Prestressed Concrete

Prestressed concrete is a method for overcoming concrete's natural weakness in

tension. Prestressing tendons (generally of high tensile steel cable or rods) are
used which produces a compressive stress that offsets the tensile stress that the
concrete compression member would otherwise experience due to self–weight and
gravity loads. Traditional reinforced concrete is based on the use of steel
reinforcement bars, rebar, and inside poured concrete.

Prestressing can be accomplished in two ways: pre-tensioned concrete and bonded or

unbounded post-tensioned concrete.
Pre-tensioned Concrete
Pre-tensioned concrete is cast around already tensioned tendons. This method
produces a good bond between the tendon and concrete, which both protects the
tendon from corrosion and allows for direct transfer of tension. The cured concrete
adheres and bonds to the bars and when the tension is released it is transferred to
the concrete as compression by static friction.

However, it requires stout anchoring points between which the tendon is to be

stretched and the tendons are usually in a straight line. Thus, most pretensioned
concrete elements are prefabricated in a factory and must be transported to the
construction site, which limits their size. Pre-tensioned elements may be balcony
elements, lintels, floor slabs, beams or foundation piles. An innovative bridge
construction method using pre-stressing is described in stressed ribbon bridge.
Bonded Post-Tensioned Concrete
Typical Layout of Bonded SystemBonded post-tensioned concrete is the descriptive
term for a method of applying compression after pouring concrete and the curing
process (in situ). The concrete is cast around a plastic, steel or aluminium curved
duct, to follow the area where otherwise tension would occur in the concrete
element. A set of tendons are fished through the duct and the concrete is poured.

Once the concrete has hardened, the tendons are tensioned by hydraulic jacks that
react against the concrete member itself. When the tendons have stretched
sufficiently, according to the design specifications (see Hooke's law), they are
wedged in position and maintain tension after the jacks are removed, transferring
pressure to the concrete.

The duct is then grouted to protect the tendons from corrosion. This method is
commonly used to create monolithic slabs for house construction in locations where
expansive soils (such as adobe clay) create problems for the typical perimeter
foundation. All stresses from seasonal expansion and contraction of the underlying
soil are taken into the entire tensioned slab, which supports the building without
significant flexure.

Post-stressing is also used in the construction of various bridges, both after

concrete is cured after support by falsework and by the assembly of prefabricated
sections, as in the segmental bridge.The advantages of this system over unbonded
post-tensioning are:
Large reduction in traditional reinforcement requirements as tendons cannot
destress in accidents.
Tendons can easily be 'weaved' allowing a more efficient design approach.
Higher ultimate strength due to bond generated between the strand and concrete.
No long term issues with maintaining the integrity of the anchor/dead end.
Unbonded Post-Tensioned Concrete
Typical Layout of Unbounded SystemUnbonded post-tensioned concrete differs from
bonded post-tensioning by providing each individual cable permanent freedom of
movement relative to the concrete. To achieve this, each individual tendon is
coated with a grease (generally lithium based) and covered by a plastic sheathing
formed in an extrusion process. The transfer of tension to the concrete is achieved
by the steel cable acting against steel anchors embedded in the perimeter of the
slab.

The main disadvantage over bonded post-tensioning is the fact that a cable can
destress itself and burst out of the slab if damaged (such as during repair on the
slab). The advantages of this system over bonded post-tensioning are:
The ability to individually adjust cables based on poor field conditions, e.g.,
shifting a group of 4 cables around an opening by placing 2 to either side).
The procedure of post-stress grouting is eliminated.
The ability to de-stress the tendons before attempting repair work.
Post-Tensioning in Building Structures
Market Factors Favoring the Post-tensioning System

Followings are the market factors, which favor implementing Post-Tensioning system
in Building structures:Dubai Pearl Project
Longer spans
Unique designs: irregular shapes
Shorter construction cycles
Cost reduction
Shorter floor-to-floor heights
Superior structural performance
Direct Cost Reduction
Beach Tower, Sharjah, UAE

Direct Cost Comparision between RC and PT Systems

Cost structure of RC vs. PT SlabsPost-tensioning offers direct cost reduction over

conventionally reinforced slabs primarily by reducing concrete and rebar material
quantities as well as rebar installation labor. Typically, savings between 10%–20%
in direct cost are achieved.

Followings are the factors which contribute to direct cost reduction:

Less concrete material
Reduction in slab thickness reduces total building height and cost
Less rebar
Less labor cost for installation of material
Reduced material handling
Simplified formwork leads to less labor cost
Rapid reuse of formwork leads to less formwork on jobsite
As a rule, the break even mark between conventional and prestressed solutions is
approx. 7m spans.

In a typical slab with spans over 7 meters, the net savings in material cost can
range between 10%–20% of original RC alternative. A typical comparative cost
structure is shown on the next page:

Material represents 60% of direct cost of a post-tensioning system. Cost structure

of PT System is shown there.
Improved Construction Efficiency
Construction CycleSince post-tensioned slabs are designed to carry their own weight
at time of stressing, they can significantly improve construction efficiency and
deliver an additional 5%-10% of indirect savings.

Following factors contribute to improved construction efficiency:

Shorter construction cycles
Less material handling and impact on other trades
Simpler slab soffit–less beams and drop caps/panels
Quicker removal of shoring gives more access to lower slabs
Typical 5-Day Construction Cycle schedule for 800-1,000 m2 of slab is shown below.
3-day cycle is also achievable with early strength concrete and industrial
formwork.
Superior Structural Performance
The prestressing in post-tensioned slabs takes optimal advantage of tendon, rebar
and concrete properties to deliver an economical structural system.

Factors contributing to superior structural performance are listed here:

Use of high-strength materials
Deflection control
Longer spans are achieved
Crack control and water-tightness
Reduced floor-to-floor height
Lighter structure requires lighter lateral load resisting system
Economy in column and footing design
Reduced noise transmission compared to RC
Lower total cost of ownership (maintenance) compared to RC alternatives
Typical Quantities
Post-Tensioning and rebar rates vary greatly depending on span configuration and
loading. Compared to other countries, PT projects in US are designed with less
loading and lower PT and rebar rates.
Bonded System
Layout of Original Design

Layout of Alternate DesignUS values (1 kN/m2 SDL & 2.5 kN/m2LL)

3 – 4 kg/m2 of PT
5 kg/m2 of Rebar
With higher loading (3 kN/m2SDL & 3 kN/m2LL)
3.5 – 5 kg/m2of PT
7 – 9 kg/m2of Rebar
Unbonded System
US values (1 kN/m2SDL & 2.5 kN/m2LL)
3.75 kg/m2of PT
6 kg/m2of Rebar
Case Study of Value Engineering
Legend Plaza, Dubai, UAE is designed using ADAPT-Floor Pro (www.adaptsoft.com).
Salient features of this project are listed here:
Project Parameters
Gross Floor Area–Superstructure: 72,000 m2
Typical Floor Gross Area: 11,000 m2
Total Floors: 7
Typical Floor Slab Spans: 10 m max / 8 m avg.
Type and Location
Type of Structure: High-end Residential
Location: Dubai, UAE
Construction Date: Aug 2004 – Jan 2005
Project Team
Prime Structural Engineers: Adnan Saffarini
Contractor: SBG
Client: Private Investment
PT Supplier: Freyssinet Gulf
PT Value Engineers: ADAPT Corporation
Design Criteria
Design Code: BS-8110
Concrete Compressive Strength Fcu: 40 MPa
Reinforcement Yield stress:460MPa
Superimposed Dead Load: 6 kN/m2
Design Live Load: 2 kN/m2
Original Design
Original Floor System: Hourdy Slab System
Depth of Floor System: 380 mm
Boundary Beams: Yes
Alternative Design offered by Freyssinet & ADAPT
Post-tensioned Floor System: 2-way Flat Plate
Depth of Slab:220 mm
Boundary Beams: None
Benefits
70 % less rebar
13 % less concrete
Elimination of all Hourdy Blocks
Unified structural slab system
Beams & drop caps were deleted, simplifying slab installation
25% less formwork
3 months shorter construction program
15% savings in site overhead and plant
Value engineering saved Contractor over 1 million US$.
References
Wikimedia Foundation, Inc., (http://en.wikipedia.org)
ADAPT Corporation (http://www.adaptsoft.com)
Interested readers can contact the author at intl@adaptsoft.com
NBMCW October 2008

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