Practical Aspects of PSC

IRSE Phase II
Course
 What is Pre Stressing ?
• It is
intentional application of a
predetermined force on a system
for resisting the internal stresses
due to external loads.

P P
 Thus PSC…….
…is the special reinforced concrete which
makes use of the intrinsic properties of steel
and concrete i.e. using the properties they are
good at
CONCRETE in compression
STEEL in tension
 PSC is called Active concrete
• Because steel is tensioned to compress the
concrete so that there is no or hardly any
tension in concrete under the service loads
• This system needs high strength concrete
(brittle) and high tensile steel (ductile)
• Makes effective use of modern high strength
materials
 In-spite of the good designs…
• There will be problems in the construction due to
• Improper understanding or lack of understanding of
the
• basic principles
• Right method of the application of the principles
• Practical aspects of execution (because everything can’t be
reduced to writing)
• In fact the failures enlighten us to highlight the
inconsistencies between assumptions on the paper
and the understanding in the field
 Practical problems and remedies
• Specifications of works are based on the theory and
also to a large extent on observations from minor to
major deformations, observed in already executed
works.

• There are many factors which are too difficult to be

precisely laid down. In such cases the decisions are
based on discretion or intuition of the Engineer-in-
Charge or the field executive
 Practical problems and remedies
Broadly there are following four causes of failures.
1. Defective design.
2. Faulty methods or wrong sequence of construction.
3. Natural causes, such as, unanticipated floods, scouring
and settlement of foundations, etc.
4. Sub-standard specifications.

• Majority of the cases of failures are found to be on

account of (2) and (3) above.
 PRE-STRESSING STEEL

• Uncoated Stress Relieved Strand As Per IS

:6006
• Uncoated Stress Relieved Low Relaxation
Strands to IS : 14268
• Hard Drawn Plain Steel Wires ( Cold Drawn
Stress Relieved Wires) to IS :1785(part-I) 1983
• High Tensile Steel Bars to IS: 2090
 PROPERTIES

TWO WIRE STRAND

THREE WIRE STRAND

• THE TWO WIRE AND THREE WIRE STRANDS ARE DESIGNATED BY

NUMBER OF ELEMENTAL WIRES AND DIA. OF ELEMENTAL WIRES.
• Nomenclature A-B
– A REPRESENTS NO. OF WIRES IN THE STRAND
– B REPRESENTS DIA. OF INDIVIDUAL WIRE IN THE STRAND
 PROPERTIES
• SEVEN WIRE STRAND

– Outer wires enclose inner wire in a helix with a

uniform pitch of 12 to 16 times nominal
diameter
– Nomenclature - A-B
– A REPRESENTS NO. OF WIRES IN THE STRAND
– B REPRESENTS NOMINAL DIA. OF STRANDS
 PROPERTIES

• THE STRAND SHALL BE EITHER CLASS I OR CLASS II

DEPENDING UPON THE BREKING STRENGTH OF
STRAND.THE BREAKING STRENGTH OF CLASS II
STRAND IS MORE.

• THE TOTAL ELONGATION UNDER LOAD SHALL

NOT BE LESS THAN 3.5%.
Detailing of Reinforcement and
Cables
 Cable Layout
• Cable layout means
– Deciding about the location of cable at various section
• Vertical profile
• Horizontal profile
– The locations between which the cable will be in
straight and on curve
• Working out the ordinates at every meter and at
every change of curvature from curved to straight
and vice versa in vertical as well horizontal plane
 Importance of Cable Layout
• Proper moment resisting couple so as to
– Carry the dead and live load moments
– Not to induce tension in the concrete under dead
load as well as live load
• Local Imperfections
– Cause increase in the losses due to friction on
account of the wobble effect
 Loss due to Friction (Wobble)
The permissible
tolerance in the
location of the pre-
stressing tendons
(sheathing duct)
shall be ± 5 mm
Cable Profile and Ordinate details for half span
END BLOCK DEATAILS
 How Proper Positioning of Cable is
ensured
• Cable tends to sag due to its self weight if not
supported properly on reinforcement chairs
and supports
• Cable tends to float and move upwards due to
buoyancy effect when concrete is poured (and
is in liquid form), if not tied down properly
• So cable has to be secured against downward
as well as upward movement unlike
reinforcement
 What else is important
• The angle of the cable at the end
– To provide the proper force
– Not to induce unintended forces causing tensions
in the direction not catered to for in design
• This can be ensured and checked only at the
time of fabrication of shuttering for end block
 What else is important?
• Sequencing of the stressing operations in
Post-tensioned construction is important and
that given in the drawing should be followed.
• If not given in the drawing this should be
asked for from the designer.
Why Reinforcement is required in PSC
• In the end block
– To take the local transverse tension around the
tendon behind the anchorage
– To cater for the tension developed between two
or more anchorages, which tends to split the
member
Why Reinforcement is required in PSC
• In the web for carrying shear
• Shear is carried in PSC by
– the vertical component of tendon
– the concrete section
– vertical reinforcement in the form of stirrups
Why Reinforcement is required in PSC
• When the concrete section is sufficient to take
the shear, theoretically no web reinforcement
is required
• This is seldom the case and shear
reinforcement in the form of vertical stirrups
is provided
Vertical Shear
links
Why Reinforcement is required in PSC
• At the junction of the web and the flange
– As shear connectors for transferring the forces for
enabling the member to carrying the moment
– These are required between the bottom flange
and the web
– As well as between the top flange and the web
Shear
Connectors
Why Reinforcement is required in PSC
• Over the bearing area
• This is required to distribute the stresses due
to distribute the reaction to the larger section
of the concrete
 Material test data
4. Strand /wire coil no. =
Tested UTS value =

5. Design Area of Cable (Ad ) = mm2

Measured Area of Cable (Am ) = mm2

6. Design Value of E (Ed) = kg/cm2

Measured Value of E (Em) = kg/cm2
7. Modified elongation :

dXAdXEd
m  mm
A XE m m

8. Jack Area (Aj ) = cm2

9. Design jack efficiency (nd) =
10. Measured jack efficiency ( nf ) = (as per certificate)

11. Pre-stressing design force (Pd ) = t x 103 kg

12. Modified pressure = Pd /Aj x nd /nf kg/cm2
STRESSING OF CABLES
 LOSS DURING ANCHORAGE
• This loss
– occurs when Pre-stressing force is
transferred from tensioning equipment
to anchorage.
– It is particularly important in short
members
– It should be cross checked at site &
compared with the values adopted by
designer
– ( it depends on type of anchorage and
pre stressing system)
 FUTURE CABLES
• For easy installation at later date
• Made in box girder to cater for increased
pre-stress force
• Provision of 15% (minimum) of design
pre-stressing force.
EFFECT OF PRESTRESS
 Other Important Issues
• Proper Storage of the HTS – HTS coils should
be stored in a closed go-down to protect it
from the harmful effects of atmosphere and
protect it from corrosion
• Use of water soluble oil coating – Insist on the
factory application of the water soluble oil
coating on the HTS to prevent corrosion
 Other Important Issues
• HTS should be handled with great care like a
baby so that it does not get a cut or even a
minor nick. The handling should be done on
raised supports avoiding dragging on ground.
• Cable should be grouted after stressing
without delay – and in no case it be allowed to
remain un-grouted after 7 days of stressing.
Difference between pressure and
elongation
The
difference
between the
elongation
and the
pressure
should not be
more than
5%
 Other Important Issues
• Grouting of the ducts – Non shrink grout or
non shrink admixture to be used (but take
care to use admixtures that do not cause
corrosion like Aluminum salts
• For longer Girders, it is preferable to provide
Air Vents to release trapped air and ensure
complete filling of the ducts with grout.
 Other Important Issues
• Cutting of HTS after pre-
stressing – HTS should be
cut using the abrasive disc
cutters and in no case using
the gas cutting
• Ends of the HTS after
cutting should be protected
and should be buried in rich
concrete ensuring covering
of the end of the end block
in rich concrete
 Windows in Forms
• Windows/openings should be left
in the formwork for vibration of
the concrete in case of tall
members like web.
• Checking by wooden mallet
should be done continuously
during the concreting particularly
at the difficult locations to ensure
proper concreting
 Practical problems and remedies
• Problem: Cracks in pre-cast pre-stressed girders in
stacking yard, girders were supported such that part of
girder length was overhanging.

• Solution: Stacking was improved. One of the randomly

selected girders was tested to its ultimate load &
found satisfactory. All girders were used.
 Practical problems and remedies
• Problem: Cracks in cast-in-situ pre-stressed deck as pre-stressing
was started after 3 Calendar days as per drawing note.

• Reason: It was winter & the concrete strength gain was not
sufficient to take pre-stressing load. Due to winter the strength gain
was slow.
•  
• Solution: Since than pre-stressing was taken up after testing field
cubes only. Cubes were cured with the parent girder/s only.
 Practical problems and remedies
• Problem: Cracks appeared from deck slab towards end
cross diaphragm window opening.

• Reason: The concrete sections from soffit slab & webs

were pre-stressed while deck was not.

• Solution: Provided closely spaced mild steel surface

reinforcement (6 mm diameter at 75 mm c/c both
ways) and the cracks reduced to acceptable / vanished.
Cracks in deck slab
 Practical problems and remedies
• Problem: Cracks appeared from deck slab towards soffit through webs near end /
intermediate supports.

• Reason: The cable layout over these sections was dipping heavily to take benefit
of vertical shear resisting component without checking stresses in concrete at
respective stage.
•  
• Solution: (1) Cable profiles at ends / intermediate supports were checked with
respect to their vertical component resisting external shear and it was found that
the relief was exceeding the permissible shear stress. (2) The top & bottom most
fiber stresses were also worked out with respective BM and it was found that the
tensile stress at top was exceeding the permissible limit. The cable profiles were
flattened & the cracking problem has vanished.
Profile of prestressed cables
 Practical problems and remedies
• Problem: While pre-stressing from both ends, it is advised through
drawing/s that pre-stressing be carried out simultaneously from
both ends. Hydraulic pressure levels v/s extensions are monitored
with the least possible difference but most of the time not
satisfying the requirements as stipulated.
•  
• Solution: (1) Pre-stress cables from both ends with minimum
difference in hydraulic pressure. (2) Increase hydraulic pressure in
multiples of say 15% to 20%. Unless the lagging end picks up the
same pressure, do not proceed ahead with the leading end. (3) Best
method of both end pre-stressing is, carry out pre-stressing from
one end first & then from the other end. The results at the end of
both end pre-stressing are the same as expected through design
calculations
 Practical problems and remedies
• Problem: Duration and cost of consumables for forms fixing
& removal was not fitting into the duration and budget.
•  
• Solution: Side forms were fabricated in 5 m long x 3.250 m
tall panels and assembled on trolleys in one piece side
shutters to cast 40 m long x 3.25 m tall pre-tensioned pre-
cast girders. It resulted in time & consumable saving and
improved quality. Ladders, walkway platforms, toe boards
& hand railings helped to save on concrete wastage,
improve in supervision & efficiency of workmen.
One piece side forms (3.25 m tall x 40 m long)
with working platforms & hand railings.
Completed rebar cage being shifted
Rebar cage being lowered on pre-cast
bed within one piece side forms for 40
m long span.
One piece side shutters with working platforms,
toe boards, ladders & hand railings
One piece side shutter in position
 Arial view of pre-cast bed for 40 m long pre-
tensioned girders (2 lines each with 3 girders)
 Practical problems and remedies
• Problem: Concreting end block was taking almost 7
calendar days per end, not fitting in completion
schedule.
•  
• Solution: The end block reinforcement cage pre-tied
against jig, anchorages & bearing sleeves and then
launched in its position with the help of crane and
could complete end block within 4 calendar days.
 Shortcomings through permanent
structure design
Shortcoming Remedial Measure
Edge distance from concrete Edge distances should be strictly as
surface per the recommendations of the
In particular it is observed that manufacturers of the strands
along edges and corners bursting
of concrete is observed due to
reduced clear cover. The designer
giving priority to HT steel without
consideration to reinforcement
clear cover.
 Shortcomings through permanent
structure design
Shortcoming Remedial Measure
Inadequate information & Shortening and hogging up of girder
precautions provided on drawings, after release of pre-stress be made
like shortening and hogging up of available in drawings.
girder after release of pre-stress.
Negative moment at the centre of Provision of additional reinforcement to
span and at the support over the pier accommodate negative moment
cap due to non availability of the
reinforcement steel in these zones,
results in cracks to the girder
 Shortcomings through Execution
Shortcomings
Honeycombing in girder bottom
flange.
Form work for in-situ deck slab
Remedial Measure
Bottom bulb top slope should be
steeper (1H :3V), to allow entrapped
air to get escaped.
Even if it leads to additional cost one
should go for this steeper bottom bulb
top slope
•Intermediate gaps between psc
girders be provided with sacrificial rcc
planks.
•Cantilever deck slab be avoided by
matching edge girders with deck slab
edge.
•For cantilever deck slab above is not
possible and a traveling form set be
used.
One piece cantilever deck slab forms
on launching girder (2.25 m wide x 40
m long)
Cantilever deck slab forms on launching girder (2.25 m
wide x 40 m long) to aligned for 2 spans at a time
Cantilever deck slab forms on launching girder (2.25 m
wide x 40 m long) completed cantilever deck slabs