Viewpoint

Creating Openings
in Unbonded
Post-Tensioned Slabs
By Don Kline
I t is often necessary to create openings in existing
concrete slabs. Openings may be large, such as
those required for a new stairway, or small core
effect on slab strength and stiffness, particularly if
several reinforcing bars are cut.
Prior to cutting small penetrations in a PT slab,
penetrations, such as those required for plumbing existing PT strands should be located using non­
risers. Post-tensioned (PT) slabs have the added destructive testing (NDT) equipment such as
complexity in that PT strands may have to be cut. ground-penetrating radar (GPR).1 Once the strands
It is a common misconception that creating open- have been located and marked on the slab, small
ings in existing PT slabs is difficult, expensive, and penetrations can be made using core-drilling equip-
dangerous. This perception is perpetuated because ment or chipping hammers.
the field procedures and hardware used to create
these penetrations are not fully understood. This Large Openings
concern is sometimes given as a reason for avoiding Sometimes it is necessary to create large openings
PT construction in particular applications. in a slab for stairwells or large duct shafts between
Cutting openings in PT slabs does require care floors. Creating a large opening in a PT slab will
and caution because of the possibility that PT ten- result in several PT strands being interrupted by the
dons may have to be cut. However, with the proper new opening. An engineer should be consulted to
knowledge of structural behavior, repair hardware, analyze the effect that the new opening will have on
and PT field practices, retrofitting openings and the slab. The slab with the new opening should be
other penetrations in PT slabs is not only feasible analyzed in accordance with ACI 318-08,2 Section
but can also be achieved safely and economically. 13.4.1. The analysis should show that strength is
adequate and that all serviceability conditions,
Types of Openings and including stress limitations and deflections, are met.
Penetrations ACI 318-08,2 Section 13.4.2, allows for the
There are two types of openings that are com- creation of openings in existing slabs without the
monly cut into existing slabs: small penetrations need for special analysis; however, it requires that
and large openings. Small penetrations are those an amount of reinforcement equivalent to the
that can be cut into a slab without affecting any of amount that is interrupted by the opening be added
the existing PT tendons; conversely, large openings on either side of the opening. Hence, in lieu of
are those that require the cutting of existing tendons. special analysis, slab strengthening would be
required to restore the original reinforcing and this
Small Penetrations would be required whether the slab is reinforced
As a general rule, it can be assumed that the with mild steel or post-tensioning.
effect of small penetrations will be negligible and It is important for the design team to understand
that the slab will behave similar to the slab without the implications of locating new openings in certain
penetrations, provided that: critical regions. Bhatti et al.3 discussed how large
1. None of the existing PT strands are cut during openings can be cut in certain regions of the slab
the coring of the penetration; without adversely affecting structural safety, ser-
2. The opening is located not less than 10 times the viceability, and integrity. For two-way flat plates
slab thickness from a supporting column; and flat slabs, the most desirable region for openings
3. The opening is not located near a concentrated is at the intersection of the two orthogonal middle
load; and strips (Area 1 in Fig. 1). The least desirable location
4. The opening or group of openings does not is adjacent to a column, where punching shear
significantly reduce the effective flange area for capacity can be severely reduced (Area 3 in Fig. 1).
a supporting beam. Although column strips and middle strips are not
When applying this general rule, good judgment commonly used in PT design, these terms, as
should be exercised. A large number of small open- defined in ACI 318-08,2 Chapter 13, are useful for
ings in a concentrated area can have a significant identifying regions in a two-way slab panel.

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 For large openings, the general tasks associated
with the planning and creation of an opening are:
1. Select the location for the new opening.
2. Evaluate the structural adequacy of the slab in
its final state with the opening. Design a slab
strengthening solution, if required.
3. Evaluate the structural capacity of the slab during
intermediate stages of construction. Design
temporary shoring, if required.
4. Install shoring, if required.
5. Identify locations of existing PT strands that
intersect the new opening.
6. Detension and reanchor strands at the perimeter
of the new opening.
7. Remove concrete from the opening.
8. Strengthen the slab, if required.
To ensure successful execution of any retrofit
project, it is vital that each member of the project Fig. 1: Areas for slab openings
team (architect/engineer, contractor, and specialty
PT contractor) clearly understands who is respon-
sible for completing the tasks listed previously.

Slab Strengthening Options

The structural analysis will determine if strength-
ening is required for the slab. Strengthening of the
slab can be achieved by4:
• Span shortening: Creating new intermediate
supports to reduce span length.
• Section enlargements: Increasing the slab depth
or adding a concrete beam to increase strength
and stiffness. Fig. 2: PT strands are cut using a grinder
• Externally bonded reinforcement: Bonding steel
plates or fiber-reinforced polymer (FRP) to the Small detensioning pockets are chipped into the
slab can create a new composite section that slab, exposing the strands using chipping hammers.
increases strength and stiffness. The strands are then individually detensioned using
• External post-tensioning: Providing additional a handheld grinder (Fig. 2). PT strands are typically
prestress force into the slab using post-tensioning detensioned in phases to minimize the loss of pre-
that is external to the slab. stress at any given time during construction.
Oxyacetylene torch heating is another effective
Typical Slab Opening Procedure method that can be used to detension tendons. When
The following discussion provides a typical the torch method is used correctly, the flame does
approach that should be used to create openings in not actually cut through the strand. Instead, heat
PT slabs. This procedure may vary depending on from the flame causes the individual wires to yield
many factors. Some of the variations are highlighted and elongate. Eventually, the wires begin to rupture,
in the discussion. thereby reducing the amount of energy released as
Step 1: The perimeter of the opening is marked the strand is severed.
on the top and bottom of the existing slab. Detensioning by means of a grinder, saw, or torch
Step 2: Shoring is installed under the opening results in a sudden release of energy in the slab. The
and extended several feet beyond the perimeter of magnitude of the energy release is directly propor-
the opening in each direction. Shoring is also placed tional to the length of the tendon that is being
below the opening to prevent debris from falling to detensioned and can be significantly affected by the
the level below during demolition. locations of intermediate anchorages, type of inter-
Step 3: PT strands intersecting with the opening mediate anchorage used, and direction of the inter-
are located using NDT methods such as GPR. mediate anchorage.
Step 4: Prior to beginning detensioning of the There are various techniques that can be employed
strands, the specialty post-tensioning contractor to protect property and the public from potential
should take appropriate measures to ensure the hazards during the detensioning operation. Some
safety of the public and mitigate risk to property. of these techniques include:

www.icri.org May/June 2013 Concrete Repair Bulletin 21

 Fig. 5: Installation of reinforcement for
anchorage pocket

Fig. 3: Anchorage pockets being chipped out

Fig. 6: Tying steel at anchorage point

Fig. 4: Anchorage pocket after chipping

a. Using a detensioning collar to temporarily

lock off the strand at a predetermined location
in the slab (normally at the boundary of the new
opening). Although detensioning collars can be
a very effective means of eliminating the sudden
release of energy during detensioning, they Fig. 7: Pouring anchorage pocket
cannot be used in situations where strands are
grouped or bundled together. Step 6: New PT anchorages are placed in the
b. Using a specially designed detensioning pockets along with the appropriate backup reinfor­
jack to release the force in the strands in a con- cing steel (Fig. 5 and 6).
trolled manner.5 Step 7: Anchorage pockets are then poured using
c. Installing a barrier at the slab edge to pre- a pre-bagged high-strength portland cement grout
vent the strand and grout plug from becoming (Fig. 7) with appropriate consolidation (Fig. 8).
projectiles during detensioning operations. Step 8: After the grout achieves at least 3000 psi
Step 5: New anchorage pockets are chipped in (21 MPa) compressive strength (normally the day
the slab at the intersection of the strand groups and after the pour), the strands are restressed using
the perimeter of the opening (Fig. 3). The width a hydraulic jack calibrated in accordance with
and length of the pockets depends on the number PTI M10.2-006 (Fig. 9).
of stands in the group and the location of the new Step 9: The strand tails are cut with an oxyacet-
anchorage relative to the strand profile’s high and ylene torch or by another approved method. Pro-
low points (Fig. 4). If the new anchorage is near tective end caps are then installed over the tendon
a strand high point, then the pocket will have to tails and the stressing pockets are patched with a
be long enough to allow the strand to be reprofiled nonshrink grout.
so that the new anchorage can be located at the Step 10: Once all of the strands are stressed and
middepth of the slab. anchored at the perimeter of the opening, demolition

22 Concrete Repair Bulletin May/june 2013 www.icri.org

Fig. 8: Vibrating repair material for proper consolidation Fig. 9: Strands are stressed using a monostrand ram

of the remaining concrete in the opening is completed

using conventional concrete breakers (Fig. 10). The
edge of the opening can be left as a rough, unfin-
ished surface or it can be formed and poured to
create a formed edge.

Designing PT Slabs for

Future Openings
Sometimes designers take additional steps during
the design of a building to provide greater flexibility
for future slab penetrations. Various methods can be
used to plan for the possibility of future penetrations. Fig. 10: Excess concrete is removed from the
Examples of techniques that have been used suc- new opening
cessfully include maximizing tendon spacing in the
slab, marking tendons in the slab, and designing Slabs,” Recent Developments in Deflection Evaluation of Con-
large areas of the slab without PT tendons (some- crete, SP-161, E. G. Nawy and D. R. Cagley, eds., American
times referred to as “knockout panels”). Concrete Institute, Farmington Hills, MI, Apr. 1996, pp. 149-164.
4. ICRI Technical Guideline No. 330.1-2006, “Guide for the
Selection of Strengthening Systems for Concrete Structures,”
Safely and Successfully Creating International Concrete Repair Institute, Rosemont, IL, 2006, 32 pp.
Openings in PT Slabs 5. Fischli, F.; Grimm, M.; and Marti, P., “Cutting Openings
Practical methods exist for creating openings in into Post-Tensioned Floor Slabs,” Concrete International, V. 10,
PT slabs after construction is complete. While the No. 2, Feb. 1988, pp. 45-47.
6. PTI M10.2-00, “Specification for Unbonded Single Strand
method will vary depending on many factors, there
Tendons,” second edition, Post-Tensioning Institute, Farmington
are standard procedures that should be followed when Hills, MI, 2000, 36 pp.
creating such openings. Modifications to existing PT
slabs can be made safely and economically when the This Viewpoint article has been selected by the editors as an
project team includes an engineer and a specialty offering to the interest of our readers. However, the opinions
contractor experienced in this type of application. given are not necessarily those of the International Concrete
Repair Institute or of the editors of this magazine. Reader com-
ment is invited.
Credits
This article is based on a Post-Tensioning Insti-
tute publication, “Creating Openings and Penetra- Don Kline, PE, is Founder and
tions in Unbonded Post-Tensioned Slabs,” authored Principal of Kline Engineering &
by Don Kline, Kline Engineering & Consulting, Consulting, LLC, with over 20 years
LLC. For a more comprehensive discussion of this of experience in the design, con-
topic, the reader is encouraged to review this pub- struction, and repair of post-ten-
lication and the following references. sioned concrete structures. He is a
Director and Fellow of the Post-
References Tensioning Institute and serves on
1. PTI TAB.1-06, Post-Tensioning Manual, sixth edition, several PTI committees, including DC-80, Repair,
Post-Tensioning Institute, Farmington Hills, MI, 2006, 254 pp. Rehabilitation & Strengthening; DC-20, Building
2. ACI Committee 318, “Building Code Requirements for Design; and the Technical Activities Board (TAB). Kline
Structural Concrete (ACI 318-08) and Commentary,” American
also serves as Vice President of the American Con-
Concrete Institute, Farmington Hills, MI, 2008, 473 pp.
3. Bhatti, M. A.; Lin, B.; and Vega, J. P. I. M., “Effect of crete Institute (ACI) National Capital Chapter and is a
Openings on Deflections and Strength of Reinforced Concrete current member of several ACI technical committees.

www.icri.org May/June 2013 Concrete Repair Bulletin 23