Special course on construction of

Pre stressed Concrete

by

K.Narasimhaswamy (GET/Design)
•

RCED 08-02-2011
 Presentation topics
• History of development of pre-stress concrete
• Concept of pre-stress
• Introduction of pre-stress technology in India
• Pre-stressing methods
• Segmental construction
• Extra dosed bridge
• Launching of PSC girders
 History of Reinforced and Pre-stressed
Concrete
• In the mid nineteenth century it was discovered that
iron and later steel bars could be embedded in
concrete to give tensile strength. However RCC
beams and slabs deflect, form cracks at bottom, thus
have shortcomings. Also not economical for spans
above about 18 m.
• In 1930s Eugene Freyssinet invented pre-stressed
concrete. High tensile steel cables were substituted
for steel bars. Cables were tensioned by jacks and
locked to concrete. Thus concrete was compressed
ridding it of cracks improving strength, appearance
and resistance to deterioration.
Contd.
• In short an external compressive force is applied to
the concrete to counter the tensile stresses generated
under the bending moments and shear forces due to
the design load. The concrete can either be fully pre-
stressed or partially pre-stressed allowing some
tension to occur under certain loading conditions.

• The high tensile cables could be designed to counter

deflections of beams and slabs allowing much more
slender structures to be built. Since cables were
many times stronger than the steel bars, fewer were
necessary reducing congestion in the beams, making
them quicker to build and less labor intensive.
Typical RCC beam cross section
 (A) Without Pressing blocks together

(B) With blocks Pressing together

Pre-stressing Building Blocks

Types of Decking
Pre-stressed Concrete Railway Bridge Siliguri.1949
Beams & Cross Diaphragms pre-cast
 Load test of proposed PSC beams
• Load test was conducted in Kalyan yard to
verify behavior under dynamic loads.
• Two 13.4 m long beams were match cast in three
segments each, assembled and pre-stressed.
• Decking was load tested using heaviest b.g.loco .
Engine was made to derail on beams.
• Construction was taken up only after satisfactory
test results.
• Incidentally this is the first match cast segmental
beam.
Siliguri Bridge1949

Precast PSC Beam

13.4 m long, pre-
stressed with
12/5mm cables
Precast Cross
Diaphragms Cross
prestressed
 Pre-stressing Methods
• Pre-tensioning : In this method, tendons are
stressed first to pre-determined tension,
reinforcement and shuttering are assembled, and
thereafter concrete is placed. Tendons are in
direct contact with freshly placed concrete. After
concrete gains adequate strength, tendons are
released and cut at the ends of the beams by means
of a grinding wheel or oxy-acetylene flame in a
particular sequence. At this stage the stress gets
transferred through the bond between concrete and
H.T.steel.
 Pre-tensioning

Requirements:
1) Strands and locking wedges.
2) Dead end and Anchor frame
3) Jacking beam
4) Hydraulic jacks of adequate capacity and extention.
Pre-tensioning system is generally used for pre-cast
construction and for multiple no. of beams in order to
become economical.
 Noida Bridge Project
Multi-strand Stressing Arrangement
•
Noida bridge casting cum stacking yard

Beams of 24m,18m & 12m lengths cast on same bed

 IRC : SP : 71 - 2006
Indian Road Congress has issued a special
publication giving guide lines for design
and construction of pre-cast pre-tensioned
girders for bridges. It has dealt with most of
the aspects in good details.
 Pre-cast Pre-tensioned Girders
Mumbai Flyovers
• Central casting yard for 4
flyovers at Sion, Kurla,
Mankhurd and Vashi
• 448 Girders (18-20m) cast by
long line method
• Pre-stressing with Mono
strand Jack
• Steam cured for gaining
strength of 32MPa.

Turbhe Casting bed

Mankhurd Flyover

Vashi Flyover

Both completed in 12 m
 Pre-tensioning with deflected tendons
As stated in IRC:SP:71 2006 pre-tensioning with
deflected tendons is possible for long span
girders where a mechanism for holding down /
holding up of the tendons and allowing them to
freely move during tensioning operation can be
installed. This may be difficult proposition but
may not be impossible. This is also given in IRS
code (2004) for concrete in bridge construction
vide cl. 7.2.6.3.2.
 Pre-stressing Methods
• Post-tensioning :In this case h. t. steel is
used in the form of cables consisting of a
group of wires or strands. These cables are
passed through m.s. sheathing duct or hdpe
tube and are provided with anchorages at the
ends. Those are assembled in correct profile
along with reinforcement. After fixing the
formwork concrete is placed. Thus cables are
not in contact with concrete. After concrete
gets adequate strength those are stressed and
grouted with neat cement grout.
Typical PSC Beam for Tapi river bridge in Gujarat
Construction of PSC beams on staging trestles
Construction of PSC beams on staging trestles
Concrete in Prestressed
Structures

Minimum Grade M40

Higher Grades Preferred
 Concrete
• Most common values of characteristic strength
for pre-stressed concrete structures are
between 40 & 60 MPa; higher compressive
strength of up to 100 MPa are also used
• M-75 grade concrete used for the JJ flyover in
Mumbai, primarily as a durability measure;
with such high grades of concrete, there is no
need for epoxy coating or similar treatments
 Concrete Grades
• The IRS Concrete Bridge Code (2004) permits use
of concrete up to M-60
• The IRC Bridge Code permits up to M-80; the IRC
has also brought out Guidelines for use of High
Strength Concrete (M-60 to M-80)
• More economical to use higher strengths for pre-
stressed concrete beams
• In the developed countries, strengths up to 120
MPa are common
 Workability of Concrete
• Concrete pumps or conveyors are commonly used
• Slump requirements : about 100 – 120 mm at the
pouring point
• Modern concretes incorporate chemical admixtures
for improving the workability of the concrete
(slump) since there is loss of workability between
the concrete leaving the batching plant and concrete
reaching at the pour point
 Workability of Concrete
• The IRS Code provides for 25-75mm slump for
medium workability or 75-125 mm for high
workability
• Slump test is more commonly used
• Improved workability obtained when rounded
aggregates are used; river gravel forms an excellent
source of aggregates for pre-stressed concrete
structures
 Aggregates – River Gravel
• As per the IRS Code, “Aggregates shall comply
with the requirements of IS 383
• IS 383 specifies aggregates from natural sources
(river gravel), crushed aggregates or a combination
of both
• A large number of pre-stressed concrete bridges
were constructed in the past utilizing river gravel as
coarse aggregate, including the first bridges built
by Railways in 1949
 Aggregates – River Gravel
• The practice of using river gravel appears to have
been discontinued by the present day Engineers, for
no valid reasons
• Many Railway tenders explicitly prohibit the use
of river gravel, despite the IRS Code
• Use of gravel as aggregate results in less water
demand in concrete & less cement consumption,
due to less surface area
• World wide, high strength concrete uses gravel
 Chloride Content in Concrete
• The IRS Code specifies permissible limit of
500mg/ l for pre-stressed concrete works
• The limit should take into account the chlorides
present in water, cement, coarse and fine
aggregates, mineral and chemical admixtures
• Excess chlorides may be prevented by controlling
the chloride content of the materials of concrete;
however, the governing criteria shall be a check on
chloride content of concrete
 Cement
• The IRS Code specifies that “cement older than 3
months should normally not be used for PSC works
unless the quality is confirmed by tests
• It is highly recommended that cement older than
one month should not be used ; cement is a
hygroscopic material and deteriorates pretty fast
particularly during monsoon
 Concrete Mix Proportioning
• Only Design Mix Concrete should be permitted
• The IRS Code makes a reference to IS 10262; the
IS was prepared about 30 years ago and is
applicable for concrete with only 33 Grade cement
and where no admixtures are used
• Thus IS 10262 is obsolete, not applicable to
present day concrete
• IS 10262 is under revision for the last several
years; the old Code should not be used
 Pre-stressing Steel
• Use High Tensile Steel that permit high
elongations; remain elastic up to relatively high
stresses; have low relaxation
• Most popular is 12.7mm dia. strand with a min.
tensile strength of 1860 MPa
 Pre-stressing Steel
• The wires / strands used for making tendons should
be of low relaxation type; otherwise the long term
losses of pre-stressing may be very high,
jeopardizing the quality of the structure
• IS Code for low relaxation strands -IS:14268
• Designs are made with assumed Modulus of
Elasticity of 195 KN / mm2 ; the actual E value,
either supplied by the manufacturer or tested by the
site should be used, elongation corrected
 Post-tensioning Tendons
• Made of wires, strands or bars
• Bars are tensioned one at a time
• Wires & strands can be tensioned singly or in
groups; in many Systems, 12 wires or strands
forming a tendon is pulled simultaneously
• Tendons carry large forces; 200 – 500 t in bridges
& 1000 t for Nuclear Reactors
• After pre-stressing the tendons are anchored using
proprietary anchorage system
 Post-tensioning
• Tendons are stressed and anchored at the
ends of the concrete member after casting
& hardening of the member
• Ducts of thin steel strips or PVC are placed
before concreting
• The tendons may be pre-placed or threaded
after concreting; after stressing and
anchoring the void between the tendon and
its duct is filled with a mortar grout
 The Pre-stressing Cable
• Cable made up of bundle of HT wires / strands
• Depending on pre-stressing force required, wires or
strands of different diameters are used
• The wires are of 3, 5, 7 or 8mm dia; strands are of
12.7, 15 or 17mm dia.
• Normal strand cables are made of 12 strands; large
force tendons have 13, 19 or 27 strands.
• Small force tendons are made of single wire, bar or
strand or groups of 2 or 3 such elements
 Pre-stressing Cable Protection
• Cables are protected after stressing by grouting
with cement / water or by grease (exceptional)
• Sometimes they are oiled or greased for corrosion
protection in storage or in the duct before grouting
• The Strands or wires are supplied from the factory
in coils of 2-3 t weight. After production the
material is wrapped with gunny / polythene for
corrosion protection during transit to site
 Losses of Pre-stress
Pre-stress losses occur due to following :
• Friction : In a curved duct tendon bears on
inside of curve and friction gets generated as
tendon extends during stressing.
• Anchor set : When load is transferred from jack
to anchorage unit, there is bound to be loss of
extension. The extent of loss depends on type of
tendon and anchorage used.
• Shrinkage : There is loss of pre-stress due to
shrinkage of concrete over a period after
pre-stressing. Contd.
• Elastic shortening of concrete : If the pre-stress
consists of more than one tendon, the tendons
already anchored suffer loss on account of
subsequent stressing of others.
• Creep : The delayed shortening of concrete due
to compression induced by pre-stress affects all
the tendons.
• Relaxation of Steel : Most modern strands have
relaxation limiting to 2.5 per cent of initial
stressing force at 1000 hrs. and that is taken as
total relaxation. Some bars and strands may lose
up to 7 to 8 per cent of their stress due to
relaxation.
 Loss of Pre-stress
• Total loss of pre-stress on account of all the six
items above may work out to even up to 25
percent of the total force applied. Design of the
psc beam is required to cater for these losses.
• Losses on account of shrinkage and creep can be
reduced by allowing the concrete to set for
longer period and attain higher strength before
stressing the cables. This is applicable only for
post-tensioned beams. This however increases the
time cycle and lower turnover. Hence overall
economy must be looked into.
 Losses of Pre-stress
Reason Post-tensioned Pre-tensioned
Friction Yes No
Anchor set Yes Yes
Shrinkage of Yes Yes
concrete
Elastic shortening Yes No
of concrete
Creep of concrete Yes Yes
Relaxation of Yes Yes
steel
Steam Curing Yes Yes
Heat
Pre-stressing Anchorage & Cables
Corrugated Sheathing Duct
 Standard Cable Configurations

Strand dia 12.7 or 15mm

No of strands
7
12
19
27
37
55
 Pre-stressing Cables
From One End / Both Ends
• Cables may be pre-stressed either from one end or
both ends
• With one end pre-stressing, the non-stressing end is
provided with a fixed anchorage; calculation for
elongation made accordingly, taking into account
the differential friction
• One end stressing convenient, recommended for
short and medium length beams up to 50m
 One End Prestressing
Anchorage at non stressing
end (Dead End)
 Installation of the Cable- Sequence
• Place Duct – Install Cable – Stress - Grout
• Internal Prestressing: Corrugated steel / Plastic ducts
placed before concreting
• External Prestressing : Steel tube ducts are used.
Tendons placed outside the concrete
• Each strand is pushed into the duct from one end
after concreting (preferred method) or the tendons
may be loosely laid before concreting
 Precautions during concreting
The sheathing ducts must be watertight so
that the cement grout does not enter the duct
during concreting operation. As a
precaution, already placed tendons are
moved to and fro to ensure that the grout
does not stick and jam the tendons. This is
applicable only for post tensioned tendons.
Stressing Jack for 27 / 15 Cables
SAR 05 Y2k
 Pre-stressing tendons
• Available sizes: Strand dia: 13mm & 15mm
• Tendon Configuration
: 7x13, 12x13, 19x13, 27x13, 37x13, 55x13
: 4x15, 7x15, 12x15, 19x15, 27x15 & 37x15
• HT Steel grades: 1770, 1860 MPa
• Anchorages: both ends / one end
• Couplers for multi-stage tendons
 Prestressing
• Prefer single stage pre-stressing
• Pre-stressing time should be based on concrete
strength; design for pre-stressing losses to suit
• Possible to pre-stress within 48-72 hrs of pre-
stressing, with appropriate mix proportioning
• Pre-stress earliest to avoid risk of unstressed beam
damage due to false work failure
• Monitor both pressures and elongation during
stressing; however locking based on elongation
 Grouting
• Grout after of pre-stressed
all cables are Cable Ducts
• Temporary protection in case of delays
• Limit w/c ratio to max 0.4
• Improve fluidity by limiting grout temperature to
max of 20oC; use chilled water for mixing grout
• Use positive displacement pump for grouting
• Continue grouting from one end until grout of
uniform consistency comes out of the other end
 Pre tensioning specifics
• Single stage pre stressing
• Elimination of sheathing ducts
• Tendon tensioning before casting of concrete
• Transfer of pre stress through bond after slackening or
cutting of strands.
• Obviation of process of grouting
• Elimination of time loss in pre- stressing operations
• Specially designed long line casting bed to impart
required pre stressing force and cast number of beams in
one operation
 Advantages over post tensioning
• Durability : No sheathing ducts, no anchorages, no
grouting, better corrosion resistance, and better quality
control possible
• Quantity reduction : Thinner webs and flanges possible
effecting weight reduction, ease of handling and erection
• Construction expediency : Reduction in number of
activities hence faster construction
• Design expediency : No friction, wobble, slip, second
stage pre-stress losses. No anchorage detailing required.
Can achieve efficient use of pre-stress in smaller sections
Pre tensioning vis-à-vis post tensioning , value
engineering for Sutlej bridge

Descripti Unit Pre Post

on

Concrete Cum 26.3 31.9

1 7

Shutterin Sqm 228 230

g

Rein MT 2.25 2.9

Steel

HT strand MT 1.38 2.08

 Case studies on
post tensioned deckings
Ratnagiri Viaducts , Konkan Railway
Launching Truss for Precast PSC Beams
Panvel Creek Bridge
Panvel Creek Bridge
Vasai Creek Bridge
DELHI NOIDA BRIDGE PROJECT
DELHI NOIDA BRIDGE PROJECT
Yamuna Bridge
Launching arrangement
DELHI NOIDA BRIDGE PROJECT
 External Prestressing - Advantages
• Concrete quality of webs improved due to absence
of tendons & anchors; also simple reinforcement
layout
• The tendons can be controlled, adjusted or replaced
after installation
• Overall saving in quantities, reduction in weight
of structure
• Tendons have high quality corrosion protection
Developments in Segmental Constn.
External Prestressing - Disadvantages
• The tendons are not bonded
• Threat of vandalism
• The sum of reinforcement steel is higher
• The bonded tendons do not participate in local
crack control
• Reduced contribution of tendons to ultimate load
• The lever arm of prestressing is shorter
DMRC Viaducts
Advantages of U shaped decking for LRT
• Formation level much lower compared to
box shape decking.
• Horizontal forces due to tractive, braking
etc. at lower level. Hence reduction in
moments on substructure & foundation.
• Reduction in decking quantities since site
beams act as parapet and noise barriers.
• Reduction in height of station buildings and
reduction in escalator height for passengers.
Delhi Metro- Extra-dosed spans
EXTRADOSED BRIDGE AT DMRC
Bangaluru Metro rail

23/02/2010
Bangaluru Metro rail

23/02/2010
Congestion at beam
end
Typical case of improper concreting
Thank You