Post Tensioning

Systems
CCL Bonded Post Tensioning

CCL Bonded Post Tensioning

Post Tensioning is the introduction of prestressing forces into the concrete after it has achieved the
specified strength. CCL Stressing Systems provide the Stressing Jacks and Pumps to pull the strand
tendons to the required load and the Anchorages to hold the tendons in tension. CCL Stressing
Systems Ltd also provide the servicing, replacement parts, and calibration service accessories to
ensure safe and quick stressing operation.

Anchorages
The CCL system of post-tensioning was introduced some 40
years ago. Over the years, CCL has established a world-wide
reputation for quality, reliability and technical expertise.

The CCL ‘E’ system of post tensioning is in use world-wide

and provides excellent technical performance and ease of
installation.

The CCL ‘N’ wedge is a new highly efficient wedge. Patents

have been applied for on the three-jaw wedge, which
incorporates a revolutionary double taper. This promotes
good fatigue performance, minimises load loss during pull-
in and facilitates easy release if re-tensioning is required.

Post Tensioning Equipment

CCL Stressing Jacks are simple to operate
and highly manoeuvrable. The jack body
can be rotated with respect to its lifting
points, enabling easy access to hydraulic
connections. The jack innards can also be
rotated, promoting easy alignment with the
tendons. The jacks may be operated in a
vertical or horizontal position and feature
hydraulic lock-off. This is to ensure the
correct seating of the wedges and to
minimise load losses at transfer.

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‘E’ Range Live End Anchorages

‘E’ Range Live End Anchorages

CCL Standard Anchors can accept tendons of 4,7,12,19 &
22 strands of 13mm diameter and tendons of 4,7,12,19,27
& 37 strands of 15mm diameter. The Anchor consists of a
cast Tube Unit to guide the strand into the duct. A taper
hole Bearing Plate, in which the strands are anchored by
hardened steel Wedges, sits against this Tube Unit.
Intermediate numbers of strands can be accommodated if
desired, by omitting Wedges from the anchorage Bearing
Plate in a uniform pattern.

The Anchor is used at the stressing end of a tendon and

can be used as a "passive" anchor should the anchorage be exposed to allow the insertion of
Wedges. Under no circumstances should this Anchor be used as a buried dead end as the Wedges
can be dislodged due to the vibration caused during concreting.

Wedge
Bearing Plate
Tube Unit Casting
Strand

f a b c

Plastic/Metal Duct
Seal Tape (as required)
d
10º

e i

CCL Standard Live End Anchorages

STRANDS DIA a b c d e f l DUCT (M) DUCT (P) FIXINGS
E1 4 13 120 102 85 40 115 240 90 45 59 M8
E2 7 13 157 125 105 40 115 260 132 50 59 M8
E2 4 15 157 125 105 45 120 260 132 50 59 M8
E3 7 15 191 145 125 45 120 260 161 65 76 M8
E4 12 13 207 172 145 46 120 260 170 75 76 M8
E5 12 15 244 208 180 54 130 320 285 80 76 M8
E6 19 13 256 208 180 59 135 330 275 80 76 M8
E7 22 13 307 250 220 69 145 350 277 100 100 M12
E7 19 15 307 250 220 69 145 350 277 100 110 M12
E8 27 15 362 300 270 80 155 475 502 110 140 M12
E9 37 15 430 365 330 100 175 475 513 140 140 M12

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‘E’ Range Dead End Anchorages

‘E’ Range Dead End Anchorages

CCL Dead End Anchors are used where the end of a
prestressing cable is buried in concrete or
inaccessible during the stressing of the tendon. The
Dead End Anchor can accept the same strand
configurations as the Standard Anchor and uses the
same Tube Unit to guide the strands. The strand
passes through a parallel hole Bearing Plate and is
anchored by means of a Compression Fitting which is
swaged on to the strand ensuring a positive anchor.
The Fittings are swaged onto the strand using a CCL
Extrusion Rig activated by a Hydraulic Pump. A
Retaining Plate is fixed to Studs in the four tapped
holes of the tube unit to ensure that the Compression Fittings bear evenly on the Bearing Plate.

The Tube Unit should be fixed with the grout exit point at the top to prevent air being trapped during
grouting. In cases where prestress is not required up to the end of a tendon and where lateral space
permits, some economy may be achieved by employing bonded or semi-bonded dead-end anchors
on certain

Nut & Lock Nut

Retaining Plate
Polystyrene Packer
Compression Fitting
Screwed Rod
Bearing Plate
Tube Unit Casting

Strand
a

Plastic/Metal Duct
Sealing Tape (as required)

b I

CCL Standard Dead End Anchorages

STRANDS DIA a b l DUCT (M) DUCT (P) FIXINGS
E1 4 13 120 150 90 45 59 M8
E2 7 13 157 160 132 50 59 M8
E2 4 15 157 160 132 50 59 M8
E3 7 15 191 160 161 65 76 M8
E4 12 13 207 155 170 75 76 M8
E5 12 15 244 165 285 80 76 M8
E6 19 13 256 165 275 80 76 M8
E7 22 13 307 180 277 100 100 M12
E7 19 15 307 180 277 100 110 M12
E8 27 15 362 195 502 110 140 M12
E9 37 15 430 200 513 140 140 M12

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‘E’ Range Basket Dead Ends

‘E’ Range Basket Dead Ends

Basket type Dead Ends can be used in
place of Standard Dead End Anchorages.
These Anchors save cost compared to
Standard Dead End Anchorages but
however require more space. The
prestressing force is transferred to the
concrete by bond. A rebar net is required
to act as a spacer for the individual
strands.

Basket Dead Ends are constructed on site

using an Extrusion Rig.

a
b d

CCL Basket Dead End Anchorages

STRANDS DIA a b c d DUCT (M) DUCT (P)
E1 4 13 1150 1300 300 300 45 59
E2 7 13 1150 1300 450 300 50 59
E2 4 15 1150 1300 450 300 50 59
E3 7 15 1150 1300 450 300 65 76
E4 12 13 1150 1300 450 450 75 76
E5 12 15 1150 1300 450 450 80 76
E6 19 13 1150 1300 600 525 80 76
E7 22 13 1150 1300 600 525 100 100
E7 19 15 1150 1300 600 525 100 110
E8 27 15 1300 1450 675 600 110 140
E9 37 15 1625 1775 825 675 140 140

5
‘E’ Range Coupler Anchorages

‘E’ Range Coupler Anchorages

In continuous bridge deck construction, it is
necessary to extend prestressing cables as
construction proceeds. The CCL Anchorage
Coupling is available in all 12, 19, 27 & 37 strand
configurations. The first stage of stressing is carried
out in the same way as with the Standard Anchor
except that a Coupler Ring is inserted between the
Tube Unit and Bearing Plate. The Coupler Ring
incorporates slots to accommodate the Compression
Fittings swaged to the strands of the second stage
cable. When first stage stressing and grouting is
complete, the Compression Fittings are swaged to
the strand using the Extrusion Rig and the strands are fitted into the slots of the Coupler Ring. The
strand is deviated through a shaped trumpet that also prevents the ingress of concrete during
casting. The trumpet contains a grout exit point which should be placed at the top to prevent any air
being trapped during grouting and the small end of the trumpet should be securely taped to the
duct.

Reducing Washer
Max Head Screw
Grout Saddle
Compression Fitting
Bearing Plate
Wedge

Plastic/Metal Duct
Sealing Tape (as required)
I Transition duct
Sealing Tape (as required)
Reducing Cone

CCL Standard Coupler Anchorages

STRANDS DIA a l DUCT (M) DUCT (P)
E1 4 13 - - - -
E2 7 13 - - - -
E2 4 15 - - - -
E3 7 15 - - - -
E4 12 13 235 800 75 76
E5 12 15 290 1070 80 76
E6 19 13 275 1000 80 76
E7 22 13 330 1200 100 100
E7 19 15 330 1200 100 110
E8 27 15 395 1350 110 140
E9 37 15 480 1250 140 140

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‘E’ Range Setting Out Details

‘E’ Range Setting Out Details

The positioning of ducts and anchorages should be set out taking into account of the dimensions
shown below.

Anchorage Setting Out Coupler Setting Out

b d

a c

a b c d

Duct Setting Out

e f

CCL Standard Live End Anchorages

STRANDS DIA a b c d e f DUCT (M) DUCT (P) FIXINGS
E1 4 13 115 150 - - 75 85 45 59 M8
E2 7 13 140 195 - - 80 105 50 59 M8
E2 4 15 140 195 - - 80 105 50 59 M8
E3 7 15 160 220 - - 85 135 65 76 M8
E4 12 13 165 250 170 275 90 155 75 76 M8
E5 12 15 190 275 205 335 95 165 80 76 M8
E6 19 13 196 295 205 325 95 165 80 76 M8
E7 22 13 230 380 245 405 105 205 100 100 M12
E7 19 15 230 380 245 405 105 205 100 110 M12
E8 27 15 272 455 275 470 110 225 110 140 M12
E9 37 15 380 550 420 580 140 290 140 140 M12

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Stressing Sequence

Stressing Sequence
1.
Place the Bearing Plate onto the strands, ensuring that the centre mark is at the top. Fit the Wedges
into the Bearing Plate, then fit the Bearing Ring and Lock-off plate.

Bearing ring
Bearing plate

Lock-off Plate

2.
Thread the Jack onto the strands. A suitable lifting device such as a mobile crane should support the
weight of the Jack.

3.
Push the Jack up to the Anchorage and insert the Jack Wedges into the Pulling Plate inside the rear
of the Jack.

Pulling Plate

Jack Wedges

4.
All stressing operations are controlled from the Pump Unit to ensure operator safety. Carry out
stressing, lock-off and retraction. The lock-off pushes the Lock-off plate forward, which seats the
Anchorage Wedges firmly into the Bearing Plate.

*See CCL technical details for stressing loads and Wedge set.

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PostPrestressing
CCL Tensioning in Buildings

Post Tensioning in Buildings

CCL is a leader in post-tensioning systems with over forty years experience supplying systems for
both buildings and civil engineering structures throughout the world.

Post-tensioning has many advantages over other methods of

floor construction and can be used in both suspended floors
and ground floor slabs. The use of post-tensioning in ground
and upper floor slabs in buildings has many advantages over
other methods of construction.

Maximise Commercial Space

Post-tensioned floor slabs can be 20-30% thinner than
conventionally reinforced concrete resulting in a reduced
storey height of up to 300mm - enough to give an extra floor
in a 10 storey building.

Reduce Building Costs

Post-tensioned floor slabs can minimise building volume. This
can lower the costs of concrete and cladding, and may reduce
heating and lighting costs. The Helicon building in London
uses post-tensioned floor slabs to reduce building height in an
area where local authority height restrictions apply.

Flexible Floor Space

Long spans reduce the number of columns required, providing
maximum flexibility for internal planning. Despite being 18
storeys high, 88 Wood Street in London has 16m spans
between each column.

Faster Construction
Post-tensioning minimises the amount of site-fixed
reinforcement and allows faster stripping and redeployment of
formwork, increasing construction speeds. Large pours can
also be used to increase speed of construction.

Unjointed Floor Slabs

Uniformly flat ground slabs can be constructed without movement joints. The 35,000 m2 Wm.
Morrison distribution centre in Wakefield has a post-tensioned ground slab. A level running surface
was required to aid the operation of picking equipment from high racking.

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Flat Slab Anchorages

Flat Slab Anchorages

The CCL Flat Slab system uses upto four 15mm or upto five 13mm diameter strands in an oval duct
with internal dimensions of 75mm x 20mm. The flat duct allows the strands to be positioned to
ensure the maximum eccentricity within the structure. Ducting can be metal or plastic.

Minimum Dimensions

Flat Ducting 75 x 25

335
198
1150 Minimum 90

240 85

Live End
Before After
Concreting Concreting
Formwork

Pocket Former

Non Shrink Mortar

Live End Casting
Anchorage

Grout Vent

75 x 20 Flat Ducting

Dead End

Grout Vent

End of duct
(to be sealed)

Strand Upset Ends

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Flat Slab Setting Out Details

Flat Slab Setting Out Details

218 385 385
100
140
140

218

Jack Type Strand a b c d

160 kN 13 300 741 100 50
300 kN 15 325 752 100 70

a Extension b c

Notes:

1. Dimension 'c' is required for clearance of the hydraulic hose.

2. Due allowance must be made for the strand extension

3. Jack effective extension is 200mm

All Dims in mm

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Unbonded Anchorages

Unbonded Anchorages
The CCL unbonded system is designed to work with both 13mm and 15mm nominal diameter
strands. The live end anchorage comprises a Casting, Wedge and Plastic Fitting to facilitate the fixing
of the anchorage to the formwork and form a stressing access pocket. On completion of the
stressing, the strand is cropped. The strand end and Wedge are then sealed with a grease filled
Plastic Cap.

Dead end anchorages utilise a cast metal plate onto which bears a compression fitting. A wire clip is
fitted over the end plate to ensure that the fitting remains against the plate during concrete pouring.
The use of a Compression Fitting ensures the integrity of the buried dead end.

Before After
Concreting Concreting
Plastic Nut and Bayonet

Formwork
Non Shrink Mortar Live End
Pocket Former
Plastic Sealing Cap

Grease
Wedge

Anchorage

Plastic Sealing Tube

Plastic Coated Strand

Plastic Coated Strand

Retaining Clip

Dead End
Dead-end Casting

Compression Fitting

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 Unbonded Anchor Dimensions

Unbonded Anchor Dimensions

UN13 / UN15 Live End Anchor
c e b

d f a

Anchor Strand a b c d e f
UN 13 13 110 63 63 53 60 100
UN 15 15 130 72 85 65 60 100

UN13 / UN15 Dead End Anchor

k j h

g
l

Anchor Strand g h j k l
UN 13 13 110 60 30 65 28
UN 15 15 130 72 30 70 33

Minimum Setting Out Details Anchor m n p q

UN 13 125 150 80 100
UN 15 145 175 100 125
m n n n n

q p

m
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Multistrand Jacks

Multistrand Jacks
CCL Stressing Jacks are simple to operate
and highly manoeuvrable. The Jack body can
be rotated with respect to its lifting points,
enabling easy access to hydraulic
connections. The Jack Innards can also be
rotated, promoting easy alignment with the
tendons. The Jacks may be operated in a
vertical or horizontal position and feature
hydraulic lock-off. This is to ensure the
correct seating of the Wedges and to
minimise load losses at transfer.

a b

d c f

Lock-off Plate
Threading Tube
e
Pulling Plate

Specification
a b c d e f WEIGHT E1 E2 E3 E4 E5 E6 E7 E8 E9
1000 MG 243 307 248 185 600 340 125 Kg
1800 MG 322 389 342 256 760 430 275 Kg
3000 MG 290 400 405 280 700 500 350 Kg
4000 MG 310 425 490 340 730 585 575 Kg
7500 MG 321 490 652 478 850 750 1150 Kg

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Equipment & Accessories

Equipment & Accessories

Grouting Equipment
CCL Grouting Equipment comprises a combined pump and mixer. The
grout is mixed in the mixing tanks and transferred to the pump tank,
which has an integral agitator to maintain the grout in suspension. While
in the pump tank, the grout is recirculated through the pipework and
valves. Grout is discharged into the tendon at rates of up to 2.5m3/hour,
controlled through a hand operated valve. Water for mixing is fed from a
calibrated 45 litre tank, the three wheel configuration provides excellent
manoeuvrability

Strand Pusher
The Strand Pusher provides the most efficient way of installing tendons.
The strands are pushed individually into the duct directly from the coil,
avoiding double handling. The leading edge of each strand has a "bullet"
attached to avoid any damage to ducting as it passes through. Tendons up
to 90 metres long can be installed by this method, depending upon the
tendon type and profile.

Extrusion Rig
The CCL Extrusion Rig is used with Dead End and Coupler Anchorages
which have Compression Fittings. The Compression Fittings are pushed
hydraulically through the Die of the Extrusion Rig ensuring a positive
anchorage on the strand

SR 5000 Pump Units

The CCL Pump Unit for Multistrand Jack operation is the SR5000 unit. The
SR5000 pump is available with an electric motor.

Strand Cropper
The hydraulically operated CCL Strand Cropping Machine cuts the strands
within the pocket. The unique off-set blades shear the strands at a fixed
distance from the wedges ensuring consistent and adequate end cover to the
strands.

Grout Caps
Grout Caps are fitted onto the Bearing Plate prior to grouting. The grout is
forced through the Wedges and strand interstices to fill the Cap. The Cap can
be left in place if required.

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 Telephone: +44 (0)113 270 1221 Fax: +44 (0)113 277 8977

Postal Address: Unit 4, Park 2000 Millennium Way, Westland Road, Leeds, LS11 5AL, England
Email: sales@cclstressing.com Website: www.cclstressing.com