DSI USA Bonded Post Tensioning Systems Us 01

DYWIDAG Post-Tensioning Systems
Multistrand Systems
Bar Systems
Repair and Strengthening
New Victory
Bridge,
Perth Amboy,
NJ

are world renowned for reliability
and performance, most suitable for
all applications in post-tensioned
construction. They embrace the entire
spectrum from bridge construction and
buildings, to civil applications, above
and below ground.
The first ever structure built with a
prototype DYWIDAG Post-Tensioning
System using bars was the Alsleben
(Germany) arch-bridge in 1927. From
that time on DYWIDAG has continuously improved its systems to keep up
with the growing demand of modern
construction technology. DYWIDAGSystems International (DSI) offers
a complete product line in strand
and bar post-tensioning (bonded,
unbonded and external) as well as
stay-cables being able to fully serve
the post-tensioning construction
industry. DYWIDAG Post-Tensioning
Systems have always combined the
highest safety and reliability standards
with the most e
conomical efficiency
in their research and development.
Dependable corrosion protection methods incorporated into the DYWIDAG
Post-Tensioning Systems contribute to
the longevity of modern construction.
High fatigue resistance is achieved with
optimized material s election and careful
detailing of all components especially in
their s ystem assembly.
Pitt River Bridge, BC, Canada
St. Anthony Falls Bridge, Minneapolis, MN
DSI looks back on many years of

valuable experience in the field of
post-tensioning which leads to our
extremely versatile product range that
offers e
conomical solutions for practically any problem. This includes our
highly d
eveloped, most sophisticated
field equipment which is easy to operate in all phases of installation including
assembly, installation, stressing and
finally grouting.
are being developed and maintained
by DYWIDAG-Systems International
and are serviced and distributed by
a worldwide network of subsidiaries,
licensees and agents. Our systems
comply with the different national
and international specifications and
recommendations (ASTM, AASHTO,
BS, Eurocode, DIN, Austrian Code, SIA,
FIP, fib, EOTA, etc.).
DSI Scope of Services:

consulting
and shop-drawing e
ngineering
n manufacturing and supply
n installation or training and/or
supervision of installation
n inspection and maintenance
n
ndesign
Woodrow Wilson Bridge, Virginia

Approach, Alexandria, VA
Water Tanks, FL
Contents
New Highlands-Sea Bright Bridge,
New Jersey
Post-Tensioning System using Strand ..................................................................... 4

Corrugated Duct......................................................................................................... 5
PE/PP Duct................................................................................................................ 6
Anchorages................................................................................................................ 7
Couplers..................................................................................................................... 9
Available anchorage types / multistrand.................................................................. 10
Installation................................................................................................................ 11
Stressing.................................................................................................................. 12
Grouting.................................................................................................................... 13
Multiplane Anchorage MA........................................................................................ 14
Flat Anchorage FA/Plate Anchorage SD.................................................................. 15
Bond Head Anchorage Z......................................................................................... 16
Coupler M/ME (Floating Anchorage Block)............................................................. 17
Coupler P................................................................................................................. 18
Equipment Overview................................................................................................ 19
Pushing and Grouting Equipment............................................................................ 21
DYWIDAG Bar Post-Tensioning System Details...................................................... 22
Prestressing Bar Properties..................................................................................... 23
Threadbar Accessories..................................................................................... 24
Repair and Strengthening........................................................................................ 28
Post-Tensioning System using Strand

Strand is manufactured from
7 individual cold-drawn wires, 6 outer
wires helically wound around one
center wire (king wire). The mechanical
properties of the strand as well as its
corrosion protection are most important
to DSI. Strand coatings do not affect
the anchorages capacity or efficiency.
For improved corrosion protection we
offer systems using p
olyethylene (PE)
or p
olypropylene (PP) ducts.
See page 6.
Strand is normally packaged

in calwrap coils that typically weigh
up to 3.2 tons.
Epoxy Coated Strand

construction joint
D = drain
V = vent
G = grout injection
V
S
V
S C
C = coupler
V
V
S
V
S = stressing anchorage
P = post-grouting injection
D G P
D G P
E Technical Data
code/specification
ASTM A 416
ASTM A 416
type
0.5 (13 mm)
0.6 (15 mm)
0.5 (13 mm)
0.6 (15 mm)
yield strength fy1) (ksi) 243
243 (N/mm2) 1,670
1,670
ultimate strength fu (ksi) 270
270 (N/mm2) 1,860
1,860
nom. diameter
(in)
0.5
0.6
(mm)
12.7
15.24
cross-sectional area
(in2)
0.153
0.217
(mm2) 98.71
140
weight
(lbs/ft) 0.52
0.74
(kg/m) 0.775
1.102
ultimate load
(kips)
41.3
58.6
(kN)
183.7
260.7
modulus of elasticity
(ksi)
28,000
28,000
(N/mm2) 195,000
195,000
relaxation after 2)
1,000 h at 0.7 x 9013
(%)
2.5
2.5
(%)
2.5
2.5
1)
2)
yield measured at 1% extension under load

applicable for relaxation class 2 according to Eurocode prEN 10138/BS 5896: or low relaxation complying with ASTM A 416, respectively.
Epoxy coated strand used in the

DYWIDAG Post-Tensioning Systems is
Flo-Fill where the interstices are filled
with epoxy during the coating process providing exceptional corrosion

protection. The epoxy coated strand
conforms to ASTM A 882 with either a

smooth or grit impregnated surface.
subject to modification, April 2006
Corrugated Duct
Corrugated metal ducts are the most
economical means to create a void for
the tensile elements. These
thin-walled galvanized corrugated
28ga/0.38 mm - 24ga/0.61 mm sheet
metal ducts a
lso provide a secondary corrosion protection with excellent bond behavior between tendon
grout and concrete. Primary corrosion
protection is p
rovided by the alkalinity
of the grout and concrete.
Dimensions of Corrugated Metal Duct (Standard Sizes)

tendon type
tendon type
sheathing
0.5
0.6
I.D. O.D.

in/mm in/mm

5907
6805
2/50 2.15/54.6
5909
6807
2.375/60 2.6/66
5912
6809
3.12/80 3.31/84
5915
6812
3.52/90 3.7/94
5920
6815
3.63/93 3.82/97

5927
6819
4/100 4.19/106.3

5937
6827
4.6/117 4.78/121.4

6837
5.26/134 5.45/138.4
I.D.
O.D.
The tendon type number (e.g. 5904, 6807) is composed as follows: the first digit (5 or 6)
identifies the nominal strand diameter in tenths of an inch, i.e. 0.5 or 0.6, the last two digits
(..07) reference the number of used strands (= 7 strands). The second digit
is an internal code.
I.D.

tendon type
tendon type
0.5
0.6

5904
6804
5905
6805
5907
6806
5909
6807
5912
6809
5915
6812
5920
6815
5927
6819
5937
6827

6837
min.
center
distances
in/mm
3.90/99
4.25/108
4.61/117
4.61/117
4.61/117
5.67/144
6.38/162
6.73/171
7.80/198
9.25/235
support
distances
up to
ft/m
5.91/1.8
5.91/1.8
5.91/1.8
5.91/1.8
5.91/1.8
5.91/1.8
5.91/1.8
5.91/1.8
5.91/1.8
5.91/1.8
O.D.
PE/PP Round Duct

Thick-walled polyethylene / polypropylene (PPEX3) plastic ducts p
rovide longterm secondary corrosion p
rotection
especially in aggressive e
nvironments
such as waste water treatment plants,
acid tanks or silos.
DYWIDAG-Systems International offers
polyethylene/polypropylene (PPEX3)
ducts in straight lengths up to 80 feet
for all sizes. Standard shipping length
is 40 feet. Longer lengths in coils are
available for all sizes except 130 mm.
Dimensions of Round Corrugated

PE/PP Duct (Standard Size)
tendon type
tendon type

0.5
0.6
5907
6805
5909
6807
5912
6809
5915
6812
5920
6815
5927
6819
5937
6827

6837
sheathing
wall thickness
I.D.
O.D.
in/mm
in/mm
in/mm
2.32/59
2.874/73
.079/2
2.32/59
2.874/73
.079/2
2.99/76
3.58/91
.1/2.54
3.31/84
3.95/100
.1/2.54
3.93/100 4.53/115
.1/2.54
3.93/100 4.53/115
.1/2.54
4.55/115 5.36/136
.14/3.56
5.12/130 5.96/151 .14/3.56
Flat PE/PP Duct

type tendon type

0.6
flat duct
6804
A
B
a
b
wall thickness
(in/mm) (in/mm) (in/mm) (in/mm)
(in/mm)
3.55/90.2 1.55/39.5 3.15/80
1.14/29
.079/2
Multiplane Anchorage MA
The two-part multiplane anchorage is
primarily used for longitudinal tendons
in beams and bridges.
The wedge plate and compact c
onical
anchor body with three load transfer
planes introduces the p
restressing
force gradually into the concrete
member.
The separation of anchor body and
wedge plate makes it possible to insert
the strand after casting the concrete.
The wedge plate self-centers on the
anchor body providing accurate installation as well as trouble-free stressing. The anchorage is also suitable for
cryogenic application (LNG-tanks).
System 100
System 100
stressing
dead end anchorage
coupling
ultimate load
anchorage
accessible not accessible
[kips/kN]

from to

4
4
4
4
287/1,302 2,168/9,644
pocket former for each anchorage system on request
The six bolt hole pattern in the

anchor body is designed to accept a
permanent plastic cap. Multiple grout
ports allow for post grout inspection.
Plate Anchorage SD
The single unit plate anchorage is
designed for slab structures as well as
transverse tendons in bridges. Small
edge and center distances allow for an
economical anchorage layout in tight
situations.
stressing
dead end anchorage
coupling
anchorage

4
4
4 N/A
ultimate load
[kips/kN]
1,040.8/234
Bond Head Anchorage ZF/ZR

Primarily used with prefabricated tendons, it is also possible to fabricate this
anchorage on site. The strand wires
are plastically deformed to ensure safe
load transfer up to ultimate capacity in
the area of the bond head. Anchorage
performance has been proven in static
as well as in dynamic applications.
Depending on the boundary conditions
either a two-dimensional or a threedimensional bond head anchorage
pattern is available.
ZF
ZR
stressing
dead end anchorage
coupling
ultimate load (0.5)
ultimate load (0.6)
anchorage
[kips/kN]
[kips/kN]

from to from to

4

41.3/184 1,115/4,961 58.6/261 1,582/7,037
Loop Anchorage HV
Often used in large plate-shaped
structures, walls, piers or LNG tanks.
The 180 loop should be positioned in
the center of the tendon to minimize
movement of the strand within the loop
during s imultaneous two-end stressing.
stressing
dead end anchorage
coupling
ultimate load
anchorage
[kips/kN]

from to

4

82/372 1.169/5,301
Flat Anchorage FA
The 3-0.6 and 4-0.6 Flat Anchorage
provides strands in one plane with a
trumpet to deviate the strands into
an oval duct. The Flat Anchorage
is designed to be installed in thin
members such as transverse
post-tensioning of bridge decks and
prestressed flat slabs.
stressing
dead end anchorage
coupling
ultimate load
anchorage
[kips/kN]

from to

4
4
4

175/782 234/1043
Flat Anchorage System 100

The two part multiplane anchorage is
designed primarily for bridge transverse
post-tensioning. The System 100
meets the Florida Department Of
Transportation specifications regarding
corrosion protection.
Coupler M/ME (Floating Anchorage Block)

Cylindrical structures (water tanks,
digestor tanks, large pipes or dome
shells) that require circumferential
post-tensioning are the principal applications for the floating coupler M/ME.
The tendon anchorage consists of an
anchorage block with wedge holes on
both sides to accept bare or greased
and sheathed strands. The strands
overlap within the block. The ringtendon is very compact and requires
a small pocket. Stressing is performed
using conventional jacks and a curved
jack nose.
ME
stressing
dead end anchorage
coupling
ultimate load
anchorage
[kips/kN]

from to

4
4

62/279 738/3,348
M anchorage available in 2, 4, 6, 8 and 12-0.6 Versions
Coupler P
P Coupler consists of a multiplane
anchorage body, a standard wedge
plate and a coupler ring that accepts
the continuing strands with swaged
anchorages instead of wedges.
The Coupler P is available in 5, 9, 12,
15, 19 and 27-0.6 versions.

fixed
floating
ultimate load
coupler
coupler [kips/kN]

from to

4
293/1303 1113/4953
Coupler D
The D Coupler is used to lengthen
unstressed tendons in segmental
bridge construction. The coupler
consists of two spring-loaded wedges
that connect two strands individually.

fixed
floating
ultimate load
coupler
coupler [kips/kN]

from

4 58.6/261

Available Anchorage Types

Tendon Type 59 (0.5 system)

59...
01 02 03 04 05 06 07 08 09 12 15 20 27 37
Anchorage Type

Multiplane Anchorage MA l
l
l
l
l
l
Plate Anchorage SD

l
l

l
l
l
l
l
l
l
l
l
l
l
Loop Anchorage HV
l
l
l
l
l
l
l
l
l
l
l
l
l
Coupler D
l
Other size tendons on request
Plate Anchor SD and Flat Anchor FA use 0.5 Jumbo Wedge
Tendon Type 68 (0.6 system)

68...
01 02 03 04 05 06 07 08 09 12 15 19 27 37
Anchorage Type

Multiplane Anchorage MA l
l
l
l
l
l
l
l
Plate Anchorage SD

l
Mono Anchorage EV
l
l
l
l
l
l
l
l
l
l
l
l
Loop Anchorage HV
l
l
l
l
l
l
l
l
l
l
l
l
Flat Anchorage FA
l
l
Coupler M and ME (Floating Anchorage)
l
l
l
l
l
Coupler P l
l
l
l
l
l
Coupler D
l
Other size tendons on request
System drawings are available on request for each type anchorage showing details and assembly instructions.
System 100 castings supplied with 6 bolt holes for installation of p
ermanent plastic cap.
10
Installation
DYWIDAG-Systems International
utilizes two different methods to
insert strands into ducts. The installation method depends on the access
conditions of the structure and the
job site.
Uncoiling Cages
Method 1: Pushing
Pushing strands into the duct on the
job site is very economical and can
be done either before or after casting
the concrete. The pushing equipment
can be installed remotely and a flexible
pipe connected to the insertion point.
DSI strand pushers provide relatively
high speeds of up to 25 ft/s (8 m/s) and
require minimal operating personnel.
These advantages make pushing the
preferred method for strand installation.
Strand Pusher
Method 2: Pulling
To install strands while pulling them
into the duct can be very efficient in
special structures, for example where
the loop anchorage is used. In most
cases the entire bundle of strands is
pulled through the duct using a winch
with a steel cable.
Pre-Assembled Tendons
The prefabrication of tendons either
in the shop or in the field can be very
economical when the tendons are short
and the location of the job site is close.
Special uncoilers and hydraulic winches
are usually required to properly install
the tendons in the structure.
11
Stressing
DYWIDAG has developed a series of
jacks and hydraulic pumps in order
to efficiently and economically stress
its tendons. Versatility is provided by
changing devices that make one unit
adaptable for many different tendon
sizes. DYWIDAG jacks have capacities ranging from 56/250 kips/kN up to
2,191/9,750 kips/kN.
Dywidag jacks are highly sophisti
cated, but still easy to operate. They
employ inner tube bundles with automatic gripping devices that guide the
strand safely through the inside of
the jack. This feature makes it possible to control the s tressing operation
with the highest degree of reliability.
Minimal wedge seating losses can be
achieved with the power seating option.
Power seating hydraulically seats the
wedges with a p
redetermined load,
individually and simultaneously, rather
than relying s imply on friction seating.
DYWIDAG jacks also make it possible
to overstress and release a tendon
to compensate for friction losses and
maximize the stress level over the
tendon length.
Every jack has a pressure relief valve
that safely limits hydraulic pressure
to prevent overload. To verify the
stressing operation a gauge port is provided directly on the jack.
Jack HoZ 4,000
Tensa 4,800
5904 6804 6801 5920
919 . 6803 . 686
Stressed tendons can be safely

destressed by employing special wedges and a special jack c
onfiguration.
Hydraulic pumps are generally
equipped with a convenient remote
control device. Further information
concerning the equipment is provided
on page 19 to 21.
Hydraulic pump
Some important notes concerning the safe handling of high strength strand for prestressed concrete:
1. Do
2. Do
3. Do
4. Do
not
not
not
not
damage surface of the strand.

weld or burn so that sparks or hot slag will touch any portion of the strand which will be under stress.
use any part of the strand as a ground connection for welding.
use strand that has been kinked or contains a sharp bend.
Disregard of these instructions may cause failure of material during stressing.
12
Grouting
The durability of post-tensioned construction depends mainly on the success of the grouting operation.
The hardened cement grout provides bond between concrete and
prestressed steel as well as primary
long-term corrosion protection for the
prestressing steel.
DYWIDAG has developed grouting
methods based on thixotropic and
highly plasticized grout and utilizes
durable grouting equipment. Advanced
methods such as pressure grouting,
post-grouting and vacuum grouting are all results of many years of
development.
Grouting is always done from a lowpoint of the tendon. This can be one of
the anchorages where a grout cap with
grout hose is the port for the grout or
along the tendon utilizing an intermediate grout saddle. All grouting components are threaded for easy, fast and
positive connection.
Mixing and pumping equipment
6819 5909 5907 6801 6802 6804
61 . 5915 . 6837 . 5909 .

Venting operation
Mixing and pumping
Vacuum grouting
13
Multiplane Anchorage MA
Grouting Accessories
J
L
H
L1
ID
XA
XB
XC
XD
OD
L2
PE-Trumpet
Duct Coupler
Duct
Multiplane Anchor
Wedge Plate
Wedges
E Technical Data
Anchorage Size

5-0.6 or
7-0.6 or
9-0.6 or
12-0.6 or
15-0.6 or
19-0.6 or
27-0.6 or
7-0.5 9-0.5 12-0.5 15-0.5 20-0.5 27-0.5 37-0.5
Min.
Block-out Dia. A
7 \ 179
Transition Length
12-3/8 \ 314
Anchor Dia.
B
5-15/16 \ 150

D
3-9/16 \ 90

H
3-9/16 \ 90
Wedge Plate C
5-1/8 \ 130

E
2 \ 50
Trumpet
L1
8-7/8 \ 225
Rebar Spiral* Size
# 4 \ 15M

Grade
60 KSI \

400 MPa 400 MPa

Pitch
1-7/8 \ 50

J
10 \ 255

OD
7-3/4 \ 190
Duct
ID
2 \ 50
Duct Coupler L2
8 \ 200
Grout
Requirements gal/ft \ l/m 0.12 \ 1.5
8 \ 203
13-7/16 \ 341
6-11/16 \ 170
3-7/8 \ 98
3-15/16 \ 100
5-1/8 \ 130
1-9/16 \ 40
9-1/2 \ 241
# 4 \ 15M
60 KSI \
400 MPa
1-7/8 \ 50
10-1/2 \ 265
9 \ 230
2-3/8 \ 60
8 \ 200
9 \ 229
15-3/4 \ 400
7-1/2 \ 190
4-7/16 \ 113
4-15/16 \ 125
5 1/2 \ 140
1-11/16 \ 43
10-13/16 \ 275
# 4 \ 15M
60 KSI \
400 MPa
1-7/8 \ 50
10-5/8 \ 270
9-1/2 \ 240
3 \ 75
8 \ 200
0.17 \ 2.1
0.28 \ 3.46
10 \ 254
11 \ 279
12 \ 305
20 \ 508
22-5/8 \ 575 25-3/16 \ 640
8-5/8 \ 220
9-7/8 \ 250
11 \ 280
5-1/16 \ 128 5-13/16 \ 148 6-3/8 \ 162
7-1/16 \ 180
7-7/8 \ 200
8-5/8 \ 220
6-5/16 \ 160 7-1/16 \ 180
7-7/8 \ 200
1-11/16 \ 43
2 \ 50
2-3/16 \ 55
12-7/8 \ 327 14-3/4 \ 375 16-1/2 \ 419
# 5 \ 15M
# 5 \ 15M
# 5 \ 15M
60 KSI \
60 KSI \
60 KSI \
400 MPa
400 MPa
400 MPa
2-1/4 \ 55
1-7/8 \ 50
1-7/8 \ 50
14 \ 355
14-3/4 \ 365
15 \ 380
11-1/4 \ 285 12-1/2 \ 315 14-1/2 \ 365
3-3/8 \ 85
3-3/4 \ 95
4 \ 100
8 \ 200
8 \ 200
8 \ 200
0.35 \ 4.39
0.44 \ 5.48
0.47 \ 5.80
37-0.6
13-1/2 \ 343
27-5/8 \ 702
12-3/8 \ 315
7-1/2 \ 190
9-7/16 \ 240
9-7/16 \ 240
2-15/16 \ 75
18-1/8 \ 460
# 6 \ 20M
60 KSI \
400 MPa
2-1/4 \ 55
16-5/8 \ 420
17 \ 430
4-1/2 \ 115
8 \ 200
16 \ 407
35 \ 890
14-1/8 \ 360
8-1/2 \ 220
12-1/2 \ 320
10-2/3 \ 270
3-1/2 \ 90
22-1/2 \ 600
# 7 \ 22M
60 KSI \
400 MPa
2-3/8 \ 60
18 \ 460
22 \ 560
5-1/8 \ 130
12 \ 300
0.58 \ 7.25
0.72 \ 8.90
* Spiral required in local anchor zone

All dimensions are nominal and are expressed in inch \ mm.
14
Flat Anchorage FA / Plate Anchorage SD
ID 2
AxB
DxE
ID 1
Flat Anchorage FA
Grouting Accessories
H
SD-Plate Anchorage
Spiral
Duct
PE-Trumpet
ID
DxE
AxB
L2
Duct Coupler
Wedge
Plate Anchorage SD
E Technical Data
Flat Anchorage FA
Tendon Size

Flat
D
Anchorage
E

F
Transition K

L
Pocket
Former

Duct

Combination Plate Anchorage SD
3-0.6 or 4-0.6 or
Tendon Size
3-0.6 or
4-0.6 or
5-0.6 or 6-0.6 or
7-0.6 or
4-0.5 5-0.5 4-0.5 5-0.5 7-0.5 8-0.5 9-0.5
10\255 13\330
Combin. D 4-15/16\125 5-5/16\135 5-7/8\150 6-1/2\165 6-11/16\170
4\100
4\100
Plate
E
5-1/2\140 6-5/16\160 7-1/16\180 8-1/16\205 8-1/2\215
2-1/4\57 2-1/4\57
H 1-5/8\41 1-5/8\41 1-9/16\40 1-3/4\44 1-3/4\44
12-1/4\310

Transition x 2-9/16\65 2-15/16\75 3-3/8\85 3-3/4\95 3-3/4\95
4-1/2 \ 115 8-5/8 \ 220
L
11-3/8 \ 290 10-7/16\265
14\355 15-15/16\405 15-15/16\405
A 10-3/4\275
13-3/4\350
Pocket
B
4-1/2\115 4-7/8\124
Former
C
5-1/2\140 5-7/8\148
ID1
1\25
1\25
Duct
ID2 3\75 3\75
A
6-1/2\165 6-1/2\165 7-1/16\180 7-7/8\200 7-7/8\200
B 7-5/16\185 7-5/16\185 8-1/4\210 9-7/16\240 9-7/16\240
C
3-15/16\100 3-15/16\100 3-15/16\100 4-5/16\110 4-5/16\110
ID 1-9/16\40 1-13/16\46 2-1/16\52 2-7/16\62 2-7/16\62
L2 8\200 8\200 8\200 8\200 8\200
All dimensions are nominal and are expressed in inch \ mm.
15
Bond Head Anchorage Z
Spacer
Grout connection
Slide on Tube
ID
KK
AxB
Grout sleeve
ID 1 x ID 2
Pipe-Sleeve
Duct
Bond Head
Spiral
L
E Technical Data
Tendon Size 3-0.6 4-0.6 5-0.6 7-0.6 9-0.6 12-0.6
15-0.6
19-0.6
Strand Arrangement
P
P
P P
PpP
PpP
PpPp
PpPpP PpPpPpP

P long
B

p short
p
p
p
P
PpP
PpPp
PpPpP PpPpPpP
P P
PpP
PpP
PpPp
PpPpP
PpPpPpP
Tendon Size 3-0.6 4-0.6 5-0.6 7-0.6 9-0.6 12-0.6

15-0.6
19-0.6
Anchorage A
7 \ 178
7 \ 178
11 \ 280
11 \ 280
15 \ 380
15 \ 380
15 \ 380
15 \ 380

B
11 \ 280
13 \ 330
11 \ 280
11 \ 280
11 \ 280
13 \ 330
15 \ 380
19 \ 483

C
3 \ 75
3 \ 75
3 \ 75
3 \ 75
3 \ 75
3 \ 75
3 \ 75
3 \ 75

D
6 \ 150
6 \ 150
6 \ 150
6 \ 150
6 \ 150
6 \ 150
6 \ 150
6 \ 150

L
40 \ 1015
40 \ 1015
40 \ 1015
40 \ 1015
40 \ 1015
40 \ 1015
40 \ 1015
40 \ 1015
Grout Sleeve N
8-1/4 \ 210
9 \ 230
9 \ 230
9 \ 230
9 \ 230
9 \ 230
9 \ 230
9 \ 230
Duct-Round ID

2 \ 50
2-3/8 \ 60
3 \ 75
3-1/2 \ 90
3-3/4 \ 95
4 \ 100
Duct-Eliptical
ID1
1 \ 25
1 \ 25

ID2
2 \ 50
3 \ 75

Spiral
K
4-1/8 \ 105
7-7/8 \ 200
7-7/8 \ 200
7-7/8 \ 200
7-7/8 \ 200
7-7/8 \ 200
7-7/8 \ 200
7-7/8 \ 200

J
10 \ 255
10 \ 255
10 \ 255
10 \ 255
10 \ 255
10 \ 255
10 \ 255
12 \ 305
Lightweight hydraulic equipment is used for fabrication of bond heads. All dimensions are nominal and are expressed in inch\mm.
16
Coupler M/ME (Floating Anchorage Block)

Coupler M
Coupler ME
E Technical Data
Tendon Size 2-0.6 4-0.6 6-0.6 8-0.6 12-0.6
Block-Out Cross Section
X
5-1/8 \ 130
7-1/16 \ 180
7-1/16 \ 180
9 \ 230
9 \ 230
for 2 [50 mm] Concrete Cover

Y
6-1/8 \ 155
7-11/16 \ 195
7-11/16 \ 195
7-11/16 \ 195
9-1/4 \ 235

A
3-1/2 \ 90
5-1/8 \ 130
5-1/8 \ 130
5-1/8 \ 130
6-5/8 \ 168

B
4-1/8 \ 105
6-1/4 \ 160
6-1/4 \ 160
8-1/4 \ 210
8-1/4 \ 210

C
4-3/4 \ 120
4-3/4 \ 120
4-3/4 \ 120
4-3/4 \ 120
4-3/4 \ 120
Duct
E
7-7/8 \ 200
25-5/8 \ 650
25-5/8 \ 650
41-3/8 \ 1050
45-1/4 \ 1150

Rectangular
AD
2-3/8 \ 60
2-3/8 \ 60
2-3/4 \ 70
2-3/4 \ 70
2-3/4 \ 70

Rectangular
BD
2-3/4 \ 70
5-1/8 \ 130
5-1/8 \ 130
6-5/8 \ 170
6-5/8 \ 170

Round
D
1-3/4 \ 45
2-1/8 \ 55
2-5/8 \ 65
3 \ 75
3-1/8 \ 80

Min. Distance
Z
2 \ 50
2-3/4 \ 70
2-3/4 \ 70
2-3/4 \ 70
3-1/2 \ 90
Min. Required Distance
L2
17-3/4 \ 450
27-1/2 \ 700
27-1/2 \ 700
53-1/8 \ 1350
59 \ 1500
after Stressing
Space Required for
LR
21-5/8 \ 550
23-5/8 \ 600
23-5/8 \ 600
23-5/8 \ 600
27-1/2 \ 700
Stressing Jack Nose
Block-Out Length
L = s + 11-1/4 (285 mm) + L2
If LR m L2 - 1/2 iL

L = s + 1/2 iL + 11-1/4 (285mm) + Ls
If LR M L2 -1/2 iL

Where s = 0.2 x 1/2 iL, but 5 (125 mm) min.

iL is Elongation
All dimensions are nominal and expressed in inch\mm.
17
Coupler P
Dywidag Coupler P utilizes a

standard wedge plate and a slotted
coupling ring bearing on the multi-plane
anchorage. An extruded grip is hydraulically installed on the ends of the coupled strands and the strands are placed
in the slots of the coupling ring. This
system provides a simple and inexpensive solution for coupling large strand
tendons.
E Technical Data
type
0.6

6805
6809
6812
6815
6819
6827
x A
x B C D
(in/mm) (in/mm) (in/mm) (in/mm)
6.93/176 4.53/115 5.2/132 20/510
9.29/236 8.07/205 5.35/136 22.44/570
10.24/260 8.86/225 5.71/145 29.72/755
11.42/290 9.84/250 5.91/150 29.72/755
12/305 10.43/265 6.1/155 34.65/880
14.37/365 12.6/320 6.69/170 35.63/905
E Details of the Coupler Zone

type
0.6

6805
6809
6812
6815
6819
6827
18
center distances
length of space
of anchorages
for installation
in/mm in/mm
11.81/300
78.75/2000
14.17/360
78.75/2000
15.35/390
78.75/2000
16.54/420
78.75/2000
18.90/480
78.75/2000
22.83/580
78.75/2000
Equipment Overview
Hydraulic Jacks
Monostrand Jack
Tensa 4,800 / 6,800 / 8,600
HoZ 3,000 / 4,000

59 .. (0.5)
68 .. (0.6)
jack type
01 02 03 04 05 06 07 08 09 12 15 19 27 37 01 02 03 04 05 06 07 08 09 12 15 19 27 37
Mono 0.6
l l
HoZ 950 l l l l l l l
HoZ 1,700 l l l l l l l
HoZ 3,000 l l l l l
HoZ 4,000 l l l l
Tensa 260 l l l
Tensa 3,000 l l l
Tensa 4,800 l l
Tensa 6,800 l l
Tensa 8,600 l
Tensa Style
HoZ Style
L
L
E Technical Data
jack type1)
length L3)
diameter D
stroke
piston area
capacity2) weight
2
2

(in/mm) (in/mm) (in/mm) (in /cm ) (kip/kN) (lbs/kg)

Mono 0.6
21.5/546
n/a
8.5/213
7.95/51.3
60/267
52/24

HoZ 950
24.45/621
8/203
3.94/100
25.1/162
218/972
144/65

HoZ 1,700
31.6/803
11/280
5.9/150
46.26/298.45
392/1,745
354/160

HoZ 3,000 44.76/1,137
15.16/385 9.84/250 78.9/509 687/3,054 884/400

HoZ 4,000 50/1,271 18.98/482 9.84/250 138.7/894.6
945/4,204 1,326/600
Tensa 2,600
30.93/785 14.57/370 9.84/250 85.2/549.8 572/2,546 729/330
Tensa 3,000
30.93/785 14.57/370 9.84/250 85.2/549.8 680/3,024 782/354
Tensa 4,800
39.63)/1,005 18.5/470 11.81/300 135.86/876.5 1,083/4,820 1,432/648
Tensa 6,800
45.33)/1,150 22/560
11.81/300 191.7/1,237 1,529/6,803 2,619/1,185
Tensa 8,600
463)/1,170
26.8/680
11.81/300 274.7/1,772.5 2,191.4/9,748 3,912/1,770
NOTE:
Detailed operating
and safety instructions are p
rovided
with all stressing and
grouting units. Read
and u
nderstand these
instructions before
operating equipment.
1) power seating included

2) without friction
3) retracted position
19
Equipment Overview
Hydraulic Pumps
PE 55
PE 4000
R 11.2 - 11.2/210

jacks
0.6
HoZ
HoZ
HoZ
HoZ
Tensa
Tensa

mono 950 1,700 3,000 4,000 6,800 8,600

Tensa
Tensa

3,000/260
4,800
Pumps
PE55
l
l
PE4000/PE55
l
l
l
R11.2 l
l
Width W
H
PE 4000
R 11.2
E Technical Data
Pumps

operating
pressure
psi/MPa
capacity
V/min
Gpm/Lpm
eff.
weight
oil amount
G/L
lbs/kg
dimensions
LxWxH
in
dimensions
LxWxH
mm
amp draw
PE55
PE4000
R11.2
10,000/69
.31/1.14 2/7.57 65/29.4 11.5/9.5/18.25 292/241/464 252)
10,000/69
1.951/7.37 20/75.7 492/223 25/24/36.5 635/610/927 173)
7,970/55 5.9/22.4 44.9/170 1,590/720 78.75/31.5/51.2 2,000/800/1,300 463)
1) At operating pressure
2) At 10,000 psi, 115 Volt
3) At 460 Volt
20
Pushing and Grouting Equipment

Pushing Equipment
802
mm
500
mm
ESG 8 - 1
type
pushing
pushing
weight
dimensions
hydraulic

force
speed
L x W x H
pumps

kips
ft/s
lbs
in
_______ _______ _______ _______

kN
m/s
kg
mm
ESG 8 - 1
0.88
20
309
55/13.8/20
ZP 57*

_______ _______ _______
_______________

3.9
6.1
140
1,400/350/510
amp
draw
44
* Can also use R35 pump.
Grouting Equipment
(mixing and pumping)
72-1/2
56
104
CG600 Colloidal
grouting equipment

CG600 Colloidal

with Moyno pumps

max
capacity
weight
injection
pressure
psi
gpm
pounds
________ ________ ________
MPa
l/h
kg
dimensions
LxWxH
with Piston
Pump

(1,000 psi)
1,000
20
1,725
90 x 37 x 63
________ ________ ________
___________________
6.9
4542
784
2286 x 940 x 1600
in
________
mm
250
20
1,100
90 x 37 x 63
________ ________ ________
___________________
1.7
4542
500
2286 x 940 x 1600
Note: Air pressure required to operate is 280 cfm@100 psi
21
DYWIDAG POST-TENSIONING SYSTEM USING BARS

DYWIDAG BARS
The components of the DYWIDAG
Bar System are manufactured in
the United States exclusively by
DYWIDAG-Systems International. Used
worldwide since 1965, the system
provides a s imple, rugged method of
efficiently applying prestress force to a
wide v ariety of structural applications
including post-tensioned concrete, as
well as rock and soil anchor systems.
Available in 1 (26.5 mm),
1 1/4 (32 mm) and 1 3/8 (36 mm)
THREADBARS are hot rolled and
proof stressed alloy steel conforming to
ASTM A722 CAN/CSA (G279-M1982).
The 1 3/4 (46 mm) and 2 1/2 (65 mm)
nominal diameter bar is cold drawn
quenched and tempered alloy steel
which after threading also c
onforms
to the strength properties specified in
A722.
The DYWIDAG THREADBAR prestressing steel has a continuous rolledin pattern of thread-like deformations
along its entire length. More durable
than machined threads, the deformations allow anchorages and couplers to
thread onto the THREADBAR at any
point. The 1 3/4 (46mm) and 2 1/2
(65mm) bar can be cold threaded for its
entire length or if enhanced bond is not
required the bars can be supplied with
threaded ends only.
The strength of the DYWIDAG

anchorages and couplers exceeds
the requirements of ACI 318 and the
PTI Acceptance Standards for PostTensioning Systems.
Bars may also be galvanized, but will
lose about 5% of their strength. Epoxy
coating is the preferred method.
Test reports are available for the
principal components of the system.
Conforming to the requirements of
ASTM A615, the deformations develop
an effective bond with cement or resin
grout. The continuous thread simplifies stressing. Lift-off readings may
be taken at any time prior to grouting
and the prestress force increased or
decreased as required without causing
any damage.
Placing DYWIDAG THREADBAR

nchorages is simplified by the use of
a
reusable plastic pocket formers. Used
at each stressing end, the truncated,
cone-shaped pocket former can extend
through, or butt up against the form
bulkhead.
Threadbars are available in mill lengths
to 60 (18.3 m), and may be cut to
specified lengths before shipment to
the job site. Where circumstances
warrant, the threadbars may be
shipped to the job site in mill lengths
for field cutting with a portable friction
saw or coupled to extend a previously
stressed bar. Cold threaded 1 3/4
(46 mm) and 2 1/2 (65 mm) diameter
are available in lengths up to 45 feet.
The DYWIDAG Bar System is primarily used for grouted construction. In

addition they are sometimes used as
external tendons with various types of
corrosion protection.
All system components are designed
to be fully integrated for quick and simple field assembly. Duct, duct transitions, grout sleeves and grout tubes all
feature thread type connections.
Tendon duct can be metal or plastic. Galvanized or epoxy coated
accessories that thread over the coated
bar are available.
Threadbar
22
Prestressing Bar Properties

Nominal
Ultimate Cross Section Ultimate
Prestressing Force
Weight
Minimum*
Maximum

Bar
Stress
Area
Strength
Elastic Bending
Bar
Diameter
fpu Aps
fpu Aps (kips)(kN) (lbs./ft.) Radius Diameter
(in.) (mm)
(ksi) (Mpa)
(in.2) (mm2)
(kips) (kN)
0.8 fpu Aps 0.7 fpu Aps 0.6 fpu Aps
(kg/m)
(ft.) (m)
(in) (mm)

1 in. 150 0.85 127.5 102.0 89.3 76.5 3.01 52 1.20

26 mm
1,030 548 567 454 397 340 4.48 15.9 30.5
11/4 in. 150 1.25 187.5 150.0 131.3 112.5 4.39 64 1.46

32 mm
1,030 806 834 662 584 500 6.54 19.5 37.1
13/8 in. 150 1.58 237.0 189.6 165.9 142.2 5.56 72 1.63

36 mm
1,030
1,018 1055 839 738 633 8.28 22.0 41.4
13/4 in.
150 2.62 400 320 280 240 9.22 92 2.00

46 mm 1,030 1,690 1,779 1,423 1,245 1,068 13.72 28.0 51.0
21/2 in.
150 5.16 774 624 546 4,618 18.2 2.79

66 mm 1,030 3,331 3,442 2,753 2,409 2,065 27.1 70.9
* Prebent bars are required for radii less than the minimum elastic radius
** Grade 160 bar may be available on special request
Steel Stress Levels

Dywidag bars may be stressed
to the allowable limits of ACI 318.The
maximum jacking stress (temporary)
shall not exceed 0.80 fpu, and the
transfer stress (lockoff) shall not
exceed 0.70 fpu.
ACI 318 does not stipulate the
magnitude of prestress losses or the
maximum final effective (working)

prestress level.
Prestress losses due to shrinkage, e
lastic shortening and creep of
concrete, as well as steel relaxation
and friction must be considered.
The final effective (working) prestress
level depends on the specific application. In the absence of a detailed
nalysis of the structural system,

a
0.60 fpu may be used as an
approximation of the effective (working)
prestress level.
Actual long term loss calculations
require structural design information
not normally present on contract documents.
Some important notes concerning the safe handling of high strength steel for prestressed concrete:
1. Do
2. Do
3. Do
4. Do
not
not
not
not
damage surface of bar.

weld or burn so that sparks or hot slag will touch any portion of bar which will be under stress.
use any part of bar as a ground connection for welding.
use bar that has been kinked or contains a sharp bend.
Disregard of these instructions may cause failure of material during stressing.
Cold Threaded bar
23
Threadbar Accessory Dimensions
Anchorage Details
Bar Diameter
1
26 mm
1-1/4
32 mm
1-3/8
36 mm
1-3/4
46 mm
Anchor Plate Size*
5 x 5 x 11/4 127 x 140 x 32 6 x 7 x 11/2 152 x 178 x 38 7 x 71/2 x 13/4 178 x 191 x 44 9 x 9 x 2 230 x 230 x 57
Anchor Plate Size*
4 x 61/2 x 11/4 102 x 165 x 32 5 x 8 x 11/2 127 x 203 x 38 5 x 91/2 x 13/4 127 x 241 x 44
-
-
Nut Extension a
1-7/8 48 21/2 64 23/4 70 27/8 74
Min. Bar Protrusion **B
3
76
31/2 89 4 102 35/8 92
*other plate sizes available on special order. **To accommodate stressing
Coupler Details
Length C
For plain bars
61/4 159 63/4 171 83/4 219 63/4 171
For epoxy coated bars
73/4 197 81/4 210 101/8 267 83/4 222
Diameter d
2
51
23/8 60 23/4 67 31/8 79
Duct Details (galvanized steel)
Bar Duct O.D.
17/8 47 2 51 21/8 55 23/4 70
Bar Duct I.D.
15/8 43 17/8 48 2 51 25/8
67
Coupler Duct O.D.
23/4 70 3 76 31/2
87
4
101
Coupler Duct I.D.
25/8 67 27/8 72 31/4 83 33/4 95
Duct Details (plastic duct)
Bar duct OD
27/8 73 27/8 73 27/8 73 27/8 73
Bar duct ID
29/32 63 29/32 63 29/32 63 29/32 63
Coupler duct OD
27/8 73 39/16 90.5 37/8 98.4 417/32 115
Coupler duct ID
29/32
63 3 76
31/4 82.5 315/16 100
Pocket Former Details
Depth 71/8 178 8 203 85/8 219 N/A N/A
Maximum Diameter
51/8 130 61/2 165 61/2 165 N/A N/A
Plate Anchorage
Coupler
c
Pocket Former Detail

Plug
Bulkhead
Grout Tube
Coupler Duct
Pocket Former
w/gasket (reusable)
Plate
Connector
Plastic Nut
(reusable)
Coupler
Grout Sleeve
Bearing Plate
Stressing End
24
2-1/2
66 mm
12 x 14 x 21/2 305 x 356 x 63.5
-
5
127
53/8 136.5
Modulus of Elasticity
Stress-strain characteristics
The modulus of elasticity E is an

intrinsic property of steel whose
magnitude remains basically constant and is little affected by normal variations in mill processes.
For Threadbars this value has been
determined to be 29,700 ksi (205 MPa).
A typical stress-strain curve for a

stretched and stress relieved bar is
substantially different from a typical curve produced for a cold drawn,
cold threaded bar. Samples of each
are illustrated below.The most notable
feature is the lack of a definite yield
point characteristic of cold drawn bars.
Relaxation

103/4 273

103/4 273

41/2 114

3 15/32 88
3 9/32 83.7
5 7/16 138

51/4 134

37/8 98.4

31/4 82.5

6
152.4

5
127

N/A N/A

N/A N/A
Fatigue strength
Relaxation is defined as the loss of
prestress load in a post-tensioning
steel subjected to a specified initial
stress while maintaining the length and
the temperature constant. Relaxation
tests are usually conducted at an initial load equal to 70% of the strands
actual ultimate strength (see chart
below). The tension loss after 1,000 hrs
for a Threadbar initially stressed to
70% of guaranteed ultimate strength
can be assumed between 1.5 and
2%.Tests indicate that the relaxation
losses in cold drawn, cold threaded
bars are significantly higher.
Relaxation
Under normal circumstances fatigue

is not a primary design consideration
for prestressing steels. However, all
Dywidag bars and accessories have
been tested and proven to exceed the
fatigue requirements specified by the
Post-Tensioning Institute.
Temperature characteristics
Tests have demonstrated that no
significant loss of strength occurs
when bars are subjected to elevated
temperatures up to 1,100 degrees F
(593 C). Only the yield strength is
reduced when temperatures exceed
approximately 750 degrees F (399 C).
Bar d
uctility is not significantly affected
by temperatures down to -60 degrees
F (-51 C).
Susceptibility to stress
corrosion cracking and hydrogen
embrittlement
Stress-strain characteristics
All prestressing steel is susceptible to

stress corrosion cracking and hydrogen
embrittlement in aggressive environments and therefore must be properly
protected. However, accelerated tests
have demonstrated that while A 416
strand failed after 5 to 7 hours, bars
still held their load when testing was
discontinued at 200 hours.
Bond
The deformations on the DYWIDAG
Threadbar exceed the deformation
requirements of A 615. Consequently
bond strength is at least equivalent to
A 615 reinforcing bars.
Shear
High strength bars are not usually
used to resist transverse shear loads.
However, their untensioned shear
strength is similar to that of any other
steel.
fy
t=

S3
25
Stressing
Dywidag Threadbars are stressed
using compact lightweight hydraulic jacks. In most cases handled by
one man, the jack fits over a pull
rod designed to thread over the
threadbar protruding from the
anchor nut. The jack nose c
ontains
a socket wrench and ratchet device
which allow the nut to be tightened as
the threadbar elongates. 13/4 and
21/2 bars utilize specially equipped
center-hole stressing jacks.
The magnitude of the prestressing
force applied is monitored by reading the hydraulic gauge pressure
and by m
easuring the threadbar
elongation. The elongation can be
measured d
irectly by noting the change
in threadbar protusion.
a**
b
d
d = Total tendon elongation
Jack Capacity Kips 67 160 220 330* 630*

kN 267 712 979 1,500
2,800
5/
Bar Size in
1, 11/4 11/4, 13/8 13/4 21/2
8

mm
15
26, 32
32, 36
46
66
a**
in 73/4 81/2 11 N/A N/A

mm 197 216 279
b
in 31/4
4 6 6 7

mm 83 102 152 145 180
Min. c
in 24 26 30 36 43

mm 610 660 762 900 1,070
Weight
lbs 50 80 110 334* 500

Kg 23 36 50 152
227
* This system should have a mechanical means of lifting and moving.
** Special nose extensions for deep stressing pockets are available on request.
NOTE: Detailed operating and safety instructions are provided with all
stressing and grouting units. Read and understand these instructions before
operating equipment.
Grouting
Grouting completes the installation
process for post-tensioned concrete
construction.The grout is important in
protecting the steel from corrosion and
contributes significantly to the ultimate
strength of the structure.
After mixing, the grout is injected into
a low point vent until consistent material is exhausted at the terminating or
anchorage vent. An admixture may
be used to control expansion and
pumpability.
CG 500
26
DYWIDAG Threadbar Details & Applications
Temporary Threadbars for Precast

Segmental Construction
Threadbar Stressing Operation

Mopac Freeway/US 183 Interchange Austin, TX.
Typical Threadbar Tendon Installation,

Aeration/Equalization Basin McIntosh, AL
Bridge Repair Threadbar Stays Route 580

Altamont Pass, California
27
Repair & Strengthening

Inspection and Repair
of Grouted Tendons
With over twenty years of experience
in the field of inspection and repair
of structures, DSI offers a complete
service package that includes
Non-Destructive Testing (NDT) for
the non-invasive detection of flaws
in s tructures, in particular, problems
of voids in grouted post-tensioning
tendons. DSI also offers special
equipment such as metal sensitive
drills and videoscopes for the limited
invasive inspection at suspect locations in the structure, digital volumeters
that measure the volume of any void
inside the tendon and vacuum grouting
equipment for subsequent filling of the
void.
Non-Destructive Testing (NDT)

DSIs procedures for NDT include
locating the ducts in the concrete using
Ground Penetrating Radar (GPR), then
using Impact Echo instrumentation to
determine the location of any voids
located inside the grouted tendons.
Using Impact Echo to locate

voids in the tendon
Locating tendons using GPR

Vibration testing of external tendons
Vibration Testing
Vibration Testing is an economical and
efficient procedure used to determine
the amount of force existing in external
tendons. The method consists of an
external sensor located on the tendon
to be tested and then generating a
Invasive Inspections
The NDT inspection
shall be followed
by limited invasive
inspection to verify
the NDT findings. DSI
offers special devices
and techniques developed to minimally
invade the structure in
order to determine the
actual conditions of
the grouted tendons
and protect the
prestressing steel
during the inspection.
28
Volume Measuring
DSI is able to determine the volume of the
void through the use
of a Digital Volumeter
with leak compen
sating capabilities.
vibration in the tendon. The tendon

response is recorded and analyzed
with special software that will compute,
based on the tendon characteristics,
the remaining force in the tendon.
Grout Remediation of PT Tendons

DSI uses vacuum grouting techniques
& experienced personnel to fill any
voids. As a necessary check, the
volume of material injected in the void
should be compared to the volume
previously measured.
DSI uses only ASBI certified grout

technicians cross trained in NDT
inspection. All technicians have
extensive experience in both pressure and vacuum grouting techniques
employing thixotropic grout.
Result of void grouted with

conventional methods
Result of void grouted with Vacuum

Grouting
Digital Volumeter
with leak compensating capabilities
Repair & Strengthening

Repair of the Trent Street Bridge, Spokane, WA
Washington Department of Transportation
DSI performed an NDT inspection
using Ground Penetrating Radar to
detect post-tensioning ducts and steel
reinforcement as well as an Impact
Echo Scanner to detect voids in the
grouted ducts. Videoscope inspections were carried out to assess
the c
ondition of the post-tensioning
strands. The volume of voids inside the
ducts was measured with state-of-theart equipment capable of compensating
for air leaks. The grouting remediation
of the post-tensioned tendons in web b
was performed using vacuum grouting.
DSI Services Inspection: NDT (GPR and Impact Echo), Special drills with shut-off
capabilities when in contact with metal, Videoscope and Void volume measurement with
air leak compensation capabilities / Repair: Vacuum Grouting
Mid Bay Bridge, Destin, FL

Mid Bay Bridge Authority
Inspection at anchorage areas of
external tendons of the bridge and
vacuum grouting of voids.
DSI Services Inspection and

Measurement of the Volume of Voids /
Repair: Vacuum injected more than
700 voids Engineering: Assisted in
preparing procedures for detensioning
and replacement of 11 external tendons
C & D Canal Bridge, SR1 over

Chesapeake & Delaware Canal,
St. Georges, New Castle Co.,
Delaware
Delaware Department of Transportation
DSI Services NDT inspection, by videoscope, of 18 cable stay guide pipes

at the stays and NDT, limited invasive
inspection and vacuum grouting of the
anchorages of the external P.T. tendons
in the bridge
I-88 & I-355 Interchange,

Downer Grove, IL
The Illinois State Toll Highway Authority
Overall inspection of the posttensioning tendons of 4 segmental
ramps. Inspection included both,
tendons in the superstructure as well as
in the substructure.
DSI planned and performed NDT
and limited invasive inspection in a
selected sample of the post-tensioning
tendon population of these ramps
and assessed the condition of those
elements of the structure (i.e. condition
of the prestressing steel and grout).
DSI Services Preparation and implementation of the inspection plan. Inspection

included the use of GPR, IE, vibration testing of external tendons, drillings, videoscope,
volume measurement of the voids found inside the ducts and report preparation
29
Repair & Strengthening Special Products

Half Pipe
DSIs half pipe is the perfect solution
for cracked or cracking HDPE external
grouted ducts.
Developed to be installed in difficult
access contitions, the Half Pipe snaps
into place over an existing HDPE
duct and has been engineered so
that the annular spaces can be pressure g
routed; restoring the tendon
to its original corrosion protection
specifications.
Cracked HDPE Duct
30
The DSI Half Pipe also allows for the

complete removal of the existing HDPE
pipe to assess the condition of the
grout and strands, if required, prior to
its installation.
Simulated Repair of Cracked

HDPE (White Pipe) duct using Half
Pipe (Outer black Pipe). Annulus
between pipes has been grouted.
DYWIDAG-Systems
International Canada Ltd.
320 Marmon Drive

Bolingbrook, IL 60440
Phone (630)-739-1100
Fax (630)-739-5517
E-Mail [email protected]
Eastern Division
37 Cardico Drive
Gormley, ON L0H-1G0
Phone (905) 888-8988
Fax
(905) 888-8987
1263 Newark Road

Toughkenamon, PA 19374
Phone (610) 268-2221
Fax (610) 268-3053
1591 E. Atlantic Blvd #200
Pompano Beach, FL 33060
Phone (954) 532-1326
Fax (954) 532-1330
5139 South Royal Atlanta Drive
Tucker, GA 30084
Phone (770) 491-3790
Fax (770) 938-1219
2400 Hwy 287 N, Suite 106
Mansfield, TX 76063
Phone (817) 473-6161
Fax (817) 473-1453
2154 South Street
Long Beach, CA 90805
Phone (562) 531-6161
Fax (562) 529-2225
Western Division
19433 - 96 th Avenue
Suite 103
Surrey, BC V4N 4C4
Phone (604) 888-8818
Fax
(604) 888-5008
Calgary Office
2816 - 21st Street N.E., # 204
Calgary, Alberta T2E 6Z2
Phone (403) 291-4414
Fax
(403) 250-5221
Quebec Office
C.P. 412
St. Bruno, Quebec
QC, J3V 5G8
Phone (450) 653-0935
Fax
(450) 653-0977
A ust r ia
A r gentina
A ust r alia
belgium
B osnia and he r zegovina
B r azil
C anada
C hile
C olombia
C osta Rica
C r oatia
C zech r epublic
D enma r k
E gypt
estonia
F inland
F r ance
G e r many
G r eece
Details, dimensions and system designs are subject to change without notice.
DYWIDAG-Systems
International USA Inc.
GUATEMALA
HONDURAS
H ong K ong
I ndonesia
I taly
J apan
K o r ea
L ebanon
L uxembou r g
M alaysia
M exico
N ethe r lands
N o r way
O man
P anama
P a r aguay
Peru
POLAND
P o r tugal
Q ata r
S audi A r abia
singapo r e
S outh A f r ica
S pain
S weden
S witze r land
T aiwan
T hailand
T u r key
U nited kingdom
U r uguay
USA
V enezuela
w w w. d s i a m e r i c a . c o m
w w w. d s i c a n a d a . c a
04190-1/04.12-ca web
Please note:
This brochure serves basic inFrmation
purposes only. Technical data and inFrmation
provided herein shall be considered
non-binding and may be subject to change
without notice. We do not assume any liability
Fr losses or damages attributed to the use
of this technical data and any improper
use of our products. Should you require
further inFrmation on particular products,
please do not hesitate to contact us.
U nited A r ab E mi r ates

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DYWIDAG Post-Tensioning Systems

DYWIDAG Post-Tensioning Systems

Pitt River Bridge, BC, Canada

St. Anthony Falls Bridge, Minneapolis, MN

DSI looks back on many years of

DSI Scope of Services:

Woodrow Wilson Bridge, Virginia

Post-Tensioning System using Strand ..................................................................... 4

Post-Tensioning System using Strand

Strand is normally packaged

Epoxy Coated Strand

yield measured at 1% extension under load

Epoxy coated strand used in the

with epoxy during the coating process providing exceptional corrosion

conforms to ASTM A 882 with either a

subject to modification, April 2006

Dimensions of Corrugated Metal Duct (Standard Sizes)

subject to modification, April 2006

PE/PP Round Duct

Dimensions of Round Corrugated

Flat PE/PP Duct

subject to modification, April 2006

The six bolt hole pattern in the

pocket former for each anchorage system on request

Bond Head Anchorage ZF/ZR

subject to modification, April 2006

Flat Anchorage System 100

subject to modification, April 2006

Coupler M/ME (Floating Anchorage Block)

subject to modification, April 2006

Available Anchorage Types

Tendon Type 68 (0.6 system)

subject to modification, April 2006

subject to modification, April 2006

Jack HoZ 4,000

5904 6804 6801 5920

919 . 6803 . 686

Stressed tendons can be safely

damage surface of the strand.

Disregard of these instructions may cause failure of material during stressing.

subject to modification, April 2006

Mixing and pumping equipment

6819 5909 5907 6801 6802 6804

61 . 5915 . 6837 . 5909 .

Mixing and pumping

subject to modification, April 2006

* Spiral required in local anchor zone

subject to modification, April 2006

Flat Anchorage FA / Plate Anchorage SD

Combination Plate Anchorage SD

All dimensions are nominal and are expressed in inch \ mm.

subject to modification, April 2006

Bond Head Anchorage Z

Tendon Size 3-0.6 4-0.6 5-0.6 7-0.6 9-0.6 12-0.6

subject to modification, April 2006

Coupler M/ME (Floating Anchorage Block)

subject to modification, April 2006

Dywidag Coupler P utilizes a

E Details of the Coupler Zone

subject to modification, April 2006