PRESTRESSED CONCRETE

Ishwar Chandra Vidya Sagar

FOAP, AKTU, Lucknow
“Pre-stressing is not a technique but a principle” -Eugene Freyssinet, 1930.

Prestressing concrete, that too with high tensile steel, is a small version of
the full scope of pre-stressing.

Prestressing could be internal or external.

It can be partial, limited or full.

Introduction
• The art of prestressing is perhaps as old as the human race.
• Man tries to protect himself, against unexpected possible situations
created by external actions. It is known as anticipatory protection.
• To protect the wheels of a bullock cart from damages, metal bands
were provided. They were fitted up in enlarged conditions and then
cooled. Now, wheels are prestressed.
• In construction industry, it is used to keep the structures in a most
desirable or optimum stress level during the maximum period in their
lifetime.
• Prestressing could be achieved in any material, in any direction, and in
any form. Hence, the scope of prestressing in general is vast and all
pervasive.
• With innovation of concrete, it was found that as a material, concrete is
weak in tension, and steel reinforcing bars were introduced to provide
the required tensile resistance.
• Later human ingenuity conceived the concept of prestressing to protect
the concrete from its weakness by introducing precompression.
• Since prestressing started with concrete to protect it from tensile cracks,
the scope and understanding were limited only to prestressing of
concrete.
• Steel reinforcement was used earlier to take care of tension, hence steel
was again chosen to prestress the concrete, although prestressing could
be achieved by other means.
• With the invention of RCC a lot of controversy is centred around the
problem of cracks caused by bending stresses.
• It was essential to prevent the development of cracks which was a
general phenomenon in RCC construction.
• The cracks are detrimental as they decrease the life of structure and
resistance to bear reversal of stresses, impact, vibration and shock.
• It virtually made impossible to construct RCC bridges, water retaining
structures and large span roofs.
• This provided an incentive for finding a method of reducing tensile
stresses in reinforced concrete members under loads. Koenen made for
the first time the suggestion that to eliminate these stresses, the tension
zone in the member should be provided with an initial compression. In
1928 Freyssinet was able to show the requisites of prestressed concrete.
He enunciated how good concrete should be made and how a permanent
prestress could be achieved.
• In 1930 Freyssinet produced a structural flexural element without cracks,
which however could not last long, since the time-dependent properties
such as creep in concrete were not accounted for in the design. Later, this
was also rectified, and lead to the development of high tensile steel.
• His most significant contributions were the quantitative assessment of
creep, shrinkage and the realization that only high strength steel at a high
stress would achieve a permanent prestress in concrete.
• He explained that it was essential to use steel for prestressing which could
be stretched so much initially that after inevitable shortening of the
concrete due to shrinkage and creep, there still remained enough strain and
hence enough tensile stress in steel, to produce desired permanent
compression in the concrete.
• The other problem was for stretching and anchoring of the prestress wires.
Freyssinet invented in 1939 a double acting jack and a cone anchorage to
overcome this difficulty. Since then rapid progress has been made in the
field of prestressed concrete.
• Prestressed concrete is a modification of reinforced concrete, which
not only eliminates the weakness of concrete in tension but also makes
it possible to take full advantage of compressive strength of concrete.
• The term ‘Prestressed concrete’ is applied to those reinforced concrete
members in which concrete is subjected to compressive stresses,
before the external loads are applied, by inducing tensile stresses in the
reinforcement to counteract tensile stresses in the concrete caused
(rather will be caused) by external loads.
• Whereas the term ‘Reinforced concrete’ applies to those members that
are not prestressed and in which steel forms an integral part of the
member.
Partial prestressing
• Use of prestressing for the purpose of keeping the structure under
desirable/optimum stress level for maximum period of its lifetime, calls
for limited or partial prestressing.
• Prestressing need not be contemplated for balancing a dream load, but the
structure could be designed for such a dream load with some sacrifice in
serviceability for a small period.
• While many countries have recognized this concept of partial
prestressing, the Indian Code does not permit this in Indian
Construction Industry.
External prestressing
• Problems of cracking and serviceability distress were identified in prestressed
concrete structures created by environmental conditions or man made
situations.
• Principle of prestressing found a new way, as a replenishable resource.
• It is in the form of external prestressing.
• This has its limitations: cable profiling may be difficult, cable layout may lead
to stress concentration, anchorages outside the structural elements will be
inconvenient.
• External prestressing has also been widely used in the rehabilitation of
structures (earlier prestressed or any other structure).
• Yamuna Bridge at Noida in New Delhi is constructed with external
Prestressing. Zuari bridge at Goa and Sharavathi Bridge at Honnavar, are two
major bridges, which were brought to service by external prestressing. The Raw
Meal silos in Madhya Pradesh, which were cracked, were also recommissioned
using external prestressing.
Applications
• The application of prestressing in the past, present and extending it to
the future under different headings includes, viz., structures which are
primarily governed by flexure, form resisting structures like shells and
domes, foundations structures, prestressing of cables without concrete,
as in cable stayed bridges, and tension structures, etc.
• Prestressed concrete is recognized as not only a structural material, but
also an ingenious principle and a unique construction technology,
ideally suited for applications involving long and slender spans (bridges,
building floor systems, and shell structures), crack-free construction
(pressure vessels, nuclear containments, water tanks and pipes), and
enhanced resistance to fatigue loading (rail track sleepers, etc.).
BASIC PRINCIPLE OF PRESTRESSING
• The basic principal of prestressing concrete is very simple, if a material
has little tensile strength it will fracture immediately its own tensile
strength is exceeded, but if such a material is given an initial compression
then when load-creating tension is applied the material will be able to
withstand the force of this load as long as the initial compression is not
exceeded.
• Concrete is a material of high compressive strength with low tensile
strength and by inserting into the concrete member, steel reinforcing bars
of the correct area and fixed to a predetermined pattern ordinary concrete
can be given an acceptable amount of tensile strength.
• Prestressing techniques are applied to concrete in an endeavour to make
full use of the material’s high compressive strength.
• In normal reinforced concrete we are unable to make full use of the high tensile
strength of steel or of the high compressive strength of the concrete.
• When loaded above a certain limit tension cracks up to 0.3 mm in width will
occur in a reinforced concrete member. This stage of cracking will normally be
reached before the full strength potential of both steel and concrete has been
obtained.
• In prestressed concrete the steel is stretched and securely anchored; it will then
try to regain its original length but since it is fully restricted, it will be
subjecting the concrete to a compressive force throughout its life.
• Since the tensile strength of concrete is low a homogeneous concrete beam has
very little flexural strength, to offset this deficiency, steel reinforcement is
provided near the bottom of simple beams to carry the tensile stresses.
• However, a substantial area of concrete below the neutral axis merely retains
the reinforcement in position, but its tensile strength is neglected in the
computations for the flexural strength in case of reinforced concrete beams.
Plain Concrete
Reinforced Concrete
Prestressed Concrete
• If tensile reinforcement of beam is subjected to tensile stresses before the
external loads are applied, then compressive stresses are induced in the
concrete of the beam (tensile stresses applied by prestressing technique).
• Usually the tensile stresses in the concrete caused by external loads are
completely absorbed or counteracted by the compressive stresses in the
concrete, resulting from prestressing the reinforcement.
• The concrete is being used effectively in resisting tensile stresses
produced by external loads rather than being neglected as in case of
reinforced concrete.
• Concrete whilst curing will shrink; it will also suffer losses in cross-
section due to creep when subjected to pressure.
• Shrinkage and creep in concrete can be reduced to an acceptable level by
using a material of high strength with a low workability.
• Under load prestressed concrete member will bend or deflect and
compressive and tensile stresses will be developed in opposite faces.
• Concrete in the member will have to resist compressive stress induced by
prestress as well as compressive stress developed during bending.
• For this reason high compressive strength concrete is used in prestressed
work to gain the maximum advantage of the prestress.
• Need to use high strength concrete is that prestressed members are
generally smaller in section than comparable reinforced concrete ones.
• Mild steel will also suffer from relaxation losses, which is the phenomenon of
the stresses in steel- under load decreasing towards a minimum value after a
period of time.
• This can be counteracted by increasing the initial stress in the steel.
• If mild steel is used to induce compressive force into concrete member amount
of shrinkage, creep and relaxation that occurs will cancel out any induced stress.
• The special alloy steels used in prestressing, however, have different properties
to induce extra stress into concrete member, thus counteracting any losses due
to shrinkage and creep and at the same time maintaining the induced
compressive stress in the concrete component.
• Plainly, if the prestress is to be maintained the steel reinforcement must
not suffer permanent elongation or creep under load as does mild steel.
• High tensile wire is used in prestressed concrete to maintain the prestress
under load.
• A prestressing force inducing precompression into concrete member can
be achieved by anchoring a suitable tendon at one end of the member and
applying an extension force at the other end that can be anchored when
the desired extension has been reached.
• Upon release, the anchored tendon in trying to regain its original length
will induce a compressive force into the member. Figure shows a typical
arrangement in which the tendon inducing the compressive force is
acting about the neutral axis and is stressed so that it will cancel out the
tension induced by the imposed load W. The stress diagrams show that
the combined or final stress will result in a compressive stress in the
upper fibres equal to twice that of the imposed load. The final stress must
not exceed the characteristic strength of the concrete as per BIS
recommendations and if the arrangement given in figure is adopted the
stress induced by the imposed load will only be half its maximum.
Prestressing Principles - 1
• To obtain better economic balance the arrangement-2 is normally adopted
where stressing tendon is placed within lower third of the section.
• Basic aim is to select a stress that when combined with dead load will
result in a compressive stress in lower fibres equal to maximum stresses
induced by any live loads, resulting in a final stress diagram having in the
upper fibres a compressive stress equal to characteristic strength of
concrete and a zero stress in the bottom fibres.
It must be observed that this is the pure theoretical case and is almost impossible to achieve
in practice, but provided any induced tension occurring in the lower fibres is not in excess of
the tensile strength of the concrete used, and an acceptable prestressed condition will exist.
• Since concrete has poor tensile strength, large part of the area of ordinary
RCC beam plays little part in flexural strength of beam under load.
• In calculation of stresses in simply supported beam strength of concrete
in the lower part of the beam is usually ignored.
Prestressing Principles - 2
• When reinforcement is stretched before or after the concrete is cast and
the stretched reinforcement is anchored to the concrete, it causes a
compressive prestress in the concrete as it resists the tendency of the
reinforcement to return to its original length.
• This compressive prestress makes more economical use of the concrete
by allowing all of the section of concrete to play some part in supporting
load.
• In prestressed concrete the whole or part of the concrete section is
compressed before the load is applied, so that when the load is applied
the compressive prestress is reduced by flexural tension.
• In ordinary RCC, the concrete around reinforcement is bonded to it and
must, therefore, take some part in resisting tensile stress.
• Because the tensile strength of concrete is low it will crack around the
reinforcement under load and when load is removed cracks will remain.
• The hair cracks on the surface of concrete are not only unsightly, they
also reduce the protection against fire and corrosion the concrete cover
is intended to give.
• In designing reinforced concrete members it is usual to limit the
anticipated tensile stress in order to limit deflection and the extent of
cracking of concrete around reinforcement. This is serious limitation in
the most efficient use of RCC, particularly in long span beams.
• When reinforcement is stretched by prestressing and anchored to concrete and
the prestress is released, the tendency of the reinforcement to return to its
original length induces a compressive prestress in concrete.
• Stretching of reinforcement before it is cast into concrete is described as pre-
tensioning and stretching after concrete has been cast as post-tensioning.
• The advantage of the induced compressive prestress caused either by pre- or
posttensioning is that under load the tensile stress developed by bending is
acting against the compressive stress induced in the concrete and in
consequence cracking is minimised.
• If cracking of the concrete surface does occur and the load is reduced or
removed, then the cracks close up due to the compressive prestress.
• Another advantage of the prestress is that the compressive strength of the
whole of the section of concrete is utilised and the resistance to shear is
considerably improved, so obviating the necessity for shear reinforcement.
Difference between RCC & PSC
1. Up to 6 m span traditional RCC is the most economic method. For spans
below 6 m, normal RCC construction is generally cheaper than PSC.
2. Spans between 6 m and 9 m the two mediums are compatible.
Between 6 and 9 m PSC may or may not prove more economical according to particular job, having regard to
such factors as reduction in size and numbers of columns and foundations likely to result from use of PSC. In this
range the composite form of construction is likely to be the cheapest.
3. Over 9 m prestressed concrete is generally more economical than
reinforced concrete. For spans greater than 9 m PSC will usually show
economic advantages over RCC specially when the imposed loading is
light, as in roof construction.
4. In RCC, steel is an integra1 part of the element and designed to replace
concrete in the tension zone when it has cracked due to tensile stress.
Stress in steel varies with intensity of loading. To control cracks within
specified limit, steel is not allowed to develop full stress. In PSC, steel
provides initial compressive stresses in the concrete to resist tensile
stresses without cracking. Stress in steel does not vary with loading and
there is no need of limiting stresses in steel to do away with the cracks as
in case of reinforced concrete.
Losses in Prestress
• It has been observed that the pre-stressing force induced in a member
does not remain constant but it decreases with the passage of time on
account of various reasons.
• Total loss may be as high as 15 to 20% of the initial prestressing force.
The designer must take into account all such losses.
• The important causes of loss prestressing force are the following:
(i) Due to elastic shortening of concrete.
(ii) Due to creep in concrete.
(iii) Due to shrinkage of concrete.
(iv) Frictional loss.
(v) Due to creep in steel.
(vi) Due to slip at anchorages.
Advantages of PSC
1. Size/Dimensions of structural members reduced, which increase the clearances or
reduce storey heights.
2. Permits use of large spans (>30m) with shallow members even when heavy loads are
encountered.
3. In addition to general advantages, such as excellent fire-resistance, low maintenance
costs, elegance, high corrosion-resistance, adaptability, etc., the PSC is found to
sustain the effects of impact or shocks, and vibrations.
4. For any given span and loading conditions, a member with a smaller cross-section
can be used giving a reduction in weight. For this reason very large spans can be
built in prestressed concrete than in reinforced concrete.
5. Because of smaller loads due to smaller dimensions being used consuming less
material, there is considerable saving in cost of supporting members and
foundations.
6. The prestressing technique has eliminated the weakness of concrete in tension and,
hence crack-free members of structure are obtained.
7. Because of better materials (i.e., controlled concrete and high tension steel) being
used and nullifying the effect of dead loads, smaller deflections are caused.
Advantages of PSC
8. Makes full use of the inherent compressive strength of concrete.
9. Makes full use of the special alloy steels used to form prestressing tendons.
10. Eliminates tension cracks thus reducing the risk of corrosion of steel
components.
11. Reduction in shear stresses.
12. Individual units can be joined together to act as a single member.
13. Sufficient horizontal compression due to prestress reduces principal tensile
stresses and shear resistance is developed without heavy reinforcement or
large webs.
14. Less steel is used in the member, it is easier to place good quality of concrete
with high compressive strength than in the case of reinforced concrete.
15. For prefabricated construction, the advantages of reduction in self-weight of
the unit are obvious.
16. The cost of shuttering and centering in large structures is reduced when
prestressed precast elements are assembled.
Disadvantages of PSC
1. The unit cost of high-strength materials being used is higher. Special
alloy steels are dearer than mild steels.
2. Extra initial cost is incurred due to use of prestressing equipment and its
installation.
3. Extra labour cost for carrying out prestressing activities is also there.
4. Prestressing is uneconomical for short spans and light loads.
5. High degree of control of materials, design and workmanship required.
Prestressing methods
• Method of applying precompression by means of jacks requires strong
abutments so of limited use & less practicable for normal building works.
• Alternative method consists of stretching high-tensile steel wires which
are then anchored to the concrete member. On release of the tension on the
steel a compressive force is applied to the concrete as the steel seeks to
contract to its original length.
• Anchorage may be by means of bond between steel & concrete or by
external mechanical means at the ends of the member, and these two
methods form the main difference between the two systems of prestressing
known as -
• pre-tensioning and
• post-tensioning.
Pre-tensioning
• In this method, wires/cables are stressed before concrete is cast around
them.
• The stressing wires are anchored at one end of the mould and stressed by
hydraulic jacks from other end until the required stress has been obtained.
• It is common practice to overstress the wires by some 10% to counteract
anticipated losses that will occur due to creep, shrinkage, and relaxation.
• After stressing the wires, the side forms of the mould are positioned and
the concrete is placed around the tensioned wires; the casting is then
usually steam cured for 24 hours to obtain the desired characteristic
strength 28N/mm2 in 24 hours.
• The wires are cut or released and the bond between the stressed wires and
concrete will prevent the tendons from regaining their original length thus
inducing the prestress.
Pre-tensioning

Typical Pre-Tensioning Arrangement

Pre-tensioning
• At extreme ends of pre-tensioned members the bond between steel and concrete is not
fully developed, and for a short length, varying from 80 to 120 times the wire diameter
according to quality of concrete and roughness of surface, the wires contract in their
length with consequent loss of stress in wires, the stress at the cut end being zero.
• At the same time this contraction, is accompanied by a lateral swelling which forms a
cone like anchor. The lateral swelling of the released wires tends to occur throughout
their length, thus further increasing the bond between wires and concrete.
• The length in which this occurs is termed transfer length and requires reinforcement
for shear in the form of stirrups.
• Small diameter wires are used so that the greatest surface area is obtained to increase
the bond, and the usual diameters lie between 2 and 5 mm.
• Wires be thoroughly degreased and allowed to rust slightly in order to produce a
satisfactory surface.
• Bond between stressed wires & concrete can be improved by using crimped or
indented wires.
• Wires have tensile strengths ranging from 1540 N/mm2 for the larger diameters to
2310 N/mm2 for the smaller.
Pre-tensioning
• Although pre-tensioning can be applied to individual members formed
and stressed in their own moulds, the most usual method is that known as
the 'long line' system in which the wires are stretched within continuous
moulds between anchorages 120 m or more apart.
• The wires pass through templates at each end which position them
correctly and the ends are gripped in anchor plates.
• Spacers are placed at various intervals along the mould according to the
required lengths of units.
• The anchor plates are then jacked away the calculated distance to stretch
the wires, the concrete is poured and after it has hardened sufficiently the
wires are released and are cut between each unit.
• Pre-tensioning is used mainly by manufacturers of precast large span
components such as floor units, slabs, beams, piles, fence posts, etc.
Pre-tensioning
• For prestressing by this method, the reinforcements/tendons are placed on
the casting bed in the designed position.
• The required tension is applied in them and are anchored with anchor posts
provided at each end of the casting bed.
• Formwork is re-erected around tensioned tendons. Concrete is then
poured in the prepared formwork and is compacted and cured．
• As soon as concrete has fully hardened and developed desired strength,
the connections between tendons and anchor posts are cut off.
• Due to bond between steel and concrete, the tensioned tendons, as they
try to shorten, transfer the induced forces to the concrete. This
compresses the hardened concrete member and it is prestressed.
• Sometimes special anchorage is provided at end of member, when bond
between concrete and tendon is insufficient to retain the applied tension.
Pre-tensioning
• As strong abutments are required between which to stretch the wires pre-
tensioning is invariably applied to precast units and is usually carried out in
factory, although a prestressing bed set up on site as means of avoiding factory
overheads might prove more economical for a very large contract.
• Factory production is generally preferable since the need for close control of the
concrete preparation and its placing and of the stressing of the steel is more
likely to be satisfied under factory conditions than on the site.
• Careful control of the concrete mix and vibration are used to produce high
quality concrete, and some form of curing is normally applied to accelerate the
hardening.
• Bond between stretched wires and concrete is maintained by adhesion of cement
to the wires, by frictional resistance and tendency of wires to shorten on release
and wedge into concrete. To improve frictional resistance the wires may be
crimped or indented.
• Stressing/casting beds required for this work are too bulky for use on site.
Post-tensioning
• In this method, the concrete is cast around ducts in which the stressing tendons can be
housed and the stressing is carried out after the concrete has hardened.
• The tendons are stressed from one or both ends and when the stress required has been
reached the tendons are anchored at their ends to prevent them returning to their
original length thus inducing the compressive force.
• The anchors used form part of the finished component.
• The ducts for housing the stressing tendons can be formed by using flexible steel
tubing or inflatable rubber tubes. The void created by the ducting will enable the
stressing cables to be threaded prior to placing the concrete, or they can be positioned
after the casting and curing of the concrete has been completed. In both cases, the
remaining space within the duct should be filled with grout to stop any moisture
present setting up a corrosive action and to assist in stress distribution.
• Post-tensioning is the method usually employed where stressing is to be carried out on
site, curved tendons are required, the complete member is to be formed by joining
together a series of precast concrete units, and where negative bending moments are
encountered. Another application of post-tensioning is in the installation of ground
anchors.
 Post-tensioning

Typical Post-Tensioning Arrangement

Difference between Pre- & Post-tensioning
pre-tensioning
• it is the bond between the tendon and
concrete that prevents the prestressing
wire returning to its original length
• most suitable for the production of large
numbers of similar units, if they are of
smaller cross-section to accommodate
relatively large post-tensioning cables
• wires must be straight so that shear
resistance from curved-up wires is not
obtainable
post-tensioning
• it is the anchorages that prevent the
stressing tendon returning to its original
length
• invariably used for prestressing on the
site and for large members
• not economical for members less than 9
m long because cost of the anchorages
relative to length is high, while cost of
jacking is the same as for a long beam
• with members carrying heavy shear
loads the cables can be curved upwards
to provide added shear resistance
Systems of post-tensioning
• Freyssinet system
• Gifford Udall-CCL system
• Lee McCall system
• Magnel-Blaton system
• PSC one wire system
Freyssinet system
• System uses a cable of eight to eighteen wires of diameter 7 approx positioned
round a central open spring forming a hollow core,
• are threaded through a duct formed in the pre-cast member which is formed by
casting an inflatable rubber tube or a greased rod into the concrete and
withdrawing it when the concrete has set.
• anchorage device cast into end concrete member consisting of a concrete
cylinder with a central conical hole and a conical concrete plug grooved on the
outside to take the cable wires which are laid between the cone and the cylinder.
• wires are held between concrete conical plug and conical hole in cylinder.
• wires are stressed by means of a jack and then anchored by hammering grooved
cone into the conical hole in cylinder and wires are then released from the jack.
• Cement and water grout is then forced under pressure into the cable duct to
protect the wires from corrosion.
Freyssinet system
Freyssinet system
Gifford Udall-CCL system
• system is designed to use one to twelve wires and each wire is separately
stressed and anchored either at one or both ends of the member.
• wires diameter 5 to 7 mm are threaded into a duct in concrete member and are
anchored to steel plates by means of barrels and wedges.
• anchored individually, by means of a pair of conical half-wedges driven into a
steel barrel accommodated in an anchor plate.
• system stresses the wires one at a time, precise stress in each wire is controlled,
whereas in the Freyssinet system, all wires are jacked together and if one were
to break, the remaining wires would take up its share of the total stress and
might be overstressed
• Secondary reinforcement is usually required in concrete immediately behind
the anchorages, and vertical stirrups at the ends of the beam to distribute the
local loading from the anchorage of the cables.
• When the wires have been stressed, the duct through which they pass is filled
with cement grout.
Gifford Udall-CCL system
Lee McCall system
• System uses alloy steel rods from 13 to 29 mm diameter instead of cables.
• threaded through a duct in concrete member and stressed by locking a nut
• The rods are anchored, after stressing by jack, by means of a special nut
screwed on to the threaded end of the rod, the thread of nut and rod being
so designed that the load is transferred by degrees to the nut in such a
way that stress concentrations are largely eliminated.
• It is possible with this system to re-stress the rods at any time before
grouting in, so that the loss of pre-stress due to shrinkage and creep in the
concrete may be wholly restored if desired.
Lee McCall system
Magnel-Blaton system
• High tensile wires are arranged in layers of four wires each and are held
in position by metal spacers.
• The layers of wires are threaded through a duct in the concrete member.
• One end of the wires is fixed in metal sandwich plates against an anchor
plate cast into the concrete.
• Pairs of wires are stressed in turn and wedged in position by steel wedges
to grooved steel plates, each of which anchors eight wires.
• The stressed wires are grouted in position in the duct by introducing
cement grout through a hole in the top of member leading to the duct.
Magnel-Blaton system
Magnel-Blaton system
PSC one wire system
• System stresses the wires from 5 to 7 mm diameter one at a time.
• One, two, or four high tensile wires are cast inside a sheath in the
concrete member.
• They are anchored individually, by a single-piece split sleeve driven into
the tapered hole of an anchor block.
• After stressing the duct is grouted as previously described.
• Secondary reinforcement is usually required in the concrete immediately
behind the anchorages, and vertical stirrups at the ends of the beam to
distribute the local loading from the anchorage of the cables.
PSC one wire system