Presented By:

LEOWALD L. PECORE
Engineer III
DPWH - X
 Construction methodology and techniques of prestressed
concrete in bridges varies depending on the type and function of
the structural member. Among the structural members of the
bridge, three are commonly under prestressed concrete, the
precast concrete pile of the foundation, concrete girder and the
deck slab.

Prestressed concrete technology has two types of stressing

techniques the Pretensioning and Post-tensioning Techniques,
and may be applied when the structure is cast-in-placed or if the
structure is precasted.

When the force is applied to the reinforcing tendons before

the concrete is being poured, the structure is said to be in
pretensioned. If the force applied after the concrete has cured,
the structure is in post-tensioned. Pretensioning technique are
commonly applied on precast concrete piles, columns and other
structures of short span, wherein deflection is negligible, while
post-tensioning technique is for longer and complicated spans.
 The method of prestressing to be used shall be
optional with the contractor subject to all requirements
herein after specified.

The contractor, prior to casting any members to be

prestressed, shall submit to the Engineer for approval
complete details of the methods, materials and equipment
he proposes to use in the prestressing operations. Such
details shall outline the method and sequence of stressing,
complete specifications and details of the prestressing
steel and anchoring devices proposed for use, anchoring
stresses, types of enclosures and all other data pertaining
to the prestressing operations, including the proposed
arrangement of the prestressing units in the members,
pressure grouting materials and equipment.
Construction Methodology
( Precast Concrete Piles & Columns)

Pretension structures are sometimes

precasted in the casting yards in the project
site and normally manufactured at an
established plants in urban areas wherein the
tendons are anchored in the bulk heads or
abutment.
 TYPICAL ELEVATION OF CASTING ANCHORS

BULK HEAD/ABUTMENT
PILE/COLUMN
TENDON /STRAND
Placing of Pestressing Reinforcing Steel:

Prior to prestressing, preparation,

fabrication and installation of prestressing
reinforcement (i.e. cage bars and spirals) shall
be placed at the position shown on the plans
and firmly held to avoid displacement during
concrete pouring.
Stressing Operation:

Using the stressing jacks, each strand will

be then pretension at about and between 20
and 35 kips (89 and 156 KN) or as indicated in
the plan prior to concrete placement. A record
shall be kept of the jacking force and the
elongation produced thereby.
 TYPICAL ELEVATION OF CASTING ANCHORS

BULK HEAD/ABUTMENT
PILE/COLUMN
TENDON /STRAND

T T
T T
Placing Concrete:

Concrete shall not be deposited in the

forms until the Engineer has inspected and
give approval to the placing of the
reinforcements and prestressing steel. The
concrete shall be vibrated with care and in
such a manner as to avoid displacement of the
reinforcements.
Curing:

Immediately following the concrete

placement the precasted structural member
will be covered with curing blanket for steam
curing. (Refer to steaming procedures in the
next topic).
Detensioning:

Bond stress shall not be transferred to the

concrete, or released to the end anchorage
until the concrete has attained a compressive
strength, as shown in the cylinder tests, of at
least 24 Mpa (3,500 psi) unless otherwise
specified. The prestressing steel shall be cut or
released in such an order that the lateral
eccentricity or prestress will be minimum.
 ELEVATION IN DETENSIONING OF TENDONS:

BULK HEAD/ABUTMENT
PILE/COLUMN
TENDON /STRAND Cut

R R
R R

7 5
3
2 1
4 8
6

CROSS SECTION
Handling and Storing Precast Prestressed
Structural Member:

Extreme care shall be exercised in handling

and moving precast prestressed concrete
structural members to prevent breakage or
damage due to flexural stresses. Long piles should
be pick-up at several points to reduce the
unsupported lengths (see pick-up points diagram).

Precast structural members shall not be

shipped until tests of concrete cylinder sample
have attained the design compressive strength and
has attained a minimum age of 14 days.
 Pick-up Points
0.70L 0.30L

1-Point
Pick-up

L
0.21L 0.58L 0.21L
2-Point
Pick-up

L
0.14L 0.36L 0.36L 0.14L

3-Point
Pick-up
Construction Methodology
( PC Concrete Girders)

After the approval of prestressed construction

scheme, fabrication of forms (steel or Wooden)
shall commence and casting bed shall be
immediately prepared. Installation of forms shall
be pre-cambered as indicated in the approved
construction scheme. Casting bed should be
constructed by compacting the base and covering
it with at least lean concrete of 50 mm in thickness
in order to obtain and maintain the plumbness and
straightness of the casted prestressed structural
member.
Cage Bar, Duct Tubes, Tendons & Anchorage
Assembly Installation:

Cage bar can be assembled in or outside the

mold depending on the type of production being
employed for the casting of desired structural
member.

If the rebar cage is being fabricated outside the

mold, extra care should be properly observe in
handling and lifting the said cage bar in placing it
inside the form by utilizing several lifting hooks at
regular intervals attached to a stiffening beam to
avoid damage or deformation.
 Duct tubes and anchor plates shall then be firmly
installed inside the cage bar as layout in the plan to avoid
possible displacement during concrete pouring.

Preassembled form (steel or wooden) shall be prepared

prior to the installation of the cage bar by applying oil to its
inner surface. As soon as the mold is ready and the concrete
spacers are already positioned to the cage bar, the said
rebar cage shall then be lifted using crane with the required
lifting device, positioned and held firmly as planed. Required
prestressing steel shall then be inserted into the duct tubes.

Mold shall not be closed until the Engineer has

inspected the placing of the reinforcements, anchorage’s or
anchor plates, and duct tubes for its alignment, dents and
rapture.
Placing Concrete:

Placing of concrete in deep structural

members shall be deposited in layers from one
end to the other or in segment from both ends
towards the center. The concrete shall be
vibrated with care in such a manner as to avoid
displacement of the reinforcement, duct tubes
and anchorage devices.
Curing:

Immediately following the concrete placement the newly

casted structural member will be covered with a curing
blanket for steam curing.

Steam curing is a modern process being used as an

alternative to water curing especially in mass production of
precasted structural member. The structural unit to be cured
with steam shall be completely enclosed by a suitable type
of curing blankets, tightly placed so as to prevent the
escape of steam and simultaneously exclude outside
atmosphere. 2-4 hours after placing concrete and after the
concrete has undergone initial set, the first application of
steam or radiant heat shall then be applied, unless retarder
is being incorporated in the concrete mixed, in which case
the waiting period before application of the steam curing
will be from 4-6 hours.
DIAGRAM OF STEAM CURING SYSTEM

50 Kgs LPG

PERFORATED PIPE WATER TANK

GEN. SET

MINI BOILER
NEWLY CASTED GIRDER

PRESSURE GAUGE
CURING BLANKET
 During the waiting period, the temperature within the curing
chamber shall not be less than 10 ̊C (50 ̊F). Live steam or radiant
heat may be applied to maintain the required minimum
temperature.

The steam shall be 100% relative humidity to prevent loss of

moisture and to provide moisture for proper hydration of the
cement. Steam flow shall not be directly towards the structural
mold in order not to cause localized high temperatures. During
steaming, the ambient air temperature shall increase at a rate not
to exceed 4.41 ̊C (40 ̊F) per hour until the maximum required
curing temperature of 71.1 ̊C (160 ̊F) is reached. The maximum
temperature shall be held until the concrete has reached the
desired strength.

Curing period for this method will cover 14-18 hours

depending on the condition and capacity of the steaming
equipment.
Installation of Anchor Blocks and Stressing:

After concrete cylinder sample has attained the

required minimum strength, anchor blocks together
with the wedges or grips shall then be installed, and
an initial stressing will commence. Stressing shall be
done only after the removal of side forms from the
newly casted structural member.

Initial stressing has two options, sometimes will

depend on the availability of the lucking devices like
wedges or grips. Initial stressing can be done either
by utilizing only 50% of the required jacking force to
all the prestressing reinforcement of the casted
structural member, or by using only 50% of the said
prestressing reinforcement and applying 100% of the
target jacking force.
 After the initial stressing operations, the
newly casted structural member can now be
removed from its casting bed and stored until
the required concrete strength of 35 Mpa
(5,000 psi) has been achieved for the final
stressing to commence. Packing of block outs
shall be done immediately after the final
stressing operation to avoid accidental slippage
of prestressing tendons.

A record shall be kept of the jacking force

or the equivalent gauge reading, the elongation
of each tendons and the camber produced after
the final stressing operation.
Grouting:
Prestressing steel shall be bonded to the
concrete by filling the void space between the duct
and tendons with grout.

Grout shall consist of Portland Cement, potable

water and an expansive admixture approved by the
Engineer, and no admixture containing chlorides
or nitrates shall be used.

Water shall first be added to the mixer followed

by the cement and admixture. The grout shall be
mixed in mechanical mixing equipment of a type
that will produce uniform and thoroughly mixed
grout. Grout shall be continuously agitated until it
is pumped. Retempering of grout will not be
permitted.
 The ducts are prepared for grouting by first flushing
it with water and then blowing air through them. Vent
openings at high points and drains at low points should
be provided for ducts in continuous structures to allow
for the dissipation of entrapped air and water
respectively. With vents open, grout is injected into the
duct at a pressure less than 1.72 Mpa (250 psi)
maximum. Grout is allowed to come out of the first vent
until the remaining air or water entrapped in the duct
has been removed, and the efflux time of ejected grout
is not less than 11 seconds, at which time the vent is
sealed, subsequent vents are capped in similar fashion.
Grouting pressure at the injection end shall be raised to
a minimum of 0.69 Mpa (100 psi) and held for a
minimum of 10 seconds.

Sample shall be taken in every grouting operation,

and a record shall be kept on the mixing proportion and
the time consumed in grouting each cable tubes for
quality control purposes.
Handling and Storing Precast Prestressed Post-tensioned
Structural Member:

Extreme care shall be exercised in handling and

moving precast prestressed concrete structural members
to prevent breakage or damage due to flexural stresses.

Precast girders and slabs shall be transported in an

upright position and the points of support and directions
of the reactions with respect to the member shall be
approximately the same during transportation and storage
as when the members are in their final position.

Post-tensioned structural member shall not be

transported until the grout has attained a minimum age of
3 days.
 Transporting structure on site
 By a Prime-mover and a Dolly Trucks
 By two Trucks in Back-to-Back

 Launching
 By Direct Launching on Cranes
 By Cranes with launching beam
 Incremental Launching Method
 Cantilevering Method