This article is a continuation of the “What’s This Report For?

” series, based on a technical session sponsored

by ACI Committee E702, Designing Concrete Structures. In keeping with ACI’s mission to provide knowledge and
information for the best use of concrete, the articles will be posted on the ACI Web site (www.concrete.org/
education/edu_online_CEU.htm) and, along with sample reports and multiple-choice questions, be used for
educational materials.

The Stressing Report

What the designer needs to know

by Jim Rogers

W hen an engineer designs a structure that uses

post-tensioned concrete, the International Building
Code (IBC) requires that the application of prestressing
force undergo continuous special inspection to verify
that the design forces have been applied.1,2 Section
1704.1.21 of the IBC requires a report of this inspection—
the stressing report—to be submitted to the licensed
design professional in charge. The report is a complete
record of the tensioning operations in each placement
and the resulting elongations of each tendon stressed.
When the design professional receives this report from
the field, it’s important that it be evaluated and acted
upon in a timely fashion. Proper field protocols dictate
that the exposed stressing tails remain uncut and the
pocket former recesses in the edge of the slab remain
unpatched until the elongations of the tendons have been
approved by the design professional.
What’s in the Report?
Essentially, the stressing report is a complete listing of
each tendon that has been installed and a record of the
stressing operations performed in each concrete place-
ment. ACI 318-08, Section 18.20,2 and ACI 301-05, Section
9.3.4.3,3 require that both tendon elongation and jacking
force be measured and that the elongations be within ±7%
of calculated values, unless stricter tolerances are stated
in project specifications.
The jacking force is typically measured by a hydraulic
gauge that has been calibrated to correlate the hydraulic
pressure in the jack with the force actually being applied
by the jack. The equipment must be accompanied in the
field by a calibration certificate that shows this correla-
tion and lists the specified jacking force. The special
inspector should verify that each tendon was stressed to
the specified jacking force and that this force was not
exceeded for any reason. The required elongation is
calculated by the post-tensioning supplier and shown on
previously submitted and approved installation drawings.
The actual elongation is measured by marking the strand
before stressing and measuring the change in position of
the mark after stressing (Fig. 1). If the difference between
the measured and calculated elongations falls outside the
allowable tolerance, the reason must be determined and
corrective action may be required.
The report also contains basic information, such as
the date of tensioning, personnel involved, site conditions,
and equipment used. A table will list each individual
tendon by number and location. For each tendon, the
specified jacking force, calculated elongation, measured
elongation, and the deviation between the calculated and
measured elongations will be reported.
What do I do with it?
Keep in mind that until the report is approved by the
licensed design professional in charge, the exposed
strand tails cannot be cut and the recesses in the slab
cannot be patched, so don’t delay in reviewing the report.
This is particularly critical in corrosive environments.
Check to see that all tendons are present, the specified
jacking force was reached, and that the elongation of

Concrete international / February 2011 63

 (a)
Fig. 1: Elongation is measured by: (a) marking the strand before stressing; and (b) measuring the change in position of the mark
after stressing (Photos courtesy of Suncoast Post-Tension Ltd.)
each tendon falls within allowable tolerances. If that’s the
case, approve the report and file it.
Unfortunately, it may not be that easy. Let’s look at the
various possibilities and what to do in each case.
What if some tendons are missing or broken?
ACI 318-08, Section 18.20.4,2 states, “Total loss of
prestress due to unreplaced broken prestressing steel
shall not exceed 2% of total prestress.” This provision
applies to each prestressed member, where a member is
that portion considered as an element in the design, such
as the column strip or middle strip in a flat plate system.
Broken tendons can be replaced to stay within this limit;
however, missing tendons require analysis of the affected
member, with remedial action as appropriate.
What if some tendons are understressed?
Recorded elongations that fall below calculated values
may indicate that specified design forces have not been
achieved. This can result in cracking and excessive deflec-
tions in the affected members. Be aware, however, that the
most common cause of a tendon appearing to be under-
stressed is an error in the process of marking the strand
and measuring its elongation. This is when it becomes
helpful to have elongation reports with all of the information
filled in so the ironworker and the special inspector can be
contacted to discuss marking and measuring operations to
ascertain the accuracy of the report.
Another cause of tendons appearing to be understressed
is the use of prestressing steel with a modulus of elasticity
E that is substantially higher than the average value that
was used in calculating the tendon elongations. In the
past, it’s been common to use a value of E = 28,500 ksi
(197 GPa) for ASTM A416/A416M Grade 270 (1860) low
relaxation prestressing steel strand; however, due to
variations in (stranding) process from one manufacturer
64 February 2011 / Concrete international
(b)
to another, it’s not uncommon to see values in excess of
E = 31,000 ksi (214 GPa); the higher the modulus of elasticity,
the lower the elongation at a given force.
Understressed tendons can occur, however. One cause is
excess seating loss at the anchorage due to failure to clean
and remove paste and other debris from the wedge cavity
before installing the wedges. Another cause is excess
friction along the length of the tendon due to too much
wobble, excess bare strand at the stressing end, or even
poorly extruded strand.
Depending on the cause, it’s possible to simply
re-tension the affected tendons to bring them up to the
correct level of tension. Keep in mind, however, that the
specified jacking force cannot be exceeded just to
overcome friction and achieve a higher elongation.
Exceeding the specified jacking force can result in
yielding or breaking the prestressing steel and exposes
the field personnel to risk of severe injury.
What if some tendons are overstressed?
If measured elongations differ from calculated
elongations by more than 7%, ACI 318 and 301 require
the determination of the cause and correction of the
discrepancy. For apparently overstressed tendons,
ACI 4234 provides guidance. The first thing to evaluate is
whether any of the tendons are so highly stressed as to
have yielded or broken. It’s helpful to use the actual
values for breaking strength and yield that are obtained
from the mill certificates, as these values are often higher
than the minimum values specified in ASTM A416/A416M.
While referencing the mill certificates, you can also check the
actual value of the modulus of elasticity for this strand and
compare it with the value used in the original calculations.
Next, evaluate the condition of the affected
member(s), particularly with regard to cracking or
excessive camber. Excess elongations may also be the
result of a coefficient of friction smaller than that
assumed in the calculations; generally this is not a
structural problem. Evaluate the affected member
taking the excess post-tensioning force into consideration.
Provided there is no damage to the structure, over- ACI member Jim Rogers is a Consultant in
stressed tendons are best left as is. Detensioning Phoenix, AZ, where he serves as the
tendons is extremely dangerous to workers, and Director of the Structural Engineers
detensioning an overstressed tendon will almost always Association of Arizona and the ACI Arizona
result in breakage or yielding. Typically, the excess force Chapter. He is also a Faculty Associate at
is not a problem to the structure. Arizona State University, where he teaches
concrete, post-tensioning, and safety
Summary courses in the Del E. Webb School of
Review this report promptly so as not to cause Construction. He has more than 25 years
delays in the field. Use the report to identify potential of experience in the evaluation and construction of concrete
problems and demand solutions from the field right structures and post-tensioning systems as well as in labor
away to avoid having the problems repeated in the relations and management of associations and certification
next placement. This report is not only a record of programs. He is Secretary of ACI Committee 332, Residential
the elongations, but also of the number of tendons Concrete Work; a member of Joint ACI-ASCE Committee 423,
that are actually installed—make sure there are no Prestressed Concrete; and a member of the ACI Faculty
missing tendons. Network and the ACI Technical Activities Committee
Pay particular attention to tendons that were to be Construction Standards Committee. He was previously the
stressed at both ends—make sure elongation measurements Director of Certification Programs and Construction Technology
are recorded at both ends. It’s common to measure for the Post-Tensioning Institute.
zero elongation at the second end (stressing was done
to proper force, wedges lifted off, but no additional
elongation is measured), but they must record the zero
elongation. A blank column is an indication that they
may not have stressed the second end as required to
equalize the force in longer tendons.
Broken tendons can typically be replaced; omitted
tendons require additional analysis. Overstressed
tendons that have not broken or yielded and are not
causing damage to the structure can generally be left
as-is. Detensioning overstressed tendons is unnecessary in
most cases. It can also be dangerous and probably
can’t be done without breaking the tendon.

References
1. International Building Code, International Code Council, Inc.,
Country Club Hills, IL, 2009, 676 pp.
2. ACI Committee 318, “Building Code Requirements for Structural
Concrete (ACI 318-08) and Commentary,” American Concrete
Institute, Farmington Hills, MI, 2008, 473 pp.
3. ACI Committee 301, “Specifications for Structural Concrete
(ACI 301-05),” American Concrete Institute, Farmington Hills, MI,
2005, 49 pp.
4. Joint ACI-ASCE Committee 423, “Specification for Unbonded
Single-Strand Tendons (ACI 423.6-01/423.6R-01) and Commentary,”
American Concrete Institute, Farmington Hills, MI, 2001, 29 pp.

Note: Additional information on the ASTM standard discussed in

this article can be found at www.astm.org.

Selected for reader interest by the editors.

Concrete international / February 2011 65