179
TMI-1 UFSAR CHAPTER 05 5B-i REV. 18, APRIL 2006 APPENDIX 5B INLAND-RYERSON'S REPORT ON BBRV TENDON SYSTEMS
TMI-1 UFSAR
CHAPTER 05 5B-i REV. 18, APRIL 2006
APPENDIX 5B
INLAND-RYERSON'S REPORT ON
BBRV TENDON SYSTEMS
TMI-1 UFSAR
CHAPTER 05 5B-ii REV. 18, APRIL 2006
REPORT ON BBRV PRESTRESSING TENDONS
TABLE OF CONTENTS SECTION TITLE A. GENERAL INTRODUCTION, PURPOSE, SUMMARY B. ECCENTRICITY & STRESS ANALYSIS Source: Western Concrete Structure, Inc. Date: October, 1969 C. DYNAMIC & FATIGUE TESTS Source: EMPA, Swiss Federal Laboratory for Testing Material and
Research. Date: February 5, 1969 D. STATIC TESTS - TECHNICAL REPORT #8 Source: Western Concrete Structures, Inc. Date: January, 1968 E. TRUMPLATE WELDING EFFECTS Source: J. Hildebrand, Gulf General Atomics Corp. Date: October 27, 1969 F. LOW TEMPERATURE TESTS Source: Western Concrete Structures, Inc. Date: December, 1969
APPENDIX 5B
INLAND-RYERSON'S REPORT ON
BBRV TENDON SYSTEMS
Section 5B 5B-1
REPORT ON BBRV PRESTRESSING TENDONS
TABLE OF CONTENTS
Part Page # A. GENERAL INTRODUCTION, PURPOSE, SUMMARY 5B-2 B. ECCENTRICITY & STRESS ANALYSIS 5B-4
Source: Western Concrete Structures, Inc. Date: October , 1969
C. DYNAMIC & FATIGUE TESTS 5B-15
Source: EMPA, Swiss Federal Laboratory For Testing Material & Research
Date: February 5, 1969 D. STATIC TESTS – TECHNICAL REPORT #8 5B-39
Source: Western Concrete Structures, Inc. Date: January, 1968
E. TRUMPLATE WELDING EFFECTS 5B-109
Source: J. Hildebrand, Gulf General Atomics Corp. Date: October 27, 1969
F. LOW TEMPERATURE TESTS 5B-114
Source: Western Concrete Structures, Inc. Date: December, 1969
TMI-1/FSAR
REPORT ON BBRV PRESTRESSING TENDONS Part A. GENERAL INTRODUCTION, PURPOSE, SUMMARY The 170 wire Inland-Ryerson BBRV Post-Tensioning System was developed specifically to post-tension the prestressed concrete reactor vessels of nuclear power plants and their secondary containments where total required force and/or spacing of tendons makes the use of large capacity tendons advantageous. In general the system utilized button-headed wires of 0.250-inch diameter anchored by heat treated alloy steel end fittings. It is the most extensively tested system in the world at the present time. The tests presented in the following section assure the integrity of the post-tensioning system in meeting the high quality control standards of the Three Mile Island station and the Atomic Energy Commission. It was the purpose of the following tests to demonstrate the ability of the prestressed, post-tensioned system to fulfill the quality control specifications for this job. Part B. of this section presents a stress analysis of the anchorage components. Part C. deals with the dynamic and fatigue testing of the composite tendon system. The static tests reported in Part D. dealt with subjecting anchorages to several levels of loading and analyzing failure modes. Part E. offers expert opinion Page 5B-2
UPDATE-1 7/82
TMI-1/FSAR
REPORT ON BBRV PRESTRESSING TENDONS concerning possible deleterious effects of welding and flame cutting on the embedded steel bearing plates. The low temperature testing as detailed in Part F. shows the performance characteristics of the loaded tendon system under extreme environmental conditions. A concensus of the results of these tests, indicates that the individual components of the system as well as the Inland-Ryerson BBRV Post-Tensioning System as a whole, performed above and beyond the minimum criteria of the job specifications. The results further indicate that the use of prestressed post-tensioned tendons as a critical structural member of this vessel was well justified. Page 5B-3
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TMI-1/FSAR
Part B. ECCENTRICITY AND STRESS ANALYSIS Page 5B-4
UPDATE-1 7/82
TMI-1/FSAR
Part B. ECCENTRICITY AND STRESS ANALYSIS Table of Contents Part Page # Introduction, Purpose, Summary 5B-6 1.0 Eccentricity Analysis 5B-7 2.0 Concrete Bearing Stress Due to Eccentricity 5B-8 3.0 Stress Analysis, General 5B-9 4.0 Washer 5B-10 5.0 Washer Nut 5B-11 6.0 Composite Washer 5B-12 7.0 Split Shims 5B-12 8.0 Bearing Plate 5B-13 Page 5B-5
UPDATE-1 7/82
TMI-1/FSAR
Part B. ECCENTRICITY AND STRESS ANALYSIS Introduction, Purpose, Summary It was the purpose of this test to furnish a stress analysis on the anchorage components to determine "order of magnitude" stresses at applicable maximum loading conditions. This report takes into consideration the conditions of maximum eccentricity and critical stress. The analysis shows that the anchorage will perform as required with all allowable stress limits. Page 5B-6
UPDATE-1 7/82
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TMI-1/FSAR
Part C. DYNAMIC AND FATIGUE TESTS Page 5B-15
UPDATE-1 7/82
TMI-1/FSAR
Part C. DYNAMIC AND FATIGUE TESTS Table of Contents Part Page Introduction 5B-17 1.0 Dynamic Test Results 5B-18 2.0 Tension and Fatigue Tests 5B-25 3.0 Fatigue Test Results 5B-31 Page 5B-16
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TMI-1/FSAR
Part C. DYNAMIC AND FATIGUE TESTS Introduction, Purpose, Summary Based on specification requirements, it was necessary to test the full scale anchorage in as representative a test as possible. Inland-Ryerson contacted the Swiss Federal Laboratory for Testing Material and Research. They agreed to conduct the tests and the materials were forwarded to Switzerland. The results are noted in their tests 67'303/1, 67'303/2 and 67'303/3 following herein. In the tests a free length of 4 meters was used and the tendon was anchored at both ends by means of small cold deformed buttonheads at each end and supported on a threaded ring at both anchor ends. The tendon system was cycled extensively by the test equipment and no significant defects or failures were observed. In each test the tendon behaved as expected. The results proved the total reliability of the tendon system beyond the specification requirements. Page 5B-17
UPDATE-1 7/82
Eidgenossische Materialprufungs- und Versuchsanstalt fur Industrie, Bauwesen und GewerbeLaboratoire federal d'essai des materiaux et lnstitut de recherches - Industrie, Genie civil, Arts et MetiersLabpratori,Q fe,derale,di.,prQva dei .materialled IStLtutotsperimeotaJe -Industria, Geoio..civil~Arti ~ Mestieri0W~SS ll'ea.eral. .LaOora'tory IOr 'fes ~ng lvlaterl.al.S ana. rtest:arcn8600 Dubendorf
67'303/2
UntersuchungsberichtProces-verbalProcesso verbaIeTEST - REPORT
EMPANo.----------
Auftraggeber:
Commettant:Committente:Customer:
ST,AHLTON AG Z U E RIC H
Gegenstand:Objet:Oggetto:Object:
A 4 meter long prestressing cable of 70 wires ¢ 1/4"
Datum des Eingangs:Date de I'arrivee:Data d'arrivo:Date ")f receipt:
12.5.1969Ausfuhrung der Untersuehung:execution de ('essai:Esecuzlone della preva:Execution of test:
FATIGUE TEST RESULTS
AnmerkunliJ: Eine Verwendung dleses Berichtes zu Werbezwecken Irgendwelcher Art, der bloBe Hinweis auf diesen Bericht eingeschlossen, bedarf derGenehmigung durch die Dlrektlon der EMPA.
Observation: Ce rapport ne peut ~tre utilise au mentionne dans un but de reclame, quel qu'il soit, sans autorisatlon de la Direction du LFEM.Os..rvazlone: Questa rapporto non pub essere utillaato n8 menzlonalo a scopo dl qualsiasi pubblicila senza I'aulorizzazione della Direzione del LFPM.
58-18Ul-TCt,::: - 1
//82
DESCRIPTION OF TEST
1. The presstressing cable
- Type:
- Free length:
BBRV 70 ~ 1/4"
4 m
- 70 round and unprofiled steel wires 0 1/4"
- Ultimate tensile strength ~z = 170 kg/mm2 (According to d:!.ta
given by the customer. Se~ also the experimental results of the
tensile tests carried out on the steel wires in EMPA-Report
No. 67'303/3).
- Anchorage: The cable was anchored at both ends by means of
small cold deformed bottom heads at each wire end
and supported on a threaded ring at both anchor
heads (see appendix 2).
2. Equipment
The tested caDle was mounted vertically in a testing frame withc
a weighing beam (see figures in appendies 1 & 3) ..Lower and upper loading limits of 225 t and 250 t respectively could be
achieved and kept constant during the test by using two hydraulic ja.cks
which were connected to two coupled Amsler pulsators.
The applied loads were controlled by means of a "load cell"
connecting the weighing beam with the lower anchor head of the
tested cable.
A shock pickup was mounted on a plate fixed to the upper anchor
head of the cable. To detel~ine the number of the ruptured wires
during the test, a recording unit was connected to the mentioned
pickup.
58-i9.: / r.::..::..
- 3 -
3. Procedure
The cable was acted upon with a pulsating load, whose frequency
was 250 cycles per minute, for six days. In spite of the failure
of 6 wires during these 2,216.106 cycles the upper and lower loads
were kept constant.
4. Results
The data concerning the failure of six wires are given in
appendix 4. Due to these failures, the initial applied stress
limits were raised from:
0"upper 112,8 kg/mm2 and 0 101,5 kg/mm2= =Lower
up to: 5'" 123,4 kg/nun2 and 0 111,1 kg/mm2= =upper lower
i. e. : at the end of the test, the applied stresses were:
°upper = 0,726· ~z and 0- - 0 654 • 0z.Lower - ,
The total elongation of the tested cable measured after 2,216.106
loading cycles was 3,2 mm. From this elongation 2 mm was a result
of the excess stresses due to the failure of the six wires. This
means that the actu~l elongation of the cable was 1,2 mID.
i.e.: The permanent strain after 2,215.106 loading cycles was
0,3 %0.======
Dtibendorf, 17th July,1969
Engineer of test:
58-20
:)~"iS: 1:3Q::rul Laboratory forTesting Materials and B888Brch
A, rzJ1
~//8~
Appendix l
View of the test equipment "/i th the mounted cable and the recording
apparatus.
58-21
Coble for tension fatigue test ot the II EMPA II
~- --E...1QQ_-----( ¢7,87S" I
Appendix 2
__ 6J~8,7
( ¢ ':j,t.6 "1 -
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58-22I
Zeichnungsnummer:4 - 34:)9
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,"' ;4 ._,:- ~.,_... '
-Appendix 3
Experimental arrangement for a fatigue test on a prestressing cable
ocoZ
Q
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I I.' • 1 ........... Pavatex (hard cardboard. 5 mm )
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J III III III III III II
IIIIIIII
I ;;~IJ I I ~ II
~l~ ,Hlreaded ring I I ; I 'II.!;:;r;::I~ II~~il~tA v anchor head I~_UJl~~ 2 x sot II• _..I -~ jacks II
load I() III cell ~ II
~ ~I-~ 0 II
7 '~r~~ ~~ ~ !ira/ I ~ ~ l:R' I!!I . weighing beam . III !' II II:: I.., ti25 ~E 1100 ~I IiII \'1 II
I I I I I I I i////////////////////////////////// //////
I~ EMPA Auffro9S-Nr°1 AuftrG9geber:V 67'3C3/2 Stchlton :\.-G., Z uric h I
Gezelchnet: IZeichn""9snummer :Juli69 se 4 - 3410
TEST RESULTS
Appendix 4
test specimen: BBRV prestressing coble 4m long
Nominal values: cross-sectional area: Fe =70 ~ 1/411 = 70· 31,65 mm2 = 2216 mm2
ultimcte tensile strength : ~z = ,70 kg / mm2
Fatigue stage 1 : 6upper = 0,663 . pz = 112,8 kg/mm2 ; p = 250 tupper
610wer = 0,596 ~z = 101,5 kg/mm2PI = 225 t; ower
range of stress A 6 = 11,3 kg/mm2
FATIGUESTAGENo.
LOADING LIMITS
PUJ)per Ptowert t
STRESSES(related to the remainedcoble cross-section atevery fatigue-stage)
Total number ofloading cycles afterevery fatigue-stage REMARKS
1 250,0 225,0 114,4 103,0 11,4
2 II II 116,1 104,5 11 ,6..,
II II 117,9 106,1 i1 ,8,,)
4 /I II 119,7 107,7 12,0
5 II II 121,5 109,3 12,2
6 II II 123,4 111,1 12,3
7 II II 123,4 111,1 12,3
I I
Lower oncnoroge
2 failures
871'10C 1. failure
1'2161900 2. ..118771700 3. ..11885 1700 4. ..1'946'900 5. ..2'198'900 6. ..2'216'300 End of test
Upper ancho rcge
4 fai lures
All of the six failures took place directly near the cold deformed small heads of the wires.
During the 2,2 . 106 loading cycles and under lower and upper loading Iimits of 21St and250 t respectively, the tested cable-including irs both anchor heads-could remain without any other defects thon these six fai lures.
OEMPAAuftregs-Nr.
67 1303/2Auftregg.ber:
Stahlton A.-G., ZU ri ch 50"24Ouelcnn.t:
Juli 69 scZeicnnungsnummer:
4 - 3411
TEST RESULTS
Appendix 4
.- ... ," -.:'; 1 ; _. , I t- .......,r1- .- ~ . _. ,,".-.
test specimen: SBRV prestressing coble 4m long
Nominal values: cross-sectional area: Fe =70 t7J 1/4" = 70· 31,65 mm2 = 2216 mm2
ultimate tensile strength : ~z = 170 kg / mm2
ratigue stage 1 : 6 upper = 0,663 . ~z = 112,8 kg/mm2 Pupper = 250 t;
blower = 0,596 ~z = 101,5 kg/mm2 o - "'25 t;I lower - 4
range of stress A 6 = 11,3 kg/mm2
STRESSES(related to the remained Total number of
FATIG UELOADING L1tv\lTS cabl e cross-section at loading cycles after
STAGE every fatigue-stage) every fatigue-stage REMARKSNo.
PuPPet PLower ~~ 6'LOW«'~ ~6
t t kglmfnl ~g/mm leg /mrrr-
I1 250,0 225,0 114,4 103,0 11 ,4 871 '10C 1. failure
2 " \I 116,1 104,5 11,6 112161900 2. ..'"'I II " 117,9 106,1 11 ,8 11877'700 3. II,,)
4 /I 119,7 107,7 12,0 11885 1700 4. II/1
5 II II 121,5 109,3 12,2 11946 1900 5. II
6 II II 123,4 111,1 12,3 2'198'900 6. II I7 II II 123,4 111,1 12,3 21216'300 End of test I
I
Lower anchorage
2 failures
Upper anchorage
4 failures
All of the six failures took place directly near the cold deformed small heads of the wires.
During the 2,2 . 106 loading cycles and under lower and upper loading limits of 225t and250 t respectively, the tested cable-including h·s both anchor heads-could remain without any other defects than these six failures.
L.- .!..I_O...;:;._E_M_P_A---:I_~_7ftr_13_~_;.;..i_2..:.I_A_Su_~_r:1_glg_t~_~_r_:_A_._-_G_.,:..'_Z_U_r_i_c_h__5_3_-_2;;>_'_..:.I_JG_u·_,7':;·" sc I ~'~n~~u~m." \;~'; ,-':~ :':: - 1
,/ /O'L
Eidgenossische Materialprufungs- und Versuchsanstalt fUr Industrie, Bauwesen und GewerbeLaboratoire federal d'essai des materiaux et Institut de recherches -. Industrie, Genie civil, Arts et MetiersLabQratori9., federale di grob'la dei r:nateriallf'ed Isti1uto ~perimental.e - Indus,tria. Genio. civile... Art~e MestieriSW1SS ~ edGrn.1 La ora"tory or TeS"tl.ng !Vl~.t;erlal. ana KeSed.rCn8600 Dubendorf
67'303/1
UntersuchungsberichtProces-verbalProcesso verbaIeTEST - REPORT
EMPANo.----------
Auftraggeber:Commettant:Committente:Cu~tomer:
STAHLTON AG Z U E RIC H
Gegenstand:Objet:Oggetto:
Objec-: 7
A 4 meter long presstressing cable of 58 wires ¢ 1/4"
Datum des Eingangs:Date de I'arrivee:Data d'arrivo:
Date of receipt:
2.5.1969AusfUhrung der Untersuchung:Execution de I'assai: till 17.7 .1969Esecuzione della prova:
Execution of test:
DYNAMIC TEST RESULTS-----------------------------------------
Anmerlwng: Eine Verwendung dieses Berlchtes zu Werbezwecken irgendwelcher Art, der bl06e Hinweis auf diesen Bericht eingeschlossen, bedart derGenehmigung dur~h die Direktion der EMPA.
Ob• .",.tlon: Ce rapport ne peut 4tre utilise ou mentionne dans un but de raclame, quet qu'i1 soit, sans autorisation de la Direction du LFEM.O...rvllZlone: auesto rapporto non puc) essere utllizzato ne menzlonato a scopo dl Qualsiasi pubblicit~ senza I'autorlzzazione della Direzions dsl LFPM.
,5713/2
56-26U~"!):-~ rE: - 1
7/8:2.
-- 2 -
DESCRIPTION OF TEST
1. The prestressing cable
Type:
Free length:
BBRV 58 ¢ 1/4"
4 m
58 round and unprofiled steel wires ¢ 1/4"
Ultimate tensile strength ~!= 170 kg/mm2 (According to data given
by the customer. Soe also the experimental results of the tensile
tests carried out on the steel wires in EMPA-Report No. 67'303/3).
Anchorage: The cable was anchored at both ends by means of small
cold deformed bottom heads at each wire end and suppor
ted on a threaded ring at both anchor heads.
2. Eauipment
The tested cable was mounted vertically in a testing frame with a
weighing beam (see Figures in appendices 1 & 3).
Lower and upper loading limits of 125 t and 250 t respectively were
adrieved by using two hydraulic jacks, which were connected to a spring
dynamometer~ These loading limits could be kept constant during the
test with the aid of the Amsler load and deformation regulating unit
"The Hydro-Pacer".
Due to the high range of stress applied on the cable, the maximum
possible frequency that could be reached~ 0,5 cycles per minute.
3. Procedure
The required loading limits could be accurately adjusted by meuns of
a "load cell lt which connected the Weighing Jeam with the loy-er anchor
head of the tested cable.
The required 50 loading cycles were exceeded and the test was carr:i?d
out up to 440 cycles.
\j ~iF: [\:: -1.
./ /!:r~
58-27
4. Results
By visual inspection, after carrying out 440 loading cycles with
stress limits of
(jlower = 0,4 • ~z and 6'"upper= 0,8 • ~z ,
any defects could not be observed either in the prestressing wires
or at the anchor heads (see appendix 4).
DUbendorf, 17th July 1969
Engineer of Test:
58-28
Swiss F~deral laboratory forTestiny r,b.i~riaI3 and Research
/.\. 12iYl
Appendix 1
View of the test equipment with the mounted cable, the measuring instru
ment and the recording apparatus.
58-29
Appendix 2
Cable for tension fatigue test at the II EMPA II
I
I¢ 200
~~-70875 ',-°l----
I¢ 138,7 _
E:Eo(J(J~
-.
I !J"-'-HI
In Ian d Ryerson Canst. Prods Co , Chicago
~ EMPA IAuftrogs .Nro/ Auftro9geber:~ 67 13iJ3/1 St"hlton A.-G., ZUrich I
Gezeichnet :
5B-30 Juli W IZeichnungsnummer:
4 - 3406
r'\ppendix 3
EX~)E:rimental arrangement for a fctigue test on a prestressing cable• O' ••• ". I
...~:' :" ~__. r~ r\
ocozCl
IIIIIIIII
M 1: 25
Cable headtwo-part steel rinq¢400mm with a hole ~140mm
Steel plate 450 ·570 ·125 mm with a hole ¢ 180mmPevate x (hard cardboard, 5mm 1
ooco
prestressing co ble
58 ¢ 1'4 11
IIIIIIIIIIIIII
IIIIIIIIIIIi
IIIIIIIIIIIIIIIIII
"·1 II III III III III II
oo(J;)N
8co
~I
I2 x 50tjacks
1100
anchor head
Z Uri c ;, 58-31
I 625E"
IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII
II1/IIIII
Zeichnunqsnummer:
4 - 3.::·07~~~_-""---';;;' --' --' ...l.- --:-:,~
Appendix 4
TEST RESULTS ; ~-'-:~--l/~-~:JAh:
test specimen: BBRV prestressing coble 4m long
Nominal values: cross-sectional area: Fe =58 ~ V4 It = 58' 31,65 mm2 =1836 mm2
ultimate tensile strength: Pz = 170 kg / mm2
6 upper = 0,80· ~z = 136,2 kg/mm2
; Pupper =250 t
blower = 0,40· Pz = 68,1 kg/mm2
; Plower =125 t
range of stress A 6 = 68,1 kg/mm2
LOADING LIMITS STRESSES LOADING CYCLES REN\ARKS
6'upperlc.g/mm1
btowerkg/mm2.
250 125 136,2 68,1 68,1 440 End of test
No defects could be
observed either in wires
or otanchor heads.
Lower anchorage Upper anchorage
no failure of wires no failure of wires
"Ui-'t}A I=- 1.L I~ EM PA IAuftrags-Nr. IAuftraggeber: IGezeichnet: IZ4eich_nUng34snuom8mer:
V 67 1303/1 Stahlton A.-G. f Z Uri c h 5B-32 Jul i 69 sc---!........::....----!....-~_~_ __1._._-!---~
Eidgenossische MateriaiprUfungs- und Versuchsanstalt fUr Industrie,Bauwesen und Gewerbe, 8600 DUbendorf
Swiss Federal Laboratory for Testing Materials and Research- 8600 Dubendorf -
UntersuchungsberichtTEST- REPORT EM P A No. 67' 303/3
Customer: S t a hIt 0 nAG, 8034 Zurich
Object: Prest ress ing wires ¢ 1/4 n
Date of receipt: 11th June 1969 Execution of investigation: till 31st July 1969
Tension and Fatigue Tests
Rema rk: The use of this report for the purpose of publicity of any kind, including mere referenceto itI requ i res the approvol of the d4 rectors of the EM PA
F.94147 58-33
67 1303/3
1. Results of two tension tests
carried out on two prestressing wires
56-34
(b) (5)
(b) (5)
(b) (5)
(b) (5)
PartD. STATIC TESTS - TECHNICAL REPORT #8
Section SB Page SB-39
PartD. STATIC TESTS - TR-8
Table of Contents
Part Page #
Introduction, Purpose, Summary 5B-4l
1.0 Interim Report, Chapter 3a. Title Page SB-42b. Original Table of Contents SB-43
2.0 Appendix to Chapter 3a. Title Page 5B-78b. Original Table of Contents 5B-83
Section SB Page 5B-40
//82
PartD. STATIC TEST - TR #8
Introduction, Purpose, Summary
This test program was designed to test the ultimate load,ultimate elongation and failure mode of the 170 wire tendons oflengths up to 30 feet; and to determine the ultimate capacity ofthe individual anchorage hardware components when loaded in sucha manner as to test the critical failure made of each component.
Testing was divided into four categories:
Series PL - ultimate load tests of 170 wire tendonsand anchorages 4 feet long.
Series A - ultimate load and elongation tests of170 wire tendons and anchorages 30 feet long.
Series B - ultimate shear load of web.Series C - ultimate shear load of 6 inch diameter
thread.
All test results were over acceptable minimums based oncons~rvative basic critera. Therefore, the end anchorage hardwareas designed and tested will not be the weakest link in the tendonsystem.
Section 5B Page 5B-41··lh~lr- - 1
TECHNICAL REPORT NUMBER 8
THE WCS 2.0.Mep/170 W
POST·TENSIONING SYSTEM
INTERIM REPORT:
CHAPTER 3 . END ANCHORAGE. JANUARY, 1968
@ 1968, Western Concrete Structures Co., Inc.5B-42
TABLE OF CONTENTS
for
CHAPTER 3.0 - END ANCHORAGE
3.1 GENERAL
3.1.1 COMPONENTS
3.1.2 PERFORMANCE CRITERIA
3.2 PROTOTYPE DESIGN 2
3.2.1 GENERAL 2
3.2.2 SPLIT SHIM - BEARING PLATE INTERFACE 9
3.2.3 COMPOSITE WASHER· SPLIT SHIM INTERFACE 10
3.2.4 9-3/8 INCH DIAMETER THREAD 11
3.2.5 6 INCH DIAMETER THREAD - WITHOUT SHIMS 12
3.2.6 6 INCH DIAMETER THREAD· WITH SHIMS 13
3.2.7 WIRE HOLE WEB SHEAR 13
3.2.8 FAI LURE MODE ANALYSIS is
3.3 PROTOTYPE TESTS 16,.-. 3.3.1 DESCRIPTION OF TEST PROGRAM 16
3.3.2 PROTOTYPE ANCHORAGE HARDWARE 16
3.3.3 TEST SERIES PL - PRELIMINARY, 4' x 170 W TENDONS 16
3.3.4 TEST SERIES A· 30' x 170 W TENDONS 19
3.3.5 TEST SERIES BAND C· GENERAL 23
3.3.6 TEST SERIES B1 - WEB SHEAR WITH SHIMS 26
3.3.7 TEST SERIES B2 - WEB SHEAR WITHOUT SHIMS 29
3.3.8 TEST SERIES C2 - 6 INCH THREAD WITHOUT SHIMS 30
3.3.9 TEST SERIES C1 ·6 INCH THREAD WITH SHIMS 32
3.3.10 ANALYSIS OF FAI LURE MODE FROM TESTS 34
3.3.11 SUMMARY CONCLUSIONS 34
56-43
CHAPTER 3.0 END ANCHORAGE
3.1 GENERAL
3.1.1 COMPONENTS
The end anchorage hardware of the WCS 2.0 Mep/170 WPost·Tensioning System is made up of the components listedin Table 3.1-1. The terminology "A end" is used to desigratethe end of the tendon which has the Washer installed andwires shop headed during tendon fabrication. The tendon tubeat the A end has an enlarged section of sufficient diameter andlength to allow the Washer to be recessed approximately 6feet inside the face of the Bearing Plate, so that the unheadedwires can project approximately 6 feet beyond the BearingPlate at the opposite end (B end) of the tendon. The "B end"is the end of the tendon (opposite the A end) which allows aComposite Washer (or optionally a Washer and Washer Nut) tobe installed on the projecting wires, which are then field headed.
I REQUIRED FOR
PART & TYPICALI
TYPICALNAME DRAWING NO. MATERIAL A END R FNn
W01her 100103 <1140 Heat Treated Yes No·Washer Nut 100104 41 40 Heat Treoled Yes No·
Composi te Washer 100105 4140 Heat Treated No Yes·
Split Shims 100106 ASTM A7 or A36 Yes Y..Beoring Plate 100107 ASTM A7 or A36 Yes Yes. .Art O1.....bly comisting of 0 Washer and Washer Nul can be subllilvled for the Composile
Wosher on Ihe 8 End.
TAB LE 3.1- 1: Tendon end anchorage components of the WCS 2.0 Mep/170 Post-Tensioning System.
3.1.2 PERFORMANCE CRITERIA
The basic criteria for performance of the end anchorage of anunbonded tendon system for a prestressed concrete reactorvessel (PCRV) or other nuclear containment is that it mustreliably: 1) sustain the permanent long term load on the tendonfor the life of the structure, 2) sustain any variations in tendonload for the life of the structure, and 3) have sufficient overload capacity to allow the full actual ultimate strength andultimate elongation of the tendon wires to be developed.Expressed more simply, the end anchorage must b~ strongerthan the tendon which it anchors, for all types of loadingcondition.
The actual physical and mechanical properties of the tendonwire can be determined by statistical analysis of test data. Asdiscussed in Section 3.3.4, a long (~ 30 feet) tendon composedof 170 individual ASTM A421 wires of 0.250 inch diametercan be expected to produce an ultimate load ~ 2002.8 kips,and an ultimate elongation ~ 3.5%. Due to the mode of failureof a multiple wire tendon, resulting from variation of the individual wires, the average or the maximum values of either ultimate load or ultimate elongation will not greatly exceed theminimums. The ultimate load capacity of the end anchoragecomponents can be determined by ulti:nate load tests conducted on prototype components so as to test all critical failure modes. It can be assumed that the ultimate load capacityof production anchorage components will fall within a rangeof the mean ultimate load capacity of the most critical failuremode (X) plus or minus three standard deviations \a) of testresults. Many specifications require that end anchorage components may not yield at the minimum guaranteed tendonstrength. Therefore the basic performance criteria for the endanchorage of the 2.0 Mep/170 W System can be established
as: P = (X - 3 a) x (Fy + Fu ) ~ 2002.6 kips.
58-44
Since neither the mean ultimate load capacity (X) nor thestandard deviation (a) are known until after prototype testsare completed, it is necessary to establish a preliminary criteriafor design purposes. Previous experience indicates that designing for a Safety Factor of 1.5 will produce test results meetingthe basic criteria. This gives: Component Design UltimateStrength (Pi) ~ 1.5 x 2002.8 ~ 3004.2 kips.
Another independent consideration influences the design ultimate capacity of the end anchorage components. Due to thecritical structural application, a proof load test of all criticalcomponents to minimum t~ndon ultimate (2002.8 kips) hasbeen established as an essential part of quality assurance procedures. It follows that all components must be below theiryield point at the proof test load in order that the proof testbe a non-destructive procedure. For 4140 steel heat treated toRC 40-44r the tensile yield point is approximately 90% of thetensile ultimate; and as a practical consideration, to reduce rejections from the proof load testingr the proof test load shouldnot exceed 90% of the minimum yield point at Rc 40. Ittherefore follows that the design ultimate strength (P') of theweakest failure mode for each component should be:
P' ~ P170 ~~ ~ 2472.6 kips0.90 x 0.90 - 0.81
Taking ali of the above into account, the preliminary criteriafor prototype end anchorage component design ultimatestrength is 3004.2 kips for the most critical failure mode withthe final criteria for performance being:
(X - 3 a) x (Fy + Fu ) ~ 2002.8 kips
U:'::'::ATE - •.
//82
3.2.1 GENERAL
3.2 PROTOTYPE DESIGN
Fabrication drawings for prototype end anchorage componentsare shown in Fig's. 3.2-1 thru 3.2-5 as follows:
The load on the tendon at all major loading conditions is presented in Table 3.2-1 as a function of the guaranteed minimlAmtendon strength (P'no) which is 2002.8 kips.
COMPONENT NAME
WasherWasher NutComposite WasherSplit ShimsBearing Plate
FIGURE
3.2-13.2-23.2-33.2-43.2-5
net effect of all these factors can be reduced to a simple ratioconcept called the rupture factor (k r ) which is the ratio of thefailure load as determined by calculation (F u x A~) to theactual failure load as determined by ultimate load test of thecomponent (P"). Therefore k r = (F u x A~) -7- P", where A~ isnominal area of steel. k r is normally greater than 1.0. Thevalue of kr is determined from previous testing of similar mechanism designed in accordance with the same type of calculation.Each series of tests allows determination of revised rupturefactors, so that calculated failure loads become more accurateas more testing experience is gained. The rupture factors initially used herein are taken from WCS Technical Report Number7, "Behavior of the WCS 520 k/d4 Post-Tensioning SystemUnder Static Loads".
,-
FACTOR LOAD
CONDITION AUTHORITY x Pi.,., r~ips)
Prototype Anchorage Design Ultimat. Section 3. 1.2 1.5 I 3~.2
Minimum Guaranteed Strength Section 3.2.1 1.0 2002.8
Appro"ima,. Tetldon Yi.ld Strength Analysis of Wir. 0.9 1802.5Ma><imum Jocltin9 Fare. (t...."orary) ACI318 0.8 1602.2
Ma"i ......", Anchoring Fore. (short te",,) ACI318 0.7 1402.0
Ma"imum Final Fore. (pe..-en,1 ACI318 0.6 1201.7
ITABLE 3.2-1: Tendon load at various conditions presented as a functionof guaranteed minimum tendon strength (P'170),
Several factors may ca\Jse the calculated ultimate load based onanalytical calculations to differ from the actual ultimate load.Among these are: a) stress concentrations due to notchesand/or geometry, b) variation in material strength, and c)variation in the area of material resisting applied loads. The
Mechanical properties for the various steels used in the proto·type end anchorage components are shown in Table 3.2-2 forvarious strength levels. Strength levels are listed by equivalenthardness on the Rockwell B or C scales (R B or Rc) sincequality assurance is based upon determination and control ofhardness. Values for mechanical properties shown in Table3.2-2 are derived from curves contained in Fig. 3.2-6 in which:1) the curve for ultimate tensile strength (F tu ) vs hardness(Rc or RB) is constructed fro~ information contained in the1965 SAE Handbook, and 2) curves for other mechanical properties are plotted as they relate to Ftu based on informationcontained in MI L-HDBK-5 "Metallic Materials and Elementsfor Flight Vehicle Structures", and from appropriate ASTM
. specifications.
58-45
SYMBOL ASTM AISI A'SI or SAE 4140 ot R: IMECHAN ICAl PROPERTIES (ksi) A7 A36 1025 40 41 42 43 44
Ultimote Tensile Strength F til 60 - 75 58 - 80 55 180 187 193 200
I207
Tensi Ie Yield Strength F ty 33 36 36 163 168 173 176 183
Compressive Yield Strength Fey 33f2\ 36~- 36 179 186 192 198 205
Ultimate Shear Strength F'II 381" 37'f 35 109 113 115 119 121
Shear Yield Strength F ,.,
I I
IUltimate Bearing Strength l' F hI' \I 98'2 95 '2 90 326 335j
344 355 364
Bearing Yield Strength rr F lin 256 265 272 280 289 II
Notes: cr For elD = 2.0
f2\ Derived using rotio (F lll'll Ftll ) as indicated for AISl 1025 times Ft\l for A7 or A36
TABLE 3.2-2: Mechanical properties of various steels used in end anchorage components. Refer to Fig. 3.2-6 for derivative curves.
2./ / tj°'::'
-------------~----------_._----------------- ----------------------
P LAN
SECTION
170 wire Washer; R&D Part No. 730-02; R&D Drawing No.t'Aaterial: 4140 commercial grade, hot finished, leaded, annealed, 6-1/2" diameter bar.Heat Treat after all machining to Rc 40-44
FIG. 3.2-': Prototype Washer Drawing
5S-46 3//8~
p L A N
1---------- '.31',. ~ ~~~ ~ € ---------\
",. X 45- CHAW,.!:"TYPICAL
:r;~~ ;;,--t
-1.111----01; glso+t
- •.000·
SECT ION
....------ ....,--------
-
170 wire Washer Nut; R&D Part No. 730-04;Material: 4140 commercial grade, hot finished, 4-inch plate,
5-1/2-inch I. D. and normalize.Heat Treat after machin ing to Rc 40-44
R&D Drawing No. 348flame cut 9-3/4 inch O. D. ,
FIG. 3.2-2: Prototype Washer Nut Drawing
58-474
.!.......G'..,eIII1MU
:..~
p L A N
\'do
#...,.~
'"•~.••..,.
...,o•
170wire Composite 'I/asher; R&D Part No. 730-05; R&D Drawing No. 349N\aterial: 4140 commercial grade, hot finished, 9-3/4 inch diameter barHeat Treat after machining to Rc 40-44
FIG. 3.2-3: Prototype Composite Washer Drawing
5S-485 U: 'UA ; t: - 1
//82
...
...
\ /\ /
\
\ //'- ~/---..,.....I II I: I: I"'--__L--L_.___________ _ ....J
1
LMATU" HAL.' "IQUlltID TO MAKI A liT
P I.. A N
~----_---------- 10' IQ·u..·~6-....-~--------_~
1""".""11\
/SIDE VIEW
tt.SU.t' THE SURfACES 0' THE PLA TtlCOMPf"SING A SET SHALL NOT VARTMORE THAN .oet-,
170 wire Split Shims; R&D Part No. 730-06; R&D Drawing No. 350tv\aterial: A7, hot finished, 2 inch plate. Flame cut 5 inches x 10 inches with 5-5/8 inch
diameter hole. 2 pieces per set.Heat Treat: None
FIG. 3.2-4: Prototype Shim Drawing
58-49 6, t:",·-\
/ / .~.::.
tO~.. '!!!!'}
.TI'- DRILL Z 5/4- DEEPTAP 1-' Z· DEEP AT4 PUCEI 011 10· .. Co P 1.1 A N
170 wire Bearing Plate; R&D Part No. 730-09; R&D Drawing No. 357N\aterial: A7, hot finished, 4-inch plate, flame cut 20-1/2 inches x 20-1/2
inches with 7-1/16 diameter center hole.Drill and tap four holes for 1 inch diameter x 8 t.p. i. bolt on a 20 inch bolt circle.
Heat Treat: None
FIG. 3.2-5: . Prototype Bearing Plate Drawing
)
58-507
U~-'DFt 11:: - 17/82
(J)
~o JOHAI2DfoJESS
10o
JZ~-.::= Fbl'1 -- =-- bearing yield stress (ksi)
.! 'I' '.
F t1 tensi Ie yield stress (ksi) .-~ .._'-,-' -..-400--:: = ~':-r~:,:
'·f'·r t "-
,- -.-,_.
F e1 compressive yield stress (ksi)1-·,
='7~- r--'-_ •• -~'.-
_. ' ...
F'1I = shear ultimate stress (ksi) r.::.:::~' ' - . -...... ~
J
)~o~t-.
Fbl'1I = bearing ultimate stress (ksi)
-FIG. 3.2-6: Mechanical properties vs. hardness. The curve for tensile ultimate (Ftu ). showing UTS ploned against Rockwell Hardness (RS orRd is derived from information contained in the 1965 SEA Handbook. pages 107 and 109. Curves designated Fbru. Fbry. cCY' Fty and Fsushow other mechanical properties relative to Ftu and are derived from Tables 2.2.1.1 and 2.3.1.1 (a) of MI L-HDBK-5.
56-51 8 ·f ,. ,-,.",
/ " 0:'::'
AU possible failure modes are listed by components in Table3.2-3, which also shows for each failure mode the type of stress,calculated ultimate load, maximum applied temporary load,and maximum applied long term loads. Safety factors are shownfor each applied load and calculated as the ratio of the calculated ultimate load to the applied load. For each component,the critical' failure mode is that having the lowest safety factor.Validity of calculated ultimate loads and resulting safety factors
; nl-l/FSA~:
and criticality of failure modes must be established as a resultof prototype tests reported in Section 3.3.
Stresses, strains, and ultimate load capacit'1 of componentsinfluenced by the supporting concrete are dependent upon thestrength, elastic modulus, creep characteristics and reinforcement in the anchorage zone concrete and are not within thescope of this section.
Predicted Ntc.x. Load Ntc.x. Permanent FailureComponent Fai It.• re Mode Type of Stress UTS (Temp. Overload) Load Mode
(kips )(kips) S.F (k ips) S.F.
Critical
Supporting Concrete Anchorage Zone Principal TensionBearing t Interface Compression I
Tendon Tubing Ancharage Zone Axial Compression I Fai lure is dependent on mechanica and
Ancharage Zone Radial Compression > physical properties of the supporting concreteand is not considered in this section.
Bearing Plate Concrete Interface Compress ion
Internal Flexural I 2002.81I....
Shim Interface Bearing 3527.9 1.76 1201 .7 2.94
Split Shims Bearing t Interface" Bearing 3527.9 2002.8 1.76 1201.7 2.94 No it
Washer Interface '" Bearing 3357.7 2002.8 1.68 1201.7 2.79 Yes '"
Composite Washer Shim Interface '" Bearing 7900.2 2002.8 3.95 1201.7 6.58 No ..
Web "If Shear and Flexure 2864.4 2002.8 1.43 1201.7 2.38 Yes ..
9-3/8" Threads Shear 4342.7 1602.2 2.71 Nane "" No
Washer Nut Shim Interface" Bearing 7908.2 2002.8 3.95 1201.7 6.58 No ..
9-3/8" Threads Shear I 4342.7 1602.2 2.71 None a> No
6" Threads with Shim: Shear I 3276.5 2002.8 1.64 1201.7 2.73 Yes *I
Washer Web Shear and Flexure I 2864.4 2002.8 1.43 1201.7 2.38 Yes
6" Threads IN i th Sh ims· Shear 3276.5 2002.8 1.64 1201.7 2.73 No ..
TABLE 3.2·3: Possible Failure Modes of 2.0 Mep/170 W System End Anchorage Components. Safety Factor IS.F.l is the predicted ultimateload divided bV the applied load. .. Indicates failure modes to be tested.
3.2.2 SPLIT SHIM· BEARING PLATE INTERFACE (Ref. Fig. 3.2·7)
Nominal Area: A~ = 10.0· 1f' X ;.06252
= 60.83 sq. in.
Rupture Factor: k r = 1:0
Fey = 36 ksi for A36 per Table 3.2-2. :..9 Fey = 32.4 ksi
.ILOADING FORMULATE FOR LOAD STRESS
CONDITION P or f (kips) (ksi) REMARKS
Calculated UTS P=FxA~' 3527.9 58 > 3004.2
Pred icted UTS P = F x A~ x 1/kr 3527.9 58 > 3004.2
Proof Test Load f = P";' A~ 2002.8 32.93 < 33
Jacking -e- I -e- Unloaded till trans.
Anchoring
I1402.0 23.05
< 3r=·9 Fey
Max. Final 1201.7 19.76
I
58-52 9
UPUA\~ - 1l-/82
- -I--? 7~~'DIA
518 DIA
_.1 _, _"
----- SUP D OI2TIr-.JG CO~CRETE-
//~-----'OE:ARI"lQ PLA-TE~
.. 1 f=UIO·~Q ""Dl~ -(APP~IED\p_ 1 I• : 9Ys'DIA \\-OAD J I
20 Yl. SQ : ,------ ~---r-'\-.;.:::::::~~
L.-__......1 __---I 1"~, (C~M~O-~,TE)/5:-~.\ I L'-- \wASl-1Et< 01<. / /r\..,J ..-:::::, "--- WASHE:.tZ. ~'
- -- WASI-1EQ I-.:ur--/
-- /J------1-- J
;1~(-------- ---
FIG. 3.2-7: Arrangement of Anchorage Components
Nominal Area:
3.2.3 COMPOSITE WASHER . SPLIT SHIM INTERFACE (REF. FIG. 3.2·7)
A, = IT (9.3752- 5.6252
) 8S 4 = 44. 1 sq. in.
Rupture Factor: k r = 1.0
Fey =36 ksi for split shim
LOADING FORMULATE FOR LOAD STRESSCONDITION P or f (kips) (ksi) REMARKS
Calculated UTS P = F x A~ 3357.7 76 CD > 3004.2
Predicted UTS P = F x A~ x l/kr 3357.7 76 CD > 3004.2
Proof Test Load f = P ~ A~ 2002.8 45.33(3) < F =179 for R 40cy C
Jacking - - No load till trans.
Anchoring 1402.0 31.73< 3r =.9 Fey
Max. Final i 1201.7 27.20
Note:
CD equivalent D = 9.375; 5.625 = 1.875
equivalent e = t + ~ = 2 + 1.~75 = 2.94 for t = 2.0 min.
:. e/D = ;'::5 = 1.57> 1.5
e
Fbru (for e/D = 1.5) ~ .8 Fbru (for e/D = 2.0)
:. Fbru (for e/D = 1.5) = .8 x 95 =76 ksi
sa-53 10
i !i.i.-llj-SAl-.:
The bearing stress of 45.33 at Proof Test Load exceeds Fey ~ 36 ksi for the A7 or A36 split shims which would therefore be expected to show permanent deformations. The split shims do not require a proof load test and the bearingstress is well below Fey <;>f 4140 steel at RC 40.
CD For the composite washer side of the interface Fbru = 326 ksi and Fey =179 ksi.
3.2.4 9-3/80.0. THREAD
A' = (Le • p) X 1r X E ; where:s 2
A~ = nominal shear area
Le = length of thread engagement
n = number of threads per inch
p =pitch = I + n
D = nominal diameter = 9·3/8
E = nominal pitch diameter
= 3.250 inches
=4
= 0.250 inches
=9.375 inches
=D· 0.3 p = 9.375 - (0.3 x 0.250) =9.300 inches
A~ = (3.25 - 0.25) x 3.1416 x 9.30 = 43.83 sq. in.2
pi =Fs~ x A; and f s = PA~ kr
r s
pi = Predicted ultimate load ,/
Fsu = Ultimate shear strength (See Table 3.2·2)
kr =Rupture factor =1.1 (Ref.: WCS Technical Report No.7)
fs = Calcu lated shear stress
LOADING HARD. LOAD STRESSCONDITION Rc (kips) (ksi) REMARKS
Calculated UTSG) 40 4777.0 109 > 3002.4
Predicted UTS 40 4342.7 109
41 4502.1 113
42 4581.7 115
43 4741.1 119 j44 4820.8 121
Proof Test Load 40 2002.8 50.27 < (.9 FSY =.9 x.9 x Fsu =88.3)
Jacking @ 40 1602.2 40.21 < 0.4 Fsu
58-54
Notes:
CD Calculated UTS does not make use of kr , :. Pc =Fsu X A~
@ The 9-3/8 thread is unloaded after transfer
11
!jl-'DAii:: - 1
3.2.5 6 INCH 0.0. THREAD· WITHOUT SHIMS (REF. FIG. 3.2·7)
A' = (Le - p) x 1T X E . where:s 2 '
A~ = nominal shear area
Le = length of thread engagement
n = number of threads per inch
p = pitch = I ~ n
o = nominal diameter
E = nominal pitch diameter
3.250 inches
4
0.250 inches
6.000 inches
= D - 0.3 p = 6.0· (0.3 x 0.250) = 5.925 inches
A ' = (3.25 - 0.25) x 3.1416 x 5.925s 2 =27.92 sq. in.
Calculated Ultimate Load:
Predicted Ultimate Loads and Stresses:
P' = pi = Fsy x A; . f P x ks k
r' and s =~ ;where
Fsu = Ultimate shear strength (See Table 3.2-2)
kr = Rupture factor = 1.1 (Ref. WCS Technical Reoprt No.7)
·fs =Calculated shear stress
LOADING HARD. LOAD STRESSCONDITION Rc (kips) (ksi) REMARKS
Calculated UTS 40 3043.4 109 > 3004.2
Predicted UTS 40 2766.7 109
41 2868.2 113
42 2919.0 115
43 3020.5 119
44 3071.3 121
Proof Test Load - 2002.8 78.9 < .9 Fsv (.9 x.9 x ~09 =88.3)
Jacking - 1602.2 63.1 =58 x Fsu (min.)
Anchoring - 1402.0 55.2 =51 x
jMax. Final - 1201.7 47.3 =.43 x
58-55 12 f/- ,/~:i~
3.2.6 6 INCH 0.0. THREADS - WITH SHIMS (Ref. Fig. 3.2-7)
The 6" washer bears on the split shims over an area Abr and thus results in a force, Pbr = fbr x A.br' This bearing force (Pbr )plus the shear force (Ps ) as derived in Section 3.2.5 reacts against any applied load (P), so that: P = Ps + Pbr. At ultimate loadlevels, all component materials are stressed within the plastic range, and we can expect fbr to be equal to Fbru which is quitehigh in terms of Ftul but is rather indeterminate. MI L-HDBK·5 gives data for Fbru of AISI 1025 steel for elD =2.0, but thisin the average stress at ultimate rather than the peak stress since it is based on a round pin of diameter D in a slightly oversizedhole. If we assume a sinusoidal stress distribution Fbru (average) = 0.636 Fbru (peak), or Fbru (peak) = 1.57 Fbru (average)Data for AISI 1025 steel indicates that Fbru = (90 -:- 55) Ftu = 1.64 Ftu . The washer-split shim interface ts a plane surfacewhere it can be assumed that average and peak bearing stresses are the same. Ftu for either A7 or A36 steel can be determinedapproximately from the Rs hardness. Therefore, we can derive an approximate expression for Pbr as follows:
Pbr ~ Fbru x Abr ~ 8.79 Ftu; where:
Abr = ~ (6.002 .5.6252) = 3.42 sq. in.
Fbru ~ 1.64 Ftu x 1.57 ~ 2.57 Ftu
Ftu is determined by hardness test from Fig. 3.2-6.
Therefore p' = P~ + Pbr ~ P~ + 8.79 Ftu
Shear stresses in the threads resulting from an applied load can be determined in much the same manner except that for loadssubstaintially below ultimate, we must assume a relatively uniform stress over the entire bearing surface as follows:
P = fbr x Abr (total) = 44.18 fbr ; or fbr =:4.18; where:
Abr (total) =~ (9.3752- 5.6252
) ~ 44.18 sq. in.
PTherefore: Pbr =fbr x Abr ='m8 x 3.42 =0.077 ~
Since: P= Ps + Pbr = Ps + .077 P
Ps = 0.923 P = fs x As = fs x 27.92 (Section 3.2.5)
f = 0.923 P = 0 0~3 Ps 27.92 . <oJ
3.2.7 WIRE HOLE WEB SHEAR
As shown in Fig. 3.2-8, shear failure of the web between the wire holes can occur along either of two critical paths. The loadapplied by the wire heads to the portion of the washer inside the shear plane (Ps ) is less than the total applied load (P) sincepart of the load applied by the wires on the shear path is applied to the portion of the washer outside the shear plane. Thisratio of load distribution and the number of webs on the shear plane can be determined by inspection of Fig. 3.2-8, whichgives the following results:
WIRES RELATIVE
ISHEAR TO SHEAR PLANE TOTAL LOAD RATIO NUMBER OF STRESS RATIO
PATH INSIDE OUTSiDE WIRES Rp = Ps/P WEBS (N) Rs = Rp/N
Shear Path 1 141 29 170 0.829 44 0.0189
Shear Path 2 133 37 170 0.782 40 0.0196
For any given condition, the web width (w), the washer thickness (t) and the applied load (P) are constants, so that the computed shear stress (fs) varies directly with the stress ratio (Rs = Rp/N) as follows:
58-56
fs=~=~ =~x_P_=RsxCAs N x w x t N '.1 X t
13
Ui-'DAT1:: - 17/8:1.
109 x 20.fi5 =2240 kips1.0
58-57
It can thus be seen that the shear stress along shear path 1 will be slightly lower than that along shear path 2, which will beused in following calculations, however, the difference is small and, due to manufacturing variables, web shear failure can beexpected to occur along either shear path.
PATH 1
I
~FIG. 3.2-8: Alternate shear paths for wire hole web shear failure with Path 1 shown abovehorizontal <t. and Path 2 below. Path 2 is slightly more critical than Path 1.
Whilethe center to center spacing between adjacentwireholescan vary ± 0.010, or 7.5% ofthenominal'web width (w =0.133),the total spacing along any line of holes has the same tolerance of ± 0.010, which is only 0.2%. Therefore the average web isthe nominal center to center hole spacing (0.397) minus the hole diameter (0.260 nominal or 0.264 maximum). The area ofsteel resisting web shear (As) along the critical Path 2 is therefore:
A~ = N X w' x t = 40 x 0.137 x 3.750 =20.55 sq. in.
As-min. == N x wmin. x t =40 x 0.133 X 3.750 = 19.95 sq. in.
N =number of webs along Path 2 =40
w' =nominal web width =0.397 . 0.260 =0.137 in.
w m in. =minimum web width = 0.397 • 0.264 = 0.133 in.
t = washer thickness = 3·3/4 = 3.750 in.
Calculated ultimate load (P~) and predicted ultimate load (P') are the same since the rupture factor (kr ) is taken as 1.0. Loadsand stresses are given by:
P' =!i =~ 2240 .R 0 782 =0.782 = 2864.4 kips
p •
f = Rp x P = 0.782 x P =0.0381 Pksis ~ 20.55
where: P = any applied tendon load
pI = tendon ultimate tensile strength
P~ = predicted ultimate shear (test) load
Rp = load ratio = 0.782 from chart above
kr =rupture factor = 1.0 (Ref. WCS Technical Report No.7)
As = nominal shear area for Path 2 = 20.55 sq. in.
14
ihi.-l/i-SAH
LOADING HARD. LOAD STRESSCONDITION Rc (kips) (ksi) REMARKS
Predicted UTS 40 2864.4 109
41 2969.5 113
42 3022.1 115 > 3004.2
43 3127.2 119 jr 44 3179.7 121
Proof Test Load 2002.8 76.2 < .9 FSY (.9 x .9 x 109 = 88.3)
Jacking 1602.2 61.0 = .56 Fsu
Anchoring 1402.0 53.4 =.49 Fsu
Max. Final 1201.7 45.7 =.42 Fsu
For shear failure along Path 1:
As =N x w' x t = 44 x 0.137 x 3.750 = 22.61 sq. in.
As min. = N x wmin. x t =44 x 0.133 x 3.750 = 21.94 sq. in.
p' = Fsu x ASS k
r
109 x 22.611.0
2464.5 kips
P' =equivalent tendon ultimate strength
=!1. =£i.. = 2464.5 =2972 8 kRp 0.829 0.829 '.
f=~S As
3.2.8 FAILURE MODE ANALYSIS
0.829 x P22.61
= .0366 P ksi
ACI 318-63 limits the concrete compressive stress on the bearingarea supporting a tendon bearing plate to:
fcp = 0.6 f~i ...yA~/Ab; but < f~i
In customary practice, fcp is considered to be a uniform stressand the bearing plate thickness is then set to limit flexuralstress in the bearing plate to Fty at minimum guaranteed tendonultimate. Although this procedure results in satisfactory performance, it does not represent the actual conditions whichexist and has no significance in analizing the mode of failure.While fcp = P/Ab gives the average stress on the bearing area,the distribution is not uniform in any case, and is dependentupon the modulus of elasticity, poissons ratio, and creep properties of both the plate and the supporting concrete. The maximum concrete stress is a function of bearing plate deflection.Since the bearing plate flexural stress could not possibly exceedFty without causing concrete failure, the bearing plate can notfail. The failure mode is thus deter"ined by the supportingconcrete, not the plate, and will not be considered in thisSection. This subject is covered in WCS Technical Report No.2.
58-58
Table 3.2-3 lists all failure modes for each component. For eachcomponent, the critical failure mode is that having the lowestSafety Factor (S.F .). The purpose of the prototype testing reported in Section 3.3 is to determine actual ultimate load forall critical failure modes.
-, ,',-, .. -,//0":'
15
3.3.1 DESCRIPTION OF TEST PROGRAM
3.3 PROTOTYPE TEST
The test program was designed to test the ultimate load, ultimate elongation, and failure mode of 170 wire tendons oflengths up to 30'; and to determine the ultimate capacity ofthe individual anchorage hardware components when loadedin such a manner as to test the critical failure mode of eachcomponent.
Testing was divided into four categories, Series PL - ultimateload tests of 170 wire tendons and anchorages 4' long; SeriesA - ultimate load and elongation tests of 170 wire tendons andanchorages 30' Ie ; Series B - ultimate shear load of web(honeycomb); and Series C - ultimate shear load of 6 inch diameter thread.
3.3.2 PROTOTYPE ANCHORAGE HARDWARE
Prototype hardware was fabricated in accordance with drawings per Figs. 3.2-1 thru 3.2-5. Prior to testing, componentswere designated by Rand 0 drawing and part numbers. Aftertestshadvalidated design, final drawing and part numbers wereassigned. These are listed in Table 3.3-1 for reference.
R&D Id.ntification Final
Port Nom. Port D,owing ~.yi,ion Po,t andNo. No. Dot. Drowina No. -
Wooh.r 730-02 346 10-21-66 100103 - 00Washer Nut 730-04 348 10-21-66 100104 - 00Composit. Wooh., 730-05 349 10-21-66 100105 - 00
Shims 730-06 350 10-21-66 100106 - 00
Bearing ptat. 730-09 357 10-10-66 100107-00
TABLE 3.3-1: Prototype Anchorage Hardware Designation
Each prototype washer, washer nut and composite washer wasassigned a serial number for identification and record. Tables3.3-2 thru 3.3-4 show the material, material supplier, chemicalanalysis, machining practice, heat-treatment, and hole diameterand spacing tolerances for the washer, washer nut and composite washers respectively. Also listed in the same tables arethe measured dimensions and loading history for each serialnumbered part.
6- 10'JliIl4' • I'·/O"'z' t~ WITH7 IA.'. CaNTelt HOI.!
....._-- ,%. "tftt.IT 'HU~' 10' $dlU"q"t""" 5~~+aNTtlt HOt.I
FIG. 3.3-1: Setup for Series PL tests.
56-5916
It should be noted that prototype anchorage hardware dimensions and material do not agree exactly with drawings andmanufacturing standards shown in Section 3.4. Even thoughtests on the prototype hardware were entirety satisfactory andand conform to design criteria, some dimensions were changedin the interest of standardization. in particular, the thicknessof the washer and composite washers were increased from3-3/4 inches to 4 inches in order to conform with the washernut; and alloy tubing for the washer nut and alloy bar (pressedround) materials are shown as preferred over flame cut plateused for prototype hardware. Since these changes are ail onthe conservative side and increase the strength of the respectivepart, the prototype tests are applicable. Predicted failure loadsfor the production parts have been established by linear increase of prototype test results to account for the increasedstrength due to these changes. All such changes are clearlynoted in the analysis of each series of tests.
3.3.3 TEST SERIES PL
The objective of Series PL tests was to provide preliminaryresults by loading prototype anchorage hardware to the tendonultimate in such a way as to limit the release of energy in theevent of failure of ar. anchorage hardware component. Allanchorage hardware components used for: 1) Series A tests(170 wire x 30 foot long tendon ultimate tests), 21 170 wirestructural tendons in the 4.0 Mep te~t bed, and 3) GeneralAtomic ultimate tests of both straight and curved tendons up to100' long were tested in this series. A secondary objective wasto provide additional statistical data in support of the designcriteria that the anchorage hardware must be stronger than theminimum guaranteed tendon strength (2002.8 kips). A thirdobjective was to repeatedly test the stressing equipment at aload equal to tendon design ultimate.
The test set-up is shown in Fig. 3.3-1. End anchorage hardware consisting of a washer and washer nut (typical A-endl onthe right and either a composite washer (typical B-end) or a
1000 TON UJA -
Measured Dimen,ion, Load Hiltory
Clearance Hordn_ Series S.ries Test Series GeneralPitch Oia. Axial R: :;:B Lab. PL A Bed B&C Atomic Tests
.015 .020 4\.5 390 - PL-4 IA-2
50, 6cI
.017 .025 41.5 390 - Pl-3 A-I 5c, Sa
.015 .020 4\.5 390 - Pl-7 60, 8b
.014 .015 42.0 401 - Pl-5 6b, 90
.028 .018 41.0 388 - PL-I IBed.014 .017 4\.5 390 - Pl-S 6c, 9b
.015 .012 41.0 388 - Pl-6 '10
.015 .011 42.0 401 - Pl-6 Sb
.013 .014 4\.5 390 - PL-2 Bed
.015 .014 42.0 401 375 C2-7
.018 .015 41. 0 388 303 Cl-IO
.020 .018 40.5 38.5 375 C2-8
.015 .012 39.0 370 363 C2-9
.014 .020 4\.0 388 352 Cl-4
.023 .018 41.5 390 I -IS IS IS 15 5
.0167 .0160 4I.n 390 365.6
.0039~ .00368 0.727 53.6 8.66
23.6 22.2 \.76 13.7 2.4
.075
.076
.075
.076
.alO
.072
.074
.alO
.073
"1
.076
.00262
3.4%
ThreadDepth
WASHERRO 730-02; Print: RO 730-340; Final Port and Drawing No.; 1001036-1/2 inch diam.t.r, hot finished. bar stoel<, leaded ana annealed per ,0.151 4142 Comm.rcial Grod.United States Sr••1Corporation
C ...... P S Si Cr Ma Pb.42 .83 .OQJ .020 .27 .92 . 18 . 15/.35Rough machin. and thread on Q ~onv.nrional engin. loth.. Hoi. drill on on outomotj~ drill press using conventional f.eds and speed, and Q "Burgh...... r..··floating ind.x table.P.. MIL-H-6875B; prot.ctiv. otmosph.re Fur"Oc. for hord.ning and tempering; circulating oil for qu.nching. Qu.nch flat in a singl. lay.r to facilitat.....bqu.nch. Hardness as quenched R: 54/55.Hal., ch.clced ... ith hoi. micrometers and "Go-No Go" gClUget ran to maximum metal side of tol...ance.Within: .010 on out.r (drill in) faceWithin: .030 on inner (drill out) face
: 3-3/~ inches overall; 3-1/4 inc" thread lengthTHICKNESS
Serial MajorNumber Diall'l.t.r
001 5.998
002 5.992
003 5.996
00. 5.9960Q5 5.991
0Cl6 5.995
001 5.995
0Ql 5.996
009 5.992
ala 5.980
all 5.993
012 5.995
013 5.995
014 5.986
015 5.987
n 15
X 5.992
a O.oo..6S
v .077%
PART NAME :PART NUMBER :MATERIAL :MATERIAL SUPPLIER ;
CHEMICAL ANALYSIS :
MACHINING ;
HEAT TREAT :
HOLE DIAMETER :HOLE CENTER SPACING :
TABLE 3.3-2: WASHER - dimensions and load history.
PART NAM: :PART NUMBER :MATERIAL :MATERIAL SUPPliER :CHEMICAL ANALYSIS :
MACHINING :
HEAT TREAT :
THICKNESS :
WASHER NUTRD 730-04; Print: RO 730-348; Final Part and On:win, No.: 100104AISI4142, annealed, 4 inch hot rolled plate, c_rcial grode. FI_ cut 9-3/4 inches outside diamet.r ... ith a 5-1/2 inch center hale and onnealed.Lukins St..l CompanyC ...... P S Si Cr Mo lib
.38 .76 .0Ql .025 .240 .90 .15 -Rough machine and thread on a conventional engine I!lthe.Per MIL-H-6875B, prorec:1ive otm~h.re furnace for hardenin9 and tempering; ci re-.oIating oi I for quenching; Hardness as quenched Rc 54/55.4 inch overall, 3-1/2" len,tl, internal threads, 3-1/4" length external thrwadI.
.......asured Dimensions Load History
External Thread Intemol Thread
SerialNumber
MaiorDiameter
Thread ClearanceDepth Pitch Oia. Ax'al
MinarDiam.,..
ClearancePitch Oia. Axial - BHN lob.
SeriesPl
Seri. T.t 5eri. GeneralA Bed 8 & L Atoftic T...
352
001
002003
00.0Q5
0Cl60f1l0Ql
n
X
9.364
9.3n
9.365
9.364
9.368
9.362
9.3689.370
89.367
.00320
.03
. aI.5
.088
.<Ya9
.a16
.al9
.al9
.al9
.~7
8
.C678
.00148
1.7
.028
.022
.031
.026
.029
.028
.025
.031
8.0274
.00282
10.3
.029
.020
.020
.014
.021
.023
.019
.019
8
.0206
.00397
19.3
5.860
5.855
5.852
5.860
5.870
5.863
5.392
5.866
a5.8648
.0116
.20
.021
.01 0
.020
.015
.030
.023
.032
.025
8.0231
.00532
23.0
.010
.014
.015
.007
.018
.012
.010
. OCIJ
8.0118
.00349
29.6
40.5 385 388
I 41. 0 388 3634\ ,5 390 I 363
40.1) 375
41.7 400
40.5 38.5
40.0 375
42.0 I 401
8 8 5
40.90 1387... 365.8.721 9. IS II . 9
1 1. 76 2.36 I 3.25
Pl-4Pl-7
I Pl-3Pl-5
Pl-6
Pl-5Pl-IPL-6
Pl-2
C2-9
C2-10
A-I A-2
So, 5c, 6b, 6d, 8b, 91:1
C2-7
5b, 60, 6c, Sa, 9a
Pull Rod T.t
Cl-4
TABLE 3.3-3: WASHER NUT· dimensions and load history'.
17Ui-'UH l t: - 1
1/ i:f2
58-60
Ne.19
PART NAMfPART NUMBERMATERIALMATERIAL SUPPLIERCHEMICAL ANALYSIS
MACHINING
HEAT TREAT
HOLE DIAMETERHOLE CENTER SPACING·
HICKNESS
_ -.\.
: ~ ~ - L / ;" .~ H r:
COMPOSITE WA5HEQRD 730-05; Prinr: RD 730-349; Final Part and Drawing No. 100105AISI 4142 Commerc:ial Grade, 9-1/2 ind' diameter pressed round, annealedBerhlehem Steel Corporation
C Mn P S Si Cr.43 .93 .008 .024 .20 .97Rough mac:hine and thread on a c:onventional engine lathe. Hole drill on an automatic drill press using conventional feeds and speeds and a "8urghmoster'f100ting ind.x table.Per MIL-H-6875B; protective atmosphere furnace for hardening and tempering; circ:ulating oi I for quenc:h i I'Ig. Quench flat in a single layer to fac:i Ii tate webquench. Hardne" as quenched R, 54/55.Hole checlced with hal. micromet.n and "Co-No Co" gauges ran to maximum metal side of toleronce.Within:t .010 on ouler (drill in) fac.Within:t .030 on inner (drill out) face3-3/4 inches overall; 3-1/4 inch thread length
""Wosured Dimensions Load History
Serial Neior Thread Clearance Hardness Series Series Test Series GeneralNumber Diameter Depth Pitch Dia. Axial R, .. 8HN Lob. PL A Oed 8&C At~mje resn
001 9.361 .070 .030 .021 41.5 390 341 81-2
002 9.372 .078 .030 .015 40.5 385 341 81-1
003 9.364 .075 .030 .017 42.0 401 PL-I Oed
004 9.365 .074 .028 .017 41.2 388 341 81-3
005 9.364 .072 .029 .014 42.0 401 352 82~
006 9.362 .072 .031 .017 40.0 375 - PL-2 Oed
007 9.369 .075 .028 .016 40.0 375 - PL-4 Pl-7 50, 5b, 5c, 60, 6c. Bo. 90
cal 9.365 .071 .030 .017 40.0 375 - PL-3 A-I A-2 ~ 10, 6b, 6d, ab, 9b
009 9.369 .075 .032 018 42.6 408 375 82-5
010 9.368 .002 .029 .019 40.0 375 -011 9.364 .073 .030 .025 42.0 401 -012 9.360 .069 .032 .Ot8 41.0 388 -013 9.362 .070 .025 .018 40.5 385 -014 9.362 .073 .027 .017 41.0 388 -015 9.358 .070 .029 .020 40.0 375 -
1
--~1'1 15 15 15 15 15 15 5
X 9.364 0733 .0293 .0179 40.95 387.3 350
0 .00368 00334 .00178 .00254 869 10.85 13.21
v .039 455 6.06 14.2 2.12 2.80 3.n
TABLE 3.3-4: COMPOSITE WASHER· dimensions and load history.
5B-61
washer and washer nut on the left were connected by 170-0.250inch diameter wires 4 feet long with button-heads. The washeron the right hand side of the 4 foot tendon was inserted thrua block consisting of eight bearing plates (R&D Part No. 730-09per Fig. 3.2-5). After installation of the washer nut, shims(R&D P~rt No. 730-06 per Fig. 3.2-4) were installed on theleft hand side as spacers and the 1000 ton stressing jack wasconnected to the washer nut on the right. In the initial tests ofthis series, the jacking load was increased until failure of twoor three wires occurred. In later tests the load was stopped at2100 k. All anchorage hardware tested in Series PL was subsequently reused in other tests. Elongations at failure were notrecorded. Series PL test results are summarized in Table 3.3-5.
Test Series Pl· Test Re.ulhPart Serial Numbe"
Test Test Mall, Load Left Ri htNumber Date (kiDS) Wmher Nut Com..... W-h·· 1\1.. , ~_.l..
Pl-I 1-28-67 1988 - - 003 005 007
Pl-2 1-30-67 2090 - - 006 009 :1Pl-J 1-30-67 2150 - - OQI 002
I
Pl-4 4-7-67 2100 - . 001 001
§IPl-5 4-7-67 2100 00& 00& - 006Pl-o 4-7-67 2100 001 OQI - OQI
Pl-7 4-7-07 2100 - - 001 003
TABLE 3.3-5: Summary of Series PL Test Results.
3.3.4 TEST SERIES A
Series A tests were conducted on 30 foot nom inal lengthstraight tendons made up of 170 wires of 0.250 inch diameter
anchored by means of button-heads to prototype anchoragehardware.
The objectives of Series A tests were to determine: 1) the loadelongation characteristics up to tendon ultimate, and 2) themode of failure. The maximum force which a multi-wire tendoncan resist, tendon ultimate, is that force at which 2-3% of thewires fail (3 to 6 wire failures for a 170 wire tendon), eventhough the remaining wires will continue to elongate at a reduced force. The number of wires which fail at each increasedelongation increment can be expected to follow a normal distribution curve, imposing increasing shock loads and higherenergy release. Since this would risk injury to test personnel andvisitors, and damage the testing equipment, all without contributing any additional significant information; Series A testswere terminated at the total elongation which produced fourwire failures.
Tests were conducted using the 4.0 million pound capacity testbed and the 1000 ton capacity stressing equipment. The testset-up is shown schematically in Fig. 3.3-2 and by photographswhich are typical of both A-1 and A-2 tests (Fig. 3.3-3 thru3.3-7). An assembled and banded 170 wire tendon having aprototype composite washer on the east end and a prototypewasher on the west end was installed in the test bed from eastto west. A prototype washer nut was installed on the west endand the tendon centered ready for test. Two 4" th ick bearingplates are used under the anchorage hardware at both ends in
WEST e.ND
.'
EAST t: lJO
4 MfLLrON POUND T~S; ~~O
56-62
Ui-'iJATE: - 1
... .,. . . . ~••• 0 •••
e.
•••••• ' ."••'" ..... it 0.:" ." ..
19
T~IANGULA~ STt.It 5' ,",leI( -----~
.., '
'.
~ .-.• •-.: ... ~ .
. '
~e! Oil '!'!~Trr...""....n.CNI r 'NA~. I
I
SGWA-': ~PUT 1M'. -. '%AI ~ !J ~ '1.0'!~I··c:aNTU HQI.a
WA.MIIil II l....----I'UJ'f./ i!li:l.1t WITWW"SH!1Il NUT, 9 Ya, 0.1'. Hc;t+ aNTI" 1'101.1
FIG. 3.3-2: Test setup for Series A tests.
56-63
FIG. 3.3-3: Series A. 170 wire banded tendon installed throughcenter hote of 4.0 Mep test bed.
·c·.~
'.-
FIG. 3.3-5: Series A. West end after Phase I elongation, showing 14" to 16" shims is place retaining elongation of prototypewasher - washer nut anchorage hardware.
Fl G. 3.3-4 Series A. Stressing jack attached to tendon atwest end for Phase I elongation.
FIG. 3.3-6: Series A. Prototype composite washer at eastend at the same test stage as that shown in Fig. 3.3-5. Thewire deflector plate, shown in place, is removed prior to installation of l,OOO-ton Stressing Ram for Phase II elongation.
FIG. 3.3-7: Series A. West end during test A-2. Two wireshave failed at a force of 2,054k at an elongation of 17.0 inchesand can be seen against the deflector plates. At this stage ofthe test, Phase II elongation is being applied at the opposite(east) end of the tendon.
20
capacity load cell, accurate to 1% full scale traceable to theNational Bureau of Standards, was added bet\'Veen the washerand the split shims at the left end. Although capacity of theload cell was only one-half that of the applied loads, load cellvseither transducer or hydraulic gauge readings showed a linearrelationship to 1000 kips and can be extrapolated linearly withsufficient accuracy. Test data for Series A, test A-1 and A-2are shown in Tables 3.3-8 and 3.3-9 respectively.
The relationship of the actual properties of wire used for SeriesA, tests A-1 and A-2 as compared to the minimum propertiesrequired by ASTM: A 421 can be ssen on Fig. 3.3-8. Thestress-strain curve shown has the same shape as a load-elongationcurve and is based on the 10 inch gauge length specified inASTM: A 421. It can be seen that the wire used has an averageyield point 16.9% greater, an average ultimate 3.1 % greater, andan average elongation 52.5% greater than corresponding minimums specified by ASTM: A 421.
.06
(250, 5.3"')
.05
Wi,. T.t - Tendon '1
.04
0.25" Of_em WIre,,,, • 0.0491 i"."1O· Gage L.\gth
.03.02Strain, I" ./1". .01
urder to transfer shear forces around the oversize (10") hole inthe ,test bed. These bearing plates are not considered to be apart of the assembly being tested.
A 1000 ton Stressing Ram having an 8 inch stroke was attachedto the west end for Phase I elongation. (Fig. 3.3-4). At approximately full 8 in~h ram stroke, shims were stacked under theanchorage hardware to maintain elongation. The jack was retracted, blocked by means of a chair extension load, re-applied,and more shims stacked. This cycle was continued to completion of Phase I elongation, shown in Fig. 3.3-5 just after removal of the Stressing Ram. Tendon elongation during Phase Iwas designed to be safely below tendon ultimate, but sufficiently great that tendon ultimate force could be obtained withina single 8 inch stroke of the Stressing Ram attached to the eastend for Phase II elongation. This was for the safety of personnel and protection of the test equipment.
The wire used for Series A tests was tested to determine meanvalues of actual ultimate strength, yield strength, and elongation as shown in Tables 3.3-6 and 3.3-7 for tests A·1 and A·2respectively.
Applied load was recorded at intermediate values of appliedelongation. Elongation was measured by means of a steel tape,accurate to 0.01 inches, which measured Stressing Ram pistontravel. Loads were measured by both a calibrated hydraulicgauge and by a calibrated hydraulic pressure transducer havinga digital read-out. Calibrations were performed with a setup'similar to that shown in Fig. 3.3-1 except that a 1000 kip
INDIVIDUAL WIRE PROPERTIES
FIG. 3.3-8: Stress-Strain curve showing mechanical properties forwire used in Series A, tests A-l and A-2, shown superimposed onthe theoretical curve for a wire having properties per ASTM: A421specified minimums.
1
Installed 15_1/4" 10'01 .hims.Transfe,red load to .hims. R......ved jock
and installed on ,ight. Two haur delay
AOX illdie:.ta, off ,cole.
AOX indicato, off scale.2 wires foiled at heads.2 wir. failed at hMOds.
12.0013.0014.0014.50'''.1014.4014.6014.9016.0016.20
!:EmTest data for Series A, test A-1.
2020200720482054o
1797189319992~4
.~
500958096.309660
845089009400980098009750
2001>
179518962000
TEST A-I DATA
Gouge Length : 385 inch",5t,... ing Rom Effective Ate : 21:<.65 sq. ;".Tronlducer : ADX-38 S.,iol No. 208; GP<46F Se,iol No. 3929(est Datil 7 Feb,uo,y I 967Penonnel : H.R. Reut.. , R.E. Hunte" A.H. 5tuDbl
LooC Elang.ADX Hvd,aulic Gouge{~i~) ,p,i) (kiP1) (inches) Remarles
96 440 ~4 0.00 Appro. i_tell' I .5 i"ch.. oftlack .200 940 200 o 2 Stressing Jack installed on left.
I"'" ; ..;0 300 o 35401 1860 396 0.50515 2400 510 0.75605 2760 S87
I
0.90698 3240 689 1 05794 3700 787 1. 20892 4160 8S5 1.40992 4640 987 160
1091 5110 1~7 1.7511~1 5580 1187 1.901295 6050 1287 2.10\400 6570 1397 2.301502 7040 1497 2.501600 7500 1595 2.70 Ii70C 7990 1699 2.951792 9440 1795 3.401810 8510 1810 4001840 8720 1854 450
IIM5 tl700 1850 5.00 Installed 6" ,hi .....
0 0 0 4.65 T'ansfe"ed load to .hi.... and ,..e' jock1865 8710 1852 5.301895 9910 1895 6.001902 9140 19404 7.00
I 1958 - - 7.4\ Installed 2_1/2" Ihi.... - 8·1/2" 'otal.0 0 0 7.15 Transfe"ed load to sh;.... ond 'eset jack.
I 1940I
9100 1935 8.00
II )970
I 9200 1956 9.001978 I ?360 1990 10.002019 9<460 2012 11.00
•
TABLE 3.3-8:21
I WIRE FOR TEST A-I
Sou,ce: United States St..1Corporation iQ; Determined by .2% off..,et IHeat Number 87 a756 1'2' Determined by tatal SlTain under ICoil Number 56 load (elastic .. plastic) !
e, : 29.3 " Id'i@ Deten!Oined by plastic strain II ,_ini"9 afm rupture. i
ISample I Position of F ... I F., (1' , % Elon90tion INo. i laD. SaIIIple in Coil (kips) (leipt) I '2' J
1 -j W.tern F,ont (ht wire) 11.82 - 5.'0
LI 1 111.99 - 5.7711.85 - 6.8 5.0511.9. - 7.2 5.72
5 Ilack - 1'.90 - 7.2 5.306
~ - 11.77 - 7.1 5.257 - 11.92 - 6.9 5.658 Middle (l7Oth wi,e) 12.20
I
- - 5.209 12.32 - - 5.12
10 12.20 - - 5.2811 12.26 - - 5.5712 Durie.. 12.00 10.90 7.0 6.013 I 12.02
I
10.90 ~.1 5.714
~12.00 10.90 - 5.9
15 12.05 10.95 - 6.016 U.S.S. F,ont (1st wire) 12.00 - - -17 U.S.S. Back 12.00 - - -" (units) I 17 4
I7 15 !
X (kips) I 12.01. 10.89 6.900 SS~ I(J (lei,.) I .1.90 .0217 .35046 i .3022.., (%) i 1.2" .199 I 5.1" i 5.41 i
WIRE FOil nST ,10,-2 ISou,ce: United States Steel ~,ation I'" Oe_ined by .2% off-.et !
Heat Nulllber 87 a756 (2' 0_;,"" '" MMI ..~;, ' .... 1Coi I Number 63 I load (el=tic + pl..ti:)
E. : 29.3 • 10"
I II-PI~1 POIition of F ,. F .. 'I~ % elon""tion--i
No. Lab. Sam,ale i" C"il (lei,.) (1<i,.) '2'1 1 Durie.. F,ont 12.35 1i .25
!5.4
I2
I I l 12.20 II .25 4 83 12.30 II .25
I5 . .5
" Ilack 12.20 11.00 5.2 I5 ~ 12.20 11.00 5.56 I U.S.S. F,ont 12.20 - - I7 U.S.S. Ilac:k 12.30 - - 'In (unit'S) 7 5 5
IX (lei,.) 12.250
I11.150 5.280
q (kips) .0598 .1225 .2638v (%) .. 1098 5.00
TABLE 3.3-6: Test results and mean values of mechanical prop.erties for wire used for Series A, test A-l.
TABLE 3.3-7: Test results and mean values of mechanical properties for wire used in Series A, test A-2.
The load-elongation data for Series A, tests A·1 and A·2 is
plotted in Fig. 3.3-9. For clarity, only the resulting curve isshown without intermediate points. A theoretical curve for atendon having mechanical properties per ASTM A 421 minimums is superimposed.
.0623.10
.OS19.25
.0415.40
170 WI,. Tend,,", A•• 8.35 In."lan;'" of Tendon = 32' - I·
•. 385·
.0311.55
.027.70
SIfts'n. 'n ./In. ,01Elon; .• in. 3.85
The summary and analysis of Series A test results are tabulatedin Table 3.3-10. Following procedures established in prior WCSTechnical Reports, performance is rated by: 1) nominal efficiency - that is, performance of the tendon relative to theminimum guaranteed wire properties, and 2) actual efficiency"that is, performance of the tendon relative to actual wiremechanical properties. Both nominal and actual efficiencies areshown for both ultimate load capacity and ultimate elongation,using notations defined in Table 3.3-10. These efficiencies aretheoretical, for comparison purposes, and cannot be consideredan exact measure of performance of a multi-wire tendon forseveral val id reasons.
T!ST RESULTSFIG. 3.3-9: Load-Elongation curve of Series A, test A-1 and A·2 results, shown superimposed on the theorectical curve for a tendonhaving properties per ASTM: A421 specified minimums.
First, the mechanical properties of sample wires are determinedby tests on a 10 inch gauge length per requirements of ASTM:A 421. There is no valid correlation of performance based ona 10 inch gauge length to performance based on much longergauge lengths - 385 inches in Series A.
Second, a multi-wire tendon cannot be assumed to perform asthe sum of the individual wire performances due to individualdifferences in the wires. since it is obviously impossible for amulti-wire tendon to be any stronger than the sum of the individual wires, it follows that it must be weaker, since to be of
equal strength would be a coincidence. Therefore, it is theoretcally impossible to have actual efficiency ratios (tR p and tRE)greater than 1.0. It further follows that nominal efficiency
I No 3929
384 inches
212.65 Iq. ,n.AOX 38 5 I N 200 GP46F S
TEST A-2 DATA
TABLE 3.3-9: Test data for Series A, test A-2.
TrQ,,':.aucer erta a ; erlO
ITe~' Dote I 7 February 1967Penonnel H ~. Reuter, Q.E. Hunter, A.H. Stubbs
Lood Elong.
ADX Hyd 'au r, c Gou ge
I\;P') T",,) I, 10\ (;nche,) Remark,
298 a 50 Jade on we.1 end.504 065600 080 Reset elongation scat. at 1 .00 inch...702 3660 778 I 15804 3620 770 I 35904 4080 868 1.50
1003 4540 965 1 .671104 4990 1061 1851201 5430 1155 2.001301 5890 1253 2 201402 6360 1352 2.371503 6820 1450 2.551602 7260 1544 2.751700 7720 1642 2.971796 8190 1742 3.271848 3.751894 4. 10
0 0 0 375 Sel load off on 4" shims.1882 8820 1876 5.101900 8860 1884 6.001924 9030 1920 7.001950 9120 1939 8.00
7.85 Sel load off on 8" shims. Added 8" c.... ir514 800 piece. Down 10 minutes
1947 9130 1941 8.751938 9130 1941 9.001980 9130 1941 10.002002 9390 1997 10.90 1 wire f"iled (in wire)1996 9410 2005 12.002010 9470 2014 13.001980 9510 2022 13.802006 9530 2026 14.00
off .cole 9500 2020 14.2513.85 Sel lood off on 14" .hims.
9570 2035 15.009610 2043 16.009610 2043 16.25
0 0 15.80 Sel load off on 16" shi".. Moved r,,'" 109610 2043 16.60 Easl erd.9660 2054 17.00 Second wire f"iled (in wire)9710 I 2065 I m::ill Third cond four'" wir.. f"iled (in wire).
Test terminated.
IGouge Lengrh
; Stre~'j!ng Rom Effecti\lle Area
P'ort Serial N ....",berTesl Te.t
Eo.' 'NestNo. O,,'e
Com"" 'NQlo"'er I Nut
A·I 2-7-67 008 OC2
I003
A-2 2-17-67 008 002 00)
(vn il1)
(ki",)(kipS)
("'o)
• 3 a (kips)
- 3 a (kips)
Te.. Re'ulrs Go·.ge AAoh.. sis of 1.Jltrmote Force Resu I,., Anolv'5;s of Ult; .. ,:·~ E::::r'I otlon Rl!1 u lrs
Load (P;') elong (e;') L.,.;ti't Elong. P~", 5 P;';" 6' n R. • R. E; 9 e:' ;0 oil, • Rr
(ki",l (inche,)(ind·•• ) (%) (k ,,,,I (ki",) S (inches) (;"c:"·~s I 'il' 12
I 2004 I 1665 385 I 4 325 2002.8 2042.4 I 041 I 020 15 40 26 57 1 001 o 627
2 2065 2' 17 50 J8-' 2" 4.557 2002.9 2002 5 1 031 099'2 15 J6 20 n , 139 o 863
2 2 2 2
2074.5 17.075 4.441 1 036 1 006 1 '10 o 745
9.500 .425 116 0.005 0.014 o 029 o '18
458 2.489 2.612 483 I J92 2 613 15 839
2103.0 18.350 4.789 I 051 1.048 1 , 97 , 099
2046.0 15.800 4.093 I 021 o 964 1.023 o )9'
Noles: 'l' Refer 10 TA8Le 3. J-8
'2' Refer 10 TA8LE 3.3-9
'3' Refer 10 TA8LE 3.3-6
'4 Refe, 10 TA8Le 3.3-7
P," / p;""P," / P;':"nominal elongation of tendon:: r.ominal elongation =,f wire (E~) .. gauge length. E~ = 4.00~
theor.tical aChJai elongation of tendon:: acNal el:r'!garion of wire (E~') , gauge length
For A-I, e~' X (elon9",ion) = 6.9"'.tJ' Therefore E;' 0.069' 385 26.57 ;nc~...
For A-2, e~' = \' (eIOn9"lion) = 5.28%·~. rner.fore E;' = 0.0528 ' 384 = 2028 incn .
e;' / E;E;' / E;'
-f n R.
a I R.
'9' E;
® e;'
1!' n R,
ft I R.
170 p~ = 170 , 11.781
170 , P~' = 170 12.041
170 , 12.250
2002.8 kips
2042.4 kips for 'e" A-11'
2002.5 kips for 'es' A-2'4'
56-65TABLE 3.3-10: Summary and Analvsis of Series A Test Results.
22 Ur-i.:; fl:: - 1? /-S"2
: MEAI-l VAI.Ue. OP"TENSILE ST12E~GTH
ratios (nR p and nRe) can only be greater than 1.0 if the wireis actua..lly better than specified minimums. As it relates toultimate tendon elongation, General Atomic has taken this intoaccount by requiring an ultimate elongation of 3.5% for a 30foot gauge length, thus requiring that nRe ~ 0.875.
If the mechanical properties are determined for each coil ofwire in any given lot of material prior to selection (such as amill heat), the quantitative values of any property for all coilswill follow a normal distribution curve similar to that shown inFig. 3.3-10 for ultimate tensile strength. ASTM: A 421 requiresa minimum ultimate tensile strength of 240 ksi (or 11.78 k) for0.250 inch diameter. Theoretically, all wire shipped could havethis minimum tensile strength and no more. In actual practicehowever, this is impossible. In order to limit rejects, the steelmills must aim to produce a product higher than the minimums, as shown by the horizontal position of the vertical linerepresenting mean tensile value (X). Approximately all coils(99.7%) will have a tensile strength within the range of themean tensile value plus or minus three standard deviations(X ± 3 a), and therefore the variance of the product, as measured by a, determines- how much higher the aimed for value(X) must be over the specified minimum in order to limitrejects. To aim for a X which is too high is to risk rejects forother specified properties, e.g. coils having the highest tensilestrength may be rejected due to low elongations.
As can be seen by reference to Tables 3.3-6 and 7, the variance,as measured by the coefficient of variation (v), is quite smallfor tensiie strength, but is four to ten times greater for elongation.
SPE'C/l="feO MI~IMUM TE'!'JS\I.E
L..=~_X_-_3_a-__l"""'"'=_;t_""_3_c:r__J·.U1.rJMATE rE.NSILE. STRE.WGiH
FIG. 3.3-10: Frequency distribution of ultimate tensile strength for allcoils of a mill heat of 0.250 inch diameter ASTM: A4':'1 wire.
There is insufficient experimental data available to draw anyval id conclusions as to the theoretical true efficiency of the tendon, that is the relationship of the tendon actual failure load(or elongation) and the sum of the actual wire properties. SeriesA would indicate: 1) a relatively high true efficiency for tensileultimate (tRp = 0.992 to 1.020) with a small variance, and 2)a somewhat lower true efficiency for ultimate elongation (tRe
=0.627 to 0.863) with a large variance. Should th is hold truein all cases, then it could be expected that a 30 foot long testtendon fabricated from 170 wires having exactly minimumproperties (that is, 11.78 k UST and 4% elongation) could failat 1986.7 k and 2.5% elongation, but the confidence in theaccuracy of this expectation would be quite low.
From the above discussion, it is reasonable to conclude 30 footlong test tendons should exhibit efficiency ratios of nR p ~ 1.0for tensile and nRe ~ 0.875 for elongation. It must be expectedhowever that test tendons fabricated from wire having minimum properties would fall below these efficiency ratios. Thisshould be of no concern as the actua~ strength of all tendons,both test tendons and those used in the structure, will exhibitthe same frequency distribution as the wire itself.
Series A tests show that the two tendons tested exceed specification requirements for both ultimate load and elongation.They also contribute significant information on the behaviorof long multi-wire tendons loaded to ultimate, from whichmore exact criteria and code requirements can eventually bederived.
3.3.5 TEST SERIES BAND C - GENERAL
In general, Series B tests were conducted to determine web(honeycomb) shear ultimate both with split shims (Series B1)and without split shims (Series B2); and Series C tests wereconducted to determine shear ultimate load for the 6 inchdiameter thread, which couples the Washer to the Washer Nut,both with split shims (Series C1) and without split shims (SeriesC2). Specific details which apply to each of the four series (Bl,B2, C1 and C2), including discussion, objective, test procedure,test results and analysis, are presented separately for each seriesin succeeding sections.
In relation to the anchorage hardware components or assemblies, the term "outer face" is used to describe the surface onwhich the wire heads bear, that is, the face on which the loadis applied; and the term "inner face" is used to describe theopposite surface, that is, the face which has a reactive force inthe opposite direction to the applied load.
The interior well of the 4 million pound capacity test bed wasused to apply the test load as shown schematically in Fig.3.3-11 and by photos in Fig. 3.3-12 a) thru c). Three - 1000ton stressing rams were attached to the inside east end of thetest bed and were hydraulically interconnected to a stressingpower unit located on top of the bed. Ram force was transmitted thru a movable load block to the component being tested.Load reaction was provided by a fixed spacer block reactingagainst the inside west end of the bed.
Redundant determination of the applied test load is providedby means of: 1) a Martin-Decker, 12" dial, 0-10,000 psighydraulic gauge measuring to 20 psig subdivisions the oil pressure being applied equally (in parallel) to three identical rams
58-6623
and 2) by a Transducers Inc. Model GP-46F-10,000-7103 hydraulic transducer attached to one ram and reading to 50pound subdivisions on a Transducers Inc. Model ADX-38 Automatic Digital Indicator. Both the gauge and ADX-38 weremounted on the hydraulic control-power unit installed on topof the test bed. Both the hydraulic gauge and the transducerindicator were calibrated to the capacitY of a 1000 ton loadcell.
but no load cell even close to this capacity was available. However, failure load as determined by the mean of gauge determined load and transducer-indicator determined load is considered to be accurate to at least 1.0 k ± since: a) all rams areidentical, b) all rams are connected in parallel by equal lengthlines to the hydraulic pump, c) calibrations showed a linearrelationship, and d) there is close correlation between gaugeand transducer-indicator calibrations.
Applied test load as measured by the gauge is determined bymultiplying the gauge reading (corrected to the calibrationcurve) by the total effective area of the three rams (AR =3 x212.65 = 637.95 sq. in.). Applied test load as measured by thetransducer-indicator is determined by multiplying the indicatorreading (corrected to the calibration curve) by three. Calibration by means of an eight million pound capacity load cellinstalled in lieu of the test assembly would be more accurate
In order to determine the degree of uniformity throughout thesection of the heat-treated components, Composite WasherSerial No. 002 was sectioned after being tested to web shearfailure (Series B1, Test 1) and Rockwell C scale hardness wasmeasured at approximately 100 points across one face. Thecenter section of a Composite Washer was chosen as being themost critical for uniform heat treat results due to this compo-
..'.; ..
"~Si ~~O
Id·.TAHOAIIlO ,.'"J------ 11,Az''TMICIit eNO ~T.
~--- ~·•• "T"'C1C It---fo,.;---- 1&'· .. ~ "I'MIQC c.cu.A"...-----.l~~-- 41-. ~""'c::K eMC.I-.
---------- UHOIW.
..l~ .....,'.. . 1' ..... " . ' ... ",
.,....TA.HCloAIilO ~,.
20·•• .,..,""ell(. It'l-WMUAU .,./''7~*U---~~
4 MILLION
FIG. 3.3-11: Schematie drawing of Test Bed setup for Series Band C tests, showiflq general arrangement and general detail of test fixture.Actual detail of test fixture varies for each series and is shown separately for each :>pecific series.
58-6724
....\IIt'. ·...··_--rl··..,:.·,...'..........•...-fit ' .' .,~~t'.:,. ,
~~:' ~'j, t-~ , ... t
&:~'I'
.' .'- -
1;\,
FIG. 3.3-12: Test setup (a) for Series 8 and C tests showing 1,000-tonrams, movable load block, and fixed spacer block in well of test bed.Three rams and movable load block are shown enlarged in (c), withmovable load block, test specimen and fixed spacer block shown en·larged in (b) .
... c)
-,
A summary of data and results for all Series Band C tests isshown in Table 3.3-11. It can be seen that actual failure loadsaverage 0.4% higher than those predicted by calculation inSection 3.2. Th is extremely small error gives considerable confidence in the design and in the assumptions on which it wasbased. It can also be seen that the safety factor of 1.5 x min.guaranteed tt!ndon strength which was established as a pre- "-11-01 !'.Ie~ 1="AC,&:
liminary criteria for component design, is met for all tests Sec.TIO ~ j.\-j.\except Series C2. This is of no concern since the condition FIG. 3.3-13: Schematic drawing of section cut from Composite Washertested oy Series C2 does not exist in the structure contem- Serial No. 002 after having been loaded to web failure in test 81-1. Rc
hardness values were measured for approximately 100 points. Distribu·plated and, in any event, the reduction in preliminary S. F. is tion of material hardress throughout the cross section is as shown bysmall. 25 the schematic iso-hardness lines. U/-'L);; rt: - 1
nent having the greatest dimensions and mass. The location ofthe section tested and iso·hardness Iines are shown in Fig. 3.3-13.Hardness distribution was approximately as expected. Thelowest hardness of Rc 30 occurs in the center of mass of theannulus outside the critical shear path at a location wherestresses are low and ductility is of more importance thanstrength. Hardness along the shear path shows a mean value ofRC 38.2 for the same component where predicted ultimatewas based on a value of RC 40.5 as measured on the outer face.It is interesting to note that the ratio of average measured hardness along the shear path to measured hardness on the outerface (38.2 7 40.5 = 0.943) is quite close to the ratio of predicted ultimate to actual ultimate (2509.7 -7- 2613 =0.9605),indicating that variation in Fsu , as measured by hardness, accounts for most of the small (3.9%) error in predicted ultimate.This is an example of the type of variable whic.n is conven·iently handled by use of a repture factor (k r ).
i3-68
• ..' .,.. ~.... 1
:'; ,:. _..t / r" .~.:.:.. .. ~-'.
Te.t Component\ (wi th Serio I No,) Fa, I~re Load Error Equl" Safety !DesignatIon Description Test \Nasher Compo Split P'edicted Actual I (Note I) Tendon Factor
ISeries Na. Date 'Nasher Nut Wa.her Sh,ms (k ipsl (j"ps) = (O~) UTS (Note 2) (Note 3) ~emorks
BI-I 1 Web Shear - With Shim. 5-1-67 002 y~s 2509 7 2613 - 4 0 3152 1 574
BI-2 2 -r- 5-1 -67 - - 001 Yes 25n5 2682 - 3.9 3236 1 616
BI-3 3 5-1-67 - - 004 Yes 2564.0 2586 - 0 9 3120 1 558
82-1 5 Web Shear - Without Shims 5-1-67 - - 009 No 2654 4 2541 .. 4.5 3~5 J .530
82-2 6 I 5-1-67 - - 005 No 2600.2 2518 .. 3.3 3038 1 517
Cl-1 4 6" Thread Shear - With Shims 5-1-67 014 008 Yes 3430.5 3378 .. I 6 3378 1.687
CI-2 10 ~ 5-3-67 011 002 Y~
I
3483.2 3561 - 2.2 3561 1.778
C2-1 7 6" Thread Shear - W,thaut Shims 5-2-67 010 005 - No 2903.5 2922 - 0.6 2922 I 459
C2-2 8 -----r- 5-2-67 012 003 - Na 2817.2 2930 - 3 8 2930 1 463
C2-3 9 5-2-67 013 001 No 2741 0 2745 - 0.1 2745 1 371
Not~: I Error ~ (Predicted Load - Acrual Load) - Actual Load; Therefore, minus error means component is acrually stronger tnan preciicted.
2. Equivalent Tendon Ultimate Load ~ Acrual Test Load at failure R, ; ( R, ~ o 829 for Series 8l
3. Safety Fac tor Equiv. Tendon Ult. - Minimum guaranteed tendon :..'/timote. S. F ~ EQu,valent Tendon Ulhmare "'" 2002.8
TABLE 3.3-11: Series B1, B2, C1 and C2 - Summary of Data and Results.
3.3.6 TEST SERIES B1 - WEB SHEAR WITH SHIMS
Web shear is a critical failure mode for both the CompositeWasher and the comparable assembly of Washer-Washer Nut.In addition to shear along the critical shear path, low orderflexural stresses exist due to bending, resulting in combinedshear and flexural tension on the inner face of the washer. Theeffect of flexural tension will be less for the assembly of WasherWasher Nut as tension cannot be transmitted in the radialdirection through the 6" thread connecting the components,resulting in a shorter lever arm as compared to the single pieceComposite Washer. Therefore the Composite Washer was selected for testing as representing the most critical condition.
From the calculations (Section 3.2.7) and analysis, there is noreason to assume any difference in ultimate strength of the webshear failure mode for assemblies either with or without splitshims. The principal reasons for testing three assemblies With.split shims in Series 81 were to: 1) verify the above assumptionby comparison with results of tests conducted without splitshims (Series 82), 2) establish a minimum ultimate strengthfor the bearing failure mode at the Split Shim - CompositeWasher interface as analized in Section 3.2.3, and 3) assist inanalysis of the effect of bearing on the ultimate strength of the6" thread tested with split shims (Series Cl I.
The test fixture for Series 81 tests is shown schematically inFig. 3.3-14. The double bearing plates are used to transfershear around the oversize (10 inch diameter) hole in the spacer
FIG. 3.3-14: Fixture for Series B1 testS. Components being tested areshown shaded. Mandrel conforms to shape illustrated in Fig. 3.3-11 forPath 1 shear failure mode.
block and are not considered as part of the components beingtested except for the Bearing Plate - Split Shim Interface (ref.Section 3.2.2), which is an accurate duplication of actual conditions. After application of an approximate 400 kip preloadto seat all parts of the loading train, the load is reduced to 1.0kips and any gap existing between the mandrel and Washer ismeasured and recorded as an indication of degree of eccentricity of applied load application.
Test results for the three tests of Series 81 are shown in Figs.3.3-15 thru 17, and are summarized and analyzed in Table3.3-12 which shows the method of calculating values indicated.The low coefficient of variation (v) for actual test results (P")indicated consistency in both components and test procedures.The small error, -2.93% average, indicates that predicted loads(P'~) are quite accurate but conservative since actual testloads (P") are higher in all cases. This is probably dueto the fact that predicted loads are based on nominal steelshear area (A~ = 22.61 sq. in.) while the actual area (A'~) maybe slightly higher. This is probably why the Rupture Factor(average k r = 0.971) is less than 1.0. Such a small variancebetween predicted and actual values does not indicate anychange in kr = 1.0 for use in identical calculations of similarmechanisms designed in the future.
I<0.=.0.... T......,..... Acrual Error Revised IMin. Equiv. Safety IT",t UTS (P;l I UTS (P;l UTS (P") Note rJ1 k. Tendon UTS Factor IO",ig. ([' (kips) f2\ (kips) (kips) (%) Note 4 1'S' (kips) Note t6"!81-1 I 2509.7 2509.7
I
2613 - 4.0 0.960 3095.2 1.55
181-2
I2577 .5 2577 .5 2682 - 3.9 0.961 3093.3 1.54
81-3 2564.0 2564.0 2586 - 0.9 0.991 2998.4 1.50 II
" I 3 3 3 3 3 3 3I
X I 2550.4 2550.4 2627 ·2.93 0.971 3~2.3 i .53a
I29.30 29 .30 40.42 1.404 .014 45.19 .022
1. 15 1.15 1.54 49.0 1.48 1.48 141X : 3~ 2638.3 2638.3 2748.3 + 1.39 1.014 3197.9 1.59X • 3 i 2462.5 2462.5 2505.7 - 7.25 0.9'28 29'26.7 1.47
Notes,
,. Caku lated UTS (P;) ~ c y A; without "se of Rupru.. Fac_ (k,), ,u
2. P,edicted UTS (P;) : Polk, ; P; : ( F", x A,)/k, ; k. : 1.03. Error : (P, - P") x 100 "'" p" ~rcent.
4. Ilevised Ilupru,e Foetor: k, : Po/P"5. Mini"""", Equivalent Tendon UTS: p" corrected to ",'nimum F,u
P, (",in.) = (P"/R.) x (Min. F,u @ Re 401 Ftu of $peci",,,")
For failure olong shear Path 1, R. " 0.829
Fo' the specified "'ini_ Re : 40, F,u = 109 k.i
6. Safety Factor, SF : P: (",in.VP"l"l " p, (",in. V 2002.8
TABLE 3.3-12: Summary Analysis of Series B1 Test Results
58-69 26 / /8~·::
ULTIMATE LOA.. rESTS - PROTOTYPE ANCHORAGl: _OMPONENTS ULTIMATe LOAU ,ESTS - PROTOTYPE ANCHORAGE ...OMPONENTS
114.
HARDNESSSCALE READING
Dcl
SERIAl.NUMBER
TEST.--Z ----TEST DATE / 1Vf.-., 1..7
COMPONENT NAME_ _ Composi te Hasher.. Split-ShiJlll ... __ ...__•..
SERIES a I - 2.
DESCRIPTION Web Shear - W, rll S'''''''''S
ICOMPONENT DATA
I-=-~H~A::rRO;,;N:.:.E~S::S~___::_I UTS I'f'SCALE READING \klij"
__. SERIALNUMBER
TEST_,;,,' TEST DATE I Wf,...,. (.7
SplitShi...
CO"'PO'it. Washer
COMPONENT NAME
SlIlES a I -I
DESCRIPTION _..:W.:.:.:::b~S::.;"-:;:;._-.-;w'.;.;.' r;.;;.N.-;s';,;""='''''..;,:.S---------------1COMPONENT DATA
:'ffOllft 1001.3.2-2 ~.
PATH 1 PATH 222.61 2'O":5r_0.829 .0:7821.0 1.0
~"-Fig.3.2-6 __.-_ _<_. .----_•. __ • _.
,.DIeTED FA/WIlE LOAD ---- - -----. • -..
~-_: P: • F,\: Ai .~ J ::::..:: F,. <•. • /14 /.1'%.101 •~ lei", .- I".. ~
P' • equi....lent tllftdon load -. ~. :-
• !i. •~. .3101.2- Iti", Ie•ruT PRoa~URE ". 8'L'1 ----
Preload to approximately 400 lei"'l "tum to ze..,Meoaure gop be_ components and punch;Effeeri". RaM ..... <A.) - 3 x 212.65 • 637.95.sq. in.
(!:IF_Fig.3.2-6 .••. _., . __• :--_ __. .- ..NDICTED FAILUR£ LOAD __ . --- ...- •.. : :..,.._.w-'" - ...---: P,' •~ .-: _. : Fn ··' ··f_T"'3.2~2 ~-..
Ie. ! i . PATH 1 ; PATH 2• 1/1 X :.~.t..1 • '1$".1-.7 lei", ".. • 22.61 2'O":5r
P' .. eqUi~l:'ttllftd""-IOCId--- ~.!- 0.829 0:782
• !i. .. !.!::.!:.L • .1."2.7.4- Iti", Ie." 1.0 1.0R. " .•11 ---- ,
TEST PROCEDUREPreload to approximately 400 Iei"'l "tum to z_,Mealure gap be_ COI'IlpCIIMftts and punch;mecti".RaMAreo(A.) - 3 X 212.65· 637.95 sq. in.
....... <D ~-.lic T., Gauge and ~-.lic T~ pM ADX 01.'" ......gi". ........,_,of the._ I0.Il.
~. L-' - T.., Gwge i'" lC 0.63'! CD L-' -. ADX-3I 1'" lC 3,
.#.• 'loin.
REMARKS
1711 6,.:> Sf!"
:.4.5' >=,... 'n~
~-.lIc T., Gauge and ~"",lIcT~ .... ADX 01.'" ....."gi".~_-.of the _ .....
~. L-j • T., Gwge I llne x 0.63'<D 1.-" - ADX-3I 1'" lC 3,
P" •
~77o
'-I"to ~.. 11f"
Inle lded Actu I
pOI •
READING LOAOI'2" ADX-38 LOAD@(pai) O<i",) . READING O<i",)
....... <D
LOAD DATA
TEST GAUGE''D TRANSDUCE~
Preload. Gap • 0.oZ4in.
REMARKS
LOAD DATATESi' GAUGE'l) TRANSOUCUrf'
READING LOADf2' ADX-38 LOAD@(pIi) (ki",) READING (lei",)
Inte lCied Aetu I4,P.. .3.. " I"", 'It" 'Z.IIS'
/1"" 11/1- 4.... 31(' Ill'$"
'%&'\ .. 18.(., t:. .... .>1!" 17'S-
'37". oz.,,' ( ..4 711 7317
3,4. 7.5'14- 83& IHt" 'Z~."
4-1." 1.4/' 87~ 87. 7..1 ..
FIG: 3.3-15: Test 61·1 Data FIG. 3.3-16: Test 61·2 Data
ULTIMATE LO~ ,ESTS - PROTOTYPE ANCHORAGI: _OMPONENTS
SERIES aI - ~ TEST ...;:;..3 TEST DATE I MAY (., 7
DESCRIPTION _,:,W.;::.b.::::Shear=..,;-;;...:;'N'.;,:'.;.i';;...:.~/'~",";.;.r:... --;
COMPONENT DATA
COMPONENT NAME
__. SERIAl.NUMIU
HARDNESSSCALE READING
_. Compos; te Washer.. _ Split-ShiJlll _ ..
1/3.4
LOAD DATATEST GAUGE'l) TRANSDUCER'1
READING LOAoI2' ADX-38 LOAo@(pai) 0<1",) . READING (ki",) REMARKS
lnte ~ed Aetu I "'-load. Ga!J - 0 ...11 In.
pt••
.... .
611. oz... 1"5'
11''1 4 •• 11S"1711 '- •• S1~
2311 8_ 11r
1/65
....... (!) ~..,lIc T., Gauee and ~_lIcT~ .... ADX Dt._.......,gi... ,.."..,__, of the _ ....
~. L-' • T., c;.,ge 1'" lC 0.631<D 1.-" -. ADX-3I 1'" lC 3·
FIG. 3.3-17: Test 61·3 Data
56-7027 u ~-' UAi£: - i
58-71
The test results do not prove that Shear Path 1 is more critical
than Shear Path 2, in contradiction to predictions based onanalysis, since the mandrel used applied load to Shear Path 1and therefore forced failure along this path. in fact, examination of the Composite Washers after failure indicates that shearfailure was trying to occur along Shear Path 2 in spite of thefact that the mandrel applied the test load to Shear Path 1. Inseveral instances failure started along Shear Path 1 at the outerface of the Composite Washer (directly under the mandrel),but ended along Shear Path 2 at the inner face of the washer.Reference to Section 3.2.7 shows that minimum equivalenttendon UTS for failure along Shear Path 2 should be 0.964times that along Shear Path 1. Since the analysis of Section3.2.7 and the examination of components after failure bothindicate that Shear Path 2 is critical, the average minimumequivalent tendon UTS of 3062.3 kips should be reduced to:
Revised P;' (min.) =0.964 x 3062.3 =2950.6
Since the value of standard deviation is not effected by thiscorrection, it follows that the lowest equivalent tendon ultimatewould be Revised P;' (min.) - 3 a = 2950.6 -3 x 45.19 =2815.0 kips, thus giving a revised S.F. = 1.41. This correctionis on the conservative side since the actual failure mode is probably along a composite of both shear paths.
FIG. 3.3-18: Outer face of Composite Washer and Split Shims oftest B1-3 after being loaded to ultimate. Note that shear failure isalong Path 1 only. Photos here and in Fig. 3.3-19 are typical for alltests in Series 81.
.-.. .. ~ j~.'~
The final acceptance criteria established in Section 3.1.2 saysthat the proof test load equal to minimum guaranteed tendonUTS must be 90% of the yield point of the weakest failuremode predicted from statistical analysis of test results. Thereis no well defined shear yield point and, in fact. shear yieldand shear ultimate probably conicide, so we may conservativelyassume FSY = .9 Fsu . Therefore, final acceptance criteria maybe expressed as:
0.9 (X, 30) x~ ~ PPT =P'170 =2002.8 kipsFsu
- 3 ::;" 2002.8 ::;" 24726 k'X - a? 0.90 x 0.90 ? • IpS
The revised Pi- (min.) of 2815.0 is 1.14 times greater than the2472.6 kips required for acceptance of test results, indicatingthat the web shear failure with split shims exceeds requirements.This series also shows that the bearing at the Split Shim Bearing Plate Interface and at the Split Shim-Composite WasherInterface are not critical failure modes as both sustained loadsas high as 2682 kips without failure.
Figs. 3.3-18 and 19 are photos of the outer and inner facesrespectively of both Composite Washer and Split Shims afterbeing loaded to failure in test B1-3. They are typical for all testsof Series B1.
FIG. 3.3-19: Innerface of Composite Washer and Split Shims of test81·2 after being loaded to ultimate. Note that shear failure is alongboth Paths 1 and 2.
28
ULTIMATE LOAD TESTS - PROTOTYPE ANCHOI:AGE COMPONENTS
FIG. 3.3-21: Test 82-1 Data
DESCRIPTION Web Sh_ - Iv' / T" .. v r .<;""h Nt S
liS.•
UTS'T'(lui)~ALf READING
HARDNESS
Z... 41. . .,
SERIALNUMBER
TEST.-;:6;;... reST DATE 1 MAY (,,7
C_DOti te Washe,
COMPONENT NM'i
~ ..
SERIES 8'1.. - '!.
COMPONENT DATA
ULTIMATE LOAD TESTS - PROTOTYPE ANCHOIlAGE COMPONENTS
[SEIUES 8 to - I TEST S reST DATE /MAyr..1
!DESCRIPTION Web Shear- k,;lITJ-ldvr S~/""f
jCOMPONENT DATA
I- . ._. SERIAL HARDNESS UTS'T'
COMPONENT NAME NUMBER SCAlf READING (leai)_. Compo.it. Wash., atl#f 12, 41.." 1174-
- -_ ..
(!) F_ Fill. 3.2-0 -_._-- __0_______ • __ _.PIlfDICTED FAILUIlf LOAD ._-- - -_.- ___ ._-.___.w~,_. -..-- -- F,u X Ai .. _~...:: Fu ' -frOrrt Tobie 3.2-2
...-. Pi • -k-.- --- -- PATH 1 PATH 2
... 117.4 x 1.1..(,/ • .3.::.!.!± I< ipl ~ . E'6'l 2O:'S5P' .. eqvivalent tendon load - -.~' -. 0.829 .0:782
. .. !:i..~. $1.,,/.1 kipl k. . 1.0 1.0
IresT PROCE;URf ". 8'Z.1 ----P..load to approxima..ly 400 kips; Retum to zero;M.asure gap betwe... campenento and p'Jnch;I Eflecti ... llam Ar_ (A.) • 3 x 212.65 • 637.95 tq. in.
'LOAi) DATA
TEST GAUGE'D TRANSDUCERf)'I
READING LOAD(j'I i ADX-38 LOAO@(pii) (leips) READING (kips) REMARKS
Int"~ed Actudl Preload. Gap • C. "1(. in .
.,4" "'''0 """I~~' S$~
(Pi"" 1/87 4 •• :1f> /ISS
'Z 8 ... 1713<:- t;". I ~-'J5' 178~
:173" 1.3eo 8"" 71S' 'l. ~ e S'
I - - 8,t 847 'Z~4-( FAI..vn.1i - N. 6.", ..Ii 1Ze.."w6
I7if K,#:IJ . fA/CAll. rJlll.v 'Wec
I A••..,. P4r»1 i
IP" . C1.~4-l)
I P" . -zs41 .;.. o. 8't1 .1" 'SO G.,nrl. 71:",~_ l,/.. rtM.Te
Net.t(i) Hydraulic T.t Gauge and Hydroulic TI'ONducer plw ADX Digital ""'t
Igiw redundant _,_t of rite _ load.
I ~. I..oaI' - T.t Gauge R.eading X 0.638
! ~ I..oaI' . -. ADX-38 R.eadinl II 3,
3.3.7 TEST SERIES B2 - WEB SHEAR WITHOUT SHIMS
The Composite Washer without split shims could only be usedon a "fixed end", that is a non-stressed end of a tendon. However, even for a tendon which will only be stressed from oneend, there are advantages to using split shims at both ends. Thesplit shims distribute the force from the washer over a greaterarea of the bearing plate, thus reducing the flexural momentarm and stiffen the bearing plate, both of which permit use ofa thinner bearing plate than would be allowable without splitshims. Using split shims at both ends of a tendon stressed fromonly one end allows both bearing plates to be of the samethickness and further provides a convenient method of takingup slack in the tendon prior to stressing.
The purpose of the two tests in Series 82 was primarily to provide additional test data on web shear strength and secondarilyto determine if the presence of split shims has a significanteffect on web shear failure.
The test setup is shown schematically in Fig. 3.3-20. Testprocedures were comparable to those used in Series 81. Datafor each test is shown in Figs. 3.3-21 and 22 and is summarizedand analized in Table 3.3-13.
Preload. Gap • iI. ,"1;n.
178~
Aclv I
4•• 1.1"",'I.•• S1S'
. .__ . ~.w-.._
-_. F,.' "frorrt Table J.2-2 ..-:_.~.. _. I PATH 1 PA.TH 2 --
~ _. E'6'l 2O:'S5. - ~.. 0.829 0'.782
Ie. • 1.0 1.0
In tei.ded
1187
1'/86
,.... iD Hydroulic T.t Gauge and HyoIroulicT~ plue ADX Digital ""'tgiw~t_.-t of rite _ '--.
~. I..oaI' - T.t Gauge inll II 0.631
~ I..oaI' -. ADX-3I 1"11 X 3,
I .)74.
(!):r:.-Fig.3.2-6 __. .• . __•
PIlfDICTED fAILURE LOAD
-.-_~ 1'; • F•• • A;k•
• -- .. II~ ~ 2't.'-1
P' .. equi""lent tendon load
. • !:i. .. ~. 3/3'.~ kipsI p..... 8-:''' ----iTEST PROCEDUREI Preload to opPrO"imately 400 kips; Retum to zero,
I Meaaure gap belW_ COlIlflO"Mti and punch;mecti... RantArea(A.)·3 )( 212.65 • 631.95tq.ln.
ILOAD DATA
1 TEST GAUGE'I)! TRANSDUCERtf'IrREADING LOADI'2'! AOX-38 i.OAO@(pai) O<;pI)! READING (kipl) REMARKS
I
Colculot. Pr.aict.a AcNaI Errot "-ised Min. Equiv. SafetyT.t UTS (P~) UTS (P;) UTS (P") No..~ k. Tendon UTS Factoro.i,. rf' (kipl) t1' (leipl) (leipl) !'llo) No.. f4\ 's' (kipl) No.. '6"&2-1 265..... 26S..... 25..1 + ".5 I 1.045 2845.8 1l.4282-2 2600.2 2600.2 2518 + 3.3 1,(l33 2878.9 ,1.44
ft 2 2 2 2 2 2 I 2X 2627.3 2627.3 2529.S + 3.9 1.039 2862." 11.43
a 27.10 27.10 11.5 0.60 0.006 16.55 0.01
v 1.03 1.03 O.~ 15.38 0.58 0.58 0.70
X + 3a 2708.6 2708.6 2564.0 5.70 1.057 2912.0 1.-46
X - 3 a 2546.0 2546.0 2"95.0 2.10 1.021 221'2.7 1.40
INot.:
1. Cclevle" UTS (~) .. F.. x A; witnout uM of ~"ture ~tor (k,)
2. Pr.lct. UTS (Pi> • Pelle.; p; .. (F", x Ai)/Ie.; k, a 1.0
3. Error .. (P~ - P") x 100 + P" (p.rCMt)
... "-ised ~pture foetor: k. • pC! p"
S. Minimum EqvivalMt Tendon UTS: P" c:orrect.a to mini_ F...
,.~ (min.) .. (p"/~) x (min. F", @ Rc 4WFN of Speci..... )
Fo, foi Iv,e Olonlll,,"' Po"" I, ~ • 0.829
TA8lE 3.3-13:'-·Summarv Analysis of Series 82 Test Results.
FIG. 3.3-20: Test setup for the two tests in Series 82.
58-72FIG. 3.3-22: Test 82-2 Data
291j\''L:'~ i t: - 1.
i" /8':::'
- .. I , ••-. I •.. .~. .' : ,:;. ~~ :~.
ULTIMATE LOAO TESTS - PROTOTYPE ANCHORAGE COMPONENTS
COMPONENT DATA
FIG. 3.3-24: Test C2-1 Data
OESCRIPTION 6" 0.0. Th",od - ../,r,,~w,..
TEST .....;7 TEST OATE -z MAy:'7SERIES C ~_ - I
ULTIMATE LOAO TESTS - PROTOTYPE ANCHORAGE COMPONENTS 1
SERIES C"1. - 1- TEST 8 TEST DATE '2. MAY"7 iOeSCRIPTION 6" 0.0. Thr_- "v"TI4 .. ..,r S,,';'N1S \
COMPONENT DATAI
SERIAL HARDNESS I UTS rf'COMPONENT NAME
\NUMIlER SCALE I READING-j (lui)
Wash., (Solid) 011- i2 £. I 4'~. S 1,'1/1. tljWash., Nvl - -- " .. 3 IZ I 4,.S J/~...
~ . -- T I([I From Fig. 3.2-<» - - ._. - .- where: ImOICTEO F.AILURi LOAW --- -- _.- .. - ..., • 27.92 oq. I".
1
P: • F.. x ...,(.!.!.!.:.!.- "~ki,. k. .. 1.1-k-r-" 25.38 F.., • 25.38
F,. r""" :robl. 3.2-2'';'. ~ x A.. '" 8.79 F... 8.79 x -- " -6-
A... 3.42 oq. in.p' • p; + p~" • ~ki,.. F_," 2.57 F.. (J~i... )
F.... from FIg. 3.2-{)
TEST PROCEDUREPr.laod 10 appro.i..... ,.ly 400 Ieipo; Retum to zero; IMeature gap betw.... co"""",..." ond PU"cft; IEUnli". Ilam A,eo (A.) .. 3 x 212.65 • 637.95 ",. I". I
I.OAD OATA iTEST GAUGE'Tl TRAN SDUCE R'I' 1
READING LOAOrf' ADX-38 I LOADQ) I(pai) (kips) READING (kips) REMARKS
I" .",jed Actu I P,.lood. Gap .. in.
~(;D ~/'2. 1-;:01. /17 5'~1
Ise .. 1/91 4", 3'" 1/ 88
'Z6 toO 171, ~.D S,~ 178S'37 f>.. 'Z'3'1,. e... 71S- ? 385"
J 3"" "1.78'1. 93, 9:S" Z77~
4-<:. .... 'Z.'3S" 'leo 1,S "Z''1 s' H''',,/z'1!! - 7;'/l.t:A~ .f"'~AIZ.
p" = (':.a~o,\ !J,I!!/lJltio# a' /:;A4JdJ6 I 4)~---NIt", CD Hydraulic T.t Gauge and Hyd..... lic Tronociucer pi... AOX Oi;'tal R.adaut Igi_ redurtdaftt _,_, of It.. _ I...
I<6' Load • T.t Gauge ll.eading )( 0.638
® Load • AOX-38 lleaIii"9 )( 3
I SERIAL T HARDNESS ! UTS'1' ICOMPONENT NAME I NUMBER j SCALE I READING i ('<Ii)
'Nrnner (Solid) I "" '" I :2<. i 4:. " I //:"
Wosner Nut _... I I'"~ S- 1/2 I 41.7 ( 4.4-')I I r I
([I From Fig. 3.2-{) - - whe,.:
PREDICTED F.AILURE LOAO - A, .. 27.92 oq. ;".
P: .. F•• ".'r ..., " 25.38 F.., .. 25.38 x 114.4 .. ~.(kips kr " 1 I
-- F•• f",m Tabl. 3.2-2P-' ,. F... x A'r '" 8.79 Ft•• 8.79 x .. -e-
A.... 3.42 oq. i".--~leipsP' . p; + p-" .
F.... 2.57 F•• (.~i ... )
F.... f""" Fig. 3.2-<»
TEST PROCEDUREPr.load 10 app,o.imal.ly 400 Ieips; Retum to zero:Mecnu,. gap betw.... com"""..." and puno:h;Eff.o:li". Ram Areo (A.) • 3 x 212.65 • 637.95 oq. I" •
LOAD DATA
TEST GAUGE')' TRANSDUCER'I'
READING LOAOI2' AOX-38 LOAD(i) i(pai) (kips) READING (kips) REMARKS
In ended Aclu I Pr.load. Gap . in •
"l80 ::'-:,$' 1.0. 11$' ':65
/8 (,0 1187 4•• 1,$' 1 I €o S"
'Z.SDQ 178<. ..... ':15 1785"
..!74o '1.:08& 9#_ 71S- '1."3e~
4-140 '2'-4-1 1:10 '!1~ 27"154 ...... 'Z.13~ 17$' "'7.. 'Z. 11" ~;tft4Un.~ - r,;.4.eA~ j"HCJlUZ.
P" " h"l'l.'t.) 4 ....enAi6. ..... ~",,"'6 I .JI(
Not.. CD Hydraulic T.t Gauge and Hyd..... llc T....,..;ucel' pM AOX Digita' R.adautgive rwdundant __t of It.. 10_ I...
~ Load • T.t Gauge ll.eading X 0.638
® Load • ADX·38 ll.eading X 3
The test setup is shown schematically in Fig. 3.3-23, and testprocedures were similar to those described for Series 81.
As shown in Table 3.3-13, the mlntmum equivalent tendonultimate which would be expected from the statistical analysisof test results would be 2812.7. For reasons set forth in Section3.3.6, this value should be reduced to give: PT(min.) = 0.964 x2812.7 = 2711.4 kips. This is 1.10 times greater than the minimum strength of 2472.6 required by the basic acceptancecriteria.
By comparing the values of X for PT (min.) as given for Series81 and 82, we can see that the use of split shims gives a 7%increase in equivalent ultimate strength, contrary to pre-testexpectations_ Comparision of Fig. 3.3-20 to 3.3-14 shows that,without shims, the moment arm is greater resulting in higherflexural stress which would reduce the ultimate load of thewasher without shims due to the effect of combined shear andtension stresses. The components after being tested to ultimate were the same as shown in Fig. 3.3-18 and 19.
FIG. 3.3-23: Test setup for the three tests in Series C2.
3.3.8 TEST SERIES C2· 6 INCH THREAD WITHOUT SHIMS
Series C2 is reported out of sequence, that is before Series C1,in order that C2 results and analysis may be used in analizingSeries C1. For the same reasons discussed in Section 3.3.7. theassembly of a Washer and Washer Nut would normally be usedin conjunction with split shims.
Test data for each of the three Series C2 tests are shownseparately in Figs. 3.3-24 through 26. Summary and analysisof test results is contained in Table 3.3-14 which also showsthe method used to calculate tabulated values.
The primary objective of Series C2 tests is to determine theultimate shear capacity of the 6" 0.0. threads (P~) isolated
• from the effect of additional load capacity resulting from bearing on the split shims (Pbr ). The secondary objective is toprovide relevant data for condition where it might be advantageous to use a Washer-Washer Nut assembly without splitshims on the fixed (non-stressing) end of a tendon.
58-73 FIG. 3.3-25: Test C2-2 Data30
- -ULTIMATE LOAD TESTS - PROTOTYPE ANCHORAGE COMPONENTS
SERIES C~-3 TEST ~ TEST DATE '2""4"('"
DESCRIPTION 6" 0.0. Thread - "/irNo",r S;.I"MS
COMPONENT DATA
SERIAL HARDNESS UTStf'COMPONENT NAME
INUMBER SCALE READING (kll)
Wa~her (Solid) C/J 2 L J.,. " (loti."WOlher Nul -- ~I 2 .. 4 ... S- 11/. Q
<!' From Fig. 3.2-6 - - _.. ~ where:
PREDICTED FAILURE LOAD .. - Ai • 27. 92 Iq. in.
p~ aFn X A,
~.~I,. Ie, .. 1.1-le-,-" 25.38 F.., .. 25.38 )(Flu from Tahl. 3.2-2p;, • F... X A~ • 8.79 F••• 8.79 X . -8-A". 3.42 sq. in.-- --
P' • P; .. Po, • ~lel,.. F.... 2.57 F.. (llii...)
F.. • from Fig. 3.2-6
TEST PROCEDUREPr.load to approximately 400 leips; ReIVm to z.ro;Measure gop between co",ponents and punch;Effective Ram Area (A.) • 3 )( 212.65 • 637.95 .... in.
J
LOAD DATA
TEST GAUGE'D TRANSDUCER~
READING LOADI'2' ADX-38 LOAO@(pai) Geips) READING (kips) REMARKS
In ended Ac:1v I Preload. Gap • in.
.11..0 ~/2. '2 .... /<J!' 585'
/89" II.,,, 4.1.- 3"7 t //1/
'2.800 178t.. ~OD .n!' 178S"
J7fo 'Z. 3'11- & .. 7"1~ '%3115
- - ""to "?If' . "Z.74!' FAI"~IZ. - 7i;n.CA~ fNliln.
AlII 604,,*'''' /ZCA~/u6
P" .. 1('2.745")
NoteIt CD Hydraulic r.t Gauge and Hydraulic TI'CINducer pM ADX DlgI.., Readoutgi.,. Ndundant _,-, of the _. load.
It!t Load • T.t Gauge Readin, X 0.038
<D Load • AOX-38 Readi", X 3·
FIG. 3.3-26: Test C2-3 Data
IColculoted Predicted Actuol Error Revi.ed Min. Equiv. Safety
Test UTS (P;_.) UTS (pn LiTS (P") Notet3' !C, UTS ( P; min) Factar
I Desig. (J' (kips) • (2' (kips) (Ie ips) ('!o) NoMt4' 1(5') llciOiI Note l6'C2-1 3193.8 2903.5 2922 - 0.6 1.09 I 2784.1 1.39
C2-2 3098.9 2817.2 2930 - 3.8 1.06 2877.2 1.44
C2-3 3015.1 2741.0 2745 - 0.1 1.10 2770.4 1.38
" 3 3 3 3 3 3 3
X 3102.6 2820.6 21165 .7 - 1.5 1.08 2810.6 1.",0
a 73.00 66.38 85.39 1.64 .017 47.45 .026
v 2.35 :.35 2.98 109.3 l.S7 1.69 1.87
X .. 30 3321.6 3019.7 3121.8 - 6.42 1.13 I 2952.9 1.48i - 30 2883.6 2621 .• 2609.5 .. 3.42 1.03 I 2668.2 1.32
Not.:I. Calculated Shear UTS (P;" e) .. F.u (acIVal) X Ai without us. of Sh_ AupIVr.
Foctor (Ie,_.). Fl. (octual) is the ultimote shear .trength baled Oft ClCtval valueof R.. A;" nominal shear orea • 27. 92 sq. in.
2. Predict-ed Shear UTS (I';) .. F.u (actual) x Ai/k,_.. Ie,_.· 1.1 fI'Ol'I palt testln, Iof similar mechani_.
3. Error.. (Pi - P")I P". Ne9ative error indicotes COf'llPO'M"t il .tronger than jpredicted.
4. Revi.ed~ AupIVre Factar (Ie,_.) .. p,_./p"S. Minimu", Equivalent UTS (P;min.)i. P" ,..,i.ed 10 FlU mi.,. PHlllln.). pt. )( F•• (,...·
IF.u (ClCtual) • p" x 100/Fou (octual). I6. Safety Fact« (S.F.) .. P; (lIIin.V",in. guaronteed tendon U.S S.F.... It; :",1", V I
2002.8
TABLE 3.3-14: Summary Analysis of Series C2 Test Results.
8-74 31
As discussed in the analysis of Series 81 and 82. the X - 3 a'Jalue for minimum equivalent UTS (P;' min.) represents theminimum strength expected in a population of Washer-WasherNut assemblies as derived from a statistical analysis of testresults, is based on nominal shear area and is corrected to theshear strength corresponding to the lowest value of Rc allowedby the quality assurance provisions established for the 2.0 Mep/170 W Post-Tensioning System. The value of ~ - 3 a for P"(min.) is shown to be 2668.2 kips which is 1.08 times the2472.6 kips established as the minimum by the basic criteriafor acceptance. The mean value of 1.08 for the revised ShearRupture Factor (kr-s) is quite close to kr = 1.1 used in pre-
dicting UTS. Photos of components after being tested in failureare shown in Fig's. 3.3-27 and 28.
_..-....-. ..-....------ ...-. -
• ..._... t._....
----: =:....==::::~:1
FIG. 3.3-27: Outerfaceof Washer Serial No. 010 and Washer NutSerial No. 005 after being loaded to ultimate in Test C2-1.
FIG. 3.3-28: Inner face of components shown in Fig. 3.3-27.80th photos are typical for Series C2 components after failure.
ULTiMATE LOAD TESTS - PROTOTYPE ANCHORAGE C.OMPONENTS
in.
SERIAL I HARDNESS I UTS If'NUMBER I SCALE I READING, (lui)
o 1 4. i,.z < I 4 /. • I ( : !, "Z" 7'7 I .~."
TRANSDUCEil'f"
wh.,.~
A; '" 27.97 sq. in.
25 .38 . / / 3.• .~kil" k, = i.l
F,u from Tobl. J. 2-28.79 . ~4,Q =~ A" 2 3.42 sq. in.-~kips F_," 2.57 Ft. (,hims)
F,. ~ from Fig. 3.2-6
ADX-38 lOADQ)READING o.ips) REMARKS
<JJ. 111' Z77S
ie,,, 11045' j/l~
Intended I Actvql I Preload. Gop •
.1::8 I
6" 0.0. Threod - ,;,.,.... S' .. ,.. \
!
Hydraulic Test Gauge and Hyd;;;fic Trorwducar plw ..,OX Oigital~,give rWund....t..-.-' of tN ..._Ioad.
(6\ L.ood • Tet' Gauge R.oding l( 0.638Q) L.ood • AOX-38 R.oding l( 3
(/- I TEST_4- TESTDATE I M4"f .1
P" ;
4'10"
f COMPONENT NAI<i'C
,Not.1 CD
ITest setup for the two tests of Series C1.
TEST SERIES C1 - 61NCH THREAD W!TH SHIMS
FIG. 3.3-29:
The test setup for Series C1 is shown in Fig. 3.3-29. Testprocedures were similar to those previously described. Data lorthe two tests of Series C1 is contained in Fig
rs. 3.3-30 and 31;
and a summary analysis of the data is contained in Table3.3-15.
3.3.9
FIG. 3.3-30: Test C1-' Data
ULTIMATE lOAD TESTS - PROTOTYPE ANCHORAGE COMPONENTS
SERIES C I - '1.. TEST I a TEST DATE .3 Nt.4 ..... " 7
in.
wner.:
A; '" 27.97 sq. in.
k, = 1.1
F,u (rom Table 3.2-2
A.. - 3.42 sq. in.
F_== 2.57 Fl. (Jhims)
Ft. '" from F;9. 3.2-6
I :Z<. I 41. a ! II? '"i k?", I ... 1.0 1111."
I i2/f I I 7"."
Preload. c..p
,,"
SERIALNUM8ER
25.38 •~ '" 1.tH7.1~ipl
a.79.~::~
,"~il"
COMPONENT NAI<i'C
'flosher Nvt _
p' •
DESCRIPTION _6:..'_'o~.D;.;._T;.;;h~r.:.::od=---..:.:.'foI..;.,_r;;."--=[.;.;"'..;.'''1;;.;.:.' ~IIi
I HARDNeSS I UTS'f' 1I SCALE! READING I (ksi) -
COMPONENT DATA
Q; Fro", Fig. J. 2-6
'PREOICTED FAILURE lOAD
P; :: F.. :, A; == 25.38 F.. '"
p.. :: F..... A" '" 8.79 Ft••
I
TEST PROCEDUREPreload to opproximately 400 ~ips; Return to z.ro;
I......asur. gap betwe.n compon..." and puncn;
p;. 2810.4' F,u(acI'Jol)/I09 Effectiv.MmAreo(A.). 3. 212.65 = 637.9Ssq. in ...:. PredicNd Bear."; UTS (P~) ~ F..... x A C.. 't Ft. Jor shims) If A.. 'n p(~ictin; P\.,.,
C...... ,.r at 2.57, lIl..-fore P" • C F.. (for ,hi ... ) • A" . 2.57 Flo • 3.•2 I ilOAC OATA
3. pt. p; ... '. I'•. Error s (P' _ P")/P" TEST GAUGE'T' I TRANSDUCER(j'\
II READING I lOAD:'j' I ....DX-38 I LOADQ)5. !lavi.... U85 __'OI1.(C..)- (P" - P; )/3 .•2 t F•• ((a< ,hi ... ) .....r. A... 3.•2 sq. in. I' (;si) o.ips) .EADING o.ips) REMARKS
o. See dilcuuiOtt in text.
7 Sof F (5 F' P: ( l/"OO2 8 I I I loteoded I Actudl__...;;,;c.c:;• ..:.ty~ac:...I0:...,=-.:.....:..._--.,;.,..:.m:...i":""';':"':.::""'::""'-- ---J. "1(,. I (;1 ... i -;:O~ i _"5', $",;5
TABLE 3.3-15: SUlTTT1ary Analysis of Series C1 Te5t Results. /~? l'La' Ii 4 •• !.3'1.. 1 118;
-:.,; ~~ IBc6 I !;~I 1S1"i i7/J 8
IPredicted UTS (1.i,.) Actual II Error Qevised Min. E.C;'.Jiv.! Sof...,.
T... Shea' (Pj) Bearing ( p;.) Total (P') UTS (P"l No•• or C.. UTS (P; min.~ Facto<
I Oesig. Not.T No··T Note d: (kips) I (%) Na,.j 1'- (kips) i No.. tCl-I 2913.7 562.4 3.76.3 3378
!• 2 91 2.12 3231 1
I1.41
Cl-2 2913.7 415.3 3529.0 3S41 - 0.90 2.70 33~.2 1.47
" 2
I
2 2 2 2 2 2 I 2
% 2913.7 589.0 3502.4
I
:w,95 1.01 2.41 3288.4 1.'-'a 0 26.35 26.35 91.5 1.905 0.29 575S
I
0030v 0 4.~ 0.75 2.'-' 'IS. 01 12.03 1.75 I.al
I . 3 < 2913.7 468.0 3581.7 37-44.0 4.72 3.28 3~1.3 1.73
% 3< 2913.7 509.9 I 3423.4 3195.0 - •. 71 1.54 3116.0 15S
No..:
1 Predicted Snear UTS (Pj) i, based on ••peri.,.c. 9"ined from Series C2. Therefor•• Pi . X for
P; (min.) from Table 3.3 .. 1.- ,he ratio of F'N (acrvai) to F'\I (min. )rwh4r. ;:,1' 'min. I = 109 kai,
58-75FIG. 3.3-31:
32Test C1-2 Data
Series C1 tests allow analysis of the total ultimate strength(PT) of an assembly of Washer-Washer Nut bearing on SplitShims, but, taken alone, give no information as to the relative,Jortion of the total load taken by either shear in the 6" threads(P~) or by bearing on the shims (Pt,r). When compared to results of Series C2, Series C1 allows the qualitative conclusionthat shims increase the total load capacity (a conclusion furthersubstantiated by design analysis) but still provide no accuratedetermination of the interaction between shear and bearingloads.
If we assume that the ultimate shear strength of the 6" threadshas been setablished by Series C2 at 2810.6 kips (the Xvalueof P;' (min.) at Fsu = 109 ksi per Table 3.3·14,then this valuecan be corrected to Fsu (acutal) for the components tested inSeries C1 and plugged for P~ in Table 3.3-15. Continuing fromthis first premise, we can then assume that the actual ultimatebearing load (P't,r) is the difference between actual total load(P") and P~. The above premise is not precise since actualshear ultimate (P'~) for Series C1 is not necessarily the same asthat established for Series C2. Still, there appears to be no betterapproach based on a limited series of tests and the error inconclusions so derived will be small. No real significance, how·ever, should be attached to the actual numerical value of theUltimate Bearing Strength Constant (Cbr ) derived from thisanalysis.
It can be seen from Table 3.3·15 that the variance of testresults, as measured by the coefficient of variation (v), is only2.64%, a small value which gives a relatively high confidence inthe values for total load (PT). The mean value for Cbr of 2.41is close to the approximate value of 2.57 arrived at in the designanalysis of Section 3.2.6, which gives reasonable confidence in
~
•.•r..'~
t
FIG. 3.3-32: Outer face of Washer Serial No. 014, Washer NutSerial No. 008 and Split Shims after being loaded to ultimate asan assembly in test C1·1.
the design approach. However variance is relatively high (v =12.03%) and in future designs of similar mechanisms, a valueCbr = 2.0 would seem both reasonable and conservative.
The value for PT (min.) is derived from correcting the valuesP~ and Pt,r to minimum values of Fu allowed by quality assurance procedures. Thus, corrected P~ = P~ x Fsu (actual)/Fsu(min.), and correct Pt,r = corrected Cbr x Ftu (min.) for shimmaterial x A~. In accordance with this procedure, P;'(min.) foreach test of Series C1 becomes:
P;' (min) =[2913.7 x Fsu (actual)/109j +[Cbr x Ftu (min.)x 3.42]
As an example, for test C1·1
PT(min.) = (2913.7 x 109/113) + (2.12 x 58 x 3.42) = 3231.1 kips
We then arrive at PT(min.) for the system at X - 3 a or 3116.0kips which is 1.26 times the minimum value of 2472.6 per basicacceptance criteria. Numerical values derived above cannot beconsidered accurate as they are based on assumptions of ques·tionable quantitiative accuracy. This is of no concern as the 6inch thread with shims is not the critical failure mode in anyevent.
Photos of the components after being tested to failure areshown in Fig's. 3.3-32 and 33. Due to the relative magnitudesof the ultimate thread shear force (P~) and the ultimate bearingload on the split shims (Pt,r), it can be assumed that the shimbearing failure which is clearly shown in Fig. 3.3-32 did notoccur until after thread shear failure.
.~
- ..-.---"r--
FIG. 3.3-33: Inner face of components shown in Fig. 3.3-32Note that inner face of Washer· Washer Nut assembly bears onouter face of Split Shims.
S8-7633
.' .. ,~, 0-'\
/ " 0":':'
3.3.10 ANALYSIS OF FAILURE MODE FROM TESTS
A summary of failure loads for each mode of failure, based onSeries Band C test results, is contained in Table 3.3-16. Failureload of the split shims at either the Bearing Plate or the morecritical Composite Washer interface was not determined, but itmust be in excess of the 3561 kip maximum load applied duringthe ten tests and must be due to bearing failure which is not acritical mode.
Wire hole web shear is shown to be slightly more critical thanshear at the 6 inch diameter threads. Failure loads shown inTable 3.3-16 for both Wire Hole Web Shear and 6" Threads(with shims) are mean \/alues.
As compared with the 6 inch threads of the same form, the9-3/8 inch threads are subjected to a temporary load only, areunloaded in the structural condition, are subject to a maximumload which is 20% less and have a nominal area which is 57%greater. This thread is obviously not critical and was not tested.
To provide uniformity in dimensions (to facilitate inspection,shipping, field procedures etc.) it was decided to increase thethickness of both the Composite Washer and the Washer from3·3/4 inches to 4 inches matching the required thickness of theWasher Nut. This increased thickness will provide additionalstrength for both the Wire Hole Web Shear and the 6 inchThread Shear failure modes of production components. Theincreased strength, computed by linear increase of prototypecomponent test results is shown in Fig. 3.3-16. The increasedload capacity is not required for conformance to design oracceptance criteria and will not substantially increase the failure load for other (non-critical) modes of failure.
It should be noted that, by the time all test Series were completed, several specific components had been loaded severaltimes to loads greater than the minimum guaranteed ultimatetendon strength of 2002.8 kips. As part of the overall testprogram, loads ~ 2002.8 kips were applied five times to Washer- Serial No. 002, seven times to Washer Nut - Serial No. 004,nine times to Composite Washer - Serial No. 007, and severaltimes to other components. While this number of cycles cannotbe considered a fatigue test, the applied load is considerablyhigher than will ever be applied in the structure, and the number
58-7734
of times which many components withstood actual tendon ultimate, without failure, gives increased confidence in the basiccriteria that the end anchorage be stronger than the tendonwh ich it anchors.
3.3.11 SUMMARY CONCLUSIONS
The average error of predicted ultimate loads was - 0.61 %,varying from -4.0 to +4.5 maximum error; therefore, it may beconcluded that the design methods used are quite accurate andgi'Je predictable results.
The coefficient of variation of test results is small, having amean value of 1.974% and varying between a low of 0.45% toa high of 2.98%, indicating that the combined effect of prototype production variables and testing variables is insignificant,therefore it may be concluded that both production methodsand test procedures were satisfactory.
All test results were over acceptance minimums based on conservative basic critera; therefore it may be concluded that theend anchorage hardware as designed and tested will not be the
weakest link in the tendon system.
Foilu,e """""e
a"ori"9 Plate - Split Shim Interface >3561
Split Shim - Compotite Washer Interface >3561
Wire Hole Web Shear 3062
6" Threads (with shims) 3289 3542
TABLE 3.3-16: Summary of failure mode, type of failure and failureload for both prototype and production end anchorage hardware, basedon Series Band C tests. Summary is for an anchorage consisting of abearing plate, split shims, and a composite washer (or a washer-washernut assembly l.
Page 5B-78
Gulf General A"'ornicIncorpora••d
TESTING LARGE TENDONS
FOR A NUCLEAR REACTOR VESSEL
by
T. E. Northup, G. S. Cho\y, and J. F. Hildebrand
December 27, 1968
GA-9155
LEGAL NOTICE
This report was prepared as an account of Government sponsored work. Neither theUnited States, nor the Commission, nor any person acting on behalfof the Commission:
A. Makes any warranty or representation, expressed or implied. with respect to theaccuracy, completeness, or usefulness of the information contained in this report, orthat the use of any information, apparatus, method, or process disclosed in this reportmay not infringe privately owned rights: or
B. Assumes any liabilities with respect to the use of, or for damages resulting fromthe use of any information, apparatus, method, or process disclosed in this report.
As used in the above, "person acting on behalf of the Commission" includes any employee or contractor of the Commission, or employee of such contractor, to the extentthat such employee or contractor of the Commission, or employee of such contractorprepares, disseminates, or provides access to, any information pursuant to his employment or contract with the CommiSSion, or his employment with such contractor.
Page 5B-791.
. J\I'-'. / ;:;;..:.:.
Gulf General A1"ornicIncorpora't.d
P. O. Box 608. San Diego. California 92112
TESTING LARGE TENDONS
FOR A NUCLEAR REACfOR VESSEL
by
T. E. Northup, G. S. Chow, and ]. F. Hildebrand
Work supported by U.S. Atomic Energy Commission,
Contract AT( 04-3)-633.
Gulf General Atomic Project 901
Page 5B-80
GA-9155
December 27, 1968
- ~ : I !' ~
l l !:lo::..
ABSTRACT
Prestressing tendons with a minimUm guaranteed ultimate tensile strength
(GUTS) of 1000 tons have been sucessfully developed for use on the first
prestressed concrete reactor vessel (PCRV) being constructed in the U.S. Measured
values for modulus of elasticity, yield and ultimate strength, friction, and
short-term relaxation, for both straight and curved tendons, are presented.
Short-term relaxation tests on long tendons made with stress-relieved Wll'e show
significantly higher relaxation losses than tendons made with low-relaxation Wire.
A cyclic test on a large curved tendon had no effect on the ultimate capacity of
the system. A tendon corrosion-protection system, and various corrosion- and
radiation-test results obtained to est.ablish the adequacy of the system, are presented.
Page SB-81 11
Page 5B-82
APPENDIX TO CHAPTER 3
TECHNICAL REPORT NUMBER 8
{ .. i·~·~/ / .r::;.:.:
-
CONTENTS
INTRODUCTION .
TENDON SYSTEM
RESEARCH AND DEVELOPMENT SCOPE
TEST FACILITY
TEST PROGRAM AND RESULTS
STRESS-STRAIN BEHAVIOR
CYCLIC-LOAD EFFECT
FRICTION ..
RELAXATION
CORROSION PROTECTION .
CONCLUSIONS . . .
ACKNOWLEDGMENT. .
FIGURES
1
3
7
7
10
10
16
16
18
21
23
24
l. Tendon end-anchor assembly arrangement 4
2. Partially fabricated coiled tendon 5
3. 1000-ton tendon prestressing jack 6
4. Prestressing system research and development test bed 8
5. Typical tendon tube splice 9
6. Prestressing system test-bed facility 11
7. Tendon stress-strain curve . 12
8. Typical coefficient-of-friction curves. 17
9. Tendon relaxation test data . 20
iiiPage 5B-83
----------------------_._------,.._----_._ ..
,/ / ~:32
TABLES
1. Prestressing systems used on PCRVs . . . . 2
2. Summary of prestressing tendon mechanical tests . 13
3. Summary of tendon wire-corrosion tests. . . . . . . . 14
4. Coefficient of friction measured along the curved tendons at
various degrees of turn. . . . . . . . . . . . . . . . . . . . . 19
Page 5B-84 iv
TESTING LARGE TENDONS FOR A NUCLEAR REACTOR VESSELa
By Tharold E. Northup,l Fellow ASCE, George S. Chow,2
and John F. Hildebrand3
INTRODUCTION
Several prestressing systems have been used successfully on PCRVs built in
France and England. The capacity of the different tendons has ranged from 146
tons for the EDF-3 vessel to 2460 tons for the Marcoule G-2 and G-3 vessels.
The capacity of all systems used to date is shown in Table 1.
The prestressing systems shown in Table 1 were either being tested or
developed for nuclear reactor vessel application when the Fort St. Vrain vessel
was being designed for the Public Service Company of Colorado by Gulf General
Atomic Incorporated. This PCRV will contain the entire primary system for a 330
"MW( e) high-temperature gas-cooled reactor (HTGR)near Platteville, Colorado, under
the AEC power-reactor demonstration program.
A single tendon, with an ultimate capacity of 1000 tons ("tons" refers to
short tons in this report) was judged to produce the lowest capital cost in-place
prestressing system. Lower-capacity tendons of similar design were also judged to
apresented at the February .3-7, 1969, ASCE Conference at New Orleans, La.
1Mgr. Struct. Engrg. Br., Gulf General Atomic Incorporated, San Diego, Calif.
2Struct. Engrg., Gulf General Atomic Incorporated, San Diego, Calif.
3Staff Metallurgical Engr., Gulf General Atomic Incorporated, San Diego, Calif.
Page 5B-851
TABLE I.-PRESTRESSING SYSTEMS USED ON PCRVsa
Ultimate Capacity,System in tons Type
Marcowe G-2 2460 Special design, multiple wiresMarcoule G-3
Oldbury 273 Freyssinet, multiple 7-wire strands
Wylfa 820 Freyssinet, multiple 7-wire strands
Dungeness B 1020 BBRV, multiple wires
EDF-3 146 SEEE, single 61-wke strand
St. Laurent I 325 SEEE, multiple 7-wire strands
aTaken from "Prestressed Concrete in Nuclear Pressure Vessels - A CriticalReview of Current Literature," by Chen Pang Tan, Oak Ridge National LaboratoryReport ORNL-4227, dated May 1, 1968.
Page 5B-862
-
be feasible. All cost evaluations included the expected research and development
costs associated with each system. The research and development programs were
necessary to demonstrate the efficiency of the selected prestressing system.
The development of anchor hardware and tendon fabrication, installation, and
stressing equipment was contracted to Western Concrete Structures, Incorporated,
Gardena, California, and is not reported in this paper. This paper summarizes the
development of system data for use in the PCRV design.
TENDON SYSTEM
The prestressing system selected consists of up to one-hundred and seventy
1/4-in. - diam high-strength wires with stressing washer assemblies at each end to
support the buttonheaded wire anchorages. This system. manufactured by Western
Concrete, is similar to the BBRV system used on the Dungeness B vessel (Table
1). A schematic view of the 1000-ton tendon anchor assembly as it will appear
on the PCRV is shown in Fig. 1. The covers shown protect the tendon from
corrosion and mechanical damage.
The system 1S partially shop-fabricated from straight wires with one
end-anchor assembly attached. Each tendon consists of two concentric bundles of
counter-twisting wire. The counter-twisting effect prevents the wrres from
unravelling and minimizes the variation of wire lengths in a curved tendon. All
wires of the tendon are coated, bound, and coiled for shipment to the site. A
coiled test tendon is shown in Fig. 2.
The partially fabricated tendons are pulled through tendon tubes embedded
m the PCRV and each wire is then threaded through the second anchor assembly
and buttonheaded. Prestressing is accomplished with high-capacity jacks from both
ends on curved tendons and from one end on straight tendons. The high-capacity
jacks developed for the lOOO-ton tendons are shown in Fig. 3.
3Page 5B-87
BEARING PLATE20-1/2 x 3-3/4X 20·1/2 IN. \
)
CONCRETE SURFACE~
j/
(/
ANCHOR CAP~~ --J-l
16 IN. OIAM ANCHORASSEMBLY COVER
LC69383
FIG. 1.-TENDON END-ANCHOR ASSEMBLY ARRANGEMENT
4
Page 5B-88
Ur'lX41 C - 1l/8~
-..
135-77-1
FIG. 2.-PARTIALLY FABRICATED COILED TENDON
Page 5B-895
-,- :',- ~ .. -~l / I::''';;'
FlG. 3.-1000-TON TENDON PRESTRESSlNG JACK
6
·Page 5B-90
l...::··'l)A ! t: - 1
I,',' r ...: :'l 1--
RESEARCH AND DEVELOPMENT SCOPE
The prestressing system was tested by GGA to determine: (1) modulus of
elasticity, (2) friction, (3) yield strength, (4) ultimate strength, (5) cyclic load
effect, (6) short-term relaxation, and (7) corrosion protection.
TEST FACILITY
The facility for testing full-size tendons in their expected environment and
load conditions is shown in Fig. 4. The test bed consists of a 90-ft-long straight
test section and variable curved test sections with maximum radius of 16 ft and
minimum radius of 10ft. These dimensions provide the full range of vertical
tendon lengths and horizontal curves required by the Fort St. Vrain vessel.
The straight part of the test bed contains five tubes. The center tube (No.5)
is 7 in. OD throughout its 90-ft length. The outer four tubes (Nos. 1 through 4)
are 4-1/2 in. OD with temperature regulation for relaxation tests at temperatures
from ambient up to 150 F.
The semicircular portion of the test bed permits testing a variety of curved
tendons. Each curved tendon-tube can be removed and replaced as required. This
feature enables several friction-reducing or corrosion-protection materials to be
investigated, starting with clean tubes for each test phase. Provisions for measuring
the tendon tangential shear force and radial force at several points around the
1800 curves are also provided. The two smaller curved (No. 9 with 10-ft radius
and No. 8 with 16-£t radius) tendons are truly semicircular. These short tendons
simulate the range of curvature of the crosshead tendons of the Fort St. Vrain
vessel. The longer curved tubes (Nos. 6 and 7) are a series of flat-curved sections
with the radius of the curved sections being 16 ft maximum. These tendons
simulate the circumferential wall tendons of the Fort St. Vrain vessel. All tubes
are ASTM A-513, Grade 1010 HREW, having splice details as shown typically in
Fig. 5.
Page SB-917 U;--'!';;;il \:: - 1
?/S:.::
CURVED TENDONSSIMULATE CURVATURESOF" CROSS-HEADTENDONS ON PSC PCRV
STRAIGHT TENDONSIMULATES VERTICALTENDONS ON PSCPCRV
TYPI CAL TENDONTUBE NUMBER 1
LOAD CElL3
LC69382
HYDRAULICHEATING LINES
FIG. 4.-PRESTRESSING SYSTEM RESEARCH AND DEVELOPMENT TEST BED
8Page SB-92
r-3 IN'----I~-----_ ..... -- - - - - - - - - ....._-------..
------
5 IN. 00 X 0.180 IN. WALL
IIIIIIIIIIIII
II1'1IIIIIIIIIII
1--- -- ---- -- -
4-1/2 IN. 00 X 0.109 IN. WALLLC71375
FIG. 5.-TYPICAL TENDON TUBE SPLICE
9
Page SB-93
The completed test facility is shown in Fig. 6. The dimensional changes of
this bed were measured with Invar rods. Tendons were heated by flowing oil into
small tubes attached to the outside of the embedded tendon tubes. Jack pressure,
tendon force, and tendon elongation measurements were also made.
TEST PROGRAM AND RESULTS
The tendon system test program was started with ASTM A-421 stress-relieved
Wlre. After the initial high results on tendon relaxations at ambient temperature
were obtained, the program was reoriented to use only Thermalized (trademark of
Richard Johnson and Nephew, Ltd., Manchester, England) wire because of its low
relaxation property. Thermalized wire meets the requirements of ASTM A-421,
including a minimum GUTS of 240,000 psi.
Table 2 summarizes the physical tests performed on the tendon system. Test
parameters, including test type, number, duration, tendon makeup, env~onment,
and material, are given. Table 3 summarizes the corrosion tests performed to
establish the adequacy of the corrosion-protection system selected for the tendon
system. Further discussion of these tables is given later.
STRESS-STRAIN BEHAVIOR
A typical stress-strain curve for a full-size straight tendon is shown in Fig. 7.
The tendon system exhibits good ductility. The initial individual wire failures have
an insigificant effect on the ultimate capacity of the tendon. The yield strength
of the tendon system at 1% elongation meets the requirement of not being less
than 75% of the minimum ultimate strength. An ultimate strain at failure of
greater than 4% provides considerable reserve above the 1 to 1.5% predicted
maximum capability required by peRv designers.
10Page 5B-94
~-
,,..... ::, /" ro'::' -::--:
K53837
FIG. 6.-PRESTRESSING SYSTEM TEST-BED FACILITY
11
Page 5B-95
ELONGAT ION (%)
0 2 3 4 5
NO. OF FAILED WIRESMAX LOAD = 2048 KIPS
2200 AT 4.35% ELONG
2000 250,000~(j-
I
1800 2,3- 200,000V') 1600 ~YIELD STRENGTH AT 40..d I 1% ELONG a 1780 KIPS-
~ 1400 5 V')
I 0..
0 1200 ? 6,7,8 150,000<t
== 28.3 X 106 PSIV')
0
VE V')
..J 1000 ~
a:
800 100,000 t-V')
600 ?400 P STRAIGHT TENDON - 168 0.25-IN. WIRES
50,000
200 GAGE LENGTH - 99 FT 0 IN.
0 0
° 10 20 30 40 SO 60
ELONGATION ( IN. )LC71374
FIG. 7.-TENOON STRESS-STRAIN CURVE
12
Page 5B-96
""d~
OQCD
VItJ:lI
\0'-J
c:"1"
[:;,:1':-
n-......
0:f< ......
w
) )
TilLE 2.-5UHHAll.Y OF PRESTRESSING TENDON HECHANlCAL TESTS
Length INUlIIber of Wire % Elongation MaximUlll ~umber of E, HodullUl of Aver~,eF~~~~~~ientTe.t Tendon Lubricant at Maximum Load, Wire. Elasticity.Type NUlllber (ft-in.) Shape a Wires Haterial Tendon Load 1n kips Failed 10' pai Ten.illning Detena10nina
II..U 98-11 Straipt 168 Stre•• -relieved 2075 7 27.4I -- 4.13 - --... 51 99-0 Straight 168 Stres.-re1ieved -_.- 4.35 2048 8 28.3 --- ---..
.-4 SC 99-0 Straight 168 Strus-reUeved --- 3.90 2050 9 28.4 - --;;I
• 61 9~8 Curved 168 Stre.s-reUeved No-Ox-Id-ot 2.30 1963 25 --- 0.138 0.165..61 99-6 1/2 Curved 168 Stress-reUeved 23.9 b 0.136 0.190! No-Ox-Id-ot 2.06 1900 15.. 6C 100-0 Curved 168 Streas -reUeved No-Ox-Id-ot 2.84 1970 38 24.8 b 0.150 0.172
.-4 + ParafUn;;I
'U168 Stres.-relieved 1966 8 25.2 b 0.135 0.169q SA 70-4 Curved No-Oll-Id-;:H 2.82
g 81 70-4 Curved 168 Stresa-reUeved NO-oll-Id-QI ---- -- -- 25.2 b 0.145 0.164
... 25.1 b.. 91 51-6 Curved 168 Stre.s-reUeved No-ox-Id-at 2.80 1962 18 0.154 0.1690 23.9 b... 91 51-6 Curved 163 Stress -reUr-ved No-Ox-Id-CH 2.84 1970 15 0.146 0.164.... ge 51-6 Curved 168 Therlllalhed No-Ox-Xd-SOO ---- 2035 15 --. 0.187 -
+Ho-ox-Id-CM
InitialTest 1 aelallation
Tut Teodoo Lenlth Wire Tempelrature. Load. Tenlioninla "UlIIber of 1n dearees Ouratioo Lo•• c
Type tlltaber (ft-io. ) Sbape Wires Katerial in % GITeS 816toryFahrenheit NOIIIinal in bour. at 1000 houn
U 91-1 1/2 Straight 1S Stre.s-relieved 68 70 1st tensioninl 1180 10.568 70 2nd tendoninl 2690 3.4
120 70 3rd tendooiq 1130 4.41C 91-1 1/2 Straight 25 Thera&Uzed 120 70 lat tenaiooiol 10 progress 3.0
21 91-1 1/2 Straight 25 Stre.s-re1ieved 68 . 70 1.t tenaiooiol 1180 10.2
&:68 70 2nd Un.ioniaa 2690 6.2
0 120 70 3rd tenaioninl 10 prolrel• 6.1.....•~ 31 91-1 1/2 Straiaht 25 Strelll-reUeved 68 70 1st ten.ioninl 1180 9.8
.-4 68 70 2nd ten..iODinl 2690 3.8.= 68 70 3rd tenlioninl 1130 3.03C 91-1 1/2 Strailht 25 Theraa1hed 68 70 lat tenaioninl In prolre•• 0.7
41 91-1 1/2 Strailht 25 Stre•• -reUeved 68 70 lat tenaioninl 1180 10.068 70 2nd tensionina II' prolres. 3.8
8C 13-0 Curved 168 Ther..lhed 120 70 lat tensioninl In proares. 2.2
aAll 168-vire tendon. are aept1y sp1ra1led to equalize their 1enlth within the tendon.All curve~ tendona Include 1800 of curvature.
bApparent .odulua.
cielaxatlon los. ia obtained a. % of initial load at anchor.
)
1--
..... :
:r-
TABU J.-SUMMAllY 0' TENDON WIllE' CORROSION TESTSi ,
TypeoCTeaI Purpoee Muerial Coacinl TeA CoadiIiou ~g
Gc...u catrOliaa ComIIioa eCCccc oa ~ Noac u JoUa· coucaI No ro. oC teMile au...... .. 30-. 110-,leui1e ptOpen_ .... enwiroftmenl ••poaun 30. uwl36S...."t...
110.365 da".. t....u. t_
Gc-ucomaoi... Proceccioa b" ~ A_ ......1t uJollac....w lIoch pro"" 10_ ptoceePoa.p'-phace couiJltl ..... (lad phoephacel cllYWOnmctd Meta lIoad rued __ procecu............. t1WI AUlO ....... 132-4&y
(ziac phoephacel I&,-are
Gc-.lc-.ioa I'tocec1ioa b" Kap''-' ~ Kap'-c (Orpaic u jolla cou&al Coaced win clln'Oded. eqll;"alenlcouia! by RjltN'i win phooplwe ual_all cn~OD""" to bare wir., 30...., eKpo.....
c...uc~ Proceelion by s-u...4 ~·Id.a.ce uJollacoutU No conoeion ai_ 2-y!NoCK·ld.cM win casinI fak enwil'onmenl Iltpoounl
Gc..ue___Proceclion oC wire ~ Metaa-l uJollacoutU Moderace ptoceelioa C.. 9O-<la"by coatinl.1 waC win ea_ Ilt,-are
GeMni eanoaioa Proceclio. by Meta "........ Maca lIontl. Meta .... 1A jolla c.-.l ........ bpoeun continllinl. nolIoad win &ad R__nl 452 _Dl.1 75~'nl..1 fail",n.161ftO
G.Mn1 eatrOlia. Strna reluacio. t" su-eliewll 0Iauia bl.ckh 25_ire tendon (UI. bpowre at t_ lila concinWnc'uwl conotion ptOleCliaa win 120 F, •.yr t_ No cortOOioa .lIack obaened
c...u~oaioa StnM r.1au&ion tnt ~1iewII NoCK·Id.cM 25...... 1..... (4.) bpooure aI _ til. conciA......&ad eOllOliDa ptDIeCdoa win casinI iiUer No cOllOliDa .ttack 0 .........
Gc...u CanoIioa Su_ r.1au&ion tnt "....u-l NoCK-ld.cM 25-win t.ndon (IC) b,-are &I tnl Pia Concinllin&....d conoaion ptoIecliaa wire casinI fak No cortOOioa .tlaCk ob~ed
GcMnl comuio. Sue. relaution teal ~ ~.1d.cM 2S-wirc teadoa (JC) bpoiun .11.. til. eoncin"",,..nd eorrotio. proaecaloa win casinl fdler No conoeion .llaCk 0 __
Gc-.l CamMllo. SI.... r.laulion "...... NoCK·1d.cM 16I-wire teadoa (IC) bpooure .t &eM aiI& conlinuia!.t....nde_lio. ..... caaiA& fak No eorralioe .raack obtened
Ce..uc--". lleuiAl plate r~inC«c" n..-liMd No-OK·ld.cM SII........ 16I-wire1..... bpolUft al t...ile cOMinuiai.and corroeio. ptOcecllOll ..... e.utl'l fillew No c_OIio. allaCk obMncd
c...u camMIloa Sclectioa oC oftflU& n..n.Iiull AI· .... win Oceu slai,... in ..-w AI In . UPI r.... hauahiPPu.a _hod wire A2· Kap'- Ited ~Iainaw A211·Nor_
11 . Utowrapped AI 14· LitI\I rUII ha.. on112 . VPl·Heuiaa butlolWcoilburlap paper an41afla .0 112· Nor_113 - VPI·Heuiaa A2 IJ· Nor....b",1ap papew an4 _ A21H·Nor..Heuaaa b",!.p ,.perIW • VPI·Hnaia.
bwlappaper
a-ft' ECfecl oC I•..,...... ~ No-01.ld.oc CoaI&d wire heW aI 120 , Film oC vu- c-.d wire
o. IINCII" oC paM wire atiaa fl11ew C.. 100 hr. u jolla .Clee 100 hr .1 t...pent.....ea~..,... No viaible ,.. 90 da".
a-ft' ECfeccoCI......... ~ NoCK.Id-CM Coaled wire heW all60' Film oC are- __ win _CI.
OD lIucil" oC paM win atiaafiller f.. 1000 lv. 1A Jolla 1000 hr alC.mpenl..... Moderate.n......._ntal.K,..... proteerioft C.. 9o..la" up-"
SeIC·halina Abilily oC.- co ~ NoCK·Id.cM Hariaonw wire pnniaI1, Noc~ o. wire .new 410Co_ bare wire wile cuinl filler cowred wilh paM !Ir in humid air. No eDrl'Oliaa
heaced in h....w air .£cew 9O....y u jolla .s,........HJdrotn HJ..... ·mbri&&Ie- s-u...4 Meta IIond aM S...wned loeci &175,.,_ slllYlftd J 12 hr wilhoul.nabriltle_.. _ nl c....o b" WCS win ~... faiI_
Macalloncl
HJcIrosn Suae.plibilil" ~ No.. NoIched.,.... caa8aOo Speci_1lII'Iiwd 0.- 200 Iw....onllle_.. h".....n •..onn... wire cslIy clwpal ucl wilhoulfail_
....111 oC wire ...-ined .....,~P_
a.dio!ylia EffecloC~ Sa_I:zlieftIi NoCs·1d-CM lnadWed 4 (lOll r-. AIllpecilMu ouniwd es,-are.
r- 0 • wire wire cui8&f.n. 1.7 (10)17 nWl (> 1.0 MeV) _embricde_
ICreAed 75~ Pili..
RadioI". 2CCecI of irradiated ~ Meta .iIond plul ~winal7S"'_ All tpecinte.. ...",;...a espoeun...__ wire .... ~·Id-CM cspooure 14 claya DO emonllle_4 (10)9 r.... 1.5 (101"nva t> 1.0 MaV)
-La jolla, c::.II'-alaItA_ .................. Trade _oll..-iDMi a-proole-apuy. C1ew1ull, Qhlo
eKap'-t Trade _ DC AMCHaM Produc.. I.... AtnW.•......,......4lUchut1joa-n ... Heph_. Maac~.!naI-'eNooOK·ld.cM: Trade _ DC prod_ oC Denrt-a 0IeaIical Dhitiaa 01 W. 1l. Gnu. 0alap,1lIinoiIfW.._ eo-. SINCIWa. GercUna. Cali£onaia
rns. Su8lcripa .... equall_ch c.lIIiIe wa- ......hl!lecuo Paint Coapu". GercUna. c.Iilomin
14
Page 5B-98Ui-'DA ! t: - ].
-
Page 5B-99
It IS impossible to directly measure the modulus of elasticity for full-size
curved tendons because of the variation in stress between the two anchor points.
The effects of transverse load, ovaling of the tendon wire bundle, friction, and
actual stress in each wire all make the determination of E, as shown in Table 2,
approximate.
The ultimate load of a tendon test specimen is reached only m the straight
portion between the anchors for a straight tendon and in the first point of
tangency for a curved tendon. Beyond the tangent point, friction reduces the
tendon load. Therefore, the measured total elongation IS mainly influenced by the
length of the straight portion. A meaningful test result interpretation is required
to relate the measured ultimate load to the strain in the wires at the failure
point. Since the wire failures always occur close to the tangent point within the
curved part, it is valid to equate the measured failure load to the tendon load at
the point of failure. The percent elongation at maximum curved tendon load is
determined by averaging the percent elongations of the straight tendons (SA, SB,
and SC) at the corresponding maximum curved tendon load. The percent
elongation at maximum curved-tendon load is about one-half to two-thirds of that
exhibited by straight tendons.
The stress in each wire of a curved tendon depends upon the actual length
of each wire. If the tendon wires are parallel, the inner wires of a curved tendon
will project approximately 6 in. further than the outer wires at each anchor. To
compensate for this, all curved test tendons were fabricated as follows: the ,center
80 wires were gradually twisted 10 turns clockwise while being greased and
combed into position, the remaining outer \vires were then greased and combed
into position, and finally the whole tendon was twisted four turns
counterclockwise. This operation reduced the variation in wire projections at
anchors to ± 3/4 in. Test tendon 6B (Table 2) was specially treated in an effort
to further study wire-length variations. In this case, the wires were cut parallel to
the bearing plate after insertion to remove the ± 3/4-in. variation. This operation,
1:...l}r·'l)A ~ t: - 1
/ / ~"i'1
however, actually increased the Wire variation In total length and resulted in a
lower· ultimate strain and strength for this tendon. As the result of these tests,
the Fort St. Vrain counter-twisted tendon wires projecting through the stressing
washer will be buttonheaded without field-cutting the wires.
CYCLIC-LOAD EFFECf
Tendon 9C was tested by cyclic loading 1000 times between a load range of
1275 kips and 1525 kips (i.e., 0.7 GUTS ± 15,000 psi) prior to the ultimate load
test. The cycles and stress range are at least double those expected to occur in a
PCRV. The jacks shown in Fig. 3 were used to apply the cyclic load and thus
also provide experience on jack reliability.
FRICfION
Coefficient-of.friction values were determined for all full-sized curved tendons
after a series of tests were performed on small, 7-wire tendons. In this series of
tests, the friction-reducing characteristics of various materials were considered
along with their ability to provide corrosion protection for the wire. A
petroleum-base compound containing microcrystalline wax, No-Ox-Id-CM, was
selected for use on all of the full-size tendon tests.
Friction values were determined by recording the load at one end of the
tendon while jacking at the other. Friction coefficients were computed using an
average wobble effect of K = 0.00027. Typical friction coefficients determined
during tensioning and detensioning are shown in Fig. 8. The lower value obtained
during tensioning is attributed to the fact that the tendon wires slid more freely
during tensioning than detensioning because sHang friction is less than static
friction. (Friction at tensioning resembles sliding friction and friction at
detensioning resembles static friction.) A factor of 0.15 during tensioning is
believed to be an adequate design value, but a value of 0.19 was used for the
Fort St. Vrain design to allow for construction variables.
16
Page 5B-IOO
i J.L -1000 r a a a a 7I MINI J.L=I
~MAX
U" 800a.
I
J.La~
Cl 600 f-z IUJ iCl I<t I
UJ 400,- Cl
I-<t
Cl<t 200a...J
00 200 400 600 800 1000 1200 1400 1600
LOAD AT JACKING END ( KIPS)
LC71373
FIG. S.-TYPICAL COEFFICIENT-OF-FRICTION CURVES
Page 5B-IOl17
---------------,--, -
Coefficient-of-friction values determined along the curved tendons are shown
in Table 4. Tube Nos. 8 and 9 are completely circular and little variation in
friction value occurs. Tube No. 6 is made up of straight and curved sections with
high values of friction occurring in the curved portions (60 0 and 150°). The
average friction values determined by load cells are consistently higher than those
determined along the curved segment. The addition of paraffin or No-Ox-Id-500
to No-Ox-Id-CM for lubricating tendons 6C and 9C did not reduce friction below
values obtained using No-Ox-Id-CM alone.
RELAXATION
Relaxation tests require considerable time to accomplish if a basis for 30-yr
predictions is expected to be established. Many relaxation tests on prestressing
steel have been performed by others, extrapolating the lcng-term relaxation loss
from a minimum of 1000-hr (approximately 42-day) test data. Relaxation tests on
the test bed have ranged from 1000 hr to approximately 1 yr. The test results to
date en Thermalized wire tendons indicated only a slight rate of change of
relaxation loss between the period of 1000 hr and less than 1 yr.
Relaxation loss was obtained as a percentage of initial prestress at anchor.
Tendon loads were measured with spool-type load cells calibrated to ± 0.5%
accuracy at rated load. Applied tendon loads and number of wires per tendon are
shown in Table 2. Temperature of each tendon is maintained within ± 5 F of the
stated values. Temperature-change adjustment was included in the test data.
A comparison of load loss vs log time is shown in Fig. 9 for straight tendons
made up of stress-relieved and Thermalized wires. Only ambient-temperature tests
were performed on stress-relieved wire units initiCllly stressed to 0.7 GUTS, and
the results shown in Fig. 9 as (68 F)S are the average of four 25-wire tendons.
Retensioning after various periods of time reduced the relaxation of stress-relieved
wire tendons to about one-third to two-thirds of its initial value as shown in
18
Page 5B-102
TABLE 4. -COEFFICIENT OF FRICTION MEASURED ALONG THE
CURVED TENDONS AT VARIOUS DEGREES OF TURN
Lubricant
No-Ox-Id-CM
plus paraffin No-ox-Id-CM
Degree of turn Tube 6 Tube 8 Tube 9
10 0.142a 0.146a
30 0.109a
50 0.126a
60 0.176a
90 0.133a
120 0.107a
130 0.127a
150 0.147a
170 0.132a 0.12Sa
Mean 0.135 0.136 0.131
1 Std deviation ±0.029 ±0.005 ±0.008
Avg values byload cells at
anchors 0.150 0.140 0.150
acoefficients of friction are derived &om normal load
and shear load measured along the curved tendons at various
degrees of tum.
Page 5B-I03·19 }Jf·'t}~t ~ c - 1
l/81.
10,000
120
6868
TEMP (F)
1000100
I I I I10
II II I
1
(68 F)S I
( 120 F)~ _---- I__-~ -- II...--- ~
-_.-....~-~:r-a--e-~--et~~~~~~-~ \
,.".- 0 ,
~RIIIII ,\
LEGEND NO. OF INITIAL LOADWIRE MAT'L WIRES % GUTS (NOMINAL)
~ THERMALIZED 25 70o THERMAL IZED 25 70• STRESS RELIEVED 25 70
~
V')100
V')
0-J
Q 10« t-o-J ~
~~
0.10 t0.010.1
LOG T I ME (HRS)
LCi1372FIG. 9.-TENDON RELAXATION TEST DATA
Page SB-I04
20- .. :1
4}··,1
,. f' :~-
-
-
Table 2. The test duration reported is related to the period following each
tensioning operation. The percent relaxation reported at 1000 hr is also related to
each tensioning operation.
CORROSION PROTECfION
The development of a satisfactory corrosion-protection system requires a
broad knowledge of all the steps in the preparation and use of a prestressing
system. This is essential since continuous corrosion protection must be provided
on all tendon components from the point of manufacture to final installation.
The total corrosion-protection system for the Fort St. Vrain prestressing tendons
consists of the following:
1. The tendon wrre is coated with a zinc-phosphate (Meta Bond), which
is then sealed with an oil film of Rustarest, both ot which are applied
just after the Thermalizing process.
2. The WIre coils, spiral-wrapped in VPI Hessian burlap paper, are shipped
from England to point of fabrication in unsealed steel containers.
3. No-Ox-Id-CM is applied to the individual wires and anchor hardware
during tendon fabrication.
4. Fabricated tendons are banded and placed in protective tendon racks for
shipment and site storage.
5. No-Ox-Id-CM is applied to the interior of the tendon tubes prior to
tendon installation.
6. After tendun installation, the ends of each anchor assembly are covered
with caps until the stressing operation is performed. These caps are
21Page 5B-I05
removed for tendon stressing and t hen reinstalled after the anchor
assembly is thoroughly coated with No-Ox-Id-CM. The tendon tube and
end caps form a protective chamber for the prestressing tendons.
The selection of this corrosion-protection system 1S based on the test
program summarized in Table 3. The most significant results show that:
1. The strength loss and elongation loss on bare wire from corrosion was
insignificant in wire after 1 yr of continuous coastal exposure. The wire
samples exhibited fine scaling corrosion.
2. The zinc-phosphate coating (Meta Bond) produced no hydrogen
embrittlement even at stress levels of 75% of the notched wire ultimate
strength. Neither the coating nor cathodic charging caused failure of
stressed wire.
3. No-Ox-Id-CM is self-healing and does not uncover the wrre at 120 F, the
maximum temperature expected to be experienced by PCRV tendons.
4. Irradiation to levels recorded does not cause delayed failure of stressed
and coated wire.
5. Scress-corrosion cracking and hydrogen embrittlement have not caused
failure of these wires, which have a pearlitic microstructure.
Corrosion tests on full-size stressed tendons in the test bed (Fig. 6) were
performed to verify the adequacy of the protectants selected on the basis of the
specimen tests summarized in Table 3. These tests are continuing and no signs of
corrosive attack have appeared.
22
Page 5B-I06//::3J.
-CONCLUSIONS
It is apparent from the test results that counter-tWIstIng of tendon wires is
essential for large-capacity curved tendons. The counter-twisting effect prevents
multiple tendon wires from unravelling after tendon fabrication and during tendon
installation, and minimizes the total wire length variation. It is important that the
wire bundle not be cut parallel to the bearing plate after curved tendon insertion.
If the wire bundle is cut, a 3 to 4% reduction of the tendon ultimate load
capacity can be expected for tendon configurations described in this report.
As expected from the curved tendon ultimate load tests, most of the WIre
failures occurred in the curved segment close to the first point of tangency on
the curve. This is the region where the simultaneous action of high-tensile,
bending, and transverse stresses. localize as a result of the effects of friction and
sudden change in curvature in the tendon profile.
Thermalized wires used in this test program meet all the mechanical
properties of ASTM A-421 wire. Thermalized wire is characterized by its low
relaxation property. The relaxation loss for Thermalized wire tendon was only
approximately 7% of the relaxation loss that was measured for the stress-relieved
wire tendons tested under similar test conditions at 68 F after 1000 hr and after
initial anchor load of 70% GUTS.
The casing-filler material No-Ox-Id-CM provided dual functions in this test
program. It was used for a friction-reducing agent and for corrosion protection of
the tendon system. The No-Ox-Id-CM material is self-healing and does not uncover
the wire at 120 F, which is the maximum temperature expected to be
experienced by PCRV tendons. The self-healing effect of No-Ox-Id-CM permits
tendons to be protected 'hi.thout resorting to completely filling the tendon tubes
with protectant.
Page SB-I07
23
//b:1.
The 1000-ton prestressing system developed for the Fort St. Vrain PCRV has
been subjected to service loads and environmental conditions far in excess of
those required to satisfy design require·ments. Mechanical properties required by
the design have been established by testing full-size tendons in configurations
simulating those of the actual vessel. Tendon-relaxation values have been shown to
be small for Therm:llized wire, and a complete corrosion-protection system has
been developed to ensure tendon stability throughout the design life of a PCRV.
ACKNOWLEDGMENT
This work was supported by the U.S. Atomic Energy Commission under
Contract AT(04-3)-633.
24Page 5B-I08
PartE.
Section 5B
TRUMPLATE WELDING EFFECTS
Page 5B-109
.. .'-·:':'S ~ \::. - -/ ,/ ~:i'~
PartE. TRUMPLATE WELDING EFFECTS
Table of Contents
Page #
1.0
Introduction, Purpose, Summary
Letter Report of J. Hildebrand
SB-lll
SB-112
Section 5B Page SB-IIO
;; ,/ 'O ..!..
PartE. TRUMPLATE WELDING EFFECTS
Introduction, Purpose, Summary
A question had been raised regarding the integrity of theThree Mile Island bearing plate because of the possible weakeningeffect of flame cut or welded areas at normal environmentaltemperatures.
In addition to actual low temperature testing covered within,it was requested we provide a professional opinion.
~rr. Hildebrand's work with Gulf General Atomics on similarquestions well qualifies his opinion and experience.
There is no question in the author's mind that the proposedprestressing system will function properly.
Section 5B Page SB-llltJr:i)';~ IE: - 1
? /t~~
John F. Hildebrand6124 Terryhill DriveLa J~lla, California 92037
27 October 1969
Inland-Ryerson Construction Products Co.Box 5532Chicago, Illinois 60680
Attention: Mr. Wi II iam A. Corson
Re: Bearing Plate Serviceability
Gentlemen:
Following recent discussions with Western Concrete Structures, I felt it was necessaryto prepare a brief statement clarifying our position relative to the metallurgical serviceability of the bearing plates for the Three Mi Ie Island containment. Flame cutting thebearing plate and attaching the trumpet by welding are not expected to detrimentallyaffect the functionality of the prestressing system at normal environmental temperatures.A test program is in the final stages of preparation at this time to assess the effects ofthese fabrication procedures at an extreme low temperature.
At normal temperatures it is-recognized that the mass of the bearing plate represents asubstantial heat sink. As such - the mass acts to drastically quench steel heated locallyabove the transition temperature. Mi Id steels with 0.25% or more carbon may formzones of brittle martensite, but for the A36 plate in question, the low (less than 0.20/0)carbon precludes the formation of embrittl ing martensite. The microstructure of the plateis simply modified by zones of less desirable coarse grains and coarse pearlite .. Thesemicrostructural variations are not likely to act as metallurgical notches. The same conditions are produced by both cuts and welds. If the welding procedure did cause cracksin the bearing piate, they would most likely follow the contour of the weld metalloasemetal interface, that is within the hardened structure of the heat affected zone. Ineffect the weld bead would remain attached to the trumpet and leave a chamfer-shapededge on the bearing plate. It Is true that branch cracks might form but their propagationdepends on both the notch sensitivity of the plate and a high strain rate loading.
.. ~. ,. ~. I
/ :' 0";:
58-112
- -2-
Inland-Ryerson Construction Products Co. 27 October 1969
58-113
The Welding Handbook points out that almost all carbon steels are notch sensitive belowa certain temperature or above a certain strain rate. The sensitivity of the steel variesconsiderably with the composition, thickness and rigidity of the structure; it is relatedto the general toughness of the steel or the ability to withstand impact or shock loads.In this regard the thickness of the bearing plates is a detriment, the composition is favorable (low carbon) and the rigidity of the structure is an asset. Since cupping of thebearing plate is resisted by the back-up concrete, the peripheral tensile stress at theedge of the hole is kept at a relatively low level. And finally, tendons and anchorhardware are a static system, not subject to impac..~ or high strain rate loadings.
It is also important to point out that the weld holding the trumpet to the plate has twofunctions; 1) it maintains the axis of the trumpet perpendicular to the face of the bearingplate and 2) it prevents leakage of the grout/concrete during construction. Once theconcrete has set, the weld has no further function; as an example, in one concretestructure, the plate is placed and grouted after the trumpets are embedded and the gapbetween the tube and plate are simply calked.
By the way of demonstration that the proposed prestressing system wi II function properlyat normal temperatures, several buildings and bridges using a similar system with simi lormaterials, have been built during the past decade and none of these has experienceddegradation such as cracking or failure of any of the components. Some of the bridgeshave also endured extremely low temperatures.
Sincerely,
Jb~~1Engineer
JFH:ko
- .. "1'"1"".':)'::'
WESTERN CONCRETE STRUCTURES, INC.
LOW TEMPERATU RE TEST
SECTION 5B 5B-114
WESTERN CONCRETE STRUCTURES, INC.
LOW TEMPERATURE TESTSTABLE OF CONTENTS
.-
SECTION TITLE PAGE
1.0 INTRODUCTION AND SUMMARY 5B-116
2.0 PURPOSE 5B-117
3.0 MATERIALS 5B-117
4.0 PREPARATION OF TEST SPECIMEN 5B-118
5.0 BEARING PLATE METALLURGICAL EVALUATION 5B-128
6.0 TEST PROCEDURE 5B-137
7.0 RESULTS 5B-141
8.0 CONCLUSIONS 5B-142
APPENDIX
Al.O ANCHORAGE DETAILS AND PROPERTIES
A2.0 MATERIAL TESTS AND EXAMINATIONS
A3.0 TEST DATA SHEETS
SECTION 5B 5B-115
WESTERN CONCRETE STRUCTURES, INC.
LOW TEMPERATURE BEHAVIOR
OF
THE WCS 2.0 Mep/170-W
POST-TENSIONING SYSTEM
1 . 0 INTRODUCTION AND SUMMARY
The WCS 2.0 Mep/170-W Post-Tensioning System has been developed primarily for use inpost-tensioned concrete reactor vessels and containment structures in which massive concretesections and large required prestressing forces dictate the need for tendons of high capacity.In some of these applications the end anchorages may be exposed to very low ambient temperatures which may exist at the exterior of the structure. Because of the critical nature andfunction of these structures, it was felt necessary to prove the adequacy of the system whensubjected to these low temperatures. The following report covers the procedures and resu Its ofa test conducted to demonstrate this adequacy.
A reinforced concrete test specimen was constructed utilizing materials and components typicalof those used in actual practice. The cross section of the specimen was square and the size wasselected to represent, on four sides, the conditions of minimum concrete cover that would existon one side of the tendon anchorage buttress in a typical containment structure. When theconcrete had achieved strength a 169-wire tendon was insta lied and stressed to a load cqu ivalent to seventy percent of its guaranteed ultimate tensile strength. An insulating enclosurewas placed around the test specimen and using liquid nitrogen, the assembly was cooled to atemperature of approximately minus eighty degrees, Farenheit. This temperature was selectedarbitrarily as being significantly lower than the lowest expected outdoor temperature for mostareas of the country. The cooling period required approximately twenty-four hours to reach andstabi Iize at the se lected temperature.
At this point the load-test phase was commenced 'Nhile maintaining the reduced temperature.The load on the tendon was increased to 80% G.U.T.S. and held for fifteen minutes. At thispoint the load was then cycled between 60% and 80% G.U.T.S. for 500 cycles. Following thecyclic loading, the force in the tendon '.'las increased to 100% of its guaranteed ultimate load.
At no time during the test was there any failure or evident distress in any component of the system.Post-test examination of the wire, bearing plate and anchorage hardware revealed no crackingor permanent damagi ng distortion.
SECTION 5B 5B-116 \Jt-; lJA ~ E: - J.
/~ ,/'Q-2.
WESTERN CONCRETE STRUCTURES, INC.
2.0 PURPOSE
The purpose of this test was to demonstrate the low temperature serviceability of the 170-wire,BBR-type buttonhead anchorage post-tensioning system, including shims and bearing plate andto determine the crack sensitivity of tendon anchorage components when stressed to 0.7G.U.T.S. cooled to a temperature of'approximately- 800 F., subjected to 500 cycles of loadingbetween 0.6 and 0.8 G.U.T.S., and then subjected to a static load of 1.0 G.U.T.S.
3.0 MATERIALS
With the exception of the bearing plates, all of the components of the test anchorage assemblyrepresent an essentially random selection of material or fabricated items from stock.
a. Wire: Domestic stress-rei ieved wire conforming to the requirements ofASTM A 421 Grade BA was used to fabricate the tendon. Certificates ofthe chemical analysis and tensile properties are included in Appendix A2.0.
The buttonhead anchorage produced by cold upsetting the shear-cut end of thewire conformed to the requirements of the WCS 1.5 FS Head-Seat Systems.
b. Shims (Part No. 101006): Hot rolled plate conforming to the.require-ments of ASTM A 36 were torch-cut to the shape and dimensions shown byFigure A1- 1 .
All loose mill scale was removed by chipping and wire-brushing; all edges weredeburred to assure full surface contact with adjacent shims, stressing washer andbearing plate. The cut edges were not machined, ground, or otherwise finishedfrom the torch-cut condition.
c. Stressing Washer (Part No. 101003): Rod stock (6-1/2" die.) of AISI4142steel was rough turned, dri lied and heat treated to a hardness of Rc 42 ± 2 andthen threaded. The seria I number of the stressi ng washer used in the test wasnumber 1024 and details are shown on Figure Al-2 which is included together withmi II chemical analysis and heat treat certification in Appendix A1 . O.
d. Washer Nut (Part No. 101004): Tube stock of AlSl4142 steel was machinedand then heat treated to a hardness of Rc 42 ± 2. The washer nut was' finished tothe dimensions shown on Figure A1,-3, which is included in Appendix A1.0 alongwith the mill chemical analysis and heat treat certifications. Threading was performed after heat treat. The serial number of the part used in the test was #561 .
e. Bearing Plate (Part No. 100121): Hot rolled plate conforming to the require-ments of ASTM A 36 (silicon killed, fine grain practice) was torch-cut to the shapeand dimensions shown on Figure A1-4, which is included in Appendix A1 .0 togetherwith the certified chemical and physical analysis.
SECTION 58 5B-117UFU~~ \::: - "1.
/ / ~:"i'1
WESTERN CONCRETE STRUCTURES, INC.
3.0 MATERIALS (continued)
f. Reinforcing Steel: Intermediate grade deformed reinforcing bars conforming to the requirements of ASTM A15 were placed in the concrete supporting thebearing plate in the manner shown on Figure 3-1 and 3-2. Mill certificates forthe reinforcing steel are contained in Appendix A2. O.
g. Concrete: The concrete used in the test specimen conformed to the mixdesign prepared by Twining Laboratories, a copy of which is included in Appendix A2.0. The criteria for the mix design were: 1) compressive strength of5,000 psi in 5 - 10 days, 2) 3/4-inch maximum size hardrock aggregate,3) 2-1/20/0 entrained air, 4) 4-in. maximum slump. Twining Laboratories alsoinspected placement of bearing plates, reinforcing steel and concrete, and madecylinder tests as reported by them in Appendix A2.0. At the time of the cyclicloading and ultimate load test the concrete strength was .5,078 psi as indicated bytwo test cylinders. The age of the concrete at this time was 12 days. The modulusof elasticity was determined to be 3,383,000 psi.
4.0 PREPARATION OF TEST SPECIMEN
4. 1 Plate Size and Preparation: In order to obtain plates for the test specimenwith as high a carbon content as has been utilized to date in construction; it wasnecessary to produce the tesrsamples from 4-inch thick plate, the only materialavai lable with a carbon content of approximately 0.2%. Consequently, a 4-inchthick piece, 21
- 0" . X 4 1- 0", was obtained and ground on one face to a thickness
of 3-3/4inches. The plate was then torch-cut into eight pieces as shown in Fig. 4-1.All cutting was started on the unground side and this side of the bearing plate, pieceNo. P1, was placed against the concrete so that any harmful effects of the mill rolledsurface wou Id be on the tensi Ie surface.
4.2 Mechanical Faults: In an attempt to make the test more severe than anycondition that would occur in practice, several artificial flaws were added inaddition to whatever metallurgical notches might be produced by torch-cutting thetendon tube hole. These mechanical faults, shown in Figures 4-1, through 4-5,consisted of 1) a V notch produced with a cold-chisel and intended to simulatea case where the edge of a plate is dropped across the hole edge of another plate,2) a 1/2 inch long radially directed torch-cut slot intended to simulate the case ofan overlooked, misdirected torch-cut and 3) a hook-shaped, torch-cut slotintended to simulate the case of an overlooked stc:rting cut that had been made onthe incorrect side of the opening. In addition, during the welding of the trumpettube to the bearing plate, the welding rod was deliberately dragged away from thejoint for a distance of one inch onto the plate and on completion the rod wasgrounded-out to the plate and then broken off to simulate an accidental weld strike.While the faults may be realistic, it is considered inconceivable that a bearing platecontaining anyone of them would escape detection and be installed on a concretestructure.
SECTION 58 5B-118
- 6-0~---:-~--------------------#-",
INTERMEDIATE GRADEREINFORCING
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SECTION 5BI9li3 SOUTH HAMILTON AVENUE
5B-119 BAADENA . CALIIl'OANIA . 321-1571
F · 3 1 i~g. -1:
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SECTION 'A-AllINTERMEOIATE GRADEREINFORCING
DATI
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lOW TEMPERATURE BEHAVIOROF
THE WCS 2.0 Mep/170-WPOST-TENSIONING SYSTEM
~"O.l. NO.
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SECTION 58 58-12019113 SOUTH HAMILTON AVENUEClARDENA . CALIFORNIA' 3Z1-la71 SHT_OF'
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SECTION 5B 5B-12219113 SOUTH HAMILTON AVENUEGARDENA' CALIFORNIA' 321-1l57' SHT_OF
-
--
WESTERN CONCRETE STRUCTURESf INC.
Figure 4-3 Test bearing plate after dye penetrant inspectionfor cracks around center hole and intentional torch-cut flaws.
SECTION 5B
Figure 4-4 Close-up of torch-cut flaws.
5B-123
:j ~ . ':':' ~.~ i t: - 1/ ,/ 'rj''::'
WESTERN CONCRETE STRUCTURES, INC.
Figure 4-5 Close-up of cold chisel notch on edge of bearingplate center hole.
4.0 PREPARATION OF TEST SPECIMEN (continued)
4.3 Inspection: The bearing plate was inspected for crocks or other surfacedefects using dye penetrant. This inspection was made on both sides of the platein an area approximately six inches wide surrounding the center hole. The surfaceof the hole was also checked.
This inspection was repeated after the trumpet tube was welded to the bearingplate. No evidence of cracking was detected as a result of these inspections.
4.4 Instrumentation Placement: Copper-constantan thermocouples and straingage rosettes were attached to the bearing plate. The strain gages were placed asclose as practical to the weld between the trumpet tube and bearing plate; thecenter of the gage was approximately 1/211 from the toe of the weld. The positionand orientation of the gage axes are shown in Figs. 4-6 and 4-7. The thermocoupleon the outside of the plate was installed. after the concrete was cast and the formsstripped. Thermocouple readout was by a Leeds and Northrop Model 8662 temperature potentiometer while strain gages were read with a Baldwin SR4 strain gagereadout.
SECTION 5B 5B-124 -.- . ~ "\ ...-,l .' ,.~.&:.:.
-PLATE P2 SHOWNPLATE P4 SIMILIAR BEARING PLATE
20 1/2" SQ. x 3 3/4 11THK.
GROUND SURFACE
,THERMOCOUPLET4
,WASHER &.WASHERNUT
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SH rMS - 4 /2
~ THERMOCOUPLES
OUTSIDE FACEOF CONCRETE
THERMOCOUPLE TI(CHAMBER TEMPERATURE)
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LOW TEMPERATURE BEHAVIOROF
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Fig. 4-6
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SECTION 5B 5B-12519113 SOUTH HANIL.JON AVINUEGARDENA' CALI·ORNIA . 321-1571 SNT_OF"
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LOV' TEMPERATURE BEHAVIOROF
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Fig. 4-7
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SECTION 5B 5B-126191:3 SOUTH H .... ,LTON .VENUEGARDENA' CALIFORNIA . 321·'~71 SHT_OF"
Sf: P1 . IS
RES INC.TRUCTU ,N CONCRETE SWESTER
b l witht assem y. late and trumpe8 Beanng pFigure 4- -n place.
t tion Iinstrumen a
Figure 4-9
SECTION 5B 5B-127
WESTERN CONCRETE STRUCTURES, INC.
5.0 BEARING PLATE METALLURGICAL EVALUATION
5. 1 Tensi Ie Properties: The tensile properties of the bearing plate steel weredetermined by Atlas Testing Laboratories for all three directions; longitudinal,transverse and short transverse, as shown in Appendix A2.0. The tests were performed in accordance with ASTM - E8 and the specimens were cut from Piece P8 asshown by Figure 5-1. Subsequent to preparation of Figure 5-1 and the test specimens,metallographic examination revealed that the 4' - 0" dimension of theplate was in fact oriented transverse to the rolling direction. The actual averagetensi Ie properties are as shown below:
Tensile Yieio Elong. ReductionStrength Point % in in Area(ksi) (ksi) 4D ok
Longitudinal 65.8 35.0 34. 1 64.3
~ong Transverse 65.8 32.7 30.5 46.0
Short Transverse 63.17 39.2 9.8 18.9
It should be noted that some of the properties listed above are below the minimumsspecified by ASTM-A 36.
A chemical analysis was also made by Atlas Testing Laboratories, Inc., a copy ofwhich is included in .A,ppendix A2.0.
5.2 Metallography: The bearing plate was sectioned for a metallographicexamination of the microstructure gssociated with a torch-cut and with the bearingplate trumpet weld. The location of these sections is shown on Figures 5-1 and5-2.
The 1/2-inch 51 ice from piece P8 of the plate material was resectioned as shown bythe fo Ilowi ng sketches:
SECTION 5B 5B-128
WESTERN CONCRETE STRUCTURES, INC. ; - "~'. ,:" ~.. .:..~ ~ ~"
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VMACHINED SURFACED
-
P81l T-L Surface - check roll ing direction.
P812 ST -L Surface - check inclusions to compare with P813.
P813 ST-L Surface - check effect of torch - cut at edge simulating BP hole edge; grain size.
P8l4 ST- T Surface - check roll ing direction and grain size.
SECTION 5B 5B-129U:-'UA ! E -- .~
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CICD. IV
SECTION 5B 5B-130.911 3 SOUTH H AW'l.TON AVENUEDARDENA . CAl.'f'ORNIA . 32'·'~71 SHT_QF'
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LOW TEMPERATURE BEHAVIOROF
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SECTION 5B 5B- 13119113 SOUTH HAMILTON AVENUEGARDENA· CALIFORNIA· 321-1571
PRO~ HO
S1-,+4
Fig. 5-2
SHT_O'
Ui-'i)Afi:: - 1//82
WESTERN CONCRETE STRUCTURES, INC.
Figure 5-3 General microstructure of the bearing plate isnormal, pearlite in a matrix of ferrite; an inclusion is shownat the top center. The grain size was estimated at ASTM 6.Piece P813, Neg. No. LTH 645-2 (SOx.)
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SECTION 5B 5B-132
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ROLLED SURFACE, CONCRETE FACING SIDEOF BEARING PLATE
DROP OF MOLTEN STEELSOLIDIFIED ON EDGEOF TORCH-CUT
~ -TORCH CUT SURFACE
HARDNESS - CD@@@
/55 DPH = RB 82202 DPH = RB 92
227 DPH =RB 97
247 DPH = RB 100 =RC 22
BASE METAL=RB 92
SECTION 58 58-133
WESTERN CONCRETE STRUCTURES, INC.
Figure 5-6 Hardness and microstructure on a mid-thickness section of the bearing plate hole. A thindark-grey layer at the edge is scaie, the white layer(0.001" thick) is a hard (R c - 67) rnartinsite, thesubsurface Widmanstatten structure is relatively soft(R c - 22) and becomes softer further from the surface.This structure may have poor ducti Iity. Neg. No.LTH 645-10 (250x).
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SECTION 58 5B-134
WESTERN CONCRETE STRUCTURES, INC.
5.3 Weld Metallography: The weld joint was good; there was no evidenceof gas porsity of cracks at the toe or root of the weld. The microstructure of theheat affected zone was normal as shown in the following photo-micrographs.
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Figure 5-7 The microstructure of the trumpet/bearingplate fi Ilet weld. No cracks or porosity were seenNeg. No. LTH 719-1 (4.5x).
SECTION 5B 5B-135
WESTERN CONCRETE STRUCTURES, INC.
,Figure 5-8 The toe of the weld at the bearing plate showedno hardened layer in the heat affect zone, see Table above.Neg. No. LTH 7i9-3 (100x).
DPH Re---1 . 222 952. 230 973. 274 (103)4. 221 955. 181 876. 186 887. 207 93
(beari ng Plate)8. 266 (101.5)
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Figure 5-9 The root of the weld showing the edge of the bearingplate hole (arrow) and the martensitic layer, see table above forhardnesses. Neg. No. 719-2 (1 OOx).
SECTION 5B 5B-136 / ,.. --
WESTERN CONCRETE STRUCTURES, INC.
6.0 TEST PROCEDURE
6.1 Test Set Up: The test set up is shown schematically in Figures 6-1 and 6-2.Figure 6-4 is a photograph of the actual test installation.
Liquid nitrogen was used for chamber cooling. Loading was accomplished by meansof a WCS 1,000 Ton stressing jack.
6.2 Stressing Jack Cal ibration: The jack was cal ibrated using a short tendonand a compression type load cell. Jack output force was obtained as a function ofhydraulic pressure at 100 kip increments from 100 to 1100 kips. This data was plottedand extrapolated to 2000 kips, as shown by the data sheet and calibration containedin Appendix A 3.0.
6.3 Cool Down: The tendon was installed in the test block, with shims at thetest end, after the concrete reached 4000 psi, and the insu lated chamber placed overthe test assembly as shown in Fig~re 6-1 and 6-4.
When concrete strength reached 4,845 psi the tendon was stressed to 1,393 kips(700/0 of G.U.T.S.) and the cooldown started. Cooling was by means of liquid nitrogenbled into the chamber. Upon entry into the chamber the nitrogen vaporized to a gasand was circu lated by the notch driven fan. .
Temperature on both faces of the bearing plate, on the inside surface of the washerand in the chamber was monitored and recorded at one-half hour intervals duringthe cooldown period. Also recorded were the strains registered by the two rosettes.These data are contained in Appendix A3. O. Cooldown required approximately24 hours. At the end of this period, the temperature at the concrete face and exposedface of the bearing plate were - 73
0F ae5'd - 81 0 F. respectively. Lowest chamber
temperature during cooldown was - 128 F.
6.4 Cyclic Loading: Immediately following the cooldown period the tendon wasstressed to a hydrau Iic pressure of 7728 psi (80% G. U •T•S.) and he Id at th is loadfor 15 minutes.
The load on the tendon was then cycled between 60% and 800k of guaranteed ultimatetensi Ie strength (1, 194,600 Ibs. and 1,592,000 Ibs . respectively) a total of fivehundred times. Each cycle consisted of an increase in load from 600k to 80% ofG. U. T. S. and then back to 60% . Cycling rate was approximately 100 cycles per hour.
Load was determined by means of the stressing jack hydraulic pressure, measured usingthe same gage that had been used for jack calibration.
A.fter each 100 cycles, strain gage data was read at 600/0 and 80% load and recordedalong with bearing plate and anchor head temperature. These data may be foundin Appendix A3.0.
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Figure 6-3 Test specimen after concrete cast and forms removed.
SECTION 58
Figure 6-4 Test set-up during cyclic loading. Load applied usinglOOO-Ton hydraulic ram.
5B-140
WESTERN CONCRETE STRUCTURES, INC.
6.0 TEST PROCEDURE (continued)
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7.0
6.5 Tendon Guaranteed Ultimate Load: Following the cyclical loading, thetendon was loaded to guaranteed ultimate tensile strength 1,990,000 Ibs. in theincrements shown on DS-3, contained in Appendix A3.0. Strain gage data wasrecorded at each increment.
Temperatures during this test were - 76°F. at the concrete face of the bearingplate, and - 87°F. at the front face .
6.6 Post Test Inspection: Upon completion of testing, the tendon was removedfrom the test assembly, the wires cut, and the anchorage hardware removed forinspection. The washer and washer nut were checked for distortion and dye penetrantinspected for cracks.
The outer face of the bearing plate, a ground surface was check for flatness.
The bearing plate was then removed from the concrete and dye penetrant inspected.
RESULTS
7.1 Chemical and physical properties of the material used in the bearing plate tested. was determined by Atlas Testing Laboratories of Los Angeles. Copies of their reports
are included in Appendix A.
Tensile yield in the longitudinal direction as determined from the average of threetests was 35,000 psi. This is almost 3% lower than the value of 36,000 psi minimumspecified in A-36. Ultimate tensile strength was in the low end of the allowablerange. Chemical composition was undistinguished with a carbon content of .21 %.This is higher than any of the plates used in production.
7.2 The plate tested showed no visible signs of damage after being loaded totendon guaranteed ultimate tensile strength, following 500 cycles of loading from60% to 80% of tendon guargnteed ultimate tensile strength, all at temperaturesbetween - 700 F. and - 90 F.
7.3 Post test inspection revealed no deformation or cracks on either the anchoragehardware or bearing plate.
7.4 Strain gage data indicated that strains were linear throughout the cyclicand ultimate load test phases showing that the bearing plate stresses remained belowthe yield point of the material at ultimate tendon load.
SECTION 58 58-141 //82
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WESTERN CONCRETE STRUCTURES, INC.
8.0 CONCLUSIONS
8.1 Due to the comparatively higher carbon content and low yield strength, it maybe concluded that, in terms of material properties, this test represented a more severecondition than would be expected on the job.
8.2 Deliberate damage to the plate, as described in Section 4.2 was severe. Thesedefects would ordinarily be cause for rejection. It may therefore be stated, that interms of material condition, the plate tested represented an extreme case.
8.3 The serviceability of the bearing plate at temperatures well below normal ambientconditions has been demonstrated.
8.4 In view of this test, wherein a defective bearing plate with unacceptably lowphysical properties was loaded to values which will not be encountered in actual use,under temperatures lower than ever expected, without failure; it may concluded that thebearing plate design is suitable for the use intended .
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..........-Figure 8-1 Test specimen anchorage immediately afterconclusion of test and removal of insulated enclosure.
SECTION 58 5B-142
WESTERN CONCRETE STRUCTURES, INC.
APPENDIX Al.O
ANCHORAGE DETAILS AND PROPERTIES
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PROCESS CERTIFICATION
TO: WESTERN CONCRETE STRUCTURES, INC. DATE 11-7-6919113 S. HAMILTON AVE.GARDENA. CALIF. 90247
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PART NO. 101003
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HARDENED & TEMPERED TO RiC 42-2 PER MIL H 68758 =SERIAl. NOS. 1053-1032-1029-1039-1034-1014-1001-1027 1024 1023
1000-1003-1007-1002-1030-1005-10171006-1 -10211057-1040-998-993-997-1041-1056-979-996-974-10431044-995-1045-1059-1054-1051-1042-1055-1052
ACCURATE STEEL TREATING
BY Paul LunghL-CJo~f:-'lQk1:r~-------
All processes involved requiring Government Proceu approval havebeen $0 approved and certifications are on file subject to examination
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MECHANICAL PROP[RTIES AND TISTS
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THE AlO\,[ HSIS CONFORM TO THE RfOUIREMENTS OF THE SPECifiCATIONS LISTED.THIS IS A FACSIMilE COpy OF THE NOTARIZED MASTER IN OUR fiLES.
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OUR SI!OP NO. 731/.9
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All processes involved rcquil"ing C:- . ..:tnmcnt Procca opproval havebcen so approved ond certifications ore on rile subicct to exomination
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1 CHEMICAL ANALYSIS;.j HEAT NO. CARSON MANG. PHOS. SULPHUR SILICON NICKEL I CH'OM' I MOtY. ICO"" n. ALUM. LOAD OTH" h( 148271 • 18 .97 .014 .029 .24 I ~ ..)),t MECHANICAL PROPERTIES ANO' TESTS ~ \:. I ,. ELONGATION ',REDUCTION HARDNESS 'BEND GIIAIN EMI. COlt., HARDENAlllITY t'· ,
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TE~~:LE Y~\~O! % ELONGATION I 6EFO~i~c~ I HAllONESS iSEND I GRAtN EMI'l COR. I HAIIOENAllLITY t; j I I I IIi, /16- '16- ';",1' r ,'\,~ MANUfACTUllU r)?, I r '" . ~
kj DESCRIPTION OF MAtERIAL AND SPECIFICATIONS t),;i ~ '~
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'" ,THIS CERTIFICATE NOTARIZED ONLY WHEN REOttfRED (j .. ,J r; ~~, 1 , w. hr.b., certify '"0' '"e fonqolll" do'o I, 0tru' CO"" 04 .11. \. jl. __ , a Notary Public do.Jt~(.~~=tIlriCfye:t~t clo'. f_',"'" WI b" .... prod..~" ",Ill or .lte de'. re,.W.q'
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lent of Joseph T. Ryerson & Son. Inc.• thls day of JOSEPH T. IY • {~ So' /~ ._''7 J.~; ~: ~~ (~ ~ ~,~.,. ~MY,COMMISSION~"'Res- NOTAIY PUllLlC If ,
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APPENDIX A2.0
METERIAL TESTS AND EXAMINATIONS
SECTION 58 58-155 Ur-> :.;. Ft l t: .. 1; .. ' ;0:,: / c..:..
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CERTifiCATION OF TESTTUF\IIRE
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,~tj.oJ ::::~:: ~:~~:~:~ .~': ::::~!: :1;1;':: ;::~ ::1'3l/::;:::.t ':,:; :~:i 1,1: ':I,~::~~; i!l; ';; :::' ;:::1::', I::: I::: ::': ":: 1:: 1:::: Ii:: ~:I~::I:::' :::: ::::--;~,-,_~:~ :•• ~ i'll 1:1' .,':' 'I""' ,1;,,11 ',II~" 'y' I 1'1 "fl ' ... 'il; :lllill' III: .41: !IIIII:, Ii ' ......... "I, ,"~ i,I; 1.,llllli 1:1,11"1 1111 Ii,' 1:1 ",( 'iilill, I'i' :'
., j-::;"Hlll~w.:::;.;4 'i::!,~'ll ,',~ "J ~':~II 1111 !III '~l~. 1;:1 '11' I I' ill I',,' I' ,:11 "I:~ 1,1' I': III ':111'11 i!',III,: 11:1111, 1,1 ;,.,w, "I!IIII III. III, ,;,.;, ::~!:w ,II '",i 'M,I I "i.' ],1 I :11: III· !'''' 'I'f ...'1111! 1,11111' I':, III: I'll III: ",,8::'11 1111 :I!I .ill ;11, I'll III I'll II IIIi i l III! ,!II I11I
~~,:r~~~~::I~;.;'iti:::'~: :!f~~'~:,~1 : .,' ;:II~ 8.~'::;: ;;'1:::II~;: :::: :::1 :,:: "" :::: ;~:' .... ~~, ::;~ II:: ::~: :::: I::: 1,1 ", '::: :~!: :::: ':",.~ .-4 .IJI II I ,I' I~ ",,-!IHi ,,"~I'II 1111111,1,. I .~i Illi lilll:'I,III' ';11' II1
'II:, ,I ." ioO.i..' I"II!I; iii ,i,. III' II', 'ii 1'1, ,i' '.1
~t~~~f+te:JII: ._.... .,;,•• :i ,ir,r~,r. .I! ,II IIli II . r.-;':£i :.i,1 111'i IIIi li.I' I' ill, 'Ii, ',Ii 1'1,11,' -""':'1111' ill: 1111 I:!' I:,: I' Il'i :1:: Iii:
~~:~-!'''''~.~I' :1,- ~ III! 11.11 1",'1. 'Til... ,...,' 111'II,111'!: l,fllill Illi ii, 1111" :;!' ,,,. 'I' .'''',~' "1" ii" II' 111:'11i :11: Iii,
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,-
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~~'-I_.c::: ',' I" .~ ',..{ ..O' :~:;~ ,r 'rrj'lll ,1.,1 : Iii:: I,~ Ie II';IIII!III! I'll :: :,11 III' ':,' ,II I II :11: 'I', III' ;11 11::1 ,.' !II:IIIII II:' 1II'ill'. , II I,ll'''': .a OIU,' Ii; .~ ;:::f~, ",00::;:' ;.";:·.11,11,. I lili IJ)~. illlIllll ,III II111 'I" ,I! .. : ", ,,, I':' " I illi III I' II,: II I IIi! 'I" II I I' ,'1 ,I' .(
,i' I" , I!: I ., i' I, I :'" I I 1I1I I 1I I 1'1 1'1 Ii II' . I ' '" I '.11' Ii! : 'Iii II ,I III! I i I ',I ',' I I II I III ,:., I" I, i III' II Ii 'II, 'I'! Ii" III ! I; I'll •i " I , I I I :':-r I I I I I iii I ! I I !. , i I I I i I ~] II I I I I I I I I I , I I I I I I I II I Ii! I I I i I I I I I I i I I I I 'i I I ! I I I i I I i I I ", I I I I I I I I I I I' I: ! I I I I I I I I I I I ' I I I! I! Iii I I Ii, I I :: I I I i I I I I I ! II I I I I I :i
Li.i!.ll-l-l-L- i i II II: I1 1II 111111111111. il'll I, III Ii ". 1II1 11111 1111, " ,III, ,I. '1'111.'111 iii I i'." iiil il'I.IIIII: "1 ,II.: 1'1 i,'·11 j I: 11'; Ii I:; II" III' III' I'll II!: I. I I I ,i 1:1' ~I'TTT ,II 1I . ! II' " I: I, I111 111 11 II;, I1111 I, Ii; I' .;., I:, I'll il" ill 111I ,1'1 jill 'II' ,," 1111 [:/' 1'1' I II' Ii I' . I' 'I '! .:, I II I! "I II' i 11" ',!I I if 1'1 I 'ii I I. I II ..~
~~': " ;111 :':I.~,I !III,II'I G"""I, ::"111,111 :!il "111,,1 ' ... 'II II!, "'1 Ili'- 'II' 'Iii I Ii , ,..,~ II ;1 ,'II I o!ll I II I I'" ~'II i!1 III' ""'= '" "I' :'11 'I -,:::=:" 'I lill I' il ii" 11'1 "i I" ! ii" ,I , " , 1I',.oi"I':111 '::: I II :,illl :;:~ ,i I" I , ,'" 1,...11' II', I'I! ,;:: II' 'ii' iill iI'! Z
1'1' 11111"
' ... : 11'11'1'1' III: ... II!:'I I" " ... ", " I,i: II' ... ,! ill' ,ii': II:, "" 1,'1 :lli II ... ·1 I". 1·1' I, ... : :Ii! Ii:: I·",T",' Ii' I' i I .."III',,·! llili, ~
... 1 I . II : I' , ,<. ~; I ! III II I Ii! I" "'! II I I • i . I! , I, ! I I I: : II':' tTti I ill I I I ; I I" I. 'I:'! I , : , t-' '. ,,' . I , ~' :' I II 'I,: '1,.1' :, I'! I·": ,.... :, , ." I I ill :~.:_ I,"~ "'IW1' T "1 'I.' :111 I.i , 1111 I,,: ' II ,I" ',I· 'II, II; ,,11 ,Iii "'I 111111'1, Ii', 1,1 II, I.il i' " ' I I 1I 'Iii 1,li ii' I Ii: '! !'II; :11111I~ ITT! II:' II!I tl,l lilt III: III, I I, :1 1 ' 'I!: I II jill il ll !! iill II! i;li 1:1: '1 i II!! ,I, ;11 1111 lill Illil t' ~', lit, i:il :'11 IIIIIl:l;
SONnOd Nt avo,··········, .. ·········· .. ···..·':l~'ea············· .. ··,····· 'e~ p~:)n~'lI·1~ J~d·· ..··················..uO!1'esUOla '1U~ J~d···········_······_··_··_··-gq)UJ···················· 011ao~~~~,:~·....·········"··_················..··········ul 'bS ·sql '11S ;)rcm!~U1····· ....············_········uI 'bS -S<rI ~a!Od PI~!A ~·,···················~JV" ..························':lZ!s··..·····_··_······_········ON ~s:I.t
SECTION 58 58-157
PHYSICAl:ltST
TEL.: (213) 6A5· 4242 - 722· BBI0
•
JOHN A. STrV(NSTOM It. EVArtS
CERTIFIEO REPORT OF
REcr-"'t:"nCH[ MIS T S .' 'II 'M I TAL I. URGI 5 T S
ATlAS TEST ING lA1tO:R:AI 0RIES, INC.6929 E AST SLAUSON AVE" Las>TRA1taE~ LE S, CAL I FOR NIA 90022
METAL SPECIALISTS
K
r
-
IN ACCOUNT WITH
.WE3TERN CONC~ETE STR~CTURES19113 SOUTH HAMILTONGARDENA. CALIF.
DATE 11/7/69 CUSTOMER ORDER NO. 6999 ClISTOMf:R SHIPPER NO.
LABORATORY NO. 16228-1 IDENTIFIED See Below PART Nt).
MATERIAL Steel SP ECI FICATION
HE AT TREATING CO. WITNESSED BY
PHYSICAL PROPERTIES
VlF.l.O POINT. I TENSILE
----.,---.---.---!-.---,-----+----,----...,...."...--..,.....~-::_c____..---~==_y_----
ACTUAL ACTUAl. I A«;"".,- I ,......~O....... I At: TU4. roo'........·.. 1·«:·-;:;".... , n.':::4. Ausuc,o ..~~;;c;:- HARDNESS
----.---+-__~tI..!__ f-_~...~__L~~~~..!:....~..__~"'.I-~•.:_r':..~~.!-...=!"~-r,~.~~--t._~----.I ..~~ .. c~_~,_ f-r'?'~!_"~!!!!!_ .!:!•...;;,.._C:;~,..~'-+- _
.352 .097: 3,300 !33,900 '16,300 64,7501 .50 135.7 .204 66.4
.337 .089~ 3,240 36,300 5,920 66,3501 .46 32.9 .202 64.1
.342 .091 £ 3,200 34,800 16,090 66 ,250 • 47 33.6 • 210 62.4
.355 .099C 3,650 36,RSO 6,280 63,4501 .15 10.7 .330 13.5
.355 .099C 3,670,37,0501
,6,030 60,900, .12 8.6 .320 18.8.352 .0973 4,260 43,800
16,340 65,150 .14 10.0 .306 24.5
i In .2".506 .201 6,500 32,35013,250 65~900 .60 30.0 1.328 58.0.504 .200 6,650 33,250 '3,150 65,750\ .65 32,5 \.386 41.4.505 .200 6,500 32,500~3,lS0 65,750 .58 29.0 .396 38.5
I
T1 LT12T351ST5253
L1 LL2L3
IREMARK~ I
- ~_-+-_----4. _+--_+_--_+_--_+---+--_+--+_---MAXIMUM RECUIREMENTS l-' I
·-~---'I -+---j--+-----+---,1-·-1---'-,---,---+--.... INIMU .... Rr:ClJIRI'"MCNTS I ,,""
YIelD STRENGTH BY EXTENSOMETER AT • 2 ~~
Code
: I IfI I"d"al.' IIawI I IGI b,o~. ouhid. 901lQ. ",a,"
: I'll b,o•• 01 9a1l9- '"0'"
__.__ doy of _
I.. "".1 f". ,t.,. .co",,'" ,.,1 lo' A"g"I,.,. Slul. 0/ Culo/or."..
SECTION 58
. .. --._-.-. T7---;ti.:%y(.:~,,~,:.-- --
~Jl~~[iM ~ 't: - .
/ / ~:)·l
-.. ~'Hl"'.
CERTIFIEO REPORT OF TEST
METAL SPECIALISTS • CHEMISTS • METALLURGISTS
ATLAS TESTING LABORATORIES, INC.6929 EAST SLAUSON AVE., LOS ANGELES, CALIFORNIA 90022
K
TOM H. (VANS JOHN A. ST[V(NS TEL.: (213) 685-4242 - 722·8810
IN ACCOUNT WITH
WESTERN CONCnETE STRUCTURES• 1911} SOUTH HAMILTON
GARD£NA. CALIF.
DATE 11/7/69 CUSTOMER ORDER NO. 6999 CUSTOMER SHIPPER NO.
LABORATORY NO. 16~28-2
MATERIAL Stee 1
IDENTIFIED PART NO.
SPECIFICATION
CARBON MANGANESE PHOSPHORUS SULFUR SILICON
0.21% 1.22 0.016 0.019 0.28
CHROMIUM
COLUMBIUM
COBALT
NICKEL
TANTALUM
VANADIUM
COPPER
SELENIUM
BORON
MOLYBDENUM
IRON
ZIRCONIUM
TITANIUM
ALUMINUM
--Subscribed and sworn 10 before me Ihis____ day of , 19 __
. Notary PublicI.. a ..d lor th. County of la, An9'.". Slut. 01 California
1M .... ..""
SECTION 56
R"P'~
//j:-ji4~~Ar>~{~ Ii/~ .0'~iORIES. INC.
56-159
- - - - - - - - - - - - - - --:- - - - - - - - -'- - - --- - _. -- - ... - _. - - - - - - -
)
2
3
7
15
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INO.
t! ?tJO I;II
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HEAT NO.'S
MILL
Clodit APP1U'd
J ~. ~ •. I t
~ ·r ~.':" .• .,dO • ..:' ' ~.
_===-=-... _, :s=-.~~
:£PORT O~ ANAl.VSES A:~D lORj)HYSICAL ~nOt':R'1ES
(./ I O,? O~ I'C\RRlcr~ TRL NC. /1/i!!J -~-"".:l
PAC:{ING LISTj.\~,lI)
TaST R;?O~T SECTION 58
I; _. (
J /r.1 I IJ,I
! _. II -" .. L ......
l ) ~ ~ t ! t'j
I certify tn3 .'l~'Ie teet InformOltion to be correct ..s contllrn~ In the recordsc.t t~lC Ccmr.:n'l.
.... ,/ ':::.: .;.'.
(b) (5)
(b) (5)
(b) (5)
(b) (5)
(b) (5)
(b) (5)
(b) (5)
WESTERN CONCRETE STRUCTURES, INC.
APPENDIX A3.0
TEST DATA SHEETS
,.~ i --1'/ >::.:;:;
SECTION 5B 5B-168
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COOL-DO\VN DATA - THREE MILE ISLAND NDT TEST~ !- !" ~
• • • ,. " hS-I(q.. .. .
DATE
RECORDER: i"/l l C Ref. Junction: :3:J 0 \:"l/)rn
WITNESS:()-f
0 TEMPERATURES STRAIN GAGES COMMENTSZ01 11 T2 T3 T" G, G2co
TIME ') e q .0X Y Z X Y Z,
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my my my my AT¥- rw,&- ~ 1ft¥- ~ RW- - - - - - - - - -of of of of fln/in ,~in/in dn/in ~n/in .An/in un/in
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Ref. Junction: 3_">cp
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G~
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DATE -llh$5L__RECORDER: (..> f)~ !I$::-.:"lIT NESS: -_._---.----_.__.. -- ....__ .
TEW. PEru\TUr~ [ S
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OAnOtNA • CALIFORNIA • ~;:1·1'::'71 : :'Hr -3..a,_~_'-------------------------------------------_. .-----/ / :'j~.
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