INSTALLATION AND

0.6”φ CFCC HANDLING, ANCHORINSTALLATION AND
MAINTENANCE MANUALTOKYO ROPE USA
8301 RONDA DRIVE
CANTON, MI 48187(734) 335 6037

MARCH 2023 | VERSION 1.00

USER INSTRUCTIONS

WWW.TOKYOROPE.CO.JP/ENGLISH

Table of Contents
1.

Preface1.1

2.

Introduction and Description of User

2

Description of the Product
2.1
2.2
2.3

3.

System Overview
Components of Anchorage System
Installation Tools and Equipment

345

Explanations of Safety Warnings

6

Safety3.1

4.

CFCC Handling
4.1
4.2
4.3
4.4
4.5

5.

Unloading and Storage of CFCC
Unpacking CFCC
Transporting CFCC to Fabrication Site
Method to Pull Out CFCC from the Reel
Initial and Final Tensioning

7
9
10
12
21

Anchorage System Installation and Removal
5.1
5.2
5.3
5.4
5.5
5.6

6.

Set Buffer Material on CFCC Strand
CFCC Sleeve Preparation
Secure Wedges and CFCC Sleeve to CFCC
Connect CFCC to Steel Strand
Remove Wedges from CFCC
CFCC Anchor Installation and Removal Videos

22
23
24
26
28
28

Anchor Staggering
6.1
6.2

7.

Anchor staggering
Precautions of Anchor Staggering

2930

Detensioning
7.1
7.2

8.

Tools
Detensioning Method

31
31

Maintenance
8.1
8.2

9

Cleaning
Inspection32
33

Equipment Return
9.1

Equipment to Return34
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PREFACE
1.1

Introduction and Description of User
Thank you for purchasing and using CFCC and the CFCC anchorage system. CFCC and the
CFCC anchorage system is designed and manufactured to the highest quality standards and isbacked by the Tokyo Rope USA commitment to service and parts support.
http://www.tokyorope.co.jp/english/
This document is intended for precast fabrication managers, foremen and installers that use
CFCC and the CFCC anchorage system. Use of CFCC and the CFCC anchorage system shall
only be carried out by properly trained personnel.
Your safety and the safety of others depend on the proper handling, installation, operation,
maintenance, and understanding in the use of this equipment.
All personnel managing and/or using CFCC must read and understand this manual prior to using
CFCC and the CFCC anchorage system. Follow all instructions, warnings, and precautions in the
manual. Failure to follow instructions can cause injury or death.
It is the responsibility of the precast fabrication managers, foremen and installers to ensure CFCC
and the CFCC anchorage system is used and maintained in a safe and appropriate manner thatwill not cause damage to or make unsafe in any way the operation of CFCC and the CFCC
anchorage system being used.
Continuing improvements and advancements of this product may occur at any time.
If any nonconformances are found in the product, do not use that portion of the product and notify
Tokyo Rope.
If any questions arise during installation or maintenance of this product, please consult your sales
representative, or contact Tokyo Rope USA’s corporate office.

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DESCRIPTION OF THE PRODUCT
2.1

System Overview

Page | 3

DESCRIPTION OF THE PRODUCT
2.2

Components of Anchorage System⑤⑤

Page | 4

DESCRIPTION OF THE PRODUCT
2.3

Installation Tools and Equipment

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SAFETY
3.1

Explanation of Safety Warnings

The following safety warnings are used throughout the manual:This symbol is used to call attention to instruction concerning personal safety. Be sure to observe andfollow these instructions.

The signal word DANGER in the manual identifies a hazardous situation which, if not avoided, WILL
result in death or serious injury.

The signal word WARNING on the machine and in the manual indicates a potentially hazardous
situation which, if not avoided, COULD result in death or serious injury. If CFCC gets damaged, DO
NOT use damaged portion of CFCC.

The signal word CAUTION in the manual indicates a potentially hazardous situation which, if not
avoided, MAY result in minor or moderate injury. It may also be used to alert against unsafe
practices.

This notice identifies procedures which must be followed to avoid damage to the machine.
Instructions are necessary before installing or operating the equipment. All personnel must
read and understand this installation and maintenance manual. Follow warnings andinstructions in the manual when installing. Failure to follow instructions can cause injury or
death.

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CFCC HANDLING
4.1 Unloading and Storage of CFCC
4.1a
CFCC is delivered on a wooden reel and packaged asshown. The wooden pallet is longer than a typical palletwith dimensions of 31” long x 6’ high and needs
unloaded/transported/moved with a forklift. If a loading
dock is not available and the reels are inaccessible by aforklift, a hand truck with 6LF forks is needed to move thereels to the back of the truck so accessible by a forklift.
Do not remove the outer cardboard layer until using CFCC
and reel is transported to the fabrication site.
Upon arrival, check the Cardboard Covering for punctures
and/or rips. If there are punctures or rips, the outer layer of
CFCC could have been damaged during shipping or or
unloading. Contact Tokyo Rope for further instruction ifpunctures and/or rips are present.

CFCC is fixed with steel bands

CFCC is covered with cardboard.

Insert the forklift into the short side tomove pallet.

Do NOT drop CFCC products off a forklift. Dropping CFCC
products CAN damage CFCC. Damaged CFCC CAN break during
tensioning and cause serious injury or death.
4.1b
If the forklift forks are less than 6 LF in length, thewooden pallet CAN break and the CFCC CAN bedamaged by the broken wood (see picture below). Use
extension forks if the fork length is less than 6 LF.

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CFCC HANDLING
Wooden pallet broken by fork resulting indamage to CFCC.

Extension forks to be used if the fork
length is less than 6 LF.

4.1c
Store CFCC in a dry flat location out of direct sunlight.
Long periods of sunlight exposure of 2 weeks or more
will not affect the strength of CFCC, but it may provide
the strand with memory of the round reel shape therefore
making it difficult to work with. The wooden reel andpallet can rot and soften if exposed to rain/water.
Store CFCC reels such that the reels are stable, will not
fall over and/or roll and will not be struck by anything that
could potentially damage the CFCC. Store anchorage
components in a dry location prior to use to prevet
rusting.

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CFCC HANDLING
4.2

Unpacking CFCC

Unpack CFCC directly before using. Cut the steel
bands that fix the reel to the pallet. Remove the outer
cardboard layer and plastic layer below the carboard.

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CFCC HANDLING
4.3

Transporting CFCC to Fabrication Site

4.3aTransport the reel to the fabrication site by crane or
forklift by Inserting the reel stand shaft into the hole in
the reel and hooking the sling rope to the shaft.

Take care not to strike and damage the CFCC with theforklift or equipment during transport.

4.3bPlace the reel on the reel stand such that the CFCC canbe drawn into the bed from the bottom of the reel. The reelstand MUST be such that the CFCC can be drawn fromthe reel and pulled through the bed without bending the
CFCC more than it’s bending limit. Best practice is toconstruct the reel stand such that CFCC is pulled from thereel into the bed without bends.
The radius (R) must be greaterthan 40 times the CFCC diameter.

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CFCC HANDLING
4.3c
Check again for tears and/or punctures in the cardboard
cover. If there are tears and/or punctures, the outer layer of
CFCC needs inspected for damage. Any damaged CFCC
MUST BE discarded. Remove the carboard cover from the
CFCC.

Remove any damaged CFCC
prior to use.

4.3d
Check for tears and/or punctures in the plastic wrap locatedunder the cardboard cover. If there are tears and/or
punctures, the outer layer of CFCC needs inspected fordamage. Any damaged CFCC MUST be discarded. Remove
the plastic wrap from the CFCC.

4.3e
Before withdrawing CFCC, set a protection sheet (cardboard, etc.)
under the reel to prevent CFCC from being scratched by any
obstructions on the ground.

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CFCC HANDLING
4.4

Method to Pull Out CFCC from the Reel

Personal Protective Equipment should be worn when installing
the CFCC anchorage system. Carbon fibers can transfer from
CFCC to the skin during installation of the anchorage systemcausing skin irritation. The metal anchors can heat up from thesunlight and be too hot to handle without gloves. Shards ofcarbon fiber can spray from the CFCC during cutting of thestrand and enter the eyes causing irritation and/or serious eye
injury.

4.4aPull out CFCC from the bottom of the reel into thebed or alongside of the bed. While CFCC is being
drawn from the reel, a worker must hold the outside
reel flanges to control the rotation speed of the reelto prevent the CFCC from unwinding too quickly andbecoming loose during this process.

If the CFCC becomesloose as it’s being drawn
from the reel, the CFCC
may potentially moveoutside the reel flange
and wrap around the shaft
damaging the CFCC due
to the tight bend.

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CFCC HANDLINGDo NOT bend CFCC such that theradius becomes less than 40 times
the diameter of CFCC. CFCC WILL lose strengh at the local bend
location and experience internal and external damage.

If the CFCC becomes loose as it’s being drawn from the reel, proceed asfollows:
If the CFCC becomes slightly loose, but does not loosen more than the outerrim of the flange (distance H), increase the braking pressure to remove
looseness.

If the CFCC becomes loose such that it sags outside of the rim of the flange(distance H), STOP pulling out the CFCC and correct the condition. Correct
the condition by pulling out the CFCC very slowly while increasing the braking
pressure until the loose CFCC is removed, rewinding afterwards asnecessary. When rewinding the CFCC, ensure the CFCC rewinds evenly
without looseness on the reel and does not overlap.
Overlapping the CFCC during rewinding may damage the CFCC when pullingit back out due to bending. Once corrected, continue pulling out the CFCC
slowly with increased braking pressure.

Ensure there is
no looseness in
CFCC while
rewinding.

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CFCC HANDLING
4.4b
Wooden headers MUST be used to prevent damage to the
CFCC from the sharp metal holes. If wooden headers are notused, the metal holes MUST be chamfered so that contact
between the CFCC and steel is with a smooth rounded steel
surface.

Wooden headers
MUST be used.

4.4c
When walking the CFCC down the bed, keep the
CFCC straight (at the same height as the hole in theheader) for a minimum of 5 LF once the CFCC isthrough the header before continuing to walk the
CFCC down the bed at a higher height.

Pull the CFCC a minimumof 5LF level with the holein the header once
through the header.

5LF

DO NOT pull the CFCC up at an angle directly after pulling it
through the header.

DO NOT pull the CFCC up
directly after pulling it
through the header.

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CFCC HANDLING
Do not pull CFCC
forcefully against
metal edges.
CFCC CAN be damaged from metal edges.
Protect edges as necessary before pulling
CFCC from the reel.

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CFCC HANDLINGDo NOT
step onelevated CFCC without distributing theload. Place a wooden board with aminimum area of 9ft² on top of CFCC
before stepping on CFCC to spread theforce evenly.
Do NOT drag
CFCC overconcrete chunks or stone on the groundwhen pulling out or moving CFCC. ThisCAN damage CFCC. Spread a safety sheetover the ground if CFCC must be pulled inthese conditions.

Do NOT step on orplace heavy objects
on CFCC on
uneven ground. This WILL result in shear force
damage and/or damage from hard edges.

Do NOT apply shear force
to CFCC. CFCC is weakagainst forces applied at right angles to its axis.

Do NOT drop hard objects such as
tools on CFCC.

Page | 16

CFCC HANDLINGDo NOT compress
CFCC. CFCC isvulnerable to compressive force in the axial
direction and CAN easily damage if compressed.

Compress

Do NOT kink CFCC.
CFCC can become
kinked if pulled while
twisting or looped. Kinked CFCC has significantly
reduced strength and WILL be damaged internallyand externally.

Do NOT apply tension to
CFCC when CFCC is crossed\or tangled.

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CFCC HANDLING
4.4d
Measure and mark the portion of CFCC to be cut.
Cut the CFCC cable with a grinder.

4.4e
Fasten the end of the CFCC to the reel with a string any time the CFCC is
not being used.

Ensure the CFCC is not protruding outside theedge of the reel flange to avoid damage to theend of the CFCC from being hit and/or rotationof the wheel.

4.4f
Transfer anchorage components to fabrication site at time of fabrication to avoid rusting while not inuse. Install anchorage system – See Chapter 5 and Chapter 6 for anchorage system installation andanchor staggering instructions, respectively. Anchor staggering is not always required as explained in
Chapter 6.
When lifting/moving CFCC and the anchors after theanchors are installed, make sure to hold the anchors andNOT the CFCC.

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CFCC HANDLINGDo NOT lift/move theanchors/CFCC after theanchors are installed by holding the CFCC. This can
reduce the strength of the CFCC near the anchor and/or
damage the CFCC.

Do NOT holdthe anchor andcompress the CFCC from one side. This willcause local bending which CAN reduce thestrength of CFCC and/or damage the CFCC at
the bend.

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CFCC HANDLING
4.5

Initial and Final Tensioning

4.5aOnce the anchorage devices are installed, perform the initial tensioning work.
4.5bCheck to ensure the CFCC and steel cables are not crossing and the CFCC anchor locations willaccommodate the anchor movement due to elongation during final tensioning.
4.5c
After the initial tensioning and verification in Step 4.5b, perform the final tensioning. If the anchors are
staggered, the tensioning order MUST be such that the anchors do not hit each other during
tensioning.
4.5d
Cover the anchorage devices with wooden boards,
tarps, or other methods to provide protection from thesunlight. Position the cover to ensure the anchorage
devices are always shaded as the sun changes
position.
The anchors MUST be managed so that their temperature does notexceed 122⁰F (50⁰C).
DO NOT
exposethe anchorage devices to the heatfrom steam produced during curing of
the concrete. The anchorage devices
MUST be covered separately from thecuring concrete.

Correct Covering Method

Do NOT expose
CFCC to fire
and/or extreme heat. CFCC is solidified withepoxy resin and vulnerable to fire. The qualityof resin WILL change and the strength of
CFCC WILL be seriously lowered when incontact with extreme heat, such as
welding sparks, flame, cigarette fire, etc.
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ANCHOR STAGGERING
5.1

Secure Buffer Material on CFCC Strand

5.1a
Undo the blue and red Velcro from each other.
5.1b
Insert the end of the CFCC through the buffer material making sure thered Velcro is at the end of the CFCC. Leave 1” of CFCC protruding fromthe end of the buffer material.
5.1cStarting with the red Velcro, tightly wind the Velcro around the 1”
protruding portion of CFCC.
5.1d
While tightly holding the end of the buffer material over the red Velcro,
twist the opposite end of the buffer material adjacent to the blue Velcro
to secure the buffer material to the CFCC. Once the buffer material istwisted as tightly as possible to the CFCC, tightly wind the blue Velcro
around the CFCC adjacent to the buffer material to keep the buffermaterial tightly in place.
5.1e

No gaps

Check the buffer material for fit. The buffermaterial should be tight to the CFCC so that
there is NO movement of the buffer materialon the strand and there should be NO gaps
in the buffer material.

Pink line on Buffer Material

No loose or gapped Buffer Material

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ANCHOR STAGGERING
5.2

CFCC Sleeve Preparation

5.2a
Shake spray can vigorously until you hear a rattling sound.

Molybdenum
Lubricant Spray

Rattling sound MUST be heard before spraying to ensure the Molybdenum
is consistently mixed with thinner.
5.2b
Spray the molybdenum lubricant inside the CFCC sleeve making sure to cover
the inside of the sleeve completely. Spray the entire inside of the sleeve forabout 2 seconds (2 turns around the inner circumference can be used as a guide).

CFCC Sleeve

5.2cCheck the molybdenum spray coating. The inner surface of each sleeve MUST
be visually inspected after being sprayed to ensure none of the steel surface isvisible and is entirely coated with molybdenum. Check both ends of sleeve. The
entire inside of the sleeve should be dark grey in color due to the coloring of themolybdenum spray. CFCC sleeve needs to be properly coated withmolybdenum allowing the wedges to move into place securing the CFCC during
tensioning.

Do not use CFCC sleeve if insufficiently coatedwith spray. Insufficient molybdenum coverage
CAN cause slippage. Slippage WILL make CFCC
and anchorage system break/fly at high speed
and CAN cause serious injury or death.

ACCEPTABLE –steel surface isentirely coated.

NOT
ACCEPTABLE –steel surface isvisible.

5.2d
Slide CFCC sleeve onto the CFCC until it passes the buffer material.

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ANCHOR STAGGERING
5.3

Secure Wedges and CFCC Sleeve to CFCC
Pink line on Buffer
Material to line up
with outer face ofWedge Holder

5.3aSlide the Wedge Holder onto the Buffer Material so thatthe outside face of the Wedge Holder is in line with thepink line on the Buffer Material (near red Velcro).
Note: The rubber band around the Wedge Holder
keeps it closed to prevent the Wedges from falling out.

Arrows on Wedge Holder to point towards CFCC.

Arrows on Wedge
Holder point
towards CFCC.

5.3b
Slide each of the (4) wedges into the (4) holes in the Wedge
Holder until the top of the Wedges are flush with the outside faceof the Wedge Holder.
5.3c
Check to ensure Wedges are sitting between blue and red
Velcro and NOT on top of the Velcro.
The Wedges MUST be fully supported by Buffer Material.

Do not set Wedges on top of the Velcro.

INCORRECT

Set Wedges between the Velcro.

CORRECT

Wedges MUST be fully supported by
Buffer Material and between red andblue Velcro.

The ends of the Wedges MUST be evenly flush.

5.3d
INCORRECT

Check to ensure Wedges are flush and even at end.

The spacing between the Wedges MUST be even.

INCORRECT

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ANCHOR STAGGERING
5.3e
Slide the CFCC Sleeve over the Wedges until it stops sliding,ensuring the Wedges stay in place.

Do not proceed to next step until Wedges are fully seated on Buffer Material, evenly flush atends and evenly spaced. Improper seating of wedges CAN cause slippage. Slippage WILL make
CFCC and anchorage system break/fly at high speed and CAN cause serious injury or death.
5.3f
Prepare Pushing Machine by fully rotating cylinder clockwise until fully seated. Once seated, set theset screw to keep the cylinder at this position and prevent it from rotating counterclockwise.
5.3g
Place Metal Ring around end of
CFCC against Wedge Holder. Thenplace the Sleeve / Wedges /Wedge Holder unit into the
Pushing Machine.

Place Metal Ring aroundend of CFCC against Wedge
Holder before setting unit
into the Pushing Machine.

Metal Ring MUST be used for Wedges to be pushed into the
CFCC Sleeve evenly.
5.3h
Push the Wedges into CFCC Sleeve by pressing the remote control button on the Pushing Machine
until the cylinder head stops and reaches it’s limit position. Once the header stops, take thumb off
button to stop machine and remove wedge holder.

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ANCHOR STAGGERING

Page | 25

ANCHOR STAGGERING
5.4

Connect CFCC to Steel Strand

Ensure the lay direction (twisting direction) is thesame as that of CFCC to prevent the CFCC fromuntwisting. It is also advised that the diameter of thesteel cable is the same as that of CFCC. CFCC loses strength when untwisted and CAN breakduring tensioning causing the anchorage system break/fly at high speed and CAN cause serious
injury or death.

5.4aConnect Coupler to Conventional Splice Chuck. Spray the inside ofConventional Multiple Splice Chuck with Molybdenum Spray andassemble chuck using the same method as a typical steel chuck.
Fully thread the Coupler onto the Conventional Multiple Splice Chuck,turning a half-turn back in opposite direction once fully threaded. Turninga half turn back in opposite direction makes it easier to remove theSplice Chuck from the Coupler.
5.4b
Connect Coupler to the Sleeve / Wedges unit. Fully thread the
opposite end of the Coupler to the Sleeve / Wedges unit by turning
the Coupler, turning a half-turn back in opposite direction once fully
threaded. Turning a half turn back in opposite direction makes it
easier to remove the CFCC Sleeve from the Coupler.
Do not turn the CFCC Sleeve to thread the sleeve to thecoupler. This will untwist the CFCC.
5.4c
Mark the Steel Cable to be connected to the CFCC 4”from the end and insert into the Conventional Multiple
Splice Chuck, making sure the entire 4” portion of steel
cable is inserted.

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ANCHOR STAGGERING
5.5

Remove Wedges from CFCC Sleeve [After Detentioning]

5.5a
Cut off CFCC from CFCC Sleeve flush with Sleeve (if
CFCC is not cut flush with Sleeve, the Sleeve / Wedges
unit may not fit in the Removal Machine).
5.5b
Detach Coupler from Conventional Multiple Splice Chuck.
5.5c
Set the Sleeve / Wedges unit into the Removal
Machine and Press the button on the Removal
Machine until the Wedges are removed.

5.5d
Save and reuse the Reuse Items and return to Tokyo Rope at completion of project. Discard the
Scrap items.

5.6 CFCC Anchor Installation and Removal Videos
Installation video
Removal video: 0.6" φ CFCC Anchor Installation Video: 0.6" φ CFCC Anchor Removal Video

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ANCHOR STAGGERING
6.1

Anchor Staggering

The width of a CFCC anchor is 2.56 inch (65mm). If the spacing between strands is less than 2.56
inches, staggering is required. Stagger the anchors and tension the CFCC per the positioning andtensioning order below.
Schematic of Bed with Staggered Anchors

Cross Section Views of Staggered Anchors

Tensioning Order with Staggered Anchors(1) Blue → (2) Red

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ANCHOR STAGGERING
6.2

Precautions of Anchor Staggering

6.2a
The length of CFCC from the end header to front anchor should be less than 5 ft. If this CFCC length isexceeded, the anchors may recoil during detensioning.

6.2b
The length of CFCC from the back anchor to the front anchor should be approximately 1 ft. Too short of alength CAN cause the front and back anchors to make contact during tensioning.

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DETENSIONING
7. Detensioning
CFCC elongation is greater than the elongation of steel cable. The higher CFCC elongation may
cause the anchors to recoil and fly resulting in an accident if the detension work is not performed
correctly.

7.1

Tools

A torch CANNOT be used to cut CFCC. A blade such as a reciprocating saw or grinder must be used
to cut CFCC.
Torch(Use to cut black steel)

7.2

Reciprocating Saw(Use to cut CFCC)

Detensioning Method
Detensioning CFCC must be done carefully to prevent anchorsfrom recoiling.

The detensioning method is project specific. Tokyo Rope will provide the detensioning method foreach project.
If the CFCC between the anchor and the beam is long, the recoiling is intense.

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MAINTENANCE
8.

Maintenance

Proper maintenance is crucial to keep the anchorage devices safe and operational.

8.1

Cleaning

The figures below show the parts of each anchorage device that must be cleaned after each casting.
Brush all threading with a wire brush and wipe the wedges and sleeve with a piece of cloth. Spraymolybdenum on the inner sleeve surface to prevent rust from forming.
Threading to be Cleaned with Wire Brush(Wire Brush)

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MAINTENANCE
8.2

Inspection

Check the anchorage device parts for damage (cracks, scratches, chips, bends, rust, etc.).

(Crack)(Scratch)(Rust)(Chip)(Parts of Buffer Material Stuck to Wedge)

The following items MUST NOT be used:a. Damaged devices (Figures above) – Store separately to avoid using in error If devices cannot be
repaired by using the cleaning procedure several times.
b. Damaged wedge holder (inside tabs are torn). Damaged wedge holders should be discarded.
CFCC may slip from anchor during tensioning if damaged
devices are used. Devices MUST be inspected before installinganchorage devices to avoid a CFCC slippage accident.

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EQUIPMENT RETURN
9.1

Equipment to Return

Return the following tools and equipment to Tokyo Rope upon completion of project:
Pushing Machines
Removal Machines
Electrical Hydraulic Pumps
Wedges
CFCC Sleeves
Couplers
Multiple Splice Chucks
Unused Buffer Material
Damaged devices described in Section 8
Ship items listed above to:Tokyo Rope USA
8301 Ronda Drive
Canton, MI 48187

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