Chapter-2 Systems of Prestressing §18. CLASSIFICATION OF PRESTRESSED CONCRETE MEMBERS: __ There are many ways of classifying prestressed concrete members based on the raethod of design, construction and application of prestresss. 'Thoso are oxplained below. (a) Externally and internally prestressed members. A member can be prestressed oithor by external reaction offered by rigid abutments or by sack h tensioned tendon. The former method is called external prestressing and the latter method is called intornal prestressing. Fig. 2.1 In the external prestressing instead of providing a tendon from which the prestress can be applied, the necessary prestressing forco can be applied by compressing the members by jacking against abutments. Fig. 2.1 shows an arrangement in which the prestress is externally applied. A sliding surface may be provided underneath the beam. After the prestressing is over. the space between the end of the beam and the abutment may be packed with concrete and the jack recovered. This method is difficult to be adopted, though this principle is adopted, in the case of arches. It is difficult to rely on this method since the prestress transferred tothe member is likely to be lost due to any possible outward displacements of the abutments. It is also found that shrinkage and creep of concrete are likely to affect the initially applied 4 prestress. It is, however, possible to produce the most desirable reactions by jacking in the case of continuous beams. But still the method is difficult to be practised. Even slight vertical deformations of the supports will disturb the stresses seriously. Fig. 2.2. Ina yet another arrangement, similar to that explained above prestressing may bedoneby using expanding cement. One end of the beam is held against: the abutment and the space between, the other end of the beanvand the other abutment is filled with concrete using expanding cement. ‘As the cement. expands, the beam gets compressed. (0) Linear or circular prestressing, The term circular prestressing is applied to prestressing circular structures like cylindrical tanks, silos and pipes. In this case, the tendons are provided in the form of rings. Linear prestressing is a term applied to prestressing straight members like beams and slabs. a () Pre-tensioning and post-tensioning In pre-tensioned members, the tendons are tensioned even before casting the concrete. One end of the reinforcement (i.e. tendon) is secured to an abutment while the other ond of the reinforcement is pulled by using a jack and this end is thon fixed to another abutment. The concrete is now poured. After the concrete has cured and hardened, the ends of the reinforcement are released from the abutements. The reinforcemont which tends to resume its original length will compress the concrete surrounding it by bond action. The prestress is thus transmitted to concrete entirely by the action of bond between the reinforcement and the surrounding concrete.Li PRESTRESSES Cony i ‘Abutment Bape IRS es “(Atter the concrete is hardened the roinforcomont is-cut off at the ands, Tho beam will get prestressed by bond action Fig. 2.3. Apost-tensioned member is one in which the reinforcement is tensioned after the concret, has fully hardened. The beam is first cast leaving ducts for placing the tendons. Tho ducts ary made in a number of ways - by leaving corrugated steel tube in the concrete, by providing steal spirals, sheet metal tubing, rubber hose or any other duct forming unit in the form work. When the concrete has hardened and developed its strength, the tendon is passed through the duct. One end is provided with an anchor and is fixed to one end of the member. Now, the other end of the tendon is pulled by a jack which is butting against the end of the member. The jack simultaneously pulls the tendon and compresses the concrete. After the tendon is subjected to the desired stress, the end of the tendon is also properly anchored to the concrete. To avoidcrushing ‘of concrete due to excessive bearing stress, a distribution plate is provided at each en Fig. 2.4. Systems of prestressing, A system of prestressing means the actual process adoptedit making aprestressed beam. A system of prestressing involves the process of tensioning the tendat® Andsecuring them firmly to the concrete. Some of the systems commonly followed are describe! Pre-tonsioning system, Thosimplost method of making apre-tonsioned member top {gendon between abutments orbulkheads which are secured or anchored firmly against? Droste is tana er cons act off at each end afar the concrete hardens. NOW : ‘concret I ig Tore tho prone th coneata, Thobulkhead atthe ends and thebedshosF-STSTEMS_OF_PRESTRESSING fu HOVER SYSTEMS ‘The Hoyer systom is usally adopted for the roduction of pre-tensioned members on a large Preje This method consists of first stretching the ‘wires botween two bulkheads at a large distance art, Tho concrete is now pouredso that a number ‘Feams can bo produced in one line, by providing suitable shuttering between them, After SS SS theconcrete has hardened, the wires are released Fig. 2.5. from the bulkheads, The wires between the different units in one line of beams will also be cut off (Fig. 2.5). The prestress is transferred to the concrete through bond between the tendons and the ‘There are similar systems based on the above principle. These systems are put to use for usually precast beams. Pre-tensioning system was widely used in earlier days but has sincebeen replaced by post tensioning system. Pre-tensioning system is found uneconomical for large spans. Tn order to grip the pre-tensioned wires properly to thebulkheads the devices shown in Fig. 2.6 are followed. == amp Post-tensioning system. The basic principle in all post-tensioning systems is to introduce prestresses in the concrete member cast previously by tightening the tendons accommodated in the duets which are formed while casting the beam. As the tendons are pulled using a jack against the end of the concrete member, the desired prestressing force is obtained. After the wires are pulled, they are anchored in their stretched position against the endof theconcrete member by asuitable wedging device. Thevarious systems followed diffor in the arrangement of wires, in the process of jacking and in the anchorage devices. * Fig. 2.6. Inorder to ensure the correct prestress in the reinforcement, it is preferable tomeasure the load applied by the jack as well as the consequent extension of the reinforcement. Extension measurements give an idea as to how much of the steel is being properly stretched. For instance the sides of the ducts may obstruct the stretching of the reinforcement particularly at the end remote from the jack and this part of the reinforcement may not receive the full tension. This defect is liable to occur when curved cables are provided. On the other hand, it may be possible that the extension might have taken place due to a certain part of the tendon being overstressed. For this reason, it is necessary to measure the prestressing force applied. Excessive bearing stresses will be produced at the ends of the members due tothe anchoring devices which bear against the concrete. In this part of the member it will be necessary toprovide additional reinforcement to prevent local splitting and failure by shear. Suitability of the system Pre-tensioning and post tensioning are the only practically adopted methods of making eee onncnata ‘members, It is worthy tonote that these methods have their own applications ractice, thoetltPte-tensioning, the compressive force in concreteis due to thebond between concrete and thesteel wires, which are kept stretched between buttresses, This method is economically adopted inmass production in factories which make concrete products of limited size. This is so because, iandling as well a transporting large products are highly expensive and may be practically possible, if thee members are too large. The length of a prestressed concrete product that can be dimernically mado by this method may not exceed 207m. Even this length involves considerable ty in transport.PRESTREGHED hod aftor tho hardening of c a Tn post tensioning, thoprestressing wires aro st i llowiny ' ' Fao a a ooclated inside sheaths bofore placing of the comerote, Boe ye tit lngsdinal holes ao that tho cables may be placed in thom at, ©) Retbearn ney hestbe made and cables may nowbo placed on each side of tho wel ty, crete is hardened. |. a ‘These mothods con be adopted in sites or on the ground, and lator hoist int pont, instance, if timber is costly or scarce it may be economical to make the member ‘SBround in, steel moulds, ; — ‘Anumber ofsystoms are available each protected by patent rights. Those sys en re atepteg for linear prestressing and with some modification for circular prestressing also, Som: the commonly followed systems of post tensioning are described below. §15. THE FREYSSINET SYSTEM , The Freyssinet system was the first to be introduced among the post- tensioning systems. High tension steel wires 5 mm to 8 mm diameter about 12 in number are arranged to form a group into a cable with a spiral spring inside, ‘The spiral spring provides the means for aproper clearance between the wires and thus provides a channel which can be coment grouted. It further assists to transfer the reaction to concrete. The Whole thing is enclosed in a thin metal stoel hit. In th gassing acally through thepiz filled with the grout, This provides additional roa his way the space Ketnets thee en ‘aint against the slippii of | ‘tendons. Advantage of the system re e slipping of the @) Securing the wires is Not expensive, @) The desired stretching fore is obtained quickly,F STSTEMS_OF_PRESTRESSING Disadvantage of the system @ All the wires of a cable are stretched beexactly thesame. (ji) The greatest stretching fc i fr @ Jesulliciont. # force applied to a cable is from 250 RN to 500 RN. This may not (ii) The jacks used are heavy and expensive, $16. THE MAGNEL BLATON SYSTEM In this system a cable of rectangular section is provided, which f wires 5 Fr There eaten prvi, which contains layer fre 5 deep for a cable of sixty four wires). The wires in the same layer and the wires in adjacent layers are separated with a clearance of 4 mm. The geometric pattern of the wires is maintained in the same form throughout the length of the cable by providing grills or spacers at regular intervals ‘The grills do not offer any appreciable frictional resistance to the wires which can be moved relative to each other during the tensioning process. together, Hence thestresses in the wires may not Steel wedge Fig. 2.9. Magnel Blaton system. The wires are anchored by wedging, two at a time into sandwich plates. The sandwich plates are about 25 min thick and are provided with two wedge-shaped grooves on its two faces. ‘The wires are taken two in each groove and tightened. Then a steel wedge is driven between the tightened wires to anchor them against the plate. A complete anchorage unit may consist of one toeight sandwich plates, the number of wires depending on the number of wires in the cable. Each plate can anchor eight wires. The various sandwich plates forming a unit are arranged one awe the other against a distribution plate. The wires are tightened by jacking two wires at a e, $17. GIFFORD UDALL SYSTEM ‘This method offers the following three methods of Prestressing : cone —Spitcone 4S First method. This is earliest of the three methods Ce of this system, Wa “ In this method the wires are stressed and anchored one by one in a separate cylinder using small wedging tips called udall grips. Each grip consists of two-half ones, Thebearing platebears against athrust ring which hay into the concrete. The duct end is encircled by a Tang Anchorages are supplied tosuit cables of 2.4,6andPRESTRESSES COVER i . hich fit direct) Tho wires aro anchored by wedges w! directly Second method. he meth bearing plac bearsagunst tube unitoogge tapered recesses mad ai This tube unit is cast into the concrete. Anchorages ar supplied the tube unit and the het ti ngemont ie compact and minimizes the congestion ofthe git ‘wires in anchor block. : are aa h i don of 28 mm diameter H.T. typ . This need, Third method. In this method 9 ier igetronger than 6 mn wires, The anchoring ig done}, jiameter. This tent e uct of only 40 m7 Giomtfta three segments interlocking wedge. This method uses a barrel why! bears directly against a tube unit which is cast into concrete. Bearing plate Thrust ring & helix ‘Wedge anchor Fig. 2.11. Gifford-Udall System. §18. P.S.C. MONOWIRE SYSTEM In this system also the wires are tensioned individually. The anchorage consists of a single Piece collet sleeve wedging in a concial hole. A steel truncated guide leads each wire from the cable to the anchorage point along a gentle curvature. In addition to the guide a central block is also provided to anchor the central wires. Removable block to anchor central wires Fig. 2.12. P.S.C. Monowire system.S SYSTEMS OF PRESTRESSING 7 §19. C.C.L. STANDARD SYSTEM é This is anchor gy required (not ex ceeding 12) where the wires are tensioned individually. As many wires as may be used ina circular cable. The size of the duct depends on the number wire-cables and 50 mm diameter for 12-wire cables. At intervals led to keep the wires separated and to prevent the outer wires from not only reduces the friction but also allows satisfactory grouting. A s used to anchor each wire separately. The anchor grip consists of steel ire and are accommodated in a steel barrel having a tapered hole. of wires — 40 mm diamet of 600 mm spacers are cao touching the sheathing. This special C.C.L..anchor grip is wedges which fit over the wi Anchor ‘grip Barret ring reinforcement Fig. 2.13. C.C.L. Standard System. ~ The barrels are 20 mm diameter anid 25 mm long. The wedges are made either in two pieces or 4 segments held together by a steel circlip to form unit. These units bear against a drilled anchor plate through which the wires are passed. The anchor plate bears against a thrust ring _which is cast into the concrete. The thrust ring is of mild steel 6 mm thick and is made rectangular with a central rectangular hole. To prevent local bursting effect a helix is provided behind the thrust ring. A vertical mesh is also provided behind the helix. "The bearing plate is 18 mm thick and has 9 mm diameter holes provided at a spacing of 25 mm centres is parallel rows to accommodate the wires. §20. LEE-MCCALL SYSTEM ‘Thisis a system in which high tensile alloy steel bars (silicomanganese steel) are used as the prestreasing tendons. These bars are provided in 22 mm, 25 mm, 28 mm and 30 mm diameter and in lengths upto 20 metres. The anchoring of the bars is done by screwing special threaded nuts. ‘The nuts bear against a distribution plate provided at the end of the beam. Washer End plate Enlarged detail of thread Fig. 2.14.PRESTRESSES COWcRER; a §21. ELECTRICAL PRESTRESSING ‘ “ pe Ths amandofpet nsoing witht hese tr elone they are ened i rovi e epee aarp tan pe iia te ture of 1’ . tt h i Bae ne oie oe aemererlceainst heavy washers. As the Ce anpap iran na preens 7 developed in the bars and the bond is again restored by the resol ' §22, PREFIX BEAM This is yet another method of prestressing beams. Asteel joist eaiaeeiyd Caras to bending andthe tom angnaf thot i encato i eonee oie novovera back tote iy i i dl am is: L. n the load producing the banding ofthe boon vee also wotkablemethod of preatressings may be noted that the joist provides a much smaller tensile resistance than the high tension steg] wires, EXERCISE -2 Differentiate between externally prestressed and internally prestressed members. Differentiate between pretensioning and post tensioning. How are prestressed members made by the Hoyer system ? Write a note on suitability of pretensioning and post-tensioning. ‘What are the ways in which the pretensional members are made ? tS deol pe Froves sinet system of Dreatneoaing: tare the advantages and disadvantages of the Freyssinet: system of prestressing. Explain the Magnel Blaton system of prestressing. a E ae the various methods of prestressing by Gifford Udall system. Write short notes on : @ P.S.C. Monowire system (#) C.C.L, standard system (ii) Lee-Mccall system Describe electrical prestressing, ie ape the Prefix. Beam method of Prestressing members) os tansmitted to concrete in i) pretensional members and (ii) post tensioned Briefly explain the devices with sketches ‘used to grip pretensional wires to the bulk heads. Sepnesaeye %O 0 ow