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IN CONCRETE
PRINCIPLE – Using high tensile strength
steel alloys producing permanent pre-
compression in areas subjected to Tension.
A portion of tensile stress is counteracted
thereby reducing the cross-sectional area of
the steel reinforcement .
METHODS :- a) Pretensioning
b)Post-tensioning
PRETENSIONING :- Placing of concrete
around reinforcing tendons that have been
stressed to the desired degree.
POST-TENSIONING :- Reinforcing tendons
are stretched by jacks whilst keeping them in
serted in voids left pre-hand during curing of
concrete.
These spaces are then pumped full of grout to
bond steel tightly to the concrete.
TENDONS
Prestressed concrete, invented by Eugene
Frevssinet in 1928 is a method for overcoming
concrete’’s natural weakness in tension . It can
be used to produce beams , floors or bridges
with a longer span than is practical with
ordinary reinforced concrete.
It can be accomplished in three ways: pre-
tensioned concrete, and bonded or unbonded.
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.
Bonded post-tensioned concrete
Bonded 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.
When the tendons have stretched sufficiently, according to the
design specifications 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 DECK STEEL LAYING
house construction in locations where expansive soils 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.
The advantages of this system over unbonded post-tensioning
are:
Large reduction in traditional reinforcement
requirements as tendons cannot destress in
accidents.
Tendons can be easily '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
Unbonded 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 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:
This refers to the case where prestressing tendons are
placed outside the concrete section and the
prestressing force is transferred to a structural member
through end anchorages or deviators. Advantages of
external prestressing include the possibility of
monitoring and replacing tendons, ease in concreting
and hence better concrete quality and the use of
narrower webs. External prestressing is being
increasingly used in the construction of new bridges
and is a primary method for the strengthening and
rehabilitation of existing structures.
At NUS, a three-year project on the application of
external prestressing in structural strengthening has
been completed, and this has resulted in design charts
being developed for such applications. Works were
also carried out on the use of fibre-reinforced polymer
(FRP) reinforcement as external tendons in both simply
supported and continuous beams.
APPLICATIONS
• Fallingwater is comprised of a series of concrete cantilever
The lower and upper terraces cantilever
“trays” 30-ft. above a waterfall. Previous efforts failed to over the stream below. The temporary
permanently address excessive deflections of the cantilever
and repair the cracks. After a thorough design review, the
structural steel shoring was placed beneath
owner and engineer selected an external post-tensioning the main level terrace.
solution for its durability, aesthetics and structural
unobtrusiveness.
• Construction plans called for strengthening of three support
girders spanning in the north-south direction with multistrand
post-tensioning tendons consisting of multiple 0.5” diameter
strands.
• Thirteen strand tendons were placed on each side of two
girders. One 10-strand tendon was placed on the western side
of the third girder (access on the eastern side of this girder
was not available). Eight monostrand tendons, 0.6” diameter,
were slated for the east-west direction.
•The monostrand tendons were stressed in the east-west
direction and then the multistrand tendons were stressed in the
north-south direction and grouted with a high quality, low-bleed
cementitious grout mixture.
•VSL’s scope of work also included welding steel cover plates,
attaching structural steel channels, injecting epoxy grout,
doweling reinforced cast in place concrete blocks and the
installation of near surface mounted carbon fiber rods.
Challenged with maintaining Fallingwater’s original setting,
furnishings and artwork, the project was successfully
completed in six months.
Seward Silo
Bicycle wheel as we know it today - each is
associated with an application of prestressing to
a structural system.
The first and most obvious is the tensioned
spokes - the rider's weight is carried from the
forks to the ground not by hanging off the top
spokes, but by reducing the pretension in the
lower spokes - only a couple of spokes are
carrying the load at any one time.
The second is the pneumatic tyre, where the
compressive load is carried to the ground by
reducing the tension in the sidewall. The air
pressure in the tyre does not change when the
load is applied.
The final prestressing system is the tyre cord,
which is shorter than the perimeter of the rim.
The cord is thus in tension, holding the tyre on
the rim, which enables the pretension in the
sidewalls to be reacted
T6Z-08 Air Powered Grout Pump
Pumps cement grout only, no sand. 32 Gallon Mixing
Tank. Mixes up to 2 sacks of material at once and allows
for grout to be pumped during mixing or mixed without
pumping.
Maximum
Length Height Weight
Torque
5,590
11.11" 4.49" 16.75 lbs.
ft./lbs.
(279 mm) (114 kg) (7.6 kg)
(773 kg/M)
8,000 ft.lbs.
12.57" 5.09" 24.95 lbs.
(1,006
(319 kg) (129 kg) (11.3 kg)
kg/M)
T8Z Torque Wrench
For applying torque to the anchor bolt
when setting the anchor. Torque
Tensioning charts Williams products can
be found here.
Bolt Square Capacity
Diameter Drive Size (ft. lbs.)
*1/2"-1" 3/4" 0-500
1/2"-1" 3/4" 0-600
*1-1/8"-2" 1" 0-1,000
4,000
GA 186 1" 1-1/2"
(ft. lbs.)
T1Z & T2Z Long Fitting Tool Adapters
For driving hex nuts and setting tools,
typically with our Spin-Lock anchor
systems. Works with torque wrench or
impact gun.
Available with 1" or 1-1/2" square
drive. Please specify square drive for 2Z Regular Socket T1Z Deep Socket
compatability with your equipment.
For applying torque to recessed anchor nuts that are under tension
when using hydraulic jacks. Available in all anchor sizes.
Methods of Corrosion Protection
Can be
Corrosion Abrasion Relative
Typical applied to
Protection Resistance Cost Lead Time
Thickness accessories
Type (4=best) (4=highest)
?
Hot Dip
4 3-4 mils 2 2-4 weeks yes
Galvanizing
Epoxy
1 7-12 mils 1 2-3 weeks yes
Coating
Pre-Grouted 2", 3" or 4"
3 3 2 weeks no
Bars tubing
Extruded
Polyethylene 2 23-25 mils 1 2-4 weeks no
Coating
Corrosion
Inhibiting 2 N.A. 2 2-4 weeks yes
Compound
Epoxy Coating
Fusion bonded epoxy coating of steel bars to help prevent
corrosion has been successfully employed in many applications
because of the chemical stability of epoxy resins. Epoxy coated
bars and fasteners should be done in accordance with ASTM A-
775 or ASTM 934. Coating thickness is generally specified
between 7 to 12 mils. Epoxy coated bars and components are
subject to damage if dragged on the ground or mishandled.
Heavy plates and nuts are often galvanized even though the bar
may be epoxy coated since they are difficult to protect against
abrasion in the field. Epoxy coating patch kits are often used in
the field for repairing nicked or scratched epoxy surfaces.
Pre-Grouted Bars
Extruded Polyethylene
Williams strand tendons contain an extruded high density
polyethylene sheathing around each individual strand in the
free-stressing portion of the anchorage. The sheathing is
minimum 60 mils thick and applied once the 7-wire strand has
been coated with a corrosion inhibiting compound. Extruded
polyethylene sheathing provides a moisture tight barrier for
corrosion protection and allows the strand to elongate freely
throughout the free-stressing length during the prestressing
operation
Corrosion Inhibiting Wax or Grease with Sheath
Williams corrosion inhibiting compounds can be placed in the free
stressing sleeves, in the end caps, or in the trumpet areas.
Often bars are greased/waxed and PVC is slipped over the
greased/waxed bar prior to shipping. Each are of an organic
compound with either a grease or wax base. They provide the
appropriate polar moisture displacement and have corrosion
inhibiting additives with self-healing properties. They can be
pumped or applied manually. Corrosion inhibiting compounds
stay permanently viscous, chemically stable and non-reactive
with the prestressing steel, duct materials or grout. Both
compounds meet PTI standards for Corrosion Inhibiting
Coating.