@ SSIEISIMA SIIMAG { ' | : a ise anes ‘ j { Fy ' : iba | 4 fhe z p | < s ar | A bas, = BON 1 i ; i bale ee c —= 1 Lees ili te | AFDUE e ie 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. 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 hos 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 : ©) Externally or Internally prestressed b) Bonded or Unbonded tendons <) Linear or Circular prestressing The various components used for post tensioning work involves use of Anchorages, H.TStrands, 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 anchorages and equipments. Dynamicis providing tailor made solutions for construction industry in the field of prestressing since last two decades. The company's specialisation includes : * Technically qualified engineers and technical supervisors having vast experience in he 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. * Ability to develop equipments and devices as per site conditions. * Wide experience with clients like NHAI, RAILWAYS, MSRDC, NPCIL, PWD, etc. for all type of Structures & has completed variety of projects in several countries like INDIA, UAE, OMAN, SAUDI ARABIA, MONGOLIA, MAURITIUS etc.DAIL a HT. 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 PER INDIAN SPECIFICATION : |S 14268/1995 AS PER BRITISH SPECIFICATION BS 5896:1980 TABLE 1 TABLE 2 Bs | se. | A Tolerance o go 82) = | 'e)see| 2885 | See le Goss 5 B/E ELSES & Css! eS] § |e s/SPE] x& es | eb § §| Dio /Secfonalle S19 8g 8/8 Bat 25/ 2 |2e es S855 | 20 ey ana | ess Bee%|5 85 mm | mm | mar] KN KN_| Ko/Km mm| mm | % [mmr] KN KN 12.7 |+0.66| 98.7] 163.7[ 165.3 | 775 Wire|. 0-40, +4% " -0.15 Super|!5-7| -2% 1150| 265 225 |1180) 15.2| +0.66| 1402607 | 234.6 | 1102 0.20) 0.15 Dynamic Group do not manufacture H.T. Strands. The above mentioned data is for reference & can be checked with the manufacturers. 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 0.7mm. strips are available in Bright Metal / Galvanized / Lead coated finish. Metallic sheathing (Duct): = TABLE : Following tests on sheathing pipes is carried out at our Nasik | WPeofduct js ogee gre worksas perlRC: 18-2000 jo beusad inte 1. Transverse Loadtest 2. Tension load test eee pace bog 3. Water losstest 4, Workability test ae Soe O28 HDPE Sheathing (Duct) should conform the following specification | Le0d coated 0.0030 0.18 *Fib Bulletin-7* NPC Specification No.PP/M/1721 * IRC: 18-2000 * Addendum and Corrigendum IRS Slip No.6 * Railway Concrete Bridge Code 1997 Friction coefficient & wobble coefficient : The friction coefficients (1!) and wobble coefficient (k) can vary depending upon various factors including the nature and ed surface condition of the prestressing steel, the type, diameter and surface condition of the sheathing duct, and the [ Parameter As per fb As per NPC eae (Units) Bulletin 7 (2000) | Report PM/T721 The value of and k given in the table 3 & 4 may be adopted | _Kipermetre) [Not spected 0.003 for calculating the friction losses. i 010-014 | 010-014 PANNA a AAO + Mark out tendon spacings ond lay duct os per approved drawings + Proper taping of duct-duct coupler joint and also anchorages - duct joints. + Use de-coiler and safely goggles while uncoiling and cutting of strands. + Use strand bullet while threading the sirand 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 forits protection til the 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 cose of, bad concrete behind the anchor or insufficient anti- burst reinforcement, the anchor cone is likely, to get crushed.OTe rte Wess) 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 Prestressed Concrete structures. SPACING OF ANCHORAGES & ANTI-BURST REINFORCEMENT Pl é cree Anchor | UTS 80% of Duct | Anchor | Pocket | Min. Edge | Spacing | Pockot | PCDof | Spiral eee Type Spiral | (Tons) UTS Diameter Cone Size (Recess) Distance | Between Depth Holes on Reinforce| of Spiral, Bar Turns - | Amchorages Anchorage | ey Spiral (AKA Exe, F [Ss [ate D 7 75 | 60 | si _| vas | zs | 20 | 20 | tos | 125 | 50 | 3 rar Tos" [st [vas [ais | v20 [20 | os | 125 [150 3) 120P13/ 2251 180/75 | 190 | 240 | 148 | 260) 120 | 165) 190 {ors 356/298 | 90/28 | 500/98 sas tad) 200 | 250 5|27DP 13 506| 405 | 105 | 305 | 350 | 295 | 485 | 120 | 274 | 300 | '* The Technical details of strand anchorages with 31DP13 & more, shall be provided by our Mumbai office on request 7[40P15.2| 106) 85 | 51 145 | 215 120 220 120 125 I 8|70P152 | 196149 | 75 v0 | 240 | 148260120) 168 -1120P 152 319/255 | 85 | 245 | 300 | 200 | 300 | 120 | 200 19DP15.2| 505. 404 | 105 275 | 350 213 350 | 120 235 _| 12/31 0e152 624 659 130/370 412358 ——«20| 140295370 t [3[a7 oP 152) 964 767 | 140 | 400 | 440 | 380 | 675_| 140 | 920. | 400 | e40 | 14/430P 15.2/1143, 914 | 150 | 435 | 485 | 400 | 725 | 140 | 975 | 435 | 960 | 15/480? 1521276 1021, 160.| 435 | 485 | 420 | 770 vs0_|a75_ [42s | 080 | 20 [18 | 60 | 16/550? 152 1462| 1169 | 170 | 455 | 500 | 430 820 | 160 | 390 | 480 | 1200/20 20 | 60 > The Technicol details of her capaciy anchorages fr 15.7 mm sirands shall be provided by our Mumbo ofce on requed [a7[ 70157 | vee] 151 | 75 | 190 | 240 | 148 | 260 | 120 | 165 | 190 | S40 | 16 | 9 | 60 (18/120P157 924) 259 85/245 | 300 | 200 300/120 | 200 | 250 | 400 | 16 | 9 | 60 19[190P 157) 513| 410 | 105 | 275 | 350 | 713 | 350 | 120 | 295 | 300 | 660 | 20| 10 | 60 ‘¢ Dimensions of Single Strand Anchorages and other flat anchorages can be provided on request. 20 4813_| 75 | 40 | 60x20 170%75|z20012) 170 | 25 | 130 | - 270x110 300 | 10| 6 | 50 zi} 5813 | 93 | 75 | 70x20 | 204x75] 255x150 170 360 | 130 | - 270x110 300 | 10 | 6 | 50 | 224813106 | 65 90025 28000 Sosa as aan 06 5/193 / 106 | 90%25/ 250x80| 300x150 200-400” 130/271 400 10,850 [al mensions ore in ee) 8G dimonsions are based on use of M45 grade of concrete. Incase grade of concrete differs hen the dimension moy be suitably altered by roerting it tour technical depariment. The sessing sequenceis important & moy influence the coneretestrengihrequirementat each phase ofstessing 2), Bursting reinforcement should perfec ston, 35 mm fromthe inner surface ofAnchor cone. 53}. Incase ofligs tobe used instead of spice os ontiburt einforcement fol anchorages thon equivalent ste! area should be providedin he form of wo lige spaced 80 mm apart. 4). Sipdueto elastic shortening of gripping length ofstrand and the sip ve to wedge se, shouldbe seporately considered 5), Wedge sein he anchorage during ransfer causes loss of prestress, Wedge sein henon-sressing anchorages and temporary lack wedge occurs during stressing ond couses an oppareatinereose in extension but no loss of prestess Tenormal wedge set in Dynamic systems 6 m.m.ofsresing end and 3 m.m.ctnonstressingend. 6) Thaload forlocking wedges hall be in the range of 1.57 0.25 /Wedge. The lacking pressure depends on the rom ‘reacfthe jack ond thetype of strand and hence the exo! lood to be applied shel be checked with our technical tear. 7), Theintenelareactthe sheathing duct shell be about threetimes he rea othe fendons or os per our individval techricol leat made or the specific structures of projet. 8). Thointonal diameter of ducts spocied above, he external diameter shall be opproximotalyS mm bigger 9}, Pocket dimensions cre for nermal pocket sizes, ny deviation inthis be studied individually ting jack dimensions ino account 10) The spacing, edge coversand grouping of cables hell conform torelevort National codes of practice 11) Lengths ofstrond quoted in the detais gripping length of stressing jack ond is measured fromthe feof he anchor cone tube unit} 12) The compatibility of lock components or'T' range ofanchorages 6 the detailed echnical inputs shall be made available on request.Dynamic provides Single Strand Coupler and Multi Sirand Coupler for Pre-Tensioning and Post-Tensioning works respectively. The coupler is a mechanical device used for structures builtin sections; in cases when the cost of scaffolding & forms for a complete siructure becomes expensive. Certain cables are stressed & anchored at paral length & later extended using couplers. The execution work of continuous spans using multi strand coupler isa 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 couplers (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 ond 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. TERS Stage Stréssing is essentiol when prestressing is to be applied in stages to the concrete as per (design requirement] or if the stroke of jack is insufficient. For presiressing in two or more stages, multi use live wedges are recommended to be used instead of single use live wedges. For detail procedure of presiressing in stages, you may contact our technical office. TRESSING ANCHORAGES Dynamic provides special type anchor plate for restressing in order to compensate for the loss of prestress of ungrouted tendon. The restressing of cables is done using tailor made jacks & shimming foot. Sea ON The mutiuse borrels & wedges alongwith monostrand jacks of stroke upto one metre length ore provided by us for the production of pretensioned girders. The Jacks, Barrels & Wedges ore available for 0.5", 0.6"8. 0.62" strands OTE Nass Dynamic provides two types dead end anchorages at the non - stressing end of the girder. This anchorages are particularly useful for single end stressing as per the design and for the cases where less gap is available in between the girders or if one. of the end of girderis not accessible. + The Bulb type of dead end anchorages (Type C) are suitable Bulb Type Dead End Anchorages “anchorages for flat post tension slab with less numbers of strands and low | | Sr.No. “°Syoe A 8 iG capacity anchorages. The bulb portion and the bonding Ld toa i length of strands embedded in the concrete. t St 330 $0 too + The Spring loaded plate type of dead end anchorages (Type J [2 4315 | 270 0 750 4 15, 350 50 750 D) are suitable for entire range of 4 to 55 strands and have been extensively used for several metro rail projectsLOU CRBS 3h COHN TN JACK THREADING SEQUENCE FOR PRESTRESSING OPERATION ae I LS Jack | Capacity Overall Ouer dia], | )Ram Area | Min.Gripping] Max. | Lock off| Cylinder] Weigh Model tons | Length | ofMain | For For Length of | Travel) Length | dia for Cylinder | Stress |» Lock })Strand to cut Lock (tons) | (maf (mm) | (em2) | tema) (om) | (mm)}|_ (mm) | (mm) | (kas) D-20 22 735 106 | 42.2 = 350 200 | 175 70 | 27.5 DP-20 22 | 480 “100 "33.4 925, | 200| 75 65 18 DP-30 30_| 450 | 118 | 4a5 | 14 125 200| 75 76 | 26 cG-12/200 | 140 | 7675 | 285 | 341.05 | 52.52 600 200| 298 | 200 | 175 ¢G-18/150 | 200 [710 | 345 | 482.4 | 66 560 155| 300 | 240 | 200 €G-18/200 | 200 [9715 | 345 | 482.4 | 66 620 Tiojasi5 | 240 | 255 G-20/200 | 300 | 7745 | 400 || 641.51| 116.8 650 20 | 315 | 270 | 280 CG-30/100 | 350 | 500 | 380, | 563.72) - | 350 100 | 210 | 300 | 270 400 [735 | 492) /1058.94| 173.3 660 210 290 | 328 | 490 500 | 745 | 525 [1196.2] 178 680 210 | 305 | 346 | 584 | €G-50/200 | Modified 500 | 735 | 494 | 1045.4 | 173.3 660 210| 290 | 328 | 480 €G-50/100 | 500 | - 494 (1045.4 [= - 100 | 7 - zi zi €G-50/300 | 500 | 750 | 494 | 1045.4| 173.3 850 300/ 210 | 328 | 550 €G-120/200| 1200 _| dimensional details of CG120/200 & 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 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 valves 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 taking into account the actual jack efficiency v/s design efficiency considered in the GFC drawing, Saeed Very large forces are introduced in the tendons during stressing and the equipment is under heavy hydraulic pressure, thus careful working con avoid accidents. The following precautions are essential :- + Onlytrained and experienced personnel, under the guidance of Dynamic technical Staff, should perform stressing, + The equipment, especially the high pressure hoses ond the adapters must be in perfect condition. Damaged hoses must be replaced immediately. Protection cops must always be placed over unused connections (elecric os well as hydraulic. + Jock should never be handled by hoses. Stressing should be done according to specified data. The allowed maximum pressure should neverbe exceeded, During stressing, nobody should stand behind or underneath the jack, since failure of strand can cause fatal accidents. Forstressing close fo traffic areas, the jack must be secured by ropes or chain hoist + Allbars, 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 moy whip back with force, ifnot 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. + Hogaing of the girder during stressing 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/cm’ and has a discharge of 25 litres /minute. It operates on 3 phase eleciric 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 unitis 100 litres of cement grout. Dynamic has used high discharge capacity positive displacement type grout pump hoving minimum outlet pressure of 10.5 kg/cm’ for continuous span bridges of length 120 meters and more, Dynamic grout caps are advantageously used for speedy grouting. The grout cap is fixed by four allen key bolts and the air nuts kept in upward position. + Protective glasses must be worn during grouting operation. + Do not start the pump while valves are in closed position as it may cause damage othe pressure gauge. + Place the grout tonk preferably at the same level as that of grout pump. + Incase of a longer stoppage (> 5 minof 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 neorest 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. Perfectly compacted conerete in the anchorage zone is a must. The anti-burst reinforcement cannot make up for local concrete defects. Precast end block can be used in case of I’ 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 ttachments must be strong enough to resist knocks & vibration and also the impact ofthe wet concrete dumped on it. The connection of the sheath with anchorage must be done with proper care to ensure that anchorage alignment is os per drawing & the connection is watertight (additional Heat Shrink tape if required should be used to ensure leak proof join) 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 ports & 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.