Pre-stressed Concrete

Codes:

1) IS 1343:2012, PRESTRESSED CONCRETE — CODE OF

PRACTICE
2) IS 1343:1980, PRESTRESSED CONCRETE — CODE OF
PRACTICE
3) IRC 18:2000 , Prestressed Concrete Road Bridges
4) IRS Concrete Bridge Coad 1997
 Introduction
This section covers the following topics.
• Development of Building Materials
• Basic Concept
• Early Attempts of Prestressing
• Brief History
 Introduction
This section covers the following topics.
• Development of Building Materials
• Basic Concept
• Early Attempts of Prestressing
• Brief History
 Buidling materials history

Figure Development of building materials

 Basic Concept
• A prestressed concrete structure is different from
a conventional reinforced concrete structure due
to the application of an initial load on the
structure prior to its use. The initial load or
‘prestress’ is applied to enable the structure to
counteract the stresses arising during its service
period.
• The concept of prestressing existed before the
applications in concrete.
• Two examples of prestressing before the
development of prestressed concrete are provided
 Basic Concept
Force-fitting of metal bands on wooden barrels
 The metal bands induce a state of initial hoop compression, to
counteract the hoop tension caused by filling of liquid in the
barrels.

Figure 1 Force-fitting of metal bands on wooden barrels

 Basic Concept
Pre-tensioning the spokes in a bicycle wheel
The pre-tension of a spoke in a bicycle wheel is applied to such
an extent that there will always be a residual tension in the
spoke.

Figure Pre-tensioning the spokes in a bicycle wheel

 Basic Concept
For concrete, internal stresses are induced (usually, by means of
tensioned steel) for the following reasons.
• The tensile strength of concrete is only about 8% to 14% of its
compressive strength.
• Cracks tend to develop at early stages of loading in flexural
members such as beams and slabs.
• To prevent such cracks, compressive force can be suitably
applied in the perpendicular direction.
• Prestressing enhances the bending, shear and torsional
capacities of the flexural members.
• In pipes and liquid storage tanks, the hoop tensile stresses can
be effectively counteracted by circular prestressing.
 Early Attempts of Prestressing
Prestressing of structures was introduced in late nineteenth
century. The following sketch explains the application of
prestress.

Figure Prestressing of concrete beams by mild steel rods

 Early Attempts of Prestressing
• Mild steel rods are stretched and concrete is poured around
them. After hardening of concrete, the tension in the rods is
released. The rods will try to regain their original length, but
this is prevented by the surrounding concrete to which the
steel is bonded.
• Thus, the concrete is now effectively in a state of pre-
compression. It is capable of counteracting tensile stress, such
as arising from the load shown in the following sketch.

Figure A prestressed beam under an external load

 Early Attempts of Prestressing
• But, the early attempts were not completely successful.
• It was observed that the effect of prestress reduced with time.
The load resisting capacities of the members were limited. Under
sustained loads, the members were found to fail. This was due to
the following reason.
i. Concrete shrinks with time. Moreover under sustained load, the
strain in concrete increases with increase in time. This is known
as creep strain. The reduction in length due to creep and
shrinkage is also applicable to the embedded steel, resulting in
significant loss in the tensile strain.

In the early applications, the strength of the mild steel and the strain
during prestressing were less. The residual strain and hence, the
residual prestress was only about 10% of the initial value. The
following sketches explain the phenomena.
 Early Attempts of Prestressing

Figure Variation of length in a prestressed beam

 Early Attempts of Prestressing

The residual strain in steel = original tensile strain in steel –

compressive strains due to short term (elastic shortening ) and long
term (creep and shrinkage)
 Original tensile strain in steel = (L2 – L1)/L1…..(1)
 Compressive strain due to elastic shortening of beam = (L2 – L3)/L1
(short-term loss in prestress)………….(2)
 Compressive strain due to creep and shrinkage = (L3 – L4)/L1
(long-term losses in prestress)………..(3)
 Therefore, residual strain in steel = (1)-(2)-(3)= (L4 – L1)/L1
 Early Attempts of Prestressing
The maximum original tensile strain in mild steel = Allowable stress /
elastic modulus = 140 MPa / 2×105 MPa
= 0.0007
The total loss in strain due to elastic shortening, creep and shrinkage
was also close to 0.0007. Thus, the residual strain was negligible.

The solution to increase the residual strain and the effective prestress
are as follows.
i. Adopt high strength steel with much higher original strain. This
leads to the scope of high prestressing force.
ii. Adopt high strength concrete to withstand the high prestressing
force. M>30 MPa
 Brief History
Before the development of prestressed concrete, two significant
developments of reinforced concrete are the invention of Portland
cement and introduction of steel in concrete. These are also mentioned
as the part of the history.
The key developments are mentioned next to the corresponding year.

1824 Aspdin, J., (England)

Obtained a patent for the manufacture of Portland cement.
1857 Monier, J., (France)
Introduced steel wires in concrete to make flower pots, pipes, arches
and slabs.
 Brief History
events were significant in the development of prestressed concrete.
1886 Jackson, P. H., (USA)
Introduced the concept of tightening steel tie rods in artificial stone and
concrete arches.

Figure 6 Steel tie rods in arches

1888 Doehring, C. E. W., (Germany)
Manufactured concrete slabs and small beams with embedded
tensioned steel.
 Brief History
1908 Stainer, C. R., (USA)
Recognised losses due to shrinkage and creep, and suggested
retightening the rods to recover lost prestress.

1923 Emperger, F., (Austria)

Developed a method of winding and pre- tensioning high tensile steel
wires around concrete pipes.
 Brief History
1924 Hewett, W. H., (USA)
 Introduced hoop-stressed horizontal reinforcement around walls of
concrete tanks through the use of turnbuckles.
 Thousands of liquid storage tanks and concrete pipes were built in
the two decades to follow.

1925 Dill, R. H., (USA)

 Used high strength unbonded steel rods.
 The rods were tensioned and anchored after hardening of the
concrete.
 Brief History
1926 Eugene Freyssinet (France)
• Used high tensile steel wires, with ultimate strength as high as 1725
MPa and yield stress over 1240 MPa.
• In 1939, he developed conical wedges for end anchorages for post-
tensioning and developed double-acting jacks.
• He is often referred to as the Father of Prestressed concrete.

1938 Hoyer, E., (Germany)

Developed ‘long line’ pre-tensioning method.

1940 Magnel, G., (Belgium)

Developed an anchoring system for post-tensioning, using flat wedges.
 Terms in prestress steel
Forms of Prestressing Steel
Wires
Prestressing wire is a single unit made of steel.
Strands
Two, three or more wires are wound to form a prestressing strand.
Tendon
A group of strands or wires are wound to form a prestressing tendon.
Cable
A group of tendons form a prestressing cable.
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.
 Terms in prestress steel
Nature of Concrete-Steel Interface

Bonded tendon
 When there is adequate bond between the prestressing tendon
and concrete it is called a bonded tendon.
 Pre-tensioned and grouted post-tensioned tendons are bonded
tendons.

Unbonded tendon
 When there is no bond between the prestressing tendon and
concrete, it is called unbonded tendon.
 When grout is not applied after post-tensioning, the tendon is
an Unbonded tendon.
 Terms in prestress steel
Stages of Loading
The analysis of prestressed members can be different for the
different stages of loading. The stages of loading are as follows.
1) Initial : It can be subdivided into two stages.
a) During tensioning of steel
b) At transfer of prestress to concrete.
2) Intermediate : This includes the loads during transportation
of the prestressed members.
3) Final : It can be subdivided into two stages.
a) At service, during operation.
b) At ultimate, during extreme events
 Advantage of prestress
1) Section remains uncracked under service loads
• Reduction of steel corrosion
• Increase in durability.
• Full section is utilized
• Higher moment of inertia (higher stiffness)
• Less deformations (improved serviceability).
• Increase in shear capacity.
• Suitable for use in pressure vessels, liquid retaining structures.
• Improved performance (resilience) under dynamic and fatigue
loading.
 Advantage of prestress
2) High span-to-depth ratios
Larger spans possible with prestressing (bridges, buildings with
large column-free spaces)
Typical values of span-to-depth ratios in slabs are given below.
Non-prestressed slab 28:1
Prestressed slab 45:1
For the same span, less depth compared to RC member.
• Reduction in self weight
• More aesthetic appeal due to slender sections
• More economical sections.
 Advantage of prestress
3) Suitable for precast construction
The advantages of precast construction are as follows.
• Rapid construction
• Better quality control
• Reduced maintenance
• Suitable for repetitive construction
• Multiple use of formwork
• Reduction of formwork
• Availability of standard shapes
 Sections Typical

Figure Typical precast members

Limitations of Prestressing

Although prestressing has advantages, some aspects need

to be carefully addressed.

• Prestressing needs skilled technology. Hence, it is not as

common as reinforced concrete.
• The use of high strength materials is costly.
• There is additional cost in auxiliary equipment's.
• There is need for quality control and inspection.
 Types of Prestressing
Prestressing of concrete can be classified in several
ways.
1. Source of prestressing force
This classification is based on the method by which
the prestressing force is generated.
Mechanical, hydraulic, electrical and chemical
2. External or internal prestressing
This classification is based on the location of the
prestressing tendon with respect to the
concrete section.
 Types of Prestressing
3. Pre-tensioning or post-tensioning
This is the most important classification and is
based on the sequence of casting the concrete and
applying tension to the tendons.
4. Linear or circular prestressing
This classification is based on the shape of the
member prestressed.
5. Full, limited or partial prestressing
Based on the amount of prestressing force, three
types of prestressing are defined.
 Types of Prestressing
6. Uniaxial, biaxial or multi-axial prestressing
As the names suggest, the classification is based on
the directions of prestressing a member.
 External prestressing of Box Girder

 the box girder of a bridge is prestressed with tendons that lie outside the concrete
 For bridge strengthen etc.
concrete will be cast around the ducts for placing the tendons.

Internal prestressing of Box Girder

Pre-tensioned electric poles
Post-tensioning of a box girder
Linearly prestressed railway sleepers
Biaxial prestressing of a slab
Lab test of external prestresed beam
 Full, Limited or Partial Prestressing
Full Prestressing
When the level of prestressing is such that no tensile
stress is allowed in concrete under service loads, it is
called Full Prestressing (IS 1343:2012, Cl 23.2, Page 29)
Limited Prestressing
When the level of prestressing is such that the tensile
stress under service loads is within the cracking stress of
concrete, it is called Limited Prestressing (Type 2).
Partial Prestressing
When the level of prestressing is such that under tensile
stresses due to service loads, the crack width is within
the allowable limit, it is called Partial Prestressing (Type
3).