CT 3 +5 prestressing b+

1
wedges
barrel
Anchorage
casting
tendon

PRESTRESSING
A very common confusion is
between the terms “prestress” and
“pretension”.
-Many people take “prestress” to
mean “pretension”.
-To them “prestressed concrete
beam” means a prestressed
concrete beam produced by
pretensioning method. 2

1. The correct term for this is
“pretensioned prestressed concrete
beam”.
2. Similarly a prestressed concrete beam
produced by post-tensioning
method is called a “post-tensioned
prestressed concrete beam”.
3. As we have noted, since
pretensioning rarely used for cast-in-
situ construction, any “pretensioned
prestressed concrete” member must
be precast.
3

4. However, it will be necessary to use
the term “precast post-tensioned
prestressed concrete” to fully describe
a precast prestressed concrete
member produced by post-tensioning
method.
5.Thus “prestressed concrete” beam
can be produced by either
pretensioning or post-tensioning.
4

1. Introduction
The pre-stressing and pre-casting of
concrete are inter-related features of the
modern building industry.
Through the application of imaginative
design and quality control, they have, since
the 1930’s, had an increasing impact on
architectural and construction procedures.
5

Definitions
Prestressed Concrete
Prestressing of concrete is defined as the
application of compressive stresses to concrete
members.
Those zones of the member ultimately required to
carry tensile stresses under working load conditions
are given an initial compressive stress before the
application of working loads so that the tensile
stresses developed by these working loads are
balanced by induced compressive strength.
6

Prestress can be applied in two ways - Pre-
tensioning or Post-tensioning.
Pre-tensioning
In pretensioning, the steel is stretched
before the concrete is placed.
High-strength steel tendons are placed
between two abutments and stretched
to 70 to 80% of their ultimate strength.
Concrete is poured into moulds around
the tendons and allowed to cure.
7

8
AbutmentWire mesh as
reinforcement
Tendon

It is usual in pretensioning factories to locate the
abutments of the stressing bed a considerable
distance apart so that a number of similar units
can be stressed at the same time, end to end
using the same tendon.
This arrangement is called the "Long Line
Process".
After pouring, the concrete is cured so that the
necessary strength and bond between the steel
and concrete has developed in 8 to 20 hours
9

10
Hydraulic jack prestressing the
tendon

12
HYDRAULIC JACK FOR STRESSING THE
TENDON

13
Tendon
Abutment
Wedge to prevent
the tendon from
pulling back
Hydraulic jack

Pre-tensioned concrete is cast around already
tensioned tendons.
This method produces a good bond between
the tendon and concrete, which both protects
the tendon from corrosion and allows for
direct transfer of tension.
The cured concrete adheres and bonds to the
bars and when the tension is released it is
transferred to the concrete as compression by
static friction.
14

Once the concrete reaches the required
strength, the stretching forces are
released.
As the steel reacts to regain its original
length, the tensile stresses are
translated into a compressive stress in
the concrete.
Typical products for pretensioned
concrete are roof or floor slabs, piles,
lintels, beams, bridge girders, wall
panels, and railroad sleepers.
15

However, it requires stout anchoring points
between which the tendon is to be stretched
and the tendons are usually in a straight line.
Thus, most pre-tensioned concrete elements
are prefabricated in a factory and must be
transported to the construction site, which
limits their size.
16

•The combination of high strength steel – to resist
tensile stress – and concrete – to provide
compressive strength and durability – make this
composite material adaptable to many situations,
especially the design and construction of bridges.

In post-tensioning, the steel is
stretched after the concrete hardens.
Concrete is cast around, but not in
contact with un-stretched steel.
In many cases, ducts or sheathing are
formed in the concrete unit using thin
walled steel or plastic forms.
Once the concrete has hardened to the
required strength, the steel tendons are
inserted and stretched against the ends
of the unit and anchored off externally,
placing the concrete into compression.20

24
Steel duct
Tendons
Metal
mould
To be filled with grout

Post-tensioned concrete is used for
cast-in-place concrete and for bridges,
large girders, floor slabs, shells, roofs,
and pavements.
The tendons are then normally grouted
in place.
Prestressed concrete has experienced
greatest growth in the field of
commercial buildings.
26

By design, unbonded tendons have a continuous
plastic sheathing to prevent the strand from
bonding with the concrete along its length.
This sheathing serves as the bond breaker;
provides protection during handling, shipping,
and construction; and limits intrusion of
corrosive elements.
Corrosion inhibiting grease coats the strands to
reduce friction between the strand and the
sheathing during stressing.
27

The forces in the stressed tendon is transferred to
the concrete via serrated wedges that lock into
anchor plates provided at its ends.
ends.
Anchors are classified as either live (stressing)
ends, or dead ends.
Dead end anchors are embedded into the
concrete and will not be stressed.
These anchors are mounted to the tendon at the
fabrication plant.
28

Live end tendons are mounted and stressed in the
field.
Each tendon is stressed individually and has its
own anchor plate (thus, mono strand).
32
Anchor
wedge
Tendon
Duct
/sheathing

33
DIFFERENT TYPES OF
ANCHORAGE
SINGLE
TENDON
THREE TENDONS

Because of post-tensioning’s ability to balance
loads and greatly reduce service load deflections,
there is a 25 percent to 35 percent reduction in
slab thickness in post-tensioned structures
compared with mild reinforced structures.
Therefore, in addition to the ability to span
further, the reduced structural depth economizes
material quantities for the slabs and
consequently the columns and foundations
34

Tendons for building construction usually are
placed with a parabolic vertical profile to
counteract a portion of the gravity loads on the
structure.
The ends of the tendons usually are located at the
section’s neutral axis (mid-height for a slab), so as
to not induce additional moment at the anchors.
35

In building construction, minimum cover
requirements per building codes are sufficient for
slabs not exposed to a corrosive environment.
Fire protection often governs the minimum
concrete cover of these structures.
36
Recommended rebar
and tendon layout at
columns uses No. 4
bars for top steel
reinforcement to
match the 1/2-inch
tendon diameter

37
Bonded tendons follow column lines with
transverse tendons spaced uniformly.

3.Advanages of Prestressing
3.1 General Advantages
The use of prestressed concrete offers distinct
advantages over ordinary reinforced concrete. These
advantages can be briefly listed as follows:
1.Prestressing minimises the effect of cracks in
concrete elements by holding the concrete in
compression.
2.Prestressing allows reduced beam and floor depths
to be achieved for equivalent design strengths.
3.Prestressed concrete is resilient and will recover
from the effects of a greater degree of overload than
any other structural material.
38

4. If the member is subject to overload, cracks,
which may develop, will close up on removal of
the overload.
5. Prestressing enables both entire structural
elements and structures to be formed from a
number of precast units, e.g. Segmented and
Modular Construction.
6. Lighter elements permit the use of longer
spanning members with a high strength to
weight characteristic.
39

7. The ability to control deflections in prestressed
beams and slabs permits longer spans to be
achieved.
8. Prestressing permits a more efficient usage of
steel and enables the economic use of high
tensile steels and high strength concrete.
9. The reduced structural depth economizes
material quantities for the slabs and
consequently the columns and foundations.
40

4. Fundamentals of Prestressing
4.1 The Tensile Strength of Concrete
The tensile strength of unreinforced concrete is
equal to about 10% of its compressive strength.
Reinforced concrete design has in the past
neglected the tensile strength of unreinforced
concrete as being too unreliable.
Cracks in the unreinforced concrete occur for
many reasons and destroy the tensile capability.
41

With prestressed concrete design however, the
tensile strength of concrete is not neglected.
In certain applications it is used as part of the
design for service loadings.
In ordinary reinforced concrete, steel bars are
introduced to overcome this low tensile strength.
They resist tensile forces and limit the width of
cracks that will develop under design loadings.
Reinforced concrete is thus designed assuming
the concrete to be cracked and unable to carry
any tensile force.
Prestressing gives crack-free construction by
placing the concrete in compression before the
application of service loads.
42

For the beam then to function properly a
compression force must be applied as in.
The beam is then "prestressed" with forces acting
in an opposite direction to those induced by
loading.
The effect of the longitudinal prestressing force is
thus to produce pre-compression in the beam
before external downward loads are applied.
The application of the external downward load
merely reduces the proportion of precompression
acting in the tensile zone of the beam.
43

44
Different types of
anchorage use for
post-tensioning

The Position of the Prestressing Force
Prestressing can be used to best advantage by
varying the position of the prestress force.
When the prestress is applied on the centroid of
the cross-section a uniform compression is
obtained. Consider the stress state of the beam
47

 Thus by varying the position of the
compressive force we can reduce the
prestress force required, reduce the concrete
strength required and sometimes reduce the
cross sectional area.
 Changes in cross sections such as using T or I
or channel sections rather than rectangular
sections can lead to further economies.
48

The Effect of Prestress on Beam Deflection
It is obvious that the designer should, unless
there are special circumstances, choose the
eccentrically applied prestress.
Consider again the non-prestressed beam.
Under external loads the beam deflects to a
profile similar to that exaggerated.
49

By applying prestress eccentrically a deflection is
induced. When the prestress is applied in the
lower portion of the beam, the deflection is
upwards producing a hogging profile.
50

By applying the loads to our prestressed beam, the
final deflection shape produced is a sum as shown in
below.
Reductions in deflections under working loads can
then be achieved by suitable eccentric prestressing.
In long span members this is the controlling factor in
the choice of the construction concept an technique
employed.
51

Prestress Losses
Most materials to varying degrees are subject to
"creep", i.e. under a sustained permanent load
the material tends to develop some small amount
of plasticity and will not return completely to its
original shape.
There has been an irreversible deformation or
permanent set.
This is known as "creep" Shrinkage of concrete
and "creep" of concrete and of steel
reinforcement are potential sources of prestress
loss and are provided for in the design of
prestressed concrete.
52

With pre-tensioning, shrinkage starts as
soon as the concrete is poured whereas with
post-tensioned concrete, there is an
opportunity for the member to experience
part of its shrinkage prior to tensioning of
the tendon, thus pre-compression loss from
concrete shrinkage is less.
53

Creep:
With prestressing of concrete the effect is to
compress and shorten the concrete.
This shortening must be added to that of concrete
shrinkage.
In the tensioned steel tendons the effect of
"creep’’ is to lengthen the tendon causing further
stress loss.
Allowance must be made in the design process for
these losses. Various formulae are available.
54

55
1. Concrete, like all other materials, will slightly
change in volume when it dries out.
2. In typical concrete this change amounts to
about 500 millionths.
3. Translated into dimensions-this is about 1/16
of an inch in 10 feet (.4 cm in 3 meters).
4. The reason that contractors put joints in
concrete pavements and floors is to allow the
concrete to crack in a neat, straight line at the
joint when the volume of the concrete
changes due to shrinkage.

Pull-in:
With all prestressing systems employing wedge
type gripping devices, some degree of pull-in at
either or both ends of a pre-tensioning bed or
post-tensioned member can be expected.
In normal operation, for most devices in common
use, this pull-in is between 3mm and 13mm and
allowance is made when tensioning the tendons
to accommodate this.
56

Materials
Steel
Early in the development of prestressing it was
found that because of its low limit of elasticity
ordinary reinforcing steel could not provide
sufficient elongation to counter concrete
shortening due to creep and shrinkage. it is
necessary to use the high tensile steels which
were developed to produce a large elongation
when tensioned.
57

This ensures that there is sufficient elongation
reserve to maintain the desired pre-compression.
The relationship between the amount of load, or
stress, in a material and the stretch, or strain,
which the material undergoes while it is being
loaded is depicted by a stress-strain curve.
At any given stress there is a corresponding strain.
Strain is defined as the elongation of a member
divided by the length of the member
58

The stress-strain properties of some grades
of steel commonly encountered in
construction.
It is apparent from these relationships that
considerable variation exists between the
properties of these steels.
All grades of steel have one feature in
common: the relationship between stress
and strain is a straight line below a certain
stress.
59

These high strength steels achieve their strength
largely through the use of special compositions in
conjunction with cold working.
Concrete
To accommodate the degree of compression
imposed by the tensioning tendons and to
minimise prestress losses, a high strength
concrete with low shrinkage properties is
required.
Units employing high strength concrete are most
successfully cast under controlled factory
conditions. 60

Prestressing Methods
General
Methods of prestressing concrete fall into two
broad categories differentiated by the stage at
which the prestress is applied.
That is, whether the steel is pre-tensioned or
post-tensioned.
From the definitions - pre-tensioning is stated as
"the application before casting, of a tensile force
to high tensile steel tendons around which the
concrete is cast.
61

63
Unbonded tendons follow column lines with
transverse tendons spaced uniformly.

64
PLACING OF SELF COMPACTING CONCRETE TO CAST THE FLOOR SLAB

Types of Tendon
There are three basic types of tendon used in the
prestressing of concrete:
Bars of high strength alloy steel.
These bar type tendons are used in certain types
of post-tensioning systems.
Bars up to 40mm diameter are used and the
alloy steel from which they are made has a
yield stress (fy Fig.5) in the order of 620
MPa.
65

This gives bar tendons a lower strength to
weight ratio than either wires or strands, but
when employed with threaded anchorages
has the advantages of eliminating the
possibility of pull-in at the anchorages and
of reducing anchorage costs
66
Thread Bar
Plain Bar

The geometry of the thread is specifically
designed to ensure ease of use on site,
providing fast, accurate and easy tightening.
Bars are available in maximum lengths of
11.7 meters.
Beyond this length, extension sleeves allow
bars to be connected together.
70

Wire, mainly used in post-tensioning systems for
prestressing concrete, is cold drawn and stress
relieved with a yield stress of about 1300 MPa.
Wire diameters most commonly used are 5mm,
7mm, and 8mm.
Strand, which is used in both pre and post-
tensioning is made by winding seven cold drawn
wires together on a stranding machine.
Six wires are wound in a helix around a centre
wire which remains straight.
71

Strands of 19 or 37 wires are formed by adding
subsequent layers of wire.
Most pre-tensioning systems are based on the
use of standard seven wire stress relieved strands
conforming to BS3617:"Seven Wire steel strand
for Prestressed concrete."
With wire tendons and strands, it may be
desirable to form a cable to cope with the
stressing requirements of large post-tensioning
applications.
72

74
… and the development of 7-wire strand to replace
individual wires
Tendons

Once the concrete has hardened, the
tendons are tensioned by hydraulic jacks that
react against the concrete member itself.
When the tendons have stretched
sufficiently, according to the design forces,
they are wedged in position and maintain
tension after the jacks are removed,
transferring pressure to the concrete. The
duct is then grouted to protect the tendons
from corrosion.
75

After the concrete has reached a suitable transfer
strength, the individual strands have a specified
load applied by calibrated jacks.
The duct is filled with a water/cement grout
mixture to ensure that the system is bonded and
corrosion protection is maintained in service.
Applications for the Structural Systems Slab
PostTensioning System include:
• Low to high rise residential and commercial
buildings
78

82
View of coupled and fully stressed
external tendons

Construction
The typical construction sequence is as follows;
• Erect formwork
• Install bottom reinforcement
• Install post-tensioning
• Install top reinforcement
• Prepour inspection and pour concrete
• Strip edge forms
• Initial/Partial stressing of tendons
86

• Final/Full stressing of tendons
• Obtain engineers approval and cut off excess
tendon strand
• Grout the tendons
• Strip formwork and back prop as require
87

Cables are formed by arranging wires or strands in
bundles with the wires or strands parallel to each
other.
In use the cable is placed in a preformed duct in the
concrete member to be stressed and tensioned by a
suitable posttensioning method.
Tendons whether bars, wires, strands, or made up
cables may be used either straight or curved.
1.Straight steel tendons are still by far the most
commonly used tendons in pre-tensioned concrete
units.
89

2. Continuously curved tendons are used primarily
in post-tensioning applications.
Cast-in ducts are positioned in the concrete unit
to a continuous curve chosen to suit the varying
bending moment distribution along the members.
90
Straight Tendon Curved Tendon

The anchorages
The anchor devices are designed to anchor the
force in the tendon and transfer it to the structure.
Three types of anchorages are available:
1. Standard anchorages with a nut and washer,
2. Hinge anchorages using a nut with a spherical
seat,
3. Fixed anchorages using a threaded end plate.
All nuts are hot forged.
Also, couplers allow primary bars to be connected
to secondary bars.
91

95
Slab system anchorage components

Pre-Tensioning
Pre-tensioning requires the tensile force to be
maintained in the steel until after the high strength
concrete has been cast and hardened around it.
The tensile force in the stressing steel is resisted by one
of three methods:
1.Abutment method - an anchor block cast in the
ground.
2.Strut method - the bed is designed to act as a strut
without deformation when tensioning forces are
applied.
3.Mould method - tensioning forces are resisted by
strong steel moulds.
96

When the strength has been achieved tendons
can be released and the units cut to length and
removed from the bed
Post-tensioning systems are based on the direct
longitudinal tensioning of a steel tendon from one
or both ends of the concrete member.
The most usual method of post-tensioning is by
cables threaded through ducts in cured concrete.
98

These cables are stressed by hydraulic jacks,
designed for the system in use and the ducts
thoroughly grouted up with cement grout after
stressing has occurred.
Cement grouting is almost always employed
where post-tensioning through ducts is carried
out to:
– Protect the tendon against corrosion by
preventing ingress of moisture.
– Eliminate the danger of loss of prestress due to
long term failure of end anchorages, especially
where moisture or corrosion is present. 99

– To bond the tendon to the structural concrete
thus limiting crack width under overload.
Resistance of Prestressed Concrete
All concrete is incombustible.
In a fire, failure of concrete members usually
occurs due to the progressive loss of strength of
the reinforcing steel or tendons at high
temperatures.
Also the physical properties of some aggregates
used in concrete can change when heated to high
temperatures.
100

Experience and tests have shown however that
ordinary reinforced concrete has greater fire
resistance than structural steel or timber.
Current fire codes recognise this by their
reference to these materials.
Prestressed concrete has been shown to have at
least the same fire resistance as ordinary
reinforced concrete.
Greater cover to the prestressing tendons is
necessary however, as the reduction in strength of
high tensile steel at high temperatures is greater
than that of ordinary mild steel. 101

Applications of Prestressing
General
The construction possibilities of prestressed
concrete are as vast as those of ordinary
reinforced concrete.
Typical applications of prestressing in building and
construction are:
1.Structural components for integration with
ordinary reinforced concrete construction, e.g.
floor slabs, columns, beams.
102

2. Structural components for bridges.
3. Water tanks and reservoirs where water
tightness (i.e. the absence of cracks) is of
paramount importance.
4. Construction components e.g. piles, wall
panels, frames, window mullions, power poles,
fence posts, etc.
5. The construction of relatively slender
structural frames.
6. Major bridges and other structures.
105

Conclusions
Prestressed concrete design and construction is
precise. The high stresses imposed by prestressing
really do occur. The following points should be
carefully considered:
1.To adequately protect against losses of prestress
and to use the materials economically requires
that the initial stresses at prestressing be at the
allowable upper limits of the material. This
imposes high stresses, which the member is
unlikely to experience again during its working
life.
106

CT 3 +5 prestressing b+

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CT 3 +5 prestressing b+