Materials Hardware and Equipment For Prestressing

LECTURE 2
Materials, Hardwares and

Equipment for Prestressing
Time-Dependent Deformation of
Concrete
Time-dependent deformation of concrete
resulting from creep and shrinkage result in a
partial loss of prestress force and significant
changes in deflection.
Creep
• Creep – property of materials by which they
continue to deform over considerable lengths
of time at constant stress or loads
• The initial deformation due to load is the
elastic strain, while the additional strain due
to the same sustained load is creep strain.
• Creep strain for concrete has been found
experimentally to depend on:
–time
–mix proportions
–humidity
–curing conditions
–age of the concrete when first loaded
Shrinkage
In a concrete element, shrinkage results to a
decrease in volume when the concrete loses
moisture by evaporation.
Types of Prestressing Steel
• There are three common forms in which steel
is used for prestressed concrete tendons:
– Cold-drawn round wires

– Stranded cable
– Alloy steel bars
• Round Wires
– The individual wires are manufactured by hot-
rolling steel billets into round rods
– After cooling, the rods are passed through dies to
reduce their diameter to the required size.
– In the process of this drawing operation, cold
work is done on the steel, greatly modifying its
mechanical properties and increasing its strength
– The wires are stress-relieved after cold drawing
by a continuous heat treatment to produce the
prescribed mechanical properties
– Available in Grades 235 (minimum ultimate
strength 235,000 psi) to Grade 250 (minimum
ultimate strength 250,000 psi)
• Stranded Cable
– Fabricated with six wires wound tightly around a seventh of
slightly larger diameter
– The pitch of the spiral winding is between 12 to 16 times the
nominal diameter of the strand
– The same type of cold-drawn stress-relieved wire is used in
making stranded cable as is used for individual prestressing
wires
– However, the apparent mechanical properties are slightly
different because of the tendency for the stranded wires to
straighten when subjected to tension because the axis of the
wires do not coincide with the direction of tension
– Strands may be obtained in a range of sizes from 0.25 in to
0.60 in diameter
– Cable is stress-relieved by heat treatment after stranding
– Two grades are manufactured:
Grade 250 – minimum ultimate strength of 250,000 psi
Grade 270 – minimum ultimate strength of 270,000 psi
• Alloy Steel Bars
– The high strength is obtained by introducing certain
alloying elements, mainly manganese, silicon and
chromium during the manufacture of the steel
– In addition, cold work is done in making the bars, further
increasing the strength
– After cold-stretching, the bars are stress-relieved to
obtain the required properties
– Available in diameters ranging from 5/8 in to 1 3/8 in ,
and in Grade 145 (minimum ultimate strength 145,000
psi) and Grade 160 (minimum ultimate strength 160,000
psi)
Importance of High Strength Steel
• The lack of success of most early attempts to
PSC was the failure to employ steel at a
sufficiently high stress and strain.
• The time-dependent length changes
permitted by shrinkage and creep of the
concrete completely relieved the steel of
stress.
EQUIPMENTS
• T6Z-08 Air Powered Grout Pump
• Pumps cement grout only, no sand. 32
Gallon Mixing Tank. Mixes up to 2 sacks
of material at once and allows for grout
to be pumped during mixing or mixed
without pumping.
Approximate size 50" long

30.5" high
52" wide
Weight 560 lbs.
Production Rate 8 gallons per

minute
at 150 psi
Pump 31.6 progressing
Pump Type
cavity
• Colloidal Grout Plant variable up to 20
Output/Pressure
• The heavy duty, high volume gpm, 261 psi
Colloidal Mixer 13.0 CF with
Colloidal Grout Plant is favored for Mix Tank
bottom clean out
precision post-tension grouting. The Mixing Pump
2 x 3 x 6 diffuser-
type centrifugal
unit features a high speed shear
13.0 paddle
mixer that thoroughly wets each Holding Tank
agitating
particle and discharges the mixed Drive Power Air 300 CFM, 100 psi
material into a 13 cubic foot capacity Physical
Dimensions
96" L x 60" W x
Specifications 63" H
agitating holding tank. A direct Weight 1800-2800 lbs.
coupled progressing cavity pump
delivers slurries at a rate of up to 20
gpm and pressures of up to 261 psi.
The unit easily mixes and pumps
slurries of Portland cement, fly ash,
bentonite, and lime flour. All controls
are conveniently located on the
operator platform for easy one-man
control.
• T7Z Hydraulic Jacks
• Used for testing and pre-
stressing anchor bolts. Available
with up to 5-1/8" center hole.
Unit comes with ram, pump,
gauge, hoses, jack stand, high
strength coupling, high strength
test rod, plate, hex nut and
knocker wrench. Calibrations
are available upon request.
• Note: Jack pull rods should
have a higher capacity than the
anchor rod.
• T80 Post-Tensioning
Jacks
• With the T80 series the
enclosed bearing
housing contains a
geared socket drive to
tighten the bolt hex nut
during tensioning. Test
jack housing will
accommodate up to a
9” deep pocket. T80 Post-Tensioning Jacks
• T8Z-18 Hydraulic Torque
Wrench
• The hydraulic torque wrench
is used for tensioning
anchors in tight fitting
locations where it would be
difficult to use an hydraulic
jack. The wrench is also
recommended for use when
setting the large diameter
Spin-Lock anchors. The Maximum
Torque
Length Height Weight
torque wrenches are light 5,590

11.11" 4.49" 16.75 lbs.
weight and can achieve a ft./lbs.
(279 mm) (114 kg) (7.6 kg)
(773 kg/M)
maximum of 8,000 ft-lbs. 8,000
ft.lbs. 12.57" 5.09" 24.95 lbs.
(1,006 (319 kg) (129 kg) (11.3 kg)
kg/M)
• T8Z Torque Wrench
• For applying torque
to the anchor bolt
when setting the Bolt Square Capacity
Diameter Drive Size (ft. lbs.)
anchor. *1/2"-1" 3/4" 0-500
1/2"-1" 3/4" 0-600
*1-1/8"-2" 1" 0-1,000
T8Z-04 Torque Multiplier (4:1)

For use with T8Z Torque Size
Square Square Maxim
Drive Drive um
Wrench. Other sizes available Input Output Torque
4,000
GA 186 1" 1-1/2"
(ft. lbs.)
 T1Z & T2Z Long Fitting Tool
Adapters
 For driving hex nuts and
setting tools, typically with our
Spin-Lock anchor systems.
Works with torque wrench or
impact gun. T1Z Deep Socket
Available with 1" or 1-1/2" 2Z Regular Socket
square drive. Please specify
square drive for compatability
with your equipment.
K3F-26 Long Fitting Wrench

Adapter
For applying torque to recessed

anchor nuts that are under tension
when using hydraulic jacks. Available
in all anchor sizes.
Corrosion Protection
Methods of Corrosion Protection
Abrasion
Corrosion Typical Relative Cost Can be applied
Resistance Lead Time
Protection Type Thickness (4=highest) to accessories?
(4=best)
Hot Dip
4 3-4 mils 2 2-4 weeks yes
Galvanizing
Epoxy Coating 1 7-12 mils 1 2-3 weeks yes
Pre-Grouted 2", 3" or 4"

3 3 2 weeks no
Bars tubing
Extruded
Polyethylene 2 23-25 mils 1 2-4 weeks no
Coating
Corrosion
Inhibiting 2 N.A. 2 2-4 weeks yes
Compound
Methods of Corrosion Protection
 Epoxy Coating
Fusion bonded epoxy coating of steel bars to
help prevent corrosion has been successfully
employed in many applications because of
the chemical stability of epoxy resins. Epoxy
coated bars and fasteners should be done in
accordance with ASTM Epoxy coating patch
kits are often used in the field for repairing
nicked or scratched epoxy surfaces.
Pre-Grouted Bars
Cement Grout filled corrugated
polyethylene tubing is often used to
provide an additional barrier against
corrosion attack in highly aggressive soils.
• Hot Dip Galvanizing
• Zinc serves as a sacrificial
metal corroding preferentially
to the steel. Galvanized bars
have excellent bond
characteristics to grout or
concrete and do not require as
much care in handling as
epoxy coated bars.
Extruded Polyethylene
Williams strand tendons contain an
extruded high density polyethylene
sheathing around each individual
strand in the free-stressing portion
of the anchorage. The sheathing is
minimum 60 mils thick and applied
once the 7-wire strand has been
coated with a corrosion inhibiting
compound.
 Field Splice for Bars
 Continuous corrosion protection can even be
accomplished for the MCP Pregrouted anchors
manufactured from Williams Form Engineering. To
achieve the equivalent levels of corrosion protection the
coupled sections of bar anchors can be wrapped in a
grease impregnated tape that is further protected with
heat shrink sleeving. This scheme is acceptable by most
governing agencies and is specified in the PTI
Recommendations for Prestresed Rock and Soil Anchors.

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LECTURE 2

Materials, Hardwares and

– Cold-drawn round wires

Approximate size 50" long

Weight 560 lbs.

Production Rate 8 gallons per

torque wrenches are light 5,590

T8Z-04 Torque Multiplier (4:1)

K3F-26 Long Fitting Wrench

For applying torque to recessed

Epoxy Coating 1 7-12 mils 1 2-3 weeks yes

Pre-Grouted 2", 3" or 4"

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