Prestressing

PLYDUCT : HDPE DUCT

Components and duct assembly:

1. SUBJECT

In order to propose a fully watertight barrier for internal

bonded post-tensioning tendons, Freyssinet has
developed the Plyduct sheath.
This duct is made of high density polyethylene (HDPE),
and fully complies with:
the requirements of Technical Report 47 issued by
the British Concrete Society,
the FIB Recommendations on Corrugated plastic
duct for internal bonded post tensioning.

the connections between elements are performed by

means of a polyolefin coupler which is threaded
onto the ends of the two adjacent sheath elements.
Special tapes or thermo-shrinkable sleeves are used
to achieve the water-tightness of the connection ;

at the anchorage the connection to the diffusion plate

is achieved by means of a thermo-shrinkable sleeve,
mechanically secured to the trumplate by a collar ;
the air vent is a flexible plastic tube welded on the
Plyduct sheath or screwed into a connection element
which is clamped or welded to the sheath.

2. DESCRIPTION
The Plyduct is a high-density polyethylene corrugated
pipe obtained from the helical welding of a ribbed flat
plastic strip. The duct is perfectly air and water tight,
made of a material which is corrosion resistant and
chemically stable in concrete.
Sheath elements:
Plyduct sheath elements are manufactured by means of
equipment designed by Freyssinet. The main features of
this highly modular product are:
standard range of nominal internal diameters from 40
mm to 130 mm (5 mm increments) ;

3. CHARACTERISTICS
The Plyduct has the following properties and qualities:

since the fabrication of the sheath is based on a

continuous welding process, the length of the
Plyduct elements can be adjusted, as required ;

watertightnes in order to prevent the ingress of

aggressive chemical agents. It is also an efficient
electric isolator and can be used as part of an
electrically insulated post-tensioning system ;

standard thickness of the Plyduct wall is 2.5 mm or

3 mm. But sheath with smaller or greater thickness
values can be manufactured also ;

low friction coefficient between the strands and the

duct ( = 0.10 to 0.14) for a more efficient
prestressing ;

the production can be performed either in Freyssinet

factories, or directly on site to reduce the
transportation costs and avoid import duties.

bond to cement mortar and concrete, thank to

specially designed ribs ;
resistance to wear to accommodate the lateral
pressure applied by strands in the deviated area of the
tendon during tensioning operations ;
calibrated stiffness to allow for an easy bending of
the duct in the deviated area of the tendon and to
ensure limited deflections between supports ;
perfect grouting resulting from the helical shape of
the ribs that prevent air pockets from being trapped in
the ribs.

FREYSSINET International & Cie

Tel.: + 33 (0)1 46 01 84 84

1 bis, Rue du Petit Clamart 78 148 VELIZY CEDEX France

Technical Document Ref.: FT A 0060

Revision: B

Fax: + 33 (0)1 46 01 85 85
http://www.freyssinet.com

Date: 09 11 01

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Prestressing
PLYDUCT : HDPE DUCT

4. INSTALLATION

The sample consists of two half shells, cut from the duct
and embedded in a cement mortar.

The Plyduct is used and installed like a traditional

corrugated steel duct, except for:
specific storage precautions are necessary to avoid
irreversible deformations and to prevent ultraviolet
ageing of the HDPE,
the sheath shall be supported in the rebar cages by at
least 12 mm diameter bars, spaced at 500 to 800 mm,
after installation and coupling of duct elements
special tapes or thermo-shrinkable sleeves are
installed.

Two samples are clamped together onto a strand (T15.7

mm) with a force calibrated to simulate the pressure
induced by the tendon curvature.

5. PERFORMANCES
Following characteristics were tested at Freyssinet
laboratories:
Water and air tightness
A complete tendon assembly has been successfully
tested under air pressure, in order to check the perfect
tightness of the sheath fitted with its connections to the
trumplate, couplers and grout vents.

Sample for wear test

The samples are slided along the strand, over 750 mm

length, to simulate the strands elongation during
tensioning operations.

Plyduct system immersed in water : no bubbles!

Slide during wear test

Wear test
Wear tests have been performed to simulate the effects
of the strands displacement (extension) during the
tensioning operations at deviators.

The minimum remaining thickness of the sheath wall

was recorded.

Reproduction of this document or part of it is submitted to Freyssinet's agreement.

Technical and commercial information contained in this document are liable to change. Though precise, they cannot involve Freyssinet's responsibility.
Technical Document Ref.: FT A 0060

Revision: B

Date: 09 11 01

Page 2 of 3

Prestressing
PLYDUCT : HDPE DUCT

Friction test

6. CONTACTS

The friction coefficient of strands in the Plyduct ranges

from = 0.10 to 0.14 and was checked during the
construction of the Medway project, in the United
Kingdom.

Commercial Contact:
Pierre GRUCHY
Tel.: + 33 (0)3 85 42 15 03
Fax: + 33 (0)3 85 42 15 10

Bond transmission length

pgruchy@freyssinet.com

The bond transmission length has been determined

through traction tests on grouted tendons in a reinforced
concrete sample. These tests have confirmed that the
transmission length is less than 40 , where is the
outer diameter of Plyduct.

Technical Contact:
Alain HUYNH TUONG
Tel.: +33 (0)1 46 01 84 84
ahuynh@freyssinet.com
Local Commercial Contact:

Local Technical Contact:

Displacement measurement during bond test

Bridge on the Medway river, Great Britain (Eurolink)

Reproduction of this document or part of it is submitted to Freyssinet's agreement.

Technical and commercial information contained in this document are liable to change. Though precise, they cannot involve Freyssinet's responsibility.
Technical Document Ref.: FT A 0060

Revision: B

Date: 09 11 01

Page 3 of 3