Helsinki University of Technology (HUT) SEMINAR Spring 2003

Bridge Engineering (BE) Rak-11.146 Sillanrakennuksen seminaari

Rak-11.163 Licentiate Seminar in B. E.
Pekka Pulkkinen 030409 1 (15)

Eurocodes

AIM

Eurocode 2 / Prestressed Bridges

Name of lecturer Pekka Pulkkinen

Presentation 10.03.2003 time 14.00, R9

ABSTRACT 2

INTRODUCTION 2

1. MATERIALS 2

2. STRUCTURAL ANALYSIS 4

3. SERVICEABILITY LIMIT STATES 9

4. DETAILING OF REINFORCEMENT AND TENDONS 12

5. SUMMARY OF THE COMPARISON CALCULATIONS BETWEEN FINNISH

CODES AND EUROCODE 2 14

6. CONCLUSIONS 15
HUT/BE/S Pekka Pulkkinen 2 (15)

ABSTRACT

In this paper the design principles and rules of pre- and post tensioning 2 are studied.
Materials, analysis and crack control of prestressed structures are presented shortly as they are
written in the present prestandards of Eurocode 2. In some issues comparison to the existing
Finnish codes are done.

There is no experience in designing bridges according to Eurocode 2 in Finland. However the

Road Administration has carried out some comparison studies regarding the design of
concrete and composite bridges. The summary of those studies is presented in this paper.

The presentation is based on the following prestandards and codes:

PrEN 1992-1-1 Eurocode 2 (Draft for Stage 49): Design of concrete structures
General rules and rules for building

PrEN 1992-2 (Draft 32): Design of concrete structures- Concrete bridges

SFS-ENV 1992-1-1: Eurocode 2: Betonirakenteiden suunnittelu

INTRODUCTION

Almost all parts of Eurocode include bridge section. Mostly they are numbered as section 2 in
code, for example in concrete structures PrEN 1992-2. The part of bridges is not an
independent code, it complements the basic code. This means that in bridge design procedure
one must take into account all code sections involved. This makes the design work quite
complicated. However the rules of pre and post tensioning are shown mostly in basic code
PrEN 1992-2.

In Finland it is not allowed to design bridges according to Eurocode 2 so far. Neither National
Annexes (NA) have been prepared. The preparing work of NA has just started and national
support group has been established. The main principle in preparing National Annexes is that
the safety level of brides will not been lowered.

The opinion of the national support group is that after completing and accepting the codes
special bridge design books similar to German practice will be prepared.

1. MATERIALS

1.1 Properties

The prestressing tendons (wires, strands and bars) shall be classified according to:
- strength, denoting the value of the 0,1% proof stress (fp0,1k) and the value of the
ratio of tensile strength to proof strength (fpk /fp0,1k) and elongation at maximum
load ( uk)
- class, indicating the relaxation behaviour
- size
- surface characteristics.
HUT/BE/S Pekka Pulkkinen 3 (15)

In the Eurocode 2, three classes of relaxation are defined:

- Class 1: wire or strand - ordinary prestressing tendons
- Class 2: wire or strand - low relaxation
- Class 3: hot rolled and processed bars

The design calculations of the losses due to relaxation of the prestressing steel should be
based on the value of 1000, the relaxation loss (in %) at 1000 hours after tensioning and at
a mean temperature of 20 C

The values for 1000 can be either assumed equal to 8% for Class 1, 2,5% for Class 2, and
4% for Class 3, or taken from the certificate.

The long term (final) values of the relaxation losses may be estimated for a time t equal to
500000 hours (i.e. around 57 years).

1.2 Strength

The 0,1% proof stress (fp0,1k ) and the specified value of the tensile strength (fpk ) are defined
as the characteristic value of the 0,1% proof load and the characteristic maximum load in axial
tension respectively, divided by the nominal cross sectional area as shown in Figure 1.

Figure 1: Stress-strain diagram for typical prestressing steel

1.3 Ductility characteristics

Adequate ductility in elongation may be assumed if the prestressing tendons obtain the
specified value of the elongation at maximum load given in EN 10138.

Adequate ductility in tension may be assumed for the prestressing tendons if fp0.1/fpk k :
The value of k for use in a Country may be found in its National Annex. The recommended
value is 1,1.

1.4 Fatigue

Prestressing tendons shall have adequate fatigue strength. The fatigue stress range for
prestressing tendons shall be in accordance with EN 10138 or given in an appropriate
European Technical Approval
HUT/BE/S Pekka Pulkkinen 4 (15)

1.5 Design assumptions

Structural analysis is performed on the basis of the nominal cross-section area of the
prestressing steel and the characteristic values fp0,1k, fpk and uk.
The design value for the modulus of elasticity, Ep may be assumed equal to 205 GPa for
wires and bars.
The design value for the modulus of elasticity, Ep may be assumed equal to 195 GPa for
strand.
The design value for the steel stress, fpd, is taken as fp0,1k/ S (see Figure 2).
For cross-section design, either of the following assumptions may be made (see Figure 2):
- an inclined branch, with a strain limit ud. The design may also be based on the actual
stress/strain relationship, if this is known, with stress above the elastic limit reduced
analogously with Figure 2, or
- a horizontal top branch without strain limit.
Note: If more accurate values are not known the recommended values are ud = 0,02 and
fp0,1k /fpk = 0,9.

Figure 2: Idealised and design stress-strain diagrams for prestressing steel

Table 1. Partial factors for materials for ultimate limit states

In Finland partial factors in bridge design are: concrete c=1,35, reinforced steel s= 1,10,
prestressing steel is s= 1,15

2. STRUCTURAL ANALYSIS

2.1 General

The effects of prestressing may be considered as an action or a resistance caused by

prestrain and precurvature. The bearing capacity should be calculated accordingly.
In general prestress is introduced in the action combinations defined in EN 1990 as part of
the loading cases and its effects should be included in the applied internal moment and axial
force.
HUT/BE/S Pekka Pulkkinen 5 (15)

Following the assumptions of above, the contribution of the prestressing tendons to the
resistance of the section should be limited to their additional strength beyond prestressing.
This may be calculated assuming that the origin of the stress/strain relationship of the
tendons is displaced by the effects of prestressing.
Brittle failure of the member caused by failure of prestressing tendons shall be avoided.

2.2 Prestressing force during tensioning

Maximum stressing force

The force applied to a tendon, Pmax (i.e. the force at the active end during tensioning)
shall not exceed the following value:

Note: The recommended values are k1 = 0,8 and k2 = 0,9

In Finland during tensioning pmax 0,75 fpk or 0,85 fp0,2k

Overstressing is permitted if the force in the jack can be measured to an accuracy of

+/-5 % of the final value of the prestressing force. In such cases the maximum prestressing
force Pmax may be increased to k3 fp0,1k (e.g. for the occurrence of an unexpected high
friction in long-line pretensioning).
Note: The recommended value is k3 = 0,95.

Limitation of concrete stress

Local concrete crushing or splitting at the end of pre- and post-tensioned members shall
be avoided.
If prestress in an individual tendon is applied in steps, the required concrete strength may
be reduced. The minimum strength fcm(t) at the time t should be k4 [%] of the required
concrete strength for full prestressing given in the European Technical Approval.
Between the minimum strength and the required concrete strength for full prestressing,
the prestress may be interpolated between k5 [%] and 100% of the full prestressing.
Note: The recommended value for k4 is 50 and for k5 is 30.
The concrete compressive stress in the structure resulting from the prestressing force and
other loads acting at the time of tensioning or release of prestress, should be limited to:

where fck(t) is the characteristic compressive strength of the concrete at time t when it is
subjected to the prestressing force.

Measurements

In post-tensioning the prestressing force and the related elongation of the tendon shall be
checked by measurements and the actual losses due to friction shall be controlled.

2.3 Prestress force

At a given time t and distance x (or arc length) from the active end of the tendon the mean
prestress force Pm,t(x) is equal to the maximum force Pmax imposed at the active end,
HUT/BE/S Pekka Pulkkinen 6 (15)

minus the immediate losses and the time dependent losses (see below). Absolute values are
considered for all the losses.
The value of the initial prestress force Pm0(x) (at time t = t0) applied to the concrete
immediately after tensioning and anchoring (post-tensioning) or after transfer of
prestressing (pre-tensioning) is obtained by subtracting from the force at tensioning Pmax
the immediate losses Pi(x) which should not exceed the following value:

Note: The recommended values are k7 = 0,75 and k8 = 0,85

In Finland after the tensioning work po 0,70 fpk or 0,80 fp0,2k

When determining the immediate losses Pi(x) the following immediate influences should
be considered for pre-tensioning and post-tensioning where relevant
- losses due to elastic deformation of concrete Pel
- losses due to short term relaxation Pr
- losses due to friction P(x)
- losses due to anchorage slip Psl
The mean value of the prestress force Pm,t(x) at the time t > t0 should be determined with
respect to the prestressing method. In addition to the immediate losses the time dependent
losses of prestress Pc+s+r(x) as a result of creep and shrinkage of the concrete and the
long term relaxation of the prestressing steel should be considered

Pm,t(x)= Pm0(x) - Pc+s+r(x).

2.4 Immediate losses of prestress for post-tensioning

Losses due to the instantaneous deformation of concrete

Account should be taken of the loss in tendon force corresponding to the deformation of
concrete, taking account the order in which the tendons are stressed.
This loss, Pel, may be assumed as a mean loss in each tendon as follows:

where:
c (t) is the variation of stress at the centre of gravity of the tendons applied at time t
j is a coefficient equal to (n -1)/2n where n is the number of identical tendons successively
prestressed.

2.5 Losses due to friction

The losses due to friction P(x) in post-tensioned tendons may be estimated from:

where:
is the sum of the angular displacements over a distance x
is the coefficient of friction between the tendon and its duct
HUT/BE/S Pekka Pulkkinen 7 (15)

k is an unintentional angular displacement for internal tendons (per unit length) values for
unintended regular displacements for internal tendons will generally be in the range 0,005 < k
< 0,01 per metre.
x is the distance along the tendon from the point where the prestressing force is equal
to Pmax (the force at the active end during tensioning)

For external tendons, the losses of prestress due to unintentional angles may be ignored.

Table 2: Coefficients of friction of post tensioned tendons and external

unbonded tendons

2.6 Losses at anchorage

Account should be taken of the losses due to wedge draw-in of the anchorage devices,
during the operation of anchoring after tensioning, and due to the deformation of the
anchorage itself.

2.7 Time dependent losses of prestress for pre- and post-tensioning

The time dependent losses may be calculated by considering the following two reductions
of stress:
(a) due to the reduction of strain, caused by the deformation of concrete due to creep and
shrinkage, under the permanent loads:
(b) the reduction of stress in the steel due to the relaxation under tension.
Note: The relaxation of steel depends on the reduction of strain due to creep and shrinkage
of concrete. This interaction can generally and approximately be taken into account by a
reduction factor 0,8.
A simplified method to evaluate time dependent losses at location x under the permanent
loads is given by Expression

where:
HUT/BE/S Pekka Pulkkinen 8 (15)

Expression shown above applies for bonded tendons when local values of stresses are used
and for unbonded tendons when mean values of stresses are used. The mean values should
be calculated between straight sections limited by the idealised deviation points for external
tendons or along the entire length in case of internal tendons.

2.8 Effects of prestressing at ultimate limit state

In general, the design value of the prestressing force may be determined by

Pd,t(x) = p,P m,t(x)

2.9 Effects of prestressing at serviceability limit state and limit state of fatigue

For serviceability calculations, allowance shall be made for possible variations in

prestress. Two characteristic values of the prestressing force at the serviceability limit state
are estimated from:
P k.sup = rsup P m,t (x)

P k.inf = r inf P m,t(x)

where:
Pk.sup is the upper characteristic value
Pk.inf is the lower characteristic value
Note: The values of rsup and rinf for use in a Country may be found in its National
Annex. The recommended values are:
- for pre-tensioning or unbonded tendons: rsup = 1,05 and rinf = 0,95
- for post-tensioning with bonded tendons: rsup = 1,10 and rinf = 0,90
- when appropriate measures (e.g. direct measurements of pretensioning under
serviceability conditions) are taken: rsup = rinf = 1,0.
HUT/BE/S Pekka Pulkkinen 9 (15)

3. SERVICEABILITY LIMIT STATES

3.1 General

The common serviceability limit states are:

1. Stress limitation
2. Crack control
3. Deflection control

In this contribution only Crack control is studied, which in many cases has significant
importance in designing post tensioned structures.

3.2 Classification of design criteria

The bridge or specific parts of it shall be classified into environmental classes according to
Table 3 and into categories according to Table 4.

Table 3: Environmental classes, EN 206-1

Surfaces protected by waterproofing, which is approved in accordance with

national requirements, may be considered as equivalent to exposure class XC3.
All surfaces directly affected by de-icing salt should be considered as exposure
HUT/BE/S Pekka Pulkkinen 10 (15)

class XD3, XF2 or XF4, This will include all parapets, walls and piers within 6m from the
carriageway and surfaces such of top of piers under expansion joints wich are likely to be
exposed to water draining from the carriageway.
For bare concrete decks, without waterproofing or surfacing, the cover should be increased
by a minimum of 10 mm to allow for ware.

Table 4: Minimum requirements according to exposure classes

In order to ensure the performance required, the design criteria for the bridge or for
specific parts of it, should be classified into design categories according to Table 5. This
rule applies to both, the construction phases and persistent situations.
Table 5 contains the criteria for the verification of decompression and crack width.
When using this Table, both criteria need to be verified.

Table 5: Classification of design criteria

For category A the decompression limit requires that the tendons lie at least 25 mm
within concrete in compression; for others categories the tendons should lie within the
concrete in compression.

In the following the Crack control is discussed.

3.3 Crack control

A limiting calculated crack width, wmax, taking into account of the proposed function and
nature of the structure and the costs of limiting cracking, should be established.

When designing to categories A, B and C of the table 4 for the limit state of decompression
no tensile stresses in the concrete are allowed under the relevant combination of actions.

For crack width control, the deemed to satisfy criteria given in Tables 5 and 6 are based on
the following design crack widths:
- 0,2 mm for prestressed concrete
HUT/BE/S Pekka Pulkkinen 11 (15)

- 0,3 mm for reinforced concrete

For members with only unbonded tendons, the requirements for reinforced concrete
elements apply. For members with a combination of bonded and unbonded tendons
requirements for prestressed concrete members with bonded tendons apply.

3.4 Minimum reinforcement areas

If crack control is required, a minimum amount of bonded reinforcement is required to

control cracking in areas where tension is expected. The amount may be estimated from
equilibrium between the tensile force in concrete just before cracking and the tensile force in
reinforcement at yielding or at a lower stress if necessary to limit the crack width.

In prestressed members no minimum reinforcement is required in sections where, under the

characteristic combination of loads and the characteristic value of prestress, the concrete
remains in compression, at least for 1,0 Mpa

3.5 Control of cracking without direct calculation

For post-tensioned concrete, where crack control is provided mainly by ordinary

reinforcement, the tables 6 and 7 may be used with the stress in this reinforcement
calculated with the effect of prestressing forces included.

Table 6 Maximum bar diameters s for crack control

Table 7. Maximum bar spacing for crack control

HUT/BE/S Pekka Pulkkinen 12 (15)

3.6 Finnish practice in crack widths

Environmental class Prestressed Reinforced

Concrete Concrete

Y1, Difficult circumstances a) and b) a) wk 0,1 mm

Limit state of
tension stresses b) wk 0,2 mm

Y2, Ordinary circumstances a) Limit state of

tension stresses a) wk 0,2 mm
b) wk 0,1 mm b) wk 0,3 mm

Y3, Easy circumstances a) wk 0,2 mm

b) wk 0,3 mm -

a) Permanent load combination

b) Short term load combination

Limitation in stresses: Tension in concrete is not allowed in combination of permanent load

and 30 % of live load.

4. DETAILING OF REINFORCEMENT AND TENDONS

4.1 Arrangement of prestressing tendons and ducts

The spacing of ducts or of pre-tensioned tendons shall be such as to ensure that placing and
compacting of the concrete can be carried out satisfactorily and that sufficient bond can be
attained between the concrete and the tendons.

4.2 Post-tension ducts

The ducts for post-tensioned tendons shall be located and constructed so that:
- the concrete can be safely placed without damaging the ducts;
- the concrete can resist the forces from the ducts in the curved parts during and after
stressing;
- no grout will leak into other ducts during grouting process.
Bundled ducts for post-tensioned members, should not normally be bundled except in the
case of a pair of ducts placed vertically one above the other.
The minimum clear spacing between ducts should be in accordance with that shown in
Figure 3 .

Figure 3. Minimum clear spacing between ducts

HUT/BE/S Pekka Pulkkinen 13 (15)

The guidelines of minimum spacing given in Finnish Codes are quite limited, in principle the
minimum spacing values shown above are in the line with Finnish design practice, however
we use as absolute minimum 1,2 dg . Additionally we have some recommendations for spacing
of vibrator and casting pipes.

4.3 Anchorage zones of post-tensioned members

The bearing stress behind anchorage plates should be checked as follows :

- in the plane of the cross section, a rectangular area should be associated with
each anchorage with the same centre and the same axes of symmetry as the
anchorage plate (which is supposed to have two axes of symmetry) and should
satisfy :

where
P0 is the maximum force applied to a tendon
c,c' are the dimensions of the associate rectangle
fck(t) is the concrete strength at time of tensioning

As a simplification the prestressing force may be assumed to disperse at an angle of

spread 2 (see Figure 4), starting at the end of the anchorage device, where may be
assumed to be arc tan 2/3.

Figure 4. Dispersion of prestress

To prevent bursting and spalling of the concrete, each regularization prism should be
crossed by a minimum area of transverse
reinforcement

where Po is the maximum force applied to the tendon and s is the design strength of
the reinforcing steel.

The minimum reinforcement may be also derived from the European Technical
Approval of the prestressing system.
HUT/BE/S Pekka Pulkkinen 14 (15)

4.4 Anchorages and couplers for prestressing tendons

The anchorage devices used for post-tensioned tendons shall be in accordance with
those specified for the prestressing system, and the anchorage lengths in the case of
pretensioned tendons shall be such as to enable the full design strength of the tendons to
be developed, taking account of any repeated, rapidly changing action effects.
In general, couplers should be located away from intermediate supports.
The placing of couplers on 50% or more of the tendons at one cross-section should be
avoided unless:

- a continuous minimum reinforcement is provided, or

- there is a minimum residual compressive stress of [ 3 N/ mm2 ] under the
characteristic combination of actions to resist local tensile stresses.

In any case at each cross section a minimum of 30% of the tendons should be not
coupled.

5. SUMMARY OF THE COMPARISON CALCULATIONS BETWEEN FINNISH

CODES AND EUROCODE 2

5.1 General

The Finnish Road Administration ordered comparison calculations from some Finnish bridge
consultants. Calculations were prepared from prestressed concrete girder bridge and
reinforced concrete slab bridge.

In the study, which was prepared some years ago prestandards prEN 1991-2, SFS ENV
1991-1-1: Eurocode 1 and SFS ENV 1992-1-1: Eurocode 2 were used. The calculations
were prepared for superstructure by calculating design forces and moments using loads and
factors of Eurocode. The resistance of cross sections in critical points were calculated using
material properties and factors respectively. Crack control was also done in critical points.

5.2 Summary of the results of prestressed girder bridge

In the following are listed the main conclusions from the study:

Loads:

Traffic load is more concentrated in Eurocode than in Finnish code - characteristic

bending moments of main girder differ 3065 %.
Factors for traffic loads differ also significantly , in Eurocode 1,35 in Finland 1,80,
which balances the design moments when span length is 20 metres, differences are
insignificant.
There is no heavy traffic load in Eurocode, which means that design moments in deck
slab are smaller.

Ultimate Limit State:

Load of temperature variation between upper and lower surface is not included in
design moment in ULS, which also balances design moments between codes.
In checking of ultimate moment resistance for prestressed concrete girder results were
very close each other
In concrete deck slab the reinforcement calculated for bending was 2025 % bigger in
Eurocode
HUT/BE/S Pekka Pulkkinen 15 (15)

Design moment of torsion in girder bridge was 24 % bigger at end support and 8%
bigger at intermediate support in ULS.
When checking combined resistance of shear and torsion at intermediate supports the
utilization rate was only 42 % according to Eurocode while it was 60 % according to
Finnish code.
In checking combined resistance of bending and torsion only main compressive stress is
checked in Eurocode often combined resistance of bending and torsion is critical
when determining width of girder

Crack control:

According to Eurocode the amount of reinforcing steel was 25 % lower in prestressed

girder bridge. In Eurocode bridges belong to the category C

6. CONCLUSIONS

This study showed that Eurocode 2 contains much more information and details for pre- and
post tensioning structures than existing Finnish codes and design instructions. Particularly
losses of pretensioning forces and detailing of structures are clearly presented. However using
of code requires understanding and know-how of full code, because bridge parts are divided in
different codes. In order to simplify to use of codes special bridge summary parts should
prepared as was done in Germany some time ago.

The crack control differs quite much from our present practice. This was also noticed in
comparison studies where amount of conventional reinforcement became smaller than the
amount of reinforcement designed according to our code. The environmental classes and
exposure classes differ from our practise, which can be seen in maximum crack widths.

REFERENCES:

[1] European Committee for Standardization (CEN): PrEN 1992-1-1 Eurocode 2 (Draft for
Stage 49): Design of concrete structures General rules and rules for building

[2] European Committee for Standardization (CEN): PrEN 1992-2 (Draft 32): Design of
concrete structures- Concrete bridges

[3] Suomen Standardoimisliitto SFS: SFS-ENV 1992-1-1 Eurocode 2: Betonirakenteiden

suunnittelu

[4] Tiehallinto: Betonirakenneohjeet

[5] Suomen Betoniyhdistys ry: Betoninormit BY 15,1993

[6] Suomen Betoniyhdistys ry: Tartunnattomat jnteet betonirakenteissa BY 27,1988

[7] Timo Rantakokko: Tiehallinnon politiikka Eurocodeen siirtymisest sillansuunnittelussa,

31.12.2002.