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Dynami­c Prestress OFFICE PRODlJ( "I'ION (INIT

72, Mahavir Centre, Sgctor-17, Vashi, Nasik, MID(' Salptlf.
_ NaYiM.UIBbai ~ 400105, INDIA. Maharashtra. INIH/\' --.:.
Tel - : 01-91-22-27892628/2789 1310,..­ _Tel: +\) I 253 2351 ·1 1 I / M() I()2l-i
- Fax: +91-22-27891186 Fax : +9 1-25.l- (lo07XSCl TECHNICAL GUIDELINES '
Webiste : www.dynamicprestress.com E-mail: dynamicmumbai@gmaii.com E-mail: dynamic Ilsk<tI'/ialll"lianll'l.ill
The prestressing technology is emerging fast growing field in construction H.T. Strands are available in various diameters such as 12. 7 ~m (0.5/1), 15.2mm(0.6/1), and 15.7mm (0.62/1).

industry particularly for buildings, bridges, metro rail, flyovers, nuclear power Properties of LRPC :
plants, LNG tanks, cement plant etc. Dynamic Prestress a specialist agency in AS PER INDIAN SPECIFICATION: IS 14268/1995 AS PER BRITISH SPECIFICATION BS 5896: 1980
TAB LE 1 TABLE 2
the field of prestressing, is accredited with an ISO 9001 certification & has state en en
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KN Kg/Km mm mm % mm
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KN KN Kg/Km
Prestressing is a technique of construction in which internal stresses of a 12.7 +0.66 98.7 183.7 165.3 775 ?Wire +0.40 +4%
II -0.15 15.7 -2% 150 265 225 1180
suitable magnitude & distribution are introduced in a member, so that the SUjJer
15.2 +0.66 140 260 .7 234 .6 11 02 -0.20
stresses resulting from external loads are counteracted to a desired degree. -0.15
Pre-tensioning & Post-tensioning :
Dynamic Group do not manufacture rl.T. Strands.The above mentioned data is for reference &can be checked with the manufacturers.
Pre-tensioning is a method of prestressing concrete in which the tendon is
tensioned before the concrete is placed. DUCT / SHEATHING PIPE
In case of Post-tensioning, the tendon is tensioned after the concrete has Sheathing creates the necessary void in the structure in which the prestressing steel (strands/wires) is free to
hardened. The prestressing force is imparted to the concrete by bearing & this move during stressing. Metallic Sheathing is corrugated throughout its length & is manufactured out of
procedure can be applied to members either precast or cast-in-situ. C.R.C.A. strip. The diameter ranges from 39mm to 130mm & strips thickness from 0.24mm to O.7mm .
strips are available in Bright Metal/Galvanized / Lead coated finish.
Prestressed concrete structures can be classified in a number of ways
depending upon theirfeatures of design & constructions like: TABLE 3
(A) Metallic sheathing (Dud) :
a) Externally or Internally prestressed Type of duct Values recommended
Following tests on sheathing pipes is carried out at our Nasik
or sheath to be used in desiQn
b) Bonded or Unbonded tendons works as per IRC : 18 - 2000
K per meter Jl
c) Linear or Circular prestressing 1. Transverse Load test 2. Tension load test BriQht metal 0 .0046 0.25
3. Water loss test 4 . Workability test Galvanized 0.0030 0.20
(8) HOPE Sheathing (Dud) should conform the following specification Lead coated 0.0030 0.18
•• •
* Fib Bulletin-7 * NPC Specification No.PP/M/1721
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The various components used for post tensioning work involves use of
* IRC: 18-2000 * Addendum and Corrigendum IRS Slip No.6 0: !'1
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Anchorages, H.T.Strands, Sheathing Ducts, Multi and Single strand Hydraulic
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* Rai lway Concrete Bridge Code 1997
Jacks with Power packs, Grout pumps, Agitators, Grout caps, Destressing 'c
Friction coefficient & wobble coefficient:
tools, etc. Dynamic has state of the art infrastructure facility for manufacturing
The friction coefficients (Jl) and wobble coefficient (k) can vary
all sizes of prestressing anchorages and equipments.
depending upon various factors including the nature and
TABLE 4
surface condition of the prestressing steel, the type, diameter
and surface condition of the sheathing duct, and the Parameter As per fib As per NPC
(Units) Bulletin 7 (2000) Report PPM/1721
installation method.
Dynamic is provid ing tailor made solutions for construction industry in the field The value of ~ and k given in the table 3 & 4 may be adopted K (per metre) Not specified 0 .003
of prestressing since last two decades. The company's specialisation includes : for calculating the friction losses. ~ 0 .10 - 0.14 0 . 10 - 0.14
* Technically qualified engineers and technical supervisors having vast
PRECAUTION DURING PROFILING & CONCRETING
exp~.rience in the prestressing industry. • Mark outtendon spacings and lay duct as per approved drawings.
* ProViding Services for installation and supervision. • Proper taping of duct-duct coupler joint and also anchorages - duct joints.
* Experienced team for quality control with in -house testing facility. • Use de-coller and safety goggles wh ile uncoiling and cutting of strands.
• Use strand bulletwhile threading the st rand in the cable duct.
* Providing equipments having low maintenance cost.
• While concreting, the duct should befilled with H.T. Strands or dummy pipe.
* Providing Smaller gripping length of prestressing jacks. • Use rust preventive oil for pre-threaded strands for its protection till the date of stressing .
* Ability to develop equipments and devices as per site conditions. • The gripping length of strand should be cleaned before mounting the anchor plate and stressing jack.
* Wide experience with clients like NHAI, RAILWAYS, MSRDC, NPCIL, PWD, • The corroded or pitted strand shall not be used for stressing purpose.
etc. for all type of Structures & has completed variety of projects in several • The anchor cone (Tube Unit) is made of grey cast iron and hence is brittle in nature. The concrete behind the
anchor cone should be sound and compact. The anchor cone is meant for transferring the load only & in case of
countries like INDIA, UAE, OMAN, SAUDI ARABIA, MONGOLIA,
bad concrete behind the anchor or insufficient anti- burst reinforcement, the anchor cone is likely. to get crushed.

MAURITIUS etc.

----------------------------------~------------~~~
 Dynamic post tensioning multi-strand anchorages includes entire range for all three types of strands viz - ~ STRANQI COUPLER
12.7 mm (0.5"L 15.2 mm (0.6") and 15.7 mm (0.62") and the anchorages are widely approved and Dynamic provides Single Strand Coupler and Multi Strand Coupler for Pre-Tensioning
accepted for all types of Prestressed Concrete structures. and Post-Tensioning works respectively.
The coupler is a mechanical device used for structures built in sections; in cases when
SPACING OF ANCHORAGES & ANTI-BURST REINFORCEMENT
the cost of scaffolding & forms for a complete structure becomes expensive. Certain

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'N'turns cables are stressed & anchored at partial length & later extended using couplers.

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The execution work of continuous spans using multi strand coupler is a bit different

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from the regular multi strand anchorages and hence special precautions needs to
be taken. As the couplers are embedded in the concrete there is likelihood of
111111111111111 "lillY strands getting corroded in the anchorage zone due to the extensive exposure to
E A Iun \\\\lnnnmn slurry and water. The strands if excessively corroded will loose the grip of wedges
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, and during the stressing activity of the next stage, the strands may slip from the
II .. • 1", , I
.. L .. other end. It is therefore mandatory and absolutely essential to complete the
concreting in shortest possible time and protect the strands and coupler when
Sr. Anchor UTS 80% of Dud Anchor Pocket Min. Edge Spacing Pocket PCDof Spiral Length Spiral No. of Pitch of installed at site.
No. Type (Tons) UTS Diameter Cone Size (Recess) Distance Between Depth Holes on Reinforce of Spiral Par Turns Spiral
Anchorages Anchorage mentOD Spiral Dai The . Multi Strand Couplers are of two different types namely pre-locked spring
loaded wedge coupler (Type-A) and swadge type of strand couplers (Type - B).
AxA ExE F G H K D L M N P
4 DP 13 75 60 51 145 215 120 220 105 125 150 240 16 6 40 • The strand coupler (Type-A) consist of anchor plate with active anchorage at the
2 7 DP13 131 105 51 145 215 120 220 105 125 150 240 16 6 40 center of anchor plate and pre locked spring loaded wedges at the periphery.
3 12 DP 13 225 180 75 190 240 148 260 120 165 480 16 8 The whole assembly is protected by tube which is seated on the bearing plate.
190 60
The other end ofthe coupler is connected to the sheathing of the next phase.
4 19 DP13 356 285 90 245 . 300 198 325 ' 120 ;.-­ 200 . 250 540 16 9 60
5 27 DP 13 506 405 105 305 350 295 485 120 274 300 600 20 10 60 • The swadge types of coupler (Type - B) constitutes of peripheral strands,
• The Technical details of strand anchorages with 31 DP13 & more, shall be provided by our Mumbai office on request. swadged and positioned in the grove provided on the bearing plate & the active
7 4 DP 15.2 106 85 51 145 215 120 220 120 125 150 480 16 8 60 anchorage at the centre. The whole assembly is protected by a tube which is
8 7 DP 15.2 186 149 75 190 240 148 260 120 165 190 480 16 8 60 seated on the concrete with a rubber gasket.
9 12 DP 15.2 319 255 85 245 300 200 300 120 200 250 540 16 9 60
ANCHORAGES FOR STAGE STRESSING
10 19 DP 15.2 505 404 105 275 350 213 350 120 235 280 600 20 10 60
11 27DP15.2 718 574 120 350 392 340 575 130 285 350 720 20 12 60 Stage Stressing is essential when prestressing is to be applied in stages to the
1231DP15.2824659 130 370 412 355 620 140 295 370 720 20 12 60 concrete as per (design requirement) or if the stroke of jack is insufficient. For
13 37 DP 15.2 984 787 140 400 440 380 675 140 320 400 840 20 14 60 prestressing in two or more stages, multi use live wedges are recommended to be
14 43DP15 .2 1143 914 150 435 485 400 725 140 375 435 960 20 16 60 used instead of single use live wedges. For detail procedure of prestressing In
15 48 DP 15.2 1276 1021 160 435 485 420 770 150 375 435 1080 20 18 60 stages, you may contact our technical office. .
16 55 DP 15.2 1462 1169 170 455 500 430 820 160 390 480 1200 20 20 60
• The Technical details of other capacity anchorages for 15.7 mm strands shall be provided by our Mumbai office on request. RESTRESSING ANCHORAGES
,'.
177DP15.7 189 151 75 190 240 148 260 120 165 190 540 16 9 60 Dynamic provides special type anchor plate for restressing in order to compensate
18 12 DP 15.7 324 259 85 245 300 200 300 120 200 250 600 16 9 60
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for the loss of prestress of ungrouted tendon. The restressing of cables is done using
19 19 DP 15.7 513 410 105 275 350 213 350 120 235 300 660 20 10 60 tailor made jacks & shimming foot.
• Dimensions of Single Strand Anchorages and other flat anchorages can be provided on request.
20 4S13 75 60 60 x 20 170x75 220x125 170 325 130 270xllC 300 10 6 50
The multiuse barrels & wedges alongwith monostrand jacks of stroke upto one
21 5S13 93 75 70x20 204x75 255x15 170 360 130 270xll 300 10 6 50
metre length are provided by us for the production of pretensioned girders. The
22 4S15 106 85 80 x 25 250x80 300x15 200 375 130 270x11 300 10 6 50
Jacks, Barrels & Wedges are available forO.5", 0.6"& 0 .62" strands.
23 5S15 133 106 90 x 25 250x80 300x15C 200 400 130 270x110 400 10 8 50
Notes : (all dimenSions are In mm)
1) The'F' & 'G' dimensions are based on use of M45 grade of concrete. In case if grade of concrete differs then the dimension may be suitably altered by referring it
DEAD END ANCHORAGES
to our technical department. The stressing sequence is important & may influence the concrete strength requirement at each phose of stressing. Dynamic provides two types dead end anchorages at the non ­
2) Bursting reinforcement should perfectly start, 35 mm from the inner surface of Anchor cone.
3) In case of ligs to be used instead of spiral as antiburst reinforcement for flat anchorages than equivalent steel area stressing end of the girder. This anchorages are particularly
should be provided in the form oflwo ligs spaced BO mm apart. useful for single end stressing as per the design and for the
4) Slip due to elastic shortening of gripping length of strand and the slip due to wedge set, should be separately considered. cases where less gap is available in between the girders orifone
5) Wedge set in the anchorage during transfer causes loss of prestress, Wedge set in the non·stressing anchorages and
temporary Jack wedge occurs during stressing and causes an apparent increase in extension but no loss of prestress. of theendofgirderisnotaccessible. BNOM
I
C
The normal wedge set in Dynamic system is 6 m.m. at stressing end and 3 m.m. at non stressing end . • The Bulb type of dead end anchorages (Type C) are suitable
Anchorages Bulb Type Dead End Anchorages
6) The load for locking wedges shall be in the range of 1.5 T to 2.5 T!Wedge. The locking pressure depends on the ram
area of the jack and the type of strand and hence the exact load to be applied shall be checked with ourtechnical team. for flat post tension slab with less numbers of strands and low Sr. N0' 1 Type ABC
7) The internal area of the sheathing duel shell be aboutthreetimes the area of the tendons or as per our individual capacity anchorages. The bulb portion and the bonding
mm mm mm
technical leaflet made for the specific struelures of projeel. AS13 270 50 600
length ofstrand is embedded in the concrete. 2 5513 350 50 600
8) The internal diameter of duct is specified above, the external diameter shall be approximately 5 mm bigger.
9) Pocket dimensions are for normal pocket sizes, any deviation in this to be studied individually taking jack dimensions into account. • The Spring loaded plate type of dead end anchorages (Type 3 451~ 270 50 750
10) The spacing, edge covers and grouping of cables shall conform to relevant National codes of praelice. D) are suitable for entire range of 4 to 55 strands and have
4 5515 50
~. . . . . 11) Lengths of strand quoted in the data is gripping length of stressing jack and is measured from the face of the anchor cone (tube unit).
12) The compatibility of Jack components for T range of anchorages & the detailed technical inputs shall be made available on request. been extensively used for several metro rail projects.
•
&STRESSING ACTIVITY
HYDRAULIC JACKS ---------------------------------------------- .--­
'

Post-tensioned cables are grouted to provide protection against co'rrosion . The grout
encases the alkaline environment and prevents corrosion, it also develops bond
between the prestress steel and surrounding concrete . Grouting should be done by
water displacement method.
The double acting reciprocating type Dynamic Grout Pump are widely used for
grouting cable ducts & pressure grouting of rock anchors and dam. The pump is
2
operated at working pressure of 5 kg/cm and has a discharge of 25 litres /minute . It
JACK THREADING SEQUENCE FOR PRESTRESSING OPERATION
operates on 3 phase electric supply and has 3 HP motor of 1440 rpm . The pump
CHARACTERISTICS OF DYNAMIC STRESSING JACKS weighs 200 kgs. and the area of piston is 19.64 cm2.
I Jack Capacity Overall Outer dia. Ram Area Min.Gripping Max. Lock off Cylinder Weight The standard grout agitator used for making a homogenous grout mix of water;
Model tons Length of Main For For Length of Travel Length dia for
cement and admixture weighs 138 kgs. The agitator has 3 HP motor and the capacity
Cylinder Stress Lock Strand to cut Lock
of mixing unit is 100 litres of cement grout.
(tons) (mm) (mm) (cm2) (cm2) (mm) (mm) (mm) (mm) (kgs) Dynamic has used high discharge capacity positive displacement type grout pump
D-20 22 735 106 42.2 - 350 " 200 175 70 27.5 2
having minimum outlet pressure of 10.5 kg/cm for continuous span bridges of
~
DP-20 22 450 100 33.3 - 125 200 75 65 18
I length 120 meters and more.
DP-30 30 450 118 48. 5 14 125 200 75 76 26 Dynamic grout caps are advantageously used for speedy grouting. The grout cap is
CG-12/200 140 675 285 341 .05 52 .52 600 200 298 200 175 fixed byfour allen key bolts and the air nut is kept in upwa rd position.
CG-18/150 200 610 345 482.4 66 560 155 300 240 I 200
CG-18/200 200 715 345 482.4 66 620 210 315 240 255
ETY PRECAUTIONS AT THE TIME OF GROUTING
CG -20/200 300 745 400 641.5 116.8 650 , 210 3 15 270 280
• Protective glasses must be worn during grouting operation.
CG-30/100 350 500 380 563.72 ' - 350 100 2 10 300 270
• Do not start the pump while valves are in closed position as it may cause damage
CG-40/200 400 735 492 1058.94 173.3 660 210 290 328 490
to the pr!=ssure gauge.
CG-50/200 500 74 5 525 1196.2 178 680 210 305 346 584
• Place the grout tank preferably at the same level as that of grout pump.
CG-50/200
• In case of a longer stoppage (> 5 min)of grouting operation, ensure that the grout
Modified 500 735 494 1045.4 173 .3 660 210 290 328 480
does not set in the pump, if necessary empty the grout and flush pump with water.
CG-50/100 500 - 494 1045 .4~ - - 100 - - -
CG-50/300 500 750 494 1045.4 173.3 850 300 210 328 550
CG-120/200 1200
Dimensional details of CG 120/200 & CG 160/400 jacks shall be provided on request The high concrete stresses in the anchorage zone requires the compliance of specific
CG-160/400 1600
conditions like the spacing of anchorages, minimum edge distance to the nearest
II
STRESSING GUIDELINES concrete surface, strength of the concrete at the time of stressing, placing of primary
anti-burst reinforcement in front of the anchorage & additional stirrups required to
All prestressed cable should be layed in smooth curve and supported at a spacing not exceeding one meter. If necessary
bind the edge & corner concrete into the mass of the end block. Perfectly compacted
reinforcement bars shall be bent or shifted locally to avoid clashing with prestressed cables and bursting reinforcement. The
revised extension shall be recalculated at site in case of variations in the design values and actual values of : a} Strand area, concrete in the anchorage zone is a must. The anti-burst reinforcement cannot make
b} Modules of elasticity c} Gripping length. Revised modified extensions shall be used for calculations. Similarly the revised up for local concrete defects. Precast end block can be used in case of 'I' girders or
pressure shall be modified taking into account the actual jack efficiency vis design efficiency considered in the GFC drawing . 'Box' girders. Transverse cables shall be avoided in the end zone portion .

SAFETY PRECAUTIONS WHILE STRESSING
Very large forces are introduced in the tendons during stressing and the equipment is under heavy hydraulic pressure, thus
careful working can avoid accidents. The following precautions are essential :­
• Only trained and experienced personnel, under the guidance of Dynamic technical Staff, should perform stressing.
• The equipment, especially the high pressure hoses and the adapters must be in perfect condition . Damaged hoses must be
replaced immediately. Protection caps must always be placed over unused connections (electric as well as hydraulic),
• Jack should never be handled by hoses. Stressing should be done according to specified data. The allowed maximum
pressure should never be exceeded .
• During stressing, nobody should stand behind or underneath the jack, since failure of strand can cause fatal accidents.
• For stressing close to traffic areas, the jack must be secured by ropes or chain hoist. ' godown to prevent corrosion of Metallic Duct & H.T. Strands. For long exposure of
• All bars, wires and strands should be stored carefully. Ensure that they are not damaged in any way and should be checked
for rust and corrosion before they are used. '
• Care should be taken while handling high tensile steel strand as they may 'whip back' with force, if not securely bound.
• Do not permit welding near high tensile Prestressing steel. A drop of molten metal if applied to the strand, will change its
mechanical properties and promote the possibilities of premature fai'lure.
• Hogging of the girder during stressin,g operation should be observed & recorded .
While placing the anchor cone in the end zone, care should be taken that the
attachments must be strong enough to resist knocks & vibration and also the impact
of the wet concrete dumped on it. The connection of the sheath w ith anchorage must
be done with proper care to ensv re that anchorage alignment is as per drawing & the
connection is watertight (additional Heat Sh rink tape if required should be used to
ensure leak proof joint) .
The steel parts of anchorages must not be exposed to rusting wh ile storing at site. '
When the anchorages are stored for more than 15 days, they should be kept in closed
godown along with H.T. Strand. VPI (Vapour Phase inhibitor)bag shall be kept in
anchor plate & anchor cones to rain & moisture at the constTuction site, the exposed
parts & holes should be oiled and later cleaned before use. The live wedges should
also be cleaned before installing in the anchor plate.
After tensioning & grouting is completed, th e exposed anchorage end & strands shall
be cleaned & coated with epoxy bonding paint. The pocket portion shall be filled with
compact concrete /mortm of approved grade.