CCL Post-Tensioning Systems

and ETAG Approval

Carol G Hayek PhD, MBA

Peter Vincent

Report Date: October 2010

 CCL Post-Tensioning Systems
and ETAG Approval
CCL is one of the first companies to gain ETAG (European Technical Approval Guide) and CE
marking on its Post-Tensioning Systems. Gaining such approval on PT systems requires
extensive load testing, major time and cost investments and requires the approved companies
to engage in thorough manufacturing quality processes and continuous auditing.

European approvals have again raised the bar to provide construction markets with higher
capacity and more durable PT systems. Regarding ETAG 013, approval is given to select
companies which can demonstrate that they possess the knowledge and experience of
design, manufacture, and installation of PT systems.

Approval of a PT system under the guidelines of ETAG 013 may only be achieved by:

Carrying out stringent load testing of the anchorage components included in the PT
system.

Having a comprehensive quality management system in place to check the

manufacturing process of all components supplied in their post-tensioning system.

Load tests required to gain approval of PT systems under the

guidelines of ETAG 013

Resistance to Static Load (of the tensile

element/anchorage/coupling assembly): PT systems
shall be able to develop a specified percentage of the
tensile element ultimate strength with a minimum
elongation, without premature failure of anchorage
components, without undue deformations in the
components, and without disproportionate relative
movements between tensile elements and anchorage
components.
 Resistance to Fatigue (of the tensile
element/ anchorage/ coupling assembly):
PT systems shall be able to withstand
specified fatigue loads (dynamic strength)
without exceeding a specified percentage
loss of tensile element cross section.

Load Transfer to the Structure

(mechanical and bond anchorages): PT
systems shall be able to transfer a specified
percentage of the tensile element ultimate
strength from the anchorage into the concrete
structure, of a defined concrete strength,
without undue cracking of the structure, and
at deformations which stabilise within a given
time frame.
Key acceptance criteria for the load tests required by ETAG

Resistance to Static Load

o Measured maximum load shall not be less than 95% of the actual
ultimate strength, i.e. an anchorage efficiency of 95% must be achieved.

o Total elongation of tensile elements on the free length at measured

maximum load shall be at least 2%.

o Failure shall be by fracture of the tensile elements. Failure of the tendon

shall not be induced by the failure of anchorage components.

o Residual deformations of anchorage components after testing shall

confirm the reliability of the anchorage.

o Rate of the displacements between anchorage components as well as

between tensile elements and anchorage components shall decrease
with the increase of the tendon load up to 80% of the tensile element
characteristic strength.

o With the load held at 80% of the tensile element characteristic strength
the relative movements mentioned in the preceding clause, shall
stabilise within the first 30 minutes.

Resistance to Fatigue

o No fatigue failure in anchorage components shall occur.

o 2 million load cycles with a minimum stress range of 80 MPa at

maximum load of 65% of tensile element characteristic strength.

o No more than 5% of tensile element cross section shall be lost during

fatigue testing.

Load Transfer to the Structure

o Maximum Crack width:

- upon first attainment of upper load of 80% of tensile element
characteristic strength not more than 0.15mm.
- upon last attainment of lower load of 12% of tensile element
characteristic strength not more than 0.15mm.
- upon last attainment of upper load of 80% of tensile element
characteristic strength not more than 0.25mm.

o Mechanical anchorages shall have a measured ultimate force 1.1 x

tensile element characteristic strength.

o Bond anchorages shall have a measured ultimate force 1.1 x tensile

element characteristic strength.

Test Type Requirement

Resistance to Static FTu as % of Fpm > 95% Efficiency and Elongation of tendon at
Load FTu > 2%.
< 5% Tendon area lost due to wire breaks after > 2 x 106
Resistance to Fatigue load cycles between 0.65 Fpk 80MPa stress amplitude of
tendon
Load Transfer to the
Fu > 1.1 Fpk (fcm,e/fcm,0)
Structure
Where: Fpk (kN) : Characteristic ultimate resisting force of the tendon.
Fpm (kN) : Actual ultimate resisting force of the tendon.
FTu (kN) : Measured maximum force of the tendon in static load test.
Fu (kN) : Measured maximum force in load transfer test.
fcm,0 (MPa) : Mean compressive strength of concrete at which full
prestressing is permitted.
fcm,e (MPa) : Mean compressive strength of concrete at final test to failure
in load transfer.

Number of tests required to gain ETAG approval per anchorage

system

Tendon Size Total No.

Test Type
Small Medium Large of Tests

Resistance to Static Load 2 1 2 5

Resistance to Fatigue 1 1 2 4

Load Transfer to the Structure for

1 1 2 4
Lowest Declared Concrete Strength
Load Transfer to the Structure for
Highest and Intermediate, if any, 1 1 2 4
Declared Concrete Strength

Relationship between an ETAG approved PT systems and CE

marking
CE mark = Approved ETAG systems + Approval of Manufacturing Quality Process

CE marking of a PT system is only attainable once ETAG

approval is gained and the manufacturing quality process
is approved.

The CE mark provides assurance of testing and continuous

manufacturing compliance.

ETAG approved companies are independently audited by accredited approval

bodies on their quality systems and products every year.

Key benefits of an ETAG approved post-tensioning system

European Structural Design: All structures designed to the latest European

design code, Eurocode 2, must use PT systems which are ETAG approved (for
load test compliance) and carry the CE mark (for manufacturing compliance).

Constructability Requirement: Along with load testing, ETAG approval entails

submitting detailed method statements and construction procedures.

Service Life: Intended service life of 100 years provided that the PT system is
subject to appropriate use and maintenance.

Quality Control: Critical components of the PT system are fully traceable to

their raw material (wedges, anchor heads, force transfer units).

Load Tests: Acceptance criteria for ETAG exceed that of any other PT system
test standards to-date. A minimum of 21 load tests are needed per anchorage
system. CCL has undergone more than 70 tests on the X range system.

Health and Safety: No hazardous material is allowed in ETAG PT systems.

 Member of

www.eota.eu

Cerema/DTecITM Mail: ete-dtecitm@cerema.fr

110 rue de Paris Tel: +33 160 523 131
77 171 Sourdun web: www.cerema.fr
FRANCE

European Technical ETA 10/0107

Assessment of 02/07/2015

Technical Assessment Body issuing the ETA: Cerema

Direction technique infrastructures de transport
et matriaux

Trade name of the construction product CCL X Range Post-Tensioning Systems

CCL XF & XU Multistrand and Monostrand
Bonded/Unbonded Systems

Product family to which the construction 16. Reinforcing and prestressing steel for
product belongs concrete (and ancillaries). Post tensioning kits.

Manufacturer CCL Stressing International Ltd

Unit 8 Park 2000 Millennium Drive
Leeds England
LS11 5BP

Manufacturing plant(s) CCL Stressing Systems Ltd

Unit 8 Park 2000 Millennium Drive
Leeds England
LS11 5BP

This European Technical Assessment 48 pages including 26 Annexes (26 pages)

contains which form an integral part of this assessment.

This European Technical Assessment is ETAG 013, edition June 2002, used as
issued in accordance with regulation (EU) No European Assessment Document (EAD)
305/2011, on the basis of

This ETA replaces ETA 10/0107, renewed on 06/08/2010


 
  





    





 
  
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