FREYSSIBAR
The prestressing bar for civil works
D e s i g n ,
B u i l d ,
M a i n t a i n
C III 3
FREYSSIBAR
Prestressing system
Developed by Freyssinet, worldwide leader in prestressing activities,
the Freyssibar prestressing system comprises a wide range of threaded
bars and associated anchoring, coupling and extension devices.
This prestressing system is adapted to many applications.
Among these are :
Permanent or temporary prestressing
Holding down bolts for cranes, wind turbines, etc.
Bridge construction systems
Ground and rock anchors, rock bolts
for geotechnical, mining, tunnelling works
Heavy lifting
Tie rods for marine works
Freyssinet is the holder of the European Technical Approval
(ETA) n ETA 09/0169 for the Freyssibar post-tensioning kit for
prestressing of structures.
The Freyssibar flat anchorages and couplers for fully threaded
bars up to 50 mm are approved to the requirements of ETAG 013.
Freyssinet has also obtained the EC-certificate of conformity:
certificate n1244-CPD-1014. The ETA and the EC-marking are
followed by a notified body.
Contents
Technology
p3
Installation
p6
Characteristics
p8
Ground and
rock anchors
p 11
C III 3 - 03/12
Technology
The bars
The bars are hot rolled from high strength alloyed steel. They are subsequently cold worked by stretching and then threaded over their full length or
on the extremities by cold rolling. The standard range of nominal diameters
is: 26.5; 32; 36; 40 and 50 mm. Non-standard diameter bars can be delivered
on request.
The fabrication process provides a high quality thread
ensuring high fatigue resistance and a low susceptibility to stress corrosion.
The nature of the Freyssibar manufacturing method also
ensures that every single bar is stress tested to 85% of
the guaranteed ultimate tensile strength of the bar.
The geometry of the thread is specifically designed to
ensure ease of use on site, providing fast, accurate and
easy tightening.
Bars are available in maximum lengths of 11.8 meters.
Beyond this length, extension sleeves allow bars to be
connected together.
Lifting : prestressed connection between a segment and a beam.
The anchorages
The anchor devices are designed to anchor the force in the bar and transfer it to
the structure. Four types of anchorages are available:
Standard anchorages with a nut and washer;
Hinge anchorages using a nut with a spherical seat;
Standard anchorages using a low rotation spherical nut and spherical washer;
Fixed anchorages using a threaded end plate.
All nuts are hot forged. Also, couplers allow primary bars to be connected to
secondary bars.
The accessories
Freyssinet offers a full range of sheathing that is easy to install.
In particular:
Steel strip corrugated sheath, threaded over its full length, which allows easy
and fast connections;
High density polyethylene tube, with elements mirror welded to achieve
a leak free and non corrodible envelope;
Sheathing accessories specific to the tensioning and coupling devices, required
to fit the coupler geometry. The length of the ducting element used is project
specific, so as to allow the coupler displacement over a sufficient length during
the tensioning operations.
C III 3 - 03/12
Anchorage of steel ropes
Technology
Properties
Fatigue : The system has a fatigue resistance in excess of two million cycles of
loading over a tensile stress range of 590-670 N/mm2, exceeding the ETAG 013
requirements.
Relaxation : After 1000 hours the loss of stress due to relaxation in the Freyssibar
system loaded to 70% Fpk is below 3% which is better than the 4% maximum as
described in pr EN 10138-4.
Anchorage strength : Freyssibar post-tensioning system is tested to ensure that
the failure load on the bar with coupler and anchorage is more than 95% of the
strength of the bar alone.
Protection against corrosion
Stress corrosion tests have been performed in accordance to prEN 10138. The
bars have been stressed under corrosive environment during 500 hours and
passed the subsequent tensile test to failure. Freyssibar is not susceptible to
stress corrosion but depending on the conditions of exposure, a specific corrosion
protection can be applied under request.
The corrosion protection system is selected in accordance to the expected
design life time and the conditions of exposure.
Permanent ties for quay walls
C III 3 - 03/12
Surface coating
Hot dip galvanizing after sand blasting (no risk of hydrogen embrittlement due
to acid pickling)
Metalization (Dunois, etc.)
Petrolatum tape
Epoxy coating
Specific injection products
Wax : hot injection
Grease
Allow for subsequent re-tensioning of the bars
Cement grout : alkaline environment
Ducting
Corrugated ducts: light and easy to install
Smooth pipes: stiff and resistant to shock
Ducts and pipes can be either in steel or in HDPE (non corrodible).
Different protection systems can be combined to enhance the degree of protection.
Quality control
The fabrication of the bars and the anchorages is carried out under a quality
assurance system in compliance with the quality standard ISO 9000 : 2000. Flat
anchorages and bars have passed all the tests required in ETAG 013.
Prefabricated bar tendons
C III 3 - 03/12
Ground anchors
Installation
The accuracy of the prestressing force actually introduced into the structure
and the durability of the tendons depend on the quality of the installation. The
detailed installation procedure is available on request.
Shimming of the anchorages
When anchorages are applied onto an existing concrete element, it is recommended to shim under the bearing plate using a non-shrink mortar, free from
chlorides.
Tensioning
The tensioning equipment provided by Freyssinet ensures the accuracy of the
load applied within +/- 2%. This is achieved through regular calibration of the
pump pressure gauge and the jacks.
Safety factors
The maximum allowable stressing force in the prestressing bars is given by the
relevant design standards. Recommendations are given below as examples:
(Note: Fpk means the guaranteed tendon tensile breaking load and Fp0.1%
means the proof load).
Load cell
A/ In post-tensioned structures, the Eurocode limits the tension
to either 0.9 Fp0.1% or 0.8 Fpk, whichever is lower.
B/ In prestressed ground anchors, the norm EN 1537 prescribes a final
force limited to 0.75 Fp0.1% for temporary ground anchors and
0.60 Fp0.1% for permanent ground anchors.
C/ In case of re-use, the tensioning force of the bar is limited to 0.60 Fpk
for the first use, and to 0.50 Fpk for all subsequent uses.
Stressing with the hinged jack
C III 3 - 03/12
Injection
Precast segments assembly
Two types of jacks
Two types of jacks can be used: with a tie rod connected to the tendon or with
a direct connection. Jacks should be used in conjunction with Freyssinet hydraulic
pumps, with high pressure and a low flow rate to allow a progressive tensioning
of the bar. Space must be allocated around the anchorage to allow the correct
installation of the jack.
Service
Freyssinet, world leader in prestressing, offers:
worldwide advice for specific works, from our specialists,
a huge material park providing jacks and equipment for the best
application of the Freyssibar installation,
an on site technical assistance given by our highly qualified
technicians, at the time of installation.
C III 3 - 03/12
Injection accessories
Characteristics
Bar
Characteristic
Unit
Steel grade
Nominal diameter (mm)
26.5
32
36
40
50
MPa
1030
1030
1030
1030
1030
Cross section area
mm
552
804
1018
1257
1964
Linear mass
kg/m
4.56
6.66
8.45
10.41
16.02
Characteristic value of maximum force: Fpk
kN
568
828
1048
1295
2022
Characteristic value of 0.1% proof force: Fp0.1%
kN
461
672
850
1049
1640
Maximum tensioning force*
kN
414
604
765
944
1475
Thread pitch
mm
Average Youngs modulus
GPa
170
170
170
170
170
Minimum elongation at maximum force
3.5
3.5
3.5
3.5
3.5
* Maximum tensioning force equals to min[0.9 Fp0.1% ; 0.8 Fpk] according to Eurocode2.
Ref.
You can order all the products
presented in the above table on
www.freyssibar.com
Flat anchorage
Nominal bar diameter (mm)
Item
Sketch
Flat nut
Flat washer
Flat plate
Injection plate
Dimensions
Unit
Length
26.5
32
36
40
50
mm
37
41
46
55
71
Width on flat surface
mm
50
56
62
65
90
External diameter
mm
65
70
75
80
105
Thickness
mm
Dimensions
mm
Thickness
mm
35
35
40
40
45
Hole diameter
mm
34
40
44
50
60
Dimensions
mm
Thickness
mm
35
35
40
40
45
Hole diameter
mm
34
40
44
50
60
Ref.
N
W
110x125 125x125 140x160 160x160 200x200
FP
110x125 125x125 140x160 160x160 200x200
FPG
You can order all the products presented in the above table on www.freyssibar.com
Fixed anchorage
Item
Threaded plate
Welded cap
(option)
Available upon request
Sketch
Nominal bar diameter (mm)
Dimensions
Unit
Dimensions
mm
Thickness
mm
40
50
50
60
70
Length
mm
15
20
20
25
25
26.5
32
36
40
50
110x125 125x125 140x140 150x150 185x185
Ref.
TEP
CW
You can order all the products presented in the above table on www.freyssibar.com
C III 3 - 03/12
Spherical anchorage type 1 3
Item
Sketch
Spherical nut
Spherical plate
Dimensions
Unit
Length
Nominal bar diameter (mm)
26.5
32
36
40
50
mm
45
51
56
60
71
Width on flat surface
mm
50
56
62
65
90
Dimensions
mm
Thickness
mm
160x115 160x125 160x140 160x160 190x190
40
40
40
40
60
Ref.
SN
SP
You can order all the products presented in the above table on www.freyssibar.com
Spherical anchorage type 2 0.6
Item
Spherical nut
Type 2
Spherical
washer
Flat plate
Injection plate
Sketch
Dimensions
Unit
Length
Nominal bar diameter (mm)
26.5
32
36
40
50
mm
37
41
46
55
71
Width on flat surface
mm
50
56
62
65
90
External diameter
mm
75
80
90
95
125
Thickness
mm
10
10
10
10
15
Dimensions
mm
Ref.
SN
Type 2
SW
Type 2
110x125 125x125 140x160 160x160 200x200
Thickness
mm
35
35
40
40
45
Hole diameter
mm
34
40
44
50
60
Dimensions
mm
Thickness
mm
35
35
40
40
45
Hole diameter
mm
34
40
44
50
60
FP
110x125 125x125 140x160 160x160 200x200
FPG
C III 3 - 03/12
You can order all the products presented in the above table on www.freyssibar.com
Couplers
Nominal bar diameter (mm)
Sketch
Dimensions
Unit
External diameter
Length
26.5
32
36
40
50
mm
45
50
60
65
76
mm
90
115
130
140
170
Ref.
You can order all the products presented in the above table on www.freyssibar.com
Accessories
Nominal bar diameter (mm)
Item
Unit
26.5
32
36
40
50
Ref.
Length
mm
250
250
250
250
250
External diameter
mm
42.9
48.5
50.8
57.2
70
Thickness
mm
Air vent connection
1/2
1/2
1/2
1/2
1/2
Short caps
Length
mm
95
100
120
120
150
CS
Long caps
Length
mm
210
220
220
220
280
CL
Formwork tube
Caps
Dimensions
You can order all the products presented in the above table on www.freyssibar.com
Ducts
Nominal bar diameter (mm)
Item
Steel corrugated sheath
HDPE tube
For prolongation sleeve
For coupling sleeve
Dimensions
Unit
Internal diameter
mm
45
50
55
60
75
Thickness
mm
0.45
0.45
0.45
0.45
0.50
Volume of grout
L/m
1.0
1.2
1.4
1.6
2.5
Connection element (internal diameter)
mm
50
55
65
70
85
External diameter
mm
63
63
75
75
90
Thickness
mm
5.8
5.8
6.8
6.8
8.2
Volume of grout
L/m
1.5
1.3
1.9
1.7
2.3
External diameter
mm
70
76.2
88.9
95
114.3
26.5
32
36
40
50
Thickness
mm
Minimum length (L = sleeve)
mm
180 + L
205 + L
220 + L
230 + L
260 + L
External diameter
mm
88.9
88.9
101.6
114.3
152.4
Thickness
mm
Maximum length
mm
210
235
255
265
320
Ref.
G1
G1
G2
GR
GC
You can order all the products presented in the above table on www.freyssibar.com
C III 3 - 03/12
10
Ground and
rock anchors
The Freyssibar prestressing bars, thanks to their thread over their full length,
allow to build ground and rock anchors fulfilling the requirements of international
standards. Lengths over 12 m can be obtained by means of one or several sleeves.
The ducting accessories and the anchorage corrosion protection systems are
adjusted to the design life time of the anchor: temporary or permanent.
In addition, the anchors can be fitted with injection tubes to fill the bore hole and
reinjection tubes to improve the bonding to the substrate.
PERMANENT
Nominal diameter bars (mm)
Spherical anchorage
Item
Dim.
26.5
32
36
40
50
Ref.
Steel formwork tube
80
89
89
89
108
FTUB
Plastic smooth sheath
60
70
70
75
90
STUB
Plastic ribbed sheath
55
65
65
70
85
RTUB
Plastic spacer
95
105
105
110
125
SPC
End protective cap
95
101,6
114,3
114,3
139,7
CE
Anchor plate
You can order all the products
presented in the above table on
www.freyssibar.com
Ribbed sheath
Spacer
Protective cap
Cap
Flexible anticorrosion product
Smooth sheath
Nominal diameter bars (mm)
Item
Dim.
Plastic smooth sheath
Plastic spacer
32
36
40
50
50
50
50
60
65
SPC
55
60
65
80
90
CE
TEMPORARY
Spherical anchorage
Spacer
C III 3 - 03/12
Cap
Smooth sheath
11
Ref.
26.5
You can order all the products
presented in the above table on
www.freyssibar.com
Over 60 locations worldwide
NORTH AND SOUTH AMERICA Argentina Brazil Canada Chile Colombia El Salvador Mexico Panama United States Venezuela
EUROPE Belgium Bulgaria Czech Republic Denmark Estonia France Hungary Iceland Ireland Latvia Lithuania Macedonia Netherlands
Norway Poland Portugal Romania Russia Serbia Slovenia Spain Sweden Switzerland Turkey United Kingdom AFRICA AND MIDDLE EAST
Abu Dhabi Algeria Duba Egypt Jordan Kuwait Morocco Oman Qatar Saudi Arabia Sharjah South Africa Tunisia ASIA Hong Kong India
Indonesia Japan Macau Malaysia Pakistan Singapore South Korea Taiwan Thailand Vietnam OCEANIA Australia New Zealand
www.freyssinet.com
2012 Soletanche Freyssinet - The texts, photos and other informations contained in this catalogue are the property of the Soletanche Freyssinet Group.
Any reproduction, display or other use without the prior consent of Soletanche Freyssinet is prohibited. - Freyssibar is a registered trademark of Soletanche Freyssinet.
Soletanche Freyssinet promotes the use of paper pulp from sustainably managed forests. The paper used in this catalogue is certified in accordance with the stringent rules of the PEFC (Program for the Endorsement of Forest Certification).
Edition: 02/2012 - C III 3 - Printed in France
