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We offer a full service from conception through detailed design and site installation utilising our in-house design team and experienced site managers and operatives.

Post-tensioning provides a great many advantages, including:
• Increasing spans and load carrying capacity;
• Reducing slab thickness;
• Eliminating beam downstands;
• Reducing self weight, quantities of materials and loads on foundations;
• Considerably reducing and simplifying passive reinforcement;
• Reducing the number of expansion joints and columns;
• Better punching shear characteristics;
• Outstanding behaviour in seismic zones;
• Increased cracking resistance;
• Increased waterproofing due to concrete compression;
• Reduced excavation in basements;
• Deflection control;
• Removal of the formwork within 3 days;
• Environmental benefits, less concrete, less steel, fewer lorry journeys.

The environmental credentials of post-tensioned construction are one of the major selling points when the client’s team are trying to determine the construction material. Typically, post-tensioned slabs save about 25% of the slab depth and hence 25% of the concrete volume, when compared to the Reinforced Concrete (RC) equivalent. The steel content (reinforcement and post-tensioned combined) is often reduced by 65%.

Vinci Construction recently appointed Freyssinet to design post-tensioned floor slabs for UPP at Byron House student accommodation in Nottingham. Freyssinet were involved with Vinci’s bid from tender stage, which contributed to them winning the contract. Frame contractor David Ashley Construction then contracted Freyssinet to complete installation works.

Freyssinet also assisted Vinci, and frame contractor Getjar, with their bid to construct the mixed use Mosaic development in Cambridge. Freyssinet’s early involvement and assistance with value engineering helped to give Vinci an edge. Construction of the superstructure will commence in July 2012.

A further post-tensioned floor slab contract recently awarded to Freyssinet is the Eldon Theatre at Portsmouth University. Again, Freyssinet’s input at tender stage assisted the Main Contractor Morgan Sindall in securing the project. Morgan Sindall then recommended Freyssinet to frame contractor Stephenson Construction and superstructure construction is due to start in mid June 2012.

Freyssinet are close to completing post-tensioned floor slab works on site at St Peters School in Stoke on Trent for frame contractor Metropolitan Developer.

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In 2007-8, the existing building on the site was demolished in preparation for redevelopment. However due to the economic climate, construction was delayed and it was not until October 2010 that the project was revived. Oxford Properties is now co-developing the property in partnership with British Land, and in July 2011 they announced Laing O’Rourke as the Main Contractor for the works.

The new tower will feature a tapered glass façade on one side which will reveal the steel bracings, along with a ladder frame that is aimed to accentuate the vertical appearance of the tower. The base will feature a 30 metre high atrium which will be open to the public, and extend the adjacent plaza.

The structural steelwork sub-contract was awarded by Laing O’Rourke to Watson Steel Ltd. Freyssinet were selected in early 2012 to supply 162No. Tetron Disc Bearings (Pot type) which will support the floor beams on the outer columns. Freyssinet’s in-house design team worked in close liaison with Watson Steel to produce bespoke bearing designs to suit the very limited dimensional requirements with high horizontal forces. Fixing arrangements have also been tailored to comply with the restricted requirements.

Production of the bearings at Freyssinet’s factory in Telford is phased to meet the installation programme and construction is scheduled for completion in 2014.

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Offering a full service package, their in-house design team can support clients from conception through detailed design and site installation utilising experienced site managers and operatives. Freyssinet sets high and specified performance criteria positioned above the usual industry standards.

Last year Freyssinet successfully completed a number of post-tensioned slab contracts for the construction of schools and colleges throughout the UK. These included:
• The Learning Centre, Ebbw Vale Campus, Wales
• Bourneville College, Birmingham
• The Big Build, Rutland
• Orminston Academy, Birmingham
• Sir Robert Woodard Academy, Lancing

Freyssinet have recently been awarded further post-tensioned floor slab contracts for Wade Deacon High School in Widnes and the Learning Resource Centre at Stafford College. Freyssinet first got involved with the Wade Deacon project over a year before it was finally let, working with VINCI Construction to give cost advice on a concrete alternative to the then conforming steel framed structure with precast concrete flooring units. The post-tensioned alternative saved significantly on the build cost and the flat soffits assisted the architectural planning and services layout.
The structure consists of a spine block running the full length of the 106m long historic façade. Springing from the spine are three teaching wings, each comprising an atrium bounded by classrooms on either side. The three storey structure has 9,750m2 of suspended PT slabs, all being 230mm deep, each floor will be concreted in six pours.
The post-tensioning system selected by Freyssinet’s in-house design team is the 4B13 bonded system. At level 1, two 1000x350mm deep PT beams have been used to span up to 13.7m to allow a pair of columns to be omitted thus creating a feature access way. And on the roof level the same sized PT beams cantilever 3.3m thus avoiding having to run columns down through teaching space below.

Post-tensioned concrete is an ideal choice for academic building construction. It reduces the depth of the structural members meaning the floor to floor height is reduced. Post-tensioned concrete also has excellent deflection control due to the inbuilt parabolic profiles of the tendons, which directly counter deflection effects.

There is plenty of experience within Freyssinet of building post-tensioned concrete academic buildings. The majority of these have been designed and detailed by our in-house team of qualified and experienced engineers and technicians.

Post-tensioning provides a great many advantages, including:
• Increasing spans and load carrying capacity;
• Reducing slab thickness;
• Eliminating beam downstands;
• Reducing self weight, quantities of materials and loads on foundations;
• Considerably reducing and simplifying passive reinforcement;
• Reducing the number of expansion joints and columns;
• Better punching shear characteristics;
• Outstanding behaviour in seismic zones;
• Increased cracking resistance;
• Increased waterproofing due to concrete compression;
• Reduced excavation in basements;
• Deflection control;
• Removal of the formwork within 3 days;
• Environmental benefits, less concrete, less steel, fewer lorry journeys.

The environmental credentials of post-tensioned construction are one of the major selling points when the client’s team are trying to determine the construction material. Typically, post-tensioned slabs save about 25% of the slab depth and hence 25% of the concrete volume, when compared to the Reinforced Concrete (RC) equivalent. The steel content (reinforcement and post-tensioned combined) is often reduced by 65%.

In addition to academic buildings, post-tensioning also suits a wide variety of projects, such as:
• Offices
• Retail developments
• Underground car parks and multi-storey car parks
• Hospitals
• Business centres
• Industrial buildings
• Sports buildings
• Residential towers

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In July 2011 Freyssinet were appointed to carry out condition surveys of the swimming pool crawl duct walls and soffits to establish the scope and quantum of repair required to the concrete surfaces. The survey undertaken included a 100% sounding survey of the service void swimming pool elevations and soffits, a cover meter survey to establish reinforcement density and continuity testing to estimate the extent of electrical bonding that may be required during concrete repair to make the reinforcement compatible with electrochemical repair techniques.

Results of the survey found there to be deteriorating reinforcement steel within the crawl duct walls and soffit, along with areas of cracked and spalling concrete. Freyssinet put forward a solution of concrete repair and the installation of a cathodic protection (CP) system, appointing their sister company Corrosion Control Services Limited (CCSL), specialists in concrete corrosion prevention, to provide the design and specification for the CP system.

The perimeter crawl ducts where the works were to be carried out were classified as confined space, therefore, careful planning, correct equipment and monitoring as well as competent certified personal was all essential to complete the project in a safe manner.

Repair works commenced in December 2001 and the project was completed in two stages. Initially, Freyssinet broke out all delaminated and spalled concrete, then tested and ensured continuity of the reinforcing steel and completed concrete repairs.

The concrete repair areas were then allowed to cure prior to the installation of the ZLA “sticky zinc” galvanic CP system. The locations of zinc were marked out on the walls and soffit, and small pockets were broken out to allow for studs to be welded to the reinforcement and then electrically connected to the ZLA.

The works were completed in January 2012 to the satisfaction of the client. It is hoped that the successful refurbishment of the swimming pool, along with a new climbing wall and cafe will increase revenue and ensure the building can remain open.

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Freyssinet are able to offer a complete solutions package for any concrete structure, no matter how large it may be, and no matter how much it may need in the way of concrete repairs. By using sustainable technologies, Freyssinet are able to do more, but with less materials and energy, which sets them apart from the competition. Freyssinet can offer a full range of integrated concrete enhancement solutions, including: concrete repair, concrete replacement, hydrodemolition, wall sawing and diamond coring.

Concrete repairs are perhaps the most effective way that Freyssinet can prolong the life of your structure. If the concrete shows signs of cracking, if it is spalled, if it has become honeycombed or damaged in any other way, a concrete repair, or in more extensive areas, concrete repairs, may be the answer.

Before any concrete repair work is completed, thorough testing needs to be carried out to assess the true nature of any damage or degradation. Freyssinet are able to offer a comprehensive range of tests to accurately identify and diagnose any problems, before advising on what structural concrete refurbishment is required. These tests can also identify any underlying causes that may need to be addressed, saving additional expense for concrete repairs later on.

Once the appropriate type of concrete repair is identified, a range of techniques are available, including: leak sealing, sprayed concrete, pressure resin injection, vacuum resin injection, or a combination of pressure and vacuum resin injection using epoxy, or patch and thin bond repairs using high quality, modified mortars.

If the concrete is in poor condition, it may be that a concrete repair is not a viable option. Concrete replacement may be necessary, and once again, Freyssinet have a range of solutions available.

Before any replacement can begin, defective concrete will need to be removed. As part of your total Freyssinet solution, removal can be performed by conventional breaking out, or by using hydrodemolition techniques, by Freyssinet’s own in-house team.

Hydrodemolition utilises high pressure water jets, and can be used in small and large areas alike. It can also be used for the removal of coatings, which will then provide an excellent surface for repair materials or new coatings to bond to. This technique reduces the risk of potential harm caused by vibrations, cleans existing steel re-enforcement whilst causing no damage, eliminates dust and debris, and can result in a more efficient programme.

The Freyssinet team have over twenty years of experience in a wide range of hydrodemolition applications. As well as being highly trained and experienced, you can rest assured that they conform with, and adhere to, all the latest health and safety and quality standards of the industry.

Once the old concrete has been removed, Freyssinet will replace this with high performance concretes and mortars.

Concrete repairs and replacement are only part of a wide range of complimentary services offered by Freyssinet. Whether your project involves concrete bridge repair, concrete building repair, or any other kind of concrete structure repair, Freyssinet can offer a holistic package of products and services. Diagnosis, prevention and cure, are all part of the service offered by a company with the reputation, credentials and experience that have secured them landmark projects for the Highways Agency, and many others.

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Freyssinet are in a position to offer clients a wide range of options when it comes to strengthening. Some of the potential applications for the various strengthening techniques include: increasing the floor slab load that is allowed, strengthening of the bridge deck, adding strengthening to new openings, and strengthening columns.

External post tensioning is appropriate when dealing with bridge decks in particular. Along with everything else Freyssinet have to offer is, a complete design and install post tensioning service for any of your existing structures. No matter how big the project may be Freyssinet can meet even the most demanding post tensioning applications. If the bridge structure is a large span box girder, Freyssinet can fit additional post tensioning inside the structure itself. External post tensioning can also be used to upgrade circular storage tanks, or to make them watertight. Tendons fitted to the outside of smaller span structures, are also something offered by Freyssinet.

In existing areas that have a high stress concentration or that may be subjected to bursting forces, pre-stress may need to be introduced. Freyssinet can meet these needs with their own Freyssibar pre-stressing system. This is a comprehensive range of fully threaded, high strength bars that are complimented by extension, coupling and anchoring systems. If you have an over-stressed area of an existing structure, this solution can be an effective remedial action. Freyssibars can also be an excellent option, if you are looking to increase the load carrying capacity of your existing structure with high tensile bars.

If under strength floor slabs or beams are the problem, you may want to consider plate bonding. This is a process where Freyssinet can take appropriately sized steel plates, then bolt them or bond them, with an epoxy adhesive to a structure’s tension zone. By applying this process to the specific area, the load carrying capacity can be increased as required, up to a certain degree.

Another alternative solution offered by Freyssinet is the use of a carbon fibre product called TFC. This reinforced polymer carbon fibre product is manufactured in house by Freyssinet, and can be an outstanding option in the right circumstances. TFC can be particularly useful if the area you need to reinforce has a complex profile, or if clearance height is an issue, such as in a multi-storey car park for example. Other advantages of TFC are that it adds no extra weight to the structure, it is suitable for use in a wide range of temperatures, and it is resistant to UV, fire and shocks.

The correct type of strengthening application is dictated by the structure, its use, its design, and the amount of desired load carrying increase to be achieved. All of these factors require careful consideration, which is why Freyssinet offer a complete design and build service for its clients. Their in-house teams can assist in deciding which is the most appropriate technical and economical solution for your strengthening requirements.

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To address the challenge of concrete corrosion prevention, there are several structural enhancement techniques to look at. These techniques include cathodic protection, coatings, grout injection, resins and wax injection. Freyssinet have been using these techniques for over thirty years, so you know that you are in good hands.

Cathodic protection is a concrete corrosion prevention technique that can be used where patch repairs are likely to be unsuccessful. Situations where cathodic protection may be the best form of concrete corrosion prevention are where there are sufficient amounts of chlorides in untreated areas of adjacent and untreated concrete. Cathodic protection may also be the best course of action where carbonation has managed to get behind the reinforcement layer.

The process of cathodic protection is achieved by passing a small amount of electric current through the reinforcement layer and offers several advantages over other concrete corrosion prevention techniques that can be used. Being a continuous process, it not only stops the existing corrosion; but also prevents further corrosion attacking the structure at a later date. There is also no need for any reapplication, it can be used on very badly damaged concrete, protects against both carbonation and chloride and can be adjusted and controlled through constant monitoring. Furthermore, it is a more economical alternative form of concrete corrosion prevention than concrete replacement. Cathodic protection is especially well suited to marine and motorway structures, which are highly susceptible to corrosion.

To prevent chemical attack whilst providing waterproofing, with limited maintenance costs and a long life expectancy; coating treatments are the answer. Freyssinet can provide clients with an extensive and full range of coatings to inhibit corrosion, provide anti-carbonation, waterproof and resist chemicals.

Void filling solutions can be applied using the injection of resins and grouts in both structural and non-structural applications. The latest vacuum assisted grouting technology, resin and polyester epoxy is used along with both high and low pressure injection equipment to deal with fine cracks within reinforced concrete structures. A wide range of different injection techniques are employed by Freyssinet’s teams of highly trained specialists. Whatever the problem, you can be assured that they have the expertise, experience and equipment to do the job.

For the full range of treatment work, from post-tensioning to ground anchors, more often now Freyssinet find it better to use wax injection, rather than more traditional grouts. The two major benefits for wax are its properties as a modern semi-solid bonding substance make it, more corrosion resistant, and a more flexible bonding agent to work with than traditional grouts. No matter how big the job, Freyssinet can provide the equipment needed, whether it’s a project needing 2 litre ‘top hat’ caps, or a 2000 litre application.

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