PC - 01 Concept 2023 04 05

Prestressed Concrete / Beton Precomprimat
Dr. NAGY-GYÖRGY Tamás

Professor
Dr. CLIPII Tudor

Professor
E-mail:
tamas.nagy-gyorgy@upt.ro
Tel:
+40 256 403 935
Web:
http://www.ct.upt.ro/users/TamasNagyGyorgy/index.htm
Office:
A219
Dr. Nagy-György T. © Faculty of Civil Engineering

1. HISTORY OF PRESTRESSED CONCRETE
2. BASIC PRINCIPLE
3. ADVANTAGES AND DISADVANTAGES
4. SPAN & CROSS SECTION SELECTION
5. TYPES OF TENDONS
5. TYPES OF PRESTRESSING
Dr. Nagy-György T. © Faculty of Civil Engineering 2

PRESTRESSING IS NOT A NEW IDEA!

IT IS INSTINCTIVE IN US!
Gustave Magnel’s drawing

that explains prestressing
By heating the metal hoop in fire

Pre-tensioning spokes in a bicycle wheel and subsequent cooling by watering
TRIAL WORKS WITH PRESTRESSING

1858 to 1888 Peter H. Jackson (US) (1829–1908) obtained at
least five patents by developing systems of applying prestress
to building construction
1888 C. F. W. Döhring (GER) – patent for the first prestressed

structural system in Europe
1894 François Chaudy (FRA) - theoretical proposal consisted Prestressed masonry arches –
of casting a beam with a groove along the center of the soffit, Peter H. Jackson (1872)
then, a bar placed in the groove is tensioned against cast-iron
caps placed at both ends, causing a uniform negative
moment.
1903 (or 1909) Charles Rabut (FRA) built a prestressed concrete cantilever spanning 7 m
1906 Mathias Koenen (GER) performed a series of tests on prestressed concrete elements
with the reinforcement pretensioned before the concrete was placed.
1907 Jens G. F. Lund (NOR) - two patents on prestressed masonry. Designed flat soffit floors
composed of precast concrete elements that were assembled and posttensioned

TRIAL WORKS WITH PRESTRESSING

1908 Charles R. Steiner (California) patented the first system of prestressed concrete that
explicitly tried to counteract the variation in concrete properties over time
1916 Walter Wilson (British) - a patent for precast, prestressed concrete floors and beams
1918 Frederick Bolton (British) - a patent for a system to prestress U-shaped segmental
concrete molds for beams or arches where concrete was subsequently placed
1919 Karl Wettstein (Czechoslovak) started producing prestressed, precast concrete joists
using thin wires directly bonded to the concrete
1923 Fritz Emperger (Austria) described a system for producing pipes of prestressed concrete
with spiral wires pretensioned
1927 Richard Färber (GER) secured a patent to obtain unbonded prestressed rods
1928 Franz Dischinger (GER) patent of a system related to his prestressed concrete
designs system. A new system was used for bridge in Aue, famous for being the first proposed
externally prestressed concrete bridge.

1928 Eugène FREYSSINET

French engineer, intellectual father of
prestressed concrete, devotes his life exclusively to
prestressed concrete
→ FREYSSINET with Jean Seailles first

patents: concrete prestressed with wires.
(was not a new invention, many others before him had thought to
embed pretensioned reinforcement in precast concrete members: (1879 –1962)
Doehring, Mandl, Lund, Zisseler and Siegwart, Mezzetti, Wettstein
and Hoyer)
→BUT was at least two qualitative differences from their predecessors:

1. they knew where to place the prestressed reinforcement to obtain a
perfectly engineered prestressed concrete element;
2. they could understand and quantify the losses due to creep and
shrinkage
FREYSSINET
Main features for practical use of prestressing in 1930:
• to use high-quality concrete and very high strength steel (wires)
• a variety of methods to tension the wires
• the possibility of using polygonal layouts
• the possibility of precasting several long elements on only one
beam of wires followed by cutting them to the length desired
• considering shear reinforcement to be unnecessary because of the
precompression of the concrete
1939 Freyssinet secured possibly his most famous and definitive

patent: the complete system to post-tension concrete members

The first modern post-tensioning system with

anchorage as designed by E. Freyssinet. The
A prestressing system for precast concrete
following are included: anchorage, wedge to
elements as designed by E. Freyssinet and
trap wires, tendon, duct, and jack.
J. Seailles.
Source: French Patent 926505 (1947).
Source: French Patent 680547 (1930).


1938 Hoyer Ewald (Germany) - Developed ‘long line’ pre-tensioning

method
→ stretching the wires at greater distance, then the concrete is poured so
that many structural elements can be produced in a single line
The Hoyer effect, graphic on basis of Consolazio (2013)
- To reduce concrete’s curing time, Hoyer established a method in which steel

formwork was heated (Hoyer 1943). He made it possible to build beams with lengths
up to 100 m. Subsequently, beams were cut to the required length after concrete
curing, because no separate anchorages were necessary
1937 Urlich Finsterwalder (GER) bridge builder and designer, was revolutionizing the
construction means and methods for prestressed concrete bridges (Wiedenbrück Bridge)
1940 Gustave Magnel (Belgian engineer and professor)

- explored Freyssinet ideas and carried out research on
prestressed concrete
- Developed an anchoring system for post-tensioning, using
flat wedges.
- writes the first book of design in prestressed concrete,
communicating this idea to designers worldwide
(1889 – 1955)
Walnut Lane Memorial Bridge (1950- 51) - Centre span of 48 m (Philadelphia, US)
2. BASIC PRINCIPLE
5. TYPES OF TENDONS

STAGES OF LOADING
The analysis of prestressed members can be different for the different
stages, depending on intensity of:
• loads – increasing in time
• prestressing force – decreasing in time
1) Initial phase: having two situations, as follows:
PRE- TENSIONING → 2 steps POST-TENSIONING → 1 step
- During tensioning of steel Transfer of prestressing force to
- At transfer (release) concrete during tensioning of steel
2) Intermediate phase: includes the loads during transport and/or handling

of the prestressed members, also in the construction process.
1) Final phase: corresponding to - service limit stage

- ultimate limit stage
INITIAL PERMANENT COMPRESSIONS ARE INTRODUCED IN

AREAS SUBJECTED BY LOADS TO TENSION
PRESTRESSING LOAD COMBINED ACTION
Mq Mq
e Pm
+ =
Pm


A)
B)
C)
fib Bulletin 31

Large
compression
stress distribution in
concrete when pre-
stressing is applied at
Very little the centre of gravity of
TENSION
the section
cross prestressing Self weight Live load STRESS
section force RESULTANT
Smaller
compression
stress distribution in
concrete when pre-
or stressing is applied
e
eccentrically with
respect to the centre of
cross Self weight Live load STRESS
section
prestressing
RESULTANT gravity of the section
force
Small
compression

or
e
cross prestressing External STRESS

section force loads RESULTANT Very little
TENSION
or
e
cross prestressing External STRESS

section force loads RESULTANT

STRESSES IN THE CONCRETE ELEMENT

B) SELFWEIGHT
C)
SELFWEIGHT
P P
P P
𝑉𝑠𝑒𝑙𝑓 𝑉𝑠𝑒𝑙𝑓
𝑀𝑠𝑒𝑙𝑓 𝑀𝑠𝑒𝑙𝑓
𝑁𝑃 𝑁𝑃
𝑉𝑝 𝑉𝑝
𝑀𝑃 𝑀𝑃

WHY THE WORD PRESTRESSING ?

INITIAL PERMANENT COMPRESSIVE STRESSES ARE
INTRODUCED IN THE ELEMENT
BEFORE THE APPLICATION OF EXTERNAL LOADING
HOW TO DO PRESTRESSING ?
SUBJECTING HIGH STRENGTH STEEL TO TENSION
&
ANCHORING STEEL AGAINST CONCRETE BY BOND OR STEEL DEVICES
FINALLY
THE STEEL (REINFORCEMENT) REMAINS IN TENSION
&
THE CONCRETE IS SUBJECTED TO COMPRESSION
2. BASIC PRINCIPLE
5. TYPES OF TENDONS

ADVANTAGES OF PRESTRESSED CONCRETE

- section remains un-cracked under service loads
- larger spans with less depth, lighter elements & smaller deflection
- increased shear strength, particularly due to curved reinforcements
- suitable for use in pressure vessels, liquid retaining structures
- increased durability (crack-free cross sections)
- resilience under dynamic and fatigue loading
- more economical sections: less steel & concrete
- accidental cracks under overload will close up on removal of the
overload
- prestressing enables structural elements to be formed from a number
of precast units

ADVANTAGES OF PRESTRESSED CONCRETE

C20/25 C20/25 C45/55
EI = 37103 kNm2
24,7
55 20 15
51,5
 3,4 cm2  3,4 cm2
15,7 cm2 *** 8,9 5

***
[cm] 25 25 25
RC → PC
RC → PC & strength class of concrete
G (kg/m) → 358 309 241

( -24 %) ( -33 %)
𝛾𝑟𝑐 = 26 𝑘𝑁/𝑚3 𝛾𝑝𝑐 = 26 𝑘𝑁/𝑚3 𝛾𝑝𝑐 = 26 𝑘𝑁/𝑚3

DISADVANTAGES OF PRESTRESSED CONCRETE
Some items that must be considered when using prestressed concrete:
- the higher material quality (concrete & steel) generates higher unit
costs
- the need for expensive accessories (tensioning equipments,
anchoring devices)
- the necessity for close inspection and quality control
- in the case of precasting, a higher initial investment in plant/factory
- needs skilled workers under skilled supervision

2. BASIC PRINCIPLE
5. TYPES OF TENDONS

SO MANY FACTORS ARE APPLIED TO DESIGN

THE FOLLOWING DATA ARE A GUIDE ONLY
SPAN SELECTION L < 6,0 m → RC elements
L = 6,0 … 9,0 m → RC or PC elements
L > 9,0 m → PC elements
CROSS SECTION SELECTION
h/L
 According to the economically minimum for bridges minimum for buildings
span 1/14 … 1/20 1/30 1/40
 According to the MEd/VEd < L/8  L/4 > L/4

loading degree h/L 1/10 … 1/12 1/14 … 1/18 1/18 … 1/22
Mself  0,3Mqp Mself  (0,3…0,5)Mqp Mself  (0,6…0,9)Mqp

ROOF GIRDERS ROOF/FLOOR GIRDERS
ROOF ELEMENTS FLOOR ELEMENTS
BRIDGE BOX GIRDER

COMPOSITE ELEMENTS (PC – RC)
FLOOR ELEMENTS
BRIDGE DECKS

LONGITUDINAL LAYOUT OF PRESTRESSED ELEMENTS



2. BASIC PRINCIPLE
5. TYPES OF TENDONS

EC2: 3.3.1 (1)P This clause applies to wires, bars and strands used as
prestressing tendons in concrete structures.
Embedded in Pre-tensioned Bonded

concrete Bonded
(internal) Post-tensioned
TENDONS Unbonded
With points of contact occurring at
External Post-tensioned
deviators and anchorages

Bonded vs Unbonded
Advantages Disadvantages
- tendons are more effective at ULS - tendons cannot be inspected or replaced
B - does not depend on the - tendons cannot be re-stressed after
O anchorage after concrete casting concrete casting
N
D - the prestressing tendons can
E contribute to the concrete shear
D capacity
- tendons can be removed for - less efficient at ULS

U inspection and are replaceable if - relies only on the integrity of the
N
B corroded anchorages and deviators
O - reduced friction losses - a broken tendon causes prestress loss for
N - generally faster construction the full length of that tendon
D - tendons can be re-stressed - less efficient in controlling cracking
E
D - thinner webs and larger lever arm - particular attention is required in design
to ensure against progressive collapse

WIRES
A pre-stressing wire is a single unit made of steel.
The nominal diameters of the wires are 2.5, 3, 4, 5, 7 and 8 mm.
- - plain wire: no indentations on the surface
- indented wire: there are circular or elliptical

indentations on the surface.

STRANDS
A few wires are spun together in a helical form
- two-wire strand: two wires are spun together to

form the strand
- three-wire strand: three wires are spun together to
form the strand
- seven-wire strand: six wires are twisted around a central
wire; the central wire is larger than the other wires.
Bonded strand
Un-bonded strand
(grease inside for corrosion protection)
MULTI-STRAND TENDONS
A group of strands placed together in a duct
The duct may be filled with

grout or grease after the post-
tensioning
These tendons are used in post-tensioninig!

Freyssinet
MULTI-STRAND TENDONS
A group of strands placed together in a duct
Movable Coupler BH
CONA CMI

MULTI-WIRE TENDONS
A group of wires placed together in a duct

CABLES → A group of tendons form a pre-stressing cable.

The cables are used in bridges
Suspension bridge
Mono design
Cable-stayed bridge
Harp design
Fan design
Star design
https://en.wikipedia.org/wiki/Cable-stayed_bridge
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.
DYWIDAG post-tensioning systems

using high-strength bars
(bonded or unbonded)

2. BASIC PRINCIPLE
5. TYPES OF TENDONS

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.

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
Tendons can be easily ‘weaved’ allowing a
more efficient design approach

Advantages Disadvantages
Pre- - no need for anchorages - heavy stressing bed required
tensioning - tendons protected by - more difficult to incorporate
concrete without the need for deflected tendons
grouting or other protection - difficult to transport long
- prestress is generally better elements
distributed in transmission
zones
- precast elements are
produced in factories
Post- - no external stressing bed - tendons require a protective
tensioning required system
- more flexibility in tendon - large concentrated forces in
layout and profile end blocks
- draped tendons can be used - high friction losses
- performed on site (in-situ)

INTERNAL PRESTRESSING
- The prestressing is achieved by elements located inside the concrete
member.
- can be carried out by pre-tenioning as well as by post-tensioning.

EXTERNAL PRESTRESSING
- The prestressing is achieved by tendons located outside the concrete
member (inside the hollow space of a box girder or outside the
member).
- can be carried only by post-tensioning.

LINEAR OR CIRCULAR PRESTRESSING

Linear prestressing
Straight or flat prestressed members, in the direction of prestressing,
as beams, piles, columns for overhead power lines and slabs.
Profile: straight deflected curved (dropped)

Prestressing type: pre- & post-tensioning pre- & post-tensioning post-tensioning
Circular prestressing
Curved members in the direction of prestressing as tanks, silos, pipes
and similar structures.
precast unit
Prestressing type:
- only post-tensioning
- internal by tendons
- external by strands anchoring rib

UNIAXIAL OR BIAXIAL PRESTRESSING

Uniaxial prestressing
Prestressing tendons are generating compressive stresses in one
direction, like in case of beams.
Prestressing type: any
Biaxial prestressing
Prestressing tendons are generating compressive stresses in two
direction, like in case of slabs.
Prestressing type:
- only post-tensioning
- by internal tendons

FULL, LIMITED OR PARTIAL PRESTRESSING

Full prestressing → the level of prestressing P is such that no tensile stress is allowed
in concrete under service loads
Limited prestressing → the level of prestressing P is such that the tensile stress
under service loads is within the cracking stress of concrete
Partial prestressing → the level of prestressing P is such that under tensile stresses
due to service loads the crack width is within the allowable limit; non-prestressed
reinforcement is required for crack control
Cracked or not
G+P G+P+Q
< fctm
Full prestressing Limited prestressing PARTIAL PRESTRESSING
Freyssinet diagram EC2: environmental conditions EC2: usual case
Dr. NAGY-GYÖRGY Tamás

Professor
Dr. CLIPII Tudor

Professor
E-mail:
tamas.nagy-gyorgy@upt.ro
Tel:
+40 256 403 935
Web:
http://www.ct.upt.ro/users/TamasNagyGyorgy/index.htm
Office:
A219

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Prestressed Concrete / Beton Precomprimat

Dr. NAGY-GYÖRGY Tamás

Dr. CLIPII Tudor

Dr. Nagy-György T. © Faculty of Civil Engineering

1. HISTORY OF PRESTRESSED CONCRETE

3. ADVANTAGES AND DISADVANTAGES

4. SPAN & CROSS SECTION SELECTION

Dr. Nagy-György T. © Faculty of Civil Engineering 2

PRESTRESSING IS NOT A NEW IDEA!

Gustave Magnel’s drawing

By heating the metal hoop in fire

TRIAL WORKS WITH PRESTRESSING

1888 C. F. W. Döhring (GER) – patent for the first prestressed

Dr. Nagy-György T. © Faculty of Civil Engineering 4

TRIAL WORKS WITH PRESTRESSING

Dr. Nagy-György T. © Faculty of Civil Engineering 5

1928 Eugène FREYSSINET

→ FREYSSINET with Jean Seailles first

→BUT was at least two qualitative differences from their predecessors:

1939 Freyssinet secured possibly his most famous and definitive

Dr. Nagy-György T. © Faculty of Civil Engineering 7

The first modern post-tensioning system with

Dr. Nagy-György T. © Faculty of Civil Engineering 8

Dr. Nagy-György T. © Faculty of Civil Engineering 9

1938 Hoyer Ewald (Germany) - Developed ‘long line’ pre-tensioning

The Hoyer effect, graphic on basis of Consolazio (2013)

- To reduce concrete’s curing time, Hoyer established a method in which steel

1940 Gustave Magnel (Belgian engineer and professor)

1. HISTORY OF PRESTRESSED CONCRETE

3. ADVANTAGES AND DISADVANTAGES

4. SPAN & CROSS SECTION SELECTION

Dr. Nagy-György T. © Faculty of Civil Engineering 12

2) Intermediate phase: includes the loads during transport and/or handling

1) Final phase: corresponding to - service limit stage

INITIAL PERMANENT COMPRESSIONS ARE INTRODUCED IN

PRESTRESSING LOAD COMBINED ACTION

Dr. Nagy-György T. © Faculty of Civil Engineering 14

INITIAL PERMANENT COMPRESSIONS ARE INTRODUCED IN

INITIAL PERMANENT COMPRESSIONS ARE INTRODUCED IN

Dr. Nagy-György T. © Faculty of Civil Engineering 16

cross prestressing External STRESS

cross prestressing External STRESS

Dr. Nagy-György T. © Faculty of Civil Engineering 17

STRESSES IN THE CONCRETE ELEMENT

Dr. Nagy-György T. © Faculty of Civil Engineering 18

WHY THE WORD PRESTRESSING ?

1. HISTORY OF PRESTRESSED CONCRETE

3. ADVANTAGES AND DISADVANTAGES

4. SPAN & CROSS SECTION SELECTION

Dr. Nagy-György T. © Faculty of Civil Engineering 20

ADVANTAGES OF PRESTRESSED CONCRETE

Dr. Nagy-György T. © Faculty of Civil Engineering 21

ADVANTAGES OF PRESTRESSED CONCRETE

15,7 cm2 *** 8,9 5

RC → PC & strength class of concrete

G (kg/m) → 358 309 241

Dr. Nagy-György T. © Faculty of Civil Engineering 22

DISADVANTAGES OF PRESTRESSED CONCRETE

Some items that must be considered when using prestressed concrete:

Dr. Nagy-György T. © Faculty of Civil Engineering 23

1. HISTORY OF PRESTRESSED CONCRETE

3. ADVANTAGES AND DISADVANTAGES