PRESTRESSING METHOD IN MULTI-STORIED BUILDING FRAME

History of Pre-stressing
The art of pre-stressing concrete evolved over many decades and from many
sources, but we can point to a few select instances in history that brought about this
technology.
In the United States, engineer John Roebling established a factory in 1841 for making
rope out of iron wire, which he initially sold to replace the hempen rope used for hoisting cars
over the portage railway in central Pennsylvania. Later, Roebling used wire ropes as
suspension cables for bridges, and he developed the technique for spinning the cables in
place.
During the 19th century, low-cost production of iron and steel, when added to the
invention of portland cement in 1824, led to the development of reinforced concrete. In
1867, Joseph Monier, a French gardener, patented a method of strengthening thin concrete
flowerpots by embedding iron wire mesh into the concrete. Monier later applied his ideas to
patents for buildings and bridges.
Swiss engineer Robert Maillarts use of reinforced concrete, beginning in 1901,
effected a revolution in structural art. Maillart, all of whose main bridges are located in
Switzerland , was the first designer to break completely with the masonry tradition by putting
concrete into forms technically appropriate to its properties yet visually surprising. His
radical use of reinforced concrete revolutionized masonry arch bridge design.
The idea of pre-stressing concrete was first applied by Eugene Freyssinet, a French
structural and civil engineer, in 1928 as a method for overcoming concretes natural
weakness in tension. Pre-stressed concrete can now be used to produce beams, floors or
bridges with a longer span than is practical with ordinary reinforced concrete.

PRE-STRESSED CONCRETE
Pre stressed concrete, like reinforced concrete, is a composite material which uses to
advantage the compressive strength of concrete, whilst circumventing its weakness in
tension. Pre stressed concrete is made from structural concrete, usually of high strength, and
high strength steel tendons which may or may not be grouped together. Prior to external
loading the tendons are tensioned in one of two ways. With pretensioning the tendon are
tensioned prior to the casting of the concrete and using post tensioning techniques
the tendons are tensioned after the concrete has hardened. Some ordinary reinforcing
steel is also often included both as subsidiary longitudinal reinforcement and
as transverse stirrups to resist shear.

Pre-stressed concrete 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. Pre-stressing tendons (generally of
hightensile steel cable or rods) are used to provide a clamping load which produces
acompressive stress that offsets the tensile stress that the concrete compression
member would otherwise experience due to a bending load. Traditional reinforced concrete is
based on the use of steel reinforcement bars, inside poured concrete. The basic purpose of
pre-stressing is to improve the performance of concrete members and this is achieved by
inducing in the beam initial deformation and stresses which tend to counteract those
produced by the service loads.

Since concrete is weak in tension in normal reinforced concrete construction cracks

develop in the tension zone at working loads and therefore all concrete in tension is ignored
in design.
Pre-stressing involves inducing compressive stresses in the zone, which will tend to
become tensile under external loads. This compressive stress neutralizes the tensile
stress so that no resultant tension exists, (or only very small values, within the tensile
strength of the concrete). Cracking is therefore eliminated under working load and all of the
concrete may be assumed effective in carrying load. Therefore lighter sections may be used

to carry a given bending moment, and pre-stressed concrete may be used for longer span
than reinforced concrete.
The pre-stressing force also reduces the magnitude of the principal tensile stress in
the web so that thin-webbed I - sections may be used without the risk of diagonal tension
failures and with further savings in self-weight.
The pre-stressing force has to be produced by a high tensile steel, and it is necessary
to use high quality concrete to resist the higher compressive stresses that are developed. As
the name itself suggests pre-stressing is the technique of stressing a structural member prior
to loading to resist excessive tensile stresses.

THE
ADVANTAGES
OF
PRE-STRESSED
CONCRETE
AS
A CONSTRUCTION MATERIAL IN MULTI STORIED FRAME CAN BE LISTED
AS FOLLOWS:

Maximum utilization of provided section of the member.

Provision of slender member for long span beams as compared to RCC.

Use of high strength materials contribute to the durability of the structure.

Pre-stresses concrete has considerable resilience and impact resistance.

Proves to be economical only in long span beam-column frames compared to other

materials.

The intermediate distance between the columns can be in increased by using prestressed concrete as compared to reinforced cement concrete.

Architectural design provisions and specifications can be achieved using pre-stressed

concrete.

Dead weight of concrete is reduced to a higher rate using pre-stressed concrete.

PRINCIPLE OF PRESTRESSING
The function of pre-stressing is to place the concrete structure under compression in
those regions where load causes tensile stress. Tension caused by the load will first have to
cancel the compression induced by the pre-stressing before it can crack the concrete. Figure
(a) shows a plainly reinforced concrete simple-span beam and fixed cantilever beam cracked
under applied load. Figure (b) shows the same unloaded beams with pre-stressing forces
applied by stressing high strength tendons. By placing the pre-stressing low in the simple-

span beam and high in the cantilever beam, compression is induced in the tension zones;
creating upward camber.
Figure (c) shows the two pre-stressed beams after loads have been applied. The
loads cause both the simple-span beam and cantilever beam to deflect down, creating tensile
stresses in the bottom of the simple-span beam and top of the cantilever beam. The
structural Designer balances the effects of load and pre-stressing in such a way that tension
from the loading is compensated by compression induced by the pre-stressing. Tension is
eliminated under the combination of the two and tension cracks are prevented.
Also, construction materials(concrete and steel) are used more efficiently; optimizing
materials, construction effort and cost.

Fig 1. - Comparison of Reinforced and Prestressed Concrete Beams

Pre-stressing can be applied to concrete members in two ways, by pre-tensioning or
post-tensioning. In pre-tensioned members the pre-stressing strands are tensioned against
restraining bulkheads before the concrete is cast. After the concrete has been placed,
allowed to harden and attain sufficient strength, the strands are released and their force is
transferred to the concrete member. Pre-stressing by post-tensioning involves installing and
stressing pre-stressing strand or bar tendons only after the concrete has been placed,
hardened and attained a minimum compressive strength for that transfer.

METHODS AND
STRESSING

SYSTEM

OF

PRE-

There are two methods of pre-stressing concrete: 1) Pre-cast Pre-tensioned

2) Pre-cast Post-tensioned
Both methods involve tensioning cables inside a concrete beam and then anchoring the
stressed cables to the concrete.

Pre-cast Pre-tensioned: Pre-tensioning is a method of pre-stressing in which the steel tendons are tensioned
before the casting of the member. In this method the tendons are tensioned using hydraulic
jacks, which bear on strong abutments between which the moulds are placed. After the
concrete attains full strength the tendons are released and the stress is transferred to the
concrete by bond action.

Procedure of precast pre-tensioned concreting

Stage 1
Tendons and reinforcement are positioned in the beam mould.

Stage
Tendons are stressed to about 70% of their ultimate strength.

Stage
Concrete is cast into the beam mould and allowed to cure to the required initial strength.

Stage
4
When the concrete has cured the stressing force is released and the tendons anchor
themselves in the concrete.

Pre-cast Post-tensioned: Post-tensioning is a method of pre-stressing in which the steel tendons are tensioned after the
casting of the member. In this method ducts or sheaths are placed in the required profile in the mould
and the tendons are passed through the ducts. After the concrete had attained sufficient strength the
tendons are tensioned using hydraulic jacks which bear on the member itself. The stress is transferred
to the concrete by bearing action of tendons which are anchored using suitable anchorages. Finally the
ducts are grouted and the anchor plates concealed by cement mortar.
Procedure of precast post-tensioned concreting
Stage 1
Cable ducts and reinforcement are positioned in the beam mould. The ducts are usually
raised towards the neutral axis at the ends to reduce the eccentricity of the stressing force.

Stage 2
Concrete is cast into the beam mould and allowed to cure to the required initial strength.

Stage 3
Tendons are threaded through the cable ducts and tensioned to about 70% of their ultimate
strength.

Stage 4
Wedges are inserted into the end anchorages and the tensioning force on the tendons is
released. Grout is then pumped into the ducts to protect the tendons.

TYPES OF POST TENSIONED CONCRETING METHODS

1. BONDED POST-TENSIONED CONCRETE METHOD
2. UNBONDED POST-TENSIONED CONCRETE METHOD
BONDED POST-TENSIONED CONCRETE
Bonded post-tensioned concrete is the descriptive term for a method of
applyingcompression 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, 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 bridge. The advantages of this system over
unbonded post-tensioning are.

1. Large reduction in traditional reinforcement requirements as tendons cannot destress in

accidents.
2. Tendons can be easily 'weaved' allowing a more efficient design approach.
3. Higher ultimate strength due to bond generated between the strand and concrete.
4. 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 (generallylithium 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:
1. The ability to individually adjust cables based on poor field conditions (For example: shifting
a group of 4 cables around an opening by placing 2 to either side).
2. The procedure of post-stress grouting is eliminated.
3. The ability to de-stress the tendons before attempting repair work.
Picture number one shows rolls of post-tensioning (PT) cables with the holding end
anchors displayed. The holding end anchors are fastened to rebar placed above and below
the cable and buried in the concrete locking that end. Pictures numbered two, three and four
shows a series of black pulling end anchors from the rear along the floor edge form. Rebar is
placed above and below the cable both in front and behind the face of the pulling end anchor.
The above and below placement of the rebar can be seen in picture number three and the
placement of the rebar in front and behind can be seen in picture number four. The blue
cable seen in picture number four is electrical conduit. Picture number five shows the plastic
sheathing stripped from the ends of the post-tensioning cables before placement through the
pulling end anchors. Picture number six shows the post-tensioning cables in place for
concrete pouring. The plastic sheathing has been removed from the end of the cable and the
cable has been pushed through the black pulling end anchor attached to the inside of the
concrete floor side form. The greased cable can be seen protruding from the concrete floor
side form. Pictures seven and eight show the post-tensioning cables protruding from the
poured concrete floor. After the concrete floor has been poured and has set for about a week,
the cable ends will be pulled with a hydraulic jack, shown in picture number nine, until it is
stretched to achieve the specified tension.

1. Rolls of post-tensioning cables

2. Pulling anchors for post-tensioning cables

3. Pulling anchors for post-tensioning cables

4. Pulling anchors for post-tensioning cables

5. Post-tensioning cables stripped for placement in pulling anchors

6. Positioned post-tensioning cables

7. Post-tensioning cable ends extending from freshly poured concrete

8. Post-tensioning cable ends extending from concrete slab

9. Hydraulic jack for tensioning cables

10. Cable conduits in formwork

THE ADVANTAGES OF POST-TENSIONING COMPARED TO PRE-TENSIONING IN THE

MULTI STORIED FRAME CONSTRUCTION CAN BE LISTED AS FOLLOWS
a) Tendons can be provided in any desired profile.
b) Stage pre-stressing can be adopted conveniently.
c) Costly factory equipments are not required.
d) Cast-in-situ construction procedure can be conveniently adopted.
e) It is possible to fabricate a beam with pre-cast and cast-in-situ elements, which are
post-tensioned together to form a single structural unit.
f) Number of systems is available in this method.

Systems of pre-stressing are as given below

Hoyer system usually adopted for pre-tensioned members.
o The system listed below are adopted for post-tensioning
Freyssinet system
Magnel Balton system
Gifford Udall system
PSC monowire system
CLL standard system
Lee -Macall system

ADVANTAGES OF PRECAST CONCRETE ELEMENTS IN BUILDING CONSTRUCTION

Lower construction cost
Thinner slabs, which are especially important in high-rise buildings where floor
thickness savings can translate into additional floors for the same or lower cost
Fewer joints since the distance that can be spanned by post-tensioned slabs exceeds
that of reinforced construction with the same thickness
Longer span lengths increase the usable unencumbered floorspace in buildings and
parking structures
Fewer joints lead to lower maintenance costs over the design life of the structure,
since joints are the major locus of weakness in concrete buildings.

 One-stop shopping sources much of a building's shell in one efficient, precast contract.
Fabrication of precast elements during permitting and/or site preparation saves time
resulting in fast efficient construction regardless of weather conditions.
Designing precast systems is easier.
Precast components can be erected in winter conditions, maintaining tight schedules.
With total precast systems, speedy erection allows the contractor to enclose the
building quickly, giving interior trades faster access.
Precast components are naturally fire protected, because they will not burn. Precast's
inherent fire resistance eliminates the messy and time-consuming fireproofing required
for a steel structure and subsequent repairs caused by other trades.
LOSS OF PRESTRESS
When the tensioning force is released and the tendons are anchored to the concrete
a series of effects result in a loss of stress in the tendons. The effects are :

Relaxation of the steel tendons

Elastic deformation of the concrete
Shrinkage and creep of the concrete
Slip or movement of the tendons at the anchorages during
anchoring
Other causes in special circumstances, such as when steam curing
is used with pre-tensioning.

Total losses in pre-stress can amount to about 30% of the initial tensioning stress.
Freyssinet system is the most widely adopted system in the construction of prestressed concrete structures. Pre-stressed Concrete is an architectural and structural
material possessing great strength. The unique characteristics of pre-stressed concrete allow
predetermined, engineering stresses to be placed in members to counteract stresses that
occur when the unit is subjected to service loads. This is accomplished by combining the best
properties of two quality materials: high strength concrete for compression and high tensile
strength steel strands for tension.

REASONS FOR USING PRESTRESSED CONCRETE

Column-Free Long Spans
With fewer columns and more usable floor space, precast, prestressed concrete
provides greater freedom for space utilization.

Conserves Energy
Pre-stressed concrete components can improve the thermal storage potential of a
building. It effectively conserves energy required for heating and cooling.
Maintenance Free
Precast concrete does not require painting and is free from corrosion. Its durability
extends building life.
Resists Fire
Durability and fire resistance mean low insurance premiums and greater personnel
safety. Those who investigate life cycle costing will appreciate the precast concrete's
excellent fire resistance characteristics.
Rapid Construction
Precast concrete construction gets the job done sooner. The manufacturing of
prestressed members and site preparation can proceed simultaneously. Early occupancy
provides obvious benefits to the client.
Versatility of Design
Precast concrete buildings are not only functional but beautiful as well. Numerous
panel configuration design possibilities are available.
Sustainability
As with all concrete wall systems, precast offers high durability and strength as well
as thermal mass, which contributes to increased energy efficiency. Precast systems use
locally derived materials, and can incorporate recycled supplementary cementitious materials
like fly ash and slag cement, one of the key reasons why they are often used in sustainable
or green buildings.
Variety, Flexibility, Utility
One of the biggest benefits of precast systems is in their design: tight controls mean
more efficient mix designs, resulting in smaller structural members and longer spans.
Construction waste is reduced because the exact amount of necessary components is
delivered to the site; any spare components can be recycled, and their materials used again
in another structure. Precast systems can adopt almost any aesthetic, incorporating a variety
of colours and textures, or emulating natural stone. By crafting systems that not only look
great, but also act as structural walls and support floor loads, designers can reduce material
redundancyand project costs.

Quality in Manufacturing
Because components are precast at manufacturing facilities, quality control measures
ensure that every piece is made to specifications. The components can be cast and
transported to the job site while designs are still being finalized, helping to speed construction
schedules. Evolutions in self-consolidating concrete also promise to offer new options and
challenges for designers using precast.
APPLICATIONS
Prestressed concrete is the predominating material for floors in high-rise
buildings and concrete chambers in nuclear reactors, as well as in columns and shear walls
in the buildings intended for a high degree of earthquake and blast protection.
Unbonded post-tensioning tendons are commonly used in parking garages as barrier
cable. Also, due to its ability to be stressed and then de-stressed, it can be used to
temporarily repair a damaged building by holding up a damaged wall or floor until permanent
repairs can be made.

GENERAL PRECAUTIONS IN PRESTRESSED CONCRETING

Working platforms
To provide a safe working environment, working platforms need adequate working
space, appropriate edge protection, and safe access and egress.

They must also be designed and constructed to safely support all expected
loads, including impact loads. Factors that will determine the selection of an appropriate
working platform include:

The type and number of items of stressing equipment that may be in use,

The number of people required, or likely to be, on the work platform at any
one time, and the likely material storage on the platform.

The platform should be large enough to enable the operators to remain

clear of anchorages during stressing, and it should be at a height which eliminates or
minimises risk of injury from over-reaching or awkward postures.
Formwork


In the case of cast in-situ concrete constructions, working platforms may be
built integrally with the formwork.

Formwork and propping systems should be designed by a structural

engineer experienced in formwork design.

Assembled formwork and propping systems should be checked by a

competent person for compliance with the formwork design drawings and documented
proof of such on-site checks should be readily available.
Provisions for stressing
Anchorages for stressing should be set out and tendon spacing marked on the ends.
Since the wedging forces at anchorages are high, anti-burst provisions, such as special
reinforcement, need to be installed and secured into position.
Pre-stressing ducts should be laid in accordance with the specified profile and
adequately secured. Inadequate cover to duct tubes can result in concrete blow-outs during
grouting operations.

Pre-stressing safety considerations

Stressing operations and associated preparations for stressing involve a variety of
tasks which if, appropriate precautions are taken, could endanger the health and safety of
workers carrying them out and/or those in the vicinity.

The area where preparations and stressing are intended to take place must
be fully barricaded with solid panels and signage prominently posted to keep
unauthorised personnel clear of this area.

All personnel involved in the tasks should wear the personal protective
equipment. This will generally include safety goggles, gloves, sturdy protective footwear
and safety helmets.

All personnel involved in the tasks should have adequate training in

identifying the hazards of stressing and their associated risks.
Uncoiling, Cutting and Placing Strands
Coils are very heavy, typically weighing 3 to 4 tonnes, and therefore the structural
adequacy of the area where coils are to be placed must be verified. Manual handling
issues associated with handling the coils should be controlled.
Ensure that the coils are restrained with uncut restraining straps when placing
them onto the strand frame. Uncontrolled release of the coil can result in whip-back with
sufficiently high force to cause serious injury.
Strands should not be cut by heat-type cutting equipment such as oxy-acetylene
or LP gas torches, as this may compromise their load-bearing capacity under tension.

 When assembling tendons, thoroughly inspect each individual wire or strand for
obvious flaws.
Pushing Strands into Ducts

All strands for each of the tendons should be pushed into place in
accordance with the drawings, making sure all personnel are kept clear of the direct line
of ducting to prevent injury from strands exiting from the other end of the duct.

Once the specified number of strands is in place, ensure that a "dead end"
is created for each strand by securing them at the end of the element.

In strand set-ups where ends will protrude above the face of the concrete
element and may create a hazard, they should be boxed or barricaded to prevent injury.
Concrete Pour
Concreting may be placed with either pumps or kibbles.

When concreting is being pumped, "chairs" or other means to support

concrete pump lines above the reinforcement and tendons should be in place and well
secured.

Where kibbles are used to place concrete, avoid dropping concrete in one
place as tendons could be displaced. Concrete should always be allowed to flow in a
controlled manner.
During concrete pouring:

Ensure that the ducts and strands are not damaged during the pour. All
damage should be promptly notified to the contractor's supervisor for repair. However,
concrete around the anchorages needs adequate vibration to ensure a safe and sound
seating for the anchorage.

Concrete test cylinders should be taken at agreed intervals for storing and
curing on site under conditions similar to those applying to the element being poured.

Stressing operations
Before stressing operations.
Prior to commencing stressing operations, the post-tensioning supervisor should verify that:

Concrete around the anchorages has been examined. The principal

contractor should be notified if the concrete is of poor quality.

All concrete test cylinders have achieved the specified strength.

The grips in the jacks on the stressing equipment are clean and free from
dirt or grit and in good condition.


The stressing equipment, i.e. jacks and their gauges, has appropriate
service records and up-to-date calibration certificates. All jacks should have a durable
tag securely attached which clearly shows the following information:

Final stressing pressure

Diameter and grade of the strand for which the jack is being
used
Jack number
Corresponding gauge number
Date calibration expires

The operator of the stressing equipment has documented evidence of appropriate training.

A "NO GO" area of at least 2 metres radius is in place around the anchorages at the dead
and live ends, with barricades behind the line of jacks and "Stressing in Progress. Keep
Clear" signage prominently displayed at all appropriate locations

During stressing operations

Tendons should be stressed in order from the furthest to the closest reachable to ensure that
no person is standing in direct line of the jack or previously stressed strands.

Ensure stress is applied gradually and evenly to tendons.

Ensure that the specified initial and final stressing levels are not exceeded.

After stressing operations

Gain the design engineer's approval prior to cutting off excess tendons.

Seal anchorage recesses following approval and prior to grouting the ducts.

Do not perform tasks requiring impact, such as hammering, drilling or coring in the vicinity
until the grouting of the ducts has been completed.
Grouting
Build-up of excessive pressure during grouting can result in "blow-outs" of the concrete,
which could injure personnel in the vicinity.

To prevent blowouts

Ducts should be blown through to ensure there are no blockages.

Avoid non-continuous grouting to ensure no blockages or voids are in the tubes.

Monitor the gauge of the equipment throughout grouting to ensure that excessive pressure
does not develop.

Retain barricades used during stressing operations and also barricade at a lower level if
formwork has already been removed.