Prestressed Concrete SMS

Introduction to
PreStressed Concrete
Shivaji M. Sarvade
Introduction
A
prestressed
concrete
structure is different from a
conventional
reinforced
concrete structure due to the
application of an initial load
on the structure prior to its
use.
The initial load or prestress
is applied to enable the
structure to counteract the
stresses arising during its
service period.
Shivaji Sarvade
Department of Civil Engineering

AIKTC
Introduction
A
prestressed
concrete
structure is different from a
conventional
reinforced
concrete structure due to the
application of an initial load
on the structure prior to its
use.
The initial load or prestress
is applied to enable the
structure to counteract the
stresses arising during its
service period.
Shivaji Sarvade

AIKTC
Introduction
For concrete, internal stresses are induced (usually, by means
of tensioned steel) for the following reasons.
The tensile strength of concrete is only about 8% to 14% of
its compressive strength.
Cracks tend to develop at early stages of loading in flexural
members such as beams and slabs.
To prevent such cracks, compressive force can be suitably
applied in the perpendicular direction.
Prestressing enhances the bending, shear and torsional
capacities of the flexural members.
In pipes and liquid storage tanks, the hoop tensile stresses
can be effectively counteracted by circular prestressing.
Shivaji Sarvade

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Introduction
Shivaji Sarvade

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Early Failures.
The residual strain in steel =
original tensile strain in steel
compressive strains
corresponding to short-term
and long-term losses.
Shivaji Sarvade

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Solution
Adopt High Strength Steel with much higher original strain.
This leads to the scope of high prestressing force.
Adopt High Strength Concrete to withstand the high
prestressing force.
Shivaji Sarvade

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Few Applications in India

The first prestressed concrete bridge was built in 1948 under
the Assam Rail Link Project.
Among bridges, the Pamban Road Bridge at Rameshwaram,
Tamilnadu, remains a classic example of the use of prestressed
concrete girders.
Shivaji Sarvade

AIKTC
Few Applications in India
Pamban Road Bridge at Rameshwaram, Tamilnadu

Shivaji Sarvade

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Advances in Building Materials
Shivaji Sarvade

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10
Forms of Prestressing Steel
Wires : Prestressing wire is a single unit made of steel.
Strands:
Two, three or seven wires are wound to form a
prestressing strand.
Tendon: A group of strands or wires are wound to form a
prestressing tendon.
Cable: A group of tendons form a prestressing cable.
Bars: A tendon can be made up of a single steel bar. The
diameter of a bar is much larger than that of a wire.
Shivaji Sarvade

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Forms of Prestressing Steel
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Nature of Concrete-Steel Interface

Bonded tendon: When there is adequate bond between the
prestressing tendon and concrete, it is called a bonded tendon.
Pre-tensioned and grouted post-tensioned tendons are bonded
tendons.
Unbonded tendon: When there is no bond between the
prestressing tendon and concrete, it is called unbonded tendon.
When grout is not applied after post-tensioning, the tendon is
an unbonded tendon.
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Stages of Loading
The analysis of prestressed members can be different for the
different stages of loading. The stages of loading are as
follows.
Initial : It can be subdivided into two stages.
During tensioning of steel.
At transfer of prestress to concrete.
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Stages of Loading
Intermediate : This includes the loads during transportation of
the prestressed members.
Final : It can be subdivided into two stages.

At service, during operation.
At ultimate, during extreme events.
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Advantages of Prestressing
The prestressing of concrete has several advantages as
compared to traditional reinforced concrete (RC) without
prestressing.
A fully prestressed concrete member is usually subjected to

compression during service life. This rectifies several
deficiencies of concrete.
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1) Section remains uncracked under service loads
Reduction of steel corrosion
Increase in durability.
Full section is utilised
Higher moment of inertia (higher stiffness)
Less deformations (improved serviceability).
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1) Section remains uncracked under service loads
Increase in shear capacity.
Suitable for use in pressure vessels, liquid retaining
structures.
Improved performance (resilience) under dynamic and
fatigue loading.
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2) High span-to-depth ratios
Larger spans possible with prestressing (bridges, buildings
with large column-free spaces)
Non-prestressed slab
Prestressed slab
28:1
45:1
Reduction in self weight

More aesthetic appeal due to slender sections
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3) Suitable for precast construction
Rapid construction
Multiple use of formwork
Better quality control
Reduction of formwork
Reduced maintenance
Availability of standard
Suitable
for
repetitive
shapes.
construction
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3) Suitable for precast construction
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Limitations of Prestressing
Prestressing needs skilled technology. Hence, it is not as
common as reinforced concrete.
The use of high strength materials is costly.
There is additional cost in auxiliary equipments.
There is need for quality control and inspection.
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Types of Prestressing
Types of
Prestressing
Source
Mechanical
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Hydraulic
Electrical

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Chemical
23
Types of
Prestressing
Location
External
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Internal

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External prestressing of a box girder

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Internal prestressing of a box girder

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Types of
Prestressing
Direction
Uni- Axial
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Bi-Axial

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Multi
Axial
27
Bi- Axial Prestressing

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28
Types of
Prestressing
Amount
of Force
Full
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Limited

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Partial
29
Types of
Prestressing
Shape
Linear
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Circular

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Linear Prestressing
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Circular Prestressing
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Sequence
PreTensioning
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PostTensioning

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Pre-Tensioning vs Post-Tensioning
Pre-Tensioning
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Pre-Tensioning
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Post-Tensioning
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Pre-Tensioning
Prestressing systems have developed over the years and
various companies have patented their products. Detailed
information of the systems is given in the product catalogues
and brochures published by companies.
There are general guidelines of prestressing in Section 12 of

IS:1343 - 1980
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Stages of Pre-tensioning
In pre-tensioning system, the high-strength steel tendons are
pulled between two end abutments (also called bulkheads)
prior to the casting of concrete. The abutments are fixed at the
ends of a prestressing bed.
Once the concrete attains the desired strength for prestressing,
the tendons are cut loose from the abutments.
The prestress is transferred to the concrete from the tendons,
due to the bond between them. During the transfer of prestress,
the member undergoes elastic shortening. If the tendons are
located eccentrically, the member is likely to bend and deflect
(camber).
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1. Anchoring of tendons against the end abutments
2. Placing of jacks
3. Applying tension to the tendons
4. Casting of concrete
5. Cutting of the tendons.
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Advantages &
Disadvantages of Pre-tensioning
Pre-tensioning is suitable for A prestressing bed is required
precast members produced in for the pre-tensioning
bulk.
operation.
In pre-tensioning large
There is a waiting period in
anchorage device is not
the prestressing bed, before
present.
the concrete attains sufficient
strength.
There should be good bond
between concrete and steel
over the transmission length.
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Devices for Pre-tensioning

1. Prestressing bed
2. End abutments
3. Shuttering / mould
4. Jack
5. Anchoring device
6. Harping device (optional)
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Hoyer system
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Stress Bench
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FBD of Stress Bench

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Stress Bench after casting

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Jacks
A double acting hydraulic jack with a load cell

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Anchoring Devices
Chuck assembly for anchoring tendons

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Harping Devices
Harping of tendons
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Hold-down anchor for

harping of tendons 50
Manufacturing of Railway Sleeper.
Stress Bed
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Anchoring of strands
51
Stretching of strands
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Stretching of strands
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Pouring of concrete
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Concrete after vibration of Mould

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Steam Curing
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Cutting of Strands.
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De-moulding of Sleeper.
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Stacking of Sleepers
Shivaji Sarvade
Water Curing

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59
Storage and dispatch of Sleepers

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60
Post-Tensioning
In post-tensioning systems, the ducts for the tendons (or

strands) are placed along with the reinforcement before the
casting of concrete. The tendons are placed in the ducts after
the casting of concrete. The duct prevents contact between
concrete and the tendons during the tensioning operation.
Unlike pre-tensioning, the tendons are pulled with the reaction

acting against the hardened concrete.
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Post-Tensioning
If the ducts are filled with grout, then it is known as bonded
post-tensioning. The grout is a neat cement paste or a sandcement mortar containing suitable admixture.
In unbonded post-tensioning, the ducts are never grouted and
the tendon is held in tension solely by the end anchorages.
For a simply supported member, the duct has a sagging profile
between the ends. For a continuous member, the duct sags in
the span and hogs over the support.
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Post-Tensioning
Post-tensioning
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Post-Tensioning
Ducts for Post-tensioning in Box Girder

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Post-Tensioning
Ducts for Post-tensioning in Box Girder

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Stages of Post-Tensioning
1. Casting of concrete.
2. Placement of the tendons.
3. Placement of the anchorage block and jack.
4. Applying tension to the tendons.
5. Seating of the wedges.
6. Cutting of the tendons.
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Post-Tensioning
Stages of post-tensioning
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Advantages and Disadvantages of

Post-Tensioning
Post-tensioning is suitable for The relative disadvantage of
heavy cast-in-place members.
The waiting period in the
post-tensioning as compared
to
pre-tensioning
requirement
casting bed is less.

The transfer of prestress is
independent of transmission
device
of
and
is
the
anchorage
grouting
equipment.
length.
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1. Casting bed
2. Mould/Shuttering
3. Ducts
4. Anchoring devices
5. Jacks
6. Couplers (optional)
7. Grouting equipment (optional).
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Casting Bed
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70

Anchoring Devices:
In post-tensioned members the anchoring devices transfer the
prestress to the concrete.
1) Wedge action
2) Direct bearing
3) Looping the wires
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Wedge action :
The anchoring device based on wedge action consists of an
anchorage block and wedges. The strands are held by frictional
grip of the wedges in the anchorage block.
Some examples of systems based on the wedge-action are
Freyssinet, Gifford-Udall, Anderson and Magnel-Blaton
anchorages
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Freyssinet T system
anchorage cones
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Anchoring devices

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Anchoring devices
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Direct bearing :
The rivet or bolt heads or button heads formed at the end of the
wires directly bear against a block. The B.B.R.V posttensioning system and the Prescon system are based on this
principle. The following figure shows the anchoring by direct
bearing.
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Anchoring with button heads

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Looping the wires :
The Baur-Leonhardt system, Leoba system and also the
Dwidag single-bar anchorage system, work on this principle
where the wires are looped around the concrete. The wires are
looped to make a bulb.
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PIC
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Final form of anchoring device
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Jacks
Jacking and anchoring with wedges

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Couplers
The couplers are used to connect strands or bars. They are
located at the junction of the members, for example at or near
columns in post-tensioned slabs, on piers in post-tensioned
bridge decks.
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Couplers
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Couplers
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Grouting.
Grouting can be defined as the filling of duct, with a material
that provides an anti-corrosive alkaline environment to the
prestressing steel and also a strong bond between the tendon
and the surrounding grout.
The major part of grout comprises of water and cement, with a
water-to-cement ratio of about 0.5, together with some waterreducing admixtures, expansion agent and pozzolans
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Grouting.
Grouting equipment
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Manufacturing of Post-tensioned
Bridge Girders
Fabrication of reinforcement
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Bridge Girders
Placement of tendons
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Bridge Girders
Stretching and anchoring of tendons

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Bridge Girders
Reinforcement cage for box girder

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Bridge Girders
Formwork for box girder

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Bridge Girders
Post-tensioning of box girder

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Bridge Girders
Transporting of box girder

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Bridge Girders
Finished Bridge
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Materials for Pre-Stressed Concrete.

Desired properties of Hardened Concrete.
High strength with low water-to-cement ratio.
Durability with low permeability, minimum cement content
and proper mixing, compaction and curing.
Minimum shrinkage and creep by limiting the cement
content.
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95
Materials for Pre-Stressed Concrete.

Minimum Grades of Concrete
30 MPa for post-tensioned members.
40 MPa for pre-tensioned members.
Minimum Grades of Concrete
60 MPa.
Shivaji Sarvade

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96
Best Wishestoday and always

: Shivaji Sarvade
AIKTC
97

Prestressed Concrete SMS

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Prestressed Concrete SMS

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Introduction to

Department of Civil Engineering

Department of Civil Engineering

Department of Civil Engineering

Department of Civil Engineering

Department of Civil Engineering

Department of Civil Engineering

Few Applications in India

Department of Civil Engineering

Few Applications in India

Pamban Road Bridge at Rameshwaram, Tamilnadu

Department of Civil Engineering

Advances in Building Materials

Department of Civil Engineering

Forms of Prestressing Steel

Wires : Prestressing wire is a single unit made of steel.

Two, three or seven wires are wound to form a

Department of Civil Engineering

Forms of Prestressing Steel

Department of Civil Engineering

Nature of Concrete-Steel Interface

Department of Civil Engineering

Department of Civil Engineering

Final : It can be subdivided into two stages.

Department of Civil Engineering

A fully prestressed concrete member is usually subjected to

Department of Civil Engineering

Department of Civil Engineering

Department of Civil Engineering

Reduction in self weight

Department of Civil Engineering

Multiple use of formwork

Better quality control

Department of Civil Engineering

Department of Civil Engineering

Department of Civil Engineering

Department of Civil Engineering

Department of Civil Engineering

External prestressing of a box girder

Department of Civil Engineering

Internal prestressing of a box girder

Department of Civil Engineering

Department of Civil Engineering

Bi- Axial Prestressing

Department of Civil Engineering

Department of Civil Engineering

Department of Civil Engineering

Department of Civil Engineering

Department of Civil Engineering

Department of Civil Engineering

Department of Civil Engineering

Department of Civil Engineering

Department of Civil Engineering

There are general guidelines of prestressing in Section 12 of

Department of Civil Engineering

Department of Civil Engineering

Department of Civil Engineering

Department of Civil Engineering

Department of Civil Engineering

Devices for Pre-tensioning

Department of Civil Engineering

Devices for Pre-tensioning

Devices for Pre-tensioning

Department of Civil Engineering