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PRESTRESSED CONCRETE DESIGN AND CONSTRUCTION: A STATE OF THE ART REPORTASEP SUMMIT 2012JUNE 08‐09, 2012
BRIAN LIMBRIAN LIMSENIOR BUSINESS DEVELOPMENT MANAGER SENIOR BUSINESS DEVELOPMENT MANAGER VSL HONG KONG LIMITEDVSL HONG KONG LIMITED
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
2
OBJECTIVES
Recent developments in national codes, construction material and emphasis on sustainable construction, have led to a significant departure in the way we design and construct prestressed concrete structures.
In this paper, a state of the art prestressed concrete design and construction of buildings, bridges and special structures will be examined.
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Gateway Bridge, Australia
Structural concrete has seen an extraordinary development and has become the material of choice for structures.Significant progress through continuous innovation
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
GBS Platform, North Sea PT floors, Chile
Success factors for concrete:‐ Local availability of concrete materials‐ Development of specific construction methods &specialised equipment‐ Improved knowledge in design of structural concrete ‐ Availability of modern post‐tensioning technology
LNG Tank, Spain
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
5
1. Systems2. Buildings3. Bridges4. Other Applications5. New Developments and Applications
PRESTRESSED CONCRETE
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
6
1. Systems2. Buildings3. Bridges4. Other Applications5. New Developments and Applications
PRESTRESSED CONCRETE
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Strand Type:
Systems:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Tendon Arrangement:
Systems:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Stressing Anchorages:
Type CS Type SC
Systems:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Stressing Anchorages: Type GC
• ETAG013 Compliant for Static Load Test, Load Transfer Test and Fatigue Test.
• Will be approved by HK Highways this year.
• Replaces Type Sc, which complies to the superseded BS4447
Systems:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Type KC
Coupling Anchorages:
Systems:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Type P
Non‐Stressing Anchorages:
Type H
Type AF
Systems:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Sheathing:
Systems:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Systems:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Type S
Stressing Anchorages:
Type VSLAB
S Series
S6‐1
S6‐2
S6‐3
S6‐4
S6‐5
Systems:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Type Bondtech Type S5‐2 S5‐1, S6‐1
Stressing Anchorages:
Systems:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Type SK Type H
Other Anchorages:
Systems:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Individual Strand Stressing
Systems:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Multi‐Strand Stressing
Systems:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Systems:
Cable Stay System & Dampers
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Cable Stays SSI2000:
Systems:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Cable Stays SSI2000:
Systems:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Cable Stay Anchorages:
Systems:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Cable Stay Damper Assembly
Deck connector
Anti‐Vandalism Pipe(AVP)
Gensui Pad
Guide Pipe(GP)
GP bracket
Damper Support(DS)
Cable flange
Systems:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
25
1. Systems2. Buildings3. Bridges4. Other Applications5. New Developments and Applications
PRESTRESSED CONCRETE
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
1. Systems2. Buildings3. Bridges4. Other Structures5. New Developments
and Applications
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Examples of:
Long Span Structures
Grade A Offices
Commercial Buildings
Transfer Beams & Plates
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Hang Seng Bank: PT Beams & RC Slab
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
900mm deep PT beams spanning 29.0m
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
During construction Completed
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Gateway II: Artist’s impression
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
10~12m span, 260mm flat slab w/ drops
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Typical floor tendon layout
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Large cantilever span – 4.5m
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Three towers constructed at the same time
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Gateway II Completed
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
One Island East
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Variable Floor Outline
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Typical Floor PT Layout
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Concreting in progress
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
One Island East:
• 70 storey building (60PT)
• 2,000m2 per floor
• 4/5‐day cycle
• Use of
– VSL Climbform
– Mini tables and
– Safety screens
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Macao Yaohan: PT band beams with 230mm slab
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
During Construction Completed
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Artist’s Impression
Venetian Cotai, Macau, Parcel 1
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Artist’s Impression
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Precast Construction: 20 x 20 m bay
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Example: Level 3 (20 x 20 m Grid)
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
During Construction
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Completed (Right)
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Transfer Beams
Festival Walk, Kowloon Tong
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
PT Transfer Beams: 4.5m deep x 46m span
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Transfer Plates
• Transfer of high concentrated forces
• Thick plates or beams with high rebar content
• Shear Controlled
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Arrangement of Load Bearing Wall & Columns
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Layered Construction
Stage 1: Casting 1st layer (~ 1/3 d)Stressing bottom tendons
Stage 2: Casting remaining plate(supported by 1st layer)
Stage 3: Stressing middle and top tendons
Stage 4: Construction of floors above can proceed
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
0
20
40
60
80
100
120
Concrete Rebars Fmwk Cost
RC
PT
MATERIAL & COST COMPARISONPT VS RC TRANSFER PLATE
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Transfer Plates in Hong Kong
0
5
10
15
20
25
30
35
40
45
88-89 90-91 92-93 94-95 96-97 98-99 00-01 02-03 04-05 06-07 08-09 10-11
Year
Nu
mb
er o
f P
late
s
Design
Completed
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Concrete
0%
20%
40%
60%
80%
100%
120%
RC PC
Reinforcement
0%
20%
40%
60%
80%
100%
120%
RC PC
PT floors help to reduce material handling and labour
Note: Reductions• Concrete: ‐20%• Reinforcement: ‐ 65%• Labour: ‐ 60% Sustainability
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
95.3129.9Total CO2 emission
3.00
PT steelRC = 0PC = 5 kg / m2
8.324.8
Reinforcing steelRC = 42 kg / m2
PC = 14 kg / m2
84.0 105.1
Concrete (300kg cement / m3)RC = 0.35 m3 / m2
PC = 0.28 m3 / m2
PC(kg CO2 / m
2)RC
(kg CO2 / m2)
Materials and quantities
CO2 emission for building floor:
PT offers 27% reduction in CO2 emission in floors!
Buildings:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
61
1. Systems2. Buildings3. Bridges4. Other Applications5. New Developments and Applications
PRESTRESSED CONCRETE
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Standard Bridges: Cast‐in‐place post‐tensioned box girders
Colorado, USA
Bridges
In‐situ post‐tensioned construction
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
In‐situ construction (form‐traveller method)
Bridges
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
In‐situ construction (form‐traveller method)
Bridges
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Precast Beam construction (with O/H Gantry)
Bridges
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Bridges
Precast Beam construction (with O/H Gantry)
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Savings in formwork and scaffolding and improved aesthetics favour precast segmental construction
Precast segmental bridges
Bridges
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Balanced cantilever construction (with O/H Gantry)
Span‐by‐span construction (with O/H Gantry)
Bridges
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Balanced cantilever construction (with Lifting frames)
Span‐by‐span construction (with crawler cranes)
Bridges
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Precast segmental bridges
Bridges
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Large‐scale projects became feasible through introduction of precast segmental construction
Dallas High Five Interchange, USA
Precast segmental bridges
Bridges
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
West Rail project, Hong Kong 13.5km of viaduct 658 spans of 35 to 44m 9400 segments 3500 t internal pt
From highway applications to light rail applicationsPrecast segmental bridges
Bridges
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Avignon viaducts, France 1.5km of twin viaduct Spans of 100m and 50m Precast segmental deck Internal and external pt
…. to high-speed rail bridge applicationsPrecast segmental bridges
Bridges
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Cable Stays for all Climatic Conditions
Cable stay bridges
Bridges
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
75
1. Systems2. Buildings3. Bridges4. Other Structures5. New Developments and Applications
PRESTRESSED CONCRETE
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Union Square, Hong Kong
PT Transfer Plates
PT Out‐Rigger
VSL AF6‐31
Other Applications:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
ELEVATIONPLAN
International Commerce Center (ICC), Hong Kong
Prestressed Out-Riggers
Other Applications:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
IR Sands, Singapore
Vertical Prestressing
Other Applications:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
34 storey leaning tower (18 degrees). Vertical tendons in building core to control leaning of tower (> tower of Pisa).
ABU DHABI, Capital Gate Tower
Vertical Prestressing
Other Applications:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Harbour Side, Union Square K11, Hanoi Road, TST
Vertical Prestressing
Other Applications:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Cable‐Stayed Roof
Alamo Dome StadiumTexas, USA
Borlmage, Sweden
Other Applications:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Thermal Storage Reservoir (14m high x 33m dia)Texas, USA
Silos and Tanks
Other Applications:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Monostrand post‐tensioning for roof (33 m diameter)
Silos and Tanks
Other Applications:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Horizontal & vertical prestressing in walls (355 mm thick)
Silos and Tanks
Other Applications:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Egg‐Shaped Digestors, Singapore
Silos and Tanks
Other Applications:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Circumferential Prestressing
Silos and Tanks
Other Applications:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Omeshi Nuclear Plant, Kansai Electric Power, Japan
Nuclear Containment Vessel (PCCV)
Other Applications:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Off‐Shore Structures
Olje Hedrun GBS
Other Applications:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Skirts and lower domes under construction in dry dock.
Troll Gravity Base Offshore Platform
Off‐Shore Structures
Other Applications:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Platform legs completed and ready to being sunk and towed out
Off‐Shore Structures
Other Applications:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Dimensions : 220 m x 46 m x 16 mDisplacement : 107,000 tons
N’KOSSA‐CONGO Barge
Off‐Shore Structures
Other Applications:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
N’KOSSA‐CONGO Barge
Off‐Shore Structures
Other Applications:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Quantities: 26,400 m3 HPC,4,700 tons Reinf2,700 tons PT
N’KOSSA‐CONGO Barge
Off‐Shore Structures
Other Applications:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
N’KOSSA‐CONGO Barge – towed out
Off‐Shore Structures
Other Applications:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
95
1. Systems2. Buildings3. Bridges4. Other Structures5. New Developments and Applications
PRESTRESSED CONCRETE
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
CONTENTS:
(1)MATERIALS
Concrete
(2)TECHNOLOGIES
PT SYSTEMS
DAMPING DEVICES
New Developments and Applications
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Strength of construction materials has evolved over last 20‐30 years, mainly for concrete
N.B.: Prestressing steel may see increase to 2160MPa soon
Evolution of material strengths
0
500
1000
1500
2000
Structural steel Reinforcing steel Prestressing steel Concrete
Str
en
gth
s (
MP
a)
1980
2000
30200
New Developments and Applications
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Development of:
High‐Strength, High‐Performance Concrete
Ultra‐High Strength Fibre Reinforced Concrete (UHPC) very low water content, small aggregates with high packing density, large amounts of relatively short fibres (≥ 2% of volume, 10‐20mm long)
New Developments and Applications
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Ductal®-FM 300 MPa 150 - 180 MPa
Maximum Charact ValueCompressive strength
0
20
40
60
80
100
120
140
160
180
200
220
0 0,2 0,4 0,6 0,8 1 1,2 1,4 1,6 1,8 2
Strain in %
Com
pres
sive
str
ess
in M
Pa
Ordinary concrete
Ductal
Compression test
®
New Developments and Applications
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Porosity
Low total porosity in range of nano-meters (10-9 m)
Cu
mu
late
d p
oro
sity
of
the
ma
trix
(in
%)
Diameter of pores (nm)
1 10 100 1µm2 3 5 20 50 200
Micro-pores Capillary
C30
C60
C100FSDuctal®
50
40
30
20
10
0
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Applications – Pedestrian bridges
Seonyu / Seoul, Korea
Sherbrooke, Canada Auckland, New Zealand
Sakata Mirai, Japan
New Developments and Applications
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Several highway bridges were built in Australia, Japan, France, USA
GSE Bridge, Haneda Airport Tokyo (2008)
Shepherds Creek bridge, Australia (2004)
New Developments and Applications
Applications – Highway bridges
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
• Haneda International Airport extension, Tokyo Japan
• One third of runway is built on steel jackets with composite
steel‐concrete deck made of HPC and UHPC precast panels
Durability & 55% weight saving the winning UHPC arguments
Applications – Haneda International Airport, Tokyo
New Developments and Applications
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
104
• Fabrication 7000 pretensionedslabs; size 3.8 x 7.8m, total 22’000m3
• 55% weight savings due to use of Ductal®
Applications – Haneda International Airport, Tokyo
New Developments and Applications
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Applications – Protection
UHPC panels as linings to protect pile caps, exposed areas of piers, and tunnels(examples from Japan)
New Developments and Applications
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
CONTENTS:
(1)MATERIALS
Concrete
(2)TECHNOLOGIES
PT SYSTEMS
DAMPING DEVICES
New Developments and Applications
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Approval of PT systems (ETA)
European Approval and Certification scheme ensure that all systems offered on market satisfy essential criteria specified in ETAG013 and have continuous surveillance (FPC and independent audits)
Initial assessment and approval of PT system
by AB
Attestation of
Conformityby CB
Continuous Surveillance(FPC and
control by CB)
Renewal of Certificate of Conformity after 5 years
This concept is considered preferrable over project specific assessment by engineerRef: Guideline for European Technical Approval of PT Kits (ETAG013)
New Developments and Applications
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Qualification of PT company and personnel
PT works shall be carried out by PT specialist companies who have qualified and trained personnel and supervisors / managers Ref: CWA 14646, FIP Recommendations (1996)
New Developments and Applications
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Corrosion protection of tendons must be a key consideration in design of any PT structure
fib/IABSE workshops in Ghent and Zurich
fib Bulletin 33 provides recommendations for corrosion protection of tendons
Ynys‐Y‐Gwas Ynys‐Y‐Gwas
Corrosion protection
New Developments and Applications
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Main problem is access of water with chlorides from the outside into the tendon (or water only if not fully grouted)
Hence, provide leak tight encapsulation to avoid ingress of water and chlorides where applicable
Problem: Access of Problem: Access of water to tendonwater to tendon
Grout voids with water: Corrosion Grout voids without water: No corrosion
Corrosion protection
New Developments and Applications
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Proposal of three protection levels for PT tendons adapted to environment/exposure and structural protection : PL1, PL2 or PL3
PL2
PL3
PL1
Lo
wM
ed
ium
Hig
h
Ag
gre
ssiv
ity
/ E
xp
os
ure
LowMediumHighAction
Structural protection layersStructuralProtection
Corrosion protection
New Developments and Applications
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
PL 1 PL 2
PL1: A duct and a filling material providing durable corrosion protection (metal duct, cement grout)
PL2: PL1 plus an envelope over full tendon length, leak tight barrier (plastic duct and cap)
Corrosion protection
New Developments and Applications
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Rebar
PL3: PL2 plus integrity of tendon or encapsulation to be monitorable or inspectable at any time (e.g. EIT in acc. with Swiss Guidelines)
PL 3
ASTRA Guideline: Measures to ensure the durability of post-tensioning tendons in structures (2001, 2007)
Corrosion protection
New Developments and Applications
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
EIT measuring : Alternating current – resistance measurement High resistance = intact encapsulation
Corrosion protection
New Developments and Applications
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
EIT Tendon : Locating of defect with measurement of magnetic field
Sector A Sector B
i
Alternating current
Pavement
DEFECT
246810121416
Length [m]
Corrosion protection
New Developments and Applications
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Grout:
• Corrosion protection of strands.
• Transfer of forces from strands to concrete.
New Developments and Applications
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Grout Specifications
≥30MPa≥30MPaStrength at 28 days
Cube or cylinder
(50‐100mm)
≥27MPa≥20MPaStrength at 7 days
Plastic Cylinder (100‐200mm high)
≤ 2%≤ 2%Bleed
Plastic Cylinder (100‐200mm high)
‐1% to +5%‐2% to +5%Volume Change
Flow cone
(Dia 10 or 12.7mm)
≤ 25 sec.Flowability / Fluidity
Test MethodEN447FIP GuideProperty
New Developments and Applications
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Standard Grout Tests :
Optimised Grout Common Grout
Standard bleed test is able to identify which grout unstable.
Grout:
New Developments and Applications
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Recommended Types of Testing
TESTS REASONS PROCEDURE
Initial testingof grout
confirmnew grout
Common: tests on sitespecial: optimisation
Approval testingof grout
approvenew grout
confirm grout complieswith requirements
Suitability testingof grout
compare testson site
and laboratory
flow time, bleed, shrinkage,expansion, strength
Quality controltest
control grouton site
local standard testsproject specifications
Full scale sitetesting
if requiredno void, no bleed,
no corrosionat high points
New Developments and Applications
Grout:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
New Grout Tests :• Wick‐Induced Test• Inclined Tube Test
Common Grout
Optimized Grout
New Developments and Applications
Grout:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Inclined Tube Test:
Common Grout
Optimised Grout
New Developments and Applications
Grout:
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Issue of protection of internal tendons in segment joints
Sealing of segment joints withepoxy resin and foam seal
Sealing plastic ducts across segment jointswith leak tight coupling device
New Developments and Applications
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Innovative bridge deck structure for span range100‐200 m
Pakse Bridge, Laos (2000):Extradosed tendons exposed similarly to stay cables
Extradosed bridges
New Developments and Applications
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Pakse Bridge, Laos (143 m extradosed span)
• Span range: 100 - 200 m• Girder depth at mid span:
Span/55• Girder depth at pier: Span/35• Height of pylon above deck:
span/12• ED tendon stress range: 20 -
50 MPa
Note: Continuous transition from segmental span into extradosed span
Extradosed bridges
New Developments and Applications
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Ibigawa/Kisogawa Bridges in Japan Completion 2001 Designer: JBS Inst. Contractors: 4 JVs
New Developments and Applications
Extradosed bridges Extradosed composite bridges with 275 m main spans
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Saddle offer simplified detailing of pylon, reduction of pylon dimensions, and savings in overall cost of pylon
Extradosed tendon specification:‐Max tendon stress 60% GUTS‐Max stress range 140MPa
Extradosed bridges
New Developments and Applications
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
128
Cable saddles with improved static, fatigue and friction performance with individual holes for each strand to comply with tendon performance
New Developments and Applications
Cable Saddles
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Through continuous innovations in structural concrete: materials, technologies and applications
Structural prestressed concrete will remain a material of choice for structures
Conclusions
ASEP SUMMIT 2012June 08-09, 2012Regalia Tower Hotel Suites, Cubao, Quezon City
Creating
Solutions
Together
The End