STRESSING AND GROUTING

PROCEDURE
What is prestressing?
 Prestressing 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 Prestressed, by
mechanical means.

 Type of Prestressing System

Prestressing System can be classified by two basic methods, as under:-
a. Pre-Tensioning
b. Post-Tensioning.

 Pre-Tensioning - is a method where Prestressing 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.
 Post-Tensioning - is a method where Prestressing 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 Prestressing 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.

 Anchorage System-

Prestressing 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:
 Nominal Breaking Strength
 (a) 15.2mm strand = 260.7 KN
 (b) 12.7mm strand= 183.7 KN
 Prestressing Anchorages

 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.

 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.

 Grips & Circlips - This is a tapered shaped components made out of Alloy Carbon Steel and
subsequently hardened & tempered. These grips are slitted in three equal parts to work like
a split jaws and contains serrations inside.
 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
 Stressing Operations-
A) Fixing of Anchorages-

 Fixing of bearing plates and wedges is done before stressing. It is ensured that the tapered
holes in bearing plates and wedges are free of rust and oil.

 Insert the protruding length into the tapered holes provided in the bearing plate.

 Slightly rotate the bearing plate to minimize the intermingling of H.T. strands near the end
block portion.

 Install the wedges over the strands and push them with a hammering pipe into the tapered
hole of the bearing plate.
 B) General Operations-
 Sequence of stressing operations shall be worked out once the stressing schedule duly
approved by the consultant is made available.

 Stressing Jack with collar plate shall be carefully seated in position. An initial seating load of
1 ton shall be applied.

 Initially, a load of 1/3rd the maximum prestressing force shall be applied to remove slackness
in the cable, if any.

 Elongation measurement shall be made for the remaining 2/3rd load & actual elongation for
the final prestressing force shall be obtained by calculation or by graphically.

 Prestressing force shall be applied in increment of 50 tones from one end of the cable.

 Strands of the cable shall be monitored by the both Jack force and through actual elongation.

 Based on the actual values of C/S area and E value of the prestressing strands, corrections
shall be applied to be theoretical elongation given in the stressing schedule in order to
obtained the true theoretical elongation.
 C) Acceptance criteria-
 If at a specified Jack Pressure required elongation is not achieved, the tensioning may be
continue until the required elongation is reached. However, at no stage the Jack pressure shall
be more than 5% of the pressure indicated in the stressing schedule.

 If at a specified Elongation required Jack Pressure is not achieved, the tensioning may be
continue until the required Jack Pressure is reached. However, at no stage the Elongation shall
be more than 5% of the Elongation indicated in the stressing schedule after applying
necessary correction for actual ‘A’ and ‘E’ values.

D) After completion of the stressing work, the cable shall be put under observation for 24
hours for slippage of strands. If any slippage is observed, the observation shall be submitted
to designer for their review and approval.
Calculation sheet for Prestressing
Sample Calculation sheet for Pre tensioning
Zero Correction- Zero correction is the elongation develop during removal of slack
between 0 to 50 bars of force interval.
Stressing record sheet
Grouting
Grouting-

 The purpose of Grouting the cable is to provide permanent protection to the high
tensile steel against corrosion & develop bond between prestressing steel and
surrounding concrete. The grout ensures encasement of high tensile steel for corrosion
protection and fill the duct space to prevent ingress of water/ air. Use of proper
plasticizer in grout would results in improved workability and reduce w/c ratio. Proper
selection of grouting method will assure that the ducts are adequately filled.
Grouting Materials-

 Water- The w/c ratio shall not exceed 0.45. Seawater shall not be used.

 Cement- Cement shall have no false setting phenomenon and shall be at a temperature less
than 25⁰ C at the time of grout. Chilled water should be used to maintain the temperature.

 Admixture- grout admixture shall be balanced blend of expanding fluidifying and water
reducing agent & containing no ingredients causing steel corrosion. Suitable admixtures shall
be used to increase the workability.( Sika Intraplast NN 0.5% by weight of cement Or Cebex
200 0.225 kg per bag)
 Grouting operation-

 The cable duct shall be filled with Lime water in order to clean rust, oil and other foreign
materials. Afterword the same shall be flushed with water.

 The Grout mix shall be pumped at pressure of at least 4-5 kg/cm2 from one end and the water
shall be displaced from the other end.

 Once the grout reaches the other end, the consistency shall be checked with the flow cone.
After getting the required consistency the value at the outlet end shall be closed.
Record sheet for grouting
Thank You!