The act of applying forces to a structure, other than the loads the structure is designed to carry, in order to enhance

the structures ability to carry those loads.

Principles of prestressing Concrete has a low tensile strength but is strong in compression: by pre-compressing a concrete element, so that when flexing under applied loads it still remains in compression, a more efficient design of the structure can be achieved.

Advantages of Prestressing over ordinary reinforced concrete

Prestressing minimizes the effect of cracks in concrete elements by holding the concrete in compression.
Prestressing allows reduced beam depths to be achieved for equivalent design strengths.

Prestressed concrete is resilient and will recover from the effects of a greater degree of overload than any other structural material.
If the member is subject to overload, cracks, which may develop, will close up on removal of the overload. Prestressing enables both entire structural elements and structures to be formed from a number of precast units, e.g. Segmented and Modular Construction. Lighter elements permit the use of longer spanning members with a high strength to weight characteristic. The ability to control deflections in prestressed beams and slabs permits longer spans to be achieved. Prestressing permits a more efficient usage of steel and enables the economic use of high tensile steels and high strength concrete.

Forms of Prestressing Steel

1. Wires Prestressing wire is a single unit made of steel. 2. Strands Two, three or seven wires are wound to form a prestressing strand. 3. Tendon A group of strands or wires are wound to form a prestressing tendon. 4. Cable A group of tendons form a prestressing cable. 5. 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.

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.

 The prestressing of concrete has several advantages as compared to traditional reinforced concrete (RC) without prestressing. A fully prestressed concrete member is usually subjected to compression during service life. This rectifies several deficiencies of concrete. Advantages of Prestressing

1) Section remains uncracked under service loads Reduction of steel corrosion Increase in durability. Full section is utilised Higher moment of inertia (higher stiffness) Less deformations (improved serviceability). Increase in shear capacity. Improved performance (resilience) under dynamic and fatigue loading.

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 Prestressed Slab 28:1 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.

3) The advantages of precast construction are as follows.

Rapid Better

construction quality control

Reduced Suitable Multiple

maintenance

for repetitive construction

use of formwork Reduction of formwork standard shapes.

Availability of

P-T v/s R.C.C.~ A Cost Benefit Ratio: P-T reduces the concrete volume by 10 to 20% Cost of reinforcing is typically 20 to 30% less Formwork can be stripped off after 6-7 days (as soon as stressing is completed), thereby saving time & money by achieving project target completion before the due date. Average bay (Column) spacing is 25 to 30 feet without increase in the slab thickness, thus saving construction cost Concrete Slabs are thinner and consequently lighter and less costly.

More clear Headroom obtained through P-T Assembly Installation. Cost Benefit in Electrical Conduits (per ft.) & relative consumption of accessories, fixtures, thereby enhancing uninterrupted electrical work.
For flat slab in 8m x 8m or 9m x 9m Grid, P-T costs approximately Rs. 40 to 50 per sq. ft. with any kind of desired geometry availed better than R.C.C. Since the reinforcement is protected, P-T reinforced structures have lower annual maintenance costs over time (life cycle costs) Prestressed concrete not only saves money, but also results in a better overall performance as PT reinforced structures have higher durability and lower Maintenance costs.

Limitations of Prestressing

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 equipments. There is need for quality control and inspection.

TYPE OF PRESTRESSING SYSTEMS Prestressing System can be classified by two basic methods, as under:a. Pre-Tensioning b. Post-Tensioning. Pre-Tensioning - is a method where Prestressing Steels are pre-stressed, prior to concreting, against two rigid abutments. This method is most widely used for mass production of short span structures, where pre-stressing is also a prerequisite, such as; Railway Sleepers, Electric Polls, Fencing Polls, PreTensioned Slabs and ISection Bridge Girders etc.

Post-Tensioning - is a method where Prestressing Steels are stressed after concrete attains its preliminary strength. Two extreme ends of the structure are considered as a reaction face, against which force is applied.

Ducts are placed inside the formwork along with reinforcement and the concreting is completed.
After achieving required concrete strength, a stipulated numbers of Prestressing Steel is then inserted in each duct for stressing purpose. After achieving required elongation and stresses they are blocked at two ends with the help of Anchor Plates and grip.

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.

Prestressing is further divided in the following ways as per the Location of Application. 1. 2. 3. 4. 5. 6. External and Internal Prestressing Pre Tensioning and Post Tensioning Linear and Circular Prestressing Full, Limited or Partial Prestressing Uniaxial, Biaxial or Multiaxial Prestressing Multiaxial Prestressing

Types of Prestressing
External Prestressing
When the prestressing is achieved by elements located outside the concrete, it is called external prestressing.

The tendons can lie outside the member (for example in I-girders or walls) or inside the hollow space of a box girder.
This technique is adopted in bridges and strengthening of buildings. In the following figure, the box girder of a bridge is prestressed with tendons that lie outside the concrete.

External prestressing of a box girder

Internal Prestressing When the prestressing is achieved by elements located inside the concrete member (commonly, by embedded tendons), it is called internal prestressing. Most of the applications of prestressing are internal prestressing. In the following figure, concrete will be cast around the ducts for placing the tendons.

Internal prestressing of a box girder

Pre-tensioning The tension is applied to the tendons before casting of the concrete. The pre-compression is transmitted from steel to concrete through bond over the transmission length near the ends.

Pre Tensioned Electric Poles

Post-tensioning The tension is applied to the tendons (located in a duct) after hardening of the concrete. The pre-compression is transmitted from steel to concrete by the anchorage device (at the end blocks).

Post-tensioning of a box girder

Linear Prestressing When the prestressed members are straight or flat, in the direction of prestressing, the prestressing is called linear prestressing. Prestressing of beams, piles, poles and slabs. The profile of the prestressing tendon may be curved.

Linearly prestressed railway sleepers

Circular Prestressing When the prestressed members are curved, in the direction of prestressing, the prestressing is called circular prestressing. For example, circumferential prestressing of tanks, silos, pipes and similar structures..

Circularly prestressed containment structure

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.
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. 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.

Uniaxial, Biaxial or Multiaxial Prestressing

Uniaxial Prestressing When the prestressing tendons are parallel to one axis, it is called Uniaxial Prestressing. For example, longitudinal prestressing of beams. Biaxial Prestressing When there are prestressing tendons parallel to two axes, it is called Biaxial Prestressing.

Biaxial prestressing of a slab

Multiaxial Prestressing When the prestressing tendons are parallel to more than two axes, it is called Multiaxial Prestressing. For example, prestressing of domes.

Advantages of Post Tensioning over Pre - Tensioning

Rapid construction Economy Maximum design flexibility Minimum storey heights Minimum number of columns Optimum clear spans Joint-free, crack-free construction Controlled deflections.
Post-tensioned floors may be totally of in-situ concrete or a hybrid of in-situ and precast concrete. Either may be prestressed or a combination of prestressed and reinforced. They can be designed as two-way spanning flat slabs, one-way spanning ribbed slabs, or as banded beam and slab construction. Flat slabs are supported, without the use of beams, by columns with or without column heads. They may be solid or may have recesses formed in the soffit to create a series of ribs running in two directions (waffle or coffered slab).

Source of Prestressing Force

Hydraulic Prestressing This is the simplest type of prestressing, producing large prestressing forces. The hydraulic jack used for the tensioning of tendons, comprises of calibrated pressure gauges which directly indicate the magnitude of force developed during the tensioning.

Mechanical Prestressing
In this type of prestressing, the devices includes weights with or without lever transmission, geared transmission in conjunction with pulley blocks, screw jacks with or without gear drives and wire-winding machines. This type of prestressing is adopted for mass scale production. Electrical Prestressing In this type of prestressing, the steel wires are electrically heated and anchored before placing concrete in the moulds. This type of prestressing is also known as thermo-electric prestressing. Chemical Prestressing A concrete made with expansive cement and reinforcement under conditions such that tensile stress is induced in the reinforcement as a result of the expansion of the cement, so as to produce prestressed concrete.

Anchorage systems Prestressing forces of the Tendons are transferred to the concrete structures through Anchorages. Anchorage for the Post Tensioning system normally comprises of a steel plates with a number of conical holes, the conical Grips and the Guide (Trumpet). Trumpet or Guide is used to connect the ducts and provides a flat surface for locating the Bearing Plate on it.

Prestressing anchorages

a. Guide - This is specially formed component made out of graded Cast iron, which generally gets embedded in the concrete and used to distribute the tendon forces to the concrete.
b. Bearing Plate - This is cylindrical round shaped component made out of forging of graded Alloy Steel. This plate contains a number of tapered holes for wedging the Prestressing Steel with the help of grips. c. Grips & Circlips - This is a tapered shaped components made out of Alloy Carbon Steel and subsequently hardened & tempered. These grips are silted in three equal parts to work like a split jaws and contains serrations inside.

Flat anchorages
The components and the functions of the FLAT ANCHORAGES are similar to that of Prestressing . Anchorages, but they are specially designed in flat shape for use in slab stress applications.

Blind end anchorages:

A Blind End Anchors are used where the end of the Prestressing cable is buried in concrete and or the location is in-accessible for stressing of the tendons. BLIND-END Anchorages are also available for complete range.

Anchorage couplers:
In the construction of continuous deck bridges, it is essential to extend Prestressing cables as the construction proceeds. In COUPLER arrangement, the first stage of Stressing is carried out in the same way as with the standard Anchorage, except that one COUPLER RING is placed between the GUIDE and the BEARING PLATE. The coupler Ring contains the required number of slotted lugs to accommodate SWAGED GRIPS fitted on the strands for Second stage cable.

After the completion of first stage of prestressing and grouting, the strands fitted with swaged grips are installed for second stage stressing. Swaged grips are prepared with the help of a specially designed sleeves and locks, on an extrusion press. The strands are then deflected through a conical shaped trumpet called REDUCER CONE, which also prevents ingress of concrete and slurry during casting of second stage. This Reducer Cone provides a grout exit point, which should be placed at the top location to prevent any air being trapped during grouting. Small end of the Reducer cone is securely tapped to the duct of second stage.

Tendon ducts (sheathing):

Sheathing is used to create a void in the concrete structure, through which the stressing steels are inserted and remain free to stretch during stressing operation. Sheathings are available in two types: A) Metallic Ducts B) H.D.P.E. Ducts A. Metallic Ducts: Metallic Sheathing ducts are manufactured, by rolling CRCA Steel Strips with a spiral corrugation throughout its length. These corrugations provide better bonding with the Concrete from outside and the Cement Grout from inside. Spiral corrugations also work as a helical thread and facilitate coupling of two ducts by screwing another oversize duct. This way a continuous length of the duct can be formed. These ducts are available in different diameters and varying wall thickness to suit various configurations of Tendons. Since these ducts are made out of Steel and the chances of corrosion is very high and hence a lot of precautions are needed to store them at work site. However coated steel strips are some times used to protect them for corrosion for a longer period and enhance its service life.

B. H.D.P.E. Ducts: Non-metallic ducts are made out of High Density Poly Propylene (HDPE) or Poly-Propylene and have a number of advantages over metallic ducts, such asI. They are highly corrosion resistant II. They are effectively resistant to passage of chloride ions. III. They are very poor for electrical conductivity. IV. The duct materials has a high co-efficient of thermal expansion (Typically - 140 x 10 -6 degC) V. It has a low Youngs Modulus (Nearly 800 N/mm2 ) VI. Can be sealed against ingress of contaminants. VII. Can be pressure tested during construction to demonstrate integrity.