VSL Construction Systems

P O S T- T E N S I O N I N G

S T A Y C A B L E S

GROUND A N C H O R S

R E TA INED EAR T H

H E AV Y L I F T I N G

C L I M B F O R M

B A R S Y S T E M S

S T R U C T U R A LB E A R I N G S

V S L C O N S T R U C T I O N S Y S T E M S

VSL s special construction systems have been used throughout the world since1956. They are technically proven and have earned a well-deserved reputation fortheir quality and reliability.

This has led to VSL becoming a recognised leader in the fieldof special construction systems/methods and related engineering.

Post-Tensioning is VSL s corebusiness. Multistrand andmonostrand systems are used inevery area of concrete construction, where prestressing forces areintroduced into the structure once the concrete has hardened. Complying with national and international standards, they are approved in every country where the use of post-tensioningrequires official certification.

The post-tensioning principle is also applicable tostay cables, external cables, as well as groundanchors using strand or bar systems. VSL s understanding of prestressing has also led tothe development of the VSL Heavy Lifting systemwhich provides safe and cost-saving solutions for lifting, lowering and horizontal jacking of large andheavy loads.

This publication represents a summary of VSL s special construction systems and includesessential design and construction information.Technical data and dimensions of anchorages, cables and equipment are given in the annexe.

Schlund Roundabout - Switzerland

Grand Central Tower - South Africa

Avignon Viaduct - France

TThe Company2

Further details concerning the use of the variousconstruction systems can also be found in a numberof technical publications available from your localVSL representative or any VSL office.

VSL operates as a transnational group of companies.Its subsidiaries and licensees are organised into closely co-operating regional units. Our customers directly benefit from the continuing development of VSL s special construction methodsand from the exchanges of information taking place within the VSL Network. This means that our customershave local access to all theresources and expertise provided by the VSL Group.

VSL also provides a comprehensive set of professional services able to meet the specific requirements of a wide range of special constructionengineering.

VSL Companies are able to execute all works usingVSL personnel and equipment. This involvement includes appropriate technicalconsultancy and support during planning and construction phases.

VSL s services can include feasibility studies, preliminary designs and alternative proposals, as well as structural design assistance. These services aim to provide fully customised solutions adapted to customer requirements. We offer our customers the strength andflexibility of our world-wide network. Our goal is to be your privileged partner and help find the best-adapted solutions to your particular needs.

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Wadi Leban Stay Cable Bridge - Saudi Arabia

A4 Motorway - Poland

Charles de Gaulle Bridge - Paris,France

The VSL Multistrand system is characterised by thefollowing features:

l standardised tendon units using up to fifty-five 13-mm (0.5) or 15-mm (0.6) diameters t r a n d s ;

l wide selection of anchorage types;l steel or plastic PT-PLUSTM ducts;l cement or other types of grouting;l tendons manufactured on-site

or in the factory;l no need to determine tendon length

in advance;l simultaneous stressing of all strands in a

tendon, with individual locking of each strandat the anchorage point;

l s t ressing carried out in any number of phases;l simple and reliable equipment for

installation, stressing and grouting.

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MMultistrand Post -Te n s i o n i n g

VSL Multistrand System Components

VSL AnchoragesTechnical data and dimensions are given in the annexe.

For reasons of clarity and simplicity, spirals are not shown in the pictures. However, they form an integralpart of the anchorage and are required to control local zone stresses. For more detailed information, seeV S L s Report Series on Detailing for Post-Tensioning.

Our SO and SK anchorages, as shown on page 13, are standard for slab post-tensioning. They are alsooften used for bridges (transversal post-tensioning) and other structure s .

5Grout connection

Anchor head

Wedges

Strands

Duct

Bearing plate (casting)

Stressing Anchorage: VSL Type EcThis compact and easy to handle anchorage system allows prestressing force to be transferred through two flanges. If necessary, the spiral can be replaced by suitably laid out orthogonal reinforcements. Equipped with an additional retainer plate, the Ec anchorage can also be used as a dead-end anchorage.

Stressing Anchorage: VSL Type CS 2000This revolutionary anchorage has a composite bearing plate (metal - high performance concrete) and is lighter,smaller and easier to handle. It comes in 3 differentconfigurations: CS 2000 - STANDARD for normal applications, CS 2000 - PLUS using VSL s PT-PLUSTM duct system for enhanced corrosion protection or improved fatigue resistance, and CS 2000 - SUPER able to provide an electrically isolated tendon. Equipped with an additionalretainer plate, the CS 2000 anchorage can also be used asdead-end anchorage.

Grout tube

Duct

Sleeve

Strands

Wedges

Anchor head

Bearing plate (steel)

Stressing Anchorage: VSL Type EThe prestressing force is transferred to the concrete by a bearing plate. If necessary,the spiral can be replaced by suitably laid out orthogonal reinforcements.

Equipped with an additional retainer plate, theE anchorage can also be used as a dead-endanchorage.

StrandsWedges

Anchor head

Bearing plate

Duct

CStrumpetGrout connection

Protection cap

Coupler: VSL Type KThis fixed coupler is used for connections to a cablethat has already been installed and stressed. The strands are anchored using compression fittingspositioned onto the coupling head grooves.

Coupler: VSL Type VThis movable coupler is used for connecting to acable that has already been installed but not stressed. The strands of the new cable are anchored usingcompression fittings positioned onto the couplinghead of the previously installed cable.

Intermediate Anchorage:VSL Type Z and ZUIntermediate anchorages are used for those tend o n sw h e re the ends cannot be fitted using normal stressing anchorages. The anchorage head is loosely placed in the blockout and moves during the stressing operation on the tendon axis.Z type intermediate anchorages are used:

l for pre s s u re shaft and pre s s u re tunnel ring tendons, avoiding the use of internalbuttresses;

l for silo and reservoir circular structure ring tendons, avoiding the use of external buttresses;

l for transversal bridge deck prestressing where,for aesthetic reasons, external anchorage blockouts are undesirable;

l for frame, arch and shell structure tension ties where there is no or limited access to endanchorages.

The VSL type ZU intermediate anchorage has similarapplication possibilities as type Z.It is particularly adapted to small cable units in structures without dynamic loading.

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Sleeve

Coupling head V

Tension ring

Compression fittingswith retainer plates

Anchor head Z

Retainer plate

Wedges

Duct

Tension ring with anchors

Grout tube

Wedges

Anchor head ZU

Grout tube

Wedges

Bearing platetype Ec or E

Tension ring

Sleeve

Coupling head K

Duct

Compression fittings

Steel band

MMultistrand Po s t - Te n s i o n i n g

Dead-End Anchorage:VSL Type PThis type of anchorage is used where the pre s t re s s i n gforce has to be transferred to the structure at the farend of the tendon. It consists of a folded plate incorporating holes forthe strands to pass through.The strands are anchored using compression fittingsbearing onto the plate.The compression fittings are locked into position by a retainer plate.Where the force can only be transferred to the concrete using a bearing plate, polyethylene tubescan be used to sheathe the strands between theend of the duct and the bearing plate.

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U-plate

Grout tube

Duct

Tension ring

Seal

P-plate

Compression fittings

Retainer plate

Duct

Tension ring

Seal

Grout tube

Dead-End Anchorage:VSL Type HThis type of anchorage is the best solution whenstrands need to be pushed through on site. The prestressing force is transferred to the concreteby bond. The spiral (for 5-7 / 6-7 and larger units)and tension ring prevent inadmissible stresses dueto deviated forces acting on the concrete. The rebar net at the anchorage end zone acts as aspacer for individual strands.

Dead-End Anchorage:VSL Type UThe transfer of the prestressing force is partially achieved by bonding the strands to the concrete,and partially by the U-shaped plate fixed to the concrete. The spiral and tension ring prevent inadmissible stresses due to deviated forces acting on the concrete. The anchorages can be used both vertically and horizontally.

Bulbs

Tension ring

Grout tube

Duct

Seal

Spacer

Sheathing and corrosion protectionGenerally speaking, corrugated steel ducts with aminimum wall thickness of 0.25 mm are used. Whileworkshop prefabricated cables normally use a flexibleduct, a semi-rigid type is the solution most often usedwhere cables are pushed or pulled through on site.

However, the VSL PT-PLUSTM system with its corrugated duct and plastic coupler can provide anumber of important advantages when comparedwith conventional ducts, such as:

l greatly enhanced tendon corrosion protection;l improved tendon fatigue resistance;l reduced sensitivity to stray electric curre n t s ;l reduced duct friction coefficient;l the PT-PLUSTM system, when used with

VSL CS and ECS anchorages, can be adapted toprovide electrically isolated tendons (EIT).

The PT-PLUSTM system is suitable for all applicationsbut, given its specific characteristics, is best adapted to:

l transverse tendons in bridge deck slabs and wherever tendons are close to the concrete surface;

l railway bridges and other structureswith highfatigue loadings or subject to stray electric currents;

l structures where severe corrosive environmentmay be expected;

l tendons that need to be electrically monitore dt h ro u g h o u t the structures service life.

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Dead-End Anchorage:VSL Type L

This type of anchorage is used for tendons installed once a structure is concreted and where there is no access to the dead-end anchorage. It is often used for vertical tendons in reservoir walls, for nailing pier head segments to piers in segmental bridge construction, or for horizontal tendons in slabs or foundation rafts. The strands areinstalled into the duct after concreting and simultaneously stressed using jacks at both stressing anchorage points.

Dead-End Anchorage:VSL Type AF

This type of anchorage is used for vertical tendons installed once a structure is concreted, where the prestressing force has to be transferred to the structureat the lowest end of the tendon and when there is no access to the dead-end a n c h o r a g e . The strands, with compression fittings at their ends, are bonded to the load-transferring casting by a special cement grout. Once stressed, the cable over the anchorage is then grouted.

Duct B

Duct A

Grout tube

MMultistrand Post -Te n s i o n i n g

Selected design considerationsDuct spacings and covers

When determining minimum spacing and concretecover requirements, reference should be made toapplicable standards and recommendations.

Tendon supports

Recommended spacing:Standard steel ducts 0.8 to 1.2 mPT-PLUSTM plastic ducts 0.8 to 1.0 m

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Minimum radius oftendon curvature Minimum tangent

length

Minimum breaking load of tendon (MN)

Minimum radius of tendon curvatures and minimum tangentlength for internal bonded tendons

Tendon force lossesThe effective prestressing force at a specific placeand time differs from the initial prestressing force.There are several reasons for this. Significant factors include:

l friction losses due to the curvature of thetendon;

l concrete shrinkage and creep;l relaxation of the prestressing steel;l draw-in of the wedges during lock-off.

Friction losses along the tendon can be determinedusing the following formula:

Px = Po.e-( + kx), in which:x = distance from stressing end (in meters);Px = prestressing force at x;Po = prestressing force at stressing end; = friction coefficient; = sum of all angular deviations (in radians)

over the distance x;k = wobble friction coefficient due to minor

unintentional tendon curvatures (installation tolerances).

The and k friction coefficients can vary fairly widelyand depend upon several factors, including: the nature and surface condition of the prestressingsteel; the type, diameter and surface condition ofthe duct, and the installation method.

The following values may be assumed for design:- tendon in standard steel ducts:

= 0.2 (range: 0.16 to 0.22) k = 0.001 (range: 0.0008 to 0.0012)

- tendon in PT-PLUSTM plastic ducts: = 0.14 (range: 0.12 to 0.15) k = 0.001 (range: 0.0008 to 0.0012)

To calculate losses due to concrete shrinkage andcreep, reference should be made to the technicaldocuments and standards applicable to each pro j e c t .

The relaxation of the prestressing steel depends primarily on the type of steel (relaxation class), theextent of the prestressing, and the temperature. For the low relaxation strands commonly usedtoday, maximum loss is 2.5% after 1,000 hours at 20C with an initial stressing at 70% of the nominaltensile strength. Further information can be found inthe relevant prestressing steel standards and manufacturers literature.

Independent of the jack or tendon type, a loss ofapproximately 6 mm due to wedge draw-in occursat lock-off.If necessary, compensation can be provided byappropriate procedures.

StressingThe unique feature of the VSL Post-Tensioning system lies in its special wedge locking procedure.The wedges always remain in contact with thestrands during the stressing operation. As the pressure in the jack is released, the wedgesautomatically lock in the conical holes of the anchor head.

GroutingVSL grouting equipment includes a combinedmixer and pump unit. Grouting is carried out as soon as possible after stressing. For long cables, and in the case of electrically isolated tendons, vacuum-aided grouting is highly recommended.

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Placing of anchor head

MMultistrand Po s t - Te n s i o n i n gPositioning of jack

Grouting of tendon

Placing of anchor head and we d g e s

Positioning of jack

Stressing

Seating of wedges

Stressing,measuring,seating of wedges

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Construction SequenceTodays building owners and designers need to provide a high level of structural flexibility to meetchanging user requirements.

Post-tensioning provides greater spans with reducedstructural beam depths, resulting in larger column-fre eareas. As a result, internal layouts are not dictated bytight column grids. Positive deflection and crackc o n t rol and, if necessary, joint-free water-tight slabs, free designers from the limitations of traditional reinforcedconcrete structures. VSL Post-Tensioning is more economical than othersystems, especially when fast construction cycles areenvisaged. There is less material handling on site anda reduced labour force, minimising site congestion. Most importantly, there is the quality and service p rovided by VSL s specialised high-performance teams.

The VSL Post-Tensioning Slab system has been used inmany prestigious buildings and structures. The system uses up to five strands contained in flat-shaped ducting, and anchorages. Strands are individually stressed and gripped bywedge action. After stressing, the duct is filled with acement grout that fully bonds the strands to the surrounding concrete.

AL Faisaliah Building - Riyadh,Saudi Arabia

Placing tendons Concreting Stressing Grouting

Dah Chong Hong Building - Hong Kong

BBonded Slab Post-Tensioning

Selected design considerationsl Spacing of tendon supports: 0.75 to 1.2 m (conventional steel ducts)

0.75 to 1.0 m (PT-PLUSTM plastic ducts)

l Minimum curvature radius: 2.5 m (vertical profile)6.0 m (horizontal profile)

l Min. straight length at anchorage: 0.75 m

l A wedge draw-in of approximately 6 mm occurs at lock-off

l Friction losses can vary fairly widely from one tendon to another and from one structure to another.This depends on factors such as surface condition of strands, duct types and surface condition, material properties, installation methods and on-site workmanship. Generally speaking,the following friction parameters can be used.

Tendons in standard steel ducts: = 0.20 (-) (range: 0.16 to 0.22)k = 0.001 (m-1) (range: 0.0008 to 0.0012)

Tendons in plastic ducts: = 0.14 (-) (range: 0.12 to 0.15)k = 0.001 (m-1) (range: 0.0008 to 0.0012)

The PT slab method allows designers to reduce building heights or to increase free heights between floors.

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Free height

Free height

Free height

Free height

Height saving

Traditional Design PT Slab Design

BBonded Slab Post -Tensioning

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Stressing Anchorage VSL Type SO

Tension ring

Seal

P-plate

Compression fittings

Retainer plate

Dead-End Anchorage VSL Type H

Coupler VSL Type SK

Dead-End Anchorage VSL Type P

Grout tube

Wedges

Strands

Recess former

Flat duct

Anchorage body

Trumpet

Grout tube

Tension ring

Seal

Bulb

Spacer

Flat duct

Grout tube

Sleeve

Compression fittings

Coupling head SK

Strands

Flat duct

Trumpet

Bearing plate

Steel band

WedgesFlat duct

The VSL Monostrand system has advantagessimilar to those of the VSL Bonded Slab Post-Tensioning system.The VSL Monostrand system uses 15 mm (0.6'')diameter strands. The strands are given a coating of permanent corrosion-preventinggrease and are enclosed in an extruded plastic sheath. The grease and plastic providedouble corrosion protection, as well as preventing any bonding between the strands and the surrounding concrete.The plastic sheath is usually in polyethylene or polypropylene with approximately 1 mm wall thickness.The monostrands are installed either singly orin bundles of two, three or four. Each strand isindividually anchored, stressed and locked-off.To ensure continuous corrosion protection,special sleeves are used to join the sheaths to the anchorages and the anchorages areprovided with a protective cap.Monostrands feature factory-applied corrosionprotection, very low friction losses, and permitthe structural depth to be fully utilised. These light, flexible monostrands can be easily and rapidly installed, and because there is no grouting, they usually lead to economical solutions.In design, the different post-cracking behaviourof unbonded versus bonded systems shouldbe considered. Detailed information is given in V S L s " P o s t - Tensioned Slabs" publication.With certain adaptations, the VSL Monostrandsystem can also be used for post-tensioningmasonry walls.

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Monostrand stuctureMonostrands specifications:

l 15-mm (0.6'') diameter strand in accordance with the concerned prestressing steel standards.

l External diameter of the plastic sheath: approximately 18 mm.

l Permanent corrosion-preventing grease and plasticsheath in accordance with FIP or PTI recommendations.

MMonostrand Post -Tensioning

CTC Building - Santiago, Chile

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Monostrand 2

Sleeve Monostrand 1

Coupling body

Coupling head andthreaded coupling

Installation piece

WedgesMonostrand

Sleeve

Anchorage body (casting)

Recess former

Installation nut

Sleeve

Stressing Anchorage:VSL Type S-6

Dead-End Anchorage:VSL Type SF-6

Stressing Jacks

Coupler:VSL Type SK-6

Twin ram jack DKP-6

Centre hole jack ZPE-23FJ

Recommended design va l u e sSpacing of tendon supports: 0.6 to 1.5 mMinimum curvature radius: 2.5 mThe following friction cfficients may be assumed:

= 0.06 (_)k = 0.5 10-3 (m-1)

For standard building slabs, this results in a tendonforce loss of approximately 2.5% per 10 m lengthof monostrand.

Reinforcement of the anchorage zoneIn addition to the slab reinforcement required by the design, additional reinforcement is necessary in the force distribution zone behindeach anchorage. Details should be established by the project engineer. The sketch shows anarrangement which has proved itself in practice.

Anchorage boby (casting)

Monostrand

Sleeve

Closure cap

External post-tensioning is well adapted to bridgesdue to the resulting savings in construction costs andthe high degree of corrosion resistance provided bythe system. External tendons are easy to inspect and,if necessary, replace. They are ideal for strengtheningexisting structures and, apart from their uses in bridges, can be used for a wide range of other applications, including buildings, silos and reservoirs.

VSL External Tendons comprise:

l strand bundle;l polyethylene ducts;l standard multistrand anchorages, and special

anchorages permitting easy tendon re p l a c e m e n t ;l grouting compound.

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Boulonnais Viaducts - France

Bois de Rosset Viaduct - Switzerland

EExternal Post-Tensioning

VSL External Post-Tensioning System Components

Stressing anchorage Strand bundle and sheathing Stressing anchorage

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Saddles at points of deviationA saddle at a point of deviation consists of:

l a structural element capable of carrying the loads exerted by the tendon in the deviation zone;l a part ensuring the geometry of the deviation.

Globally, a saddle at a point of deviation must satisfy the following requirements:l withstand both the longitudinal and transversal forces that the tendon applies to it and transmit these

forces to the structure;l e n s u re, without unacceptable angular breaking, the connection between two straight tendon sections;l unless otherwise stipulated in the contract, enable removal of the tendon without traumatic effect on

the structural elements;l withstand movements of external tendon during stressing without compromising the tendon's

corrosion protection system.

When designing saddles it is important to consider the following:Various solutions have been used in practice, as shown on the sketch. In most cases, saddles consist of a pre-bent steel tube cast into the surrounding concrete or attached to a steel structure by stiffening plates. The connection between the free tendon length and the saddle must be carefully detailed in order not to damage the prestressing steel by sharp angular deviations during stressing and in service. It is also important that the protective sheathing be properly joined.If tendon replacement is a design requirement, the saddle arrangement must be chosen accordingly,i. e. double sheathing as shown on alternative (3) of the sketch.

Minimum tendon radii:Minimum tendon radii as recommended in Table 1 must be respected in order to avoid damage to the prestressing steel and the plastic sheathings, as well as to the outer tubing. It is well-established that friction problems may occur if tendon radii are too small.

Tendon size (VSL tendon unit) Minimum radius (m)up to 5-19 or 6-12 2.50up to 5-31 or 6-19 3.00up to 5-55 or 6-37 4.00

Table 1: recommended minimum tendon radii

Various saddle arrangements

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VSL Stay Cable System SSI 2000

VSL Stay Cable SystemThe VSL Stay Cable system was developed to meetthe stringent design, construction and maintenancerequirements of cable-stayed bridges.

The VSL Stay Cable Systemcomprises:

l a tendon formed from multiple and parallel 15-mm (0.6) dia. high tensile 7-wire steels t r a n d s ;

l a greased or waxed extruded plastic coating to each strand;

l an outer thick-walled plastic stay pipe;l factory prefabricated anchorages.

The system features are asfollows:

l 200 MPa high fatigue resistance at 45% of tendon capacity over 2,000,000 load cycles;

l high degree of corrosion resistance using multi-layer corrosion protection;

l an extruded coating providing excellent strandcorrosion protection during construction;

l individual strand encapsulation and sealing in anchorages;

l easy installation of the strands into the erectedstay pipe (single strand installation);

l all strands are parallel with no risk of twisting;l single strand stressing;l no requirement for on-site cable grouting;l easy tendon force monitoring and adjustment

throughout the cable's service life;l ability to remove and replace individual

strands without dismantling the installedanchorages, or the entire cable at any time;

l system adapted for the future installation of an anti-vibration damper.

SBundle of monostrands

HDPE stay pipe

Grease or wax

PE sheath Strand

Huerfanos Footbridge - Chile

Stay Cables

Transition pipewith individualstrand protection

Guide pipe

Dead-end anchorage

Centering elastomeric device

Individual VSL monostrand and stay pipe

Anchorage head and ring nut

CompactnessThe reduced size of the anchorage componentsallows for easy installation and savings in the cost of structural works.

Aestheticsl using coloured co-extruded stay pipes,

different colours can be obtained;l vibration damping devices can be placed

inside guide pipes or stay pipes.

Dynamic stability of the cabl e sl stay pipes can be equipped with external

helical ribs to suppress rain-wind induced vibrations;

l the stay cable system is adapted for the future installation of anti-vibration dampers.

DurabilityA high degree of corrosion protection:

l each strand is individually protected not only in the stay pipe, but also in the transition part of the anchorage;

l individual anchorage sealing joints protecteach strand not only in service, but also during bridge erection;

l VSL s Stay Cable system has the unique featureof providing complete encapsulation for eachindividual monostrand along the free lengthand into the anchorage. Unlike systems usedby competitors which compromise the encapsulation near the anchorage point andresult in exposure of the entire cable, VSL s StayCable system reduces the potential exposure toa single strand.

Reduced maintenance costsl easy corrosion control of anchorage

components;l good access to vibration damping systems.

Stay cable installationl system optimised for strand-by-strand

installation, with easily handled, lightweightequipment and reduced construction loads on the bridge during construction.

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Val de Rennes - France

Uddevalla Stay Cable Bridge - Sweden

VSL Anchors can be divided into two main categories strand and bar anchors. The type of anchors used depends on whether it is for rock or soil, for temporaryor permanent use, whether or not it is to be tensioned, and whether or not permanent corrosion protection is required.

VSL offers all of these alternatives and can support a full anchor materialsupply service (anchors and accessories) with back-up including designservices, advice, consultancy, testing, installation, tensioning andsite supervision. VSL has obtained ISO 9002 Quality Approvalfor its technology.

The construction of the VSL Strand Anchordepends on the type of application (rock or soil), the design, the corrosiveness of the environment, the pre s e n c eof stray electrical currents and the intended service life. While temporary groundanchors require limited or no corrosion protection, permanent ground anchors(with a service life exceeding two or three years) need to have a comprehensive permanent corrosion protection system.

The anchor construction can beadapted to a wide range of specific requirements.Anchorages can be designed to allow theanchor force to be adjustable,releasable or be used as amonitoring anchor. VSL s rangeof anchors extends from permanent anchors that allow electrical resistance measurementsto be taken to check the integrity ofthe encapsulation during the entire service life, to temporary anchors that can be easily extracted after use. VSL also offers load cells that allow the anchor performance to be monitored.

The anchor shown on this page represents a typical permanent strand anchor with a thick walled polyethylene encapsulation acting as a protective barrier against corrosion.

Temporary anchors are similarly constructed except that, being designed for a shorter service life, corrosionprotection requirements are usually less demanding. The anchor is not normally encapsulated and can takethe form of a bundle of bare strands in contact with grout over the bond length of the anchor.

Both types of anchor systems comprise the anchor with a bearing plate, anchor head and wedges.

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GGround Anchorsspacer

tightly sealed, strong protective cap

corrugated polyethylenesheath in bond length

bare strand spreader

Alternative anchorages

Type ER (adjustable anchorage) / EA

l identical to type EF, but with threaded anchorhead and ring nut;

l depending on the height of the ring nut, theanchorage permits anchor force adjustments;

l minimal strand projection for load checks / force adjustments;

l complete detensioning possible with slightlydifferent features (type EA).

Type EG (control anchorage)

l used for periodical load checks with removable or permanent load cell;

l load checks using a lift-off jacking system.

Type EF (electrically isolated)

l same features as basic EF type but allowsmonitoring of integrity by measuring electricalresistance;

l electrical isolation features can be applied to all other anchorage types as well.

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grout inlet

smooth polyethylenesheath in free length

polyethylene coated and greased strand with tensile / yield strength acc. tolocal requirements

transition from free length (smooth polyethylene sheath)to bond length (corrugated polyethylene sheath)

Type EF (basic anchorage)

l generally used for service anchors;

l force cannot subsequently be adjusted;

l minimal strand projection allows load checks using a lift-off jacking system.

Bajikrachen Rock - Switzerland

protective cap

Electrically Isolated AnchorsThese anchors use tight PE encapsulation combinedwith an electrically non-conductive anchorage isolation.The integrity of the anchor can be checked thro u g h o u tits service life using electrical resistance measure m e n t s .

Force measurementsVSL is able to provide specially developed load cellsfor temporary and permanent control anchors, aswell as for permanent surveillance anchors.The following three types are available:

l type G hydraulic load cell, permanently installed for control anchors;

l type GW hydraulic load cell, used as a removable load cell allowing several permanent anchors to be measured from timeto time by moving the cell from one anchorhead to the other;

l type D electrical load cell, providing supervision of permanent and temporaryanchors and allowing continuous loadmeasuring using either a direct or remotereading system.

All load cell types are fully compatible with the VSL Anchor system.Our scope of services includes consultancy, supplyand installation of load cells, as well as controlanchor readings.

Anchor load checksVSL performs periodic anchor load checks using suitableequipment and competent personnel. This is carriedout by lift-off checks using VSL jacks or the requiredtype GW load cells. These standard load checks canbe carried out on type EG, ER and EA anchorages.With our specially developed APP jacks, we are inthe unique position to carry out lift-off checks on

anchors with type EF anchorages where the anchorhead has no thread and where pro j e c t i n g strandswere cut after installation. The jack has a mechanismto grip standard size anchor heads with up to twelve 0.5-dia. strands or seven 0.6-dia. strands.This allows clients to carry out load checks in situations that, in the past, had been particularly difficult.

Anchor extractionIt is often undesirable to leave temporary anchors inthe ground, particularly in urban areas where theynormally extend into adjacent property. The methoddeveloped by VSL for extracting the free anchorlength is based on a specially designed mechanismlocated at the point where the strand is disconnected.VSL has a long tradition in this special technique, withthousands of anchors successfully extracted.

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Securing a slope

Strengthening of a gravity dam

GGround Anchors

23

The VSoL Retained Earth system is a composite soilreinforcing system that uses welded wire mesh or polymeric strips to resist the horizontal forcesgenerated within an earth backfill. A retained earthstructure is a stable, unified gravity mass that can be designed for use in a wide range of civil engineering applications. The VSoL system is widelyused and accepted as a major construction methodin projects ranging from retaining walls to highwaybridge abutments. The basic retained earth principleinvolves transferring stresses from the soil to the reinforcing elements. In the case of welded wiremesh soil reinforcement, this is achieved by thedevelopment of passive resistance on the projectedarea of the mesh crossbars, which in turn transfersload into the longitudinal bars. In the case of polymeric strip reinforcement, load transfer from the backfill is achieved by the frictional interaction of the soil particles with the polymeric reinforcing strip.

In addition to its high performance level, the VSoL system ensures economical design andconstruction. The system requires only three components: reinforcing elements, precast facingpanels and backfill material. This simplicity results in easy and rapid construction. Cost savings of up to 50% below those of traditional retaining wall systems are regularly achieved.

Fast, easy and economicalThe construction of a VSoL structure is particularlystraightforward. A five-man crew using standardconstruction equipment can place an average of 75 m2 - and as much as 140 m2 - of wall per shift.

Complete servicesVSL advises customers and their consulting engineersduring the feasibility stages of projects, and preparespreliminary design and cost estimates, as well asdetailed designs, drawings and specifications. The company also assists contractors with the pricing of tenders, and provides quotations during tenderstages. Execution of the on-site project can be tailore dto suit the customers' requirements, from a supplyonly arrangement to a full sub-contract agreement.

Complete flexibilityVSoL system concrete facing panels are available in a wide range of shapes, textures and colours.Because local materials are used in the production of these precast panels, the visible exposed surfacecan easily be coloured to match the natural surroundings. Raised relief, sandblasted finish, exposed aggregate, and conventional smooth facec o n c rete re p resent just a few of the available standardretained earth panel finishes. Other facing systems,such as modular blocks, and mesh are also availablefor both permanent and temporary structures.

Eje Prat Road Walls - Chile

F5 Freeway - Australia

VVSoL: VSL Retained Earth System

Architectural Panels

24

Custom engineered solutions for tough jobs

For economic or technical reasons, todays civil engineering structures and industrial plants are oftenassembled from large, heavy, prefabricated components. VSL Heavy Lifting will often provide the most effective solution for projects where cranesor other conventional handling equipment cannotbe used.

Individual solutions VSL can plan lifting, horizontal jacking, or loweringoperations and design the necessary temporarystructures needed to meet your requirements.

Safety The safety of your personnel and works is VSL s first priority. Our specialised hydraulic lifting equipment is designed to provide the highest levelof reliability, and VSL field services are based on atotal commitment to safety.

Flexibility Our equipment includes a large number of hydraulicstrand units, jacks, pumps, control units, monitoringdevices and modular lifting / jacking frames, givingus the capacity to perform virtually any project requiring lifting, lowering or horizontal jacking.

The VSL Service PackageOur approach is flexible, and the range of our services is tailored to the specific project requirements. They include:

l feasibility studies and preliminary consultation;l project design and planning;l design, manufacture, and supply of special

equipment;l leasing of VSL equipment and execution of work.

Malaysia / Singapore Second Crossing

Vereina Tunnel - Klosters,Switzerland

Soccer Stadium - Torino, Italy

HHeavy Lifting

Proven equipment forhandling heavy loadsThe VSL Strand systemThe main components of the VSL Strand system arethe motive unit, the tensile member with the anchorage for the load, and the pump with its contro l s .

Motive unit The motive unit consists of a hydraulic centre holejack with upper and lower anchorages. During lifting the jack is extended, causing the individualstrands of the tensile member to be gripped by theupper anchorage and thus to be moved upwards.At the start of the pistons downward movement, thestrands are immediately gripped by the loweranchorage. In this way, the load is raised using astep-by-step process.For lowering operations, VSL s motive units areequipped with an auxiliary device which automatically controls the opening and closing of the anchorages.

Tensile member The tensile member consists of 7-wire prestressingsteel strands with a 15-mm nominal diameter.The tensile member is anchored to the load by aspecially designed end anchorage.

Hydraulic pumps VSL electro-hydraulic pumps can be manuallycontrolled or operated in groups from a centralcontrol board.VSL has a wide range of pumps with either single ormultiple outlets. The characteristics of these pumpsensure the synchronised movement of the jacks.P re s s u re control devices allow forces to be monitore dat all times. The movement speed varies accordingto the project and, if required, can be in excess of 20 m / hour.

C o n t rol and monitoring systemsThe lifting of hangar roofs or of similar statically overdetermined structures usually requires that liftingmovements be precisely co-ordinated. This is achieved by specially designed, computer-based multi-point monitoring systems, which allowthe operation to be centrally controlled and monitored up to the final, precise height.

Special hydraulic equipmentOur range of equipment also includes a large number of different hydraulic jacks. VSL can also design and supply custom-built hydraulic systems for special applications.

25

Normandie Bridge - France

Burj Al Arab Hotel - Dubai

Autofonage and Autoripageare methods allowing roads and railways to be crossed rapidly with minimum traffic disruption.

The Autoripage system is used when the road ortrack to be crossed can have its traffic interrupted fora period not exceeding 24-72 hours. This perioddepends on the extent of the associated works. The actual slide duration is typically about 6 hours.

The Autofonage system consists of passing a p recast concrete underpass through an embankment,generally bearing a railway or a motorway, withoutinterrupting the traffic. This can be accomplishedeither by using two half structures pulled togetherbeneath a road or a railway, or as a single box structure jacked into position from one side only.

The first Autofonage operation was carried outnear Paris in 1984 and since then the system hasbeen used successfully in a number of Europeancountries. VSL has worked closely on projects withSNCF (French Railways), SNCB (Belgian Railways),Railtrack (British Rail) and Portuguese Railways.The sliding operation uses motive units of the VSLstrand system. The equipment is operated by VSLand provides a continuous, rapid, accurate and reliable pulling operation. The displacement ofthe concrete structure displays information aboutthe structure position on monitoring screens placed alongside the system operators.This system can be used for structures weighingin excess of 5,000 t., and the accuracy of thefinal positioning is approximately one centimetrein all three axes.

Considerable improvements have been made to thesystem over the last decade and owners, engineersand contractors can now benefit from these developments that have led to work being carriedout rapidly, efficiently and economically.

26

Troyes West Diversion - France

Francilienne Highway Underpass - Louvres,France

AAutofonage and Autoripage MethodsA26 - Yvetot,France

27

VSL has been active in climbforms forover 15 years, first in Australia, thenAsia and, more recently, Europe. Thesystem has consistently proven itselfover this period. Constant developmentsand improvements made followingsuggestions from contractors have ledto VSL Climbform achieving the highlevel of standards needed to meettodays requirements. The system is particularly adapted to the constructionof high-rise building cores.

VSL Climbform systemThe 6-m high VSL Climbform has three platformlevels, and the formwork panels hanging from theexternal frame and internal platforms permit poursover a height of 4.2 m. The external frame is assembled from standardisedsteel components and others components which arespecific to each project and designed by ourTechnical Centres. The internal steel platforms, incorporating the formpanel hooks and rollers, arespecifically designed and manufactured for eachproject - guaranteeing accurate and economicassembly operations. The climbform is raised using a number of hydraulic jack systems, including telescopic jacks, climbrams, long stroke jacks, androd jacks. It takes approximately one hour to raisethe climbform system up to the next level. The external frame construction cycle depends onseveral factors but generally takes around 3 to 4 days per level.

AdvantagesVSL Climbform permits an excellent production rate.It permits the accurate placing of door frames, openings, blockouts and cast-in components. VSL Climbform also offers the direct placing of prefabricated reinforcement cages.Another advantage lies in the safety of the climbform. This is achieved through the use of wide platforms and the methods used to providethe best possible access to the different frameworkcomponents.

VSL PackageThe VSL service package generally includes:

l feasibility studies and preliminary consultationand pricing;

l tender design and planning;l design, manufacture and supply of

equipment;l leasing of VSL equipment, training of site-staff,

supervision of the works for the first few levels,followed by dismantling operations.

CClimbformCoeur Dfense - Paris,France

Central Plaza - Hong Kong

Bar technologyVSL has been manufacturing and designing bars forthe Construction Industry since 1971.VSL has now decided to widen its range of bar products by adding an extensive list of hot-rolledhigh performance products to the original VSL cold-rolled bars.

VSL s new product line complies with most international standards, including DIN, BS, ASTM, etc.VSL Bar systems are specifically designed to suit allgeotechnical applications as well as civil works andbuilding applications.

28

BLainzer Tunnel - A u s t r i a

Productreference

Y1030H26.5R-RY1030H32R-RY1030H36R-R

Y 1 0 3 0 H 2 6 . 5 R - R( * )

Y1030H32R-R(*)

Y1030H36R-R(*)

Y1030H40R-R(*)

Y 1 0 5 0 H 1 8 R - R( * ) ( * * )

Y 1 0 5 0 H 2 6 R - R( * )

Y 1 0 5 0 H 3 2 R - R( * )

Y 1 0 5 0 H 3 6 R - R( * )

Y 1 0 5 0 H 4 0 R - R( * ) ( * * )

Y1230H26.5R-RY1230H32R-RY1230H36R-R

Diameter(int. / ext.)

d/da(mm)/(mm)

26.5/3032/3636/40

26.5/3032/3636/4040/44

18/2126/2932/3636/4040/44

26.5/3032/3636/40

Crosssection area

A(mm2)

551804

1,020

551804

1,0201,257

254531804

1,0201,257

551804

1,020

StrengthYield/tensile

f0.1k/ftk(MPa)/(MPa)835/1,030835/1,030835/1,030

900/1,030900/1,030900/1,030900/1,030

950/1,050950/1,050950/1,050950/1,050950/1,050

1,080/1,2301,080/1,2301,080/1,230

Yield load

F0.1k(kN)

460671850

496724916

1,131

240500760960

1,190

595868

1,099

Tensile load

Ftk(kN)

568828

1,049

568828

1,0491,295

270560850

1,0701,320

678989

1,252

Weight

G(kg/m)

4.486.538.27

4.486.538.27

10.2

2.064.316.538.27

10.2

4.486.538.27

Productreference

B500H20R-LB500H25R-LB500H28R-LB500H32R-LB500H40R-LB500H50R-L

S555H63.5R-L

S670H18R-RS670H22R-RS670H25R-RS670H28R-RS670H30R-RS670H35R-RS670H43R-R

S680H57.5R-RS680H63.5R-R

Diameter

d/da(mm)/(mm)

20/2325/2828/3232/3640/4550/5563/68

18/2022/2525/2828/3130/3335/3843/47

57.5/6163.5/68

Crosssection area

A(mm2)

314491616804

1,2601,9603,167

250380491616720962

1,4662,5973,167

StrengthYield/tensile

f0.2k/ftk(MPa)/(MPa)

500/550500/550500/550500/550500/550500/550555/700

670/780670/780670/780670/780670/780670/780670/780680/850680/850

Yield load

F0 . 2 k(kN)

160245310405630980

1,760

160240320400480640980

1,7602,150

Tensile load

Ftk(kN)

175270340440690

1,0802,215

185280370460560750

1,1302,2002,600

Weight

G(kg/m)

2.473.854.836.319.87

15.424.85

1.962.983.854.835.657.55

11.5120.3824.86

Bar Systems

(*) Water cooled fabrication process(**) Availability upon request

29

Rock Boltsl stabilising galleries during excavationsl stabilising unstable rock/soill flexible attachment thanks to the high level of steel elongation/ductilityl a range of different anchoring systemsl grouted, resin anchors, expansion shellsl a large number of special accessories

Soil Nailsl slope stabilisationl retaining wall strengtheningl flexible attachment thanks to the high level of steel elongation/ductility,

permitting soil movementl permanent and temporary use

Micropilesl foundations (compressive load)l tensile piles (tensile load)l ideal for alternating tensile and compressive loadingsl securing of building foundation walls, embankments, compacted soil

areas, high-rise buildings, structures in seismic areas

Ground Anchorsl tie-backsl retaining wallsl stabilising deep excavations, anchoring tower cranesl permanent and temporary use

Tie Rodsl tie-backsl retaining wallsl sea wallsl permanent and temporary use

Reinforcementsl DIN 488 accreditation for B500 steel qualityl convenient for coupling through the use of continuous threadingl efficient coupling solution in areas where there are too many steel componentsl alternative to shear studs

Stress Barsl high performance for forces

ranging from 270 to 1,320 kNl prestressed/post-tensioned

concrete structuresl strengthening of buildingsl temporary prestressing

and bracing

Westbound Off-Ramp to Western A rterial Road - A u s t r a l i a

Form Tiesl same production quality level

as high grade stress barsl additional steel qualities, e.g.

St 1,000/1,100 (weldable,high ductility, suitable for lowtemperatures), S850/900 steelwith cold-rolled thread

l accessories to suit all assemblysituations

G e n e r a l l y, structural bearings are required to connect differentparts of a given structure, such as abridge deck to piers and abutments.The most widely used structural bearings are plain or reinforced elastomeric bearings, and pot bearings. They are capable of transmitting forces while absorbingthe structures deformations and rotations. The strength of reinforced elastomeric bearings is limited by the shear properties of the elastomeric block, especially when compression, shear and bending occur at the same time. Pot bearings maximise the shearstrength of the bearings elastomerby encasing it in a steel cylinder.

30

l TOP PLATEQuality steel St37 or St52according to DIN 17.100

l Stainless steel according to AISI 304

l LUBRICANTSilicone grease type 300l P.T.F.E. P.T.F.E. pad with dimples accordingto ASTM D1457-91a Type 1Grade 2 BS 3784 Grade Al GUIDEQuality steel St37 or St52 according to DIN 17.100

l EXTERNAL SEALING RINGSpongy neoprenel PISTONQuality steel St37 or St52 according to DIN 17.100

l INTERNAL SEALING RINGDouble gasket brass ring

l ELASTOMER PADNatural rubber accordingto AASHTO 50Sh5

Pot bearingType PU

SStructural Bearings

Pot bearings for incrementally launched bridges have adual function. First, they provide low friction sliding surfacesover piers as the deck is pushed during construction.Thereafter, they become permanent bearings for thecompleted bridge. A pot bearing serving both functionsis shown in the picture above. During construction, a fixing device avoids relative movement between the sliding plate and the pot cylinder.

The sliding plate is equipped with an upper stainlesssteel panel. This is followed by the insertion of neoprene-teflon padsbetween the deck and structural bearings which allowsthe launching operation to be carried out. The pads,upper stainless steel panel and fixing device are removedafter launching. Finally, the sliding plate is connected toa previously embedded steel plate in the deck.

l POT (STEEL RING + BASE PLATE)Quality steel St37 or St52 according to DIN 17.100

l ANCHOR SOCKETSGalvanized boltsSteel CK35 according to DIN 17.200

Pot bearings for incrementally launched bridges

Pot bearing for incrementallylaunched bridges

l DU-metal

The Company 2

Multistrand Post-Tensioning 4

Bonded Slab Post-Tensioning 11

Monostrand Post-Tensioning 14

External Post-Tensioning 16

Stay Cables 18

Ground Anchors 20

VSoL: VSL Retained Earth system 23

Heavy Lifting 24

Autofonage and Autoripage methods 26

Climbform 27

Bar Systems 28

Structural Bearings 30

PHOTO CREDIT:Desair-Foto, Photo Gasser,Y. Chanoit,Bouygues photo bankSaudi Archirodon,Dar-Al-Handasah,X.

Your solution network

Australia /Pacific territories

REGIONAL OFFICEVSL Pre s t ressing (Aust.) Pty. Ltd. 6 Pioneer AvenueTHORNLEIGH, NSW 2120AUSTRALIAPhone: +61 - 2 - 9484 59 44Fax: +61 - 2 - 9875 38 94

AUSTRALIA - QueenslandVSL Pre s t ressing (Aust.) Pty. Ltd.GEEBUNGPhone: +61 - 7 - 326 564 00Fax: +61 - 7 - 326 575 34

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AUSTRALIA - S o u t h e rn DivisionVSL Pre s t ressing (Aust.) Pty. Ltd.NOBLE PARKPhone: +61 - 3 - 979 503 66Fax: +61 - 3 - 979 505 47

GUAMStructural Technologies Inc.TUMONPhone: +67 - 1 - 646 80 10Fax: +67 - 1 - 646 80 60

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We s t e rn Europe, Africa and Latin America

REGIONAL OFFICELOdysse - Bt. A2-12 Chemin des Femmes91886 MASSY CedexFRANCEPhone: +33 - 1 - 69 19 43 00Fax: +33 - 1 - 69 19 43 01

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REGIONAL OFFICEVSL North East Asia3/F Stelux House698 Prince Edward Road EastSan Po Kong / KowloonHONG KONGPhone: +852 - 2590 22 22Fax: +852 - 2590 95 93

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REGIONAL OFFICEVSL Singapore Pte. Ltd.75 Bukit Timah Road04-08 Boon Siew BuildingSingapore 229833 SINGAPOREPhone: +65 336 29 23Fax: +65 337 64 61

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- 381 827Fax: +673 - 2 - 381 954

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