Materials and Hardware for Prestressing  Mix Proportions

 Humidity
 Concrete
 Curing Conditions
 Prestressing Steel
 Age of the concrete when first loaded
 Prestressing Hardware
Shrinkage – results to a decrease in volume when the
Mechanical Properties of concrete
concrete loses moisture by evaporation.
 Compressive Strength
Prestressing Tendons forms
 Modulus of Elasticity
 Modulus of Rupture  Strands
 Wires
Compressive Strength
 Round bar
- AASHTO LRFD  Threaded rods
- Compressive strength for prestressed
Prestressing Materials
concrete should be from 28-70 MPa at 28
days  High Strength Steel
- Compressive strength for reinforced  Fiber-Reinforced Composite (Glass or Carbon
concrete should be from 16-70 MPa at 28 Fibers)
days.
- Concrete with f’c > 70 MPa can be used Common Shapes or Prestressing Tendons
when supported by test data  Plain round wire
Modulus of Elasticity  Indented wire
 Sumi-twist
- AASHTO (5.4.2.4)  Two-wire strand
- Ec = 0.043 γc1.5(f’c)0.5 MPa  Seven-wire strand
- γc1.5 in kg/m3  Nineteen-wire strand
- f’c in MPa  Round bar
- For normal weight concrete, we can use Ec =  Threaded bar
4800 (f’c)0.5 MPa
2 Grades of prestressing grades
Modulus of Rupture
 Grade 250; fpu = 250 ksi or 1725 MPa
- Indicates the tensile capacity of concrete  Grade 270; fpu = 270 ksi or 1860 MPa
under bending
- Tested simply-supported concrete beam 2 Types of strands
under 4-point bending configuration
 Stressed Relieved Strand
- fr = My/l = PL/bd2
 Low Relaxation Strand( lower prestress due to
- AASHTO (5.4.2.6)
relaxation of strand)
- fr = 0.63 (f’c)0.5 MPa
Prestressing Strands
Time-Dependent Deformation of Concrete – resulting
from creep and shrinkage result in a partial loss of 1. Modulus of Elasticity
pretress force and significant changes in deflection. a. 197000 MPa for Strand
b. 207000 MPa for Bar
Creep – property of materials by which they continue to
2. The modulus of elasticity of strand is lower than
deform over considerable lengths of time at constant
that of steel bar because strand is made from
stress or loads.
twisting of small wires together.
Elastic Strain - the initial deformation due to its load.
3 Common Forms of Prestressing Steel
Creep Strain – the additional strain due to the same
 Cold-drawn round wires
sustained load.
 Stranded cable
Creep strain for concrete depends on  Alloy steel bars
 Time
Round wires - Available in diameters ranging from 5/8 in
to 1 3/8 in, and in Grade 145 (minimum
- The individual wires are manufactured by
ultimate strength 145,000 psi) and Grade
hot-rolling steel billets into round rods.
160 (minimum ultimate strength 160,000
- After cooling, the rods are passed through
psi).
dies to reduce their diameter to the
required size. Importance of High Strength Steel
- In the process of this drawing operation,
 The lack of success of most early attempts
cold work is done on the steel, greatly
to PSC was the failure to employ steel at a
modifying its mechanical properties and
sufficiently high stress and strain.
increasing its strength.
- The wires are stress-relieved after cold  The time-dependent length changes
drawing by a continuous heat treatment to permitted by shrinkage and creep of the
produce the prescribed mechanical concrete completely relieved the steel of
properties. stress.
- Available in Grades 235 (minimum ultimate Hardware & Prestressing Equipment
strength 235,000 psi) to Grade 250
(minimum ultimate strength 250,000 psi).  Pretensioned Members
o Hold-Down Devices
Stranded Cable  Posttensioned Members
- Fabricated with six wires wound tightly o Anchorages
around a seventh of slightly larger diameter.  Stressing Anchorage
- The pitch of the spiral winding is between  Dead-End Anchorage
12 to 16 times the nominal diameters of the o Ducts
strand. o Posttensioning Procedures
- The same type of cold-drawn stress-relieved Pretensioned Hardware
wire is used in making stranded cable as is
used for individual prestressing wires.  Pretensioned beam
- However, the apparent mechanical  Hold-down devices
properties are slightly different because of Posttension Hardware
the tendency for the stranded wires to
straighten when subjected to tension  Stressing Anchorage
because the axis of the wires do not  Dead-End Anchorage
coincide with the direction of tension.  Duct/Grout Tube
- Strands may be obtained in a range of sizes
from 0.25 in to 0.60 in diameter. Anchorage Parts?
- Cable is stress-relieved by heat treatment  Strands
after stranding.  Wedges
- Two grades are manufactured:  Bearing plate
- Grade 250 – minimum ultimate  Anchor head
strength of 250,000psi  Duct
- Grade 270 – minimum ultimate
 Sleeve
strength of 270,000psi.
 Grout tube
Alloy Steel Bars  P-plate
 Seal
- The high strength is obtained by introducing
 Compression fittings
certain alloying elements, mainly
 Retainer plate
manganese, silicon and chromium during
the manufacture of the steel.  Spacer
- In addition, cold work is done in making the  Bulbs
bars, further increasing the strength.  Tension ring
- After cold-stretching, the bars are stress-
relieved to obtain the required properties.
Types of Anchorage? T1Z & T2Z Long Fitting Tool Adapters
 VSL Type SO - for driving hex nuts and setting tools,
 VSL Type S typically with our spin-lock anchor systems.
 VSL Type Bondtech K3F-26 Long Fitting Wrench Adpater
 VSL Type S5-2
 VSL Type S5-1 , S6-1 - for applying torque to recessed anchor nuts
that are under tension when using hydraulic
Types of Ducts? jacks.
 Steel duct Corrosion Protection Type
 Plastic duct PT-PLUS
 Hot Dip Galvanizing
Equipment  Epoxy Coating
 T6Z-08 Air Powered Grout Pump  Pre-Grouted Bars
 Colloidal Grout Plant  Extruded Polyethylene Coating
 T7Z Hydraulic Jacks  Corrosion Inhibiting Compound
 T80 Post-tensioning Jacks  Field Splice for Bars
 T8Z-18 Hydraulic Torque Wrench Epoxy Coatings
 T8Z Torque Wrench
 T8Z-04 Torque Multiplier (4:1) - Fusion bounded epoxy coating of steel bars
 T1Z & T2Z Ling Fitting Tool Adapters to help prevent corrosion has been
 K3F-26 Long Fitting Wrench Adapter successfully employed in many applications
because of the chemical stability of epoxy
T6Z-08 Air Powered Grout Pump resins.
- Pumps cement grout only, no sand. Pre-Grouted Bars
Colloidal Grout Plant - Cement grout filled corrugated
polyethylene tubing is often used to provide
- is favoured for precision post-tension
an additional barrier against corrosion
grouting.
attack in highly aggressive soils.
T7Z Hydraulic Jacks
Hot Dip Galvanizing
- used for testing and pre-stressing anchor
- Zinc serves as a sacrificial metal corroding
bolts.
preferentially to the steel.
T80 Post-tensioning Jacks - Galvanized bars have excellent bond
characteristics to grout or concrete and do
- the enclosed bearing housing contains a
not require as much care in handling as
geared socket drive to tighten the bolt hex
epoxy coated bars.
but during tensioning.
Extruded Polyethylene
T8Z-18 Hydraulic Torque Wrench
- William strand tendons contain an extruded
- is used for tensioning anchors in tight fitting
high density polyethylene sheathing around
location where it would be difficult to use
each individual strand in the free-stressing
an hydraulic jack.
portion of the anchorage.
T8Z Torque Wrench - The sheathing is minimum 60 mils thick and
applied once the 7-wire strand has been
- for applying torque to the anchor bolt when
coated with a corrosion inhibiting
setting the anchor.
compound.
T8Z-04 Torque Multiplier (4:1)
Field Splice for Bars
- for use with T8Z Torque Wrench.
- Continuous corrosion protection can even
be accomplished for the MCP Pregrouted
 anchors manufactured from Williams Form
Engineering.
- To achieve the equivalent levels of
corrosion protection the coupled sections of
bar anchors can be wrapped in a grease
impregnated tape that is further protected
with heat shrink sleeving. This scheme is
acceptable by most governing agencies and
is specified in the PTI Recommendations for
Prestressed Rock and Soil Anchors.
Hardware & Devices
 Prestressing bed
 Abutments
 Moulds
 Hydraulic Jacks
 Anchoring Device
 Harping Device
 Ducts
 Couplers
Pretensioning Systems
 Hoyer System (Long Line Method)
 Shorer System
Posttensioning Systems
 Freyssinet System
 Magnel Blaton System
 Gifford Udall System
 Lee McCall System
Other Prestressing Method
 Electrical Prestressing
 Chemical Prestressing
Hoyer System
- Used for mass production
- In this system, the end abutments are kept
sufficient distance apart, and several
members are cast in a single line
- The shuttering is provided at the sides and
b/w the members
- The end abutments have to be sufficiently
stiff and have good foundations.
Shorer System
- In this system a central tube of high
strength steel carries the prestress form
surrounding wires and the entire assembly
is placed in position and concreted.
- After the concrete has attained sufficient
strength, the tube is removed and the
prestress is transferred to concrete through
bond.
- The hole left by the tube is grouted.
Freyssinet System
- The first post-tensioning method
introduced by the French Engineer
Freyssinet.
- In this system, high strength steel wires of
5mm or 7mm diameter, numbering 8 or 12
or 16 or 2 are grouped into a cable with a
helical spring inside and a cable is inserted
in the duct.
- Anchorage device consists of a concrete
cylinder with a concentric conical hole and
corrugation on its surface, and a conical
plug carrying grooves on its surface where
steel wires are carried along these grooves
at the ends.
- Wires are pulled by Freyssinet double acting
jacks which can pull through suitable
grooves all the wires in the cable at a time.
- One end of the wires is anchored and the
other end is pulled till the wires are
stretched to the required length
- An inner piston in the jack then pushes the
plug into the cylinder to grip the wires.
Magnel Blaton System
- Each plate carries wires and between the
two ends the spacing of the wires is
maintained by spacers.
- A specially deviced jack pulls two wires at a
time and anchors them
Gifford Udall System
- Originated in Great Britain and is widely
used in India.
- This is a single wire system in which each
wire is stressed independently using a
double acting jack.
- In this system, any number of wires can be
grouped together to form a cable and wires
are locked into the tapered holes by means
of anchor wedges.
- The anchor wedges are attached to the end
shutters and form an efficient cast-in
component of the anchorage.
Lee McCall System
- In this system, the steel bars with diameter
of between 12 and 28mm, provided with
 threads at the ends, are inserted in the
performed ducts.
- After stretching the bars to the required
length, they are tightened using nuts
against bearing plates provided at the end
sections of the member.
Electrical Prestressing
- In this method, reinforcing bars is coated
with thermoplastic material such as sulphur
or low melting alloy and buried in the
concrete.
- After the concrete is set, electric current of
low voltage but high amperage is passed
through the bar.
- Electric current heats the bar and the bar
elongates
- Bars provided with threads at the other end
are tightened against heavy washers, after
required elongation is obtained.
- When the bar cools, prestress develops and
the bond is restored by resolidification of
the coating.
Chemical Prestressing
- Prestressing can be applied by embedding
steel in concrete made of expanding
cement.
- Steel is elongated by the expansion of the
concrete and thus gets prestressed
- Steel in turn produces compressive stress in
concrete.
Equivalent Loads
- The effect of a change in the vertical
alignment of a prestressing tendon is to
produce a transverse vertical force on the
concrete member.
- That force, together with the prestressing
forces acting at the ends of the member
through the tendon anchorage, may be
looked upon as a system of external forces
in studying the effect of prestressing.
- For any arrangement of applied loads, a
tendon profile can be selected such that the
equivalent loads acting on the beam from
the tendon are just equal and opposite to
the applied loads.
- The result would be a state of pure
compression in the beam. This is always
true for statically determinate beams, but
not for indeterminate spans.