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WORKSHOP ON IRC:112-2011

BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

CODE OF PRACTICE FOR


CONCRETE ROAD BRIDGES

SECTION 13
PRESTRESSING SYSTEM

ALOK BHOWMICK
B&S ENGINEERING CONSULTANTS PVT. LTD.
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Coverage of Section 13 of the Code :


 Section 13 covers specific requirements for parts of
prestressing systems in PSC members. Though it covers
both pre-tensioned as well as post-tensioned bridges,
primarily the section is for Post Tensioned System.

 The Chapter deals with :

 Prestressing Systems
 Installation, Stressing & Grouting Equipments
 Hardwares like Anchorages, Sheathing Ducts, Wedges
 End Block Design - Spalling & Bursting Reinforcement
 Protective Grouting
 Corrosion Protection of Tendons & Anchorages
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

1. What is Prestressing
System ?

2. What are the essential


Requirements of
Prestressing System ?
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

 Modern development of prestressed concrete is attributed to


Eugene Freyssinet of France, who started the ‘Freyssinet
System’ in 1939 with conical concrete wedges & f 5mm
wire.

 Since then, significant development has taken place


worldwide in the development of Prestressing Systems.

 Early 1950’s saw the creation of the International Federation


of Prestressing (FIP) who subsequently contributed
significantly to the development of Prestressed Concrete
through preparation of recommendations and guides for
Prestressing Materials and Systems
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

PRESTRESSING SYSTEM

PRE-TENSIONING POST TENSIONING


SYSTEM SYSTEM

WIRES STRANDS BONDED UNBONDED


TENDON TENDON

BARS STRANDS
MONO STRESSING MULTI-PULL
STRESSING
(Wires, Bars &
Strands) (Wires & Strands)
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Essential Requirements of a Prestressing System :

Prestressing Hardware
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

 Pre & Post Tensioning Tendons are important structural


elements, decisive for the functioning of PSC structures.

 Consequence of inadequate design, detailing and poor


execution of prestressing systems can lead to :

a) High cost for rehabilitation or replacement


b) Collapse
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

• What is the difference between Pre-


Tensioning & Post Tensioning ?
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

PRE-TENSIONED GIRDERS

• Steel tendons are stressed before the concrete is placed


at a precast plant remote from the construction site.
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

POST-TENSIONED GIRDERS

• Steel tendon are stressed after the concrete has been


placed and gained sufficient strength at the
construction site.
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Type of Advantages Disadvantages


Construction
Pre-Tensioned 1. No need for Anchorages 1. Special casting bed with
System 2. Tendons protected by facility for external stressing
concrete without the need required
for grouting. 2. Difficult to incorporate
3. Better distribution of deflected tendons
prestressing in transmission
zone
Post Tensioned 1. No external stressing bed Tendons require a protective
System required system
2. More flexibility in tendon Large concentreated force in
layout and profiles end blocks
3. Draped tendons can be
easily used.
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Post Tensioning can be with :

1. Internal prestressing, with grout, grease or wax


protection

2. Partially bonded external prestressing with grout


protection (non replaceable)

3. Unbonded external prestressing, grease or wax


injected.
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Prestressing Material
(Wires, Strands & Bars)
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Strands

TYPES UTS
STRANDS 1860 Mpa
WIRES 1570 Mpa TO
1865 Mpa
BARS 980 Mpa
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

INDENTED
BARS WIRES
IS:2090 IS:6003
STRANDS
PLAIN WIRES IS:14268 & IS:6006
Bars: IS:1785 (Part 1)

High strength steel. The normally available sizes are from 20mm to 44mm (5/8 to 1-3/4in) diameter with 20, 22,
25, 28 and 32 mm dia. being more common. The bars are usually threaded with very coarse thread.
Wires:
The nominal dia. of wires are 4.0, 5.0, 7.0 and 8.0 mm. The different types of wires are as follows.
1) Plain wire: No indentations on the surface.
2) Indented wire: There are circular or elliptical indentations on the surface (4mm & 5mm dia only).
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

PRESTRESSING STEEL TENDONS :


 Mono-Strand : One single strand per tendon

 Multi-Strand : Multiple Strands per tendon

 Unbonded : Tendon encased in plastic


sheathing. Does not bond to concrete. Force is
transferred by anchorage only

 Bonded : Tendon installed in ducts that are


pumped with grout after stressing. Bonds to concrete.
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Prestressing Hardware for


Post Tensioning System
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Prestressing Hardware - Anchorages

Guide – Trumpet
Bearing Plate: :
A specially
Made formedofcomponent
of forging graded alloymade of
steel.
graded cast
Transfers loadiron,
fromembedded in concrete
prestressing strand to
and distribute
Concrete, the tendon
through Guide. force

Wedges (Grips) & Circlips :


Made of Alloy Carbon steel & subsequently hardened and
tempered. It transfers load from strand to bearing plate.
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Prestressing Hardware - Anchorages

Mono Group Anchorages for


Wedges
Girder post tensioning
Anchorages for Slab post
tensioning
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Prestressing Hardware - Anchorages :


• Prestressing Anchorages distribute the prestressing force
into the structural member without damage to the member.

• When damage of anchorage zone occurs, it is either due to


concrete crushing or due to bursting or spalling of
reinforcement.

• Anchorages are the key components for safety of post


tensioning system. Performance shall be in accordance
with the “FIP-Recommendations for the acceptance of post
tensioning system – June 1993”
(In IRC:18, reference was made to BS:4447 for acceptance)
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Acceptance Criteria for Anchorages :


• The anchorage-tendon assembly shall
comply with the acceptance tests as
indicated in this guideline.

• There are 3 types of tests included in this


guideline :

• Static Load Test

• Dynamic Load Test with tendon-


anchorage assembly

• Load Transfer Test.


SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Acceptance Criteria for Anchorages :


1. Static Load Test :

The aim of the static load test with tendon-anchorage


assembly is to assess the performance of the
anchorage assembly in its capability to hold and transfer
the prestressing force to concrete.

The measured anchorage efficiency, at breaking load


shall be more than 95%. The anchorage assembly shall
be capable of holding and transferring a force not less
than 95% of the actual mean ultimate tensile strength.
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Acceptance Criteria for Anchorages :


2. Dynamic Load Test :

The aim of the dynamic load test is to determine the


capacity of the tendon-anchorage assembly under load
fluctuations as an indication of the reliability and
durability of the assembly.

The anchorage-tendon assembly shall be capable of


withstanding not less than 2 million cycles of fatigue
load varying between 60% to 65% of the UTS.
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Acceptance Criteria for Anchorages :


3. Load Transfer Test :

The aim of load transfer test is to verify the transfer of


prestressing force from the mechanical anchorage and
its component to the concrete.

Effective transfer of load to concrete behind the


anchorage will depend upon the grade of concrete at
the time of load transfer and the detailing of local zone
reinforcement.
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Sheathing Ducts &


Duct Joints
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Prestressing Hardware – Sheathing Duct

Corrugated HDPE
Sheathing
Bright Metal / Galvanised Sheathing (Non-metallic duct)
• Material shall be CRCA (Cold Rolled
& Cold Annealed) • System approval to conform to fib
Bulletin 7
• Minimum Wall thickness of metal
sheathing : 0.3mm, 0.4mm and • Minimum Wall thickness of HDPE :
0.5mm for ducts of internal diameter 2.0mm, 2.5mm, 3.0mm & 4.0mm for
upto 50mm, 75mm & 90mm ducts internal diameter upto 50mm,
respectively (No change from past 85mm, 100mm & 125mm
code IRC:18) respectively (Changed from IRC:18)
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Prestressing Hardware – Sheathing Duct size


(For HDPE)
ANCHORAGE REQUIRED DUCT MINIMUM ANCHORAGE REQUIRED DUCT MINIMUM
SYSTEM SIZE THICKNESS SYSTEM SIZE THICKNESS
(ID / OD) (in mm) (mm) (ID / OD) (in mm) (mm)

7 K 13 59 / 74 2.5 4 K 15 59 / 74 2.5
12 K 13 76 / 91 2.5 7 K 15 69 / 84 2.5
19 K 13 86 / 101 3.0 12 K 15 86 / 101 3.0
27 K 13 107 / 123 4.0 19 K 15 107 / 123 4.0
32 K 13 115 / 131 4.0 22 K 15 115 / 131 4.0
37 K 13 130 / 146 > 4.0 27 K 15 130 / 146 > 4.0
55 K 13 150 / 167 > 4.0 37 K 15 150 / 167 > 4.0

NOTE: The wall thicknesses as per IRC:112 is higher than IRC:18. As per
IRC:18, the thickness was fixed at 2.3mm ± 0.3mm irrespective of duct dia.
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Prestressing Hardware – Sheathing Duct


Sheathing Duct must be :

1. Grout-tight. Should be capable of taking pressure equivalent of 1.1 x


(grouting pressure + gravity head). [Grout Pressure : 0.5Mpa to 1.0
Mpa]

2. Enable bond forces to be transferred from tendon to the concrete.

3. Should not react with prestressing steel.

4. Should be flexible enough to resist handling and prevent damage


during placement and vibration.

5. Cross section area of sheathing duct shall be at least 2.5 to 3 times


the strand area.
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Prestressing Hardware – Sheathing Duct


Corrugated Plastic Ducts (HDPE) are
more popular than Bright Metal
Sheathing due to :

1. Improved corrosion & fatigue


resistance
2. Leak tight encapsulation
3. Reduced Friction Losses

Various accessories of sheathing ducts


are :

1. Duct couplers
2. Duct vents & drains
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Prestressing Hardware – Sheathing Duct

Methods of jointing in Sheathing :

1. Using corrugated threaded sleeve


coupler

2. Integrating the two ends by welding

3. Using heat shrink coupler


SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Mechanical Tendon
Couplers
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Courtesy : Freyssinet Catalogue


SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Fixed & Moveable Type


Couplers
Stressing of second tendon should not disturb the anchorage of the first tendon in case of fixed coupler
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

1. Couplers form a discontinuity in the tendons for the


flow of tendon forces and for grouting.

2. Discontinuity in the flow of forces at coupling points


demands special care on detailing and provision of
supplementary reinforcement.

3. Special procedures and care are needed to assure


reliable filling of couplings with grout.

4. With multi strand couplers, local thickening will be


required to accommodate increased size of coupler
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Provisions of IRC:SP:65 – 2005 on Prestressing Coupler

1. At any section, not more than 50% of the tendons shall be


coupled.

2. Longitudinally the couplers shall be staggered by at least a


segment length or twice the overall depth of girder, whichever is
more.

3. 2 immediately adjacent cables shall not be coupled at one place.

4. Minimum web thickness around coupler shall take into account


the increased dimension of coupler.

5. Void areas around coupler shall be deducted while when


computing stresses at the stages before grouting.
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Design & Detailing


of End Block Zone
The End Block zone is the portion of concrete near the
anchorage, through which the concentrated prestressing
force at the anchorage device spreads transversely to a
linear stress distribution across the entire cross section.
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

1. In case of Pretensioned Girders, the transfer of pre-


stress is through bond and therefore the problem of
high anchorage zone stresses do not occur.

2. In contrast, the use of post-tensioned concrete puts


high demand on designer, anchorage device supplier,
and constructor due to its greater versatility and more
concentrated stress in the anchorage zone.

3. Confusion exists regarding the responsibilities of


designer, anchorage device supplier in the detailing of
the local zone behind anchorages.
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

4. Provision of less reinforcement in anchorage zone


leads to cracks & spalling of concrete while providing
excessive reinforcement leads to highly congested
zones resulting in poor concrete placement.

5. Failures of local zone at anchorage is quite common


at sites, which occurs at the time of prestressing.

6. This has led to putting more emphasis on


prestressing system than ever before and therefore a
special chapter has been dedicated to cover this
aspect in this code.
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Failure of Anchorage Zone during stressing –


A common problem faced at site
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Anchorage Zone details depends upon :

1. Zone . . . . . . . . . .

2. Location . . . . . . . . . . . . . . .
Direction & Position

3. Geometry . . . . . . . . . .
Spacing between anchors

4. Loads . . . . . . . .
Magnitude of Prestress in each anchor
& Sequence of Loading
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Anchorage zones for post tensioning


tendons are the regions of dual
responsibility, which is shared
between the Design Consultant and
the System Supplier.

Local Zone
(Areas of High Bearing Stress,
requiring confinement of
concrete and bursting steel)
(Responsibility of System Supplier)

General Zone
(Areas of Spalling Stress &
Bursting Stress. Equilibrium
reinforcement required to
maintain equilibrium)
(Responsibility of Consultant)
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Local tensile stresses along Bursting Stress occurs


the loaded edge (Spalling) behind Anchorage

Very high compressive stress


behind anchorage

LOCAL ZONE & GENERAL ZONE


SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Reinforcement requirements in End Block Zone


SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Local Zone Design :

1. Detailing strongly influenced by Anchor Force, Bearing Plate


Size, Concrete Grade …etc. Design insensitive to section
geometry, surrounding anchors.

2. Local Zone detailing is the responsibility of the anchorage


device supplier. The code specifies special tests as per FIP
recommendations, to determine if the anchor is properly
reinforced or not.

3. Clause 13.2.3 of the code specifies that the concrete and the
reinforcement shall be capable of transferring 110% of UTS
(ULS) & crack width shall not exceed 0.25mm at 0.8UTS. This
clause is applicable for both local as well as general zone.
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

DETAILS PROVIDED
BY SYSTEM
SUPPLIER
1. Minimum concrete
strength at the time of
stressing.

2. Edge Distance

3. C/C Spacing

4. Minimum confining
reinforcement behind
anchorage

5. Required Supplementary
reinforcement
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Local Zone Design :

The Eq. 16.13 of the code


can be used for checking
of stress behind
anchorage. Anchorage
can be considered as a
partially loaded area
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

General Zone Design :

Following methods may be used for the design of General


Zone :

a) Based on Strut & Tie Model

b) Based on FEM Method

c) Based on Approximate / Empirical Methods


SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

1st Stage Post-Tensioning 2nd Stage Post-Tensioning

2nd Stage P/T


T
T
T
Stage 1
& P/S T
1st Stage
& P/S

End Block Design with Strut & Tie Model


SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

This is an excellent literature on Design of


End Block Zone

Can be downloaded from :


http://www.vsl.net/Portals/0/vsl_techreports/PT_Detailing.pdf
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Bursting Reinforcement

1. It is sufficiently accurate to consider the resultant of these


stress Fbst.

2. Fbst is assumed to act in a region between 0.2yo to 2yo

3. The value of Fbst as a proportion


of Pk is given in the code
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Bursting Reinforcement for Pre-Tensioned


Members :

Bursting resistance shall not be less than 4 (Four) percent of


the prestressing force at transfer. Stress in steel for the
calculation of this reinforcement shall be taken as 140 Mpa
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Grouting & Protection of


Post Tensioned Tendons
& Anchorages
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

1. Temporary Protection :

• Protection of ducts, anchorages, tendons from


manufacture to incorporation in structure.

2. Semi-Permanent Protection :

• Required in situations where the system is exposed to


atmosphere for an extended period of time

3. Permanent Protection :

• Shall be as per the climatic condition of the surrounding.


SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Permanent Corrosion Protection :

For Bonded Tendons, Most


common method is by injection
of cementitious grout.

Level of protection for


Internal Bonded Tendons
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Grout

Grout
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Poor quality Grouting

Good quality Grouting


Poor quality Grouting
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Grouting by cement wax, nuclear


grade (low sulphur) grease are
some of the options. Arrangement
for inspection and refilling or
replacement of grout material shall
be made in case the grout material
is not cement

Level of protection for External Tendons


SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

1. This is an excellent literature on


Durability of Post Tensioning tendons.
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

For Aggressive
Environment including
stray currents

For Aggressive
Environment

For Moderately Aggressive


Environment
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015
SECTION 13
PRESTRESSING SYSTEM BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015
WORKED EXAMPLE
ANCHORAGE ZONE REINFORCEMENT
BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Nos of Strands per Tendon = 12


Area of Strands = 140 Sqmm
Breaking strength of Strands = 1860 Mpa
Dimension of Anchorage , Ypo = 190 mm

Salient Details of Beam & Cables


Tendon 3
Overall Depth, D = 1.80 m
Width of Flange, b = 1.50 m
Depth of Flange, hf = 0.20 m Tendon 2
Width of Web, bw = 0.60 m
Area of Beam , A = 1.26 Sqm
Cg of Beam from bottom, y = 1.014 m Tendon 1
Moment of Inertia of Beam, I = 0.3909 m4
Zt, Top Sectional Modulus of Beam = 0.4973 m3
Zb, Bottom Sectional Modulus of Beam = 0.3855 m3
Cg of Tendon 1 from bottom = 0.20 m VIEW AT END BLOCK
Cg of Tendon 2 from bottom = 0.70 m
Cg of Tendon 3 from bottom = 1.20 m
WORKED EXAMPLE
ANCHORAGE ZONE REINFORCEMENT
BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Calculation of Bursting Reinforcement – Local Zone :

As per clause 13.5.1.2 of IRC:112 – Recommendation of the Anchorage


System Supplier shall be followed for Anchorage Dimension, Minimum
Spacing, Minimum Concrete Grade and Reinforcement for Bursting.

There is no need for any additional calculation by the Designer.

Minimum required
Concrete Strength
behind anchorage
for stressing,
fck = 35 Mpa
WORKED EXAMPLE
ANCHORAGE ZONE REINFORCEMENT
BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Calculation of Bursting Reinforcement as per Annex J of EC2-2 :

fck (t) = 35 Mpa (cube) = 28 Mpa (cylinder)

Pmax = Max. Force applied to the Tendon


= 12 x 140 x 0.77 x 1860 x 10-3 = 2406 KN

C x C’ = 400 x 400 = 160000 mm2 for Tendon 1


= 500 x 500 = 250000 mm2 for Tendon 2 & 3
Tendon Prism Dimensions (2Yo)
Pmax / CxC’ = 15.04 Mpa for Tendon 1, No. Vertically Laterally
= 9.6 Mpa for Tendon 2 & 3
1 400 600
0.6 x fck = 0.6 x 28 = 16.8 Mpa > 15.04 Mpa , 2 500 600
Hence OK 3 500 600
WORKED EXAMPLE
ANCHORAGE ZONE REINFORCEMENT
BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Calculation of Bursting Reinforcement as per Annex J of EC2-2 :

Pmax = 2406 KN, fyk = 500 Mpa, fyk = 0.87x500 = 435 Mpa, gp,unfav = 1.2

As = 0.15 x 2406 x 103 / 435 x 1.2 = 995.6 mm2

Strictly, a check of crack width would be necessary. To avoid such checks,


stress in reinforcement can be restricted to 250 Mpa

As, revised = 995.6 x 435 / 250 = 1732 mm2

Spiral Reinforcement provided = 2x16f – 8 legs = 3216 mm2

Hence OK
WORKED EXAMPLE
ANCHORAGE ZONE REINFORCEMENT
BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Spalling Reinforcement
1. Clause 13.5.2 describes the need for spalling reinforcement.

2. As per EC2, Area of such reinforcement shall not be less than 0.03
x Pmax / fyd x gp,unfav.

3. Consider fyd = 250 Mpa to avoid crack width calculations

4. As per CIRIA guide, the minimum reinforcement required is 0.04 x


Pmax.

As = 0.04 x 2406 x 103 / 250 = 384.96 mm2

Provide 2 Nos. f16 bars in each direction.


WORKED EXAMPLE
ANCHORAGE ZONE REINFORCEMENT
BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Overall Equilibrium outside primary prism


a) Horizontal Direction (through thickness of web)

The stresses do not continue to spread beyond the local zone in the horizontal
direction, so no further reinforcement would be necessary.
p2
b) Vertical Direction (Over depth of Beam)

Stressing sequence is considered as below:


M
Load Stressed V
Case Tendon
1 1 y
P
2 2 k
3 3

p1
WORKED EXAMPLE
ANCHORAGE ZONE REINFORCEMENT
BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Overall Equilibrium outside primary prism


Moment (KN.m)

Distance of Zero stress


p1 = Pk/A + Pk (y-e) /zb)
Location

p2 = Pk/A - Pk (y-e)/zt

from bottom (m)


Ecc. of p at
of
Load, cable (in KN/Sqm) section =

(KN/Sqm)
Section
Case

Pk from p1 - (p1- Due to


Due to
from Stress Net
(KN) bottom, p2)/D*X Anchor
Bottom, Distribution
e (m) (KN/Sqm)
X (mm)

200 8556.2 114.1 0 114.1


1 3438 200 9988 -2899 1.395 700 4976.6 1222.7 1719 -496.3
1200 1397.0 3077.7 3438 -360.3
200 4976.6 64.1 0 64.1
2 3438 700 5529 558 2.002 700 3595.7 718.0 0 718.0
1200 2214.9 1911.3 1719 192.3
200 1397.0 14.1 0 14.1
3 3438 1200 1070 4014 -0.654 700 2214.9 213.4 0 213.4
1200 3032.8 744.8 0 744.8
WORKED EXAMPLE
ANCHORAGE ZONE REINFORCEMENT
BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Overall Equilibrium outside primary prism

Maximum clockwise moment = 745 KNm


Lever arm = 0.5*Block length = 0.9 m
Force on reinforcement = 745 / 0.9 = 828 KN
Ast required = 828 * 1000 / 250 = 2760 Sqmm

Using 5 nos closed links of 20mm diameter reinforcement area provided


= 3142.00 sqmm.

This reinforcement shall be provided at a distance of 0.9m from the far end.
WORKED EXAMPLE
ANCHORAGE ZONE REINFORCEMENT
BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Overall Equilibrium outside primary prism

Maximum anti-clockwise moment = 496 KN.m


Force on reinforcement = 496/0.9= 551 KN
Ast required = 551*1000/300= 1837 Sqmm

This reinforcement has to be provided within a distance of 1.8/4 = 0.45m


from loaded end block zone, hence it is the same zone of bursting
reinforcement.

Using 3 nos closed links of 20mm diameter reinforcement area provided


= 1885 sqmm.
WORKED EXAMPLE
ANCHORAGE ZONE REINFORCEMENT
BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

Tendon 3

Tendon 2

Tendon 1

A
REINFORCEMENT DETAIL AT END BLOCK ZONE
WORKSHOP ON IRC:112-2011
BSEC
WORKSHOP ON CODE OF PRACTICE FOR CONCRETE ROAD BRIDGES IRC:112 – 2011, ORGANISED BY IAHE, OCTOBER 2015

For any query, please contact at


bsec.ab@gmail.com

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