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Prestressed Concrete
Structures
Module 1
Introduction, Prestressing Systems
and Material Properties
Prepared by:
Amlan K Sengupta
Devdas Menon
Indian Institute of Technology Madras
Module 1-c (3
rd
Hour)
Prestressing Systems and Devices
Pre-tensioning Pre tensioning
Introduction
Stages
Advantages & Disadvantages
Devices
Manufacturing of Pre-tensioned Bridge Girders
Self-Equilibrating Systems
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Prestressing Systems and Devices
Introduction
Prestressing Systems and Devices
Prestressing systems have developed over the years
and various companies have patented their products.
Detailed information of the systems is given in the
product catalogues and company brochures.
There are general guidelines of prestressing in g g p g
Section 13 of IS:1343 - 2012. The information given
here is introductory in nature, with emphasis on the
basic concepts of the systems.
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Introduction
Prestressing Systems and Devices
The prestressing systems and devices are described
for the two types of prestressing, pre-tensioning and
post-tensioning, separately.
Pre-tensioning
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Introduction
Pre-tensioning
In pre-tensioning, the tension is applied to the
tendons before casting of the concrete. The stages of
pre-tensioning are described next.
Stages
Pre-tensioning
In pre-tensioning system, the high-strength steel
tendons are pulled between two end abutments (also
called bulkheads) prior to the casting of concrete. The
abutments are fixed at the ends of a prestressing bed.
Once the casted concrete attains the desired strength Once the casted concrete attains the desired strength
for the transfer of prestress, the tendons are cut loose
from the abutments.
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Stages
Pre-tensioning
The prestress is transferred to the concrete from the
tendons, due to the bond at their interface. During the
transfer of prestress, the member undergoes elastic
shortening. If the tendons are located eccentrically, the
member is likely to bend and deflect upwards (camber).
Stages
Pre-tensioning
The various stages of the pre-tensioning operation are
summarised as follows.
1) Anchoring of tendons against the end abutments
2) Placing of jacks
3) Applying tension to the tendons
Continued
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Stages (continued)
Pre-tensioning
4) Casting of concrete
5) Curing of concrete
6) Cutting of the tendons
Transfer of prestress
Loss due to elastic shortening.
The stages are shown schematically in the following
figures.
Stages
Pre-tensioning
End
Prestressing bed
Steel tendon
End
abutment
Jack
Anchoring
Mould
Fig. 1c-1 Applying tension to tendons
Anchoring
device
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Pre-tensioning
Stages
Fig. 1c-2 Casting of concrete
Pre-tensioning
Stages
Cutting of
tendon
Fig. 1c-3 Transferring of prestress
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Stages
Pre-tensioning
The following figure explains the operation of pre-
tensioning through various stages by animation.
Fig 1c-4 Pre-tensioning of a beam
Prestressing bed
Advantages
Pre-tensioning
The advantages of pre-tensioning as compared to post-
tensioning are as follows.
Suitable for precast members produced in bulk.
Absence of large anchorage device.
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Disadvantages
Pre-tensioning
The relative disadvantages are as follows.
Requirement of prestressing bed.
Waiting period in prestressing bed, before concrete
attains sufficient strength.
Requires good bond between concrete and steel over Requires good bond between concrete and steel over
the transmission length.
Devices
Pre-tensioning
The essential devices for pre-tensioning are as follows.
Prestressing bed with end abutments
Mould / shuttering
Jack Jack
Anchoring device
Harping device (optional)
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Jacks
Pre-tensioning
The jacks are used to apply tension to the tendons.
Hydraulic jacks are commonly used. These jacks work
on oil pressure generated by a pump. The principle
behind the design of jacks is Pascals law.
Fig 1c-5 Double acting hydraulic jack
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Anchoring Devices
Pre-tensioning
Anchoring devices are often made on the wedge and
friction principle. In pre-tensioned members, the
tendons are to be held in tension during the casting and
hardening of concrete. Here simple and cheap quick-
release grips are generally adopted. Two grips are
placed inside a barrel placed inside a barrel.
Fig 1c-6 Original anchoring device patented by
Eugene Freyssinet
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Fig 1c-7 Chuck assembly for anchoring tendons
(Courtesy: Lin, T. Y. and Burns, N. H.,
Design of Prestressed Concrete Structures )
Pre-tensioning
Harping Devices
The tendons are frequently bent except in cases of The tendons are frequently bent, except in cases of
slabs-on-grade, poles, piles etc. The tendons are bent
(harped) in between the supports with a shallow sag as
shown below.
Harping point Hold up
device
Fig 1c-8 Harping of tendons
a) Before casting of concrete
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Pre-tensioning
Harping Devices
b) After casting of concrete
Fig 1c-9 Harping of tendons (continued)
Harping Devices
Pre-tensioning
The tendons are harped using
special hold-down devices as
shown in the figure.
Fig 1c-10 Hold-down anchor for
harping of tendons (Courtesy:
Nawy, E. G., Prestressed
Concrete: A Fundamental
Approach)
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Devices
Pre-tensioning
Devices
An extension of the previous system is the Hoyer
system. This system is generally used for mass
production. The end abutments are kept sufficient
distance apart, and several members are cast in a p
single line. The shuttering is provided at the sides and
between the members. This system is also called the
Long Line Method.
Devices
Pre-tensioning
Devices
A series of moulds
Fig 1c-11 Schematic representation of Hoyer system
Prestressing bed
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Manufacturing of Pre-tensioned
Bridge Girders
Fig. 1c-12 Precasting yard
(Courtesy: Airport Authority of India)
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Fig. 1c-13 Long-line casting of girders
(Courtesy: Airport Authority of India)
Fig. 1c-14 Prestressing bed
(Courtesy: Airport Authority of India)
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Fig. 1c-15 Fabrication of reinforcing bars
(Courtesy: Airport Authority of India)
Fig. 1c-16 Anchoring of strands
(Courtesy: Airport Authority of India)
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Fig. 1c-17 Stretching of strands
(Courtesy: Airport Authority of India)
Fig. 1c-18 Positioning of shuttering
(Courtesy: Airport Authority of India)
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Fig. 1c-19 Batching plant
(Courtesy: Airport Authority of India)
Fig. 1c-20 Transferring to concrete boom pump
(Courtesy: Airport Authority of India)
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Fig. 1c-21 Pumping of concrete
(Courtesy: Airport Authority of India)
Fig. 1c-22 Placing and compaction of concrete
(Courtesy: Airport Authority of India)
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Fig. 1c-23 Steam curing
(Courtesy: Airport Authority of India)
Fig. 1c-24 Stripping of shuttering
(Courtesy: Airport Authority of India)
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Fig. 1c-25 Lifting from curing chamber
(Courtesy: Airport Authority of India)
Fig. 1c-26 Stacking of girders
(Courtesy: Airport Authority of India)
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Self-Equilibrating Systems
Devices
Pre-tensioning
The abutments should be sufficiently stiff and should
have good foundations. This is usually an expensive
proposition, particularly when large prestressing
forces are required.
Is there a simpler solution?
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Devices
Pre-tensioning
It is possible to avoid transmitting the heavy loads to
foundations, by adopting self-equilibrating systems.
Typically, in laboratory testing, this is done by means of a
tension frame.
Devices
Pre-tensioning
P
Test
specimen
High
strength
steel rods
Loading
jack
Free bodies Plan or Elevation
steel rods
Fig 1c-27 A tension frame
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Pre-tensioning
Devices
The frame that is generally adopted in a pre-tensioning
system is called a stress bench. The concrete mould is
placed within the frame and the tendons are stretched
d h d th b f th f and anchored on the booms of the frame.
Devices
Pre-tensioning
Jack
Threaded rod
Elevation
Mould
Strands
Fig 1c-28 A stress bench
Plan
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Devices
Pre-tensioning
Load by jack
Pl
Load by jack
Fig 1c-29 Free body diagram
Plan
Tension in
strands
Devices
Pre-tensioning
Elevation
Fig 1c-30 The stress bench after casting concrete
Plan
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Devices
Pre-tensioning
The following example of a self-equilibrating system
was demonstrated in the Manufacturing of Railroad
Sleepers .
A similar set-up can be devised in the laboratory to
prepare pre-tensioned specimens.
Fig 1c-31 Travelling pre-tensioning stress bench
(Courtesy: Concrete Products and Construction Co.)
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Summary
Prestressing Systems and Devices
Pre-tensioning Pre tensioning
Introduction
Stages
Advantages & Disadvantages
Devices
Manufacturing of Pre-tensioned Bridge Girders
Self-Equilibrating Systems