Professional Documents
Culture Documents
Concrete Poles Desing
Concrete Poles Desing
Design and
Use of
CONCRETE
POLES
Prepared by the
Concrete Pole Task Committee of the
Committee on Electrical Transmission Structures
of the Structural Division of the
American Society of Civil Engineers
April 1987
Published by the
American Society of Civil Engineers
345 East 47th Street
New York, New York 10017-2398
PREFACE
INTRODUCTION
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CONCRETE POLES DESIGN
the conductors in such a configuration that the line remains energized.
A pole which has collapsed is one which has reached such a state that
the line can no longer carry power.
1.4 Determination of "Normal Everyday" (Frequent Condition) Loads
For unguyed angle or deadend pole structures, it is desirable to
consider deflections under "normal everyday" loads. A pole with large
deflections under such conditions is undesirable. User should specify
what loads are to be considered "normal everyday".
1.5 Longitudinal Loading
Because of the possibility of catastrophic cascading failure, the
most important loading condition to be evaluated for any transmission
line is that caused by the simultaneous loss of tension on all condutors. For pole type self-supporting structures, the deflection of the
structure itself, will provide a significant tension reduction in the
wires. The length of suspension insulator strings can also greatly
influence the structure loading under unbalanced longitudinal loading
conditions since the decrease in tension caused by the swing of long
insulator strings can be significant. Both of these factors should be
included in the unbalanced loading condition as long as proper consideration is given to any impact loading imposed on the structure. For
longitudinal loading calculations, spans used should approximate actual
line spans.
A longitudinal analysis is particularly essential when comparing
alternate designs and materials because it is necessary to be sure that
the alternates being considered are, indeed, equivalents. For example, a
lattice tower, being a much more rigid structure than a pole structure,
must be designed significantly stronger in order to provide the same degree of protection against cascading failures. The combination of flexibility, mass and mode of failure that are inherent in concrete poles
make them more resistant to cascading failures than are structures made
of other materials.
Under individual broken conductor conditions, restraint will be
offered to the structures by the intact wires. Calculations should
properly reflect the structure deflection and insulator swing, and the
resulting change in wire spans and tensions.
Proper evaluation of the effects of broken conductors requires the
use of sophisticated computer programs. From such an analysis, an equivalent static load can be established for the design and testing of the
structure. If testing of the structure does not confirm the expected
deflections, additional evaluations should be made.
1.6 Geometry
The basic pole structure configuration, conductor and shielding
geometry (i.e., horizontal, vertical, delta, single poles, H-frames,
etc.), insulation assembly length, swing angles, electrical clearances
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CONCRETE POLES DESIGN
down drop and line angle at the structure and the required clearance.
This clearance should be maintained to the deflected structure under the
specified loading condition.
1.9.3 Appearance
Deflections can play an important part in the appearance of a
structure. At line angles or where all vertical conductors are on one
side of a pole structure, the constant load in one direction will cause
the structure to bow and, if the pole was originally set vertically, it
may appear to be near failure. There are several methods that can be
used to compensate for this. One method is to rake the pole when setting
it. The deflection at the top of the pole is determined for the everyday
loading and the pole is tilted this predetermined amount so that, under
the everyday loading, the top of the pole is vertical. In this case, the
pole will be curved, but because the top portion is vertical, the curvature is unlikely to be noticeable.
Designing the structure to limit deflection is a possibility,
but this can be expensive because of the extra heavy pole that will be
required.
Precambered poles are another possibility. It should be recognized, however, that the predictability of results in precambering
concrete poles is poor, at best, and few manufacturers are prepared to
precamber at all.
Finally, guys may be used to limit deflections.
1.10 Transportation and Erection
The design should consider equipment or access limitations and
loads caused by methods of loading, unloading, hauling, assembly, erection and stringing (including longitudinal load due to line snagging in
traveller).
It should be kept in mind that the largest stress level a concrete
pole may see in its lifetime can occur by lifting it clear of the ground
while it is in a horizontal position, as is common in loading and unloading. Indeed, the induced stresses can be so great that it may
sometimes be necessary to require the use of multiple point picks to
avoid damaging the poles.
Experience suggests that transportation and erection loads generally should not be controlling among the various construction loads.
Transportation loads can be controlled by using adequate support under
the poles (i.e. do not allow long overhangs or unsupported lengths).
Erection with single point picks is not a problem as long as much of the
weight of the pole is supported on the ground until the pole is in an
upright position. Since poles and structures are normally erected by
lifting at a point well above the center of gravity, the pole butts
remain on the ground until the pole is erect and excessive bending loads
during erection are thus avoided.
It is the manufacturer's responsibility to clearly indicate on the
grounding.
1.15 Other Considerations
Any other special conditions that may affect the design should be
considered (e.g. reverse wind on bisector guyed light angle structure
may control design or environmental conditions may suggest special
concrete mixes).
Finally, it should be remembered that, like wood poles, concrete
poles lend themselves to use under standardized design conditions using
a strength/length classification system. In fact, concrete poles can be
designed so as to meet the same loading conditions as the wood pole
heights and classes. As more users and designers begin to treat concrete
poles conceptually like wood poles for design purposes, the costs of
both design and manufacturing will decrease substantially.
2.0 - DESIGN
2.1 General
For each loading condition considered, it is necessary to analyze
the effects of the loads on the structure to determine the tensions,
compressions, moments, shears and torsions that the structure must resist at its different locations and the resultant deflections.
The reason for using reinforced concrete as a construction material
is to take advantage of the best attributes of both concrete and steel.
Concrete is relatively inexpensive, excellent in compressive strength
and, when properly made, is relatively unaffected by the environment.
The primary disadvantage is its low tensile strength. Steel, on the
other hand, is excellent in tension but it is more expensive than concrete and is also readily attacked by the environment. Thus the objectives are to use as little steel as possible, to place it in the tension
zones of the member and to use the concrete to protect the steel from
the elements. In some ordinary reinforced applications, steel may, on
occasion, be used to resist compression.
2.2 Design Theory
2.2.1 General
As outlined in paragraph 1.3, concrete poles are designed by
the ultimate strength method wherein the applied service loads are
multiplied by overload factors and the pole is designed to resist the
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CONCRETE POLES DESIGN
cannot be guaranteed that the pole did not crack anyway.
2.2.2.4 The stress/strain relationships must be determined
for the specific materials used. A balanced design is one in which the
yield strain of the steel and the limit strain of the concrete are
reached simultaneously. A balanced design produces the most efficient
section.
2.2.2.5 When designing to allow damage but resist collapse,
the concept of balanced design is not valid since some of the steel may
be intentionally allowed to exceed its elastic limit. Except in a rare
case of a highly under reinforced section, the failure will occur in the
concrete, and the steel will not rupture. This is due to the steel going
into a plastic state, thereby picking up an ever increasing load; while
the neutral axis moves toward the compression side of the section, which
must balance the increasing steel load on a decreasing concrete area,
until the concrete strain reaches the point where the concrete ruptures.
2.2.3 Column Loading
Buckling is seldom a limiting factor in the design of concrete
poles. However, when unusually large vertical loads are encountered
(e.g. large guyed loads or guys with short guy leads) it is necessary to
check for a buckling condition, particularly on taller poles.
2.2.4 Shear
Shear is seldom a consideration in concrete pole design. For
normal direct burial conditions, soil strengths dictate that the pole
must be buried deeply enough to preclude shear problems. Normal burial
depths will equal or exceed 10% of the pole length plus 2 feet and poles
with such burial depths need not even be checked for shear. The critical
conditions that bear checking occur when very large moments are applied
near either end of the pole. For example, poles set into solid rock or
buried into a concrete foundation socket, may not be buried very deeply,
in which case, it is necessary to check for shear to ensure that the
pole does not split lengthwise along the neutral axis due to exceeding
the concrete shear stress limits.
2.2.5 Torsion
Good theory for the design of concrete poles to resist torsional loads does not exist. Furthermore, the combined effect of the
stresses occurring in a prestressed concrete pole which is subjected to
simultaneous bending, column loading, prestress loading and torsional
loading is so complex as to defy reasonable mathematical modeling. Only
after extensive research will it be possible to develop mathematical
formulas and prove them out to the point where they can be used with
confidence. In the meantime, little can be done to assure proper performance under torsional loads other than to test a pole for those
conditions that suggest the liklihood of significant torsional loads
being applied.
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CONCRETE POLES DESIGN
strains greater than that corresponding to f , stress in reinforcement
shall be considered independent of strain and equal to f . Since
prestressing sttand behaves differently than reinforcing steely the PCI
Design Handbook
suggests the following formulas for the stress/strain
relationships of the prestressing steel:
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2.7
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CONCRETE POLES DESIGN
is necessary to insure that the reinforcing steel and the connection apparatus are properly anchored as a part of the pole (see discussion in
section 2.6 Concrete/Steel Bond). Since the connections are made of
steel, reference to ASCE Steel Pole Design Guide
for design and fabrication practices is recommended.
2.15 Pole Identification Data
All poles (including each piece of two piece poles) will have certain data indicated on a data plate or cast into the pole itself. At a
minimum, data to be shown will include:
Manufacturer's name.
Weight of pole (or weight of pole section).
Ultimate design moment (at ground line except for the top section of a two piece pole where ultimate design moment will be
that at the connection).
Length of pole (or length of pole section).
Date of manufacture.
Identification number (to allow manufacturer to match a
specific pole with the manufacturing data records).
2.16 Attachments and Accessories
An almost unlimited variety of attachments and accessories are
appropriate for use with concrete poles. The design of steel attachments, accessories and guys should follow applicable provisions of the
ASCE Steel Pole Design Guide. Pieces made of wood, fiberglass, aluminum
or other materials should be designed to meet established standards for
those materials as appropriate to the intended end use.
3.0
FABRICATION
3.1 General
Since one of the primary reasons for using concrete poles is to
achieve a long, maintenance free life as a support structure, it follows
that the concrete and other materials should reflect the use of the
finest available materials and workmanship. The design and manufacturing
techniques should make use of the latest and best thinking in terms of
producing durable and high strength concrete. Not only does the emphasis
on high strength produce lighter poles, the various techniques and procedures that produce high strength concrete also make for more durable
concrete.
The particular mix to be used is at the discretion of the manufacturer and should be considered as proprietary information. The manufacturer is responsible to the purchaser to demonstrate that finished
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CONCRETE POLES DESIGN
particular protection from corrosion (except in the severe case where
the pole will be placed in or immediately adjacent to salt water) since
the probability of a detrimental level of corrosion occuring inside the
holes is very small.
3.6 Finishing
The manufacturer's basic responsibility is to provide poles that
meet or exceed the design strength requirements, that have a pleasing
and workmanlike appearance and that have smooth, dense and hard surfaces
that will not deteriorate in the elements. Patching will be acceptable
provided that the structural adequacy and the appearance of the product
are not impaired.
Many other custom services are available at a price. Items in this
category include but are not limited to such things as plugging either
or both ends of a hollow pole, providing a rain cap for the pole, creating a special textured finish for the pole, installing hardware items
on the poles in the factory, painting the pole, etc.
3.7 Fabrication Tolerances
Following is a list of tolerances that manufacturers usually meet
in the normal course of business. Stricter tolerances can usually be met
if that should be necessary, but tighter tolerances have a cost.
Length - Plus 12 inches and minus 6 inches.
Cross Section - Plus or minus 5% with a minimum 1/4 inch.
Wall Thickness - Plus 20% and minus 10% with a minimum of 1/4
inch. Note that the wall thickness requirements are normally determined for some critical section such as the
groundline. Other areas of the pole may not require as
much thickness. Therefore, greater minus tolerances are
acceptable in some areas of the pole where calculations
and/or tests indicate that the pole will perform satisfactorily.
Weight - Plus 20% and minus 10% except that, with the approval
of the purchaser, poles heavier than 20% over the estimated weight may be used. (Caution: Be certain that poles
are marked with actual or greater than actual weights to
avoid accidents during construction.)
Sweep - 1/4 inch per 10 feet of length.
Bolt Holes - Plus or minus 1/8 inch for holes within a bolting
group and plus or minus 1 inch for the centerline of the
group from the end of the pole. Bolt hole diameters will
be 1/8 inch greater than the bolt diameter.
Blockouts - Plus or minus 1 inch.
End Squareness - Plus or minus 1/2 inch per foot of diameter.
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CONCRETE POLES DESIGN
not all cracks are detrimental to the product and, indeed, poles are
expected to crack under certain conditions.
Hairline cracks, although they may be quite visible during times
when the pole has been wet and is surface dry, will probably not cause a
problem with long term durability. It is not likely that oxygen or
moisture will enter hairline cracks to cause degradation of either the
concrete or the steel.
If a crack is opened wide enough to accept an ordinary sheet of
paper (approximately 8 mils), it should be sealed to keep moisture out.
Wide cracks are unacceptable except within one or two feet of the bottom
of the pole which will be buried.
Cracks within one or two feet of the ends of poles may occur during
the detensioning process. Unless they are open cracks, they will not
cause structural problems. Those cracks that are buried will never be a
problem. If there is concern about sufficient moisture penetrating
cracks near the top of the pole to cause freeze/thaw damage, those
cracks can be waterproofed. Structurally, they are not a problem unless
a very large moment is to be applied to the end of the pole.
Longitudinal cracks (other than hairline cracks) are generally
undesirable. Circumferential cracks that do not close generally indicate
that the steel has been stretched beyond its elastic limit. If that is
determined to be the case, the pole will no longer perform the job for
which it was intended and should not be used.
4.0 LOAD TESTING
4.1 General
The ultimate check on the adequacy of the entire design and
manufacturing process is the full scale test. Poles may be tested in
either a horizontal or an upright position. If only the pole is being
tested, a horizontal test is entirely satisfactory and easier than an
upright test. In instances where the pole is being tested as a part of
an entire structure, it is likely that the entire assembled structure
will need to be tested in the vertical position.
A pole structure test should be considered a guide to good structural design practice. The contract documents shall designate the
organization that is responsible for the structural design specifications set forth in the contract. Overall responsibility for the structure testing should lie with one person representing this organization.
This person should be totally familiar with the structure's design and
approve the proposed procedure for structure testing. Also, this person
should be present at all times during the testing sequence and approve
each decision made during the process. The single person having these
responsibilities shall be called the Responsible Test Engineer.
In a traditional proof test, the test set up is made to conform to
the design conditions (i.e. only static loads are applied), the structure has level, well-designed foundations and the restraints at the load
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4.4
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CONCRETE POLES DESIGN
acceptable.
4.12 Failures
Following the provisions of Paragraph 1.3, the decision will have
already been made as to whether failure occurs when there is a permanently deformed structure or when the structure collapses.
If a premature structural failure occurs, the cause of the failure
mechanism shall be determined and corrected. Failed and damaged members
shall be replaced. The load case that caused the failure shall be repeated. Load cases previously completed need not be repeated.
After the structure has successfully withstood all load cases, and
assuming that the structure was not tested to destruction, the structure
shall be dismantled and all members inspected.
4.13 Disposition of Test Structure
The test specification should state what use, if any, may be made
of the test structure after the test is completed. Undamaged components
are usually accepted for use in the line. If an overload test to failure
has been performed, caution should be exercised in accepting the parts
that appear to be undamaged since they may have been overloaded.
4.14 Report
The testing agency shall furnish a test report in the number of
copies required by the job specifications. The report should include:
a. The designation and description of the structure tested.
b. The name of the utility that will use the structure.
c. The name of the organization that specifed the loading and test
arrangement of the structure.
d. The name of the Responsible Test Engineer.
e. The name of the fabricator.
f. A brief description and the location of the test facility.
g. The names and affiliations of the test witnesses.
h. The dates of testing each load case.
i. Design and detail drawings of the structure including any
changes made during the testing program.
j. A rigging diagram with detail of the point of attachment to the
structure.
k. Calibration records of the load measuring devices.
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5.2
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CONCRETE POLES DESIGN
manner as for the previous poles. A cutting torch will still be necessary because even though the tendons are to be avoided, there is still a
high probability of having to cut through the spiral steel.
5.5.3 Circumferential Steel
Cutting of circumferential steel is difficult to avoid, but is
acceptable at any time unless the pole is to be subjected to severe torsional loads.
5.6 Field Cutting
There will be occasions in which it is desirable to shorten a pole
in the field. This can be accomplished without damage to the pole by
cutting with a small, hand held concrete saw and an abrasive cut off
blade. The blade will cut both the concrete and the steel. For hollow
spun poles, carefully mark a straight line around the circumference and
saw along the mark.
5.7 Erection
Concrete poles are erected in the same manner as other poles.
Assuming that the poles were properly placed before they were framed, a
single point pick with a choker is usually permissible. The choker
should be placed well above the center of gravity unless the drawings
indicate that the pole can be single point picked at the center of gravity. This means that as the pole is raised from the horizontal, much of
the weight stays on the ground until the pole is nearly in the vertical
position. Once it reaches the vertical position, it will not be damaged
by lifting its full weight with a single point pick.
Because the surface of a concrete pole is smooth and hard, safe
operations require use of the same choker techniques as for steel poles.
IMPROPER USE OF CHOKERS CAN RESULT IN THE POLE SLIPPING AND CAUSING
INJURY OR PROPERTY DAMAGE. Chokers must be tight around the pole. If the
chokers are slippery, they may be padded with a sticky material. A
positive stop against sliding can be provided by attaching the choker
below a solid piece of hardware (Note that a ladder clip does NOT
qualify as solid hardware).
Guyed poles, whether or not they are raked, should be initially set
in what ever positions they will be under normal every-day loads. This
means that regardless of what ever bending and flexing occurs during
construction and long term use, once the conductor installation is complete and the guys are adjusted under normal everyday loads, the top of
the pole should be in the same location as it was originally set.
5.8 Climbing
Concrete poles are climbed in the same manner as steel poles. Just
as most steel poles are climbed with the standard climbing ladders, all
of the manufacturers provide attachments to concrete poles to accomodate
the same ladders. Other climbing arrangements are also available and may
have been selected by the user.
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CONCRETE POLES DESIGN
including all attachments and connections, should be considered. The
fabricator's drawings need checking to ensure they contain proper and
sufficient information for fabrication and erection in accordance with
the requirements of the user's specification. (Refer to Section 2.0
Design.)
6.3 Fabrication
6.3.1 Materials
The specification should include the requirement for review
and agreement on the manufacturer's material specifications, his sources
of supply, material identification, storage, traceability procedures and
acceptance of certified mill test reports. (Refer to Sections 3.2 Concrete and 3.3 Reinforcing Steel.)
6.3.2 Material Preparation
The user may specify that either he or his agent inspect the
manufacturer's equipment and process facility to ascertain that the
procedures are satisfactory, the tolerances are within specified limits
and the existing quality
control program is satisfactory. (Refer to
Section 3.8 Testing.)
6.3.3 Nondestructive Testing
The specification should indicate the requirements for acceptance of the type and procedure of all nondestructive testing and
inspection programs employed during each step in the fabrication
process.
The user may specify that the manufacturer furnish copies of
testing and inspection reports. The user may also perform independent
random sample testing to verify results of manufacturer's testing.
(Refer to Section 3.9 Inspection.)
6.3.4 Tolerances
It is necessary that acceptable fabrication tolerances be
specified and agreed upon by the purchaser and manufacturer. Good
fabrication quality is an important factor in minimizing field construction and performance problems. (Refer to Section 3.7 Fabrication
Tolerances.)
6.3.5 Surface Coatings
Where painting or other coloring is required, the system,
procedures and methods of application should be acceptable to both the
user and the manufacturer. Also the system should be suitable for both
the product and its intended exposure.
If galvanizing of accessories is required, the procedure and
facilities should be agreed upon by the user and the manufacturer. After
galvanizing, nondestructive testing may be specified to ensure that
there have been no adverse changes to the finished product.
Appendix A
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
BIBLIOGRAPHY
ACI Committee 318, "Building Code Requirements for Reinforced
Concrete (ACI 318-83)", American Concrete Institute, Detroit, 1983,
111 pp.
ACI Committee 318R, "Commentary on Building Code Requirements for
Reinforced Concrete (ACI 318R-83)", American Concrete Institute,
Detroit, 1983, 155 pp.
National Electrical Safety Code, 1987 Edition, American National
Standards Institute ANSI C2, Institute of Electrical and Electronic
Engineers, Inc., New York, NY.
Guidelines for Transmission Line Structural Loading, Committee on
Electrical Transmission Structures, American Society of Civil
Engineers, New York, 1984, 166 pp.
Standard Specifications for Structural Supports for Highway Signs,
Luminaires and Traffic Signals, AASHTO Subcommittee on Bridges and
Structures, 1986.
EIA-RS-222-C, Electronic Industries Association Standard, March
1960.
PCI Design Handbook, Precast and Prestressed Concrete, Third
Edition. Prestressed Concrete Institute, Chicago, 1985.
PCI Committee on Prestressed Concrete Poles, "Guide Specification
for Prestressed Concrete Poles", PCI Journal, V. 27. No. 3, MayJune 1982, pp. 18-29.
PCI Committee on Prestressed Concrete Poles, "Guide for Design of
Prestressed Concrete Poles", PCI Journal, V. 28, No. 3, May-June
1983. pp. 22-87.
Task Committee on Steel Transmission Poles, "Design of Steel
Transmission Pole Structures", Committee on Analysis and Design of
Structures, ASCE Structural Division, 1978.
Manual for Quality Control for Plants and Production of Precast and
Prestressed Concrete Products, MNL-116-85, Prestressed Concrete
Institute, Chicago, 1985.
"State of the Art - Prestressed Concrete Poles", PCI Journal, Vol.
29, No. 5, Sept-Oct 1984.
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Appendix C
DEFINITIONS
CASTING METHODS
Precast Member - A member which is cast in some location other than
the location in which it is to be used. All poles are likely to be precast.
Spun Cast Member - A member cast in a mold that spins during the
consolidation phase. The resulting centrifugal force causes the pole to
be hollow and the concrete to be highly consolidated. Since this force
is very large, dry (low water/cement ratio) concrete can be consolidated
in this manner, usually with some of the water spinning out to reduce
the water/cement ratio even further. Because spun concrete has a lower
than normal water/cement ratio and a higher than normal density it is
much stronger and more durable than static cast concrete. The end result
is that the member can be lighter because less concrete is required when
it is stronger. The concrete is much more impermeable and, therefore,
more durable.
Static Cast Member - A member which is cast in a mold that does not
move during the casting and consolidating of the concrete (except for
the possibility of vibrating the mold as an aid in consolidating the
concrete).
LOADINGS
Maximum (Ultimate) Design Load - The load that the pole is designed
to resist. This load is the maximum service load multiplied by some
overload factor. The user must select not only the load and the load
factor, but also must determine whether the pole is to resist the maximum design load without permanent unacceptable deformation (damage) or
without failure (collapse). A stronger pole is required to resist
without permanent deformation than without collapse.
Maximum Service Load - The maximum load that the pole is ever
expectedto encounter (exclusive of overload factors). This load may be
used for checking deflections and clearances.
Normal Everyday (Frequent Condition) Load - A load that a pole may
be expected to encounter on a frequent basis. User should specify the
normal everyday load.
MOMENTS
ultimate Moment - Depending on the user's choice as to whether the
pole must resist permanent deformation or collapse, this is the moment
at which the chosen one of these events occurs. The moment capacity at
each section must be equal to or greater than the ultimate moment produced in the section by the maximum design loads.
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46
DEFINITION
47
TENSIONING
Post Tensioned Member - A prestress member in which the concrete is
poured and cured without tensioning the steel. Usually ducts are cast
into the concrete to keep the steel from bonding to the concrete or to
provide a space for placement of the steel after the concrete is cured.
In this method, the steel is initially stretched against the cured concrete itself rather than against the molds or bulkheads. The advantage
of post tensioning is that bulkheads or heavy stressing molds are not
required. The disadvantage is that it requires more work in manufacturing.
Pretensioned Member - A member in which the prestressing steel is
stretched against bulkheads or the mold while the concrete is cured and
forms its bond with the steel. When the steel is cut loose from the end
supports, the bond between the concrete and steel allows the steel to
impart the prestressing load to the concrete.