Australian Prestressing Services

Australian Prestressing Services

Melbourne, Sydney, Brisbane, Canberra, Adelaide, Perth, Dubai, Abu Dhabi, Muscat, Doha, Domascus, Cairo, New Delhi

www.apspt.com

Incorporated in Sydney in 1982, Australian Prestressing Services (APS) have steadily grown into one of the leading Specialist Post Tensioned Concrete Contractors in the world. With branch offices covering Australia the Middle East and Asia, APS have a proud reputation of excellence in expertise and professionalism with a track record

of completing an ever growing list of high profile civil and structural projects.

APS was established by civil engineers with vast experience across a multitude of construction sectors and many years of involvement in the industry, both locally and abroad. With this knowledge base, APS continues to provide the construction industry

with innovative solutions to structural designs, construction refurbishment and repair works.

With over 25 years of experience, Australian Prestressing Services have received many construction awards and takes pride in its reputation of exceeding customer expectations.

APS Group has enjoyed excellent growth over the last decade, diversifying into a broad spectrum of specialist engineering and construction services. With our technical expertise and resources, APS is very well placed to continue to seek growth and extend its services to construction industries both in Australia and overseas.

APS offer the following services:

> Civil and Structural Design Services

> Project Management Services

> Project Development Services

> Prestressed Concrete Contracting

> Building Construction

> Civil Engineering Works

> Concrete Repair and Remediation

> Industrial Coatings

> Ground Anchoring

> Heavy Lifting

> Supply of Prestressing Equipment and Material

> Reinforcing Bar Coupler Supply and Installation

Innovative Solutions for the Construction Industry

Melbourne, VIC21B Edinburgh St Oakleigh South Vic 3167 T 61 3 9543 5236 F 61 3 9544 3102 E [email protected]

Sydney, NSW36 Lonsdale St Lilyfield NSW 2040 T 61 2 9569 5522 F 61 2 9569 9471 E [email protected]

Brisbane, QLD14 Bronze St Summer Park QLD 4074 T 61 7 3376 4400 F 61 7 3376 4600 E [email protected]

Canberra, ACT32 Percy Cr Chapman ACT 2611 T 61 2 6287 1339 F 61 2 6287 2339 E [email protected]

Adelaide, Perth, New Delhi

Dubai, UAEPO Box 98370 Dubai, UAE T 971 4 262 2622 F 971 4 262 2292 E [email protected]

Abu Dhabi, Doha, Muscat, Damascus, Cairo

Australia/Asia

Middle East

Services Offered by APS

Completed Projects> The Dubai Mall (Dubai U.A.E)> Burj Al Arab Hotel (Dubai U.A.E)> Westfield Doncaster Shopping Mall (Victoria)> Westfield Tuggerah Shopping Mall (NSW)> Emirates Towers (Dubai U.A.E)> Mong Kok Train Station (Hong Kong S.A.R)> Abu Dhabi Trade Centre (Abu Dhabi U.A.E)> The Gate D.I.F.C (Dubai U.A.E)> Sydney Customs House (NSW)> Jumeira Beach Residence (Dubai, UAE)> Adelaide Desalination Plant (S.A.)> Sydney Desalination Plant (NSW)> Jamestown Windfarm (S.A.)> Hindmarsh Square (S.A.)> Masafah Bridge (Abu Dhabi (U.A.E)> Rose Hill Race Course (NSW)> RPA Hospital (NSW)> Kogarah Stadium (NSW)> American University Sharjah (Sharjah U.A.E)> Chifley Hotel (Melbourne VIC)> Alto tower (Melbourne, VIC)

Burj Al Arab Hotel (Dubai U.A.E.)

The Dubai Mall (Dubai U.A.E.)

The Dubai international Financial Centre Gate (Dubai U.A.E.)

PAGE 4

The fundamental action that gives the Post-tensioned method of Concreate Technology the advantage over other forms of concreate construction lies in the following:

> Design> Economics> Floor cycles> Materials Handling> Deflection free slabs> Reduced floor to floor height> Column free space> Column and footing design

These advantages result in more efficient use of construction materials, allowing lower building cost, and providing for innovative contemporary design incorporating the flexibility of large, open column free space.

DesignDesigners have the opportunity to impart forces internally to the concrete structure to counteract and balance loads sustained by the structure thereby enabling design optimization.

Designers can utilize the advantage of the compressive strength of concrete while circumventing its inherent weakness in tension.

Post-tensioned concrete combines and optimizes today’s very high strength concrete and steel to result in a practical and efficient structural system.

A lighter more efficient structure can be achieved as slab thickness is reduced with Post-tensioned slab systems.

EconomicsThe selection of the most appropriate floor system for a building project should be based upon macro-economic considerations as an important element of which the unit cost for each floor system is expressed in terms of cost per m². Speed of construction, together with material savings is improved with post-tensioned slab systems.

Floor CyclesEarly transfer of prestress increases the rate of recovery and re-assembly of formwork by permitting early stripping and back propping. There is generally a corresponding reduction in the number of formwork sets required, which services the program.

Materials HandlingAn estimated saving in reinforcement materials handling for a post-tensioned design of 60%, in comparison with reinforced concrete, allows the crane to service other trades on the critical path.

Deflection Free SlabsPost-tensioned concrete slabs may be designed as deflection free under a specific applied loading.

Long term building maintenance costs are likely to be lower as long term deflection, including distortion and cracking of glazing and partitions, is minimized and exposed concrete structures may be rendered crack free by designing an appropriate level of prestress into the concrete slab.

Reduced Floor to Floor HeightThe design of a multi-storey may allow for additional floors within a defined maximum building height by reducing the structural depth of the floor system.

Column Free SpaceA longer span floor system may be designed as a post-tensioned floor at the same price as a given reinforcement concrete floor system. A reduction in the number of expansion joints could be a further saving.

Column and Footing DesignThe reduced floor dead loads may be utilized in more economical design for the sizes of columns which may increase the floor net lettable area. Loads on columns are lower so foundation costs can be reduced.

WaterproofPost-tensioned slabs may be designed as waterproof by providing sufficient residual prestress to overcome the tensile stress generated by differential shrinkage, column restraint, thermal loading and service load space, thereby obviating the need for a waterproof membrane.

Material SavingsPost-tensioned structures generally have less concrete and reinforcement and require less labour. The savings are all very important in these day of escalating costs and material shortages.

Advantages of the Post-Tensioned System


PAGE 5

Slab System (bonded and unbonded)A.P.S. are an established market leader in the design, supply and installation of post tensioned structures for the construction industry. With specially developed components for post tensioning applications, APS remains at the forefront of this technology.

The APS slab system offers a cost effective and programme friendly structural solution for medium to long span structures.

Multi-Strand SystemThe A.P.S. Multi Strand System is designed to accommodate from 1 to 48 strands of 12.7mm diameter or 1 to 42 strands of 15.2 dia achieving up to 10,000 KN (1,000 tonnes) of breaking load. Cables are stressed with all strands pulled simultaneously. Anchorages use a self seating wedge system in a machined anchor head.

Cables can be stage stressed in stages, re-stressed or coupled as required. APS provide both a bonded and an unbonded multi strand system depending on specified application requirements.

Heavy Lifting EquipmentA.P.S. have a full range of lifting and jacking systems using bar or strand Cables for the lifting of both steel and concrete structures. Using similar principals and equipment we have, systems for the horizontal jacking of large culverts under roads and/or rail lines.

The A.P.S. system utilises hydraulic jacking, with various capacity jacks and tendon configurations available to suit any application.

APS Systems

PAGE 6

Reinforcing Bar Coupling SystemA.P.S. manufacture, supply and install reinforcing bar couplers for all sizes and grade of reinforcement bar from 12mm to 45mm.

Ground Anchor SystemRock bolts, permanent and temporary strand anchors and permanent and temporary bar anchors are all available in the APS range. The Company provides full design and installation services including drilling and long term monitoring. Single Bar anchors up to 1250KN (125 tonne)and strand anchors up to 10,OOOKN (1,000 tonne) are readily available.

Where larger load application is required special components can be provided. For some applications, anchors capable of being re-stressed, de-stressed and/or removable can also be provided.

Pile testing has also become a common application of the APS anchor system.


PAGE 7

Australian Prestressing Services Water Storage Reservoir System provides a cost effective and durable concrete water storage solution. Reservoir capacity from 2 Mega Litre to 60ML can be designed and constructed on the most difficult of sites. APS can also design, supply and install associated pipework necessary for any individual reservoir.

Floor slabs are monolithic with ground beams and eliminates floor joints. The walls can be cast on site or delivered from precast facilities. Roofing of concrete, steel or aluminum are available as per design, budget or as per the requirements.

The precast post-tensioned reservoir copes with all climate conditions. The reservoir can be constructed inground or above ground hidden within hills and trees.

Water tightness and durability is ensured with the high compressive strength built into the concrete wall during construction.

Some projects completed by APS include:

> 2ML Fernvale QLD

> 4ML Echuca VIC

> 5ML East Bowral NSW

> 2 x 5ML Mudgee NSW

> 12ML Murwillumbah NSW

> 13.2ML Riverview QLD

> 5ML Tumut NSW

> 40ML Sydney Desalination Project

NSW

You can discuss your full design and budget requirements with any of our APS offices.

Post-Tensioned Reservoirs

Slab pour in progress

Pre-cast wall being erected

5ML East Bowral Reservoir hidden within the wall

5ML Mudgee Reservoir

PAGE 8

Slab System

Strand Dia (mm)

No of strands

Uts (kN) Steel Area

(mm²)

Weight/Meter (kg/m)

Duct Size (mm)

Dimension (mm)

Live End Dead End

H W A B C D E F G H

12.7 1 184 100.1 0.79 19 42 100 100 100 - 75 650 - -

2 368 200.02 1.58 19 70 300 220 100 155 65 650 60 160

3 552 300.3 2.37 19 70 300 220 100 210 70 650 60 250

4 736 400.4 3.16 19 70 300 220 100 210 70 650 60 320

5 920 500.5 3.95 19 70 300 220 100 210 70 650 60 420

15.2 1 250 143.3 1.13 19 42 100 100 100 - 75 700 - -

2 500 286.6 2.26 19 42 200 100 100 155 65 700 60 160

3 750 429.9 3.39 19 70 300 220 100 210 70 700 60 250

4 1000 573.2 4.52 19 70 300 220 100 210 70 700 60 320

5 1250 716.5 5.65 19 90 300 220 100 210 80 700 60 420

Cable Properties

Note: All strands are Low Relaxation Supa-Seven to AS1311 with a Youngs Modulus of 196GPa


PAGE 9

Live End Anchorage Dead End Anchorage

Jacking Equipment

PAGE 10

Strand Dia (mm)

Dimension (mm)

A B C D E

12.5 45 35 116 48 34

12.7 45 35 116 48 34

15.2 50 42 140 50 45

15.7 50 42 140 50 45

Strand Dia (mm)

Dimension (mm)

A B C D

12.5 200 110 600 90

12.7 200 110 600 90

15.2 210 120 650 100

15.7 210 120 650 100

Strand Joiner

Casting

Coupling Slab Systems


PAGE 11

APS anchor

size

No of strands

Cable UTS (kN)

Minimum ID duct

size (mm)

Preferred ID duct

size (mm)

1 1 184 30 40

4 2 368 30 40

3 552 30 45

4 736 35 45

7 5 920 40 50

6 1104 40 50

7 1288 45 50

12 8 1472 50 65

9 1656 55 70

10 1840 60 70

11 2024 60 75

12 2208 65 75

20 13 2392 65 75

14 2576 70 80

15 2760 70 80

16 2944 75 80

17 3128 75 80

18 3312 75 85

19 3496 80 85

20 3680 80 85

27 21 3864 85 90

22 4048 85 90

23 4232 85 90

24 4416 85 90

25 4600 90 95

26 4784 90 95

27 4968 95 100

32 28 5152 95 110

29 5336 100 110

30 5520 105 110

31 5704 105 110

32 5888 110 110

Tendon properties: 12.7 Super seven low relaxation strand to as1311, youngs modules 196 gpa 1000 hr relax max 2.5%, Steel area 100.1mm nom wt.0.786kg/m

APS anchor

size

No of strands

Cable UTS (kN)

Minimum ID duct

size (mm)

Preferred ID duct

size (mm)

37 33 6072 110 120

34 6256 110 120

35 6440 110 120

36 6624 110 120

37 6808 115 125

42 38 6992 115 125

39 7176 115 125

40 7360 120 130

41 7544 120 130

42 7728 120 130

48 43 7912 130 135

44 8096 130 140

45 8280 130 140

46 8464 130 140

47 8648 130 140

48 8832 130 140

Multi-Strand SystemStrand Type 12.7

PAGE 12

Strand Dia (mm)

Anchor type

A (mm)

BØ (mm)

C (mm)

D (mm)

E (mm)

F (mm)

SDØ (mm)

SL (mm)

12.7 7 155 110 50 90 200 100 200 180

12 180 142 50 125 220 100 260 180

20 250 185 60 200 290 120 350 250

27 280 220 75 220 330 150 400 280

32 300 235 75 220 370 150 400 300

37 315 295 90 240 370 180 450 300

15.2 and 15.7

7 180 142 50 125 220 100 260 180

12 220 170 60 180 220 100 300 220

15 250 185 60 200 290 120 350 250

19 280 220 75 220 330 150 400 280

22 300 235 75 220 370 150 400 300

27 315 295 90 240 370 180 450 300

APS anchor

size

No of strands

Cable UTS (kN)

Preferred ID duct

size (mm)

3 2 500 39

3 750 39

4 4 1000 51

7 5 1250 69

6 1500 69

7 1750 69

12 8 2000 84

9 2250 84

10 2500 84

11 2750 84

12 3000 84

19 13 3250 96

14 3500 96

15 3750 96

16 4000 96

17 4250 96

18 4500 96

19 4750 96

22 20 5000 105

21 5250 105

22 5500 105

27 23 5750 115

244 6000 115

25 6250 115

26 6500 115

27 6750 115

31 28 7000 118

29 7250 118

30 7500 118

31 7750 118

Strand Type 15.2 Caste Steel Anchorage

Caste Steel Anchorage


PAGE 13

Strand Dia (mm)

Anchor Type

A (mm)

B (mm)

C (mm)

D (mm)

Eø (mm)

SDØ (mm)

SL (mm)

12.5 and 12.7

7 170 25 115 50 110 200 180

12 230 30 160 50 142 260 180

20 290 40 195 60 185 350 250

27 350 55 235 75 220 400 280

32 370 55 260 75 235 400 300

42 420 60 285 80 260 450 300

48 480 60 325 85 280 450 350

15.2 and 15.7

7 210 35 300 50 142 260 180

12 280 40 450 60 170 300 220

19 350 45 550 75 220 400 280

22 400 50 600 75 235 400 300

27 450 60 600 90 295 450 300

Steel Plate Anchorage

Steel Plate Anchorage

PAGE 14

Multistrand Post Tensioning JacksJack type 150T 200T 300T 500T 900T

Strand no. 12.5 & 12.7 7 12 20 27, 32, 37 48

Strand no. 15.2 & 15.7 4 7 12 19, 22 37

A (mm) (min) 140 182 223 258 383

B (mm) (min) 785 1180 1260 1420 1430

Jack weight (mm) (min) 70 200 450 650 1500

300T Multistrand Jack


PAGE 15

Slab System UnbondedStrand

dia (mm)UTS (kN) Steel

area (mm²)

Weight/ metre (kg/m)

Dimension (mm)

A B C

12.5 165 97 0.76 130 62 50

12.7 184 100.1 0.79 130 62 50

15.2 250 143.3 1.13 153 81 55

15.7 265 153 1.2 153 81 55

Anchorage Detail

PAGE 16

Ground Anchor System

Strand 12.7 (mm) 7 12 20 27 48

Bearing plate A x B x C (mm) 170 x 170 x 24 230 x 230 x 40 290 x 290 x 40 350 x 350 x 55 500 x 500 x 60

Stressing block dia (mm) 110 150 180 220 280

Stressing block height (mm) 51 55 60 75 85

Strands 15.2 & 15.7 (mm) 7 12 20 27

Bearing plate A x B x C (mm) 210 x 210 x 35 280 x 280 x 40 350 x 350 x 45 450 x 450 x 60

Stressing block dia (mm) 142 170 220 295

Stressing block height (mm) 50 60 75 90

Anchor Details


PAGE 17

Permanent Rock Anchor Temporary Rock Anchor

PAGE 18

Reinforcing Bar Coupling SystemBar size

(mm)Pre-

pressed length (mm)

OD (mm) ID (mm) Approx length after

pressing (mm)

Approx weight sleeve (kg)

Length RH stud

(mm)

Weight RH stud

(kg)

Length RH/LH

stud (mm)

Weight RH/LH

stud (kg)

End of sleeve to end of bar

(mm)

A B D E C F F G

16 91 29.9 19 94 0.3 45 0.11 58 0.15 27

20 113 36 23.5 116 0.52 53 0.19 70 0.25 31

25 140 45 29.5 146 1.06 69 0.42 91 0.56 40

28 155 51.4 32.5 162 1.52 73 0.52 95 0.68 42

32 180 58.3 37 188 2.25 83 0.78 112 1.05 47

40 222 73.5 46.5 232 4.44 106.5 1.55 142 2.08 58

Right Hand CouplersRight/Left Hand Couplers


Melbourne, VIC21B Edinburgh St Oakleigh South Vic 3167 T 61 3 9543 5236 F 61 3 9544 3102E [email protected]

Sydney, NSW36 Lonsdale St Lilyfield NSW 2040 T 61 2 9569 5522 F 61 2 9569 9471 E [email protected]

Brisbane, QLD14 Bronze St Summer Park QLD 4074 T 61 7 3376 4400 F 61 7 3376 4600 E [email protected]

Canberra, ACT32 Percy Cr Chapman ACT 2611 T 61 2 6287 1339 F 61 2 6287 2339 E [email protected]

Dubai, UAEPO Box 98370 Dubai, UAE T 971 4 262 2622 F 971 4 262 2292 E [email protected]

www.apspt.com


Australian Prestressing Services

Documents