Aalto University

School of Engineering
Department of Structural Engineering and Building Technology

Rak-11.3001 Design of Bridges 21.11.2012

Prestressed Concrete Bridges

Markus Fränti

Jenni Pellinen
Contents

1 Introduction .....................................................................................................................3

1.1 The concept of prestressed concrete..........................................................................3

1.2 History of Prestressed Concrete Bridges ...................................................................4
1.3 Types of Prestressed Concrete Bridges .....................................................................6
1.4 Distinctive Features ..................................................................................................7
1.5 Examples of prestressed concrete bridges .................................................................8
2 Design of pre-stressed bridges .......................................................................................11

2.1 Basics ..................................................................................................................... 11

2.2 Principle ................................................................................................................. 12
2.3 Basic Equations ...................................................................................................... 12
3 Benefits and disadvantages of prestressed concrete bridges ........................................... 17

Literature.............................................................................................................................. 18
Symbols and abbreviations

M Bending moment

w Deflection of the beam

E Modulud of Elasticity

I Moment of Inertia

P Tension force
1 Introduction

1.1 The concept of prestressed concrete

Prestressed concrete is made by stretching high tensile steel cables between abutments at the
casting bed. Concrete is then poured into the forms. As the concrete sets, it bonds to the ten-
sioned steel. When the concrete reaches a specific strength, the cables are released from the
abutments.

The basic goal is to decrease deflection. This can be accomplished by applying compressive
force to the beam to neutralize the tension force caused by self-weight as shown in figure 1.

Figure 1. Diagram of prestressing forces [1].

Self-weight causes tension force to the beam and the beam to deflect. When compressive
force is applied tension force can be made to disappear. Compression is applied by prestress-
ing the steel cables. Prestressing causes the beam to deflect upward. When the beam is re-
leased the tension force due to self-weight and the compressive force due to prestressing neu-
tralizes each other. Basically self-weight is taken out of the equation with prestressing.

The advantages of prestressed concrete bridges are

decreased creep and shrinkage of the concrete

decreased deflection
decreased cracking of the concrete deck
 increased service life
increased load-carrying capacity
longer spans
faster construction phase
decreased false work
slenderness
water tightness
saving on materials.

1.2 History of Prestressed Concrete Bridges

In 1872 an American engineer P.A. Jackson patented a system of iron tie rods trough blocks
and tightening them with nuts [2]. In 1888 a German engineer W. Döring patented a system
for the construction of slabs, planks and beams which cracking was reduced by the use of pre-
stressed wires [3].

Major prestressing losses, use of low-strength steel and poor stressing systems were a prob-
lem. Therefore large cracking and deformations were unavoidable and the use of prestressed
concrete in bridge building was not fully adopted. World’s first prestressed concrete bridge
was built in Aue, Germany completed in 1937 (figure 2).

Figure 2. First prestressed concrete bridge in Aue, Germany [3].

The bridge consisted of three spans of 25,2m, 69,0m and 23,4m. The German engineer Dis-
chinger used steel bars of 70 mm in diameter prestressed to 220 MPa (42% of tensile
strength). The steel bars were prestressed by pushing them away from the structure. After 25
years 75 % of the initial prestress had been lost due to creep and shrinkage which resulted in
large cracks and vertical deflection, w = 200 mm. [3]

From 1928 to 1936 a French engineer E. Freyssinet developed and patented stressing jacks
and anchors. Freyssinet insisted the use of high-strength steel bonded to the concrete. He also
discovered the phenomena of creep in concrete where the concrete deforms over time when
placed under stress. Freyssinet constructed 55 m long Luzancy Bridge over the Marne com-
pleted on 1945 (figure 3). [3]

Figure 3. Luzancy Bridge, France, by E. Freyssinet. [4]

Freyssinet’s ideas guided the further development of prestressed concrete. The use of high-
strength steel increased the load-carrying capacity which rapidly increased the use of pre
stressing in bridge building.
1.3 Types of Prestressed Concrete Bridges

Types of prestressed concrete bridges are box girder, T-girder and multiple-cell box girder.

Figure 4. Box girder cross-section. Felsenau Bridge, Berne, Switzerland (1975) [3].

Figure 5. T-girder cross-section. Vorland Bridge, Germany (1968) [3].

Figure 6. Multiple-cell box girder. Grenzbrücke, Basel, Switzerland (1980) [3].

1.4 Distinctive Features

Typically prestressed concrete bridges are slender, visually unremarkable and simply formed
constructions. They can good places where the environment requires not so massive bridges
as shown in figure 9.

Figure 7. Medway Bridge under construction (UK, 1964) [2].

Figure 8. Medway Bridge finished [2].

Figure 9. Kylesky Bridge, Cunhamn, Scotland (1984) [2].

1.5 Examples of prestressed concrete bridges

World’s longest prestressed concrete bridges are show in table 1 and in figures below. The
longest bridges in Finland are in table 2.

Table 1. The Longest Prestressed Concrete Bridges in the world. [5]

No. Bridge Span Built Country / Location Note
[m]
1 Shibanpo 330 2006 China / Chongqing 1.)
Fig. 10 & 11
2 Stolmasundet 301 1998 Norway / Austevoll Figure 12
3 Raftsundet 298 1998 Norway / Lofoten Figure 13
4 Sundöy 298 2003 Norway / Leirfjord
5 Beipanjiang 2012 290 2012 China / Guizhou
6 Humen-2 270 1997 China / Guangdong
7 Sutong-2 268 2009 China / Suzhou-Nantong
8 Honghe 265 2003 China / Yuanjiang
9 Gateway-1 260 1986 Australia / Birsbane
10 Varodd 260 1994 Norway / Kirstiansand

1.) Central part of the main span is a steel girder

Figure 10. Shibanpo Bridge span 330 m, China [7].

Figure 11. Shibanpo Bridge, China. [6]

Figure 12. Stolmasundet Bridge, Norway. [8]

Figure 13. Raftsundet Bridge, Norway [9].

Table 2. The longest Prestressed Concrete Bridges in Finland [5]

No. Bridge Span Buil Location Note
[m] t
1 Norrströmmen 135 1986 Nauvo Figure 14
? Wattkast 76 2004 Saaristomeri
Figure 14. Norrströmmen Bridge in Nauvo, Finland [10].

Length of the spans in Norrströmmen are 30 + 80 + 135 + 65 m. The bridge is a box girder
bridge constructed in 1986.

Figure 15. Wattkast Bridge, Finland [10].

2 Design of pre-stressed bridges

2.1 Basics

Prestressed bridge design usually starts with a preliminary tendon-braid design. It is very es-
sential to think about how the braid is lifted by higher up, and how the tendon descends down
to the field. Sharp bends tendon cannot be done, so the status of booking and gentle curves
planning is therefore a key part of the preliminary design. Figure 16 shape design sketching
up. Why as the figure shown in above is not too real implement?

Figure 16. Basic prestressed beam.

One of the most important things is to understand the used terminology about prestressed
structures (figure 17). Net cross-section is used by design of braids, and in the steel area per-
centage deducted from the total surface area. Steels item is assumed, therefore, hollow holes.
Cross-section obtained when the surface of steels replaced by concrete. Area is calculated
thus failing to completely ignore the steels in concrete and replacing them with concrete. The
dimensioning of the core cross-section is modified cross-section. The modulus of elasticity of
the steel is chanced to the E of the concrete with the coefficient ns (1).

ns = Es / Ecm (1)

This concrete surface area is the actual geometric surface area significantly greater. This
cross-section is used to determine crack deflection creep-estimates the structure. The modified
cross-section is right design simplification of the structure, which is the union of the effects
adding components. Such components include, for example, the surface of concrete, steel re-
inforcement and concrete beam elastic coefficient different from the materials.
Figure 17. Cross-sections types.

2.2 Principle

Prestressed structures collapse mechanism is substantially different compared whit the normal
passive reinforced structures. Tendons tension causes in the opposite direction compressive
stress in the concrete (figure 18).

Figure 18. Stress diagram.

For that reason, the designer has to simultaneously consider the concrete compressive
strength, and tensile capacity of the tendon. Normally, the structures planned to be imple-
mented flexion-tension-breaking. Before the structure lose the bearing capacity it occurs large
deflections in the structure. This caution is safe report that bearing load is exceeded.

2.3 Basic Equations

The following figure (figure 19) shows the most important equations which can be solved by
the maximum load, if the tendon force is well known. Also the pre-stressing force is possible
to solve about the function. In this case the load have to well known. Equations not observe
that in the fact the tension force is not transmit in full to the braid, because the phase-locking
occurs the tension lose. This reduces the actual braiding tension, which have to be taken into
the calculations. If the tendon braid angle changes very much it will produce friction loss.
Friction losses cause that the braid tension is not same whole the time. In generally the fric-
tion loses depending on how far the angle change is from the active end. It could be assume
that the friction losses occurring during the first trimester of the beam length. Friction losses
have to be taken carefully into planning. Normally the friction loss cannot be completely re-
moved, but the precise geometric design is the essential element of it, how much friction loss-
es effects on.

Figure 19. Formulary for tension force stability.

Tendon braids ccontact of the concrete could be designed differently depending on it what
kind of method is used. Injection anchor tendon is a strand, casting, and the tension then in-
jected into the cladding inside injection concrete mass. In this case, the concrete protect ten-
don braids from corrosion and moisture. In some cases the injection could be partial injection
procedure. Such a process can control relaxation better. Also, different loads may cause that
the braid is not fully injected.
Non-hook tendon is a braid, which is a lubricant within the cable protection. This cable is not
hooked to the slab. Very rarely, the tendon is completely non-hooked, but in certain circum-
stances this can be arranged. Serviceability could be one reason why this kind of method is
used. Grease protects against corrosion then braid and moisture. Cure of the concrete in these
cases is extremely important.

Typical plan view of tendons for continuous girder is shown in figure 20. The layout of the
cables must be carefully planned because there is not much extra room.

Figure 20. Tendon layout for continuous girders. Tendons lapped at intermediate supports.
[3]
Figure 21. Tension bars in the concrete slab before the casting step.

In figure 21 tendons are show right before the casting of the concrete. Note the covered ten-
dons (black in the picture). Supporting braids are often ordinary concrete steel. Anchor end
are often outside of the casting. It will cast after the tension has been done successfully.
Figure 22. Tendon roll.

Figure 23. Anchor end.

3 Benefits and disadvantages of prestressed concrete bridges

Deflections are possible to get much smaller compared whit corresponding passive re-
inforcement mention.

Concrete consumption is smaller compared with normal mention. Slender structures

are possible to do only this mention.

Guite safe to use and it is possible to exploit both materials benefits. Concrete com-
pressive strength, Steel good tension strength.

Bridges spans could be longer. Otherwise, the intermediate supports are needed more.

Requires special know-how. Very often this mention is expensive to operate. Foreman
in Finland need an AA-gualifigation.

Works must be fairly large in order to pre-stress worthwhile. Not suitable for individ-
ual foundations and structural elements.

Errors and mistakes difficult to cure. The success of the tension is always at the theo-
retical level than in practice.

Locking and friction losses are eating beneficial stress method.

Figure 24. Old Myllysilta Bridge, Turku, Finland, span of 92,7 m (1975-2010).
Literature

[1] http://en.wikipedia.org/wiki/File:Prestressed_concrete_en.svg. 18.11.2012

[3] Menn, Christian, 1990, Prestressed Concrete Bridges, Birkhäuser Verlag, Basel, ISBN
0-8176-2414-7
[2] Brown, David J., 1996, Bridges Three thousand years of defying nature, Mitchell
Beazley, London, ISBN 1-85732-163-4
[4] http://test.classconnection.s3.amazonaws.com/830/flashcards/400830/jpg/luzancy.jpg.
18.11.2012
[5] http://bridge.aalto.fi/en/longspan.html. 18.11.2012
[6] http://en.wikipedia.org/wiki/File:Shibanpo-bridge.svg. 18.11.2012
[7] http://sunengineering.cn/siteen/hxcydbxm/897.html. 18.11.2012
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[9] http://www.stalite.com/continuing-education.php?cat=117
[10] http://torsti.pp.fi/sillat/sillat/0058.htm. 18.11.2012