Construction begins with rotary or rotary-percussion drilling of a large-diameter borehole, typically 6 to 12 inches across to accommodate the multi-strand tendon, the corrosion-protection sheathing on permanent installations, and the required grout cover. The hole is advanced through the active failure zone and into competent rock or dense soil at the design inclination, usually 15 to 45 degrees below horizontal for slope and dam-abutment work. In caving ground or where the borehole must pass through fractured rock, duplex drilling or temporary casing keeps the hole open until the tendon is in place.
The tendon is a bundle of 0.5 or 0.6 inch diameter seven-wire prestressing strands per ASTM A416, with bundle counts scaling from 4 strands for 100 kip systems up to 30 plus strands for 2000 kip systems. The unbonded free length is sleeved in smooth plastic sheathing filled with corrosion-inhibiting grease, and the bonded fixed length is left bare or encapsulated in a corrugated plastic duct depending on the corrosion class. PTI Class I (encapsulated double corrosion protection) is specified for permanent installations with 75 to 100 plus year design lives, while PTI Class II (grout-protected) is used for temporary construction-phase applications. The assembly is inserted with centralizers and spacers to maintain consistent grout cover, and neat cement grout is pumped through a tremie line from the toe of the bond zone upward, displacing drilling fluid and filling the bonded length around the strands.
Once grout reaches design strength, typically 7 to 10 days, the anchor is stressed using a multi-strand hydraulic jack acting against a steel bearing plate at the head. The tendon is loaded incrementally per a defined performance test or proof test sequence, with displacement measured at each load increment to verify that the bonded fixed length is fully engaged and creep is within acceptance limits. After stressing, individual strands are locked off by setting tapered wedges into a steel anchor block, transferring load permanently to the structure. Every production anchor is proof-tested to 133 percent of design load per PTI DC35.1, and a defined sample of anchors receives extended performance and creep testing on cohesive bond zones.
1
Borehole Drilling
A 6 to 12 inch diameter borehole is drilled through the active failure zone into competent rock or dense soil at the design inclination.
2
Tendon Installation
A multi-strand seven-wire tendon per ASTM A416 is placed inside corrosion-protection sheathing with centralizers and spacers.
3
Bond Zone Grouting
Neat cement grout is tremie-pumped from the toe upward, filling the bonded fixed length while the unbonded free length remains isolated.
4
Stressing
After grout reaches design strength, the anchor is stressed using a multi-strand hydraulic jack to apply active design load.
5
Lock-Off and Testing
Tapered wedges lock individual strands at the bearing plate; every anchor is proof-tested to 133 percent of design load per PTI DC35.1.