Text

App 5J,Part 2,of AR Nuclear 1 PSAR, Nuclear Reactor Post-Tensioning Tendons for Bechtel Corp. Prepared for Submittal to Util
	ML19329E168
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Site:	Arkansas Nuclear
Issue date:	11/24/1967
From:	; ARKANSAS POWER & LIGHT CO.
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{{#Wiki_filter:._~----... ). i j T t .1 1 i i NUCLEAR REACTOR POST'-TENSIONING TENDONS 4 j FOR THE BECHTEL CORPORATION 3 i-i~ FROM f, G PRESTRESSING INDUSTRIES j Division of The'Texstar Corporation i 1338 North W. W. White Road l 512 - 333-3910 San Antonio, Texas 78219' i - May 20,- 19 68 i-1 i. mQ og35 800530'O. (U i: i L

t e-E' i i TABLE OF CONTENTS - I General Introduction to Prestressing Industries 1 II Static Strength i j' III Dynamic Strength a 4 .- IV Type H. Anchorage Details V-Type E. Anchorage Details VI Tentative Quality Control ,VII Installation Procedures & Equipment v + I l 4 f i 'I i. r i t j x W 0236 1 i ., L.. - __...,_._.__,.._,._..._..-.,..,..,_-.-.,_..___...-..._,..,._____;,,-,_,__.,_.._,___......._,I

\\L Disclosure Notice The material, drawings and the designs illustrated thereon are the confidential property of Prestressing Industries and is expressly for the use of The Bechtel Corporation and The Atomic Energy Commission and may not be copied in whole or part for any. other purpose without the written permission of Prestressing Industries. 6 = 023? W

( I PRESTRESSING INDUSTRIES May 20,1968 0238 9

i THE'TEXSTAR CORPORATION P. O. BOX 6 0 5 f-AVENUE J EAST AT 10GTH ST. GRAND PRAIRIE. TEXAS 75050 W.1. SPITLER DALL.As. 214 AN 4 4731 wassiosur pr. wears. e 7 cR 4.oo7s APRIL 12, 1968 t 4 -THE RESOURCES OF THE TEXSTAR CORPORATION AND THE SUPPORT OF ITS OTHER DIVISIONS, INCLUDING ITS EXPANDE0 COMPUTER CENTER, HAVE BEEN MADE AVAILABLE TO PRESTRESSING INDUSTRIES IN AN ALL'0VT EFFORT TO BC FIRST IN THE POST-TENS 10NING FIELD. O!)R PROGRESS IS FURTHER EVICENCED BY EXPANDED ENGINEERING, PRODUCTION AND SALES FACILITIES AND THE OUTSTANDING ENGINEERING TEAM THAT HAS BEEN ASSEMDLED ALONG WITH FOUR NEW REGlDNAL SALES OFFICES THAT-HAVE SEEN OPENED. 9& W. SPITLER- , RESIDENT i 4 4 k M 02a3 --+ ~ -.w- ,m e y v

_. _ _ _. _. _. _ n. s. Araericen BBR Bnc. l THE BBRV SYSTEM OF PRESTRESSING [' , A Nr -:ounN, 1338 NORTH W. W. WHITE ROAD ev=sau een $4N ANTONIO CFMC ,o, SAN ANTON.O. TEXAS 78210 mAnn n.4ust ooso zwancH TEL. AC 512 333-310 SWIT2 ERL AND April 18, 1968 To Whom it may concern: Prestressing Industries has requested American BBR to evaluate PI's capability to supply the post-tensioning requirements for your above referenced project. I have made the following observations of Prestressing Industries.during my assignment to them as a BBR Technical Consultant on their tentative Nuclear Projects: 1. Their financial and management position is sound. 2. .Their engineering staff is experienced and large enough to handle the expanded work requirements of this project. 3. Their knouledge of the post-tensioning requirements of Nuclear Containment Vessels is above average. They have established a qualified Nuclear Projects Staff headed by Mr. Gene Dabney. 4. Their production _ facilities and knowledge of fabricating large tendons is adequate. 5. Their tendons and end anchorages exceed all of the minimum requirements of our BBR Standards. Picase call me if you desire further information about Prestressing Industries or BBRV Tendons. Yours very truly, AMERICAN BBR, INC. l d ' Mark K. Rust MKR:1s OE40 E <~

1 II STATIC STRENGTH May 20,1968 02<ij. i M

-. - ~-. I THEORY OF STATIC FAILURE The modern theory of fail' re of metals - based on the theories of 'u Maxwell, Huber, von Mises, Haigh, Hencky and Malaval - states: the shear stress in the octahedral plane permits to determine the risk of structural failure and replaces the invalidated theory of maximum elongation (Prof. Dr. M. Ros: "Skatic Failure and Fatigue of Steels",) 2 In a publication of the Tor - Isteg Steel Corporation Luxembourg on the change of properties of steel under nuclear reactor radiations, we read: " Fundamental for the mechanical behaviour is the critical shear stress". .... - - -...73 I'l }5k /=

- t I

/ "F2 \\f/ N.L __F ( / o- \\ Fg m a Fm* '/3(Fi+F2+F3) Fig.I Shear stress in the octahedral plane: T:d

+ 7 + 3 +E E ~67~EJ 3

2 I 2 5 23 The plastic deformation produced by this shear stress is called: compamtive elongation bc* b + 6 + b -b b ~b b ~ b 023 l 2 5 l 2 l 5 0242

i The corresponding stress: G" 0l YO$+0$~V OCb0 ~00 C 5 2 comparative stress .0

Y Z ~0O ~00'V0 YbNT y T ST, Y

C X y Xf XZ fZ Two bodies will be in the same loading condition, if their comparative stresses re (and consequently also their s ) are the same. c 3 F3 Example 1: I I F2* l 2 , J- /,J--- / l V / l t li 73 tc =v3 rFe =/F*+Fl+F*+0iF-F9 -7 Oi Fig. 2 c i 3 2 23 3 The left element loaded along one axis and the right element loaded along three axis are equally loaded when 10c = rFc Examp.le 2; 3 3 ! / /! / i l l F- -F=0.57, 2 2 j ___/ y j___ } a, = o.,ay

/

/ sm 4 33 Fig. 3

The body at left is lodded by tension only along one axis. The body at right is loaded by a tension r and two compressions 3 2 equal to ' alf the value of 7 vi and 7 n 3 For the body at right we receive a comparative stress of: Fc = / (-o.5c3)2+(-o.57-)2+ Fj-(-0.57 )2-(-o.57")-(-0.57 ) 2 3 3 3 3 F

F / 2.25 = 1.57 c

3 3 Example 3: y A wire under the same loading condition and 73 equal to the u.t. s. or e. g. 240,000 psi, V will have a reduced ;1.t.s. of 240,000/1.5= 2 N ,/ 160,000 psi only. \\ Fl F2 V U F 3 Fig. 4 The validity of this theory has been demonstrated by tests for all kinds of metals. Tests with high tensile steel wires carried out by Felten & Guillaume Carlswerk AG and by Huttenwerk Rheinhausen are published in Leonhardt: "Prt. stressed Concrete Design and Construction" (page 37,38) TEST FELTEN & GUILIAUME CARLSWERK AG Tests on locked-coil cables (often used for suspension bridges) showed a remarkable reduction of their ultimate tensile strength due to lateral pressure which results of the point contact between wires of ()gg

adjacent layers. In the test, this pressure is exerted by rectangular steel bars (contact length 0.4"). (Fig. 5) TEST HUETTENWERK RHEINHAUSEN Fig. 6 shows the measured reduction in tensile strength on a heat treated wire of 0.205" (5.2mm) diameter due to transverse pressure. 6 0245

i (tr.u-a.w3-ww.. cm=--m--- a,m ew w.u-o.,-

w. -

--s-.-- mww un - ' d I d g y 11 .C; .i 4 m o i t ),,r l e 2 += I O s.' O f u) <li 1,1 e ii / C ? 1 / i g v -O 5) l s / g to / ,/ i hl f / i r .y O / C L. l ! l D '/ .~ O = t

===m. 1

3

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\\%'(.
s\\bY

l f hk A s awas - o<,s,.... w. s s. .s - N. ,2. t' j y . >Q, o 4 6.s : E i .. s x. 1 4 ? - o a n !I

1

! I 6 0 0 1 i = - - -. - ,O 1 O 3 O 1 I ed ra r , c[ ,,,l...,,,..,. ...e s... 2, ...a m, ,_ m.m _, _ m, m, ,,.__ m. OT4.4 6..._

e : =... a a u.e

=am.

i i Test Huettenwerk Rheinhausen F I 20

%)

/ c b 6* A e o 15 F + P sin CC / /' E / / O 10 O F 7 / v 7 Q P - h P O / ,\\ O m.. l 20 A0 .CO .80 1.00 i,20 LAO IRA?;1 VERSE FO9CE "F" tt; gjp3 f l t : l i t Fi-c oun-- a

y III BBRV ANCHORS ( Stress state in the_B_BRV - button head Fig. 8 and 9 s' how in an idealized manner how-the tensile force is transferred by the button head to the anchor plate. We imagine the principle tensions to form a bundle of ropes, (a-g) while the principle compressions form a series of domes (1-6). The ropes - are suspended in the domes, loading them with an evenly distributed load p. According to the membrane theory, we can calculate the stress distribution for each dome. The plurality of the domes corresponds to the button. At each point of the dome we have the forces N, N and N (Fig. 9) 1 For an evenly distributed load p, Ni and N are compression forces of equal -magnitude, and constant for all values of C i and<a - N1=N2 =-pr/2 7: =F2 =-pr/2t ( t varies with ci and (C 2 ) As has been shown, a triaxial stress combination tension-compression-compression may reduce the u.t.s. considerably. In the button head we have in the plane of minimum section s-s (perpendicular.to the. wire axis) no triaxal state of stress. A triaxial state of stress develops along the surfaces of the domes 1-6. The area where a triaxal state of stress occurs is shown shaded. The load p decreases from section s-s (p= r ts) to dome 6. The critical u surface in the button head is dome 1. i 0248 1

c,11n,u m e m.a~ < mm : ms,. a., --ww-n....-. <,~.~ a -- ~~~~.~ m.re.,nnn..n,w 2 J t e I i, r l r f C t 4 1 I l i t o 4 C I \\ g'S (\\- \\ h.... : y M. N 5 ca \\ l -c N,,. \\ :. #.,.- ;C {- s. f \\ /' l - N., ?' \\ /\\/'i / < \\ N / N /.p m __ .E. D' %!; f h v ;,;S: v. 5S Y ~- =, /c Of [.'y's/h]J,. N7*, j [h_ W x lw9 j =~~~p, mn-l N,, w - g3 n -1

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_W - W i / / to / 2 / ~/ / / / / / \\ / i N / TZ I I I = I I I I N l d i I I I i .? l Lt. I I I 1 I \\ \\ l \\ l \\ \\ \\ -\\ \\ l \\ s k ~1. \\ f \\ 1 N . g N /' N s W M, '.'. _ da **' / 0250 . _ _ _.. _ _. _ _ _ ~ _ _ - - e p

The comparative stresses depend on the button heads dimensions. As long as the comparative stresses in dome 1 are smaller than r,,, the o button head will bear the full ultimate load of the wire and rupture must take place in the wire itself, not in the head. The tendons strength will therefore be determined by the wires ultimate tensile strength. -The critical comparative dtress will be less than Futs, if the button, heads dimensions respect the following limitations: Buttonhead diameter / wire diameter D/d = 1. 4 5 - 1. 65 o Height of buttonhead h = 0. 9 - 1. 2 d The following table shows results of tests carried out by the Swiss Federal Laboratories for Testing Materials and Research (EMPA). Group D/d of the wirg) Wire stress leading to rupture 2 (kg/mm (kg/mm ) A 1.20 17 6 71.4 58.6 69.6 B 1.33 128 138 128 C 1.45 172 173 171 D 1.60 17 6 176 176 E 1.66_ 176 175 176 F 1.75 116 139 129 G 2.00 .176, 12 8 117 125 I S 0251

TESTED SAMPLES A - G g, -.s .. A. a.*.e gN

f 1)

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0.. **

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1 -

__,.,y { L. s, w 6,. .t6 ,,e..-....p..ip g.,-m.e== mea.s.r e, y .e m. 6. s g-ey**.*'-..**. -es.*.- e.pe rwmm.my, e y..e ,,.g / p, j-.. .. _.; O .\\ .-t 0,*-** ~e. s-...,%

* *._.s

._.e*.. . g L. s -~ g3 .,j 'N G. _...t.g ,-). ,,/ g ~.. .-w- _..~e. - e w .e .,~..s s 9 0252 Fig. 10

The results confirm, that button heads with proper dimensions develop the wire's full ultimate strength (compare Fig.10). Hundreds of tests carried out by BBRV Licencees and by neutral institutes show the same result. Out of this large number, we mention a test series which demonstrates that even cracked buttonheads be'ir the full ultimate load. When upsetting certain steel wires which otherwise have fully satisfactory properties, vertical dr slightly sloping cracks become noticeable at the side of the heads. These cracks have no bearing on the strength of the anchorage. Small eccentricities when upsetting are likewise unimportant. It must be emphasized that shce1957 the introduction of the spherical button head top has reduced the tendency to develop even fine cracks practically to zero. The following table shows test results from tensile strength tests on samples with the old (flat top) button shape carried out by the laboratory of the Westfalische Drahtindustries, Hamm, Germany. Average strength of button heads: 177,8 kg/mm Average strength of wire: 178,3 kg/mm Difference 0.3% 02:53 Y J

Bundic Sampic Sample with Sample without Cracks Number Number button head button head f.c. = fina-no uts in kg/mm' r ts in kg/mm a.c. = average F u st

c. = strong I-II 21 18 0,0 180,0 f.c.

22 17 8,5 180,0 st.c. 23 179,0 180,0 f.c. 24 18 0,0 180,0 a.c. 25 17 8,8 180,0 f.c. 26 17 6,0 178,0 a.c. 27 17 8,0 178,0 st. c. 28 177,0 180,0

f. c.

29 177,0 180,0 f. c. '. 30 18 0,0 18 0,6 st. c. 31 17 8,0 180,0 f.c. 32 17 7,5 179,0 st.c! 33 18 0,0 180,0 st. c. 34 178,0 179,0 a.c. III 1 17 7,0 178,2 a.c. 2 17 8,0 178,0 f.c. 3 177,0 177,O f.c. 4 17 7,0 177,2

f. c.

5 178,0 178,2 f.c. 6 178,0 179,0

a. c.

7 17 7,5 177,5 f.c. 8 177,5 177,5 a.c. 9 177,5 177,6 a.c. 10 177,2 178,0 st. c. 11 17 7,0 177,6

a. c.

12 177,5 178,2

f. c.

13 17 8,0 178,2 f.c. 14 17 7,0 177,5 st. c. 15 177,5 178,2 st. c. l 16 177,0 177,8 st. c. 17 179,0 179,2 st. c. 18 177,8 178,0 st. c. 19 177,6 178,0 st. c. 20 178,0 178,0 st.c. 21 178,0 180,0 f.c. { 22 179, 0 179,0 a.c. 23 17 7,0 177,6 st. c. 24 17 6,0 177,5 st. c. p 25 178,0 178,0 st.c. 26 17 8,0 178,3 f.c. W 27 177,0 180,0 a.c. 28 176,5 179,0 st.c. l 79 17 7,8 178,0 a.c. 30 17 8,0 178,0 st. c. I 31 177,5 177,5 st.c. 32 17 6,0 177,8 a.c. 33 175,2 178,0 st.c. { ozm

IV EFFICIENCY OF BBRV ANCHORAGES : To prove the efficiency of the anchorage, BBR did not only test wire samples in a testing machine but also tendons under the conditions which occur in reality. We show the following tests on straight 163 wire reactor tendons and on curved tendons with 121 wires'. EFFICIENCY OF IARGE TENDONS 1. The efficiency of a tendon is often defined as the ratio between the ultimate strength of the entire tendon and the ultimate strength derived by multiplying the mean ultimate strength of a wire with the total number of wires, whereby the mean of ultimate strength is determined from a large number of test samples (e.g. one for each 10 wires employed in the tendon). This efficiency value can refer to straight tendons or to ones with various degrees of curvature. Ultimate Load of a Straight Tendon 2. The ultimate strength and the elongation at mpture are both subject to random scatter. 3. In a wire bundle in which all the wires are equally stressed, the first . wire to break is the one with the smallest elo'ngation at rupture. The rupture load in such a case is then the sum of the wire stresses at this elongation. It is possible that the load can be further increased following the failure of the first or even of the first several wires. The ultimate load cannot be derived from the wire strengths alone, nor can it be computed by multiplying the mean wire strength with the number of wires. In practice, however, the resulting discrepancies do not make much difference, but they should be taken into account whun one considers the efficiency of a curved tendon in comparison L 0235

with that of a straight one. In ary case, it would be more correct to make a comparison between the ultimate loads of straight and curved tendons, wh3re it is necessary to make a sufficient number of tests to eliminate as far as possible the unavoidable scatter in the small differences obtained. Ultimate Load of a Curved Tendon 4. The following influences can reduce the ultimate load of a curved tendon: (a) elongation of the extreme fibers due to the additional bending; (b) pinch effects and prevention of elongation, as a result of friction; (c) unequal lengths of wires due to the curvature; (d) local disturbances in the duct wall or in the wire bundle. The rupture will take place at the point where these influences have the grectest effect, i.e. usually in the first few meters of the curved portion. 5. A curved wire undergoes extreme fiber elongations amounting to: Ep where r = radius of wire section, and R = radius of tendon curvature corresponding to an elongation of 0.1% for a 7 mm (0.276 in.) wire in a tendon with a radius of 3.5m (11.48 ft.). I:ven though this radius is extremely small, it can still be maintained that such additional extreme-fiber elongations have no practical influence on the ultimate load. 6. Fig.11 shows some date on the quite considerable lateral forces that are exerted by the external wires on the internal ones near the duct in the case of a large-size tendon. Assuming a pile of 10 dia. 0.276 in. wires (e.g. ( m:.::. in a tendon of 163 wires in a round duct) an u.t.s. of 240 ksi and a stress of 0. 70 u.t.s. 025G l

M N M M7NO d.M*MY,

E O ".

N Id 5M .4 e dMSN Fe dY. h Y. E fpOId N I Iek M [, M E i r, [ .c. t L'_.* f" f [ i n / ) A i / l 1 i /,' ) .i I g y' E i i l { i 9 j /- 2 o a i e, s I l ,/ l .h .j n' M6 l 5 ,{ i h ?! ,9, !l I C )' 'S h N o 3 0 .\\ O NlZ NlC .d Nl ? = I Ci

f. '

i NOO-cnO Ok4 \\bx 2!, x -t - ::x s - =-w -:.:r - = =. ---c.~ p O Y ~ !s d bx e 3 i 'bh s t wk s\\sW : s a .Ax N s Ny\\esaysh' l\\ tx'\\s c ~ 3 j,QA'

y. gs'

+ 0257 -._,,~.__,._.-.--,.~.._~.-~--.~..-...-~.:-.

~- R = 6.0m n Z/R = 51 k/ft. R = 12.0m n Z/R = 2 5,5 k/ft. \\ The difference of the lateral force s acting on one wire, multiplied by the friction factor, gives the friction loss per wire,which regarded from a theoretical point of view, is equally large for all the wires. Test Results 7. Following a series of preliminary tests in Bochum, West Germany, in Southall, England, and at the Swiss Federal Laboratories for Testing Materials and Research (EMPA), the first systematic tests of large-size BBRV tendons with straight and curved axis were undertaken in connectionwith the construction e of the Dungeness B nuclear power station. 8. The tests of straight tendons were carried out in Cheadle Heath, England, by the English licencee, Simon-Carves Ltd (Table 1), whereas it was necessary to construct an expensive facility in Frick, Switzerland in order to carry out full-scale tests on curved tendons with radii of from 6-12m (19. 69-39.27 ft.) (Table 2). The purpose of this facility was nevertheless conceived to offer other possibilities than solely for the specific problems connected with the prestressing tendons to be delivered for Dungeness B. Fig.12 shows a general view of the facility in Trick. 9. Even though the two facilities are not identically equipped from a mechanical point of view, the high precision of measurement of the instruments employed still permits the comparison of the results obtained with straight and curved tendons.

10. At the time of carrying out the tests in Frick, there was only a stressing dav=c avaikbic for up to C50 tons, so th:t a reduced tendon unit h,aving 0258

121 wires of 7mm (0.276 in.) diarneter was chosen. The tests comprised tendons with two different radii, a total curvature of 1800 and straight end sections corresponding to the arrangement of Dungeness B.

11. The reliability of the results is dependent on the one hand on the actual precision of measurement of the dynamometers and on the test methods, and on the other hand on the statistical selection of the 12-20 wire samples which are used for the determination of the theoretical ultimate load.

12. The first point to note is that the results of the two test groups can be termed excellent; these large-size BBRV tendons make it possible to exploit the prestressing wire far into the plastic range, which is a fundamental prerequisite in any investigation of ultimate loads of pressure vessels, o

13. Nevertheless, it can be established that the influences discussed in 4-6 bring about a slight reduction in the mean efficiency, from 99. 7% in the case of straight tendons to approximately 96.5% in the case of curved This becomes even mo're apparent in the reduction of the mean elongation ones.

at rupture from approximately 4.3% to approximately 2.8%.

14. About 90% of the fracture points in curved tendons are t'o be found in the first 1-3 m (3-10 ft.) of the curved portion, because in this region the high lateral pressure prevents further plastic elongation of the innermost wires,

or because a minor random irregularity in the duct leads to a notch effect. Further along, in the curved portions., the frictional forces bring about a reduction of the prestressing force, thereby automatically precluding any risk r of rupture, in as much as the tendon soon finds itself in a state of elastic stress again. 0253 5

TABLE 1 Cheadle Heath Straight tendons: 163 wires of 0.276 in. (7mm) diameter,18.37 ft.(5.60 m). Test Wire Theo-Measured Efficiency Elonga-no. manu-retical ultimate tion facturer ultimate load at load tonnes rupture tonnes 1 A 1055 1052 99.7 4.22 2 1055 1052 99.7 4.49 3 1046 1021 97.4 3.96 4 1044 1031 98.6 3.95 5 B 1059 1067 100.7 4.78 6 1058 1041 98.4 4.40 7 1046 1046 100.0 4.41 8 Test No. 8 not completed for technical reasons 9 C 1073 1077 100.3 4.20 10 1070 1082 101.0 4.24 11 1087 1102 101.4 4.53 6 1 tonne = 0.98 ton TABLE 2 Frick Curved tendons: 121 wires of 0.2761n. (7mm) diameter. Test Wire Theo-Measured Efficiency Co-Elonga-no. manu-retical ultimate e fficient*

tion at facturer ultimate load of rupture load i tonnes friction,

tonnes (R = 39. 37 ft. (12. 0 m) 1 = 141. 07 ft. (43 m) 1** C 774.4 744 96.1 0.122 3.04 2 A 775.2 740 95.4 0.123 2.37 3 B 791.5 764 96.5 0.135 2.72 (R = 20. 01 ft. (6. 2 0 m),1 = 114. 8 ft. (35 m) 4 C 749 718 95.9 0.116 2.96 5 A 770 751 97.5 0.122 2.52 6 B 786 767 97.6 0.141 2.96 1 tonne = 0.9 8 ton

Tendon with 120 wires.

Both concepts employed here, that of the theoretical ultimate load as wall as *. hat of the efficiency, were defined in 1-14. t la the range from 0.50 to 0.75 x the ultimate load; tendon treaded with commercial-grade drilling oil. Q2(jf)

Fig.12. Schematic plan of test block showing location of test ducts 90* op? [ Plan l b[k / / ~ ?J)'4 / N@ 6 ,.< / ii r 'h ^ '

[*\\

i 9; / y /f %[ - ~

M a

--s : : 5 / N d_, _ U ]I / g-If g l 26.50 Cross-Section 1-1 I I I si j "X- - - - -.; =g _ _ _ _ _ ~ _ _ c _ ___ _. ?_._ _-. i. 1 I-v~. _w __ - =J t g;t t _..g_ i PI based the development of their large tendons on these BBRV experiences. The external threaded PI anchor is nearly identical to the tested anchor. The button i heads have the same shape, wire and hardware materials are duplicated as close as possible. (Comparative tests show equal friction coefficients for large 7mm and 1/4" wire bundlos). For both PI-types (internal and external threaded) there is a difterence in fabrication and handling, but both of them will show the same behavior and exactly the same efficiency as the tendons used in these tests. 0261 M b

s o i 2 a h. g ..k .g 8.2 g { N ej l l e e00-l o5 f I J m-g4 e - - - - t.n=.= _;.t::'.

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^ 1 ~- v 0262 { ~ f

III e DYNAMIC STRENGTH May 20,19 68 0263 g

~ I BBRV - BUTTON HEAD If a body is alternatively stressed between two limits re and 0u, and if the upper limit 0u is so selected that rupture takes place after 2 million stress changes. then we call the difference: a a = 00 - at the relevant fatigue strength. From the curves (Fig.1) we see that the fatigue strength decreases with increasing lower limit 01 (the oscillating load becomes smaller), but the higher the value of the lower limit, the higher the upper limit becomes i. e. (OC 00 -i ). / The fatigue strength in the anchoring zone is always less than that of the basic material. Fatigue ranges of tendon anchorages (for at = o.s 6ts ) Wedge anchorage (according to wedge shape) 15,000 to 20,000 psi BBRV button head (individual wire) 15,000 to 27,000 psi BBRV Special button head 35,000 to 45,000 psi At the transition of the upset head, there are unavoidable concentrations of stress. In the case of a static load, there is an adjustment by means of plastic deformation. In 1:w case of fatigue stress, such an adjustment is not possible to the same extent; hence fracture takes place chiefly at the transition from head to shaft. The main reason for the wide range (15,000 to 27,000 psi) is the wire quality. Wirns from different manufacturers shows different test re sults. i Tests carried out by the Swiss Federal Laboratories for Testing Materials and Research (CMPA): 02M \\ .)

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,/

my a ~ is is c o 'e r C /. - if u / l+=ng Q. i ~ t c. / l 's I I 4 / 'r' / 0 s' / l r l \\ { .N l /s___s ,I ~. / N C 'm i N ,/ N / c l ?H n / ,I f w.' _.2 l J h' N. N 'G' '/ / x ---s,.- - _ _. _ _ _ l I ~,N, l I t --y /, l l l / 'L =_-- -i s O 0.0,l l' a_ z-p ees s,[ I h,/ s s I i J / f_ /

-t

__= / \\./(*% ~ / g i_ "1 pg 'V 0265 t

2 x 10 Load applications, lower stress limit E = 124,000 - 140,000 psi EMPA-report Manufacturer A. 3854/3 fatigue strength 18,500 - 19,0d0 psi B. 33745/1 22,000 psi C. 32163 14,000 psi D. 55939/2 24,000 - 26,000 psi Tests at the Technological University of Darmstadt, Germany showed that measurement tolerances and cracks in the button heads have no influence on the fatigue strength: Test report 850. 66

== Conclusions:== "The tests do not show any influence of the dimension tolerances on the fatigue strength. It is not possible to find any relationship between cracks in the button head and the fatigue strength. The fractures didn't show any connection between the cracks and the starting-point of the failures." 0266

13cMon-iP.:.d DialNitr (m m) 8.70 -8.90 8.91-9.10 9.11 - 9.4 0 C:':; I ead Haight (m m) 4.9

4. 9 - 5.1 5.1

< 4.9 4.9 - 5. I > 5.1 < 4.9 4.9 - 5.1 1> 5.1 l Serios A Series B Serlos C Serlos D Series F ,lcne 81 i i l j 16 14 Il 28 l 12 2 C i Series E Series G Cru.h.. t errarmi :o. ir o exis 0 0 21 12 4 4 l Series H + Oiesonal or Transvorse ~~ retigua Straagth

A F" 6~u - O~L =

C:19,000 psi D:20,000 psi l E:17,000pst F : 21,500 p s t G:20,000 ps! H: 23pOO A :19,000 psi l 0:18,500 psi l 30,000 - c p .a 25,000 - v> 0 l .s. s j o .'s b ~1 3 ed 20,000 - s M EN \\ f~

C-O I' $

G-O A-O D-O ^ ~ ' b E-6 H -+') B-o 15,000 - j O s 10 x 0.5 1.0 1.5 20 2.5 30 0.5 1.0 1.5 2.0 2.5 3.0 0.5 1.0 1.5 2.0 2.5 3.0 g t* Stress Applications II ,':r. v. s.1 023 r, 11 st t e ph ? S'i,000 r si 3 .t.m n 2 <t.e- /? ( (!~ * (>L ) = 133,000 psi f 0.52 Futs ) f ea, y of ?ress arr!:catiens 7000 per rmnii*e

Ito II BBRV - ANCHORAGE A BBRV-tendon is a bundle of individual wires. The first wire breakage in a bundle is naturally a minimum value, but it doesn't give the real fatigue strength of the tendon. Tests have shown that after the first wire has broken, the load can, as a rule, increase, i.e., the fatigue strength of a cable is not exhausted when the first wire breakage occurs. i Tests on BBRV-tendons: A 42 wire tendon was pulsated between 80 and 86.5 tons corresponding to a stress of from 124,000 to 134,000 psi. After 1. 3 million stress-application cycles, a wire fractured. The load limits were main-tained and pulsating continued; the stress limit was thus increased by 1/42. The cable was in a position to withstand a further two million stress application cycles without a single wire fracturing. Tests were carried out by the EMPA in 1960 on cables consisting of 18 7mm wires each. With a lower limit of 135,000 psi the cable withstood over two million stress-application cycles to an upper limit of 158,000 psi without any of the wires fracturing; only after the upper limit was raised to 161,000 psi did one of the wires break, after an additional hundred thousand cycles. As shown in tests carried out at the same time, the 7mm wire itself is capable of sustaining two million stress-application cycles with an upper- -limit of about 185,000 psi when the lower limit is, as above, 135,000 psi. l .s i 0268

Patigue Strength Tests on BBF.V Tendons EMPA - Reports 23549/1-8 28238/1-4 6 W 0263

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Jatigue Strength Tests on Tendons CC227 (55 wires d 0.276"i EMPA-report 23549/1-8 Button Head: Anchor Head: ,- m i 1 - ADDITIONAL PLATE g g [ I ~~~~~~~ _ O.425" g e d CO.8mm) ^ l l 0.335" 9 h I l O E M [m lkf E e 1 ( 8.5mm) rd 8 l o O c) 9 <0. P.95" ~ I l e = ~ l l-N b =M t (7.5 mm) l ,q E. E h I I d A EL 1 v e I v 5 I w 4.41" (ll2mm) Fig. 4 In order to find the influence of the anchor head on the fatigue strength, the anchor head material and hardness br the borehole size and shape were changed from test to test. {b = 230,000 psi 0- = 0.70{ = 160,000 psi Testing machines: 2 Amsler pulsators, ca. 270 load-applications per minute 2 Amsler jacks, 55 tons each 0271 O

TEST t 3 4 3 M* :' If t:*e 4 Hait Trcste d Hest Trested Ury cr ecee d echorce cd Ar *+' "*r He:1 4140 464Q 414 0 lG40 1063 F*r1* ti$ 300/ 3CQ/ 30J/ 204 234 (f!rire f t) / 3E] / 360 < 3CO Ortsetteed ado;f;CnOf P:Q't 8040 Tt:ckness o334 o S9: Pord9est 204 i 63 rep 3let 0 2e P* '0337' 0 30?* ' 0 3J7" '0 307-( 73evi (75mm) (76mmi (?e e m) ?e== g _e ^ .T T ,j_ j_' e g 7 E - E m o e E m o D q o[c ep e o e e!_ 0 - .l_ 03M* 0 335.' O 3 5S_'_ _ 0 335'. it s em : is la m ) (eSe e te Sr-1 l l l i i l i I I i i i j i t' I, i i. I 2 2.8 0 0 ~ 5----e*--**+- E-4, sa s -we I.n - - + ~ - - - - 4--- + +-e----- 2 4 .'s4 1 ( 7 4' 6 h, I l i l %9,*,C - 4.- .. + -,. g w d 4 2 -- - --+- - 3 5 t b 17.000 - I--+-- --+ c 4 i .t,. l k .f-.n-. _.~. p at en 14.200 - 2 T- -I.-- i -., z a ~ i t,4; w i_.._ i.__ J'. t l i I i l l 1 I i i t

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J: ' PI uses C1048 hot rolled anchor head material with a Brinell hardness of 200 - 260 and the same button hea'd shape as used in the tendon tests. As the 1/4" diameter wire has about the same fatigue strengt!' as' the 7mm wire, PI tendons will show the same' behaviour as the tendons used in the tests 3, 4, and 5. With a lower stress limit of 70% (or less) of the ultimate tensile strength, a PI tendon is capable to withstand 2 million stress applications t with a stress amplitude of at least 12,000 psi. (The average is much higher! GROUTED TENDONS Fatigue tests on bare anchors certainly provides some indications, but they furnish no reliable standard for judging the fatigue strength of the entire structure. In the case of stmetures subjected to repeated stress under full load, the anchors are normally in zones where the moments are-( zero, or the change in magnitude is slight. Tendons in principle structures subject to fatigue are always grouted. The results from test 6 and 7 show that even a short grouted anchoring length increases the fatigue strength of an anchor considerably. The adhesive strength in the case of smooth wires, is roughly 17,000 psi. For an enbedding length of one foot in mortar, one obtains the following forces for a wire 1/4" in diameter: 12 x Ti x 1/4 x 17,000 = 160,000 lbs. This corresponds to a stress of 32,500 psi. If, after prestressing, the wire has a stress of 144,000 psi, then this stress will occur in the trumpet zone 'also. - If the stress is now increased outside the trumpet (embedded) zone, an increase in stress from 144,000 to 176,500 psi can i 3 g 0274 m

take place, before the upset head experience additional stress, i.e. before 4 4 fatigue stresses can occur in the c5nchor head. Since the trumpets are always provided with connecting openings, their filling is insured even if injection of the whole cable should fail for one reason"or another. This means, however, that the combination of the fatigue strength of the anchor and the adhesive strength of the mortar produce such an anchorage in the trumpet that, in the event of fatigue stress,the fracture must always occur in the free wire. For the acceptance tests of various railway authorities beams were subjected to fatigue loading. By selecting short anchoring lengths L and high shear forces V an attempt was made to destroy the bond along the anchoring length. In spite of the fact that L was only 3 feet and that the beam was loaded beyond the cracking load,~it was not possible to reach the fatigue _ strength of the anchor in any one case, although an injection mortar of 4 low strength was deliberately employed. The beams, on reaching the - fatigue strength of the wires or concrete, were destroyed in the middle portion. It is well-known that steel, in particular steel with high tensile strength, is extremaly sensitive to surface friction and the squeezing effect, i.e., the fatigue starts at places which are subjected to such ' additional stresses The fatigue strength of the drawn steel wire in the range of stresses of interest to us is approximately 40,000 - 60,000 psi. Since the chango in stress in uncracked concrete under live load is_ at k. ' most 1,400 psi, the stress in the steel wire will. increase by a maximum ' of 7,000 psi (the relationship of Young's modulus of the stcci to that of y 02'7s

e the concrete' = 5). Consequently, only 1/6 to 1/8 of the available fatigue strength is utilized. For prestressed structural parts there is no risk of an exhaustion of the fatigue strength of the steel wire. The question of fatigue safety is present at most in the case of structures in which crack formation'is permitted (partial prestressing). Therefore, in principle, structures subject to fatigue must be fully prestressed. In the infrequent cases in which the wires are subjected to pronounc' d e fatigue stresses, as in suspension bridges, etc., an anchorage such as that 4 provided in the ordinary BBRV process does not suffice. That's why BBRV designed a special button head for fatigue loading. This type of opset head J is tulip-shaped. The support is made of somewhat softer material than the wire and its drill-holes are simply conical, rather than having exactly the tulip shape of the head. Consequently, the head embeds itself to a certain exterlt in its support. The greater part of the head's supporting surface extends i ~ untouched into the drill-hole; thus the wire has a relatively large amount of free play (about 10 to 15% of the wire' diameter) in passing through the hole, i but still cannot be pulled through. The tests results shown on various loads on the accompanying diagram have confirmed that, with the new anchorage, double amplitudes of 35,000 to 45,000 psi (approx. twice that othenvise attainable) can be reached. The range up to about 125,000 psi applies to suspension bridges, whereas prestressed concrete is concerned with the higher values. t 0276

h 1 227 213 - E $,,[ ,,,@ fl llll f s j q l' E / 9.l / t 8 / / rl i /

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l

'8 e = l b]'. ! / gj / g H l o I es I ~ 45* 6 8' d I w o e 8 H 9 l ce to o o r s a g 64 125 14 8 170 200 227 g I I TENSILE STRESS SUSPENSION BRIDGES PRESTRESSED CONCRETE i APPLICATIONG i l i MECHANICAL ENGlNEERING i Fatigua tencile tests en hich-quality st:el wire w;th cn u.t.s. cf 227h.s.t. S= Double cr ptitudo p!otted cgoinst the lowcr lirnit of stress-cap;icatien cyc!c @ ------ Wire l Wi.c cnchecc"c wi!h uu;ci E.3RV b>; ten-rxd. I E " 'i r. he"? ' th r:: r.m ! 6,77/ 'ul!v-;. :.i -~ i _ _._ _,O-- . !c_7___ Ok:77

-=. - :-. BUREAU BBR Dept. 3 Technicc1 report Zurich No. 9 002 Tests on the Eridae over the.iiver "Glatt" in Opfikon. Switzerland j? = 30. a S.w/ 70 DEf' ?7/ /rk 77& = nee s2, - g,- e so zs':s'12C .c rn as a w-i~ ., ~ 'n ..,'*' 4 " 20'. 0 0 2" l,,. I *

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.i/ l . = I M... 5't .._.. _ f * . A yggy _ p. ____,.ssW *m, "M,] Q ~~ ,~ e no 22 %e Langssd m> cuerschnitt e "' b ' (ic.vs..m:rm:) (cwsc-SECTLV) The bridge across the rivar "ilatt' in Cyfikon (prestressad frame bridge wit-ir.clir.ed struts and tiea) bu.lt in the years 1954/55 had to be de:olished for traffic reasons at the end of 1950 after a service life of-5 years. The Swiss :?ederal Material Teating :aboratory availed its alf of this opportunity and carried cut exhaustive dynamic and static tests finally leading to failure of the supporting structure. Prior to the load tests, the condition cf the supporting struc-ture wac carefully examined. 2he concrete surface was found to be in good condition. No rock pockets, d:.r. integrated damp spots or rusted reinforcement were fcund. At the lovar face of the edgc cpans seve:?al longitudinal cracks were found extending approxirrately parallel to the prestressing cables. The ultimate cuba strength ws3 alcut 7CL kg/cm2 (/C,Ccc :wI.) Purrose n' the tes-a

l. Faticue teats.

troef that the bridge can tal. a the livs J.oad any number c,f times (i.e. 2 mil.lian lead cycles).. ( Progressive increa.se of live 'ud c p to fe.tigue failure c.nd deter-tination cf dynamic safct;, as: cr s,. failure. OM8 2 S t. t i e i e.c t r. m.,.....

)

Result.:f tests

1. Fatiate tes_ts Oy p

.:.,-.0c'n! A* Yo *. *Y f.nt::ht Lostwe:M elin 10* LO " %c. g 0.04. tCR 0.?? 0)$ . $23f a> l "f f.

st.f.hrtekst. ; n? 3J L f f

k,, f5Jy f l,- ll o I(s - 4 [i J t g L Q $,o "'=-- . ;.l..-~"'T"', y1 s ,l 6 s.s 4..... r.. ii y l o. l ,,b 1 2 3 4 ..5 6 7 L T. h nieves Ls.twechsel (cvscit..ncw <*i Miwws) a) The bridge withs.tood 2 millicn. load cycles with full live load practically without impair:.:ent of its elastic behaviour. No permanent deforr.ation was fcund. Except at the er.d of the inclined tien there occurred only in-significant cracks at the edge beam of the cantilever. b) At a to al of 6.65 million load cycles, increased in ctepo, a fatigue failure oc::urred la one of t't.o ties after the last 0,35 million load cycles, corregonding to 2.54 times the live load. At the fatigue failure the safety fac;or amounted to ,. 6 (dsid 3 wd 4 live ".oad) The fin.11 load-capacity of the bridge was not yet attained. After the repair of the broken tie a utatic load test was carried out. 2.' Static Fest y,.,,, m, n:....,, <.; w.u ~ x.>va ., ~.- ~,w. n, 4[Q &ursvr 427 >271? / ,~ a sea y st.s.v. ,.t: Si *i }X 5 t, '{ s \\- e.

5. : w A /

4 / M 5._ V I-l 0279 + t b .v 6' .:6 [y'Cb j :n

_3_ The mnximun load entacity of ;he t:-idge,as attained when plastic hingcc sta.;2c occurring recceding to t.. following illuctration. z P.<!y, t asy, t t "? 03M5? 00? as t u'cettex r } a n ^':r- ,. cm,. S 60 Y <u. r g d.*l .g. ...-o ..o yu.i-23.:= With the s tatic test '.oai the s afety facuor amounted to 2.75 (3ead ly d + live load) c' e' v Cor.unicat ec b:. Is. .2sli and -

n; ale: 7.<

F.1. F. Co r..c e.3 a Ror.e 1962 Cetober 156:: KE/ac 0280

IV ANCHORAGE DETAILS TYPE H May 20,1968 g 0281

F TENTATIVE DIMENSIONAL TOLCRANCE FOR ANCHORAGE DRAWINGS f 3.243" Indicates dimension tolerance shall be as shown to f 0.008 inched unless othenvise indicated. 3.24" Indicates dimension tolerance shall be as shown to f 0.020 inches unless othenvise indicated. 7.8" Indicates dimension tolerance shall be as shown to 10.030 inches ur' ss othenvise indicated. 6" Indicates dimt. sion tolerance shall be as shown to 1/32 inches unless otherwise indicated. 7/8" Indicates dimcnsional tolerance shall be as shown to 11/32" inches unless otherwise indicated. 0.270"/0.290" Indicates dimensional limits of tolerance.

3. 2 5 7 " Max., 3. 2 37 " Min.

Indicates dimensional tolerances.

4. 9 67 " - 0. 000" + 0. 015 "

Indicate limits of tolerances and also indicates that 4.967"is the absolute minimum dimension. 02S2 M 1

I t e ~ de M yt.pcsed me em n 9e conPaene.el peopwty of P'tr.STNS04%. INDt.;3TRIES oad may not be copied er ee;eekces. m who'e or part...thout the me.e ee camas.on of Pkrsf5:4 SE'%.%Dus?wt t re ' Cip c.

tvf

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.i - M { on 1 i o i l a a TYPICAL TYPE H GREASED TENDON ANCHOR. AGE L l 4 ~,...._ _ _

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i.

v }t.m,._,__,,.___._..__- -. ~ -.,. - ~ ~.-

x; L w __ _ _..y _ f ,j,. h___._ _ U_ l X i j j %" Squerg Hoed P!cgq {.~ I 1 ) s s _1 : t. _ s _ s, s sx !b ,s . Weld --- ' I 3/.s" I/ s -DG f; ;- 4 j j \\ e"-27 NPT V ( l / / / / l / / 8 / / ) i i / { l ,/ l / / s } / / / / 5 i

l F

/ j / I n T t ,r- %" Crill Ir ,/ ,f I i / G i ' N. e [ 3 / N N e \\ i / \\ t E n m is Y i i .l j' 'N \\ / E \\ l / j -s 1 i I %lM \\%" Drill N@- g E i t j Number U W X Y Number U W X Y of e of e [ Wires IN lil IN IN. Wires IN Ifl IN IP. 60 ' 4 29 8% Vs 7 14 4 672 CW 84 3 72 =1.70 9'/s W 7 !E2 7CS IF.i n 9 I 90 L20 9 /e' 3/;. 74 136 759 13 % /4 94 { 120 6C9 14 '.'4 Y-S f.! <t Ler.;n = F/ n :.er;ta e I: ii .0310 l$; GREASE CAP FOR TYPE E TENDON ANCHORAGE l .4 i a ,w ,30 ft ets s

U I 3%" l 4 Enterr'cl used tJ: twt f* i I Q come Threes - o ine:ds ~ ~ ~ ~' 2.997" f.tox - 2 932" M:n~ ~ ~ ~l Per tr.ch - Cns 2A fit - ~ ~~~ o f[ '2.862".t.tc.x.-- 2,82G" Min,______ j ' <j'j 2"-llW NPT W i Bore _2.219_. ___; i 'y r' { t_x i _I~ o ' *2d 5 ::smE=.e5 a= =.%--2?-=-E: E!Y:5:5Y-d =5 5* ' = = ^ E ? i o I ls ~~ ' > +, = ;. - i.~~. t. - ~ =- E=

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o i.au 3 IW" g l s / b t I I .a .t 6 -- - -- 3/3" Y.e c 6,.ve! I .e.- i b i Q311 i: GROUT m GREASE PASSAGE i

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_m,- _m - y ,r....

VI TENTATIVE QUALITY CONTROL PROCEDURES May 20,1968 0312 Br

TENTATIVE QUALITY CONTROL OUTLINE (A) Anchorages (1) Anchorage Plates All materials shall be purchased from reputable steel suppliers who shall furnish a mill certificate which shall show the chemical and physical properties of the steel for each heat of steel. All plates 2" and thicker shall have been ultra-sonic tested and any plate showing lamination or other flaws shall be rejected. Verification of this test shall be indicated on the mill certificate. Brinell hardness test shall be run on each bar (+20') of each heat, of all materials to be used in bearing plates and anchor heads, to insure uniformity of materials specifications. All heats shall be separated in storage areas or each bar shall be marked for identification as heat number. Only those types of steel specified on the anchorage drawings shall be used unless othemise approved. All steel shall be specified by an appropriate AISI designation or by ASTM designation. All anchorage plates shall be fabricated according to appropriate drawings and size and location tolerances shall be strictly adhered to. All dimensions marked by 2.500" shall be checked on each part with a go and no-go gage to insure proper fit. Those plates not fitting shall be set aside for further inspection. All burned edges shall be clean and free from slag and the finished part shall be within tolerances shown on drawing. (2) Trumpet /and Sheathing Sleeve Materials shall be fabricated from electric resistance welded mechanical tubing (MT-1010/20) with flash comoved or controlled to 0.010 inch maximum. g oaia

Any new weldable tubing may be substituted provided it has at least the same wall thickness and meets the same straightness requirements and ovality tolerances as the above material. This material shall be cut I square within tolerances shown on drawings. The trumpet shall be welded to bearing plate while being securely positioned to insure accurate location. The angle tolerance shall not exceed 0 30' or 3/8" in 4'. Welds shall be 3/16" continuous fillets. (3) _ Transition Cone Material shall be C1010/20. These parts shall be stamped from strip or sheet stock. They shall be positioned and welded with 3/16" continuous fillets within tolerances indicated for trumpets. (4) Anchor Heads All materials shall be purchased from reputable steel suppliers who shall furnish a mill certificate which shall show the chemical and physical properties for each heat of steel. All heats must be separated in storage areas or each bar shall be marked for identification as to heat numbers. All anchor heads for 60 wires and larger shall be C1048 hot rolled steel bars in the as rolled condition with a minimum Brinell hardness of 200. These anchor heads or blanks stall be cu+. from continuous bars. After cutting, each slug shall be Brinell tested to insure conformity to minimum n' ardness requirements. Those parts which are lower than 200 and higher than 280 shall be discarded. All blanks shall then be machined to the sizes shown on the drawing. s All threads n.ast be checked using go and na-go gages. The blank shall then be u]tra-sonic tested. An:, washer showing flaws shall be rejected. E 0314

'The blank shall then be drilled with the appropriate number of wire holes. These holes shall be a minimum size of 0.257 inches and i a maximum size of 0.267 inches. Each drill bit shall be test-drilled prior to use to insure drilling tolerances. In addition, random checks i shall be made of each washer. In the event that this hole is out of tolerances, all holes must be checked. The drilling pattern shall be layed out so that holes on the pattern are in the position shown to a tolerance of f0.0025". This applies to drilling heads or any type of drilling pattern. Actual hole positioning shall be as shown on the drawing 20.008". The smaller drill (0.257") shall be drilled from the top surface to the depth shown to +0.050". (5) Grease caps and accessories The grease nipple shall be a malleable iron casting graue 32510 (ASTM 47-52) or equal. The rough casting shall be machined to the tolerances shown on the drawings. All threaded portions of the nipple as well as the nut shall be checked with go and no-go gages to insure thread fits. Grease cap nuts and washers shall be machined from C1018/20 steel as shown on the drawing. Each grease cap nut shall be checked with a go, no-go gage to insure fit. (6) Marking Bearing Plates Each bearing plate assembly will be stamped with a Quality Control Number (Q.C.N.) consisting of an eight digit number which shall be permanently indented into the stressing face of each plate in one cored out-side of the anchor holes. 7dA007PI The 7 shall indicate the month the anchor was corr.pleted and the 8 indicates the year "68". O would indicate 70. The A007 is the number which 0315

shall be assigned for each heat as the bearing plate material is received. (This allows for approximately 23000 heats.) The materials required for the trumpet, the transistion cone, and sheathing sleeve is relatively un-important as far as strength is concerned and,therefore, no marking of this material is necessary. The bearing plate will also he e a mark number painted on the back surface indicating its relative position in the structure. A record shall be kept coordinating the QCN and the mark numbers. (7) Marking Anchor Heads Each anchor head shall be stamped with a quality control number (QCN) consisting of an eight digit number which shall be permanently embedded into the stressing face of the anchor head outside of the largest wire hole ( circle s. 92C012 P1 The 9 indicates the month and the 2 indicates the year (1972) the part was inspected and parked ready for use. The C012 is a number that shall be assigned for each heat as the material is rec, ived (which allows for approximately 23000 heats). A mark shall be straped on each anchor head, indicating it has been ultra-sonicly tested and found satisfactory for use. A V merk shail be stamped on the enchor head indicating that it has been Brinell tested and found to be within the specified hardness tolerance. Any anchor head without these marks shall not be used in tendon fabrication and shall be retested or discarded. (B) 'iendons 0316 (1) Wire

Wire shall be purchased from re:Jutable steel suppliers and/or importers shall furnisl a mill certificate which shall show the chemical and physical properties of the test f ar each heat of steel. All heats shall be separated in storage areas or marked for identification as by heat numbers. Random samples shall be taken from approximately every fifth coil on arrival at plant. Six samples approximately 3 feet in length shall be taken and marked with the manufacturers heat number and coil number on which 5 tests shall be performed. Test Number 1: A specimen shall be button-headed and inspected to insure button head quality wire has been furnished. Test Number 2: The wire diameter shall be carefully measured by a means of a micrometer with an accuracy of +0.0001 to insure compliance with size conformity. Test Number 3: The hardness of the wires shall be measured utilizing a Rockwell hardness tester using the C scale. These values shall be tabulated. Test Number 4: A bend test shall be performed on the specimen in accordance with DIN 51211 for the specific wire diameter. R ._s _ l o<A= SEND W r f e+ owarm of mee - ri The test specimen shall be bent without impact and equally, one bending per second - d = 0. 2 40 " to 0. 310 " R = 0.800" H = 3. 0 " 0317-

The number of bendings shall be recorded for each test conducted. At least 6 bonds is required as the minimum standard for quality wire. Test Number 5: The physical values for one specimen shall be determined. The values to be datermined shall be the yleid strength, ultimate strength, modules of elasticity, percent elongation. These values shall conform to the requirements of ASTM 421. These tests shall be con-ducted on a universal testing machine located at the plant site and shall be periodically calibrated by factory representatives with U.S. Bureau of Standards equipment. If these specimens meet the requirements of ASTM 421 and those imposed by Prestressing Industries, the entire heat shall be given a WCN and the test reports from Quality Control shall be filed with the mill reports. if one specimen does not meet these requirements, the entire heat shall be rejected until further tests can verify these results. If the wire is still unsatisfactory, the wire shall be rejected and marked with Red Tags. Each coil shall be tagged with a Green QCN if the wire is satisfactory. (2) Button Heads Button heads shall be formed by mechanical or by hydraulic means and shall conform to the physical shape shown in the drawings. The tolerances shall be maintained by constant checking of-the heading machine. There are two specific characteristics that must be continually monitored. The button head diameter shall be checked with go and no-go gages. At least two heads out of each tendon and or every tenth wire shall be checked. If any head is under sine, all head on that tendon end must be checked. If any head is undersize, that wire must be replaced before the tendon will be f 0318

acceptable for shipment to the project. The eccentricity of the head is ( also important. Each buttonhead machine shall be checked every four hours to insure that the wire and the button head have the same axis within'the tolerance shown on the drawings. (3) Tendon Fabrication Tendons shall be fabricated from wire and anchorages that have a WCN number. Each tendon will have a number or mark and as it is fabricated, the QCNs from the wire and the anchorage shall be tabulated so that each individual tendon can have its wire and anchor QCN identified. The fabrication and cutting table shall be calibrated so that each wire in any tendon will be the prescribed length + 3/32". The cutting index on the table shall be recalibrated with a precise measuring tape periodically or after any changes are made because of maintenance or repair. Each completed tendon s' hall be tagged with its identifying mark or number. This tag shall also contain the QCN for the wire used in the tendon. The . tag shall be metal with the identifying lettering indented in the metal and shall be securely wired to the te'ndon. Tendons shall be coiled for shipment with this tag visible in the completed package. (C) Quality Control Equipment (1) Anchorages Quality control department shall maintain in good order, standard measuring blocks for checking and calibration of measuring devices such as micronometers and calipers which shall be checked at least once every 60 days unless used 0319 I -.-,..y

regularly, then they shall be chbcked every 30 days. Should any main-tenance or repair work be performed on these devices, then they shall be re-calibrated to insure their accuracy. For all threading operations, a standard ring and plug gage shall be main-tained by quality control and weekly checks for wear shall be made of go and no-go gaging equipment when being used. All drilling and welding fixtures shall be checked for accuracy weekly when in service. (2) Test Eauloment Test equipment shall be maintained in good repair and constant checks shall be made to insure accuracy. (D) Service Equipment Hydraulic rams shall be calibrated together with pumping equipment and a calibration curve developed for each pair. In the event that either is changed, recalibration shall be done before using. Calibration shall be accomplished by using an electronic load cell with an accuracy of 1%. The quipmcnt shall be loaded in increments and the hydraulic gage reading recorded resulting in a calibration curve. Each hydraulic gage shall be accurate to 1% of the maximum gage reading or to +100 psi. If a hydraulic gage appears to be defective, it shall be tested against a standard gage whose accuracy shall be I 1/4% of the maximum reading. All recalibration shall be done by using dead weight calibration. All hydraulic equipment including pump, ram, hose, gages and fittings shall be tested against a dead load up to 10,000 psi which it must \\ be capabic of maintaining for a minimum period of 10 minutes with a minimum pressure loss of 500 psi. All hydraulic pumps shall be checked g 03%0

monthly to insure proper functioning of the safety val.ving and the maximum pressure relief valving. Any malfunction shall be repaired before continued use shall be allowed. ) e e i } i l 1 s 03'1 4 M

=- I 6x8" TIMBER FCid n n n n - y SmE LDING. O O O O AscHoRAse Stoc.g f~ Size %Riss WITH TEsoos Size. - (oOOO es.i. REiNF. CONCRETE TESTING 8LocKG 3.5'x 4. 5 'x /s.5' N RHa^o Moviso CsAns i I i i $ tress lNg) TRANSIT FCR MEASUREMENT C HAIR OF Eto N G AT IO N. j HYDRAUC LJ_T sic.a r tme RAM I POWER 6VPPLY I O 05' 9 0 09 HYDRALic PUMPlN C, UNIT O I O O G c O O O O I \\ g> 7 2.5 MILLION !e-mo m a, x,g,, car,s. .l;. i n O,/ rcVNC ESTINC- $TANO 032 secxto av .ssccr so I-- j ,....,j, 4, enesraessiNa iNousraies l,,,, 'i I </20 a civisios or Tsc Tcxs rA9 CORPORATION i hne

VII INSTALLATION PROCEDURES & EQUIPMENI l l May 20,1968 0323

FIELD EQUIPMENT The tendons shall be delivered to the jobsite by truck from the tendon fabrication plant. These tendons will be protected by a P.V.C. sack and sealed with V.P.I. powder placed inside. The tendon will be hoisted to the scaffold and made ready for insertion into the conduit. A fish cable is inserted into the conduit to retrieve the pulling cable. A hydraulic tugger is placed on anchor at the opposite end of the tendon and the tendon is drawn through the conduit. The metal banding is removed from the tendon as they enter the bearing plate. The tendon is then positioned and made ready for heading. The heading operation is performed within a BBR wire upsetting tool complete with a foot valve. A drawing of this tool is enclosed. This machine operates automatically as far as the heading cycle is concerned. Upon completion of the heading operation, the tendon is riade ready for stressing. Stressing is done by using a centerhob hydraulic ram connected to the tendon by a pull rod threaded into the center hob anchor head. The centering operation is accomplished by the alignment holes in the bearing plates. The pill rod is mounted in bearings inside the center hole ram to make it easy to turn. A rachet crank is mounted on end of the ram and with 16 to 18 turns the anchor head is fully engaged and ready to stress. Prior to stressing, the anchor head must be inspected to insure full thread engagement. The ram is elongated by a hydraulic pump equipped with two hydraulic gages. These gages will be calibrated in kips force as well as psi. This pump is equipped with a variable relief valve which allows the operator to select and set the relief valve to the maximum pressure required. A sketch of this pumping unit is also enclosed. ' 0;.M S

}_ _ ___ g* ,g - 9 d Botts f:r Ar cher:a; Tere:ns l Formwork 3 to Fc - *ork Pr:ct to P!,:ng r /, 3 ef Ccncrete Vent Ptet r q \\La;, s f < ~ r - Trampat w y _ /,,- s 6 p. _ __ -. __.. _ _ _ } ? l 1 Formwork / x N Shea;hr.g _/ ~ Bearing Pto'e --- / e L Keltum Gnp ['p ; y-Il h h __ s a 7..._.- 2 y y,- e \\ C L ) .w w \\---V' ire Group l f -u ench j Anchor He:3 g W. 1 8 Trumpet ~ m -1 \\ .e n { n c ~--------} e =:D 1 } 3

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7 g J SheathM9 ,5 L Pcrf ble Hydrculie He der Vent Pcrt a Button-Heads q q p_ /---Button Heads 3 i m L g 4 a r- / Pes < ten of Ty;e E Anchere;e { Pr.or to Stress ng of Tendon 3 \\ ~ Li - d J ~ > ~U \\__Pcsif.cn cf Typs H Anchorc;e I Pr.or to S.ress ag of Terden Hydr:a!c R: n 7 g j mHoldir'g Ring ll = I p f / 4 __m____.__-._..___--_-.n -.r -] 5) n g \\.3 Eecring Picta ' g Stre:s'.9g Cheir-( m Trumpet a/ f-Shecthing e. Anchor HecJ w t / a__ ~ { . n, 1 6 ,p v \\ v r = f Mc! ding Reg f Wi e Gr up {., /. E ~*

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} Greese Fu;rrg A;;: rat.s, - ( Bleeding Plug j -Greese h; pie i =[ i ( Y m j N b70) 0 i g // sypo H Ancher:ge \\ -G.a:se C:o thf i ,i L Grease Cep 1 g -Ee:m] P:st: 3, Gre:se Cea E:'s-g/ Gre:sa Pesso;a -- - g',ee,ng p,gg \\- / a r b 1] v r 3 -l s [<'i___, \\ Type E Amnc :;e b- \\ s Grecse %;;e.g A:cer:tus - ' --G ease Pcsse 3 Gre:sa C:s rI i +i ,t } e : a W TENDON INSTALLATION PROCEDU.rE 0325 1 a = __- _. _ _ _ _ m t____

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N f i_~ t' i l Weight Upsetting Tool = 55 Pounds f DISCLOSURE NOTICE: This drawing and the design illustrated thereon is the confidential property of PRESTRESSING INDUSTRIES and may not be copied or reproduced, in whole or part, without the written permission of PRESTRESSING INDIISTRI ES. l Hydr. Stauchwerkzeug PROCEQ 8.//6/ PROCEO Hydr. Upsetting Tool o: IAassbild '6 Asccm' ly Drawing Type DSH 7 o M e g._d U 2.ii.i_aLO] E.=,e. rl... 3.-=- bu,-O 4-204119 -x

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9 I l g B 99 I i i k I I _. 3RQ I s _332 zum Stouchwerkzeug to UpsettingToo! JVf_l6 j !T ,7 i f5 f l 3 \\ } ~. e-..- k i o / N w 1 fCl '{ 7 WEIGITT OF FOOT VALVE = 25 POUNDS l 7 l tM6 %ll~% F .YgNW2O XCD.@!.Pumpe '~- Q from Pump zur Pumpe.__., _. ___._ _ _. to Pump DISCLOSURE 30TICE: This drawing and the design illustrated thereon is the confidential property of PRESTRESSING INDUSTRIES and may not be copied or reproduced, in uhole or part, without the uritten permission of PRESTRESST.NG L INDUSTRIES, i t i' FUSSVCMil lG.fl.6/\\./GU i 0327 c- - 4 ,I If ~$.m[ l l 1:5 i u.ancs Ass,mNv Drc"rinn I ..,. -.... g. :~.,. 7. g. g...,7__. ~ ......z.., 1 g 4-2 04 l18 \\ i

1 l Lifting Lug ( b ') ___e II h II il il il i D \\ l! i l ll +1 f f ll -4 l O i i h i ll i 1 3 { ll Louvers 11 i il u r___________________,'l 1 IL l 1. I . 6.- . 6..

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.~ Instrument Panel Cover-removes and attaches to form desh surface. Reservoir - 30 Gal. min.- + 4.7 GPM at 8500 PSI y ~N y 2'-O" DISCLOSURE NOTICE: This drawing and the design illustrated thercon is the confidential property of PRESTRESSING INDUSTRIES and may not be copied or reproduced, in whole l or part, without the written permission of PRESTRESSING INDUSTRIES. I f t t- -I I ' 7/ NUCLEAR REACTOR HYbRAULIC RThewy 7ht'.n. t 's S PU"VolNG U' NIT i'""" " P"" ~ i 0328 Lee.m I l-e, s / PRESTRESSING INDUSTRIES

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I 0 t [ Lifting Lug g / ON - OFF - Red Motor Load run light Meter ) / a \\ O m O / O Q 2-8"0 0-10,000 / p-PSI Gages with / 1% accuracy Control Valve {NR S C Elongate = E l I g Neutral = N -Calibration Valve Rotract = R Calibration Valve ,r-' Stress Position = S / Calibrate = C / Normoily open / push button for d actuating valve Oil Level Sight -h Glass Q Reservoir-30 Gal. -Min. - 4.7 GPM ai 8500 PSI \\. .==a c=_ 2'- 0"

i

DISCLOSURE NOTICE: This drawing and the design illustrated thereon is the confidential property of Prostressing Industries and may not be copied or reproduced, in whole or

'cart, witheat the svritten permission of PRESTRESSING INDUSTRIES. j i 8 4 I '; I NUCLEAR REACTOR HYDRAULIC Ts'?""bW="EY QimLlSJ PUMPlNG UNIT F """ " "' P""7 l M 03'29 F" " i d ? g PRESTRESSING INCUSTRIES i d

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c e .e ms: cssimo enoustarts ? 7,-,.._,, l -i l. 0. [f 9W" l 4W" l X Y I f i j' BEARING PLATE l' HYDRAULIC RAM 3 4 l ) SUPPORT PIN h / IM ' l l L f / I i j _ p__ STRESSING CHAIR]- { 7 I, '/ - HYDRAULIC PORTS s~~ 2e a , One.T;G Roo j -~ V l I j g t:UT,, 1 j j Ii i l-1 5 i 1 i

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'i .i - l ll Q ".----.----...Q-- y l i i ,s -/ I' t }) ; s-LIFTING ATTACHMENTS \\ l \\ e } , /- g y i i ~. s 0 1 j / f ot':c :- f,w'E UP c.uNK y, V 6'. l l 1 // 037,[ fy [y fy Trove! Weight ) l l .300_ Ton 25'h _ _17_ 27'h _ 12_ _1000', C ~ GOO Ton 2GW ~22 29W ~~I2~ ~~ 800 Ten '28'i 2f' ~~ 3SOO' 12 1200 Ton 35'4 ' 30 ~~33W~'l6 8700~ ~ iOO' 5 . f ck.. 37W t C s 1 HYDRAULIC STRESSING EQUIPMENT L 1}}

ML19329E168

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