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TECHNICAL GUIDELlNES=
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The prestressing technology is emerging fast growing field in construction
industry particularly for buildings, bridges, metro rail, flyovers, nuclear power
plants, LNG tanks, cement plant etc. Dynamic Prestress a specialist agency in
the field of prestressing, is accredited with an ISO 9001 certification & has state
of the art facility for development, production and testing of related products
and equipments required for prestressing industry.

STRESSING
Prestressing is a technique of construction in which internal stresses of a
suitable magnitude & distribution are introduced in a member, so that the
stresses resulting from external loads are counteracted to a desired degree.
Pre-tensioning & Post-tensioning:
Pre-tensioning is a method of prestressing concrete in which the tendon is
tensioned before the concrete is placed. .

In case of Post-tensioning, the tendon is tensioned after the concrete has

hardened. The prestressing force is imparted to the concrete by bearing &this
procedure can be applied to members either precast or cast-in-situ.
Prestressed concrete structures can be classified in a number of ways
depending upon their features of design &constructions like:
a) Externally or Internally prestressed
b) Bonded or Unbonded tendons
c) Linear or Circular prestressing

~-ts for Stressing and Grouting Works

The various components used for post tensioning work involves use of
Anchorages, H.T.Strands, Sheathing Ducts, Multi and Single strand Hydraulic
Jacks with Power packs, Grout pumps, Agitators, Grout caps, Destressing
tools, etc. Dynamic has state of the art infrastructure facility for manufacturing
all sizes of prestressing ~nchorages and equipments.

'" I]W{e)~"I:.]iiV.l!J~'!""',,{.I..'!'n.
Dynamic is providing tai'lor made solutions for construction industry in the field
of prestressing since last two decades. The company's specialisation includes:
* Technically qualifi~d engineers and technical supervisors having vast
experience in the prestressing industry.
*
Providing Services for installation and supervision.
*
Experienced team for quality control with in-house testing facility.
*
Providing equipments having low maintenance cost.
*
Providing Smaller gripping length of prestressing jacks.
*
Abilityto develop equipments and devices as per site conditions.
*
Wide experience with clients like NHAI,RAILWAYS, MSRDC, NPClL, PWD,
etc. for all type of Structures & has completed variety of projects in several
countries like INDIA, UAE, OMAN, SAUDI ARABIA, MONGOLIA,
MAURITIUS etc.
 H.T.Strands are available in various diameters such as 12.7mm (0.5"), 15.2mm(0.6"), and 15.7mm (0.62").
Properties of LRPC :
AS PERINDIAN SPECIFICATION: IS 14268/1995 AS PERBRITISHSPECIFICATIONBS 5896: 1980
TABLE1 TABLE2
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12.7 +0.66 98.7 183.7 165.3 775 7Wire +0.40 +4%
II -0.15 15.7 -2% 150 265 225 1180
Super
15.2 +0.66 140 260.7 234.6 1102 -0.20
-0.15

DynamicGroupdonotmanufactureH.T.Strands.Theabovementioneddataisfor reference& canbecheckedwiththemanufacturers.

DUCT / SHEATHING PIPE .~.--:,-

Sheathing creates the necessary void in the structure in which the prestressing steel (strands/wires) is free to
move during stressing. Metallic Sheathing is corrugated throughout its length & is manufactured out of
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. .

A Metallicsheathin Dud: TABLE3

Type of duct Values recommended
Followingtests on sheathing pipes is carried out at our Nasik or sheath to be used in desi n
works as per IRC: 18 - 2000
1. Transverse Load test 2. Tension load test K per meter Jl
Bright metal 0.0046 0.25
3. Water loss test 4. Workability test Galvanized 0.0030 0.20
B HDPE
Sheathin Dud shouldconformthefollowin s ecification Lead coated 0.0030 0.18
* FibBulletin-7 * NPCSpecificationNo.PP/M/1721
* IRC:18-2000 * Addendum and Corrigendum IRSSlipNo.6
* RailwayConcrete BridgeCode 1997
Friction coefficient &wobble coefficient:
The friction coefficients (Jl)and wobble coefficient (k) can vary
depending upon various factof,s including the nature and
TABLE4
surface condition of the prestressing steel, the type, diameter
and surface condition ;,of the sheathing duct, and the
installation method. .
Parameter
(Units)
Asperfib
Bulletin 7 (2000)
As per NPC
Report ppt.n 721
I
I
K (per metre) 0.003 I
The value of /-rand k given in the table 3 &4 may be adopted Not specified
for calculatingthe friction10sses. Jl 0.10 - 0.14 O.W - G.' 4

PRECAUTION DURING PROFILING & CONCRETING

· Mark out tendon spacings .and lay duct as per approved drawings.
· Proper taping of duct-duct coupler joint and a/so anchorages -duct joints.
· Use de-coiler and safety goggles while uncoiling and cutting of strands.
· Use strand bullet while threading the strand in the cable duct.
· While concreting, the duct should be filled with H.T.Strands or dummy pipe.
· Use rust preventive oil for pre-threaded strands for its protection tillthe date of stressing.
· The gripping length of strand should be cleaned before mounting the anchor plate and stressing jack.
· The corroded or pitted strand shall not be used for stressing purpose.
· 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
bad concrete behind the anchor or insufficient anti- burst reinforcement, the anchor cone is,likely.to get crushed.
 Dynamic post tensioning multi-strand anchorages includes entire range for all three types of strands viz -
12.7 mm (0.5"), 15.2 mm (0.6") and 15.7 mm (0.62") and the anchorages are widely approved and
accepted for all types of PrestressedConcrete structures.
SPACING OF ANCHORAGES & ANTI-BURSTREINFORCEMENT
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Sr. Anchor UTS 80%o' Dud Anchor Pocket Min.Edge Spacing Pocket PCDo' Spiral LengthSpiralNo.o' Pitcho'
No. Type (Tons) UTS DiameterConeSize (Recess) Distance Between Depth Holeson Rein'orce
o' Spiral Bar Turns Spiral
AnchoragesAnchorage mentO D Spiral Dai
Ax A ExE F ..'. -.,. G H K D L M N P
1 4 DP 13 75 60 51 145 215 120 220 105 125 150 240 16 6 40
2 7 DP13 131 105 51 145 215 120 220 105 125 150 240 16 6 40
3 12 DP 13 225 180 75 190 240 148 260 120 165 190 480 16 8 60
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
· TheTechnicaldetailsof strandanchorageswith31DP13& more, shall be provided by our Mumbai office on request.
7 4 DP 15.2 106 85 51 145 215 120 220 120 125 150 480 16 8 60
8 7 DP 15.2 186 149 75 190 240 148 260 120 165 190 480 16 8 60
9 12 DP 15.2 319 255 85 245 300 200 300 120 200 250 540 16 9 60
10 19 DP 15.2 505 404 105 275 350 Lb(J 350 120 235 280 600 20 10 60
11 27 DP 15.2 718 574 120 350 392 340 575 130 285 350 720 20 12 60
12 31 DP 15.2 824 659 130 370 412 355 620 140 295 370 720 20 12 60
13 37 DP 15.2 984 787 140 400 440 380 675 140 320 400 840 20 14 60
14 43 DP 15.2 1143 914 150 435 485 400 725 140 375 435 960 20 16 60
r
15 48 DP 15.2 1276 1021 160 435 485 420 770 150 375 435 1080 20 18 60
16 55 DP 15.2 1462 1169 170 455 500 430 820 160 390 480 1200 20 20 60
:
· The Technicaldetails of other capacity anchorages for 15.7 mm strands shall be provided by our Mumbai office on request.
17 7DP15.7 189. 151 75 190 240 148 260 120 165 190 540 16 9 60 I
18 12 DP 15.7 324 .259 85 245 300 200 300 120 200 250 600 16 9 60

.19 19DP15.7 513 410 105 , : 275 . 350 213 350 120
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
235

-
300

270x11 C 300
660 20

10
10

6
60

50
21 5S13 93 75 70 x 20 204x75 255x15C 170 360 130 - 270x11C 300 10 6 50
22 4S15 106 85 80 x 25 250x80 300x 15C 200 375 130 - 270x11C 300 10 6 50
23 5S15 133 106 90 x 25 250x80 300x15C 200 400 130 - 270x11C 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
to our technical department. The stressing sequence is important & may influence the concrete strength requirement at each phase of stressing.
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 reinforcementforflat anchorages than equivalent steel area
should be provided in the form of two ligs spaced 80 mm apart.
4) Slip due to elastic shortening of gripping length of strand and the slip due to wedge set, should be separately considered.
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.
The normal wedge set in Dynamic system is 6 m.m. at stressing end and 3 m.m. at non stressing end.
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 our technical team.
7) The internal areaofthe sheathing duct shell be aboutthree times the area ofthe tendons or as per our individual
technical leaflet made for the specific structures of project.
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.
10) The spacing, edge covers and grouping of cables shall conform to relevant National codes of practice.
11) lengths of strand quoted in the data is gripping length of stressing jack and is measured from the face ofthe anchor cone (tube unit).
12) The compatibility of Jack components for 'T' range of anchorages & the detailed \eW'lical inputs shall be made available on request.
 --Dynamic provides Single Strand Coupler and Multi Strand Coupler for Pre-Tensioning
and Post-Tensioning works respectively.
The coupler is a mechanical device used for structures built in sections; in cases when
the cost of scaffolding & forms for a complete structure becomes expensive. Certain
cables are stressed & anchored at partial length & later extended using couplers.
The execution work of continuous spans using multi strand coupler is a bit different
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
strands getting corroded in the anchorage zone due to the extensive exposure to
slurry and water. The strands if excessively corroded will loose the grip of wedges
and during the stressing activity of the next stage, the strands may slip from the
other end. It is therefore mandatory and absolutely essential to complete the
concreting in shortest possible time and protect the strands and coupler when
installed at site.
The Multi Strand Couplers are of two different types namely pre-locked spring
loaded wedge coupler (Type - A) and swadge type of strand coul3lers (Type - B).
.. · The strand coupler (Type-A) consist of anchor plate with active anchorage at the
center of anchor plate and pre locked spring loaded wedges at the periphery.
The whole assembly is protected by tube which is seated on the bearing plate.
The other end of the coupler is connected to the sheathing of the next phase.
· The swadge types of coupler (Type - B) constitutes of peripheral strands, '"
swadged and positioned in the grove provided on the bearing plate & the active
anchorage at the centre. The whole assembly is protected by a tube which is
seated on the concrete with a rubber gasket.

Stage Stressing is essential when prestressing is to be applied in stages to the

concrete as per (design requirement) or if the stroke of jack is insufficient. For
prestressing in two or more stages, multi use live wedges are recommended to be
used instead of single use live wedges. For detail procedure of prestressing in
stages, you may contact our technical office.

Dynamic provides special type anchor plate for restressing in order to compensate
for the loss of prestressof ungrouted tendon. The restressing of cables isdone using
tailor made jacks & shimming foot..
"

The multiuse barrels & wedges alongwith monostrand jacks of stroke upto one
metre length are p~ovided by us for the production of pretensioned girders. The
Jacks,Barrels8; Wedgesareavailablefor 0.5",0.6"& 0.62" strands.

:f.!
Dynamic provides two types dead end anchorages at the non - D
stressing end of the girder. This anchorages are particularly X
<
useful for single end stressing as per the design and for the
caseswhere lessgap is available in between the girders or if one
of the end of girder is not accessible. BNCU c

· The Bulb type of dead end anchorages (TypeC) are suitable Anchorages Bulb Type Dead End Anchorages
Sr. No. A B
for flat post tension slab with lessnumbers of strands and low Type C
mm mm mm
capacity anchorages. The bulb portion and the bonding 1 4S13 270 50 600
length of strand is embedded in the concrete. 2 5S13 350 50 600
3 4S15 270 50 750
The Spring loaded plate type of dead end anchorages (Type
4 5S15 350 50 750
D) are suitable for entire range of 4 to 55 strands and have
been extensively used for several metro rail projects.
 .., ~Wed~~
. 'Bearina.S!t..w. .
JACK THREADING SEQUENCE FOR PRESTRESSING OPERATION

CHARACTERISTICSOF DYNAMIC STRESSINGJACKS .

Jack Capacity Overall Outer dia. 'Ram Area Min.Gripping Max. Lockoff Cylinder Weight
Model tons Length of Main For For Lengthof Travel Length dia for
Lock Strand to cut Lock
Cylinder Stress
(tons) (mm) (mm) (cm2) (cm2) (mm) (mm) (mm) (mm) (kgs)
D-20 22 735 106 42.2 - 350 200 175 70 27.5
DP-20 22 450 100 33.3 - 125 200 75 65 18
DP-30 30 450 118 48.5 14<- 125 200 75 76 26
CG- 12/200 140 675 285 341 .05 52.52 600 200 298 200 175
CG- 18/150 200 610 345 482.4 66 560 155 300 240 200
CG- 18/200 200 715 345 482.4 66 620 210 315 240 255
CG-20/200 300 745 400 641.5 116.8 650 ,210 315 270 280
CG-30/100 350 500 380 563.72 - 350 100 210 300 270
CG-40/200 400 735 492 1058.94 173.3 660 210 290 328 490
CG-50/200 500 745 525 1196.2 178 680 210 305 346 584
CG-50/200 _..
Modified 500 735 494 1045.4 173.3 660 210 290 328 480
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 & CG160/400 jacks shall be provided on request
CG- 160/400 1600

STRESSING GUIDELINES
All prestressed cable should be layed in smooth curve and supported at a spacing not exceeding one meter. If necessary
reinforcement bars sholl be .bent or shifted locally to avoid clashing with prestressed cables and bursting reinforcement. The
revised extension shall be recalculat,ed at site in case of variations in the design values and actual values of : a) Strand area,
b) Modules of elasticity c) Gripping length. Revised modified extensions shall be used for calculations. Similarly the revised
pressure shall be modified tqking
. ", irito accountthe actual jack efficiencyv/s design efficiency considered in the GFC drawing.

SAFETY PRE(:AUTIONS 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 acsidents. Thefollowing 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. Stressingshould 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.
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 failure.
Hogging of the girder during stressillg operation should be observed & recorded.
Post-tensioned cables are grouted to provide protection against corrosion. 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
operated at working pressure of 5 kg/cm2 and has a discharge of 25 litres /minute. It
operates on 3 phase electric supply and has 3 HP motor of 1440 rpm. The pump
weighs 200 kgs. and the area of piston is 19.64 cm2.
The standard grout agitator used for making a homogenous grout mix of water,
cement and admixture weighs 138 kgs. The agitator has 3 HP motor and the capacity
of mixing unit is 100 litres of cement grout.
Dynamic has used high discharge capacity positive displacement type grout pump
having minimum outlet pressure of 10.5 kg/cm2 for continuous span bridges of
length 120 meters and more.
Dynamic grout caps are advantageously used for speedy gr,Quting.The grout cap is
fixed byfour alien key bolts and the air nut is kept in upward p~~ition.

~ J.

. Protective glasses must be worn during grouting operation. '"

. Do not start the pump while valves are in closed position as it may cause damage
to the pressure gauge.
. Place the grout tank preferably at the same level as that of grout pump.
In case of a longer stoppage (> 5 min)of grouting operation, ensure that the grout
does not set in the pump, ifnecessary empty the grout and flush pump with water.

The high concrete stresses in the anchorage zone requires the compliance of specific
conditions like the spacing of anchorages, minimum edge distance to the nearest
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
bind the edge & corner concrete into the mass of the end block. Perfectlycompacted
concrete in the anchQrag~ zone is a must. The anti-burst reinforcement cannot make
up for local concrete defects. Preciast end block can be used in case of'!, girders or
'Box' girders. Transverse cables shall be avoided in the end zone portion.
While placing the, anchor. cone in the end zone, care should be taken that the
attachments rn,ustbe strong enough to resist knocks & vibration and also the impact
of the wet concrete dump~d on it. The connection of the sheath with anchorage must
be done with proper care tq ensure that anchorage alignment is as per drawing &the
connection is watertight (additional Heat Shrink tape if required should be used to
ensure leak proof joint).
The steel parts of anchorages must not be exposed to rusting while 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
godown to prevent corrosion of Metallic Duct & H.T. Strands. For long exposure of
anchor plate & anchor cones to rain & moisture at the construction 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, the exposed anchorage end &strands shall
be cleaned &coated with epoxy bonding paint. The pocket portion shall be filled with
compact concrete /mortar of approved grade.
 --- -~- -. -.. --.-~-:o!:
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ISO 9001 : 2000
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E MJ.D.C.. SATPUR.NASHIK-422007. -
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DesIgn. Manulaclunt. Supply and &ectton 01
Preslresslng System and Components

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Segmental Construction Al Mawaleh Interchange

DMRC, Delhi. OMAN MUSCAT -
-- -- - - ---
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_OF~I~~ ._ - - --
.72;MahavirCentre,Sector-17,-Vashi,
-- - - -<- - :NaYi:Mumbai.=.400L05, .:INDIA,
-~-- ....- Tel~: ,f-91-22-27.892628/2789...1310,..-
fax~:-+91-22~27891186 -
Webiste.: www.~ynami~prestress.com ~E-mail:dyn~cmumbai@~1..~om
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