VSL Construction Systems AUSPAC 2001 Anglais

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CONSTRUCTION SYSTEMS
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INSTA L L AT I O N
VSL PRESTRESSING (AUST) PTY LT D
VSL
Production by: P & M Format Graphics

Tel: (08) 9414 8643 March 2001.
CONTENTS
THE COMPANY 5
MULTISTRAND POST-TENSIONING 8
SLAB POST-TENSIONING 22
STRESSBAR 36
GROUND ANCHORS 44
VSoL RETAINED EARTH 50
SPECIALISED FOUNDATIONS 52
CLIMBFORM 54
DUCTAL 56
STAY CABLES 58
EXTERNAL POST-TENSIONING 60
HEAVY LIFTING 62
FLAT JACKS 63
BRIDGE ENGINEERING 64
INDEX 66
3
THE VSL MISSION
VSL is the international leading specialist contractor in the field of post

tensioning and related construction techniques. In Australia we will:
• create optimised design and construction solutions to
benefit our clients
• maintain a corporate culture of generating staff and
shareholder benefit
• use the VSL worldwide group resources to enhance our local expertise
QUALITY
OBJECTIVES
The VSL Group objective is to be the preferred
Solution Network for our client and customer
needs.
To assist in achieving this objective we have

established and will continuously maintain a
quality assurance system in compliance with ISO
9001.
VSL Management is committed to continuous

quality improvement through the participation of all
employees in the preparation, implementation and
evaluation of improvement activities.
It is recognised that all our employees are vitally

important to our competitiveness and prosperity
and with this in mind, we aspire to maintain the
highest level of satisfaction, health and safety of
DNVQA-ANZ our people.
ACCREDITED QUALITY SYSTEM
CERTIFIED AS/ANZ ISO 9001
4
VSL
T H E C O M PA N Y
The vision upon which VSL Prestressing (Aust) Pty Ltd was founded in
1965 was to provide specialist post-tensioning services supported by
professional engineering design, construction methods and manufacture of
components.
The standard of quality of the VSL system was soon endorsed by

engineers, contractors and authorities and it became the preferred technical
and practical solutions to a wide range of structural applications.
Our early major projects included the free cantilevering Victoria Bridge in
Brisbane, the Westgate Bridge concrete approach spans in Melbourne, the
Phillip Island Bridge in Victoria and the Narrows Interchange N/6 in Perth.
In 1969 VSL Australia developed operations in South-East Asia, first in

Singapore, followed by Hong Kong, Malaysia, Indonesia, Brunei and Guam.
Our Melbourne office was also opened in 1969, followed by the
commissioning of the VSL manufacturing plant which provides
sophisticated high strength components for export as well as the Australian
market. This is also the site of our NATA registered testing facility used to
calibrate some of the world’s largest hydraulic jacking equipment.
In 2000 the specialist foundation companies Intrafor and IP Foundations

joined with VSL to form VSL-Intrafor, adding to VSL’s exisitng post-
tensioning and construction capabilities to include expertise in specialised
foundations and soil engineering techniques.
Since those early days our range of specialist construction techniques has
broadened to meet the emerging needs of our clients. Many of these
solutions are outlined in this manual.
VSL Australia is an integral member of the worldwide VSL Group,

established in over 36 countries in 5 continents. Hence as we create,
together with our client, the optimal solutions to construction needs, we are
able to enhance our Australian knowledge and experience with the
resources of our colleagues around the world.
VSL is your Solution Network.
5
VSL
HEADING
Design Detail
DESIGN SERVICES
VSL provides an extensive range of design services to assist developers,
engineers, architects, government departments and contractors in solving
technical problems and in assessing the viability of the use of post-tensioning in
a structure.
In particular, the services available include:

• preliminary design for budget estimates
• alternative design proposals
• final detail design, in conjunction with the Consulting Engineer
• technical assistance.
Site Services
In preparing any structural design, the aim is to arrive at the most economical
solution that meets all the design criteria. This requires that all factors in the
construction be taken into account including material costs, formwork,
interaction of trades, construction sequence and construction time. Expertise
gained from many years of experience and the use of in-house design
Engineers enables VSL to assess quickly the alternatives and arrive at an
answer that will best meet the client's requirements for economy of materials,
speed of construction and quality of finished structure.
6
VSL
VSL
I N T E R N AT I O N A L LY
he VSL Group has made major contributions to
T the advancement of civil engineering practice

throughout the world. Internationally, VSL
incorporates a depth of technical knowledge and
construction experience that is unsurpassed within the
prestressing industry. Access to this international
Gateway Bridge, Australia Kwung Tong Bypass, Hong Kong Off-shore Platform, North Sea
experience enables VSL to undertake projects using

highly specialised teams. An example of this co-
operation is the Gateway Bridge in Brisbane, where
VSL in conjunction with the Gateway Bridge Company,
conceived and designed the world-record main-span for
a concrete cantilever bridge. The final design was
prepared by VSL with all materials and equipment
manufactured and supplied within Australia.
Activity world-wide over a broad range of projects has

developed VSL methods into the successful systems
existing today. VSL can offer its clients an entire range
of specialised construction systems from its position
as leader in the field internationally in research,
development and engineering practice.
As a specialist sub-contractor VSL can provide services

using its own personnel and equipment. This
personalised service represents know-how, experience
and availability. Use of in-house engineering design in
the development of alternatives ensures the most
economical construction method is used.
Technical reports covering specialised design and

construction topics are available from VSL on request.
7
VSL
M U LT I S T R A N D P O S T- T E N S I O N I N G
S ince 1954, designers and constructors of bridges, buildings and civil engineering works the world
over have relied on the VSL Multistrand post-tensioning system. These conventional uses of post-
tensioning have been augmented by numerous applications of the system to projects such as
stayed structures, offshore platforms, towers, tanks, silos, nuclear power plants and underground
and submerged structures.
Patented in 36 countries, the VSL strand system complies in all respects with the
Recommendations for the Acceptance and Application of Post-Tensioning Systems of the
Fédération Internationale de la Précontrainte (FIP) and is approved in every country where the use
of post-tensioning systems is subject to an official authorisation.
The VSL Multistrand system comprises from three to fifty-five strands (either 12.7 or 15.2mm
diameter), round duct and anchorages. Prestressing force is applied to the tendons after the
casting and curing of surrounding concrete. All strands are stressed simultaneously using an
hydraulic jack and are fastened at the live end by wedge grips. The free space inside the duct is
then pressure-filled with cement grout.
A number of features are incorporated as a result of many years of experience in the field:
• stressing in one or any number of stages

• accurate control of prestress force
• no uncontrolled slippage of strands
• no requirement for a precise determination of tendon length
• simultaneous stressing of all strands
VSL stressing equipment is easily operated to ensure a safe and rapid stressing procedure.
Special emphasis has been placed on rationalised manufacturing of equipment and anchorage
parts as well as efficient work site practice.
Maribyrnong Bridge, Victoria
8
VSL
S T R A N D P R O P E R T I E S – T O A S 1 3 11
Nominal Nominal Nominal Minimum Minimum Min. Elong. Relaxation Modulus
Diameter Steel Area Mass Breaking Load Proof Load to Fracture After 1,000hrs of Elasticity
(0.2% Offset) in 600mm at 0.7
Breaking Load
mm mm2 kg/m kN kN % % MPa
12.7 Super 100.1 0.786 184 156.4 3.5 2.5
15.2 Super 143.3 1.125 250 212.5 3.5 2.5 180–205
x 10 3
15.2 EHT 143.3 1.125 261 221.9 3.5 2.5
TENDON PROPERTIES
STRAND TYPE 12.7mm Super STRAND TYPE 15.2mm Super
TENDON No. OF Minimum STEEL DUCT. TENDON No. OF Minimum STEEL DUCT.
UNIT STRANDS Breaking Internal UNIT STRANDS Breaking Internal
Load Diameter Load Diameter
kN mm kN mm
5-3 2 368 39 6-3 2 500 39
3 552 39 3 750 39
4 736 39 6-4 4 1000 51
5-7 5 920 51 6-7 5 1250 69
6 1100 51 6 1500 69
7 1290 51 7 1750 69
5-12 8 1470 69 6-12 8 2000 84
9 1660 69 9 2250 84
10 1840 69 10 2500 84
11 2020 69 11 2750 84
12 2210 69 12 3000 84
5-19 13 2390 84 6-19 13 3250 96
14 2580 84 14 3500 96
15 2760 84 15 3750 96
16 2940 84 16 4000 96
17 3130 84 17 4250 96
18 3310 84 18 4500 96
19 3500 84 19 4750 96
5-22 20 3680 90 6-22 20 5000 105
21 3860 90 21 5250 105
22 4050 90 22 5500 105
5-27 23 4230 96 6-27 23 5750 112
24 4420 96 24 6000 112
25 4600 96 25 6250 112
26 4780 96 26 6500 112
27 4970 96 27 6750 112
5-31 28 5150 105 6-31 28 7000 118
29 5340 105 29 7250 118
30 5520 105 30 7500 118
31 5700 105 31 7750 118
5-37 32 5890 112 6-37 32 8000 127
33 6070 112 33 8250 127
34 6260 112 34 8500 127
35 6440 112 35 8750 127
36 6620 112 36 9000 135
37 6810 112 37 9250 135
5-42 38 6990 118 6-42 38 9500 135
39 7180 118 39 9750 135
40 7360 118 40 10000 135
41 7540 118 41 10250 135
42 7730 118 42 10500 135
5-48 43 7910 127 6-48 43 10750 144
44 8100 127 44 11000 144
45 8280 127 45 11250 144
46 8460 127 46 11500 144
47 8650 127 47 11750 144
48 8830 127 48 12000 144
5-55 49 9020 135 6-55 49 12250 154
50 9200 135 50 12500 154
51 9380 135 51 12750 154
52 9570 135 52 13000 154
53 9750 135 53 13250 154
54 9940 135 54 13500 154
55 10120 135 55 13750 154
Note: 1. Intermediate duct diameters may be available on application.

2. Duct diameters are for corrugated steel duct.
3. Duct external dia. = Inside dia. + 6mm nominal
4. Corrugated polyethylene PT-Plus™ duct is also available, refer page 16.
5. For special applications other strand and tendon capacities are available.
6. Anchorages for 15.2mm system are compatible with 261 EHT strand.
9
VSL
GROUT INLET
DUCT
CAST IN ANCHOR TYPE Sc
WEDGE GRIPS ANCHOR HEAD
VSL STRESSING ANCHORAGE TYPE Sc LIVE END
A
E
H
15 omin
Duct Dia.
nominal
H
G
F
A
C
R
25min
20 B D
DIMENSIONS (mm)
TENDON A B C D E F G H R
UNIT Int. Dia.
5-3 135 50 90 191 16 56 39 116 210
STRAND TYPE 12.7mm
5-4 150 50 90 216 16 64 39 125 210

5-7 165 57 120 100 60 85 51 125 275
5-12 215 54 160 160 84 120 69 151 320
5-19 265 66 180 210 110 145 84 200 360
5-22 290 77 200 215 140 153 90 230 360
5-27 315 92 220 250 160 176 96 250 360
5-31 315 92 230 250 161 175 105 250 360
5-37 370 107 250 320 160 200 115 305 650
5-42 390 112 290 346 168 217 118 325 650
5-48 430 122 300 340 161 233 127 365 750
5-55 465 142 320 340 160 250 135 400 750
*6-3P 150 60 90 190 16 56 39 116 210
*6-4P 165 54 120 100 60 85 51 125 270
STRAND TYPE 15.2mm
6-7 215 54 160 160 85 120 69 150 320

6-12 265 66 180 210 110 145 84 200 360
6-19 315 92 220 250 160 175 96 250 360
6-22 315 92 230 250 160 175 105 250 360
6-27 370 107 250 320 160 200 115 305 650
6-31 390 112 290 340 160 217 118 325 650
6-37 430 122 300 340 160 235 135 365 750
6-42 465 142 320 340 160 250 135 400 750
*6-48P 575 155 340 1035 110 269 144 495 900
*6-55P 600 190 360 1070 120 294 154 520 900
Note: Dimension R does not allow for Lift Off force check. Smaller recesses can be provided for special cases. Refer VSL office for details.
*Plate type anchorages (Type P). Also available for other tendon units.
10
VSL
GROUT TUBE
GROUT CONNECTION DUCT
COMPACT ANCHOR
HEAD
WEDGE GRIPS
POLYETHYLENE TRUMPET
STRANDS
COMPOSITE BEARING PLATE

(METAL/HIGH PERFORMANCE
MORTAR)
VSL STRESSING ANCHORAGE TYPE CS LIVE END
ØD 20 B
25 min
C
ØG
ØF
R
15° min
E H
ØA
TENDON UNIT Dimensions (mm)

STRAND STRAND øA B C øD E øF øG H H R
TYPE TYPE Ext. Dia. Ext. Dia. CS-Std CS-Plus
12.7mm 15.2mm CS-Super
5-12 6-7 222 60 135 153/143 49 110 80 400 535 320
5-19 6-12 258 80 149 178 49 137 95 500 638 360
– 6-19 300 90 170 210 59 156 110 540 660 360
5-31 6-22 320 100 180 229 59/65 174 125 570 740 360
5-43 6-31 390 120 217 279/283 69/75 224 146 880 * 640
5-55 6-37 420 130 233 302 78/82 237 160 850 * 750
*Check with VSL office
The trumpets for the CS-PLUS and CS-SUPER configurations have short, profiled extension for PT-PLUS™ coupling.
T E N D O N C O N F I G U R AT I O N S
VSL SYSTEM Anchorage Type Duct Type Fully Electrically
HD PE Encapsulated Isolated
Conventional CS Steel PT-PLUS Tendon Tendon
Conventional l l
PT-PLUS l l
CS-Standard l l
CS-Plus l l l
CS-Super l l l l
The Type CS anchorage should be used for applications requiring high fatigue
resistance, high corrosion resistance, reduced anchorage friction and the possibility of
electrical isolation. For conventional applications the Type Sc anchorage should be used.
11
VSL
GROUT TUBE
SWAGED DEAD END
COUPLING COVER DUCT
DUCT
CAST IN ANCHOR
COUPLING BLOCK
VSL COUPLING ANCHORAGE TYPE C

B
30 A STANDARD CAST IN
C ANCHOR TYPE Sc
STRAND TYPE 12.7mm STRAND TYPE 15.2mm

TENDON A B C TENDON A B C
UNIT Dimensions (mm) UNIT Dimensions (mm)
5-3 108 130 430 6-3 125 150 490
5-4 108 150 500 6-4 125 160 520
5-7 108 170 550 6-7 125 200 630
5-12 108 200 650 6-12 125 230 730
5-19 108 230 740 6-19 125 270 860
5-22 108 250 830 6-22 125 300 930
5-27 108 300 1000 6-27 135 320 1000
5-31 108 340 1140 6-31 145 350 1090
5-37 148 380 1320 6-37 165 410 1390
5-42 148 385 1320
5-48 148 410 1370
5-55 168 480 1370
Note: In some applications the coupler cover may not be required.
12
VSL
GROUT TUBE
WEDGE GRIPS
DUCT
ANCHOR BLOCK
STRANDS
I N T E R M E D I AT E A N C H O R A G E T Y P E Z
Stressing jack
Curved stressing chair

E
H
D
Tendon 1
Tendon 2 F+ L B
G+ L L = Elongation of tendon 2
E = C 2 + required cover
Centre-stressing anchorages are used for ring tendons in circular

structures, or for those tendons where the ends cannot be fitted with
normal stressing anchorages.
STRAND TENDON A B C D F* G* H
TYPE UNIT Dimensions (mm)
12.7mm 5-2 130 60 80 60 400 560 170
5-4 160 70 90 65 500 720 200
5-6 200 90 130 85 700 990 240
5-12 280 140 140 90 1000 1490 320
5-18 320 160 180 110 1300 1910 360
5-22 350 160 200 120 1450 2110 390
15.2mm 6-2 140 70 90 65 450 620 180
6-4 170 80 100 70 900 1180 210
6-6 210 100 140 90 1000 1400 250
6-12 300 160 160 100 1350 1960 340
6-18 380 180 200 120 1450 2280 420
6-22 400 180 250 145 1500 2380 440
* Dependent upon the shape of the concrete surface.
The values stated apply for surfaces which are not curved.
13
VSL
SPACER PLATE
GROUT TUBE
(NOT ALWAYS REQUIRED -3, -4,
-7)
DUCT
TYPE H
GROUT TUBE
DEAD END
DUCT
TYPE P
SWAGED DEAD END
ANCHORAGE PLATE
VSL DEAD END ANCHORAGE

AxB
DxE
3 12
150 C 60 F
Dead End Anchorage Type H Dead End Anchorage Type P

TENDON TYPE ‘H’ TYPE ‘P’ TENDON TYPE ‘H’ TYPE ‘P’
UNIT A B C D E F UNIT A B C D E F
5-3 125 125 600 100 100 100 6-3 150 150 600 150 150 250
5-4 125 125 600 120 120 150 6-4 150 150 600 150 150 250
5-7 175 150 600 150 150 250 6-7 200 170 600 200 200 350
5-12 300 250 1000 200 200 350 6-12 350 300 1000 250 250 500
5-19 375 300 1000 250 250 500 6-19 450 350 1000 300 300 500
5-22 400 300 1000 300 250 500 6-22 500 350 1000 300 300 500
5-27 450 400 1000 300 300 650 6-27 550 450 1100 350 350 650
5-31 450 425 1000 350 300 650 6-31 550 475 1100 350 350 650
5-37 525 450 1100 375 350 850 6-37 600 550 1100 400 350 850
5-42 600 450 1100 375 375 850 6-42 700 550 1200 400 350 850
5-48 645 450 1200 400 400 1000 6-48 745 550 1200 475 475 1000
5-55 700 500 1200 425 425 1000 6-55 800 600 1200 550 475 1000
Dimensions (mm) Dimensions (mm)
14
VSL
B o/
Grout
Vent
VSL DEAD END ANCHORAGE TYPE L
TENDON A B R TENDON A B R
UNIT Int/Ext Int/Ext min UNIT Int/Ext Int/Ext min
5-4 50/55 45/50 600 6-2 50/55 45/50 600
5-7 65/72 55/60 600 6-3 50/55 45/50 600
5-12 80/87 65/72 900 6-4 55/60 50/55 600
5-19 90/97 80/87 1100 6-7 75/82 60/67 750
5-22 95/102 85/92 1200 6-12 90/97 80/87 1000
5-31 110/117 100/107 1400 6-19 100/117 95/102 1300
Dimensions (mm) Dimensions (mm)
F
2nd injection G
E
Overflow of
first injection
L o/
M
D
B
1st injection
K- Anchorage spacing
C
J
VSL DEAD END ANCHORAGE TYPE AF

STRAND TYPE 15.2mm
TENDON A B C D E F G H J K Lo/ M
UNIT Int/Ext
6-12 265 700 60 460 90 95/102 380 450 60 410 6 9
6-19 315 700 60 460 90 120/127 480 540 60 510 20 9
6-31 375 900 60 660 90 150/157 620 660 80 650 20 11
Dimensions (mm)
M = Number of spiral turns or orthogonal stirrups.
15
VSL
S H E AT H I N G & C O R R O S I O N P R O T E C T I O N
For conventional applications, corrugated galvanised steel ducts are used.
For applications requiring enhanced corrosion protection and improved fatigue resistance of the
tendons, use of the VSL PT-PLUS™ System with corrugated plastic duct is recommended. This
fully encapsulated, watertight system offers superb corrosion protection, and the plastic duct
eliminates fretting fatigue between the strand and duct. It also provides reduced duct friction. The
PT-PLUS™ System may, in conjunction with VSL CS Anchorages, be configured with special
details and installation techniques to provide Electrically Isolated Tendons. These tendons may be
electrically monitored at any time throughout the life of the structure.
All ducts are manufactured in a variety of standard lengths and are coupled on site.
For diameters of steel ducts see page 9.
D I M E N S I O N S O F P O LY E T H Y L E N E D U C T S P T - P L U S ™
s
STRAND TYPE STRAND TYPE DUCT
12.7mm 15.2mm Dimensions (mm)
D
d
TENDON UNIT TENDON UNIT d D s
5-10 6-7 59 73 2
5-18 6-12 76 91 2.5
5-31 6-19/6-22 100 116 3
5-42 6-31 130 146 3
5-53 6-37 130 146 3
Other units on request
POLYETHYLENE DUCT PT-PLUS™ STEEL DUCT
STRAND BUNDLE
ECCENTRICITY OF TENDONS
Centre line of duct
STEEL PLASTIC STEEL PLASTIC e Centre gravity of strands
TENDON DUCT DUCT TENDON DUCT DUCT
UNIT e (mm) e (mm) UNIT e (mm) e (mm)
5-1 4 – 6-1 5 –
5-3 7 – 6-3 6 – STRAND POSITION AT HIGH POINT OF TENDON
5-7 8 – 6-4 6 –
5-12 11 7 6-7 10 9
5-19 13 9 6-12 14 12
5-22 12 22 6-19 17 18
5-27 13 17 6-22 14 15 e
5-31 14 14 6-27 13 32
5-37 16 32 6-31 15 28
5-42 18 28 6-37 17 19
5-48 17 24
5-55 19 14 STRAND POSITION AT LOW POINT OF TENDON
16
VSL
S E L E C T E D D E S I G N C O N S I D E R AT I O N S
Tendon Supports
Recommended spacings:
• Conventional steel ducts: 0.8 to 1.2m
• Polyethylene ducts PT-PLUS™: 0.8 to 1.0m
Tendon Force Losses
The friction losses in the anchorage due to curvature of the strand and friction of the strand in the
wedges usually amount to:
• Anchorage type Sc: 2 to 4%
• Anchorage type CS: 1 to 2%
Friction losses along the tendon can vary fairly widely and depend upon several factors, including:
the nature and surface condition of the prestressing steel, the type, diameter and surface
conditions of the duct and the installation method.
The following values may be assumed for design:
• Tendon in conventional steel ducts: µ = 0.20
• Tendon in polyethylene ducts PT-PLUS™: µ = 0.14
Irrespective of the type of jack or tendon, a loss due to wedge draw-in of nominally 6mm occurs
at lock-off.
EDGE D I S TA N C E S
10mm NOMINAL
TENDON UNIT E
(mm)
5-7 30 E
5-12 50
12.7mm
5-19 50
STRAND TYPE
5-27 80
5-42 80 10mm
5-55 80 NOMINAL
6-7 50
6-12 50
15.2mm
6-19 80
6-27 80 E
6-42 100
6-55 100
Lmin
Rmin (m)
12
MIN. RADIUS OF CURVATURE Rmin

10
MIN. STRAIGHT LENGTH Lmin
BEHIND ANCHORAGE
8
Rmin.
6
4
Lmin.
2 1.5
0.8 1.0
0 The radii of curvature given in the opposite

0 2000 4000 6000 8000 10000 12000 14000 16000 diagram may be reduced, provided the local
Tendon breaking load (kN) concrete strength and the steel stresses
resulting from the curvature are checked.
MINIMUM RADII OF TENDON
C U R VAT U R E
17
VSL
STRESSING
The wedges always remain in contact with the strands during the stressing
operation. As the pressure in the jack is released, the wedges automatically lock in
the conical holes of the anchor head.
Placing of anchor head and wedges
Placing of anchor head
Positioning of the jack
Positioning of jack
Stressing
Seating of wedges Stressing, measuring, seating of wedges
GROUTING
VSL grouting equipment includes mixer and pump in one unit. Grouting is usually carried out as
soon as possible after stressing. For special applications vacuum assisted grouting procedures
can be used
Grouting equipment Grouting of tendon
18
VSL
VSL Jack
Jack stroke
A
JACK CLEARANCE REQUIREMENTS

Dimensions VSL JACK TYPE
(mm) VSL50 VSLB7 VSL190 VSL 290 VSL460 VSL670
A 145 180 195 235 285 370
B 1000 1000 1600 1600 1400 2400
VSL750 VSL1000 VSL1250 VSL1650 VSL1700
A 300 435 395 495 480
B 2600 2300 2800 1800 2600
D1
L1
L X D L X D
S T R E S S I N G J A C K D E TA I L S
VSL JACK TENDON TENDON NOMINAL D D1 L L1 X STROKE MASS
TYPE UNIT UNIT CAP (kN) Dimensions (mm) (mm) (kg)
VSL50 5-3 & 4 500 210 – 430 – – 150 34
VSLB7 5-7 6-3 & 4 1000 275 – 405 – – 160 76
VSL190 5-12 6-7 1900 310 230 430 200 135 100 151
VSL290 5-19 6-12 2900 390 270 450 215 240 100 202
VSL460 5-22, -27, -31 6-19 4600 485 330 510 200 85 100 425
VSL670 5-42 6-22, -27, -31 6700 660 – 840 – 250 200 1550
VSL750 5-42 6-35 7500 570 410 1030 215 165 200 1500
VSL1000 5-55 6-47 10000 790 – 885 – 165 200 2200
VSL1250 5-55 6-55 12500 710 420 1125 220 165 150 1730
VSL1650 5-64 6-55 16500 910 600 615 140 – 150 1750
VSL1700 5-91 6-91 17000 875 – 1030 – 165 150 3085
Note: other equipment is available for special situations.
19
VSL
In-situ Cantilever Bridge, Moonee Moonee, N.S.W.
Precast Segmental Bridge, F9 Freeway, Melbourne, Victoria F9 Freeway, Melbourne, Victoria
20
VSL
Foundation Raft Hilton Hotel, Guam
In-situ Rail Bridge, Brisbane, Queensland Floors for High Rise Offices, Governor Philip Tower, Sydney, NSW
Melbourne Cricket Ground – Great Southern Stand
21
VSL
S L A B P O S T- T E N S I O N I N G
Stadium Australia, Sydney NSW
Owners and designers of the buildings of today and tomorrow need to incorporate sufficient flexibility into their
structures to accommodate the changing needs of the users of the building.
Post-tensioning offers larger spans with reduced structural depth, resulting in larger column-free areas. Internal
tenancy layouts are thus not restricted by tight column grids. Positive deflection and crack control and, if
necessary, crack-free watertight slabs offer the designer the opportunity to break free of the limitations of the
passive methods of reinforced concrete or structural steel.
VSL post-tensioning is more economical than other systems, especially when the typically faster construction
cycles are considered. There is less material handling on site. There is a reduced site labour force which reduces
site activity congestion. Most importantly, there is the quality and service of VSL specialised high-performance
site teams and unequalled back-up.
The VSL post-tensioning slab system has been used in many thousands of buildings and other structures
throughout Australia. The system uses up to five strands in flat-shaped ducting and anchorages.
The strands are stressed individually and then gripped by wedge action. The entire duct is subsequently fully
filled with cement grout injected under pressure so that the strands are fully bonded to the surrounding
concrete.
CONSTRUCTION SEQUENCE
Placing tendons Concreting Stressing Grouting
22
VSL
S T R A N D P R O P E R T I E S – T O A S 1 3 11
Nominal Nominal Nominal Minimum Minimum Min. Elong. Relaxation Modulus
Diameter Steel Area Mass Breaking Load Proof Load to Fracture After 1,000hrs of Elasticity
(0.2% Offset) in 600mm at 0.7
Breaking Load
mm mm2 kg/m kN kN % % MPa
12.7 Super 100.1 0.786 184 156.4 3.5 2.5
15.2 Super 143.3 1.125 250 212.5 3.5 2.5 180–2053
x 10
15.2 EHT 143.3 1.125 261 221.9 3.5 2.5
TENDON PROPERTIES
STRAND TYPE 12.7mm Super STRAND TYPE 15.2mm Super
TENDON No. OF Minimum TENDON No. OF Minimum
UNIT STRANDS Breaking UNIT STRANDS Breaking
Load kN Load kN
S5-1 1 184 S6-1 1 250
S5-2 2 368 S6-2 2 500
S5-3 3 552 S6-3 3 750
S5-4 4 736 S6-4 4 1000
S5-5 5 920 S6-5 5 1250
For special applications other strand and tendon capacities are available.
S E L E C T E D D E S I G N C O N S I D E R AT I O N S
Tendon Supports
Recommended spacings:
• Conventional steel ducts 0.8 to 1.2m
• Polyethylene ducts PT-PLUS™ 0.8 to 1.0m
• Minimum radius of curvature for flat ducts: About X axis 2.5m
About Y axis 7.0m
• Minimum tangent length behind the anchorage 0.5m
Tendon Force Losses

The friction losses in the anchorage due to curvature of the strand and friction of the strand in the
wedges usually amount to:
• Edge stressing 3% average

• Internal pocket stressing 5% average
Frictional losses along the tendon can vary fairly widely and depend upon several factors, including
the nature and surface condition of the prestressing steel; the type, diameter and surface
conditions of the duct and the installation method.
The following values may be assumed for design:
• Tendon in conventional steel ducts: µ = 0.20
• Tendon in polyethylene ducts PT-PLUS™ µ = 0.14
A loss due to wedge draw-in of nominally 6mm occurs at lock-off.
Y
DIMENSION OF DUCTS
DUCT TYPE Bi Ba Br Hi Ha Hr
Dimensions (mm) X Hi Ha
Galv. Steel Hr
S5-1/S6-1 20 21 – 20 21 –
S5-2/S6-2 50 51 – 19 20 –
S5-5 70 71 – 19 20 – Bi
S6-5 90 91 – 19 20 –
Polyethylene
Ba
PT-PLUS™
S5-5/S6-4 72 76 86 21 25 35
Br
S6-5 Not available
23
VSL
GROUT TUBE
WEDGE GRIPS
DUCT
STRANDS
CAST IN ANCHOR
ANCHOR HEAD
PLASTIC RECESS
FORMER
VSL STRESSING ANCHORAGES TYPE S5-S6
LIVE END
R C
D
A
B
F
E 70 x 19 duct
20 90 x 19 Duct – S6-5 only
STRAND TENDON A B C D E F R
12.7mm S5-3 265 100 215 225 45 70 90
S5-4 265 100 215 225 45 70 90
S5-5 265 100 215 225 45 70 90
15.2mm S6-2 265 100 215 225 50 70 90
S6-3 265 100 215 225 45 70 90
S6-4 265 100 215 225 45 70 90
S6-5 265 100 238 265 45 70 90
Note: S6-2 supplied with barrels and wedges in lieu of cast anchor head
24
VSL
GROUT TUBE
BARRELS &
WEDGE GRIPS
CAST IN ANCHOR
DUCT DUCT
STRANDS
WEDGE GRIP
GROUT TUBE
CAST IN ANCHOR
STRAND
STYRENE RECESS FORMER PLASTIC RECESS FORMER
VSL STRESSING VSL STRESSING ANCHORAGES

ANCHORAGE TYPE S5-2 TYPE S5-1, S6-1
LIVE END LIVE END
100 150
170
S5-2
85
45 50 x 19 Duct
20
35 95
152
146
58
52
S5-1, S6-1
Duct 20 Dia.
50
25
VSL
SPACER PLATE GROUT TUBE

(NOT ALWAYS REQUIRED)
DUCT
TYPE H
DEAD END
TYPE P
ANCHOR PLATE
SWAGED DEAD END
VSL DEAD END ANCHORAGES TYPE H – TYPE P

AxB
DxE
12
3 C 60 F
Dead End Anchorage Type H Dead End Anchorage Type P
TENDON UNIT A B C TENDON UNIT D E F

TYPE H Dimensions (mm) TYPE P Dimensions (mm)
5-1 75 50 600 5-1 100 75 100
12.7mm
12.7mm
5-2 135 50 600 5-2 125 75 150

STRAND TYPE
STRAND TYPE
5-3 230 50 600 5-3 200 75 350

5-4 270 50 600 5-4 250 75 500
5-5 350 50 600 5-5 300 75 500
6-1 75 50 600 6-1 125 75 100
15.2mm
15.2mm
6-2 135 50 600 6-2 150 75 150

6-3 230 50 600 6-3 225 75 350
6-4 270 50 600 6-4 300 75 500
6-5 350 50 600 6-5 350 75 500
26
VSL
GROUT TUBE
SWAGED ENDS
DUCT
GROUT TUBE
CAST IN ANCHOR
ANCHOR HEAD
CAST COUPLING
BLOCK
DUCT
VSL SLAB COUPLING ANCHORAGE TYPE S
A
C
D
E
600
STRAND TENDON A B C D E
12.7mm S5-4 95 190 110 240 215
S5-5 95 235 110 240 215
15.2mm S6-4 95 190 110 240 215
S6-5 95 235 110 265 238
27
VSL
GROUT TUBE
SPACER BARRELS
CAST IN ANCHOR
STRANDS
SWAGED ENDS
COUPLING BLOCK
BARRELS
& WEDGE GRIPS
DUCT
VSL SLAB COUPLING ANCHORAGES TYPE S5-2, S6-2
C
A
600 D
STRAND TENDON A B C D
12.7mm S5-2 170 75 125 80
15.2mm S6-2 170 75 135 85
28
VSL
JACK CLEARANCE
REQUIREMENTS
75
605 330
935
S T R E S S I N G J A C K D E TA I L S
135 180
125
80
70
605
600 200
VSL CH JACK VSL TCH JACK

Max. Capacity..............................................................................300 kN Max. Capacity ............................................................................290 kN
Mass ............................................................................................. .26 kg Mass.............................................................................................20 kg
Stroke.........................................................................................300 mm Stroke .......................................................................................250 mm
Max. hydraulic pressure .............................................................68 MPa Max. hydraulic pressure ...........................................................68 MPa
INTERNAL STRESSING POCKET

12.7mm STRAND 15.2mm STRAND
DETAILS SHOWN ARE TYPICAL AND MAY VARY FOR PARTICULAR APPLICATIONS
B
Anchor
PLAN STRESSING POCKET

450 450
30 420 50 175 175 50
165
100
Anchor
25
SECTION A SECTION B
29
VSL
ANCHORAGE REINFORCEMENT – HELIX
S5-2
S5-4
S5-5
S6-5
GROUT VENT
min
min
min
min
60
80
90
100
TYPICAL EDGE REINFORCEMENT
D E TA I L AT S L A B E D G E
A N C H O R A G E AT S L A B E D G E
120 75
R6
130
S5-2 ANCHOR
TYPICAL EDGE REINFORCEMENT
210 110
R10
S5-3, S5-4, S5-5 ANCHORS

250
S6-2, S6-3, S6-4 ANCHORS
350 150
R10
S6-5 ANCHOR
290
NOTE: 1. REINFORCEMENT SHOWN IS INDICATIVE, ACTUAL ANCHORAGE REINFORCEMENT IS TO BE AS DETAILED BY THE

CONSULTING ENGINEER, ANCHORAGE REINFORCEMENT SHALL BE LOCATED CENTRALLY ABOUT ANCHOR AND HARD
AGAINST CASTING AS SHOWN.
2. MIN. CONCRETE CYLINDER STRENGTH AT JACKING = 22MPa GENERALLY AND 25 MPa
FOR S6-5. REINFORCEMENT FOR HELIX IS ROUND BAR WITH fy = 250 MPa.
30
VSL
ANCHORAGE REINFORCEMENT – TIES
A N C H O R A G E AT S L A B E D G E A N C H O R A G E AT E D G E B E A M
GROUT VENT
EXTRA TIES WHERE
SHOWN FOR S6-5 ONLY. R10 CLOSED TIES
R6 FOR S5-2 ONLY
Y12 OR BEAM
REINFORCEMNT
B
PLACE INNERMOST TIE

B
HARD AGAINST
2Y12 TOP & BTM CASTING
x 1000 min. AS SHOWN
A
A 3Y12 TOP & BTM
S6-5 only
D E TA I L AT S L A B E D G E
EXTRA TIES WHERE A GROUT VENT

SHOWN FOR S6-5 ONLY.
2Y12 TOP x 1000
min.
2-R10 TIES AT 50mm CRS.
EACH SIDE OF EACH
B
ANCHORAGE TYPICAL
1 EACH SIDE FOR S5-2
ONLY
300
OPEN TIES
PLAN
D E TA I L AT E D G E B E A M NOTE: 1. REINFORCEMENT SHOWN IS
INDICATIVE. ACTUAL ANCHORAGE
REINFORCEMENT IS TO BE AS DETAILED
STRAND TENDON No. OF TIES A B BY THE CONSULTING ENGINEER.
TYPE UNIT EACH SIDE mm mm ANCHORAGE REINFORCEMENT SHALL
BE LOCATED CENTRALLY ABOUT
S5-2 1 100 60 ANCHOR AND HARD AGAINST CASTING
12.7mm S5-3, S5-4 2 200 80 AS SHOWN.
S5-5 2 200 90
2. MIN. CONCRETE CYLINDER STRENGTH
S6-2, S6-3 2 200 80 AT JACKING = 22MPa GENERALLY AND 25
15.2mm S6-4 2 200 90 MPa
S6-5 2+2 200 100 FOR S6-5. REINFORCEMENT FOR TIES IS
ROUND BAR WITH fy = 250 MPa.
31
VSL
Floors and Watertight Roofs, Tooronga, Melbourne, Victoria
Floors for Commuter Car Park Floors for High Live Load
Gosford, N.S.W. Exhibition Centre, Melbourne, Victoria
Floors for Retail Development, Tuggerah, N.S.W.
32
VSL
Floors for Carpark,

Commercial, Retail and High Rise Offices
World Square, Sydney, N.S.W.
Floors for High Rise Office

Foundation Raft Slab
Bourke Place, Melbourne, Victoria
Sydney, N.S.W.
Floors for Princess Alexandra Hospital, Brisbane, Queensland
33
VSL
SLAB ON GRADE
Distribution Centre and

Warehouse, Brisbane,
Queensland
The VSL post-tensioning system is widely used in the construction of slabs on grade. Warehouses,
distribution centres, container terminals, airports, pavements, residential slabs and recreational
slabs for tennis courts and skating rinks are common applications.
E L I M I N AT E J O I N T S
Joints in reinforced concrete slabs on grade have long been a cause of cost and delay to owners
because of the constant maintenance they require. Owners and operators of facilities with slabs
on grade can eliminate these costs by eliminating the joints themselves. The VSL post-tensioned
concrete slab on grade is cast in very large areas, often exceeding 2,500 sq.m, in which there are
no joints. In certain applications, slabs in the order of 10,000 sq.m have been constructed without
movement joints.
CRACK-FREE PERFORMANCE
The VSL post-tensioning axially compresses the concrete slab to counteract tensile stresses which
would otherwise cause cracking under the worst combinations of temperature and applied loads.
The prestress applied can even control the initial concrete shrinkage sufficiently to prevent initial
shrinkage cracking.
Float Glass Plant,

Ingleburn, N.S.W.
34
VSL
THINNER SLAB
The VSL slab is much thinner than its equivalent in reinforced concrete. The VSL slab generally
contains no reinforcement except at the perimeter and for trimming at penetrations.
INITIAL COST
The thinner slab, absence of reinforcement, absence of costly internal jointing and the cost saving
available from the construction program time saved by casting large areas, all contribute to a
competitive initial cost.
FUTURE MAINTENANCE
During the life of the slab, the joint maintenance costs which the owner no longer need endure, will
reap great improvements in the efficiency of the facility. A life cycle analysis can be readily
undertaken to demonstrate that future savings to the owner more than justify the selection of a VSL
slab on grade.
White City Tennis Centre,

Sydney, N.S.W.
Intermodal Terminal,
Residential Housing
Acacia Ridge, Queensland
Brisbane, Queensland
35
VSL
STRESSBAR
Hong Kong Stadium, Hong Kong
BAR SYSTEMS
VSL have been manufacturing and designing bar systems in Australia for use by the
construction industry since 1971. These have proven to be one of the most popular
tools of Engineers wishing to induce and control loads and forces in structures.
The systems range from High Tensile Cold Worked Stressbar to Low Tensile
Architectural Tendons, all with compact and easy to assemble fittings.
A range of diameters is available to give a wide selection of tendon forces. The
prestressing force is anchored at the end of the bar by a rolled thread, nut, washer and
bearing plate. Where necessary bars can be joined with threaded couplers, and clevis
fittings may be used where pin connections are required.
The VSL bar system complies with the requirements of AS1313 and AS1314.
V S L B A R C O N F I G U R AT I O N S
Thread Details Architectural Max Bar length m
VSL BAR SYSTEM Full Short Right Left Cold Hot Components Export Containers
Thread Thread Hand Hand Rolled Rolled Available 20ft 40ft
CT STRESS BAR
15 - 46mm CT Bar l l l l l l 5.85 11.85
56mm CT Bar l l l l l l 5.85 8
73mm Bar l l l l 5.85 8
DEFORMED BAR
15mm Tie Bar l l l 5.85 11.85
26.5 - 40mm HR Bar* l l l 5.85 11.85
THREADLOK BAR
20–25mm l l l 5.85 11.85
ARCHITECTURAL BAR
20 -100mm MT Bar * l l l l l 5.85 11.85
* Note: Check availability as some sizes may not be stocked.
36
VSL
STRESSBAR
A P P L I C AT I O N
VSL bar systems are ideal for the economic application of post tensioning forces on relatively short
tendons. Through the use of threaded connections and anchorages they are simple to use and
lend themselves to many applications.
T Y P I C A L A P P L I C AT I O N S :
Buildings
• Prestressed Beams and Columns Anchors
• Precast Connections • Permanent and Temporary Ground Anchors
Bridges • Uplift Anchors (Dam & Foundation)
• Stay Cable • Roof Bolting
• Hangers • Soil Nails (Slope Stabilisation)
• Prestressed Segments • Crane Bases
• Strengthening • Light Towers
• Tension Piles and Caissons Specialist Engineering
Wharves & Jetties • Heavy Lifting
• Stressed Deck Planks • Formwork Ties or Hangers
• Tie Backs • Frame Ties
• Pile testing
• Architectural Ties
CHARACTERISTIC PROPERTIES
VSL Bar properties are nominally as listed in the Tables.
These specifications may be subject to change without notice.
Check with the VSL office regarding availability.
CORROSION PROTECTION
All bars and fittings must receive protection when installed under permanent conditions. In normal
concrete construction the use of galvanised duct, injected with grout, provides good protection.
Anchorage recesses must also be filled with cement mortar to protect the ends.
Bars
When bars are used in an exposed environment,one of the following coating systems may be used.
• Single coat of inorganic zinc • Greased and sheathed in poly tube
• Three coat epoxy paint system • Galvanising—(Threadlok Bar only)
A combination of the above systems may also be specified. Consideration must also be given to
the threaded ends to ensure correct installation of fittings after coating.
Fittings
Fittings may be treated as above but with preference given to galvanising.
Temporary Bar Anchors

Anchors used in a temporary environment may be used without protection apart from grout cover.
Permanent Bar Anchors

These anchors require installation into corrugated polyethylene sheathing to provide
multiple levels of protection. This is accomplished by the internal grout and sheathing
barrier. Additional protection may also be used by incorporating the above bar coatings.
37
VSL
STRESSBAR
VSL CT STRESSBAR
Nominal Nominal Nominal Nominal Tensile Nominal 0.1% Characteristic Strength Minimum Appr. Modulus Major Dia. Thread
Dia. Area Mass Strength Proof Stress kN Elongation of Elasticity of Thread Pitch
mm sq. mm kg./m MPa MPa Max. Force 0.1% Proof at max force % x 10 3 MPa mm mm
15 177 1.52 1080 930 190 165 3.5 170 17.2 6
20 314 2.39 1030 835 325 260 3.5 170 21.2 6
23 415 3.46 1080 930 450 385 3.5 170 25.2 6
26 531 4.40 1080 930 575 495 3.5 170 28.2 6
29 661 5.44 1080 930 715 615 3.5 170 31.2 6
32 804 6.59 1080 930 870 750 3.5 170 34.4 6
36 1018 7.86 1030 835 1050 850 3.5 170 37.4 6
38 1134 9.23 1080 930 1225 1055 3.5 170 40.4 6
40 1257 9.72 1030 835 1295 1050 3.5 170 41.4 6
46 1662 14.03 1030 835 1710 1390 3.5 170 49.4 6
56 2463 19.33 1000 810 2460 1995 3.5 205 58.5 6
73 4185 34.68 1000 810 *3873 *3140 3.5 205 75 4
Note: 1. Relaxation properties, as per AS1313, are 4% maximum at 1000 hrs when loaded to 70% of minimum breaking load.
2. Fatigue results exceed two million cycles when loaded over a stress range of 80 MPa.
3. Minimum bending radius = 200 x Bar Dia.
4. The modulus of elasticity may be increased to 205 x 103 MPa for bars up to 46 dia., where the bars are supplied with additional heat treatment.
5. CT bars may be supplied rolled thread over full length, except 73mm (* cut thread with reduced capacity).
VSL HR STRESSBAR
*15 177 1.39 1080 885 191 157 3.5 205 17.4 10
26.5 552 4.48 1030 835 568 460 3.5 165 30 13
32 804 6.53 1030 835 828 671 3.5 165 36 16
36 1018 8.27 1030 835 1048 849 3.5 165 40 18
40 1257 10.2 1030 835 1294 1048 3.5 165 45 20
Note: 1. Refer to CT Stressbar notes.

* VSL Deformed tie bar
VSL THREADLOK BAR

20 314 2.47 600 500 188 157 16 205 22.7 10 LH
25 491 3.85 600 500 295 246 16 205 28 12.5 LH
Note: 1. Threadlok bars incorporate LEFT-HAND threads (LH)
2. Minimum bending radius = 4 x Bar Dia.
VSL MT600 BAR

20 314 2.47 620 460 186 138 16 205 21.4 2
23 415 3.26 620 460 241 179 16 205 25.0 3
30 707 5.55 620 460 416 309 16 205 32.0 3
36 1018 7.99 620 460 595 441 16 205 38.7 4
39 1195 9.38 620 460 701 520 16 205 41.7 4
45 1590 12.48 620 460 945 701 16 205 47.8 4
56 2463 19.33 620 460 1475 1095 16 205 58.8 4
60 2827 22.19 620 460 1665 1235 16 205 64.1 6
75 4418 34.68 620 460 2628 1950 16 205 79.1 6
90 6362 49.94 620 460 3811 2828 16 205 94.1 6
100 7854 61.65 620 460 4721 3503 16 205 104.1 6
Note: These specifications may be subject to change without notice. Check with the VSL office regarding availability.
38
VSL
STRESSBAR
V S L C T S T R E S S B A R — S TA N D A R D C O M P O N E N T D E TA I L S ( m m )
ITEM BAR DIAMETER 15 20 23 26 29 32 36 38 40 46 56 73
A B PART No. NC15 NC20 NC23 NC26 NC29 NC32 NC36 NC38 NC40 NC46 NC56 NC73
A 28 33 38 42 47 52 56 62 65 90* 100* 140*
NUTS
B 40 45 45 50 50 55 55 60 60 75 100 120
PART No. LNC15 LNC20 LNC23 LNC26 LNC29 LNC32 LNC36 LNC38 LNC40 LNC46 LNC56 LNC73
LOCKNUTS
B 13 16 19 22 24 26 29 31 32 40 45 60
A C PART No. BP15 BP20 BP23 BP26 BP29 BP32 BP36 BP38 BP40 BP46 BP56 BP73
D
A 75 100 130 130 150 150 150 180 180 250 250 300
BEARING
B 75 100 130 130 130 130 150 150 150 200 200 300
PLATES**
B
C 25 32 40 40 40 50 50 50 50 60 70 70
D 21 25 29 32 35 38 42 45 47 54 63 80
A B PART No. CC15 CC20 CC23 CC26 CC29 CC32 CC36 CC38 CC40 CC46 CC56 CC73
COUPLERS A 32 36 39 42 45 54 56 60 65 75 85 110
B 90 100 100 110 110 120 125 130 130 150 190 250
A
PART No. CCV15 CCV20 CCV23 CCV26 CCV29 CCV32 CCV36 CCV38 CCV40 CCV46 CCV56 CCV73
COUPLER
B
A 230 230 230 230 230 230 230 230 230 250 290 350
COVERS
B 57 57 57 57 57 70 70 70 75 90 96 118
PART No. WF15 WF20 WF23 WF26 WF29 WF32 WF36 WF38 WF40 WF46 WF56 WF73
B A B
FLAT
A 34 39 50 56 60 66 72 78 84 100 120 150
WASHER
B 3 3 4 4 5 5 6 6 6 8 8 8
PART No. WS15 WS20 WS23 WS26 WS29 WS32 WS36 WS38 WS40 WS46 WS56 WS73
SPHERICAL A 39 45 45 50 56 64 70 75 80 100 120 160
WASHER
B 5 7 10 10 10 10 10 12 12 12 18 20
PART No. D36 D36 D39 D39 D39 D45 D45 D51 D54 D60 D69 D96
A
DUCTING A 36 36 39 39 39 45 45 51 54 60 69 96
Note: 1. *Nuts for 46, 56 and 73-mm are supplied from round material with peg holes as standard.
2. ** Where tapped bearing plates are specified then they are supplied with a locknut as standard.
GROUT TUBE
LIVE END ANCHORAGE
GROUT INJECTION
NUT FERRULE
DUCT
COUPLER ASSEMBLY DEAD-END ANCHORAGE
VSL CT STRESSBAR TENDON ARRANGEMENT
VSL Stressbar is produced from Australian

raw materials and by Australian labour at
our manufacturing plant in Noble Park,
Victoria.
All bars and fittings comply with relevant

codes and are now exported to some 20
countries worldwide.
39
VSL
STRESSBAR
V S L C T S T R E S S B A R — A R C H I T E C T U R A L C O M P O N E N T D E TA I L S ( m m )
ITEM BAR DIAMETER 15 20 23 26 29 32 36 38 40 46 56 73
SPADE PART No. CLS15C CLS20C CLS23C CLS26C CLS29C CLS32C CLS36C CLS38C CLS40C CLS46C CLS56C CLS73C
E C CLEVIS A 20 25 32 36 40 40 45 50 50 55 80 100
F B A
PART No. CLF15C CLF20C CLF23C CLF26C CLF29C CLF32C CLF36C CLF38C CLF40C CLF46C CLF56C CLF73C
B 23 28 35 39 43 43 48 53 53 58 83 103
G
C 39 48 59 67 73 77 86 93 93 98 141 189
D 173 198 220 240 254 277 294 330 330 363 412 542
J
FORKED
E 52 66 72 82 98 98 106 130 130 154 168 210
CLEVIS
F 22 27 31 37 40 43 46 57 57 61 76 101
G 34 42 46 54 59 63 68 84 84 100 113 150
H H 33 42 48 50 56 65 70 80 80 90 110 140
J 59 71 79 88 95 109 116 131 131 148 154 222
B PART No. CLP15C CLP20C CLP23C CLP26C CLP29C CLP32C CLP36C CLP38C CLP40C CLP46C CLP56C CLP73C
CLEVIS
A
A 21 26 30 36 39 42 45 56 56 60 75 100
PIN
B 40 49 60 63 74 78 87 94 94 99 142 190
CONICAL PART No. LNC15S LNC20S LNC23S LNC26S LNC29S LNC32S LNC36S LNC38S LNC40S LNC46S LNC56S LNC73S
A B COVER A 33 42 48 50 56 65 70 80 80 90 110 140
(STANDARD) B 40 50 60 65 75 80 90 95 100 120 140 190
CONICAL PART No. LNC15T LNC20T LNC23T LNC26T LNC29T LNC32T LNC36T LNC38T LNC40T LNC46T LNC56T LNC73T
COVER
A 33 39 48 50 56 65 70 80 80 90 110 140
(TURNBUCKL
E) B 60 70 80 90 100 110 110 120 120 140 160 210
A B PART No. TC15R TC20R TC23R TC26R TC29R TC32R TC36R TC38R TC40R TC46R TC56R TC73R
TURNBUCKL A 33 39 48 50 56 65 70 80 80 90 110 140

E COUPLER B 160 170 180 190 200 220 220 230 230 250 280 340
C C 80 80 90 90 100 100 100 100 100 100 100 100
Yarra Boulevarde Bridge - Melbourne, Victoria
40
VSL
STRESSBAR
Olympic Aquatic Centre, Homebush, NSW Netball Centre, Waverley, Victoria
V S L M T 6 0 0 B A R — S TA N D A R D C O M P O N E N T D E TA I L S ( m m )
ITEM BAR DIAMETER 20 23 30 36 39 45 56 60 75 90 100
A B PART No. NM20 NM23 NM30 NM36 NM39 NM45 NM56 NM60 NM75 NM90 NM100
NUTS A 30 36 46 55 65 75 85 95 115 160* 180*
B 18 21 25 31 34 38 45 52 60 75 80
A B PART No. CM20 CM23 CM30 CM36 CM39 CM45 CM56 CM60 CM75 CM90 CM100
COUPLERS A 33 39 48 56 65 80 90 110 120 140 150
B 45 53 65 77 89 101 117 133 157 192 212
B A PART No. WM20 WM23 WM30 WM36 WM39 WM45 WM56 WM60 WM75 WM90 WM100
FLAT A 37 44 56 66 78 92 105 115 140 160 180
WASHER B 3 4 4 5 7 8 9 9 12 12 14
Note: 1. *Nuts for 90 and 100mm are supplied from round material with peg holes as standard.
V S L M T 6 0 0 B A R — A R C H I T E C T U R A L C O M P O N E N T D E TA I L S ( m m )
ITEM BAR DIAMETER 20 23 30 36 39 45 56 60 75 90 100
PART No. CLSM20C CLSM23C CLSM30C CLSM36C CLSM39C CLSM45C CLSM56C CLSM60C CLSM75C CLSM90C CLSM100C
SPADE CLEVIS
E C A 20 20 25 36 40 45 50 55 80 100 100
F B A
PART No. CLFM20C CLFM23C CLFM30C CLFM36C CLFM39C CLFM45C CLFM56C CLFM60C CLFM75C CLFM90C CLFM100C
B 23 23 28 39 43 48 53 58 83 103 103
G
C 39 39 48 67 73 86 93 98 141 189 189

D 173 173 198 240 254 294 330 363 412 542 542
J
FORKED E 52 52 66 82 98 106 130 154 168 210 210

CLEVIS F 22 22 27 37 40 46 57 61 76 101 101
G 34 34 42 54 59 68 84 100 113 150 150
H H 33 33 42 50 56 70 80 90 110 140 140
J 59 59 71 88 95 116 131 148 154 222 222
B PART No. CLPM20CCLPM23CCLPM30CCLPM36CCLPM39C CLPM45C CLPM56C CLPM60C CLPM75C CLPM90CCLPM100C
A
CLEVIS PIN A 21 21 26 36 39 45 56 60 75 100 100

B 40 40 49 63 74 87 94 99 142 190 190
CONICAL PART No. LNM20S LNM23S LNM30S LNM36S LNM39S LNM45S LNM56S LNM60S LNM75S LNM90S LNM100S
A B COVER A 33 33 42 50 56 70 80 90 110 140 140
(STANDARD) B 40 45 50 65 75 90 95 120 140 190 190
CONICAL PART No. LNM20T LNM23T LNM30T LNM36T LNM39T LNM45T LNM56T LNM60T LNM75T LNM90T LNM100T
COVER A 33 39 48 56 65 80 90 100 120 140 150
(TURNBUCKLE) B 60 60 70 90 100 110 120 140 160 210 210
A B PART No. TM20R TM23R TM30R TM36R TM39R TM45R TM56R TM60R TM75R TM90R TM100R
TURNBUCKLE A 33 39 48 56 65 80 90 100 120 140 150

COUPLER B 120 128 150 168 184 196 212 228 252 280 300
C C 80 80 80 100 100 100 100 100 100 100 100
41
VSL
STRESSBAR
VSL TIE & THREADLOK BAR

C O M P O N E N T D E TA I L S ( m m )
15mm 20mm 25MM
ITEM BAR DIAMETER
TIE BAR THREADLOCK THREADLOCK
A B PART No. NTB15 NTL20 NTL25
NUTS A 28 33 42
STANDARD B 50 42 52
A B PART No. NTB15D NTL20D NTL25D

NUTS A - 38 42
C
DOME B - 42 52
C - 55 55
A B PART No. NTB15W NTL20W MTL25W
NUTS A 25 36 -
WING B 50 50 -
A C PART No. PTB15 PTL20 PTL25

D BEARING
A 75 130 130
B 75 130 130
PLATES
B
C 25 20 25
D 20 25 32
A C PART No. PTB15D PTB20D PTB25D

DOMED A - 150 250
BEARING B - 150 250
B
PLATES C - 8 12
D
D - 34 34
A B PART No. CTB15 CTL20 CTL25

COUPLERS A 33 33 42
B 110 94 116
B A FLAT PART No. WM16 WTL20 WTL25

WASHERS A 34 39 56
B 3 3 4
Vertical Prestressing of Precast Shaft Segments

Airport Control Tower, Sydney, N.S.W.
C
25
Ax
B
25
Stroke
200 L E D
Chair Height Hydraulic Stressing Jack and Accessories
J A C K C L E A R A N C E D E TA I L S ( m m )
JACK CHAIR
MODEL F G H HEIGHT
B55 680 95 125
B90 665 105 150
H Chair dia.
B90L 810 105 150

250
300
B100 540 110 150

B100L 740 110 150
G
B150 995 150 150

B200 1025 160 200
F 460
VSL190 1600 220 200
VSL460 1600 260 250 580
42
VSL
STRESSBAR
VSL HR STRESSBAR
S TA N D A R D C O M P O N E N T D E TA I L S ( m m )
ITEM BAR DIAMETER 26.5 32 36 40
PART No. NH26 NH32 MH36 NH40
A B
NUTS A 47 56 62 65
B 80 90 110 129
PART No. LNH26 LNH32 LNH36 LNH40

LOCKNUTS B 40 45 55 60
A C PART No. PH26 PH32 PH36 PH40

D
A 130 150 150 180

BEARING
B 130 130 150 150
B
PLATES
C 40 50 50 50
D 35 41 45 47
PART No. CH26 CH32 CH36 CH40

Vertical Web Tendons
COUPLERS A 48 57 70 75 Gateway Bridge, Brisbane,
A B STANDARD Queensland
B 150 180 210 210
COUPLER PART No. CH26H CH32H CH36H CH40H

S A 45 54 56 66
HI- B 130 160 180 180
TENSILE
A PART No. CCH26 CCH32 CCH36 CCH40
COUPLER
A 250 280 310 310
B
COVERS
B 57 70 90 90
STANDARD
PART No. WFH26 WFH32 WFH36 WFH40
FLAT
B A B A 56 66 78 92
WASHERS
B 4 5 7 8
PART No. WSH26 WSH32 WSH36 WSH40

SPHERICAL A 56 70 75 80
WASHERS
B 10 10 12 12
PART No. D39 D45 D50 D54

A
DUCTING
A 39 45 50 54
Transverse Stressing
Bridge Beams, Beenleigh, Queensland
R E C E S S D E TA I L S ( m m )
Bar Recommended Minimum
Dia A B C A B C
15, 20 120 120 90 100 100 90
23, 26 150 150 95 130 130 95
29, 32, 36 170 170 100 150 150 100
38, 40 200 170 110 180 170 110
46 270 220 140 250 200 140
56 270 220 160 250 200 160
73 320 320 180 300 300 180
J A C K D E TA I L S ( m m )
Nom
Bar Jack Jack Dimension Capacity Weight
Dia. Model D L E Stroke kN kg
15 to 25 B55 165 245 85 125 550 33
29, 36 B90 190 280 105 80 900 48
29 to 36 B90L 190 355 105 150 900 62
38, 40 B100 200 170 130 50 1000 28
38, 40 B100L 200 270 130 150 1000 48
46 B150 275 300 150 150 1500 100
46, 56 B200 300 380 170 150 2000 160
Prestressing of Precast Segmental Beams,
56 VSL190 410 565 220 100 1900 151 Chaing Mai Grandstand, Thailand
73 VSL460 485 510 220 100 4600 425
43
VSL
GROUND ANCHORS
Burrinjuck Dam, NSW
GENERAL
Anchors may be constructed in virtually any type of ground to provide large concentrated forces in precise
locations to carry any combination of applied loads. Ground anchors are more specifically referred to as rock
anchors or soil anchors, depending on whether the anchor takes its bond in rock or soil.
Each anchor consists of a high-tensile steel tendon inserted into a drilled hole. At the lower end the anchor is bonded
to the rock or soil by high strength cement grout. The top of the anchor is fitted with a VSL stressing anchorage.
Once the grout has achieved sufficient strength, the anchor tendon is stressed to the required force using a
calibrated jack. This force is maintained by the stressing anchorage after release of the jack.
Corrosion protection is provided by the cement grout in temporary anchors and by full encapsulation of the entire
anchor in a thick walled polyethylene sheath for permanent anchors.
ROCK ANCHORS
VSL Rock Anchors range in ultimate capacities up to 23,750kN. Tendons are constructed from either a number
of 12.7mm or 15.2mm diameter, high tensile steel strands or single VSL stressbars.
SOIL ANCHORS
VSL Soil Anchors are used in alluvial soils, stiff clays or highly weathered rock. The ultimate capacity of these
anchors is determined by the capability of the ground in the bond zone to transfer the load from the anchor.
Anchor details are similar to rock anchors.
SOIL NAILS
VSL Soil Nails are used to reinforce in-situ soil in an excavation or embankment. They are formed by inserting
VSL Bar into a drilled hole which is filled with cement grout. Corrosion protection similar to ground anchors can
be provided depending on the application. Soil nails have no or only nominal initial applied force.
R O C K B O LT S
VSL Rock Bolts are used to strengthen and stabilise jointed rock, and to stabilise defined blocks of rock. They
are formed by inserting VSL Bar into a drilled hole and anchoring it in place with either a mechanical anchorage,
a chemical anchorage or cement grout. The bar is stressed to apply an initial force.
44
VSL
GROUND ANCHORS
Grout tubes TH
NG
LE
ON
ND
Bare clean strand
E TE
F RE
Corrugated sheath
Internal spacer ring Anchor head
B Bearing Plate
External spacer
ON
Bore hole
E ND
O FT
SECTION A.A GT
H
N
LE
ND Smooth sheath (Polyethylene)
BO
or continuous corrugated sheath
Greased and plastic coated strand
A
B
Grout Grout tubes
Grout tubes Smooth
Bare clean strand sheath
Internal spacer ring
Corrugated sheath (Polyethylene)
Greased
and plastic
A
coated strand
External spacer
External spacer
Bore hole Bore hole
Nose cone SECTION B.B
V S L P E R M A N E N T A N C H O R F U L LY E N C A P S U L AT E D
Grout tubes
Bare clean strand

TH
NG
LE
ON
Spacer ring ND
E TE
F RE
Bore hole
SECTION A.A Anchor head
B
Bearing Plate
ON
E ND
O FT
H A
N GT
LE
ND
BO Greased and plastic coated strand (optional)
B
Grout tube
Grout (free length optional)
Bare clean strand
A
Grout tube
Greased and plastic

Spacer ring Bore hole coated strand (optional)
Bore Hole SECTION B.B
VSL TEMPORARY ANCHOR
45
VSL
GROUND ANCHORS
VSL PERMANENT GROUND ANCHORS

15.2mm STRAND
Sheath diameters mm
No. of Ultimate Drill Jack
15.2mm capacity hole corrugated smooth type
strand 15.2mm Super kN dia. mm ID OD ID OD required
2 500 100 50 65 59 63 VSL 50
4 1000 130 65 80 70 75 VSL 100
8 2000 150 80 100 84 90 VSL 190
14 3500 175 100 120 102 110 VSL 290
27 6750 215 130 150 130 140 VSL 670
55 13750 310 210 230 225 235 VSL1250
65 16250 310 210 230 225 235 VSL1650
91 22750 350 250 270 260 270 VSL1700
Note: Where block outs, voids or drill hole casing are required, drill hole diameters and bearing plate
dimensions should be confirmed with the VSL office.
Drill hole sizes are based on 10mm external cover.
Anchors for 15.2mm system are compatible with 261kN EHT strand.
VSL CT STRESSBAR GROUND ANCHORS

Permanent Epoxy
Encapsulated Coated Temporary
Bar Ultimate Drill Corrugated Drill Drill Jack
dia. capacity hole Sheath mm hole hole type
mm kN dia. mm ID OD dia. mm dia. mm required
15 190 100 50 65 75 50 B 55
*15 191 100 50 65 75 50 B 55
**20 188 100 50 65 75 50 B 55
20 325 100 50 65 75 50 B 55
23 450 125 65 80 87 75 B 55
**25 295 125 65 80 87 75 B 55
26 575 125 65 80 87 75 B 55
29 715 150 80 100 100 87 B 90
32 870 150 80 100 100 100 B 90
36 1050 150 80 100 112 100 B 90
38 1225 150 80 100 112 100 B100
40 1295 150 80 100 112 100 VSL190
56 2460 175 100 120 165 125 VSL460
Drill hole sizes are based on 10mm external cover

*VSL Deformed Tie Bar
**VSL Threadlok Bar
VSL TEMPORARY GROUND ANCHORS

15.2mm STRAND 12.7mm STRAND
No. of Ultimate Minimum Jack No. of Ultimate Minimum Jack
15.2mm capacity drill hole type 15.2mm capacity drill hole type
strand 15.2mm Super kN dia. mm required strand 12.7mm Super kN dia. mm required
6 1500 75 VSL190 7 1290 75 VSL100
14 2580 100 VSL290
12 3000 100 VSL290
24 4420 125 VSL460
18 4500 130 VSL460
24 6000 150 VSL670
Note: Anchors for 15.2mm and 12.7mm system are compatible with 261 kN EHT strand.
46
VSL
GROUND ANCHORS
VSL PERMANENT GROUND ANCHORS

B E A R I N G P L AT E A N D A N C H O R H E A D
AxA
15.2mm STRAND STRESSBAR
C
nominal Bar Dia. A B
No. of A B C D
Strands mm mm mm mm mm mm mm
D
2 200 30 80 60 15 150 25
B 4 200 35 110 60 20 150 25
8 300 45 180 80 23 200 40
14 400 60 220 100 26 200 40
27 500 80 270 130 29 225 50
55 670 120 360 190 32 250 50
65 700 140 380 190 36 250 50
*Dimensions may vary depending upon anchor
drilling methods and project specific criteria. 91 850 160 470 200 38 300 50
40 300 60
56 350 70
NOTES
• Details given may be varied for particular
applications
• For strand anchors the maximum configuration
size is shown. Lesser number of strands may be
specified
• Additional capacities available on request
• Drill hole sizes are based on 10mm external cover
Bearing plate and anchorhead
• Anchors can be monitorable and restressable
• Removable ground anchors are available
• Electrically isolated ground anchors available
STRESSING
• Jack sizes are the same as for multistrand or
stressbar systems
• Additional special purpose jacking chairs are
provided to permit test loading
• Load cells can be provided that screw onto the
anchorhead to permit load measurement at any
time, or permanently attached to enable rapid
load checking
• Both hydraulic and electrical load cells are
Anchor stressing
available
47
VSL
GROUND ANCHORS
Permanent Rock Anchors, Lapstone, N.S.W.
Prefabricated Permanent Stressbar Anchors

Sydney, N.S.W.
Soil Nails VSL Threadlok Rock Bolts, Permanent Anchors

Bell Banksia, Melbourne, Victoria Kangaroo Point, Queensland
48
VSL
GROUND ANCHORS
Temporary Anchors, Brisbane Casino, Queensland
Stressing Permanent Anchors
Installation Uplift Restraint, Permanent Anchors Prefabricated Permanent Anchor and Transportation Train
Sydney, N.S.W. Burrinjuck Dam, N.S.W.
49
VSL
V S o L R E TA I N E D E A R T H
Browns Plaons Interchange, Queensland
VSL RETAINED EARTH SYSTEM - VSoL is a composite soil reinforcing system which employs
welded wire mesh to improve the shear and compressive strength of an earth backfill.
A RETAINED EARTH structure is a stable, unified gravity mass which may be designed for use in
a broad variety of civil engineering applications. In projects ranging from commercial retaining
walls to highway bridge abutments, VSoL has found widespread use
and acceptance as a major construction system.The effective
principle of RETAINED EARTH involves the transfer of stresses from
the soils to the reinforcing mesh through bearing. Bearing pressure is
developed on the projected areas of the mesh crossbars, and the
pressure is in turn transferred to the longitudinal bars. The longitudinal
bars are thus placed in tension, which enables the soil mass to
withstand loads in the direction of the reinforcement.
In addition to the significant

performance advantages, the VSoL
Typical Section
system is also extremely economical to VSoL RETAINED EARTH Wall
design and construct. The system at a Bridge Abutment
consists of only three components,

reinforcing mesh, precast facing panels
and backfill material. This simplicity
allows construction to proceed easily and
rapidly. Cost savings of up to 50% are
regularly realised when compared with
traditional stabilisation systems.
F A S T, E A S Y, E C O N O M I C A L
The construction of a RETAINED EARTH structure is extremely
straightforward. A five-man crew using standard construction
Perspective View
equipment will average 75 square metres of wall per shift, and can VSoL RETAINED EARTH
Retaining Wall
place up to 140 square metres per shift.
50
VSL
V S o L R E TA I N E D E A R T H
C O M P L E T E C A PA B I L I T I E S
VSL provides the client with a complete range of design and
engineering services for a RETAINED EARTH structure.
Services provided include analysis of internal stability, bridge

load, overturning, external stability and base sliding. In addition,
VSL furnishes all preliminary drawings, shop drawings and
complete erection sequencing documents.
COMPLETE FLEXIBILITY
The VSoL concrete facing panels are available in a broad range of textures
and colours. Because local materials are used in the production of these
precast panels, the exposed surface can easily be coloured to complement
the natural surroundings. Standard RETAINED EARTH panel treatments
include raised relief, sandblast finish, exposed aggregate, and conventional
smooth face concrete. These are only a very few of the possibilities however.
Non-concrete faces, such as welded mesh or steel faced are available.The
range of architectural treatments is virtually unlimited.
Yarrie Iron Ore, WA. – Welded mesh
face
F5 Freeway, Heathcote NSW - Raised Relief Panel Penrith Lakes Scheme, NSW – Plain face square panel
Yarrie Iron Ore, WA, – Steel face Rode Road - Queensland - Architectural finish plain face square panels
51
VSL
S P E C I A L I S E D F O U N D AT I O N S
Diaphragm walls and jet grouting - New Southern Railway, Sydney, NSW
Intrafor is a world leader in the field of soil engineering. Since its founding in 1850, Intrafor has
developed extensive experience and expertise in soil engineering techniques such as
foundations, retaining structures, soil improvement, environmental protection, soil waterproofing,
consolidation and instrumentation.
Intrafor’s skilled engineers and site operators, operating under ISO 9001 Certification and
employing heavy duty specialist plant and equipment, are dedicated to the efficient and practical
achievement of our client’s needs and objectives on site. VSL-Intrafor’s design offices are able to
propose budget solutions for soil engineering projects or to undertake fully detailed working
designs, procedures and systems.
The integration of Intrafor skills with VSL Australia’s proven expertise in ground anchoring and
Retained Earth walling systems, and expertise, enable VSL-Intrafor to offer our clients the most
comprehensive of foundation works packages as the solution to the increasingly complex
foundation engineering challenges.
52
VSL
S P E C I A L I S E D F O U N D AT I O N S
A P P L I C AT I O N S
Retaining structures
• Diaphragm Wall
• Secant Piles
Foundations
• Bored Piles
• Driven Piles
• Micro-Piles
• Jet Grouting
• Barrettes Diaphragm walls and bored piles - M5 East Motorway. Cooks River crossing, Sydney, NSW
Soil improvement
• Stone Columns
• Jet Grouting
• Dynamic Compaction
• Compaction grouting
• Vibrocompaction
Environmental protection/
Waterproofing
• Dewatering
• Cut off Walls
Diaphragm walls - International Station, New Southern Railway, Sydney, NSW
• Bentonite cement cut-off wall
• Directional drilling
• Contaminated site
confinement
Ground Investigation and

Instrumentation
• Site investigation
• Monitoring
• Various tests
Diaphragm walls/Barrettes, Jet Grouting - Airport Link, Sydney, NSW
53
VSL
CLIMBFORM
Central Plaza Building, Hong Kong
The VSL Climbform System is a self climbing heavy duty construction platform used primarily to lift
static panel vertical wall formwork. The system provides the wall designer with complete flexibility in
both the structural design and selection of finishes.
Standard features include:

• Custom designed formwork panels which may be ganged in any shape or size to lift as one unit
• form heights ranging from 2.5 to 4.0 metres
• unobstructed access to the forms for:
– cleaning and oiling
– fixing of door frames and blockouts
– reinforcement and reinforcing fabric fixing, including prefabricated reinforcement
• truss members of fixed height assembled in “Meccano like fashion” to form a platform
of any plan shape or size
• easy levelling and plumbing of the external platform, which is typically supported on
four, six or eight seatings
• minimum adjustment of individual forms after the initial set-up
• an achievable vertical tolerance range of 10mm per 4.0 metre height
• variation of wall thickness by moving the internal or external forms
• parking the internal platforms at mid-lift to facilitate blockout and reinforcement fixing,
eliminating the requirement for temporary scaffolds
• cycle times as low as three days
• access to external walls for curing
• hanging access stairway
54
VSL
CLIMBFORM
VSL Climbform services include the design of the climbing

system and formwork, hire of all Climbform equipment,
prefabrication of forms and platforms off-site and
supervision of the installation of the climbing platform.
Optional features include:
• steel formwork to enable pouring within 50mm
of boundaries
• support of concrete placing booms on the platform
• access hatches and/or temporary removal of
platforms to install precast stairs
• external trailing platforms for:
– patching of tie bolt holes
Tsing Ma Bridge Piers, Hong Kong
– concrete finishing and curing
– welding of beam stubs/brackets to support
steel floor beams
– secondary egress
• internal trailing platforms to allow early installation:
– Lift rails
– Electrical and mechanical services
• support of site sheds and toilets on the platform
• provision to allow manhoists to service the top
working platform
• provision to locate tower cranes within internal
and corridor platforms
• collapsible door formers
• trailing formwork and platforms for vertical
and raking walls.
The VSL Climbform System is the most powerful
commercial formwork system available in the world today
and has been specified on the largest and tallest vertical
Melbourne Central Building, Victoria structures in Asia and Australia.
Top Construction /Storage Platform Sky Tower, Circular Structure, Auckland
55
VSL
D U C TA L
Sherbrooke Footbridge, Canada
Ductal is a material with a unique combination of superior characteristics.
The material was developed by Bouygues under the generic name of Reactive Powder Concrete and is
marketed under the brand name of Ductal. Composed of fine particles with a maximum size less than
0.8mm, Ductal reaches compressive strengths of 170 to 230 MPa.
In structural applications, Ductal is used without any passive reinforcing bars. Very fine, high strength
steel fibres are provided to withstand secondary tensile stresses due to shear, tension, small bending
moments and concentrated loads. Pre or post-tensioning counterbalances the main tensile stresses due
to large bending moments. The steel fibres also provide significant ductility to the cementitious paste.
In non-structural applications, Ductal is used with non-metalic fibres. Passive steel reinforcement and
prestressing are not required. Ductal has the ability to replicate the micro and nano-texture of the mould.
When combined with the fluidity and the ability to have a range of colours, the result is a material that
provides a high quality surface appearance together with high strength and durability.
The durability properties are those of an impermeable material. There is almost no risk of carbonation or
penetration of chlorides and sulfides, and the resistance to acids is improved.
ADVANTAGES
• Eliminates completely the need for conventional reinforcement
• Greatly improves durability, with a resistance to permeability 50 times better
than normal high strength concrete
• Permits the use of much thinner sections
• Provides complete freedom on the shape of the section
• Reduces the concrete volume of a structural member to only one third to
one half of its conventional volume
• Dramatically reduces the structural weight to be supported by a structure
• Provides both direct and indirect cost savings
56
VSL
D U C TA L
STRENGTH CHARACTERISTICS
• Compressive Strength (cylinder) 170-230MPa
• Flexural Strength (3 point bending test)40-50 MPa
• Youngs Modulus(E) 50-60 GPa
• Total Fracture Energy 20,000-30,000 J/m2
RHEOLOGY
• Fluid to self compacting
• Flow (Abrams cone) 50-70cm
• Flow (ASTM shock table) 250mm
Precast beams - Cattenom power plant, France
DURABILITY
• Chloride ion diffusion (CI) 10 -12 m2/s T Y P I C A L A P P L I C AT I O N S
• Carbonation penetration depth <0.5mm
• Freeze/thaw (after 300 cycles) 100% Bridges
• Salt-scaling (loss of residue) <10g/m • Beams
• Abrasion (relative volume loss index) 1.2 • Truss type structures
• Decks of steel bridges
OTHER PROPERTIES Buildings
• Density 2450-2550 kg/m3 • Beams
• Entrapped air content 2-4% • Slabs
• Freeze/thaw (after 300 cycles) 100% • Permanent floor formwork
• Total porosity 2-6% • Curtain wall panels
• Post cure shrinkage <10 -5 • Facade panels
• Creep coefficient 0.2-0.5 • Columns
• False floor panels
• Grandstand seating plats
Railways
• Sleepers
• Sound absorbing panels
• Noise walls
Highways
• Light poles
• Crash barriers
• Noise walls
Civil
• Pipes
• Hazardous waste
containment
• Arch culverts
Other
• Blast protection
• Vaults
Facade panels - Monaco rail station.
57
VSL
S TAY C A B L E S
V S L S TAY C A B L E S Y S T E M S S I 2 0 0 0
VSL Stay Cable System SSI 2000 has been developed to fulfil the stringent requirements for the
design, construction and maintenance of cable stayed bridges.
VSL Stay Cable System SSI 2000

consists of:
• a tendon made of multiple

parallel 15.2mm high tensile
steel strands
• each strand having an extruded
coating of grease and
polyethylene
• an outer sheath of thick walled
polyethylene pipe
• anchorages that are
prefabricated in the factory.
Batam-Tonton Bridge, Indonesia
The features of the system are:
• high fatigue resistance of 200 MPa at 45% of tendon capacity through 2,000.000 load cycles
• multi-layer corrosion protection with full encapsulation of each individual strand for increased
durability
• excellent corrosion protection of individual strands during construction provided by the extruded
coating
• simple erection of stay cable assembly
• simple Single Strand Installation (SSI) of the tendon into the erected stay assembly
• the VSL developed automatic stressing system enables each individual strand to be stressed
according to specific data via the use of a laptop computer
• no requirement for on site grouting of cable
• easy to adjust or monitor the tendon force at any stage of the cable life
• lightness and versatility to provide full compatibility with modern construction methods
• easy maintenance
• ability to remove and replace individual strands at any time
• vibration control of cable by use of a patented mechanical damper fixed to the stay pipe
• coloured polyethylene stay pipe (co-extruded or fully coloured) available
• special helical anti-vibration ribs on stay pipe available.
V S L S TAY C A B L E S Y S T E M S S T R E S S B A R
VSL Stressbars are particularly suitable and economical for shorter road bridges, pedestrian
bridges and stays for suspended roofs. Individual bars are available with ultimate capacities up to
3,873kN – refer stressbar section of this manual for details.
58
VSL
S TAY C A B L E S
HDPE Stay Pipe
Individual
Monostrand
SECTION (TENDON UNIT 6- Monostrand Tendon

and Stay Pipe
12)
V S L S TAY C A B L E
DEAD END
SYSTEM SSI 2000 ANCHORAGE
S
ND
T RA
OS
Elastomeric Damping ON
Deviator 7M
Transition pipe with 12
Individual Strand TO
12
Protection Permanent Corrosion
Protective Grease
Plastic Sheath Seven Wire Strand

Tightly Extruded
ADJUSTABLE STRESSING ANCHORAGE WITH

THREADED ANCHOR HEAD AND RING NUT
TYPICAL MONOSTRAND
370 C L Guide Pipe N min Dead End Fixed Anchorage M D

Transition Pipe Neoprene boot 100
min min P min Adjustable Stressing Archorage min Protection cap
(4) Guide Pipe
F o/
G o/
H o/
Kn
B o/
E o/
A o/
Jn
Elastomeric Damping Anchor head

Anchor head Stay Pipe Deviator Bearing Plate with wedges
Protection cap with wedges Bearing Plate
A D J U S TA B L E S T R E S S I N G DEAD END FIXED

ANCHORAGE ANCHORAGE
TENDON MINIMUM Dimensions in mm

UNIT BREAKING Aø Bø C D Eø Fø Gø Hø J K L M N P
15.2mm LOAD kN (1) (2) (2) (2) (3) (3)
6-12 3185 190 185 90 105 230 219.1/6.3 177.8/4.5 125/5.0 290 260 30 35 1500 950
6-19 5045 235 230 105 120 285 267/6.3 219.1/6.3 140/5.4 355 335 35 50 1800 1200
6-22 5840 255 250 115 120 310 298.5/7.1 219.1/6.3 160/6.2 385 355 40 50 1950 1350
6-31 8230 285 280 135 145 350 323.9/7.1 244.5/6.3 160/6.2 440 415 45 60 2150 1550
6-37 9825 310 300 150 170 380 355.6/8.0 273/6.3 180/5.6 485 455 50 70 2350 1750
6-43 11415 350 340 155 175 425 406.4/8.8 323.9/7.1 200/6.2 540 505 55 75 2600 2000
6-55 14605 385 380 175 195 470 419/10.0 323.9/7.1 200/6.2 585 550 60 75 2650 2100
6-61 16195 385 380 190 210 470 419/10.0 355.6/8.0 225/6.9 600 585 65 85 2850 2300
6-73 19380 440 430 190 210 530 508/11.0 406.4/8.8 250/7.7 680 650 75 95 3050 2500
6-81 21505 440 430 220 240 540 508/11.0 406.4/8.8 250/7.7 710 685 80 110 3200 2650
6-91 24160 490 480 230 250 590 559/12.5 457/10.0 280/8.6 760 730 80 110 3450 2850
6-109 28940 505 495 240 265 610 559/12.5 457/10.0 315/9.8 795 775 90 120 3600 3000
6-127 33720 560 550 290 315 670 610/12.5 508/11.0 315/9.8 865 845 95 130 3950 3400
Notes: 1. Min height of anchor head allows an adjustability of ±20mm

2. External diameter/wall thickness
3. Valid for nominal concrete strength at 28 days of 36 MPa (cylinder)
4. Dimensions valid only for load monitoring/adjustment
59
VSL
E X T E R N A L P O S T- T E N S I O N I N G
Bois de Rosset Viaduct, Switzerland
External post-tensioning is well suited to bridges due to the resulting economies in construction
costs and the high degree of corrosion resistance provided by the system. External tendons are
easy to inspect and can be replaced if necessary. They are ideal for strengthening existing
structures and have a multitude of applications in addition to bridges.
VSL External tendons consist of:
• strand bundle
• duct of polyethylene or steel
• end and intermediate anchorages as well as tendon couplers
• grouting compound.
External tendons, usually guided polygonally over deviation saddles, have many similarities to stay
cables and permanent soil and rock anchors.
Detailed information about design and construction is given in the VSL publication “External Post-
Tensioning”.
V S L E X T E R N A L P O S T- T E N S I O N I N G S Y S T E M C O M P O N E N T S
Tendon deviation
saddle
Stressing anchorage Strand bundle and sheathing Dead end anchorage
60
VSL
E X T E R N A L P O S T- T E N S I O N I N G
A wide selection of VSL anchorage types is available to meet the full range of practical requirements. In addition
to the anchorages illustrated here, intermediate anchorages and couplers are also available. The strand bundle
can be assembled from uncoated or individually greased and sheathed strands. The anchorages for these two
types of tendon differ only in detail, the principle remains the same.
Yonne Bridge, France
Second Stage Expressway, Bangkok
Dimensions (mm)
TENDON UNIT A B øC D øE(1)
5-3 135 110 – – 50/4.9
5-4 150 110 – – 50/4.9
B
5-7 167 110 – – 63/4.1
STRAND TYPE 12.7mm
5-12 215 105 222 100 75/3.9

E
5-19 265 115 258 100 90/4.6

5-22 290 130 – – 110/5.7
A
5-27 315 140 – – 110/5.7

5-31 315 140 320 110 125/6.4
5-37 370 160 – – 140/7.1
5-42 390 160 – – 140/7.1
5-43 – – 390 120 140/7.1
5-48 430 170 – – 160/8.2 ANCHORAGE TYPE Scd
5-55 465 190 420 130 160/8.2
6-3 150 110 – – 63/4.1
6-4 165 105 – – 63/4.1
STRAND TYPE 15.2mm
6-7 215 105 222 100 75/3.9 D

6-12 265 115 258 100 90/4.6
6-19 315 140 300 110 110/5.7
E
6-22 315 140 320 115 125/6.4

C
6-27 370 160 – – 140/7.1

6-31 390 160 390 125 140/7.1
6-37 430 170 420 130 160/8.2
6-42 465 190 – – 160/8.2
6-43 575 205 – – 180/5.9
6-48 575 205 – – 180/5.9 ANCHORAGE TYPE CSd
6-55 600 240 – – 180/5.9
Note: (1) External diameter/wall thickness
61
VSL
H E AV Y L I F T I N G
Horizontal Jacking, Rail Underbridge, Blacktown, N.S.W.
Today's civil engineering structures and industrial plants are often assembled from large, heavy,
prefabricated components. This may be done for economic or technical reasons, or to save construction
time. For projects in which cranes or other conventional handling equipment cannot be used because of
excessive weight, dimensions or space limitations, VSL Heavy Lifting will often provide the most
effective solution.
VSL Heavy Lifting provides builders, engineers and owners with a broad range of advantages, including:
• custom-designed solutions for each project
• The highest level of safety, based upon sound engineering practices and over three decades
of experience
• Economy and efficiency through the use of advanced and reliable hydraulic equipment.
UNIQUE SOLUTIONS
VSL will plan lifting, horizontal jacking, or lowering operations
and design the necessary temporary structures to suit your
requirements. Sound engineering, clear thinking, the ability to
innovate, and years of successful experience give you a
guarantee of reliable and cost-effective solutions.
Tower Lift, 911 Tonne Vessel Qantas Hangar Lift.

Mobil Oil, Singapore Sydney, N.S.W.
62
VSL
H E AV Y L I F T I N G
SAFETY
Safety is VSL’s first priority. Our specialised hydraulic lifting
equipment is designed for the highest level of reliability, and all
equipment is rigorously tested and serviced through VSL’s
quality control and maintenance programme. VSL field services
are also based upon a total commitment to safety, the
extensive experience of our personnel and VSL’s exceptional
record provide
further assurance of reliable performance.
FLEXIBILITY
VSL’s heavy lifting equipment includes a large selection of hydraulic
jacks, pumps, control units, monitoring devices and jacking frames. This
range of equipment gives us the capability to perform virtually any
Segment Erection, Normandy Bridge, France project requiring lifting, lowering or horizontal jacking.
F L AT J A C K S
Flat jacks are widely used for a multitude of civil engineering and construction applications such
as:
• under pinning
• prestressing of columns
• counteracting sinking foundations
• prestressing of road works or airport runways
• prestressing concrete in confined spaces
• lifting and lowering of bridge superstructures for bridge bearing adjustments
• counteracting loads applied during back filling
• lifting heavy weights
• pile testing.
The VSL flat jack is constructed of two moulded steel sections welded together to form a containment vessel.
Hydraulic fluid or grout is injected at pressures of up to 13.5MPa into the peripheral ring, moving the lifting plates
apart, so that a force is applied with a maximum lifting stroke of 25mm per jack.
Type Outside Maximum Effective Area at T E
Diameter D Force at Zero Extension
3 2
Thickness Maximum Installation
mm 13.5MPa 10 mm ** Travel Gap
kN mm mm mm
D
150c 150 155 11.5 25 25 38

220c 220 390 29 25 25 38
250c 250 525 39 25 25 38
270c 270 605 45 25 25 38 Plan
300c 300 780 58 25 25 38
350c 350 1080 80 25 25 38
T
420c 420 1605 119 25 25 38

480c 480 2170 161 25 25 38
600c 600 3470 257 25 25 38 Closed
750c 750 5400 400 25 25 45
E+T
870c 870 7385 547 25 25 45

T
920c 920 8975 665 25 25 45

*1150c 1150 13635 1010 25 25 50
Fully Inflated
* 1150c Flat Jacks are specially produced to order and could be subject to a delay
** Flat Jack thickness may vary ±3 mm
63
VSL
BRIDGE ENGINEERING
As a specialist involved in the design and construction of bridges VSLhas considerable experience and expertise
in:
• conceptual, preliminary and final detailed design of bridge structures
• developing construction methods with full engineering
• full design and detail for formwork and erection systems
• on-site construction of selected elements of the structure, from post-tensioning through to entire bridge
superstructures.
The application of this knowledge by VSL assists owners, developers, main contractors and consultants with initial
design concepts, alternative designs and construction methods. The result for the project is that:
• the cost is minimised • the quality is enhanced
• the methods are simplified • the safety is improved
• the time is reduced • the value of the structure is increased
The list of successful projects is impressive in scale and diversity. For example:
T H E G AT E W AY B R I D G E , B R I S B A N E
In-Situ Cantilever Construction
VSL Scope of Work:

Design of the six lane main superstructure consisting of a main span of 260m and side spans of 145m.
Design of the travelling formwork system and supply of the post-tensioning.
T H E S E C O N D S TA G E E X P R E S S W AY
BANGKOK
Precast Segmental Construction
VSL Scope of Work

Concept and design of the erection
system, steelwork and equipment. External
post-tensioning and erection of 9000 matchcast
segments for 12km of dual elevated
expressway. The spans are simply supported
with a
maximum length of 48.5m and a maximum
segment weight of 70 tonnes.
64
VSL
BRIDGE ENGINEERING
WORONORA RIVER
BRIDGE, NSW
Incremental Launch Construction
VSL Scope of Work:

Design, supply and operation of the
launching and braking equipment.
Supply and installation of post-
tensioning. The curved bridge has a
length of 520m with typical spans of
59m and was launched down a
maximum 5% grade.
PA K S E B R I D G E , L A O S
Precast Segmental Construction
VSL Scope of Work:

Design and commissioning of formwork,
and precasting of 384 precast box girder
segments. the design of the erection truss
and full erection of the segments. Supply
and installation of permanent and
temporary post tensioning. Supply and
installation of stay cables. the 13 span
bridge has a length of 1380m with typical
spans of 102m and incorporating a stay
cable main span of 143m.
NORTH-SOUTH
ROAD LINK
J A K A R TA
Precast Girder Construction
VSL Scope of Work:

Design and supply of erection gantry.
Supply and installation of post-tensioning.
Erection of 12km of expressway
consisting of 4,100 beams.
65
VSL
VSL
VSL is a registered trademark ' 2001,

VSL Prestressing (Aust) Pty Ltd printed in Australia - Patented.
The information set forth in this brochure including technical and

engineering data is presented for general information only.
While every effort has been made to ensure its accuracy, this information
should not be used or relied upon for any specific application without
independent professional examination and verification of its
accuracy, suitability and applicability.
Anyone using this material assumes any and all liability resulting from
such use.
VSL disclaims any and all express or implied warranties of merchantibility

fitness for any general or particular purpose or freedom from infringement
of any patent, trademark, or copyright in regard to the information
or products contained or referred to herein.
Nothing herein contained shall be construed as granting a license,

express or implied under any patents.
Photo credits:
Bouygues photobank, Y. Chanoit, L. Zylberman, Skycam Australia, X
V S L P R E S T R E S S I N G ( A U S T ) P T Y LT D
ABN 56 000 528 914
NEW SOUTH WALES QUEENSLAND VICTORIA

6 Pioneer Avenue, Thornleigh 2120 81 Granite Street, Geebung 4034 2-8 Summit Road, Noble Park 3174
Locked Bag 102, Pennant Hills 2120 P O Box 10, Virginia 4014 P O Box 398, Noble Park 3174
Tel:: (02) 9484 5944 Tel:: (07) 3265 6400 Tel:: (03) 9795 0366
Fax: (02) 9875 3894 Fax: (07) 3265 7534 Fax: (03) 9795 0547
N O RTHERN TERRITO RY TASMANIA SOUTH AUSTRALIA WESTERN AUSTRALIA

Tel:: (03) 9795 0366 Tel:: (03) 6225 3567 Tel:: (03) 9795 0366 Tel:: (03) 9795 0366
Fax: (03) 9795 0547 Fax: (03) 6225 2226 Fax: (03) 9795 0547 Fax: (03) 9795 0547
http://www .vsl-intl.com email: design@vslsyd.aust.com

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VSL PRESTRESSING (AUST) PTY LT D
VSL
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Tel: (08) 9414 8643 March 2001.

VSL Construction Systems AUSPAC 2001 Anglais

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VSoL RETAINED EARTH 50

VSL is the international leading specialist contractor in the field of post

To assist in achieving this objective we have

VSL Management is committed to continuous

It is recognised that all our employees are vitally

The standard of quality of the VSL system was soon endorsed by

In 1969 VSL Australia developed operations in South-East Asia, first in

In 2000 the specialist foundation companies Intrafor and IP Foundations

VSL Australia is an integral member of the worldwide VSL Group,

VSL is your Solution Network.

In particular, the services available include:

he VSL Group has made major contributions to

T the advancement of civil engineering practice

experience enables VSL to undertake projects using

Activity world-wide over a broad range of projects has

As a specialist sub-contractor VSL can provide services

Technical reports covering specialised design and

• stressing in one or any number of stages

Note: 1. Intermediate duct diameters may be available on application.

CAST IN ANCHOR TYPE Sc

WEDGE GRIPS ANCHOR HEAD

VSL STRESSING ANCHORAGE TYPE Sc LIVE END

5-4 150 50 90 216 16 64 39 125 210

6-7 215 54 160 160 85 120 69 150 320

GROUT CONNECTION DUCT

COMPOSITE BEARING PLATE

VSL STRESSING ANCHORAGE TYPE CS LIVE END

TENDON UNIT Dimensions (mm)

SWAGED DEAD END

COUPLING COVER DUCT

VSL COUPLING ANCHORAGE TYPE C

STRAND TYPE 12.7mm STRAND TYPE 15.2mm

Curved stressing chair

Centre-stressing anchorages are used for ring tendons in circular

SWAGED DEAD END

VSL DEAD END ANCHORAGE

Dead End Anchorage Type H Dead End Anchorage Type P

STRAND TYPE 12.7mm STRAND TYPE 15.2mm

VSL DEAD END ANCHORAGE TYPE AF

POLYETHYLENE DUCT PT-PLUS™ STEEL DUCT

MIN. RADIUS OF CURVATURE Rmin

0 The radii of curvature given in the opposite

Placing of anchor head and wedges

Placing of anchor head

Positioning of the jack

Seating of wedges Stressing, measuring, seating of wedges

Grouting equipment Grouting of tendon

JACK CLEARANCE REQUIREMENTS

In-situ Cantilever Bridge, Moonee Moonee, N.S.W.

Precast Segmental Bridge, F9 Freeway, Melbourne, Victoria F9 Freeway, Melbourne, Victoria

Foundation Raft Hilton Hotel, Guam

Melbourne Cricket Ground – Great Southern Stand

Stadium Australia, Sydney NSW

Placing tendons Concreting Stressing Grouting

Tendon Force Losses

• Edge stressing 3% average

STYRENE RECESS FORMER PLASTIC RECESS FORMER

VSL STRESSING VSL STRESSING ANCHORAGES

SPACER PLATE GROUT TUBE

SWAGED DEAD END

VSL DEAD END ANCHORAGES TYPE H – TYPE P

Dead End Anchorage Type H Dead End Anchorage Type P