VSL CONSTRUCTION SYSTEMS

DESIGN
C O NS T RU C TI ON
ENGINEERING
S U P P LY
I N S TA L L AT I O N
 CONTENTS
CONTENTS 2

CONTACTS 3

THE COMPANY 4

MULTISTRAND POST-TENSIONING 8

SLAB POST-TENSIONING 22

STRESSBAR 34

GROUND ANCHORS 41

VSoL RETAINED EARTH 47

SPECIALISED FOUNDATIONS 49

CLIMBFORM 51

DUCTAL 53

STAY CABLES 55

EXTERNAL POST-TENSIONING 57

HEAVY LIFTING 59

FLAT JACKS 60

BRIDGE ENGINEERING 61

2
 C O N TA C T S

V S L P R E ST R E S S IN G ( A U S T ) P T Y LT D
ABN 56 000 528 914

VSL is a registered trademark © 2002,

VSL Prestressing (Aust) Pty Ltd printed in Australia - Patented.

NEW SOUTH WALES QUEENSLAND VICTORIA

6 Pioneer Avenue, Thornleigh 2120 75 Radley Street, Virginia 4014 2-8 Summit Road, Noble Park 3174
Locked Bag 102, Pennant Hills 2120 PO Box 10, Virginia 4014 PO 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

NORTHERN TERRITORY TASMANIA SOUTH AUSTRALIA WESTERN AUSTRALIA

Tel: (03) 9795 0366 Tel: (03) 6225 3567 Tel: (08) 8212 0371 Tel: (03) 9795 0366
Fax: (03) 9795 0547 Fax: (03) 6225 2226 Fax: (08) 8212 0397 Fax: (03) 9795 0547

h t t p : / / w w w. v s l - i n t r a f o r. c o m • e m a i l : d e s i g n @ v s l s y d . a u s t . c o m

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

SEPTEMBER 2002
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 THE COMPANY

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 our people.

DNVQA-ANZ
ACCREDITED QUALITY SYSTEM
CERTIFIED AS/ANZ ISO 9001

4
THE COMPANY
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 N6 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 existing 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
 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.

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 V S L I N T E R N AT I O N A L LY

he VSL Group has made major contributions to the

T 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
experience enables VSL to undertake projects using highly

Gateway Bridge, Australia Kwung Tong Bypass, Hong Kong Off-shore Platform, North Sea

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.

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 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

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 M U LT I S T R A N D P O S T- T E N S I O N I N G

STRAND PROPERTIES – TO AS1311

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 m m2 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
5-7 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
5-27 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
5-42 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
5-55 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.

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 M U LT I S T R A N D P O S T- T E N S I O N I N G

GROUT INLET

DUCT

CAST IN ANCHOR TYPE Sc

WEDGE GRIPS ANCHOR HEAD

VSL STRESSING ANCHORAGE TYPE Sc LIVE END

A
E
H
15omin

25min

20 B D

D I M E N S I O NS ( m m )
TENDON A B C D E F G H R
UNIT Int. Dia.
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
5-27 315 92 220 250 160 176 96 250 360
5-31 315 92 230 250 161 175 105 250 360
5-42 390 112 290 346 168 217 118 325 650
5-55 465 142 320 340 160 250 135 400 750
6-7 215 54 140 160 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
6-27 370 107 250 320 160 200 115 305 650
6-31 390 112 270 340 160 217 118 325 650
6-42 465 142 320 340 160 250 135 400 750
*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.

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 M U LTI S T R A N D P O S T-T E N S I O NI N G

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

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 – 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.

TE N D O N C ON F IG UR 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 ● ●

PT-PLUS ● ●

CS-Standard ● ●

CS-Plus ● ● ●

CS-Super ● ● ● ●

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.

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 M U LT I S T R A N D P O S T- T E N S I O N I N G

GROUT TUBE

SWAGED DEAD END

COUPLING COVER DUCT

DUCT

CAST IN ANCHOR

COUPLING BLOCK

VSL COUPLING ANCHORAGE TYPE C

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)
5-7 108 170 550 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
5-27 108 300 1000 6-27 135 320 1000
5-31 108 340 1140 6-31 145 350 1090
5-42 148 385 1320
5-55 168 480 1370
Note: In some applications the coupler cover may not be required.

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 M U LT I S T R A N D P O S T- T E N S I O N I N G

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

Tendon 1
Tendon 2 F+ L B
G+ L L = Elongation of tendon 2
E = 2C + 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
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
* Dependent upon the shape of the concrete surface.
The values stated apply for surfaces which are not curved.

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 M U LT I S T R A N D P O S T- T E N S I O N I N G

SPACER PLATE
GROUT TUBE
(NOT ALWAYS REQUIRED)

DUCT

TYPE H
GROUT TUBE

DEAD END

DUCT

TYPE P

SWAGED DEAD END

ANCHORAGE PLATE

VSL DEAD END ANCHORAGE

3 12

150 C 60 F

Dead End Anchorage Type H Dead End Anchorage Type P

STRAND TYPE 12.7mm STRAND TYPE 15.2mm

TENDON TYPE ‘H’ TYPE ‘P’ TENDON TYPE ‘H’ TYPE ‘P’
UNIT A B C D E F UNIT A B C D E F
5-7 175 150 1000 150 150 300 6-7 200 170 1000 200 200 350
5-12 300 250 1000 200 200 350 6-12 350 300 1000 250 250 450
5-19 375 300 1000 250 250 450 6-19 450 350 1000 300 300 650
5-27 450 400 1200 300 300 750 6-27 550 450 1400 350 350 950
5-31 450 425 1200 350 300 750 6-31 550 475 1400 350 350 950
5-42 600 450 1400 375 375 950 6-42 700 550 1700 400 350 1250
5-55 700 500 1700 425 425 1250 6-55 800 600 2000 550 475 1550
Dimensions (mm) Dimensions (mm)

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 M U LT I S T R A N D P O S T- T E N S I O N I N G

B o/

Grout
Vent

VSL DEAD END ANCHORAGE TYPE L

STRAND TYPE 12.7mm STRAND TYPE 15.2mm

TENDON A B R TENDON A B R
UNIT Int/Ext Int/Ext min UNIT Int/Ext Int/Ext min
5-7 65/72 55/60 600 6-7 75/82 60/67 750
5-12 80/87 65/72 900 6-12 90/97 80/87 1000
5-19 90/97 80/87 1100 6-19 100/117 95/102 1300
5-31 110/117 100/107 1400 Dimensions (mm)
Dimensions (mm)

2nd injection G

Overflow of
first injection

L o/

1st injection
K- Anchorage spacing

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.

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 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 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 7.

D I M E N S I O N S O F P O L Y E T H Y L E N E D U C T S P T- P L U S ™

STRAND TYPE STRAND TYPE DUCT

12.7mm 15.2mm Dimensions (mm)
TENDON UNIT TENDON UNIT d D s
5-10 6-7 59 73 2
5-18 6-12 76 91 2.5
5-31 6-19 100 116 3
5-42 6-31 130 146 3
5-55 – 140 150 3
Other units on request

POLYETHYLENE DUCT PT-PLUS™ STEEL DUCT

STRAND BUNDLE

ECCENTRICITY OF TENDONS Centre line of duct

e Centre gravity of strands
STRAND TYPE 12.7mm STRAND TYPE 15.2mm
STEEL PLASTIC STEEL PLASTIC
TENDON DUCT DUCT TENDON DUCT DUCT
UNIT e (mm) e (mm) UNIT e (mm) e (mm) STRAND POSITION AT HIGH POINT OF TENDON
5-7 8 – 6-7 10 9
5-12 11 7 6-12 14 12
5-19 13 9 6-19 17 18
5-27 13 17 6-27 13 32
5-31 14 14 6-31 15 28 e
5-42 18 28
5-55 19 14

STRAND POSITION AT LOW POINT OF TENDON

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 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 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.

E D G E D I S TA N C E S
1 0m m NOMINAL
TENDON UNIT E
(mm)
5-7 30 E
5-12 50
5-19 50
5-27 80
5-42 80 10mm
5-55 80 NOMINAL
6-7 50
6-12 50
6-19 80
6-27 80 E
6-42 100
6-55 100

L min
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

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 M U LT I S T R A N D P O S T- T E N S I O N I N G

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

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 M U LT I S T R A N D P O S T- T E N S I O N I N G

VSL Jack
Jack stroke

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

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 – 500 210 – 430 – – 150 34
VSLB7 5-7 – 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 5-27, -31 6-19 4600 485 330 510 200 85 100 425
VSL670 5-42 6-27, -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.

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 M U LT I S T R A N D P O S T- T E N S I O N I N G

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

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

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 M U LT I S T R A N D P O S T- T E N S I O N I N G

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

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 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

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 S L A B P O S T- T E N S I O N I N G

STRAND PROPERTIES – TO AS1311

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 m m2 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
15.2 EHT 143.3 1.125 261 221.9 3.5 2.5 x 10 3

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
S5-3 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 X Hi Ha
Dimensions (mm)
Hr
Galv. Steel
S5-5 70 71 – 19 20 –
S6-5 90 91 – 19 20 – Bi
Polyethylene
PT-PLUS™
S5-5/S6-4 72 76 86 21 25 35 Ba
S6-5 Not available
Br

23
 S L A B P O S T- T E N S I O N I N G

GROUT TUBE

WEDGE GRIPS
DUCT
STRANDS

CAST IN ANCHOR

ANCHOR HEAD

PLASTIC RECESS FORMER

VSL STRESSING ANCHORAGES TYPE S5-S6

LIVE END

R C

E 70 x 19 duct
90 x 19 Duct – S6-5 only

STRAND TENDON A B C D E F R
TYPE UNIT Dimensions (mm)
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 S6-3 265 100 215 225 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
 S L A B P O S T- T E N S I O N I N G

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

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)
5-3 230 50 800 5-3 200 75 300
5-4 270 50 800 5-4 250 75 400
5-5 350 50 800 5-5 300 75 500
6-3 230 50 800 6-3 225 75 300
6-4 270 50 800 6-4 300 75 400
6-5 350 50 800 6-5 350 75 500

25
 S L A B P O S T- T E N S I O N I N G

GROUT TUBE

SWAGED ENDS

DUCT

GROUT TUBE

CAST IN ANCHOR

ANCHOR HEAD

CAST COUPLING
BLOCK

DUCT

VSL SLAB COUPLING ANCHORAGE TYPE S

E
600

STRAND TENDON A B C D E
TYPE UNIT Dimensions (mm)
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

26
 S L A B P O S T- T E N S I O N I N G

JACK CLEARANCE REQUIREMENTS

75

605 330

935

S T R E S S I N G J A C K DE TA I L S
135 180

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

PLAN STRESSING POCKET

450 450

30 420 50 175 175 50

SECTION A SECTION B

27
 S L A B P O S T- T E N S I O N I N G

ANCHORAGE REINFORCEMENT – HELIX

GROUT VENT

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

210 110
R10

S5-3, S5-4, S5-5 ANCHORS

S6-3, S6-4 ANCHORS

350 150
R10

S6-5 ANCHOR

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.

28
 S L A B P O S T- T E N S I O N I N G

ANCHORAGE REINFORCEMENT – TIES

A N C H O R A G E AT S L A B E D G E A N CH 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
Y12 OR BEAM
REINFORCEMENT

PLACE INNERMOST
TIE HARD AGAINST
CASTING AS
2Y12 TOP & BTM SHOWN
A x 1000 min.
A 3Y12 TOP & BTM
S6-5 only

D E TA I L AT S L A B E D G E

A GROUT VENT
EXTRA TIES WHERE
SHOWN FOR S6-5 ONLY.
2Y12 TOP x 1000 min.

2-R10 TIES AT
50mm CRS.
EACH SIDE OF EACH
ANCHORAGE TYPICAL

OPEN TIES

PLAN
D E TA I L AT E D G E B E A M
NOTE: 1. REINFORCEMENT SHOWN IS INDICATIVE.
STRAND TENDON No. OF TIES A B ACTUAL ANCHORAGE REINFORCEMENT IS TO
TYPE UNIT EACH SIDE mm mm BE AS DETAILED BY THE CONSULTING
ENGINEER. ANCHORAGE REINFORCEMENT
S5-3, S5-4 2 200 80 SHALL BE LOCATED CENTRALLY ABOUT
12.7mm
S5-5 2 200 90 ANCHOR AND HARD AGAINST CASTING AS
S6-3 2 200 80 SHOWN.
15.2mm S6-4 2 200 90
2. MIN. CONCRETE CYLINDER STRENGTH AT
S6-5 2+2 200 100
JACKING = 22MPa GENERALLY AND 25 MPa
FOR S6-5. REINFORCEMENT FOR TIES IS
ROUND BAR WITH fy = 250 MPa.

29
 S L A B P O S T- T E N S I O N I N G

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.

30
 S L A B P O S T- T E N S I O N I N G

Floors for Carpark,

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

Foundation Raft Slab Floors for High Rise Office

Sydney, N.S.W. Bourke Place, Melbourne, Victoria

Floors for Princess Alexandra Hospital, Brisbane, Queensland

31
 S L A B P O S T- T E N S I O N I N G

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.

32
 S L A B P O S T- T E N S I O N I N G

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.

Residential Housing Intermodal Terminal,

Brisbane, Queensland Acacia Ridge, Queensland

33
 STRESSBAR

Qantas Arrivals/Departure Hall, Sydney

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 the Australian Standards.

V S L B A R C ON F IG UR 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
26 - 40mm CT Bar ● ● ● ● ● ● 5.85 11.85
56mm CT Bar ● ● ● ● ● ● 5.85 7.5
75mm Bar ● ● ● ● ● 5.85 7.5

ARCHITECTURAL BAR
30, 36mm MT Bar * ● ● ● ● ● 5.85 11.85
45, 60mm MT Bar * ● ● ● ● ● 5.85 11.85
* Note: Check availability as some sizes may not be stocked.

34
 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 Anchors
• Prestressed Beams and Columns • Permanent and Temporary Ground Anchors
• Precast Connections • Uplift Anchors (Dam & Foundation)
Bridges • Roof Bolting
• Stay Cable • Soil Nails (Slope Stabilisation)
• Hangers • Crane Bases
• Prestressed Segments • Light Towers
• Strengthening Specialist Engineering
• Tension Piles and Caissons • Heavy Lifting
Wharves & Jetties • Formwork Ties or Hangers
• Stressed Deck Planks • Frame Ties
• Tie Backs • 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
• Three coat epoxy paint system
• Greased and sheathed in poly tube
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.

35
 STRESSBAR

VSL CT STRESSBAR
C HARACTERISTIC PROP ER TIES
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 103 MPa mm mm
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
40 1257 9.72 1030 835 1295 1050 3.5 170 41.4 6
56 2463 19.33 1000 810 2460 1995 3.5 205 58.5 6
75 4418 34.68 1000 810 4418 3580 3.5 205 78.1 6
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 75mm.
6.Intermediate diameters are sometimes produced. Check for availability.

VSL MT600 BAR

CHARACTE RI STIC P ROPERTIES
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 103 MPa mm mm
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
45 1590 12.48 620 460 945 701 16 205 47.8 4
60 2827 22.19 620 460 1665 1235 16 205 64.1 6
Note: 1. Intermediate diameters are sometimes produced. Check for availability.
2.These specifications may be subject to change without notice. Check with the VSL office regarding availability.

Vertical Web Tendons, Gateway Bridge, Brisbane, Queensland

Prestressing of Precast Segmental Beams,

Chaing Mai Grandstand, Thailand

Transverse Stressing, Bridge Beams, Beenleigh, Queensland

36
 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 26 29 32 36 40 56 75
PART No. NC26 NC29 NC32 NC36 NC40 NC56 NC75
A 42 47 52 56 65 100* 140*
NUTS
B 50 50 55 55 66 100 120
PART No. LNC26 LNC29 LNC32 LNC36 LNC40 LNC56 LNC75
LOCKNUTS
B 22 24 26 29 32 45 60
PART No. BP26 BP29 BP32 BP36 BP40 BP56 BP75
A 130 150 150 150 180 250 300
BEARING
B 130 130 130 150 150 200 300
PLATES**
C 40 40 50 50 50 70 70
D 32 35 38 42 47 63 80
PART No. CC26 CC29 CC32 CC36 CC40 CC56 CC75
COUPLERS A 42 45 54 56 65 85 110
B 110 110 120 125 130 190 250
PART No. CCV26 CCV29 CCV32 CCV36 CCV40 CCV56 CCV75
COUPLER A 230 230 230 230 230 290 350
COVERS
B 57 57 70 70 75 96 118
PART No. WF26 WF29 WF32 WF36 WF40 WF56 WF75
FLAT
A 56 60 66 72 84 120 150
WASHER
B 4 5 5 6 6 8 8
PART No. WS26 WS29 WS32 WS36 WS40 WS56 WS75
SPHERICAL A 50 56 64 70 80 120 160
WASHER
B 10 10 10 10 12 18 20
PART No. D39 D39 D45 D45 D54 D69 D96
DUCTING A 39 39 45 45 54 69 96

Note: 1. *Nuts for 56 and 75-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

Telok Blangah, elevated highway, Singapore Bridges, Korea

37
 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 26 29 32 36 40 56 75
SPADE PART No. CLS26C CLS29C CLS32C CLS36C CLS40C CLS56C CLS75C
CLEVIS A 36 40 40 45 50 80 100
PART No. CLF26C CLF29C CLF32C CLF36C CLF40C CLF56C CLF75C
B 39 43 43 48 53 83 103
C 67 73 77 86 93 141 189
D 240 254 277 294 330 412 542
FORKED
E 82 98 98 106 130 168 210
CLEVIS
F 37 40 43 46 57 76 101
G 54 59 63 68 84 113 150
H 50 56 65 70 80 110 140
J 88 95 109 116 131 154 222
PART No. CLP26C CLP29C CLP32C CLP36C CLP40C CLP56C CLP75C
CLEVIS
A 36 39 42 45 56 75 100
PIN
B 63 74 78 87 94 142 190
CONICAL PART No. LNC26S LNC29S LNC32S LNC36S LNC40S LNC56S LNC75S
COVER A 50 56 65 70 80 110 140
(STANDARD) B 65 75 80 90 100 140 190

CONICAL PART No. LNC26T LNC29T LNC32T LNC36T LNC40T LNC56T LNC75T
COVER A 50 56 65 70 80 110 140
(TURNBUCKLE) B 90 100 110 110 120 160 210
PART No. TC26R TC29R TC32R TC36R TC40R TC56R TC75R

TURNBUCKLE A 50 56 65 70 80 110 140

COUPLER B 190 200 220 220 230 280 340
C 90 100 100 100 100 100 100

Yarra Boulevard Bridge - Melbourne, Victoria

38
 STRESSBAR

Bisham Stadium, Singapore Yarra Boulevard Bridge, Melbourne

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 T A I L S ( m m )
ITEM BAR DIAMETER 30 36 45 60
PART No. NM30 NM36 NM45 NM60
NUTS A 46 55 75 95
B 25 31 38 52
PART No. CM30 CM36 CM45 CM60
COUPLERS A 48 56 80 110
B 65 77 101 133
PART No. WM30 WM36 WM45 WM60
FLAT A 56 66 92 115
WASHER B 4 5 8 9

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 30 36 45 60
PART No. CLSM30C CLSM36C CLSM45C CLSM60C
SPADE CLEVIS
A 25 36 45 55
PART No. CLFM30C CLFM36C CLFM45C CLFM60C
B 28 39 48 58
C 48 67 86 98
D 198 240 294 363
FORKED E 66 82 106 154
CLEVIS F 27 37 46 61
G 42 54 68 100
H 42 50 70 90
J 71 88 116 148
PART No. CLPM30C CLPM36C CLPM45C CLPM60C
CLEVIS PIN A 26 36 45 60
B 49 63 87 99
CONICAL PART No. LNM30S LNM36S LNM45S LNM60S
COVER A 42 50 70 90
(STANDARD) B 50 65 90 120

CONICAL PART No. LNM30T LNM36T LNM45T LNM60T

COVER A 48 56 80 100
(TURNBUCKLE) B 70 90 110 140
PART No. TM30R TM36R TM45R TM60R

TURNBUCKLE A 48 56 80 100
COUPLER B 150 168 196 228
C 80 100 100 100

39
 STRESSBAR

Stroke
200 L E D
Chair Height

Heyington Avenue, Eastern Freeway, Melbourne.

R E C E S S D E TA I L S ( m m )
Bar Recommended Minimum
Dia A B C A B C
Hydraulic Stressing Jack and Accessories
26 150 150 95 130 130 95
29, 32, 36 170 170 100 150 150 100
40 200 170 110 180 170 110
56 270 220 160 250 200 160
75 320 320 180 300 300 180

J A C K D E TA I L S ( m m ) JA C K C LE A R A N C E D E TA I L S ( m m )
Nom JACK CHAIR
Bar Jack Jack Dimension Capacity Weight MODEL F G H HEIGHT
Dia. Model D L E Stroke kN kg B55 680 95 125
26 B55 165 245 85 125 550 33 B90 665 105 150
29, 36 B90 190 280 105 80 900 48 B90L 810 105 150
29 to 36 B90L 190 355 105 150 900 62 250
B100 540 110 150
40 B100 200 170 130 50 1000 28
B100L 740 110 150
40 B100L 200 270 130 150 1000 48
B150 995 150 150
– B150 275 300 150 150 1500 100
B200 1025 160 200
56 B200 300 380 170 150 2000 160 460
56 VSL190 410 565 220 100 1900 151 VSL190 1600 220 200
75 VSL460 485 510 220 100 4600 425 VSL460 1600 260 250 580

40
 G R O U N DS A
T RNECSHS O
BAR SR

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.

41
 GROUND ANCHORS

Grout tubes

Bare clean strand

Corrugated sheath
Internal spacer ring Anchor head

External spacer Bearing Plate

Bore hole

SECTION A.A
Smooth sheath (Polyethylene)
or continuous corrugated sheath
Greased and plastic coated strand

Grout Grout tubes

Grout tubes Smooth
Bare clean strand sheath
Internal spacer ring
Corrugated sheath (Polyethylene)
Greased
and plastic
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

Spacer ring

Bore hole
SECTION A.A Anchor head

Bearing Plate

Greased and plastic coated strand (optional)

Grout tube
Grout (free length optional)
Bare clean strand

Grout tube

Greased and plastic coated

Spacer ring Bore hole strand (optional)

Bore Hole SECTION B.B

VSL TEMPORARY ANCHOR

42
 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
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
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
40 1295 150 80 100 112 100 B 100
56 2460 175 100 120 165 125 B 200
Drill hole sizes are based on 10mm external cover

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 12.7mm 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.

43
 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
4 200 35 110 60 26 200 40
B 8 300 45 180 80 29 225 50
14 400 60 220 100 32 250 50
27 500 80 270 130 36 250 50
55 670 120 360 190 40 300 60
65 700 140 380 190 56 350 70
91 850 160 470 200
*Dimensions may vary depending upon anchor
drilling methods and project specific criteria.

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 available
Anchor stressing

44
 GROUND ANCHORS

Permanent Rock Anchors, Lapstone, N.S.W.

Prefabricated Permanent CT Stressbar Ground Anchors.

Soil Nails VSL Threadlok Rock Bolts, Permanent Anchors

Bell Banksia, Melbourne, Victoria Kangaroo Point, Queensland

45
 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.

46
 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 system is also
Typical Section
extremely economical to design and VSoL RETAINED EARTH Wall
construct. The system consists of only three at a Bridge Abutment

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 equipment
will average 75 square metres of wall per shift, and can place up to 140 Perspective View
square metres per shift. VSoL RETA I N E DE A RT H
Retaining Wall

47
 VSoL RETAINED EART 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

48
 S P E C I AL I S E D FO 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.

49
 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

50
 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

51
 CLIMBFORM
Tsing Ma Bridge Piers, Hong Kong
Melbourne Central Building, Victoria
Top Construction /Storage Platform
52
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
– 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 structures in Asia
and Australia.
Sky Tower, Circular Structure, Auckland
 D U C TA L

Peace Footbridge, Seoul - 120m span Ductal Arch

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.

A D VA N TA G E S
• 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 fire, impact and abrasion resistance

53
 DUCTA L

STRENGTH CHARACTERISTICS
• Compressive Strength (cylinder) 170-230MPa
• Flexural Strength (M.O.R. AS1012) 30-35 MPa
• Youngs Modulus (E) 47-50 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 TYPICAL applications
• 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 2400-2500 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.

54
 S TA Y C A B L E S

V S L S TA Y 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 TA Y 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.

55
 S TA Y C A B L E S

HDPE Stay Pipe

Individual
Monostrand

SECTION (TENDON UNIT 6-12) Monostrand Tendon

and Stay Pipe
V S L S TAY CA B L E
SYSTEM SSI 2000
DEAD END
ANCHORAGE

Elastomeric Damping
Transition pipe with Deviator
Individual Strand
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

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 D im e ns io n s i n m m
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

56
 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

57
 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)

5-7 167 110 – – 63/4.1
5-12 215 105 222 100 75/3.9
5-19 265 115 258 100 90/4.6
5-27 315 140 – – 110/5.7
5-31 315 140 320 110 125/6.4 ANCHORAGE TYPE Scd
5-42 390 160 – – 140/7.1
5-55 465 190 420 130 160/8.2

6-7 215 105 222 100 75/3.9

6-12 265 115 258 100 90/4.6 D
6-19 315 140 300 110 110/5.7
6-27 370 160 – – 140/7.1
6-31 390 160 390 125 140/7.1
6-42 465 190 – – 160/8.2
6-55 600 240 – – 180/5.9

Note: (1) External diameter/wall thickness

ANCHORAGE TYPE CSd

58
 H E AV Y L I FT 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.

59
 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 program. 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 project requiring lifting, lowering or horizontal jacking.
Segment Erection, Normandy Bridge, France

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 Thickness Maximum Installation
mm 13.5MPa 10 3mm 2 ** Travel Gap
kN mm mm mm
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
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
870c 870 7385 547 25 25 45
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

60
 BRIDGE ENGINEERING

As a specialist involved in the design and construction of bridges VSL has 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 A T E WA Y 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 T A G E E X P R E S S WA Y B A N G K O K
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.

61
 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.

62