CHAPTER 1

INTRODUCTION
Bigger is better, as many in the building product and bridge industries would say, and its
certainly true of precast concrete products. Steel reinforcement bars add a great deal of
strength to large concrete products, but rebar alone cant provide the tensile strength
necessary for precast products that stretch for extended lengths. There is a bit of wizardry
that imparts sufficient strength to these enormous products, and its called prestressing.
In more formal terms, prestressing means the intentional creation of permanent stresses in
a structure or assembly to improve its behaviour and strength under various service
conditions.
1.1 PURPOSE BEHIND PROJECT:
The main purpose of taking this project is to study PRESTRESSING
TECHNIQUE used in construction work. As we know that many of large structures
are constructing day by day and need of strength is also a concerned aspect indeed. So
starting our project with a general knowledge of how slabs are construct using prestress
ans also the construction of railway prestressed sleepers. As a keen reason of taking this
project is it has a vast scope in upcoming years.
1.2 HISTORY OF PRESTRESSING:
Prestressing of structures was introduced in late nineteenth century.Mild steel rods are
stretched and concrete is poured around them. After hardening of concrete, the tension in
the rods is released. The rods will try to regain their original length, but this is prevented
by the surrounding concrete to which the steel is bonded. Thus, the concrete is now
effectively in a state of pre-compression. It is capable of counteracting tensile stress.
But, the early attempts of prestressing were not completely successful. It was observed
that the effect of prestress reduced with time. The load resisting capacities of the
members were limited. Under sustained loads, the members were found to fail. This was
due to the following reason.
Concrete shrinks with time. Moreover under sustained load, the strain in concrete

increases with increase in time. This is known as creep strain. The reduction in length
due to creep and shrinkage is also applicable to the embedded steel, resulting in
significant loss in the tensile strain.
The development of prestressed concrete can be studied in the perspective of traditional
building materials. In the ancient period, stones and bricks were extensively used. These
materials are strong in compression, but weak in tension. For tension, bamboos and coir
ropes were used in bridges. Subsequently iron and steel bars were used to resist tension.
These members tend to buckle under compression. Wood and structural steel members
were effective both in tension and compression.
In reinforced concrete, concrete and steel are combined such that concrete resists
compression and steel resists tension. This is a passive combination of the two materials.
In prestressed concrete high strength concrete and high strength steel are combined such
that the full section is effective in resisting tension and compression. This is an active
combination of the two materials. The following sketch shows the use of the different
materials with the progress of time.
1.3 AT PRESENT:
In India prestessing in done on a great extent. In every large and major structure ,
prestressing is done to increase their expected life. For example we can see the Rajiv
Gandhi Sea link in Mumbai, precast prestressed concrete blocks were being used during
construction.
At present prestressing is done in different structures like in bridge girders, railway
sleepers, slab design, column design, prestress circular water tanks and in many more
structures.

1.4 CONCEPT OF PRESTRESSING:

The basic principle of prestressing was applied to construction, perhaps centuries ago,
when ropes or metal bands were wound around the wooden staves to form a barrel. When
the bands were tightened, they were under tensile prestress, which in turn created

compressive prestress between the staves and enabled them to resist hoop tension
produced by internal liquid pressure. In other words, the bands and the staves were
prestressed before they were subjected to any service loads.

CHAPTER 2
LITERATURE SURVEY
2.1 TYPES OF PRESTRESSING
Prestressing of concrete can be classified in several ways. The following classifications
are discussed.
2.1.1 SOURCE OF PRESTRESSING FORCE:

This classification is based on the method by which the prestressing force is generasted.
There are four sources of prestressing force: Mechanical, hydraulic, electrical and
chemical.
A) Hydraulic Prestressing: This is the simplest type of prestressing, producing large
prestressing forces. The hydraulic jack used for the tensioning of tendons, comprises of
calibrated pressure gauges which directly indicate the magnitude of force developed
during the tensioning.
B) Mechanical Prestressing:In this type of prestressing, the devices includes weights
with or without lever transmission, geared transmission in conjunction with pulley
blocks, screw jacks with or without gear drives and wire-winding machines. This type of
prestressing is adopted for mass scale production.
C) Electrical Prestressing:In this type of prestressing, the steel wires are electrically
heated and anchored before placing concrete in the moulds. This type of prestressing is
also known as thermo- electric prestressing.
2.1.2 FULL, LIMITED OR PARTIAL PRESTRESSING:
A) Full Prestressing: When the level of prestressing is such that no tensile stress is
allowed in concrete under service loads, it is called Full Prestressing (Type 1, as per
IS:1343 - 1980).
B) Limited Prestressing: When the level of prestressing is such that the tensile stress
under service loads is within the cracking stress of concrete, it is called Limited
Prestressing (Type 2).
C) Partial Prestressing: When the level of prestressing is such that under tensile stresses
due to service loads, the crack width is within the allowable limit, it is called Partial
Prestressing (Type 3).
2.1.3 PRE-TENSIONING AND POST-TENSIONING PRESTRESSING:
A) 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 over the
transmission length near the ends.
B) 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 (at the end blocks).
We will discuss it further later in detail.
2.2 PRESTRESSING STEEL
2.2.1 WIRES:
A prestressing wire is a single unit made of steel. The nominal diameters of the wires are
2.0, 3.0, 4.0, 5.0, 7.0 and 8.0 mm.
2.2.2 STRANDS:
A few wires are spun together in a helical form to form a prestressing strand. The
different types of strands are as follows.
1) Two-wire strand: Two wires are spun together to form the strand.
2) Three-wire strand: Three wires are spun together to form the strand.
3) Seven-wire strand: In this type of strand, six wires are spun around a central
wire. The central wire is larger than the other wires.
2.2.3 TENDONS:
A group of strands or wires are placed together to form a prestressing tendon. The
tendons are used in post-tensioned members.
A group of tendons form a prestressing cable. The cables are used in bridges.
The minimum tensile strengths for different types of wires as specified by the codes are
reproduced.
Nominal Diameter (mm)

2.50

3.00

4.00

5.00

7.00

8.00

Minimum Tensile Strengthfpk(N/mm2)

2010

1865

1715

1570

1470

1375

Table 2.1 tensile strength of different types of wires

2.3 PRE TENSIONING

In pre- tensioning, the tension is applied to the tendons before casting of the concrete.
The stages of pre-tensioning are described next.

2.3.1 STAGES OF PRE-TENSIONING:

In pre-tensioning system, the high-strength steel tendons are pulled between two end
abutments (also called bulkheads) prior to the casting of concrete. The abutments are
fixed at the ends of a prestressing bed.Once the concrete attains the desired strength for
prestressing, the tendons are cut loose from the abutments.
The prestress is transferred to the concrete from the tendons, due to the bond between
them. During the transfer of prestress, the member undergoes elastic shortening. If the
tendons are located eccentrically, the member is likely to bend and deflect (camber). The
various stages of the pre-tensioning operation are summarised as follows.

Anchoring of tendons against the end abutments.

Placing of jacks.

Applying tension to the tendons.

Casting of concrete.

Cutting of the tendons.

2.3.2 DEVICES:
The essential devices for pre-tensioning are as follows:A) Prestressing Bed, End Abutments and Mould:
A prestressing bed is that where pre or post tensioning of concrete is done. It consists of
end abutments and a mould.
End abutments are permanent structures made to fix or anchoring the tendons at both
ends in position which then starched by different gauges.
A mould or formwork is place in which concrete is poured or casted.