Post-Tensioning System, Hirun-Catalogo-Hipost

HIPOST
HIPOST POST TENSIONING SYSTEM
POST TENSIONING SYSTEM
Kaohsiung Port Expressway

Kaohsing, Taiwan
INTERNATIONAL
The engineering solution.

1. The light and easily handled

solution for unattainable places.
Post tensioning is mainly applied to concrete structures but may
also be applied to structures made of different materials like steel,
wood or others.
It became possible when the industry became able to supply

extremely high resistance steel, with tensile stress between 1000
and 2000 MPa. That happened in the first half of the XX century.
Since then the post tensioning has been applied to a countless

number of structures like bridges, buildings, tanks, marine
structures and many others.
Post tensioning can be applied utilizing high tensile steel bars or
wires or strands.
Strands are normally made of 7 wires, 1 of them straight, the other

6 twisted around it and are the most commonly used because
they minimize the cost of assembling of the post tensioning
tendon made of several strands grouped in the same duct.
HIPOST post tensioning system foresees the use of 15 mm

diameter 7 wires strands.
Requires specialized team

Main Field INSTALLATION
Any structure, particularly unattainable > 100 years
places like the inside of box girders. DURABILITY
None
MAINTENANCE
Medium
COST
2. Stressing structures
to improve their strength.
The HIPOST system) is composed of a tendon or cable, made out of steel

strands, in quantity from 4 to 31, and the associated set of anchorages
and accessories.
The HIPOST system is mainly intended for use for “bonded” applications
for internal bonded tendon for concrete and composite structures with
anchors placed in the concrete and for “unbonded application” for
Internal unbonded tendon for concrete and composite structures with
anchors placed in the concrete
In the case of “bonded cables” the strands are located within a duct that
constitutes a round conduit. The void created is then filled with a grout
according to EN 447 or EAD 160027-00-0301 for the purpose of bonding
with the structure and inhibiting corrosion.
In case of “unbonded cables” the strands are individually protected by
HDPE pipes, with thickness from 1.0 to 1.5 mm, and to ensure the single
corrosion protection they are greased with normally a quantity of grease
equal to 35 g/m.
In case of particular requirements the HIRUN INTERNATIONAL POST
TENSIONING KIT can also be used with unbonded strand, with HDPE
single pipe protection, with strand galvanization in accordance with
prEN10337 and waxed or greased.
The HIPOST system passed all the static and fatigue tests foreseen
by the EAD - 160027 - 00 - 0301. All test certificates endorsed by the
Notified body are available.
The main test certificates in accordance with ETAG 013

3. Strands
The constituting strands are those defined in the European standard "prEN 10138-3: Prestressing steels - Part 3: Strand".
They are 7-wire strands with nominal diameters of ϕ 15.2 and ϕ 15.7 mm (fpk = 1860 N/mm2 or fpk = 1770 N/mm2).
As long as EN 10138 does not exist, 7-wire strands in accordance with national standards shall be used.
CHARACTERISTIC MAXIMUM VALUE CHARACTERISTIC

NOMINAL DIA- NOMINAL CROSS TENSILE
VALUE OF OF MAXIMUM VALUE OF 0,1%
TYPE STEEL NUMBER METER SECTION STRENGTH
MAXIMUM FORCE FORCE PROOF FORCE
(MM) (MM2) (MPa)
(kN) (kN) (kN)
Y1770 S7 15.2 A 1.1365 15.2 140.00 1770 148.00 282 213.00
Y1770 S7 15.7 A 1.1365 15.7 150.00 1770 265.00 302 228.00
Y1860 S7 15.2 A 1.1366 15.2 140.00 1860 260.00 298 224.00
Y1860 S7 15.7 A 1.1366 15.7 150.00 1860 279.00 319 240.00
By varying both the strand diameter and number (and, if applicable, their specified characteristic tensile strength), it is
possible to obtain a value for the characteristic tensile strength per tendon that varies between 496 kN and 8649 kN.
The number of strands in a tendon may be reduced by leaving out the strands positioned radial-symmetrically in the wedge
plate. The provisions for tendons with completely filled wedge plates (basic types) also apply to tendons with only partly
filled wedges plates.
The standard prEN 10138-3 gives the following nominal values for the other useful characteristics of prestressing strands
composing the HIRUN PT system units:
PERFORMANCE VALUES
Elongation at maximal force 0,035
Relaxation at 0.70 fpk after 1000 hours 0,025
Relaxation at 0.80 fpk after 1000 hours 0.045
Fatigue behaviour (0.70 fpk ; 190 N/mm2) 2X106 CYCLES
Maximum D value of deflected tensile test 0.28
Modulus of elasticity Ep 195.000 N/mm2
The actual modulus of elasticity of the strand, measured by the supplier A 15 mm diameter strand coil.
and communicated at the time of its supply, shall be taken into account Approximate weight 2000 kg
for calculation of the cable elongations.
HIRUN INTERNATIONAL CO.LTD

No. 7, Lane 275, Jianguo East Road, Changhua City,
Taiwan | T +886 47262093 | hirun.eu | [email protected]
INTERNATIONAL
4. Ducts
Ducts can be made by a spiral wrapped, corrugated steel strip steel strip.
In the following table and drawing are defined the recommended

parameters for the geometry of the ducts.
The radius stated are minimum ones. The actual values have to be found
in national regulations valid in the place of use.
For a more complete definition of the geometry please refer to our ETA.
Manufacturing of corrugated steel strip ducts
CABLE TYPE 4T15 7T15 9T15 12T15 15T15 19T15 22T15 27T15 31T15
1 Duct Φi / Φe 45/51 55/61 64/70 75/81 80/86 90/96 100/106 110/116 115/121
2 Coupling sleeve 50/56 60/66 70/76 80/86 85/91 95/101 105/111 115/121 120/126
3 Compensating sleeve 55/61 65/71 75/81 85/91 90/96 100/106 110/116 120/126 125/131
Radius Rmin 2500 3500 4000 4500 5500 6000 6000 7000 7500
Straight duct Gmin 500 600 650 750 900 1000 1100 1200 1300
Note: cables to be pushed through require ducts with increased diameter of 10 mm

Recommended diameters of the corrugated steel ducts

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5. Anchorages
The general feature of the HIRUN HIPOST anchorages is shown in the
following figure
1
1 Anchor head
2 Casting
2 3 Fixing slot
4 Load transferring ribs
5 Cylindrical shape
6 Threaded connection
9 7 Connector for standard ducts
8 Connector for larger ducts
3 9 Bolt connections
10 Bolt connections
10
4 5 6 7 8
5.1 Anchor heads

HIRUN HIPOST tensioning system is composed by the anchor heads
made by steel C45 according to EN 10083-2; details of anchor heads are
shown in the following chapters and annexes.
Anchor heads, after the production, shall be clean and provided with a
corrosion protection.
The anchorages types from 22T15 to 31T15, even if partially filled with
strands, shall be provided with antifriction bush (see the following
chapters and annexes) for every hole in its cylindrical part; these bushes
guide the strand outside the head.
HIRUN HIPOST holes pattern is following the layout mentioned in the
table shown here below:
4 7 9 12 15
19 22 27 31

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5.2 Couplers
HIRUN HIPOST tensioning system is including, when necessary, the
couplers made by steel C45 according to EN 10083-2 (for the anchor
heads used in the couplers) and steel S355J0H in accordance with EN
10210.
Anchor heads, after the production, shall be clean and provided with a
corrosion protection.
The anchorages used in the coupling anchors types from 22T15 to 31T15,
even if partially filled with strands, shall be provided with antifriction
bush (see Annexes 2, chapters 1,2,3) for every hole in its cylindrical part;
these bushes guide the strand outside the head.
5.3 Wedges
HIRUN HIPOST tensioning system is composed by wedges made of
case-hardened steel type 16NiCr4+Pb according to EN 10084. They
are composed in three segments with, in the internal diameter, teeth to
grant the proper tension transfer from the strand to the anchor heads.
The segments of wedges for strands mentioned in the chapter 1.2.1 are
Ø28 mm and they shall be marked HT15. Wedges, after the production,
shall be carefully cleaned and provided with a corrosion protection.
View - Section A-A Front view
5.4 Casting units

HIRUN HIPOST tensioning system is composed by casting units made
of cast iron type GS 500-7 according to EN 1563 standard. Casting unit
properly machined and formed in order to grant the correct flat contact
with the anchor head to transfer the tension load to the concrete section.
On the other end the casting unit have specific thread to surely connect
the plastic cones to avoid undesired concrete penetration in the hole
designed for the strand bundle.
5.5 Reinforcing steel (spirals and stirrups)

HIRUN HIPOST tensioning system is composed by the reinforcing steel,
like spiral and/or the stirrups, which comply with the steel grades and
dimensions given in the detailed drawings.

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5.6 Stressing anchorages
These anchorages (also known as live end anchorages) have been

designed to anchor tendons at the end where stressing will be
performed. They are composed of a cast iron casting unit, an anchor
head for tendons of 4 to 31 strands, in which the strands are anchored by
means of wedges, plus wedges and accessories.
The continuity of protection and the waterproof sealing between the duct
and the anchorage are provided by means of a plastic trumpet (sleeve).
TENDON SIZE 4T15 7T15 9T15 12T15 15T15 19T15 22T15 27T15 31T15
T 128 165 185 205 235 257 285 313 331

Casting
L 130 160 175 190 200 220 240 280 320
A 100 125 150 170 190 200 230 250 260

Anchor head
H 46 46 50 56 64 71 76 86 96
Z 112 179 203 227 262 297 340 362 396

Bolt
U 10 10 10 12 12 12 12 14 14
Cone J 195 195 210 230 265 275 330 325 326
Tums N 5 6 6 6 6 7 8 8 8
D 170 220 250 310 330 370 380 410 430

Spiral
ΦΦ 16 16 16 16 20 20 20 20 20
Duct ΦΦi 45 55 65 75 80 90 100 110 115
R 90 90 100 105 110 110 120 150 150

Recess
N 170 200 220 250 280 300 330 355 370
Grout Φl/m 1.1 1.5 2.1 2.8 3.0 3.8 4.8 5.8 6.1
Max stressing force kN 893 1562 2008 2678 3348 4241 4910 6026 6919
Distance X 220 290 330 385 400 440 480 530 570

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5.8 Fixed anchorages
These anchorages ensure the locking of tendons at the end on which no

stressing force is being exerted by mean of the jack.
They are composed of a cast iron casting unit, an anchor head for
tendons of 4 to 31 strands, in which the strands are anchored by means
of wedges, plus wedges, springs, locking plate and accessories.
The wedges have been locked into the anchor head body and pushed
in their cavities, by springs, in order to prevent any slipping movement.
The continuity of protection and the waterproof sealing between the duct
and the anchorage are provided by means of a plastic trumpet (sleeve).
These kind of anchorages shall be always be used when they shall be
totally embedded in the concrete.
If the fixed anchorage is not embedded in the concrete a stressing
anchorage may be used in alternative, without applying stressing.
T 128 165 185 205 235 257 285 313 331

Casting
L 130 160 175 190 200 220 240 280 320
A 100 125 150 170 190 200 230 250 260

Anchor head
H 84 80 80 80 80 90 95 105 115
Cone J 195 195 210 230 265 275 330 325 326
Tums N 5 6 6 6 6 7 8 8 8
D 170 220 250 310 330 370 380 410 430

Spiral
ΦΦ 16 16 16 16 20 20 20 20 20
Duct ΦΦi 45 55 65 75 80 90 100 110 115
Grout l/m 1.1 1.5 2.1 2.8 3.0 3.8 4.8 5.8 6.1
Embedment Rf 130 130 160 130 130 140 140 150 160

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5.9 Couplers
These anchorages ensure the continuity of the tendons in case of

particular structure construction sequence as described in EAD 160004-
00-0301 chapter 1.3.27; it allows the stressing on one tendon, by mean
of the jack, and following joining a second tendon by coupler and fixed
head.
They are suitable for tendons from of 4 to 31 strands. They are composed
of a cast iron casting unit, one stressing anchor head, in which the
strands are anchored by means of wedges, one threaded coupler, one
fixed anchor head, in which the strands are fixed by springs and wedges,
plus wedges, locking plate and accessories.
In the fixed anchor head the wedges have been locked and pushed in
their cavities, by springs, in order to prevent any slipping movement.
The continuity of protection and the waterproof sealing between the
duct and the anchorage are provided by means of a steel and a plastic
trumpet (sleeve).
T 128 165 185 205 235 257 285 313 331

Casting
L 130 160 175 190 200 220 240 280 320
G 121 153 186 219 229 254 298 305 336

Coupling sleeve
Q 150 155 165 170 180 200 210 230 250
Stressing head H’ 46 46 50 56 64 71 76 86 96
Fixed head H’’ 84 80 80 80 80 90 95 105 115
Cone J 170 220 220 310 330 370 380 410 430
Cone J’ 140 210 220 320 410 440 510 550 580
Turns n 5 6 6 6 6 7 8 8 8
D 170 220 250 310 330 370 380 410 430

Spiral
Φ 16 16 16 16 20 20 20 20 20
Duct ΦI 45 55 65 75 80 90 100 110 115
O 140 170 200 240 250 275 320 325 345

Tube
P 300 300 310 320 330 350 360 380 400
Al = Elongation of the tendon at right

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Use categories,
options and possibilities
The HIPOST system anchorages are normally used internally to the
concrete structure.
The system may be:
Bonded, i.e. with "bare" strands placed inside a duct filled with a
permanent grout, providing bonding to the structure.
Unbonded, i.e. with individually greased and sheathed strands,

unbonded to the structure.
Injection pipe
Cap Anti-adhesion film
Wedge Spiral Strand Diafram
Venting HDPE pipe
HDPE sleeve
HDPE duct
Fixing strips
Anchor head Steel pipe
Casting Grouting
Unbonded tendon replaceable, non re-stressable
Injection pipe Unbonded Strand Venting Grout

Cap Anti-adhesion film
Wax or grease Spiral Steel pipe
Venting
HDPE sleeve
HDPE duct
Fixing strips
Stressing lenght
Casting Wax or grease injection
Unbonded tendon replaceable, re-stressable

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Injection (optional) Duct Strands
Anchorage Diverter Anchorage
Typical layout of external post tensioning (unbonded)
Example of application of external post tensioning inside a box girder
Installation of the tendons

Generally the empty ducts are installed first in the structure before
concreting. The strands are pushed into the empty ducts one by one
utilizing a strand pushing machine.
SPECIFICATION
Hydraulic strand pushing machine
Velocity up to 120 m/min
Electric strand pushing machine
Velocity up to 500 m/min
Installation of the strands by pushing machine Specification of the strand pushing machine

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Stressing operations
Each tendon is stressed with suitable multistrand jack and becomes

locked within a conical anchoring hole by means of wedges. The locking
function is performed by the jacks locking system that is pressing the
wedges in their conical holes than the jack pressure can be released so,
when the strand moves back, due to its elasticity, at the time of pressure
release in the jack, the wedges are completely locked in the anchor heads.
In particular jobsite conditions the tendon can be stressed by every single
strand at the time, in this case a special tension procedure, according to
HIRUN dual jacks stressing method statement, shall be applied to grant
the proper stress in every single strand.
Hydraulic jacks for the stressing operation have been designed in order to
minimize their dimensions and weight and to minimize the required length
of the strand to be wasted for clamping in the jack.
For the stressing operations the jack is placed over the strands protruding
from the stressing anchor. When the stressing starts the strands are
automatically and simultaneously engaged in the pulling head of the jack.
Once the required elongation and force are reached the lock-off device of
the jack can be activated to press the wedges in the anchor head uniformly.
The stressing may be performed in more steps if required. A stressed cable
may be de-tensioned utilizing the appropriate releasing device.
JACK TYPE M4-T15 M7-T15 M9-T15 M12-T15 M15-T15 M19-T15 M22-T15 M27-T15 M31-T15
Max capacity (kN) 850 1650 2100 2750 3350 4350 4950 6150 7050
S 10 10 15 15 15 20 20 25 30
A 440 450 475 475 500 500 530 540 555

Dimensions (mm)
B 530 540 570 570 630 630 6554 685 705
Φ 180 225 260 290 325 365 390 440 460
Stroke (mm) 125 125 125 125 125 125 125 125 125
Overlength (mm) 440 450 480 480 530 530 570 620 640
Weight (kg) 60 85 120 140 205 260 315 405 475
Geometry and weight of the HIPOST stressing jacks

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Stressing operations
SPECIFICATION
Capacity 5000 kN
Working pressure 70 MPa
Stroke 250 mm
Weight 610 kg
Overlength 1000 mm
Note: Hollow core jacks with different

capacities and strokes are available.
Multistrand HIPOST stressing jack Multistrand hollow core jack
(can be used in alternative)
The stressing operations are performed in the following steps
Installation of anchor head and stressing chair
Placing of the stressing jack
Stressing (normally in more steps)
Fastening of the wedges in the anchor head
Releasing of the jack

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Computation of the elongation

of the cables during stressing
• The verification of the elongation is of crucial importance
• If the measured elongation is within 5% of the theoretical one is OK
• A greater elongation normally shows settlements or failures that shall be
investigated and removed
• A smaller elongation normally shows excessive friction or a blockage of
the cable. The reasons shall be analysed and removed
It shall be emphasized that applying the force without getting the
elongation we are NOT prestressing the structure.
The stress in the cable at a distance x from the anchorage is given by the
expression:
Where:
• σ0 = stress at the anchorage
• x = distance from the anchorage
• α = total angle of deviation
• k = random angle of deviation for length unit
Recommended values:
• Nacked strand: µ=0,2/rad; k=0,008 rad/m
• Unbonded strand: µ=0,06/rad; k=0,008 rad/m
The above recommended values are given under the assumption of cable
supports spaced not more than 1 m.
The elongation of the cable is given by the expression:

x
σx
Δx = ∫ dx
0
E
Where E is the effective elasticity modulus of the strand, normally 195 GPa
The measured elongation shall be depurate from the following effect to σ

get the effective elongation: σi
• Geometrical settlement of the cable σd
• Elastic shortening of the structure
• Settlement of the wedges at the stressing jack (normally 4-5 mm) σa
• Settlement of the wedges at the opposite end, if applicable (normally 4–5 mm) σl
After the wedges are finally locked, they set in the anchor head for 5 – 6
mm, causing a small loss of tension as shown in the figure on the right.
The loss of tension due to the wedges settlement may be compensated d x

by a suitable overstressing. l

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Grouting
Grouting shall be performed after the stressing is completed, sealing the

anchorages with concrete or applying the proper grouting cups.
The cables shall be provided with suitable inlet and venting pipes as shown
in the figure
Detail of the venting pipes of the prestressing tendons
SPECIFICATION
Piston or endless screw pump

Flow up to 40 liter/min
Max pressure 2.5 MPa
Capacity up to 280 liter
Specification of the grouting pump
Recommended grouting material shall be cement-water admixture with

water/cement ratio 0,36-0,38 or pre-mixed products according to the
manufacturer’s specifications.

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Monostrand and
Flat HIPOST System
Monostrand and Flat HIPOST system is utilized for the prestressing of thin
structures as for instance concrete floor slabs.
It utilizes greased or zincked and greased unbonded strands with HDPE
ducts.
The main advantages of this system are the following:
• Slab geometry can be optimized due to the reduced tendon size
• Less tension loss due to the reduced friction thanks to the greased
strands
• Great flexibility of the tendons layout o meet particular design
requirements
• Easy fitting of the rebar inside the structure, especially in correspondence
of the column-beam junctions
• Easy handling on site
• Easy stressing. Stressing jacks can be handled by hands.
• No need of injection
Monostrand and Flat HIPOST system includes fixed and stressing

anchorages with 1 to 4 strands diameter 15 mm and is composed by.
• Anchor heads in cast steel directly in contact with the concrete
• Wedges
• Unbonded strand greased or greased and galvanize diameter 15 mm
• Plastic cover caps
Monostrand and Flat HIPOST system are tensioned using a monostrand

jack
Monostrand and Flat HIPOST system typical anchorages
Stressing operation with monostrand jack

INTERNATIONAL
References
Kaohsiung Port Expressway Dalin Powerplant

Kaohsing, Taiwan Kaohsiung, Taiwan

INTERNATIONAL

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HIPOST

HIPOST POST TENSIONING SYSTEM

POST TENSIONING SYSTEM

Kaohsiung Port Expressway

The engineering solution.

1. The light and easily handled

It became possible when the industry became able to supply

Since then the post tensioning has been applied to a countless

Strands are normally made of 7 wires, 1 of them straight, the other

HIPOST post tensioning system foresees the use of 15 mm

Requires specialized team

The HIPOST system) is composed of a tendon or cable, made out of steel

The main test certificates in accordance with ETAG 013

CHARACTERISTIC MAXIMUM VALUE CHARACTERISTIC

Y1770 S7 15.2 A 1.1365 15.2 140.00 1770 148.00 282 213.00

Y1770 S7 15.7 A 1.1365 15.7 150.00 1770 265.00 302 228.00

Y1860 S7 15.2 A 1.1366 15.2 140.00 1860 260.00 298 224.00

Y1860 S7 15.7 A 1.1366 15.7 150.00 1860 279.00 319 240.00

Elongation at maximal force 0,035

Relaxation at 0.70 fpk after 1000 hours 0,025

Relaxation at 0.80 fpk after 1000 hours 0.045

Fatigue behaviour (0.70 fpk ; 190 N/mm2) 2X106 CYCLES

Maximum D value of deflected tensile test 0.28

Modulus of elasticity Ep 195.000 N/mm2

HIRUN INTERNATIONAL CO.LTD

In the following table and drawing are defined the recommended

Manufacturing of corrugated steel strip ducts

Note: cables to be pushed through require ducts with increased diameter of 10 mm

HIRUN INTERNATIONAL CO.LTD

5.1 Anchor heads

HIRUN INTERNATIONAL CO.LTD

View - Section A-A Front view

5.4 Casting units

5.5 Reinforcing steel (spirals and stirrups)

HIRUN INTERNATIONAL CO.LTD

5.6 Stressing anchorages

These anchorages (also known as live end anchorages) have been

T 128 165 185 205 235 257 285 313 331

A 100 125 150 170 190 200 230 250 260

Z 112 179 203 227 262 297 340 362 396

D 170 220 250 310 330 370 380 410 430

Duct ΦΦi 45 55 65 75 80 90 100 110 115

R 90 90 100 105 110 110 120 150 150

HIRUN INTERNATIONAL CO.LTD

5.8 Fixed anchorages

These anchorages ensure the locking of tendons at the end on which no

T 128 165 185 205 235 257 285 313 331

A 100 125 150 170 190 200 230 250 260

D 170 220 250 310 330 370 380 410 430

Duct ΦΦi 45 55 65 75 80 90 100 110 115

HIRUN INTERNATIONAL CO.LTD

These anchorages ensure the continuity of the tendons in case of

T 128 165 185 205 235 257 285 313 331

G 121 153 186 219 229 254 298 305 336

D 170 220 250 310 330 370 380 410 430

O 140 170 200 240 250 275 320 325 345

Al = Elongation of the tendon at right

Unbonded, i.e. with individually greased and sheathed strands,

Unbonded tendon replaceable, non re-stressable

Injection pipe Unbonded Strand Venting Grout