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Prestressed Concrete
Prestressed Concrete
IN CONCRETE
PRESTRESSED CONCRETE
PRINCIPLE Using high tensile strength
a) Pretensioning
b)Post-tensioning
POST - TENSIONING
WHAT IS POST-TENSIONING?
Post-tensioning-
is a method of reinforcing
(strengthening) concrete or other materials with highstrength steel strands called tendons.
Post-tensioning
Applications
BENEFITS
ADVANTAGES/APPLICATIONS
Post-tensioning allows longer clear spans, thinner
prestressed concrete.
Bridge decks
CONSTRUCTION
strength, usually between 3000 and 3500 psi
(pounds per
square inch), the tendons are stressed and
anchored.
Limitations of Prestressing
The limitations of prestressed concrete are few and really
depend only upon the imagination of the designer and the
terms of his brief. The only real limitation where
prestressing is a possible solution may be the cost of
providing moulds for runs of limited quantity of small
numbers of non-standard units.
Method of post-tensioning
Wedges tensioned by
Tendons
jacks
TENDONS
PRESTRESSED CONCRETE
Prestressed concrete, invented by Eugene
Pre-tensioned concrete
underlying soil are taken into the entire tensioned slab, which
supports the building without significant flexure. Post-stressing
is also used in the construction of various bridges.
The advantages of this system over unbonded post-tensioning
are
Unbonded post-tensioned
concrete
Unbonded post-tensioned concrete differs
External Prestressing
APPLICATIONS
Fallingwater is comprised of a series of concrete cantilever
trays 30-ft. above a waterfall. Previous efforts failed to
permanently address excessive deflections of the cantilever
and repair the cracks. After a thorough design review, the
owner and engineer selected an external post-tensioning
solution for its durability, aesthetics and structural
unobtrusiveness.
Construction plans called for strengthening of three support
girders spanning in the north-south direction with multistrand
post-tensioning tendons consisting of multiple 0.5 diameter
strands.
Thirteen strand tendons were placed on each side of two
girders. One 10-strand tendon was placed on the western side
of the third girder (access on the eastern side of this girder
was not available). Eight monostrand tendons, 0.6 diameter,
were slated for the east-west direction.
The monostrand tendons were stressed in the east-west
direction and then the multistrand tendons were stressed in
the north-south direction and grouted with a high quality, lowbleed cementitious grout mixture.
VSLs scope of work also included welding steel cover plates,
attaching structural steel channels, injecting epoxy grout,
doweling reinforced cast in place concrete blocks and the
installation of near surface mounted carbon fiber rods.
Challenged with maintaining Fallingwaters original setting,
furnishings and artwork, the project was successfully
completed in six months.
VSL approached the Cline Avenue project with a guideline that outlines a statistically
sound method of sampling the tendons. A statistical sample pool (which consisted of
the mainline structure and the ramps) was defined by referencing the American
National Standard Institutes (ANSI) guideline Sampling Procedures and Tables for
Inspection by Attributes as published by the American Society for Quality Control
(1993).
The probable void locations throughout the structures mainline segments and ramps
were initially identified by VSL to appropriately distribute the sampling population.
Such areas consisted of high points, areas approaching and leaving the high points,
and couplers.
Using non-destructive Ground Penetrating Radar (GPR) and field layout drawings,
VSL located existing post-tensioning tendons. Once the layout was performed,
specific tendons throughout the bridge and ramp structures were sampled by drilling
into the duct and exposing the tendon for visual inspection. The use of a borescope
allowed for detailed visual inspection of the tendon and also captured video footage
to share with the owner and the engineer. After review of each inspection, VSL placed
epoxy in the borescope hole to protect the tendons from air and moisture intrusion.
When voids were encountered, the project team observed and documented the
condition of the strand based on the PCI Journal guideline, Evaluation of Degree of
Rusting on Prestressed Concrete Strand. VSL used vacuum grouting technology to
fill the void, thereby protecting the previously exposed strand.
The tendon inspection data was analyzed with other findings (such as crack survey
findings) to determine what type of rehabilitation was required. VSLs goal to establish
a statistically sound sample of physically inspected tendons that provided valid data
as to the current state of the existing PT system was accomplished
Grouting of void using VSLs specialized vacuum grouting equipment
Seward Silo
Approximate
size
50" long
30.5" high
52" wide
Weight
560 lbs.
Production Rate
8 gallons per
minute
at 150 psi
The heavy duty, high volume Colloidal Grout Plant is favored for precision
post-tension grouting. The unit features a high speed shear mixer that
thoroughly wets each particle and discharges the mixed material into a 13
cubic foot capacity agitating holding tank. A direct coupled progressing
cavity pump delivers slurries at a rate of up to 20 gpm and pressures of up
to 261 psi. The unit easily mixes and pumps slurries of Portland cement,
fly ash, bentonite, and lime flour. All controls are conveniently located on
the operator platform for easy one-man control.
Pump
Pump Type
31.6 progressing
cavity
Output/Pressure
variable up to 20
gpm, 261 psi
Mix Tank
13.0 CF with
bottom clean out
Mixing Pump
2 x 3 x 6 diffusertype centrifugal
Holding Tank
13.0 paddle
agitating
Drive Power
Air
Physical
Specifications
Dimensions
Colloidal Mixer
eight
1800-2800 lbs.
Note: Jack pull rods should have a higher capacity than the
anchor rod.
Maximum
Torque
Length
Height
Weight
5,590
ft./lbs.
(773 kg/M)
11.11"
(279 mm)
4.49"
(114 kg)
16.75 lbs.
(7.6 kg)
8,000 ft.lbs.
(1,006
kg/M)
12.57"
(319 kg)
5.09"
(129 kg)
24.95 lbs.
(11.3 kg)
Size
GA 186
1"
1-1/2"
4,000
(ft. lbs.)
Bolt
Diameter
Square
Drive Size
Capacity
(ft. lbs.)
*1/2"-1"
3/4"
0-500
1/2"-1"
3/4"
0-600
*1-1/8"-2"
1"
0-1,000
Corrosion Protection
Methods of Corrosion Protection
Typical
Thickness
Relative
Cost
(4=highest)
Lead Time
Can be
applied to
accessories
?
3-4 mils
2-4 weeks
yes
Epoxy
Coating
7-12 mils
2-3 weeks
yes
Pre-Grouted
Bars
2 weeks
no
Extruded
Polyethylene
Coating
23-25 mils
2-4 weeks
no
Corrosion
Inhibiting
Compound
N.A.
2-4 weeks
yes
Corrosion
Protection
Type
Abrasion
Resistance
(4=best)
Hot Dip
Galvanizing
Methods of Corrosion
Protection
Epoxy Coating
Fusion bonded epoxy coating of steel bars to help prevent
corrosion has been successfully employed in many applications
because of the chemical stability of epoxy resins. Epoxy coated
bars and fasteners should be done in accordance with ASTM A775 or ASTM 934. Coating thickness is generally specified
between 7 to 12 mils. Epoxy coated bars and components are
subject to damage if dragged on the ground or mishandled.
Heavy plates and nuts are often galvanized even though the bar
may be epoxy coated since they are difficult to protect against
abrasion in the field. Epoxy coating patch kits are often used in
the field for repairing nicked or scratched epoxy surfaces.
Pre-Grouted Bars
Cement Grout filled corrugated polyethylene tubing is often used to
provide an additional barrier against corrosion attack in highly
aggressive soils. These anchors are often referred to as MCP or
Multiple Corrosion Protection anchors. The steel bars are wrapped
with an internal centralizer then placed inside of the polyethylene tube
where they are then factory pre-grouted. When specifying couplings
with MCP ground anchors, verify coupling locations with a Williams
representative.
Extruded Polyethylene
Williams strand tendons contain an extruded high density
polyethylene sheathing around each individual strand in the
free-stressing portion of the anchorage. The sheathing is
minimum 60 mils thick and applied once the 7-wire strand
has been coated with a corrosion inhibiting compound.
Extruded polyethylene sheathing provides a moisture tight
barrier for corrosion protection and allows the strand to
elongate freely throughout the free-stressing length during
the prestressing operation
ScrewOn
PVC
Cap