Pretensioning and Post-Tensioning Technology I believe that one of the greatest retardants to prestressed concrete con- struction is the lack of a simple, practical, inexpensive method of applying and anchoring the prestressing force. WEE. Dean, 1951 2.1 INTRODUCTION The designer of prestressed concrete structures must be knowledgeable about the techniques and the technology associated with prestressing and must be familiar with the terminology. {mn this chapter we briefly review the basic techniques of prestressing, give details of some of the more widely used prestressing systems, and introduce prestressing terminology. The information on prestressing operations is subdivided into two elesicaions: Pretensioning and post-tensioning. In pretensioning the tendon is tensioned prior to casting the Concrete, while in post-tensioning the tendon is tensioned after the concrete has been cast, 23 2 PRESTRESSING TENDONS The term “tendon” is used to describe either an individual wire, strand, ar oe ee Sroup of wires, strands, or bars (see Fig. 2-1). The most widely used type of pres 25 Pe —————SS Chap. 2 26 Pretensioning and Post-Tensioning Technology reinforcement is seven-wire strand. Because the seven-wire strand was deve United States, the standard nominal diameters used worldwide are given in inches, with 3¢ in. (9.53 mm), 1/2 in, (12.70 mm), and 0.6, (15.24 mm) being the most popular diameter. ‘These strands are used in both pretensioned and post-tensioned construction. The ultimate tensile strength of these strands ranges from 250 to 270 ksi (1720 to 1860 MPa). eloped in the nominal dia. (a) 7-wire monostrand tendon (6) Multi-strand tendon button head (c) Single bar tendon (@) Multi-wire tendon Figure 2-1. Typical tendons. Deformed prestressing bars are a more specialized type of reinforcement which are Useful in some types of post-tensioned construction. Their nominal diameters vary from 5/8 in. (15 mm) to 1 3/8 in. (36 mm), and their ultimate tensile strengths are about 150 ksi (1030 MPa). Individual wires were the first successful form of prestressed reinforcement and are still used today for special applications such as railway ties. The wires typically have 0.196 in. (5 mm) or 0.276 in. (7 mm) diameters and have ultimate strengths ranging from 235 to 250 ksi (1620 to 1720 MPa),Sec 2.3 Pretensioning Operations 27 2.3 PRETENSIONING OPERATIONS The first step in pretensioning is the stressing of high-strength steel tendons (usually seven-wire strands) between the abutments of a pretensioning bed (see Fig, 2-2 2-2a). The concrete is then placed in the formwork. After the desired concrete strength has been reached, the tendons are detensioned and the member becomes prestressed (see Fig, 2-2h) stressing removable abutment end lack , original | abutment _- formwork Pretensioning bed (b) Tendons detensioned (elastic shortening = a ) Figure 2-2 Pretensioning on a stressing bed. An excellent summary of pretensioning technology has been given by Scott in Ref. 2-1. The stressing beds, which also serve as casting and curing beds, must typi- cally allow a daily production cycle using minimum labor. A typical layout for a stressing bed is shown in Fig. 2-2a, with an abutment at each end for stressing and anchoring the tendons. Very long stressing beds can be subdivided into shorter beds by the use of re- movable abutments as shown in Fig. 2-2a. The length of stressing and casting beds varies from about 80 ft (25 m) to about 650 ft (200 m), depending on the product. Single-strand Jacking is the most common form of tensioning the strand. Special long-stroke jacks which react against the fixed abutments are used (see Fig. 2-3). Strands that have been tensioned individually are typically released by flame-cutting or sawing. The sequence of cutting should be such that the stresses are kept as symmetrical 4s possible. The cutting should be done gradually and as close to the member as possible o minimize the amount of energy transferred dynamically by bond stresses upon release The use of headers that allow multiple-strand detensioning using hydraulic rams reduces damage to the bond near the end of the member. To achieve a more favorable profile, pretensioned tendons are often “draped” or “harped” as shown in Fig. 2-4. Shallow members such as double tees are usually draped at the center of the span, while deep sections such as bridge girders usually have two harping Points, Strands are either first tensioned straight and then deflected using a hydraulic ram, oF tensioned in the draped position, in which case the hold-down device must allow for the longitudinal movement of the strands during the tensioning operation.i. en Pretensioning and Post-Tensioning Technology Chap, 2 Figure 2-3 Jacking of single strand with long-stroke jack against abutment Photograph courtesy of Con-Force Structures Ltd. \ { \ és) tL hydraulic ram | pushes pin down hold-down pin (removed trom hardened concrete) hold-down ratchet reaction beam adjustment — double-tee form 1. Figure 2-4 Draping or harping of tendons. Adapted from Ref. 2 a a oeSec.2.3. Pretensioning Operations S Draping of the tendons decreases their end eccentricity, which should prevent cracking of the concrete at the top surface near the ends. An altemative way of achieving this objective is to reduce the effective prestressing force in this region by debonding some of the strands to produce so-called “blanketed strands” (Ref. 2-2)(see Fig. 2-5), ———————— / Dlanketed strand Tength Plastic tubs (debonded by plastic tubes) over strands in bottom Figure 2-5 Blanketing of strands. The steel molds that are used for standard cross-sectional shapes are usually 20 to 50 ft (6 to 15 m) in length and can be interconnected for long members. Figure 2-6 illustrates a bridge girder mold with demountable side forms and an external vibrator. Figure 2-7 shows a precast double-tee beam being lifted out of the mold. external brator sled and track form underties transverse sleepers Figure 2-6 Detail of steel mold for bridge I-girder. Adapted from Ref, 2-1. Extemal and/or internal vibration is used for compacting the concrete in the molds. Superplasticizers are commonly used to reduce the water/cement ratio while maintaining Workability. Vibrating screeds are used to strike-off and to compact pretensioned productsBa Pretensioning and Post-Tensioning Technolog Yoh "aD. 2 5 Sa Figure 2-7 _Long-span, double-tee beam being lifted from mold. Photograph courtesy of CPCI with wide top surfaces. A rake may be used to provide surface roughening for those surfaces that will become interfaces between the pretensioned member and cast-in-place concrete, To achieve a daily production cycle, the concrete must reach a strength sufficient to Permit release of the strands in about 16 hours. This can be achieved either by heating the concrete or by using high early strength concrete in insulated forms. The heating can be achieved either by electrical-resistance heating, steam curing (wet system), or by circulating hot fluid (dry system) 2.4 STANDARD PRECAST PRETENSIONED MEMBERS Details of cross-sectional shapes that are recommended standards in the precast, Prt” sioned concrete industry in North America are provided by the Prestressed Concrete ee tute (Ref. 2-3) and the Canadian Prestressed Concrete Institute (Ref. 2-4). Some © cross sections are shown in Fig. 2-8. The standard shapes include: stemmed deck elements (double-tee and | elements members); flat deck elements (solid flat slabs and hollow-core slabs); wall Lane members (solid wall panels, double-tee wall panels, and hollow-core wall panels); Cos eats (piles (rectangular beams, L-beams, inverted-tee beams and columns); foundation ¢! ler and sheet piles); and bridge I-girders. by ano The hollow-core slab elements shown in Fig. 2-8 are typically produce yee i tusion process on a “long line” pretensioning bed. Low-slump concret singletSec. 2.5 Post-Tensioning Operations double-tee I single-tee | eooS SO} 31 hollow -core peeroes pee L-shaped inverted-tee beams beams TT beard double-tee wall panels piles == I -girders sheet piles Figure 2-8 Standard precast pretensioned elements, the hopper of an extruding machine which moves on rails along the bed and extrudes the concrete around the pretensioned tendons (see Fig. 2-9). Tay ipered mandrels or augers shape the cores as the extruder moves along the track. After the concrete has cured, the strands ‘are released from the abutments and the hollow-core slab is cut into the desired lengths. While there are recommended standard cross sections, there is a considerable range in the specific sections produced in different precast plants. Hence the engineer should investigate the specific sections available from local precasters in the early stages of the design. Some sectional properties of the PCI double-tee and single-tee cross sections are Sven in Fig. 2-10, These includs the cross-sectional area, A, the moment of inertia, I. the distance from the bottom face to the centroid, ys, and the volume-to-surface area ratio. v/s. 25 POST-TENSIONING OPERATIONS The first stey P in producing a post-tensioned member is to place the reinforcing cage and the Post-tensioning ducts in the formwork. After the casting and curing of the concrete, theFigure 2-9 Manufacturing hollow-core slabs. From Ref. 2-5, courtesy of Dy-Core Systems Inc. act against tendons are tensioned and anchored using special post-tensioning jacks that react 950 the member. Unless unbonded tendons are being used, the duct is then grouted to com? the post-tensioning operation (see Fig. 2-11). In the bonded Figure 2-12 shows a typical bonded and a typical unbonded tendon. 1 ion tendon the grout bonds the tendon to the surrounding concrete and provi i at its protection for the tendon. The unbonded tendon is attached to the concrete oned plasté anchors. Corrosion protection for the unbonded tendon is provided by grease” tubes and by special details at the anchorages. Unbonded tendons are often used in applications such as postientt grease slabs where the small duct diameter, the low friction between the strand anor wit duct, and the elimination of the grouting operation all offer considerable & way joned 10" tensioned PP cedSec. 2.6 Post-Tensioning Systems 33 ee c L = a 1 4 [ein gin, Simm 4 emi we | 4 ain odin double-tee sections single-tee sections > f=] A ws Meee tre | fe | in| ine nt, [im] | type | | in| ing a, [Mie |i fetal cts [ts) eta et clea) ei [lt ot 8 287 zere | 122 | sro [2601] easr7 , | 2.16 sor'e | ads | ado] erties || cles [285 | | e88 [abn] ao] dt [863] een | BOTH | cgay [case] carsto®> cite 85 | 198796 |csote| sen] cezetors | G90)| coo oooh | (9 welt, [| as ase [a8 i ae 80716 | cata | ce] cosoreds | em | carenei’ | lad | [108748 [ed cecton [288] oliBe | BDT18 | coaaey | c457)| (222x109 | esrox10% | 4) e | 20 | aes tess, [ras BOT2O | cease |c508)| (254x10*) cs22ex10 | Ga) 8724 | caaaey | c6100| (259x10°) (a730x10 | (38) eae | ser sate, | 9 BOTS2 | coaney | cava)| (366% 10%) | (599) | (23 100% | (46) [100T24 | cs0¢e) | céron| c290n10%) | (451) | C9950x00 | a) vo. | 32 | eve, |2rse| saree, | 149 YODTS2 | 3940) | cary] (997410%) | (S88) | (2486ox10% | C43) Figure 2-10 Sectional properties of PCI stemmed deck elements. unbonded tendons, special attention is required to ensure that the strand is protected from corrosion, where it enters the end anchorages. Further, it may be necessary to place additional reinforcing bars to provide adequate crack control. 2.6 POST-TENSIONING SYSTEMS ‘Various proprietary post-tensioning systems are available. These systems differ in the type of tendon that they employ, in the manner in which the tendons are tensioned, and in the anchorage devices which are used. There are four common types of tendon systems: monostrand tendons, single-bar tendons, multi-wire tendons, and multi-strand tendons. Figure 2-13 compares the tendon forces that can be achieved with these different types of tendon systems. Apart from tendon force, other considerations that may influence the choice of tendon type include (1) the compactness of the monostrand jacking and anchorage systems; (2) the ease of coupling and anchoring threaded bars; (3) the positive anchorage and low friction of smooth—_ Chap, 2 ss Pretensioning and Post-Tensioning Technology tendon section 1-4 (@) Stagewise sequential tensioning from one end jack section 2-2 (b) Stagewise sequential tensioning from other end [PARR NDE yoy venting tube inject grout (©) Grouting of ducts Figure 2-11 — Post-tensioning operations. button-headed wires; and (4) the versatility and economy of multi-strand systems. A brief summary of the details of some of the more widely used post-tensioning systems is given below. The Freyssinet K-Range System (Ref. 2-6) is illustrated in Fig. 2-14. In this mult strand system, each strand is individually gripped by three-piece conical jaws that seat into tapered holes inside the anchorage block. The stressing is performed by a center-hole jack which simultaneously tensions all the strands in a tendon (see Fig. 2-14b). Upon release of the jack, pull-in of the strand engages the wedge-like jaws that anchor the strands. The loss of tendon elongation associated with this seating of the anchorage (anchorage set oss) must be accounted for in design. Details useful in design such as minimum tendon spacins, ‘inimum free edge distances, minimum dimensions for anchorage recesses, and clearane required for different jack capacities are given in Fig. 2-14, tem Figure 2-15 summarizes useful design details of the VSL multi-strand SiS? (Ref, 2-7). The jacking and anchoring devices for this system are similar t0 her tered Previously for the Freyssinet System. Multi-strand tendons can be jacked f both ends to reduce frictional losses (see Fig. 2-11) or can be jacked from one end Wit, other end of the tendon terminating in a dead-end anchor. Boih the Freyssinet and 5 mm) Peenin® utilize seven-wire strand with nominal diameters of 0.5 and 0.6 in. (13 and having cross-sectional areas of 0.153 and 0.215 in? (99 and 140 mm?), respe een a ‘The Dywidag post-tensioning system, summarized in Fig. 2-16, uses BBE gahs Oy bars with rolled threads (Ref. 2-8). These threaded bars, which are available aSec. 2.6 Post-Tensioning Systems Plastic grdace tube 7 filled with grout (a) Grouted, corrugated metal sheath containing bonded multi-strand tendon strand (b) Plastic sheath filed with grease containing unbonded monostrand_ tendon fore, 0.7 Ap 400 200 1.9/8 in, (18 mm to 36 mm) (33 mm and 15 mm) threadbar 5/8 in. a5 3 07-08 in, (17-19 ens) ‘et monostrand 1/2 in. and 0.6 in, i (38 mn) ure 2-12 Bonded and unbonded tendons. (138 me) 2000 1000 Figure 2-13 Tendon forces for different tendon types.pretensioning and Post-Tensioning Technology c Chap, » 36 sheatn tendon raoatay is _ pressure plate jack foot jock piston sean (@) Jacking and anchorage components a 8 c o |e Faek type | in. Cuma in. Crnmd| in. Geom ine Gram | in fr) ws 38 G40 | 48 G00) | 43 G00) 1S 446 | 625(100| 45 C100) | cocsa8) | rcs | asc6m) 1.5 716 | 72800] «sc20 | roc | 3029 | acm 128 00.200} 45:25) | 80 c200 | ss.s80 | 0 reo 1918 1100 c6000] so.cv4e> | so 250) | 20.810 | a5 0) (b) Jacking detais uit ] range in] sheath Jrendon yorc. wit sheath | Sat | |e aes $49.3 (2449) 2 i 492.0 (2188) 00 878.2 (2572) 19.6 13 43.6100) | s3a0 c@70 106s (arse) a (20 | Moro wane 590.0 (7072) ar (190) | Igtro ree) (A) 0.6 in. (15mm)-270K seriesSec. 2.6 Post-Tensioning Systems tumpet (a) Stressing anchorage details wedge anchor head 7 inch oe Jin fam | n,m in Sma nm | n,m ESS wae | scan | ore | aoa | sas 65-7 £63 | rcs | scan | ocean | reca0s) | secre e512 66-7 | wasn | seen | rorsn | rcs | secsen e519 6-12 | 220889 | ream | voces | racasr | 55 (1207 | 5-31 €6-19 | aren | rear | sycarar | 20000 | 57 cr440) 6555 €6-31 {accor | 02s | secs | 2062 | 70.1770) (b) Jacking deta’ unit | range in | sheath | tendon force, voit | range in | sheatn | tendon force, fool” | inside dia. | hips (KN) oof” | insige ga. | ps (KN) slrands | in. (mm) | 07 Ase siranas | in. tmm) | O Asstow esa} 2 | rasan | srocasn f63] 2 | rsoam | eeocsss 3 | Soca | esr Gee 3 | an | sei ea] « nse (510 cea} «| 2o0cso | sees cro) e7| 5 as (540) cer) os | sen | sesso , zoe (300) 7 | zesen | derrcar Jesr2] 2 | zeocsa | esracioe cere] 9 | acre | ses2cus | Bao | Ses tse | Seo) | M322 cen E519 asace | arscsrn e619} 13 | aasen | ssuaczarn 31308) | 5093 Ge) 1 | 3355) | rea coaes) e522| 2 | azscen | srazcesrn e6-22| 22 | ao0cr00) | azo assy ze | 33s 6300 (2020) 22 | Soo tee | Soe cored e531| 2 | aso cm eosn sear] a | esocre | seas cans 51 | S00 tam | ese (3988) 51 | soocias) |rarna cose e555] ss | rs904cra70) e655} ss | eso ciss [20661 e009 a (c) VSL 1/2 in.(13mm)-270K ‘E series’ Figure 2-13. VSL mult: (@) VSL 0.6 in. (15mm)-270K *E series" strand system. From Ref. 2-7.38 Pretensioning and Post-Tensioning Technology hap, 9 up 0 60 ft (18 m)can be coupled conveniently at any location and are postive by means of a nut with a conical nose that seas into a plate anchor ora bette? ord (Gee Fig. 2-16) This anchorage system typically has negligibly small anchors! hn ‘The basic concept of the BBR System (Ref. 2-9), which is summarises ts ne use of smooth, high-strength steel wires anchored at each end by eoitg® 2 “button neads."" The wires are 0.276 in. (7 mm) in diameter and have a een 7d area of 0.060 in? (38.5 mm?). The parallel wires of a tendon all pass through (tae anchor head (see Fig, 2-17b and c). Before detensioning, shim plates are inserted on the anchor head and the bearing plate, locking the tendon elongation into place," Monostrands, which are usually unbonded (see Fig. 2-18), offer an economical ang versatile means of post-tensioning thin slabs and narrow members. The monostrands be arranged in a single horizontal layer which, together with the small-diameter duce provides maximum possible eccentricity. Monostrand post-tensioning systems also utiin, compact anchorages and grommets together with small, lightweight stressing jacks, thu permitting the stressing operation to be carried out by one person. Figure 2-19 illustrates a number of different dead-end anchorages for different pe- stressing systems. It is sometimes necessary to couple tendons together. For example, in the construction of a segmental box-girder bridge it is necessary to couple the tendons stressed during phase 1 of the construction to the tendons that are to be stressed in phase 2. Figure 2-20 illustrates typical couplers. 17, 2.7 GROUTING OF DUCTS In bonded post-tensioned construction the ducts are grouted as soon as possible after stressing the tendons. The objective of the grouting operation is to fill the duct completely with material that provides an alkaline environment for corrosion protection of the pre- stressing steel and has sufficient strength to bond the tendons to the surrounding concrete. To minimize the time that the ungrouted tendons are exposed to corrosive conditions, ‘dvisable to insert the tendons into the ducts just prior to stressing the tendons. Grout usually consists of a mixture of cement and water (water/cement ratio Ges 0.50) together with a water-reducing admixture and an expansive agent. Grout for diameter duets may also contain filler materials such as sand, fly ash, or pozz0lans. 1” isfactory grout should maintain sufficient fluidity during the grouting operation, shor hibit minimum bleeding and segregation, should not shrink, should have adequate and should not contain detrimental amounts of chlorides, nitrates, sulfides. oF Pounds that contribute to corrosion, member __The grout is injected at the low points of the tendon or at the ends of mile. ag the Yenting tubes are provided at the high points of the tendon, as shown in Fig: 2-1 (ee duct is not properly vented, pockets of air may be trapped at high points of 1." ious Fig. 2-21). Freezing of water that may collect in these air pockets can result deterioration of the structure and may lead to corrosion of the tendon. of the Iris not usually possible to grout the ducts successfully if the temPA" eave Strfounding concrete is less than about 40°F (5°C). Hence it may be neces hk itisSec. 2.7 Grouting of Ducts (2) Bel and plate anchorage peste former w ( Gsneter Xtongn 3) rout ube | ‘grout sleeve astc num bel anchorage omigel | bell anchor | anchor pte | A ] 8 ] © ] 0] © Sande ste Se (om) (om) em) | ce | crm) | comm | cod | Comm se | oasyerso | axosar | ans | ars | ass | 2 | ae GH | ee | AES | ae || |S | eo 1 | ssoexz6n | sxssoxsas| sin | 7 | [ane | a 2) | ASTER | BENE | Gah | ote | ode | G88 | bs te | eregeze | sererse | ao |e |e | asa | oe | CATER | obi it'tin | 688 | cdo | oda | d83 | a | 725 ¢2a0 |r rso 0126 | oso | a6 | | ars | 0 | ee Gat | Taaeetes | BS | B | ode | Gb | (0) Jacking and anchorage details gomcal [aes] staat | ainate | tas free andi | hee. | inside da. | strate, | tie thn in Geum) | in? Grint) | “in Gum) | tira | OP Anat | secs] ozram | orem | ssromn | 0820 1 ao] oss | rasa | socom | e308 riets2 | 12500060 | soca | sso coon | 1919 00 13400 | seco | v7scan | ssociose | e800 (c) Bar sizes and properties Figure 2-16 — Dywidag threadbar post-tensioning system. From Ref. 2-8.40 costormes threaded anchor head (b) Multi-wire tendon shim plate, pull rod bearing plat (€) Tendon tensioned by pull rod (@ Shimming of anchor plate weal [ite ne Gasewoee leva B | ‘wees fin. Crm). [in comm) | in, ove) sen pip ee a >) ssa} | 8 - 4 3 wee es reyenten 207 (73) | 333 (0473 18 45D eating slate! | 2 >| 388 RBS ecu ss tes eo] gaa] coe |e (e) Jack details 6 ‘ass cea) as cgas) | 10802709 8 com | 5 tag [ease as |e | caro) gpg) > |" mm) 1388 (Gr) [| (0 BBR tendon sizes and jack dimensions Figure 2-17 BBR multi-wire system, From Ref. 2-9- aeSec. 2.7 Grouting of Ducts a _-— corrosion protection cap Corrosion protection sieeve plastic (orommen) (2) Anchor details (2) place grippers (4) stress and ‘anchor strand > (2) remove grommet (1) placement of monostrand and anchor nailed to formwork (©) Construction sequence for a post-tensioned slab Figure 2-18 Monostrand post-tensioning system. From Refs. 2-7 and 2-10. ducts ungrouted for some period of time if the temperature stays near freezing. In such cases, particular care must be taken to prevent water from entering the ducts and to ensure that all low points in the ducts are properly drained. Prior to grouting, the ducts should be blown out using oil-free compressed air to remove debris from the ducts. Sometimes the ducts are flushed out with water prior to Brouting. If blockage of a duct occurs during grouting, the duct needs to be flushed out immediately by injecting water into the closest air vent, against the direction of grouting. Records of the grouting pressures, volume of grout used, temperatures, and other details of the grouting operation need to be kept. High grouting pressures (e.g.. over 200 psi or 1.5 MPa) may indicate blockage in the duct and may cause segregation of the Brout or splitting of the concrete surrounding the duct.fa Pretensioning and Post-Tensioning Technolog, S y Chap,» 1, seout vent spiral Feinforcemnt gd (©) BBR individual wire anchorage (@) VSL splayed strand anchorage Figure 2-19 Examples of dead-end anchorages. From Refs. 2-6 to 2-9, -term durability of a bonded, Post-tensioned structure depends on the success ing operation. Specifications for this highly specialized and critical procedure are given by the Post-Tensioning Institute in Ref. 2-11. Further details on grouting a given in Ref. 2-12, 2.8 PROFILES OF POST-TENSIONED TENDONS " . The In poststensioned construction, tendon Profiles are usually of parabolic a wi tendon profile for a simply Supported beam usually consists of one parabolic profiles it the maximum eccentricity being located at midspan (see Fig. 2-22a). anal segments Continuous beams can be described ass series of parabolic segments with conc ‘n the spans and convex segments over the supports (see Fig. 2-22b). adSec. 2.8 Profiles of Post-Tensioned Tendons 43 (a) Freyssinet coupler (b) Dywidag coupler ‘coupler block side view (©) VSL coupler and center stressing (@) BBR coupler anchorage Figure 2-20 Tendon couplers and center-stressing anchorages. From Refs. 2-6 to 2-9. air pocket tendon profile near high point section 1-1 Figure 2-21 Air pocket formed at tendon high point due to inadequate venting. Useful geometric relationships for a parabolic segment are given in Fig. 2-23a. Fig- ure 2-23b illustrates how a series of parabolic segments fit together. At the location of maximum eccentricity, e;, parabola 1 and parabola 2 both have zero slopes and hence are~*~ \ Pretensioning and Post-Tensioning Technology hap, 2 centroidal axis tendon profile (a) Parabolic tendon profile for simply supported beam Point of max. eccentricity max. eccentricity _contraflexure in span at_support Cinflection point) ep PR OR | | parabola 1 2 34 5 6 78 9 10 (b) Parabolic segments used to describe tendon profile of three-span continuous beam Figure 2-22 Parabolic tendon profiles. compatible. In order that parabola 2 and parabola 3 are compatible, their slopes at the inflection point must be equal and hence eC fa) _ ha = Thus the inflection point must be located a distance, hz below the high point, where =p ho= See +e) en The inflection point must therefore lie on as eccentricities as shown in Fig. 2-23b. Note that the common slope of the two parabolas meeting at the inflection point given by traight line connecting the points of maximum 2e1 +2) 2) slope = in te ‘The convex segment over the support is required in order to avoid @ Kink Kendon at this location. ‘The length of the conver segment, {¢, in Fig. 2-250. Mss Meachosen such that over the support the radius of cuvature, FR of the tendon i ™ i than the minimum radius of curvature recommended for the particular tendon- able 2+ of fcommended minimum radii for a multi-strand tendon cyvtem are given ftSec. 2.8 Profiles of Post-Tensioned Tendons end slope — bo f eo! t, (a) Geometry of parabolic segment ha = (e+ €,) xy parabola 3 iw radius of curvature, R 2e,* en) (b) Parabolic segments with compatible slopes Figure 2-23 Geometry of parabolic profiles. For monostrand systems, Ref. 2-14 recommends 2 minimum radius of curvature of 8 ft (2.5 m) for 1/2 in. (13 mm) and 0.6 in. (15 mm) diameter strands. In determining duct locations it is importan: to recognize that the centroid of the tendon, called the center of gravity of steel (c.g.s.) will not always coincide with the Center of the duct. When the tendon is stressed it will be pulled toward the inside wall of Curved ducts (see Fig. 2-24). The resulting eccentricities of the tendon inside the duct for One post-tensioning system (Ref. 2-7) are given in Fig. 2-24. It can be seen that for large tendons these eccentricities can be significant.—— Pretensioning and Post- fe 9 Tensioning Technoiogy a duct centerline ep. duct centerline eccentri ( eccentricity iy fduct 6 centerline a strands at top strands at bottom of duct of duct tendon size | sheath diameter | eccentricity in, Crm) in. (mm) no, of 172 in. dia. | + ism) ‘steanss 3 1.25 (82) 0.2807) 4 1.63 (41) 02807) 7 2.00 61) 0.32 (8) | oe 2.50 (64) asain 19 3.13 (80) 0.51.13) 22 3.38 (88) 0.47 (12) a 4.00 (102) 0.85 (14) 58 5.50 (140) 0.90 (23) no. of 0.6 in. dia ism) strands 3 1.50 (38) 0.20 (5) 4 2.00 (38) 0.20 (5) 7 2.25 (57) 9.40 (10) 2 3.00 (78) 0.50 (19) 19 3.75 (98) 0.70 (18) a 5.00 (127) 0.90 (23) 55 6.50 (165) 1.20 (80) - Ref. 27, Figure 2-24 Location and eccentricity of tendon in duct after stressing. From 2.9 LOSSES DURING POST-TENSIONING he length ; ng t When a tendon is tensioned by a jack, the force produced is not constant A102 copii of the tendon due to friction between the tendon and the duct. It is custom aSec. 2.9 Losses during Post-Tensioning a7 Table 2-1 Recommended minimum radii of curvature. From Ref. 2-13, Sheath inside in. | 18-22] 263213337] 3943 diameter (mm) | (45-35) | (65-80) | (85-95) | (100-110) Minimum radius | ft 2 15 16 2B of curvature @ | 65 | 45) | 6H | @o the frictional.loss.as consisting of two components: the-curvature and the-wobble frictional - losses. Curvature frictional loss results from the intended change of angle of the tendon profile. If over a tendon length of dz the tendon direction changes by angle da, a normal force, N, equal to 2P sin(da/2) results (see Fig. 2-25). If the coefficient of friction between the tendon and the duct is 1, then the friction loss in length dr will be NV. As the angles involved are typically small, 2 sin(da/2) can be taken equal to da’ and hence the friction loss becomes uP day Additional frictional losses result from unintended angle changes of the tendon along its length (see Fig. 2-26). The magnitude of these wobble losses depends on the rigidity of the sheathing, the diameter of the sheathing (larger sheaths have lower losses), the spacing of the sheath supports, the tendon type, and the sheath type, as well as the form of. construction. Wobble losses over the tendon length, dx, are expressed as KP dx, where K is the empirical wobble coefficient. The total friction loss over length dz is thus dPR.=pPdaerKP dee The change in tendon force between point A and point B can be found as follows: Pa @ f cara I da+K f de PoP 9 o Solving this equation gives PypaPyertuarKon (23) where P, = tendon force at location A Pg = tendon force at location B 12 = friction coefficient @ = total intended, cumulative angie change between A and B, radians K = wobble friction coefficient per foot or per meter of tendon = tendon length between A and B, feet or meters ; 5 .__, The range of friction coefficients recommended by ACI Committee 343 (Ref. 2-15) is given in Table 2-2. Representative friction coefficients recommended in the CEE-FP ' Model Code (Ref. 2-16) are given in Table 2-3. From these tables it can be seen int the coefficient of friction, z, depends on the surface characteristics of the tendon and of the duct and may vary between 0.05 and 0.50. It can be seen that the wobble coe Ais K, is a function of both the coefficient of friction, 1, and the sheath rigidity, and may= “s Pretensioning and Post-Tensioning Techno oh 5 Py dale 7 P-aP force triangle x curved tendon Figure 2-25 Curvature frictional loss actual profile due c] to‘wobbling” pe profile sheath ~~ ae supports ST a= intended a angle change Figure 2-26 Wobble frictional loss. Table 2-2 _ Range of friction coefficients recommended by ACI. From Ref. 2-15. Curvature | Wobble Coefficient, K ‘Coefficient, |______ “Type of Tendon a per foot | _permete Tendons in flexible metal sheathing ‘Wire tadoas 0.15-0.25 | o.0010-0.0015 | 0.0033-2009 wire strand 0.15-0.25 | 0.0005-0.0020 | 0.0016-0.0066 High-stength bars 008-029 | 0,0001-0,0006 | 0.0003-00020 [Redo gid mea aict~ Ts wand oso Poca |Unbonded pregreased tendons ~ wires and 7-wire strand] "0.05-0.18 | 0.0003-0.0020 OT Ee eter), Since both of in order is clear that in 0 vay pete 0.0001 and 0,002 per foot (0.0003 and 0.0066 per m¢ ese, is used is friction Coefficients can vary over an order of magnitude, it i s calculate frictional losses accurately, information on the specific system poe sys needed. As well as obtaining the friction coefficients for the specific post-tensionin 2Sec. 2.9 Losses during Post-Tensioning 49 being employed, it is also necessary to take into account the influ construction type. For example, segmental construction results curvatures at the locations of the segment interfaces. The FIP recommendations (Ref. 2- 17) suggest doubling the K coefficients given in Table 2-3 for this type of construction. A study (Ref. 2-18) of a variety of tendons in eight segmentally constructed bridges resulted in a mean 1 of 0.36 and a mean K of 0.001 per foot (0.003 per meter). For multi. stage construction having complex tendon geometry, the actual friction losses should be determined during stressing and empty ducts for supplementary tendons should be provided in case the friction losses are greater than expected. Additional considerations are that the friction coefficients increase with decreasing radius of curvature, force, and increase when surface corrosion is present. rence of workmanship and in additional unintended increase with increasing Table 2-3 Representative friction values recommended by CEB-FIP for tendons with radii of curvature not less than 6 m (20 ft). From Ref. 2-16. Curvature | Wobble Coefficient, KT Coefficient, ‘Type of Tendon ue per foot | per meter Cables in concrete ducts 0.50 | 0.0015 0.0050 Tendons in metal sheathing Drawn wires 0.20 | 0.0006 0.0020 Strand 0.20 | 0.0006 0.0020 Smooth rolled wires 0.25 | 0.0008, 0.0025 Deformed wire 030 | 0.0009 0.0030 ‘Multiply values by 0.90 if tendon is slightly lubricated. "In the CEB-FIP Model Code, Kis expressed as 0.01y per meter (0.003, per foot). Figure 2-27 illustrates the manner in whi in tendon force along the length of the member. In using Eq. (2-3) to determine frictional losses, it is sufficiently accurate to calculate the tendon force only at the ends of each Parabolic segment and then assume that the force varies linearly between these points, as shown in Fig. 2-27b. If a reasonably long tendon, One end, there may be a considera ence of frictional losses is reduced overstressing of the tendon followe: the variation in tendon force cause: ‘o be taken if this overstressing self-anchoring wedges such as Permitted to stress the tendon tensile strength of the tendon. Couplers is usually limited to ch frictional losses influence the variation such as that shown in Fig. 2-27, is stressed from only ible loss in force along the member length. The influ- if the member is stressed from both ends. Temporary d by release and subsequent restressing will also reduce -d by friction (sce Fig. 2-27c). Additional measures need technique is to be used for post-tensioning systems with multi-strand tendons. During post-tensioning it is usually temporarily to a maximum of about 80% of the specified After anchoring, the stress in the tendon at anchorages and 70% of the specified tensile ‘strength (Ref. 2-19). During the tensioning of the tendon, both the jack force and the corresponding tendon clongation are recorded. The elongation readings are compared to the calculated elongationo—_: 50 Pretensioning and Post-Tensioning Technol YY gy hap, 2 a) Tendon profile consisting of parabolic segments end A stressed to 70% oP Uitimate 40% (b) Force variation when tendon stressed from end A only () ends A and g,, ) en8s A and Boa, vox sed te : 70% 60% sox}. (3) ends A and B restressed to 70% (c) Force variation when tendon stressed in stages from both ends Figure 2-27 Tendon force variation due to frictional losses, and must agree within specified tolerances (+ 5% is usually acceptable). Smaller than expected elongations may indicate that the tendon is jammed in the duct and hence only 2 portion of the tendon length is being stressed or it may indicate higher than normal frictional losses. The elongation of the tendon can be calculated as follows: Pal (2-4) ApsEp where 4 = expected tendon elongation Pay = average force in tendon determined from calculated force variation along tendon total length of tendon cross-sectional area of tendon Young's modulus of tendon {cis useful to recognize that the term Payé in Eq. (2-4) is equal to the area under the cH ‘hich shows the variation of tendon force along the length of the tendon. Far Afr the stressing operation is completed it is necessary to anchor the tendeoe most posttensioning systems the anchoring operation will result in an adition® tendon force due either to seating of the wedges or to deformation of the s! ). anchorage set for strand tendons anchored by wedges is usually about 0 neat Figure 2-28 shows the influence of anchorage set on the force varia! ie end of the tendon. The length of tendon affected by anchorage set is a fun eeSec. 2.10 Example of Friction Loss Calculations 51 frictional losses. If friction is low (e.g., for unbonded tendons), the length affected may be very large. The anchorage set is equal to the shortening of the tendon which results rom the force change in the tendon. As this shortening is proportional to the shaded ares my Fig. 2-28, the length affected by anchorage set can be calculated in the following manner: O5AP beet ApsBp (2-5) Assuming a constant frictional loss per unit length, p, set = we obtain AP = 2plset (2-6) where p is the friction loss expressed as a change in force per unit length calculated from 4 tendon force variation diagram. Substituting for AP in Eq, (2-5) gives a = | SeetneEe en P ‘tendon 4 force force variation ri¢r to anchoring |—force variation after anchor set distance from anchor Figure 2-28 Influence of anchorage set on force variation, 210 EXAMPLE OF FRICTION Loss CALCULATIONS The four-span continuous bridge girder shown in Fig. 2-29 is post-tensioned with tendons Consisting of twenty 0.6 in. (15 mm) diameter strands with f,,, = 270 ksi (1860 MPa). The symmetrical tendons are simultaneously stressed to 75% fou, that is, 871 kips (3870 KN), from both ends and then anchored. Pt= 52 Pretensioning and Post-Tensioning Techno} . og Chay 251 (076m) 2006 — | Bln fly ESET oily a | Ragteons {E82 016 arecane Cueshe | on | cone boitome cose Luasted 9 oats ouoy, I pate Ztwaenn ass Saat + Tuas ‘ 1 initat 1 stressing Jt Sage 900 final force Variation 600 Figure 2-29 Example of frictional loss calculation. For this application the tendon properties are: Aps = 4.30 in? (2800 mm?) Ey = 28,200 ksi (195000 MPa) H = 0.20 K = 0.0006/ft (0.0020 /m) Asee = 0.25 in. (6 mm) 1 Calculate the expected elongation due to the stressing operation. eeSec. 2.10 Example of Friction Loss Calculations 53 2. Calculate the tendon force variation after anchorage. (a) Determination of Tendon Force Variation ‘The a + Ker values for each parabolic segment are first determined. Since each parabolic segment has one end which is horizontal (zero slope) the angular change, a, within each segment is equal to the slope at the inclined end. The equation in Fig. 2-23a and Eq. (2-2) are used to find these slopes. During stressing, the force at location « along the tendon is given by Py = Pye Lark) ‘The tendon force variation after jacking is shown in Fig. 2-29. (b) Calculation of Elongation ‘The average force in the tendon can be approximated as Poy =[ 5@n +829) x 45+ 529+ 781) x 45 + 581 +751) x 10+ 5751 +725) x 12 + dos +683) x 50+ 51683 +644) x 50 + 40644 +621) x 12] /224 = 745 kips (3315 kN) The calculation above assumes a linear force variation between the ends of each parabolic segment. From Eq. (2-4), the expected elongation is TAS x 224 x 12 4 = Fax aa200 = 165 in. (419 mm) (© Anchorage Set Within the first 45 ft (13.7 m) of the tendon the friction loss per inch is (871 — 829)/(45 x 12) = 0.078 kips/in. (13.6 N/mm). The length of tendon affected by anchorage set is given by Eq. (2-7): [9:25 % 4:30°% 28,200 _ 605 in. = 59 £ (15.8 m) Because tse, exceeds 45 ft (13.7 m), the friction loss per inch, p, could be recalculated if a more accurate answer is desired, However, in this case the small difference will be neglected. From Eq. (2-6), AP = 2 x 0.078 x 623 = 97.2 kips (432 KN) Hence after anchoring, the force at the end of the tendon is 871 — 97.2 = 773.8 kips (3442 kN) This force in the tendon corresponds to a stress of 0.67. ‘fou, which is less than the stress limit of 0.70fpu permitted by the ACI Code (Ref. 2-19) at end anchorages. The force Variation after anchoring is shown in Fig. 2-29. boet> /~ Pretensioning and Post-Tensioning Technolog, 54 Chap » References “The Long Li s Method,” Proceed ».1 Sook an L., “The Long Line Pretensioning M 1," Proceedings of ys vom 3, Canadian Prestressed Concrete Institute, Ottawa, aaa incl m FP ey ymposia, Vo + PP. 7-25 +> Kaar, PH., and Magura, D.D., “Effect of Strand Blanketing on Perform, ~~ Oiiders.” PCI Journal, Vol. 10, No. 6, Dec. 1965, pp. 20-34. 2.5 Prestressed Concrete Institute, PCY Design Handbook: Precast and Prestressed ¢ ed., PCI, Chicago, 1985. 2-4 Canadian Prestressed Concrete Institute, Metric Design Manual — Concrete, 2nd ed., CPCI, Ottawa, 1987. 2-5 Dy-Core Integrated Building Systems, a product brochure of Dy-Core Systems, Dy-Form Engineering Ltd., Vancouver, Canada. ANCE Of Pretenseay ‘oncrete, 3 Precast and Presto, 8 Division of 2-6 The K-Range System, a product brochure of Freyssinet International Ltd., Paris, France 2-7 Post-Tensioning Systems, a product manual of VSL Corporation, Los Gatos, C: 2-8 Dywidag Threadbar Post-Tensioning System, a product brochure of Dywidag Systems Intems tional, Lincoln Park, N.J BBR Cona Multi Prestressing Systems, a product brochure of Bureau BBR Lid., Zurich, Switzer land. 2 10 VSL Monostrand Post-Tensioning System, a product brochure of VSL Corporation, Campbell Calif., 1989, 16 pp. Post-Tensioning Institute, Post-Tensioning Manual, Post-Tensioning Institute, Phoenix, Ar 1976, "12 PCI Committee on Post-Tensioning, “Recommended Practice for Grouting of Post-Tensioned Prestressed Concrete,” PCI Journal, Vol. 17, No. 6, Nov.-Dec. 1972, pp. 18-25. TESIT Post-Tensioning Systems: Technical Information and Data, TESIT Spa, Milan, lal Riz. P. Matt, R, Tellenbach, Ch., Schlub, P, and Aebethard, H.U., Post-Tensioned Slat Losinger Ltd. VSL Intemational, Beme, Switzerland, Jan. 1981, 41 pp. AC! Committee 343, “Analysis and Design of Reinforced Concrete Bridge Structures. “3R-88, American Concrete Institute, Detroit, 1988. 16 CEB-FIP, Model Code . Jor Concrete Structures: CEB-FIP International Recommendations Smité Euro-Intemational du Béton, Paris, 1978, 348 pp. "acl au. FIP Commission on Pra infor? ond Preserscr cu Practical Design, FIP Recommendations — Practical Design of Re aa Telford bad to gimrete Structures Based on the CEB-FIP Model Code (MC78) ‘3. London, 1984, 36 pp, “alogeun. M., and Jaeger, des ponds "eraits par encarbelleme D.. Pertes de Précontrainte par frottement, dans le cS tal BUSS ‘ms Successifs (Prestressing Friction Losses in Segment struction), Technique F 1m, Swede ¥82. pp. 251-779 ME Prangaise du Béton Précontrainte, FIP Congress, Stockho! 219 ACI Comunitee 444 318) Commentary «ne baron Code Requirements for Reinforced Concrete ee a RKO," American Concrete Institute, Detroit, 1989,Chap. 2 Demonstration Problems es Demonstration Problems 2-1 Define the following terms: anchorage block, anchoras \ge set, blanketed strand, button head, center-hole jack, composite topping, coupler block, dead-end anchor, duct, grommet, harped strand, hold-down device, jack chair, monostrand, multiple strand detensioning, pretension- ing bed, removable abutment, sheath, splayed strand, stemmed deck elements, stressing bed, tendon, trumpet, venting tubes, and wobble. 2-2. The inside diameter of a sheath for a post-tensioned tendon must be sufficiently large to ensure adequate space around the tendon for grout. Prepare a plot that shows the relationship between the ratio of the duct area to the tendon area (Aduct/Apa) and the inside diameters of the sheaths for the VSL 1/2 in, (13 mm) multi-strand system. Comment on the variation observed. 2-5 In constructing the four-span continuous bridge girder described in Fig. 2-29, it is necessary to support the tendon sheaths at 3 ft (0.9 m) centers along the length of the girder. If the Concrete centroidal axis shown in Fig. 2-29 is 3 ft (0.9 m) above the bottom surface of the Birder, prepare a table giving the elevations of the sheath centerline relative to the bottom Surface of the girder at the sheath support locations in span AB. The eccentricities given in Fig. 2-29 are to the centroid of the tendon. Allow for the fact that the tendon centroid will not coincide with the sheath centroid. 2-4 A four-span post-tensioned one-way floor slab is described in Fig. 2-30. The tendons are stressed from both ends and the stressing procedure is: jack to 80% of the ultimate tensile strength (UTS), release to 60% UTS, rejack to 70% UTS, and anchor. Assuming that 1 = 0.25, K = 0.0015/ft (0.005/m), calculate (a) the tendon force at 1.44, 2.0, 2.5, and 3.0 and (b) the average tendon force in each span. Express the forces as a ratio of the UTS of the tendon. Assume that the anchor set is negligibly small. 1.5 ft Zin. 4.5 tt Parabolic segments (0.46 m) (76 mm) (0.46 m) 1.03 in, 2.5 in (76 mm) (4.27 m) |! centerline 9 in. (229 mm) | 1.0 1.44 2.0 25 44 ft" 18 ft 16 ft 16 ft (64 mm) (5.49 m) (4.88 m) (4.88 'm) Figure 2-30 Post-tensioned one-way floor slab. 2-5 A straight post-tensioning tendon has a wobble factor, K, of 0.001/ft (0.0033/m). The tendon he 864 © 200 ksi (1400 MPa) at the jacking end and then anchored. Due to wedge draw-in, the tendon slips back a distance of 0.25 in. (6 mm) during anchoring. Over what length of {fadon will the stress be reduced because of wedge draw-in? What will be the highest stress in the tendon immediately after anchoring? What will be the stress in the tendon at the anchor? Assume that Ep = 29,000 ksi (200000 MPa). 2-6 A cylindrical tank isto be post-tensioned with strands in small semi-rigid ducts [K = 0.0015/ft (0.005im), 4 = 0.20}. The tendons will be anchored in buttresses and will be stressed from both ends, ‘The stressing procedure will be to stress to 80% UTS, release to 60%, restress to —— ee~*~ +6 Pretensioning and Post-Tensioning Tech ology Om, 70%, and then anchor. If the tank size is such that the tendon far apart can the buttresses be if the average force in the tend radius is 65 f¢, lon is not t0 be Jess UTS? Neglect anchor set losses. © be less than fe [A post-tensioning supplier has devised a testing system in order to deter the frictional loss coefficients for different tendon systems. Two con cast, one being straight and the other being a circular arc with a radius of 35 ¢ The losses in prestress force measured were 4.3% in the case ofthe straight sce in the case of the curved tendon, Find the frictional loss coefficients, 1 and fe ine ex; rete clemenn nelly MS have (eign and 15, jacks load cell ———— | | (a) Straight tendon | | | R=75 tt (22.9 m) 30 ft (9.1 m) (b) Curved tendon Figure 2-31 Experimental determination of j: and K.