Set of components for tendon encapsulation process in active anchor plate in prestressed concrete
This patent refers to improvements introduced in the encapsulation technique regarding the field of tendons with anchor plates and anchor tensors, applied in the construction system of prestressed concrete in its assembly, demoulding, tensioning and final finishing with obtaining anticorrosion protection of metal parts through a set of improved components applied to the current processes and an innovative process that will ensure the seal against entry of concrete cream into the greased system during the assembly of the system, in forms prior to concreting, which will also ensure their perpendicularity to the shape and bringing advantages that will increase the speed of installation, speed of calculation response, speed in the installation of hydraulic jacks for tensioning the pull rods, ease application and perfect fittings in the tools, improvement of the finishing process ensuring thus effective protection for durability, reuse of components, increased safety at work and elimination of all improper process that occurs in the preparation and fixing of the anchor plate and subsequent closing and finishing.
1. A set of components for a tendon encapsulation system, comprising:
a flanged cap ( 1 ) having elongated shape, an anterior sleeve with truncated-cone shaped fixing tabs ( 1 -A), a cylindrical shaped central body ( 1 -B) and a truncated-cone shaped posterior end ( 1 -C) fittable to an anchor plate ( 2 ), the flanged cap secured to the anchor plate by plastic double pull rod fasteners ( 3 ) and fittable to a tendon (C),
the system comprising a hose (M), the anchor plate ( 2 ) having a taper-shaped posterior sleeve ( 2 -A) with a female plug ( 2 -A- 1 ), and fittable to the flanged cap ( 1 ) by a mountable pocket form ( 4 );
a front of the double pull rod fasteners ( 3 ) having cylindrical shape, locking rings ( 3 -A) and a fixed washer ( 3 -B) and a back of the fasteners with locking rings ( 3 -C) each with a lock ( 3 -D) of ringed and truncated-cone shape with cuts forming locking wedges;
the mountable pocket form ( 4 ) comprising two pluggable parts,
a truncated-cone shaped hollow outer cover ( 4 -A) with trapezoidal shaped internal guides ( 4 -A- 1 ) and a ring shaped leveling stopper ( 4 -A- 2 ) with sealing skirt ( 4 -A- 2 -A) having cylindrical and conical shape and
a core ( 4 -B) having a hollow cylindrical shape with a removing ring ( 4 -B- 1 ), support ring ( 4 -B- 2 ) having the shape of a ring and a fitting bounce ( 4 -B- 3 ) also in the shape of ring and fittable on the anchor plate ( 2 ) and passing through the form (F); and
a plug ( 5 ) made from concrete or mortar, having truncated-cone shape, closed on one side and with a sealing seal ( 5 -B) adhered and closing the one side, fittable and adhered to an anchor niche (NF).
2. The set of components according to claim 1 , wherein the plug ( 5 ) comprises a handle ( 5 -C), having shape of an “A”, fixed in the other side.
3. The set of components according to claim 1 , wherein the flanged cap comprises a fittable cap ( 6 ) having elongated shape with a truncated-cone-shaped anterior sleeve ( 6 -A) and with a click type male fitting bounce ( 6 -A- 1 ), cylindrical-shaped central body ( 6 -B) and a truncated-cone-shaped posterior end ( 6 -C).
4. The set of components according to claim 1 , wherein the pull rod fasteners comprise simple head tapping screw type pull rod fastener ( 7 ) complemented by a lock ( 3 -D).
5. The set of components according to claim 1 , wherein the pocket form comprises a monoblock pocket form ( 8 ).
6. The set of components according to claim 1 further comprising a pocket form removal tool ( 9 ) having an offset shaft lever shape, with a handle at a top part, two curves at an intermediate part and a “U”-shaped ear at a bottom part.
7. The set of components according to claim 1 wherein the plug ( 5 ) is filled with antioxidant grease ( 5 -A).
8. A process for encapsulating an anchored tendon using the set of components of claim 1 , comprising:
removing excess of the hose from the tendon;
installing the flanged cap having a posterior end onto the tendon proximate a position of the anchor plate;
installing the anchor plate onto the tendon;
installing a form onto the anchor plate using the plastic double pull rod fasteners;
installing a sealing cap and the pocket form onto the anchor plate;
pouring and curing concrete;
removing the pocket form using a tool comprising an offset shaft lever shape, with a handle at a top part, two curves at an intermediate part and a “U”-shaped ear at a bottom part;
tensioning the tendon and locking the tensioned tendon in the anchor plate with locking wedges;
cutting the locked tendon; and
installing the plug made from concrete or mortar, having the truncated-cone shape, closed on one side and filled with antioxidant grease, with a sealing seal adhered and closing an anchor niche made by the pocket form in the concrete.