gigaway qsm prestressing system · giga tegasan through giga engineering have been involved in...

GIGAWAY QSM PRESTRESSING SYSTEM

CONTENT

• INTRODUCTION 2

• ANCHORAGE SYSTEMS 4

• STRESSING JACKS 17

• BLOCK OUT DIMENSION 18

• DESIGN PARAMETER 20

• QUALITY MANAGEMENT 21

• PROJECTS 30

1

Giga Tegasan through Giga Engineering have

been involved in bridge construction, ground

improvement works, water treatment plants, port

facilities, infrastructure works, power plants and

building works with a track record of over 20

years.

Today, Giga is also providing design and built

Construction services by incorporating the best

and most innovative design through prestressing

system in the bridge construction.

As we strive to deliver on promises in today’s vast global market of complex construction

challenges, we know innovative partnerships are absolutely key to the answer.

Our alliances of Giga Tegasan, Asiaway Technology and QSM has developed GIGAWAY

QSM SYSTEM, which has three critical components:

a) Construction Expertise

b) Installation Expertise

c) Innovation Research and Production Of Post Tensioning System

Our mission is to develop and deliver the best system to the construction industry.

With our in depth knowledge and experience

in bridge and building construction together

with the inception of Gigaway QSM system,

we have combine the right elements from our

portfolio to solve your specific construction

challenges.

KVMRT V3, Malaysia

Subang-Kelana Link, Malaysia

2Tg. Sedili bridge, Johor, Malaysia

GIGAWAY QSM – INTRODUCTION

QSM started in year 2000 providing ultimate

prestressing system with high performance and

durability anchorage systems.

In order to guarantee high quality service and

products, Gigaway QSM system manufactures

its anchorage systems such as anchor blocks

and wedges at its own manufacturing plant in

Liuzhou, China.

Gigaway QSM also have been manufacturing

high quality stressing jacks and installation

equipment such as grouting machine,

threading machine and ducting machine.

The two manufacturing plant in Liuzhou

covers an area of 40,000 square meters.

Gigaway QSM will continue with design,

research and develop on the prestressing

system and post-tension jacking system.

The company emphasizes on quality

management and was accredited the Quality

Management System ISO 9001 in 2007.

Asiaway Technology is a specialised

company that provide technical solutions,

design and installation of stay cables, post

tensioning in bridges and building and

erection of box girders and PT beams.

Our workers are well trained teams in

many fields of post-tensioning

applications capable of providing

contractors and engineers with

construction and engineering services for

highly complex and demanding projects.LRT, Jakarta, Indonesia

Kualanamu Railway, Medan, Indonesia Kualanamu Railway, Medan, Indonesia

3

Liuzhou QSM, China

Systematic Production Floor, QSM

GIGAWAY QSM – INTRODUCTION

GIGAWAY QSM – ANCHORAGE SYSTEMS

GIGAWAY QSM anchorage assemblyincludes a stressing-end anchorage (typeQSM or BM), a fixed end anchorage (typeH or P), couplers and duct.

It can be widely applied in the pre-stressingof concrete structures and components inpre-tensioning and post-tensioningprocess. Applicable diameters of steelstrands are of 12.7mm, 12.9mm,15.24mm, and 15.7mm. Gigaway QSManchorage can anchor from 1 up to 55strands with advantages of good self-anchoring, draw-in of wedges, good andreliable anchoring performance, highanchoring efficiency, convenientoperations etc.

4


`ROUND ANCHORAGE -15 Series

GA 15 SERIES

Type

No of Anchor Head Bearing Plate Spiral Reinforcement Duct

Strand Ø E x F Ø A x B Ø C Ø l L f dNumber of Coils fD

QSM 15-1 1 Ø 46 x 45 -- -- Ø 80 30 Ø 6 4 --

QSM 15-2A 2 Ø 83 x 45 Ø 134 x 87 Ø 109 Ø 120 40 Ø 6.5 4 50

QSM 15-3 3 Ø 83.5 x 45 Ø 133 x 94 Ø 109 Ø 120 40 Ø 8 4 50

QSM 15-4 4 Ø 98.6 x 47 Ø 145 x 105 Ø 121 Ø 133 40 Ø 10 4 50

QSM 15-5A 5 Ø 108 x 49 Ø 151 x 130 Ø 124 Ø 133 40 Ø 10 4 55

QSM 15-6 6 Ø 126 x 47 Ø 170 x 140 Ø 141 Ø 152 50 Ø 12 4 70

QSM 15-7 7 Ø 126 x 53 Ø 172 x 170 Ø 141 Ø 152 50 Ø 12 4 70

QSM 15-8A 8 Ø 136 x 55 Ø 185 x 180 Ø 164 Ø 180 50 Ø 12 4 80

QSM 15-9A 9 Ø 146 x 58 Ø 200 x 190 Ø 171 Ø 180 50 Ø 12 4 80

QSM 15-10A 10 Ø 156 x 58 Ø 210 x 210 Ø 183 Ø 180 50 Ø 12 5 90

QSM 15-11 11 Ø 166 x 58 Ø 210 x 220 Ø 189 Ø 180 50 Ø 12 5 90

QSM 15-12 12 Ø 166 x 60 Ø 214 x 230 Ø 189 Ø 180 50 Ø 14 5 90

QSM 15-13 13 Ø 170 x 63 Ø 224 x 230 Ø 189 Ø 200 50 Ø 14 5 90

QSM 15-14 14 Ø 176 x 65 Ø 233 x 260 Ø 204 Ø 200 50 Ø 14 5 90

QSM 15-15A 15 Ø 186 x 68 Ø 246 x 290 Ø 204 Ø 228 50 Ø 14 5 90

QSM 15-16 16 Ø 196 x 70 Ø 246 x 330 Ø 218 Ø 228 50 Ø 16 5 90

QSM 15-17 17 Ø 196 x 73 Ø 254 x 395 Ø 218 Ø 228 50 Ø 16 5 90

QSM 15-18 18 Ø 206 x 75 Ø 272 x 325 Ø 231 Ø 230 60 Ø 16 6 100

QSM 15-19 19 Ø 206 x 75 Ø 272 x 325 Ø 231 Ø 230 60 Ø 16 6 100

QSM 15-20 20 Ø 226 x 80 Ø 300 x 325 Ø 258 Ø 260 65 Ø 16 6 120

QSM 15-21 21 Ø 226 x 80 Ø 300 x 325 Ø 258 Ø 260 65 Ø 16 6 120

QSM 15-22 22 Ø 226 x 80 Ø 300 x 325 Ø 258 Ø 260 65 Ø 16 6 120

QSM 15-23 23 Ø 244 x 80 Ø 310 x 280 Ø 286 Ø 280 65 Ø 18 6 120

QSM 15-24 24 Ø 244 x 80 Ø 310 x 280 Ø 286 Ø 280 65 Ø 18 6 120

QSM 15-25 25 Ø 244 x 83 Ø 310 x 280 Ø 286 Ø 280 65 Ø 18 6 120

QSM 15-26 26 Ø 244 x 83 Ø 310 x 280 Ø 286 Ø 280 65 Ø 18 6 120

QSM 15-27 27 Ø 244 x 83 Ø 310 x 280 Ø 286 Ø 280 65 Ø 18 6 120

QSM 15-28 28 Ø 260 x 88 Ø 350 x 320 Ø 320 Ø 330 65 Ø 20 6 130

QSM 15-29 29 Ø 260 x 88 Ø 350 x 320 Ø 320 Ø 330 65 Ø 20 6 130

QSM 15-30 30 Ø 260 x 90 Ø 350 x 320 Ø 320 Ø 330 65 Ø 20 6 130

QSM 15-31 31 Ø 260 x 90 Ø 350 x 320 Ø 320 Ø 330 65 Ø 20 6 130

GA 15 SERIES

5

GIGA TEGASAN


ROUND ANCHORAGE -13 Series

GA 13 SERIES

Type

No of Anchor Head Bearing Plate Spiral Reinforcement Duct

Strand Ø E x F Ø A x B Ø C Ø l L f dNumber of Coils ØD (I.D)

QSM 13-1 1 Ø43 x 45 Ø80 x 80 Ø14 Ø80 30 Ø6 4 --

QSM 13-2 2 Ø75 x 45 Ø125 x 110 Ø80 Ø120 40 Ø6.5 4 50

QSM 13-3 3 Ø80 x 45 Ø125 x 110 Ø80 Ø120 40 Ø8 4 50

QSM 13-4 4 Ø90 x 47 Ø135 x 110 Ø80 Ø133 40 Ø10 4 50

QSM 13-5 5 Ø98 x 49 Ø140 x 110 Ø80 Ø135 40 Ø10 4 50

QSM 13-6/7 6/7 Ø115 x 47 Ø155 x 110 Ø94 Ø152 50 Ø12 4.5 60

QSM 13-8 8 Ø128 x 54 Ø170 x 130 Ø100 Ø180 50 Ø12 4.5 60

QSM 13-9 9 Ø137 x 53 Ø180 x 130 Ø108 Ø180 50 Ø12 4.5 70

QSM 13-10 10 Ø157 x 58 Ø200 x 140 Ø134 Ø180 50 Ø12 5 80

QSM 13-11/12 11/12 Ø157 x 56 Ø200 x 140 Ø134 Ø180 50 Ø12 5 80

QSM 13-13 13 Ø157 x 60 Ø205 x 140 Ø136 Ø200 50 Ø14 5 80

QSM 13-14 14 Ø165 x 62 Ø210 x 190 Ø136 Ø200 50 Ø14 5 80

QSM 13-15 15 Ø195 x 68 Ø230 x 230 Ø154 Ø228 50 Ø14 5 90

QSM 13-16/17 16/17 Ø195 x 65 Ø230 x 230 Ø154 Ø228 50 Ø16 5 90

QSM 13-18/19 18/19 Ø195 x 70 Ø240 x 230 Ø154 Ø230 60 Ø16 6 90

QSM 13-20 20 Ø217 x 70 Ø265 x 290 Ø176 Ø260 60 Ø16 6 90

QSM 13-21/22 21/22 Ø217 x 76 Ø265 x 290 Ø176 Ø260 60 Ø16 6 90

QSM 13-23/27 23-27 Ø230 x 80/83 Ø280 x 310 Ø185 Ø280 60 Ø18 6 100

QSM 13-28/31 28-31 Ø245 x 85/90 Ø315 x 250 Ø190 Ø330 60 Ø20 6 105

GA 13 SERIES

6

GIGA TEGASAN

FIXED END TYPE P ANCHORAGE -15 SERIES

GA 15 P SERIES

TypeNo of

Fix-end anchor head

InstallationDimension

O.D of Restraining

RingSpiral Reinforcement Duct

Strand A x A B (min) C ØE Ø l L f dNumber of

CoilsØD(I.D)

QSM15P-2A 2 85 180 100 Ø68 Ø120 40 Ø6.5 4 Ø50

QSM15P-3A 3 105 180 100 Ø68 Ø120 40 Ø8 4 Ø50

QSM15P-4A 4 120 240 100 Ø73 Ø133 40 Ø10 4 Ø50

QSM15P-5A 5 135 300 100 Ø73 Ø133 40 Ø10 4 Ø55

QSM15P-6A 6 150 380 120 Ø90 Ø152 50 Ø12 4 Ø70

QSM15P-7A 7 160 380 120 Ø90 Ø152 50 Ø12 4 Ø70

QSM15P-8A 8 170 440 120 Ø100 Ø180 50 Ø12 4 Ø80

QSM15P-9A 9 180 440 120 Ø100 Ø180 50 Ø12 4 Ø80

QSM15P-10A 10 190 500 135 Ø114 Ø180 50 Ø12 5 Ø90

QSM15P-11A 11 200 500 135 Ø114 Ø180 50 Ø12 5 Ø90

QSM15P-12A 12 210 500 135 Ø114 Ø180 50 Ø14 5 Ø90

QSM15P-13A 13 220 500 135 Ø114 Ø200 50 Ø14 5 Ø90

QSM15P-14A 14 230 560 135 Ø114 Ø200 50 Ø14 5 Ø90

QSM15P-15A 15 235 560 135 Ø114 Ø228 50 Ø14 5 Ø90

QSM15P-16A 16 245 560 135 Ø114 Ø228 50 Ø16 5 Ø90

QSM15P-17A 17 255 720 135 Ø114 Ø228 50 Ø16 5 Ø90

QSM15P-18A 18 260 720 135 Ø120 Ø230 60 Ø16 6 Ø100

QSM15P-19A 19 265 720 135 Ø120 Ø230 60 Ø16 6 Ø100

QSM15P-20A 20 275 860 135 Ø146 Ø260 65 Ø16 6 Ø120

QSM15P-21A 21 280 860 135 Ø146 Ø260 65 Ø16 6 Ø120

QSM15P-22A 22 290 860 135 Ø146 Ø260 65 Ø16 6 Ø120

QSM15P-23/24A 23/24 300 860 135 Ø146 Ø280 65 Ø18 6 Ø120

QSM15P-25A 25 305 860 135 Ø146 Ø280 65 Ø18 6 Ø120

QSM15P-26A 26 310 860 135 Ø146 Ø280 65 Ø18 6 Ø120

QSM15P-27A 27 320 860 135 Ø146 Ø280 65 Ø18 6 Ø120

QSM15P-28A 28 320 860 135 Ø159 Ø330 65 Ø20 6 Ø130

GA 15 P SERIES

7


GIGA TEGASAN

FIXED END TYPE P ANCHORAGE -13 SERIES

QSM13P-27

TypeNo of

Fix-end anchor head

Installation Dimension

O.D of restraining

RingSpiral Reinforcement Duct

Strand A x A B (min) C ØE Ø l L f dNumber of

CoilsØD(I.D)

QSM13P-2 2 80 120 100 Ø68 Ø120 40 Ø6.5 4 Ø50

QSM13P-3 3 95 120 100 Ø68 Ø120 40 Ø8 4 Ø50

QSM13P-4 4 110 180 100 Ø73 Ø133 40 Ø10 4 Ø50

QSM13P-5 5 120 180 100 Ø73 Ø133 40 Ø10 4 Ø50

QSM13P-6 6 130 300 120 Ø90 Ø152 50 Ø12 4.5 Ø60

QSM13P-7 7 140 300 120 Ø90 Ø152 50 Ø12 4.5 Ø60

QSM13P-8 8 150 380 120 Ø100 Ø180 50 Ø12 4.5 Ø60

QSM13P-10 10 170 440 135 Ø114 Ø180 50 Ø12 5 Ø80

QSM13P-11 11 180 440 135 Ø114 Ø180 50 Ø12 5 Ø80

QSM13P-12 12 190 440 135 Ø114 Ø180 50 Ø12 5 Ø80

QSM13P-13 13 195 440 135 Ø114 Ø200 50 Ø14 5 Ø80

QSM13P-14 14 205 500 135 Ø114 Ø200 50 Ø14 5 Ø80

QSM13P-15 15 210 500 135 Ø114 Ø228 50 Ø14 5 Ø90

QSM13P-16 16 220 500 135 Ø114 Ø228 50 Ø16 5 Ø90

QSM13P-17 17 225 500 135 Ø114 Ø228 50 Ø16 5 Ø90

QSM13P-18 18 235 500 135 Ø120 Ø230 60 Ø16 6 Ø90

QSM13P-19 19 240 500 135 Ø120 Ø230 60 Ø16 6 Ø90

QSM13P-20 20 245 720 135 Ø146 Ø260 60 Ø16 6 Ø90

QSM13P-21 21 250 720 135 Ø146 Ø260 60 Ø16 6 Ø90

QSM13P-22 22 255 720 135 Ø146 Ø260 60 Ø16 6 Ø90

QSM13P-23 23 260 720 135 Ø146 Ø280 60 Ø18 6 Ø100

QSM13P-24 24 270 720 135 Ø146 Ø280 60 Ø18 6 Ø100

QSM13P-25 25 270 720 135 Ø146 Ø280 60 Ø18 6 Ø100

QSM13P-26 26 280 720 135 Ø146 Ø280 60 Ø18 6 Ø100

QSM13P-27

8


GIGA TEGASAN

BM STRESSING -END FLAT ANCHORAGE SYSTEM

BM FIXED – END TYPE P ANCHROAGE SYSTEM

GA BM FLAT ANCHORAGE SERIES

TypeQuantity

of Strand

Fixed-end

Anchor Head

Installation

Dimension

Outer Dimension of

Restraining RingSpiral Reinforcement

Inner

Dimension of

Flat Duct

A B C(min) F G J Ød LNumber

of CoilsI D E

BM15, 13-2 2 105 70 190 70 40 90 Ø6.5 50 4 130 50 22

BM15, 13-3 3 155 10 250 80 40 90 Ø6.5 50 4.5 170 60 22

BM15. 13-4 4 208 10 320 90 40 90 Ø6.5 50 5 210 70 22

BM15, 13-5A 5 260 70 400 110 40 90 Ø6.5 50 6 250 90 22

GA BM FIXED TYPE P

TypeQuantity

of Strand

Fixed-end

Anchor Head

Installation

Dimension

Outer Dimension of

Restraining RingSpiral Reinforcement

Inner

Dimension of

Flat Duct

A B C(min) F G J Ød LNumber of

CoilsI D E

BM15, 13P-2A 2 105 70 190 70 40 90 Ø6.5 50 4 130 50 22

BM15, 13P-3A 3 155 70 250 80 40 90 Ø6.5 50 4.5 170 60 22

BM15. 13P-4A 4 208 70 320 90 40 90 Ø6.5 50 5 210 70 22

BM15, 13P-5A 5 260 70 400 110 40 90 Ø6.5 50 6 250 90 22

9


GIGA TEGASAN

GIGAWAY QSM –H TYPE ANCHORAGE

GA - 15 SERIES TYPE H FIXED END ANCHORAGE

Type No.No of

StrandA B C(min) D φE

QSM15H-3 1-3 190 90 950 145 -

QSM15H-4 4 190 210 950 145 -

QSM15H-5 5 200 220 950 145 -

QSM15H-6/7 6-7 210 230 1300 155 152

QSM15H-9 8-9 270 310 1300 155 180

QSM15H-12 10-12 330 390 1300 155 180

QSM15H-19 13-19 390 470 1300 155 230

QSM15H-27 20-27 450 520 1700 155 280

QSM15H-31 28-31 510 570 1700 165 330

GA - 13 Series Type H Fixed End Anchorage

Type No.No of

StrandA B C(min) D φE

QSM13H-3 1-3 130 70 650 145 -

QSM13H-4 4 150 170 650 145 -

QSM13H-5 5 160 180 650 145 -

QSM13H-6/7 6-7 170 190 850 155 152

QSM13H-9 8-9 220 250 850 155 180

QSM13H-12 10-12 270 310 850 155 180

QSM13H-19 13-19 310 390 950 155 230

QSM13H-27 20-27 410 430 1150 155 280

QSM13H-31 28-31 430 470 1150 155 330

10


GIGA TEGASAN

ROUND COUPLING ANCHORAGE

There are two types of couplers i.e. mono-strand coupler for onestrand extension and multi-strand couplers for strand bundle,which is mainly applied in continuous girders.

FLAT COUPLING ANCHORAGE

GA - ROUND COUPLING ANCHORAGE

Type A B ØC I.D. of DuctO.D.of Restraining

ring

QSM15L-2A/3 660 195 155 50 68

QSM15L-4/5A 730 221 181 55 73

QSM15L-6/7 748 239 199 70 90

QSM15L-8A/9A 801 261 221 80 100

QSM15L-10A/13 845 281 241 90 114

QSM15L-14 888 291 251 90 114

QSM15L-15A/16/17 950 315 275 90 114

QSM15L-18/19 985 323 283 100 120

QSM15L-20/21122 976 341 301 120 146

QSM15L-25/26/27 1091 375 335 120 146

GA - FLAT COUPLING ANCHORAGE

Type A B C Inner Dimension of Duct (E x F)

BM15L-2 600 130 120 50 x 22

BM15L-3 600 165 120 60 x 22

BM15L-4 600 205 120 70 x 22

BM15L-5 600 235 120 90 x 22

11


GIGA TEGASAN

FIXED END TYPE PT ANCHORAGE

This type of anchorage has a compact structure and can beapplied to where the structure has a space requirement. Itcan efficiently increase the length of stressing tendons andavoid the strands from in direct contact to the concrete and toreduce the corrosion of the strands.

GA - FIXED END TYPE PT

Type

Number of Anchor Head Bearing Plate Spiral Reinforcement Duct

Strands ØE x F ØA x B ØC ØI Ød LNumber of

CoilsØD (I.D)

QSM15-3PT 3 Ø83.5 x 35 Ø133 x 94 Ø109 Ø120 Ø8 40 4 50

QSM15-4PT 4 Ø98.6 x 35 Ø145 x 105 Ø121 Ø133 Ø10 40 4 50

QSM15-5PT 5 Ø108 x 40 Ø151 x 130 Ø124 Ø133 Ø10 40 4 55

QSM15-6PT 6 Ø126 x 45

Ø170 x 140 Ø141

Ø152 Ø12 50 4 70

QSM15-7PT 7 Ø126 x 45 Ø152 Ø12 50 4 70

QSM15-8PT 8 Ø138 x 45 Ø185 x 155 Ø164 Ø180 Ø12 50 4 80

QSM15-9PT 9 Ø147 x 50 Ø198 x 158 Ø171 Ø180 Ø12 50 4 80

QSM15-10PT 10 Ø158 x 50 Ø208 x 170 Ø183 Ø180 Ø12 50 5 90

QSM15-11PT 11 Ø166 x 50

Ø213 x 190 Ø189

Ø180 Ø12 50 5 90

QSM15-12PT 12 Ø166 x 55 Ø180 Ø14 50 5 90

QSM15-13PT 13 Ø166 x 55 Ø200 Ø14 50 5 90

QSM15-14PT 14 Ø175 x 60Ø238 x

230Ø204

Ø200 Ø14 50 5 90

QSM15-15PT 15 Ø178 x 60 Ø228 Ø14 50 5 90

QSM15-16PT 16 Ø195 x 60

Ø246 x 242 Ø218

Ø228 Ø16 50 5 90

QSM15-17PT 17 Ø195 x 60 Ø228 Ø16 50 5 90

QSM15-18PT 18 Ø205 x 60

Ø265 x 250 Ø231

Ø230 Ø16 60 6 100

QSM15-19PT 19 Ø205 x 60 Ø230 Ø16 60 6 100

12


GIGA TEGASAN

The main characteristics of the common strands are shown in below table and is suitable with

Gigaway-QSM prestressing system.

Low Relaxation Strands prEN 10138-3 ASTM416-12

Grade 1770 (Y1770S7) 1860 (Y1860S7) 270

Type 13mm 15mm 13mm 15mm 13mm 15mm

(0.5") (0.6") (0.5") (0.6") (0.5") (0.6")

Nominal Diameter 12.5 12.9 15.3 15.7 12.5 12.9 15.3 15.7 12.7 15.2

Nominal Cross Section (mm2) 93 100 140 150 93 100 140 150 98.7 140

Nominal Weight (kg/m) 0.726 0.781 1.093 1.172 0.726 0.781 1.093 1.172 0.775 1.102

Nominal Yield Strength (MPa) 1634 1640 1636 1640 1634 1640 1636 1640 1675 1676

Nominal Tensile Strength

(Mpa) 1860 1860 1860 1860 1860 1860 1860 1860 1860 1860

Min Breaking Load (kN) 173 186 260 279 173 186 260 279 183.7 260

Relaxation after 1000h at 20o

Max 2.5at 70% Breaking Load (%)

The range for Gigaway QSM system range from 13mm to 15mm strands with grades 1770Mpa or

1860Mpa for internal or external prestressing for concrete and steel structures.

The seven wire strands are comprised of a central wire and an external six wires which are twisted

around the centre wire.

PRESTRESSING STRAND

13


GIGA TEGASAN


PLASTIC CORRUGATED DUCT

Plastic Duct is made of high density polyethylene (HDPE) andhas a smaller friction force compare to steel duct.

Advantages of Plastic Duct over Steel Ducti) Reduce frictional forceii) Good Sealingiii) Anti corrosion performanceiv) High strength and stiffness

Duct Type u K

Steel Duct 0.16 – 0.25 0.001

Plastic Duct 0.12 – 0.19 0.001

FLAT PLASTIC CORRUGATED DUCT

For internal bonded post-tensioning systems,strands are inserted into a metal or plasticduct that is then filled with cementitiousgrout, creating a bonding with thesurrounding concrete.The grout creates an alkaline environmentwhich ensures corrosion protection of theprestressing steel.Quality of the grout complies withinternational standards or local Standardsand specification where the systems is to beused.

GROUTING

Grouting of tendon ducts shall be executed usingcement mortar, with a composition variabledepending on temperature and length of tendons.Tendon ducts shall be provided with air vent pipes atthe highest section to ensure that air gets out duringgrouting and the duct is completely filled with grout.Grouting is carried out using Gigaway QSM groutingequipment which consist of a pump, a mixer and aturbo mixer.

14

GIGA TEGASAN


FLAT PLASTIC CORRUGATED DUCT

ROUND PLASTIC CORRUGATED DUCT

GA - ROUND PLASTIC CORRUGATED DUCT

TypeInnerDiameter

ConnectorNumber of strands

(mm) Ø15 strand Ø13 strand

SBG -30YA 30 Ø30 SBG -30YA -BJ - 1

SBG-40YA 40 Ø40 SBG-40YA-BJ 1 -

SBG -50YA 50 Ø50 SBG-50YA-BJ 2-4 2-5

SBG-55YA 55 Ø55 SBG-55YA-BJ 5 -

SBG-60YA 60 Ø60 SBG-60YA-BJ - 6-8

SBG-70YA 70 Ø70 SBG - 70YA-BJ 6-7 9

SBG-80YA 80 Ø80 SBG- 8 0 YA-BJ 8-9 10-14

SBG-85YA 85 Ø85 SBG-85YA-BJ 9-12 -

SBG-90YA 90 Ø90 SBG-90YA-BJ 10-17 15-22

SBG-100YA 100 Ø100 SBG-100YA-BJ 18-19 25-27

SBG-110YA 110 Ø110 SBG-110YA-BJ 20-22 31

SBG-120YA 120 Ø120 SBG-120YA-BJ 21- 27 34-37

SBG-130YA 130 Ø130 SBG-130Y A-BJ 27- 34 43- 44

SBG-140YA 140 Ø140 SBG-140YA-JB 34-37 54- 55

GA - FLAT PLASTIC CORRUGATED DUCT

TypeInnerDiameter

Connector Number of strandsA (mm) B (mm)

SBG -50B 50 Ø50 SBG -50B -BJ 2

SBG-60B 60 Ø60 SBG-60B-BJ 3



15

GIGA TEGASAN


STEEL CORRUGATED ROUND DUCT

Steel duct is made of low carbon steel tape with or withoutgalvanizing. This simple structure duct requires lowmanufacturing requirements and can be fabricated in houseor at site. With the characteristics of anti-leaking, pressuremaintainence, high strength and good flexibility,

GA - ROUND STEEL CORRUGATED DUCTSInner Diameter 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

Tolerance ± 0.5 ± 1.0

Thickness of standard steel tape 0.25 0.3

Thickness strength steel tape - 0.4

Inner Diameter 105 110 115 120 125 130 135 140 150 160 180 200 220 240 280

Tolerance ± 1.0

Thickness of standard steel tape 0.3 -

Thickness strength steel tape 0.4 0.5 0.6

Inner Diameter 30 50 55 60 70 80 90

Number of strands

Ø15 strand 1 2-4 5 - 6-7 8-9 10-17

Ø13 strand 1 2-5 - 6-8 9 10-14 15-22

Inner Diameter 100 105 120 130 140 160

Number of strands

Ø15 strand 18-19 - 20-27 31 34-37 43-55

Ø13 strand 25-27 31 34-37 43-44 54-55 -

STEEL CORRUGATED FLAT DUCT

GA - FLAT STEEL CORRUGATED DUCTS

Major lengthLength A 50 56 60 66 70 76 90 96

Tolerance ±3.0

Minor LengthLength B 22 28 22 28 22 28 22 28

Tolerance ±2 ±3

Thickness of steel tape 0.3

Number of strands 2 3 4 5

16

GIGA TEGASAN

GIGAWAY QSM – STRESSING JACKS

YCWB SERIES JACKS

GA - STRESSING JACK

Jack Type YCW100B YCW120B YCW150B YCW200B YCW250B YCW300B YCW350B YCW400B YCW450B YCW500B YCW550B YCW600B YCW650B

Nominal stressing force (kN) 973 1202 1492 1960 2480 3042 3460 3956 4575 4924 5360 6061 6434

Nominal oil pressure (MPa) 51 48 50 52 54 54 51 52 52 49 50 49 49

Stress piston area (m2) 0.01908 0.02505 0.0298 0.0377 0.04592 0.0563 0.06785 0.07607 0.08799 0.10053 0.1072 0.1237 0.1313

Return piston area (m2) 0.00777 0.01131 0.0138 0.0184 0.02802 0.0313 0.0346 0.04359 0.05785 0.04773 0.05442 0.0552 0.0629

Return oil pressure (MPa) <25 <25 <25 <25 <25 <25 <25 <25 <25 <25 <25 <25 <25

Center hole diameter (mm) Ø78 Ø78 Ø120 Ø120 Ø140 Ø152 Ø165 Ø175 Ø175 Ø196 Ø196 Ø241 Ø241

Stroke (mm) 200 200 200 200 200 200 200 200 200 200 200 200 200

Jack weight (kg) 70 80 108 146 170 220 265 286 324 434 472 614 636

Overall dimension (Length x O.D) (mm) 350 x Ø214 340 x Ø240 375 x Ø285 380 x Ø310 380 x Ø344 380 x Ø385 378 x Ø416 400 x Ø432 400 x Ø460 433 x Ø490 437 x Ø505 453 x Ø563 462 x Ø573

Seat diameter for working anchorage (mm) Ø151 Ø151 Ø196 Ø196 Ø210 Ø230 Ø252 Ø252 Ø252 Ø305 Ø305 Ø340 Ø340

Seat diameter for tooling anchorage (mm) Ø122 Ø122 Ø176 Ø176 Ø186 Ø216 Ø252 Ø252 Ø252 Ø302 Ø302 Ø320 Ø320

Minimum working space BxC (mm) 1220 x 150 1220 x 175 1250 x 190 1270 x 220 1270 x 220 1320 x 250 1320 x 265 1320 x 265 1350 x 280 1484 x 295 1505 x 310 1525 x 330 1591 x 380

Strand length for operation A (mm) 570 570 570 590 590 600 620 620 620 620 620 620 620

NO OF STRANDS

Applicable anchorages

Ø15 2 - 5 2 - 5 6 - 7 8 - 9 8 - 12 11 - 14 13 - 17 13 - 19 13 - 19 20 - 24 20 - 27 28 - 29 28 - 31

Ø13 2 - 7 2 - 7 8 - 10 8 - 13 11 - 19 15 - 22 18 - 27 20 - 31 20 - 31 - - - -

Accessories for DM & LZM anchorages Supporting frame, supporting ring, stressing nut, stressing accessories etc. subject to customer requirements

Stressing pump Pump ZB4-500 Pump ZB6-800

Oil type Machine oil 22#, 32# or 46#

Pressure pipe G6 III-00 Length: 3 m or 6m

MONOJACK YDC240Q SERIES

Lightweight jack type YCBW is a structure-optimized, lighter jackwith a center hole for pre-stressing. Manufactured by specialprocesses, the jack has many advantages such as good sealing,lighter weight, small overall size etc. With different accessories.itcan be used to stress wedge anchorages, DM swaged anchorageand casting anchorage. It can be widely used in pre-tensioning andpost-tensioning in building structures, bridges, power station,highway, high-rise building, soil and dam anchoring etc.

JACK SPECIFICATION

Nominal Stressing Force 240kN

Nominal Oil Pressure 50mPa

Returning Oil Pressure <25Mpa

Tensioning Piston Area 4.712x10 -3m2

Returning Piston Area 1.355x10 -3m2

Diameter of Centre Hole Ø 18mm

Tensioning Stroke 200mm

Oil Pump Pump ZB4-500

Outside Dimension Ø 115 x 485mm

Jack Weight 22kg

17

GIGA TEGASAN

Anchors must be positioned at an adequatedistance from the concrete wall and aminimum spacing is required between twoanchor blocks.

x, x’ ≥ x。y, y’ ≥ y。x。——minimum interval

between bearing platey。——minimum distance from

bearing plate center to concrete side

Type No.

Actual concrete Strength of Anchored Area(Cube Sample)

40(MPa) 50(MPa) 60(MPa)

x。 (mm) y。(mm) x。(mm) y。(mm) x。(mm) y 。(mm)

QSM.M15(13)-2 140(120) 90(85) 135(120) 85(85) 130(120) 85(85)

QSM.M15(13)-3 170(145) 110(95) 155(135) 95(90) 14 5(125) 95(90)

QSM.M15(13)-4 198( 180) 120(115) 176(150) 110(100) 168(140) 107(100)

QSM.M15(13)-5 220(195) 135(115) 200(170) 120(105) 184(155) 117(105)

QSM.M15(13)-6 240(200) 155(125 ) 224(180) 135(115) 224(180) 132(115)

QSM.M15(13)-7 260(220) 160(135) 235(200) 140(115) 224(190) 132(115)

QSM.Ml5(13)-8 275(235) 165(140) 250(210) 150( 120) 246(200) 147(120)

QSM.M15(13)-9 295(245) 175(155) 265(225) 155( 130) 256(210) 153(128)

QSM.M15(13)-10 310(260) 180(155) 280(235) 170(141) 290(232) 170(141)

QSM.M15(13)-11 325(270) 185(165) 295(245) 170(145) 290(232) 170(141)

QSM.M15(13)-12 340(285) 190(180) 310(260) 170(150) 290(245) 170(141)

QSM.M15(13)-13 355(300) 195(190) 320(270) 175(160) 300(255) 170(150)

QSM.M15(13)-14 365(310) 210(195) 330(280) 180(165) 320(255) 178(150)

QSM.M15(13)-15 380(316) 220(195) 345(290) 185(165) 330(275) 185(155)

QSM.M15(13)-16 390(330) 235(200) 355(300) 195( 170) 335(285) 185(155)

QSM.M15(13)-17 405(340) 250(205) 370(310) 210(175) 345(295) 187(155)

QSM.M15(13)-18 445(350) 255(205) 380(315) 215(175) 355(300) 190(170)

QSM.M15(13)-19 430(360) 255(215) 390(325) 215(180) 365(3 10) 190(170)

QSM.M15(13)-21 455(380) 268(225) 410(345) 223(190) 390(325) 205(180)

QSM.M15(13)-22 485(390) 270(230) 415(350) 225(195) 410(330) 205(180)

QSM.M15(13)-25 500(410) 285(240) 450(375) 235(200 ) 425(350) 220(190)

QSM.M15(13)-27 510(430) 295(250) 460(390) 245(210) 435(370) 220(190)

QSM.M15(13)-37 600(500) 350(285) 545(460) 295(250 ) 510(4 30) 270(221)

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X’

Y’

xxy

y

X’

Y’

GIGAWAY QSM – BLOCK OUT DIMENSION

GIGA TEGASAN

GIGAWAY QSM – BLOCK OUT DIMENSION

Type No.No of

Strandx(mm) y(mm) z(mm)

M15(13) 2-4 265 (265) 160 (160) 90 (90)

M15(13) 5 335 (265) 230 (160) 90 (90)

M15(13) 6-7 430 (275) 290 (160) 120 (100)

M15(13) 8-11 (8-12) 430 (370) 290 (220) 120 (130)

M15(13) 12-14 490 340 130

M15(13) 15-19 (13-19) 520 (437) 360 (275) 140 (140)

M15(13) 20-22 575 (500) 400 (330) 150 (150)

M15(13) 23-29 (23-31) 620 (535) 440 (340) 150 (170)

M15(13) 30-37 (32-37) 710 (600) 510 (385) 170 (190)

Recess Dimension

Recess Dimension (Slab Tendon 0⁰)

Type No. A1 A2 B1 B2 c

BM15-2 275 170 195 90 90

BM15-3 305 200 195 90 90

BM15-4 345 240 195 90 90

BM15-5 385 280 195 90 90

Minimum Bearing Plate Interval

Type No.

Actual Concrete Strength (Cube Sample)

40(MPa) 50(MPa)

a b c a b c

BM15-2 230 75 115 220 70 110

BM15-3 270 80 135 240 75 130

BM15-4 340 95 170 330 90 165

BM15-5 370 95 185 360 90 180

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y x

z

GIGA TEGASAN

GIGAWAY QSM – DESIGN PARAMETER

Short Term Losses

a. Losses due to deformation of concrete. Reference can be made to EC2 for calculation of thedeformation losses.

b. Anchorage Draw-In• QSM Anchorage system draw-in is ≤ 6mm.

c. Losses Due to Friction

The recommended value in design for bondedstrands :-

Duct Type m k

Corrugated Steel Duct 0.22 0.005

HDPE Duct 0.14 0.001

* Non Lubricated

Long Term Losses

a) Losses due to creep and shrinkage of concrete. Factors affecting these arei) Concrete age

ii) Stress Leveliii) Density of Concreteiv) Cement Content in Concretev) Water-Cement ratio

vi) Relative Humidityvii) Temperature

b) Relaxation of Steel.Relaxation after 1000 h at 20⁰ C for low relaxation strand is 2.5% max at 70% UTS.

To calculate losses for shrinkage and creep, reference should be made to the technical documentsand standards applicable on the local project.

Px = Pm . e- (ma + kx) Px = Stress at distance x from the jacking point

Pm = Stress at Jacking Point

m = Coefficient of angular friction

a = Sum of angular displacements over a distance x

x = Distance from the stressing point

k = Wobble coefficient of Friction

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Our in house production for anchorage system

and stressing jacks goes through intensive

quality control and inspection in accordance to

ISO Quality Management System ISO 9001 :

2008.

All Materials will have certificate of origin and

will be tested using Metallographic Analysis to

ensure material used meets the requirement to

EN standard.

All wedges and anchor blocks machining and

geometry check compliance to European

Technical specification.

All wedges and anchor blocks will go through

heat-treatment process to achieve hardness

requirement to European technical

specification.

Internal hardness test is carried out using

Brinell-Rockwell Vickers Hardness Tester.

Metallographic study on the sample is carried

out using Neophot microscope by qualified

metallurgist on randomly selected samples.

All anchor blocks are being tested for

compressive strength by going through the

Press Machine.

Wedges, Anchor blocks and strands are then

randomly tested physically using a test frame

with stressing jacks.

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GIGAWAY QSM – QUALITY MANAGEMENT

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Our company R&D has been

developing new products since

2006. We have been awarded

patents awards for at least 2

products every year.

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PROJECT : MENAIKTARAF LALUAN B49 PERSIARAN MOKHTAR DAHARI,

PETALING JAYA, SELANGOR DARUL EHSAN

DESIGN, SUPERVISION & OPERATION OF FORM TRAVELLER

GIGA TEGASAN – PROJECTS

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PROJECT : MENAIKTARAF LALUAN B49 PERSIARAN MOKHTAR DAHARI,

PETALING JAYA, SELANGOR DARUL EHSAN

BALANCED CANTILEVER BRIDGE – POST TENSIONING


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PROJECT : EAST KLANG VALLEY EXPRESSWAY (EKVE) – PACKAGE 2

T BEAM (30m, 35m, 40m, 45m) – POST TENSIONING


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PROJECT : EAST KLANG VALLEY EXPRESSWAY (EKVE) – PACKAGE 1

T BEAM (30m, 35m, 40m) – POST TENSIONING (BR3)


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PROJECT : CADANGAN PEMBINAAN SEBUAH JAMBATAN BARU

MERENTASI SUNGAI KUANTAN BAGI MENGHUBUNGKAN BANDAR

KUANTAN KE BANDAR PUTRA, TANJUNG LUMPUR, PAHANG DARUL

MAKMUR

DESIGN, SUPERVISION & OPERATION OF FORM TRAVELLER


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MAKMUR

BALANCED CANTILEVER BRIDGE – POST TENSIONING





MAKMUR

T BEAM– POST TENSIONING

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GIGA TEGASAN SDN BHD

No A-1-10, Jalan SS7/13B,

Plaza Kelana Jaya,

47301 Petaling Jaya,

Selangor Darul Ehsan

Tel: 03-7877 0805 Fax: 03-7877 7805

Email: [email protected]

Website: www.gigategasan.com

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