Freyssinet Prestressing

The system of the inventor of prestressed concrete

D E S I G N , B U I L D , M A I N T A I N
C Range 4
High strength prestressing 4
Active anchorages 7 High durability prestressing
Application categories 8
Couplers 10 Freyssinet Australia has been providing solutions for building
Passive anchorages 12 post-tensioning, specialised civil and remedial engineering for
Spacing and edge distance 13 more than fifty years in Australia, New Zealand, Papua New
Anti-burst reinforcement 14
Guinea and the neighbouring islands of the Pacific Ocean.
S Range 16 We inherited the tradition of technical excellence and attention
Slab prestressing anchorage 16 to detail from our founder Eugène Freyssinet, who made his first
Application categories 16 experiments on prestressed concrete in 1906 and took out a
Components 16 patent for prestressing in 1928.
Active anchorages 17
Spacing and edge distance 18 Since then, Freyssinet has pioneered the use of high-strength
Anti-burst reinforcement 19 prestressing wire and has continually innovated over the years,
to now offer the best prestressing system combining high
Components common to C and S Ranges 20 performance, durability and flexibility that can be applied to
Prestressing strands 20 many different types of structures.
Ducts 21
Geometry 22
Freyssinet prestressing anchors from the C Range, F Range and
Losses and friction 22 the S Range have been proven in structures over the world to
Injection products 23 comply with the most stringent requirements: bridge decks
and piers, nuclear reactor containment vessels, liquefied natural
Installation 24 gas storage tanks, offshore platforms, wind towers, building
Tensioning C Range 25 slabs etc. With the X Range and the R Range, Freyssinet has
Tensioning S Range 27 also designed optimised solutions for existing structure
Recess 27 strengthening applications as well as a full range of Freyssibar
Injection and sealing 28
pre-stressing bars and fittings.
F Range 30 In order to guarantee the best quality of service to all of its
Anchors for thin elements 30 clients around the world, Freyssinet manufactures its anchors at
Bonded Internal Prestressing 31 its industrial subsidiary FPC (Freyssinet Product Company) and
Unbonded internal prestressing with operates a central bank of site equipment.
greased sheathed strands 32
C1 single-strand fixed couplers 33 Because workmanship is essential to the quality and durability,
Layout for F Range anchors 34 Freyssinet trains its teams in properly installing and grouting
Hoop reinforcement for F Range anchors 35 post-tensioning. Each year, operators, prestressing installation
Embedded anchors for F Range 36 specialists, supervisors and engineers obtain qualifications
certifying their skills, to Freyssinet standards as well as local
R Range 37
authority requirements.
External monostrand anchorage 37
Application categories 37
Components 38
Anchorage 38 Freyssinet Australia has an
Corrosion protection 39 experienced team of Approved
Geometry 39 RMS Supervisors.
X Range 40
External hoop tendon anchorage 40
Application categories 40
Components 40
Corrosion protection 41
1X15 anchorage 41
2X15 anchorage 42

Freyssibar 43
Technology 43
Installation 45
Characteristics 46
Anti-burst reinforcement 49
Ground and rock anchors 50 Freyssinet Australia & New Zealand’s management system certifications

2
 EUROPEAN TECHNICAL APPROVAL (ETA)
Freyssinet has been granted European Technical Approvals (ETA) for its prestressing
anchorage ranges:
• C Range for 3 to 55 strand tendons (ETA 06/0226)
• B Range for 1 to 5 strand tendons (ETA 11/0172)
• F Range for 1 to 4 strand tendons (ETA 06/0226)
• X Range for 1 to 2 strand tendons (ETA 06/0226)
The European Technical Approvals were issued in particular after performance
of the tests defined in ETAG 013 (European Technical Approval Guidelines for
post-tensioning kits for prestressing of structures). ETA is subject to continuous
monitoring by an official body.
Freyssinet is also the holder of the European Technical Approval (ETA) n° ETA 09/0169
for the Freyssibar post-tensioning kit for prestressing of structures.
ETA 013 -
“European The Freyssibar flat anchorages and couplers for fully threaded bars up to 50mm
Technical
Approval” are approved to the requirements of ETAG 013 (with exception of 29mm diameter).

ETA 09/0169 -
“European
Technical
Approval”

Testing facility

C Range stressing blocks

For confirmation of Prestressing and Bar Products approved by RMS (Roads &
Maritime Services, NSW) or TMR (Department of Transport & Main Roads, QLD)
their respective approval lists should be consulted.

The S Range as defined in this brochure is used in Australia and New Zealand in
lieu of the B Range. The S Range is not ETA approved.

The R Range 1R15 as defined in this brochure is approved for use with the NZTA
(New Zealand Transport Authority) with a design life of 50+ years, and has been
successfully used with project specific approval on RMS and VicRoads projects
in Australia.

3
 C RANGE HIGH STRENGTH PRESTRESSING

Introduction
The C Range prestressing system is designed and certified for a wide range of applications:
• 15.2 mm and 15.7 mm diameter strands, grade 1770 MPa to 1860 MPa including galvanised strands or greased and sheathed strands,
• prestressing units holding up to 55 strands.
The system can be used in internal or external prestressing for concrete, steel, timber or brick structures:
• bonded or unbonded
• with or without ducts
• retensioning possible
• replaceable
• adjustable
• detensioning possible
• with electrical insulation
• for cryogenic applications

Internal prestressing

Bonded Unbonded
C RANGE

With duct Without duct With duct

Bare strands Greased and sheathed Greased and sheathed Bare strands
strands strands
Cement grout Cement grout Wax, grease

p8 - reference AnC15 p8 - reference AnC15Gi

Cryogenic Restressable*** Restressable*** Restressable***

Leaktight* Replaceable Replaceable Replaceable
Electrically insulated** Encapsulated Encapsulated* Encapsulated*
* if there is continuous encapsulated sheathing ** given special provisions - page 9 *** if strand overlengths are stressed

Bonded internal prestressing configurations

The most common use of C Range anchors in bonded internal prestressing
is based on the use of bare strands in a steel corrugated duct, galvanised or
ungalvanised, bendable by hand and injected with cement grout after tensioning
of the strands. In curved sections and to reduce the coefficient of friction
between the strands and the sheath, Freyssinet offers factory lubrication of the
steel corrugated sheath using a unique Freyssinet process known as LFC.
To increase the durability of the prestressing or for applications in very aggressive
environments in terms of corrosion of prestressing steel, it can be advantageous
to encapsulate the tendon with a plastic sheath (as well as its interconnections).
Freyssinet has developed the Plyduct® prestressing duct, a HDPE sheath with
a corrugated profile to ensure bonding of the tendon to the structure. Sheath
Internal bonded prestressing, blisters for tendon lapping
thickness is chosen depending on the lateral pressure exerted in the curved
sections and the movement of the strands during tensioning.

4
 C RANGE HIGH STRENGTH PRESTRESSING
For encapsulated tendons on marine structures, Freyssinet also offers a steel
duct made up of thick, plain steel tubes with robust joints created by lapping and
resin sealed, by means of a heat-shrink sleeve.
For structures made of precast elements with match-cast joints, Freyssinet
has developed the Liaseal® sheath coupler. This plastic coupler is watertight to
prevent seepage of water between segment joints.
For each configuration there is an appropriate anchor head protection
method by injection with the same protection product as used in the main run
of the tendon. This can be done either by sealing (concreting the anchor head
into a recess) or via a permanent cover made of cast iron (galvanised or painted)
Bolte Bridge, Melbourne, Australia
or plastic.
To protect tendons from stray currents or for electrical checks on
watertightness of plastic sheaths, Freyssinet offers an electrically insulated
prestressing system. This is based on the use of an insulating plate under the
anchor head with a plastic sheath and cover to create a permanent, watertight
casing completely enclosing the strands.

Pluto LNG, Karratha, Australia

Unbonded internal prestressing configurations
Unbonded prestressing tendons are mainly used in applications where the
tension of the tendon needs to be measured, or where it may need to be
retensioned, detensioned or replaced.
To achieve unbonded prestressing it is possible simply to use a flexible,
corrosion-resistant protective product instead of the cement grout, normally
grease or wax, specially designed for this purpose. Special processes are then
followed to detect any leakage along the ducts.
To increase the durability of the prestressing by using a number of corrosion
protection barriers or to allow, for example, for individual strands to be
replaced, Freyssinet recommends the use of greased and sheathed strands.
Karuah Bypass Bridge, Australia These greased and sheathed strands can be placed inside a duct injected
with cement grout before tensioning of the tendon or incorporated directly
into the reinforcement before concreting.

External post-tensioning with greased and sheathed strands,

Pheasants Nest Bridge, Australia

Iron Cove Bridge, Sydney, Australia

5
 C RANGE HIGH STRENGTH PRESTRESSING

External prestressing

Unbonded (replaceable)

Plastic duct
Greased and sheathed strands being winched through

Greased and sheathed strands Bare strands

Cement grout Cement grout Wax, grease, etc.

p8 - reference p9 - reference p9 - reference

ADnC15Gi ADnC15 ADnC15W

Restressable*** Replaceable Restressable***

Replaceable Encapsulated* Replaceable
Encapsulated Electrically insulated** Encapsulated*
Electrically insulated**
C RANGE

* if there is a continuous encapsulated duct

** given special provisions - page 9
*** if strand overlengths are stressed
External prestressing, Western Link, Melbourne, Australia

External prestressing configurations

External prestressing is well suited to structures made of thin concrete and also
allows for easy inspection of the main run of the tendons.
The most common use of C Range anchors in external prestressing is based on
the use of bare strands placed inside sections of thick HDPE ducts assembled
by mirror welding, which are injected with cement grout after tensioning of the
tendon.
To ensure that the external prestressing can be removed without damaging the
structure, the tendons are passing through a double tubing, at deviator and end
block. The HDPE ducts run inside a formwork tube that separates the tendon from
the structure and distributes the transverse loads caused by local deviation.
To produce tendons in which the strands are independent from each other,
External prestressing, West Gate Bridge, Melbourne, Australia Freyssinet recommends using greased and sheathed strands placed in a duct
injected with cement grout before tensioning of the tendon. This configuration
has the advantage of increasing the durability of the prestressing by increasing the
number of barriers against corrosion, by making each strand independent from
each other such that the breakage of one strand doesn’t affect the force in the
remaining strands and by allowing for individual strands to be replaced if needed.
Another solution involves injecting the tendon with a flexible corrosion-resistant
protective product, such as grease or wax specially designed for this purpose.
Special care must be taken when hot-injecting these products.

6
 C RANGE HIGH STRENGTH PRESTRESSING
ACTIVE
ANCHORAGES
Composition
Each anchor consists of:
• Freyssinet “Unigrip” wedges (with high performances for strand anchorage under
static or dynamic loading),
• anchorage block (circular steel block drilled with conical holes to suit the shape of the
wedges),
• trumplate (multi-ribbed cast iron component for improved distribution of the
prestressing force into the concrete),
• grout cap (temporary or permanent - optional).

Compact anchorage
The small size of the C Range anchor allows for:
Central hole anchor units • reducing the thickness of the flanges and webs in a box girder,

3C15*
• improved concentration of anchors at tendon termination,
• minimal strand deviation. Injection vent
Wedge Trumplate
4C15* Duct

7C15

Strands
13C15

Anchor nC15
19C15 Anchor block

E Grout cap
Kxn (optional)

25C15
A
E

31C15 C

B H C

Units A B C D E H Kxn
(mm) (mm) (mm) (mm) (mm) (mm) (mm)

37C15 3C15 150 110 120 85 91 50 M10x2

4C15 150 120 125 95 101 50 M10x2
7C15 180 150 186 110 128 55 M12x2
13C15 250 210 246 160 168 70 M12x4
19C15 300 250 256 185 208 80 M12x4
55C15 25C15 360 300 400 230 268 95 M16x4
31C15 385 320 346 230 268 105 M16x4
37C15 420 350 466 255 300 110 M16x4
* Configuration of strands in anchor without central holes -
55C15 510 420 516 300 370 145 M20x4
other units without a central hole are available on request

7
 C RANGE HIGH STRENGTH PRESTRESSING
APPLICATION
CATEGORIES ID: Inside Diameter
OD: Outside Diameter
Ø1: Main Duct
For bonded internal prestressing with bare strands with cement grouting Ø2: Transitional Duct

ID ID
AnC15 Units Ø1 Ø2
Steel corrugated duct Ø1 (mm) (mm)
3C15 40 45
4C15 45 50
7C15 60 65

Ø1

Ø2
13C15 80 85
19C15 95 100
25C15 110 115
Steel corrugated duct Ø2 31C15 120 125
Oversleeve
37C15 130 135
55C15 160 165

For unbonded internal prestressing with greased and sheathed strands with cement grouting
C RANGE

(before tensioning) ID OD
N
Units Ø1 Ø2
AnC15Gi (mm)
(mm) (mm)
Steel corrugated duct Ø1 3C15 40 76.1 3.6
4C15 65 88.9 4.0
7C15 65 101.6 4.0
Ø2 x N

13C15 95 114.3 3.2

Ø1

19C15 115 139.7 5.0

25C15 130 165.1 5.4
31C15 145 168.3 4.8
Steel tube Ø2 x N
37C15 145 168.3 4.8

For unbonded external prestressing with greased and sheathed strands with cement grouting
(before tensioning) OD OD
E N
Units Ø1 Ø2
(mm) (mm)
(mm) (mm)

ADnC15Gi 3C15 63 4.7 76.1 3.6

HDPE duct Ø1 x E 4C15 75 5.5 88.9 4.0
7C15 90 6.6 101.6 4.0
13C15 110 5.3 114.3 3.2
19C15 125 6.0 139.7 5.0
Ø2 x N
Ø1 x E

25C15 140 6.7 165.1 5.4

31C15 160 7.7 168.3 4.8
37C15 160 7.7 168.3 4.8
Steel tube Ø2 x N
55C15 200 9.6 219.1 6.4

8
 C RANGE HIGH STRENGTH PRESTRESSING

ID: Inside Diameter

OD: Outside Diameter
Ø1: Main Duct
Ø2: Transitional Duct For unbonded external prestressing with bare strands with cement grouting

OD OD
E N
Units Ø1 Ø2 ADnC15 HDPE duct Ø1 x E
(mm) (mm)
(mm) (mm) HDPE trumpet
3C15 50 3.7 76.1 3.6
4C15 63 4.7 88.9 4.0
7C15 63 4.7 101.6 4.0

Ø2 x N
Ø1 x E
13C15 90 6.6 114.3 3.2
19C15 110 5.3 139.7 5.0
25C15 125 6.0 165.1 5.4
31C15 140 6.7 168.3 4.8 Steel tube Ø2 x N
37C15 140 6.7 168.3 4.8

For unbonded external prestressing with bare strands with injection of flexible product
OD OD
E N
Units Ø1 Ø2
(mm) (mm) ADnC15W
(mm) (mm) HDPE duct Ø1 x E
3C15 50 3.7 76.1 3.6 HDPE trumpet

4C15 63 4.7 88.9 4.0

7C15 63 4.7 101.6 4.0

Ø2 x N
Ø1 x E
13C15 90 6.6 114.3 3.2
19C15 110 8.1 139.7 5.0
25C15 125 9.2 165.1 5.4
31C15 140 10.3 168.3 4.8
Steel tube Ø2 x N
37C15 140 10.3 168.3 4.8

For prestressing with electrical insulation

ID ID Tendons with C Range anchors can be enclosed in continuous non-conductive sheathing
Units Ø1 Ø2 to obtain an electrically insulated prestressing system. Typical applications are railway
(mm) (mm)
structures where stray currents can compromise tendon durability.
3C15 40 45
4C15 45 50
Insulating plate
7C15 60 65 HDPE trumpet Plyduct sheath
13C15 80 85
19C15 95 100
25C15 110 115
Ø2

Ø1

31C15 120 125

37C15 130 135
55C15 160 165
Cement grout or wax/grease

9
 C RANGE HIGH STRENGTH PRESTRESSING
CU AND CC FIXED
MULTI-STRAND Couplers are needed when a continuous structure is built in successive phases with primary
tendons already in place, tensioned and grouted in the previous segment. They are generally
COUPLERS used in internal prestressing. Two types of multistrand couplers are available:

CU couplers
For these CU couplers, the stressing block of the primary tendon is modified to receive the
anchoring wedges of the secondary tendon. The assembly is protected by a cover with a
trumpet at one end to provide the connection with the duct of the secondary tendon. The
CU couplers are covered by European Technical Approval ETA-10/0326.

L E H ØP ØD ØG
Units
(mm) (mm) (mm) (mm) (mm) (mm)

CU 3C15 410 120 150 146 140 40

CU 4C15 415 127 155 156 150 45

CU 7C15 615 120 275 206 200 60

CU 13C15 775 130 435 282 276 80

CU 19C15 785 140 445 312 306 95

CU 25C15 891 145 561 352 346 110

CU 31C15 1030 150 690 362 356 120 L

Coupler cover Coupler anchor head CU nC15

CU 37C15 1060 156 720 392 386 130
C RANGE

ØP
ØG

ØD

E
H
Steel corrugated duct
Anchor nC15

CC couplers
For these CC couplers, a notched collar is inserted between the trumplate and the
stressing block of the primary tendon. The secondary tendon is attached by means of
swages resting onto the collar.

L E MxN* ØP ØG
Units
(mm) (mm) (mm) (mm) (mm)

CC 3C15** 570 10 220 x 220 210 40

CC 4C15** 600 10 240 x 240 220 45

CC 7C15** 670 10 260 x 260 230 60

CC 13C15 770 10 290 x 290 275 80

CC 19C15 825 12 320 x 320 305 95

E
CC 25C15 900 5 360 x 360 340 110
Coupler anchor head CC nC15
CC 31C15 1110 5 420 x 420 400 120 Coupler cover

* Dimensions of the retaining plate.

** Available on request.
ØG

ØP

MxN

L
Anchor nC15
Anchorage block

10
 C RANGE HIGH STRENGTH PRESTRESSING
CI FIXED
MONO-STRAND
COUPLERS
CI couplers
CI fixed couplers allow for a secondary tendon to be connected to a primary
tendon using machined monostrand couplers with automatic locking by a spring
inserted between the two opposing wedges. The primary anchor is a typical C
Range anchor. The monostrand couplers are staggered to offer a very compact
configuration.

X3

X2
Coupler cover
Steel corrugated duct Outside diameter ØP X1
Inside Diameter ØD

Monostrand couplers Seal Anchor nC15

N

Monostrand couplers

ØD ØP X1 X2 X3
Units M (mm) N (mm)
(mm) (mm) (mm) (mm) (mm)
CI 3C15 40 1,050 1,000 102 250 500 750

CI 4C15 45 1,050 1,000 127 250 500 750

CI 7C15 60 1,050 1,000 127 250 500 750

CI 13C15 80 1,200 1,150 219 300 550 800

CI 19C15 95 1,200 1,150 219 300 550 800

CI 25C15 110 1,250 1,200 273 350 600 850

CI 31C15 120 1,350 1,300 273 400 650 900

Coupler cover installed
CI 37C15 130 1,530 1,480 324 400 650 900

3C15 4C15 7C15 13C15

Coupled tendons 19C15 25C15 31C15 37C15

11
 C RANGE HIGH STRENGTH PRESTRESSING
PASSIVE There are two types of cast in passive anchorages, embedded into concrete and used
ANCHORAGES in combination with C Range active anchorages: NB and DE. In both cases, strands are
installed before concreting.

NB anchorage
NB anchorages comprise of a stressing block drilled with cylindrical holes and on which
swages are maintained by a retaining plate.

T15 DC sleeve
NB nC15 block
AnC15 trumplate
A B C D H G J Sheath (steel or plastic)
Units Kxn
(mm) (mm) (mm) (mm) (mm) (mm) (mm)

3C15 150 110 120* 85 50 40** 91 M10x2

øD

G
4C15 150 120 125* 95 50 45*** 101 M10x2

7C15 180 150 186 110 55 60 128 M12x2 H C

13C15 250 210 246 160 70 80 168 M12x4

19C15 300 250 256 185 80 95 208 M12x4 J

25C15 360 300 400 230 95 110 268 M16x4 Kxn

31C15 385 320 346 230 105 120 268 M16x4

C RANGE

37C15 420 350 466 255 110 130 300 M16x4 A J

55C15 510 420 516 300 145 160 370 M20x4

* 2-stage trumplate ** Oval duct version 58x21

*** Oval duct version 75x21
B

DE anchorage
DE (for Dead End) passive anchors are installed together with the strands, the ducts and
the steel reinforcements inside the formwork before concreting. They are inaccessible
once concrete is poured and during tensioning. DE anchors are made of a steel plate and
swages or pre-blocked barrels and wedges (power seating load shall not be less than 75%
of the strand load). Adequate local reinforcements shall be designed and installed around
the anchorage as per AS-5100.5 section 12.2.

H J
Units
(mm) (mm) Grout vent
3C15 120 300 Distribution plate
Swages or power seated
16mm thick Steel corrugated duct
barrel and wedge
4C15 140 300
7C15 180 400 Denso mastic + denso tape
13C15 245 600
19C15 300 800 H
25C15 340 950
31C15 380 1100
37C15 420 1200
H 60 mm J

12
 C RANGE HIGH STRENGTH PRESTRESSING
LAYOUTS OF
C RANGE
ANCHORS
The anchors must be positioned at an adequate distance from the wall and spaced at a
minimum centre-to-centre distance. These distances are obtained using dimensions a
and b of the test assemblies created under the European Technical Approval procedure.
In the following, it is taken that the anchors are positioned along two normal direction
axes: x and y, with the short side of the trumplate aligned on the y axis.

Notation
• A, B: plane dimensions of the trumplate ( A ≥ B ).
• a, b: side lengths of test specimen ( a ≥ b ).
• x, y: minimum centre distance between two anchorages in the structure in x and y
directions.
• x’, y’: minimum edge distance between anchorages and the closest external
surface in x and y directions.
• fcm,o: mean compressive strength measured on cylinder required before tensioning.

Dimensions x and y must

x‘ x‘
meet the following conditions:
A
x ≥ A + 30 (mm)
x x
y ≥ B + 30 (mm)
x.y≥a•b
x ≥ 0.85 a
y ≥ 0.85 b
x’ ≥ 0.5 x + concrete cover — 10 (mm)
y’ ≥ 0.5 y + concrete cover — 10 (mm)
y‘ y‘ y y‘

Distances a and b

a=b (mm) Values a and b are given in the table opposite, for three different classes of concrete
strength fcm,o.
fcm,0 (MPa)
Units
24 44 60 If, for fcm,o, the design provides for a value other than the values given in the table,
3C15 220 200 180 straight-line interpolation can be used to determine the x and y values. However,
4C15 250 220 200 tensioning cannot be carried out at full force if fcm,o is lower than the lowest of the
7C15 330 260 240 values given in the tables opposite.
13C15 450 340 310
If the design provides for partial tensioning or a tensioning rate of less than min
19C15 530 400 380
[0.8 Fpk ; 0.9 Fp0.1% ], interpolation can be used to determine the required value of
25C15 630 460 440
fcm,o, given that at 50% of full force, the required strength for the concrete can be
31C15 690 520 500
brought to 2/3 of the values given in the two previous tables and that at 30% of
37C15 750 580 540
this force, the required strength for the concrete can be brought down to half of the
55C15 1070 750 690
values shown.

13
 C RANGE HIGH STRENGTH PRESTRESSING
ANTI-BURST
REINFORCEMENT
In anchorage zone, prestressing tendons impose to the structure concentrated
forces requiring a specific arrangement of reinforcement. The C Range anchors
use trumplates with three load spreading layers. These ribbed anchors are more
compact than single plate anchors and are not covered by AS 5100.5 - 12.2 for
bursting forces calculation.
Anti-burst reinforcement as defined hereunder results from load transfer testing.
Outside Diameter D
It consists of the superimposition of:
C0 • Helical steel,
• Additional reinforcement.
S
P Helical steel and additional reinforcements are defined in the tables below.
The shape of the additional reinforcement has to be designed to suit the concrete
d
outlines around the anchorage and are generally made of rectangular stirrups.
F The tables below have been adapted from Freyssinet European Technical Approval
to reinforcement bars readily available in Australia.
Helical steel and additional reinforcement
The reinforcements detailed in the tables must, in most cases be supplemented
by general reinforcement ensuring the general balance of the anchorage zones.
With regards to multiple eccentric anchorages and spalling reinforcements, refer
to Appendix G of AS-5100.5 called End Zones for prestressing anchorages.
C RANGE

Complementary Stirrups Complementary Stirrups

Type Helical Bursting Steel (grade R250N) Type Helical Bursting Steel (grade R250N)
(grade D500N) (grade D500N)
Pitch Bar Concrete External Bar Pitch Bar Concrete External Bar
Anchor Number Pitch Number Anchor Number Pitch Number
P Dia. cover Dia. Dia. P Dia. cover Dia. Dia.
(-) (-) (mm) (-) (-) (-) (mm) (-)
(mm) d (mm) C0 (mm) D (mm) F (mm) (mm) d (mm) C0 (mm) D (mm) F (mm)
3C15 50 10 5 40 160 110 10 3 3C15 50 10 5 40 150 150 10 2
4C15 60 10 5 40 190 115 10 3 4C15 60 10 5 40 160 250 10 3
7C15 60 16 6 40 270 120 10 3 7C15 60 12 6 40 200 140 10 4
13C15 70 16 7 40 390 130 16 4 13C15 70 16 7 40 290 120 16 3
19C15 60 16 8 40 470 180 20 4 19C15 60 16 8 40 320 200 16 3
25C15 80 20 7 40 550 175 20 5 25C15 80 20 7 40 380 165 16 3
31C15 80 20 7 40 600 180 20 5 31C15 80 20 8 40 420 210 16 4
37C15 90 20 7 40 660 130 24 6 37C15 90 20 9 40 520 210 20 5
55C15 100 24 9 40 930 200 24 6 55C15 100 24 10 40 650 250 20 6
For fcm,0 = 24 MPa For fcm,0 = 44 MPa

Complementary Stirrups (grade

Type Helical Bursting Steel (grade R250N)
D500N)
Concrete External
Anchor Pitch Bar Dia. Number Pitch Bar Dia. Number
cover Dia.
(-) P (mm) d (mm) (-) (mm) F (mm) (-)
C0 (mm) D (mm)
3C15 50 10 5 40 150 150 10 2
4C15 60 10 5 40 160 150 10 2
7C15 60 12 6 40 200 160 10 3
13C15 70 16 7 40 290 135 12 3
19C15 60 16 8 40 320 250 12 3
25C15 80 20 7 40 390 220 16 3
31C15 80 20 8 40 420 220 16 4
37C15 90 20 9 40 470 180 16 4
55C15 100 24 10 40 600 180 16 4
For fcm,0 = 60 MPa

14
 C RANGE HIGH STRENGTH PRESTRESSING

The yield strength of the helical steel can be either fy=250 MPa or 500 MPa since
anti-burst is governed by crack opening control and not by design for ultimate
conditions thus the cross sectional area and the modulus prevail over the tensile
strength.
If required for practical reasons, (to reduce congestion of the reinforcement or to
overcome difficulties of the steel fixer to bend helix) helical steel and additional
stirrups can be combined together. This alternative reinforcement arrangement
provides the same or a greater cross sectional area, and the overall dimensions are
similar to what is shown on the table.
For example, for the 13C15 anchorage at fcm,0=44 MPa, it specifies helical steel
at 7 loops of 16 mm diameter bar, pitch 70, outside diameter 290 plus 4 layers of
additional reinforcement made of 12 mm diameter bar ligatures spaced at 120
mm spacing. They could be replaced by 10 square closed ligatures 350x350 made
of 16 mm diameter bar spaced at 50 mm.
Reinforced concrete test prism for anti-burst test of 13C15 anchor
Another example, for the 19C15 anchorage at fcm,0=44 MPa, it specifies helical
steel at 8 loops of 16 mm diameter bar, pitch 60, outside diameter 320 plus 3
layers of additional reinforcement made of 16 mm diameter bar ligatures spaced
at 200 mm spacing. It can be replaced by only one helical steel at 11 loops of 16
mm diameter bar, outside diameter 320, pitch 50.

Closed Ligatures with 135 degrees hook

Check clash with central duct

Closed Ligatures with 90 degrees cog

Example of anti-burst reinforcement

Closed Ligatures with 90 degrees cog
Check if enough lap length - weld if not

Anti-burst reinforcement

Helical steel

Additional
reinforcement

Typical anti-burst in a blister Typical anti-burst for a group of anchors

15
 S RANGE SLAB PRESTRESSING ANCHORAGE

Application Categories

Freyssinet developed the S Range post-tensioning system in order to offer a range of small
tendons with flat anchorages, especially adapted for post-tensioning of slabs, walls, or for
transverse post-tensioning of a bridge top slab.
The S Range is usually based on bonded tendons (bare strands threaded into a flat duct
and injected with cement grout), but can also be used with unbonded tendons (greased
and sheathed strands encased or not in a flat duct).

Components

Strand and duct

Strands used with the S Range conform to AS4672 or prEN10138 (refer to paragraph
on strands on page 20). Tendons are made of 2 to 5 strands, with 12.7 mm or 15.2 mm
diameter placed inside a flat duct that can be either smooth or corrugated.
S RANGE

Anchorage
The strands are anchored individually by means of a 2 wedge pulled into the conical holes
of the anchorage block that is bearing onto the trumplate. A recess former is used during
concreting to connect the trumplate to the formwork.

5S13 Anchor

Slab post-tensioning using S Range Anchors

16
 S RANGE SLAB PRESTRESSING ANCHORAGE

Active Anchorages
Corrugated flat duct

Anchorage block

Strands
(mm) Strand Anchorage Block Trumplate
No of
Diam
Strands
UNIT (mm) A B C D E F

3S13 3 12.7 Trumplate

50 135 45 80 150 137 Wedges
2S15 2 15.2

4S13 4 12.7
S Range Anchorage
5S13 5 12.7
50 214 45 83 233 215
3S15 3 15.2
Wedges Injection tube
4S15 4 15.2 ØK

5 x monostrand
5S15 5 15.2 77 260 269
anchor
M
D
A

G2 int
Corrugated
(mm) Injection Tube
Duct
UNIT G1 x G2 ØK
nS13 or nS15 Anchorage Block F Tape
2S13 40 x 19 18
S Range Anchorage - elevation
4S13

3S13
P
5S13 70 x 19 18

3S15

4S15 nS13 or nS15 Trumplate

5S15 90 x 19 18
G1 int
N

B
E

(mm) Recess

UNIT M N
Corrugated flat duct (steel or plastic)
3S13 C
240 130
2S15
S Range Anchorage - plane view
4S13

5S13
300 130
3S15
25

4S15
N

5S15 380 130

M
S Range Anchorage Recess- front view

17
 S RANGE SLAB PRESTRESSING ANCHORAGE
SPACING & EDGE
DISTANCE
The anchorages must be positioned with a minimum spacing centre-to-centre and with
a minimum slab thickness. These distances have been obtained using load transfer test
results on concrete blocks under the European Technical Approval procedure and are
summarised in the tables below.
In practice, flat anchorages are located at mid depth of the slab.
For intermediate values of spacing or slab thickness that are different from the values
shown in the table, interpolation shall be used such as the area thickness x spacing
remains identical.
For instance, if a slab thickness of 200 is used with 4S15 anchorages, the minimum
spacing shall be 475 x 170 / 200 = 404 mm.

The minimum compressive strength measured on concrete cylinder

required before tensioning is:
• 20 MPa if strands are 12.7 mm diameter to AS4672.
• 22 MPa if strands are 15.2 mm diameter to AS4672.
t=tmin
x t
UNIT
(mm) (mm)
S RANGE

3S13 350 150

4S13 415 170
t

5S13 475 170

3S15 415 170
4S15 475 170 x/2 x
5S15 525 190
S Range anchorages spacing and slab thickness
Minimum spacing when t=tmin

x=xmin
x t
UNIT
(mm) (mm)
3S13 255 210
4S13 300 235
5S13 340 240
3S15 300 235
4S15 340 240
5S15 385 260

Minimum slab thickness when x=xmin

S Range anchorages prior to placing concrete

18
 S RANGE SLAB PRESTRESSING ANCHORAGE
ANTI-BURST
REINFORCEMENT
Anti-burst reinforcement shall be placed around the anchorage to adequately transfer
the prestressing force from the anchorage to the structure while limiting the concrete
cracking. Anti-burst arrangement is the result of load transfer test results on concrete
blocks under European Technical Approval procedure and is defined by the following
tables as a combination of helical steel (1) and additional reinforcement (2).
Co
For project specific antiburst requirements, please consult Freyssinet design engineers.
C

D
B

d
Pitch 1
N x Pitch
2
A
e 1 2

S Range anchorages anti-burst reinforcement

S Range anchorages anti-burst reinforcement

The following table has been adapted from Freyssinet European Technical Approval and S Range testing to
reinforcement bars readily available in Australia.
Helical Steel 1 Additional reinforcement 2
UNIT
Pitch d N A B Co e C D

3S13 60 10 4 120 200 45 10 120 120

4S13 60 10 6 140 240 45 10 140 160

5S13 60 10 6 140 260 45 10 140 190

3S15 60 10 6 140 240 45 10 140 160

4S15 60 10 6 140 280 45 10 140 190

5S15 60 12 6 140 320 45 10 140 240

Anti-burst reinforcement schedule – grade D500N

19
 COMPONENTS COMMON TO C & S RANGES

PRESTRESSING
STRANDS
The table below gives the main characteristics of the most common strands used in
Australia with the Freyssinet prestressing system:
Characteristics of strands to Australian and European Standards
Standard AS 4672 AS 4672 AS 4672 pr EN 10138

Nominal diameter 12.7 mm 15.2 mm 15.2 mm 15.7 mm

Minimum tensile strength 1870 MPa 1750 MPa 1830 MPa 1860 MPa

Nominal cross sectional area 99 mm2 143 mm2 143 mm2 150 mm2

Nominal mass per length 0.774 kg/m 1.122 kg/m 1.122 kg/m 1.172 kg/m

Nominal modulus of elasticity 195 GPa 195 GPa 195 GPa 195 GPa

Minimum breaking load Fpk 184 kN 250 kN 262 kN 279 kN

Minimum 0.1% Proof force Fp0,1

151 kN 205 kN 214 kN 246 kN
(Yield Load)
COMPONENTS

Minimum elongation at
3.5 % 3.5 % 3.5 % 3.5 %
maximum Load
Maximum relaxation 1000 hours
2.5 % 2.5 % 2.5 % 2.5 %
at 70% of Min. Breaking load
Maximum relaxation 1000 hours
3.5 % 3.5 % 3.5 % 4.5 %
at 80% of Min. Breaking load

Characteristics of tendons made up of 15.7 mm diameter strands

Units 15.7mm diameter strand to pr EN-10138
Nominal Tendon minimum
Number of Mass per metre
cross-section breaking load
strands (kg/m)
(mm2) (kN)
1 150 1.17 279
2 300 2.34 558
3 450 3.52 837
4 600 4.69 1,116
7 1050 8.20 1,953
13 1950 15.24 3,627
19 2850 22.27 5,301
25 3750 29.30 6,975
31 4650 36.33 8,649
37 5550 43.36 10,323
55 8250 64.46 15,345

Bli Bli Reservoir, Australia

20
 COMPONENTS COMMON TO C & R RANGES

DUCTS

The following duct types are used for C Range and S Range tendons:
Internal
Steel corrugated duct
The recommended dimensions for ducts are given in the tables associated with each
anchor. However, it must be checked that the suggested dimensions are compatible
with applicable regulations. When a lower coefficient of friction is required, a phosphate
treated/soaped corrugated metal duct (L.F.C.) can be used.

Corrugated plastic Plyduct duct

Developed and patented by Freyssinet to meet the requirements of FIB (International
Federation for Structural Concrete) recommendations
"Corrugated Plastic Ducts for Internal Bonded Post-Tensioning Systems" (2000) and the
Concrete Society TR47 "Durable Bonded Post-tensioned Concrete Bridges", this duct is air
and watertight.
Inside diameter of PLYDUCT duct (with sleeve = d + 10)

Thickness 2.5 mm 40 45 50 60 65 70 80 90 95

Thickness 3.0 mm 100 105 110 115 120 130 160 - -

Steel corrugated duct
Liaseal
Developed by Freyssinet, the Liaseal duct coupler ensures leaktightness of ducts at
segment joints, in particular if they are match-cast and are no longer accessible. Used in
association with the Plyduct duct, it allows for the creation of continuous, leaktight plastic
ducts.

LIASEAL

Outside diameter of LIASEAL (mm) 125 140* 155*

Liaseal
Inside diameter of sheath (mm) 65 80 95
*Available on request

Steel tubes
For totally leaktight or highly deviated ducts.

External
Insert no. 1 Sealing component Insert no. 2 Tendons injected with cement grout
High Density Polyethylene (HDPE) duct in zones external to the concrete. The material is to be
grade PE80 or PE100. Use of tubes with nominal pressure rating PN 6.3 is recommended, steel
tube in end block, diaphragms and deviators blocks.

Tendons injected with grease or wax

Use of HDPE duct with nominal pressure rating PN 10 is recommended, unless
preliminary study suggests otherwise.

21
 COMPONENTS COMMON TO C & S RANGES
Special case
If LFC sheaths are used, it is possible to reduce the radius of curvature of sheaths bendable by
GEOMETRY hand, while maintaining correct transmission of the prestressing forces. The lower limit of the
radius of curvature is then Rmin≥ 1.35√ n, n representing the number of strands in the tendon.

Internal
The radius of curvature of the duct must be at least equal to:
• 100 Ø for circular or flat rigid ducts bendable by hand (with Ø = inside diameter of duct),
• 3 m for steel tubes.
As an exception, the radius of curvature may be reduced to 20 Ø for steel tubes on the
condition that:
• this radius is not less than 1.3 m for 15.2 mm or 15.7 mm dia. strands,
• the tension does not exceed 70% of the minimum breaking load of the tendon in the
area where the radius is less than three metres,
HDPE ducts for external prestressing
• the sum of the angular deviations along the length of the tendon does not exceed 3 π
radians, Minimum radius of Minimum radius of
Units curvature in anchors curvature in deviators
• the highly curved area is considered as a dead end when the angular deviation is (m) (m)

greater than π radians. 7C15 3.0 2.0

13C15 3.5* 2.5*
19C15 4.0* 3.0*
25C15 4.5 3.5
COMPONENTS

37C15 5.0* 4.0

External * as per standard ENV 1992-1-5:1994

In the absence of more stringent national requirements, the radius of curvature of

the tendon in deviators, generally comprising bent steel tubing, shall comply with the
minimum values indicated in the table on the side.
For greased and sheathed strands placed in ducts pre-injected with cement grout, the
following curvature radius should be maintained:
• isolated strands: R min ≥ 1 m
• strands grouped in bundles: R min ≥ 2.5 m

LOSSES AND
FRICTION LFC duct
Friction coefficient µ (rad--1) Wobble
Use Type of duct
Coefficient of friction lubricated strand unlubricated strand coefficient k (rad/m)
Steel corrugated duct 0.17 0.19 0.007
For the calculation of the prestressing force
Bonded LFC duct 0.10 0.12 0.007
and the tendon elongation, the values of the internal
prestressing Plyduct 0.10 0.12 0.007
friction coefficient (µ) and the unintended
Steel tube 0.16 0.24 0.007
angular deviation or wobble coefficient
Unbonded Single strand 0.05 - 0.007
(k), vary depending on the type of ducts internal
and surface treatment. The force along the prestressing Bundle of pre-injected single strands 0.05 - 0.012
tendon is given by P(x)=Pjackinge-µ[j(x)+kx] External HDPE tube 0.10 0.12 0
prestressing Steel tube 0.16 0.24 0

Fluctuation in the coefficient of friction is normally ± 25%.

22
 COMPONENTS COMMON TO C & R RANGES
INJECTION
PRODUCTS
Prestressing strands, if not individually greased and sheathed, are protected by injecting the
duct containing them. The fill product can be a cement grout, which provides a passivating
layer on the surface of the steel to protect against corrosion, or a flexible product that
encapsulates strands in a watertight casing.

Cement grout
To ensure perfect filling of the ducts and therefore durable protection of the prestressing steels,
the properties of the cement grout must be adjusted to suit the injection technique, which differs
depending on the tendon layout, site temperatures, the position of vents and injection points, etc.
Based on test results to meet specific requirements and using locally available products,
Freyssinet Australia has developed its own prestressing grout.

Freyssinet Grout
Freyssinet Grout grout is a low shrink, cementitious grout. It is non-metallic and contains no
chlorides and no fines (sand free). Freyssinet Grout compensates for shrinkage in both the
plastic and hardened states.
FreyssiGrout is accredited as RMS approved grout product for post-tensioning tendons, and as
such, was developed to meet requirements of RMS specifications B113.

Freyssinet Grout
Properties of Freyssinet Grout
Parameters Freyssinet Grout

10 kg bag
Packaging
200 kg cement
Between 128L and 133L per 10 kg bag
Yield
+ 200 kg cement

Water/Cement ratio Between 0.28 and 0.33

1 day 20 MPa
Compressive strength 7 days 65 MPa
28 days 80 MPa

Bleeding 4 hours: <0.5%

Shrinkage 24 hours: <1%

Store in cool conditions

Storage Grouting
Shelf life is 12 months
Grout mixing

Flexible product
Flexible corrosion-resistant products are chemically inert with regards to prestressing steels.
They can be split into two main categories: greases and waxes (hot-injected). Freyssinet
uses microcrystalline wax, a long-chain synthetic wax specifically designed to be stable
over time and to minimise bleed.

23
 INSTALLATION
Installation of the Freyssinet Prestressing System follows 5 main stages:
• installing the ducts and trumplates (and thread strands for flat ducts),
• pour concrete then remove recess and formwork,
• threading the strands and installing the anchorage blocks,
• tensioning,
• injection and sealing.

Installing the ducts and trumplates

For internal prestressing, the ducts are positioned before concreting. Corrugated steel
or HDPE ducts are the most commonly used. Special care is taken with positioning and
supporting the ducts
For external prestressing, HDPE tubes are used. Strands are threaded through flat ducts
before pouring concrete to avoid duct crushing.

Removing recess and formwork

• undo bolts connecting recess former (if any) to formwork and anchorage after
stripping formwork,
• for slab post-tensioning, a tool enables extraction of the plastic recess former.

Threading the strands and installing the anchors

INSTALLATION

After checking on free passage in the ducts, the tendons are, in general, threaded by pushing
each strand from one end. Freyssinet's threading equipment can be used to produce
prestressing tendons over 200m in length.

Tensioning
C Range tendons are tensioned using multi-strand hydraulic jacks. Monostrand jacks
can be used under certain conditions. S Range tendons are stressed with a monostrand
jack.

The maximum stressing force applied to the prestressing tendon before lock-off during
tensioning shall be 80% of the tendon minimum breaking load.
In the case of the slippage or breakage of one or more strands, or in case of unexpected
high friction along the tendon, overstressing is permitted if the force in the jack can
be measured to accuracy of +/-5% of the final value of the prestressing force. In such
cases, the maximum stressing force may be increased to 85% of the tendon minimum
breaking load.

The tensioning operation can only start once the compressive strength of the concrete,
is greater than the value fcm,0 defined for the project. Refer to page 13 for C Range and
page 18 for S Range.

Multistrand jacks

24
 INSTALLATION
There are a number of hydraulics jacks that can be used to stress the tendons using C
TENSIONING C Range anchors. However, the most common jacks used by Freyssinet Australia are the
KC350, KC500, KC700, KC1000 and CC350, CC500 & CC1000.
RANGE Tendons can be stressed with a monostrand jack if the tendon is straight, short and with
parallel strands or if the strands are individually greased and sheathed.
H (overall height)

D (outside diameter)

R (jack length - fully retracted)

S (strand overlength)
E (jack length - fully extended)
KC jack
KC jacks
KC jacks are the jacks historically used by Freyssinet Australia.
Jack No of strands D (mm) H (mm) R (mm) E (mm) S (mm)
KC 350 7 - 13 395 475 1160 1410 1200

KC 500 14 - 19 500 580 1160 1410 1200

KC 700 20 - 31 610 690 1290 1540 1400

KC 1000 32 - 37 720 800 1400 1650 1400

CC jacks
CC jacks are very compact and as such have the following advantages: Q x

• hydraulic locking off of the anchorage wedges,

L
• reducing the dimensions of the recess and the volume of concrete to patch the recess,
• increase tendon eccentricity leading to greater drape from centroid and therefore
increase the efficiency of post-tensioning, G (strand overlength)

• facilitate handling and tensioning operations. E (jack completely closed)

C (jack open at end of stroke) = E + stroke
Top view

Jacks Units ØA (mm) E (mm) G (mm) L(mm) Qfor x ≈ 50 (°) Stroke mm)

CC 7C15 1,105 690 120 11°

360 250
350 13C15 1,074 660 150 9°
7C15 1,085 688 120 15°
CC Minimum clearance at rear = E + G + 20
13C15 438 1,100 703 150 12° 250
500 Front
19C15 1,071 674 170 11°
ØA
19C15 1,160 723 170 16°
CC
25C15 593 1,175 738 210 13° 250
1000
31C15 1,146 709 210 13°
37C15 1,151 714 240 10°
CC 50
50

37C15 722 1,550 770 240 9° 350

1500
55C15 1,986 700 280 8°
CC jacks Transverse clearances
The sketch above is based on a jack suspension device located in a
plane perpendicular to the plane of the sketch.

25
 INSTALLATION
C/F jacks
a for
Jacks Units ØA (mm) ØB (mm) C (mm) D (mm) E (mm) F (mm) G (mm) L (mm) a’ actual
x=50
7C15 1,415 731 1,165 1,120 120 4°30’ 8°
C350F 355 263 250
13C15 1,374 675 1,124 1,080 150 2°20’ 7°
x
7C15 1,513 714 1,213 1,080 120 7°39’ 12°

C500F 13C15 432 320 1,538 724 1,238 300 1,100 150 5°13’ 9°

L
øA

F
19C15 1,482 668 1,182 1,050 170 3°56’ 8°
125 øB
19C15 1,583 754 1,283 1,110 170 9° 13°
D
G 25C15 1,593 764 1,293 1,120 210 6°03’ 10°
E C1000F 582 417 300
C
31C15 1,603 774 1,303 1,130 210 5°58’ 10°
C/F jacks
37C15 1,552 718 1,252 1,080 240 4°04’ 8°
31C15 2,423 134 1,923 1,250 210 7°13’ 10°
C1500F 37C15 707 512 2,438 1,144 1,938 500 1,270 140 5°39’ 8°
55C15 2,375 1,076 1,875 1,200 280 3°54’ 7°
K/C jacks
a for
Jacks Units ØA (mm) ØB (mm) C (mm) D (mm) E (mm) F (mm) G (mm) L (mm) a’ actual
x=50
X

3C15 913 256 713 820 100 9°21’ 19°

F K100C 290 220 250
x

4C15 918 256 718 820 100 9°21’ 19°

L

K200C 7C15 350 263 1,154 435 954 200 1,060 120 6°52’ 13°
øB
øA

K350C 13C15 440 263 1,168 339 918 250 1,020 150 9°33’ 16°
D
INSTALLATION

E K500C 19C15 515 320 1,333 361 1,083 250 1,136 170 13°23’ 21°
G
C 25C15 1,465 420 1,215 1,320 210 12°25’ 18°
K700C 640 419 250
K/C jacks 31C15 1,475 430 1,225 1,330 210 12°09’ 18°
K1000C 37C15 770 492 1,497 434 1,247 250 1,350 240 14°23’ 20°
K500F jacks
x

ØA ØB C D E F G L a’ a for
Jacks Units
(mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) actual x=50
F
13C15 1,462 580 1,212 840 150 9°41’ 14°
K500F 565 364 250
L
øB
øA

19C15 1,433 551 1,183 810 170 9°17’ 13°

D
G
E
C
K500F jacks

VP/C jacks
x

ØA ØB a’ a for
Jacks Units C (mm) D (mm) E (mm) F (mm) G (mm) L (mm)
(mm) (mm) actual x=50
F
7C15 1,151 299 735 980 120 12°19’ 21°
VP260C 375 270 250
L
øA

13C15 1,126 264 700 945 150 8°5’ 19°

19C15 1,602 310 1,052 1,400 170 19°32’ 28°

øB VP650C 560 395 300
125 D 31C15 1,441 320 973 1,410 210 12°20’ 21°
E
G
C The sketches above are based on a jack suspension device
VP/C jack
located in a plane perpendicular to the plane of the sketch.

26
 INSTALLATION
TENSIONING S
RANGE
Tendons with S Range anchorages are tensioned with AJ150 or AJ300
monostrand jacks.

S (strand overlength)
R (retracted)
E (extended)

Monostrand jack

Jack AJ150 AJ300

R (mm) 360 510

E (mm) 515 815

S (mm) 300 300 Sioule Viaduct, France

RECESS

Permanent recess of anchors

M N H H
Units
(mm) (mm) (mm)
3C15 200 170 120
4C15 200 180 125
7C15 230 210 125
13C15 300 270 150
19C15 350 310 160
25C15 410 360 170
31C15 435 380 180 10°
37C15 470 410 195
55C15 560 480 230 N

C Range
M

C Range recess

27
 INSTALLATION
INJECTION &
SEALING
The purpose of injecting the free length of the tendons and sealing the anchors is to
protect the tendons against corrosion. Tendons are injected using either cement grout
containing a passivating agent for steel, or using hydrophobic products, grease or wax,
which create a continuous encapsulated cover to fully protect against aggressive agents.
In order for corrosion protection to be effective, the ducts must be completely filled, without
any air pockets that could constitute an area where water seepage could accumulate.
Such a result is generally achieved by selecting the correct speed at which the grout fills the
duct and by vents at high points in deviated tendons.
For complex tendon layout, for example highly deviated or vertical tendons, or to overcome
any problems installing drain openings at high points, Freyssinet has developed specific
injection techniques, described below.
Formulation of cement grout in a Freyssinet laboratory
Vacuum injection
The purpose of this technique is to create a partial air vacuum in the duct before filling in
order to avoid trapping air pockets. This technique is only used for leaktight ducts and is
very suitable for tendons which it is not possible to have high point vents.
INSTALLATION

In the case of deviated horizontal tendons, it can be combined with the use of Freyssiflow TX
thixotropic grout to achieve better fill results.
It also allows for the injection of U-shaped tendons from a top anchor without having to
worry about the effects of the grout interface collapsing.
Injection caps
Reinjection of high points
When there is significant risk of bleed at high points of a tendon profile, highly deviated
or vertical tendons, these high points should be reinjected to drain any weak grout.
The volume to be bled is assessed case by case on the basis of experience acquired by
Freyssinet.
Freyssinet has also developed special technological provisions for cases where it is not
possible to locate a reinjection tube in the facing.

Injection of tendons with greased and sheathed strands before tensioning

Tendons comprising greased and sheathed strands within a duct must be injected with
cement grout prior to tensioning. Once hardened, the grout performs the role of strand
separator and prevents crushing of individual plastic sheaths where the tendon route
deviates. This technique, designed and perfected by Freyssinet, guarantees that the
sheathing of every strand is leaktight and smooth operation of the tensioning process.

Low pressure injection filling

To reduce hydraulic pressure losses at injection points, Freyssinet has designed a special
injection device so that the injection product can be injected at the rear of the anchor
block through a large diameter tube.
This arrangement is well suited to very high vertical tendons. It also facilitates any anchor
head reinjection operations. Low pressure injection device

28
 INSTALLATION

Permanent caps
The prestressing anchors are protected either by a concrete seal if the anchor is in a recess,
or a permanent cover if they have to remain accessible for later interventions. Permanent
covers are also used for duct injection. They can be made from cast iron (galvanised or
painted) or plastic.

Vents and drain openings

The diagrams below show the positioning of vents and injection tubes for relatively simple
tendon profiles.
Figure 1 For U-shaped parabolic profiles with height variation greater than 1.2 m, the low
point is fitted with an injection tube.
Figure 2 For inverted U-shape parabolic profiles with height variation greater than 1.2 m,
the high point is fitted with a vent and two offset tubes. On reinjection of the high point,
one of them serves as an injection tube while the other serves as a drain opening.
Figure 3 Horizontal tendons with two U-shaped drapes separated by a straight section,
and with height variation greater than 1.2m, must be injected from one of the low points
including the straight section, then reinjected from the other high point while draining the
horizontal section.
h ≥1.20m
Fig 1
h

Injection inlets on HDPE pipes Fig 2

h

h ≥1.20m
1m

h ≥1.20m
Fig 3
h

1m 1m

For more complex profiles consult Freyssinet Australia Technical Services.

Injection caps Plastic permanent caps

29
 F RANGE ANCHORS FOR THIN ELEMENTS

Composition of F range anchor

F range anchors comprise:
• an anchor body embedded in the concrete and acting as both anchor
• head and distribution element,
• jaws, to anchor the strands,
• elements for permanent protection of the jaws, comprising HDPE (or metal)
covers, filled with grease.

Application categories
F range anchors are intended for the prestressing of thin elements
(slabs, concrete floors, etc.).
They are used for:
• unbonded prestressed concrete,
• bonded prestressed concrete,
• Seismic strengthening of walls (URM and concrete), floors, beams, and
columns

Bonded internal prestressing configurations

F RANGE

The most common use of type F anchors in bonded internal prestressing is

based on the use of uncoated strands in a corrugated metal sheath, galvanised
or ungalvanised, generally flat for easier insertion into thin elements, and injected
with cement grout after tensioning of the strands.
The anchors, sheath and prestressing reinforcements are installed before
concreting the structure. In particular, this prevents the risk of flat ducts being
crushed during concreting which would prevent the subsequent threading of the
strands.

Unbonded internal prestressing configurations

F range anchors for unbonded internal prestressing are used with grease-
protected strands, each with individual HDPE sheathing. These elements are
directly incorporated into the reinforcement before concreting, with precautions
being taken not to damage each individual sheath.
The individual AF13/15 anchor for 13mm and 15mm strands respectively allows
for the beneficial effects of the prestressing to be distributed very evenly in thin
elements.

Jamuna Bridge, Bangladesh

30
 F RANGE ANCHORS FOR THIN ELEMENTS
BONDED INTERNAL
PRESTRESSING

Multi-strand units 3 to 5 F13/F15

Injection pipe
Sealant
Notes: F range anchors are designed

( INT )
G2
for minimum concrete strength

A
fcmin= 22 MPa (on cylinder).
The usual installation method is Jaws C13 AnF15 - A nF13 flat anchor
threading the strands into the ducts 50 min. Jaws C15

(flat sheaths) before concreting.

However, if necessary, it is also Formwork
Flat sleeve Flat sheath
possible to thread the strands after
concreting the structure, on condition

( INT )
B

G1
that special provisions are made.

A B C G1 x G2 G G H
Units
(mm) (mm) (mm) (mm2) (mm) (mm) (mm)
A3 F13/15 85 190 163 58 x 21 95 95 200
A4 F13/15 90 230 163 75 x 21 100 100 240
A5 F13/15 90 270 163 90 x 21 100 100 280

Bridge at Rousson, France

31
 F RANGE ANCHORS FOR THIN ELEMENTS
UNBONDED INTERNAL PRESTRESSING
WITH GREASED SHEATHED STRANDS

Single-strand unit (1F13/1F15)

F RANGE

Multi-strand units (3 to 5 F13/15)

HDPE cap
HDPE cap
B

F anchor
F anchor
Steel retaining plate
50 min. Steel retaining plate
50 min.

Formwork A B C G H
Formwork Grease filling Units
Grease filling (mm) (mm) (mm) (mm) (mm)
Filler A 3F 13/15 190 85 163 95 200
Filler
A 4F 13/15 230 90 163 100 240
Grease
Grease A 5F 13/15 270 90 163 100 280
A

Greased sheathed strands

Greased sheathed strands

32
 F RANGE ANCHORS FOR THIN ELEMENTS
CI SINGLE-STRAND
FIXED COUPLERS

Bonded prestressing
3F15
A

1F15
M
N
B Anchor AnF15
Seal
ExF B Protective cover Vent G1/2”

4F15 5F15
E
A A

30
X1
X2
B Flat sheath Single-strand coupler
B
X3

A B E F M N X1 X2 X3
Units
(mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm)
CI 1F13/15 - - - - 550 550 250 - -
CI 3F13/15 100 100 58 20 800 750 250 500 750
CI 4F13/115 100 110 75 20 1,050 1,000 250 500 750
CI 5F13/15 100 140 90 20 1,050 1,000 250 500 750

Unbonded prestressing
3F15
A

1F15
M
N
B Anchor AnF15
Seal
B Bare strands Protective cover Vent G1/2”

4F15 5F15
A
A
30
Filler X1
Cement grout X2
B Injection
B Single-strand coupler
opening
X3

A B M N X1 X2 X3
Units
(mm) (mm) (mm) (mm) (mm) (mm) (mm)
CI 1F13/15 - - 550 500 250 - -
CI 3F13/15 100 100 800 750 250 500 750
CI 4F13/15 100 110 1,050 1,000 250 500 750
CI 5F13/15 100 140 1,050 1,000 250 500 750

33
 F RANGE ANCHORS FOR THIN ELEMENTS
LAYOUTS
FOR F RANGE
ANCHORS
The anchors must be positioned at an adequate distance from the wall and spaced at a
minimum centre-to-centre distance. These distances are obtained using dimensions a
and b of the test assemblies created under the European Technical Approval procedure.
In the following, it is taken that the anchors are positioned along two normal direction
axes: x and y, with the short side of the trumplate aligned on the y axis.

Notation
• A, B: plane dimensions of the trumplate ( A ≥ B ).
• a, b: side lengths of test specimen ( a ≥ b ).
• x, y: minimum centre distance between two anchorages in the structure in x and y
directions.
• x’, y’: minimum edge distance between anchorages and the closest external
surface in x and y directions.
• fcm,o: mean compressive strength measured on cylinder required before
B tensioning.

x’ x‘
Dimensions x and y must meet the
following conditions:
F RANGE

A
x ≥ A + 30 (mm)
x x y > B + 30 (mm)
x.y≥a• b
x ≥ 0.85 a
y ≥ 0.85 b
x’ ≥ 0.5 x + concrete cover — 10 (mm)
y’ ≥ 0.5 y + concrete cover — 10 (mm)
y y‘
y’ y’
Values a and b are given in the table opposite, for three different concrete strengths fcm,o in
the case of type F.
If the design provides for partial tensioning or a tensioning rate of less than min
[0.8 Fpk ; 0.9 Fp0.1% ], interpolation can be used to determine the required value of fcm,o ,
bearing in mind that at 50% of full force, the required strength for the concrete can be
brought to 2/3 of the values given in the two tables above and that at 30% of this force,
the required strength for the concrete can be brought down to half of the values given.
Distances a and b
Units fcm,o (MPa) a (mm) b (mm)

1F 13/15 22 190 140

3/4 F 13 22 500 160
3/4 F 15 22 390 190
5 F 13 22 570 260
5 F 15 22 510 240

34
 F RANGE ANCHORS FOR THIN ELEMENTS
HOOP
REINFORCEMENT
FOR TYPE F ANCHORS
Single-strand unit
1 1
160 EXT

A 1F13
A 1F15 Ø8

110 EXT
2x1
FoE235

Elevation Dimensions in mm
75 35 70
Multi-strand units (3 to 5 F13/15)
1 1 3 1 2 3 1 2 3 1

A 3F13
Ø L1 L2 L3 h
A 4F13 Type No.
(mm) (mm) (mm) (mm) (mm)
1 12 10 320
2 3 10 320 20 160 140
3 3 10 320 20 160 140
See types of bars below.
1 2 3 1 2 3 1 2 3 1
15 70 70

4 2 3 4 2 3 4 4

A 3F15
Ø L1 L2 L3 h
A 4F15 Type No.
(mm) (mm) (mm) (mm) (mm)
2 2 10 350 60 160 160
3 2 10 350 60 160 160
4 4 12 350 160 160
See types of bars below.
4 2 3 4 2 3 4 4

25 75 75 75

1 2 3 1 1 2 3 1 1 2 3 1 5

A 5F15 Ø L1 L2 L3 h
Type No.
A 5F13 (mm) (mm) (mm) (mm) (mm)
1 12 10 380 - - -
2 3 10 380 55 190 145
3 3 10 380 55 190 145
See types of bars below.
40 75 75

Type No. 1 Type No. 2 Type No. 3 Type No. 4

L2 L2 L1

L3
80
50 h h h
80
L3
L1
L2 L2 L1
L1

35
 F RANGE ANCHORS FOR THIN ELEMENTS
There are three types of passive anchors embedded in concrete used in combination
with F range active anchors: prelocked anchor NB1F15, type N using an individual plate
supporting an extruded sleeve and the type G dead end anchor. The tendons are positioned
before concreting.

Single-strand unit

Prelocked anchor NB 1F15 Anchor with extruded sleeve

Spring Sleeve T15D

Prelocked jaws Grease Bearing plate

Multi-strand units (3 to 5 F13/15)

Type N embedded anchor Strand

spacer ØT Deviator
In the type N anchor, each strand has
F RANGE

grid
Hoop reinforcement
an extruded sleeve, each supported Vent Sheath
individually by a steel plate.
C

N
ØT
Units W1 W2 (mm)
(mm) (mm)
N3 F13/15 300 300 G 1/2” Plates 90 x 90 x 15 mm Filler

N4 F13/15 350 350 G 1/2” W1 or W2

N5 F13/15 500 400 G 1/2” type 1 or 2
110 mm

Type 1 Type 2

110 mm 110 mm

W
Type G embedded anchor Unlubricated bare strands
The type G anchor is a dead end anchor. The end
of each strand is preformed into a bulb shape.

W Ø H L
Units
(mm) (mm) (mm) (mm)
3F13 950 10 120 300 80 4 bars ø 100
4F13 950 10 120 320
Bar ø10 55 55 55 55
5F13 950 12 120 340
260
3F15 950 10 120 300 FeE235
4F15 950 12 145 340
h
5F15 950 14 145 380
L

36
 R RANGE EXTERNAL MONOSTRAND ANCHORAGE

APPLICATION
CATEGORIES
The 1R15 anchorage is an external prestressing monostrand anchorage designed
for the strengthening of existing structures, especially for concrete beams or pier
headstocks.
The longitudinal prestressing force of the strand is transferred to the structure
by the friction between the 1R15 anchorage and the surface of the structure.
This friction is created by stressing a clamping bar going through the structure
or sealed in a blind hole. An epoxy resin is applied at the interface between the
anchorage and the concrete, to enhance the friction.
The length of the 1R15 anchorage allows stressing with a monostrand jack fitted
with a curved nose with minimum jacking clearances.
Compared to traditional solutions such as concrete anchor blocks or fabricated
steel anchorages, the 1R15 anchorage provides multiple advantages:
• simple and fast installation (no grout or concrete cast on site),
• compact solution allowing stressing with light equipment (monostrand
jack),
• reliable and competitive solution due to the industrialisation of a
R RANGE

mechanical cast anchorage.

1R15 anchorages stressed

Live ends before stressing

Pier headstock strengthening, M2 Upgrade, Sydney, Australia

37
 R RANGE EXTERNAL MONOSTRAND ANCHORAGE

COMPONENTS

Prestressing strand
• 15.7mm strand to prEN10138 (279 kN minimum breaking load),
• maximum tensioning force in the jack 223 kN (80% of the minimum breaking load),
• maximum effective force in the strand 200 kN (after losses due to curved nose and
wedge draw-in).
Prestressing bar
• Freyssibar 26.5 mm diameter to AS 4672 (568 kN breaking load),
• clamping force 250 kN after losses.

Surface preparation
• epoxy resin Eponal 380 or Sikadur 30,
• concrete 20 MPa minimum strength, adequately scabbled.
R RANGE

Stressing of the 1R15 anchorage with curved nose and

monostrand jack

Anchorage
The 1R15 anchorage is made of cast iron. The bottom surface at the back end of the
anchorage (below the nut) is provided with steel indentations to create shear interlock
with concrete through the epoxy resin.

Freyssibar Ø26.5 mm Barrel and 3-piece wedge

1R15 anchorage in final configuration
+ nut and washer (Freyssinet Unigrip)
45 mm

35 mm

L
W

L W H Weight
Units
(mm) (mm) (mm) (kg)
Active 760 150 78 22

1R15 anchorage - 3D view Passive 470 150 78 19

38
 R RANGE EXTERNAL MONOSTRAND ANCHORAGE
CORROSION
PROTECTION
The longitudinal prestressing can be made of:
Grease nipple
1. galvanised greased and sheathed strand – most common option,
2. greased and sheathed strand encased in a HDPE duct injected with grout before
tensioning.
The prestressing bar is protected by hot metal spray (100Nm thickness 85% Zn - 15%
Al cold process). The void around the bar is left ungrouted to allow for bar replacement if
required.
Plastic cap with o-ring
filled with grease The 1R15 anchorage is protected by fusion bonded nylon (performance available upon
request). This coating is applied in the factory.
Plastic fittings with o-ring to seal
Heat shrink sleeve the unsheathed strand length

Galvanised greased and sheathed

strand

1R15 Anchorage details, galvanised greased and sheathed

strand

GEOMETRY
External prestressing tendon using 1R15 anchorages can be straight or draped. If the
tendon is draped, it is recommended to provide a physical separation of the greased and
sheathed strands along they entire profile. Otherwise in the curved section of the tendon,
within the bundle of strands, the transverse pressure arising from stressing the tendon
on a curve leads to ripping of the individual HDPE sheath which is too thin to withstand
the corresponding strains. In practice, a multitube saddle with flared ends to allow for
strand angular misalignment is generally provided.

Multitube deviation saddle Southern Link Upgrade, Melbourne, more than 2000 No of 1R15 anchorages installed

39
 X RANGE EXTERNAL HOOP TENDON ANCHORAGE

APPLICATION
CATEGORIES
Freyssinet has developed the X Range anchorage system for the active strengthening of
circular structures. These anchorages use external post-tensioning hoop tendons to apply
a radial pressure onto the structure being strengthened and are suitable for all circular
structures including silos, tanks, chimneys, cooling towers, pipes, old brickwork, etc.

COMPONENTS

Anchorage
The anchorage is made of ductile cast iron and has the following functions:
• guiding the strand from the duct to the anchorage,
• anchorage of the strand with conical holes and 3 piece wedges (Freyssinet “Unigrip”
wedges),
• connection between the duct and the anchorage, using HDPE fittings for cement
grout injection.
X RANGE

The 1X15 anchorage is designed for single hoop tendon (one full loop around the
structure).
The 2X15 anchorage is more suited for structures with high strengthening demand where
the spacing between consecutive hoop tendons is significantly reduced. They can anchor:
• 2 hoop tendons (one full loop anchored at each end),
• 4 hoop tendons (each tendon is doing 2 loops around the structure prior to being
1x15 Anchorage, Underbool Grain Silos, Australia anchored).
The 1X15 anchorage is suitable for structure diameters ranging from 13 m to 27.5 m.
The 2X15 anchorage is suitable for structure diameters ranging from 3.7 m to 5.5 m.
Other structural diameters are possible but they will require a specific case study.
Prestressing strand
The hoop tendons are made of greased and sheathed strands encased in a HDPE outer
duct injected with cement grout. The following strands may be used with the X Range
anchorages:
• 15.2 mm diameter strand at 261 kN min. breaking load (to AS4672),
• 15.7 mm diameter strand at 279 kN min. breaking load (to prEN10138),
• 15.2 mm diameter strand at 300 kN min. breaking load (to AS4672) – compacted
strand.

Underbool Grain Silos strengthening, Australia

40
 X RANGE EXTERNAL HOOP TENDON ANCHORAGE
CORROSION
PROTECTION

The strands are greased and sheathed, which allow the strand to slide freely inside its
sheath without bonding to the structure. For applications in a more aggressive environment
or if longer durability is required, galvanised strands may also be used.
Cement grout is injected into the outer duct before tensioning the tendon so that the
grease and sheathed strand is perfectly embedded and a more uniform pressure is applied
on the concrete surface. The external tendon is then perfectly protected against corrosion
by two barriers:
• the individual grease protection & HDPE sheath, to prevent the circulation of humidity,
• the HDPE outer duct, filled with cement grout.
The corrosion protection of the X Range anchorage is addressed as follows:
• inside the anchorage Plastic fittings to seal the outer HDPE duct
filling with grease through injection nipples and HDPE caps to protect the wedges and
the unsheathed strand lengths,
• outside the anchorage
coating of the anchorage with fusion bonded nylon applied in the factory (performance
available upon request),
or covering the anchorage with shotcrete.

1X15 ANCHORAGE

Grease nipple
Wedge Cap Grout
screw HDPE outer
Threaded end cap
duct
filled with grease

Cast iron anchor block 1X15 Greased and sheathed strand

100 mm
Min

Geraldton Grain Silos, Australia

435 mm
87 mm

167 mm

160 mm

325 mm
1X15 Anchorage

41
 X RANGE EXTERNAL HOOP TENDON ANCHORAGE

2X15 ANCHORAGE

Hose stem Grease nipple

Wedge
Grout
HDPE outer duct
Threaded end cap
filled with grease
187 mm

89 mm
Greased and sheathed strand Cast iron anchor block 2X15
212 mm (18 strands / metre max)
X RANGE

272 mm

70 mm 70 mm 70 mm

2X15 Anchorage

Cap screw Outer HDPE duct

Internal plastic fittings

with o-ring

Plastic cap with

o-rings Grease inlet plugged
with hexagonal screw
2X15 Anchorage anti corrosion protection

42
 FREYSSIBAR

TECHNOLOGY

The bars
The bars are hot rolled from high strength alloyed steel. They are subsequently cold worked
by stretching and then threaded over their full length or on the extremities by cold rolling.
The standard range of nominal diameters is: 26.5; 32; 36; 40 and 50 mm. Non-standard
diameter bars can be delivered on request.
The fabrication process provides a high quality thread ensuring high fatigue resistance
and a low susceptibility to stress corrosion.
The nature of the Freyssibar manufacturing method also ensures that every single bar is
stress tested to 85% of the guaranteed ultimate tensile strength of the bar.
The geometry of the thread is specifically designed to ensure ease of use on site, providing
fast, accurate and easy tightening.
Lifting : prestressed connection between a segment and a beam.
Bars are available in maximum lengths of 11.8 meters. Beyond this length, extension
sleeves allow bars to be connected together.
FREYSSIBAR

The anchorages
• The anchor devices are designed to anchor the force in the bar and transfer it to the
structure. Four types of anchorages are available:
• Standard anchorages with a nut and washer;
• Hinge anchorages using a nut with a spherical seat;
• Standard anchorages using a low rotation spherical nut and spherical washer;
• Fixed anchorages using a threaded end plate.
All nuts are hot forged. Also, couplers allow primary bars to be connected to secondary
bars.

Anchorage of steel ropes The accessories

Freyssinet offers a full range of sheathing that is easy to install.
In particular:
• Steel strip corrugated sheath, threaded over its full length, which allows easy and fast
connections;
• High density polyethylene tube, with elements mirror welded to achieve a leak free
and non-corrosive envelope;
• Sheathing accessories specific to the tensioning and coupling devices, required to fit
the coupler geometry. The length of the ducting element used is project specific, so
as to allow the coupler displacement over a sufficient length during the tensioning
operations.

43
 FREYSSIBAR
Properties
Fatigue : The system has a fatigue resistance in excess of two million cycles of loading
over a tensile stress range of 590-670 N/mm2, exceeding the ETAG 013 requirements.
Relaxation : After 1000 hours the loss of stress due to relaxation in the Freyssibar system
loaded to 70% Fpk is below 3% which is better than the 4% maximum as described in pr
EN 10138-4.
Anchorage strength : Freyssibar post-tensioning system is tested to ensure that the
failure load on the bar with coupler and anchorage is more than 95% of the strength of
the bar alone.

Protection against corrosion Permanent ties for quay walls

Stress corrosion tests have been performed in accordance to prEN 10138. The bars have
been stressed under corrosive environment during 500 hours and passed the subsequent
tensile test to failure. Freyssibar is not susceptible to stress corrosion but depending on
the conditions of exposure, a specific corrosion protection can be applied under request.
The corrosion protection system is selected in accordance to the expected design life
time and the conditions of exposure.
FREYSSIBAR

Surface coating
Hot dip galvanizing after sand blasting (no risk of hydrogen embrittlement
due to acid pickling)
• Metalization (Dunois, etc.)
• Petrolatum tape
• Epoxy coating

Specific injection products

} Allow for subsequent re-tensioning of the bars

Wax : hot injection
• Grease
• Cement grout : alkaline environment Prefabricated bar tendons

Ducting
• Corrugated ducts: light and easy to install
• Smooth pipes: stiff and resistant to shock
Ducts and pipes can be either in steel or in HDPE (non-corrosive).
Different protection systems can be combined to enhance the degree of
protection.

Quality control
The fabrication of the bars and the anchorages is carried out under a
quality assurance system in compliance with the quality standard ISO
9000 : 2000. Flat anchorages and bars have passed all the tests required
in ETAG 013.
Ground anchors

44
 FREYSSIBAR

INSTALLATION The accuracy of the prestressing force actually introduced into the structure and the
durability of the tendons depend on the quality of the installation. The detailed installation
procedure is available on request.

Shimming of the anchorages

When anchorages are applied onto an existing concrete element, it is recommended to
shim under the bearing plate using a non-shrink mortar, free from chlorides.

Tensioning
The tensioning equipment provided by Freyssinet ensures the accuracy of the load applied
within +/- 2%. This is achieved through regular calibration of the pump pressure gauge and
the jacks.
Load cell

Safety factors
The maximum allowable stressing force in the prestressing bars is given by the relevant
design standards. Recommendations are given below as examples: (Note: Fpk means the
guaranteed tendon tensile breaking load and Fp0.1% means the proof load).
A/ In post-tensioned structures, the Eurocode limits the tension to either 0.9 Fp0.1% or
0.8 Fpk, whichever is lower.
B/ In prestressed ground anchors, the norm EN 1537 prescribes a final force limited to 0.75
Fp0.1% for temporary ground anchors and 0.60 Fp0.1% for permanent ground anchors.
C/ In case of re-use, the tensioning force of the bar is limited to 0.60 Fpk for the first use,
Stressing with the hinged jack and to 0.50 Fpk for all subsequent uses.

Two types of jacks

Two types of jacks can be used: with a tie rod connected to the tendon or with a direct
connection. Jacks should be used in conjunction with Freyssinet hydraulic pumps, with
high pressure and a low flow rate to allow a progressive tensioning of the bar. Space must
be allocated around the anchorage to allow the correct installation of the jack.

Service
Injection Freyssinet, world leader in prestressing, offers:
• worldwide advice for specific works, from our
specialists,
• a huge material park providing jacks and
equipment for the best application of the
Freyssibar installation,
• on-site technical assistance given by our
highly qualified technicians, at the time of
installation.

Precast segments assembly

Injection accessories

45
 FREYSSIBAR CHARACTERISTICS

Bar
Nominal diameter (mm)
Characteristic Unit Ref.
26.5 29* 32 36 40 50

Steel grade MPa 1030 1030 1030 1030 1030 1030

Cross section area mm2 552 661 804 1018 1257 1964
Linear mass kg/m 4.56 5.18 6.66 8.45 10.41 16.02
Characteristic value of maximum force: Fpk kN 568 681 828 1048 1295 2022
Characteristic value of 0.1% proof force: Fp0.1% kN 461 552 672 850 1049 1640 B

Maximum tensioning force kN 414 496 604 765 944 1475

Thread pitch mm 6 6 6 6 8 8
Average Young’s modulus GPa 170 170 170 170 170 170
Minimum elongation at maximum force % 3.5 3.5 3.5 3.5 3.5 3.5

* 29mm diameter not ETA approved

Flat and fixed anchorage

Nominal diameter (mm)

Item Sketch Dimensions Unit Ref.
FREYSSIBAR

26.5 29* 32 36 40 50
Length mm 37 41 41 46 55 71
Flat nut N
Width on flat surface mm 50 56 56 62 65 90
External diameter mm 65 70 70 75 80 105
Flat washer W
Thickness mm 6 6 6 6 6 6
Dimensions mm 110x125 125x125 125x125 140x160 160x160 200x200
Flat plate Thickness mm 35 35 35 40 40 45 FP
Hole diameter mm 34 37 40 44 50 60
Dimensions mm 110x125 125x125 125x125 140x160 160x160 200x200
Thickness mm 35 35 35 40 40 45
Injection
Hole diameter mm 34 37 40 44 50 60 FPG
plate
Slot Length (from hole centre) mm 45 47.5 47.5 55 55 71
Recess Depth mm 10 10 10 10 10 10

* 29mm diameter not ETA approved

NOTE: For fixed anchorage a flat washer and nut must be tack welded to the
anchorage plate in 4No. locations as detailed in these diagrams.

4 tack welds

46
 FREYSSIBAR
Spherical anchorage type 1 ± 3°

Nominal diameter (mm)

Item Sketch Dimensions Unit Ref.
26.5 29* 32 36 40 50

Length mm 45 51 51 56 60 71
Spherical
SN
nut Width on flat surface mm 50 56 56 62 65 90

Dimensions mm 160x115 160x125 160x125 160x140 160x160 190x190

Spherical
SP
plate Thickness mm 40 40 40 40 40 60

* 29mm diameter not ETA approved

Spherical anchorage type 2 ± 0.6°

Nominal diameter (mm)

Item Sketch Dimensions Unit Ref.
26.5 29* 32 36 40 50
Spherical Length mm 37 41 41 46 55 71 SN
nut Type
Width on flat surface mm 50 56 56 62 65 90 Type 2
2
Spherical External diameter mm 75 80 80 90 95 125 SW
washer Thickness mm 10 10 10 10 10 15 Type 2

Dimensions mm 110x125 125x125 125x125 140x160 160x160 200x200

Flat plate Thickness mm 35 35 35 40 40 45 FP
Hole diameter mm 34 37 40 44 50 60
Dimensions mm 110x125 125x125 125x125 140x160 160x160 200x200
Thickness mm 35 35 35 40 40 45
Injection
Hole diameter mm 34 37 40 44 50 60 FPG
plate
Slot Length (from hole centre) mm 45 47.5 47.5 55 55 71
Recess Depth mm 10 10 10 10 10 10

* 29mm diameter not ETA approved

47
 FREYSSIBAR CHARACTERISTICS

Couplers

Moveable Coupler Fixed Coupler

Nominal diameter (mm)

Sketch Dimensions Unit Ref.
26.5 29* 32 36 40 50

External diameter mm 45 50 50 60 65 76
C
Length mm 90 105 115 130 140 170

* 29mm diameter not ETA approved

Accessories

Nominal diameter (mm)

Item Dimensions Unit Ref.
26.5 29* 32 36 40 50

Length mm 250 250 250 250 250 250

External diameter mm 42.9 48.5 48.5 50.8 57.2 70 C

Formwork tube
Thickness mm 2 2 2 2 2 2
FREYSSIBAR

Air vent connection mm 1/2 1/2 1/2 1/2 1/2 1/2 V

Short caps Length mm 95 100 100 120 120 150 CS

Caps
Long caps Length mm 210 234 220 220 220 280 CL

* 29mm diameter not ETA approved

Ducts

Nominal diameter (mm)

Item Dimensions Unit Ref.
26.5 29* 32 36 40 50

Internal diameter mm 45 50 50 55 60 75

Thickness mm 0.45 0.45 0.45 0.45 0.45 0.50 G1

Steel corrugated sheath
Volume of grout L/m 1.0 1.2 1.2 1.4 1.6 2.5
Connection element (internal
mm 50 55 55 65 70 85 G1
diameter)
External diameter mm 63 63 63 75 75 90

HDPE tube Thickness mm 5.8 5.8 5.8 6.8 6.8 8.2 G2

Volume of grout L/m 1.5 1.3 1.3 1.9 1.7 2.3

External diameter mm 70 76.2 76.2 88.9 95 114.3

For prolongation sleeve Thickness mm 2 2 2 2 2 2 GR

Minimum length (L = sleeve) mm 180 + L 205 + L 205 + L 220 + L 230 + L 260 + L

External diameter mm 88.9 88.9 88.9 101.6 114.3 152.4

For coupling sleeve Thickness mm 2 2 2 2 2 2 GC

Maximum length mm 210 235 235 255 265 320

* 29mm diameter not ETA approved

48
 FREYSSIBAR

ANTI-BURST
REINFORCEMENT

Freyssibar anti-burst reinforcement

BURSTING REINFORCEMENT
Nominal Bar Rebar Number of
Diameter Diameter Frames C P Ø Dmax Hx x Hy
(mm) (mm) (-) (mm) (mm) mm (mm x mm)

26.5 12 4 20 40 42.9 160 x 160

29 12 4 20 50 48.5 175 x 175

32 12 4 20 50 48.5 185 x 185

36 12 5 20 50 50.8 210 x 210

40 12 7 20 60 57.2 240 x 240

50 16 6 20 60 70 310 x 310

49
 FREYSSIBAR
The Freyssibar prestressing bars, thanks to their thread over their full length, allow to build
GROUND AND ground and rock anchors fulfilling the requirements of international standards. Lengths over 12

ROCK ANCHORS m can be obtained by means of one or several sleeves.

The ducting accessories and the anchorage corrosion protection systems are adjusted to
the design life time of the anchor: temporary or permanent.
In addition, the anchors can be fitted with injection tubes to fill the bore hole and reinjection
tubes to improve the bonding to the substrate.
Permanent
Nominal diameter bars (mm)
Item Dim. Ref.
26.5 29* 32 36 40 50

Steel formwork tube Ø 80 89 89 89 89 108 FTUB

Plastic smooth sheath Ø 60 70 70 70 75 90 STUB

Plastic ribbed sheath Ø 55 65 65 65 70 85 RTUB

Plastic spacer Ø 95 105 105 105 110 125 SPC

End protective cap Ø 95 101,6 101,6 114,3 114,3 139,7 CE

* 29mm diameter not ETA approved

Spherical anchorage Anchor plate

Ribbed sheath
FREYSSIBAR

Spacer
Protective cap

Cap Flexible anti-corrosion product Smooth sheath

Temporary

Nominal diameter bars (mm)

Item Dim. Ref.
26.5 29* 32 36 40 50
Plastic smooth sheath Ø 50 50 50 50 60 65 SPC
Plastic spacer Ø 55 60 60 65 80 90 CE

* 29mm diameter not ETA approved

Spherical anchorage

Spacer

Cap Smooth sheath

50
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03/2017