On-site Assembly and Installation Instructions for DCP Threadbar Anchors

1. Receiving the anchors

Check for possible transportation damage.
Do not use anchors that have been bent or that have any surface damage, do not use bars as ground for welding, do not allow hot slag to touch the bars, do not weld to bars.
Handle anchors with care using nylon lifting slings (2 legs minimum).
Upon unloading, protect the bars from dirt and mechanical damage.
Important: the bars must not be dropped, thrown or dragged.

2. DCP couplers in the bond and free lengths

3. DCP couplers in the free length only

Centre coupler tube over the heatshrink sleeve (refer to 2. above) allowing for displacement of the heat-shrink sleeve during stressing.
Secure coupler tube firmly by taping both end to the smooth sheathing.

4. Grout tube and outer spacer assembly

Install outer spacers (alternatively: segment spacers) within the bond length using adhesive tape and/or wire at the required spacing.
If applicable, install grout tube using adhesive tape. The grout tube must start 50 to 100mm from the bottom of the anchor and extend at least 1 metre above the anchor head.

5. Installing the bar plates and bar nuts

Install anchor plates pre-filled with anti-corrosion compound over the bar leaving enough bar protruding behind the plate for the anchor nut and the stressing coupler. Also, ensure that there is sufficient bare bar (typically 100 mm) inside the steel tube welded to the steel plate to allow for free movement of the vent cap during tensioning of the anchor.
Screw anchor nut tight against the bearing plate making sure that the spherical end of the nut contacts the plate.

6. Installing the bearing & wedge washer and anchor nut

Install the wedge washer (2 pcs maximum) followed by the bearing washer with welded steel tube prefilled with anti-corrosion compound over the bar leaving enough bar protruding behind the plate for the anchor nut and the stressing coupler. Also, ensure that there is sufficient bare bar inside to steel tube welded to the steel plate to allow for free movement of the vent cap during tensioning of the anchor.
Screw anchor nut hand tight against the bearing plate making sure that the spherical end of the nut contacts the plate.

7. Inserting the anchor into the borehole

If necessary, water-test the borehole according to the project specifications.
Using a lifting eye or another equivalent attachment, lift the anchor from the anchor head end, Important: do not drag.
Insert the anchor into the borehole gradually making sure that it does not get damaged.

8. Grouting the anchors with plates and nuts installed

Grout the anchor along its entire length in one stage according to the project specifications.

9. Grouting the anchors without plates and nuts installed

Ensure that the anchor is centred in the borehole.
Leave enough bar protruding behind the plate for the anchor nut and the stressing coupler. Also, ensure that there will be sufficient bare bar inside the steel tube welded to the steel plate to allow for free movement of the vent cap during tensioning of the bar. Grout the entire anchor in one stage according to the project specifications.
While the grout is still wet, wash-out half a metre below the location of the anchor plate.
Install the anchor plate and nut as instructed above (Installing the anchor plates and anchor nuts).
Tremmie grout the entire void behind the plate.

10. Testing and stressing

Stress the bars according to project specifications and contract drawings. CAUTION: the stressing equipment is capable of developing very large forces. Read the safety and operating instructions.

11. Installing protective caps