Prestressed and Precast Concrete

Spring 2020 – Eng. Amthal Hakim

Chapter 2: Prestressing Material and Systsems

1
Outlines
2.1. Concrete
2.2. Reinforcing Steel
2.3. Prestressing Steel
2.4. Classification and types of prestressed concrete
2.5. Loading stages
2.6. Pretensioning systems and devices
2.7. Stages of pretensionned systems
2.8. Post tensioning systems and devices
2.9. Unbonded Post tensioning systems
2.10. Bonded Post tensioning systems
2.11. Stages of Post Tensioning systems
2.12. External Prestressing

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2.1. Concrete
2.2.1. Concrete is known to have 3 main properties:
1. Compressive strength
2. Shear Strength
3. Tesnile Strength
• Compressive strength of concrete is determined by testing a 150x300 mm (6x12 in) cylinder
at an age of 28 days.
• The specified compressive strength of concrete is denoted by the symbol f’c .
• For most applications, the range of concrete strength is 21 to 28 MPa (3,000 to 4,000 psi).
• For prestressed concrete, the range of concrete strength is 35 to 42 MPa (5,000 to 6,000 psi).
• Recently, higher values of compressive strength are reached for both, normal and prestressed
concrete.

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2.1. Concrete
2.1.2. Stress – Strain curve of concrete

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2.1. Concrete
2.1.3. Static Modulus of Elasticity
• With wc varying from 1500 to 2500 kg/m3

𝐸𝑐 = 𝑤𝑐 1.5 (0.043) 𝑓𝑐′

• Should normal crushed stone or gravel concrete (with a mass of approximately 2320 kg/m3)
be used,

• 𝐸𝑐 = 4700 𝑓𝑐′
• For high strength concrete f’c > 43 Mpa
𝑤𝑐 1.5
𝐸𝑐 = 3.32 𝑓𝑐′ + 6895 ( )
2320
with 𝑓𝑐′ in MPa and wc in kg/m3

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2.1. Concrete
2.1.4. Poisson’s ratio
• The ratio of lateral expansion to longitudinal shortening is called Poisson’s ratio.
• Cylinder subjected to compressive loads expands laterally.
• The value is about 0.21 for low strength concrete and 0.11 for high strength concrete.
• The average value is about 0.16.

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2.1. Concrete
2.1.5. Shrinkage
• The effect of evaporating water is shrinkage and cracking of the concrete.
• Workable concrete requires more water than is necessary to fully hydrate the cement.
• As concrete cures, water not used in hydration begins to evaporate.
• The amount of shrinkage depends on exposure of the member.
• Shrinkage occurs for many years, but about 90 % occurs within the first year.
• Members with large surface area have a higher rate of shrinkage.
• Shrinkage strain ranges from 0,000 to 0,0010.
• For purpose of design: shrinkage strain = 0,0002 to 0,0006.
• To minimize shrinkage:
• keep amount of mixing water to minimum,
• use shrinkage reinforcement,
• use dense nonporous aggregates.
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2.1. Concrete
2.1.5. Shrinkage

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2.1. Concrete
2.1.6. Creep
• Creep deformations may be 2 to 3 times as large as instantaneous deformation.
• Creep is deformation under sustained load.
• Creep is also called plastic flow.
• 75% of creep occurs during the first year.
• Creep can also cause concrete strength reduction of 15 to 25 percent.
• The longer concrete cures before load is applied, the smaller the creep.
• High strength concrete experiences less creep than low strength concrete.
• The amount of creep is dependent on the stress present .

𝛿𝑡 𝑡𝑜𝑡𝑎𝑙 𝑠𝑡𝑟𝑎𝑖𝑛
Creep coefficient: 𝐶𝛼 = 𝛿𝑖
=
𝑖𝑛𝑠𝑡𝑎𝑛𝑡𝑎𝑛𝑒𝑜𝑢𝑠 𝑠𝑡𝑟𝑎𝑖𝑛
≈ 2.5 𝑡𝑜 3

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2.2. Reinforcing Steel
• The reinforcing used for concrete structures may be in the form of bars or welded wire fabric.
• Reinforcing bars are referred to as plain or deformed.
• The deformed bars, which have ribbed projections rolled onto their surfaces (patterns differing
with different manufacturers) to provide better bonding between the concrete and the steel, are
used for almost all applications.
• Plain bars are not used very often except for wrapping around longitudinal bars, primarily in
columns.

Deformed Bars Plain Bars

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2.2. Reinforcing Steel
• The metric version of the ACI Code 318M-11 makes use of the same reinforcing bars used for
designs using U.S. customary units.
• The metric bar dimensions are merely soft conversions (i.e., almost equivalent) of the
customary sizes. Deformed bars come in these sizes: No 10 to No 36, No 43 and No 57.
• The diameter of the bar is roughly equal the bar’s number in mm.
• These steels are available in different grades as Grade 50, Grade 60, and so on, where Grade 50
means the steel has a specified yield point of 50,000 psi, Grade 60 means 60,000 psi, and so on.
ASTM A615: Deformed and plain billet steel bars.
• These bars, which must be marked with the letter S (for type of steel), are the most widely used
reinforcing bars in the United States. Bars are of four minimum yield strength levels: 40,000 psi
(280 MPa); 60,000 psi (420 MPa); 75,000 psi (520 MPa); and 80,000 psi (550 MPa).

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2.2. Reinforcing Steel
• It is essential for people in the shop and the field to be able
to identify at a glance the sizes and grades of reinforcing
bars.
• If they are not able to do this, smaller and lower-grade bars
other than those intended by the designer may be used. To
prevent such mistakes, deformed bars have rolled-in
identification markings on their surfaces. These markings
are described in the following list and are illustrated in next
figure.
1. The producing company is identified with a letter.
2. The bar size (10 to 57) is given next.
3. Another letter is shown to identify the type of steel.
4. Finally the grade of the bars is shown.

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2.2. Reinforcing Steel
• The initial tangent modulus of elasticity for all reinforcing bars can be taken as
𝐸𝑠 = 200000 𝑀𝑃𝑎 = 200𝐺𝑃𝑎

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2.2. Reinforcing Steel

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2.3. Prestressing Steel
The development of prestressed concrete was influenced by the invention of high strength steel. It
is an alloy of iron, carbon, manganese and optional materials.
Wires
• A prestressing wire is a single unit made of steel.
• The nominal diameters of the wires are 2.5, 3.0, 4.0, 5.0, 7.0 and 8.0 mm.
• The different types of wires are as follows.
• Plain wire: No indentations on the surface.
• Indented wire: There are circular or elliptical indentations on the surface.

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2.3. Prestressing Steel
Strands
• A few wires are spun together in a helical form to
form a prestressing strand.
• The different types of strands are as follows.
1. Two-wire strand: Two wires are spun together
to form the strand.
2. Three-wire strand: Three wires are spun
together to form the strand.
3. Seven-wire strand: In this type of strand, six
wires are spun around a central wire. The
central wire is larger than the other wires.

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2.3. Prestressing Steel
Tendons
• A group of strands or wires are placed together to
form a prestressing tendon.
• The tendons are used in post-tensioned members.
T
• The following figure shows the cross section of a
typical tendon.
• The strands are placed in a duct which may be
filled with grout after the post-tensioning
operation is completed

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2.3. Prestressing Steel
Cable
• A group of tendons form a prestressing cable.
• The cables are used in bridges.
Bars
• A tendon can be made up of a single steel bar.
• The diameter of a bar is much larger than that of a wire.
• Bars are available in the following sizes: 10, 12, 16, 20, 22,
25, 28 and 32 mm.

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2.3. Prestressing Steel
Properties of prestressing steel:
• Minimum corrosion
• Has High strength exceeding 1860 MPa
• Helps in achieving Adequate ductility
• Reduces losses due to its low relaxation: Property of steel having the tendency to lose stress
with time after it has been stressed and anchored.
• Provides high bond
• Has high bending ability especially at harping points and near the anchorage

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2.4. Classification and types of prestressed concrete
Prestressed concrete can be classified in many ways depending on the design features and
construction :
2.4.1. Externally or internally prestressed
• External prestressing is usually done by jacking the ends.
• Internal prestressing is done by tensioning the steel.
2.4.2. Linear or circular prestressing
• Circular prestressing is applied to circular structure where tendons are mounted around in
circles.
• Tendons in linearly prestressed structure can be straight, bent and curve but not circles.

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2.4. Classification and types of prestressed concrete
2.4.2. Partially or fully stressed concrete
a) Fully prestressed
When a member is designed so that under working loads there is no tension. Applied
normally to bridges.
b) Partially prestressed
When some tensile stresses are produced under working loads. Applied often to road beams
where live loads is not critical.

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2.4. Classification and types of prestressed concrete
2.4.3. Ways of pretensionning : Prestension
• Tendons are tensioned before the concrete is placed.
• Well suited for mass production using long line method where it saves labor cost, forms,
and anchorage.
• Prestressing here is only precast in beds.

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2.4. Classification and types of prestressed concrete
2.4.4. Ways of pretensionning : Post-tension
• Tendons are tensioned after concrete is hardened.
• Can be applied either precast or cast in place.
• Anchorage is needed.
• Variable eccentricity is obtained easier.

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2.4. Classification and types of prestressed concrete
2.4.5. End anchored or non-end anchored tendons
• End-anchored tendons: When prestressing is transferred to concrete member through
anchors at the end.
• Non-end anchored tendons: When prestressing is transferred by grouting cement.

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2.4. Classification and types of prestressed concrete
2.4.6. Precast, cast in place, and composite construction

Precasting Cast in place Composite construction

• Involves placing of concrete • Requires more forms. • Consists of using precast
away from its final position. • Saves transportation and elements then completing by
• It permits better control. erection costs. elements cast in place.
• Economical for mass • It is necessary for large heavy • Economical to precast part of
production. members. a member.
• We cast the remaining
member.
• This results in forms and
transportation saving.

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2.5. Loading Stages
2.5.1.: Initial Stage
The member is only subjected to the prestressing forces and to its self weight:
a) Before prestressing
Provisions must be made for shrinkage, cracks, curing, and supports yielding.
b) During prestressing
Check the strength of tendons against breaking and concrete against crushing.
c) At transfer of prestressing
For pretensioning: the transfer is done in one operation in a short period.
For post-tensioning: the transfer is done in a gradual manner.
At this stage, no external load is considered, only the weight of the beam which opposes the
cambering. It is important to secure the supports so they will not fail when casting on
ground.

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2.5. Loading Stages
2.5.2.: Trsanfer Stage
• The stage of transportation and erection of precast members.
• Ensure proper handling and supporting.

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2.5. Loading Stages
2.5.3.: Final Stage
The stage when actual loads come into the structure.
a) Sustained load (dead)
Try to control the deflection and cambering.
b) Working load
Check the strength of the concrete member.
c) Cracking load
Signifies a sudden change in bond and shear stresses.
Try to investigate this load.
c) Ultimate load
It’s the maximal load carried before collapse.

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2.6. Pre-tensioning Systems and Devices
• In pre-tensioning, the tension is applied to the tendons before casting of the concrete.
• The stages of pre-tensioning are described next Stages of 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 concrete attains the desired strength for prestressing, the tendons are cut loose from
the abutments.
• The prestress is transferred to the concrete from the tendons, due to the bond between them.
• During the transfer of prestress, the member undergoes elastic shortening. If the tendons are
located eccentrically, the member is likely to bend and deflect (camber).

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2.6. Pre-tensioning Systems and Devices
Prestressing bed, end abutment and mould
Hoyer system (Long Line method):used for mass production, the end abutments are kept
sufficient distance apart where several members are cast in a single line.

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2.6. Pre-tensioning Systems and Devices
Jack
Used for applying tension to tendons; mostly used: hydraulic jack which work on oil pressure
generated by a pump:
• Single acting
• Double acting

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2.6. Pre-tensioning Systems and Devices
Anchoring Devices
Used for fixing the tendon at dead end, while at the other end, end plates move due to pushing of
jack.

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2.7. Stages of Pretensionned System
The various stages of the pre-tensioning operation are summarized as follows.
1) Anchoring of tendons against the end abutments
1
2) Placing of jacks
3) Applying tension to the tendons
2
4) Casting of concrete
5) Cutting of the tendons after hardening of the concrete. 3

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2.8. Post-tensioning Systems and Devices
In post-tensioning, the tension is applied to the tendons after hardening of the concrete.
3 Types of Post – Tensioning Systems exist:
1. Unbonded : Can be either standard or encapsulated
2. Bonded
3. External

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2.9. Unbonded Post-tensioning Systems
Basic Components of unbonded mono-strand Post-tensioning System:
• Extruded cables
• Anchors
• Wedges

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2.9. Unbonded Post-tensioning Systems

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2.10. Bonded Post-tensioning Systems
• In post-tensioning systems, the ducts for the tendons (or strands) are placed along with the
reinforcement before the casting of concrete.
• The tendons are placed in the ducts and the duct prevents contact between concrete and the
tendons during the tensioning operation.
• Unlike pre-tensioning, the tendons are pulled with the reaction acting against the hardened
concrete.
• If the ducts are filled with grout, then it is known as bonded post-tensioning.
• The grout is a neat cement paste or a sand-cement mortar containing suitable admixture.
• In unbonded post-tensioning, as the name suggests, the ducts are never grouted and the tendon
is held in tension solely by the end anchorages.

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2.10. Bonded Post-tensioning Systems
• In post-tensioning systems, the ducts for the tendons (or strands) are placed along with the
reinforcement before the casting of concrete.
• The tendons are placed in the ducts and the duct prevents contact between concrete and the
tendons during the tensioning operation.
• Unlike pre-tensioning, the tendons are pulled with the reaction acting against the hardened
concrete.
• If the ducts are filled with grout, then it is known as bonded post-tensioning.
• The grout is a neat cement paste or a sand-cement mortar containing suitable admixture.

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2.10. Bonded Post-tensioning Systems
• The profile of the duct depends on the support conditions.
• For a simply supported member, the duct has a drooping profile between the ends.
• For a continuous member, the duct falls in the span and goes up over the support.

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2.10. Bonded Post-tensioning Systems
The essential devices for post-tensioning are as follows:
1) Casting bed
2) Mould/Shuttering
3) Ducts
4) Anchoring devices
5) Jacks
6) Couplers: Used to connect strands or bars and located at the junction of the members
7) Grouting equipment: Filling of duct, with a material that provides an anti-corrosive
alkaline environment to the prestressing steel and also a strong bond between the tendon
and the surrounding grout.

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2.11. Stages of Post-Tensioning System
The main steps for post-tensioning are as follows:
1) Placement of the tendons.
2) Placement of the anchorage block
3) Casting of concrete.
4) Applying tension to the tendons after the concrete attains sufficient strength
5) Seating of the wedges.
6) Cutting of the tendons.

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2.12. External Prestressing
• When the prestressing is achieved by elements
located outside the concrete, it is called external
prestressing.
• The tendons can lie outside the member (for
example in I-girders or walls) or inside the hollow
space of a box girder.
• This technique is adopted in bridges and
strengthening of buildings.

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