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IN CONCRETE
ADVANTAGES/APPLICATIONS
Post-tensioning allows longer clear spans, thinner slabs, fewer
beams and more slender, dramatic elements.
Thinner slabs mean less concrete is required. It means a lower
overall building height for the same floor-to-floor height.
Post-tensioning can thus allow a significant reduction in building
weight versus a conventional concrete building with the same
number of floors reducing the foundation load and can be a major
advantage in seismic areas.
A lower building height can also translate to considerable savings
in mechanical systems and façade costs.
Another advantage of post-tensioning is that beams Bridge decks
and slabs can be continuous, i.e. a single beam can
run continuously from one end of the building to
the other.
Reduces occurrence of cracks .
Freezing & thawing durability is higher than non
prestressed concrete.
Post-tensioning is the system of choice for parking
structures since it allows a high degree of flexibility
in the column layout, span lengths and ramp
configurations.
In areas where there are expansive clays or soils
with low bearing capacity, post-tensioned slabs-on-
ground and mat foundations reduce problems with
cracking and differential settlement.
Post-tensioning allows bridges to be built to very
demanding geometry requirements, including
complex curves, and significant grade changes.
Post-tensioning also allows extremely long span
bridges to be constructed without the use of
temporary intermediate supports. This minimizes
the impact on the environment
and avoids disruption to water or road traffic below.
In stadiums, post-tensioning allows long clear spans
and very creative architecture. \
Post-tensioning can also be used to produce
virtually crack-free concrete for water-tanks.
The high tensile strength & precision of placement
gives maximum efficiency in size & weight of
structural members.
Applications of various prestressed techniques enable quick assembly of
standard units such as bridge members,building frames, bridge decks
providing cost-time savings.
Since post-tensioned concrete is cast in place at the
CONSTRUCTION job site, there is almost no limit to the shapes that
can be formed.
In slab-on-ground construction, unbonded tendons
are typically prefabricated at a plant and delivered to
the construction site, ready to install.
The tendons are laid out in the forms in accordance
with installation drawings that .
After the concrete is placed and has reached its
required
strength, usually between 3000 and 3500 psi
(“pounds per square inch”), the tendons are
stressed and anchored.
The tendons, like rubber bands, want to return to
their original length but are prevented from doing so
by the anchorages.
The fact the tendons are kept in a permanently
stressed
(elongated) state causes a compressive force to
act on the concrete.
The compression that results from the post-
tensioning counteracts the tensile forces created by
subsequent applied loading (cars, people, the weight
of the beam itself when the shoring is removed).
This significantly increases the load-carrying
capacity of the concrete.
Limitations of Prestressing prestressing is a possible solution may be the cost of
The limitations of prestressed concrete are few and really providing moulds for runs of limited quantity of small
depend only upon the imagination of the designer and the numbers of non-standard units.
terms of his brief. The only real limitation where
Method of post-tensioning
Tendons Wedges tensioned by
jacks
TENDONS
PRESTRESSED CONCRETE
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:
pretensioned 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 posttensioning 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:
External Prestressing
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 “trays” 30-ft. above a waterfall. Previous efforts failed to permanently
address excessive deflections of the cantilever and repair the cracks.
• Fallingwater is comprised of a series of concrete
After a thorough design review, the owner and engineer selected an
cantilever
external post-tensioning solution for its durability, aesthetics was placed beneath the main level terrace.
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.
The lower and upper terraces
cantilever over the stream below. The
temporary structural steel shoring
Frank Lloyd Wright's Fallingwater Mill Run, Pennsylvania
Cline Avenue Bridge Gary, Indiana
The Cline Avenue Bridge (SR 912) is a predominately cast-in-place post-
tensioned structure located in Gary, Indiana. The bridge mainline is over
6,000 LF, has two adjacent segments nearly 35 feet wide each, and
contains four connecting ramps. An inspection and analysis team was
assembled to perform a thorough investigation of the bridge. The team
concentrated on the existing post-tensioning system and interior and
exterior concrete cracks. The engineer retained VSL to assist with the
inspection of the tendons.
VSL approached the Cline Avenue project with a guideline that outlines a
statistically sound method of sampling the tendons. A statistical sample pool
(which consisted of the mainline structure and the ramps) was defined by
referencing the American National Standard Institute’s (ANSI) guideline
“Sampling Procedures and Tables for Inspection by Attributes as published
by the American Society for Quality Control (1993).” The probable void
locations throughout the structure’s mainline segments and ramps were
initially identified by VSL to appropriately distribute the sampling population.
Such areas consisted of high points, areas approaching and leaving the
high points, and couplers.
Using non-destructive Ground Penetrating Radar (GPR) and field layout
drawings, VSL located existing post-tensioning tendons. Once the layout
was performed, specific tendons throughout the bridge and ramp structures
were sampled by drilling into the duct and exposing the tendon for visual
inspection. The use of a borescope allowed for detailed visual inspection of
the tendon and also captured video footage to share with the owner and the
engineer. After review of each inspection, VSL placed epoxy in the
borescope hole to protect the tendons from air and moisture intrusion.
When voids were encountered, the project team observed and documented
the condition of the strand based on the PCI Journal guideline, “Evaluation
of Degree of Rusting on Prestressed Concrete Strand.” VSL used vacuum
grouting technology to fill the void, thereby protecting the previously
exposed strand.
The tendon inspection data was analyzed with other findings (such as crack survey findings) to determine what type of rehabilitation
was required. VSL’s goal to establish a statistically sound sample of physically inspected tendons that provided
valid data as to the current state of the existing PT system was accomplishedGrouting of void using VSL’s specialized vacuum grouting equipment
85th Street Bridge Valley Center, Kansas
The 85th Street North Bridge is a seven span post-tensioned
haunched slab bridge with a typical span of 26 meters for the
middle five spans, and 20 meters at the ends. This 170 meter
long bridge accommodates two lanes of traffic reaching over the
Wichita Valley Center Floodway. VSL post-tensioning systems
utilized for this project include 5-19 longitudinal tendons as well
as 6-4 transverse tendons.
Post-tensioned haunched slab bridges are noted for ease of
construction. Once the geometry of the bridge falsework has
been obtained, prefabricated spacer frames are set into place.
The spacer frames serve as templates for profiling the
longitudinal post-tensioning tendons and aid in the placement of
the remaining conventional reinforcement. Transverse tendons
maintain mid-depth placement along the geometry of the
haunched slab and provide the minimum precompression over
the length of the structure.
The fi nished product has several advantages over
conventionally reinforced concrete. Dead loads are balanced by
the use of longitudinal post-tensioning reducing the sustained
loading and associated creep. Corrosion resistance is increased
due to the encapsulation of the posttensioning reinforcement.
Through the use of transverse post-tensioning, added
compression improves the longevity of the structure by adding
resistance to de-icing methods such as salt and magnesium
chloride. Post-tensioned haunched slab bridges allow for a larger
span to depth ratio than that of conventionally reinforced
haunched slab bridges. The labor and material savings on mild
reinforcement is another clear advantage to using post-
tensioning for this Overlooking the 85th Street Bridge prior to concrete placement application.
Colorado Convention Center
Expansion
Denver, Colorado
The Colorado Convention Center Expansion
project is a 1.4 million square foot expansion of the existing facility. This was a multi-level project, which included a 1,000-car
attached parking garage.
The garage above the street was constructed using precast tees and columns with a cast-inplace topping slab. In order to
maintain regular spacing for the columns in the precast section of the garage and still maintain an unobstructed path for the
road and light rail, large post-tensioned transfer girders were required to support several of the columns above. The transfer
girders allowed for the placement of columns required for the precast design despite the restricted column locations at the
street level.
Post-tensioning the transfer girders resulted in smaller dimensions than a conventional reinforced concrete design, an
important factor given the girders are over 7 feet high and up to 7 feet wide and a larger section would not fit within the
space constraints of the building. The girders could not be stressed until after the precast garage was fully erected and the
topping slab poured on the truck dock. Temporary columns were placed under the girders to support the load until stressing.
The effective post-tensioning force required for the beams ranged from 2176 to 5457 kips. A multistrand bonded system was
installed
The Seward Silo project involved the post-tensioning of three
interconnected ash silos that are part of the Seward Re-
Powering Project in Seward, Pennsylvania. The overall project
involved the construction of a new, state-of-the-art 208 MW
power plant designed to burn low-grade coal that can not be
burned in ordinary coal plants. This is a design-build project
with Drake-Fluor Daniel as the owner/construction manager
until the completed plant is turned over to Reliant Energy, the
ultimate owner.
T.E. Ibberson Company was contracted to build three 187’-6”
tall, interconnected, in-line silos; two 82’-4” diameter fly ash
silos and one 64’-8” diameter bed ash silo. The silos were built
using the slip-form method of construction and are believed to
be the first interconnected silos in the world built using post-
tensioning as the primary circumferential reinforcement.
VSL’s work was performed from November 2003 through
February 2004, during the second coldest winter on record
locally. Significant snowfall and subzero temperatures made
progress challenging, yet with a strong focus on safety, both
cold-related and otherwise, the job was completed with no
incidents. The job required close coordination between the
various trades working in close proximity and constant
communication between parties working above and below
VSL’s work locations to phase the work to avoid having
personnel under an active work zone.
The strand installation, stressing and grouting operations were
completed successfully, with cold-weather grouting made
possible through a variety of heating methods.
Seward Silo
EQUIPMENTS :-
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.
Approximate size 50" long
30.5" high
52" wide
variable up to 20
Output/Pressure gpm, 261 psi
2x3x6
Mixing Pump diffusertype
centrifugal
13.0 paddle
Holding Tank agitating
Maximum
T8Z Torque Wrench
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.
Corrosion Protection
Methods of Corrosion Protection
Can be
Corrosion Abrasion Relative
Typical applied to
Protection Resistance Cost Lead Time accessories ?
Thickness
Type (4=best) (4=highest)
Hot Dip
Galvanizing 4 3-4 mils 2 2-4 weeks yes
Epoxy
Coating 1 7-12 mils 1 2-3 weeks yes