Text

Revision 24 to Updated Final Safety Analysis Report, Chapter 5, Appendix 5B
	ML19066A377
Person / Time
Site:	Three Mile Island
Issue date:	04/06/2018
From:	; Exelon Generation Co
To:	; Office of Nuclear Reactor Regulation
	Poole J C, NRR/DORL/LPLI, 301-415-2048
References
	TMI-18-047
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{{#Wiki_filter:APPENDIX 5B INLAND-RYERSON'S REPORT ON BBRV TENDON SYSTEMS

Section 5B 5B-1 REPORT ON BBRV PRESTRESSING TENDONS TABLE OF CONTENTS Part Page # A. GENERAL INTRODUCTION, PURPOSE,

SUMMARY

5B-2 B. ECCENTRICITY & STRESS ANALYSIS 5B-4 Source: Western Concrete Structures, Inc. Date: October , 1969

C. DYNAMIC & FATIGUE TESTS 5B-15 Source: EMPA, Swiss Federal Laboratory For Testing Material & Research Date: February 5, 1969

D. STATIC TESTS - TECHNICAL REPORT #8 5B-39 Source: Western Concrete Structures, Inc. Date: January, 1968

E. TRUMPLATE WELDING EFFECTS 5B-109 Source: J. Hildebrand, Gulf General Atomics Corp. Date: October 27, 1969 F. LOW TEMPERATURE TESTS 5B-114 Source: Western Concrete Structures, Inc. Date: December, 1969

TMI-1/FSAR REPORT ON BBRV PRESTRESSING TENDONS

Part A. GENERAL INTRODUCTION, PURPOSE,

SUMMARY

The 170 wire Inland-Ryerson BBRV Post-Tensi oning System was developed specifically to post-tension the prestressed concrete reactor vessels of nuclear power plants and

their secondary containments where total required force and/or spacing of tendons

makes the use of large capacity tendons advantageous. In general the system utilized

button-headed wires of 0.250-inch diameter anchored by heat treated alloy steel end

fittings. It is the most extensively tested system in the world at the present time. The

tests presented in the following section assure the integrity of the post-tensioning system

in meeting the high quality control standards of the Three Mile Island station and the

Atomic Energy Commission.

It was the purpose of the following tests to demonstrate the ability of the prestressed, post-tensioned system to fulfill the quality control specifications for this job. Part B. of

this section presents a stress analysis of the anchorage components. Part C. deals with

the dynamic and fatigue testing of the composite tendon system.

The static tests reported in Part D. dealt with subjecting anchorages to several levels of

loading and analyzing failure modes. Part E. offers expert opinion

Page 5B-2 UPDATE-1 7/82

TMI-1/FSAR REPORT ON BBRV PRESTRESSING TENDONS

concerning possible deleterious effects of welding and flame cutting on the embedded

steel bearing plates. The low temperature testing as detailed in Part F. shows the

performance characteristics of the loaded tendon system under extreme environmental conditions.

A concensus of the results of these tests, indicates that the individual components of the

system as well as the Inland-Ryerson BBR V Post-Tensioning System as a whole, performed above and beyond the minimum criteria of the job specifications. The results

further indicate that the use of prestressed post-tensioned tendons as a critical structural

member of this vessel was well justified.

Page 5B-3 UPDATE-1 7/82

TMI-1/FSAR

Part B. ECCENTRICITY AND STRESS ANALYSIS

Page 5B-4 UPDATE-1 7/82

TMI-1/FSAR Part B. ECCENTRICITY AND STRESS ANALYSIS

Table of Contents

Part Page #

Introduction, Purpose, Summary 5B-6

1.0 Eccentricity

Analysis 5B-7

2.0 Concrete

Bearing Stress Due to Eccentricity 5B-8

3.0 Stress

Analysis, General 5B-9

4.0 Washer

5B-10

5.0 Washer

Nut 5B-11

6.0 Composite

Washer 5B-12

7.0 Split

Shims 5B-12

8.0 Bearing

Plate 5B-13

Page 5B-5 UPDATE-1 7/82

TMI-1/FSAR Part B. ECCENTRICITY AND STRESS ANALYSIS

Introduction, Purpose, Summary

It was the purpose of this test to furnish a stress analysis on the anchorage components

to determine "order of magnitude" stresses at applicable maximum loading conditions.

This report takes into consideration the conditions of maximum eccentricity and critical

stress.

The analysis shows that the anchorage will perform as required with all allowable stress

limits.

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TMI-1/FSAR

Part C. DYNAMIC AND FATIGUE TESTS

Page 5B-15 UPDATE-1 7/82

TMI-1/FSAR Part C. DYNAMIC AND FATIGUE TESTS

Table of Contents

Part Page

Introduction 5B-17

1.0 Dynamic

Test Results 5B-18

2.0 Tension

and Fatigue Tests 5B-25

3.0 Fatigue

Test Results 5B-31

Page 5B-16 UPDATE-1 7/82

TMI-1/FSAR Part C. DYNAMIC AND FATIGUE TESTS

Introduction, Purpose, Summary

Based on specification requirements, it was necessary to test the full scale

anchorage in as representative a test as possible. Inland-Ryerson contacted the Swiss

Federal Laboratory for Testing Material and Research. They agreed to conduct the tests

and the materials were forwarded to Switzerland. The results are noted in their tests

67'303/1, 67'303/2 and 67'303/3 following herein.

In the tests a free length of 4 meters was used and the tendon was anchored at both

ends by means of small cold deformed buttonheads at each end and supported on a

threaded ring at both anchor ends. The tendon sy stem was cycled extensively by the test equipment and no significant defects or failures were observed.

In each test the tendon behaved as expected. The results proved the total reliability

of the tendon system beyond the specification requirements.

Page 5B-17 UPDATE-1 7/82 Eidgenossische Materialprufungs-und Versuchsanstalt fur Industrie, Bauwesen und Gewerbe Laboratoire federal d'essai des materiaux et lnstitut de recherches -Industrie, Genie civil, Arts et Metiers Labpratori,Q fe,derale,di.,prQva dei.materialled IStLtutotsperimeotaJe-Industria, ArtiMestieri ll'ea.eral..LaO ora'tory IOr'fes l v la terl.al.S ana.rtest:arcn 8600 Dubendorf 67'303/2 Untersuchungsbericht Proces-verbal Processo verba Ie TEST-REPORT EMPANo.---------- Auftraggeber: Commettant: Committente: Customer: ST,AHLTON AGZUE RIC H Gegenstand: Objet: Oggetto: Object:A4 meter long prestressing cable of 70 wires¢1/4" Datum des Eingangs: Date de I'arrivee: Data d'arrivo: Date")f receipt: 12.5.1969 Ausfuhrung der Untersuehung: execution de ('essai: Esecuzlone della preva: Execution of test: FATIGUE TEST RESULTS AnmerkunliJ: Eine Verwendung dleses Berichtes zu Werbezwecken Irgendwelcher Art, der bloBe Hinweis auf diesen Bericht eingeschlossen, bedarf der Genehmigung durch die Dlrektlon der EMPA.Observation: Ce rapport ne peut utilise au mentionne dans un but de reclame, quel qu'il soit, sans autorisatlon de la Direction du LFEM.Os..rvazlone: Questa rapporto non pub essere utillaato n8 menzlonalo a scopo dl qualsiasi pubblicila senza I'aulorizzazione della Direzione del LFPM.58-18 Ul-TCt,::: -1//82 DESCRIPTION OF TEST 1.The presstressing cable-Type:-Free length: BBRV 701/4" 4 m-70 round and unprofiled steel wires 0 1/4"-Ultimate tensile strength=170 kg/mm 2 (According to d:!.ta given by the customer.also the experimental results of the tensile tests carried out on the steel wires in EMPA-Report No.67'303/3). -Anchorage: The cable was anchored at both ends by means of small cold deformed bottom heads at each wire end and supported on a threaded ring at both anchor heads (see appendix 2).2.Equipment The tested caDle was mounted vertically in a testing frame with c a weighing beam (see figures in appendies 1&3)..Lower and upper loading limits of 225 t and 250 t respectively could be achieved and kept constant during the test by using two hydraulic ja.cks which were connected to two coupled Amsler pulsators. The applied loads were controlled by means of a"load cell" connecting the weighing beam with the lower anchor head of the tested cable.A shock pickup was mounted on a plate fixed to the upper anchor head of the cable.To the number of the ruptured wires during the test, a recording unit was connected to the mentioned pickup.58-i9.:/r.::..::.. 3.Procedure The cable was acted upon with a pulsating load, whose frequency was 250 cycles per minute, for six days.In spite of the failure of 6 wires during these 2,216.10 6 cycles the upper and lower loads were kept constant.4.Results The data concerning the failure of six wires are given in appendix 4.Due to these failures, the initial applied stress limits were raised from: 0" upper 112,8 kg/mm 2 and 0 101,5 kg/mm 2==Lower up to: 5'" 123,4 kg/nun 2 and 0 111,1 kg/mm 2==upper lower i.e.: at the end of the test, the applied stresses were:°upper=0,726* and 0--0 654*0z.Lower-, The total elongation of the tested cable measured after 2,216.10 6 loading cycles was 3,2 mm.From this elongation 2 mm was a result of the excess stresses due to the failure of the six wires.This means that the elongation of the cable was 1,2 mID.i.e.: The permanent strain after 2,215.10 6 loading cycles was 0,3%0.======Dtibendorf, 17th July,1969 Engineer of test: 58-20 1:3Q::rul Laboratory for Testing Materials and B888Brch A, rzJ1 Appendix l View of the test equipment"/i th the mounted cable and the recording apparatus. 58-21 Coble for tension fatigue test ot the II EMPA II (¢7,87S" I Appendix 2__ (¢':j,t.6"1-In I and_Ryerson I------I IiE*---: a a 0-,-..3-'-.-"--.----,I I I I I I.---1:.----r ,'"--i I!'.....;':N I-t"-I C\i__I r Const" Prods. , Chicagu 58-22 I Zeichnungsnummer:4-34:)9 =-1. ,"';4._,:-_...'-Appendix 3 Experimental arrangement for a fatigue test on a prestressing cable o co Z Q M.1;25--L Cable head .two-port steel rinq¢400mm wittlahole ¢140mm I::"::::', 450*S70*125mm wittlahole¢180mm I I.'*1........... Pavatex (hard cardboard. 5 mm)II II II II II II II II W II 180 II II'I II II II II II II II I 1!1: H'I";prestressing ca ble _:il!70¢1'4" Iii: I I,!'I'ii1i\1" 1;;;\1 II II II II II II II II II II II: II I II: II , II I II: I I o o co J II I II I II I II I II I II I I II II I I I I III,Hlreaded ring II;I'II II v anchor head I 2 x sot II*_..Ijacks II load I()II I cellII0 II 7!i ra/Il:R'I!!I.weighing beam.II I!'II II:: I.., ti25 1100 Ii II\'1 IIIIIIIIIi////////////////////////////////// //////IEMPA Auffro 9 S-Nr°1 Auftr G 9geber: V 67'3C3/2 Stchlton:\.-G., Z uric h I Gezelchnet: I Zeichn""9s nummer: Juli69 se4-3410 TEST RESULTS Appendix 4 test specimen: BBRV prestressing coble 4m long Nominal values: cross-sectional area: Fe=701/4 11=70*31,65 mm 2=2216 mm 2 ultimcte tensile strength:=, 70 kg/mm 2 Fatigue stage 1: 6 upper=0,663.pz=112,8 kg/mm 2;p=250 t upper 610wer=0,596=101,5 kg/mm 2 PI=225 t;ower range of stress A 6=11,3 kg/mm 2 FATIGUE STAGE No.LOADING LIMITS PUJ)per Ptower t t STRESSES (related to the remained coble cross-section at every fatigue-stage) Total number of loading cycles after every fatigue-stage REMARKS 1 250,0 225,0 114,4 103,0 11,4 2 II II 116,1 104,5 11 ,6.., II II 117,9 106,1 i1 ,8 ,,)4/I II 119,7 107,7 12,0 5 II II121,5109,3 12,2 6 II II 123,4 111,1 12,3 7 II II 123,4 111,1 12,3 I I Lower oncnoroge 2 failures 871'10C 1.failure 1'216 1 900 2...1 1 877 1 7003...1 1 885 1 700 4...1'946'900 5...2'198'900 6...2'216'300 End of test Upper ancho rcge 4 fai lures All of the six failures took place directly near the cold deformed small heads of the wires.During the 2,2.10 6 loading cycles and under lower and upper loading I imits of 21St and 250 t respectively, the tested cable-including irs both anchor heads-could remainout any other defects thon these six fai lures.OEMPA Auftregs-Nr. 67 1 303/2 Auftregg.ber: Stahlton A.-G., ZU ri ch 50"24 Ouelcnn.t: Juli 69 sc Zeicnnungsnummer:4-3411 TEST RESULTS Appendix 4.-...,"-.:';1;_., I t-.......,r1-.-._.,,".-.test specimen: SBRV prestressing coble 4m long Nominal values: cross-sectional area: Fe=70 t7J 1/4"=70*31,65 mm 2=2216 mm 2 ultimate tensile strength:=170 kg/mm 2 ratigue stage 1: 6 upper=0,663.=112,8 kg/mm 2 P upper=250 t;blower=0,596=101,5 kg/mm 2o-"'25 t;I lower-4 range of stress A 6=11,3 kg/mm 2 STRESSES (related to the remained Total number of FATIG UE LOADING L1tv\lTS cabl e cross-section at loading cycles after STAGE every fatigue-stage) every fatigue-stage REMARKS No.PuPPet PLower t t kglmfnl leg/mrrr-I 1 250,0 225,0 114,4 103,0 11 ,4 871'10C 1.failure 2"\I 116,1 104,5 11,6 1 1 216 1 900 2...'"'I II" 117,9 106,1 11 ,8 1 1 877'700 3.II ,,)4/I 119,7 107,7 12,0 1 1 885 1 700 4.II/1 5 II II 121,5 109,3 12,2 1 1 946 1 900 5.II 6 II II 123,4 111,1 12,3 2'198'900 6.II I 7 II II 123,4 111,1 12,3 2 1 216'300 End of test I I Lower anchorage 2 failures Upper anchorage 4 failures All of the six failures took place directly near the cold deformed small heads of the wires.During the 2,2.10 6 loading cycles and under lower and upper loading limits of 225t and 250 t respectively, the tested cable-including h*s both anchor heads-could remainout any other defects than these six failures.L.- _A_._-_G_.,:..' _Z_U_r_i_c_h__5_3_-_2;;>_'_..:.I_J G_u*_, 7':;*" sc I\

'::-1 ,//O'L Eidgenossische Materialprufungs-und Versuchsanstalt fUr Industrie, Bauwesen und Gewerbe Laboratoire federal d'essai des materiaux et Institut de recherches

-.Industrie, Genie civil, Arts et Metiers LabQratori9., federale di grob'la dei r:nateriallf' ed Isti1uto -Indus,tria. Genio.civile... Mestieri SW1SSedGrn.1 La ora"tory or TeS"tl.ng ana KeSed.rCn 8600 Dubendorf 67'303/1 Untersuchungsbericht Proces-verbal Processo verba Ie TEST-REPORT EMPANo.---------- Auftraggeber: Commettant: Committente: STAHLTON AGZUE RIC H Gegenstand: Objet: Oggetto: Objec-: 7 A 4 meter long presstressing cable of 58 wires¢1/4" Datum des Eingangs: Date de I'arrivee: Data d'arrivo: Date of receipt: 2.5.1969 AusfUhrung der Untersuchung: Execution de I'assai: till 17.7.1969 Esecuzione della prova: Execution of test: DYNAMIC TEST RESULTS-------------------

Anmerlwng: Eine Verwendung dieses Berlchtes zu Werbezwecken irgendwelcher Art, der bl06e Hinweis auf diesen Bericht eingeschlossen, bedart der Genehmigung die Direktion der EMPA.Ob*.",.tlon: Ce rapport ne peut 4tre utilise ou mentionne dans un but de raclame, quet qu'i1 soit, sans autorisation de la Direction du LFEM.O...rvllZlone: auesto rapporto non puc)essere utllizzato ne menzlonato a scopo dl Qualsiasi senza I'autorlzzazione della Direzions dsl LFPM.,5713/2 56-26 rE:-1 7/8:2. --2-DESCRIPTION OF TEST 1.The prestressing cable Type: Free length: BBRV 58¢1/4" 4 m 58 round and unprofiled steel wires¢1/4" Ultimate tensile strength170 kg/mm 2 (According to data given by the customer.Soe also the experimental results of the tensile tests carried out on the steel wires in EMPA-Report No.67'303/3). Anchorage: The cable was anchored at both ends by means of small cold deformed bottom heads at each wire end andted on a threaded ring at both anchor heads.2.Eauipment The tested cable was mounted vertically in a testing frame with a weighing beam (see Figures in appendices 1&3).Lower and upper loading limits of 125 t and 250 t respectively were adrieved by using two hydraulic jacks, which were connected to a spring These loading limits could be kept constant during the test with the aid of the Amsler load and deformation regulating unit"The Hydro-Pacer". Due to the high range of stress applied on the cable, the maximum possible frequency that could be 0,5 cycles per minute.3.Procedure The required loading limits could be accurately adjusted by meuns of a"load cell lt which connected the Weighing Jeam with the loy-er anchor head of the tested cable.The required 50 loading cycles were exceeded and the test was carr:i?d out up to 440 cycles.\j[\::-1../ 58-27 4.Results By visual inspection, after carrying out 440 loading cycles with stress limits of (jlower=0,4* and 6'" upper=0,8* , any defects could not be observed either in the prestressing wires or at the anchor heads (see appendix 4).DUbendorf, 17th July 1969 Engineer of Test: 58-28 Swiss laboratory for T estiny and Research/.\.12iYl Appendix 1 View of the test equipment with the mounted cable, the measuringment and the recording apparatus. 58-29 Appendix 2 Cable for tension fatigue test at the II EMPA II I I¢200 ',-°l----I¢138,7_E: E o (J (J-.I!J"-'-HIIn Ian d Ryerson Canst.Prods Co , ChicagoEMPA I Auftrogs.Nro/Auftro9geber:67 1 3iJ3/1 St"hlton A.-G., ZUrich I Gezeichnet

5B-30 Juli W I Zeichnungsnummer:4-3406 r'\ppendix 3

arrangement for a fctigue test on a prestressing cable*O'***".I...:"__.r\o co z Cl II I II II II M 1: 25 Cable head two-part steel rinq¢400mm with a hole Steel plate 450*570*125 mm with a hole¢180mm Pevate x (hard cardboard, 5 mm 1 o o co prestressing co ble 58¢1'4 11 II II II II II II II II II II II II Ii II II II II II II II II II"*1 I I II I II I II I II I II o o (J;)N 8 co I 2 x 50t jacks 1100 anchor head Z Uri c;, 58-31 I 625 E" II II II II II II II II II II II II II II II II II II II 1/II II I Zeichnunqsnummer:4-3.::*07 --'--'...l.- Appendix 4 TEST RESULTS; test specimen: BBRV prestressing coble 4m long Nominal values: cross-sectional area: Fe=58V4 It=58'31,65 mm 2=1836 mm 2 ultimate tensile strength: Pz=170 kg/mm 2 6 upper=0,80*=136,2 kg/mm 2;P upper=250 t blower=0,40*Pz=68,1 kg/mm 2;Plower=125 t range of stress A 6=68,1 kg/mm 2 LOADING LIMITS STRESSES LOADING CYCLES REN\ARKS 6'upper lc.g/mm 1 btower kg/mm2.250 125 136,2 68,1 68,1 440 End of test No defects could be observed either in wires or otanchor heads.Lower anchorage Upper anchorage no failure of wires no failure of wires" Ui-'t}A I=-1.L IEM PA I Auftrags-Nr. I Auftraggeber: I Gezeichnet: I Z4eich_nUng34snuom8mer: V 67 1 303/1 Stahlton A.-G.f Z Urich 5B-32 Jul i 69 sc _ Eidgenossische MateriaiprUfungs-und Versuchsanstalt fUr Industrie, Bauwesen und Gewerbe, 8600 DUbendorf Swiss Federal Laboratory for Testing Materials and Research-8600 Dubendorf-Untersuchungsbericht TEST-REPORT EMPA No.67'303/3 Customer:St a hIt 0 nAG, 8034 Zurich Object: Prest ress ing wires¢1/4 n Date of receipt: 11 th June 1969 Execution of investigation: till 31 st July 1969 Tension and Fatigue Tests Rema rk: The use of this report for the purpose of publicity of any kind, including mere reference to it I requ i res the approvol of the d4 rectors of the EMPA F.94147 58-33 67 1 303/3 1.Results of two tension tests carried out on two prestressing wires 56-34

Part D.STATIC TESTS-TECHNICAL REPORT#8 Section SB Page SB-39 Part D.STATIC TESTS-TR-8 Table of Contents Part Page#Introduction, Purpose, Summary 5B-4l 1.0 Interim Report, Chapter 3 a.Title Page SB-42 b.Original Table of Contents SB-43 2.0 Appendix to Chapter 3 a.Title Page 5B-78 b.Original Table of Contents 5B-83 Section SB Page 5B-40//82 Part D.STATIC TEST-TR#8 Introduction, Purpose, Summary This test program was designed to test the ultimate load, ultimate elongation and failure mode of the 170 wire tendons of lengths up to 30 feet;and to determine the ultimate capacity of the individual anchorage hardware components when loaded in such a manner as to test the critical failure made of each component. Testing was divided into four categories: Series PL-ultimate load tests of 170 wire tendons and anchorages 4 feet long.SeriesA-ultimate load and elongation tests of 170 wire tendons and anchorages 30 feet long.SeriesB-ultimate shear load of web.SeriesC-ultimate shear load of 6 inch diameter thread.All test results were over acceptable minimums based on basic critera.Therefore, the end anchorage hardware as designed and tested will not be the weakest link in the tendon system.Section 5B Page 5B-41 -1 TECHNICAL REPORT NUMBER 8 THE WCS 2.0.Mep/170 W POST*TENSIONING SYSTEM INTERIM REPORT: CHAPTER3.END ANCHORAGE. JANUARY, 1968@1968, Western Concrete Structures Co., Inc.5B-42 TABLE OF CONTENTS for CHAPTER 3.0-END ANCHORAGE 3.1 GENERAL 3.1.1 COMPONENTS

3.1.2 PERFORMANCE

CRITERIA 3.2 PROTOTYPE DESIGN 2 3.2.1 GENERAL 2 3.2.2 SPLIT SHIM-BEARING PLATE INTERFACE 9 3.2.3 COMPOSITE WASHER*SPLIT SHIM INTERFACE 10 3.2.4 9-3/8 INCH DIAMETER THREAD 11 3.2.5 6 INCH DIAMETER THREAD-WITHOUT SHIMS 12 3.2.6 6 INCH DIAMETER THREAD*WITH SHIMS 13 3.2.7 WIRE HOLE WEB SHEAR 13 3.2.8 FAI LURE MODE ANALYSIS is 3.3 PROTOTYPE TESTS 16 ,.-.3.

3.1 DESCRIPTION

OF TEST PROGRAM 16 3.3.2 PROTOTYPE ANCHORAGE HARDWARE 16 3.3.3 TEST SERIES PL-PRELIMINARY, 4'x 170 W TENDONS 16 3.3.4 TEST SERIES A*30'x 170 W TENDONS 19 3.3.5 TEST SERIES BAND C*GENERAL 23 3.3.6 TEST SERIES B1-WEB SHEAR WITH SHIMS 26 3.3.7 TEST SERIES B2-WEB SHEAR WITHOUT SHIMS 29 3.3.8 TEST SERIES C2-6 INCH THREAD WITHOUT SHIMS 30 3.3.9 TEST SERIES C1*6 INCH THREAD WITH SHIMS 32 3.3.10 ANAL YSIS OF FAI LURE MODE FROM TESTS 34 3.3.11

SUMMARY

CONCLUSIONS 34 56-43 CHAPTER 3.0 END ANCHORAGE 3.1 GENERAL 3.1.1 COMPONENTS The end anchorage hardware of the WCS 2.0 Mep/170 W Post*Tensioning System is made up of the components listed in Table 3.1-1.The terminology"A end" is used to desigrate the end of the tendon which has the Washer installed and wires shop headed during tendon fabrication. The tendon tube at the A end has an enlarged section of sufficient diameter and length to allow the Washer to be recessed approximately 6 feet inside the face of the Bearing Plate, so that the unheaded wires can project approximately 6 feet beyond the Bearing Plate at the opposite end (B end)of the tendon.The"B end" is the end of the tendon (opposite the A end)which allows a Composite Washer (or optionally a Washer and Washer Nut)to be installed on the projecting wires, which are then field headed.I REQUIRED FOR PART&TYPICAL I TYPICAL NAME DRAWING NO.MATERIAL A END R FNn W01her 100103<1140 Heat Treated Yes No*Washer Nut 100104 41 40 Heat T reoled Yes No*Composi te Washer 100105 4140 Heat Treated No Yes*Split Shims 100106 ASTM A7 or A36 Yes Y..Beoring Plate 100107 ASTM A7 or A36 Yes Yes..Art O1.....bly comisting of 0 Washer and Washer Nul can be subllilvled for the Composile Wosher on Ihe 8 End.TAB LE 3.1-1: Tendon end anchorage components of the WCS 2.0 Mep/170 Post-Tensioning System.3.1.2 PERFORMANCE CRITERIA The basic criteria for performance of the end anchorage of an unbonded tendon system for a prestressed concrete reactor vessel (PCRV)or other nuclear containment is that it must reliably: 1)sustain the permanent long term load on the tendon for the life of the structure, 2)sustain any variations in tendon load for the life of the structure, and 3)have sufficientload capacity to allow the full actual ultimate strength and ultimate elongation of the tendon wires to be developed. Expressed more simply, the end anchorage muststronger than the tendon which it anchors, for all types of loading condition. The actual physical and mechanical properties of the tendon wire can be determined by statistical analysis of test data.As discussed in Section 3.3.4, a long30 feet)tendon composed of 170 individual ASTM A421 wires of 0.250 inch diameter can be expected to produce an ultimate load2002.8 kips, and an ultimate elongation3.5%.Due to the mode of failure of a multiple wire tendon, resulting from variation of thevidual wires, the average or the maximum values of eithermate load or ultimate elongation will not greatly exceed the minimums.The ultimate load capacity of the end anchorage components can be determined by ulti:nate load testsducted on prototype components so as to test all criticalure modes.It can be assumed that the ultimate load capacity of production anchorage components will fall within a range of the mean ultimate load capacity of the most critical failure mode (X)plus or minus three standard deviations \a)of test results.Many specifications require that end anchoragenents may not yield at the minimum guaranteed tendon strength.Therefore the basic performance criteria for the end anchorage of the 2.0 Mep/170 W System can be established as: P=(X-3 a)x (F y+F u)2002.6 kips.58-44 Since neither the mean ultimate load capacity (X)nor the standard deviation (a)are known until after prototype tests are completed, it is necessary to establish a preliminary criteria for design purposes.Previous experience indicates thating for a Safety Factor of 1.5 will produce test results meeting the basic criteria.This gives: Component Design Ultimate Strength (Pi)1.5 x 2002.83004.2 kips.Another independent consideration influences the designmate capacity of the end anchorage components. Due to the critical structural application, a proof load test of all critical components to minimum ultimate (2002.8 kips)has been established as an essential part of quality assurancecedures.It follows that all components must be below their yield point at the proof test load in order that the proof test be a non-destructive procedure. For 4140 steel heat treated to RC 40-44 r the tensile yield point is approximately 90%of the tensile ultimate;and as a practical consideration, to reducejections from the proof load testing r the proof test load should not exceed 90%of the minimum yield point at R c 40.It therefore follows that the design ultimate strength (P')of the weakest failure mode for each component should be: P'P1702472.6 kips 0.90 x 0.90-0.81 Taking ali of the above into account, the preliminary criteria for prototype end anchorage component design ultimate strength is 3004.2 kips for the most critical failure mode with the final criteria for performance being: (X-3 a)x (F y+F u)2002.8 kips U:'::'::ATE -*.//82

3.2.1 GENERAL

3.2 PROTOTYPE DESIGN Fabrication drawings for prototype end anchorage components are shown in Fig's.3.2-1 thru 3.2-5 as follows: The load on the tendon at all major loading conditions issented in Table 3.2-1 as a function of the guaranteed minimlAm tendon strength (P'no)which is 2002.8 kips.COMPONENT NAME Washer Washer Nut Composite Washer Split Shims Bearing Plate FIGURE 3.2-1 3.2-2 3.2-3 3.2-4 3.2-5 net effect of all these factors can be reduced to a simple ratio concept called the rupture factor (k r)which is the ratio of the failure load as determined by calculation (F u xto the actual failure load as determined by ultimate load test of the component (P").Therefore k r=(F u x-7-P", whereis nominal area of steel.k r is normally greater than 1.0.The value of k r is determined from previous testing of similaranism designed in accordance with the same type of calculation. Each series of tests allows determination of revised rupture factors, so that calculated failure loads become more accurate as more testing experience is gained.The rupture factorsly used herein are taken from WCS Technical Report Number 7,"Behavior of the WCS 520 k/d4 Post-Tensioning System Under Static Loads".,-FACTOR LOAD CONDITION AUTHORITY x Pi.,., Prototype Anchorage Design Ultimat.Section 3.1.2 1.5 I Minimum Guaranteed Strength Section 3.2.1 1.0 2002.8 Appro"ima,. Tetldon Yi.ld Strength Analysis of Wir.0.9 1802.5 Ma><imum Jocltin9 Fare.(t...."orary) ACI318 0.8 1602.2 Ma"i......", Anchoring Fore.(short te",,)ACI318 0.7 1402.0 Ma"imum Final Fore.(pe..-en,1 ACI318 0.6 1201.7 I TABLE 3.2-1: Tendon load at various conditions presented as a function of guaranteed minimum tendon strength (P'170), Several factors may ca\Jse the calculated ultimate load based on analytical calculations to differ from the actual ultimate load.Among these are: a)stress concentrations due to notches and/or geometry, b)variation in material strength, and c)variation in the area of material resisting applied loads.The Mechanical properties for the various steels used in the proto*type end anchorage components are shown in Table 3.2-2 for various strength levels.Strength levels are listed by equivalent hardness on the Rockwell B or C scales (R B or Rc)since quality assurance is based upon determination and control of hardness.Values for mechanical properties shown in Table 3.2-2 are derived from curves contained in Fig.3.2-6 in which: 1)the curve for ultimate tensile strength (F tu)vs hardness (Rc or RB)is constructedinformation contained in the 1965 SAE Handbook, and 2)curves for other mechanicalerties are plotted as they relate to F tu based on information contained in MI L-HDBK-5"Metallic Materials and Elements for Flight Vehicle Structures", and from appropriate ASTM.specifications. 58-45 SYMBOL ASTM AISI A'SI or SAE 4140 ot R: I MECHAN ICAl PROPERTIES (ksi)A7 A36 1025 40 41 42 43 44 Ultimote Tensile Strength F til 60-75 58-80 55 180 187 193 200 I 207 Tensi Ie Yield Strength F ty3336 36 163 168173176183 Compressive Yield Strength Fey 33f2\36 179 186 192 198 205 Ultimate Shear Strength F'II 381" 37'f 35 109 113 115 119 121 Shear Yield Strength F ,., I I I Ultimate Bearing Strength l'F hI'\I 98'2 95'2 90 326 335 j 344 355 364 Bearing Yield Strength rr F lin 256 265 272 280 289 I I Notes: cr For elD=2.0 f2\Derived using rotio (F ll l'll F tll)as indicated for AISl 1025 times Ft\l for A7 or A36 TABLE 3.2-2: Mechanical properties of various steels used in end anchorage components. Refer to Fig.3.2-6 for derivative curves.2.//tj°'::'

P LAN SECTION 170 wire Washer;R&D Part No.730-02;R&D Drawing No.t'Aaterial: 4140 commercial grade, hot finished, leaded, annealed, 6-1/2" diameter bar.Heat Treat after all machining to R c 40-44 FIG.3.2-': Prototype Washer Drawing 5S-46 3 p L A N 1---------- '.31',.*---------\ ",.X 45-CHAW,.!:" TYPICAL:r;;,--t-1.111----01; gls o+t-*.000*SECT ION....------....,---------170 wire Washer Nut;R&D Part No.730-04;Material: 4140 commercial grade, hot finished, 4-inch plate, 5-1/2-inch I.D.and normalize. Heat Treat after machin ing to R c 40-44 R&D Drawing No.348 flame cut 9-3/4 inch O.D., FIG.3.2-2: Prototype Washer Nut Drawing 58-47 4 .!.......G'.., e III 1M U:..p L A N\'do#...,.'"*.**..,...., o*170wire Composite'I/asher;R&D Part No.730-05;R&D Drawing No.349 N\aterial: 4140 commercial grade, hot finished, 9-3/4 inch diameter bar Heat Treat after machining to R c 40-44 FIG.3.2-3: Prototype Composite Washer Drawing 5S-48 5 U: 'UA;t:-1//82 ......\/\/\\//'----..,.....I I I I: I: I"'--__L--L_.___________ _....J 1 L MATU" HAL.'"IQUlltID TO MAKI A liT P I..A N 10' .... 1""".""1 1\/SIDE VIEW tt.SU.t'THE SURfACES 0'THE PLA Ttl COMPf"SING A SET SHALL NOT VART MORE THAN.oet-, 170 wire Split Shims;R&D Part No.730-06;R&D Drawing No.350 tv\aterial: A7, hot finished, 2 inch plate.Flame cut 5 inches x 10 inches with 5-5/8 inch diameter hole.2 pieces per set.Heat Treat: None FIG.3.2-4: Prototype Shim Drawing 58-49 6 , t:",*-\// ..'!!!!'}.TI'-DRILL Z 5/4-DEEP TAP 1-'Z*DEEP AT 4 PUCEI 011 10*..Co P 1.1AN 170 wire Bearing Plate;R&D Part No.730-09;R&D Drawing No.357 N\aterial: A7, hot finished, 4-inch plate, flame cut 20-1/2 inches x 20-1/2 inches with 7-1/16 diameter center hole.Drill and tap four holes for 1 inch diameterx8 t.p.i.bolt on a 20 inch bolt circle.Heat Treat: None FIG.3.2-5:.Prototype Bearing Plate Drawing)58-50 7 11::-1 7/82 (J) JO HAI2DfoJESS 10 o Fbl'1--=--bearing yield stress (ksi).!'I.F t1 tensi Ie yield stress (ksi).._'-,-'-..-400--::= '*f'*r t"-,--.-,_.F e1 compressive yield stress (ksi)1-*,=r--'-_** _.'...F'1I=shear ultimate stress (ksi) '-.-......Jt-.Fbl'1I=bearing ultimate stress (ksi)-FIG.3.2-6: Mechanical properties vs.hardness.The curve for tensile ultimate (F tu).showing UTS ploned against Rockwell Hardness (RS or Rd is derived from information contained in the 1965 SEA Handbook.pages 107 and 109.Curves designated Fbru.Fbry.cCY'Fty and F su show other mechanical properties relative to F tu and are derived from Tables 2.2.1.1 and 2.3.1.1 (a)of MI L-HDBK-5.56-51 8*f ,.,-,.",/" 0:'::' AU possible failure modes are listed by components in Table 3.2-3, which also shows for each failure mode the type of stress, calculated ultimate load, maximum applied temporary load, and maximum applied long term loads.Safety factors are shown for each applied load and calculated as the ratio of thelated ultimate load to the applied load.For each component, the critical'failure mode is that having the lowest safety factor.Validity of calculated ultimate loads and resulting safety factors; and criticality of failure modes must be established as a result of prototype tests reported in Section 3.3.Stresses, strains, and ultimate load capacit'1 of components influenced by the supporting concrete are dependent upon the strength, elastic modulus, creep characteristics and ment in the anchorage zone concrete and are not within the scope of this section.Predicted Ntc.x.Load Ntc.x.Permanent Failure Component Fai It.*re Mode Type of Stress UTS (Temp.Overload)Load Mode (kips)(kips)S.F (k ips)S.F.Critical Supporting Concrete Anchorage Zone Principal Tension Bearing t Interface Compression I Tendon Tubing Ancharage Zone Axial Compression I Fai lure is dependent on mechanica and Ancharage Zone Radial Compression >physical properties of the supporting concrete and is not considered in this section.Bearing Plate Concrete Interface Compress ion Internal Flexural I 2002.81 I....Shim Interface Bearing 3527.9 1.76 1201.7 2.94 Split Shims Bearing t Interface" Bearing 3527.9 2002.8 1.76 1201.7 2.94 No it Washer Interface'" Bearing 3357.7 2002.8 1.68 1201.7 2.79 Yes'" Composite Washer Shim Interface'" Bearing 7900.2 2002.8 3.95 1201.7 6.58 No..Web"If Shear and Flexure 2864.4 2002.8 1.43 1201.7 2.38 Yes..9-3/8" Threads Shear 4342.7 1602.2 2.71 Nane"" No Washer Nut Shim Interface" Bearing 7908.2 2002.8 3.95 1201.7 6.58 No..9-3/8" Threads Shear I 4342.7 1602.2 2.71 None a>No 6" Threads with Shim: Shear I 3276.5 2002.8 1.64 1201.7 2.73 Yes*I Washer Web Shear and Flexure I 2864.4 2002.8 1.43 1201.7 2.38 Yes 6" Threads IN i th Sh i ms*Shear 3276.5 2002.8 1.64 1201.7 2.73 No..TABLE 3.2*3: Possible Failure Modes of 2.0 Mep/170 W System End Anchorage Components. Safety Factor IS.F.l is the predicted ultimate load divided bV the applied load...Indicates failure modes to be tested.3.2.2 SPLIT SHIM*BEARING PLATE INTERFACE (Ref.Fig.3.2*7)Nominal Area:=10.0*1f'X;.0625 2=60.83 sq.in.Rupture Factor: k r=1:0 Fey=36 ksi for A36 per Table 3.2-2.:..9 Fey=32.4 ksi.I LOADING FORMULATE FOR LOAD STRESS CONDITION P or f (kips)(ksi)REMARKS Calculated UTS 3527.9 58>3004.2 Pred icted UTSP=Fxx 1/k r 3527.9 58>3004.2 Proof Test Loadf=P";'2002.8 32.93<33 Jacking-e-I-e-Unloaded till trans.Anchoring I 1402.0 23.05<3r=*9 Fey Max.Final 1201.7 19.76 I 58-52 9-1 l-/82 --I--? 518 DIA_.1_,_"-----SUP D OI2TIr-.JG PLA-TE..1 f=U 1 I*: 9Ys'DIA\\-OAD J I 20 Yl.SQ: ,------ L.-__......1__---I .\I L'--\wASl-1Et< 01<.//r\..,J..-:::::,"---WASHE:.tZ.---WASI-1EQ I-.:ur--/--/J------1-- J;1(-----------FIG.3.2-7: Arrangement of Anchorage Components Nominal Area: 3.2.3 COMPOSITE WASHER.SPLIT SHIM INTERFACE (REF.FIG.3.2*7)A ,=IT (9.375 2-5.625 2)8 S 4=44.1 sq.in.Rupture Factor: k r=1.0 Fey=36 ksi for split shim LOADING FORMULATE FOR LOAD STRESS CONDITION P or f (kips)(ksi)REMARKS Calculated UTS P=Fx3357.7 76 CD>3004.2 Predicted UTS P=Fxx l/k r 3357.7 76 CD>3004.2 Proof Test Load f=P2002.8 45.33(3)<F=179 for R 40 cy C Jacking--No load till trans.Anchoring 1402.0 31.73<3r=.9 Fey Max.Final i 1201.7 27.20 Note: CD equivalentD=9.375;5.625=1.875 equivalent e=t+=2+ =2.94 for t=2.0 min.:.e/D=;'::5=1.57>1.5 e F bru (for e/D=1.5).8 F bru (for e/D=2.0):.F bru (for e/D=1.5)=.8 x 95=76 ksi sa-53 10 i!i.i.-llj-SAl-.: The bearing stress of 45.33 at Proof Test Load exceeds Fey36 ksi for the A7 or A36 split shims which wouldfore be expected to show permanent deformations. The split shims do not require a proof load test and the bearing stress is well below Fey<;>f 4140 steel at RC 40.CD For the composite washer side of the interface F bru=326 ksi and Fey=179 ksi.3.2.4 9-3/80.0.THREAD A'=(L e*p)X 1r XE;where: s 2=nominal shear area L e=length of thread engagementn=number of threads per inch p=pitch=I+nD=nominal diameter=9*3/8E=nominal pitch diameter=3.250 inches=4=0.250 inches=9.375 inches=D*0.3 p=9.375-(0.3 x 0.250)=9.300 inches=(3.25-0.25)x 3.1416 x 9.30=43.83 sq.in.2 pi=Fx A;and f s=Pk r r s pi=Predicted ultimate load ,/F su=Ultimate shear strength (See Table 3.2*2)k r=Rupture factor=1.1 (Ref.: WCS Technical Report No.7)f s=Calcu lated shear stress LOADING HARD.LOAD STRESS CONDITION R c (kips)(ksi)REMARKS Calculated UTSG)40 4777.0 109>3002.4 Predicted UTS 40 4342.7 109 41 4502.1 113 42 4581.7 115 43 4741.1 119 j 44 4820.8 121 Proof Test Load 40 2002.8 50.27<(.9 F SY=.9 x.9 x F su=88.3)Jacking@40 1602.2 40.21<0.4 F su 58-54 Notes: CD Calculated UTS does not make use of k r ,:.Pc=F su X@The 9-3/8 thread is unloaded after transfer 11!jl-'DAii::-1 3.2.5 6 INCH 0.0.THREAD*WITHOUT SHIMS (REF.FIG.3.2*7)A'=(L e-p)x 1T XE.where: s2'=nominal shear area L e=length of thread engagementn=number of threads per inchp=pitch=In o=nominal diameter E=nominal pitch diameter 3.250 inches 4 0.250 inches 6.000 inches=D-0.3p=6.0*(0.3 x 0.250)=5.925 inches A'=(3.25-0.25)x 3.1416 x 5.925 s 2=27.92 sq.in.Calculated Ultimate Load: Predicted Ultimate Loads and Stresses: P'=pi=F sy x A;.f P x k s k r'and s=;where F su=Ultimate shear strength (See Table 3.2-2)k r=Rupture factor=1.1 (Ref.WCS Technical Reoprt No.7)*f s=Calculated shear stress LOADING HARD.LOAD STRESS CONDITION R c (kips)(ksi)REMARKS Calculated UTS 40 3043.4 109>3004.2 Predicted UTS 40 2766.7 109 41 2868.2 113 42 2919.0 115 43 3020.5 119 44 3071.3 121 Proof Test Load-2002.8 78.9<.9 F sv (.9 x.9 x=88.3)Jacking-1602.2 63.1=58 x F su (min.)Anchoring-1402.0 55.2=51 x j Max.Final-1201.7 47.3=.43 x 58-55 12 f/- 3.2.6 6 INCH 0.0.THREADS-WITH SHIMS (Ref.Fig.3.2-7)The 6" washer bears on the split shims over an area A br and thus results in a force, P br=f br x A.br'This bearing force (P br)plus the shear force (P s)as derived in Section 3.2.5 reacts against any applied load (P), so that:P=P s+P br.At ultimate load levels, all component materials are stressed within the plastic range, and we can expect f br to be equal to F bru which is quite high in terms of F tul but is rather indeterminate. MI L-HDBK*5 gives data for F bru of AISI 1025 steel for elD=2.0, but this in the average stress at ultimate rather than the peak stress since it is based on a round pin of diameter D in a slightly oversized hole.If we assume a sinusoidal stress distribution F bru (average)=0.636 F bru (peak), or F bru (peak)=1.57 F bru (average)Data for AISI 1025 steel indicates that F bru=(90-:-55)F tu=1.64 F tu.The washer-split shim interface ts a plane surface where it can be assumed that average and peak bearing stresses are the same.F tu for either A7 or A36 steel can be determined approximately from the Rs hardness.Therefore, we can derive an approximate expression for P br as follows: P brF bru x Abr8.79 F tu;where: Abr=(6.00 2.5.625 2)=3.42 sq.in.Fbru1.64 F tu x 1.572.57 F tu F tu is determined by hardness test from Fig.3.2-6.Therefore p'=+P br+8.79 F tu Shear stresses in the threads resulting from an applied load can be determined in much the same manner except that for loads substaintially below ultimate, we must assume a relatively uniform stress over the entire bearing surface as follows: P=f br x Abr (total)=44.18 f br;or f br=:4.18;where: Abr (total)=(9.375 2-5.625 2)44.18 sq.in.P Therefore: P br=fbr x Abr='m8 x 3.42=0.077Since: P=P s+P br=P s+.077 P P s=0.923P=f s x As=f s x 27.92 (Section 3.2.5)f=0.923P=0 P s 27.92.<oJ 3.2.7 WIRE HOLE WEB SHEAR As shown in Fig.3.2-8, shear failure of the web between the wire holes can occur along either of two critical paths.The load applied by the wire heads to the portion of the washer inside the shear plane (P s)is less than the total applied load (P)since part of the load applied by the wires on the shear path is applied to the portion of the washer outside the shear plane.This ratio of load distribution and the number of webs on the shear plane can be determined by inspection of Fig.3.2-8, which gives the following results: WIRES RELATIVE I SHEAR TO SHEAR PLANE TOTAL LOAD RATIO NUMBER OF STRESS RATIO PATH INSIDE OUTSiDE WIRES R p=Ps/P WEBS (N)R s=Rp/N Shear Path 1 141 29 170 0.829 44 0.0189 Shear Path 2 133 37 170 0.782 40 0.0196 For any given condition, the web width (w), the washer thickness (t)and the applied load (P)are constants, so that theputed shear stress (f s)varies directly with the stress ratio (R s=Rp/N)as follows: 58-56 AsNx w x t N'.1 X t 13 Ui-'DAT1::-1 7/8:1. 109 x 20.fi5=2240 kips 1.0 58-57 It can thus be seen that the shear stress along shear path 1 will be slightly lower than that along shear path 2, which will be used in following calculations, however, the difference is small and, due to manufacturing variables, web shear failure can be expected to occur along either shear path.PATH 1 IFIG.3.2-8: Alternate shear paths for wire hole web shear failure with Path 1 shown above horizontal <t.and Path 2 below.Path 2 is slightly more critical than Path 1.Whilethe center to center spacing between adjacentwireholescan vary+/-0.010, or 7.5%ofthenominal'web width (w=0.133), the total spacing along any line of holes has the same tolerance of+/-0.010, which is only 0.2%.Therefore the average web is the nominal center to center hole spacing (0.397)minus the hole diameter (0.260 nominal or 0.264 maximum).The area of steel resisting web shear (As)along the critical Path 2 is therefore:=N X w'x t=40 x 0.137 x 3.750=20.55 sq.in.As-min.==N x wmin.x t=40 x 0.133 X 3.750=19.95 sq.in.N=number of webs along Path 2=40 w'=nominal web width=0.397.0.260=0.137 in.w m in.=minimum web width=0.397*0.264=0.133 in.t=washer thickness=3*3/4=3.750 in.Calculated ultimate loadand predicted ultimate load (P')are the same since the rupture factor (k r)is taken as 1.0.Loads and stresses are given by: P'=!i2240.R0 782=0.782=2864.4 kipsp*f=R pxP=0.782xP=0.0381 Pksi s20.55 where: P=any applied tendon load pI=tendon ultimate tensile strength=predicted ultimate shear (test)load R p=load ratio=0.782 from chart above k r=rupture factor=1.0 (Ref.WCS Technical Report No.7)As=nominal shear area for Path2=20.55 sq.in.14 ihi.-l/i-SAH LOADING HARD.LOAD STRESS CONDITION R c (kips)(ksi)REMARKS Predicted UTS 40 2864.4 109 41 2969.5 113 42 3022.1 115>3004.2 43 3127.2 119 j r 44 3179.7 121 Proof Test Load 2002.8 76.2<.9 F SY (.9 x.9 x 109=88.3)Jacking 1602.2 61.0=.56 F su Anchoring 1402.0 53.4=.49 F su Max.Final 1201.7 45.7=.42 F su For shear failure along Path 1: As=Nx w'xt=44 x 0.137 x 3.750=22.61 sq.in.As min.=Nx wmin.x t=44 x 0.133 x 3.750=21.94 sq.in.p'=F su x AS S k r 109 x 22.61 1.0 2464.5 kips P'=equivalent tendon ultimate strength=!1.=£i..=2464.5=29728k R p 0.829 0.829'.S As 3.2.8 FAILURE MODE ANALYSIS 0.829xP 22.61=.0366 P ksi ACI 318-63 limits the concrete compressive stress on the bearing area supporting a tendon bearing plate to: f cp=0.6 but< In customary practice, f cp is considered to be a uniform stress and the bearing plate thickness is then set to limit flexural stress in the bearing plate to Fty at minimum guaranteed tendon ultimate.Although this procedure results in satisfactoryformance, it does not represent the actual conditions which exist and has no significance in analizing the mode of failure.While f cp=P/A b gives the average stress on the bearing area, the distribution is not uniform in any case, and is dependent upon the modulus of elasticity, poissons ratio, and creeperties of both the plate and the supporting concrete.Theimum concrete stress is a function of bearing plate deflection. Since the bearing plate flexural stress could not possibly exceed F ty without causing concrete failure, the bearing plate can not fail.The failure mode is thus deter"ined by the supporting concrete, not the plate, and will not be considered in this Section.This subject is covered in WCS Technical Report No.2.58-58 Table 3.2-3 lists all failure modes for each component. For each component, the critical failure mode is that having the lowest Safety Factor (S.F.).The purpose of the prototype testingported in Section 3.3 is to determine actual ultimate load for all critical failure modes.-, ,',-,..-,//0":'15 3.

3.1 DESCRIPTION

OF TEST PROGRAM 3.3 PROTOTYPE TEST The test program was designed to test the ultimate load,mate elongation, and failure mode of 170 wire tendons of lengths up to 30';and to determine the ultimate capacity of the individual anchorage hardware components when loaded in such a manner as to test the critical failure mode of each component. Testing was divided into four categories, Series PL-ultimate load tests of 170 wire tendons and anchorages 4'long;Series A-ultimate load and elongation tests of 170 wire tendons and anchorages 30'Ie;Series B-ultimate shear load of web (honeycomb); and SeriesC-ultimate shear load of 6 inchmeter thread.3.3.2 PROTOTYPE ANCHORAGE HARDWARE Prototype hardware was fabricated in accordance withings per Figs.3.2-1 thru 3.2-5.Prior to testing, components were designated by Rand 0 drawing and part numbers.After testshadvalidated design, final drawing and part numbers were assigned.These are listed in Table 3.3-1 for reference. R&D Id.ntification Final Port Nom.Port D,owing Po,t andNo.No.Dot.Drowina No.-Wooh.r 730-02 346 10-21-66 100103-00 Washer Nut 730-04 348 10-21-66 100104-00 Composit.Wooh., 730-05 349 10-21-66 100105-00 Shims 730-06 350 10-21-66 100106-00 Bearing ptat.730-09 357 10-10-66 100107-00 TABLE 3.3-1: Prototype Anchorage Hardware Designation Each prototype washer, washer nut and composite washer was assigned a serial number for identification and record.Tables 3.3-2 thru 3.3-4 show thematerial,material supplier, chemical analysis, machining practice, heat-treatment, and hole diameter and spacing tolerances for the washer, washer nut andposite washers respectively. Also listed in the same tables are the measured dimensions and loading history for each serial numbered part.6-10'Jli Il4'*I'*/O"'z'WITH 7 I A.'.CaNTelt HOI.!....._--,%."tftt.IT 10'$dlU"q"t""" 5+aN Ttlt HOt.I FIG.3.3-1: Setup for Series PL tests.56-59 16 It should be noted that prototype anchorage hardwaresions and material do not agree exactly with drawings and manufacturing standards shown in Section 3.4.Even though tests on the prototype hardware were entirety satisfactory and and conform to design criteria, some dimensions were changed in the interest of standardization. in particular, the thickness of the washer and composite washers were increased from 3-3/4 inches to 4 inches in order to conform with the washer nut;and alloy tubing for the washer nut and alloy bar (pressed round)materials are shown as preferred over flame cut plate used for prototype hardware.Since these changes are ail on the conservative side and increase the strength of the respective part, the prototype tests are applicable. Predicted failure loads for the production parts have been established by linearcrease of prototype test results to account for the increased strength due to these changes.All such changes are clearly noted in the analysis of each series of tests.3.3.3 TEST SERIES PL The objective of Series PL tests was to provide preliminary results by loading prototype anchorage hardware to the tendon ultimate in such a way as to limit the release of energy in the event of failure of ar.anchorage hardware component. All anchorage hardware components used for: 1)Series A tests (170 wire x 30 foot long tendon ultimate tests), 21 170 wire structural tendons in the 4.0 Mep bed, and 3)General Atomic ultimate tests of both straight and curved tendons up to 100'long were tested in this series.A secondary objective was to provide additional statistical data in support of the design criteria that the anchorage hardware must be stronger than the minimum guaranteed tendon strength (2002.8 kips).A third objective was to repeatedly test the stressing equipment at a load equal to tendon design ultimate.The test set-up is shown in Fig.3.3-1.End anchorageware consisting of a washer and washer nut (typical A-endl on the right and either a composite washer (typical B-end)or a 1000 TON UJA-Measured Dimen,ion, Load Hiltory Clearance Hordn_Series S.ries Test Series General Pitch Oia.Axial R::;:B Lab.PL A Bed B&C Atomic Tests.015.020 4\.5 390-PL-4 I A-2 50, 6cI.017.025 41.5 390-Pl-3 A-I 5c, Sa.015.020 4\.5 390-Pl-7 60, 8b.014.015 42.0 401-Pl-5 6b, 90.028.018 41.0 388-PL-I I Bed.014.017 4\.5 390-Pl-S 6c, 9b.015.012 41.0 388-Pl-6'10.015.011 42.0 401-Pl-6 Sb.013.014 4\.5 390-PL-2 Bed.015.014 42.0 401 375 C2-7.018.015 41.0 388 303 Cl-IO.020.018 40.5 38.5 375 C2-8.015.012 39.0 370 363 C2-9.014.020 4\.0 388 352 Cl-4.023.018 41.5 390 I-IS IS IS 15 5.0167.0160 4I.n 390 365.6 .00368 0.727 53.6 8.66 23.6 22.2\.76 13.7 2.4.075.076.075.076.alO.072.074.alO.073"1.076.00262 3.4%Thread Depth WASHER RO 730-02;Print: RO 730-340;Final Port and Drawing No.;100103 6-1/2 inch diam.t.r, hot finished.bar stoel<, leaded ana annealed per ,0.151 4142 Comm.rcial Grod.United States Sr**1 Corporation C......PS Si Cr Ma Pb.42.83.OQJ.020.27.92.18.15/.35 Rough machin.and thread on Q engin.loth..Hoi.drill on on drill press using conventional f.eds and speed, and Q"Burgh......r..**floating ind.x table.P..MIL-H-6875B; prot.ctiv. otmosph.re Fur"Oc.for hord.ning and tempering; circulating oil for qu.nching. Qu.nch flat in a singl.lay.r to facilitat.....b qu.nch.Hardness as quenched R: 54/55.Hal., ch.clced...ith hoi.micrometers and"Go-No Go" gClUget ran to maximum metal side of tol...ance.Within:.010 on out.r (drill in)face Within:.030 on inner (drill out)face: inches overall;3-1/4 inc" thread length THICKNESS Serial Major Number Diall'l.t.r 001 5.998 002 5.992 003 5.996 00.5.996 0Q5 5.991 0Cl6 5.995 001 5.995 0Ql 5.996 009 5.992 ala 5.980 all 5.993 012 5.995 013 5.995 014 5.986 015 5.987 n 15 X 5.992 a O.oo..6S v.077%PART NAME: PART NUMBER: MATERIAL: MATERIAL SUPPLIER;CHEMICAL ANALYSIS: MACHINING;HEAT TREAT: HOLE DIAMETER: HOLE CENTER SPACING: TABLE 3.3-2: WASHER-dimensions and load history.PART NAM:: PART NUMBER: MATERIAL: MATERIAL SUPPliER: CHEMICAL ANALYSIS: MACHINING: HEAT TREAT: THICKNESS: WASHER NUT RD 730-04;Print: RO 730-348;Final Part and On:win, No.: 100104 AISI4142, annealed, 4 inch hot rolled plate, c_rcial grode.FI_cut 9-3/4 inches outside diamet.r...ith a 5-1/2 inch center hale and onnealed.Lukins St..l Company C......PS Si Cr Mo lib.38.76.0Ql.025.240.90.15-Rough machine and thread on a conventional engine I!lthe.Per MIL-H-6875B, prorec:1ive furnace for hardenin9 and tempering; ci re-.oIating oi I for quenching; Hardness as quenched R c 54/55.4 inch overall, 3-1/2" len,tl, internal threads, 3-1/4" length external thrwadI........asured Dimensions Load History External Thread Intemol Thread Serial Number Maior Diameter Thread Clearance Depth Pitch Oia.Ax'al Minar Diam.,..Clearance Pitch Oia.Axial-BHN lob.Series Pl Seri.T.t 5eri.General A Bed 8&L Atoftic T...352 001 002 003 00.0Q5 0Cl6 0f1l 0Ql n X 9.364 9.3n 9.365 9.364 9.368 9.362 9.368 9.370 8 9.367.00320.03.aI.5.088.<Ya9.a16.al9.al9.al9 8.C678.00148 1.7.028.022.031.026.029.028.025.031 8.0274.00282 10.3.029.020.020.014.021.023.019.019 8.0206.00397 19.3 5.860 5.855 5.852 5.860 5.870 5.863 5.392 5.866 a 5.8648.0116.20.021.01 0.020.015.030.023.032.025 8.0231.00532 23.0.010.014.015.007.018.012.010.OCIJ 8.0118.00349 29.6 40.5385388 I 41.0 388 363 4\,5 390 I 363 40.1)375 41.7 400 40.5 38.5 40.0 375 42.0 I 401885 40.90 1387...365.8.721 9.IS II.9 1 1.76 2.36 I 3.25 Pl-4 Pl-7 I Pl-3 Pl-5 Pl-6 Pl-5 Pl-I PL-6 Pl-2 C2-9 C2-10 A-I A-2 So, 5c, 6b, 6d, 8b, 91:1 C2-7 5b, 60, 6c, Sa, 9a Pull Rod T.t Cl-4 TABLE 3.3-3: WASHER NUT*dimensions and load history'.17 Ui-'UH l t:-1 1/i:f2 58-60 Ne.19 PART NAMf PART NUMBER MATERIAL MATERIAL SUPPLIER CHEMICAL ANALYSIS MACHINING HEAT TREAT HOLE DIAMETER HOLE CENTER SPACING*HICKNESS_-.\.:-L/;"H r: COMPOSITE WA5HEQ RD 730-05;Prinr: RD 730-349;Final Part and Drawing No.100105 AISI 4142 Commerc:ial Grade, 9-1/2 ind'diameter pressed round, annealed Berhlehem Steel Corporation C MnPS Si Cr.43.93.008.024.20.97 Rough mac:hine and thread on a c:onventional engine lathe.Hole drill on an automatic drill press using conventional feeds and speeds and a"8urghmoster' f100ting ind.x table.Per MIL-H-6875B; protective atmosphere furnace for hardening and tempering; circ:ulating oi I for quenc:h i I'Ig.Quench flat in a single layer to fac:iIi tate web quench.Hardne" as quenched R, 54/55.Hole checlced with hal.micromet.n and"Co-No Co" gauges ran to maximum metal side of toleronce. Within:t.010 on ouler (drill in)fac.Within:t.030 on inner (drill out)face 3-3/4 inches overall;3-1/4 inch thread length""Wosured Dimensions Load History Serial Neio r Thread Clearance Hardness Series Series Test Series General Number Diameter Depth Pitch Dia.Axial R,..8HN Lob.PL A Oed 8&C resn 001 9.361.070.030.021 41.5 390 341 81-2 002 9.372.078.030.015 40.5 385 341 81-1 003 9.364.075.030.017 42.0 401 PL-I Oed 004 9.365.074.028.017 41.2 388 341 81-3 005 9.364.072.029.014 42.0 401 352006 9.362.072.031.017 40.0 375-PL-2 Oed 007 9.369.075.028.016 40.0 375-PL-4 Pl-7 50, 5b, 5c, 60, 6c.Bo.9 0 cal 9.365.071.030.017 40.0 375-PL-3 A-I A-21 0, 6b, 6d, ab, 9b 009 9.369.075.032 018 42.6 408 375 82-5 010 9.368.002.029.019 40.0 375-011 9.364.073.030.025 42.0 401-012 9.360.069.032.Ot8 41.0 388-013 9.362.070.025.018 40.5 385-014 9.362.073.027.017 41.0 388-015 9.358.070.029.020 40.0 375-11'1 15 15 151515 15 5 X 9.364 0733.0293.0179 40.95 387.3 350 0.00368 00334.00178.00254 869 10.85 13.21 v.039 455 6.06 14.2 2.12 2.80 3.n TABLE 3.3-4: COMPOSITE WASHER*dimensions and load history.5B-61 washer and washer nut on the left were connected by 170-0.250 inch diameter wires 4 feet long with button-heads. The washer on the right hand side of the 4 foot tendon was inserted thru a block consisting of eight bearing plates (R&D Part No.730-09 per Fig.3.2-5).After installation of the washer nut, shims (R&D No.730-06 per Fig.3.2-4)were installed on the left hand side as spacers and the 1000 ton stressing jack was connected to the washer nut on the right.In the initial tests of this series, the jacking load was increased until failure of two or three wires occurred.I n later tests the load was stopped at 2100 k.All anchorage hardware tested in Series PL wassequently reused in other tests.Elongations at failure were not recorded.Series PL test results are summarized in Table 3.3-5.Test Series Pl*Test Re.ulh Part Serial Numbe" Test Test Mall, Load Left Ri ht Number Date (kiDS)Wmher Nut Com.....W-h**1\1.., Pl-I 1-28-67 1988--003 005 007 Pl-2 1-30-67 2090--006 009:1 Pl-J 1-30-67 2150--OQI 002 I Pl-4 4-7-67 2100-.001 001§I Pl-5 4-7-67 2100 00&00&-006 Pl-o 4-7-67 2100 001 OQI-OQI Pl-7 4-7-07 2100--001 003 TABLE 3.3-5: Summary of Series PL Test Results.3.3.4 TEST SER I ES A Series A tests were conducted on 30 foot nom inal length straight tendons made up of 170 wires of 0.250 inch diameter anchored by means of button-heads to prototype anchorage hardware.The objectives of Series A tests were to determine: 1)theelongation characteristics up to tendon ultimate, and 2)the mode of failure.The maximum force which a multi-wire tendon can resist, tendon ultimate, is that force at which 2-3%of the wires fail (3 to 6 wire failures for a 170 wire tendon), even though the remaining wires will continue to elongate at aduced force.The number of wires which fail at each increased elongation increment can be expected to follow a normaltribution curve, imposing increasing shock loads and higher energy release.Since this would risk injury to test personnel and visitors, and damage the testing equipment, all withouttributing any additional significant information; Series A tests were terminated at the total elongation which produced four wire failures.Tests were conducted using the 4.0 million pound capacity test bed and the 1000 ton capacity stressing equipment. The test set-up is shown schematically in Fig.3.3-2 and by photographs which are typical of both A-1 and A-2 tests (Fig.3.3-3 thru 3.3-7).An assembled and banded 170 wire tendon having a prototype composite washer on the east end and a prototype washer on the west end was installed in the test bed from east to west.A prototype washer nut was installed on the west end and the tendon centered ready for test.Two 4" th ick bearing plates are used under the anchorage hardware at both ends in WEST e.ND.'EAST t: lJO 4 MfLLrON POUND 56-62 Ui-'iJATE:-1....,....***0***e.******'."**'".....it 0.:"."..19 STt.It 5',",leI( ..,..-.**-.:.....'Oil rr...""....n.CN I r I I SGWA-': 1M'.-.'%AI!J'1.0' HQI.a WA.MIIil II l....----I'UJ'f./ i!li:l.1t WITW W"SH!1Il NUT, 9 Ya, 0.1'.Hc;t+aNTI" 1'101.1 FIG.3.3-2: Test setup for Series A tests. 56-63 FIG.3.3-3: Series A.170 wire banded tendon installed through center hote of 4.0 Mep test bed. '.-FIG.3.3-5: Series A.West end after Phase I elongation,ing 14" to 16" shims is place retaining elongation of prototype washer-washer nut anchorage hardware.Fl G.3.3-4 Series A.Stressing jack attached to tendon at west end for Phase I elongation. FIG.3.3-6: Series A.Prototype composite washer at east end at the same test stage as that shown in Fig.3.3-5.The wire deflector plate, shown in place, is removed prior tostallation of l,OOO-ton Stressing Ram for Phase II elongation. FIG.3.3-7: Series A.West end during test A-2.Two wires have failed at a force of 2,054k at an elongation of 17.0 inches and can be seen against the deflector plates.At this stage of the test, Phase II elongation is being applied at the opposite (east)end of the tendon.20 capacity load cell, accurate to1%full scale traceable to the National Bureau of Standards, was added bet\'Veen the washer and the split shims at the left end.Although capacity of the load cell was only one-half that of the applied loads, load cell vseither transducer or hydraulic gauge readings showed a linear relationship to 1000 kips and can be extrapolated linearly with sufficient accuracy.Test data for Series A, test A-1 and A-2 are shown in Tables 3.3-8 and 3.3-9 respectively. The relationship of the actual properties of wire used for Series A, tests A-1 and A-2 as compared to the minimum properties required by ASTM: A 421 can be ssen on Fig.3.3-8.The stress-strain curve shown has the same shape as a load-elongation curve and is based on the 10 inch gauge length specified in ASTM: A 421.It can be seen that the wire used has an average yield point 16.9%greater, an average ultimate 3.1%greater, and an average elongation 52.5%greater than correspondingmums specified by ASTM: A 421..06 (250, 5.3"').05 Wi,.T.t-Tendon'1.04 0.25" Of_em WIre,,,,*0.0491 i"." 1 O*Gage L.\gth.03.02 Strain, I"./1"..01 urder to transfer shear forces around the oversize (10")hole in the ,test bed.These bearing plates are not considered to be a part of the assembly being tested.A1 000 ton Stressing Ram having an 8 inch stroke was attached to the west end for Phase I elongation.(Fig.3.3-4).Atimately full 8 ram stroke, shims were stacked under the anchorage hardware to maintain elongation. The jack wastracted, blocked by means of a chair extension load, re-applied, and more shims stacked.This cycle was continued totion of Phase I elongation, shown in Fig.3.3-5 just aftermoval of the Stressing Ram.Tendon elongation during Phase I was designed to be safely below tendon ultimate, but ly great that tendon ultimate force could be obtained within a single 8 inch stroke of the Stressing Ram attached to the east end for Phase II elongation. This was for the safety ofnel and protection of the test equipment. The wire used for Series A tests was tested to determine mean values of actual ultimate strength, yield strength, andtion as shown in Tables 3.3-6 and 3.3-7 for tests A*1 and A*2 respectively. Applied load was recorded at intermediate values of applied elongation. Elongation was measured by means of a steel tape, accurate to 0.01 inches, which measured Stressing Ram piston travel.Loads were measured by both a calibrated hydraulic gauge and by a calibrated hydraulic pressure transducer having a digital read-out.Calibrations were performed with a setup'similar to that shown in Fig.3.3-1 except that a 1000 kip INDIVIDUAL WIRE PROPERTIES FIG.3.3-8: Stress-Strain curve showing mechanical properties for wire used in Series A, tests A-l and A-2, shown superimposed on the theoretical curve for a wire having properties per ASTM: A421 specified minimums.1 Installed 15_1/4" 10'01.hims.Transfe,red load to.hims.R......ved jock and installed on ,ight.Two haur delay AOX illdie:.ta, off ,cole.AOX indicato, off scale.2 wires foiled at heads.2 wir.failed at hMOds.12.00 13.00 14.00 14.50.10 14.40 14.60 14.90 16.00 16.20!:Em Test data for Series A, test A-1.2020 2007 2048 2054 o 1797 1893 1999.500 9580 96.30 9660 8450 8900 9400 9800 9800 9750 2001>1795 1896 2000 TEST A-I DATA Gouge Length: 385 inch", 5t,...ing Rom Effective Ate: 21:<.65 sq.;".Tronlducer

ADX-38 S.,iol No.208;GP<46F Se,iol No.3929 (est Datil 7 Feb,uo,y I 967 Penonnel: H.R.Reut.., R.E.Hunte" A.H.5tuDbl LooC Elang.ADX Hvd,aulic Gouge,p,i)(kiP1)(inches)Remarles 96 440 0.00 Appro.i_tell'I.5 i"ch..oftlack.200 940 200 o 2 Stressing Jack installed on left.I"'";..;0 300 o 35 401 1860 396 0.50 515 2400 510 0.75 605 2760 S87 I 0.90 698 3240 689 1 05 794 3700 787 1.20 892 4160 8S5 1.40 992 4640 987 160 1091 5110 1.75 5580 1187 1.90 1295 6050 1287 2.10\400 6570 1397 2.30 1502 7040 1497 2.50 1600 7500 1595 2.70 I i70C 7990 1699 2.95 1792 9440 1795 3.40 1810 8510 1810 400 1840 8720 1854 450 I IM5 tl700 1850 5.00 Installed 6" ,hi.....0 0 0 4.65 T'ansfe"ed load to.hi....and ,..e'jock 1865 8710 1852 5.30 1895 9910 1895 6.00 1902 9140 19404 7.00 I 1958--7.4\Installed 2_1/2" Ihi....-8*1/2"'otal.000 7.15 Transfe"ed load to sh;....ond'eset jack.I 1940 I 9100 1935 8.00 I I)970 I 9200 1956 9.00 1978 I?360 1990 10.00 2019 9<460 2012 11.00*TABLE 3.3-8: 21 I WIRE FOR TEST A-I Sou,ce: United States St..1 Corporation iQ;Determined by.2%off..,et I Heat Number 87 a 756 1'2'Determined by tatal SlTain under I Coil Number 56 load (elastic..plastic)!e,: 29.3" Id'i@Deten!Oined by plastic strain I I ,_ini"9 afm rupture.i I Sample I Position of F...I F., (1',%Elon90 tion I No.i laD.SaIIIple in Coil (kips)(leipt)I'2'J 1-j W.tern F,ont (ht wire)11.82-5.'0 LI 1 1 11.99-5.77 11.85-6.8 5.05 11.9.-7.2 5.72 5 Ilack-1'.90-7.2 5.30 6-11.77-7.1 5.25 7-11.92-6.9 5.65 8 Middle (l7Oth wi,e)12.20 I--5.20 9 12.32--5.12 10 12.20--5.28 11 12.26--5.57 12 Durie..12.00 10.90 7.0 6.0 13 I 12.02 I 10.90 5.7 1412.00 10.90-5.9 15 12.05 10.95-6.0 16 U.S.S.F,ont (1st wire)12.00---17 U.S.S.Back 12.00---" (units)I 17 4 I 7 15!X (kips)I 12.01.10.89 6.900I (J (lei,.)I.1.90.0217.35046 i.3022.., (%)i 1.2".199 I 5.1" i 5.41 i WIRE FOil nST ,10,-2 I Sou,ce: United States Steel I'" Oe_ined by.2%off-.et!Heat Nulllber 87 a 756 (2'0_;,""'" MMI..'....1 Coi I Number 63 I load (el=tic+pl..ti:)E.: 29.3*10" I I POIition of F ,.F..%elon""tion--i No.Lab.Sam,ale i" C"il (lei,.)(1<i,.)'2'1 1 Durie..F,ont 12.35 1 i.25!5.4 I 2 I I l 12.20 II.25 4 8 3 12.30 II.25 I5..5" Ilack 12.20 11.00 5.2 I 512.20 11.00 5.5 6 I U.S.S.F,ont 12.20--I 7 U.S.S.Ilac:k 12.30--'I n (unit'S)7 5 5 I X (lei,.)12.250 I 11.150 5.280 q (kips).0598.1225.2638 v (%)..1098 5.00 TABLE 3.3-6: Test results and mean values of mechanical prop.erties for wire used for Series A, test A-l.TABLE 3.3-7: Test results and mean values of mechanicalerties for wire used in Series A, test A-2.

The load-elongation data for Series A, tests A*1 and A*2 is plotted in Fig.3.3-9.For clarity, only the resulting curve is shown without intermediate points.A theoretical curve for a tendon having mechanical properties per ASTM A 421mums is superimposed. .06 23.10.OS 19.25.04 15.40 170 WI,.Tend,,", A**8.35 In." lan;'" of Tendon=32'-I**.385*.03 11.55.02 7.70 SIfts'n.'n./In.,01 Elon;.*in.3.85 The summary and analysis of Series A test results are tabulated in Table 3.3-10.Following procedures established in prior WCS Technical Reports, performance is rated by: 1)nominalciency-that is, performance of the tendon relative to the minimum guaranteed wire properties, and 2)actual efficiency" that is, performance of the tendon relative to actual wire mechanical properties. Both nominal and actual efficiencies are shown for both ultimate load capacity and ultimate elongation, using notations defined in Table 3.3-10.These efficiencies are theoretical, for comparison purposes, and cannot be considered an exact measure of performance of a multi-wire tendon for several val id reasons.T!ST RESULTS FIG.3.3-9: Load-Elongation curve of Series A, test A-1 and A*2sults, shown superimposed on the theorectical curve for a tendon having properties per ASTM: A421 specified minimums.First, the mechanical properties of sample wires are determined by tests on a 10 inch gauge length per requirements of ASTM: A 421.There is no valid correlation of performance based on a 10 inch gauge length to performance based on much longer gauge lengths-385 inches in Series A.Second, a multi-wire tendon cannot be assumed to perform as the sum oftheindividual wire performances due to individual differences in the wires.since it is obviously impossible for a multi-wire tendon to be any stronger than the sum of thedividual wires, it follows that it must be weaker, since to be of equal strength would be a coincidence. Therefore, it iscally impossible to have actual efficiency ratios (tR p and tRE)greater than 1.0.It further follows that nominal efficiency I No 3929 384 inches 212.65 Iq.,n.AOX 385I N 200 GP46F S TEST A-2 DATA TABLE 3.3-9: Test data for Series A, test A-2.TrQ,,':.aucer erta a;erlO I TDote I 7 February 1967 Penonnel HReuter, Q.E.Hunter, A.H.Stubbs Lood Elong.ADX Hyd'au r, c Gou ge I\;P')T",,)I, 10\(;nche,)Remark, 298 a 50 Jade on we.1 end.504 065 600 080 Reset elongation scat.at 1.00 inch...702 3660 778 I 15 804 3620 770 I 35 904 4080 868 1.50 1003 4540 965 1.67 1104 4990 1061 185 1201 5430 1155 2.00 1301 5890 1253 2 20 1402 6360 1352 2.37 1503 6820 1450 2.55 1602 7260 1544 2.75 1700 7720 1642 2.97 1796 8190 1742 3.27 1848 3.75 1894 4.1000 0 375 Sel load off on 4" shims.1882 8820 1876 5.10 1900 8860 1884 6.00 1924 9030 1920 7.00 1950 9120 1939 8.00 7.85 Sel load off on 8" shims.Added 8" c....ir 514 800 piece.Down 10 minutes 1947 9130 1941 8.75 1938 9130 1941 9.00 1980 9130 1941 10.00 2002 9390 1997 10.90 1 wire f"iled (in wire)1996 9410 2005 12.00 2010 9470 2014 13.00 1980 9510 2022 13.80 2006 9530 2026 14.00 off.cole 9500 2020 14.25 13.85 Sel lood off on 14".hims.9570 2035 15.00 9610 2043 16.00 9610 2043 16.2500 15.80 Sel load off on 16" shi"..Moved r,,'" 10 9610 2043 16.60 Easl erd.9660 2054 17.00 Second wire f"iled (in wire)9710 I 2065 I m::ill Third cond four'" wir..f"iled (in wire).Test terminated. I Gouge Lengrh; Rom Effecti\lle Area P'ort Serial N....",ber Tesl Te.t Eo.Nest No.O,,'e Com""'NQlo"'er I Nut A*I 2-7-67 008 OC2 I 003 A-2 2-17-67 008 002 00)(v n il1)(ki",)(kipS)("'o)*3 a (kips)-3 a (kips)Te..Re'ulrs Go*.ge AAoh..sis of 1.Jltrmote Force Resu I,., Anolv'5;s of Ult;..E::::r'I otlon Rl!1 u lrs Load (P;')elong (e;')L.,.;ti't Elong. 5 P;';" 6'n R.*R.E;9 e:';0 oil,*R r (ki",l (inche,)(ind***)(%)(k ,,,,I (ki",)S (inches) I'il'12 I 2004 I 1665 385 I 4 325 2002.8 2042.4 I 041 I 020 15 40 26 57 1 001 o 627 2 2065 2'17 50 J8-'2" 4.557 2002.9 2002 5 1 031 099'2 15 J6 20 n , 139 o 863 2 2 2 2 2074.5 17.075 4.441 1 036 1 006 1'10 o 745 9.500.425 116 0.005 0.014 o 029 o'18 458 2.489 2.612 483 I J92 2 613 15 839 2103.0 18.350 4.789 I 051 1.048 1 , 97 , 099 2046.0 15.800 4.093 I 021 o 964 1.023 o)9'Noles: 'l'Refer 10 T A8Le 3.J-8'2'Refer 10 T A8LE 3.3-9'3'Refer 10 T A8LE 3.3-6'4 Refe, 10 T A8Le 3.3-7 P,"/p;"" P,"/P;':" nominal elongation of tendon:: r.ominal elongation

,f wire..gauge length.

theor.tical aChJai elongation of tendon:: acNal el:r'!garion of wire , gauge length For A-I,X (elon9",ion) =6.9"'.tJ'Therefore E;'0.069'385 26.57...For A-2,=\'(eIOn9"lion) = rner.fore E;'=0.0528'384=2028 incn.e;'/E;E;'/E;'-f n R.a I R.'9'E;e;'1!'n R, ft I R.170=170 , 11.781 170 ,=170 12.041 170 , 12.250 2002.8 kips 2042.4 kips for'e" A-11'2002.5 kips for'es'A-2'4'56-65 TABLE 3.3-10: Summary and Analvsis of Series A Test Results.22 Ur-i.:;fl::-1?/-S"2

MEAI-l VAI.Ue.OP" TENSILE ratios (nR p and nRe)can only be greater than 1.0 if the wire is actua..lly better than specified minimums.As it relates to ultimate tendon elongation, General Atomic has taken this into account by requiring an ultimate elongation of 3.5%for a 30 foot gauge length, thus requiring that nRe0.875.If the mechanical properties are determined for each coil of wire in any given lot of material prior to selection (such as a mill heat), the quantitative values of any property for all coils will follow a normal distribution curve similar to that shown in Fig.3.3-10 for ultimate tensile strength.ASTM: A 421 requires a minimum ultimate tensile strength of 240 ksi (or 11.78 k)for 0.250 inch diameter.Theoretically, all wire shipped could have this minimum tensile strength and no more.In actual practice however, this is impossible.

In order to limit rejects, the steel mills must aim to produce a product higher than themums, as shown by the horizontal position of the vertical line representing mean tensile value (X).Approximately all coils (99.7%)will have a tensile strength within the range of the mean tensile value plus or minus three standard deviations (X+/-3 a), and therefore the variance of the product, asured by a, determines-how much higher the aimed for value (X)must be over the specified minimum in order to limit rejects.To aim for a X which is too high is to risk rejects for other specified properties, e.g.coils having the highest tensile strength may be rejected due to low elongations. As can be seen by reference to Tables 3.3-6 and 7, the variance, as measured by the coefficient of variation (v), is quite small for tensiie strength, but is four to ten times greater fortion.SPE'C/l="feO TE'!'JS\I.E L.. __l"""'"'=_;t_""_3_c:r __J*.U1.rJMATE rE.NSILE.STRE.WGiH FIG.3.3-10: Frequency distribution of ultimate tensile strength for all coils of a mill heat of 0.250 inch diameter ASTM: A4':'1 wire.There is insufficient experimental data available to draw any val id conclusions as to the theoretical true efficiency of thedon, that is the relationship of the tendon actual failure load (or elongation) and the sum of the actual wire properties. Series A would indicate: 1)a relatively high true efficiency for tensile ultimate (tR p=0.992 to 1.020)with a small variance, and 2)a somewhat lower true efficiency for ultimate elongation (tRe=0.627 to 0.863)with a large variance.Should th is hold true in all cases, then it could be expected that a 30 foot long test tendon fabricated from 170 wires having exactly minimum properties (that is, 11.78 k UST and 4%elongation) could fail at 1986.7 k and 2.5%elongation, but the confidence in the accuracy of this expectation would be quite low.From the above discussion, it is reasonable to conclude 30 foot long test tendons should exhibit efficiency ratios of nR p1.0 for tensile and nRe0.875 for elongation. It must be expected however that test tendons fabricated from wire havingmum properties would fall below these efficiency ratios.This should be of no concern as the strength of all tendons, both test tendons and those used in the structure, will exhibit the same frequency distribution as the wire itself.Series A tests show that the two tendons tested exceedfication requirements for both ultimate load and elongation. They also contribute significant information on the behavior of long multi-wire tendons loaded to ultimate, from which more exact criteria and code requirements can eventually be derived.3.3.5 TEST SERIES BANDC-GENERAL In general, Series B tests were conducted to determine web (honeycomb) shear ultimate both with split shims (Series B 1)and without split shims (Series B2);and Series C tests were conducted to determine shear ultimate load for the 6 inch diameter thread, which couples the Washer to the Washer Nut, both with split shims (Series C1)and without split shims (Series C2).Specific details which apply to each of the four series (Bl, B2, C1 and C2), including discussion, objective, test procedure, test results and analysis, are presented separately for each series in succeeding sections.In relation to the anchorage hardware components orblies, the term"outer face" is used to describe the surface on which the wire heads bear, that is, the face on which the load is applied;and the term"inner face" is used to describe the opposite surface, that is, the face which has a reactive force in the opposite direction to the applied load.The interior well of the 4 million pound capacity test bed was used to apply the test load as shown schematically in Fig.3.3-11 and by photos in Fig.3.3-12 a)thru c).Three-1000 ton stressing rams were attached to the inside east end of the test bed and were hydraulically interconnected to a stressing power unit located on top of the bed.Ram force wasted thru a movable load block to the component being tested.Load reaction was provided by a fixed spacer block reacting against the inside west end of the bed.Redundant determination of the applied test load is provided by means of: 1)a Martin-Decker, 12" dial, 0-10,000 psig hydraulic gauge measuring to 20 psig subdivisions the oilsure being applied equally (in parallel)to three identical rams 58-66 23 and 2)by a Transducers Inc.Model GP-46F-10,000-7103draulictransducerattached to one ram and reading to 50 pound subdivisions on a Transducers Inc.Model ADX-38matic Digital Indicator. Both the gauge and ADX-38 were mounted on the hydraulic control-power unit installed on top of the test bed.Both the hydraulic gauge and the indicator were calibrated to the capacitY of a 1000 ton load cell.but no load cell even close to this capacity was available.ever, failure load as determined by the mean of gaugemined load and transducer-indicator determined load issidered to be accurate to at least 1.0 k+/-since: a)all rams are identical, b)all rams are connected in parallel by equal length lines to the hydraulic pump, c)calibrations showed a linear relationship, and d)there is close correlation between gauge and transducer-indicator calibrations. Applied test load as measured by the gauge is determined by multiplying the gauge reading (corrected to the calibration curve)by the total effective area of the three rams (AR=3x 212.65=637.95 sq.in.).Applied test load as measured by the transducer-indicator is determined by multiplying the indicator reading (corrected to the calibration curve)by three.tion by means of an eight million pound capacity load cell installed in lieu of the test assembly would be more accurateIn order to determine the degree of uniformity throughout the section of the heat-treated components, CompositeSerial No.002 was sectioned after being tested to web shear failure (Series B 1, Test 1)and Rockwell C scale hardness was measured at approximately 100 points across one face.The center section of a Composite Washer was chosen as being the most critical for uniform heat treat results due to this compo-..'.;.. Id*.TAHOAIIlO ,.'" J------11,AzTMICIit eNO**"T"'C1C It---fo,.;---- 1&'*.."I'MIQC c.cu.A"... 41-. eMC.I-.---------- UHOIW........,'...1'.....".'...",.,....TA.HCloAIilO20***.,..,""ell(. It'l-WMUAU., 4 MILLION FIG.3.3-11: Schematie drawing of Test Bed setup for Series Band C tests, showiflq general arrangement and general detail of test fixture.Actual detail of test fixture varies for each series and is shown separately for each:>pecific series.58-67 24 ....\IIt'.*...**_--rl**..,:.*,...'..........*...-fit'.' ,'j, t-,...t .'.'--1;\, FIG.3.3-12: Test setup (a)for Series 8 and C tests showing 1,000-ton rams, movable load block, and fixed spacer block in well of test bed.Three rams and movable load block are shown enlarged in (c), with movable load block, test specimen and fixed spacer block shown en*larged in (b)....c)-, A summary of data and results for all Series Band C tests is shown in Table 3.3-11.It can be seen that actual failure loads average 0.4%higher than those predicted by calculation in Section 3.2.Th is extremely small error gives considerablefidence in the design and in the assumptions on which it was based.It can also be seen that the safety factor of 1.5 x min.guaranteed tt!ndon strength which was established as a pre-"-11-01 1="AC,&: liminary criteria for component design, is met for all tests Sec.TIOj.\-j.\except Series C2.This is of no concern since the condition FIG.3.3-13: Schematic drawing of section cut from Composite Washer tested oy Series C2 does not exist in the structure contem-Serial No.002 after having been loaded to web failure in test 81-1.R c hardness values were measured for approximately 100 points.Distribu*plated and, in any event, the reduction in preliminary S.F.is tion of material hardress throughout the cross section is as shown by small.25 the schematic iso-hardness lines.U/-'L);;rt:-1 nent having the greatest dimensions and mass.The location of the section tested and iso*hardness I ines are shown in Fig.3.3-13.Hardness distribution was approximately as expected.The lowest hardness of Rc 30 occurs in the center of mass of the annulus outside the critical shear path at a location where stresses are low and ductility is of more importance than strength.Hardness along the shear path shows a mean value of RC 38.2 for the same component where predicted ultimate was based on a value of RC 40.5 as measured on the outer face.It is interesting to note that the ratio of average measuredness along the shear path to measured hardness on the outer face (38.2 7 40.5=0.943)is quite close to the ratio ofdicted ultimate to actual ultimate (2509.7-7-2613=0.9605), indicating that variation in F su , as measured by hardness,counts for most of the small (3.9%)error in predicted ultimate.This is an example of the type of variable whic.n is conven*iently handled by use of a repture factor (k r).i3-68

..'.,..

1:';,:._..t/r" ..Te.t Component\(wi th Serio I No,)Fa, Load Error Equl" Safety!DesignatIon Description Test\Nasher Compo Split P'edicted Actual I (Note I)Tendon Factor I Series Na.Date'Nasher Nut Wa.her Sh,ms (k ipsl (j"ps)=UTS (Note 2)(Note 3) BI-I 1 Web Shear-With Shim.5-1-67 002 2509 7 2613-4 0 3152 1 574 BI-2 2-r-5-1-67--001 Yes 25n5 2682-3.9 3236 1 616 BI-3 3 5-1-67--004 Yes 2564.0 2586-09 3120 1 558 82-1 5 Web Shear-Without Shims 5-1-67--009 No 2654 4 2541..4.5 J.530 82-2 6 I 5-1-67--005 No 2600.2 2518..3.3 3038 1 517 Cl-1 4 6" Thread Shear-With Shims 5-1-67 014 008 Yes 3430.5 3378..I 6 3378 1.687 CI-2 105-3-67 011 002I 3483.2 3561-2.2 3561 1.778 C2-1 7 6" Thread Shear-W,thaut Shims 5-2-67 010 005-No 2903.5 2922-0.6 2922 I 459 C2-2 8-----r-5-2-67 012 003-Na 2817.2 2930-38 2930 1 463 C2-3 9 5-2-67 013 001 No 2741 0 2745-0.1 2745 1 371 I Error(Predicted Load-Acrual Load)-Actual Load;Therefore, minus error means component is acrually stronger tnan preciicted. 2.Equivalent Tendon Ultimate LoadAcrual Test Load at failure R,;(R,o 829 for Series 8l 3.Safety Fac tor Equiv.Tendon Ult.-Minimum guaranteed tendon:..'/timote.S.FEQu,valent Tendon Ulhmare"'" 2002.8 TABLE 3.3-11: Series B1, B2, C1 and C2-Summary of Data and Results.3.3.6 TEST SERIES B1-WEB SHEAR WITH SHIMS Web shear is a critical failure mode for both the Composite Washer and the comparable assembly of Washer-Washer Nut.In addition to shear along the critical shear path, low order flexural stresses exist due to bending, resulting in combined shear and flexural tension on the inner face of the washer.The effect of flexural tension will be less for the assembly ofWasher Nut as tension cannot be transmitted in the radial direction through the 6" thread connecting the components, resulting in a shorter lever arm as compared to the single piece Composite Washer.Therefore the Composite Washer wased for testing as representing the most critical condition. From the calculations (Section 3.2.7)and analysis, there is no reason to assume any difference in ultimate strength of the web shear failure mode for assemblies either with or without split shims.The principal reasons for testing three assemblies With.split shims in Series 81 were to: 1)verify the above assumption by comparison with results of tests conducted without split shims (Series 82), 2)establish a minimum ultimate strength for the bearing failure mode at the Split Shim-Composite Washer interface as analized in Section 3.2.3, and 3)assist in analysis of the effect of bearing on the ultimate strength of the 6" thread tested with split shims (Series Cl I.The test fixture for Series 81 tests is shown schematically in Fig.3.3-14.The double bearing plates are used to transfer shear around the oversize (10 inch diameter)hole in the spacer FIG.3.3-14: Fixture for Series B1 testS.Components being tested are shown shaded.Mandrel conforms to shape illustrated in Fig.3.3-11 for Path 1 shear failure mode.block and are not considered as part of the components being tested except for the Bearing Plate-Split Shim Interface (ref.Section 3.2.2), which is an accurate duplication of actualditions.After application of an approximate 400 kip preload to seat all parts of the loading train, the load is reduced to 1.0 kips and any gap existing between the mandrel and Washer is measured and recorded as an indication of degree of ity of applied load application. Test results for the three tests of Series 81 are shown in Figs.3.3-15 thru 17, and are summarized and analyzed in Table 3.3-12 which shows the method of calculating values indicated. The low coefficient of variation (v)for actual test results (P")indicated consistency in both components and test procedures. The small error,-2.93%average, indicates that predicted loads are quite accurate but conservative since actual test loads (P")are higher in all cases.This is probably due to the fact that predicted loads are based on nominal steel shear area=22.61 sq.in.)while the actual area may be slightly higher.This is probably why the Rupture Factor (average k r=0.971)is less than 1.0.Such a small variance between predicted and actual values does not indicate any change in k r=1.0 for use in identical calculations of similar mechanisms designed in the future.I<0.=.0....T......,.....Acrual Error Revised I Min.Equiv.Safety I T",t UTS (P;l I UTS (P;l UTS (P")Note rJ1 k.Tendon UTS Factor I O",ig.(['(kips)f2\(kips)(kips)(%)Note 4 1'S'(kips)Note t6"!81-1 I 2509.7 2509.7 I 2613-4.0 0.960 3095.2 1.55 1 81-2 I 2577.5 2577.5 2682-3.9 0.961 3093.3 1.54 81-3 2564.0 2564.0 2586-0.9 0.991 2998.4 1.50 I I" I 3 3 3 3 3 3 3 I X I 2550.4 2550.4 2627*2.93 0.971 i.53 a I 29.30 2 9.30 40.42 1.404.014 45.19.022 1.15 1.15 1.54 49.0 1.48 1.48 141 X:2638.3 2638.3 2748.3+1.39 1.014 3197.9 1.59 X*3 i 2462.5 2462.5 2505.7-7.25 0.9'28 29'26.7 1.47 Notes, ,.Caku lated UTS (P;)c y A;without"se of Rupru..Fac_(k,), ,u 2.P,edicted UTS (P;): Polk,;P;: (F", x A,)/k,;k.: 1.0 3.Error: (P,-P")x 100"'" p" 4.Ilevised Ilupru,e Foetor: k,: Po/P" 5.Mini"""", Equivalent Tendon UTS: p" corrected to",'nimum F,u P, (",in.)=(P"/R.)x (Min.F,u@R e 401 F tu of$peci",,,") For failure olong shear Path 1, R." 0.829 Fo'the specified"'ini_R e: 40, F,u=109 k.i 6.Safety Factor, SF: P: (",in.VP"l"l " p, (",in.V 2002.8 TABLE 3.3-12: Summary Analysis of Series B1 Test Results 58-69 26/ ULTIMATE LOA..rESTS-PROTOTYPE ANCHORAGl: _OMPONENTS ULTIMATe LOAU ,ESTS-PROTOTYPE ANCHORAGE...OMPONENTS 114.HARDNESS SCALE READING Dcl SERIAl.NUMBER TEST.--Z----TEST DATE/1Vf.-., 1..7 COMPONENT NAME__Composi te Hasher..Split-ShiJlll ...__...__*..SERIES aI-2.DESCRIPTION Web Shear-W, rll S''''S ICOMPONENT DATA UTS I'f'SCALE READING\klij"__.SERIAL NUMBER TEST_,;,,' TEST DATE I Wf,...,.(.7 SplitShi...CO"'PO'it. Washer COMPONENT NAME SlIlES a I-I DESCRIPTION r;.;;.N.-;s';,;""=..;,:.S

1 COMPONENT DATA:'ffOllft 1001.3.2-2PATH 1 PATH 2 22.61 2'O":5r_0.829.0:7821.01.0

__.-__<_..----_*.__*_.,.DIeTED FA/WIlE LOAD----------.*-.. P:*F,\: AiJ::::..:: F,.<*.*/14/.1'%.101*lei",.-I"..P'*equi....lent tllftdon load-.:-*!i.*.3101.2-Iti", Ie*ruT ".8'L'1----Preload to approximately 400 lei"'l"tum to ze.., Meoaure gop be_components and punch;Effeeri".RaM.....<A.)-3x 212.65*637.95.sq. in.(!:IF_Fig.3.2-6 .**._.,.__*:--___..-..NDICTED FAILUR£LOAD__.---...-*..::..,.._.w-'"-...---: P,'*.-:_.: F n**'..Ie.!i.PATH1;PATH 2*1/1 X

'1$".1-.7 lei","..*22.61 2'O":5r P'..0.829 0:782*!i...!.!::.!:.L
.1."2.7.4-Iti", Ie."1.01.0 R.".*11----, TEST PROCEDURE Preload to approximately 400 Iei"'l"tum to z_, Mealure gap be_COI'IlpCIIMftts and punch;mecti".RaMAreo(A.)-3 X 212.65*637.95 sq.in........<D T., Gauge andpM ADX 01.'"......gi".........,_, of the._I0.Il.L-'-T.., Gwge i'" lC 0.63'!CD L-'-.ADX-3I 1'" lC 3,.#.*'loin.REMARKS 1711 6,.:>Sf!":.4.5'>=,...

T., Gauge and....ADX 01.'"....." gi"._-.of the_.....L-j*T., Gwge I llne x 0.63'<D 1.-"-ADX-3I 1'" lC 3, P"*'-I"to11f" Inle lded Actu I pOI*READING LOAOI'2" ADX-38 LOAD@(pai)O<i",).READING O<i",).......<D LOAD DATA TEST GAUGED Preload.Gap*0.oZ4in.REMARKS LOAD DATA TESi'GAUGE'l)TRANSOUCUrf' READING LOADf2'ADX-38 LOAD@(pIi)(ki",)READING (lei",)Inte lCied Aetu I 4,P...3.." I"",'It"'Z.IIS'/1"" 11/1-4....31('Ill'$"'%&'\..18.(., t:......>1!" 17'S-'37".oz.,,'(..4 711 7317 3,4.7.5'14-83&IHt" 4-1." 1.4/'87.7..1..FIG: 3.3-15: Test 61*1 Data FIG.3.3-16: Test 61*2 Data ULTIMATE,ESTS-PROTOTYPE ANCHORAGI: _OMPONENTS SERIES aI-TEST...;:;..3 TEST DATE I MAY (., 7 DESCRIPTION --;COMPONENT DATA COMPONENT NAME__.SERIAl.NUMIU HARDNESS SCALE READING_.Compos;te Washer.._Split-ShiJlll _..1/3.4 LOAD DATA TEST GAUGE'l)TRANSDUCER'1 READING LOAoI2'ADX-38 LOAo@(pai)0<1",).READING (ki",)REMARKS lnte Aetu I"'-load.Ga!J-0...11 In.pt**.....611.oz...1"5'111 4**11S" 1711'-**2311 8_11r 1/65.......(!) T., Gauee and....ADX Dt._......., gi...,.."..,__, of the_....L-'*T., c;.,ge 1'" lC 0.631<D 1.-"-.ADX-3I 1'" lC 3*FIG.3.3-17: Test 61*3 Data 56-70 27 uU Ai£:-i 58-71 The test results do not prove that Shear Path 1 is more critical than Shear Path 2, in contradiction to predictions based on analysis, since the mandrel used applied load to Shear Path 1 and therefore forced failure along this path.in fact,tion of the Composite Washers after failure indicates that shear failure was trying to occur along Shear Path 2 in spite of the fact that the mandrel applied the test load to Shear Path 1.In several instances failure started along Shear Path 1 at the outer face of the Composite Washer (directly under the mandrel), but ended along Shear Path 2 at the inner face of the washer.Reference to Section 3.2.7 shows that minimum equivalent tendon UTS for failure along Shear Path 2 should be 0.964 times that along Shear Path 1.Since the analysis of Section 3.2.7 and the examination of components after failure both indicate that Shear Path 2 is critical, the average minimum equivalent tendon UTS of 3062.3 kips should be reduced to: Revised P;'(min.)=0.964 x 3062.3=2950.6 Since the value of standard deviation is not effected by this correction, it follows that the lowest equivalent tendon ultimate would be Revised P;'(min.)-3 a=2950.6-3 x 45.19=2815.0 kips, thus giving a revised S.F.=1.41.This correction is on the conservative side since the actual failure mode isably along a composite of both shear paths.FIG.3.3-18: Outer face of Composite Washer and Split Shims of test B 1-3 after being loaded to ultimate.Note that shear failure is along Path 1 only.Photos here and in Fig.3.3-19 are typical for all tests in Series 81..-.... The final acceptance criteria established in Section 3.1.2 says that the proof test load equal to minimum guaranteed tendon UTS must be 90%of the yield point of the weakest failure mode predicted from statistical analysis of test results.There is no well defined shear yield point and, in fact.shear yield and shear ultimate probably conicide, so we may conservatively assume F SY=.9 F su.Therefore, final acceptance criteria may be expressed as: 0.9 (X, 30)xPPT=P'170=2002.8 kips F su-3::;" 2002.8::;" 24726 k'X-a?0.90 x 0.90?*IpS The revised Pi-(min.)of 2815.0 is 1.14 times greater than the 2472.6 kips required for acceptance of test results, indicating that the web shear failure with split shims exceeds requirements. This series also shows that the bearing at the Split ShimBearing Plate Interface and at the Split Shim-Composite Washer Interface are not critical failure modes as both sustained loads as high as 2682 kips without failure.Figs.3.3-18 and 19 are photos of the outer and inner faces respectively of both Composite Washer and Split Shims after being loaded to failure in test B 1-3.They are typical for all tests of Series B 1.FIG.3.3-19: Innerface of Composite Washer and Split Shims of test 81*2 after being loaded to ultimate.Note that shear failure is along both Paths 1 and 2.28 ULTIMATE LOAD TESTS-PROTOTYPE ANCHOI:AGE COMPONENTS FIG.3.3-21: Test 82-1 Data DESCRIPTION Web Sh_-Iv'/T"..v r.<;""h Nt S liS.*UTS'T'(lui) READING HARDNESS Z...41..., SERIAL NUMBER TEST.-;:6;;... reST DATE 1 MAY (,,7 C_DOti te Washe, COMPONENT NM'i..SERIES 8'1..-'!.COMPONENT DATA ULTIMATE LOAD TESTS-PROTOTYPE ANCHOIlAGE COMPONENTS [SEIUES 8 to-I TEST S reST DATE/MAyr..1!DESCRIPTION Web Shear-k,;lITJ-ldvr jCOMPONENT DATA I-.._.SERIAL HARDNESS UTS'T'COMPONENT NAME NUMBER SCAlf READING (leai)_.Compo.it.Wash., atl#f 12, 41.." 1174---_..(!)F_Fill.3.2-0-_._--__0_______*___.PIlfDICTED FAILUIlf LOAD._----_.-___._-.___..-..----F,u X Ai.. F u'-frOrrt Tobie 3.2-2...-.Pi*-k-.------PATH 1 PATH 2...117.4 x 1.1..(,/*.3.::.!.!+/- I<ipl.E'6'l 2O:'S5 P'..eqvivalent tendon load--.0.829.0:782...!:i..$1.,,/.1 kipl k..1.0 1.0 IresT PROCE;URf".8'Z.1----P..load to approxima..ly 400 kips;Retum to zero;M.asure gap betwe...campenento and p'Jnch;I Eflecti...llam Ar_(A.)*3 x 212.65*637.95 tq.in.'LOAi)DATA TEST GAUGE'D TRANSDUCERf)'I READING LOAD(j'I i ADX-38 LOAO@(pii)(leips)READING (kips)REMARKS Actudl Preload.Gap*C."1(.in..,4""'0"""(Pi"" 1/87 4**:1f>/ISS'Z 8...1713<:-t;".I:173" 1.3eo 8"" 71Sl.e S'I--8,t 847FAI..vn.1i-N.6.",..Ii 1Ze.."w6 I 7if K,#:IJ.fA/CAll.rJlll.v'Wec I A**..,.P4r>>1 i I P". I P".-zs41.;..o.8't1.1"'SO G.,nrl. l,/..rtM.Te Net.t(i)Hydraulic T.t Gauge and Hydroulic TI'ONducer plw ADX Digital""'t I giw redundant_,_t of rite_load.II..oaI'-T.t Gauge R.eading X 0.638!I..oaI'.-.ADX-38 R.eadinl II 3, 3.3.7 TEST SERIES B2-WEB SHEAR WITHOUT SHIMS The Composite Washer without split shims could only be used on a"fixed end", that is a non-stressed end of a tendon.ever, even for a tendon which will only be stressed from one end, there are advantages to using split shims at both ends.The split shims distribute the force from the washer over a greater area of the bearing plate, thus reducing the flexural moment arm and stiffen the bearing plate, both of which permit use of a thinner bearing plate than would be allowable without split shims.Using split shims at both ends of a tendon stressed from only one end allows both bearing plates to be of the same thickness and further provides a convenient method of taking up slack in the tendon prior to stressing. The purpose of the two tests in Series 82 was primarily tovide additional test data on web shear strength and secondarily to determine if the presence of split shims has a significant effect on web shear failure.The test setup is shown schematically in Fig.3.3-20.Test procedures were comparable to those used in Series 81.Data for each test is shown in Figs.3.3-21 and 22 and is summarized and analized in Table 3.3-13.Preload.Gap*iI.,"1;n.Aclv I 4**1.1"",'I.**S1S'..__. -_.F,.'"frorrt Table J.2-2.. _.I PATH 1 PA.TH 2--_.E'6'l 2O:'S5.-0.829 0'.782 Ie.*1.01.0 In tei.d ed 1187 1'/86 ,....iD Hydroulic T.t Gauge and HyoIroulicplue ADX Digital""'t giw_.-t of rite_'--.I..oaI'-T.t Gauge inll II 0.631I..oaI'-.ADX-3I 1"11 X 3, I.)74.(!):r:.-Fig.3.2-6 __..*.__*PIlfDICTED fAILURE LOAD 1';*F***A;k**--..2't.'-1 P'..equi""lent tendon load.*!:i... kips I p.....8-:----iTEST PROCEDURE I Preload to opPrO"imately 400 kips;Retum to zero, I Meaaure gap belW_COlIlflO"Mti and punch;mecti...RantArea(A.)*3 )(212.65*631.95tq.ln. I LOAD DATA 1 TEST GAUGE'I)!TRANSDUCERtf'I r READING LOADI'2'!AOX-38 i.OAO@(pai)O<;pI)!READING (kipl)REMARKS I Colculot.Pr.aict.a AcNaI Errot"-ised Min.Equiv.Safety T.t UTSUTS (P;)UTS (P")No..k.Tendon UTS Factor o.i,.rf'(kipl)t1'(leipl)(leipl)!'llo)No..f4\'s'(kipl)No..'6"&2-1 265.....26S.....25..1+".5 I 1.045 2845.8 1l.42 82-2 2600.2 2600.2 2518+3.3 1,(l33 2878.9 ,1.44 ft 2 2 2 2 2 2 I 2 X2627.32627.3 2529.S+3.9 1.039 2862." 11.43 a 27.10 27.10 11.5 0.60 0.006 16.55 0.01 v 1.03 1.0315.38 0.58 0.58 0.70 X+3a 2708.6 2708.6 2564.0 5.70 1.057 2912.0 1.-46 X-3 a 2546.0 2546.0 2"95.0 2.10 1.021 221'2.7 1.40 I Not.: 1.Cclevle" UTS..F..x A;witnout uM of (k,)2.Pr.lct.UTS (Pi>*Pelle.;p;..(F", x Ai)/Ie.;k, a 1.0 3.Error..-P")x 100+P" (p.rCMt)..."-ised foetor: k.*pC!p" S.Minimum EqvivalMt Tendon UTS: P" c:orrect.a to mini_F...(min.).. x (min.F",@R c 4WF N of Speci.....)Fo, foi Iv,e Olonlll,,"' Po"" I,*0.829 TA8lE 3.3-13:'-*Summarv Analysis of Series 82 Test Results.FIG.3.3-20: Test setup for the two tests in Series 82.58-72 FIG.3.3-22: Test 82-2 Data 29 i t:-1.i"/8':::' -..I ,**-.I*.....': ,:;.ULTIMATE LOAO TESTS-PROTOTYPE ANCHORAGE COMPONENTS COMPONENT DATA FIG.3.3-24: Test C2-1 Data OESCRIPTION 6" 0.0.Th",od-TEST.....;7 TEST OATE-z MAy:'7 SERIES C-I ULTIMATE LOAO TESTS-PROTOTYPE ANCHORAGE COMPONENTS 1 SERIES C"1.-1-TEST 8 TEST DATE'2.MAY"7 i OeSCRIPTION 6" 0.0.Thr_-"v"TI4....,r S,,';'N1S\COMPONENT DATA I SERIAL HARDNESS I UTS rf'COMPONENT NAME\NUMIlER SCALE I READING-j (lui)Wash., (Solid)011-i2£.IS 1,'1/1.tlj Wash., Nvl---"..3 IZ I 4,.S....--T I ([I From Fig.3.2-<>>--._.-.-where: I mOICTEO F.AILURi LOAW-----_.-..-...,*27.92 oq.I".1 P:*F..x..., (.!.!.!.:.!.- k...1.1-k-r-" 25.38 F..,*25.38 F,.r""":robl.3.2-2;'.x A..'" 8.79 F...8.79 x--"-6-A...3.42 oq.in.p'*p;+* F_," 2.57 F.....)F....from FIg.3.2-{)TEST PROCEDURE Pr.laod 10 appro.i.....,.ly 400 Ieipo;Retum to zero;I Meature gap betw....co"""",..." ond PU"cft;I EUnli".Ilam A,eo (A.)..3 x 212.65*637.95",.I".I I.OAD OATA i TEST GAUGE'Tl TRAN SDUCE R'I'1 READING LOAOrf'ADX-38 I LOADQ)I (pai)(kips)READING (kips)REMARKS I".",jed Actu I P,.lood.Gap..in. 1-;:01./17 Ise..1/91 4", 3'" 1/88'Z6 toO 171,178S'37 f>..'Z'3'1,.e...71S-?385" J 3"""1.78'1.93, 9:S"4-<:.....'Z.'3S"'leo 1,S"Z1 s'H',,/z'1!! - p"= !J,I!!/lJltio# a'/:;A4JdJ6 I---NIt", CD Hydraulic T.t Gauge and Hyd.....lic Tronociucer pi...AOX Oi;'tal R.adaut I gi_redurtdaftt _,_, of It.._I...I<6'Load*T.t Gauge ll.eading)(0.638Load*AOX-38 lleaIii"9)(3 I SERIAL T HARDNESS!UTS'1'I COMPONENT NAME I NUMBER j SCALE I READING i ('<Ii)'Nrnner (Solid)I""'" I:2<.i 4:." I//:" Wosner Nut_...IS-1/2 I 41.7 (4.4-')II r I ([I From Fig.3.2-{)--whe,.: PREDICTED F.AILURE LOAO-A,..27.92 oq.;".P:..F**".'r...," 25.38 F..,..25.38 x 114.4.. k r" 1 I--F**f",m Tabl.3.2-2 P-',.F...x A'r'" 8.79 Ft**8.79 x..-e-A....3.42 oq.i".-- P'.p;+p-".F....2.57 F**...)F....f""" Fig.3.2-<>>TEST PROCEDURE Pr.load 10 app,o.imal.ly 400 Ieips;Retum to zero: Mecnu,.gap betw....com"""..." and puno:h;Eff.o:li". Ram Areo (A.)*3x 212.65*637.95 oq.I"*LOAD DATA TEST GAUGE')'TRANSDUCER'I' READING LOAOI2'AOX-38 LOAD(i)i (pai)(kips)READING (kips)REMARKS In ended Aclu I Pr.load.Gap.in*"l80::'-:,$'1.0.11$:65/8 (,0 1187 4**1,$'1I*o S"'Z.SDQ 178<......':15 1785"..!74o'1.:08&9#_71S-4-140'2'-4-1 1:1027"15 4...... 17$'"'7..'Z.11" - j"HCJlUZ.P"" h"l'l.'t.) 4....enAi6...... I.JI(Not..CD Hydraulic T.t Gauge and Hyd.....llc T....,..;ucel' pM AOX Digita'R.adaut give rwdundant__t of It..10_I...Load*T.t Gauge ll.eading X 0.638Load*ADX*38 ll.eading X 3 The test setup is shown schematically in Fig.3.3-23, and test procedures were similar to those described for Series 81.As shown in Table 3.3-13, the mlntmum equivalent tendon ultimate which would be expected from the statistical analysis of test results would be 2812.7.For reasons set forth in Section 3.3.6, this value should be reduced to give: P T (min.)=0.964 x 2812.7=2711.4 kips.This is 1.10 times greater than theimum strength of 2472.6 required by the basic acceptance criteria.By comparing the values of X for P T (min.)as given for Series 81 and 82, we can see that the use of split shims gives a 7%increase in equivalent ultimate strength, contrary to pre-test expectations_ Comparision of Fig.3.3-20 to 3.3-14 shows that, without shims, the moment arm is greater resulting in higher flexural stress which would reduce the ultimate load of the washer without shims due to the effect of combined shear and tension stresses.The components after being tested tomate were the same as shown in Fig.3.3-18 and 19.FIG.3.3-23: Test setup for the three tests in Series C2.3.3.8 TEST SERIES C2*6 INCH THREAD WITHOUT SHIMS Series C2 is reported out of sequence, that is before Series C 1, in order that C2 results and analysis may be used in analizing Series C1.For the same reasons discussed in Section 3.3.7.the assembly of a Washer and Washer Nut would normally be used in conjunction with split shims.Test data for each of the three Series C2 tests are shown separately in Figs.3.3-24 through 26.Summary and analysis of test results is contained in Table 3.3-14 which also shows the method used to calculate tabulated values.The primary objective of Series C2 tests is to determine the ultimate shear capacity of the 6" 0.0.threadsisolated*from the effect of additional load capacity resulting froming on the split shims (P br).The secondary objective is to provide relevant data for condition where it might betageous to use a Washer-Washer Nut assembly without split shims on the fixed (non-stressing) end of a tendon.58-73 FIG.3.3-25: Test C2-2 Data 30 --ULTIMATE LOAD TESTS-PROTOTYPE ANCHORAGE COMPONENTS SERIES TESTTEST DATE'2""4"('" DESCRIPTION 6" 0.0.Thread-"/irNo",r S;.I"MS COMPONENT DATA SERIAL HARDNESS UTStf'COMPONENT NAME I NUMBER SCALE READING (kll) (Solid)C/J 2 L J.,." (loti." WOlher Nul-- 2..4...S-11/.Q<!'From Fig.3.2-6--_..where: PREDICTED FAILURE LOAD..-Ai*27.92 Iq.in.a F n X A, Ie,..1.1-le-,-" 25.38 F..,..25.38)(Flu from Tahl.3.2-2 p;,*F...X*8.79 F***8.79 X.-8-A".3.42 sq.in.----P'*P;..Po,* F....2.57 F..(llii...)F..*from Fig.3.2-6 TEST PROCEDURE Pr.load to approximately 400 leips;ReIVm to z.ro;Measure gop between co",ponents and punch;Effective Ram Area (A.)*3)(212.65*637.95....in.J LOAD DATA TEST GAUGE'D READING LOADI'2'ADX-38 LOAO@(pai)Geips)READING (kips)REMARKS In ended Ac:1v I Preload.Gap*in..11..0'2..../<J!'585'/89" II.,,, 4.1.-3"7 t//1/'2.800 178t...n!'178S" J7fo'Z.3'11-&..'%3115--""to"?If'."Z.74!' - fNliln.AlII 604,,*' P"..1('2.745") NoteIt CD Hydraulic r.t Gauge and Hydraulic TI'CINducer pM ADX DlgI.., Readout gi.,.Ndundant_,-, of the_.load.I t!t Load*T.t Gauge Readin, X 0.038<D Load*AOX-38 Readi", X 3*FIG.3.3-26: Test C2-3 Data I Colculoted Predicted Actuol Error Revi.ed Min.Equiv.Safety Test UTS (P;_.)UTS (pn LiTS (P")Notet3'!C, UTS (P;min)Factar I Desig.(J'(kips)*(2'(kips)(Ie ips)('!o)NoMt4'1(5')llciOiI Note l6'C2-1 3193.8 2903.5 2922-0.6 1.09 I 2784.1 1.39 C2-2 3098.9 2817.2 2930-3.8 1.06 2877.2 1.44 C2-3 3015.1 2741.0 2745-0.1 1.10 2770.4 1.38" 3 3 3 3 3 3 3 X 3102.6 2820.6 21165.7-1.5 1.08 2810.6 1.",0 a 73.00 66.38 85.39 1.64.017 47.45.026 v 2.35:.35 2.98 109.3 l.S7 1.69 1.87 X..30 3321.6 3019.7 3121.8-6.42 1.13 I 2952.9 1.48 i-30 2883.6 2621.*2609.5..3.42 1.03 I 2668.2 1.32 Not.: I.Calculated Shear UTS (P;" e)..F.u (acIVal)X Ai without us.of Sh_AupIVr.Foctor (Ie,_.).Fl.(octual)is the ultimote shear.trength baled Oft ClCtval value of R..A;" nominal shear orea*27.92 sq.in.2.Predict-ed Shear UTS (I';)..F.u (actual)x Ai/k,_..Ie,_.*1.1 fI'Ol'I palt testln, I of similar mechani_.3.Error..(Pi-P")I P".Ne9ative error indicotes COf'llPO'M"t il.tronger than j predicted. 4.Revi.edAupIVre Factar (Ie,_.)..p,_./p" S.Minimu", Equivalent UTS (P;min.)i. P" ,..,i.ed 10 FlU mi.,.PHlllln.). pt.)(F**(,...*IF.u (ClCtual)*p" x 100/F ou (octual).I 6.Safety Fact<<(S.F.)..P;(lIIin.V",in. guaronteed tendon U.S S.F....It;:",1", V I 2002.8 TABLE 3.3-14: Summary Analysis of Series C2 Test Results.8-74 31 As discussed in the analysis of Series 81 and 82.the X-3 a'Jalue for minimum equivalent UTS (P;'min.)represents the minimum strength expected in a population of Washer-Washer Nut assemblies as derived from a statistical analysis of test results, is based on nominal shear area and is corrected to the shear strength corresponding to the lowest value of Rc allowed by the quality assurance provisions established for the 2.0 Mep/170 W Post-Tensioning System.The value of-3 a for P" (min.)is shown to be 2668.2 kips which is 1.08 times the 2472.6 kips established as the minimum by the basic criteria for acceptance. The mean value of 1.08 for the revised Shear Rupture Factor (k r-s)is quite close to k r=1.1 used in pre-dicting UTS.Photos of components after being tested in failure are shown in Fig's.3.3-27 and 28._..-....-...-....------...-.-*..._...t._....----: FIG.3.3-27: Outerfaceof Washer Serial No.010 and Washer Nut Serial No.005 after being loaded to ultimate in Test C2-1.FIG.3.3-28: Inner face of components shown in Fig.3.3-27.80th photos are typical for Series C2 components after failure. ULTiMATE LOAD TESTS-PROTOTYPE ANCHORAGE C.OMPONENTS in.SERIAL I HARDNESS I UTS If'NUMBER I SCALE I READING, (lui)o 1 4.i,.z<I4/.*I (:!," Z" 7'7 I TRANSDUCEil'f" A;'" 27.97 sq.in.25.38.//3.*. k,=i.l F,u from Tobl.J.2-2 8.79.=A" 2 3.42 sq.in.- F_," 2.57 Ft.(,hims)F,.from Fig.3.2-6 ADX-38 lOADQ)READING o.ips)REMARKS<JJ.111'Z77S ie,,, 11045'Intended I Actvql I Preload.Gop*.1::8 I 6" 0.0.Threod-,;,.,....S'..,..\!Hydraulic Test Gauge and Hyd;;;fic Trorwducar plw..,OX Oigital give rWund....t..-.-'of tN..._Ioad.(6\L.ood*Tet'Gauge R.oding l(0.638 Q)L.ood*AOX-38 R.oding l(3 (/-I TEST_4-TESTDATE I M4"f.1 P";4'10" f COMPONENT NAI<i'C ,Not.1 CD I Test setup for the two tests of Series C1.TEST SERIES C1-61NCH THREAD W!TH SHIMS FIG.3.3-29: The test setup for Series C1 is shown in Fig.3.3-29.Test procedures were similar to those previously described. Data lor the two tests of SeriesC1 is contained in F ig r s.3.3-30 and 31;and a summary analysis of the data is contained in Table 3.3-15.3.3.9 FIG.3.3-30: Test C1-'Data ULTIMATE lOAD TESTS-PROTOTYPE ANCHORAGE COMPONENTS SERIES C I-'1..TEST I a TEST DATE.3 Nt.4....." 7 in.wner.: A;'" 27.97 sq.in.k,=1.1 F,u (rom Table 3.2-2 A..-3.42 sq.in.F_==2.57 Fl.(Jhims)Ft.'" from F;9.3.2-6 I:Z<.I 41.a!II?'" i k?", I...1.0 1111." I i2/f I I 7"." Preload.c..p ,," SERIAL NUM8ER 25.38*'" COMPONENT NAI<i'C'flosher Nvt_p'*DESCRIPTION _6:..'_'--=[.;.;"'..;.1;;.;.:.' I i I HARDNeSS I UTS'f'1 I SCALE!READING I (ksi)-COMPONENT DATA Q;Fro", Fig.J.2-6'PREOICTED FAILURE lOAD P;:: F..:, A;==25.38 F..'" p..:: F.....A"'" 8.79 Ft**I TEST PROCEDURE Preload to opproximately 400 Return to z.ro;I......asur.gap betwe.n compon..." and puncn;p;.2810.4'F,u(acI'Jol)/I09 Effectiv.MmAreo(A.). 3.212.65=637.9Ssq.in...:.PredicNd Bear.";UTSF.....xAC..'t Ft.Jor shims)If A..'n P\.,., C......,.r at 2.57, lIl..-fore P"*C F..(for ,hi...)*A".2.57 Flo*3.*2 I ilOAC OATA 3.pt.p;...'.I'*.Error s (P'_P")/P" TEST GAUGE'T'I TRANSDUCER(j'\ I I READING I lOAD:'j'I....DX-38 I LOADQ)5.!lavi....U85__'OI1.(C..)-(P"-P;)/3.*2 t F**((a<,hi...).....r.A...3.*2 sq.in.I'(;si)o.ips).EADING o.ips)REMARKS o.See dilcuuiOtt in text.7 Sof F (5 F'P: (l/"OO2 8 I I I loteoded I Actudl__...;;,;c.c:;

..:..._--.,;.,..:.m:...i":""';':"':.::""'::""'-- ---J."1(,.I (;1...i i_"5',$",;5 TABLE 3.3-15: SUlTTT1ary Analysis of Series C1 Te5t Results.l'La'Ii 4**!.3'1..1 118;-:.,;IBc6 I 1 S1"i i7/J 8 I Predicted UTS (1.i,.)Actual II Error Qevised Min.E.C;'.Jiv.! Sof...,.T...Shea'(Pj)Bearing (p;.)Total (P')UTS (P"l No**or C..UTS (P; Facto<I Oesig.Not.T No**T Note d: (kips)I (%)Na,.j 1'-(kips)i No..t Cl-I 2913.7 562.4 3.76.3 3378!*2 91 2.12 3231 1 I 1.41 Cl-2 2913.7 415.3 3529.0 3S41-0.90 2.70 1.47" 2 I22 2 2 2 2 I 2%2913.7 589.0 3502.4 I:w,95 1.01 2.41 3288.4 1.'-'a 0 26.35 26.35 91.5 1.905 0.29 575S I 0030 v 00.75 2.'-IS.01 12.03 1.75 I.al I.3<2913.7 468.0 3581.7 37-44.0 4.72 3.28 1.73%3<2913.7 509.9 I 3423.4 3195.0-*.71 1.54 3116.0 15S No..: 1 Predicted Snear UTS (Pj)i, based on**peri.,.c.9"ined from Series C2.Therefor**Pi.X for P;(min.)from Table 3.3..1.-,he ratio of F'N (acrvai)to F'\I (min.)rwh4r.;:,1min.I=109 kai, 58-75 FIG.3.3-31: 32 Test C1-2 Data Series C1 tests allow analysis of the total ultimate strength (PT)of an assembly of Washer-Washer Nut bearing on Split Shims, but, taken alone, give no information as to the relative ,Jortion of the total load taken by either shear in the 6" threadsor by bearing on the shims (Pt,r).When compared tosults of Series C2, Series C1 allows the qualitative conclusion that shims increase the total load capacity (a conclusion further substantiated by design analysis)but still provide no accurate determination of the interaction between shear and bearing loads.If we assume that the ultimate shear strength of the 6" threads has been setablished by Series C2 at 2810.6 kips (the X value of P;'(min.)at F su=109 ksi per Table 3.3*14,then this value can be corrected to F su (acutal)for the components tested in Series C1 and plugged forin Table 3.3-15.Continuing from this first premise, we can then assume that the actual ultimate bearing load (P't,r)is the difference between actual total load (P")andThe above premise is not precise since actual shear ultimate for Series C1 is not necessarily the same as that established for Series C2.Still, there appears to be no better approach based on a limited series of tests and the error in conclusions so derived will be small.No real significance, how*ever, should be attached to the actual numerical value of the Ultimate Bearing Strength Constant (C br)derived from this analysis.It can be seen from Table 3.3*15 that the variance of test results, as measured by the coefficient of variation (v), is only 2.64%, a small value which gives a relatively high confidence in the values for total load (PT).The mean value for C br of 2.41 is close to the approximate value of 2.57 arrived at in the design analysis of Section 3.2.6, which gives reasonable confidence in*.* t FIG.3.3-32: Outer face of Washer Serial No.014, Washer Nut Serial No.008 and Split Shims after being loaded to ultimate as an assembly in test C1*1.the design approach.However variance is relatively high (v=12.03%)and in future designs of similar mechanisms, a value C br=2.0 would seem both reasonable and conservative. The value for P T (min.)is derived from correcting the valuesand Pt,r to minimum values of F u allowed by qualityance procedures. Thus, corrected=xF su (actual)/F su (min.), and correct Pt,r=corrected C br x F tu (min.)for shim material xIn accordance with this procedure, P;'(min.)for each test of SeriesC1 becomes: P;'(min)=[2913.7xF su (actual)/109j +[C br x F tu (min.)x 3.42]As an example, for test C1*1 PT(min.)=(2913.7 x 109/113)+(2.12 x 58 x 3.42)=3231.1 kips We then arrive at P T (min.)for the system at X-3 a or 3116.0 kips which is 1.26 times the minimum value of 2472.6 per basic acceptance criteria.Numerical values derived above cannot be considered accurate as they are based on assumptions of ques*tionable quantitiative accuracy.This is of no concern as the 6 inch thread with shims is not the critical failure mode in any event.Photos of the components after being tested to failure are shown in Fig's.3.3-32 and 33.Due to the relative magnitudes of the ultimate thread shear forceand the ultimate bearing load on the split shims (Pt,r), it can be assumed that the shim bearing failure which is clearly shown in Fig.3.3-32 did not occur until after thread shear failure.-..-.---"r--FIG.3.3-33: Inner face of components shown in Fig.3.3-32 Note that inner face of Washer*Washer Nut assembly bears on outer face of Split Shims.S8-76 33.'.. 0-'\/" 0":':' 3.3.10 ANALYSIS OF FAILURE MODE FROM TESTS A summary of failure loads for each mode of failure, based on Series Band C test results, is contained in Table 3.3-16.Failure load of the split shims at either the Bearing Plate or the more critical Composite Washer interface was not determined, but it must be in excess of the 3561 kip maximum load applied during the ten tests and must be due to bearing failure which is not a critical mode.Wire hole web shear is shown to be slightly more critical than shear at the 6 inch diameter threads.Failure loads shown in Table 3.3-16 for both Wire Hole Web Shear and 6" Threads (with shims)are mean\/alues.As compared with the 6 inch threads of the same form, the 9-3/8 inch threads are subjected to a temporary load only, are unloaded in the structural condition, are subject to a maximum load which is 20%less and have a nominal area which is 57%greater.This thread is obviously not critical and was not tested.To provide uniformity in dimensions (to facilitate inspection, shipping, field procedures etc.)it was decided to increase the thickness of both the Composite Washer and the Washer from 3*3/4 inches to 4 inches matching the required thickness of the Washer Nut.This increased thickness will provide additional strength for both the Wire Hole Web Shear and the 6 inch Thread Shear failure modes of production components. The increased strength, computed by linear increase of prototype component test results is shown in Fig.3.3-16.The increased load capacity is not required for conformance to design or acceptance criteria and will not substantially increase theure load for other (non-critical) modes of failure.It should be noted that, by the time all test Series werepleted, several specific components had been loaded several times to loads greater than the minimum guaranteed ultimate tendon strength of 2002.8 kips.As part of the overall test program, loads2002.8 kips were applied five times to Washer-Serial No.002, seven times to Washer Nut-Serial No.004, nine times to Composite Washer-Serial No.007, and several times to other components. While this number of cycles cannot be considered a fatigue test, the applied load is considerably higher than will ever be applied in the structure, and the number 58-77 34 of times which many components withstood actual tendonmate, without failure, gives increased confidence in the basic criteria that the end anchorage be stronger than the tendon wh ich it anchors.3.3.11

SUMMARY

CONCLUSIONS The average error of predicted ultimate loads was-0.61%, varying from-4.0 to+4.5 maximum error;therefore, it may be concluded that the design methods used are quite accurate and gi'Je predictable results.The coefficient of variation of test results is small, having a mean value of 1.974%and varying between a low of 0.45%to a high of 2.98%, indicating that the combined effect oftype production variables and testing variables is insignificant, therefore it may be concluded that both production methods and test procedures were satisfactory. All test results were over acceptance minimums based onservative basic critera;therefore it may be concluded that the end anchorage hardware as designed and tested will not be the weakest link in the tendon system.Foilu,e"""""e a"ori"9 Plate-Split Shim Interface>3561 Split Shim-Compotite Washer Interface>3561 Wire Hole Web Shear 3062 6" Threads (with shims)3289 3542 TABLE 3.3-16: Summary of failure mode, type of failure and failure load for both prototype and production end anchorage hardware, based on Series Band C tests.Summary is for an anchorage consisting of a bearing plate, split shims, and a composite washer (or a washer-washer nut assembly l. Page 5B-78 Gulf General A"'ornic Incorpora**d TESTING LARGE TENDONS FOR A NUCLEAR REACTOR VESSEL by T.E.Northup, G.S.Cho\y, and J.F.Hildebrand December 27, 1968 GA-9155 LEGAL NOTICE This report was prepared as an account of Government sponsored work.Neither the United States, nor the Commission, nor any person acting on behalf of the Commission: A.Makes any warranty or representation, expressed or implied.with respect to the accuracy, completeness, or usefulness of the information contained in this report, or that the use of any information, apparatus, method, or process disclosed in this report may not infringe privately owned rights: or B.Assumes any liabilities with respect to the use of, or for damages resulting from the use of any information, apparatus, method, or process disclosed in this report.As used in the above,"person acting on behalf of the Commission" includes anyployee or contractor of the Commission, or employee of such contractor, to the extent that such employee or contractor of the Commission, or employee of such contractor prepares, disseminates, or provides access to, any information pursuant to hisment or contract with the CommiSSion, or his employment with such contractor. Page 5B-79 1..J\I'-'./;:;;..:.:. Gulf General A1"ornic Incorpora't.d P.O.Box 608.San Diego.California 92112 TESTING LARGE TENDONS FOR A NUCLEAR REACfOR VESSEL by T.E.Northup, G.S.Chow, and].F.Hildebrand Work supported by U.S.Atomic Energy Commission, Contract AT(04-3)-633.Gulf General Atomic Project 901 Page 5B-80 GA-9155 December 27, 1968-: I!'l l!:lo::.. ABSTRACT Prestressing tendons with a minimUm guaranteed ultimate tensile strength (GUTS)of 1000 tons have been sucessfully developed for use on the first prestressed concrete reactor vessel (PCRV)being constructed in the U.S.Measured values for modulus of elasticity, yield and ultimate strength, friction, and short-term relaxation, for both straight and curved tendons, are presented. Short-term relaxation tests on long tendons made with stress-relieved Wll'e show significantly higher relaxation losses than tendons made with low-relaxation Wire.A cyclic test on a large curved tendon had no effect on the ultimate capacity of the system.A tendon corrosion-protection system, and various corrosion-and radiation-test results obtained to est.ablish the adequacy of the system, are presented. Page SB-81 11 Page 5B-82 APPENDIX TO CHAPTER 3 TECHNICAL REPORT NUMBER 8{.. //.r::;.:.: -CONTENTS INTRODUCTION .TENDON SYSTEM RESEARCH AND DEVELOPMENT SCOPE TEST FACILITY TEST PROGRAM AND RESULTS STRESS-STRAIN BEHAVIOR CYCLIC-LOAD EFFECT FRICTION..RELAXATION CORROSION PROTECTION .CONCLUSIONS...ACKNOWLEDGMENT. .FIGURES 1 3 7 7 10 10 16 16 18 21 23 24 l.Tendon end-anchor assembly arrangement 4 2.Partially fabricated coiled tendon 5 3.1000-ton tendon prestressing jack 6 4.Prestressing system research and development test bed 8 5.Typical tendon tube splice 9 6.Prestressing system test-bed facility 11 7.Tendon stress-strain curve.12 8.Typical coefficient-of-friction curves.17 9.Tendon relaxation test data.20 iii Page 5B-83----------------------_._------,.._----_._..,// TABLES 1.Prestressing systems used on PCRVs....2 2.Summary of prestressing tendon mechanical tests.13 3.Summary of tendon wire-corrosion tests........14 4.Coefficient of friction measured along the curved tendons at various degrees of turn..................... 19 Page 5B-84 iv TESTING LARGE TENDONS FOR A NUCLEAR REACTOR VESSEL a By Tharold E.Northup,l Fellow ASCE, George S.Chow,2 and John F.Hildebrand 3 INTRODUCTION Several prestressing systems have been used successfully on PCR Vs built in France and England.The capacity of the different tendons has ranged from 146 tons for the EDF-3 vessel to 2460 tons for the Marcoule G-2 and G-3 vessels.The capacity of all systems used to date is shown in Table 1.The prestressing systems shown in Table 1 were either being tested or developed for nuclear reactor vessel application when the Fort St.Vrain vessel was being designed for the Public Service Company of Colorado by Gulf General Atomic Incorporated. This PCRV will contain the entire primary system for a 330"MW(e)high-temperature gas-cooled reactor (HTGR)near Platteville, Colorado, under the AEC power-reactor demonstration program.A single tendon, with an ultimate capacity of 1000 tons ("tons" refers to short tons in this report)was judged to produce the lowest capital cost in-place prestressing system.Lower-capacity tendons of similar design were also judged to apresented at the February.3-7, 1969, ASCE Conference at New Orleans, La.1 Mgr.Struct.Engrg.Br., Gulf General Atomic Incorporated, San Diego, Calif.2Struct.Engrg., Gulf General Atomic Incorporated, San Diego, Calif.3 Sta ff Metallurgical Engr., Gulf General Atomic Incorporated, SanDiego,Calif. Page 5B-85 1 TABLE I.-PRESTRESSING SYSTEMS USED ON PCRVs a Ultimate Capacity, System in tons Type Marcowe G-2 2460 Special design, multiple wires Marcoule G-3 Oldbury 273 Freyssinet, multiple 7-wire strands Wylfa 820 Freyssinet, multiple 7-wire strands Dungeness B 1020 BBRV, multiple wires EDF-3 146 SEEE, single 61-wke strand St.Laurent I 325 SEEE, multiple 7-wire strands aTaken from"Prestressed Concrete in Nuclear Pressure Vessels-A Critical Review of Current Literature," by Chen Pang Tan, Oak Ridge National Laboratory Report ORNL-4227, dated May 1, 1968.Page 5B-86 2 -be feasible.All cost evaluations included the expected research and development costs associated with each system.The research and development programs were necessary to demonstrate the efficiency of the selected prestressing system.The development of anchor hardware and tendon fabrication, installation, and stressing equipment was contracted to Western Concrete Structures, Incorporated, Gardena, California, and is not reported in this paper.This paper summarizes the development of system data for use in the PCR V design.TENDON SYSTEM The prestressing system selected consists of up to one-hundred and seventy 1/4-in.-diam high-strength wires with stressing washer assemblies at each end to support the buttonheaded wire anchorages. This system.manufactured by Western Concrete, is similar to the BBR V system used on the Dungeness B vessel (Table 1).A schematic view of the 1000-ton tendon anchor assembly as it will appear on the PCR V is shown in Fig.1.The covers shown protect the tendon from corrosion and mechanical damage.The system 1S partially shop-fabricated from straight wires with one end-anchor assembly attached.Each tendon consists of two concentric bundles of counter-twisting wire.The counter-twisting effect prevents the wrres from unravelling and minimizes the variation of wire lengths in a curved tendon.All wires of the tendon are coated, bound, and coiled for shipment to the site.A coiled test tendon is shown in Fig.2.The partially fabricated tendons are pulled through tendon tubes embedded m the PCR V and each wire is then threaded through the second anchor assembly and buttonheaded. Prestressing is accomplished with high-capacity jacks from both ends on curved tendons and from one end on straight tendons.The high-capacity jacks developed for the lOOO-ton tendons are shown in Fig.3.3 Page 5B-87 BEARING PLATE 20-1/2 x 3-3/4 X 20*1/2 IN.\)CONCRETE j/(/ANCHOR --J-l 16 IN.OIAM ANCHOR ASSEMBLY COVER LC69383 FIG.1.-TENDON END-ANCHOR ASSEMBLY ARRANGEMENT 4 Page 5B-88 Ur'lX41 C-1 -..135-77-1 FIG.2.-PARTIALLY FABRICATED COILED TENDON Page 5B-89 5-,-:',-..l/I::;;' FlG.3.-1000-TON TENDON PRESTRESSlNG JACK 6*Page 5B-90 l...::**'l)A!t:-1 I,','r...::'l 1--RESEARCH AND DEVELOPMENT SCOPE The prestressing system was tested by GGA to determine: (1)modulus of elasticity, (2)friction, (3)yield strength, (4)ultimate strength, (5)cyclic load effect, (6)short-term relaxation, and (7)corrosion protection. TEST FACILITY The facility for testing full-size tendons in their expected environment and load conditions is shown in Fig.4.The test bed consists of a 90-ft-long straight test section and variable curved test sections with maximum radius of 16 ft and minimum radius of 10ft.These dimensions provide the full range of vertical tendon lengths and horizontal curves required by the Fort St.Vrain vessel.The straight part of the test bed contains five tubes.The center tube (No.5)is 7 in.OD throughout its 90-ft length.The outer four tubes (Nos.1 through 4)are 4-1/2 in.OD with temperature regulation for relaxation tests at temperatures from ambient up to 150 F.The semicircular portion of the test bed permits testing a variety of curved tendons.Each curved tendon-tube can be removed and replaced as required.This feature enables several friction-reducing or corrosion-protection materials to be investigated, starting with clean tubes for each test phase.Provisions for measuring the tendon tangential shear force and radial force at several points around the 180 0 curves are also provided.The two smaller curved (No.9 with 10-ft radius and No.8 with 16-£t radius)tendons are truly semicircular. These short tendons simulate the range of curvature of the crosshead tendons of the Fort St.Vrain vessel.The longer curved tubes (Nos.6 and 7)are a series of flat-curved sections with the radius of the curved sections being 16 ft maximum.These tendons simulate the circumferential wall tendons of the Fort St.Vrain vessel.All tubes are ASTM A-513, Grade 1010 HREW, having splice details as shown typically in Fig.5.Page SB-91 7 U;--'!';;;il \::-1?/S:.:: CURVED TENDONS SIMULATE CURVATURES OF" CROSS-HEAD TENDONS ON PSC PCRV STRAIGHT TENDON SIMULATES VERTICAL TENDONS ON PSC PCRV TYPI CAL TENDON TUBE NUMBER 1 LOAD CElL 3 LC69382 HYDRAULIC HEATING LINES FIG.4.-PRESTRESSING SYSTEM RESEARCH AND DEVELOPMENT TEST BED 8 Page SB-92 r-3 IN'----I .....----------....._-------..

5 IN.00 X 0.180 IN.WALL II II II II II III II 1'1 II II II II III 1------------4-1/2 IN.00 X 0.109 IN.WALL LC71375 FIG.5.-TYPICAL TENDON TUBE SPLICE 9 Page SB-93 The completed test facility is shown in Fig.6.The dimensional changes of this bed were measured with Invar rods.Tendons were heated by flowing oil into small tubes attached to the outside of the embedded tendon tubes.Jack pressure, tendon force, and tendon elongation measurements were also made.TEST PROGRAM AND RESULTS The tendon system test program was started with ASTM A-421 stress-relieved Wlre.After the initial high results on tendon relaxations at ambient temperature were obtained, the program was reoriented to use only Thermalized (trademark of Richard Johnson and Nephew, Ltd., Manchester, England)wire because of its low relaxation property.Thermalized wire meets the requirements of ASTM A-421, including a minimum GUTS of 240,000 psi.Table 2 summarizes the physical tests performed on the tendon system.Test parameters, including test type, number, duration, tendon makeup, and material, are given.Table 3 summarizes the corrosion tests performed to establish the adequacy of the corrosion-protection system selected for the tendon system.Further discussion of these tables is given later.STRESS-STRAIN BEHAVIOR A typical stress-strain curve for a full-size straight tendon is shown in Fig.7.The tendon system exhibits good ductility.

The initial individual wire failures have an insigificant effect on the ultimate capacity of the tendon.The yield strength of the tendon system at 1%elongation meets the requirement of not being less than 75%of the minimum ultimate strength.An ultimate strain at failure of greater than 4%provides considerable reserve above the 1 to 1.5%predicted maximum capability required by peR v designers. 10 Page 5B-94 ,,.....::,/" r o'::'-::--: K53837 FIG.6.-PRESTRESSING SYSTEM TEST-BED FACILITY 11 Page 5B-95 ELONGAT ION (%)0 2 3 4 5 NO.OF FAILED WIRES MAX LOAD=2048 KIPS 2200 AT 4.35%ELONG 2000 250,000I 1800 2,3-200,000 V')1600 STRENGTH AT 4 0..d I 1%ELONG a 1780 KIPS-1400 5 V')I 0..0 1200?6,7,8 150,000<t==28.3 X 10 6 PSI V')0 V E V')..J 1000a: 800 100,000 t-V')600?400 P STRAIGHT TENDON-168 0.25-IN.WIRES 50,000 200 GAGE LENGTH-99 FT 0 IN.0 0°10 20 30 40 SO 60 ELONGATION (IN.)LC71374 FIG.7.-TENOON STRESS-STRAIN CURVE 12 Page 5B-96 ""dOQ CD VI tJ:l I\0'-J c: "1"[:;,:1':-n-......0: f<......w))TilLE 2.-5UHHAll.Y OF PRESTRESSING TENDON HECHANlCAL TESTS Length INUlIIber of Wire%Elongation MaximUlll of E, HodullUl of Te.t Tendon Lubricant at Maximum Load, Wire.Elasticity. Type NUlllber (ft-in.)Shape a Wires Haterial Tendon Load 1n kips Failed 10'pai Ten.illning Detena10nina II..U 98-11 Straipt 168 Stre**-relieved 2075 7 27.4 I--4.13---...51 99-0 Straight 168 Stres.-re1ieved -_.-4.35 2048 8 28.3------...-4 SC 99-0 Straight 168 Strus-reUeved ---3.90 2050 9 28.4---;;I*61 Curved 168 Stre.s-reUeved No-Ox-Id-ot 2.30 1963 25---0.138 0.165..61 99-6 1/2 Curved 168 Stress-reUeved 23.9 b0.1360.190 !No-Ox-Id-ot 2.06 1900 15..6C 100-0 Curved 168 Streas-reUeved No-Ox-Id-ot 2.84 1970 38 24.8 b 0.150 0.172.-4+ParafUn;;I'U 168 Stres.-relieved 1966 8 25.2 b 0.135 0.169 q SA 70-4 Curved No-Oll-Id-;:H 2.82 g 81 70-4 Curved 168 Stresa-reUeved NO-oll-Id-QI

25.2 b 0.145 0.164...25.1 b..91 51-6 Curved 168 Stre.s-reUeved No-ox-Id-at 2.80 1962 18 0.154 0.169 0 23.9 b...91 51-6 Curved 163 Stress-reUr-ved No-Ox-Id-CH 2.84 1970 15 0.146 0.164....ge 51-6 Curved 168 The rlllalhed No-Ox-Xd-SOO

2035 15--.0.187-+Ho-ox-Id-CM Initial Test 1 aelallation Tut Teodoo Lenlth Wire Tempelrature.

Load.Tenlioninl a"UlIIber of 1n dearees Ouratioo Lo**c Type tlltaber (ft-io.)Sbape Wires Katerial in%GITeS 816tory Fahrenheit NOIIIinal in bour.at 1000 houn U 91-1 1/2 Straight 1S Stre.s-relieved 68 70 1st tensioninl 1180 10.5 68 70 2nd tendoninl 2690 3.4 120 70 3rd tendooiq 1130 4.4 1C 91-1 1/2 Straight 25 Thera&Uzed 120 70 lat tenaiooiol 10 progress 3.0 21 91-1 1/2 Straight 25 Stre.s-re1ieved 68.70 1.t tenaiooiol 1180 10.2&: 68 70 2nd Un.ioniaa 2690 6.2 0 120 70 3rd tenaioninl 10 prolrel*6.1.....*31 91-1 1/2 Straiaht 25 Strelll-reUeved 68 70 1st ten.ioninl 1180 9.8.-4 68 70 2nd ten..iODinl 2690 3.8.=68 70 3rd tenlioninl 1130 3.0 3C 91-1 1/2 Strailht 25 Theraa1hed 68 70 lat tenaioninl In prolre**0.7 41 91-1 1/2 Strailht 25 Stre**-reUeved 68 70 lat tenaioninl 1180 10.0 68 70 2nd tensionina II'prolres.3.8 8C 13-0 Curved 168 Ther..lhed 120 70 lat tensioninl In proares.2.2 a All 168-vire tendon.are aept1y sp1ra1led to equalize their 1enlth within the tendon.All tendona Include 180 0 of curvature. bApparent.odulua.cielaxatlon los.ia obtained a.%of initial load at anchor.)1--.....::r-TABU J.-SUMMAllY 0'TENDON WIllE'CORROSION TESTS i , TypeoCTeaI Purpoee Muerial Coacinl TeA CoadiIiou Gc...u catrOliaa ComIIioa eCCccc oaNoac u JoUa*coucaI No ro.oC teMile au........30-.110-, leui1e ptOpen_....enwiroftmenl

- poaun 30.uwl36S...."t...110.365 da"..t....u.t_Gc-ucomaoi

...Proceccioa b"A_......1t uJollac....w lIoch pro"" 10_ptoceePoa. p'-phace couiJltl.....(lad phoephacel cllYWOnmctd Meta lIoad rued__procecu............. t1WI AUlO.......132-4&y (ziac phoephacel I&,-are Gc-.lc-.ioa I'tocec1ioa b" Kap-'Kap'-c (Orpaic u jolla cou&al Coaced win clln'Oded. eqll;"alenl couia!by RjltN'i win phooplwe ual_all to bare wir., 30...., eKpo..... Proceelion by s-u...4 uJollacoutU No conoeion ai_2-y!NoCK*ld.cM win casinI fak enwil'onmenl Iltpoounl Gc..ue___Proceclion oC wireMetaa-l uJollacoutU Moderace ptoceelioa C..9O-<la" by coatinl.1 waC win ea_Ilt,-are GeMni eanoaioa Proceclio. by Meta"........Maca lIontl.Meta....1A jolla c.-.l........bpoeun continllinl. no lIoad win&ad R__nl 452_Dl.1 ..1 fail",n.161ftO G.Mn1 eatrOlia.Strna reluacio.t" su-eliewll 0Iauia bl.ck h 25_ire tendon (UI.bpowre at t_lila concinWnc' uwl conotion ptOleCliaa win 120 F,*.yr t_No cortOOioa.lIack obaened StnM r.1au&ion tnt NoCK*Id.cM 25......1.....(4.)bpooure aI_til.conciA......&ad eOllOliDa ptDIeCdoa win casinI iiUer No cOllOliDa.ttack 0.........Gc...u CanoIioa Su_r.1au&ion tnt"....u-l NoCK-ld.cM 25-win t.ndon (IC)b,-are&I tnl Pia Concinllin&. ...d conoaion ptoIecliaa wire casinI fak No cortOOioa.tlaCk GcMnl comuio.Sue.relaution teal 2S-wirc teadoa (JC)bpoiun.11..til.eoncin"",,..nd eorrotio.proaecaloa win casinl fdler No conoeion.llaCk 0__Gc-.l CamMllo.SI....r.laulion"......NoCK*1d.cM 16I-wire teadoa (IC)bpooure.t&eM aiI&conlinuia!. t....nde_lio......caaiA&fak No eorralioe.raack obtened Ce..uc--". lleuiAl plate n..-liMd No-OK*ld.cM SII........16I-wire1.....bpolUft al t...ile cOMinuiai. and corroeio.ptOcecllOll .....e.utl'l fillew No c_OIio.allaCk obMncd c...u camMIloa Sclectioa oC oftflU&n..n.Iiull AI*....win Oceu slai,...in..-w AI In.UPI r....hau ahiPPu.a_hod wire A2*Kap'-Ited A211*Nor_11.Utowrapped AI 14*LitI\I rUII ha..on 112.VPl*Heuiaa butlolWcoil burlap paper an41afla.0 112*Nor_113-VPI*Heuiaa A2 IJ*Nor....b",1ap papew an4_A21H*Nor..Heuaaa b",!.p ,.per IW*VPI*Hnaia. bwlappaper a-ft'ECfecl oCI*..,......No-01.ld.oc CoaI&d wire heW aI 120 , Film oC vu-c-.d wire o.IINCII" oC paM wire atiaa fl11 ew C..100 hr.u jolla.Clee 100 hr.1 t...pent.......,...No viaible ,..90 da".a-ft'ECfeccoCI.........NoCK.Id-CM Coaled wire heW all60'Film oC are-__win_CI.OD lIucil" oC paM win atiaafiller f..1000 lv.1A Jolla 1000 hr alC.mpenl.....Moderate.n......._ntal.K,..... proteerioft C..9o..la" up-" SeIC*halina Abilily oC.-coNoCK*Id.cM Hariaonw wire pnniaI1, Noo.wire.new 410 Co_bare wire wile cuinl filler cowred wilh paM!Ir in humid air.No eDrl'Oliaa heaced in h....w air.£cew 9O....y u jolla.s,........ HJdrotn HJ.....*mbri&&Ie-s-u...4 Meta IIond aM S...wned loeci&175,.,_slllYlftd J 12 hr wilhoul.nabriltle_ .._nl c....o b" WCS win...faiI_Macalloncl HJcIrosn Suae.plibilil"No..NoIched.,.... caa8aOo Speci_1lII'Iiwd 0.-200 Iw....onllle_..h".....n*..onn...wire cslIy clwpal ucl wilhoulfail_ ....111 oC wire...-ined.....a.dio!ylia Sa_I:zlieftIi NoCs*1d-CM lnadWed 4 (lOll r-.AIllpecilMu ouniwd es,-are.r-0*wire wire cui8&f.n.1.7 (10)17 nWl (>1.0 MeV)_embricde_ ICreAedPili..RadioI".2CCecI of irradiatedMeta.iIond plul All tpecinte.....",;...a espoeun...__wire.... cspooure 14 claya DO emonllle_4 (10)9 r....1.5 (101" nva t>1.0 MaV)-La jolla, c::.II'-ala It A_.................. Trade_oll..-iDMi a-prool e-apuy.C1ew1ull, Qhlo eKap'-t Trade_DC AMCHaM Produc..I....AtnW.*......,......4lUchut1joa-n ...Heph_. !naI-'eNooOK*ld.cM: Trade_DC prod_oC Denrt-a 0IeaIical Dhitiaa 01 W.1l.Gnu.0alap,1lIinoiI f W.._eo-.SINCIWa.GercUna.Cali£onaia rns.Su8lcripa....equall_ch c.lIIiIe wa-......hl!lecuo Paint Coapu".GercUna.c.Iilomin 14 Page 5B-98 Ui-'DA!t:-]. -Page 5B-99 It IS impossible to directly measure the modulus of elasticity for full-size curved tendons because of the variation in stress between the two anchor points.The effects of transverse load, ovaling of the tendon wire bundle, friction, and actual stress in each wire all make the determination of E, as shown in Table 2, approximate. The ultimate load of a tendon test specimen is reached only m the straight portion between the anchors for a straight tendon and in the first point of tangency for a curved tendon.Beyond the tangent point, friction reduces the tendon load.Therefore, the measured total elongation IS mainly influenced by the length of the straight portion.A meaningful test result interpretation is required to relate the measured ultimate load to the strain in the wires at the failure point.Since the wire failures always occur close to the tangent point within the curved part, it is valid to equate the measured failure load to the tendon load at the point of failure.The percent elongation at maximum curved tendon load is determined by averaging the percent elongations of the straight tendons (SA, SB, and SC)at the corresponding maximum curved tendon load.The percent elongation at maximum curved-tendon load is about one-half to two-thirds of that exhibited by straight tendons.The stress in each wire of a curved tendon depends upon the actual length of each wire.If the tendon wires are parallel, the inner wires of a curved tendon will project approximately 6 in.further than the outer wires at each anchor.To compensate for this, all curved test tendons were fabricated as follows: the ,center 80 wires were gradually twisted 10 turns clockwise while being greased and combed into position, the remaining outer\vires were then greased and combed into position, and finally the whole tendon was twisted four turns counterclockwise. This operation reduced the variation in wire projections at anchors to+/-3/4 in.Test tendon 6B (Table 2)was specially treated in an effort to further study wire-length variations. In this case, the wires were cut parallel to thebearingplate after insertion to remove the+/-3/4-in.variation. This operation, 1:...l}r*'l)At:-1// however, actually increased the Wire variation In total length and resulted in a lower*ultimate strain and strength for this tendon.As the result of these tests, the Fort St.Vrain counter-twisted tendon wires projecting through the stressing washer will be buttonheaded without field-cutting the wires.CYCLIC-LOAD EFFECf Tendon 9C was tested by cyclic loading 1000 times between a load range of 1275 kips and 1525 kips (i.e., 0.7 GUTS+/-15,000 psi)prior to the ultimate load test.The cycles and stress range are at least double those expected to occur in a PCRV.The jacks shown in Fig.3 were used to apply the cyclic load and thus also provide experience on jack reliability. FRICfION Coefficient-of. friction values were determined for all full-sized curved tendons after a series of tests were performed on small, 7-wire tendons.In this series of tests, the friction-reducing characteristics of various materials were considered along with their ability to provide corrosion protection for the wire.A petroleum-base compound containing microcrystalline wax, No-Ox-Id-CM, was selected for use on all of the full-size tendon tests.Friction values were determined by recording the load at one end of the tendon while jacking at the other.Friction coefficients were computed using an average wobble effect of K=0.00027.Typical friction coefficients determined during tensioning and detensioning are shown in Fig.8.The lower value obtained during tensioning is attributed to the fact that the tendon wires slid more freely during tensioning than detensioning because sHang friction is less than static friction.(Friction at tensioning resembles sliding friction and friction at detensioning resembles static friction.) A factor of 0.15 during tensioning is believed to be an adequate design value, but a value of 0.19 was used for the Fort St.Vrain design to allow for construction variables. 16 Page 5B-IOO i J.L-1000 r aaa a 7 I MIN I J.L=IMAX U" 800 a.I J.LaCl 600 f-z I UJ i Cl I<t I UJ 400 ,-Cl I-<t Cl<t 200 a...J 0 0 200 400 600 800 1000 1200 1400 1600 LOAD AT JACKING END (KIPS)LC71373 FIG.S.-TYPICAL COEFFICIENT-OF-FRICTION CURVES Page 5B-IOl 17---------------,--,- Coefficient-of-friction values determined along the curved tendons are shown in Table 4.Tube Nos.8 and 9 are completely circular and little variation in friction value occurs.Tube No.6 is made up of straight and curved sections with high values of friction occurring in the curved portions (60 0 and 150°).The average friction values determined by load cells are consistently higher than those determined along the curved segment.The addition of paraffin or No-Ox-Id-500 to No-Ox-Id-CM for lubricating tendons 6C and 9C did not reduce friction below values obtained using No-Ox-Id-CM alone.RELAXATION Relaxation tests require considerable time to accomplish if a basis for 30-yr predictions is expected to be established. Many relaxation tests on prestressing steel have been performed by others, extrapolating the lcng-term relaxation loss from a minimum of 1000-hr (approximately 42-day)test data.Relaxation tests on the test bed have ranged from 1000 hr to approximately 1 yr.The test results to date en Thermalized wire tendons indicated only a slight rate of change of relaxation loss between the period of 1000 hr and less than 1 yr.Relaxation loss was obtained as a percentage of initial prestress at anchor.Tendon loads were measured with spool-type load cells calibrated to+/-0.5%accuracy at rated load.Applied tendon loads and number of wires per tendon are shown in Table 2.Temperature of each tendon is maintained within+/-5 F of the stated values.Temperature-change adjustment was included in the test data.A comparison of load loss vs log time is shown in Fig.9 for straight tendons made up of stress-relieved and Thermalized wires.Only ambient-temperature tests were performed on stress-relieved wire units initiCllly stressed to 0.7 GUTS, and the results shown in Fig.9 as (68 F)S are the average of four 25-wire tendons.Retensioning after various periods of time reduced the relaxation of stress-relieved wire tendons to about one-third to two-thirds of its initial value as shown in 18 Page 5B-102 TABLE 4.-COEFFICIENT OF FRICTION MEASURED ALONG THE CURVED TENDONS AT VARIOUS DEGREES OF TURN Lubricant No-Ox-Id-CM plus paraffin No-ox-Id-CM Degree of turn Tube 6 Tube 8 Tube 9 10 0.142 a 0.146 a 30 0.109 a 50 0.126 a 60 0.176 a 90 0.133 a 120 0.107 a 130 0.127 a 150 0.147 a 170 0.132 a 0.12S a Mean 0.135 0.136 0.131 1 Std deviation+/-0.029+/-0.005+/-0.008 Avg values by load cells at anchors 0.150 0.140 0.150 acoefficients of friction are derived&om normal load and shear load measured along the curved tendons at various degrees of tum.Page 5B-I03*19c-1 l/81. 10,000 120 68 68 TEMP (F)1000 100III I 10 III I I 1 (68 F)S I(1 20_----I__--II...---\,.".-0, III ,\LEGEND NO.OF INITIAL LOAD WIRE MAT'L WIRES%GUTS (NOMINAL)THERMALIZED 25 70 o THERMAL I ZED 25 70*STRESS RELIEVED 25 70V')100 V')0-J Q 10<<t-o-J0.10 t 0.01 0.1 LOGTI ME (HRS)LCi1372 FIG.9.-TENDON RELAXATION TEST DATA Page SB-I04 20-..:1 4}**,1 ,.f' --Table 2.The test duration reported is related to the period following each tensioning operation. The percent relaxation reported at 1000 hr is also related to each tensioning operation. CORROSION PROTECfION The development of a satisfactory corrosion-protection system requires a broad knowledge of all the steps in the preparation and use of a prestressing system.This is essential since continuous corrosion protection must be provided on all tendon components from the point of manufacture to final installation. The total corrosion-protection system for the Fort St.Vrain prestressing tendons consists of the following: 1.The tendon wrre is coated with a zinc-phosphate (Meta Bond), which is then sealed with an oil film of Rustarest, both ot which are applied just after the Thermalizing process.2.The WIre coils, spiral-wrapped in VPI Hessian burlap paper, are shipped from England to point of fabrication in unsealed steel containers. 3.No-Ox-Id-CM is applied to the individual wires and anchor hardware during tendon fabrication. 4.Fabricated tendons are banded and placed in protective tendon racks for shipment and site storage.5.No-Ox-Id-CM is applied to the interior of the tendon tubes prior to tendon installation. 6.After tendun installation, the ends of each anchor assembly are covered with caps until the stressing operation is performed. These caps are 21 Page 5B-I05 removed for tendon stressing and t hen reinstalled after the anchor assembly is thoroughly coated with No-Ox-Id-CM. The tendon tube and end caps form a protective chamber for the prestressing tendons.The selection of this corrosion-protection system 1S based on the test program summarized in Table 3.The most significant results show that: 1.The strength loss and elongation loss on bare wire from corrosion was insignificant in wire after 1 yr of continuous coastal exposure.The wire samples exhibited fine scaling corrosion. 2.The zinc-phosphate coating (Meta Bond)produced no hydrogen embrittlement even at stress levels of 75%of the notched wire ultimate strength.Neither the coating nor cathodic charging caused failure of stressed wire.3.No-Ox-Id-CM is self-healing and does not uncover the wrre at 120 F, the maximum temperature expected to be experienced by PCR V tendons.4.Irradiation to levels recorded does not cause delayed failure of stressed and coated wire.5.Scress-corrosion cracking and hydrogen embrittlement have not caused failure of these wires, which have a pearlitic microstructure. Corrosion tests on full-size stressed tendons in the test bed (Fig.6)were performed to verify the adequacy of the protectants selected on the basis of the specimen tests summarized in Table 3.These tests are continuing and no signs of corrosive attack have appeared.22 Page 5B-I06//::3J. -CONCLUSIONS It is apparent from the test results that counter-tWIstIng of tendon wires is essential for large-capacity curved tendons.The counter-twisting effect prevents multiple tendon wires from unravelling after tendon fabrication and during tendon installation, and minimizes the total wire length variation. It is important that the wire bundle not be cut parallel to the bearing plate after curved tendon insertion. If the wire bundle is cut,a3 to 4%reduction of the tendon ultimate load capacity can be expected for tendon configurations described in this report.As expected from the curved tendon ultimate load tests, most of the WIre failures occurred in the curved segment close to the first point of tangency on the curve.This is the region where the simultaneous action of high-tensile, bending, and transverse stresses.localize as a result of the effects of friction and sudden change in curvature in the tendon profile.Thermalized wires used in this test program meet all the mechanical properties of ASTM A-421 wire.Thermalized wire is characterized by its low relaxation property.The relaxation loss for Thermalized wire tendon was only approximately 7%of the relaxation loss that was measured for the stress-relieved wire tendons tested under similar test conditions at 68 F after 1000 hr and after initial anchor load of 70%GUTS.The casing-filler material No-Ox-Id-CM provided dual functions in this test program.It was used for a friction-reducing agent and for corrosion protection of the tendon system.The No-Ox-Id-CM material is self-healing and does not uncover the wire at 120 F, which is the maximum temperature expected to be experienced by PCRV tendons.The self-healing effect of No-Ox-Id-CM permits tendons to be protected'hi.thout resorting to completely filling the tendon tubes with protectant. Page SB-I07 23//b:1. The 1000-ton prestressing system developed for the Fort St.Vrain PCR V has been subjected to service loads and environmental conditions far in excess of those required to satisfy design require*ments. Mechanical properties required by the design have been established by testing full-size tendons in configurations simulating those of the actual vessel.Tendon-relaxation values have been shown to be small for Therm:llized wire, and a complete corrosion-protection system has been developed to ensure tendon stability throughout the design life of a PCR V.ACKNOWLEDGMENT This work was supported by the U.S.Atomic Energy Commission under Contract AT(04-3)-633. 24 Page 5B-I08 Part E.Section 5B TRUMPLATE WELDING EFFECTS Page 5B-109...'-*:':'S\::.--/,/ Part E.TRUMPLATE WELDING EFFECTS Table of Contents Page#1.0 Introduction, Purpose, Summary Letter Report of J.Hildebrand SB-lll SB-112 Section 5B Page SB-IIO;;,/'O..!.. Part E.TRUMPLATE WELDING EFFECTS Introduction, Purpose, Summary A question had been raised regarding the integrity of the Three Mile Island bearing plate because of the possible weakening effect of flame cut or welded areas at normal environmental temperatures. In addition to actual low temperature testing covered within, it was requested we provide a professional opinion.Hildebrand's work with Gulf General Atomics on similar questions well qualifies his opinion and experience. There is no question in the author's mind that the proposed prestressing system will function properly.Section 5B Page SB-lll IE:-1? John F.Hildebrand 6124 Terryhill Drive La California 92037 27 October 1969 Inland-Ryerson Construction Products Co.Box 5532 Chicago, Illinois 60680 Attention: Mr.Wi II iam A.Corson Re: Bearing Plate Serviceability Gentlemen: Following recent discussions with Western Concrete Structures, I felt it was necessary to prepare a brief statement clarifying our position relative to the metallurgicalability of the bearing plates for the Three Mi Ie Island containment. Flame cutting the bearing plate and attaching the trumpet by welding are not expected to detrimentally affect the functionality of the prestressing system at normal environmental temperatures. A test program is in the final stages of preparation at this time to assess the effects of these fabrication procedures at an extreme low temperature. At normal temperatures it is-recognized that the mass of the bearing plate represents a substantial heat sink.As such-the mass acts to drastically quench steel heated locally above the transition temperature. Mi Id steels with 0.25%or more carbon may form zones of brittle martensite, but for the A36 plate in question, the low (less than 0.20/0)carbon precludes the formation of embrittl ing martensite. The microstructure of the plate is simply modified by zones of less desirable coarse grains and coarse pearlite..These microstructural variations are not likely to act as metallurgical notches.The sameditions are produced by both cuts and welds.If the welding procedure did cause cracks in the bearing piate, they would most likely follow the contour of the weld metalloase metal interface, that is within the hardened structure of the heat affected zone.In effect the weld bead would remain attached to the trumpet and leave a chamfer-shaped edge on the bearing plate.It Is true that branch cracks might form but their propagation depends on both the notch sensitivity of the plate and a high strain rate loading...,.I/:'0";: 58-112 --2-Inland-Ryerson Construction Products Co.27 October 1969 58-113 The Welding Handbook points out that almost all carbon steels are notch sensitive below a certain temperature or above a certain strain rate.The sensitivity of the steel varies considerably with the composition, thickness and rigidity of the structure; it is related to the general toughness of the steel or the ability to withstand impact or shock loads.In this regard the thickness of the bearing plates is a detriment, the composition isable (low carbon)and the rigidity of the structure is an asset.Since cupping of the bearing plate is resisted by the back-up concrete, the peripheral tensile stress at the edge of the hole is kept at a relatively low level.And finally, tendons and anchor hardware are a static system, not subject to impac..or high strain rate loadings.It is also important to point out that the weld holding the trumpet to the plate has two functions; 1)it maintains the axis of the trumpet perpendicular to the face of the bearing plate and 2)it prevents leakage of the grout/concrete during construction. Once the concrete has set, the weld has no further function;as an example, in one concrete structure, the plate is placed and grouted after the trumpets are embedded and the gap between the tube and plate are simply calked.By the way of demonstration that the proposed prestressing system wi II function properly at normal temperatures, several buildings and bridges using a similar system with simi lor materials, have been built during the past decade and none of these has experienced degradation such as cracking or failure of any of the components. Some of the bridges have also endured extremely low temperatures. Sincerely, Engineer JFH:ko-.."1'"1"".':)'::' WESTERN CONCRETE STRUCTURES, INC.LOW TEMPERA TU RE TEST SECTION 5B 5B-114 WESTERN CONCRETE STRUCTURES, INC.LOW TEMPERATURE TESTS TABLE OF CONTENTS.-SECTION TITLE PAGE

1.0 INTRODUCTION

AND

SUMMARY

5B-116 2.0 PURPOSE 5B-117 3.0 MATERIALS 5B-117 4.0 PREPARATION OF TEST SPECIMEN 5B-118 5.0 BEARING PLATE METALLURGICAL EVALUATION 5B-128 6.0 TEST PROCEDURE 5B-137 7.0 RESULTS 5B-141

8.0 CONCLUSION

S 5B-142 APPENDIX Al.O ANCHORAGE DETAILS AND PROPERTIES A2.0 MATERIAL TESTS AND EXAMINATIONS A3.0 TEST DATA SHEETS SECTION 5B 5B-115 WESTERN CONCRETE STRUCTURES, INC.LOW TEMPERATURE BEHAVIOR OF THE WCS 2.0 Mep/170-W POST-TENSIONING SYSTEM

1.0 INTRODUCTION

AND

SUMMARY

The WCS 2.0 Mep/170-W Post-Tensioning System has been developed primarily for use in post-tensioned concrete reactor vessels and containment structures in which massive concrete sections and large required prestressing forces dictate the need for tendons of high capacity.In some of these applications the end anchorages may be exposed to very low ambienteratures which may exist at the exterior of the structure. Because of the critical nature and function of these structures, it was felt necessary to prove the adequacy of the system when subjected to these low temperatures. The following report covers the procedures and resu Its of a test conducted to demonstrate this adequacy.A reinforced concrete test specimen was constructed utilizing materials and components typical of those used in actual practice.The cross section of the specimen was square and the size was selected to represent, on four sides, the conditions of minimum concrete cover that would exist on one side of the tendon anchorage buttress in a typical containment structure. When the concrete had achieved strength a 169-wire tendon was insta lied and stressed to a load cqualent to seventy percent of its guaranteed ultimate tensile strength.An insulating enclosure was placed around the test specimen and using liquid nitrogen, the assembly was cooled to a temperature of approximately minus eighty degrees, Farenheit. This temperature was selected arbitrarily as being significantly lower than the lowest expected outdoor temperature for most areas of the country.The cooling period required approximately twenty-four hours to reach and stabi I ize at the se lected temperature. At this point the load-test phase was commenced'Nhile maintaining the reduced temperature. The load on the tendon was increased to 80%G.U.T.S.and held for fifteen minutes.At this point the load was then cycled between 60%and 80%G.U.T.S.for 500 cycles.Following the cyclic loading, the force in the tendon'.'las increased to 100%of its guaranteed ultimate load.At no time during the test was there any failure or evident distress in any component of the system.Post-test examination of the wire, bearing plate and anchorage hardware revealed no cracking or permanent damagi ng distortion. SECTION 5B 5B-116\Jt-;lJAE:-J.,/'Q-2. WESTERN CONCRETE STRUCTURES, INC.2.0 PURPOSE The purpose of this test was to demonstrate the low temperature serviceability of the 170-wire, BBR-type buttonhead anchorage post-tensioning system, including shims and bearing plate and to determine the crack sensitivity of tendon anchorage components when stressed to 0.7 G.U.T.S.cooled to a temperature of'approximately-80 0 F., subjected to 500 cycles of loading between 0.6 and 0.8 G.U.T.S., and then subjected to a static load of 1.0 G.U.T.S.3.0 MATERIALS With the exception of the bearing plates, all of the components of the test anchorage assembly represent an essentially random selection of material or fabricated items from stock.a.Wire: Domestic stress-rei ieved wire conforming to the requirements of ASTM A 421 Grade BA was used to fabricate the tendon.Certificates of the chemical analysis and tensile properties are included in Appendix A2.0.The buttonhead anchorage produced by cold upsetting the shear-cut end of the wire conformed to the requirements of the WCS 1.5 FS Head-Seat Systems.b.Shims (Part No.101006): Hot rolled plate conforming to the.require-ments of ASTM A 36 were torch-cut to the shape and dimensions shown by F i gu reA1-1.All loose mill scale was removed by chipping and wire-brushing; all edges were deburred to assure full surface contact with adjacent shims, stressing washer and bearing plate.The cut edges were not machined, ground, or otherwise finished from the torch-cut condition. c.Stressing Washer (Part No.101003): Rod stock (6-1/2" die.)of AISI4142 steel was rough turned, dri lied and heat treated to a hardness of R c 42+/-2 and then threaded.The seria I number of the stressi ng washer used in the test was number 1024 and details are shown on Figure Al-2 which is included together with mi II chemical analysis and heat treat certification in AppendixA1.O.d.Washer Nut (Part No.101004): Tube stock of AlSl4142 steel was machined and then heat treated to a hardness of R c 42+/-2.The washer nut was'finished to the dimensions shown on Figure A 1,-3, which is included in AppendixA1.0 along with the mill chemical analysis and heat treat certifications. Threading wasformed after heat treat.The serial number of the part used in the test was#561.e.Bearing Plate (Part No.100121): Hot rolled plate conforming to the require-ments of ASTM A 36 (silicon killed, fine grain practice)was torch-cut to the shape and dimensions shown on Figure A 1-4, which is included in AppendixA1.0 together with the certified chemical and physical analysis.SECTION 58 5B-117 \:::-"1.// WESTERN CONCRETE STRUCTURES, INC.3.0 MATERIALS (continued) f.Reinforcing Steel: Intermediate grade deformed reinforcing barsing to the requirements of ASTM A15 were placed in the concrete supporting the bearing plate in the manner shown on Figure 3-1 and 3-2.Mill certificates for the reinforcing steel are contained in Appendix A2.O.g.Concrete: The concrete used in the test specimen conformed to the mix design prepared by Twining Laboratories, a copy of which is included indix A2.0.The criteria for the mix design were: 1)compressive strength of 5,000 psi in5-10 days, 2)3/4-inch maximum size hardrock aggregate, 3)2-1/20/0 entrained air, 4)4-in.maximum slump.Twining Laboratories also inspected placement of bearing plates, reinforcing steel and concrete, and made cylinder tests as reported by them in Appendix A2.0.At the time of the cyclic loading and ultimate load test the concrete strength was.5,078 psi as indicated by two test cylinders. The age of the concrete at this time was 12 days.The modulus of elasticity was determined to be 3,383,000 psi.4.0 PREPARATION OF TEST SPECIMEN 4.1 Plate Size and Preparation: In order to obtain plates for the test specimen with as high a carbon content as has been utilized to date in construction; it was necessary to produce the tesrsamples from 4-inch thick plate, the only material avai lable with a carbon content of approximately 0.2%.Consequently, a 4-inch thick piece, 2 1-0".X 4 1-0", was obtained and ground on one face to a thickness of 3-3/4inches. The plate was then torch-cut into eight pieces as shown in Fig.4-1.All cutting was started on the unground side and this side of the bearing plate, piece No.P1, was placed against the concrete so that any harmful effects of the mill rolled surface wou Id be on the tensi Ie surface.4.2 Mechanical Faults: In an attempt to make the test more severe than any condition that would occur in practice, several artificial flaws were added in addition to whatever metallurgical notches might be produced by torch-cutting the tendon tube hole.These mechanical faults, shown in Figures 4-1, through 4-5, consisted of 1)aV notch produced with a cold-chisel and intended to simulate a case where the edge of a plate is dropped across the hole edge of another plate, 2)a 1/2 inch long radially directed torch-cut slot intended to simulate the case of an overlooked, misdirected torch-cut and 3)a hook-shaped, torch-cut slot intended to simulate the case of an overlooked stc:rting cut that had been made on the incorrect side of the opening.In addition, during the welding of the trumpet tube to the bearing plate, the welding rod was deliberately dragged away from the joint for a distance of one inch onto the plate and on completion the rod was grounded-out to the plate and then broken off to simulate an accidental weld strike.While the faults may be realistic, it is considered inconceivable that a bearing plate containing anyone of them would escape detection and be installed on a concrete structure. SECTION 58 5B-118 0 INTERMEDIATE GRADE REINFORCING \\II A PLANi Ii I'"I I CDI I.(0).1\01 I'.#/I-It...,.--JJ-END VIEW DATI DIS.av OWN.av eKO.av LOW TEMPERATURE BEHAVIOR OF THE WCS 2.0 Mep/170-W POST-TENSION ING SYSTEJ'v\SECTION 5B I9li3 SOUTH HAMILTON AVENUE 5B-119 BAADENA.CALIIl'OANIA .321-1571 F*3 1 i-1: j , 1 SEPT*n ....-....L-..-..-**:3-*10 e Iii o.c.5/a'$SPIRAL 2d'DIA.EA.FACE'3 1/2" PITCH x SLS 3/4" LG.COLD DRAWN\#4 HAIR PINS, 3 EA.FACE EA.END SECTION'A-All INTERMEOIATE GRADE REINFORCING DATI Ola.a...OWN.a...lOW TEMPERATURE BEHAVIOR OF THE WCS 2.0 Mep/170-W POST-TENSIONING SYSTEM NO.1-445 Fig.3-2 CICO.a...SECTION 58 58-120 19113 SOUTH HAMILTON AVENUE ClARDENA.CALIFORNIA' 3Z1-la71 SHT_OF'SHY*II: ,.- )))l.f.1"--I 1/2 1\SAMPLE TEST J.... P8 r<>*..1/II I II+If>P5 3 17/32 R.-O" THRU..II-20 1/2"+/-3/32'LAYOUT I.'III II 7 lib It\+II G THRU'I'_0" tP3......NOTES: 1-SAVE ALL SCRAPS.2-INOENTIFY ALL PIECES (PI,P2,ETC) 3-INDENTIFY WITH ARROWS TO MATCH PIECES.4-N-I=III Le,.DRAG WELD N-2='12" LG, (THRU)TORCH CUT N-3=1/2" LG.\\J" START TORCH CUT N-4=I/a'/COLD CHISEL N-')=WELD STRIKE.L If..-3 3/4" THK.L'II.._4-0_ ClJTTING--- I:-tlofLlJO*........tTl/""'-OQ""'O-t r I I PI 0:1: 0::::-tm""" m()-ZVl""'0 0 Vl N m rq-,;)Z II-t"Hc Z(I):-0,.....--:0m, N'G)'" 0" N;::'"....m I 0 o C\I V'l I>>.....<m-s:I 10 P7 ,_.'0 31=OW III z".0*s oJ:*,.xli-z"_-f.0.z w.111<":'111-z_1'1 o.z*lJI 0" Vl m ()-...%..111 0" I....N....I a L_, n I 1/"+/-3/II00 I 20 2 32 Jl*..0!"..***..**10 1/4" i.:.:-': c::;IT..,:.'.I lr 1<...... WELD STRIKE II I LG, DRAG WELD//L I/i.(LG" TORC H (THRU)CUT TEST DETAIL-:'I'**-*-, I I:',.",."." 1/21/LG.\\J II START TORCH CUT I II/S COLD CHISEL"V" NOTCH W/,0 lO" BOT, RADIUS DATC olta**1'OWN**1'LOW TEMPERATURE BEHAViOR OF THE WCS 2.0 i\\epj170-W POST-TENSION ING SYSTEM Fig.4-2 eKD**1'SHY*" SECTION 5B 5B-122 19113 SOUTH HAMILTON AVENUE GARDENA'CALIFORNIA' 321-1l57'SHT_OF ---WESTERN CONCRETE STRUCTURES f INC.Figure 4-3 Test bearing plate after dye penetrant inspection for cracks around center hole and intentional torch-cut flaws.SECTION 5B Figure 4-4 Close-up of torch-cut flaws.5B-123: j.':':'i t:-1/,/'rj::' WESTERN CONCRETE STRUCTURES, INC.Figure 4-5 Close-up of cold chisel notch on edge of bearing plate center hole.4.0 PREPARATION OF TEST SPECIMEN (continued)

4.3 Inspection

The bearing plate was inspected for crocks or other surface defects using dye penetrant. This inspection was made on both sides of the plate in an area approximately six inches wide surrounding the center hole.The surface of the hole was also checked.This inspection was repeated after the trumpet tube was welded to the bearing plate.No evidence of cracking was detected as a result of these inspections.

4.4 Instrumentation

Placement: Copper-constantan thermocouples and strain gage rosettes were attached to the bearing plate.The strain gages were placed as close as practical to the weld between the trumpet tube and bearing plate;the center of the gage was approximately 1/2 11 from the toe of the weld.The position and orientation of the gage axes are shown in Figs.4-6 and 4-7.The thermocouple on the outside of the plate was installed. after the concrete was cast and the forms stripped.Thermocouple readout was by a Leeds and Northrop Model 8662ature potentiometer while strain gages were read with a Baldwin SR4 strain gage readout.SECTION 5B 5B-124-.-."\...-, l.' -PLATE P2 SHOWN PLATE P4 SIMILIAR BEARING PLATE 20 1/2" SQ.x 3 3/4 11 THK.GROUND SURFACE ,THERMOCOUPLE T4 ,WASHER&.WASHER NUT I II SH rMS-4/2THERMOCOUPLES OUTSIDE FACE OF CONCRETE THERMOCOUPLE TI (CHAMBER TEMPERATURE) DATI Dlta.av OWN.av LOW TEMPERATURE BEHAVIOR OF THE WCS 2.0 Mep/170-W POST-TENSIONING SYSTEM""OJ.NO.1-445 Fig.4-6 eKD.av SECTION 5B 5B-125 19113 SOUTH HANIL.JON AVINUE GARDENA'CALI*ORNIA .321-1571 SNT_OF" SU'T*n I1'-+-1---I J---+1+-t-I--r STRA IN GAGES--4-+----+-----I.....-++__. THERMOCOUPLE T2 GI I.--r-._---I'I....l..\__'f'CONCRETE SIDE OF BEARING FE..DATI oa*.*" OWN**., LOV'TEMPERATURE BEHAVIOR OF THE WCS 2.0 Mep/170-W POST-TENSIONING SYSTEM Fig.4-7 CKO**1'SECTION 5B 5B-126 191:3 SOUTH H....,LTON.VENUE GARDENA'CALIFORNIA . SHT_OF" Sf: P1.IS RE S INC.TRUCTU , N CONCRETE S WESTER b l with t assem y.late and trumpe 8 Beanng p Figure 4--n place.t tion I instrumen a Figure 4-9 SECTION 5B 5B-127 WESTERN CONCRETE STRUCTURES, INC.5.0 BEARING PLATE METALLURGICAL EVALUATION

5.1 Tensi

Ie Properties: The tensile properties of the bearing plate steel were determined by Atlas Testing Laboratories for all three directions; longitudinal, transverse and short transverse, as shown in Appendix A2.0.The tests wereformed in accordance with ASTM-E8 and the specimens were cut from Piece P8 as shown by Figure 5-1.Subsequent to preparation of Figure 5-1 and the test specimens, metallographic examination revealed that the 4'-0" dimension of the plate was in fact oriented transverse to the rolling direction. The actual average tensi Ie properties are as shown below: Tensile Yieio Elong.Reduction Strength Point%in in Area (ksi)(ksi)4D ok Longitudinal 65.8 35.0 34.1 64.3 Transverse 65.8 32.7 30.5 46.0 Short Transverse 63.17 39.2 9.8 18.9 It should be noted that some of the properties listed above are below the minimums specified by ASTM-A 36.A chemical analysis was also made by Atlas Testing Laboratories, Inc., a copy of which is included in.A,ppendix A2.0.5.2 Metallography: The bearing plate was sectioned for a metallographic examination of the microstructure gssociated with a torch-cut and with the bearing plate trumpet weld.The location of these sections is shown on Figures 5-1 and 5-2.The 1/2-inch 51 ice from piece P8 of the plate material was resectioned as shown by the fo Ilowi ng sketches: SECTION 5B 5B-128 WESTERN CONCRETE STRUCTURES, INC.;-,:"\'\\\\""-'.'-\CONe RETE SIDE OF BEARING PLATE (CS)r PSI.:zi/SAW CUT r[f 7 71/'//I:@)J.II.I i I: P8 ST T I;z' TORCH CUT SURFACE SAW CUT SURFACE R V.-POINT OF VIEW, POLISHED SURFACE EXAMINED VMACHINED SURFACED-P81l T-L Surface-check roll ing direction. P812 ST-L Surface-check inclusions to compare with P813.P813 ST-L Surface-check effect of torch-cut at edge simulating BP hole edge;grain size.P8l4 ST-T Surface-check roll ing direction and grain size.SECTION 5B 5B-129 U:-'UA!E--;,: '/O*d. -.....;, r0-rt)rI)X-=.x X...--:x-=.)(::)(II II II/'C)rf)r()-J l-if)Q('.Sr r--r-N N (\J-J l-Ui'" r-,....--J l-Ui\\\\\l-\,\\\, ,\\\\\\\\rt)\\t-\\\\\\\\\!I-------!-1-'1 i f\--n!I 1;\,,I t<)I,,!\l-II,I\II I'II \':'I'"I'-Ii\(\J'J 1\I l-l., Ii'\..II" 11'\: k--t,-fiII-I\I'\j I\\11\\'.!I;:\\,: l-'./1\\.:J\I\'\I\,"\.\\\I\\I\\\I\k\\I\\;\\I\-l l.t\\1\\\I\\\'\-'t\1\./\J\\,\\>-t--DAn: LOW TEMPERATURE BEHAVIOR OF THE WCS 2.0 Mep/170-W POST-TENSIONING SYSTEM PRO".NO.1-445 Fig.5-1 CICD.IV SECTION 5B 5B-130.911 3 SOUTH H AW'l.TON AVENUE DARDENA.CAl.'f'ORNIA . SHT_QF'SEPT*&! SEE F" A B. PROC.II il 7 0.D.x.l25 WALL H.R, GALV.TUalNG DATI DIS.SV DWN.SV eKD.SV LOW TEMPERATURE BEHAVIOR OF THE WCS 2.0 Mep/170-W POST-TENSIONING SYSTEM SECTION 5B 5B-131 19113 SOUTH HAMILTON AVENUE GARDENA*CALIFORNIA* 321-1571HO S 1-,+4 Fig.5-2 SHT_O'Ui-'i)Afi:: -1//82 WESTERN CONCRETE STRUCTURES, INC.Figure 5-3 General microstructure of the bearing plate is normal, pearlite in a matrix of ferrite;an inclusion is shown at the top center.The grain size was estimated at ASTM 6.Piece P813, Neg.No.LTH 645-2 (SOx.)J'.:;.f,\.;..'-.'. "-",...,;...)';\',:-:.....-,...;_;IIJ$..........a T Figure 5-4 Microstructure at the rolled surface of the plate is normal.Piece P813, Neg Nc.LTH 645-4 (200x.)SECTION 5B 5B-132 WESTERN CONCRETE STRUCTURES, INC...._.-,'..-..s..",";".,,"'".....-""-....-.../'_.':....,...-Figure 5-5 A torch-cut surface (right)near ro/led surface of bearing plate (see sketch below.)Piece P813, Neg.No.LTH 645-3 (SOx).ROLLED SURFACE, CONCRETE FACING SIDE OF BEARING PLATE DROP OF MOLTEN STEEL SOLIDIFIED ON EDGE OF TORCH-CUT-TORCH CUT SURFACE HARDNESS-CD@@@/55 DPH=RB 82 202 DPH=RB 92 227 DPH=R B 97 247 DPH=RB 100=RC 22 BASE METAL=RB 92 SECTION 58 58-133 WESTERN CONCRETE STRUCTURES, INC.Figure 5-6 Hardness and microstructure on a mid-thickness section of the bearing plate hole.A thin dark-grey layer at the edge is scaie, the white layer (0.001" thick)is a hard (Rc-67)rnartinsite, the subsurface Widmanstatten structure is relatively soft (Rc-22)and becomes softer further from the surface.This structure may have poor ducti I ity.Neg.No.LTH 645-10 (250x).-1./SECTION 58 5B-134 WESTERN CONCRETE STRUCTURES, INC.5.3 Weld Metallography: The weld joint was good;there was no evidence of gas porsity of cracks atthetoe or root of the weld.The microstructure of the heat affected zone was normal as shown in the following photo-micrographs. ..-..::1*., ..,. ..,'.'. .....,-.' -.-Figure 5-7 The microstructure of the trumpet/bearing plate fi Ilet weld.No cracks or porosity were seen Neg.No.LTH 719-1 (4.5x).SECTION 5B 5B-135 WESTERN CONCRETE STRUCTURES, INC.,Figure 5-8 The toe of the weld at the bearing plate showed no hardened layer in the heat affect zone, see Table above.Neg.No.LTH 7i9-3 (100x).DPH R e---1.222 95 2.230 97 3.274 (103)4.221 95 5.181 87 6.186 88 7.207 93 (beari ng Plate)8.266 (101.5).....-.'j,.* '-,--:.-.';,'.j-..-.;,."""-..

..

: ,"_..,..-DPH R e 1.242 98 2.230 97 3.168 85 4.221 95 5 203 92 Figure 5-9 The root of the weld showing the edge of the bearing plate hole (arrow)and the martensitic layer, see table above for hardnesses.

Neg.No.719-2 (1 OOx).SECTION 5B 5B-136/,..-- WESTERN CONCRETE STRUCTURES, INC.6.0 TEST PROCEDURE 6.1 Test Set Up: The test set up is shown schematically in Figures 6-1 and 6-2.Figure 6-4 is a photograph of the actual test installation. Liquid nitrogen was used for chamber cooling.Loading was accomplished by means of a WCS 1,000 Ton stressing jack.6.2 Stressing Jack Cal ibration: The jack was cal ibrated using a short tendon and a compression type load cell.Jack output force was obtained as a function of hydraulic pressure at 100 kip increments from 100 to 1100 kips.This data was plotted and extrapolated to 2000 kips, as shown by the data sheet and calibration contained in Appendix A 3.0.6.3 Cool Down: The tendon was installed in the test block, with shims at the test end, after the concrete reached 4000 psi, and the insu lated chamber placed over the test assembly as shown in 6-1 and 6-4.When concrete strength reached 4,845 psi the tendon was stressed to 1 ,393 kips (700/0 of G.U.T.S.)and the cooldown started.Cooling was by means of liquid nitrogen bled into the chamber.Upon entry into the chamber the nitrogen vaporized to a gas and was circu lated by the notch driven fan..Temperature on both faces of the bearing plate, on the inside surface of the washer and in the chamber was monitored and recorded at one-half hour intervals during the cooldown period.Also recorded were the strains registered by the two rosettes.These data are contained in Appendix A3.O.Cooldown required approximately 24 hours.At the end of this period, the temperature at the concrete face and exposed face of the bearing plate were-73 0 F ae5'd-81 0 F.respectively. Lowest chamber temperature during cooldown was-128 F.6.4 Cyclic Loading: Immediately following the cooldown period the tendon was stressed to a hydrauIic pressure of 7728 psi (80%G.U*T*S.)and he Id at th is load for 15 minutes.The load on the tendon was then cycled between 60%and 80 0 k of guaranteed ultimate tensi Ie strength (1, 194,600 Ibs.and 1,592,000 Ibs.respectively) a total of five hundred times.Each cycle consisted of an increase in load from 60 0 k to 80%of G.U.T.S.and then back to 60%.Cycling rate was approximately 1 00 cycles per hour.Load was determined by means of the stressing jack hydraulic pressure, measured using the same gage that had been used for jack calibration. A.fter each 100 cycles, strain gage data was read at 600/0 and 80%load and recorded along with bearing plate and anchor head temperature. These data may be found in Appendix A3.0.SECTION 5B 5B-137

- - i"'[.1-" I....,._-::1;: THERMOCOUPLE TO LN Z VALVES 600 GAL LN2 DEWAR 1/2'1 ANNEALED COPPER TUBING (INSUL)-LN2 DEFLECTOR OTOR 1/2" THK PLYWOOD (FOIL WRAP)

..'vvvv /'" VV/'v lEA0S SEE ENLARGED DETAILI"_._. _I 1/I/I 6-0__1/J13-3__ f9 U*-C i.,- 9'-f/SECTION-COOL4plT HOUSING(J\STYROFOAM FILLED OU)....1...1...'" ,.0:1 0*.."-<Vl r m'"0-1 0 ()O::r:-I Vl m 0-i m Z0.ZVl-0 m (T1 Vlr-v:;;0 -.;;:0 Z CD m'j"Z 0'-m I o>>v')I<-"1 0:;;0 01 0'I.....W (X)-,,-JI-a w"'Ill Zo)OC....n:z:)o:z::!:)o dE JI-Z'-_...)00.z 101)0 N<-'" U1 C::!...-I"7j..r t-" H OG L...*"'j.: 1:;(J"\:t"'Ir-'..........I1-' , I'LU o A 1'1 CICO.a,.LOW TEMPERA TU RE BEHAVIOR OF THE WCS 2.0 Mep/170-W POST-TENSIONING SYSTEM SECTION 58 5B-139 19113 SOUTH HAMILTON AVENUE GARDENA'CALI'ORNIA

321-H571 HO.1-445 t Fig.6-2 I SHr o,-J SEPT as//0:'::

WESTERN CONCRETE STRUCTURES, INC.Figure 6-3 Test specimen after concrete cast and forms removed.SECTION 58 Figure 6-4 Test set-up during cyclic loading.Load applied using lOOO-Ton hydraulic ram.5B-140 WESTERN CONCRETE STRUCTURES, INC.6.0 TEST PROCEDURE (continued) .1."-.0*-7.0 6.5 Tendon Guaranteed Ultimate Load: Following the cyclical loading, the tendon was loaded to guaranteed ultimate tensile strength 1,990,000 Ibs.in the increments shown on DS-3, contained in Appendix A3.0.Strain gage data was recorded at each increment. Temperatures during this test were-76°F.at the concrete face of the bearing plate, and-87°F.at the front face.6.6 Post Test Inspection: Upon completion of testing, the tendon was removed from the test assembly, the wires cut, and the anchorage hardware removed for inspection. The washer and washer nut were checked for distortion and dye penetrant inspected for cracks.The outer face of the bearing plate, a ground surface was check for flatness.The bearing plate was then removed from the concrete and dye penetrant inspected. RESULTS 7.1 Chemical and physical properties of the material used in the bearing plate tested.was determined by Atlas Testing Laboratories of Los Angeles.Copies of their reports are included in Appendix A.Tensile yield in the longitudinal direction as determined from the average of three tests was 35,000 psi.This is almost 3%lower than the value of 36,000 psi minimum specified in A-36.Ultimate tensile strength was in the low end of the allowable range.Chemical composition was undistinguished with a carbon content of.21%.This is higher than any of the plates used in production. 7.2 The plate tested showed no visible signs of damage after being loaded to tendon guaranteed ultimate tensile strength, following 500 cycles of loading from 60%to 80%of tendon guargnteed ultimate tensile strength, all at temperatures between-70 0 F.and-90 F.7.3 Post test inspection revealed no deformation or cracks on either the anchorage hardware or bearing plate.7.4 Strain gage data indicated that strains were linear throughout the cyclic and ultimate load test phases showing that the bearing plate stresses remained below the yield point of the material at ultimate tendon load.SECTION 58 58-141//82-----------_._----,..,,,.,.,..._------,,... WESTERN CONCRETE STRUCTURES, INC.

8.0 CONCLUSION

S 8.1 Due to the comparatively higher carbon content and low yield strength, it may be concluded that, in terms of material properties, this test represented a more severe condition than would be expected on the job.8.2 Deliberate damage to the plate, as described in Section 4.2 was severe.These defects would ordinarily be cause for rejection. It may therefore be stated, that in terms of material condition, the plate tested represented an extreme case.8.3 The serviceability of the bearing plate at temperatures well below normal ambient conditions has been demonstrated. 8.4 In view of this test, wherein a defective bearing plate with unacceptably low physical properties was loaded to values which will not be encountered in actual use, under temperatures lower than ever expected, without failure;it may concluded that the bearing plate design is suitable for the use intended. ",,"'-"-.......... -Figure 8-1 Test specimen anchorage immediately after conclusion of test and removal of insulated enclosure. SECTION 58 5B-142 WESTERN CONCRETE STRUCTURES, INC.APPENDIX Al.O ANCHORAGE DETAILS AND PROPERTIES -..-::.....,:':.;..-...:- SECTION 58------_._--_._---_._--------------- 5R-143 I t!;"" i I , I I:;I , ," I ,:i I I::.;.:....:..I'H I I I 1 ir------i: i!I -\\i\i, 1 1-- )-If I J:i: I tl i./Il()II I!-I ," I I'I I L-----JIL__It_I I.I:*\----'-+-1-'---'<)

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Quatty Assurance P'rovisions 01 CP I--'().*A)Each material ticat to be processed sep4rately.

B)Serial Numberlto be placed on pads prior to removalcolor coding, or as soon as practicable thereafter °C)10 thread irlspcction to be performc(} by vendor WCS lIGolI_1I No"-=Goll gauges, inspcction certification required°D)'Heat Treat Certification required for e4ch furnace batcb°Vapor-hone to remove sea Ie after heat treat.E)'icndor to Serial Number to and heat treat certifications per V/CS Form 100.__i.'11""'::.J...:-: LV\101003......"...'"!J0e q-rr:;7'J (:':-":8'......**..,".'"0(...".--,....,*.*r OA*'..;)"23 tr.O...**......IL'J'..'.1[......, Cr<::'By HRR D,.\TE 30 Dec 68----..ornJ bY N\B H REVISIONS....:'._----. J J Q./C..Approval E:lock

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)))WESTERN COnCRETE STRUCTURES co., 19113 so.HAMILTON ST.GARDENA , CALIF. .......-.__..-,.....-...-.....---...--..._..._....-._......---_...--'.-.- , OU)U...v....n"."c.'",..u.......,:::.:..:,2"'1 1'..i'*I'it",t,., 7JIS3H 6-1/2" Rll REPORT"('CI"If.....1""0..IC_..L-.........*....If"'-,.......'f'.,..*"4" TEST...._--------------_ ..---------.,.--- If.n i In'"'iI"0 I INC....-."-..CERTIFIED 5377---?-, R\'ERSON i 12-AX-500164A: I...-,.: ,.....-,-.6..__,. .....-../.I-.-f!-i;:.:i: 'j ,.3)3120 I):t),"')'1.-01..11 ASTH322 HAIDIHA.Hlff ".--..r"r oe CO"..j II.I ALUM'lIAD'.I I'!,_._.__.J_.J 6-1/2" RD X 0-1/8" 80 OARS DISCRIPTION Of MA HRI"l AND Sr£ClfICA liONS STPIPf FULL OF OAR-BROWN'ALACK VACUlIH OfC/\$SCO t;rAH!5-£rf:p FI12£.r.._.__._-_._..._-....-CHlMICAl ANALYSIS.......G I tttOi I IUlh4UI,Slllco"'l NICIU I I I I I..97 1.011 i.0221.2e!

_..---.........MECHANICAL

'lflO Pl'(A"O'"N'.... ..**"fAr t.O--......:.:": 7IIS3H."2- ..(H.O....I"",,ou.1 1*02.;.18 PROPERTIES AND TESTS I""ONC411OH I I 1.....0.CUlM Of AlIA...I ,_.1..1._.i._.__ I 0'1411 '.O'ltliU AND IU1, 1/59 2/53 315M 4/58 S/57 7/57 8/57 10/56 12/55c p.p p r: n\of r: I.05T r E L CORP*J 4/52 1 6/5 2 20/0 2'.1 L: R 2 8/47 32/If ().1 TH[ABOVE TEStS CONfORM TO THE REQUIREMENTS OF THE SPECifiCATIONS LISTED.'rHIS IS A COpy OF THE NOTARIZED MASTEIl IN OUR fiLES.w.h.,..., ct,I.,.,.hQ' Jol.I,".c,.f thoI Of"\...US E l.L o._YOUNG.*H.,.,.,'",bile d.h.,.b, ce,"'y.ha'dol...nl....d'I'b, ,..od'I\.n,""III do'"**lftt.",""0."-,*...4 on4 ,..,.,....b***,."'.by*411 1 , o,,'.....h.d GQ.nl".'"*****,.,'.,m." j.. ..o.r..'.,I h U'*., tf\1, t."::'.""..., (O IlolIU.a...

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Vl m ()--t o Z 01 CP ACCURATE STEEL TREATING, INC.J I\\10008 MILLER WAY*SOUTH GATE, CALIF.90280*869-3385 PROCESS CERTIFICATION TO: WESTERN CONCRETE STRUCTURES, INC.DATE 11-7-69 19113 S.HAMILTON AVE.GARDENA.CALIF.90247 01 CP I.p..co ORDER NO.2769---378 CONTRACT NO.MATERIAL 4142 PART NO.101003 OUR SHOP NO.12891 NO.OF PeS.40'i ,L'.., n",: WE HEREBY CERTIFY THAT THE MATERIALS DESCRIBED WERE PROCESSED AS INDICATED BELOW: HARDENED&TEMPERED TO RiC 42-2 PER MIL H 68758=SERIAl.NOS.1053-1032-1029-1039-1034-1014-1001-1027 10241000-1003-1007-1002-1030-1005-10171006-1 1044-995-1045-1059-1054-1051-1042-1055-1052 ACCURATE STEEL TREATING BY Paul All processes involved requiring Government Proceu approval have been$0 approved and certifications are on file subject to examination 1,- i:\...'-1;-rrt'4"'II"II t::i I 4)I-4<..p U"I" 7-a\-J:J a\\l<<.J'"5 D-.i1"{.Ulr-a:z.V)FIG.A 1-3 5B-149-+-'l+---.--.---- -+.+-----Jl ,...v 7'V r I)';:::;::-;::"-.,---.",. 'I r;,.//C..:.. -.'.-*-.-. -:,..;**...1"_.-:.:-*.;.: .LIST C-F!'vi I\T E 1-\L S---------1 {'_'---*--0-'-_--- ___.._.'.;..r'-.\"'),,,.L.\("'.r.. NUl_.._....._._;,.______0\" ,,)'J ()._. ._-*"'t'";;7 ,.""-*.',r'oj (: l:...-:-.: REO 4[.;.T f.R I A L 0 ESC/-i I P 11 0 r.1 t/r t}11:_L[C 1 S T l-C K ("".It&.I)'1f i-(IG I" 5:-U C T*I 5"j.: SC'iIPT ION-.'-..'.-**--..c.--.....-**-=-, ""'*.*.-_._.Vl m ()-i o Z<..n OJ V/oshcr Nut Hot Fini shed, SeomlessJ A 51 lv\-A-519 l\\echanical Tubing, 4142 ti, Open Hearth, Vacuum Degassed, Annealed, Pickled, Oiled, Machine Strai ghtened*.9 3/4 11 O.D.x 5 1/8" I.D.x 4 1/1'stock.Mill'material chemical and certifications requ ired. code cach blank with full length strip and record Heat Number-color relation on W,ill Certification.

Quality Assuranc rl Provisions

--.--J_<..n OJ I-'*01 a#A.)Each matcriallheat to be processed sep(lfotely. B)Serial Nurnbcll to be placed on parts p1ior to removal of Color Coding, or as soon cis practicable thereafl(;r. C}10threa?il,spection to be b'y vendor \VeS

gauges, cation require!.D)Heat Treat Ccltification re9uired for furnace botql.Vapor-h'one to remove scale after heat treat.E)Vendor to Serial Number traceJ.Jbility to materjJJl and Heat Treat Certifications per vies Form 100.:,.:: Lt-A 101004 r'-,

j..... ...." ......c I...--]1_.*,I r I-I I ..DATE.....c"..;:: 30 Decow N BY MBH-_..I":.l4?I!>dJed Q./e.pprovol Blockl (C t<BY.",__._"."'.*"., l-.'--'1 S Q C HRR ..r...*,.CQ-....u*" I...'_1...L.f-I REVIS I O N**_.'i, c: "'::[, 1"1":.::\... )'))TUBES 46"\'1ESTERN CONCRETE STRUCTURES 19113 s.HAMILTON AVE.GARDENA, CALIF.90247 Vl m ()--f o Z 01 CP D CA'.-z 1-69 CERTIFIED'<.'01(1...,,.i (I.I\'OMU*' 01011 4927 I TEST REflORT It".I"" I$'IC.-_SlOCI"".9=.3/_Lt_ II_OQ_9-3/4"00 X 5-1/8"10 X 0.'4-1/8" et cJ p£t(//I/ I:, I.F i.t I*:.*..: "rl.'J oJ.":>J'---.-__.L-----1).-tDlSCRIPTION Of MATlRIAl AND SPfClflCATIONS HFS1-11 ....C?H qUJ!'L .. E Q A_N_t-!_CHEMICAL AUAl lSI: hi At NO PttOt i IU,,"'ul 1111lCO,,", I NICllH lOtiO...I MOLY I CO"II I" I AlUM!lUI)I Qntlt ,:I I I I 1 I 57758.42 ,.90.013.015;.28"II.97,.22:.08;._........___..__.___.1.._.4_._*.1_MECHANICAL PROP[RTIES AND TISTS __ _1_ __ __r*1 (0]u "".""J.CfVIl.or.... nO'UflU AND 11111.ii/58 2/58 4/57 6/57 8/56 10/55 12/54 14/52 TIt*'KENR0LL ERR EARINGI 61 5 0.....1 0, L 4 Z 2 41 4 5 2 8/it 2 321ft 0 4 0 lJ.B THE AlO\,[HSIS CONFORM TO THE RfOUIREMENTS OF THE SPECifiCATIONS LISTED.THIS IS A FACSIMilE COpy OF THE NOTARIZED MASTER IN OUR fiLES.w.h...b, ur1i', th.t ttl.'.'.I.lng dill.It*trw.lOp'.f 1M O\1("'CELL 0 yOU t'......*..*l.\1**Notary"'bll(d.".'ltlt, CIt"", Ihot clalo'lH'ftllh.d '"., Ih."od\lclntl m.1I..th.4alO ,**..,hln, j".'I,c!**I w.....bOl**bed."d........'0 la,*d"l,. "0'".....,,,'01,,,,.11 I" I".Iy/"o...lobOlal-r."I".up" T.'r""oo aIt\(***". d.,.t.1-1l .JOSU'H T.I 1'7....J.Jl'-./.A J'"I.""'i..>'cC.l/l r L9:::J:/_____. .......1...*.;..-"r:;'"_.Ll_.."", ((,..."'UIO.......'...b

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...t1...I r-,...\. 0 OU".G1'.".'." t',';'.,.-.'..,r'..',.'IOU"" I.J'Il'ON&SON.INC.f*......r:.,*.*,*. ,",'*r**.**h.O*,..

("." ,\****It.*....**1*.,*****",,*...u,*'.,.'.,...,1 0,'.1....,........11.,...\",,".....\*

""f..*:,'"':':'1,*,,......'**Al**c--I.'.r'.......1',.....'*I'.'...-.'*: to ,'.....) ..,<,-,I'.lc........*:.c.*,__....I**""'..:.\.:*&>,.,".,*)"'("-"....(I<.**,I.........-.--****_....-...".. ..."-....,......-...............",_W"...........-w.....**..".,....,..........",;**.N... ...,........_................ _*';.'...,..,**,':.\, I I'..,";'...'-=...1.:..U-:;_I.c.'....:......}Jto.'_'10 I'i' 01 CP I--'01 0,: to.:*.-"-...-..-.....-.... - Vl m ()-i o Z lJ1 OJ l_!\--_-j STEEL-rRE.\'TIl'-IC; I ,,!(:. I.HLLER'NAY*SOIJTIl GA fE, CALIf. II 669-333S:1:i:: '.l J I.::...\'rI0 TO: D,\rE 11**1l.-6919 113 S.I L".i If.LT U-J/\V E*CAaOENA, lJ1 O::J I--" lJ1 N nPDER NO, 2777---378 (OJ,;TRACT NO.,",;\T ERIAL[.1 1.2 PART NO.10100lJ OUR SI!OP NO.7 31/.9 NO.OF res.28 C'..;:: I": i: il'0: 1-..: t-*, WE HEREBY Cf.RTlFY THAT THE."'ATERI/\lS OESCRlf:ED \'/ERE .0\5 I:--JOICATED GElO\V: HARDENED&TE1*IPEH I;:n'fO RIC t:*2-2 PE:{ L If I)S 7 513 S E R I At NOS.593-5 a I*..5 ()9-5 G 2 ,-59 7-GOO-5 G3-)/2-5<)6..5 G G-.576-595 561.-575.;;r;5**593-571;-535-5 I)t*..573-591-5 GO-57 1-f\CCU1.\TE STEEl BY ......__.All processes involved rcquil"ing C:-...:tnmcnt Procca opproval have bcen so approved ond certifications ore on rile subicct to exomination

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REPORT TEST CERTIFIED RYERSON YIRD PSI TENSILE PSI.'f'l ,..-----:-OA.,.-,T'""E--.....-:-:R.{(-lis-orToTo£RNUM8£R cUsro"i:".I*EJl'S ORDER NUM8H1'1, r'Los Angeles*Attn: Scheibel 10/30/69 14-406820 12loX)1631A '\:: ....N:O-;;O..F..---a;Mi7"'ATERIAL AND SPEC1FICATION"="S------l'---------H r,\', r.J _HR=.;.....;;.A,;.;;3 __ 0:=-;':7'1 CHEMICAL ANALYSIS;.j HEAT NO.CARSON MANG.PHOS.SULPHUR SILICON NICKEL I CH'OM'I MOt Y.ICO"" n.ALUM.LOAD OTH" h (148271*18.97.014.029.24 I..)), t MECHANICAL PROPERTIES ANO'TESTS\:.I ,.ELONGATION ',REDUCTION HARDNESS'BEND GIIAIN EMI.COlt., HARDENAlllITY t'*,1-:;.;::..L.:::...:..::....--l......:..::.L.:...::.;:;. .......--10_-'--.1.-_,_,,_- __[;:MAHUFACTUltEl OTHER MECHAHICAL PROPERTIES AND TESTSKaiaer Steel1,1'-'-H-EA-T-NO-;--CA-Il-IO-N-I-M-A-N-G-' (.f!.)II MECHANICAL PROPERTIES AND TESTS %ELONGATION I I HAllONESS i SEND I GRAtN EMI'l COR.I HAIIOENAllLITY t;j I I I I Ii,/16-'16-';",1'r ,'\MANUfACTUllU r)?, I r'".kj DESCRIPTION OF MAtERIAL AND SPECIFICATIONS t),;i,J HOAf NO.CAIlON I MANG.'HO'.'ULPHU.SlllcOl NICIll I CH<OM'I MOlY.CO""I n'l ALUM.LOAD I OfH"'j----.l--.......-...-.l.-- ......."I.ELONGATION I II HARCN£SS lllENO ,I GRAIN ,I EMI'I'cOIl'j HAROENAIllITY )"'-I"'- l--... ....ST-S-----l---J.---J.-----..J..------:-".-"(,: (I;';'."[r.J THE: ABOVE TESTS CONFORM TO HiE OF THE SPECIFICATIONS LISTED*'" ,THIS CERTIFICATE NOTARIZED ONLY WHEN REOttfRED (j..,J r; 1 , w.hr.b., certify'"0"e fonqolll" do'o I, 0 tru'CO"" 04.11.\.jl.__, a Notary Public clo'.f_',"'" WI b"....prod..",Ill or.lte de'.re,.W.q'<;4this affidavit was subscribed dnd swornbefore me '""" tn., II\.obore'ory.

, lent of Joseph T.Ryerson&Son.Inc.*thls day of JOSEPH T.IY*So'._7 J.

NOTAIY PUllLlC If ,'1'A1]h\T ru.or.**If:..sw*.,*****1.4.'0'

.c:o...."AlO....'l***U.....C"A'Lonl.II.c.*"/./U"'Q.JOSEPH*RYERSON&SON.INC.,,,........

c,....u...CI..C"*"'101'*"'LW.U'"*C".c**o*IT.LOUII;.)" J\'OIM"O.2'*J JUL 62 COrYIIOM'In,**u.u*"OUlto.*******IOU.*'01...nll**...

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5Bi...',.-..-,.5B-154_._,......_-.-**-*_ I;,.'rt..'.1\'w.*... _..-t}'dSO:," Ij'[.' ..t*f..",.2.,... .. -,.,--WESTERN CONCRETE STRUCTURES, INC.APPENDIX A2.0 METERIAL TESTS AND EXAMINATIONS SECTION 58 58-155 Ur->:.;.Ft l t:..1;..';0: ,:/c..:.. "," ,".to...*.\00011*' .3 c!)OATE__ _CERTifiCATION OF TEST TUF\IIRE Armco Steel Corporation Kansas City, Mo.64125\)ARMCO V CUSTOMER: " NOMINAL.WIRE 01,1.._-::.....::....;;...------------ P.SoI.MIN.SPECIFICATIONS ".,..4O) REQ'O.BREAKING STRENGTH L.BSo.........,.A.U E_R_C_E_N_T ...-k2-1 UL T.TENSIL.E STR.PSI COIL.NO.01 AMETER FRONT BACK aREAKING STRENGTH L.BS. BACK FRONT BACKEL.ONG 10"'BENOS STRAIGHT-BUTTON NESS HEAO.., .,?t'..:""j.....-.."" _i)..*:a..........1?C:'J ...2/).......0":-)*'V--":;-:;:.') "".t:t.. jJ-s<;.)!::,'J*.s 1:;.:;,')....')

'7],

373 u!}()21:!,..:.:r:.;) z.:;;1:J);) ).'.J m:J2':}.,) 12 C";C... HE AT NO.__ _AN AL.YSI s: .... -:: MN P 5THE PHYSICAL.OR MECHANICAl.. TEST REPORTEO ABOVE ARE CORRECT AS CpN T AINEO jN THe: RECORDS OF"1;HECORPCR ATION**Suoscribed ana to cefore me.A 10tary PUblic, in.anj far ..te of Tln.s'th'3 Clay 01........---.19.. MU-2:1l1l1 7/6.!!:7 1970 SECTION.58 58-156 BY***,.**"..:-..'..-<.T1TL.E.... \...41 o u..z X u c:I" Z=...."i';!, I I: ii, I: 1 I!II i!;'(I': iII;:!iIIII I!I'i r I: i I I t Ii!I ,I:IIi:',: I I'I.,!.", ,i,,!.II ,,II I'i'II:I: , Ii': 'i!: ill.I I'i ii: f!III ,,!iI I ,I'," I:: I I'!I ,il'Ii,!II, I;;'Ilil**]lli" il]111., II Ii 11'1 i!I;i*:1'I'111'1'11:1 ,I'""f I.;.1: i:I'lli ,,'1111 I I: ,,1: """ I ,"1.:;:.: 1'1: " ,I,.I',**11 ii"":1 11:1'I Iii I Il'i Iii 11 1 11 lilill ,II, ,il'I::I, ,;II," 1*1'" ,:1.,:I!II, II Ii,!I: "1'11111 i'l i,!II'II:,'ii',li,li" ,'I'll:!l1 ,I!III!II'II;1 III'I'll:'Ilil ,I'Iii: I Ii 1!!111 ii,l:11 ,I'I,'i,i:'" 1111: ,.:,1:,1 11:,:,i 1:1'I,!I:: I:i ii, 1.1,11 I: I,'ii'Iii: II'i 1;,1 II"1111111 I III'Ii!I,,*i Ii 1,Ii" i ,II!I!'I" iii,;,'i'I: ,,1.I!!I:::::lI!I!,:'i,l: ,'"!I:*1111,: IIi I,:,1'I!: II',.II III'i;'il ,:11 III I 1 II:i"III': il:,11 I 11I1 II,!i:l:.';.:1 I'1il, III ii,II'"1'Ii:, Ii!I II ,I!ill 1 1 11: I I'ilil 1 I11'III II I*11",;!I.I::'III II,*",'I11I1111 1 III': I I I'II: Ii:!: II 1 Ii'I ,,1'11111 I!II ITT: i,II'I'I'iI": I: i I I,'!i I'., I'1'1 II,'"i I I II i'l'\'1" iii:,: I!, lill ,IIIIIIIIII!: I,'il II III II llil I1I'I'll II" I'I!I" ii,':'1::1 II!!'ill:1,'11,11" III!I.: 'I" I ,Iii 111,111::*'Ii",'l'lli,: 111111111' 1111 III Ii, 1IIIIt 1:111 1':11.:1 11,lillll'IIII;IIII'11 111I11"II 11.1111:'llil Ii'1" IIII!I'IIIIIIII!IIIII II: Ii*i;"1 I, Z I II/I ,1.11'1'II 1'11111:1:, III"II ,: 1',1:,'1 ,I,I'!II Ii'.!i ,II'"il'111 1 ,11 I'"i I II Ii 1'11"':11:: I 1,1: I!'li:'III,I' 0 ,i".,:, II;.11 I:,: 11'1 I;'I,'I'll Iii Ili'!1" ,III II:, II!!11111 II11"'I, III;1'!:'I,ll'I ,: II I, I,ll'11111111 Iii'II" ,.III: il:1" Ii.'en: I:!:'!: ,.cf.Illl ill!i'III.i,*'i'I: i'II,: II", III:: 1 Ii;II: Ii I II 11'1 I, I III':: I: 'II I!II II" Ii II: III!I':': I:: II" I: I I, iII en t-i'+'i 1'1", j--'---++H,"", 1+';+,'p..:Ii I!I, III": I: II II Ii 1111I i IIIIII,'I i'I111',iI, ill: II'I i I IIII II I:,.'i: I I!Ii:II'I,.II: 'II II'I III'1 1 11',II 1'1" II:" II:!ill', I,!i:.'I'I!I'll I l:;4.i II i ill ii'I!'II II"I:;I: i,i ii, II'", ii, I:, II!II II: I II.'.i ,I I',!I;IIII:, I'IIII, IiI;I 11II I i II II!II II,'","":I,,'Ii;II L'I'a.Ii;,: 1)."."1,"...*11111'i*j , I,::111),'I I:i";il,'i!: 'i*I:ii Ii:: I'i.i Iii: II" 1II1!III ,:'1111111,111111' ")1.,,'1'1'1.,II, I)" ,II,',." ,0 II::,Ii:III,il'"!!Iil ,,'.1.1":11"'I'"II:O::::i",':" I!I"": 'I III.';i'II*,.','I',II'il:i ,I,::.'i::i: I:: 1,1,': " 8,':iil'I!!!'ill!,II 1 1: 1 I!i II I II Iii Iii il 101:Iii ill'11 Iii II Ij I II;I,':'I)111 1,1\1'II:il: 1111:11 1 IiI..:.::..;II!.I.I',, II Ii,"I, II, I I',i*I I: I II;;i.I II'II I IIII III 1I11I I.'"'\" I,'I I:':,:: I I II Ii,..I I'I iI!I,I:I.:1,I',.,I":., i I I I:z I:".:;.r,>=1"1'I: illl 1:1', II 1I1I I,:;.I!II:'ill: I:!I':1,1'i 11,,1'Iii!I': "Ii I': II,'", 1'1111: III'!i'i;, iii'1*,1.:i:.,i I'!'0 illl.1'1 I:,!"': I': ,;.i: r: III, II, I i II:, 111 1:"*I!ii'III, II III ,: '!I, Ii.!'1;I, I,,:: II ,I: I: I, III ,I Ii':':!I"i: I: 11111'1'II:'I:: Ii: " i,!: I, I i II ,II'II II ,:il"'I"III""'1',1,",',Iii'III III!,i" ,.;'.U III;"iI 1'1 ,li'll,:11,:1'I':: ,I.11 ,,"'11111,1:,".Ii Illi ,II*,iI, t'::: 'j';::::::1:1::::

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CHEMISTS*METALLURGISTS ATLAS TESTING LABORATORIES, INC.6929 EAST SLAUSON AVE., LOS ANGELES, CALIFORNIA 90022 K TOM H.(VANS JOHN A.ST[V(NS TEL.: (213)685-4242-722*8810 IN ACCOUNT WITH WESTERN CONCnETE STRUCTURES
1911}SOUTH HAMILTON GARD£NA.CALIF.DATE 11/7/69 CUSTOMER ORDER NO.6999 CUSTOMER SHIPPER NO.LABORATORY NO.

MATERIAL Stee 1 IDENTIFIED PART NO.SPECIFICATION CARBON MANGANESE PHOSPHORUS SULFUR SILICON 0.21%1.22 0.016 0.019 0.28 CHROMIUM COLUMBIUM COBALT NICKEL TANTALUM VANADIUM COPPER SELENIUM BORON MOLYBDENUM IRON ZIRCONIUM TITANIUM ALUMINUM--Subscribed and sworn 10 before me Ihis____day of , 19__.Notary Public I..a..d lor th.County of la, An9'.".Slut.01 California 1M......"" SECTION 56 INC.56-159

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1 Jf.:...../)Certified By.!._

Merrill R.V/Clbtad C......*., f.----;:'1';" r:.*\;',.n r!"*,<::!Jr r\ll,(.l 1911"";','... , c...*'.*'..:,.}}

ML19066A377

Text

SUMMARY

SUMMARY

1.0 Eccentricity

2.0 Concrete

3.0 Stress

4.0 Washer

5.0 Washer

6.0 Composite

7.0 Split

8.0 Bearing

1.0 Dynamic

2.0 Tension

3.0 Fatigue

3.1.2 PERFORMANCE

3.1 DESCRIPTION

SUMMARY

3.2.1 GENERAL

3.1 DESCRIPTION

,f wire..gauge length.

SUMMARY

1.0 INTRODUCTION

SUMMARY

8.0 CONCLUSION

1.0 INTRODUCTION

SUMMARY

4.3 Inspection

4.4 Instrumentation

5.1 Tensi

8.0 CONCLUSION

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