Post Tensioned Concrete cables

Post-tensioning is a form of prestressing. Prestressing simply means that the steel is stressed
(pulled or tensioned) before the concrete has to support the service loads. Most precast,
prestressed concrete is actually pre-tensioned-the steel is pulled before the concrete is
poured.

Used in

 Commercial Buildings and Bridges

 Tanks
 Wind Energy Structures
 Car Parks
 Structural Repair Solutions

Post-tension (PT) cables are used in concrete construction to allow thinner slabs and greater
span lengths between support columns. These cables, composed of steel wires inserted into a
plastic sheath, are subsequently "tensioned" and grouted after the concrete is poured.

Post tensioning is a technique for reinforcing concrete. Post-tensioning tendons, which are
prestressing steel cables inside plastic ducts or sleeves, are positioned in the forms before the
concrete is placed. Afterwards, once the concrete has gained strength but before the service
loads are applied, the cables are pulled tight, or tensioned, and anchored against the outer
edges of the concrete. Post-tensioning is a form of prestressing. Prestressing simply means
that the steel is stressed (pulled or tensioned) before the concrete has to support the service
loads. Most precast, prestressed concrete is actually pre-tensioned-the steel is pulled before
the concrete is poured. Post-tensioned concrete means that the concrete is poured and then the
tension is applied-but it is still stressed before the loads are applied so it is still prestressed.

Post-tensioning is a method of producing prestressed concrete, masonry and other structural

elements. The term prestressing is used to describe the process of introducing internal forces
(or stress) into a concrete or masonry element during the construction process in order to
counteract the external loads that will be applied when the structure is put into use (known as
service loads). These internal forces are applied by tensioning high strength steel, which can
be done either before or after the concrete is actually placed. When the steel is tensioned
before concrete placement the process is called pre-tensioning. When the steel
is tensioned after concrete placement the process is called post tensioning.

The advantages of utilizing prestressed concrete and masonry have long been recognized by
engineers. When a designer wants to take advantage of those benefits, they must determine
whether the structure is to be constructed using the pre-tension method or the post-tension
method. Pre-tensioning is generally accomplished at a manufacturing facility where concrete
members are constructed in special casting beds with steel bulkheads that hold the steel in
place while tension is applied. Concrete is then placed around the pre-tensioned steel and
allowed to harden. The steel is then cut loose from the bulkheads and the entire precast
concrete member is transported to the project site for assembly. This process may be limited
to the use of standard shapes, and sizes that can be easily transported. Post-tensioning is done
at a project site and requires little to no modifications of the same forming system that would
be used to construct non-prestressed concrete. The systems used to post-tension concrete and
masonry consist of prestressing steel thatis housed inside a duct or sheath, which allows the
prestressing steel to be placed inside the typical job site formwork at the same time rebar and
other reinforcing is placed. Concrete is placed in a typical manner and allowed to reach a
predetermined strength before the steel is tensioned. Since the prestressing steel is housed in
the sheathing or duct, it will be free to move inside the concrete during the tensioning
operation, and since the steel is tensioned after concrete placement, the tensioning is done
against the hardened concrete instead of relying on large steel bulkheads. Using the post-
tensioning method of prestressing enables a builder to get all the advantages of prestressed
concrete or masonry while still enabling the freedom to construct the member (slab, wall,
column, etc,) on the job site in almost any shape or configuration imaginable.

What does it do to masonry

When a concrete or masonry element is prestressed, it means that the steel is being tensioned
and the concrete or masonry is being compressed. Compressionis a force that squeezes or
crushes and tension is a force that pulls something apart. As building materials, concrete and
masonry are very strong in compression, but they are relatively weak in tension. Steel, on
the other hand, is very strong in tension. Putting the concrete or masonry into compression
and the steel into tension before any substantial service loads are applied puts both of these
building materials into their strongest states. The result is a stiffer concrete or masonry
member that is being actively compressed and has more capacity to resist tensile forces.

Adding post-tensioned reinforcing combines the action of reinforcing the tension zones with
the advantages of compressing the concrete or masonry structure. Additional benefits are
obtained when the post-tensioned reinforcing is installed in a draped profileinstead of running
in a straight line. A typical draped profile in an elevated concrete slab would route the post-
tensioned reinforcing through a high point over the slab’s supports, and through a low point
in between those supports. Now optimum efficiency is obtained because the post-tensioned
reinforcing is located in the tension zones, the concrete is being compressed, and the post-
tensioned reinforcing is creating an uplift force in the middle of the spans where it is needed
the most.

One of the things that happens to a concrete floor, or a masonry wall, is that they are
subjected to forces that cause them to flex and bend. Examples of this include slabs on
ground where the edges of the slab are forced upward by swelling soils, elevated concrete
slabs where gravity and other applied loads pull down on the slab in between supports, and
walls that might be subjected to lateral forces from wind or seismic activity. This bending
creates high tensile forces that can cause the concrete and masonry to crack. This is where the
use of reinforcing is applied. Since steel has a high capacity to resist tensile forces, it can be
embedded in the concrete at the tension zones(the areas that tensile failures could occur)
allowing the tensile forces to be handled by the reinforcing steel.
 Advantages & Applications of Post-Tensioning
Post-tensioning, which is a form of prestressing, has several advantages over standard
reinforcing steel (rebars):

 It reduces or eliminates shrinkage cracking-therefore no joints, or fewer joints, are

needed.
 Cracks that do form are held tightly together #Here Cracks are held but it wouldn’t
heal
 It allows slabs and other structural members to be thinner
 It allows us to build slabs on expansive or soft soils #still soil has to tested and
minimum stability is needed

It lets us design longer spans in elevated members, like floors or beams
#Span is the distance between two intermediate supports for a structure, e.g. a beam or a
bridge.

Common Applications:
At one time there were problems with corrosion of the cables, especially in deicing-salt-laden
parking structures, but better materials and construction methods (plus good training and
certification programs) have eliminated most problems.

1. Slabs on ground: Today, PT is used extensively for slabs on grade where soils are
likely to move (expansive soils)-especially in the American southwest. Jim Rogers,
 editor and publisher of Post Tension Magazine, says that until housing construction
ground to a halt last year, about half of all post-tensioning work was slabs-on-ground
for homes. Residential Concrete magazine had a good review of this in its September
2006 issue.
2. Another good application for PT slabs is producing crack-free tennis courts.
3. A recently developed application of PT is external post-tensioning for strengthening
of existing structures, especially as an upgrade to resist seismic forces.
4. Bridge designers have used PT both for cast-in-place concrete and for precast
segmental construction. PT allows longer spans and keeps cracks tight.
5. Concrete water tanks are often post-tensioned to reduce crack width and leakage.
6. Masonry walls can be post-tensioned-this is usually done with a solid steel bar
fastened to the foundation and stressed with a nut at the wall's top.
7. One interesting application is for a concrete countertop that needed to span 6 feet and
carry a heavy load.

Post-Tensioning Construction Basics

Even congested tendons can be routed around obstructions.

Construction of post-tensioned slabs on grade is very similar to using reinforcing steel,

except for the tensioning step. Cables are arranged as indicated by the engineer and chaired to
run through the center of the slab. For residential construction, tendons at 48 inches on center
are common. Commercial foundations will have much more steel. Tendons can be easily
routed around obstructions.

A residential post-tensioned concrete slab will typically be 8 inches thick and use 3000 psi
concrete. Once the concrete has gained strength to 2000 psi, typically within the 3 to 10 days
recommended by PTI, the tendons are stressed.

What is 2000psi concrete? Now basics of concrete are listed here:

There are many different types, strengths, and compositions of concrete, each with
characteristics that make them perform better for different applications. Here are a few
examples:

 Strength is usually determined by compression testing, and is expressed in Pounds per

Square Inch (PSI). Normal concrete mixes range from 2500 PSI to 5000 PSI, with
engineered design mixes of over 10,000 PSI used in specialized applications. Lower
strengths are also available for grouts, but since these are usually used for
displacement, block-fill, and filling abandoned utility lines, we won't spend much
time on these products. Here are some common uses for different strength concretes.
 Note that these are not exclusive, as designers and structural engineers may spec
different uses in specialized construction projects.
o 2500PSI concrete may be used in driveways, walkways, and even floor slabs
on grade. This concrete is usually the cheapest available from batch plants.
Used on solidly compacted fill material (subgrade), this concrete performs
satisfactorily for these projects, but many professional concrete workers prefer
a higher strength product due to warranty concerns, and some building codes
may not allow its use for all of these applications.
o 3000PSI concrete in many locations is a standard multipurpose mixture for
general use in construction. It is durable, has sufficient cement to give it good
finishing characteristics, and can be placed fairly wet without sacrificing
quality.
o 3500PSI concrete is used for applications where surface spalling is not
acceptable, and significant loading is expected. One example would be paving
curbs, where heavy traffic may drive on the surface. Other uses include
building footings, bond beams, grade beams, and floor slabs where heavy
loads may be moved or stored.
o 4000PSI concrete is used for heavy traffic pavement, heavy use floor slabs
like shops and warehouses, and concrete footings designed to support heavy
loads.
o 5000PSI and higher concrete mixes are usually used for specialized
construction projects where high impact resistances, very low wear rates, or
extreme conditions are expected.

 Water/cement ratio (w/c ratio) theory states that for a given combination of
materials and as long as workable consistency is obtained, the strength of concrete at a given
age depends on the w/c ratio. 


The lower the w/c ratio, the higher the concrete strength. 


Whereas strength depends on the w/c ratio, economy depends on the percentage of
aggregate present that would still give a workable mix. 


The aim of the designer should always be to get concrete mixtures of optimum
strength at minimum cement content and acceptable workability. 


One of the greatest advances in concrete technology was the development of air-entrained
concrete in the late 1930s.

Today, air entrainment is recommended for nearly all concretes, principally to improve
resistance to freezing when exposed to water and deicing chemicals.

Air-entrained concrete contains billions of microscopic air cells 


These relieve internal pressure on the concrete by providing tiny chambers for the
expansion of water when it freezes. 

 Requirements of concrete mix design

The requirements which form the basis of selection and proportioning of mix
ingredients are:

a) The minimum compressive strength required from structural consideration

b) The adequate workability necessary for full compaction with the compacting
equipment available.

c) Maximum water-cement ratio and/or maximum cement content to give adequate

durability for the particular site conditions

d) Maximum cement content to avoid shrinkage cracking due to temperature cycle in

mass concrete.

Types of Mixes

1. Nominal Mixes

In the past the specifications for concrete prescribed the proportions of cement, fine and
coarse aggregates. These mixes of fixed cement-aggregate ratio which ensures adequate
strength are termed nominal mixes. This offers simplicity and under normal
circumstances, have a margin of strength above that specified. However, due to the
variability of mix ingredients the nominal concrete for a given workability varies
widely in strength.

2. Standard mixes

The nominal mixes of fixed cement-aggregate ratio (by volume) vary widely in strength and
may result in under- or over-rich mixes. For this reason, the minimum compressive strength
has been included in many specifications. These mixes are termed standard mixes.

IS 456-2000 has designated the concrete mixes into a number of grades as M10, M15, M20,
M25, M30, M35 and M40. In this designation the letter M refers to the mix and the number
to the specified 28 day cube strength of mix in N/mm2. The mixes of grades M10, M15, M20
 and M25 correspond approximately to the mix proportions (1:3:6), (1:2:4), (1:1.5:3) and
(1:1:2) respectively (cement:fine aggregates:coarse aggregates)
.
( Letter M represents mix (concrete mix) and the number followed after M represents the compressive
strength to be attained in N/sq.mm at 28 days age when a standard cube of 150x150x150 mm is
subjected to standard compressive test. Both combinedly termed as Grade of Concrete.)

The concrete slump test is an empirical test that measures workability of fresh concrete. The
test measures consistency of concrete in that specific batch. It is performed to check
consistency of freshly made concrete. Consistency refers to the ease with which concrete
flows.

Designed Mixes

In these mixes the performance of the concrete is specified by the designer but the mix
proportions are determined by the producer of concrete, except that the minimum cement
content can be laid down. This is most rational approach to the selection of mix proportions
with specific materials in mind possessing more or less unique characteristics. The approach
results in the production of concrete with the appropriate properties most economically.
However, the designed mix does not serve as a guide since this does not guarantee the correct
mix proportions for the prescribed performance.

For the concrete with undemanding performance nominal or standard mixes (prescribed in the
codes by quantities of dry ingredients per cubic meter and by slump) may be used only for very
small jobs, when the 28-day strength of concrete does not exceed 30 N/mm2. No control testing
is necessary reliance being placed on the masses of the ingredients.

Factors affecting the choice of mix proportions

The various factors affecting the mix design are:

1. Compressive strength

It is one of the most important properties of concrete and influences many other describable
properties of the hardened concrete. The mean compressive strength required at a specific age,
usually 28 days, determines the nominal water-cement ratio of the mix. The other factor
affecting the strength of concrete at a given age and cured at a prescribed temperature is the
degree of compaction. According to Abraham’s law the strength of fully compacted concrete
is inversely proportional to the water-cement ratio.

2. Workability

Workability -- A good mix design must be capable of being placed and compacted, with
minimal bleeding and segregation, and be finishable. Water requirements depend on the
aggregate rather than the cement characteristics. In general, the minimum compressive
strength and a range of w/c ratios are specified for a given concrete mix. Therefore, a balance
or compromise must be made between strength and workability.
 Possible requirements for resistance to freeze-thaw and chemical attack must be considered.
The increases in volume of the ice exerts pressure on the cracks in the rock, causing them to
split further open. During the day the ice melts and the water seeps deeper into the cracks. At
night the water freezes again resulting the breaking of rocks.

A measure of the degree of consistency and extent of workability is the slump. 


The degree of workability required depends on three factors. These are the size of the section
to be concreted, the amount of reinforcement, and the method of compaction to be used. For
the narrow and complicated section with numerous corners or inaccessible parts, the concrete
must have a high workability so that full compaction can be achieved with a reasonable amount
of effort. This also applies to the embedded steel sections. The desired workability depends on
the compacting equipment available at the site.

3. Durability

The durability of concrete is its resistance to the aggressive environmental conditions. High
strength concrete is generally more durable than low strength concrete. In the situations when
the high strength is not necessary but the conditions of exposure are such that high durability
is vital, the durability requirement will determine the water-cement ratio to be used.

Durability -- If there are severe exposure conditions, such as freezing and thawing,
exposure to seawater, or sulfates, the w/c ratio requirements may have to be adjusted.



4. Maximum nominal size of aggregate

In general, larger the maximum size of aggregate, smaller is the cement requirement for a
particular water-cement ratio, because the workability of concrete increases with increase in
maximum size of the aggregate. However, the compressive strength tends to increase with the
decrease in size of aggregate.

IS 456:2000 and IS 1343:1980 recommend that the nominal size of the aggregate should be as
large as possible.

5. Grading and type of aggregate

The grading of aggregate influences the mix proportions for a specified workability and water-
cement ratio. Coarser(rough or harsh in texture) the grading leaner will be mix which can be
used. Very lean mix is not desirable since it does not contain enough finer material to make the
concrete cohesive.

The type of aggregate influences strongly the aggregate-cement ratio for the desired
workability and stipulated water cement ratio. An important feature of a satisfactory aggregate
is the uniformity of the grading which can be achieved by mixing different size fractions.
6. Quality Control

The degree of control can be estimated statistically by the variations in test results. The
variation in strength results from the variations in the properties of the mix ingredients and lack
of control of accuracy in batching, mixing, placing, curing and testing. The lower the difference
between the mean and minimum strengths of the mix lower will be the cement-content
required. The factor controlling this difference is termed as quality control.

Mix Proportion designations

The common method of expressing the proportions of ingredients of a concrete mix is in the
terms of parts or ratios of cement, fine and coarse aggregates. For e.g., a concrete mix of
proportions 1:2:4 means that cement, fine and coarse aggregate are in the ratio 1:2:4 or the mix
contains one part of cement, two parts of fine aggregate and four parts of coarse aggregate. The
proportions are either by volume or by mass. The water-cement ratio is usually expressed in
mass

Factors to be considered for mix design

 The grade designation giving the characteristic strength requirement of concrete.

 The type of cement influences the rate of development of compressive strength of concrete.

 Maximum nominal size of aggregates to be used in concrete may be as large as possible within
the limits prescribed by IS 456:2000.

 The cement content is to be limited from shrinkage, cracking and creep.

 The workability of concrete for satisfactory placing and compaction is related to the size and
shape of section, quantity and spacing of reinforcement and technique used for transportation,
placing and compaction.
Now back to Post concrete cables:

Tendons today are seven high-strength steel wires wound together and placed inside a plastic
duct. At each end a PT anchor is located and these are located in pockets embedded into the
slab edge. When the strands are stressed, the wires will stretch—about 4 inches for a 50 foot
strand—to apply 33,000 pounds of load. Stressing should only be done by qualified workers.
After stressing, the tendon is cut off and the pocket in which the anchors are located is filled
with grout to protect them from corrosion.

Larger structural concrete members may also be post-tensioned, especially in bridges and
floors and beams in parking structures. The process is very similar to that used for slabs,
except on a bigger scale. One interesting difference is that the tendons will often be "draped"
so that they are low at the midpoint of a beam and high at the supports—this places the steel
at the point of highest tension where it can keep the concrete held together tightly. With
structural members the duct is often grouted full following stressing to bond the strand to the
concrete along its entire length—these are called bonded tendons. Unbonded tendons, used in
residential slabs, remain free to move within the duct and are protected from corrosion by
grease. PT tendon placement and stressing is usually done by companies with certified
workers who specialize in this work.

Since PT is simply reinforcement, there really aren't any specific decorative applications
related to post tensioning. The advantages of PT as noted in the opening page are the lack of
cracking (or at least very narrow cracks) and the ability to span farther. PT slabs on ground
can be placed and stamped just like with any other concrete slab. Surfaces can be stained or
overlaid. The only concern is to always remember not to cut or drill into post-tensioned
concrete slabs, since once a tendon has been cut, it is very difficult to repair. Many post-
tensioned slabs will be stamped to alert the owner and any renovation contractors that the
slab is post tensioned.

Post-Tensioned vs. Reinforced Concrete Tennis Courts

The two most common types of concrete slabs for outdoor play courts are reinforced concrete
and post-tensioned concrete. However, post-tensioned concrete provides the best overall
performance, according to the American Sports Builders Association, a national organization
for builders and designers of tennis courts and other sports surfaces.

Post-tensioned concrete is reinforced with a grid of high-strength sheathed steel tendons, or

cables. While the concrete is curing, the cables are tensioned in both directions and held
permanently under stress by anchoring them in a perimeter beam. This squeezing actionkeeps
the concrete in compression, improving its tensile (or bending) strength. The more the
concrete is squeezed together, the less likely it is that shrinkage cracks will develop or open.
(See a more complete description of post-tensioning from the Post-Tensioning Institute.)

Other benefits of post-tensioning: Contractors can build larger slabs using thinner concrete
sections, and they don't have to install control joints, which can interfere with play. "In order
to build a reinforced concrete court that has the same structural capabilities as a post-
tensioned court, we would have to install so much steel and concrete that the reinforced court
would actually cost more," says Kolkmann. "Also, a reinforced court needs control joints,
usually at a spacing of 10 to 15 feet, including in the playing area. Eventually these joints
may widen, as well as any cracks that appear."

Case study: DYWIDAG

DYWIDAG Strand Post-Tensioning Systems, DYWIDAG Bar Post-Tensioning Systems and

DYNA Grip® Stay Cable Systems offer durability, safety, quality and reliability and are
tailored to suit your specific requirements. We are not only using our know-how for new
construction projects, but also for the structural repair and strengthening of existing
structures.

We offer the following Services:

 We design and develop technically sophisticated and flexible Post-Tensioning

Systems and methods
 We are happy to support you with technical planning
 We produce in our own factories and ensure the availability of our systems and our
special equipment – anytime and anywhere
 On demand, we take care of installation, training or installation supervision
 Inspections and maintenance also form part of our services

Why we are different

DYWIDAG Post-Tensioning Systems are known around the world for their superior load-
carrying performance, durability and simple design. For decades, our systems have been
renowned for their extraordinary versatility and reliability. The first-rate corrosion protection
of our Post-Tensioning Systems contributes significantly to the longevity of structures. As
permanent members in the corresponding committees of experts and standards, we are
continuously promoting technical developments as well as the safety and applicability of our
products and systems.

DYWIDAG Post-Tensioning Systems – Flexibility and Technical Approvals

Adaptation – Flexibility in all Areas

Our systems offer a high degree of flexibility in many applications around the globe.
Furthermore, we always supply custom-designed products matching your individual
requirements.

Certified Quality – Technical Approvals for Post-Tensioning Supporting Structures

We hold technical approvals for internal and external Post-Tensioning Systems consisting of
high-strength strands, wires and post-tensioning bars and have the authority to carry out
tensioning work. Our systems are certified in accordance with ETAG 013 inspection
guidelines (guideline for the European Technical Approval for construction sets for post-
tensioning supporting structures). These European approvals are complemented by existent
national technical approvals and general approvals issued by local building inspection
agencies. Our systems are developed and produced for regional markets in accordance with
national specifications and norms (ASTM, AASHTO, BS, Eurocode, DIN, SIA, FIP, fib,
EOTA, pti, etc.).