post-tension de 3 à


prévue du produit de construction: 55 torons adhérent/non adhérent
Generic type and use of
construction product: Post-Tensioning Kit for prestressing of structures
with bonded/unbonded tendons of 3–55 strands

Valid from: 08/08/2012


to: 08/08/2017

Producteur du procédé: CCL Stressing Systems Ltd


Kit manufacturer: Unit 8 Park 2000 Millennium Drive
Leeds England
LS11 5BP

Cet Agrément Technique Européen ETA-07/0035 valide du 09/08/2007 au


est un renouvellement de validité 09/08/2012
de
This European Technical Approval ETA-07/0035 with validity from 09/08/2007
extends to 09/08/2012

Le présent agrément technique 63 Pages


européen contient:
This European Technical Approval 63 Pages
contains:

Organisation pour l'Agrément Technique Européen


European Organisation for Technical Approvals
ETA-07/0035 European Technical Approval CCL ‘X’ Range Post-tensioning system 2

I LEGAL BASES AND GENERAL CONDITIONS


1 This European Technical Approval is issued by Sétra in accordance with:

Council Directive 89/106/EEC of 21 December 1988 on the


approximation of laws, regulations and administrative provisions of
Member States relating to construction products1, modified by
Council Directive 93/68/EEC2 and Regulation (EC) No 1882/2003 of
the European Parliament and of the Council3;

décret n°92-647 du 8 juillet 19924 concernant l'aptitude à l'usage


des produits de construction;

Common Procedural Rules for Requesting, Preparing and the


Granting of European Technical Approvals set out in the Annex to
Commission Decision 94/23/EC5;

ETAG 013, Edition June 2002, Post-Tensioning Kits for Prestressing


of Structures.

2 Sétra 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.

3 This European Technical Approval is not to be transferred to manufacturers or


agents of manufacturers other than those indicated on page 1, or manufacturing
plants other than those indicated on page 1 of this European Technical Approval.

4 This European Technical Approval may be withdrawn by Sétra, in particular


pursuant to information by the Commission according to Article 5(1) of Council
Directive 89/106/EEC.

5 Reproduction of this European Technical Approval including transmission by


electronic means shall be in full. However, partial reproduction can be made with
the written consent of Sétra. In this case partial reproduction has to be
designated as such. Texts and drawings of advertising brochures shall not
contradict or misuse the European Technical Approval.

6 The European Technical Approval is issued by the approval body in its official
language(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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ETA-07/0035 European Technical Approval CCL ‘X’ Range Post-tensioning system 3

II SPECIFIC CONDITIONS OF THE EUROPEAN


TECHNICAL APPROVAL
1 Definition of Products and Intended Use

1.1 Definition of the Construction Product (Kit)

This European Technical Approval applies to:

CCL ‘XM’ Multistrand Bonded/Unbonded Post-Tensioning System

Consisting of the following components:

Tendon: Bonded/Unbonded multistrand tendons with 3-55 tensile


elements

Tensile Elements: 7-wire prestressing steel strand with nominal tensile


strengths of 1770MPa/1860MPa and nominal diameters of
12.5mm / 12.9mm / 13.0mm / 15.2mm / 15.3mm / 15.7mm

Anchorages: Live End and Dead End anchorages with 3-55 strands

Reinforcement: Local anchorage zone reinforcement in Helix and Link layouts

Corrosion Protection: Grout/Grease/Wax & sealing around the anchorage zone &
duct

CCL ‘XMC’ Multistrand Coupler Bonded Post-Tensioning System

Consisting of the following components:

Tendon: Bonded tendons with 3-37 tensile elements

Tensile Elements: 7-wire prestressing steel strand with nominal tensile


strengths of 1770MPa/1860MPa and nominal diameters of
15.2mm / 15.3mm / 15.7mm

Anchorages: Live End and Dead End anchorages with 3-37 strands

Reinforcement: Local anchorage zone reinforcement in Helix and Link layouts

Corrosion Protection: Grout and sealing around the anchorage zone & duct

1.2 Intended Use

For ‘XM’ Multistrand Bonded/Unbonded System

Basic categories of use are:

Internal bonded tendon for concrete and composite structures


Internal unbonded tendon for concrete and composite structures
External tendon for concrete structures with a tendon path situated outside the
cross-section of the structure or member but inside its envelope

Optional categories of use are:

Bonded tendon for cryogenic applications inside the possible cryogenic zone
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Internal bonded tendon with plastic duct


Encapsulated tendon

For ‘XMC’ Multistrand Coupler Bonded Post-Tensioning System:

Basic categories of use are:

Internal bonded tendon for concrete and composite structures


Internal unbonded tendon for concrete and composite structures
External tendon for concrete structures with a tendon path situated outside the
cross-section of the structure or member but inside its envelope

Optional categories of use are :

Internal bonded tendon with plastic duct

PT anchorage zones must be designed to resist 1.1Fpk according to the relevant Eurocode
when used with materials other than concrete.

1.3 Working Life

The provisions made in this ETA are based on an assumed intended working life of the
CCL ‘XM’ and ‘XMC’ PT System of 100 years (provided that the conditions laid down in
section(s) 4.2 / 5.1 / 5.2 for packaging / transport / storage / installation / use /
maintenance / repair are met). The indications given on the working life can not be
interpreted as a guarantee given by the producer or the approval body, 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 works.

Tests performed to assess the cryogenic optional category of use were made according
to the 2002 version of ETAG 013
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2 Characteristics of Products and Methods of Verification

2.1 Range and Designation of Anchorages

The type of anchorage is designated depending on its function in the structure in the
following order:

The first letters signify the System Type;

The next numbers signify the size of the Force Transfer Unit;

The next numbers signify the maximum number of strands in the tendon;

The next numbers signify the nominal diameter of the strands in the tendon;

The next letter shows the type of anchorage.

The optional last letter (only for XM systems) signifies whether the system is
encapsulated.

Examples:

XM-60-19-15.7-L-E – Encapsulated Live End multistrand anchorage with a size 60


Force Transfer Unit having 19 strands of Ø15.7mm.

XM-40-18-12.9-D – Dead End multistrand anchorage with a size 40 Force Transfer Unit
having 18 strands of Ø12.9mm.

XMC-60-19-15.2-L – Live End multistrand coupler anchorage with a size 60 Force


Transfer Unit having 19 strands of Ø15.2mm.

XMC-40-12-15.7-D – Dead End multistrand coupler anchorage with a size 40 Force


Transfer Unit having 12 strands of Ø15.7mm.

The various types of anchorage are specified in Tables 2a, 2b & 2c.

Table 2a: CCL ‘XM’ Anchorages for 15mm Systems

Anchorage No. of Strands Strand Ø


XM-10 3 15.2/15.3/15.7
XM-20 4 15.2/15.3/15.7
XM-30 7 15.2/15.3/15.7
XM-35 9 15.2/15.3/15.7
XM-40 12 15.2/15.3/15.7
XM-45 13 15.2/15.3/15.7
XM-50 15 15.2/15.3/15.7
XM-55 17 15.2/15.3/15.7
XM-60 19 15.2/15.3/15.7
XM-70 22 15.2/15.3/15.7
XM-75 25 15.2/15.3/15.7
XM-80 27 15.2/15.3/15.7
XM-90 31 15.2/15.3/15.7
XM-95 35 15.2/15.3/15.7
XM-100 37 15.2/15.3/15.7

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Table 2b: CCL ‘XM’ Anchorages for 13mm Systems

Anchorage No. of Strands Strand Ø


XM-10 4 12.5/12.9/13.0
XM-20 6 12.5/12.9/13.0
XM-30 9 12.5/12.9/13.0
XM-35 12 12.5/12.9/13.0
XM-40 18 12.5/12.9/13.0
XM-45 19 12.5/12.9/13.0
XM-50 22 12.5/12.9/13.0
XM-55 25 12.5/12.9/13.0
XM-60 27 12.5/12.9/13.0
XM-70 31 12.5/12.9/13.0
XM-75 37 12.5/12.9/13.0
XM-80 40 12.5/12.9/13.0
XM-90 46 12.5/12.9/13.0
XM-95 51 12.5/12.9/13.0
XM-100 55 12.5/12.9/13.0

Table 2c: CCL ‘XMC’ Anchorages for 15mm Systems

Anchorage No. of Strands Strand Ø


XMC-10 3 15.2/15.3/15.7
XMC-20 4 15.2/15.3/15.7
XMC-30 7 15.2/15.3/15.7
XMC-35 9 15.2/15.3/15.7
XMC-40 12 15.2/15.3/15.7
XMC-45 13 15.2/15.3/15.7
XMC-50 15 15.2/15.3/15.7
XMC-55 17 15.2/15.3/15.7
XMC-60 19 15.2/15.3/15.7
XMC-70 22 15.2/15.3/15.7
XMC-75 25 15.2/15.3/15.7
XMC-80 27 15.2/15.3/15.7
XMC-90 31 15.2/15.3/15.7
XMC-95 35 15.2/15.3/15.7
XMC-100 37 15.2/15.3/15.7

For better utilisation of the prestressing force within the structure, it is possible to use
CCL ‘XM’ and ‘XMC’ anchorages with a number of strands lower than the maximum
number specified. In this case, intermediate units can be modified from the existing
designs provided strands lie symmetrically around the anchor head to ensure the force is
safely aligned.

2.1.1 CCL ‘XM’ Live End Anchorages

CCL ‘XM’ Live End (LE) Anchorages are circular section multistrand anchorages shown in
Annexes A01 & A03. The anchorage comprises:

Steel Wedges
Steel Anchor Head (AH)
Cast Iron Force Transfer Unit (FTU)
Plastic Deviation Cone (DC)

The strands of the anchorage are simultaneously stressed by a Jack bearing on the FTU
by means of a Bearing Ring (BR).

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The prestressing force is applied to the strands and locked in place by the wedges into
the AH which is supported on the FTU cast into the concrete. This FTU ensures the
transmission of the prestressing force into the concrete.

The FTU and the DC ensure the correct deviation of the strands from the AH to the Duct.

LE anchorages can be used as Active or Passive anchorages.

2.1.2 CCL ‘XM’ Dead End Anchorages

CCL ‘XM’ Dead End (DE) Anchorages are circular section multistrand anchorages shown in
Annexes A02 & A04. The anchorage comprises:

Steel Wedges
Steel Anchor Head
Cast Iron Force Transfer Unit
Plastic Deviation Cone
Spring Loaded Spring Plate (SP) and Fixings

The wedges are locked in place with the SP while the prestressing force is applied to the
opposite (live) end of the tendon. The prestressing force in the strands is locked by the
wedges into the AH which is supported on the FTU cast into the concrete. This FTU
ensures the transmission of the prestressing force to the concrete.

The FTU and the DC ensure the correct deviation of the strands from the AH to the Duct.

No Jacking is required at this end of the anchorage.

DE anchorages can be used as Passive anchorages only.

If required by a specific project, DE anchorages can be used as buried passive


anchorages with the provision of a sealing cap and a suitable grout vent. Threading of
strands must be completed before concreting. CCL must be consulted before the use of a
buried DE anchorage.

2.1.3 CCL ‘XM’ Encapsulated Live End Anchorages

CCL ‘XM’ Encapsulated Live End (ELE) Anchorages are circular section multistrand
anchorages shown in Annex A05. The anchorage comprises:

Steel Wedges
Steel Anchor Head (AH)
Cast Iron Force Transfer Unit (FTU)
Plastic Deviation Cone (DC)
Plastic Sealing Cap (SC)
Connecting Accessories

The strands of the anchorage are simultaneously stressed by a Jack bearing on the FTU
by means of a Bearing Ring (BR).

The prestressing force is applied to the strands and locked in place by the wedges into
the AH which is supported on the FTU cast into the concrete. This FTU ensures the
transmission of the prestressing force into the concrete.

The FTU and the DC ensure the correct deviation of the strands from the AH to the Duct.

LE anchorages can be used as Active or Passive anchorages.

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2.1.4 CCL ‘XM’ Encapsulated Dead End Anchorages

CCL ‘XM’ Encapsulated Dead End (EDE) Anchorages are circular section multistrand
anchorages shown in Annex A06. The anchorage comprises:

Steel Wedges
Steel Anchor Head
Cast Iron Force Transfer Unit
Plastic Deviation Cone
Spring Loaded Spring Plate (SP) and Fixings
Plastic Sealing Cap (SC)
Connecting Accessories

The wedges are locked in place with the SP while the prestressing force is applied to the
opposite (live) end of the tendon. The prestressing force in the strands is locked by the
wedges into the AH which is supported on the FTU cast into the concrete. This FTU
ensures the transmission of the prestressing force to the concrete.

The FTU and the DC ensure the correct deviation of the strands from the AH to the Duct.

No Jacking is required at this end of the anchorage.

DE anchorages can be used as Passive anchorages only.

If required by a specific project, EDE anchorages can be used as buried passive


anchorages with the provision a suitable grout vent linked to the SC. Threading of
strands must be completed before concreting. CCL must be consulted before the use of a
buried EDE anchorage.

2.1.5 CCL ‘XMC’ Live End Anchorages

CCL ‘XMC’ Live End (LE) Anchorages are circular section multistrand anchorages shown in
Annex A07.

The anchorage comprises:

Steel Wedges
Steel Coupler (C)
Cast Iron Force Transfer Unit (FTU)
Plastic Deviation Cone (DC)
SG Iron Coupler Extension Ring (CER)
Steel Coupler Reducing Cone Retainer (CRCR)
Plastic Coupler Reducing Cone (CRC)
Spring Loaded Coupler Outer Spring Plate (COSP) and Fixings

The 1st stage strands of the anchorage are simultaneously stressed by a Jack bearing on
the Coupler by means of a Bearing Ring (BR).

The prestressing force is applied to the strands and locked in place by the wedges into
the Coupler which is supported on the CER which is in turn supported on the CRCR and
FTU which is cast into the concrete. This FTU ensures the transmission of the
prestressing force into the concrete.

The FTU and the DC ensure the correct deviation of the 1st stage strands from the
Coupler to the Duct.

The 2nd stage strands are positioned through the outer holes of the Coupler and are
locked in place by the wedges and COSP. The CRC is positioned over the 2nd stage
strands and Coupler and is locked in place by the CRCR. The prestressing force is applied
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to the opposite (live) end of the tendon. The prestressing force in the strands is locked
by the wedges into the Coupler. When cast into the concrete, the CRC ensures the
correct deviation of the 2nd stage strands from the Coupler to the Duct.

2.1.6 CCL ‘XMC’ Dead End Anchorages

CCL ‘XMC’ Dead End (DE) Anchorages are circular section multistrand anchorages shown
in Annex A08. The anchorage comprises:

Steel Wedges
Steel Coupler (C)
Cast Iron Force Transfer Unit (FTU)
Plastic Deviation Cone (DC)
SG Iron Coupler Extension Ring (CER)
Steel Coupler Reducing Cone Retainer (CRCR)
Plastic Coupler Reducing Cone (CRC)
Spring Loaded Coupler Outer Spring Plate and Fixings (COSP)
Spring Loaded Spring Plate and Fixings (SP)

The 1st stage strands of the anchorage are locked in place with the SP while the
prestressing force is applied to the opposite (live) end of the tendon. The prestressing
force in the strands is locked by the wedges into the Coupler which is supported on the
CER which is in turn supported on the CRCR and FTU which is cast into the concrete. This
FTU ensures the transmission of the prestressing force into the concrete.

The FTU and the DC ensure the correct deviation of the 1st stage strands from the
Coupler to the Duct.

The 2nd stage strands are positioned through the outer holes of the Coupler and are
locked in place by the wedges and COSP. The CRC is positioned over the 2nd stage
strands and Coupler and is locked in place by the CRCR. The prestressing force is applied
to the opposite end of the tendon. The prestressing force in the strands is locked by the
wedges into the Coupler. When cast into the concrete, the CRC ensures the correct
deviation of the 2nd stage strands from the Coupler to the Duct.

No Jacking is required at this end of the anchorage

DE anchorages can be used as Passive anchorages only.

2.2 Anchorage Components

2.2.1 Wedges Type ‘X’

CCL Type ‘X’ wedges are manufactured from a suitable case-hardening steel to European
Standard EN 10084 or BS 970.

The wedges are machined from bar stock according to the dimensions provided in
Annex A08. Wedges are roll marked on their cylindrical face for identification purposes.

The wedges are then heat treated to a specific process to obtain the necessary hardness
and ductility.

2.2.2 Anchor Heads

CCL ‘XM’ AHs are manufactured from a suitable steel to European Standard EN 10083.

The AHs are machined from cylindrical blanks made from steel bars according to the
patterns provided in Annexes A11 & A12. AHs are marked with the CCL Logo, TDC (Top
Dead Centre), Part Number and Traceability Reference for identification purposes.

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There are 2 types of Anchor Head:

The Live End Anchor Head.

The Dead End Anchor Head. This AH allows the fixing of a SP to ensure correct
seating of the wedges during single end stressing.

2.2.3 Force Transfer Units

CCL ‘XM’ FTUs are manufactured from a suitable cast iron to European Standard EN
1561.

The FTUs are cast; then the bearing face, grout entry connection and tapped holes for
connection to the bearing ring/grout cap are machined according to the dimensions
provided in Annex A14. FTUs are marked with the CCL Logo, Part Number and
Traceability Reference for identification purposes.

CCL ‘XM’ FTUs have a circular bearing face (which supports the cylindrical AH) and
multiple surfaces of load transfer for transmission of prestressing force from the tendon
to the reinforced concrete that surrounds them. The FTU also supports the Jack during
stressing via a Bearing Ring (BR). Filling material entry is through a tapped hole with
parallel pipe thread EN10226 Rp 3/4 (¾ BSP) to EN 10226-1 in the face of the casting.
Venting may also take place through this connection when required. The opposite end of
the casting is internally threaded for connection of the DC.

2.2.4 Couplers

CCL ‘XM’ Couplers are manufactured from a suitable steel to European Standard EN
10083.

The Couplers are machined from cylindrical blanks made from steel bars according to the
patterns provided in Annex A13. The hole patterns of the 1st stage tendon match that of
the XM AHs. Couplers are marked with the CCL Logo, TDC (Top Dead Centre), Part
Number and Traceability Reference for identification purposes.

The 1st stage of the Coupler can be used as a Dead End anchorage when fitted with an SP
to ensure correct seating of the wedges during single end stressing.

2.2.5 Coupler Extension Rings

CCL ‘XMC’ CERs are manufactured from a suitable SG cast iron to European Standard EN
1563.

The CERs are cast; then the load-bearing faces and holes are machined according to the
dimensions provided in Annex A15. CERs are marked with the CCL Logo, Part Number
and Traceability Reference for identification purposes.

CCL ‘XMC’ CERs have a recessed circular bearing face which supports the cylindrical
Coupler and transfers the prestress force to the FTU via the CRCR.

2.2.6 Deviation Cones, Coupler Reducing Cones, Sealing Caps and Ducts

CCL ‘XM’ DCs are moulded plastic cones threaded onto CCL ‘XM’ FTUs. For Encapsulated
tendons, the joint between the FTU and DC is sealed using a heat shrink sleeve. These
cones provide the deviation point for the strands in the tendon. The duct is connected to
the DC via a coupler sleeve fitted to the location lugs on the cone.

CCL ‘XMC’ CRCs are moulded plastic cones locked onto CCL ‘XM’ FTUs by CCL CRCRs
These cones provide the deviation point for the 2nd stage strands in the tendon. The duct
is connected to the CRC via a coupler sleeve fitted to the location lugs on the cone.
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CCL ‘XM’ SCs are moulded plastic caps fitted with an O-Ring to CCLL ‘XM’ FTUs. These
caps completely encapsulate both types of anchor head and provide an air-tight seal.

DCs and CRCs and SCs can be manufactured from HDPE or Polypropylene according to
the dimensions provided in Annexes A16, A17 and A18 and are supplied in the colour
black. They are marked with the CCL Logo, Part Number and Traceability Reference for
identification purposes.

Details of the connection between DCs, CRCs and metal ducts are shown in Annex A19.
connections between the DCs, CRCs and plastic ducts are shown in Annex A20. Ducts
should comply with the following standards:

Metal ducts – EN 523


Smooth steel pipes – EN 10255
Plastic ducts – ETAG 013 Annex C.2
Plastic pipes – ETAG 013 Annex C.3

2.2.7 Spring Loaded Retaining Plates

CCL ‘XM’ SPs and ‘XMC’ COSPs are manufactured from steel according to the dimensions
provided in Annexes A21 and A22 with hole patterns to match the AHs / 1st stage strand
pattern of the Couplers and the 2nd stage hole patterns of the Couplers respectively. The
SPs and COSPs are marked with the CCL Logo, TDC (Top Dead Centre), Part Number and
Traceability Reference for identification purposes.

2.2.8 Coupler Reducing Cone Retaining Plates

CCL ‘XMC’ CRCRs are manufactured from steel according to the dimensions provided in
Annex A23 with hole diameters to match the bores of the CERs and FTUs. The CRCRs are
marked with the CCL Logo, TDC (Top Dead Centre), Part Number and Traceability
Reference for identification purposes.

2.2.9 Bursting Reinforcement

For each unit of the CCL ‘XM’ and ‘XMC’ PT System three types of reinforcement can be
employed:

Helices
Links
A combination of Helices and Links*

As the bursting reinforcement cannot compensate for a local defect of filling of the
concrete behind the anchorage, the designer of the structure will have to ensure that the
density and the distribution of the reinforcement in the vicinity of the anchorages allows
pouring and adequate compaction of the concrete whilst maintaining containment of the
bursting forces.

If required, the local zone reinforcement specified in the ETA and confirmed in the load
transfer test may be modified for a specific project design in accordance with national
regulations and relevant approval of the local authority and of the ETA holder to provide
equivalent performance.

The local anchorage zone bursting reinforcement design rules for the CCL ‘XM’ and ‘XMC’
PT System are based on a modified version of the equation proposed by Roberts6.

6
Roberts C., Behaviour and Design of the Local Anchorage Zone in Post-Tensioned Concrete. M.S. Thesis,
University of Texas at Austin, May 1990
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The design rules were established on the assumption of a single anchorage in a concrete
prism tested in axial compression, with side lengths a and b (where a = b) and specimen
height equal to twice the side length. Testing was carried out with 2 mean compressive
concrete strengths; fcm,0 on cube = 30MPa and 55Mpa for units XM10-100. Additional
testing was carried out with 1 mean compressive concrete strength; fcm,0 on
cube = 46MPa for units XM10-80.

A copy of the local anchorage zone bursting reinforcement design rules for the CCL ‘XM’
and ‘XMC’ PT System is available from CCL on request.

The minimum bursting reinforcement dimensions for concrete strengths; fcm,0 on


cube = 30MPa and 55MPa for units XM10-100 are shown in Annexes A25-A29 and for
fcm,0 on cube = 46MPa for units XM10-80 see Annexes A31-A32.

*Not available for units XM10-80 with concrete strength fcm,0 on cube = 46MPa

2.3 Tendons

2.3.1 Standard Notation

Table 2d lists the standard notation and its intended meaning used within this ETA.

Table 2d: Standard Notation

Notation Definition
d Nominal Diameter of an individual strand / mm

fpk Characteristic Tensile Strength of the strand / MPa

n Number of individual strands in the tendon

Ap Nominal Cross-Sectional Area of the tendon / mm2

As Nominal Cross-Sectional Area of an individual strand / mm2

Fpk Characteristic Ultimate Resisting Force of the tendon / kN (Fpk = Ap x fpk)

Fp0.1k Characteristic 0.1% Proof Force of the tendon / kN (Fp0.1k = Ap x fp0.1k)

Fpks Characteristic Ultimate Resisting Force of an individual strand / kN (Fpks = As x fpk)

Fp0.1ks Characteristic 0.1% Proof Force of an individual strand / kN

F0 Min (k1Fpk ; k2Fp0.1k) / kN

F0s Min (k1Fpks ; k2Fp0.1ks) / kN

Mp Nominal Mass per Metre of the tendon / kg/m

Ms Nominal Mass per Metre of an individual strand / g/m

The maximum allowable stressing force that can be applied to the tendon immediately
prior to lock-off must be determined in accordance with EN 1992-1.1, with values given
in the relevant national annex for k1 and k2. Values given in the tables below are
indicative values respecting recommended values by EN 1992-1.1 for k1 and k2.
Overstressing is permitted if the force in the jack can be measured to an accuracy of ± 5
% of the final value of the prestressing force. In such cases the maximum prestressing
force Pmax may be increased to k3Fp0,1ks with k3=0.95.

2.3.2 Strand Designation


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Strand designation is in accordance with European Standard White Draft prEN 10138-
3:2006 "Prestressing Steels - Part 3: Strand". For example, prestressing steel strand with
a nominal tensile strength of 1860MPa, 7 wires and a nominal diameter of 15.7mm is
designated as “EN10138-3-Y1860S7-15.7”. Prestressing steel strand with a nominal
tensile strength of 1770MPa, 7 wires and a nominal diameter of 12.9mm is designated as
“EN10138-3-Y1770S7-12.9”. In the interest of simplicity and for the purpose of this
document, the various classes of strand will be referred to as Y(nominal tensile
strength)-(nominal diameter), e.g. Y1770-15.2, as the standard prEN 10138-3:2006 and
number of wires in the strand remain constant.

2.3.3 Strand Characteristics

The tendons consist of 3-55 7-wire prestressing steel strands, factory-provided with a
corrosion protection system with characteristics in accordance with prEN 10138-3:2006.
Some typical characteristics are provided in Table 2e and Annex A32.

In the absence of European standards for prestressing steel, strands complying with
national provisions and with the characteristics given in Table 2e and Annex A32 shall be
used.

Table 2e: Strand Characteristics

d As Ms fpk Fpks Fp0.1ks F0s


Designation
mm mm2 g/m MPa kN kN kN
Y1770-12.5 12.5 93 726 1770 165 145 131
Y1860-12.5 12.5 93 726 1860 173 152 137
Y1770-12.9 12.9 100 781 1770 177 156 140
Y1860-12.9 12.9 100 781 1860 186 164 148
Y1860-13.0 13.0 102 797 1860 190 167 150
Y1770-15.2 15.2 139 1086 1770 246 216 194
Y1860-15.2 15.2 139 1086 1860 259 228 205
Y1770-15.3 15.3 140 1093 1770 248 218 196
Y1860-15.3 15.3 140 1093 1860 260 229 206
Y1770-15.7 15.7 150 1172 1770 266 234 211
Y1860-15.7 15.7 150 1172 1860 279 246 221

2.3.4 Prestressing Forces

Tables 2f to 2k list the maximum allowable prestressing forces for all tendons specified in
this ETA as a guide only. For certain countries where national provisions are more
restrictive, lower prestressing forces than specified below should be applied.

Table 2f: Maximum Allowable Stressing Force of Tendons with Ø12.5mm Strand

Y1770-12.5 Y1860-12.5

Ap Mp Fpk F0 Fpk F0
Anchorage n
mm2 kg/m kN kN kN kN

XM-10 4 372 2.91 658 522 692 547


XM-20 6 558 4.36 988 783 1038 821
XM-30 9 837 6.54 1481 1175 1557 1231
XM-35 12 1116 8.72 1975 1566 2076 1642
XM-40 18 1674 13.07 2963 2349 3114 2462
XM-45 19 1767 13.80 3128 2480 3287 2599
XM-50 22 2046 15.98 3621 2871 3806 3010
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XM-55 25 2325 18.16 4115 3263 4325 3420


XM-60 27 2511 19.61 4444 3524 4670 3694
XM-70 31 2883 22.52 5103 4046 5362 4241
XM-75 37 3441 26.87 6091 4829 6400 5062
XM-80 40 3720 29.05 6584 5220 6919 5472
XM-90 46 4278 33.41 7572 6003 7957 6293
XM-95 51 4743 37.04 8395 6656 8822 6977
XM-100 55 5115 39.95 9054 7178 9514 7524

Table 2g: Maximum Allowable Stressing Force of Tendons with Ø12.9mm Strand

Y1770-12.9 Y1860-12.9

Ap Mp Fpk F0 Fpk F0
Anchorage n
mm2 kg/m kN kN kN kN

XM-10 4 400 3.12 708 562 744 590


XM-20 6 600 4.69 1062 842 1116 886
XM-30 9 900 7.03 1593 1264 1674 1328
XM-35 12 1200 9.37 2124 1685 2232 1771
XM-40 18 1800 14.06 3186 2527 3348 2657
XM-45 19 1900 14.84 3363 2668 3534 2804
XM-50 22 2200 17.18 3894 3089 4092 3247
XM-55 25 2500 19.53 4425 3510 4650 3690
XM-60 27 2700 21.09 4779 3791 5022 3985
XM-70 31 3100 24.21 5487 4352 5766 4576
XM-75 37 3700 28.90 6549 5195 6882 5461
XM-80 40 4000 31.24 7080 5616 7440 5904
XM-90 46 4600 35.93 8142 6458 8556 6790
XM-95 51 5100 39.83 9027 7160 9486 7528
XM-100 55 5500 42.96 9735 7722 10230 8118

Table 2h: Maximum Allowable Stressing Force of Tendons with Ø13.0mm Strand

Y1860-13.0

Ap Mp Fpk F0
Anchorage n
mm2 kg/m kN kN

XM-10 4 408 3.19 759 601


XM-20 6 612 4.78 1138 902
XM-30 9 918 7.17 1707 1353
XM-35 12 1224 9.56 2277 1804
XM-40 18 1836 14.34 3415 2705
XM-45 19 1938 15.14 3605 2856
XM-50 22 2244 17.53 4174 3307
XM-55 25 2550 19.92 4743 3758
XM-60 27 2754 21.51 5122 4058
XM-70 31 3162 24.69 5881 4659
XM-75 37 3774 29.47 7020 5561
XM-80 40 4080 31.86 7589 6012
XM-90 46 4692 36.64 8727 6914
XM-95 51 5202 40.63 9676 7665
XM-100 55 5610 43.81 10435 8267

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Table 2i: Maximum Allowable Stressing Force of Tendons with Ø15.2mm Strand

Y1770-15.2 Y1860-15.2

Ap Mp Fpk F0 Fpk F0
Anchorage n
mm2 kg/m kN kN kN kN

XM/XMC-10 3 417 3.26 738 583 776 616


XM/XMC-20 4 556 4.34 984 778 1034 821
XM/XMC-30 7 973 7.60 1722 1361 1810 1436
XM/XMC-35 9 1251 9.77 2214 1750 2327 1847
XM/XMC-40 12 1668 13.03 2952 2333 3102 2462
XM/XMC-45 13 1807 14.12 3198 2527 3361 2668
XM/XMC-50 15 2085 16.29 3690 2916 3878 3078
XM/XMC-55 17 2363 18.46 4183 3305 4395 3488
XM/XMC-60 19 2641 20.63 4675 3694 4912 3899
XM/XMC-70 22 3058 23.89 5413 4277 5688 4514
XM/XMC-75 25 3475 27.15 6151 4860 6464 5130
XM/XMC-80 27 3753 29.32 6643 5249 6981 5540
XM/XMC-90 31 4309 33.67 7627 6026 8015 6361
XM/XMC-95 35 4865 38.01 8611 6804 9049 7182
XM/XMC-100 37 5143 40.18 9103 7193 9566 7592

Table 2j: Maximum Allowable Stressing Force of Tendons with Ø15.3mm Strand

Y1770-15.3 Y1860-15.3

Ap Mp Fpk F0 Fpk F0
Anchorage n
mm2 kg/m kN kN kN kN

XM/XMC-10 3 420 3.28 743 589 781 618


XM/XMC-20 4 560 4.37 991 785 1042 824
XM/XMC-30 7 980 7.65 1735 1373 1823 1443
XM/XMC-35 9 1260 9.84 2230 1766 2344 1855
XM/XMC-40 12 1680 13.12 2974 2354 3125 2473
XM/XMC-45 13 1820 14.21 3221 2551 3385 2679
XM/XMC-50 15 2100 16.40 3717 2943 3906 3092
XM/XMC-55 17 2380 18.58 4213 3335 4427 3504
XM/XMC-60 19 2660 20.77 4708 3728 4948 3916
XM/XMC-70 22 3080 24.05 5452 4316 5729 4534
XM/XMC-75 25 3500 27.33 6195 4905 6510 5153
XM/XMC-80 27 3780 29.51 6691 5297 7031 5565
XM/XMC-90 31 4340 33.88 7682 6082 8072 6389
XM/XMC-95 35 4900 38.26 8673 6867 9114 7214
XM/XMC-100 37 5180 40.44 9169 7259 9635 7626

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Table 2k: Maximum Allowable Stressing Force of Tendons with Ø15.7mm Strand

Y1770-15.7 Y1860-15.7

Ap Mp Fpk F0 Fpk F0
Anchorage n
mm2 kg/m kN kN kN kN

XM/XMC-10 3 450 3.52 797 632 837 664


XM/XMC-20 4 600 4.69 1062 842 1116 886
XM/XMC-30 7 1050 8.20 1859 1474 1953 1550
XM/XMC-35 9 1350 10.55 2390 1895 2511 1993
XM/XMC-40 12 1800 14.06 3186 2527 3348 2657
XM/XMC-45 13 1950 15.24 3452 2738 3627 2878
XM/XMC-50 15 2250 17.58 3983 3159 4185 3321
XM/XMC-55 17 2550 19.92 4514 3580 4743 3764
XM/XMC-60 19 2850 22.27 5045 4001 5301 4207
XM/XMC-70 22 3300 25.78 5841 4633 6138 4871
XM/XMC-75 25 3750 29.30 6638 5265 6975 5535
XM/XMC-80 27 4050 31.64 7169 5686 7533 5978
XM/XMC-90 31 4650 36.33 8231 6529 8649 6863
XM/XMC-95 35 5250 41.02 9293 7371 9765 7749
XM/XMC-100 37 5550 43.36 9824 7792 10323 8192

2.4 CCL Stressing Jacks

The CCL ‘MG’ Stressing Jacks used for the CCL ‘XM’ and ‘XMC’ Systems have the
following features:

Automatic gripping of the wedges on the strands.

The simultaneous stressing of all the strands of the tendon.

Support of the Jack on the FTU, by means of a temporary Bearing Ring.

The simultaneous hydraulic lock-off of all the wedges in the AH.

Partial stressing of the tendons with later recovery up to the final values of the
prestressing force.

The stressing by successive loadings of the Jack when the final extension is
greater than the full extension of the CCL Jack.

Other different Jacks may be used by the CCL Specialist PT Distribution/Licence


Company, provided their suitability to the CCL ‘XM’ and ‘XMC’ Anchorages is approved by
CCL before use.

Manuals and procedures are supplied with each CCL Stressing Jack.

Various dimensions and characteristics of CCL ‘MG’ Stressing Jacks are given in
Annex A33 & A34. CCL ‘MG’ Jacks are marked on the Outer Cylinder with their Serial
Numbers for identification purposes.

Different Jack innards are required for each system type.

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Table 2l: Jacks for Multistrand Anchorages

No. of No. of
Anchorage Strands Strands 1800MG 3000MG 4000MG 6000MG 7500MG
(15.7mm) (13.0mm)
XM/XMC-10 3 4
XM/XMC-20 4 6
XM/XMC-30 7 9
XM/XMC-35 9 12
XM/XMC-40 12 18
XM/XMC-45 13 19
XM/XMC-50 15 22
XM/XMC-55 17 25
XM/XMC-60 19 27
XM/XMC-70 22 31
XM/XMC-75 25 37
XM/XMC-80 27 40
XM/XMC-90 31 46
XM/XMC-95 35 51
XM/XMC-100 37 55

2.5 Friction Losses

With Post-Tensioned steel the effect of friction may be the single greatest factor causing
loss of prestress. There are three main causes of friction loss in the Post-Tensioned
tendon:

Friction due to the deviation of the tendon through the anchorage.

Friction between the tendon and the duct due to unintentional lack of
alignment (or wobble) of the duct.

Friction due to the curvature of the duct.

Friction Loss in CCL ‘XM’ and ‘XMC’ anchorages determined from testing is 2-3%.

Friction Loss in the duct for Post-Tensioned tendons can be estimated from:

(
∆Pµ ( x ) = Pmax 1 − e
− µ (θ + kx )
)
Where:

∆Pµ ( x ) = losses due to friction


Pmax = force at the active end during tensioning
θ = sum of the angular displacements over a distance x (irrespective of direction or sign)
µ = coefficient of friction between the tendon and its duct
k = unintentional angular displacement (per unit length)
x = distance along the tendon from the point where the prestressing force is equal to Pmax

The values for coefficient of friction, µ, and unintentional angular displacement, k, should
be in line with EN 1992 Eurocode 2: Design of Concrete Structures, as shown in
Table 2m.

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Table 2m: Coefficients of Friction and Unintentional Angular Displacement

µ k
Application Duct Type Non
Lubricated Minimum Maximum
Lubricated
Corrugated
0.19 0.17 0.005 0.01
Metal
Internal
HDPE 0.12 0.10 0.005 0.01
Prestressing
Smooth
0.24 0.16 0.005 0.01
Steel Pipe
HDPE 0.12 0.10 N/A N/A
External
Smooth
Prestressing 0.24 0.16 N/A N/A
Steel Pipe

When the tendon to be controlled has 2 Active/LE anchorages, i.e. with the tendon being
able to be stressed with the Jack at both ends, the measurement on site of the friction
loss of the tendon is possible by comparing the load applied by one Jack to the load
measured on the other Jack.

2.6 Anchorage Wedge Set

CCL ‘X’ Range Jacks are equipped with a hydraulic lock-off system ensuring even seating
of the wedges in the AH and Coupler before removal of the Jack. After the transfer of
load from the Jack to the anchorage, the strand and wedges draw a little further into the
AH or Coupler. This further movement is known as wedge set. The wedge set leads to a
loss of tension in the strand, which must be taken into account in the load
loss/elongation calculations.

The values for wedge set to be used in the calculations for all tendons are:

For active anchorages with Jacks with hydraulic lock-off:

Wedge Set, g = 6mm ±2mm

For passive anchorages with spring-loaded retaining plates:

Wedge Set, g = 8mm ±2mm

2.7 Tendon Elongation

The force in the tendon during stressing is measured with a hydraulic pressure gauge.
Elastic elongation of the tendon can also be used to monitor this force. The designer
specifies an expected elongation (including acceptable tolerance). The following formula
can be used to estimate the elongation:

PLt
δ =
(A E )
p s

Where:

δ = elongation of the tendon


P = average force in a tendon
Lt = tendon length between anchorages
Ap = nominal cross-sectional area of a tendon
Es = modulus of elasticity of the tendon steel

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Before being stressed, a tendon almost always has slack in it, so a tendon is usually
partially stressed up to a value of about 10% of the specified jacking force (CCL
recommend a datum of 1/3 of the specified stressing load, F0). This point is then taken
as the reference zero point for the measurement of elongation. The measurement is
taken from the extension of the jack; therefore Lt must include the length of the tendon
within the jack between the anchor head and the jack wedges. It is also necessary that
the elongation measured from the reference point is multiplied by a correction factor
before being compared to the estimated elongation specified by the designer.

2.8 Spacing of the Supports

For tendons in corrugated steel or plastic ducts, the maximum spacing of the supports
will be 1.0m for straight sections or sections with large radii of curvature, or 0.5m for
sections with small radii of curvature. For tendons in smooth steel tubes, spacing could
be increased according to the rigidity of the tube and its slope, but can not exceed 3.0m.

The supports carrying the ducting should be sufficiently strong to carry the weight of the
duct and the strands passing through it when threaded prior to concreting, as well as the
forces occurring during and after concreting, including compaction of the concrete.

2.9 Radii of Curvature

Generally radii of curvature depend on duct type. The formula below is used to calculate
minimum radii of curvature (Rmin). The following values specified for Rmin are within those
successfully used from known experience (French Fascicule 65, chapter 11). Minimum
radii of curvature must comply with national regulations.

2 F0 d
Rmin =
( PRmax Øi )

When the number of individual tendon strands (n) < 5, Rmin = 100Øi

Where:

PRmax = maximum allowable pressure under a strand (130-150kN/m2)


Øi = internal diameter of the duct

For internal prestressing, the table below shows indicative values for 15.7mm strand with
PRmax = 150kN/m2
Steel Ducts Plastic Ducts
Anchorage
Øi /Øo (mm) Rmin (mm) Øi /Øo (mm) Rmin (mm)
XM/XMC-10 55/60 5500 48/59 4800
XM/XMC-20 55/60 5500 48/59 4800
XM/XMC-30 70/75 4700 76/91 4300
XM/XMC-35 80/85 5300 76/91 5500
XM/XMC-40 80/85 7000 76/91 7400
XM/XMC-45 80/85 7600 76/91 8000
XM/XMC-50 90/95 7800 86/101 8100
XM/XMC-55 100/105 7900 100/116 7900
XM/XMC-60 100/105 8800 100/116 8800
XM/XMC-70 100/105 10200 100/116 10200
XM/XMC-75 115/120 10100 115/135 10100
XM/XMC-80 115/120 10900 115/135 10900
XM/XMC-90 125/130 11500 129/152 11200
XM/XMC-95 140/145 11600 146/169 11200
XM/XMC-100 140/145 12300 146/169 11800
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When 3000mm < R < 6000mm, the coefficient of friction, µ, depends on the radius of
curvature, R.

The minimum radius of curvature can be decreased to 20Øi assuming:

when R ≤ 3000mm, the load along the curve is limited to 0.70Fpk

the total deviation, α ≤ 1.5π

the curved zone is considered as a dead end anchorage if, in this zone,
α ≥ 0.5π

For external prestressing of steel ducts:

Rmin
No. of No. of Rmin
at
Anchorage* Strands Strands Øi /Øo (mm) at deviator
anchorage
(15.7mm) (13.0mm) (mm)
(mm)
XM-30 7 9 70/75 3300 2300
XM-40 12 18 80/85 3600 2600
XM-60 19 27 100/105 4200 3200
XM-80 27 40 115/120 4600 3600
XM-100 37 55 140/145 5400 4400
*Linear interpolation is permitted for anchorages not quoted in the above table.

For external prestressing of plastic ducts

Rmin
No. of No. of Rmin
at
Anchorage* Strands Strands Øi /Øo (mm) at deviator
anchorage
(15.7mm) (13.0mm) (mm)
(mm)
XM-30 7 9 76/91 3800 2800
XM-40 12 18 76/91 3800 2800
XM-60 19 27 100/116 4500 3500
XM-80 27 40 115/135 5100 4100
XM-100 37 55 146/169 6100 5100
*Linear interpolation is permitted for anchorages not quoted in the above table.

2.10 Compressive Strength of Concrete

The mean compressive strength of concrete at which full prestressing is permitted, fcm,0,
specified by the designer of the structure must be greater than or equal to 30MPa cube
strength. In the case of partial stressing of a standard anchorage to 50% of Fpk, the
minimum mean compressive strength of concrete could be reduced by 30%.

2.11 Anchorage Spacing and Concrete Cover

Taking into account the tested values of mean compressive concrete strength, fcm,0,
(30MPa and 55MPa cube strength for units XM10-100); the test specimen side lengths of
the end block (a and b) are provided in Annex A24 for 3 levels of mean compressive
concrete strength.

For values of fcm,0 between 30MPa and 55MPa cube strength, a and b can be determined
by straight line interpolation, as is the case for values quoted for fcm,0 on cube = 45MPa.

For the tested value of mean compressive strength, fcm,0, (46MPa cube strength for units
XM10-80); the test specimen side lengths of the end block (a and b) are provided in
Annex A30.

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The minimum concrete cover from the reinforcement to the edge of the structure, cmin,
should be established according to EN 1992 Eurocode 2: Design of Concrete Structures
and must be taken into account when determining the minimum distances from the axis
of an anchorage to the edge of the structure (x1 and y1).

Given the test specimen side lengths a and b in Annex A24 and A30, the minimum
distances between two axes of anchorages (x2 and y2) and to the edge of the structure
(x1 and y1) result from the following formulae (where c is the concrete cover):

a
≤ x2 ≤ 1.15a
1.15

a×b
y2 =
x2

x2
x1 = + c − 10 mm
2

y2
y1 = + c − 10 mm
2

2.12 Emission of Dangerous Substances or Radiation

A declaration was made by the manufacturer that the product does not contain any
dangerous substances.

In addition to the specific clauses relating to dangerous substances contained in this


European Technical Approval, there may be other requirements applicable to the
products falling within its scope (e.g. 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.

2.13 Methods of Verification

The assessment of the fitness of the CCL ‘XM’ and ‘XMC’ PT System for the intended use
in relation to the requirements for mechanical resistance and stability in the sense of
Essential Requirements 1 and 3 has been made in compliance with ETAG 013, Edition
June 2002, European Technical Approvals Guideline of Post-Tensioning Kits for
Prestressing of Structures based on the provisions for all systems.

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3 Evaluation and Attestation of Conformity and CE Marking

3.1 System of Attestation of Conformity

According to the decision 98/456/EC of the European Commission7 the system 1+ of


attestation of conformity applies.

This system of attestation of conformity is defined as follows:

System 1+: Certification of the conformity of the product by an approved certification


body on the basis of:

(a) Tasks for the manufacturer:


(1) factory production control;
(2) further testing of samples taken at the factory by the manufacturer in
accordance with a prescribed test plan;

(b) Tasks for the approved body:


(3) initial type-testing of the product;
(4) initial inspection of factory and of factory production control;
(5) continuous surveillance, assessment and approval of factory production control;
(6) audit-testing of samples taken at the factory.

Note: Approved bodies are also referred to as “notified bodies”.

3.2 Responsibilities

3.2.1 Tasks of the Manufacturer

3.2.1.1 Factory Production Control

The manufacturer shall exercise permanent internal control of production. All the
elements, requirements and provisions adopted by the manufacturer shall be
documented in a systematic manner in the form of written policies and procedures,
including records of results performed. This production control system shall ensure that
the product is in conformity with this European Technical Approval.

The manufacturer may only use initial / raw / constituent materials (as relevant) stated
in the technical documentation of this European Technical Approval.

The factory production control shall be in accordance with the “Control Plan of
17/06/2006 relating to the European Technical Approval ETA-07/0035 issued on
09/08/2007 and extended the 08/08/2012 which is part of the technical documentation
of this European Technical Approval. The “Control Plan” is laid down in the context of the
factory production control system operated by the manufacturer and deposited at Sétra.8

The results of factory production control shall be recorded and evaluated in accordance
with the provisions of the “Control Plan”.

The kit manufacturer is responsible for the manufacture and the quality of each
component that is manufactured or supplied by a subcontractor.

7
Official Journal of the European Communities L201/112 of 3 July 1998.
8
The “Control Plan” is a confidential part of the European Technical Approval and only handed over to the
approved body or bodies involved in the procedure of attestation of conformity. See section 3.2.2.
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ETA-07/0035 European Technical Approval CCL ‘X’ Range Post-tensioning system 23

Table 3a: Prescribed Test Plan

1 2 3 4 5 6
Test/ 4 Minimum Documen-
Component Item Traceability
Check Frequency tation
Material Check 100% 3.11
Treatment, 0.5%
Test Yes
Hardness5 ≥ 2 Specimen
Wedge
Detailed Full 5%
Test Yes
Dimensions2 ≥ 2 Specimen7
Visual
Check 100% No
Inspection3,6
Material Check 100% 3.11
Detailed 5%
Test Yes
Anchor Head Dimensions2 Full ≥ 2 Specimen
Visual
Check 100% No
Inspection3
Material Check 100% 3.11
Detailed 3%
Test Yes
FTU Dimensions2 Bulk ≥ 2 Specimen
Visual
Check 100% No
Inspection3
Material Check 100% 3.11
Detailed 5%
Test Yes
Coupler Dimensions2 Full ≥ 2 Specimen
Visual
Check 100% No
Inspection3
Plastic
Sealing Cap, Material Check 100% 3.11
Deviation
Bulk
and Coupler Visual
Reducing Check 100% No
Inspection3
Cone
Material Check 100% 3.11
Coupler Detailed 3%
Test Yes
Extension Dimensions2 Bulk ≥ 2 Specimen
Ring Visual
Check 100% No
Inspection3
Material Check 100% 3.11
Duct,
Visual Full
Sheathing Check 100% No
Inspection3
Material Check 100% CE
Tensile Each Coil /
Diameter Test No
Element CE Bundle
Strand Visual Each Coil /
Check No
Inspection3 Bundle
Constituents Cement Check 100% Yes
of Filling
Admixtures, Bulk
Material as Check 100% Yes
Additions
per EN 447
Material Check 100% Yes
Helix Visual Full
Check 100% No
Inspection3
Material Check 100% Yes
Stirrups Visual Full
Check 100% No
Inspection3

All samples shall be randomly selected and clearly identified.

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1. Inspection certificate type ''3.1'' according to EN 10204.

2. Measurement of all dimensions and angles as stated in the Control Plan and Process
Control Record Sheet.

3. Visual inspection covers main dimensions, gauge testing, correct marking or


labelling, appropriate performance, surface finish, fins, kinks, smoothness, corrosion,
coating etc. as detailed in the Control Plan.

4. Full: Full traceability of each component to its raw material.


Bulk: Traceability of each delivery of components to a defined point.

5. Surface hardness.

6. Wedge teeth.

7. Test quantities are assumed as wedge segments.

3.2.1.2 Other Tasks of the Manufacturer

The manufacturer shall, on the basis of a contract, involve a body (bodies) which is (are)
approved for the tasks referred to in section 3.1 in the field of the CCL ‘XM’ and ‘XMC’ PT
Systems in order to undertake the actions laid down in section 3.3. For this purpose, the
“Control Plan” referred to in sections 3.2.1.1 and 3.2.2 shall be handed over by the
manufacturer to the approved body or bodies involved.

The manufacturer shall make a declaration of conformity, stating that the construction
product is in conformity with the provisions of the European Technical Approval ETA-
07/0035 issued on 09/08/2007 and extended the 08/08/2012.

At least once a year, each component producer is audited by the kit manufacturer. The
results of the audit shall be made available to the approval body.

3.2.2 Tasks of Approved Bodies

The approved body (bodies) shall perform the

initial type-testing of the product,

initial inspection of factory and of factory production control,

continuous surveillance, assessment and approval of factory production control,

audit-testing of samples taken at the factory

in accordance with the provisions laid down in the “Control Plan of 17/06/2006 relating to
the European Technical Approval ETA-07/0035 issued on 09/08/2007 and extended the
08/08/2012”.

The approved body (bodies) shall retain the essential points of its (their) actions referred
to above and state the results obtained and conclusions drawn in (a) written report
(reports).

The main production centre is checked at least once a year by the approved body. Each
component producer is checked at least once every five years by the approved body.

The approved certification body involved by the manufacturer shall issue an EC certificate
of conformity of the product stating the conformity with the provisions of this European
Technical Approval.
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In cases where the provisions of the European Technical Approval and its “Control Plan”
are no longer fulfilled the certification body shall withdraw the certificate of conformity
and inform Sétra without delay.

During surveillance inspections, the Certification Body has to take samples of


components of the PT System or the individual components for which the ETA has been
granted for independent testing. For the most important components, Table 3b
summarises the minimum procedures which have to be performed by the Certification
Body.
Table 3b: Audit Testing

1 2 3 4
Sampling –
Test/ No. of
Component Item
Check Components
Per Visit
Material
Check,
According to 2
Test
Specification
Treatment Test 2
Detailed
Test 1
Wedge Dimensions
Main
Dimensions,
Test 5
Surface
Hardness
Visual
Check 5
Inspection
Material
Check,
According to
Test
Specification
Anchor Head Detailed 1
Test
Dimensions
Visual
Check
Inspection
Material
Check,
According to
Test
Specification
FTU Detailed 1
Test
Dimensions
Visual
Check
Inspection
Material
Check,
According to
Test
Specification
Coupler Detailed 1
Test
Dimensions
Visual
Check
Inspection
Single
Tensile ETAG 013
Test 1 Series
Element Annex E.3
Test

All Samples shall be randomly selected and clearly identified.

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3.3 CE Marking

The CE marking shall be affixed on the accompanying document or delivery note. The
letters “CE” shall be followed by the identification number of the approved certification
body, where relevant, and be accompanied by the following additional information:

The name and address of the producer (legal entity responsible for the
manufacture);

The last two digits of the year in which the CE marking was affixed;

The number of the EC certificate of conformity for the product;

The number of the European Technical Approval;

The category(ies) of use;

“For further information, refer to the ETA”.

4 Assumptions Under Which the Fitness of the Products for


the Intended Use was Favourably Assessed

4.1 Manufacturing

The European Technical Approval is issued for the product on the basis of agreed
data/information deposited with Sétra, which identifies the product that has been
assessed and judged. Changes to the product or production process, which could result in
this deposited data/information being incorrect, should be notified to Sétra before the
changes are introduced. Sétra will decide whether or not such changes affect the ETA
and consequently the validity of the CE marking on the basis of the ETA and if so
whether further assessment or alterations to the ETA shall be necessary.

4.2 Installation

4.2.1 ‘XM’ and ‘XMC’ Anchorages

The FTU is fixed to the formwork, then the DC is screwed into the FTU, in the case of the
encapsulated system, the joint between the FTU and DC is sealed using a heat shrink
sleeve. The local bursting reinforcement is attached with the general reinforcement.

The ducting is connected, and the sealing of the connection between the duct and the
anchorage is carried out, either by an adhesive sealing tape, or a heat-shrink sleeve, in
the case of the encapsulated system, a plastic sleeve and a heat-shrink sleeve are used
at each duct connection.

To facilitate the installation of the AH or Coupler and the wedges a sufficient open space
must be reserved behind each anchorage. This open space must also allow for
implementation of sealing caps.

Setting out dimensions of the anchorage and space reserved behind each anchorage are
to be checked before concreting.

AH or Coupler (1st Stage) and wedges are assembled immediately prior to stressing of
the tendon in order to avoid corrosion.

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4.2.1.1 Active Anchorages

Sufficient space must be reserved behind the anchorage for the installation and operation
of the stressing Jack.

Stressing must only be carried out when the concrete has cured to the required minimum
compressive strength.

The cut length of the strands, calculated from exposed face of the FTU must be sufficient
to allow installation of the AH or Coupler and wedges, the threading of the stressing Jack
and insertion of the Jack wedges. These lengths should be checked with the local agent
to ensure the suitability to the particular stressing Jack to be used.

4.2.1.2 Passive Anchorages

For tendons where the tension is applied at one end only, a dead end anchorage can be
used. The wedge retaining plates and springs are fixed to the AH or Coupler holding the
wedges in place with sufficient force to help prevent wedge-stepping.
The cut length of the strands, calculated from exposed face of the FTU must be sufficient
to allow installation of the AH or Coupler and wedges, then the locking of the wedges
with the retaining plate and springs. An extra length of 50mm beyond the AH or Coupler
is necessary.

4.2.1.3 Deviators for External Tendons

For this ETA, no deviators has been tested according to the deviated tendon test of
ETAG 013. Unless there are stricter regulations at the place of use, external tendon
deviators must be in line with French Fascicule 65 of C.C.T.G. – chapter 11.

4.2.2 Pre-Sealing and Grouting of Anchorages

After stressing and cutting back of the tendon, CCL ‘XM’ and ‘XMC’ anchorages can be
equipped with temporary or permanent sealing caps fixed onto the FTU or coupler,
respectively. This makes it possible to inject the ducts before the final sealing.

4.2.3 Corrosion Protection

After stressing of the tendon, the free volume between the duct and the strands is filled
to protect the tendon from corrosion.

CCL ‘XM’ and ‘XMC’ anchorages shall be injected with a corrosion protection substance in
accordance with the local regulations and with the specifications of implementation laid
out by CCL.

Corrosion protection is usually carried out in internal prestressing in concrete by a


cement grout which ensures a mechanical connection between the reinforcement and the
concrete structure. Common grouts must comply with requirements of EN 445, EN 446
and ETAG 013. Common grout to be used should have been subject to and have results
of the inclined tube test as laid out in ETAG 013.

Grouting procedures should conform to EN 447 and fib Bulletin No. 20 “Grouting of
tendons in prestressed concrete”. Manufacture and the placement of a cement grout
must respect the local specifications and the guidelines laid out in ETAG 013.

Greases and Waxes of various origins can be used with the CCL ‘XM’ System, especially
for external PT. Greases and Waxes must conform to the specifications of ETAG 013
(Annex C.4.1 for Grease and Annex C.4.2 for Wax).

Grease and Waxes have not been tested for the delivery of this ETA and they shall
comply with EN447 and ETAG013 Annex C.4.3.
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An up to date list of corrosion protection products that can be used with the CCL ‘XM’ and
‘XMC’ System is available from CCL.

5 Indications to the Manufacturer

5.1 Packaging, Transport and Storage

For delivery to construction sites, the anchorage components are usually supplied in the
following ways:

Wedges – Packed in 50-150 units in plastic packing with CCL labelling.

Anchor Heads and Couplers – Packed in cases of wood, metal or board


protected in a suitable way against the elements.

Force Transfer Units and Coupler Extension Rings – Packed on pallets


protected in a suitable way against the elements.

Sealing Caps, Deviation and Coupler Reducing Cones – Packed on pallets


protected in a suitable way against the elements and to avoid excessive
exposure to heat.

Required components are usually delivered as follows:

Before concreting – Force Transfer Units, Deviation Cones and Duct.

Before setting stressing - Strand, Anchor Heads, Couplers, Coupler


Extension Rings, Coupler Outer Spring Plates, Coupler Reducing Cone
Retainers, Coupler Reducing Cones, Sealing Caps and Wedges.

Between the reception of these components and their implementation it must be ensured
that adequate corrosion protection of these components is taken by observing the
following conditions of storage:

Force Transfer Units, Coupler Extension Rings, Coupler Outer Spring Plates,
Coupler Reducing Cone Retainers, Deviation Cones, Coupler Reducing Cones
and Sealing Caps - Store on pallets and cover with sheeting to shelter from
adverse weather conditions.

Anchor Heads and Couplers - Store in cases or baskets inside a closed area
(site store or container, etc.).

Wedges - Retain them in the supplied original packing, and store the packing
in a closed area as for the Anchor Heads.

Duct and Strands - Store them on supports raising the material off the
ground and cover them with sheeting or similar materials so that the
circulation of air is ensured under the covering. Plastic duct should be stored
carefully to avoid excessive exposure to heat and supported sufficiently to
ensure duct is kept straight (usually supported at approximately 1 metre
intervals).

5.2 Use, Maintenance, Repair

Guidelines relating to the use, maintenance and repair of the CCL ‘XM’ and ‘XMC’ PT
Systems should be followed according to the “Recommended minimum contents of a
quality plan for a job site” provided in ETAG 013, Annex D.3.

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CCL ‘XM’ System Annex A01


Live End Anchorage Ø15.2/15.3/15.7mm Strand

Anchorage A B ØC D ØE
XM-10 234 70 48 45 95
XM-20 300 70 50 45 105
XM-30 362 100 64 48 130
XM-35 493 113 74 47 155
XM-40 629 113 74 54 180
XM-45 629 113 74 63 180
XM-50 693 130 84 60 195
XM-55 742 150 98 62 215
XM-60 749 150 98 76 220
XM-70 913 150 98 70 245
XM-75 1001 175 113 80 265
XM-80 1001 175 113 83 270
XM-90 1118 190 123 94 295
XM-95 1079 210 138 94 305
XM-100 1089 210 138 102 310
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CCL ‘XM’ System Annex A02


Dead End Anchorage Ø15.2/15.3/15.7mm Strand

Anchorage A B ØC D ØE ØF G
XM-10 234 70 48 45 95 95 29
XM-20 300 70 50 45 105 105 29
XM-30 362 100 64 48 130 130 29
XM-35 493 113 74 47 155 155 29
XM-40 629 113 74 54 180 180 29
XM-45 629 113 74 63 180 180 29
XM-50 693 130 84 60 195 195 29
XM-55 742 150 98 62 215 215 29
XM-60 749 150 98 76 220 220 29
XM-70 913 150 98 70 245 245 29
XM-75 1001 175 113 80 265 265 29
XM-80 1001 175 113 83 270 270 29
XM-90 1118 190 123 94 295 295 29
XM-95 1079 210 138 94 305 305 29
XM-100 1089 210 138 102 310 310 29
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CCL ‘XM’ System Annex A03


Live End Anchorage Ø12.5/12.9/13.0mm Strand

Anchorage A B ØC D ØE
XM-10 234 70 48 40 95
XM-20 300 70 50 40 105
XM-30 362 100 64 43 130
XM-35 493 113 74 48 155
XM-40 629 113 74 62 180
XM-45 629 113 74 67 180
XM-50 693 130 84 69 195
XM-55 742 150 98 67 215
XM-60 749 150 98 76 220
XM-70 913 150 98 74 245
XM-75 1001 175 113 80 265
XM-80 1001 175 113 84 270
XM-90 1118 190 123 87 295
XM-95 1079 210 138 97 305
XM-100 1089 210 138 98 310
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CCL ‘XM’ System Annex A04


Dead End Anchorage Ø12.5/12.9/13.0mm Strand

Anchorage A B ØC D ØE ØF G
XM-10 234 70 48 40 95 95 29
XM-20 300 70 50 40 105 105 29
XM-30 362 100 64 43 130 130 29
XM-35 493 113 74 48 155 155 29
XM-40 629 113 74 62 180 180 29
XM-45 629 113 74 67 180 180 29
XM-50 693 130 84 69 195 195 29
XM-55 742 150 98 67 215 215 29
XM-60 749 150 98 76 220 220 29
XM-70 913 150 98 74 245 245 29
XM-75 1001 175 113 80 265 265 29
XM-80 1001 175 113 84 270 270 29
XM-90 1118 190 123 87 295 295 29
XM-95 1079 210 138 97 305 305 29
XM-100 1089 210 138 98 310 310 29
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CCL ‘XM’ System Annex A05


Encapsulated Live End Anchorage
Ø15.2/15.3/15.7mm/12.5/12.9/13.0mm Strand

Anchorage A B ØC ØD ØE F
XM-10 234 70 48 80 - -
XM-20 300 70 50 93 - -
XM-30 362 100 64 111 - -
XM-35 493 113 74 130 185 160
XM-40 629 113 74 146 211 190
XM-45 629 113 74 146 211 190
XM-50 693 130 84 158 231 190
XM-55 742 150 98 174 247 195
XM-60 749 150 98 174 255 210
XM-70 913 150 98 193 280 210
XM-75 1001 175 113 209 305 210
XM-80 1001 175 113 209 319 220
XM-90 1118 190 123 230 344 210
XM-95 1079 210 138 232 361 235
XM-100 1089 210 138 232 361 235

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CCL ‘XM’ System Annex A06


Encapsulated Dead End Anchorage
Ø15.2/15.3/15.7mm/12.5/12.9/13.0mm Strand

Anchorage A B ØC ØD ØE F
XM-10 234 70 48 80 - -
XM-20 300 70 50 93 - -
XM-30 362 100 64 111 - -
XM-35 493 113 74 130 185 160
XM-40 629 113 74 146 211 190
XM-45 629 113 74 146 211 190
XM-50 693 130 84 158 231 190
XM-55 742 150 98 174 247 195
XM-60 749 150 98 174 255 210
XM-70 913 150 98 193 280 210
XM-75 1001 175 113 209 305 210
XM-80 1001 175 113 209 319 220
XM-90 1118 190 123 230 344 210
XM-95 1079 210 138 232 361 235
XM-100 1089 210 138 232 361 235

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CCL ‘XMC’ System Annex A07


Stage 1 Live End Anchorage Ø15.2/15.3/15.7mm Strand

Anchorage A B ØC D E ØF
XMC-10 234 70 48 67 60 185
XMC-20 300 70 50 67 60 195
XMC-30 362 100 64 67 60 220
XMC-35 493 113 74 67 60 245
XMC-40 629 113 74 67 69 265
XMC-45 629 113 74 67 71 265
XMC-50 693 130 84 67 75 285
XMC-55 742 150 98 67 77 300
XMC-60 749 150 98 67 84 305
XMC-70 913 150 98 67 86 325
XMC-75 1001 175 113 67 92 350
XMC-80 1001 175 113 67 96 375
XMC-90 1118 190 123 67 109 410
XMC-95 1079 210 138 67 112 430
XMC-100 1089 210 138 67 116 435

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CCL ‘XMC’ System Annex A08


Stage 1 Dead End Anchorage Ø15.2/15.3/15.7mm Strand

Anchorage A B ØC D E ØF ØG H
XMC-10 234 70 48 67 60 185 95 29
XMC-20 300 70 50 67 60 195 105 29
XMC-30 362 100 64 67 60 220 130 29
XMC-35 493 113 74 67 60 245 155 29
XMC-40 629 113 74 67 69 265 180 29
XMC-45 629 113 74 67 71 265 180 29
XMC-50 693 130 84 67 75 285 195 29
XMC-55 742 150 98 67 77 300 215 29
XMC-60 749 150 98 67 84 305 220 29
XMC-70 913 150 98 67 86 325 245 29
XMC-75 1001 175 113 67 92 350 265 29
XMC-80 1001 175 113 67 96 375 270 29
XMC-90 1118 190 123 67 109 410 295 29
XMC-95 1079 210 138 67 112 430 305 29
XMC-100 1089 210 138 67 116 435 310 29

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CCL ‘XMC’ System Annex A09


Stage 2 Anchorage Ø15.2/15.3/15.7mm Strand

Anchorage A B ØC ØD
XMC-10 496 70 48 201
XMC-20 518 70 50 211
XMC-30 579 100 64 236
XMC-35 635 113 74 261
XMC-40 692 113 74 284
XMC-45 692 113 74 284
XMC-50 737 130 84 301
XMC-55 760 150 98 318
XMC-60 774 150 98 329
XMC-70 831 150 98 381
XMC-75 884 175 113 391
XMC-80 1174 175 113 406
XMC-90 1250 190 123 434
XMC-95 1270 210 138 452
XMC-100 1270 210 138 452
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CCL ‘XM’ and ‘XMC’ System Annex A10


Wedges Type ‘X’

Wedge A ØB ØC ØD α
X13.0 41 25 11.9 16 14°
X15.3 46 29 14.5 19 14°
X15.7 46 29 14.8 19 14°

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CCL ‘XM’ System Annex A11


Anchor Head Hole Patterns Ø15.2/15.3/15.7mm Strand

Anchorage n Layout
XM-10 3 A
XM-20 4 B
XM-30 7 C
XM-35 9 D
XM-40 12 E
XM-45 13 F
XM-50 15 G
XM-55 17 H
XM-60 19 J
XM-70 22 K
XM-75 25 L
XM-80 27 M
XM-90 31 N
XM-95 35 P
XM-100 37 Q

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CCL ‘XM’ System Annex A12


Anchor Head Hole Patterns Ø12.5/12.9/13.0mm Strand

Anchorage n Layout
XM-10 4 A
XM-20 6 B
XM-30 9 C
XM-35 12 D
XM-40 18 E
XM-45 19 F
XM-50 22 G
XM-55 25 H
XM-60 27 J
XM-70 31 K
XM-75 37 L
XM-80 40 M
XM-90 46 N
XM-95 51 P
XM-100 55 Q

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CCL ‘XMC’ System Annex A13


Coupler Hole Patterns Ø15.2/15.3/15.7mm Strand

Anchorage n Layout
XMC-10 3 A
XMC-20 4 B
XMC-30 7 C
XMC-35 9 D
XMC-40 12 E
XMC-45 13 F
XMC-50 15 G
XMC-55 17 H
XMC-60 19 J
XMC-70 22 K
XMC-75 25 L
XMC-80 27 M
XMC-90 31 N
XMC-95 35 P
XMC-100 37 Q
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CCL ‘XM’ and ‘XMC’ System Annex A14


Force Transfer Unit

Anchorage A B C ØD ØE ØF ØG ØH J K L
XM/XMC-10 160 130 149 66 60 113 130 130 65 92 M8
XM/XMC-20 170 140 160 80 68 126 140 140 70 99 M8
XM/XMC-30 228 178 195 98 86 144 178 168 83 119 M10
XM/XMC-35 270 220 231 123 105 163 200 210 110 148 M12
XM/XMC-40 275 225 266 138 121 178 232 236 123 167 M12
XM/XMC-45 275 225 270 138 121 178 236 236 125 167 M12
XM/XMC-50 310 260 291 154 132 191 260 253 134 179 M12
XM/XMC-55 330 280 309 173 148 207 280 270 142 191 M12
XM/XMC-60 337 287 317 173 148 206 288 280 146 198 M12
XM/XMC-70 370 320 351 193 165 225 320 325 164 230 M16
XM/XMC-75 418 368 376 216 181 241 345 335 176 237 M16
XM/XMC-80 418 368 390 216 181 241 360 350 183 247 M16
XM/XMC-90 440 390 418 238 200 263 390 378 196 267 M16
XM/XMC-95 480 430 433 247 202 266 405 396 203 280 M16
XM/XMC-100 490 440 435 250 202 264 410 396 203 280 M16

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CCL ‘XMC’ System Annex A15


Coupler Extension Ring

Anchorage ØA ØB ØC D ØE
XMC-10 130 66 9 70 95
XMC-20 140 80 9 70 105
XMC-30 168 98 11 70 130
XMC-35 210 123 14 70 155
XMC-40/45 236 138 14 70 175
XMC-50 253 154 14 70 195
XMC-55 270 173 14 70 210
XMC-60 280 173 14 70 215
XMC-70 325 193 18 70 235
XMC-75 335 216 18 70 260
XMC-80 350 216 18 70 260
XMC-90 378 238 18 70 285
XMC-95/100 396 250 18 70 300

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CCL ‘XM’ and ‘XMC’ System Annex A16


Deviation Cone

Anchorage A ØB ØC ØD ØE F
XM/XMC-10 114 58 53 48 56 70
XM/XMC-20 170 66 62 50 58 70
XM/XMC-30 196 84 79 64 72 100
XM/XMC-35 285 103 95 74 82 113
XM/XMC-40 416 119 111 74 82 113
XM/XMC-45 416 119 111 74 82 113
XM/XMC-50 445 130 122 84 92 130
XM/XMC-55 474 146 138 98 106 150
XM/XMC-60 474 146 138 98 106 150
XM/XMC-70 605 163 155 98 106 150
XM/XMC-75 645 179 171 113 121 175
XM/XMC-80 645 179 171 113 121 175
XM/XMC-90 740 198 190 123 131 190
XM/XMC-95 661 200 192 138 146 210
XM/XMC-100 661 200 192 138 146 210

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CCL ‘XMC’ System Annex A17


Coupler Reducing Cone

Anchorage A ØB ØC ØD ØE ØF G
XMC-10 495 220 201 193 48 56 69
XMC-20 517 230 211 203 50 58 70
XMC-30 578 255 236 228 64 72 100
XMC-35 634 280 261 253 74 82 113
XMC-40/45 691 303 284 276 74 82 113
XMC-50 736 320 301 293 84 92 130
XMC-55 759 337 318 310 98 106 150
XMC-60 773 348 329 321 98 106 150
XMC-70 830 400 381 373 98 106 150
XMC-75 883 410 391 383 113 121 175
XMC-80 1173 425 406 398 113 121 175
XMC-90 1249 453 434 426 123 131 190
XMC-95 1269 471 452 444 138 146 210
XMC-100 1269 471 452 444 138 146 210

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CCL ‘XM’ System Annex A18


Sealing Cap

Anchorage ØA ØB ØC D ØE
XM-10 - - - - -
XM-20 - - - - -
XM-30 - - - - -
XM-35 210 175 14 160 185
XM-40/45 236 201 14 190 211
XM-50 253 221 14 190 231
XM-55 270 236 14 195 247
XM-60 280 245 14 210 255
XM-70 325 270 18 210 280
XM-75 335 295 18 210 305
XM-80 350 309 18 220 319
XM-90 378 334 18 210 344
XM-95/100 396 348 18 235 361

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CCL ‘XM’ and ‘XMC’ System Annex A19


Connection Between Deviation & Coupler Reducing Cone and
Metal Ducts

ØA
ØC
Deviation & ØB
Duct
Anchorage Coupler Duct
Coupler
Reducing Cone mm*
mm*
mm*
XM/XMC-10 48/56 55/60 60/65
XM/XMC-20 50/58 55/60 60/65
XM/XMC-30 64/72 70/75 75/80
XM/XMC-35 74/82 80/85 85/90
XM/XMC-40 74/82 80/85 85/90
XM/XMC-45 74/82 80/85 85/90
XM/XMC-50 84/92 90/95 95/100
XM/XMC-55 98/106 100/105 105/110
XM/XMC-60 98/106 100/105 105/110
XM/XMC-70 98/106 100/105 105/110
XM/XMC-75 113/121 115/120 120/125
XM/XMC-80 113/121 115/120 120/125
XM/XMC-90 123/131 125/130 130/135
XM/XMC-95 138/146 140/145 145/150
XM/XMC-100 138/146 140/145 145/150

*All dimensions are internal/external

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CCL ‘XM’ and ‘XMC’ System Annex A20


Connection Between Deviation & Coupler Reducing Cone and
Plastic Ducts

ØA
ØC
Deviation & ØB
Duct
Anchorage Coupler Duct
Coupler
Reducing Cone mm*
mm*
mm*
XM/XMC-10 48/56 48/59 59/63
XM/XMC-20 50/58 48/59 59/63
XM/XMC-30 64/72 76/91 91/97
XM/XMC-35 74/82 76/91 91/97
XM/XMC-40 74/82 76/91 91/97
XM/XMC-45 74/82 76/91 91/97
XM/XMC-50 84/92 86/101 101/106
XM/XMC-55 98/106 100/116 116/102
XM/XMC-60 98/106 100/116 116/102
XM/XMC-70 98/106 100/116 116/102
XM/XMC-75 113/121 115/135 135/141
XM/XMC-80 113/121 115/135 135/141
XM/XMC-90 123/131 129/152 152/157
XM/XMC-95 138/146 146/169 169/175
XM/XMC-100 138/146 146/169 169/175

*All dimensions are internal/external

Version of 4th January 2013 Valid from 08/08/2012 to 08/08/2017


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CCL ‘XM’ and ‘XMC’ System Annex A21


Dead End Spring Plates and Springs

Anchorage ØA B
XM/XMC-10 95 13
XM/XMC-20 105 13
XM/XMC-30 130 13
XM/XMC-35 155 13
XM/XMC-40 180 13
XM/XMC-45 180 13
XM/XMC-50 195 13
XM/XMC-55 215 13
XM/XMC-60 220 13
XM/XMC-70 245 13
XM/XMC-75 265 13
XM/XMC-80 270 13
XM/XMC-90 295 13
XM/XMC-95 305 13
XM/XMC-100 310 13

Version of 4th January 2013 Valid from 08/08/2012 to 08/08/2017


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CCL ‘XMC’ System Annex A22


Coupler Outer Spring Plate

Anchorage ØA ØB C
XMC-10 105 175 12
XMC-20 115 185 12
XMC-30 140 210 12
XMC-35 165 235 12
XMC-40 185 255 12
XMC-45 185 255 12
XMC-50 205 275 12
XMC-55 220 290 12
XMC-60 225 295 12
XMC-70 245 315 12
XMC-75 270 340 12
XMC-80 270 365 12
XMC-90 295 400 12
XMC-95 310 420 12
XMC-100 310 425 12

Version of 4th January 2013 Valid from 08/08/2012 to 08/08/2017


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CCL ‘XMC’ System Annex A23


Coupler Reducing Cone Retainer

Anchorage ØA ØB ØC D ØE F
XMC-10 36 130 68 226 9 17
XMC-20 36 140 82 236 9 17
XMC-30 36 168 100 261 11 17
XMC-35 36 210 125 286 14 17
XMC-40/45 38 236 140 309 14 17
XMC-50 36 253 156 326 14 17
XMC-55 36 270 175 343 14 17
XMC-60 36 280 175 354 14 17
XMC-70 36 325 195 406 18 17
XMC-75 36 335 218 416 18 17
XMC-80 36 350 218 431 18 17
XMC-90 36 378 240 459 18 17
XMC-95/100 36 396 252 477 18 17

Version of 4th January 2013 Valid from 08/08/2012 to 08/08/2017


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CCL ‘XM’ and ‘XMC’ System Annex A24


Anchorage Spacing and Edge Distances

a a×b x y
≤ x2 ≤ 1.15a ; y2 = ; x1 = 2 + c − 10 mm ; y1 = 2 + c − 10 mm
1.15 x2 2 2

fcm,0 on cube
30MPa 45MPa 55MPa
Anchorage a b a b a b
XM/XMC-10 245 245 245 245 245 245
XM/XMC-20 285 285 270 270 255 255
XM/XMC-30 340 340 320 320 300 300
XM/XMC-35 385 385 370 370 355 355
XM/XMC-40 440 440 420 420 400 400
XM/XMC-45 465 465 435 435 405 405
XM/XMC-50 500 500 460 460 415 415
XM/XMC-55 525 525 480 480 435 435
XM/XMC-60 550 550 505 505 460 460
XM/XMC-70 600 600 545 545 490 490
XM/XMC-75 640 640 580 580 520 520
XM/XMC-80 665 665 600 600 530 530
XM/XMC-90 730 730 650 650 570 570
XM/XMC-95 760 760 680 680 600 600
XM/XMC-100 770 770 695 695 620 620

*See Section 2.11 for further clarification of the spacing & edge distances x1, x2, y1 & y2.

Version of 4th January 2013 Valid from 08/08/2012 to 08/08/2017


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CCL ‘XM’ and ‘XMC’ System Annex A25


Bursting Reinforcement Sizes for Helices (fyk = 355MPa)

N = No. of turns in Helix

fcm,0 on cube
30MPa 45MPa 55MPa
Anchorage ØA B ØC D N ØA B ØC D N ØA B ØC D N
XM/XMC-10 195 245 12 40 5.5 195 245 10 45 5 195 245 10 50 4.5
XM/XMC-20 235 285 12 45 5.5 220 270 10 40 6 205 255 10 45 5
XM/XMC-30 290 340 16 45 7 270 320 16 45 6.5 250 300 12 40 7
XM/XMC-35 335 385 16 50 7 320 370 16 55 6.5 305 355 12 40 8
XM/XMC-40 390 440 16 45 9 370 420 16 50 8 350 400 16 55 7
XM/XMC-45 415 465 16 45 9.5 385 435 16 50 8 355 405 16 55 7
XM/XMC-50 450 500 16 45 10.5 410 460 16 50 8.5 365 415 20 55 7
XM/XMC-55 475 525 16 45 11 430 480 16 45 10 385 435 20 50 8
XM/XMC-60 500 550 20 60 9 455 505 20 60 8 410 460 20 50 8.5
XM/XMC-70 540 600 20 60 9.5 485 545 20 60 8.5 430 490 20 50 9.5
XM/XMC-75 580 640 20 55 11 520 580 20 60 9.5 460 520 20 50 10
XM/XMC-80 605 665 20 50 13 540 600 20 55 10.5 470 530 20 50 10
XM/XMC-90 670 730 20 50 14 590 650 20 55 11.5 510 570 20 50 11
XM/XMC-95 690 760 20 45 16.5 610 680 20 50 13 530 600 25 55 10.5
XM/XMC-100 700 770 20 45 16.5 625 695 20 50 13.5 550 620 25 55 11

*fyk = 355MPa (Smooth Rebar)

Version of 4th January 2013 Valid from 08/08/2012 to 08/08/2017


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CCL ‘XM’ and ‘XMC’ System Annex A26


Bursting Reinforcement Sizes for Helices (fyk = 500MPa)

N = No. of turns in Helix

fcm,0 on cube
30MPa 45MPa 55MPa
Anchorage ØA B ØC D N ØA B ØC D N ØA B ØC D N
XM/XMC-10 195 245 10 40 5.5 195 245 8 45 5 195 245 8 45 5
XM/XMC-20 235 285 10 45 5.5 220 270 10 50 5 205 255 10 55 4
XM/XMC-30 290 340 12 40 8 270 320 12 40 7.5 250 300 12 40 7
XM/XMC-35 335 385 12 40 9 320 370 12 45 7.5 305 355 12 50 6.5
XM/XMC-40 390 440 12 40 10.5 370 420 12 45 8.5 350 400 12 50 7.5
XM/XMC-45 415 465 12 40 11 385 435 12 40 10 355 405 12 45 8.5
XM/XMC-50 450 500 16 60 8 410 460 12 40 11 365 415 12 40 9.5
XM/XMC-55 475 525 16 55 9 430 480 16 60 7.5 385 435 16 50 8
XM/XMC-60 500 550 16 55 9.5 455 505 16 55 8.5 410 460 16 50 8.5
XM/XMC-70 540 600 16 55 10.5 485 545 16 55 9.5 430 490 16 50 9.5
XM/XMC-75 580 640 16 50 12.5 520 580 16 50 11 460 520 16 50 10
XM/XMC-80 605 665 20 70 9 540 600 16 50 11.5 470 530 16 50 10
XM/XMC-90 670 730 20 70 10 590 650 16 50 12.5 510 570 16 50 11
XM/XMC-95 690 760 20 65 11.5 610 680 16 45 14.5 530 600 16 45 12.5
XM/XMC-100 700 770 20 60 12.5 625 695 16 45 15 550 620 16 45 13

*fyk = 500MPa (Deformed/Ribbed Rebar)

Version of 4th January 2013 Valid from 08/08/2012 to 08/08/2017


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CCL ‘XM’ and ‘XMC’ System Annex A27


Bursting Reinforcement Sizes for Links (fyk = 500MPa)

N = No. of sets of Links

fcm,0 on cube
30MPa 45MPa 55MPa
Anchorage A B C ØD ØE F N A B C ØD ØE F N A B C ØD ØE F N
XM/XMC-10 195 N/A 245 16 N/A 60 5 195 N/A 245 12 N/A 55 5 195 N/A 245 10 N/A 50 5
XM/XMC-20 235 N/A 285 16 N/A 60 5 220 N/A 270 12 N/A 45 6 205 N/A 255 12 N/A 50 6
XM/XMC-30 290 225 340 16 12 60 6 270 210 320 16 12 65 6 250 200 300 12 12 55 6
XM/XMC-35 335 260 385 16 12 60 7 320 250 370 16 12 65 6 305 235 355 12 12 55 7
XM/XMC-40 390 295 440 16 12 55 9 370 285 420 16 12 60 8 350 270 400 16 12 65 7
XM/XMC-45 415 320 465 16 16 65 8 385 295 435 16 12 60 8 355 270 405 16 12 60 7
XM/XMC-50 450 345 500 16 16 65 8 410 320 460 16 16 65 8 365 285 415 16 16 65 7
XM/XMC-55 475 365 525 16 16 60 9 430 330 480 16 16 60 9 385 300 435 16 16 60 8
XM/XMC-60 500 380 550 16 16 60 10 455 350 505 16 16 60 9 410 320 460 16 16 60 8
XM/XMC-70 540 410 600 20 16 70 9 485 370 545 16 16 60 10 430 330 490 20 16 70 8
XM/XMC-75 580 440 640 20 16 70 10 520 395 580 20 16 70 9 460 355 520 20 16 70 8
XM/XMC-80 605 455 665 20 16 65 11 540 410 600 20 16 70 9 470 360 530 20 16 65 9
XM/XMC-90 670 500 730 20 16 65 12 590 445 650 20 16 70 10 510 390 570 20 16 65 9
XM/XMC-95 690 515 760 20 20 70 12 610 465 680 20 20 75 10 530 410 600 20 20 70 9
XM/XMC-100 700 530 770 20 20 65 13 625 475 695 20 20 70 11 550 425 620 20 20 70 10

*fyk = 500MPa (Deformed/Ribbed Rebar)

Version of 4th January 2013 Valid from 08/08/2012 to 08/08/2017


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CCL ‘XM’ and ‘XMC’ System Annex A28


Bursting Reinforcement for Combined Links/Helices
(fyk = 355MPa for Helix)

NL = No. of Links
NH = No. of turns in Helix

fcm,0 on cube
30MPa 45MPa 55MPa
Anchorage A ØB C ØD ØE F NL NH A ØB C ØD ØE F NL NH A ØB C ØD ØE F NL NH
XM/XMC-10 195 170 245 8 10 45 6 5 195 170 245 8 8 50 5 4.5 195 175 245 6 8 50 5 4.5
XM/XMC-20 235 205 285 10 10 50 6 5 220 195 270 8 10 50 6 5 205 180 255 8 8 45 6 5
XM/XMC-30 290 260 340 10 12 45 8 7 270 240 320 10 12 50 7 6 250 225 300 8 10 40 8 7
XM/XMC-35 335 300 385 10 12 45 9 8 320 290 370 10 12 50 8 7 305 275 355 10 10 45 8 7.5
XM/XMC-40 390 355 440 10 12 40 11 10.5 370 340 420 10 12 45 10 8.5 350 320 400 10 10 45 9 8.5
XM/XMC-45 415 380 465 10 12 40 12 11 385 350 435 10 12 45 10 9 355 320 405 10 12 45 9 8.5
XM/XMC-50 450 415 500 10 12 40 13 12 410 375 460 10 12 40 12 11 365 330 415 10 12 40 11 9.5
XM/XMC-55 475 440 525 12 12 45 12 11 430 395 480 12 12 45 11 10 385 350 435 12 12 45 10 9
XM/XMC-60 500 465 550 12 16 55 11 9.5 455 420 505 12 16 55 10 8.5 410 375 460 12 16 55 9 8
XM/XMC-70 540 505 600 12 16 55 11 10.5 485 450 545 12 16 55 10 9.5 430 395 490 12 16 55 9 8.5
XM/XMC-75 580 545 640 12 16 50 13 12.5 520 485 580 12 16 50 12 11 460 425 520 12 16 50 11 10
XM/XMC-80 605 570 665 16 16 60 12 10.5 540 505 600 12 16 50 12 11.5 470 435 530 12 16 50 11 10
XM/XMC-90 670 635 730 16 16 60 13 12 555 555 650 12 16 50 13 12.5 510 475 570 12 16 50 12 11
XM/XMC-95 690 650 760 16 16 55 14 13.5 570 570 680 16 16 55 13 12 530 490 600 16 16 55 11 10.5
XM/XMC-100 700 660 770 16 20 65 12 11.5 585 585 695 16 16 55 13 12 550 510 620 16 16 55 12 11

*fyk = 355MPa (Smooth Rebar)

Version of 4th January 2013 Valid from 08/08/2012 to 08/08/2017


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CCL ‘XM’ and ‘XMC’ System Annex A29


Bursting Reinforcement for Combined Links/Helices
(fyk = 500MPa for Helix)

NL = No. of Links
NH = No. of turns in Helix

fcm,0 on cube
30MPa 45MPa 55MPa
Anchorage A ØB C ØD ØE F NL NH A ØB C ØD ØE F NL NH A ØB C ØD ØE F NL NH
XM/XMC-10 195 170 245 8 6 35 7 6 195 170 245 6 8 45 6 5 195 175 245 6 8 55 5 4
XM/XMC-20 235 205 285 8 10 50 6 5 220 195 270 8 8 45 6 5.5 205 180 255 8 8 50 6 4.5
XM/XMC-30 290 260 340 10 10 45 8 7 270 240 320 10 10 50 7 6 250 225 300 8 10 45 7 6
XM/XMC-35 335 300 385 10 10 45 9 8 320 290 370 10 10 50 8 7 305 275 355 10 8 45 8 7.5
XM/XMC-40 390 355 440 10 10 40 11 10.5 370 340 420 10 10 45 10 8.5 350 320 400 10 10 50 8 7.5
XM/XMC-45 415 380 465 10 10 40 12 11 385 350 435 10 10 45 10 9 355 320 405 10 10 45 9 8.5
XM/XMC-50 450 415 500 10 12 50 10 9.5 410 375 460 10 12 50 10 8.5 365 330 415 10 12 50 9 8
XM/XMC-55 475 440 525 10 12 45 12 11 430 395 480 10 12 45 11 10 385 350 435 10 12 45 10 9
XM/XMC-60 500 465 550 10 12 45 13 11.5 455 420 505 10 12 45 12 10.5 410 375 460 10 12 45 11 9.5
XM/XMC-70 540 505 600 12 12 50 12 11.5 485 450 545 12 12 50 11 10.5 430 395 490 12 10 40 13 11.5
XM/XMC-75 580 545 640 12 12 45 15 13.5 520 485 580 12 12 45 13 12.5 460 425 520 12 12 45 12 11
XM/XMC-80 605 570 665 12 16 60 12 10.5 540 505 600 12 12 45 14 12.5 470 435 530 12 12 45 12 11
XM/XMC-90 670 635 730 12 16 60 13 12 555 555 650 12 12 45 15 14 510 475 570 12 12 45 13 12
XM/XMC-95 690 650 760 12 16 55 14 13.5 570 570 680 12 16 55 13 12 530 490 600 12 16 55 11 10.5
XM/XMC-100 700 660 770 16 16 60 13 12.5 585 585 695 12 16 55 13 12 550 510 620 12 16 55 12 11

*fyk = 500MPa (Deformed/Ribbed Rebar)

Version of 4th January 2013 Valid from 08/08/2012 to 08/08/2017


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CCL ‘XM’ and ‘XMC’ System Annex A30


Anchorage Spacing and Edge Distances fcm,0 on cube 46MPa

fcm,0 on cube
46MPa
Anchorage a b
XM/XMC-10 200 200
XM/XMC-20 220 220
XM/XMC-30 260 260
XM/XMC-35 300 300
XM/XMC-40 320 320
XM/XMC-45 340 340
XM/XMC-50 360 360
XM/XMC-55 380 380
XM/XMC-60 400 400
XM/XMC-70 430 430
XM/XMC-75 460 460
XM/XMC-80 480 480

*See Section 2.11 for further clarification of the spacing & edge distances x1, x2, y1 & y2.

Version of 4th January 2013 Valid from 08/08/2012 to 08/08/2017


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CCL ‘XM’ and ‘XMC’ System Annex A31


Bursting Reinforcement Sizes for Helices fcm,0 on cube 46MPa
(fyk = 500MPa)

N = No. of turns in Helix

fcm,0 on cube
46MPa
Anchorage ØA B ØC D N
XM/XMC-10 160 200 8 55 3
XM/XMC-20 170 220 10 50 4
XM/XMC-30 230 260 10 40 5.5
XM/XMC-35 250 300 12 45 6
XM/XMC-40 290 320 12 45 6.5
XM/XMC-45 300 340 16 50 6
XM/XMC-50 315 360 16 50 6.5
XM/XMC-55 340 380 16 50 7
XM/XMC-60 365 400 16 60 6
XM/XMC-70 385 430 16 60 6.5
XM/XMC-75 415 460 16 60 7
XM/XMC-80 445 480 16 65 7

*fyk = 500MPa (Deformed/Ribbed Rebar)

Version of 4th January 2013 Valid from 08/08/2012 to 08/08/2017


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CCL ‘XM’ and ‘XMC’ System Annex A32


Bursting Reinforcement Sizes for Links fcm,0 on cube 46MPa
(fyk = 500MPa)

N = No. of sets of Links

fcm,0 on cube
46MPa
Anchorage A B C ØD ØE F G N
XM/XMC-10 160 - 200 8 - 75 40 4
XM/XMC-20 170 - 220 10 - 60 40 4
XM/XMC-30 225 175 260 12 10 65 70 4
XM/XMC-35 260 200 300 12 10 65 65 5
XM/XMC-40 300 235 320 12 12 65 75 5
XM/XMC-45 300 230 340 12 12 60 75 6
XM/XMC-50 315 240 360 16 12 80 70 5
XM/XMC-55 345 265 380 16 12 75 80 5
XM/XMC-60 365 275 400 16 12 70 80 6
XM/XMC-70 395 300 430 16 12 70 75 7
XM/XMC-75 425 325 460 16 16 80 90 6
XM/XMC-80 435 335 480 16 16 80 85 6

*fyk = 500MPa (Deformed/Ribbed Rebar)

Version of 4th January 2013 Valid from 08/08/2012 to 08/08/2017


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CCL ‘XM’ and ‘XMC’ System Annex A33


Multistrand Jacks Type ‘MG’

Jack Size A B C ØD ØE ØF G H min Weight


1800MG 322 388 210 256 232 342 426 760 275kg
3000MG 290 388 200 280 270 405 500 700 350kg
4000MG 307 415 210 344 360 490 585 730 575kg
6000MG 304 462 209 386 410 576 680 770 700kg
7500MG 321 480 220 480 490 652 760 850 1150kg

Version of 4th January 2013 Valid from 08/08/2012 to 08/08/2017


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CCL ‘XM’ and ‘XMC’ System Annex A34


Characteristics of the CCL Multistrand Jacks Type ‘MG’

Maximum Pressure Area


1800MG
N/mm2 mm2
Main Ram Extend 44.82 46875
Main Ram Retract 2.06 24732
Lock-Off Ram Extend 27.58 6635
Lock-Off Ram Retract 2.06 5781
Stroke Length 210mm

Maximum Pressure Area


3000MG
N/mm2 mm2
Main Ram Extend 48.61 65391
Main Ram Retract 2.06 33627
Lock-Off Ram Extend 24.13 13974
Lock-Off Ram Retract 2.06 10694
Stroke Length 200mm

Maximum Pressure Area


4000MG
N/mm2 mm2
Main Ram Extend 42.06 102629
Main Ram Retract 2.06 39874
Lock-Off Ram Extend 27.58 17403
Lock-Off Ram Retract 2.06 13634
Stroke Length 210mm

Maximum Pressure Area


6000MG
N/mm2 mm2
Main Ram Extend 47.00 133525
Main Ram Retract 2.06 56609
Lock-Off Ram Extend 27.58 15030
Lock-Off Ram Retract 2.06 15030
Stroke Length 209mm

Maximum Pressure Area


7500MG
N/mm2 mm2
Main Ram Extend 48.61 170901
Main Ram Retract 2.06 57822
Lock-Off Ram Extend 27.58 30030
Lock-Off Ram Retract 2.06 30030
Stroke Length 220mm

Version of 4th January 2013 Valid from 08/08/2012 to 08/08/2017


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CCL ‘XM’ and ‘XMC’ System Annex A35


Designation of Tendon

Prestressing steel:

- Type: Strand according to prEN 10183-3: 2006


- Strength: fpk 1860MPa or 1770MPa
- Nominal cross section: As See 2.3.3 Strand Characteristics
- Relaxation at 0.70fpk
after 1000 hours: 2.5%
- Modulus of elasticity: Es 195GPa

Tendon:

- Type: Internal/External Bonded/Unbonded


- Use category: Concrete, Composite, Steel, Masonry, Timber
- Corrosion protection: Grout, Grease, Wax
- Weight of tendon: Mp See 2.3.4 Prestressing Forces
- Force at 1.00fpk: Fpk See 2.3.4 Prestressing Forces
- Friction coefficient: µ See 2.5 Friction Losses
- Unintentional deviation/
Wobble coefficient: k See 2.5 Friction Losses
- Minimum radius of curvature: Rmin See 2.9 Radii of Curvature
- Duct outside & inside diameter: dout dint See Annex A19 and A20
- Maximum spacing
of duct supports: smax See 2.8 Spacing of the Supports

Anchorages:

- Type: See 2.1 – 2.2 & Annexes A01 – A25


- Minimum centre spacing: x2, y2 See Annex A24 and
2.11 Anchorage Spacing and
Concrete Cover
- Minimum edge distance: x1, y1 See Annex A24 and 2.11
- Anchorage seating: g See 2.6 Anchorage Wedge Set

Version of 4th January 2013 Valid from 08/08/2012 to 08/08/2017