VSL-INTRAFOR

CONSTRUCTION SYSTEMS

Australi

a

Brunei

Darus

salam

Guam

Indone

sia

Malays

ia

New Ze

aland

Singap

ore

Thaila

nd

Hong K

ong

China

Japan

Korea

Philippines

Taiwan

Vietna

m

USA

France

Austria

German

y

Poland

Czech

Republ

ic

Greece

Pakist

an

Norway

Sweden

Switze

rland

United Ar

ab Emi

rates

Argent

ina

Chile

Great Brit

ain

Portug

al

Spain

Nether

lands

Mexico

South

Africa

Belgiu

m

Luxemb

ourg

VSL PRESTRESSING (AUST) PTY LTD

Production by: P & M Format GraphicsTel: (08) 9414 8643 March 2001.

VSL

VS

L

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

D E S I G N

C O N S T R U C T I O N

E N G I N E E R I N G

S U P P LY

INSTA L L AT I O N

3

C O N T E N T S

THE COMPANY 5

MULTISTRAND POST-TENSIONING 8

SLAB POST-TENSIONING 22

STRESSBAR 36

GROUND ANCHORS 44

VSoL RETAINED EARTH 50

SPECIALISED FOUNDATIONS 52

CLIMBFORM 54

DUCTAL 56

STAY CABLES 58

EXTERNAL POST-TENSIONING 60

HEAVY LIFTING 62

FLAT JACKS 63

BRIDGE ENGINEERING 64

INDEX 66

VSL4

VSL is the international leading specialist contractor in the field of posttensioning and related construction techniques. In Australia we will:• create optimised design and construction solutions to

benefit our clients• maintain a corporate culture of generating staff and

shareholder benefit• use the VSL worldwide group resources to enhance our local expertise

T H E V S L M I S S I O N

The VSL Group objective is to be the preferredSolution Network for our client and customerneeds.

To assist in achieving this objective we haveestablished and will continuously maintain aquality assurance system in compliance with ISO9001.

VSL Management is committed to continuousquality improvement through the participation of allemployees in the preparation, implementation andevaluation of improvement activities.

It is recognised that all our employees are vitallyimportant to our competitiveness and prosperityand with this in mind, we aspire to maintain thehighest level of satisfaction, health and safety ofour people.

Q U A L I T YO B J E C T I V E S

DNVQA-ANZACCREDITED QUALITY SYSTEMCERTIFIED AS/ANZ ISO 9001

VSL5

T H E C O M P A N Y

The vision upon which VSL Prestressing (Aust) Pty Ltd was founded in1965 was to provide specialist post-tensioning services supported byprofessional engineering design, construction methods and manufacture ofcomponents.

The standard of quality of the VSL system was soon endorsed byengineers, contractors and authorities and it became the preferred technicaland practical solutions to a wide range of structural applications.

Our early major projects included the free cantilevering Victoria Bridge inBrisbane, the Westgate Bridge concrete approach spans in Melbourne, thePhillip Island Bridge in Victoria and the Narrows Interchange N/6 in Perth.

In 1969 VSL Australia developed operations in South-East Asia, first inSingapore, followed by Hong Kong, Malaysia, Indonesia, Brunei and Guam.Our Melbourne office was also opened in 1969, followed by thecommissioning of the VSL manufacturing plant which providessophisticated high strength components for export as well as the Australianmarket. This is also the site of our NATA registered testing facility used tocalibrate some of the world’s largest hydraulic jacking equipment.

In 2000 the specialist foundation companies Intrafor and IP Foundationsjoined with VSL to form VSL-Intrafor, adding to VSL’s exisitng post-tensioning and construction capabilities to include expertise in specialisedfoundations and soil engineering techniques.

Since those early days our range of specialist construction techniques hasbroadened to meet the emerging needs of our clients. Many of thesesolutions are outlined in this manual.

VSL Australia is an integral member of the worldwide VSL Group,established in over 36 countries in 5 continents. Hence as we create,together with our client, the optimal solutions to construction needs, we areable to enhance our Australian knowledge and experience with theresources of our colleagues around the world.

VSL is your Solution Network.

VSL6

H E A D I N G

VSL provides an extensive range of design services to assist developers,engineers, architects, government departments and contractors in solvingtechnical problems and in assessing the viability of the use of post-tensioning ina structure.

In particular, the services available include:• preliminary design for budget estimates• alternative design proposals• final detail design, in conjunction with the Consulting Engineer• technical assistance.

Design

Site Services

Detail

D E S I G N S E R V I C E S

In preparing any structural design, the aim is to arrive at the most economicalsolution that meets all the design criteria. This requires that all factors in theconstruction be taken into account including material costs, formwork, interaction of trades, construction sequence and construction time. Expertisegained from many years of experience and the use of in-house design Engineers enables VSL to assess quickly the alternatives and arrive at an answer that will best meet the client's requirements for economy of materials,speed of construction and quality of finished structure.

VSL7

V S LI N T E R N A T I O N A L L Y

The VSL Group has made major contributions tothe advancement of civil engineering practicethroughout the world. Internationally, VSL

incorporates a depth of technical knowledge andconstruction experience that is unsurpassed within theprestressing industry. Access to this international

experience enables VSL to undertake projects usinghighly specialised teams. An example of this co-operation is the Gateway Bridge in Brisbane, whereVSL in conjunction with the Gateway Bridge Company,conceived and designed the world-record main-span fora concrete cantilever bridge. The final design wasprepared by VSL with all materials and equipmentmanufactured and supplied within Australia.

Activity world-wide over a broad range of projects hasdeveloped VSL methods into the successful systemsexisting today. VSL can offer its clients an entire range of specialised construction systems from its position as leader in the field internationally in research, development and engineering practice.

As a specialist sub-contractor VSL can provide servicesusing its own personnel and equipment. This personalised service represents know-how, experienceand availability. Use of in-house engineering design inthe development of alternatives ensures the most economical construction method is used.

Technical reports covering specialised design and construction topics are available from VSL on request.

Off-shore Platform, North SeaGateway Bridge, Australia Kwung Tong Bypass, Hong Kong

VSL8

M U L T I S T R A N D P O S T - T E N S I O N I N G

Maribyrnong Bridge, Victoria

Since 1954, designers and constructors of bridges, buildings and civil engineering works the worldover have relied on the VSL Multistrand post-tensioning system. These conventional uses of post-tensioning have been augmented by numerous applications of the system to projects such asstayed structures, offshore platforms, towers, tanks, silos, nuclear power plants and undergroundand submerged structures.

Patented in 36 countries, the VSL strand system complies in all respects with theRecommendations for the Acceptance and Application of Post-Tensioning Systems of theFédération Internationale de la Précontrainte (FIP) and is approved in every country where the useof post-tensioning systems is subject to an official authorisation.

The VSL Multistrand system comprises from three to fifty-five strands (either 12.7 or 15.2mmdiameter), round duct and anchorages. Prestressing force is applied to the tendons after thecasting and curing of surrounding concrete. All strands are stressed simultaneously using anhydraulic jack and are fastened at the live end by wedge grips. The free space inside the duct isthen pressure-filled with cement grout.

A number of features are incorporated as a result of many years of experience in the field:

• stressing in one or any number of stages• accurate control of prestress force• no uncontrolled slippage of strands• no requirement for a precise determination of tendon length• simultaneous stressing of all strands

VSL stressing equipment is easily operated to ensure a safe and rapid stressing procedure.Special emphasis has been placed on rationalised manufacturing of equipment and anchorageparts as well as efficient work site practice.

STRAND TYPE 12.7mm SuperTENDON No. OF Minimum STEEL DUCT.

UNIT STRANDS Breaking InternalLoad DiameterkN mm

5-3 2 368 393 552 394 736 39

5-7 5 920 516 1100 517 1290 51

5-12 8 1470 699 1660 69

10 1840 6911 2020 6912 2210 69

5-19 13 2390 8414 2580 8415 2760 8416 2940 8417 3130 8418 3310 8419 3500 84

5-22 20 3680 9021 3860 9022 4050 90

5-27 23 4230 9624 4420 9625 4600 9626 4780 9627 4970 96

5-31 28 5150 10529 5340 10530 5520 10531 5700 105

5-37 32 5890 11233 6070 11234 6260 11235 6440 11236 6620 11237 6810 112

5-42 38 6990 11839 7180 11840 7360 11841 7540 11842 7730 118

5-48 43 7910 12744 8100 12745 8280 12746 8460 12747 8650 12748 8830 127

5-55 49 9020 13550 9200 13551 9380 13552 9570 13553 9750 13554 9940 13555 10120 135

STRAND TYPE 15.2mm SuperTENDON No. OF Minimum STEEL DUCT.

UNIT STRANDS Breaking InternalLoad DiameterkN mm

6-3 2 500 393 750 39

6-4 4 1000 516-7 5 1250 69

6 1500 697 1750 69

6-12 8 2000 849 2250 84

10 2500 8411 2750 8412 3000 84

6-19 13 3250 9614 3500 9615 3750 9616 4000 9617 4250 9618 4500 9619 4750 96

6-22 20 5000 10521 5250 10522 5500 105

6-27 23 5750 11224 6000 11225 6250 11226 6500 11227 6750 112

6-31 28 7000 11829 7250 11830 7500 11831 7750 118

6-37 32 8000 12733 8250 12734 8500 12735 8750 12736 9000 13537 9250 135

6-42 38 9500 13539 9750 13540 10000 13541 10250 13542 10500 135

6-48 43 10750 14444 11000 14445 11250 14446 11500 14447 11750 14448 12000 144

6-55 49 12250 15450 12500 15451 12750 15452 13000 15453 13250 15454 13500 15455 13750 154

Nominal Nominal Nominal Minimum Minimum Min. Elong. Relaxation ModulusDiameter Steel Area Mass Breaking Load Proof Load to Fracture After 1,000hrs of Elasticity

(0.2% Offset) in 600mm at 0.7Breaking Load

mm mm2 kg/m kN kN % % MPa12.7 Super 100.1 0.786 184 156.4 3.5 2.5

180–20515.2 Super 143.3 1.125 250 212.5 3.5 2.5x 10 3

15.2 EHT 143.3 1.125 261 221.9 3.5 2.5

S T R A N D P R O P E R T I E S – T O A S 1 3 11

T E N D O N P R O P E R T I E S

Note: 1. Intermediate duct diameters may be available on application.2. Duct diameters are for corrugated steel duct.3. Duct external dia. = Inside dia. + 6mm nominal4. Corrugated polyethylene PT-Plus™ duct is also available, refer page 16.5. For special applications other strand and tendon capacities are available.6. Anchorages for 15.2mm system are compatible with 261 EHT strand.

VSL9

M U L T I S T R A N D P O S T - T E N S I O N I N G

VSL10

M U L T I S T R A N D P O S T - T E N S I O N I N GS

TRA

ND

TY

PE

15.

2mm

STR

AN

D T

YP

E 1

2.7m

m

D IMENSIONS (mm)TENDON A B C D E F G H R

UNIT Int. Dia.

5-3 135 50 90 191 16 56 39 116 2105-4 150 50 90 216 16 64 39 125 2105-7 165 57 120 100 60 85 51 125 275

5-12 215 54 160 160 84 120 69 151 3205-19 265 66 180 210 110 145 84 200 3605-22 290 77 200 215 140 153 90 230 3605-27 315 92 220 250 160 176 96 250 3605-31 315 92 230 250 161 175 105 250 3605-37 370 107 250 320 160 200 115 305 6505-42 390 112 290 346 168 217 118 325 6505-48 430 122 300 340 161 233 127 365 7505-55 465 142 320 340 160 250 135 400 750*6-3P 150 60 90 190 16 56 39 116 210*6-4P 165 54 120 100 60 85 51 125 2706-7 215 54 160 160 85 120 69 150 320

6-12 265 66 180 210 110 145 84 200 3606-19 315 92 220 250 160 175 96 250 3606-22 315 92 230 250 160 175 105 250 3606-27 370 107 250 320 160 200 115 305 6506-31 390 112 290 340 160 217 118 325 6506-37 430 122 300 340 160 235 135 365 7506-42 465 142 320 340 160 250 135 400 750

*6-48P 575 155 340 1035 110 269 144 495 900*6-55P 600 190 360 1070 120 294 154 520 900

Note: Dimension R does not allow for Lift Off force check. Smaller recesses can be provided for special cases. Refer VSL office for details.*Plate type anchorages (Type P). Also available for other tendon units.

V S L S T R E S S I N G A N C H O R A G E T Y P E S c L I V E E N D

ANCHOR HEADWEDGE GRIPS

GROUT INLET

DUCT

CAST IN ANCHOR TYPE Sc

A

15omin

25min

20 B

E

GD

uct D

ia.

F

D

H

H A R Cno

min

al

VSL11

M U L T I S T R A N D P O S T - T E N S I O N I N G

TENDON UNIT Dimensions (mm)STRAND STRAND øA B C øD E øF øG H H R

TYPE TYPE Ext. Dia. Ext. Dia. CS-Std CS-Plus12.7mm 15.2mm CS-Super

5-12 6-7 222 60 135 153/143 49 110 80 400 535 3205-19 6-12 258 80 149 178 49 137 95 500 638 360

– 6-19 300 90 170 210 59 156 110 540 660 3605-31 6-22 320 100 180 229 59/65 174 125 570 740 3605-43 6-31 390 120 217 279/283 69/75 224 146 880 * 6405-55 6-37 420 130 233 302 78/82 237 160 850 * 750

*Check with VSL officeThe trumpets for the CS-PLUS and CS-SUPER configurations have short, profiled extension for PT-PLUS™ coupling.

T E N D O N C O N F I G U R AT I O N SVSL SYSTEM Anchorage Type Duct Type Fully Electrically

HD PE Encapsulated IsolatedConventional CS Steel PT-PLUS Tendon Tendon

Conventional l l

PT-PLUS l l

CS-Standard l l

CS-Plus l l l

CS-Super l l l l

GROUT TUBE

DUCTGROUT CONNECTION

COMPACT ANCHORHEAD

POLYETHYLENE TRUMPETWEDGE GRIPS

STRANDS

COMPOSITE BEARING PLATE(METAL/HIGH PERFORMANCEMORTAR)

Ø D

Ø A

C

B

HE

2025 min

R Ø F

Ø G

15° min

The Type CS anchorage should be used for applications requiring high fatigueresistance, high corrosion resistance, reduced anchorage friction and the possibility ofelectrical isolation. For conventional applications the Type Sc anchorage should be used.

V S L S T R E S S I N G A N C H O R A G E T Y P E C S L I V E E N D

VSL12

M U L T I S T R A N D P O S T - T E N S I O N I N G

STRAND TYPE 12.7mmTENDON A B C

UNIT Dimensions (mm)5-3 108 130 4305-4 108 150 5005-7 108 170 550

5-12 108 200 6505-19 108 230 7405-22 108 250 8305-27 108 300 10005-31 108 340 11405-37 148 380 13205-42 148 385 13205-48 148 410 13705-55 168 480 1370

STRAND TYPE 15.2mmTENDON A B C

UNIT Dimensions (mm)6-3 125 150 4906-4 125 160 5206-7 125 200 630

6-12 125 230 7306-19 125 270 8606-22 125 300 9306-27 135 320 10006-31 145 350 10906-37 165 410 1390

GROUT TUBE

SWAGED DEAD END

COUPLING BLOCK

COUPLING COVER

CAST IN ANCHOR

DUCT

DUCT

Note: In some applications the coupler cover may not be required.

B

C

30 A STANDARD CAST INANCHOR TYPE Sc

V S L C O U P L I N G A N C H O R A G E T Y P E C

VSL13

M U L T I S T R A N D P O S T - T E N S I O N I N G

Centre-stressing anchorages are used for ring tendons in circularstructures, or for those tendons where the ends cannot be fitted withnormal stressing anchorages.

* Dependent upon the shape of the concrete surface.The values stated apply for surfaces which are not curved.

STRAND TENDON A B C D F* G* HTYPE UNIT Dimensions (mm)

12.7mm 5-2 130 60 80 60 400 560 1705-4 160 70 90 65 500 720 2005-6 200 90 130 85 700 990 2405-12 280 140 140 90 1000 1490 3205-18 320 160 180 110 1300 1910 3605-22 350 160 200 120 1450 2110 390

15.2mm 6-2 140 70 90 65 450 620 1806-4 170 80 100 70 900 1180 2106-6 210 100 140 90 1000 1400 2506-12 300 160 160 100 1350 1960 3406-18 380 180 200 120 1450 2280 4206-22 400 180 250 145 1500 2380 440

GROUT TUBE

STRANDS

ANCHOR BLOCK

DUCT

WEDGE GRIPS

Stressing jack

Curved stressing chair

H

D C

A

E

BF + L

G + L

Tendon 1Tendon 2

L = Elongation of tendon 2

E = C + required cover 2

I N T E R M E D I AT E A N C H O R A G E T Y P E Z

VSL14

M U L T I S T R A N D P O S T - T E N S I O N I N G

STRAND TYPE 12.7mmTENDON TYPE ‘H’ TYPE ‘P’

UNIT A B C D E F5-3 125 125 600 100 100 1005-4 125 125 600 120 120 1505-7 175 150 600 150 150 250

5-12 300 250 1000 200 200 3505-19 375 300 1000 250 250 5005-22 400 300 1000 300 250 5005-27 450 400 1000 300 300 6505-31 450 425 1000 350 300 6505-37 525 450 1100 375 350 8505-42 600 450 1100 375 375 8505-48 645 450 1200 400 400 10005-55 700 500 1200 425 425 1000

STRAND TYPE 15.2mmTENDON TYPE ‘H’ TYPE ‘P’

UNIT A B C D E F6-3 150 150 600 150 150 2506-4 150 150 600 150 150 2506-7 200 170 600 200 200 350

6-12 350 300 1000 250 250 5006-19 450 350 1000 300 300 5006-22 500 350 1000 300 300 5006-27 550 450 1100 350 350 6506-31 550 475 1100 350 350 6506-37 600 550 1100 400 350 8506-42 700 550 1200 400 350 8506-48 745 550 1200 475 475 10006-55 800 600 1200 550 475 1000

V S L D E A D E N D A N C H O R A G E

SPACER PLATE(NOT ALWAYS REQUIRED -3, -4,

-7)GROUT TUBE

DUCT

DEAD END

SWAGED DEAD END

ANCHORAGE PLATE

GROUT TUBE

DUCT

T Y P E H

Dimensions (mm) Dimensions (mm)

F

12

60150 C

3

D x

E

Ax

B

T Y P E P

Dead End Anchorage Type H Dead End Anchorage Type P

V S L D E A D E N D A N C H O R A G E T Y P E L

V S L D E A D E N D A N C H O R A G E T Y P E A F

VSL15

M U L T I S T R A N D P O S T - T E N S I O N I N G

STRAND TYPE 15.2mmTENDON A B C D E F G H J K Lo/ M

UNIT Int/Ext6-12 265 700 60 460 90 95/102 380 450 60 410 6 96-19 315 700 60 460 90 120/127 480 540 60 510 20 96-31 375 900 60 660 90 150/157 620 660 80 650 20 11

Dimensions (mm)M = Number of spiral turns or orthogonal stirrups.

Dimensions (mm) Dimensions (mm)

STRAND TYPE 12.7mmTENDON A B R

UNIT Int/Ext Int/Ext min5-4 50/55 45/50 6005-7 65/72 55/60 6005-12 80/87 65/72 9005-19 90/97 80/87 11005-22 95/102 85/92 12005-31 110/117 100/107 1400

STRAND TYPE 15.2mmTENDON A B R

UNIT Int/Ext Int/Ext min6-2 50/55 45/50 6006-3 50/55 45/50 6006-4 55/60 50/55 6006-7 75/82 60/67 7506-12 90/97 80/87 10006-19 100/117 95/102 1300

2nd injection

F

G

A

L o/

J

B H M DC

E

Overflow offirst injection

1st injectionK- Anchorage spacing

B o/

GroutVent

R

VSL16

M U L T I S T R A N D P O S T - T E N S I O N I N G

S H E AT H I N G & C O R R O S I O N P R O T E C T I O NFor conventional applications, corrugated galvanised steel ducts are used.

For applications requiring enhanced corrosion protection and improved fatigue resistance of thetendons, use of the VSL PT-PLUS™ System with corrugated plastic duct is recommended. Thisfully encapsulated, watertight system offers superb corrosion protection, and the plastic ducteliminates fretting fatigue between the strand and duct. It also provides reduced duct friction. ThePT-PLUS™ System may, in conjunction with VSL CS Anchorages, be configured with specialdetails and installation techniques to provide Electrically Isolated Tendons. These tendons may beelectrically monitored at any time throughout the life of the structure.

All ducts are manufactured in a variety of standard lengths and are coupled on site.For diameters of steel ducts see page 9.

STRAND TYPE STRAND TYPE DUCT12.7mm 15.2mm Dimensions (mm)

TENDON UNIT TENDON UNIT d D s5-10 6-7 59 73 25-18 6-12 76 91 2.55-31 6-19/6-22 100 116 35-42 6-31 130 146 35-53 6-37 130 146 3

Other units on request

D I M E N S I O N S O F P O LY E T H Y L E N E D U C T S P T- P L U S ™

STRAND POSITION AT LOW POINT OF TENDON

STEEL DUCT

STRAND POSITION AT HIGH POINT OF TENDON

Centre gravity of strandsCentre line of duct

STRAND BUNDLE

STEEL PLASTICTENDON DUCT DUCT

UNIT e (mm) e (mm)5-1 4 –5-3 7 –5-7 8 –5-12 11 75-19 13 95-22 12 225-27 13 175-31 14 145-37 16 325-42 18 285-48 17 245-55 19 14

STEEL PLASTICTENDON DUCT DUCT

UNIT e (mm) e (mm)6-1 5 –6-3 6 –6-4 6 –6-7 10 96-12 14 126-19 17 186-22 14 156-27 13 326-31 15 286-37 17 19

E C C E N T R I C I T Y O F T E N D O N SSTRAND TYPE 12.7mm STRAND TYPE 15.2mm

POLYETHYLENE DUCT PT-PLUS™

e

e

ds

D

VSL17

M U L T I S T R A N D P O S T - T E N S I O N I N G

S E L E C T E D D E S I G N C O N S I D E R AT I O N STendon SupportsRecommended spacings:• Conventional steel ducts: 0.8 to 1.2m• Polyethylene ducts PT-PLUS™: 0.8 to 1.0mTendon Force LossesThe friction losses in the anchorage due to curvature of the strand and friction of the strand in thewedges usually amount to:• Anchorage type Sc: 2 to 4%• Anchorage type CS: 1 to 2%

Friction losses along the tendon can vary fairly widely and depend upon several factors, including:the nature and surface condition of the prestressing steel, the type, diameter and surfaceconditions of the duct and the installation method.

The following values may be assumed for design:• Tendon in conventional steel ducts: µ = 0.20• Tendon in polyethylene ducts PT-PLUS™: µ = 0.14

Irrespective of the type of jack or tendon, a loss due to wedge draw-in of nominally 6mm occurs at lock-off.

M I N I M U M R A D I I O F T E N D O NC U R VAT U R E

The radii of curvature given in the opposite diagram may be reduced, provided the local concrete strength and the steel stressesresulting from the curvature are checked.

MIN. RADIUS OF CURVATURE Rmin

10mm NOMINAL

10mmNOMINAL

MIN. STRAIGHT LENGTH Lmin BEHIND ANCHORAGE

EDGE DISTANCESTENDON UNIT E

(mm)5-7 30

5-12 505-19 505-27 805-42 805-55 806-7 50

6-12 506-19 806-27 806-42 1006-55 100

12.7

mm

15.2

mm

STR

AN

D T

YP

E

E

E

LminRmin

(m)

0 2000 4000 6000 8000 10000 12000 14000 16000

12

10

8

6

4

2

0

Tendon breaking load (kN)

0.8

Rmin.

Lmin.1.5

1.0

VSL18

M U L T I S T R A N D P O S T - T E N S I O N I N G

STRESSING

The wedges always remain in contact with the strands during the stressingoperation. As the pressure in the jack is released, the wedges automatically lock inthe conical holes of the anchor head.

Placing of anchor head and wedges

Positioning of the jack

Stressing

Seating of wedges

Grouting equipment Grouting of tendon

G R O U T I N GVSL grouting equipment includes mixer and pump in one unit. Grouting is usually carried out assoon as possible after stressing. For special applications vacuum assisted grouting procedurescan be used

Placing of anchor head

Positioning of jack

Stressing, measuring, seating of wedges

VSL19

M U L T I S T R A N D P O S T - T E N S I O N I N G

Dimensions VSL JACK TYPE(mm) VSL50 VSLB7 VSL190 VSL 290 VSL460 VSL670

A 145 180 195 235 285 370B 1000 1000 1600 1600 1400 2400

VSL750 VSL1000 VSL1250 VSL1650 VSL1700A 300 435 395 495 480B 2600 2300 2800 1800 2600

VSL JACK TENDON TENDON NOMINAL D D1 L L1 X STROKE MASSTYPE UNIT UNIT CAP (kN) Dimensions (mm) (mm) (kg)

VSL50 5-3 & 4 500 210 – 430 – – 150 34VSLB7 5-7 6-3 & 4 1000 275 – 405 – – 160 76VSL190 5-12 6-7 1900 310 230 430 200 135 100 151VSL290 5-19 6-12 2900 390 270 450 215 240 100 202VSL460 5-22, -27, -31 6-19 4600 485 330 510 200 85 100 425VSL670 5-42 6-22, -27, -31 6700 660 – 840 – 250 200 1550VSL750 5-42 6-35 7500 570 410 1030 215 165 200 1500VSL1000 5-55 6-47 10000 790 – 885 – 165 200 2200VSL1250 5-55 6-55 12500 710 420 1125 220 165 150 1730VSL1650 5-64 6-55 16500 910 600 615 140 – 150 1750VSL1700 5-91 6-91 17000 875 – 1030 – 165 150 3085

J A C K C L E A R A N C E R E Q U I R E M E N T S

S T R E S S I N G J A C K D E TA I L S

Note: other equipment is available for special situations.

VSL JackJack stroke

B

A

L

L1

D1

X XD DL

VSL20

M U L T I S T R A N D P O S T - T E N S I O N I N G

In-situ Cantilever Bridge, Moonee Moonee, N.S.W.

Precast Segmental Bridge, F9 Freeway, Melbourne, Victoria F9 Freeway, Melbourne, Victoria

VSL21

M U L T I S T R A N D P O S T - T E N S I O N I N G

Floors for High Rise Offices, Governor Philip Tower, Sydney, NSW

Foundation Raft Hilton Hotel, Guam

In-situ Rail Bridge, Brisbane, Queensland

Melbourne Cricket Ground – Great Southern Stand

VSL22

S L A B P O S T - T E N S I O N I N G

Placing tendons Concreting Stressing Grouting

C O N S T R U C T I O N S E Q U E N C E

Owners and designers of the buildings of today and tomorrow need to incorporate sufficient flexibility into theirstructures to accommodate the changing needs of the users of the building.

Post-tensioning offers larger spans with reduced structural depth, resulting in larger column-free areas. Internaltenancy layouts are thus not restricted by tight column grids. Positive deflection and crack control and, ifnecessary, crack-free watertight slabs offer the designer the opportunity to break free of the limitations of thepassive methods of reinforced concrete or structural steel.

VSL post-tensioning is more economical than other systems, especially when the typically faster constructioncycles are considered. There is less material handling on site. There is a reduced site labour force which reducessite activity congestion. Most importantly, there is the quality and service of VSL specialised high-performancesite teams and unequalled back-up.

The VSL post-tensioning slab system has been used in many thousands of buildings and other structuresthroughout Australia. The system uses up to five strands in flat-shaped ducting and anchorages. The strands are stressed individually and then gripped by wedge action. The entire duct is subsequently fullyfilled with cement grout injected under pressure so that the strands are fully bonded to the surroundingconcrete.

Stadium Australia, Sydney NSW

VSL23

S L A B P O S T - T E N S I O N I N G

S E L E C T E D D E S I G N C O N S I D E R AT I O N STendon Supports

Recommended spacings:• Conventional steel ducts 0.8 to 1.2m• Polyethylene ducts PT-PLUS™ 0.8 to 1.0m• Minimum radius of curvature for flat ducts: About X axis 2.5m

About Y axis 7.0m• Minimum tangent length behind the anchorage 0.5m

Tendon Force LossesThe friction losses in the anchorage due to curvature of the strand and friction of the strand in thewedges usually amount to:

• Edge stressing 3% average• Internal pocket stressing 5% average

Frictional losses along the tendon can vary fairly widely and depend upon several factors, includingthe nature and surface condition of the prestressing steel; the type, diameter and surfaceconditions of the duct and the installation method.

The following values may be assumed for design:• Tendon in conventional steel ducts: µ = 0.20• Tendon in polyethylene ducts PT-PLUS™ µ = 0.14

A loss due to wedge draw-in of nominally 6mm occurs at lock-off.

DUCT TYPE Bi Ba Br Hi Ha HrDimensions (mm)

Galv. SteelS5-1/S6-1 20 21 – 20 21 –S5-2/S6-2 50 51 – 19 20 –

S5-5 70 71 – 19 20 –S6-5 90 91 – 19 20 –

PolyethylenePT-PLUS™S5-5/S6-4 72 76 86 21 25 35

S6-5 Not available

D I M E N S I O N O F D U C T S

STRAND TYPE 12.7mm SuperTENDON No. OF Minimum

UNIT STRANDS BreakingLoad kN

S5-1 1 184S5-2 2 368S5-3 3 552S5-4 4 736S5-5 5 920

STRAND TYPE 15.2mm SuperTENDON No. OF Minimum

UNIT STRANDS BreakingLoad kN

S6-1 1 250S6-2 2 500S6-3 3 750S6-4 4 1000S6-5 5 1250

For special applications other strand and tendon capacities are available.

S T R A N D P R O P E R T I E S – T O A S 1 3 11

T E N D O N P R O P E R T I E S

Y

X Hi

Bi

Ba

Br

HrHa

Nominal Nominal Nominal Minimum Minimum Min. Elong. Relaxation ModulusDiameter Steel Area Mass Breaking Load Proof Load to Fracture After 1,000hrs of Elasticity

(0.2% Offset) in 600mm at 0.7Breaking Load

mm mm2 kg/m kN kN % % MPa12.7 Super 100.1 0.786 184 156.4 3.5 2.5

180–20515.2 Super 143.3 1.125 250 212.5 3.5 2.5x 10

3

15.2 EHT 143.3 1.125 261 221.9 3.5 2.5

VSL24

S L A B P O S T - T E N S I O N I N G

STRAND TENDON A B C D E F RTYPE UNIT Dimensions (mm)

12.7mm S5-3 265 100 215 225 45 70 90S5-4 265 100 215 225 45 70 90S5-5 265 100 215 225 45 70 90

15.2mm S6-2 265 100 215 225 50 70 90S6-3 265 100 215 225 45 70 90S6-4 265 100 215 225 45 70 90S6-5 265 100 238 265 45 70 90

V S L S T R E S S I N G A N C H O R A G E S T Y P E S 5 - S 6L I V E E N D

GROUT TUBE

DUCT

CAST IN ANCHOR

ANCHOR HEAD

PLASTIC RECESSFORMER

STRANDS

WEDGE GRIPS

Note: S6-2 supplied with barrels and wedges in lieu of cast anchor head

70 x 19 duct90 x 19 Duct – S6-5 only

CR

E20

A D

B F

VSL25

S L A B P O S T - T E N S I O N I N G

V S L S T R E S S I N GA N C H O R A G E T Y P E S 5 - 2

L I V E E N D

V S L S T R E S S I N G A N C H O R A G E ST Y P E S 5 - 1 , S 6 - 1

L I V E E N D

GROUT TUBE

GROUT TUBE

WEDGE GRIP

BARRELS &WEDGE GRIPS

STRANDS

STRAND

DUCT DUCT

STYRENE RECESS FORMER PLASTIC RECESS FORMER

CAST IN ANCHOR

S 5 - 2

S 5 - 1 , S 6 - 1

100

20 45

9535

50

50 x 19 Duct

Duct 20 Dia.

150

8558 52

170

152

146

CAST IN ANCHOR

GROUT TUBE

DUCT

DEAD END

SPACER PLATE(NOT ALWAYS REQUIRED)

ANCHOR PLATE

SWAGED DEAD END

VSL26

S L A B P O S T - T E N S I O N I N G

TENDON UNIT A B CTYPE H Dimensions (mm)

5-1 75 50 6005-2 135 50 6005-3 230 50 6005-4 270 50 6005-5 350 50 6006-1 75 50 6006-2 135 50 6006-3 230 50 6006-4 270 50 6006-5 350 50 600

STR

AN

D T

YP

E

12.7

mm

15.2

mm

TENDON UNIT D E FTYPE P Dimensions (mm)

5-1 100 75 1005-2 125 75 1505-3 200 75 3505-4 250 75 5005-5 300 75 5006-1 125 75 1006-2 150 75 1506-3 225 75 3506-4 300 75 5006-5 350 75 500

STR

AN

D T

YP

E

12.7

mm

15.2

mm

V S L D E A D E N D A N C H O R A G E S T Y P E H – T Y P E P

Dead End Anchorage Type H Dead End Anchorage Type P

3 C

Ax

B

D x

E

F

12

60

T Y P E H

T Y P E P

VSL27

S L A B P O S T - T E N S I O N I N G

STRAND TENDON A B C D ETYPE UNIT Dimensions (mm)

12.7mm S5-4 95 190 110 240 215S5-5 95 235 110 240 215

15.2mm S6-4 95 190 110 240 215S6-5 95 235 110 265 238

V S L S L A B C O U P L I N G A N C H O R A G E T Y P E S

GROUT TUBE

DUCT

CAST IN ANCHOR

ANCHOR HEAD

CAST COUPLINGBLOCK

DUCT

GROUT TUBE

SWAGED ENDS

E

A

600

D

C

B

VSL28

S L A B P O S T - T E N S I O N I N G

C

D600

STRAND TENDON A B C DTYPE UNIT Dimensions (mm)

12.7mm S5-2 170 75 125 8015.2mm S6-2 170 75 135 85

V S L S L A B C O U P L I N G A N C H O R A G E S T Y P E S 5 - 2 , S 6 - 2

GROUT TUBE

CAST IN ANCHOR

SWAGED ENDS

COUPLING BLOCK

BARRELS & WEDGE GRIPS

DUCT

STRANDS

SPACER BARRELS

A

B

VSL29

S L A B P O S T - T E N S I O N I N G

S E C T I O N A S E C T I O N B

P L A N S T R E S S I N G P O C K E T

I N T E R N A L S T R E S S I N G P O C K E T12.7mm STRAND 15.2mm STRAND

DETAILS SHOWN ARE TYPICAL AND MAY VARY FOR PARTICULAR APPLICATIONS

VSL CH JACKMax. Capacity..............................................................................300 kNMass............................................................................................. .26 kgStroke.........................................................................................300 mmMax. hydraulic pressure .............................................................68 MPa

VSL TCH JACKMax. Capacity ............................................................................290 kNMass.............................................................................................20 kgStroke.......................................................................................250 mmMax. hydraulic pressure ...........................................................68 MPa

S T R E S S I N G J A C K D E TA I L S

J A C K C L E A R A N C ER E Q U I R E M E N T S

605

75

135 180

605600

B

A

Anch

or

Anch

or165

100

25

450 450

50 175 175 5042030

200

7080125

330

935

VSL30

S L A B P O S T - T E N S I O N I N G

60 m

in S

5-2

80 m

in S

5-4

90 m

in S

5-5

100

min

S6-

5

GROUT VENT

TYPICAL EDGE REINFORCEMENT

D E TA I L AT S L A B E D G E

S 5 - 2 A N C H O R

S 5 - 3 , S 5 - 4 , S 5 - 5 A N C H O R SS 6 - 2 , S 6 - 3 , S 6 - 4 A N C H O R S

S 6 - 5 A N C H O R

NOTE: 1. REINFORCEMENT SHOWN IS INDICATIVE, ACTUAL ANCHORAGE REINFORCEMENT IS TO BE AS DETAILED BY THECONSULTING ENGINEER, ANCHORAGE REINFORCEMENT SHALL BE LOCATED CENTRALLY ABOUT ANCHOR AND HARDAGAINST CASTING AS SHOWN.

2. MIN. CONCRETE CYLINDER STRENGTH AT JACKING = 22MPa GENERALLY AND 25 MPaFOR S6-5. REINFORCEMENT FOR HELIX IS ROUND BAR WITH fy = 250 MPa.

A N C H O R A G E R E I N F O R C E M E N T – H E L I X

A N C H O R A G E AT S L A B E D G E

120 75

130

R6

210 110

250

R10

350 150

290

R10

TYPICAL EDGE REINFORCEMENT

VSL31

S L A B P O S T - T E N S I O N I N G

A N C H O R A G E R E I N F O R C E M E N T – T I E S

A N C H O R A G E AT S L A B E D G E A N C H O R A G E AT E D G E B E A M

STRAND TENDON No. OF TIES A BTYPE UNIT EACH SIDE mm mm

S5-2 1 100 6012.7mm S5-3, S5-4 2 200 80

S5-5 2 200 90S6-2, S6-3 2 200 80

15.2mm S6-4 2 200 90S6-5 2+2 200 100

NOTE: 1. REINFORCEMENT SHOWN ISINDICATIVE. ACTUAL ANCHORAGEREINFORCEMENT IS TO BE AS DETAILEDBY THE CONSULTING ENGINEER.ANCHORAGE REINFORCEMENT SHALLBE LOCATED CENTRALLY ABOUTANCHOR AND HARD AGAINST CASTINGAS SHOWN.

2. MIN. CONCRETE CYLINDER STRENGTHAT JACKING = 22MPa GENERALLY AND 25MPaFOR S6-5. REINFORCEMENT FOR TIES ISROUND BAR WITH fy = 250 MPa.

EXTRA TIES WHERESHOWN FOR S6-5 ONLY.

EXTRA TIES WHERESHOWN FOR S6-5 ONLY.

R10 CLOSED TIESR6 FOR S5-2 ONLY

Y12 OR BEAM REINFORCEMNT

2Y12 TOP & BTM x 1000 min.3Y12 TOP & BTMS6-5 only

PLACE INNERMOST TIEHARD AGAINSTCASTING AS SHOWN

2-R10 TIES AT 50mm CRS.EACH SIDE OF EACHANCHORAGE TYPICAL1 EACH SIDE FOR S5-2ONLY

2Y12 TOP x 1000min.

GROUT VENT

GROUT VENT

OPEN TIES

D E TA I L AT S L A B E D G E

AA

A

BB

B30

0

D E TA I L AT E D G E B E A MP L A N

VSL32

S L A B P O S T - T E N S I O N I N G

Floors and Watertight Roofs, Tooronga, Melbourne, Victoria

Floors for Commuter Car ParkGosford, N.S.W.

Floors for High Live LoadExhibition Centre, Melbourne, Victoria

Floors for Retail Development, Tuggerah, N.S.W.

VSL33

S L A B P O S T - T E N S I O N I N G

Floors for Princess Alexandra Hospital, Brisbane, Queensland

Floors for High Rise OfficeBourke Place, Melbourne, Victoria

Floors for Carpark, Commercial, Retail and High Rise OfficesWorld Square, Sydney, N.S.W.

Foundation Raft SlabSydney, N.S.W.

VSL34

S L A B P O S T - T E N S I O N I N G

Distribution Centre andWarehouse, Brisbane,Queensland

The VSL post-tensioning system is widely used in the construction of slabs on grade. Warehouses,distribution centres, container terminals, airports, pavements, residential slabs and recreationalslabs for tennis courts and skating rinks are common applications.

E L I M I N AT E J O I N T S

Joints in reinforced concrete slabs on grade have long been a cause of cost and delay to ownersbecause of the constant maintenance they require. Owners and operators of facilities with slabson grade can eliminate these costs by eliminating the joints themselves. The VSL post-tensionedconcrete slab on grade is cast in very large areas, often exceeding 2,500 sq.m, in which there areno joints. In certain applications, slabs in the order of 10,000 sq.m have been constructed withoutmovement joints.

C R A C K - F R E E P E R F O R M A N C E

The VSL post-tensioning axially compresses the concrete slab to counteract tensile stresses whichwould otherwise cause cracking under the worst combinations of temperature and applied loads.The prestress applied can even control the initial concrete shrinkage sufficiently to prevent initialshrinkage cracking.

S L A B O N G R A D E

Float Glass Plant,Ingleburn, N.S.W.

VSL35

S L A B P O S T - T E N S I O N I N G

T H I N N E R S L A BThe VSL slab is much thinner than its equivalent in reinforced concrete. The VSL slab generallycontains no reinforcement except at the perimeter and for trimming at penetrations.

I N I T I A L C O S TThe thinner slab, absence of reinforcement, absence of costly internal jointing and the cost savingavailable from the construction program time saved by casting large areas, all contribute to acompetitive initial cost.

F U T U R E M A I N T E N A N C EDuring the life of the slab, the joint maintenance costs which the owner no longer need endure, willreap great improvements in the efficiency of the facility. A life cycle analysis can be readilyundertaken to demonstrate that future savings to the owner more than justify the selection of a VSLslab on grade.

Intermodal Terminal,Acacia Ridge, QueenslandResidential Housing

Brisbane, Queensland

White City Tennis Centre,Sydney, N.S.W.

VSL36

S T R E S S B A R

BAR SYSTEMSVSL have been manufacturing and designing bar systems in Australia for use by theconstruction industry since 1971. These have proven to be one of the most populartools of Engineers wishing to induce and control loads and forces in structures.

The systems range from High Tensile Cold Worked Stressbar to Low TensileArchitectural Tendons, all with compact and easy to assemble fittings.

A range of diameters is available to give a wide selection of tendon forces. Theprestressing force is anchored at the end of the bar by a rolled thread, nut, washer andbearing plate. Where necessary bars can be joined with threaded couplers, and clevisfittings may be used where pin connections are required.

The VSL bar system complies with the requirements of AS1313 and AS1314.

Architectural Max Bar length mFull Short Right Left Cold Hot Components Export Containers

Thread Thread Hand Hand Rolled Rolled Available 20ft 40ft

CT STRESS BAR15 - 46mm CT Bar l l l l l l 5.85 11.85

56mm CT Bar l l l l l l 5.85 873mm Bar l l l l 5.85 8

DEFORMED BAR15mm Tie Bar l l l 5.85 11.85

26.5 - 40mm HR Bar* l l l 5.85 11.85

THREADLOK BAR20–25mm l l l 5.85 11.85

ARCHITECTURAL BAR20 -100mm MT Bar * l l l l l 5.85 11.85

V S L B A R C O N F I G U R AT I O N S

Hong Kong Stadium, Hong Kong

Thread DetailsVSL BAR SYSTEM

* Note: Check availability as some sizes may not be stocked.

VSL37

S T R E S S B A R

Buildings• Prestressed Beams and Columns• Precast Connections

Bridges• Stay Cable • Hangers• Prestressed Segments• Strengthening• Tension Piles and Caissons

Wharves & Jetties• Stressed Deck Planks• Tie Backs

Anchors• Permanent and Temporary Ground Anchors• Uplift Anchors (Dam & Foundation)• Roof Bolting• Soil Nails (Slope Stabilisation)• Crane Bases• Light Towers

Specialist Engineering• Heavy Lifting• Formwork Ties or Hangers• Frame Ties• Pile testing• Architectural Ties

A P P L I C AT I O NVSL bar systems are ideal for the economic application of post tensioning forces on relatively shorttendons. Through the use of threaded connections and anchorages they are simple to use andlend themselves to many applications.

T Y P I C A L A P P L I C AT I O N S :

C H A R A C T E R I S T I C P R O P E R T I E SVSL Bar properties are nominally as listed in the Tables. These specifications may be subject to change without notice. Check with the VSL office regarding availability.

C O R R O S I O N P R O T E C T I O NAll bars and fittings must receive protection when installed under permanent conditions. In normalconcrete construction the use of galvanised duct, injected with grout, provides good protection.Anchorage recesses must also be filled with cement mortar to protect the ends.

BarsWhen bars are used in an exposed environment,one of the following coating systems may be used.• Single coat of inorganic zinc• Three coat epoxy paint system

• Greased and sheathed in poly tube• Galvanising—(Threadlok Bar only)

A combination of the above systems may also be specified. Consideration must also be given tothe threaded ends to ensure correct installation of fittings after coating.

FittingsFittings may be treated as above but with preference given to galvanising.

Temporary Bar AnchorsAnchors used in a temporary environment may be used without protection apart from grout cover.

Permanent Bar AnchorsThese anchors require installation into corrugated polyethylene sheathing to provide multiple levels of protection. This is accomplished by the internal grout and sheathing barrier. Additional protection may also be used by incorporating the above bar coatings.

Nominal Nominal Nominal Nominal Tensile Nominal 0.1% Characteristic Strength Minimum Appr. Modulus Major Dia. ThreadDia. Area Mass Strength Proof Stress kN Elongation of Elasticity of Thread Pitchmm sq. mm kg./m MPa MPa Max. Force 0.1% Proof at max force % x 103 MPa mm mm20 314 2.47 620 460 186 138 16 205 21.4 223 415 3.26 620 460 241 179 16 205 25.0 330 707 5.55 620 460 416 309 16 205 32.0 336 1018 7.99 620 460 595 441 16 205 38.7 439 1195 9.38 620 460 701 520 16 205 41.7 445 1590 12.48 620 460 945 701 16 205 47.8 456 2463 19.33 620 460 1475 1095 16 205 58.8 460 2827 22.19 620 460 1665 1235 16 205 64.1 675 4418 34.68 620 460 2628 1950 16 205 79.1 690 6362 49.94 620 460 3811 2828 16 205 94.1 6

100 7854 61.65 620 460 4721 3503 16 205 104.1 6

Nominal Nominal Nominal Nominal Tensile Nominal 0.1% Characteristic Strength Minimum Appr. Modulus Major Dia. ThreadDia. Area Mass Strength Proof Stress kN Elongation of Elasticity of Thread Pitchmm sq. mm kg./m MPa MPa Max. Force 0.1% Proof at max force % x 103 MPa mm mm

*15 177 1.39 1080 885 191 157 3.5 205 17.4 1026.5 552 4.48 1030 835 568 460 3.5 165 30 1332 804 6.53 1030 835 828 671 3.5 165 36 1636 1018 8.27 1030 835 1048 849 3.5 165 40 1840 1257 10.2 1030 835 1294 1048 3.5 165 45 20

VSL38

S T R E S S B A R

V S L C T S T R E S S B A RC H A R A C T E R I S T I C P R O P E R T I E S

V S L T H R E A D L O K B A RC H A R A C T E R I S T I C P R O P E R T I E S

V S L M T 6 0 0 B A RC H A R A C T E R I S T I C P R O P E R T I E S

Note: 1. Relaxation properties, as per AS1313, are 4% maximum at 1000 hrs when loaded to 70% of minimum breaking load.2. Fatigue results exceed two million cycles when loaded over a stress range of 80 MPa.3. Minimum bending radius = 200 x Bar Dia.4. The modulus of elasticity may be increased to 205 x 103 MPa for bars up to 46 dia., where the bars are supplied with additional heat treatment.5. CT bars may be supplied rolled thread over full length, except 73mm (* cut thread with reduced capacity).

Note: 1. Refer to CT Stressbar notes.* VSL Deformed tie bar

Note: 1. Threadlok bars incorporate LEFT-HAND threads (LH)2. Minimum bending radius = 4 x Bar Dia.

Note: These specifications may be subject to change without notice. Check with the VSL office regarding availability.

Nominal Nominal Nominal Nominal Tensile Nominal 0.1% Characteristic Strength Minimum Appr. Modulus Major Dia. ThreadDia. Area Mass Strength Proof Stress kN Elongation of Elasticity of Thread Pitchmm sq. mm kg./m MPa MPa Max. Force 0.1% Proof at max force % x 103 MPa mm mm15 177 1.52 1080 930 190 165 3.5 170 17.2 620 314 2.39 1030 835 325 260 3.5 170 21.2 623 415 3.46 1080 930 450 385 3.5 170 25.2 626 531 4.40 1080 930 575 495 3.5 170 28.2 629 661 5.44 1080 930 715 615 3.5 170 31.2 632 804 6.59 1080 930 870 750 3.5 170 34.4 6 36 1018 7.86 1030 835 1050 850 3.5 170 37.4 638 1134 9.23 1080 930 1225 1055 3.5 170 40.4 640 1257 9.72 1030 835 1295 1050 3.5 170 41.4 646 1662 14.03 1030 835 1710 1390 3.5 170 49.4 656 2463 19.33 1000 810 2460 1995 3.5 205 58.5 673 4185 34.68 1000 810 *3873 *3140 3.5 205 75 4

Nominal Nominal Nominal Nominal Tensile Nominal 0.1% Characteristic Strength Minimum Appr. Modulus Major Dia. ThreadDia. Area Mass Strength Proof Stress kN Elongation of Elasticity of Thread Pitchmm sq. mm kg./m MPa MPa Max. Force 0.1% Proof at max force % x 103 MPa mm mm20 314 2.47 600 500 188 157 16 205 22.7 10 LH25 491 3.85 600 500 295 246 16 205 28 12.5 LH

V S L H R S T R E S S B A RC H A R A C T E R I S T I C P R O P E R T I E S

VSL39

S T R E S S B A R

V S L C T S T R E S S B A R — S TA N D A R D C O M P O N E N T D E TA I L S ( m m )

V S L C T S T R E S S B A R T E N D O N A R R A N G E M E N T

GROUT INJECTION

NUT

LIVE END ANCHORAGE

DUCT

GROUT TUBE

FERRULEDEAD-END ANCHORAGECOUPLER ASSEMBLY

VSL Stressbar is produced from Australianraw materials and by Australian labour atour manufacturing plant in Noble Park,Victoria.

All bars and fittings comply with relevantcodes and are now exported to some 20countries worldwide.

ITEM BAR DIAMETER 15 20 23 26 29 32 36 38 40 46 56 73

PART No. NC15 NC20 NC23 NC26 NC29 NC32 NC36 NC38 NC40 NC46 NC56 NC73

NUTSA 28 33 38 42 47 52 56 62 65 90* 100* 140*

B 40 45 45 50 50 55 55 60 60 75 100 120

PART No. LNC15 LNC20 LNC23 LNC26 LNC29 LNC32 LNC36 LNC38 LNC40 LNC46 LNC56 LNC73LOCKNUTS B 13 16 19 22 24 26 29 31 32 40 45 60

PART No. BP15 BP20 BP23 BP26 BP29 BP32 BP36 BP38 BP40 BP46 BP56 BP73

BEARINGA 75 100 130 130 150 150 150 180 180 250 250 300

PLATES**B 75 100 130 130 130 130 150 150 150 200 200 300

C 25 32 40 40 40 50 50 50 50 60 70 70D 21 25 29 32 35 38 42 45 47 54 63 80

PART No. CC15 CC20 CC23 CC26 CC29 CC32 CC36 CC38 CC40 CC46 CC56 CC73

COUPLERS A 32 36 39 42 45 54 56 60 65 75 85 110

B 90 100 100 110 110 120 125 130 130 150 190 250

PART No. CCV15 CCV20 CCV23 CCV26 CCV29 CCV32 CCV36 CCV38 CCV40 CCV46 CCV56 CCV73COUPLER A 230 230 230 230 230 230 230 230 230 250 290 350COVERS B 57 57 57 57 57 70 70 70 75 90 96 118

PART No. WF15 WF20 WF23 WF26 WF29 WF32 WF36 WF38 WF40 WF46 WF56 WF73FLAT A 34 39 50 56 60 66 72 78 84 100 120 150

WASHERB 3 3 4 4 5 5 6 6 6 8 8 8

PART No. WS15 WS20 WS23 WS26 WS29 WS32 WS36 WS38 WS40 WS46 WS56 WS73SPHERICAL A 39 45 45 50 56 64 70 75 80 100 120 160

WASHERB 5 7 10 10 10 10 10 12 12 12 18 20

PART No. D36 D36 D39 D39 D39 D45 D45 D51 D54 D60 D69 D96DUCTING A 36 36 39 39 39 45 45 51 54 60 69 96

Note: 1. *Nuts for 46, 56 and 73-mm are supplied from round material with peg holes as standard.2. ** Where tapped bearing plates are specified then they are supplied with a locknut as standard.

A

A

A

A

A BB

B

A

B

C

D

B

B

VSL40

S T R E S S B A R

ITEM BAR DIAMETER 15 20 23 26 29 32 36 38 40 46 56 73PART No. CLS15C CLS20C CLS23C CLS26C CLS29C CLS32C CLS36C CLS38C CLS40C CLS46C CLS56C CLS73C

A 20 25 32 36 40 40 45 50 50 55 80 100PART No. CLF15C CLF20C CLF23C CLF26C CLF29C CLF32C CLF36C CLF38C CLF40C CLF46C CLF56C CLF73C

B 23 28 35 39 43 43 48 53 53 58 83 103C 39 48 59 67 73 77 86 93 93 98 141 189D 173 198 220 240 254 277 294 330 330 363 412 542E 52 66 72 82 98 98 106 130 130 154 168 210F 22 27 31 37 40 43 46 57 57 61 76 101G 34 42 46 54 59 63 68 84 84 100 113 150H 33 42 48 50 56 65 70 80 80 90 110 140J 59 71 79 88 95 109 116 131 131 148 154 222

PART No. CLP15C CLP20C CLP23C CLP26C CLP29C CLP32C CLP36C CLP38C CLP40C CLP46C CLP56C CLP73CA 21 26 30 36 39 42 45 56 56 60 75 100B 40 49 60 63 74 78 87 94 94 99 142 190

PART No. LNC15S LNC20S LNC23S LNC26S LNC29S LNC32S LNC36S LNC38S LNC40S LNC46S LNC56S LNC73SA 33 42 48 50 56 65 70 80 80 90 110 140B 40 50 60 65 75 80 90 95 100 120 140 190

PART No. LNC15T LNC20T LNC23T LNC26T LNC29T LNC32T LNC36T LNC38T LNC40T LNC46T LNC56T LNC73TA 33 39 48 50 56 65 70 80 80 90 110 140B 60 70 80 90 100 110 110 120 120 140 160 210

PART No. TC15R TC20R TC23R TC26R TC29R TC32R TC36R TC38R TC40R TC46R TC56R TC73RA 33 39 48 50 56 65 70 80 80 90 110 140B 160 170 180 190 200 220 220 230 230 250 280 340C 80 80 90 90 100 100 100 100 100 100 100 100

VSL CT STRESSBAR—ARCHITECTURAL COMPONENT DETAILS (mm)

Yarra Boulevarde Bridge - Melbourne, Victoria

CONICALCOVER

(STANDARD)

FORKEDCLEVIS

SPADE CLEVIS

CLEVISPIN

CONICALCOVER

(TURNBUCKLE)

TURNBUCKLE COUPLER

E CAF B

H

B

A

A B

C

B

AD

GJ

ITEM BAR DIAMETER 20 23 30 36 39 45 56 60 75 90 100PART No. NM20 NM23 NM30 NM36 NM39 NM45 NM56 NM60 NM75 NM90 NM100

NUTS A 30 36 46 55 65 75 85 95 115 160* 180*B 18 21 25 31 34 38 45 52 60 75 80

PART No. CM20 CM23 CM30 CM36 CM39 CM45 CM56 CM60 CM75 CM90 CM100COUPLERS A 33 39 48 56 65 80 90 110 120 140 150

B 45 53 65 77 89 101 117 133 157 192 212PART No. WM20 WM23 WM30 WM36 WM39 WM45 WM56 WM60 WM75 WM90 WM100

FLAT A 37 44 56 66 78 92 105 115 140 160 180WASHER B 3 4 4 5 7 8 9 9 12 12 14

VSL41

S T R E S S B A R

Note: 1. *Nuts for 90 and 100mm are supplied from round material with peg holes as standard.

V S L M T 6 0 0 B A R — S TA N D A R D C O M P O N E N T D E TA I L S ( m m )

ITEM BAR DIAMETER 20 23 30 36 39 45 56 60 75 90 100

SPADE CLEVISPART No. CLSM20C CLSM23C CLSM30C CLSM36C CLSM39C CLSM45C CLSM56C CLSM60C CLSM75C CLSM90C CLSM100C

A 20 20 25 36 40 45 50 55 80 100 100PART No. CLFM20C CLFM23C CLFM30C CLFM36C CLFM39C CLFM45C CLFM56C CLFM60C CLFM75C CLFM90C CLFM100C

B 23 23 28 39 43 48 53 58 83 103 103C 39 39 48 67 73 86 93 98 141 189 189D 173 173 198 240 254 294 330 363 412 542 542E 52 52 66 82 98 106 130 154 168 210 210F 22 22 27 37 40 46 57 61 76 101 101G 34 34 42 54 59 68 84 100 113 150 150H 33 33 42 50 56 70 80 90 110 140 140J 59 59 71 88 95 116 131 148 154 222 222

PART No. CLPM20CCLPM23CCLPM30CCLPM36CCLPM39C CLPM45C CLPM56C CLPM60C CLPM75C CLPM90CCLPM100CA 21 21 26 36 39 45 56 60 75 100 100B 40 40 49 63 74 87 94 99 142 190 190

PART No. LNM20S LNM23S LNM30S LNM36S LNM39S LNM45S LNM56S LNM60S LNM75S LNM90S LNM100SA 33 33 42 50 56 70 80 90 110 140 140B 40 45 50 65 75 90 95 120 140 190 190

PART No. LNM20T LNM23T LNM30T LNM36T LNM39T LNM45T LNM56T LNM60T LNM75T LNM90T LNM100TA 33 39 48 56 65 80 90 100 120 140 150B 60 60 70 90 100 110 120 140 160 210 210

PART No. TM20R TM23R TM30R TM36R TM39R TM45R TM56R TM60R TM75R TM90R TM100RA 33 39 48 56 65 80 90 100 120 140 150B 120 128 150 168 184 196 212 228 252 280 300C 80 80 80 100 100 100 100 100 100 100 100

VSL MT600 BAR — ARCHITECTURAL COMPONENT DETAILS ( m m )

Olympic Aquatic Centre, Homebush, NSW Netball Centre, Waverley, Victoria

FORKEDCLEVIS

CLEVIS PIN

CONICALCOVER

(STANDARD)

CONICALCOVER

(TURNBUCKLE)

TURNBUCKLECOUPLER

E

A

A

B A

B

B

CAF B

H

B

A

A B

C

B

AD

GJ

VSL42

S T R E S S B A R

VSL TIE & THREADLOK BAR COMPONENT DETAILS (mm)

JACK CHAIRMODEL F G H HEIGHT

B55 680 95 125B90 665 105 150

B90L 810 105 150B100 540 110 150

B100L 740 110 150B150 995 150 150B200 1025 160 200

VSL190 1600 220 200VSL460 1600 260 250 580

JACK CLEARANCE DETAILS ( m m )

BEARING PLATES

COUPLERS

FLATWASHERS

DOMEDBEARING PLATES

ITEM BAR DIAMETER15mm 20mm 25MM

TIE BAR THREADLOCK THREADLOCKPART No. NTB15 NTL20 NTL25

NUTS A 28 33 42STANDARD B 50 42 52

PART No. NTB15D NTL20D NTL25DNUTS A - 38 42DOME B - 42 52

C - 55 55

PART No. NTB15W NTL20W MTL25WNUTS A 25 36 -WING B 50 50 -

PART No. PTB15 PTL20 PTL25A 75 130 130B 75 130 130C 25 20 25D 20 25 32

PART No. PTB15D PTB20D PTB25DA - 150 250B - 150 250C - 8 12D - 34 34

PART No. CTB15 CTL20 CTL25A 33 33 42

B 110 94 116

PART No. WM16 WTL20 WTL25A 34 39 56B 3 3 4

250

460

Hydraulic Stressing Jack and Accessories

Vertical Prestressing of Precast Shaft SegmentsAirport Control Tower, Sydney, N.S.W.

C

200 L

F

E DStroke

Chair Height

2525

GH C

hair

dia.

300

Ax BA

A

A

A

A

A

B A

B

C

B

DC D

B

B

B

C

B

VSL43

S T R E S S B A R

NomBar Jack Jack Dimension Capacity WeightDia. Model D L E Stroke kN kg

15 to 25 B55 165 245 85 125 550 3329, 36 B90 190 280 105 80 900 48

29 to 36 B90L 190 355 105 150 900 6238, 40 B100 200 170 130 50 1000 2838, 40 B100L 200 270 130 150 1000 48

46 B150 275 300 150 150 1500 10046, 56 B200 300 380 170 150 2000 160

56 VSL190 410 565 220 100 1900 15173 VSL460 485 510 220 100 4600 425

J A C K D E TA I L S ( m m )

Bar Recommended MinimumDia A B C A B C

15, 20 120 120 90 100 100 9023, 26 150 150 95 130 130 95

29, 32, 36 170 170 100 150 150 10038, 40 200 170 110 180 170 110

46 270 220 140 250 200 14056 270 220 160 250 200 16073 320 320 180 300 300 180

R E C E S S D E TA I L S ( m m )

ITEM BAR DIAMETER 26.5 32 36 40PART No. NH26 NH32 MH36 NH40

NUTS A 47 56 62 65B 80 90 110 129

PART No. LNH26 LNH32 LNH36 LNH40LOCKNUTS B 40 45 55 60

PART No. PH26 PH32 PH36 PH40

BEARINGA 130 150 150 180

PLATESB 130 130 150 150C 40 50 50 50D 35 41 45 47

PART No. CH26 CH32 CH36 CH40A 48 57 70 75B 150 180 210 210

PART No. CH26H CH32H CH36H CH40HA 45 54 56 66B 130 160 180 180

PART No. CCH26 CCH32 CCH36 CCH40A 250 280 310 310B 57 70 90 90

PART No. WFH26 WFH32 WFH36 WFH40FLAT A 56 66 78 92

WASHERSB 4 5 7 8

PART No. WSH26 WSH32 WSH36 WSH40SPHERICAL A 56 70 75 80WASHERS

B 10 10 12 12

PART No. D39 D45 D50 D54DUCTING A 39 45 50 54

V S L H R S T R E S S B A RS TA N D A R D C O M P O N E N T D E TA I L S ( m m )

COUPLERCOVERS

STANDARD

COUPLERSSTANDARD

COUPLERS

HI-TENSILE

Prestressing of Precast Segmental Beams,Chaing Mai Grandstand, Thailand

Vertical Web TendonsGateway Bridge, Brisbane,Queensland

Transverse StressingBridge Beams, Beenleigh, Queensland

A B

A

A

A

A

A

BB

B

B

C D

B

VSL44

G R O U N D A N C H O R S

GENERALAnchors may be constructed in virtually any type of ground to provide large concentrated forces in preciselocations to carry any combination of applied loads. Ground anchors are more specifically referred to as rockanchors or soil anchors, depending on whether the anchor takes its bond in rock or soil.

Each anchor consists of a high-tensile steel tendon inserted into a drilled hole. At the lower end the anchor is bondedto the rock or soil by high strength cement grout. The top of the anchor is fitted with a VSL stressing anchorage.Once the grout has achieved sufficient strength, the anchor tendon is stressed to the required force using acalibrated jack. This force is maintained by the stressing anchorage after release of the jack.

Corrosion protection is provided by the cement grout in temporary anchors and by full encapsulation of the entireanchor in a thick walled polyethylene sheath for permanent anchors.

ROCK ANCHORSVSL Rock Anchors range in ultimate capacities up to 23,750kN. Tendons are constructed from either a numberof 12.7mm or 15.2mm diameter, high tensile steel strands or single VSL stressbars.

SOIL ANCHORS VSL Soil Anchors are used in alluvial soils, stiff clays or highly weathered rock. The ultimate capacity of theseanchors is determined by the capability of the ground in the bond zone to transfer the load from the anchor.Anchor details are similar to rock anchors.

SOIL NAILS VSL Soil Nails are used to reinforce in-situ soil in an excavation or embankment. They are formed by insertingVSL Bar into a drilled hole which is filled with cement grout. Corrosion protection similar to ground anchors canbe provided depending on the application. Soil nails have no or only nominal initial applied force.

R OCK BOLTS VSL Rock Bolts are used to strengthen and stabilise jointed rock, and to stabilise defined blocks of rock. Theyare formed by inserting VSLBar into a drilled hole and anchoring it in place with either a mechanical anchorage,a chemical anchorage or cement grout. The bar is stressed to apply an initial force.

Burrinjuck Dam, NSW

VSL45

G R O U N D A N C H O R S

SECTION B.B

SECTION A.A

Grout tubes

A

A

B

B

Bare clean strand

Corrugated sheathInternal spacer ring

BOND LENGTH OF TENDON

Greased and plastic coated strand

FREE TENDON LENGTH

Anchor head

Bearing Plate

Smooth sheath (Polyethylene)or continuous corrugated sheath

External spacer

External spacerBore hole

Nose cone

Bore hole

Bore hole

Grout tubes

Grout tubes

Smoothsheath

Greasedand plasticcoated strand

External spacer

Bare clean strandInternal spacer ring

Corrugated sheath (Polyethylene)

Grout

V S L P E R M A N E N T A N C H O R F U L LY E N C A P S U L AT E D

V S L T E M P O R A R Y A N C H O R

SECTION B.B

SECTION A.A

Grout tubes

A

A

B

B

Bare clean strand

Spacer ring

BOND LENGTH OF TENDON

Greased and plastic coated strand (optional)

FREE TENDON LENGTH

Anchor head

Bearing Plate

Grout tube

Spacer ring

Bore Hole

Bore hole

Bore hole

Grout tube

Greased and plasticcoated strand (optional)

Bare clean strand

Grout (free length optional)

VSL46

G R O U N D A N C H O R S

No. of Ultimate DrillSheath diameters mm

Jack15.2mm capacity hole corrugated smooth typestrand 15.2mm Super kN dia. mm ID OD ID OD required

2 500 100 50 65 59 63 VSL 504 1000 130 65 80 70 75 VSL 1008 2000 150 80 100 84 90 VSL 190

14 3500 175 100 120 102 110 VSL 29027 6750 215 130 150 130 140 VSL 67055 13750 310 210 230 225 235 VSL125065 16250 310 210 230 225 235 VSL165091 22750 350 250 270 260 270 VSL1700

Permanent EpoxyEncapsulated Coated Temporary

Bar Ultimate Drill Corrugated Drill Drill Jackdia. capacity hole Sheath mm hole hole typemm kN dia. mm ID OD dia. mm dia. mm required

15 190 100 50 65 75 50 B 55*15 191 100 50 65 75 50 B 55

**20 188 100 50 65 75 50 B 5520 325 100 50 65 75 50 B 5523 450 125 65 80 87 75 B 55

**25 295 125 65 80 87 75 B 5526 575 125 65 80 87 75 B 5529 715 150 80 100 100 87 B 9032 870 150 80 100 100 100 B 9036 1050 150 80 100 112 100 B 9038 1225 150 80 100 112 100 B10040 1295 150 80 100 112 100 VSL19056 2460 175 100 120 165 125 VSL460

No. of Ultimate Minimum Jack15.2mm capacity drill hole typestrand 15.2mm Super kN dia. mm required

6 1500 75 VSL19012 3000 100 VSL29018 4500 130 VSL46024 6000 150 VSL670

No. of Ultimate Minimum Jack15.2mm capacity drill hole typestrand 12.7mm Super kN dia. mm required

7 1290 75 VSL10014 2580 100 VSL29024 4420 125 VSL460

V S L P E R M A N E N T G R O U N D A N C H O R S1 5 . 2 m m S T R A N D

V S L C T S T R E S S B A R G R O U N D A N C H O R S

V S L T E M P O R A R Y G R O U N D A N C H O R S1 5 . 2 m m S T R A N D 1 2 . 7 m m S T R A N D

Note: Where block outs, voids or drill hole casing are required, drill hole diameters and bearing platedimensions should be confirmed with the VSL office.Drill hole sizes are based on 10mm external cover.Anchors for 15.2mm system are compatible with 261kN EHT strand.

Drill hole sizes are based on 10mm external cover*VSL Deformed Tie Bar

**VSL Threadlok Bar

Note: Anchors for 15.2mm and 12.7mm system are compatible with 261 kN EHT strand.

No. of A B C DStrands mm mm mm mm

2 200 30 80 604 200 35 110 608 300 45 180 80

14 400 60 220 10027 500 80 270 13055 670 120 360 19065 700 140 380 19091 850 160 470 200

VSL47

G R O U N D A N C H O R S

N O T E S• Details given may be varied for particular

applications• For strand anchors the maximum configuration

size is shown. Lesser number of strands may be specified

• Additional capacities available on request• Drill hole sizes are based on 10mm external cover• Anchors can be monitorable and restressable• Removable ground anchors are available• Electrically isolated ground anchors available

S T R E S S I N G• Jack sizes are the same as for multistrand or

stressbar systems• Additional special purpose jacking chairs are

provided to permit test loading• Load cells can be provided that screw onto the

anchorhead to permit load measurement at any time, or permanently attached to enable rapid load checking

• Both hydraulic and electrical load cells areavailable

*Dimensions may vary depending upon anchordrilling methods and project specific criteria.

V S L P E R M A N E N T G R O U N D A N C H O R SB E A R I N G P L AT E A N D A N C H O R H E A D

Anchor stressing

Bearing plate and anchorhead

S T R E S S B A R1 5 . 2 m m S T R A N DBar Dia. A B

mm mm mm

15 150 2520 150 2523 200 4026 200 4029 225 5032 250 5036 250 5038 300 5040 300 6056 350 70

A x A

Cnominal

D

B

VSL48

G R O U N D A N C H O R S

Permanent Rock Anchors, Lapstone, N.S.W.

Prefabricated Permanent Stressbar AnchorsSydney, N.S.W.

Soil NailsBell Banksia, Melbourne, Victoria

VSL Threadlok Rock Bolts, Permanent AnchorsKangaroo Point, Queensland

VSL49

G R O U N D A N C H O R S

Temporary Anchors, Brisbane Casino, Queensland

Installation Uplift Restraint, Permanent AnchorsSydney, N.S.W.

Stressing Permanent Anchors

Prefabricated Permanent Anchor and Transportation TrainBurrinjuck Dam, N.S.W.

VSL50

V S o L R E T A I N E D E A R T H

VSL RETAINED EARTH SYSTEM - VSoL is a composite soil reinforcing system which employswelded wire mesh to improve the shear and compressive strength of an earth backfill.

A RETAINED EARTH structure is a stable, unified gravity mass which may be designed for use ina broad variety of civil engineering applications. In projects ranging from commercial retainingwalls to highway bridge abutments, VSoL has found widespread useand acceptance as a major construction system.The effectiveprinciple of RETAINED EARTH involves the transfer of stresses fromthe soils to the reinforcing mesh through bearing. Bearing pressure isdeveloped on the projected areas of the mesh crossbars, and thepressure is in turn transferred to the longitudinal bars. The longitudinalbars are thus placed in tension, which enables the soil mass towithstand loads in the direction of the reinforcement.

In addition to the significant performance advantages, the VSoLsystem is also extremely economical todesign and construct. The systemconsists of only three components,reinforcing mesh, precast facing panelsand backfill material. This simplicityallows construction to proceed easily andrapidly. Cost savings of up to 50% areregularly realised when compared withtraditional stabilisation systems.

FA S T, E A S Y, E C O N O M I C A LThe construction of a RETAINED EARTH structure is extremelystraightforward. A five-man crew using standard constructionequipment will average 75 square metres of wall per shift, and canplace up to 140 square metres per shift.

Typical SectionVSoL RETAINED EARTH Wallat a Bridge Abutment

Perspective ViewVSoL RETAINED EARTHRetaining Wall

Browns Plaons Interchange, Queensland

VSL51

V S o L R E T A I N E D E A R T H

C O M P L E T E C A PA B I L I T I E S

VSL provides the client with a complete range of design andengineering services for a RETAINED EARTH structure.

Services provided include analysis of internal stability, bridgeload, overturning, external stability and base sliding. In addition,VSL furnishes all preliminary drawings, shop drawings andcomplete erection sequencing documents.

Yarrie Iron Ore, WA, – Steel face

Penrith Lakes Scheme, NSW – Plain face square panel

Rode Road - Queensland - Architectural finish plain face square panels

Yarrie Iron Ore, WA. – Welded meshface

COMPLETE FLEXIBILITY

The VSoL concrete facing panels are available in a broad range of texturesand colours. Because local materials are used in the production of theseprecast panels, the exposed surface can easily be coloured to complementthe natural surroundings. Standard RETAINED EARTH panel treatmentsinclude raised relief, sandblast finish, exposed aggregate, and conventionalsmooth face concrete. These are only a very few of the possibilities however.Non-concrete faces, such as welded mesh or steel faced are available.Therange of architectural treatments is virtually unlimited.

F5 Freeway, Heathcote NSW - Raised Relief Panel

VSL52

S P E C I A L I S E D F O U N D A T I O N S

Intrafor is a world leader in the field of soil engineering. Since its founding in 1850, Intrafor hasdeveloped extensive experience and expertise in soil engineering techniques such asfoundations, retaining structures, soil improvement, environmental protection, soil waterproofing,consolidation and instrumentation.

Intrafor’s skilled engineers and site operators, operating under ISO 9001 Certification andemploying heavy duty specialist plant and equipment, are dedicated to the efficient and practicalachievement of our client’s needs and objectives on site. VSL-Intrafor’s design offices are able topropose budget solutions for soil engineering projects or to undertake fully detailed workingdesigns, procedures and systems.

The integration of Intrafor skills with VSL Australia’s proven expertise in ground anchoring andRetained Earth walling systems, and expertise, enable VSL-Intrafor to offer our clients the mostcomprehensive of foundation works packages as the solution to the increasingly complexfoundation engineering challenges.

Diaphragm walls and jet grouting - New Southern Railway, Sydney, NSW

VSL53

S P E C I A L I S E D F O U N D A T I O N S

Diaphragm walls and bored piles - M5 East Motorway. Cooks River crossing, Sydney, NSW

Diaphragm walls - International Station, New Southern Railway, Sydney, NSW

Diaphragm walls/Barrettes, Jet Grouting - Airport Link, Sydney, NSW

A P P L I C AT I O N S

Retaining structures

• Diaphragm Wall

• Secant Piles

Foundations

• Bored Piles

• Driven Piles

• Micro-Piles

• Jet Grouting

• Barrettes

Soil improvement

• Stone Columns

• Jet Grouting

• Dynamic Compaction

• Compaction grouting

• Vibrocompaction

Environmental protection/ Waterproofing

• Dewatering

• Cut off Walls

• Bentonite cement cut-off wall

• Directional drilling

• Contaminated siteconfinement

Ground Investigation andInstrumentation

• Site investigation

• Monitoring

• Various tests

VSL54

C L I M B F O R M

The VSL Climbform System is a self climbing heavy duty construction platform used primarily to liftstatic panel vertical wall formwork. The system provides the wall designer with complete flexibility inboth the structural design and selection of finishes.

Standard features include:• Custom designed formwork panels which may be ganged in any shape or size to lift as one unit• form heights ranging from 2.5 to 4.0 metres• unobstructed access to the forms for:

– cleaning and oiling– fixing of door frames and blockouts– reinforcement and reinforcing fabric fixing, including prefabricated reinforcement

• truss members of fixed height assembled in “Meccano like fashion” to form a platform of any plan shape or size

• easy levelling and plumbing of the external platform, which is typically supported on four, six or eight seatings

• minimum adjustment of individual forms after the initial set-up• an achievable vertical tolerance range of 10mm per 4.0 metre height• variation of wall thickness by moving the internal or external forms• parking the internal platforms at mid-lift to facilitate blockout and reinforcement fixing,

eliminating the requirement for temporary scaffolds• cycle times as low as three days• access to external walls for curing• hanging access stairway

Central Plaza Building, Hong Kong

VSL55

C L I M B F O R M

Melbourne Central Building, Victoria

Top Construction /Storage Platform

VSL Climbform services include the design of the climbingsystem and formwork, hire of all Climbform equipment,prefabrication of forms and platforms off-site andsupervision of the installation of the climbing platform.

Optional features include:

• steel formwork to enable pouring within 50mm of boundaries

• support of concrete placing booms on the platform

• access hatches and/or temporary removal of platforms to install precast stairs

• external trailing platforms for:– patching of tie bolt holes– concrete finishing and curing– welding of beam stubs/brackets to support

steel floor beams

– secondary egress

• internal trailing platforms to allow early installation:– Lift rails– Electrical and mechanical services

• support of site sheds and toilets on the platform

• provision to allow manhoists to service the top working platform

• provision to locate tower cranes within internal and corridor platforms

• collapsible door formers

• trailing formwork and platforms for vertical and raking walls.

The VSL Climbform System is the most powerfulcommercial formwork system available in the world todayand has been specified on the largest and tallest verticalstructures in Asia and Australia.

Tsing Ma Bridge Piers, Hong Kong

Sky Tower, Circular Structure, Auckland

VSL56

D U C T A L

Ductal is a material with a unique combination of superior characteristics.

The material was developed by Bouygues under the generic name of Reactive Powder Concrete and ismarketed under the brand name of Ductal. Composed of fine particles with a maximum size less than0.8mm, Ductal reaches compressive strengths of 170 to 230 MPa.

In structural applications, Ductal is used without any passive reinforcing bars. Very fine, high strengthsteel fibres are provided to withstand secondary tensile stresses due to shear, tension, small bendingmoments and concentrated loads. Pre or post-tensioning counterbalances the main tensile stresses dueto large bending moments. The steel fibres also provide significant ductility to the cementitious paste.

In non-structural applications, Ductal is used with non-metalic fibres. Passive steel reinforcement andprestressing are not required. Ductal has the ability to replicate the micro and nano-texture of the mould.When combined with the fluidity and the ability to have a range of colours, the result is a material thatprovides a high quality surface appearance together with high strength and durability.

The durability properties are those of an impermeable material. There is almost no risk of carbonation orpenetration of chlorides and sulfides, and the resistance to acids is improved.

ADVANTAGES• Eliminates completely the need for conventional reinforcement• Greatly improves durability, with a resistance to permeability 50 times better

than normal high strength concrete• Permits the use of much thinner sections• Provides complete freedom on the shape of the section• Reduces the concrete volume of a structural member to only one third to

one half of its conventional volume• Dramatically reduces the structural weight to be supported by a structure• Provides both direct and indirect cost savings

Sherbrooke Footbridge, Canada

VSL57

D U C T A L

S T R E N G T H C H A R A C T E R I S T I C S• Compressive Strength (cylinder)170-230MPa• Flexural Strength (3 point bending test)40-50 MPa• Youngs Modulus(E) 50-60 GPa• Total Fracture Energy 20,000-30,000 J/m2

R H E O L O G Y• Fluid to self compacting• Flow (Abrams cone) 50-70cm• Flow (ASTM shock table) 250mm

D U R A B I L I T Y• Chloride ion diffusion (CI) 10-12 m2/s• Carbonation penetration depth <0.5mm• Freeze/thaw (after 300 cycles) 100%• Salt-scaling (loss of residue) <10g/m• Abrasion (relative volume loss index) 1.2

O T H E R P R O P E R T I E S• Density 2450-2550 kg/m3

• Entrapped air content 2-4%• Freeze/thaw (after 300 cycles) 100%• Total porosity 2-6%• Post cure shrinkage <10-5

• Creep coefficient 0.2-0.5

Facade panels - Monaco rail station.

Precast beams - Cattenom power plant, France

T Y P I C A L A P P L I C AT I O N SBridges• Beams• Truss type structures• Decks of steel bridgesBuildings• Beams• Slabs• Permanent floor formwork• Curtain wall panels• Facade panels• Columns• False floor panels• Grandstand seating platsRailways• Sleepers• Sound absorbing panels • Noise wallsHighways• Light poles• Crash barriers• Noise wallsCivil• Pipes• Hazardous waste

containment• Arch culvertsOther• Blast protection• Vaults

VSL58

S T A Y C A B L E S

V S L S TAY C A B L E S Y S T E M S S I 2 0 0 0VSL Stay Cable System SSI 2000 has been developed to fulfil the stringent requirements for thedesign, construction and maintenance of cable stayed bridges.

VSL Stay Cable System SSI 2000consists of:

• a tendon made of multipleparallel 15.2mm high tensile steel strands

• each strand having an extrudedcoating of grease andpolyethylene

• an outer sheath of thick walledpolyethylene pipe

• anchorages that are prefabricated in the factory.

The features of the system are:

• high fatigue resistance of 200 MPa at 45% of tendon capacity through 2,000.000 load cycles• multi-layer corrosion protection with full encapsulation of each individual strand for increased

durability• excellent corrosion protection of individual strands during construction provided by the extruded

coating• simple erection of stay cable assembly• simple Single Strand Installation (SSI) of the tendon into the erected stay assembly• the VSL developed automatic stressing system enables each individual strand to be stressed

according to specific data via the use of a laptop computer• no requirement for on site grouting of cable• easy to adjust or monitor the tendon force at any stage of the cable life• lightness and versatility to provide full compatibility with modern construction methods• easy maintenance• ability to remove and replace individual strands at any time• vibration control of cable by use of a patented mechanical damper fixed to the stay pipe• coloured polyethylene stay pipe (co-extruded or fully coloured) available• special helical anti-vibration ribs on stay pipe available.

V S L S TAY C A B L E S Y S T E M S S T R E S S B A RVSL Stressbars are particularly suitable and economical for shorter road bridges, pedestrianbridges and stays for suspended roofs. Individual bars are available with ultimate capacities up to3,873kN – refer stressbar section of this manual for details.

Batam-Tonton Bridge, Indonesia

VSL59

S T A Y C A B L E S

TENDON MINIMUM Dimensions in mmUNIT BREAKING Aø Bø C D Eø Fø Gø Hø J K L M N P

15.2mm LOAD kN (1) (2) (2) (2) (3) (3)6-12 3185 190 185 90 105 230 219.1/6.3 177.8/4.5 125/5.0 290 260 30 35 1500 9506-19 5045 235 230 105 120 285 267/6.3 219.1/6.3 140/5.4 355 335 35 50 1800 12006-22 5840 255 250 115 120 310 298.5/7.1 219.1/6.3 160/6.2 385 355 40 50 1950 13506-31 8230 285 280 135 145 350 323.9/7.1 244.5/6.3 160/6.2 440 415 45 60 2150 15506-37 9825 310 300 150 170 380 355.6/8.0 273/6.3 180/5.6 485 455 50 70 2350 17506-43 11415 350 340 155 175 425 406.4/8.8 323.9/7.1 200/6.2 540 505 55 75 2600 20006-55 14605 385 380 175 195 470 419/10.0 323.9/7.1 200/6.2 585 550 60 75 2650 21006-61 16195 385 380 190 210 470 419/10.0 355.6/8.0 225/6.9 600 585 65 85 2850 23006-73 19380 440 430 190 210 530 508/11.0 406.4/8.8 250/7.7 680 650 75 95 3050 25006-81 21505 440 430 220 240 540 508/11.0 406.4/8.8 250/7.7 710 685 80 110 3200 26506-91 24160 490 480 230 250 590 559/12.5 457/10.0 280/8.6 760 730 80 110 3450 2850

6-109 28940 505 495 240 265 610 559/12.5 457/10.0 315/9.8 795 775 90 120 3600 30006-127 33720 560 550 290 315 670 610/12.5 508/11.0 315/9.8 865 845 95 130 3950 3400

Notes: 1. Min height of anchor head allows an adjustability of ±20mm2. External diameter/wall thickness3. Valid for nominal concrete strength at 28 days of 36 MPa (cylinder)4. Dimensions valid only for load monitoring/adjustment

DEAD ENDANCHORAGE

Transition pipe withIndividual Strand

Protection

Monostrand Tendon and Stay Pipe

12 TO 127 MONOSTRANDS

Plastic SheathTightly Extruded

ADJUSTABLE STRESSING ANCHORAGE WITHTHREADED ANCHOR HEAD AND RING NUT

Seven Wire Strand

Permanent CorrosionProtective Grease

T Y P I C A L M O N O S T R A N D

S E C T I O N ( T E N D O N U N I T 6 -1 2 )

V S L S TAY C A B L E S Y S T E M S S I 2 0 0 0

HDPE Stay Pipe

IndividualMonostrand

A D J U S TA B L E S T R E S S I N GA N C H O R A G E

D E A D E N D F I X E DA N C H O R A G E

Elastomeric DampingDeviator

370min(4)

Cmin

Transition Pipe

J n

L

E o/

Ao/

F o/

H o/ G

o/

B o/

M D 100min

Guide Pipe

Guide PipeNeoprene boot N min Dead End Fixed Anchorage

P min Adjustable Stressing Archorage

Stay PipeElastomeric Damping

DeviatorBearing Plate

Bearing PlateAnchor headwith wedges

Anchor headwith wedgesProtection cap

Protection cap

K n

VSL60

E X T E R N A L P O S T - T E N S I O N I N G

External post-tensioning is well suited to bridges due to the resulting economies in constructioncosts and the high degree of corrosion resistance provided by the system. External tendons areeasy to inspect and can be replaced if necessary. They are ideal for strengthening existingstructures and have a multitude of applications in addition to bridges.

VSL External tendons consist of:

• strand bundle• duct of polyethylene or steel• end and intermediate anchorages as well as tendon couplers• grouting compound.

External tendons, usually guided polygonally over deviation saddles, have many similarities to staycables and permanent soil and rock anchors.

Detailed information about design and construction is given in the VSL publication “External Post-Tensioning”.

V S L E X T E R N A L P O S T- T E N S I O N I N G S Y S T E M C O M P O N E N T S

Bois de Rosset Viaduct, Switzerland

Strand bundle and sheathing

Tendon deviationsaddle

Dead end anchorageStressing anchorage

VSL61

E X T E R N A L P O S T - T E N S I O N I N G

Note: (1) External diameter/wall thickness

Awide selection of VSLanchorage types is available to meet the full range of practical requirements. In additionto the anchorages illustrated here, intermediate anchorages and couplers are also available. The strand bundlecan be assembled from uncoated or individually greased and sheathed strands. The anchorages for these twotypes of tendon differ only in detail, the principle remains the same.

Dimensions (mm)

TENDON UNIT A B øC D øE(1)

5-3 135 110 – – 50/4.95-4 150 110 – – 50/4.95-7 167 110 – – 63/4.15-12 215 105 222 100 75/3.95-19 265 115 258 100 90/4.65-22 290 130 – – 110/5.75-27 315 140 – – 110/5.75-31 315 140 320 110 125/6.45-37 370 160 – – 140/7.15-42 390 160 – – 140/7.15-43 – – 390 120 140/7.15-48 430 170 – – 160/8.25-55 465 190 420 130 160/8.2

6-3 150 110 – – 63/4.16-4 165 105 – – 63/4.16-7 215 105 222 100 75/3.96-12 265 115 258 100 90/4.66-19 315 140 300 110 110/5.76-22 315 140 320 115 125/6.46-27 370 160 – – 140/7.16-31 390 160 390 125 140/7.16-37 430 170 420 130 160/8.26-42 465 190 – – 160/8.26-43 575 205 – – 180/5.96-48 575 205 – – 180/5.96-55 600 240 – – 180/5.9

STR

AN

D T

YP

E 1

2.7m

mST

RA

ND

TYP

E 15

.2m

m

A N C H O R A G E T Y P E S c d

A N C H O R A G E T Y P E C S d

Yonne Bridge, France

Second Stage Expressway, Bangkok

B

A

E

D

C

E

VSL62

H E A V Y L I F T I N G

Today's civil engineering structures and industrial plants are often assembled from large, heavy,prefabricated components. This may be done for economic or technical reasons, or to save constructiontime. For projects in which cranes or other conventional handling equipment cannot be used because ofexcessive weight, dimensions or space limitations, VSL Heavy Lifting will often provide the most effective solution.

VSL Heavy Lifting provides builders, engineers and owners with a broad range of advantages, including:• custom-designed solutions for each project• The highest level of safety, based upon sound engineering practices and over three decades

of experience• Economy and efficiency through the use of advanced and reliable hydraulic equipment.

U N I Q U E S O L U T I O N SVSL will plan lifting, horizontal jacking, or lowering operationsand design the necessary temporary structures to suit yourrequirements. Sound engineering, clear thinking, the ability toinnovate, and years of successful experience give you aguarantee of reliable and cost-effective solutions.

Horizontal Jacking, Rail Underbridge, Blacktown, N.S.W.

Tower Lift, 911 Tonne VesselMobil Oil, Singapore

Qantas Hangar Lift. Sydney, N.S.W.

VSL63

H E A V Y L I F T I N G

F L AT J A C K SFlat jacks are widely used for a multitude of civil engineering and construction applications such

as:• under pinning• prestressing of columns• counteracting sinking foundations• prestressing of road works or airport runways• prestressing concrete in confined spaces• lifting and lowering of bridge superstructures for bridge bearing adjustments• counteracting loads applied during back filling• lifting heavy weights• pile testing.The VSL flat jack is constructed of two moulded steel sections welded together to form a containment vessel.Hydraulic fluid or grout is injected at pressures of up to 13.5MPa into the peripheral ring, moving the lifting platesapart, so that a force is applied with a maximum lifting stroke of 25mm per jack.

Type Outside Maximum Effective Area at T EDiameter D Force at Zero Extension Thickness Maximum Installation

mm 13.5MPa 103mm

2** Travel Gap

kN mm mm mm

150c 150 155 11.5 25 25 38220c 220 390 29 25 25 38250c 250 525 39 25 25 38270c 270 605 45 25 25 38300c 300 780 58 25 25 38350c 350 1080 80 25 25 38420c 420 1605 119 25 25 38480c 480 2170 161 25 25 38600c 600 3470 257 25 25 38750c 750 5400 400 25 25 45870c 870 7385 547 25 25 45920c 920 8975 665 25 25 45

*1150c 1150 13635 1010 25 25 50

* 1150c Flat Jacks are specially produced to order and could be subject to a delay ** Flat Jack thickness may vary ±3 mm

S A F E T YSafety is VSL’s first priority. Our specialised hydraulic liftingequipment is designed for the highest level of reliability, and allequipment is rigorously tested and serviced through VSL’squality control and maintenance programme. VSL field servicesare also based upon a total commitment to safety, theextensive experience of our personnel and VSL’s exceptionalrecord provide further assurance of reliable performance.

F L E X I B I L I T YVSL’s heavy lifting equipment includes a large selection of hydraulicjacks, pumps, control units, monitoring devices and jacking frames. Thisrange of equipment gives us the capability to perform virtually anyproject requiring lifting, lowering or horizontal jacking.Segment Erection, Normandy Bridge, France

DT

T E+T

Fully Inflated

Closed

Plan

VSL64

B R I D G E E N G I N E E R I N G

As a specialist involved in the design and construction of bridges VSLhas considerable experience and expertisein:• conceptual, preliminary and final detailed design of bridge structures• developing construction methods with full engineering• full design and detail for formwork and erection systems• on-site construction of selected elements of the structure, from post-tensioning through to entire bridge

superstructures.The application of this knowledge by VSL assists owners, developers, main contractors and consultants with initialdesign concepts, alternative designs and construction methods. The result for the project is that:• the cost is minimised • the quality is enhanced• the methods are simplified • the safety is improved• the time is reduced • the value of the structure is increasedThe list of successful projects is impressive in scale and diversity. For example:

T H E G AT E WAY B R I D G E , B R I S B A N EIn-Situ Cantilever Construction

VSL Scope of Work:Design of the six lane main superstructure consisting of a main span of 260m and side spans of 145m.Design of the travelling formwork system and supply of the post-tensioning.

T H E S E C O N D S TA G E E X P R E S S WAYB A N G K O KPrecast Segmental Construction

VSL Scope of WorkConcept and design of the erection system, steelwork and equipment. Externalpost-tensioning and erection of 9000 matchcastsegments for 12km of dual elevatedexpressway. The spans are simply supportedwith a maximum length of 48.5m and a maximumsegment weight of 70 tonnes.

VSL65

B R I D G E E N G I N E E R I N G

N O R T H - S O U T H R O A D L I N KJ A K A R TAPrecast Girder Construction

VSL Scope of Work:Design and supply of erection gantry.Supply and installation of post-tensioning.Erection of 12km of expresswayconsisting of 4,100 beams.

W O R O N O R A R I V E RB R I D G E , N S WIncremental Launch Construction

VSL Scope of Work:Design, supply and operation of thelaunching and braking equipment.Supply and installation of post-tensioning. The curved bridge has alength of 520m with typical spans of59m and was launched down amaximum 5% grade.

PA K S E B R I D G E , L A O SPrecast Segmental Construction

VSL Scope of Work:Design and commissioning of formwork,and precasting of 384 precast box girdersegments. the design of the erection trussand full erection of the segments. Supplyand installation of permanent andtemporary post tensioning. Supply andinstallation of stay cables. the 13 spanbridge has a length of 1380m with typicalspans of 102m and incorporating a staycable main span of 143m.

V S L PRESTRESSING (AUST) PTY LT DABN 56 000 528 914

NEW SOUTH WALES

6 Pioneer Avenue, Thornleigh 2120

Locked Bag 102, Pennant Hills 2120

Tel:: (02) 9484 5944

Fax: (02) 9875 3894

QUEENSLAND

81 Granite Street, Geebung 4034

P O Box 10, Virginia 4014

Tel:: (07) 3265 6400

Fax: (07) 3265 7534

VICTORIA

2-8 Summit Road, Noble Park 3174

P O Box 398, Noble Park 3174

Tel:: (03) 9795 0366

Fax: (03) 9795 0547

N O RTHERN TERRITO RY

Tel:: (03) 9795 0366

Fax: (03) 9795 0547

TASMANIA

Tel:: (03) 6225 3567

Fax: (03) 6225 2226

SOUTH AUSTRALIA

Tel:: (03) 9795 0366

Fax: (03) 9795 0547

WESTERN AUSTRALIA

Tel:: (03) 9795 0366

Fax: (03) 9795 0547

http://www.vsl-intl.com email: design@vslsyd.aust.com

VSL is a registered trademark ' 2001,

VSL Prestressing (Aust) Pty Ltd printed in Australia - Patented.

The information set forth in this brochure including technical and

engineering data is presented for general information only.

While every effort has been made to ensure its accuracy, this information

should not be used or relied upon for any specific application without

independent professional examination and verification of its

accuracy, suitability and applicability.

Anyone using this material assumes any and all liability resulting from

such use.

VSL disclaims any and all express or implied warranties of merchantibility

fitness for any general or particular purpose or freedom from infringement

of any patent, trademark, or copyright in regard to the information

or products contained or referred to herein.

Nothing herein contained shall be construed as granting a license,

express or implied under any patents.

Photo credits:

Bouygues photobank, Y. Chanoit, L. Zylberman, Skycam Australia, X

VSL

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ourg

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Production by: P & M Format GraphicsTel: (08) 9414 8643 March 2001.

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