Materials For Prestressed Concrete

4/3/2022
Prestressed Concrete
Engr. Dr. Muhammad Aslam
Assistant Professor,
Dept. of Civil Engineering
(Structural Engineering & Materials)
General Details
• Department of Civil Engineering.
• Course: Prestressed Concrete.
• Instructor: Engr. Dr. Muhammad Aslam.
• Lecture No. 03.
• Week No. 03.
• Class: MSc Civil Engineering (Structural Engineering).
• Semesters: 1st & 2nd (MSc. Civil Engineering).
• Section: One.
• Session: Fall-2019 & Spring-20.
Institute of Southern Punjab (ISP), Multan Prepared by: Engr. Dr. Muhammad Aslam
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Materials for
Prestressed Concrete
Engr. Dr. Muhammad Aslam
Assistant Professor,
Dept. of Civil Engineering
(Structural Engineering & Materials)
Course: Prestressed Concrete
Text Books
1. Prestressed Concrete Structures by Michael P. Collins.
2. Prestressed Concrete by Edward G. Nawy.
3. Modern Prestressed Concrete - 3rd Ed. by James G. Libby.
4. Design of Prestressed Concrete – 2nd Ed. by A. H. Nilson.
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Summary of Previous Lecture

1. Prestressed Concrete.
2. Concept & Principles of Prestressing.
3. Methods & Stages of Prestressing.
4. Tendon Profiles.
5. Components of Prestressing.
6. Advantages and Applications of Prestressing.
Contents
1. Aggregates.
2. Cement / Binder.
3. Water.
4. Admixtures.
5. Concrete.
6. Grout.
7. Non-prestressing Steel.
8. Prestressing Steel.
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1. Aggregate
• The coarse aggregate are granular materials obtained from rocks and
crushedstones.
• They may be also obtained from synthetic material like slag, shale,
fly ash and clayfor use in lightweight concrete.
• The sand obtained from river beds or quarries is used as fine
aggregate.
• The fine aggregate along with the hydrated cement paste fill the
spacebetweenthe coarseaggregate.
1. Aggregate
• The nominal maximum coarse aggregate size is limited by the
lowest of the following quantities:
1. 1/4 times the minimum thickness of the member,
2. Spacing between the tendons / strands minus 5 mm,
3. 40 mm.
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2. Cement
• In present day concrete, cement is a mixture of lime stone
and clay heated in a kiln to 1400 - 1600 ºC.
3. Water
• Water used for mixing and curing shall be clean and free
from injurious amounts of oils, acids, alkalis, salts, sugar,
organic materials or other substances that may be
deleterious to concrete and steel.
4. Admixtures
• The admixtures can be broadly divided into two types: Chemical
admixtures and Mineral admixtures.
 The common chemical admixtures are as follows.
1) Air-entraining admixtures
2) Water reducing admixtures
3) Set retarding admixtures
4) Set accelerating admixtures
5) Water reducing and set retarding admixtures
6) Water reducing and set accelerating admixtures.
 The common Mineral admixtures are:
1) Fly ash, 2) Ground granulated blast-furnace slag,
3) Silica fumes, 4) Rice husk ash, 5) Metakoline
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5. Concrete
• Concrete, particularly high-strength concrete, is a major
constituent of all prestressed concrete elements.
• Hence, its strength and long-term endurance have to be achieved
through proper quality control and quality assurance at the
production stage.
• Following discussion is intended to highlight the topics directly
related to concrete in prestressed elements and systems.
5. Concrete
• Concrete is a composite material composed of gravels or
crushed stones (coarse aggregate), sand (fine aggregate) and
hydrated cement (binder). It is expected that the student of this
course is familiar with the basics of concrete technology.
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5. Concrete
1.1. Parameters Affecting the Quality of Concrete
• Strength and endurance are two major qualities that are
particularly important in prestressed concrete structures.
• Long-term detrimental effects can rapidly reduce the
prestressing forces and could result in unexpected failure.
• Hence, measures have to be taken to ensure strict quality
control and quality assurance at the various stages of production
and construction as well as maintenance.
• Principal properties of good quality concrete are shown in Fig.
Principal Properties of Good Concrete
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5. Concrete
1.2. Properties of Hardened Concrete
• The mechanical properties of hardened concrete can be
classified into two categories: short-term or instantaneous
properties, and long-term properties.
• Short-term properties are strength in compression, tension,
shear, stiffness, and modulus of elasticity.
• Long-term properties can be classified in terms of creep and
shrinkage.
a. Properties of Hardened Concrete

1) High strength
2) Durability
3) Stiffness
4) Minimum shrinkage and creep
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a. High Strength Concrete

• The maximum grade of concrete is 60 MPa.
• The minimum grades of concrete for prestressed
applications are as follows.
1. 30 MPa - Post-tensioned members
2. 40 MPa - Pre-tensioned members.
b. Stiffness of Concrete
• The stiffness of concrete is required to estimate the deflection
of members. The stiffness is given by the modulus of
elasticity.
c. Durability of Concrete
• The durability of concrete is of vital importance
regarding the life cycle cost of a structure. The
life cycle cost includes not only the initial cost of
the materials and labour, but also the cost of
maintenance and repair.
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d. Creep of Concrete
• Creep of concrete is defined as the increase in
deformation with time under constant load.
• Initial deformation due to load is the elastic strain, while
the additional strain due to the same sustained load is the
creep strain.
• Figure illustrates the increase in creep strain with time,
and as in the case of shrinkage, it can be seen that creep
rate decreases with time.
• Creep cannot be observed directly and can be determined
by deducting elastic strain and shrinkage strain from the
total deformation.
Prepared by: Engr. Dr. Muhammad Aslam
• Creep cannot be observed directly and can be determined
by deducting elastic strain and shrinkage strain from the
total deformation.
• Although shrinkage and creep are not independent
phenomena, it can be assumed that superposition of strain
is valid; hence,
= + + ℎ
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Figure: Strain-time Curve
• Due to the creep of concrete, the prestress in the tendon
is reduced with time. Hence, the study of creep is
important in prestressed concrete to calculate the loss in
prestress.
• The creep occurs due to two causes.
1. Rearrangement of hydrated cement paste (especially
the layered products),
2. Expulsion of water from voids under load.
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• Effects of Creep
 As in shrinkage, creep increases the deflection of beams and slabs
and causes loss of prestress.
 In addition, the initial eccentricity of a RC column increases with
time due to creep, resulting in the transfer of compressive load
from concrete to steel in section.
 Once the steel yields, additional load has to be carried by the
concrete. Consequently, the resisting capacity of the column is
reduced and the curvature of the column increases further, resulting
in overstress in the concrete, leading to failure.
e. Shrinkage of Concrete
• Shrinkage of concrete is defined as the contraction due
to loss of moisture. The study of shrinkage is also
important in prestressed concrete to calculate the loss in
prestress.
• The shrinkage occurs due to two causes.
1. Loss of water from voids,
2. Reduction of volume during carbonation.
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 Basically, there are two types of shrinkage: plastic and drying
shrinkage.
 Plastic shrinkage occurs during the first few hours after
placing fresh concrete in the forms. Exposed surfaces such a
floor slabs are more easily affected by exposure to dry air
because of their large contact surface. In such cases, moisture
evaporates faster from the concrete surface than it is replaced
by the bleed water from the lower layers of the concrete
elements.
 Basically, there are two types of shrinkage: plastic and
drying shrinkage.
 Plastic shrinkage occurs during the first few hours after
placing fresh concrete in the forms.
 Drying shrinkage, on the other hand, occurs after the
concrete has already attained its final set and a good portion
of the chemical hydration process in the cement gel has
been accomplished.
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• Factors Affecting Magnitude of Shrinkage
1. Aggregate: Aggregate acts to restrain the shrinkage of the cement
paste, hence, high aggregate content resulted lower shrinkage.
2. Water / Cement Ratio: Higher the water / cement ratio, the higher
the shrinkage effects.
3. Size of Concrete Element: Both the rate and the total magnitude of
shrinkage decrease with an increase in the volume of the member.
4. Medium Ambient Conditions: Relative humidity of the medium
greatly affects the magnitude of shrinkage; the rate of shrinkage is
lower at high states of relative humidity.
5. Amount of Reinforcement: Reinforced concrete shrinks less than
plain concrete; the relative difference is a function of the
reinforcement percentage.
6. Admixtures: This effect varies depending on the type of admixture.
An accelerator such as calcium chloride, used to accelerate the
hardening and setting of the concrete, increases the shrinkage.
7. Type of Cement: Rapid-hardening cement shrinks somewhat more
than other types, while shrinkage-compensating cement minimizes
or -------------------
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7. Type of Cement: Rapid-hardening cement shrinks somewhat more
than other types, while shrinkage-compensating cement minimizes
or eliminates shrinkage cracking if used with restraining
reinforcement.
8. Carbonation: Carbonation shrinkage is caused by the reaction
between the carbon dioxide present in the atmosphere and
that present in the cement paste. Amount of the combined shrinkage
varies according to occurrence of carbonation and drying processes.
Process of carbonation is significantly reduced at RH below 50%.
6. Grouting of Post-tensioned Tendons

• In order to provide permanent protection for post-tensioned steel
and to develop a bond between the prestressing steel and the
surrounding concrete, the prestressing ducts have to be filled under
pressure with the appropriate cement grout in an injection process.
• Grout is a mixture of water, cement and optional materials like
sand, water-reducing admixtures, expansion agent and pozzolans.
• The water-to-cement ratio is around 0.5.
• Fine sand is used to avoid segregation.
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6.1. Grouting Materials
a. Portland Cement: Portland cement should conform to one of the
following specifications: ASTM C150, Type I, II, or III.
• Cement used for grouting should be fresh and should not contain
any lumps or other indications of hydration or “pack set”.
b. Water: Must be potable, clean, and free from injurious substances.
c. Admixtures: Admixtures, if used, should impart the properties of
low water content, good flow, minimum bleed, and expansion if
desired. Their formulation should contain no chemicals in
quantities that may have a harmful effect on prestressing steel etc.

6.2. Properties of Grout
The desirable properties of grout are as follows.
a. Fluidity,
b. Minimum bleeding and segregation,
c. Low shrinkage,
d. Adequate strength after hardening,
e. No detrimental compounds,
f. Durable.
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6. Grout

6.3. Grouting Process
1. Ducts with concrete wall (cored ducts) should be flushed to ensure
that the concrete is thoroughly wetted.
2. All grout and high-point vent openings should be open when
grouting starts. Grout should be allowed to flow from the first vent
after the inlet pipe until any residual flushing water or entrapped air
has been removed.
3. Grout should be pumped through the duct and continuously wasted
at the outlet pipe until no visible slugs of water or air are ejected.
The efflux time of the ejected grout should -----------
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3. Grout should be pumped through the duct and continuously wasted
at the outlet pipe until no visible slugs of water or air are ejected.
The efflux time of the ejected grout should not be less than the
injected grout. To ensure that the tendon remains filled with grout,
the outlet and/or inlet should be closed. Plugs, caps, or valves thus
required should not be removed or opened until the grout has set.
4. When one-way flow of grout cannot be maintained, the grout
should be immediately flushed out of the duct with water.

5. In temperature below 32 ° , ducts should be kept free of water to
avoid damage due to freezing.
6. The temperature of the concrete should be 35 ° or higher from the
time of grouting until job-cured 2-in cubes of grout reach a
minimum compressive strength of 800 psi.
7. Grout should not be above 90° during mixing or pumping. If
necessary, the mixing water should be cooled.
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7. Nonprestressing Reinforcement
• Steel reinforcement for concrete consists of bars, wires, and welded
wire fabric, all of which are manufactured in accordance with
ASTM standards. The most important properties of reinforcing
steel are:
1. Young’s Modulus, .
2. Yield Strength, .
3. Ultimate strength, .
4. Steel grade designation.
5. Size or diameter of the bar or wire.
• To increase the bond between concrete and steel, projections called
deformations are rolled onto the bar surface as shown in Figure, as
per ASTM specifications.
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8. Pre-stressing Reinforcement
8.1. Types of Reinforcement
• Because of the high creep and shrinkage losses in concrete,
effective pre-stressing can be achieved by using very high-strength
steels in the range of 270,000 psi or more (1862 MPa or higher).
• Such high-stressed steels are able to counterbalance these losses in
the surrounding concrete and have adequate leftover stress levels to
sustain the required pre-stressing force. The magnitude of normal
prestress losses can be expected to be in the range of 35000 to
60000 psi (241 to 414 MPa). Initial prestress would thus have to be
very high, on the order of 180000 to 220000 psi.
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• Prestressing reinforcement can be in the form of single wires,
strands composed of several wires twisted to form a single element,
and high-strength bars. Three types commonly used in the United
States are:
a. Uncoated stress-relieved or low-relaxation wires.
b. Uncoated stress-relieved strands or low-relaxation strands.
c. Uncoated high-strength steel bars.
8.1.1. Stress-Relieved & Low-Relaxation Wires and Strands
• Stress-relieved wires are cold-drawn single wires conforming to
ASTM standard A421; stress-relieved strands conform to ASTM
standard A416.
• Strands are made from seven wires by twisting six of them on a
pitch of 12- to 16-wire diameter around a slightly larger, straight
control wire. Stress-relieving is done after the wires are woven into
the strand. Geometrical properties of the wires and strands as
required by ASTM are given in Tables 2.6 & 2.7.
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• To maximize the steel area of the 7-wire strand for any nominal
diameter, the standard wire can be drawn through a die to form a
compacted strand as shown in figure 2.17b, this is opposed to the
standard 7 wire strand in figure 2.17a.
• ASTM standard A779 requires the minimum strengths and
geometrical properties given in Table 2.8.
• Figure 2.18a shows a typical stress-strain diagram for wire and
strands prestressing steels, while figure 2.18b shows mild steel.
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8.1.2. High-Tensile-Strength Prestressing Bars
• High-tensile-strength alloy steel bars for prestressing are either
smooth or deformed, and are available in nominal diameters from
19 mm to 35 mm. They must conform to ASTM standard A722.
• Cold drawn in order to raise their yield strength, these bars are
stress relieved as well to increase their ductility.
• Stress relieving is achieved by heating the bar to an appropriate
temperature, generally below 500 ° . Table 2.9 lists the geometrical
properties of the prestressing bars (ASTM A722).
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8.1.2. High-Tensile-Strength Prestressing Bars
8.1.3. Steel Relaxation
• Stress relaxation in prestressing steel is the loss of prestress when
the wires or strands are subjected to essentially constant strain. It is
identical to creep in concrete, except that creep is a change in strain
whereas steel relaxation is a loss in steel stress.
• Figure 2.19 shows the relative relaxation loss for stress-relieved
and low-relaxation steels for 7-wire strands.
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8.1.3. Steel Relaxation
8.1.4. Corrosion & Deterioration of Strands
• Protection against corrosion of prestressing steel is more critical
than in the case of non-prestressed steel.
• Such precaution is necessary since the strength of the prestressed
concrete element is a function of the prestressing force, which in
turn is a function of the prestressing tendon area.
• Reduction of prestressing steel area due to corrosion can drastically
reduce the nominal moment strength of the prestressed section,
which can lead to premature failure of the structural system.
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• In pre-tensioned members, protection against corrosion is
provided by the concrete surrounding the tendon, provided
that adequate concrete cover is available.
• In post-tensioned members, protection can be obtained by full
grouting of the ducts after prestressing is completed or by
greasing.
• Another form of wire or strand deterioration is stress
corrosion, which is characterized by the formation of
microscopic cracks in the steel which lead to brittleness and
failure. This type of reduction in strength can occur only
under very high stress and, through infrequent, is difficult to
prevent.
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Ten Principles
Ten Principles
• The following ten principles are applicable not only to
prestressing concrete but to any endeavour that the engineer is
called upon to undertake:
Ten Principles
Ten Principles
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Assignment No. 03
• Prepare the detailed report of the following documents:
1. Describe the materials used for prestressed concrete.
2. ASTM A779 / 779M – 98: Standard Specification for steel
strand, seven-wire, uncoated, compacted, stress-relieved for
prestressed concrete.
3. ASTM A722 / A722M – 98: Standard Specification for
Uncoated High-Strength Steel Bars for Prestressing Concrete.
Thank You
31

Materials For Prestressed Concrete

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4/3/2022

Engr. Dr. Muhammad Aslam

Course: Prestressed Concrete

2. Prestressed Concrete by Edward G. Nawy.

3. Modern Prestressed Concrete - 3rd Ed. by James G. Libby.

4. Design of Prestressed Concrete – 2nd Ed. by A. H. Nilson.

Summary of Previous Lecture

lowest of the following quantities:

1. 1/4 times the minimum thickness of the member,

2. Spacing between the tendons / strands minus 5 mm,

a. Properties of Hardened Concrete

a. High Strength Concrete

Figure: Strain-time Curve

6. Grouting of Post-tensioned Tendons

6. Grouting of Post-tensioned Tendons

6. Grouting of Post-tensioned Tendons

6. Grouting of Post-tensioned Tendons

6. Grouting of Post-tensioned Tendons

6. Grouting of Post-tensioned Tendons

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