PRE-STRESSED & PRE-CAST CONCRETE

LABORTARY MANNUAL
CODE CET-321
 Vision and Mission

VISION
To lead global technological education and embed the market-driven
employable and entrepreneurial skills to empower community.

MISSION
The mission of BBSUTSD Khairpur Mir’s is to empower community with the
hands-on technological knowledge through high quality teaching & research
environment, innovative tools & techniques, and entrepreneurial & global
leadership skills with the consciousness of ethical norms & values.
List of Experiments

S.No. Experiment
1 A general study of essential equipment for precast concrete
industry.
2 Form work for the pre-stressed members.
3 Study of equipment and machinery for pre-stressed concrete
industry.
4 Casting and testing of specimens (beam) of pre-stressed
concrete units.
5 Casting and testing of specimens (beam) of precast RC
concrete units.
 INTRODUCTION

PRINCPLES OF PRESTRESSING

Pre stressing is a method of inducing known permanent

stresses in a structure or member before the full or live load is applied. These stresses are induced
by tensioning the High Tensile Strands, wires or rods, and then anchored to the member being Pre
stressed, by mechanical means. The Pre stressing counteracts the stresses, produced by subsequent
loading on the structures, thereby extending the range of stresses to which a structural member can
safely be subjected. This also improves the behavior of the material of which the member or
structure is composed. For Example; The Concrete which has relatively a low Tensile strength,
shall behave like a member having high tensile strength, after Pre stressing. The High Tensile
wires/strands, when bunched together are called Cables. These cables are generally placed inside
a cylindrical duct made out of either metallic or HDPE material. The Anchorages, one of the main
components of the Pre stressing activity, are used to anchor the H.T. Cable after inducing the Load.
The whole assembly of the Anchorage and the H.T. Cable is named as ‘TENDON’.

APPLICATION AND USE OF PRESTRESSING

In structural Member, where the span length is very

high with low rises and low structural height, the application of Reinforced Cement Concrete shall
be virtually impractical. In such a case, Pre stressing is used to achieve a light weight, elegant
looking and much economical structure with high durability. Pre stressing, therefore, is widely
used for long span beams and Bridges. In building structure also, Pre stressing method is very
effectively used to achieve lighter beams and slabs; thus reducing their dead load considerably as
compared to R.C.C. Structures. Application of Pre stressing in building construction also facilitates
a larger span between the columns, thus reduces the number of columns. This also makes the
structure more versatile for interior planning. Pre stressing is also very widely used in the
construction of Mega Structures like Containment Wall of Nuclear Reactors, LNG Storage Tanks,
Cement Silos, Chimneys, Dams and Rock Anchors etc.

TYPE OF PRESTRESSING SYSTEMS

Pre stressing System can be classified by two basic methods, as under:-

(a). Pre-Tensioning

(b). Post-Tensioning.

PRE-TENSIONING

It is a method where Pre stressing Steels are pre-stressed, prior to concreting,

against two rigid abutments. This method is most widely used for mass production of short span
structures, where pre-stressing is also a prerequisite, such as; Railway Sleepers, Electric Polls,
Fencing Polls, Pre-Tensioned Slabs and I-Section Bridge Girders etc. In this system, a number of
identical structural frames are placed in between the two rigid abutments or reaction bolster.
Prestressing Steel is then placed longitudinally across these frames and abutments, in the required
orientation, and stressed. After achieving required elongation and stresses they are blocked at two
abutments and then concrete is poured in the frames with stressed steels in position.

POST-TENSIONING

It is a method where Pre stressing Steels are stressed after concrete attains its
preliminary strength. Two extreme ends of the structure are considered as a reaction face, against
which force is applied. Ducts are placed inside the formwork along with reinforcement and the
concreting is completed. After achieving required concrete strength, a stipulated numbers of Pre
stressing Steel is then inserted in each duct for stressing purpose. After achieving required
elongation and stresses they are blocked at two ends with the help of Anchor Plates and grip. The
broad classifications are given as under.
SCHEMATIC DIAGRAM
 EXPERIMENT # 1

A general study of essential equipment for precast concrete

industry.
1) High Strength Concrete

High-strength concrete is defined as concrete with a specified

compressive strength of 50 MPa (8000 psi) or higher. Concrete having a specified compressive
strength in excess of 69 MPa (10,000 psi High-strength concrete is typically used in the erection
of high-rise structures. It has been used in components such as columns, shear walls, and
foundations also used in bridge applications as well.

2) PRESTRESSING / HIGH TENSILE STRENGTH STEEL

Pre stressing Steels are best known as the High Tensile Steel
Wires, Strand or Bars and are available in various sizes and configurations. A
few of them are as listed below:
3). ANCHORAGE SYSTEMS

Pre stressing forces of the Tendons are transferred to the concrete structures
through Anchorages. Anchorage for the Post Tensioning system normally comprises of a steel
plates with a number of conical holes, the conical Grips and the Guide (Trumpet). Trumpet or
Guide is used to connect the ducts and provides a flat surface for locating the Bearing Plate on it.
As shown in the figure below:

a. Guide - This is specially formed component made out of graded Cast Iron, which
generally gets embedded in the concrete and used to distribute the tendon forces to the concrete.

b. Bearing Plate - This is cylindrical round shaped component made out of forging of
graded Alloy Steel. This plate contains a number of tapered holes for wedging the Prestressing
Steel with the help of grips.
c. Grips & Circlips - This is a tapered shaped components made out of Alloy Carbon Steel
and subsequently hardened & tempered. These grips are silted in three equal parts to work like a
split jaws and contains serrations insides.

4). FLAT ANCHORAGES

The components and the functions of the FLAT ANCHORAGES are similar to
that of Pre stressing Anchorages, but they are specially designed in flat shape for use in slab
stress applications.

5). ANCHORAGE COUPLERS

In the construction of continuous deck bridges, it is essential to extend

Prestressing cables as the construction proceeds. In COUPLER arrangement, the first stage of
Stressing is carried out in the same way as with the standard Anchorage, except that one
COUPLER RING is placed between the GUIDE and the BEARING PLATE. The coupler Ring
contains the required number of slotted lugs to accommodate SWAGED GRIPS fitted on the
strands for Second stage cables.
PURPOSE: After the completion of first stage of pre stressing and grouting, the strands fitted
with swaged grips are installed for second stage stressing. Swaged grips are prepared with the
help of a specially designed sleeves and locks, on an extrusion press. The strands are then
deflected through a conical shaped trumpet called REDUCER CONE, which also prevents
ingress of concrete and slurry during casting of second stage. This Reducer Cone provides a
grout exit point, which should be placed at the top location to prevent any air being trapped
during grouting. Small end of the Reducer cone is securely tapped to the duct of second stage.

6). TENDON DUCTS (SHEATHING)

Sheathing is used to create a void in the concrete structure, through which the stressing steels are
inserted and remain free to stretch during stressing operation. Sheathings are available in two
types:

a). Metallic Ducts

b). H.D.P.E. Ducts NG):

Metallic Duct HDPE Duct

7). PRESTRESSING Jacks

The tensioning of the steel strand (or individual wires) is usually by means
of hydraulic jacks. In pre-tensioning, single strand jacks may be used. In post-tensioning the
strands are often grouped to form tendons. These may be stressed by large, multi-strand jacks.
The load induced into the strand is determined from the pressure in the hydraulic oil supplied to
the jack or from the extension of the strand.

Wedge grips are used to grip each strand during stressing and to hold the strand permanently in
the tendon anchor after stressing. The jack is removed after stressing and anchoring. In post-
tensioning the pre stressing force is applied directly to the concrete. In the case of pre-tensioning
the anchor holds the strands until after the concrete has gained sufficient strength; the strands are
then released, transferring the pre stressing force to the concrete.

8). GROUT PUMP

Grouting of the post-tensioned cables in the post or pre stressed concrete is with
the help of Grouting Pump carried out to provide permanent protection to the steel cables against
corrosion. It also develops a bond between cables and surrounding concrete which fills the duct
space and prevents water collection and freezing

What type of equipment is used to stretch the tendons and reason of stretching?

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How much strength of concrete and yielding strength of steel is required in prestressing? Explain
the need of duct in post tensioned members.

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 EXPERIMENT # 2

Form work for the pre-stressed members.

1. Form work
A mould or box into which wet precast concrete can be poured and
compacted so that it will flow and finally set to the inner profile of the box or mould.” Form
mold the concrete to desired size and shape and control its position and alignment. Form works
also act as a temporary structure that support its own weight, the freshly placed concrete and
construction live loads (material, human, logistic).

Formwork is a classic temporary structure in a sense that it can be erected quickly, highly
loaded for a few hours during the concrete placement and within a few days it is disassembled
for future use
A good formwork would have the following characteristics:
 Safe
 Cost effective or economical
 High Quality – finished concrete surface is of acceptable quality to produce the
required shape and surface

Formwork design includes loads in design process are as follows

 Fresh high strength concrete
 Rebar
 Formwork material
 Wind and lateral loads
 Live loads due to – Formwork construction - Reinforcing installation – High Strength
Concrete placement.

Although there are many formwork materials, the following are general performance features
to meet the needs of concrete construction:

 Capable of withstanding dead and live loads.

 Retaining its shape with adequate props and braces.

 Joints must be leak-proof.

 If formwork is removable, the process must not damage the concrete.

 Reusable material.

 As light weight as possible.

  The formwork material should not warp or distort.

Types of Formwork based on material:

 Timber formwork
Timber formwork was one the first types used in construction
industry. It is assembled on site and is the most flexible type,
bringing the following advantages:

 Easy to produce and remove

 Lightweight, especially when compared with metallic

 formwork

 Workable, allowing any shape, size and height

 Economical in small projects

 Allows the use of local timber

However, before using timber its condition must be checked carefully, making sure it is free of
termites. Timber formwork also has two limitations that must be considered: it has a short life span
and is time consuming in large projects. In general, timber formwork is recommended when labor
costs are low, or when complex concrete sections require flexible formwork.

 Plywood formwork
Plywood is often used along with timber. It is a manufactured
wooden material, which is available in different sizes and
thicknesses. In formwork applications, it is mainly used for
sheathing, decking and form linings.

Plywood formwork has similar properties as timber formwork,

including strength, durability and being lightweight.
 Metallic Formwork: Steel and Aluminum
Steel formwork and steel hardware is becoming more popular due to its long service life and
multiple reuses. Although it is costly, steel formwork is useful for multiple projects, and it is
a viable option when many opportunities for reuse are expected.
The following are some of the main features of steel formwork:
1. Strong and durable, with a long lifespan
2. Creates a smooth finish on concrete surfaces
3. Waterproof
4. Reduces honeycombing effect in concrete
5. Easily installed and dismantled
6. Suitable for curved structures
Aluminum formwork is very similar to steel
formwork. The main difference is that aluminum
has a lower density than steel, which makes
formwork lighter. Aluminum also has a lower strength than steel, and this must be considered
before using it.

 Plastic Formwork
This type of formwork is assembled from interlocking
panels or modular systems, made of lightweight and
robust plastic. Plastic formwork works best in small
projects consisting on repetitive tasks, such as low-cost
housing estates.
Plastic formwork is light and can be cleaned with
water, while being suitable for large sections and
multiple reuses. Its main drawback is having less
flexibility than timber, since many components are
prefabricated.
  Fabric Formwork
Fabric formwork is also known as
flexible formwork. This system uses
lightweight and high- strength sheets
of fabric, designed to adjust to the
fluidity of concrete and create
interesting architectural forms.
Fabric formwork is not as uniform as
standard formwork. “We had to
create some structure to gives us the
appearance of what we wanted, but
in the same breath it gave us a lot of
design freedom. It’s really an exciting medium,” he says. As for fabric formwork’s
limitations, “It’s wide open. We haven’t tested its limits yet.

2. REQUIREMENTS FOR PRESTRESSING FORMWORK

The ACI Standard Specifications for Structural Concrete for
Buildings (ACI 301-72) requires that formwork for pre stressed concrete "shall not restrain
elastic shortening, deflection or camber resulting from application of the pre stressing
force.” It also provides that "form supports shall not be removed until sufficient pre
stressing force has been applied to support the dead load, formwork and anticipated
construction loads. When a structure is pre stressed in two directions formwork shall
support the load which is redistributed by the partially completed stressing operation."
Formwork must be rigid enough to prevent pre stressing tendons from being displaced
beyond specified tolerances, according to the same Standard.

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What are the requirements of a good form work?

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Is there any difference between form work for conventional concrete and pre-stressed concrete?

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 EXPERIMENT # 3

Study of equipment and machinery for pre-stressed concrete

industry.
1. CUTTING SAW
On the production bed the
concrete is formed as a continuous element by
the casting machine along the entire length of
the bed. A cutting saw is then used to cut the
elements into the required lengths. The saw is
moved along the bed and is positioned at the
desired cutting point where the element is to be
cut using a diamond blade. Cuts can be
transversal, angular or longitudinal depending
on the cutting machine used. The amount of
time needed to make a cut varies between 1- 6 min. according to the kind and height
of element to be cut. During the cutting phase the blade is continuously cooled by a
jet of water either from an onboard tank or through a motorized water tube reel and
connected to a tap at the end of the bed.

2. CLAMPING EQUIPMENT
After the elements are cut on the production
beds they are ready to be lifted and
transported to the stocking area. Special
clamping equipment is used for the lifting
and transportation operation. This lifting
equipment can be hooked onto the overhead
crane or onto a special mobile lifting
machine independently powered. This
particular lifting machine runs along the
production bed, lifts the cut concrete elements off the production bed and deposits
them outside at the head end of the shed.
3. RAIL TROLLEY
The transfer of concrete elements from the
production area to the stocking area can also
be done using a rail trolley connected to a
pulling system device. The drive motor of
the pulling system is radio-controlled and
located at the end of the storage area. The
trolleys can either handle elements in a single
or double stacked for greater volumes. The element transport line can cover
considerable distances and is therefore a flexible and economically viable solution.

4. CLEANING MACHINE
A certain amount of concrete residue remains
on the production beds once the
manufactured elements have been removed.
Therefore the beds must be thoroughly
cleaned before re-using them. This could be
carried out manually using a broom, a shovel
and a wheel barrow but would take a
considerable waste of time. The best solution
is to use a multi-function cleaning machine
that moves along the production bed removing debris and water. A special oil
sprayer is situated at the back of the machine and evenly sprays a fine film of
detaching oil onto the surface of the production bed. By the time the machine has
reached the end of the production bed it is once again ready for re-use

5. STRESSING JACK

The reinforcing steel wires have to be fixed

at each end of the production bed and then
put in tension before concrete casting. The
tensioning operation can be done in two
ways, single wire or multi-stressing:
SINGLE WIRE STRESSING:
This tensioning operation is done with a
wires stressing machine composed of a
hydraulic central unit and a stressing jack,
which with its conical indented metal rod
 catches each wire pulling them to a pre-determined tension. An electronic control
device interrupts the tensioning operation once the load on the wire reaches the pre-
determined necessary number of kilo Newton required.
MULTI-STRESSING:
This tensioning operation is done with a multi-stressing machine composed of a 2
big hydraulic cylinders which pull a movable anchor where all wires have been
fixed. In this way all the wires are tensioned simultaneously in one operation. In
both cases the pre-stressing wires or strands are fixed at the reaction beams with
appropriate anchor grips.
6. FLYING BUCKET

The concrete transport from the batching plant

to the casting machine can be carried out in
different ways depending on the customer’s
requirements and the factory layout. The most
economical method is to use a bucket hooked to
an overhead crane. In cases where quick and
high volume production is required it is possible
to use a flying bucket and a concrete distributor
which follow the casting machine along the
production bed reducing the time and manpower needed to deliver the concrete.

7. EXTRUDER:
The machine works with a semi-dry concrete
and form the element by means of an extrusion
method without any vibration. The Extruder
machine can be fitted with various forming
inserts according to the height of element that is
to be produced

8. SLIPFORMER:
The machine works with a semi-dry concrete and
form the element by means of a moulding-vibrating-
pressing-finishing action. The Slipfomer machine
can be fitted with various forming inserts according
to the element that is to be produced.
9. SURFACE GROOVING:
Concrete elements normally have a smooth upper
part finish. However, with particular applications,
it may be required to increase the degree of
adhesion key between the upper part of the element
and the final in-situ finish casting. To achieve this,
it is possible to lightly scratch the surface of the
element or to create more indented defined
transversal grooves. This is done during the casting of the element when the concrete is
still fresh using a groover machine. The dimensions and the depth of the grooves can be
tuned according to the customer’s requirements.

10. MAKING CUT OUTS AND

NOTCHES:
The concrete elements may require notches,
holes and breaks according to the design of
the building. This operation can be carried
out by a special machine that sucks up
concrete from the element whilst the concrete
is still wet. The removed concrete is
deposited within an on board debris container that can be easily and quickly emptied.
Why surface grooving is important and if it is ignore what will be the impact on concrete
bonding?
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Is there any difference between rail trolley and flying equipment?

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 EXPERIMENT # 4
Casting and testing of specimens (beam) of pre-stressed
concrete units.

Pre-stressing concrete unit procedure

Phases of production process are as follows:

 Preparing the mould.
 Placing of reinforcement,
 Pre-stressing,
 Casting of concrete,
 Removing the mould,
 Storage
 Testing

Preparing the mould

Before any of the production process phase is applied, the mould must first be prepared.
For production of one pre-stressed beam, quantity of concrete should be calculated. Moulds
 that are used for purposes like this must be very strong and that is the reason why steel
mould are used of the specified dimensions as shown in figure.

Placing of Reinforcement
In addition to wires which will be used for pre-stressing, every concrete element has
traditional reinforcement (in the top and bottom of element, vertical shear reinforcement)
that always must be present, no matter which method of prestressing is applied. In pre-
tensioned concrete, wires for prestressing are places to the mould together with traditional
reinforcement.

Prestressing
This type of production uses long line method of prestressing with parts shown in figure.
Figure shows that one end of wires is strongly connected to the abutment by an anchor.
Other end of wires via anchor and spindle is connected with hydraulic jack. Wires are
tensioned by hydraulic jack to the sufficient prestressing force. So wires remain tensioned
and casting of concrete can begin.

Casting of concrete
Quantity of concrete needed to make an element depends on element dimensions and it’s
specified according to project documentation. Casting of concrete must be performed with
no interruption. Ideal temperature is 14-20 °C. After concrete has been placed into the
 mould, compacting of fresh concrete must be performed. When concrete achieve
compressive strength around 30 MPa, connection between wires and anchors is released
and prestressed element was made.

Removing the mould

Mould can be removed from an element when concrete has achieved sufficient strength.
Removal must be taken with a care in order not to damage the edges of element. In
prestressed concrete beams production where prestressed force is applied, it is
recommended to remove the mould after concrete has achieved maximum compressive
strength and that is for 28 days after casting the concrete.

Storage of specimens
By removing the mould production process is finished so the next phase is storage as shown
in figure. Storage must be taken with a care. The most important is transportation of an
element to the place of storage. During the process of storage elements may not be damaged
and must be perfectly placed without providing the freedom of movement. In addition,
elements must be on the straight surface without possibility for bending moment to be

occurred.
Testing of Prestressed members
The testing procedure is same as of conventional concrete. The member is placed between
two load plates of universal testing machine (UTM). The load sustained by the member up
to rupture and crakes formation is started must be noted down.
Explain the testing procedure of the pre-stressed beam.
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What are the steps to design a mix (DOE) of high strength concrete?

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 EXPERIMENT # 5
Casting and testing of specimens (beam) of precast RC
concrete units.

Post-tensioning of specimens
Phases of production process are as follows:
 Preparing the mould,
 Placing of reinforcement and duct,
 Pasting of concrete,
 Removing the mould,
 Prestressing,
 Storage
 Testing
Production process is similar as a process previously described with some differences.
Phases of production such as: preparing the mould, casting of concrete, removing the
mould and storage can be done in quite the same way as process described above.
Therefore, next text will describe only a production phases that are essentially different
from the phases of previous prestressing method.

Placing of reinforcement and duct

In this phase only traditional reinforcement is placed to the mould. In addition, in the mould
is also placed a duct (usually steel or plastic pipes) and prestressing wires will be put
through the duct later. Now concreting can be applied. When concrete has thoroughly
hardened mould can be removed. After mould has been removed presressing can be applied
and that is what makes this method of prestressing different from pre-stressing.
Prestressing
In this case prestressing is applied by hydraulic jack as shown in figure (a) after concrete
has achieved maximum compressive strength. Wires or cables must first be placed into the
duct. At the one end of beam, cables are permanently anchored (usually into the concrete)
by dead anchor. At the other end there is an active anchor used for anchoring the wires
after prestressing. Nowadays, there are many tolls for anchoring the cables and wires at the
end of beam as shown in figure (b).

What is the difference in the procedure of pre-stress and pre-cast concrete?

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Enlist the steps to form a post-tensioning of a pre-cast member.

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